Conveyor maintenance manual FlexLink conveyors XS, XL, XM, XH, XK, XB Contents General safety and design considerations ................. 2 Introduction ........................................................... 2 Maintenance............................................................... 4 System maintenance............................................. 4 Maintenance instructions ...................................... 4 Introduction to drive units ......................................
General safety and design considerations Introduction Critical factor • To achieve an operational installation which is reasonably safe for all people involved in its use and maintenance, it is necessary to consider certain aspects. This is done when designing a conveyor system. The chain is generally the critical factor to consider with guarding.
Introduction (continued) Special considerations Horizontal bend drive unit When correctly applied, the FlexLink family of components are safe to use and maintain. It is however necessary for those responsible for design, installation, operation and maintenance of the FlexLink installation to be aware of certain areas where special attention is required.
Maintenance System maintenance Introduction Safety considerations The following section is designed to offer assistance for your planned maintenance schedule. It may become evident that the suggested maintenance intervals can be extended to accommodate your local environmental conditions. Maintenance of the FlexLink conveyor systems should only be carried out by competent persons, who are familiar with FlexLink equipment.
Introduction to drive units Four types Catenary drive units There are four different types of drive unit: end drive units, intermediate drive units, catenary drive units and horizontal bend drive units. End drive units Catenary drive unit without return chain, located at an intermediate position along the conveyor. Horizontal bend drive units End drive unit with return chain, located at the ‘pulling’ end of the conveyor.
Slip clutch adjustment Old and new versions The slip clutch is available in two versions. Shipping of the new version began in 2001. Adjustment of both versions are described here. Introduction The slip clutch on the drive unit is a safety device which allows the chain to stop if the load becomes excessive.
Slip clutch adjustment (continued) Clutch adjustment, new type Traction force, Fmax (N) No. 2 3 1 1 Remove the drive unit protection cover. 2 Use an Allen key, 3 mm, to loosen the screw (1) on the slip clutch so that the adjustment nut (2) can be freely rotated. 3 Turn the adjustment nut (2) clockwise with a hook spanner until the arrow on the nut is aligned with the desired Fmax value (3). See the following table for correct values.
Inspection – drive units Roller chain transmission • Loose disposable guides in plastic. The roller chain transmission should be checked and lubricated after 50, 250, 500 hours of operation, and then every 500 hours. If the roller chain transmission is not fitted with a chain tensioner the chain tension should be checked on this occasion. At the same time as the roller chain tension is checked, the chain must also be lubricated with a suitable chain spray or similar.
Inspection – conveyor chains Conveyor chains Cleated, friction and wedge chains The most common types of conveyor chains are: Cleated chains, friction chains and wedge chains, or other special chains should be inspected regularly, and any defective links replaced or cleaned. • Plain conveyor chains. . Warning Only warm water (50°C), with soap if necessary, may be used for cleaning conveyor chains. • Check the guards on cleated chain conveyors.
Inspection – conveyor chains (continued) Important: The chain should therefore be pre-tensioned while the conveyor is stationary, but must never be so tight that there is no slack during operation. There should be no appreciable slack on the chain when the conveyor is stationary. This can, however, vary depending on the total length of the chain. If there is too much slack, there will be excessive wear on the chain guides and the chain. This could be a risk for injury.
Inspection – slide rails, beams, idlers, bends Checking slide rails The condition of the slide rails is fundamental to the functioning of the installation. It is therefore essential that these are in good condition. Checking the slide rail with the conveyor chain in place The slide rail must be checked after every 250 hours’ operation. Carry on the checking on a stationary conveyor with the chain in place. • Check the fastening points on the slide rail. • Check the joints on the slide rail.
Inspection – safety devices Protective and safety devices Safety devices should be checked at regular intervals. • Check the chain guard for roller chain transmission. This guard must always be in place when the conveyor is in motion. • Check the protective cover on the cleated chain conveyor return chain. • Drive units type H, have a slack protection for the conveyor chain. Check that the slack protection plates are in place, and that the chain does not slacken enough to hang below the plates.
Replacement of worn parts – conveyor chain Removal of conveyor chain 1 Ensure that the power to the drive motor is disconnected. 2 Disengage the motor; there are various methods depending on the type of drive unit: — Detach the slip clutch. — Remove the roller chain. — Disengage the gear from the drive wheel. 3 Split the chain by removing the steel pin from the pivot. Use the special tool for insertion/removal. 4 Pull out the chain.
Replacement of worn parts – slide rails Replacing slide rails It is very important to assemble slide rails correctly to ensure smooth system operation. Follow the illustrated instructions on the following pages carefully. Observe the following points: • Single-cut pliers are suitable tools for cutting the slide rails. • Use a high quality drill bit to avoid forming a shoulder, preferably one which is intended for drilling aluminium. • Use XLAH 4×6/XLAH 3×6 rivets.
Anchoring slide rail Fixing slide rail to the conveyor beam Hand drill Drill fixture for slide rail 4,2 mm (XS: 3,2 mm) Countersink The beginning of each slide rail section must be fixed to the beam, since the chain will cause the slide rail to be pushed forward. Slide rail which moves into a wheel bend or a drive unit can block the chain completely. There are two different methods for fixing slide rail to the conveyor beam: using aluminium rivets or plastic screws.
Anchoring slide rail (continued) Method 2: Using plastic screws Pliers/screwdriver Knife Hammer Plastic screws XLAG 5 An alternative to aluminium rivets is to use plastic screws XLAG 5: Mounting: 3 Make sure the slide rail surface is smooth and that screws do not protrude over the surface of the slide rail. If the surface should be uneven, file the edges smooth. Check both top and underneath surface of slide rail for protruding plastic or metal.
Troubleshooting Jerky running Noise Cause Corrective action Cause Corrective action Damaged or badly fitted slide rail Inspect and replace as necessary. Worn or damaged bearings in drive unit Check/replace drive unit. Wrongly adjusted slip clutch Check and adjust slip clutch. Damaged/badly fitted slide Check the free running of the conveyor rail chain, especially in slide rail joints. Worn transmission parts Check/replace transmission chain, chain drive sprocket.
Checklist/maintenance schedule No. 1. 2. 3. 4. 5. 6. 7. 8. 18 General checks Check roller chain, sprocket, chain tension and lubrication of drive unit Check/adjustment of slip clutch Check conveyor chain guides in drive units and idler ends Check tension of conveyor chain Check slide rails Check slide rails, conveyor chain removed. Check slide rails in plain bends.
System dismantling and disposal Important safety precautions Dismantling Dismantling of the FlexLink conveyor system should be carried out by competent persons, who are familiar with the equipment being decommissioned. In the absence of detailed information, every care should be taken to ensure that all items are securely retained during the decommissioning process. This is to ensure that the equipment remains stable and will not fall if left unattended.
