Installation & Maintenance Manual

For parts/service/support inquiries, please provide the serial number. The serial number tag is typically located next to the drive unit.

Machinery

General Conveyor Co. Ltd.

Innovative Solutions in Motion

General Conveyor Co. Ltd.245 Industrial Parkway South, P.O. Box 610, Aurora, Ontario CANADA L4G 4J9

Tel: (905) 727-7922 Fax: (905) 841-1056Service: 1-888-927-7922 Email: gcc@gccl.com

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Putting the pieces together.Putting the pieces together from individual pieces of equipment to complete system integration, we can provide the missing pieces of the puzzle to make your system complete.

Celebrating 60 years in business, General Conveyor Co. Ltd. has been delivering Innovative Solutions in Motion to customers worldwide. Our product line includes conveyors, machinery, systems integration, distributed equipment as well as parts and service.

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TTaabbllee ooff CCoonntteennttss Company Profile Identifying and Understanding Equipment Labels Equipment Maintenance Safety Sample Lockout/Tagout Procedure Safety Regulations Receiving Your Equipment Warranty Activation Service Installation and Pre-start Considerations Preventative Maintenance Schedule Incidental Maintenance and Troubleshooting

Conveyors Air Belt Case Roller Mattop Pallet Roller Roller Chain - for environments where lubrication is permitted Roller Chain - for high radiation zone components Table Top

Machines Dip Tanks (Water Baths) Pallet Dispenser - RA10 Compact Dispensers Pallet Dispenser - RA20 Stacker/Destacker Palletizers Slat Diverters Slip Sheet Extractors

Components Bearings Case/Bag Turner Assemblies Motors and Reducers Pneumatic and Vacuum Devices

(valves, cylinders, air bags, vacuum generators/pumps, suction cups) Roller Pop-up Assemblies Wear Bars and Slide Shoes

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CCoommppaannyy PPrrooffiillee Founded in 1949, General Conveyor Co. Ltd. is a privately owned Canadian company based in Aurora, Ontario - about 20 minutes north of Toronto. The GCCL product line includes all types of conveyor systems, packaging machinery, palletizer/depalletizer equipment, robotic automation, innovative system integration, advanced technology distribution, qualified technical support, and service of all supplied equipment. Our primary focus is in the food, personal care, pharmaceutical, beverage, irradiation, plastics and warehousing industries. General Conveyor's reputation for providing high performance products and service translates to satisfied customers worldwide. GCCLs serious, ongoing commitment and investment in advanced technology and manufacturing methods ensures minimal waste, superior quality, lower costs, and competitive value. Capabilities include:

Mechanical, Electrical, Controls, and Applications Engineering Custom control panel building Mechanical and Electrical site service and equipment installations/removals Full scope, in-house system testing with customer materials Substantial and responsive spare parts supply Full service metal fabrication, certified welding, and industrial coatings

From complete packaging lines to single conveyors, General Conveyor is your one source for reliable solutions. With our excellent combination of experience and technology, we can meet all of your material handling needs. Call on General Conveyor today!

245 Industrial Parkway South, P.O. Box 610

Aurora, Ontario L4G 4J9 Canada Tel: (905) 727-7922 Fax: (905) 841-1056 Service: 1-888-927-7922

Email: gcc@gccl.com Website: www.gccl.com

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IIddeennttiiffyyiinngg aanndd UUnnddeerrssttaannddiinngg EEqquuiippmmeenntt LLaabbeellss Various standard labels will be placed on your equipment depending on the features and dangers that may be associated with certain components. These serve both to alert personnel of potential hazards, and to identify key equipment information. Finding Your Serial Number and Model Information Each major component of a system or piece of individual equipment will feature a unique product label. This information should be recorded and provided when referencing the equipment, or contacting General Conveyor with enquiries. Serial #: - This is the identifying number for your equipment. If this equipment is part of a larger system that was built simultaneously, it may be universal to an entire section of similar components. Alternatively it may be unique to the specific machine, depending on the design of the system. Model #: - This is the unique identifying number for the specific machine, section, or major component to which it is attached. If drawings are included with your documentation package, this will be the main assembly drawing number containing the specific piece of equipment.

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Mechanical Hazard Labels Note: Other manufacturers labels may also appear in some cases. Please consult all documentation included with your equipment and familiarize personnel with all labels.

Placed near guarding

Placed near mechanical joints and pinch points

Placed near components that may start automatically

Placed on accessible sections of conveyor that should not be

crossed

Placed where chain slack may be accessible

Placed near major pneumatic components or connections

Electrical Hazard Labels Note: Other manufacturers labels may also appear in some cases. Please consult all documentation included with your equipment and familiarize personnel with all labels.

Placed on electrical enclosures

Placed near electrical disconnect points

Placed on enclosures housing more than one source of energy.

This may be electrical, pneumatic, hydraulic, etc.

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EEqquuiippmmeenntt MMaaiinntteennaannccee SSaaffeettyy A number of important safety features have been incorporated into the design of this equipment to reduce the risk of injury. However, equipment designed for automated purposes poses risk of serious injury or death in the event that the equipment is not operated or maintained as intended. The end user is responsible for approving and operating the equipment in a safe and lawful manner in compliance with applicable health and safety regulations. Compliance with safety standards, including OSHA and other Federal, Provincial, State and local codes or regulations is the responsibility of the equipments end user. Placement of guards and other safety components or devices in accordance with safety standards is dependent upon the area and use in which the equipment is installed and operated. The following Safety Considerations, stated as examples only, cover various types of GCCL supplied equipment and may or may not apply to the specific equipment that this Equipment Manual package accompanies. Employee training and familiarization with the supplied equipment is recommended during installation/commissioning and at regular intervals thereafter. All personnel who will operate, maintain, or come into contact with this equipment should read the complete Equipment Manual before interacting with it. Electrical & Pneumatic Lock-out Electrical and pneumatic lockout procedures shall be adhered to according to the end users in-house safety strategies. Access Guards Access guards have been provided to limit access to moving or rotating components. All fixed access guards shall remain fastened to the machinery during operation. Warning Labels Various warning labels are fastened to the equipment to alert personnel of potential safety risks or hazards. It is the end users responsibility to ensure these labels are visible to personnel interacting with the equipment. These labels should never be removed, defaced or covered up. Pinch & Catch Points Pinch points exist where moving equipment components meet with other moving or stationary equipment components. Furthermore, some equipment may contain large openings between components or parts that create potential catch points. All personnel interacting with the equipment must be aware of potential catch and pinch point hazards, as hair, apendages or clothing can become trapped in these areas. Lifting Mechanisms Before performing any inspection, maintenance or adjustment in the general area of any lift assembly, ensure the lift carriage is located, and supported at the appropriately Safe position. Carry out both of the following methods of carriage supporting with electrical and pneumatic lockout procedures according to end user in-house safety strategies. For equipment supplied with a Safety Pin, the carriage shall be located at the labeled Safety Pin Position, and the Safety Pin inserted to provide mechanical support, negating carriage freefall (examples include Palletizer, Depalletizer). Where a Safety Pin is not used, the lifting mechanism shall be raised to its highest position of travel. Block any downward vertical movement by inserting approved support beams under either side of the lifting carriage. Ensure the carriage structure finally rests firmly on top of the secured, supporting beams. The carriage must be resting on the inserted support beams to prevent any free fall (examples include Sheet Tower Systems, RA20 Pallet Stacker/Destacker).

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Sheet Storage Towers The sheet storage drawers supplied with these systems are maintained in "home" position by magnets and spring-loaded drawer stops. DO NOT climb on the front or rear drawer faces, as the drawers may disengage from their holding magnets. DO NOT enter the caged area of the lifting carriage until a visual check has been completed to ensure all drawers are in the "home" position, engaging their holding magnets, and all spring-loaded drawer stops are properly closed. If any drawer needs to be manually secured to a "home" position magnet; approach and adjust from the rear face of the tower when safe, prior to entering the caged area.

SSaammppllee LLoocckkoouutt//TTaaggoouutt PPrroocceedduurree A practiced, standardized procedure for the safe control of energy and equipment is a key component of working safely. If your company already has a LOCKOUT/TAGOUT procedure in place it should be followed instead. This procedure is only a guideline if no other lockout/tagout procedure exists, and can not account for all hazards that may be present in your work environment. There is no substitute for a well understood procedure that addresses concerns specific to your facility. Always consult your supervisor or health and safety representative to ensure safe work practice is followed. General Responsibilities

1. The employer shall provide information, instruction and supervision to workers on proper lockout procedures for each piece of equipment they will be operating.

2. An initial review should be made to determine which switches, valves, or other energy isolating devices apply to the equipment being locked out. More than one energy source (electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravitational) may be involved.

3. The employer should ensure that workers know which energy sources may need to be controlled. Workers should check with a supervisor or other knowledgeable person if in doubt about which energy sources may need to be controlled.

4. When equipment is to be locked out, employers, supervisors and workers should follow accepted lockout principles, including:

Pre-planning for the lockout by identifying all energy sources, switches, etc. Where lockout is complex, a written sequence in checklist form should be prepared for

equipment access, lockout/tagout, clearance, release and start-up. All workers affected by the lockout should be notified. Equipment should be shut down by normal means by turning of switches and closing valves etc. Equipment should be isolated from energy sources by disconnecting or blocking the sources of

energy. Lockout and tag the energy isolating devices by padlock or some other locking device that the

worker has control over as well as a tag indicating that the equipment has been shut down. Verify that all energy sources have been isolated by attempting to cycle the equipment prior to

working on it. When work is completed, release equipment from lockout. Test equipment.

Preparation

1. Notify all affected workers that a lockout is required and the reason for the lockout.

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Machine or Equipment Shutdown and Isolation 1. If the equipment is operating, shut it down by the normal stopping procedure (depress stop button,

open toggle switch, etc.). Only workers knowledgeable in the operation of the specific equipment should perform shutdown or re-start procedures.

2. Operate the energy-isolating device(s) so that all energy sources (electrical, mechanical, hydraulic, etc.) are disconnected or isolated from the equipment.

3. Electrical disconnect switches should never be pulled while under load, because of the possibility of arcing or even explosion.

4. Stored energy, such as that in capacitors, springs, elevated machine parts, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc., must also be released, disconnected, or restrained by methods such as grounding, repositioning, blocking or bleeding-down.

5. Pulling fuses is not a substitute for locking out. A pulled fuse is no guarantee the circuit is dead. Even if a circuit is dead, another person could inadvertently replace the fuse.

6. Equipment that operates intermittently, such as a pump, blower, fan or compressor may seem harmless when it is not running. Do not assume that because equipment is not operating at a particular point in time that it will remain off for the duration of any work to be performed on it.

Application of Lockout/Tagout

1. Lock out and tag the energy-isolating device with an assigned, individual lock. A worker will not be protected unless he/she uses his/her own padlock.

2. If more than one worker is working on the same piece of equipment at the same time, each one should lock out the equipment, by placing a personal lock and tag on the group lockout device when he/she begins work, and should remove those devices when he/she stops working on the machine or equipment.

3. Locks and tags should clearly show the name of the person who applied the device, the date, and the reason for the lockout. This identifies who is servicing the machinery or equipment. In a multiple lockout/tagout situation, it will also identify any worker(s) who may not have finished working.

4. Locks and tags must be durable enough to withstand the environment in which they are to be used. Information on the locks and tags should remain legible.

5. Locks must be substantial enough to prevent removal without the use of excessive force. Tags must be substantial enough to prevent accidental or inadvertent removal.

6. Both locks and tags are to be standardized by colour, shape, or size. Tags should be easily recognized and provide appropriate information about the lockout.

7. For some equipment it may be necessary to construct attachments to which locks can be applied. An example is a common hasp to cover an operating button. Tags must be attached to the energy isolating device(s) and to the normal operating control in such a manner as to prevent operation during the lockout.

Verification of Isolation

1. After ensuring that no workers can be injured, operate the push button or other normal controls to verify that all energy sources have been disconnected and the equipment will not operate.

2. If there is a possibility of re-accumulation of stored energy, such as an increase in pressure to a hazardous level, isolation of the equipment must be periodically verified until the maintenance or repair is completed, or until the possibility of such accumulation no longer exists.

3. Return operating controls to neutral position after the test. A check of system activation (e.g. use of voltmeter for electrical circuits) should be performed to ensure isolation.

4. The equipment is now locked out.

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Lockout/Tagout Interruption 1. If a machine is locked/tagged and there is a need for testing or positioning of the equipment/process,

the following steps should be followed: Clear the equipment/process of tools and materials. Ensure workers are a safe distance from any potential hazard. Remove locks/tags according to established procedure. Proceed with test. De-energize all systems and re-lock/re-tag the controls before resuming work.

Release From Lockout/Tagout

1. Before locks and tags are removed and energy is restored to the machine or equipment, inspect the work area to ensure that non-essential items have been removed and that machine or equipment components are operationally intact.

2. Ensure workers are a safe distance from any potential hazard. 3. Each lock and tag should be removed from each energy-isolating device by the worker who applied the

lock and tag. 4. Notify affected workers that locks and tags have been removed.

Lockout for Hydraulic Systems

1. Workers should always follow instructions in the operator's manual for servicing hydraulic systems. Where appropriate, a properly qualified and certified mechanic should perform repairs and maintenance.

2. Shut off the motor that powers the hydraulic pump. 3. Lower equipment onto a solid support. 4. Actuate the hydraulics several times to relieve pressure. 5. When applicable, blanking (supporting) devices should be used.

SSaaffeettyy RReegguullaattiioonnss General Conveyor is a manufacturer of quality equipment which meets and exceeds the requirements for safety and protection. By default, all equipment is designed to comply with the strict regulations set in place by the Canadian Standards Association CSA Z432-04, and CSA Z142 for machine guarding. Equipment shipping outside of Canada will be designed to comply with customer local regulations, as they may apply. All guarding and safety related components must be maintained and installed as they are intended, for equipment to operate safely and continue to comply with safety regulations. No machine should ever operate with guarding equipment that has been tampered with or removed. Health and safety regulations change constantly to reflect new practices and technology in industry. To ensure equipment remains compliant, it is recommended that customers contact General Conveyor on an annual basis to review guarding and safety requirements as they may have changed from the time of original equipment purchase. General Conveyor works with customers to ensure equipment is sold safe, and continues to remain safe throughout the lifecycle.

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RReecceeiivviinngg YYoouurr EEqquuiippmmeenntt Checking Your Shipment Verify with the bill of lading that all listed crates and packages are accounted for, being careful to mark down the condition of shrink-wrapping and enclosing material. Any discrepancies should be immediately brought to the deliverers attention, recorded on the bill of lading, and photographed. Unloading And Moving General Conveyor equipment ships on standardized crating or skids. These skids are designed to be commonly handled by forklift, from either end. Consider the following when unloading:

Consult your internal policy for proper unloading and handling procedures.

Always wear appropriate Personal Protective Equipment (PPE).

Use caution as the load may have shifted during transportation.

Inspecting Your Equipment All items included with your shipment will be listed on the packing slip, located within your documentation package. Verify that all components listed on the packing slip, and bill of lading are present. Take the time to thoroughly inspect your equipment for damage that may have occurred during or after shipping. This is the first step in accepting your equipment and activating your warranty.

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WWaarrrraannttyy AAccttiivvaattiioonn General Conveyor guarantees all new equipment manufactured by General Conveyor to be free from defects in material and workmanship for a period of 2080 hours of operation, or one year from the date of shipment (whichever occurs first). Provided that:

Equipment being purchased is new, or warranty has been included in the purchase agreement. The proper procedure for product acceptance and warranty activation has been completed in a timely

manner. The conditions of the Warranty Certificate have been fulfilled.

To Activate Your Warranty The completed equipment inspection form must be signed, dated, and faxed to General Conveyor (contact information on rear of this manual). General Conveyor will inspect the document for completion and review any discrepancies. If there are discrepancies to be addressed, warranty activation will be delayed until they are resolved and equipment is found to be fit. Upon receipt of the acceptable equipment inspection form, General Conveyor will send the warranty certificate. This certificate must be completed, signed, and faxed to General Conveyor in a timely manner. The warranty does not become active until General Conveyor confirms receipt of the completed and signed warranty certificate.

SSeerrvviiccee General Conveyor maintains a staff of factory-trained mechanical and electrical controls technicians. Our service and installation staff are available 24/7 to meet your needs. This includes installation, commissioning, maintenance, and retrofitting of new and existing General Conveyor, or third party equipment. Canadian and United States service rates are outlined below. For other international locations, service rates will be negotiated on a per-customer basis. Any enquiries are welcome and may be made to General Conveyor Sales Department.

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IInnssttaallllaattiioonn aanndd PPrree--SSttaarrtt CCoonnssiiddeerraattiioonnss Installation Surface When installing equipment, ensure that all foot-pad surfaces are free of debris. Floor or mounting surfaces should be of stable material which will not chip or come loose during installation or operation. For large equipment, the mounting surface must allow for a level equipment placement. Leveling feet are for minor adjustment only. Ensure that the mounting surface is in suitable condition to allow for lagging of all feet, and to withstand the forces experienced during machine operation. Conveyors must be level before operation to allow proper tracking of the belt, and free operation of rollers. Equipment provided on rolling casters must be operated on a level surface, and with caster brakes engaged. Check for interference with nearby machinery once the equipment is located, prior to lagging or fastening. Headroom When equipment is installed above passageways, exits, aisles, or corridors, there should be a minimum clearance of 2m (6ft 8in) vertically from the floor or walking surface to the lowest part of the equipment or guarding. In cases where system function will be impaired by providing this minimum clearance, it is acceptable to allow passage under the equipment with lower headroom so long as a Low Headroom warning label is applied in easy view, and the equipment is visibly marked. In this case an alternate passageway must be provided. The equipment may not however, block any emergency exits. Any changes to passageways must be inspected to comply with local fire and emergency exit code. Pre-Start Health and Safety Review (PHSR) All equipment is required to be inspected and pass a Pre-Start Health and Safety Review before it may be used. This process must be completed by the end-user and will vary based on local code. Should any issues be revealed during the PHSR process, contact General Conveyor immediately for recommendations and solutions. Do not use the equipment before a PHSR has been performed, and passed. Prior to starting any equipment, the following must be verified:

Proper, secure installation of equipment All packaging has been removed All guarding is in place and is secure All pop-out rollers are in place and move freely without binding A check for any loose hardware has been performed A PHSR has been performed and passed The system is free of debris which may hinder its operation Safety interlock devices are in place

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PPrreevveennttaattiivvee MMaaiinntteennaannccee SScchheedduullee NOTE: Before accessing or addressing any components on the supplied equipment, ensure in-house safety strategies are upheld and ample time has lapsed for any heat producing components to cool. Daily While the system is in operation, check the following issues and refer to all relevant safety warnings and information:

Regularly walk around both sides of the system and note the condition, as well as any unusual behavior of all he moving components.

Note points of material buildup. Look for any signs of misalignment or improper belt tracking. Check drive amperage requirements and compare amperages to previous. Check motors for increase or excessive temperature rise as specified by the manufacturer. Test control equipment.

Check the following while system is at rest and with any applicable potential sources locked out:

Confirm that components are in proper alignment and make necessary adjustments. Closely inspect suspect components and take corrective action as appropriate. Check all safety systems. Inspect belting material and lacing for surface wear and frayed edge. Check for damage or wear at loading and transfer points. Remove any material build up on components and clean-up any spills along the system. Note: the causes

of such should be investigated and corrected. Check the condition and functionality of belt and adjust or replace as needed. Confirm that all guards and covers are in place. Check and replace all broken or missing drive bands. If conveyor is equipped with pneumatic units, drain the air filter. Check roller tubes for dents. Examine chain wear and check for chain cracks. Inspect bearings for mounting bolts and check if setscrew is loose. Ensure lead-screw and linear guide surfaces are lubricated.

Weekly

Look for damage to conduit and wiring. Look for evidence of lubricant leakage from gear case. Check for proper oil level. Look for damage to motor and reducer housings. Remove any accumulated debris from beneath the surfaces of the conveyor. Check if belt tension and belt lacing is secure. Check conveyor chain for elongation. Inspect wear strip sections for excessive wear and uneven scoring, and replace as necessary.

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Monthly With the conveyor running, listen for abnormal noise coming from rollers, tabletop chain, belt, pulleys &

bearings. With the conveyor running, look for damage to belt or belt lacing. Check all drive motors by jogging units to ensure mounting bolts are tight. Check hold-down bolts and lagging to ensure equipment will not come loose from floor hold down

devices. Inspect electrical cable to ensure that cable is not pulling out from a cable connector. Check all electrical conduit and fittings. Monitor dust build up on all non-mechanical triggered sensors and remove as necessary. Re-lubricate all pillow block bearings per the manufacturers schedule or the specific requirements of the

installation. Inspect all rollers.

Semi-annually

Monitor dust build up on and inside electrical panels and remove as necessary. Inspect wires for discoloration. Look for burned wiring and loose terminal connections. With the conveyor running, detect excessive vibration from bearings or gears. Listen for evidence of wear or damage to internal parts. Adjust motor mechanical brake per vendor documentation.

Annually Contact General Conveyor to ensure equipment complies with current safety standards for guarding, as these standards may have changed from the time of original equipment purchase. Operating Time

Inspect all motors every 500 hours of operation. Check drive element set screws for tightness, and ensure the sprocket always rotates clear of the

reducer face. Keep the motor clean and the ventilation openings clear. Inspect the motor and reducer for leakage, accumulation of dirt, oil, and grease. Check motors for excessive temperature. Every 10,000 hours, check motor ball bearings and replace if necessary. Replace oil seal and clean oil

passages. See Vendor Documentation for further information on oil change intervals, dependent upon application

and use. Adjust mechanical brakes per vendor documentation.

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IInncciiddeennttaall MMaaiinntteennaannccee aanndd TTrroouubblleesshhoooottiinngg The following discusses important factors to consider for the regular maintenance of listed equipment, as installed in an atmosphere free of extreme temperatures, or other notably extreme conditions. Always ensure the equipment and surrounding areas are kept clean and free of debris to promote life expectancy. Daily equipment visual and audible inspections should be performed to check for oil and pneumatic leaks, hardware security and unusual operating noises or tones. The following information is intended for use as a guideline only. If any other specific maintenance information is required, please contact General Conveyor directly for further maintenance recommendations of supplied components. NOTE: Before accessing or addressing any components on the supplied equipment, ensure in-house safety strategies are upheld and ample time has lapsed for any heat producing components to cool. Conveyors : Air Air conveyor (or air deck) must be kept clean and free of debris to operate efficiently. Any debris buildup on the louvered surface, or on guiding rails may cause increased friction and hinder operation. Louvers must not be damaged, as they direct air flow to cause product transport.

Problem Possible Cause Action Product jamming Guiderail is not adjusted

correctly or may have burrs Check guiderail adjustment is close to product and does not allow twisting or jamming. File any burrs smooth.

Product stopping or moving slowly

Airflow is being restricted or baffles are out of place

Clean airflow path including any blocked louvers, check blower flow. Check that baffles are in place and hardware is secure. Ensure that there are no leaks.

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Conveyors: Belt Belts and belt conveyor must be kept clean and free of debris to operate efficiently. Belts should be free of visible tears or cracks. Edges should be neat and free of fraying, as this indicates improper wearing. Pulleys should be tensioned enough only to fully engage the belt along the contact surface and move the load, without over-stressing the belting material. Ensure the belt is always properly tracked, especially after maintenance work or major fluctuation in operating temperature or humidity.

Problem Possible Cause Action Belt slips and fails to move a load

Improper belt tension or debris on rollers

Re-track belt. Check rollers for debris limiting belt traction.

Belt does not stay centered on rollers

Improper belt tracking Re-track belt.

Belt edges are frayed or torn

Improper belt tracking, or belt is worn out

Re-track belt. If wear is excessive, replace belt.

Belt is tearing or lacing is failing

Belt tension is too high or conveyor bed has burrs

Re-track belt. Check conveyor bed and rollers for burrs or debris.

Conveyors: Case Roller Case roller conveyor typically utilizes plastic sprocket fitted tubular rollers. Sprockets should not be excessively worn or missing teeth, and rollers should not be dented or warped. Wear is to be expected in more areas than others along the roller length, as the product bottom profile may contact only specific places. Roller life will be longer for products with more even contact area along the bottom profile. Bearings in these roller assemblies are generally lubricated for life and therefore do not require supplemental lubrication.

Problem Possible Cause Action Roller slips or skips Roller chain has stretched or

sprocket teeth are worn Remove a chain link or replace the roller chain. Replace the roller if teeth are excessively worn.

Roller is bent Roller has been loaded unevenly or impacted

Replace affected roller(s)

Roller does not rotate freely

Bearing has worn out or shaft is bent

If bearing does not rotate freely, replace the roller. If shaft is bent, replace shaft if it is removable, or replace roller assembly.

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Conveyors: Mattop Mattop conveyor should be kept clean and free of debris. Dirt and debris are abrasive and will reduce the life of the conveyor. Broken or excessively worn belt sections should be replaced immediately. Transitions and catenary supports should be free of dust or residue buildup after the first 30 days of operation. Wear strips should not be excessively worn or unevenly gouged/worn. Sprocket teeth should not be worn, and should engage the belting evenly without skipping.

Problem Possible Cause Action Conveyor is surging during operation

Belt has stretched Remove link from catenary.

Residue buildup or belt catching

Uneven transition or wear strip is worn out

Smooth belt transitions or replace excessively worn wear strip.

Drive is skipping Worn drive sprocket or excessive chain slack

Check for worn or missing teeth on drive sprocket and replace if necessary. Remove links causing excessive chain slack.

Conveyors: Pallet Roller Pallet roller conveyor must be kept clean and free of debris. Because of the heavy nature of most product transported, it is important to keep guarding and guiding in good condition, clear from interfering with sprockets or rollers, causing early component failure. Sprockets should be in good condition, free of missing teeth or excessive wear. Roller chain should be well lubricated.

Problem Possible Cause Action Roller slips or skips Roller chain has stretched or

sprocket teeth are worn Remove a chain link or replace the roller chain. Replace the roller if teeth are excessively worn.

Roller is bent Roller has been loaded unevenly or impacted

Replace affected roller(s)

Roller does not rotate freely

Bearing has worn out or shaft is bent

If bearing does not rotate freely, replace the roller. If shaft is bent, replace shaft if it is removable, or replace roller assembly.

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Conveyors: Roller Chain For Environments Where Lubrication Is Permitted Roller chain conveyor wear bars, chain, and sprockets must be kept free of abrasive debris which will decrease component life. The roller chain must be kept well lubricated and should be inspected often for uneven wearing, and chain stretch. Stainless steel chain is softer than mild steel and must therefore be maintained more frequently.

Problem Possible Cause Action Chain skips off guide/wear bars

sprockets/wearbars are out of alignment

Align sprockets with wearbars and ensure a smooth, level transition from sprocket to wearbar.

Chain is surging or skipping

Excessive slack or chain has stretched

Adjust chain tensioner or remove an appropriate amount of chain links. If chain is excessively worn, replace the entire chain section.

Chain is binding Links are damaged Replace damaged links. If the chain is excessively worn, replace the entire chain section.

Conveyors: Roller Chain For High Radiation Zone Components Components that will be subject to high radiation dosing require special treatment, and must be monitored more closely than components intended for standard use. Due to the nature of the operation environment, component life expectancy is much shorter, and can be drastically reduced if not properly maintained. Chain rollers should be inspected daily for any signs of uneven wear. Sprocket teeth should always be kept in good condition, and must be replaced when worn, or risk of further chain damage is increased. Wear bars must not be wearing unevenly, as this suggests other components may be experiencing side loading or other uneven wear. If special lubrication is permitted, special lubrication documentation will be provided as an appendix to this manual.

Problem Possible Cause Action Chain skips off guide/wear bars

sprockets/wearbars are out of alignment

Align sprockets with wearbars and ensure a smooth, level transition from sprocket to wearbar.

Chain is surging or skipping

Excessive slack or chain has stretched

Adjust chain tensioner or remove an appropriate amount of chain links. If chain is worn, replace the entire chain section.

Chain is binding Links are damaged Replace all damaged links. If the chain is worn, replace the entire chain section.

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Conveyors: Table Top Table top conveyor should be kept clean and free of debris. Dirt and debris are abrasive and will reduce the life of the conveyor. Broken or excessively worn belt sections should be replaced immediately. Transitions and catenary supports should be free of dust or residue buildup after the first 30 days of operation. Wear strips should not be excessively worn or unevenly gouged/worn. Sprocket teeth should not be worn, and should engage the belting evenly without skipping.

Problem Possible Cause Action Conveyor is surging during operation

Belt has stretched Remove link from catenary.

Residue buildup or belt catching

Uneven transition or wear strip is worn out

Smooth belt transitions or replace excessively worn wear strip.

Drive is skipping Worn drive sprocket or excessive chain slack

Check for worn or missing teeth on drive sprocket and replace if necessary. Remove links causing excessive chain slack.

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Machines: Dip Tanks (Water Baths) Dip tanks must be kept clean and free of any debris, or components producing debris which may hinder equipment operation, or build up in fluid lines restricting pump operation. Gaskets must be seated squarely and must not be torn or folded. Wear strips and indexing teeth should not be excessively or unevenly worn. If equipped, pre-form handling pins must be perpendicular to the conveyor surface, and must not be deformed or broken. Machines: Pallet Dispensers - RA10 Compact Dispenser RA10 compact pallet dispensers must be kept clean and free of debris. Pallet fingers are crucial load bearing components which must operate freely and relatively simultaneously (some minor differences are acceptable, so long as all fingers collectively reach each limit within 0.5sec). Fasteners holding fingers, finger enclosures, and pallet guides must be secure. The main pallet carriage must operate freely without binding through the entire travel distance, and with minimal backlash. The pallet discharge assembly must operate freely without binding through the entire travel distance, and must not start or stop harshly (proper flow control adjustment). Spring loaded pallet pusher fingers must operate freely without binding, and must not be deformed, bent, or excessively worn.

Problem Possible Cause Action Main carriage not level

Uneven chain stretch or chain has skipped

Remove drive chains, level main carriage and reinstall chains. Adjust chain tension or remove links if necessary. If replacement is necessary, both chains must be replaced.

Fingers do not operate. Solenoid operates

Finger bushing worn or binding. Air pressure is low

Inspect bushing and ensure proper lubrication. Adjust air pressure (not to exceed 5.5bar/80psi).

Pusher fingers do not operate

Finger bushing worn or finger is binding. Spring is misaligned

Inspect bushing and ensure finger is not bent and binding on carriage frame. Ensure spring is properly installed.

Pusher carriage does not return home. Solenoid operates

Forklift impact has shifted dispenser, dispenser is jamming on conveyor deadplate

Realign dispenser and ensure pusher/pusher fingers are not binding on deadplate.

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Machines: Pallet Dispensers - RA20 Stacker/Destacker RA20 pallet stacker/destackers must be kept clean and free of debris. Pallet fingers are crucial load bearing components which must operate freely and relatively simultaneously (some minor differences are acceptable, so long as all fingers collectively reach each limit within 0.5sec). Fasteners holding fingers, finger enclosures, and pallet guides must be secure. The carriage must be level with both lift chains bearing equal load. Pickup arms must be square to each other and should be checked for deformation from overloading weekly. The carriage wear bars are fabricated from hardened steel, and must be kept clean and continuously lubricated.

Problem Possible Cause Action Carriage not level Uneven chain stretch or chain

has skipped Remove drive chains, level main carriage and reinstall chains. Adjust chain tension or remove links if necessary. If replacement is necessary, both chains must be replaced.

Carriage binds Wear bar is not lubricated or bearings are damaged

Ensure bearings rotate freely and are not damaged. Lubricate wear bar.

Fingers do not operate. Solenoid operates

Finger bushing worn or binding. Air pressure is low

Inspect bushing and ensure proper lubrication. Adjust air pressure (not to exceed 5.5bar/80psi).

Pallets bind during operation

Pallet guides are not adjusted. Adjustable arms are not locked

Adjust pallet guides to allow close, unrestricted flow of pallet stack. Lock screw levers after adjusting arms (if equipped).

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Machines: Palletizers Palletizers must be kept clean and free of debris. Wear strips should not be excessively worn or unevenly gouged. Case stops should operate freely and should not stop harshly (flow control adjustment). These systems generally employ several assemblies referred to in this manual. For individual component inspection, please see the specific section covering the applicable equipment. All linear guide or wear bar components must be lubricated. All roller chain components must be lubricated. All drives and drive chains must be tensioned. Magnetic Pickup Carriage Head: Magnetic surface must be kept clean and free of debris, particularly metallic shavings which may stick to the magnets, damaging product and reducing efficiency. Suction Pickup Carriage Head: All suction cups should be at equal length and level, with the exception of those intended for dispensing tier sheets or close-packing product. Assembly drawings will indicate the appropriate configuration and distance. See the Suction cups section under Pneumatic components for further information on suction cup inspection. Vacuum Plate Pickup Carriage Head: The vacuum plate must be kept clean and free of debris. The plate material must not be torn or missing sections which would inhibit proper seal and vacuum with the product surface. Ensure the vacuum plate is kept dry. Replace damaged vacuum plate material immediately, as tears and contamination may spread with continued use. Gripper Finger Pickup Head: Gripper fingers must be square and true. All hardware and key plates must be secure and should not allow fingers to move. Straight fingers secured by locking collars may rotate, but should not have any angular or linear freedom.

Problem Possible Cause Action Carriage not level Uneven chain stretch or chain

has skipped Remove drive chains, level main carriage and reinstall chains. Adjust chain tension or remove links if necessary. If replacement is necessary, both chains must be replaced.

Carriage binds Wear bar is not lubricated or bearings are damaged

Ensure bearings rotate freely and are not damaged. Lubricate wear bar.

All issues Regardless Palletizers are complex systems. It is typically recommended that customers contact General Conveyor Service for all major maintenance or repair assistance.

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Machines: Slat Diverters Slat diverters must be kept clean and free of debris. Dirt and debris on guide shoes and wear strips can drastically reduce component life, and equipment operation. Diversion guides must not be excessively worn, and must operate freely without binding, as this will seriously affect timing and performance. Linear guides must be kept well lubricated. The conveying components must be kept in good condition, and any chipped or broken slats must be replaced.

Problem Possible Cause Action Diverter does not travel to a specific zone. Solenoid operates

Actuator or guide for this zone is binding

Align guiding with center of cylinder operation and remove any burrs on wear strips.

Specific slat does not operate

Slat guiding is damaged Inspect slat guiding, replace the damaged slat(s) or guide bars if necessary.

Slat conveying assembly skips

Drive sprocket is not engaging

Inspect drive sprocket teeth and conveying assembly tension. Replace drive sprocket if necessary.

Machines: Slip Sheet Extractors Slip sheet extractors must be kept clean and free of debris. Slip sheet gripper fingers should be free of debris such as lodged or torn cardboard pieces, which will hinder proper gripping operation. Linear bearing slides (slides with bearing blocks) should have some grease present, and should be lubricated to manufacturer specification. Linear guides (with wearbars and bearing rollers) should be lubricated.

Problem Possible Cause Action Gripper carriage does not operate. Solenoid operates

Linear slide is binding or low air pressure

Ensure linear slide is lubricated and bearings are not contaminated with debris. Adjust air pressure (not to exceed 5.5bar/80psi).

Gripper does not operate. Solenoid operates

Gripper is jammed or low air pressure

Ensure gripper is not deformed or binding on the axel. Remove any debris from gripper. Adjust air pressure (not to exceed 5.5bar/80psi).

Gripper carriage operation is harsh

Flow controls are improperly adjusted

Adjust flow controls for smooth operation (not to exceed 1m/s / 3.3fps).

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Components: Bearings Bearings should be kept clean and free of debris buildup. Dirt and dust are abrasive and can shorten bearing life. Mounting bolts and set screws must be secure. Under normal conditions, grease replenishment is not necessary for bearings supplied with bearing nipple plugs (lubricated for life). However, if bearings containing grease nipples are to be greased, see the supplied manufacturers documentation for the appropriate type, and continuously use the same brand of grease to avoid compatibility issues. Bearings must not be over lubricated, as this may blow out the seals. The recommended grease fill is approximately 30-35% of the available internal space.

Problem Possible Cause Action Bearing is hot Excessive or insufficient

greasing Check that seals are intact and not over-filled. Check that the bearing is not dry.

Bearing seizes or rotates roughly

Balls or rollers are damaged Replace the bearing

Components: Case/Bag Turner Assemblies Case/bag turner assemblies must be closely maintained to ensure proper operation. The coiled pneumatic and electrical wiring bundle feeding the gripper paddle must be free of wear which would indicate rubbing on other components. Gripper paddle surface material must be in good condition, free of excessive wear.

Problem Possible Cause Action Product is slipping from gripper paddles

Gripper surface is worn or air pressure is low

Inspect gripping material for excessive wear and replace if necessary. Adjust pneumatic pressure (should not exceed 5.5bar / 80psi).

Gripper paddles fail to operate

Pneumatic/wiring assembly may be damaged

Inspect pneumatic/wiring assembly for wear or leaks and replace if necessary.

Assembly binds when operating

Wear strip surface is damaged or rotating joint fasteners are too tight

Inspect wear strip surface for uneven or excessive wear and replace if necessary. Adjust joint fastener torque to allow free operation.

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Components: Motors and Reducers Motors must be kept clean and free of dust and debris buildup that would hinder airflow and cooling from heatsink fins. The ventilation openings must be free from obstructions to allow airflow through the fan. Proper lubrication levels must be maintained in the reducer for operation. Motors should not operate excessively hot. Vendor documentation will be supplied with your specific motor for more details.

Problem Possible Cause Action Motor is operating hot or tripping a motor overload

Motor overload may be damaged, or motor may be under a higher than rated load

Measure motor amperage during operation, replace overload if within acceptable range. If above acceptable range, check for binding in equipment loading down the drive.

Reducer is operating hot or binding

Reducer may be under lubricated or damaged, or operating under a higher than rated load

Check reducer lubrication level. Check for binding in equipment or reducer loading down the drive.

Reducer is leaking Seal or vent may be broken Inspect all bearing seals for tears and replace if necessary. Check that vents are not damaged.

Components: Pneumatic and Vacuum Devices Valves & Cylinders: Under normal operating conditions, (speeds of up to 1 m/s), Festo and Numatics brand valves and cylinders can be operated with non-lubricated, compressed air. If lubricated compressed air is used in the pneumatic system, however, it must always be used continuously thereafter. The first occurrence of lubricated air run through the pneumatic system will void the original manufacturers lubrication techniques. Supplied air must be properly prepared, free of aggressive media and be maintained at the specified pressure level. Inspect air exhaust silencers and input filters regularly (dependent on environment) for soiling and replace as necessary. Keep water traps drained for exhaust silencer components equipped with such. Air Bags: Inspect Air Bag components daily for any tears, rips or cuts. If a regulator is supplied, ensure pressure is adjusted appropriately, according to specification. Supplied air must be properly prepared, free of aggressive media. Vacuum Generators: Supplied air must be properly prepared, free of aggressive media, be lubricant free and maintained at the specified air pressure level. Inspect Vacuum line filter bowl and exhaust silencers for buildup, and clean dependent on surrounding environment. Vacuum Pumps (Motor Driven): The Pressure Relief Valve is set to manufacturers specification. Any adjustment of this device shall be guided by GCCL with co-operation of the original manufacturer. The internal inlet and outlet silencers should be inspected for soiling every 500 hours. Vacuum filter condition can be tested with a Vacuum gauge on either side of the filter. If the difference between the inlet and outlet of the Vacuum filter is greater than 5 InH20, the filter should be replaced. Ensure the intake to atmosphere damper operates free of excess friction and maintains an appropriate seal when closed, to achieve ultimate vacuum. Suction Cups: Inspect Suction Cups for cleanliness and tears daily (or after product jamming), dependent on the application. Clean each suction cup using a mild soap and water solution. Ensure Suction Cup Screens (found at the Cup inlet) are kept clean. No lubrication needs to be applied to the Suction Cups. If tears develop, replace the damaged Suction Cup immediately.

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Components: Roller Pop-Up Assemblies Pop-up assemblies must be kept clean and free of debris. All roller wheels and pulleys must rotate freely and be clear of burrs or scoring that may reduce drive band life. Drive band condition must be closely monitored as wear may indicate other issues within the assembly. The unit should operate vertically without binding.

Problem Possible Cause Action Unit does not operate vertically or binds. Solenoid is operating

Cylinder is misaligned, or guide is worn or adjusted improperly

Ensure smooth vertical operation. Adjust vertical guiding with center of cylinder operation. Remove any burrs on vertical guide.

Drive band is skipping off of pulley

Pulley is misaligned Align drive pulley with slave pulleys. Adjust any retaining collars.

Slave pulleys bind Pulley fastener is too tight, or is worn

Adjust pulley fastener to free rotation. Replace excessively worn pulley(s).

Drive band rotates in opposite direction

Drive band was installed improperly after maintenance

Remove drive band and reinstall twisted in opposite direction on drive pulley.

Components: Wear Bars and Slide Shoes Single Post Carriage Cam Follower Wear Bars: Carriage Wear Bars are fabricated out of hardened steel. Ensure the surface is kept clean and continuously lubricated, with a thin film of spray-on Lithium grease. Monitor regularly for any signs of wear and check the mounting bolts for tightness (torque to 200 inch lbs.) every month of service. RA10 Dispenser Slide Shoe Guide: The Slide Shoe Guide is lined with UHMW plastic. No lubrication is required for this material. Check for pallet dust and buildup on a daily basis and monitor the guides for uneven scoring or wear. Wear Bars (Overhead Pusher, RA20 Dispenser/Stacker): Wear Bars found on these types of equipment are fabricated from treated steel. Ensure the surface is kept clean and continuously lubricated, with a thin film of spray-on Lithium grease.

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