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3. General & Preventive Maintenance

1.Maintenance Cautionary Notes

1.1 Important Precautions.

READ this manual before operating or servicing this equipment.

  • ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.

  • ALWAYS take proper precautions when handling static sensitive devices.

  • SAVE this manual for future reference.

  • DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment. 

  • DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.

  • Do not use any chemicals to clean this equipment, unless otherwise stated in this manual.

  • When using compressed air to blow down this equipment, do not direct the air stream at electrical/pneumatics or other sensitive devices.  Ensure correct PPE is used appropriately.

  • Do not wet wash any of the equipment unless stated to do so.

  • Report all defects immediately to your supervisor or manager.

  • When first installed all surfaces must be cleaned of all foreign material.

 

Ensure all energy sources are isolated before attempting to clean this machinery. All loose products should be gently brushed off the machine components with a small hand brush. If a vacuum system is installed for cleaning purposes use a small application head to remove loose product from this equipment. 

 Where applicable, follow the manufactures instructions stated in the original equipment manual. All safety warnings and cautionary advice must be observed. 

 Cleaning should occur at the end of each day’s production or before maintenance work.  Cleaning of every station and work area on the process and line equipment is very important.

 Clean with a dry lint free cloth or soft brush; use a vacuum attachment if installed. 

 Include cleaning for these areas: 

  • All access points including guards.

  • All the floor area underneath and around the machine.

  • Sensors and switches.

  • Motors and gearbox units.

  • Pneumatic cylinders and fittings.

  • Internal and external surfaces and the dust extraction ducting including flexible tubing.

  • All product contact surfaces must be cleaned to an acceptable hygiene level.

 

If the product has been exposed to moisture and solidified a scraper with a hard plastic blade can be used. Under no circumstances is a metal blade scraper to be used. Once the hardened product has been removed the scraper and the cleaned area must be wiped down. Any wet areas after washing must be cleaned using a clean dry cloth. Wipe all areas afterwards using a clean dry cloth.​

1.1 Important Precautions.
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1.2 Personnel

Only qualified personnel are permitted to operate, adjust, service or maintain `BRML' equipment.Personnel are prohibited from interfering with machinery in any way when it is in operation.

1.2 Personnel
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1.3 Safety.     

 

WARNING     

Safety screens and covers must be maintained where fitted and replaced in the correct position after maintenance or servicing is completed.

1.3 Safety

​1.4 Service, Repair & Adjustments.

  1. Before servicing or repairing, stop the machine and disconnect all energy sources.Maintenance and adjustments must be performed with all energy sources isolated unless otherwise specified in this manual.  

  2. To isolate the machinery, refer to the “warning” page in this manual.​

​1.4 Service, Repair & Adjustments.

1.5. Pneumatic Supply.

  1. High pressure pneumatic systems are dangerous.

  2. Do not service or troubleshoot systems with the compressed air supply on.

  3.  Be sure to bleed off any trapped compressed air before working on components since it is possible to have high pressures trapped in the pneumatic or gas lines.

1.5. Pneumatic Supply.

2.Maintenance Specifications

2.1 Pneumatic Cylinder Torques
For further information please refer to the OEM or the manufacturer.

2.2 Pneumatic System Settings.
Pneumatic Pressure – Regulator. 

Regulator Pressure

Operating Pressure

KPA

kilopascal

PSI

Pounds per Square Inch

Equivalent Pressure

600

87

Electrical Voltage Supply

Parameter

Value

Supply Voltage

415 V AC

Frequency

Phase

Control Voltage

50Hz

3

24V DC

3.Maintenance Specifications ( Electrical )

Ensure proper grounding and stable power supply before operating the machine.

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4.1 Infeed conveyor Assembly Maintenance Schedule

4.1.1  Bearings, Bushes and Cam Tracks.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

Grease linear bearings.

X

Inspect bushes.

Inspect cam tracks

Inspect and Grease bearings, as applicable.

X

Inspect linear bearing tracks.

X

X

X

Inspect linear bearing bolts.

X

Grease spherical ball ends where applicable.

X

6 Monthly

4.1.2  Motor, Gearboxes, & Brakes.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease electric motors if required.

X

Inspect motor brake adjustments.

X

Inspect oil level.

X

4.1.3  Belts and Pulleys/Chains and Sprockets.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect for product build up

X

Inspect chain and sprockets.

X

Inspect belts and pulleys.

X

Inspect belt/chain tension

Inspect belt/chain alignment.

X

X

4.1.4 Chassis and Fasteners

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect all nuts and Bolts

X

Inspect for product build up.

X

Inspect for stress fatigue fractures

X

4.1.5  Pneumatic System

  Task ID.

Inspect vacuum filters

Inspect all pneumatic cylinder mounts.

Clean vacuum filters

Test all pneumatic cylinders for air leaks.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

Inspect the pneumatic service unit.

X

Inspect valves

Test pressure and inspect sensor switch settings.

Inspect all regulators and settings.

X

X

X

4.2 Collation Unit Maintenance Schedule

4.2.1  Bearings, Bushes and Cam Tracks.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease linear bearings.

X

Inspect bushes.

Inspect cam tracks

Inspect and Grease bearings, as applicable.

X

Inspect linear bearing tracks.

X

X

X

Inspect linear bearing bolts.

X

Grease spherical ball ends where applicable.

X

4.2.2  Belts and Pulleys/Chains and Sprockets.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect for product build up

X

Inspect chain and sprockets.

X

Inspect belts and pulleys.

X

Inspect belt/chain tension

Inspect belt/chain alignment.

X

X

4.2.3  Chassis and Fasteners

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect all nuts and Bolts

X

Inspect for product build up.

X

Inspect for stress fatigue fractures

X

4.2.5  Pneumatic System

  Task ID.

Inspect vacuum filters

Inspect all pneumatic cylinder mounts.

Clean vacuum filters

Test all pneumatic cylinders for air leaks.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

Inspect the pneumatic service unit.

Inspect valves

Test pressure and inspect sensor switch settings.

Inspect all regulators and settings.

X

X

X

X

4.3 Pusher Assembly Maintenance Schedule

4.3.1  Bearings, Bushes and Cam Tracks.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease linear bearings.

X

Inspect bushes.

Inspect cam tracks

Inspect and Grease bearings, as applicable.

X

Inspect linear bearing tracks.

X

X

X

Inspect linear bearing bolts.

X

Grease spherical ball ends where applicable.

X

4.3.2  Belts and Pulleys/Chains and Sprockets.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect for product build up

X

Inspect chain and sprockets.

X

Inspect belts and pulleys.

X

Inspect belt/chain tension

Inspect belt/chain alignment.

X

X

4.3.3  Chassis and Fasteners

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect all nuts and Bolts

X

Inspect for product build up.

X

Inspect for stress fatigue fractures

X

4.3.4  Pneumatic System

  Task ID.

Inspect vacuum filters

Inspect all pneumatic cylinder mounts.

Clean vacuum filters

Test all pneumatic cylinders for air leaks.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

Inspect the pneumatic service unit.

Inspect valves

Test pressure and inspect sensor switch settings.

Inspect all regulators and settings.

X

X

X

X

4.4 Shipper Filling & Tilting Assembly Maintenance Schedule

4.4.1  Bearings, Bushes and Cam Tracks.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease linear bearings.

X

Inspect bushes.

Inspect cam tracks

Inspect and Grease bearings, as applicable.

X

Inspect linear bearing tracks.

X

X

X

Inspect linear bearing bolts.

X

Grease spherical ball ends where applicable.

X

4.4.2  Belts and Pulleys/Chains and Sprockets.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect for product build up

X

Inspect chain and sprockets.

X

Inspect belts and pulleys.

X

Inspect belt/chain tension

Inspect belt/chain alignment.

X

X

4.4.3  Chassis and Fasteners

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect all nuts and Bolts

X

Inspect for product build up.

X

Inspect for stress fatigue fractures

X

4.4.4  Motor, Gearboxes, & Brakes.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease electric motors if required.

X

Inspect motor brake adjustments.

X

Inspect oil level.

X

4.4.5  Pneumatic System

  Task ID.

Inspect vacuum filters

Inspect all pneumatic cylinder mounts.

Clean vacuum filters

Test all pneumatic cylinders for air leaks.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

Inspect the pneumatic service unit.

Inspect valves

Test pressure and inspect sensor switch settings.

Inspect all regulators and settings.

X

X

X

X

4.6 Taping Machine Maintenance Schedule

4.6.1 Bearings and Bushes

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease linear bearings.

X

Inspect bushes.

Inspect and Grease bearings, as applicable.

X

Inspect linear bearing tracks.

X

X

Inspect linear bearing bolts.

X

Grease spherical ball ends where applicable.

X

4.6.2.  Motors, Gearboxes, & Brakes.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease electric motors if required.

X

Inspect motor brake adjustments.

X

Inspect oil level.

X

4.6.3.  Belts and Pulleys/Chains and Sprockets.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect for product build up

X

Inspect chain and sprockets.

X

Inspect belts and pulleys.

X

Inspect belt/chain tension

Inspect belt/chain alignment.

X

X

4.6.4 Chassis and Fasteners

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect all nuts and Bolts

X

Inspect for product build up.

X

Inspect for stress fatigue fractures

X

4.6.5 Pneumatic System

  Task ID.

Inspect vacuum filters

Inspect all pneumatic cylinder mounts.

Clean vacuum filters

Inspect the pneumatic service unit.

Inspect valves

Test pressure and inspect sensor switch settings.

Inspect all regulators and settings.

Test all pneumatic cylinders for air leaks.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

X

X

X

X

4.6.6 Cutter Blade

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Blade Inspection

X

Blade Replacement

X

Cleaning and Lubrication

X

Tightening Check

X

4.6.7 Roller

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Roller Adhesive Check

X

Roller Movement Check

X

Roller Replacement

X

4.6.8 Tap Head

  Task ID.

Check smooth rotation of tap head

Inspect brush mechanism

Check collet/chuck tightness

Inspect gear teeth for wear or damage

Check spring tension & clutch operation

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

X

Lubricate gears, shafts, and moving parts

Inspect overall wear of gears, bearings, springs

X

X

4.5 Power Roller Conveyor Maintenance Schedule

4.5.1 Bearings, Bushes and Cam Tracks.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

Grease linear bearings.

X

Inspect bushes.

Inspect cam tracks

Inspect and Grease bearings, as applicable.

Inspect linear bearing tracks.

X

X

Inspect linear bearing bolts.

Grease spherical ball ends where applicable.

6 Monthly

X

X

X

X

4.5.2.  Motors, Gearboxes, & Brakes.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Grease electric motors if required.

X

Inspect motor brake adjustments.

X

Inspect oil level.

X

4.5.3 Belts and Pulleys/Chains and Sprockets.

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect for product build up

X

Inspect chain and sprockets.

X

Inspect belts and pulleys.

X

Inspect belt/chain tension

Inspect belt/chain alignment.

X

X

4.5.4 Pneumatic and Vacuum System

  Task ID.

Inspect vacuum filters

Clean vacuum cups

Inspect all pneumatic cylinder mounts.

Clean vacuum filters

Inspect the pneumatic service unit.

Inspect valves

Test pressure and inspect sensor switch settings.

Inspect all regulators and settings.

Test all pneumatic cylinders for air leaks.

Test all pneumatic cylinders for air leaks.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

X

X

X

X

X

X

X

X

X

X

4.5.5 Chassis and Fasteners

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Inspect all nuts and Bolts

X

Inspect for product build up.

X

Inspect for stress fatigue fractures

X

4.5.6 Roller

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Roller Adhesive Check

X

Roller Movement Check

X

Roller Replacement

X

4.7 Enclosure Maintenance Schedule

  Task ID.

Daily.

Weekly.

Monthly.

3 Monthly

6 Monthly

Clean photo eyes, reflectors and proximity sensors

X

Inspect the fan filter in control console (if fitted).

X

Inspect proximity switch adjustments.

X

Inspect reed switches.

X

Inspect mechanical switches.

X

Inspect the PLC battery indicator.

X

Inspect the PLC battery indicator.

X

Inspect all other switches and buttons.

X

Test 24-volt DC supplies for adjustment.

X

All cabinet wiring shall be inspected prior to power up

X

X

Random ferrule tagging visual check, should be clear and readable

Random Point to Point (resistance test)

X

Random Point to Ground (resistance test)

X

Earth bonding test shall not execute 0.1 ohms between bounded item and earth bus bar, use megger to check earthing

X

Randomly check the wiring for proper crimping & termination (Tug test)

X

Check the cabinet are connected to a suitable earthing point in the FAT premise

X

Check all MCB's for the correct rating protection (refer to Electrical Drawing)

X

Switch ON circuit breaker 'MCB', check voltage on its output terminals.

X

Ensure no alarm on the IO modules after power up of the 24V DC field power supply

X

For each type of power feed, measure voltage & total system current with system "No-Load" condition and record the results

X

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