ULF 2 Procter & Gamble Product Supply UK Ltd

Maintenance

INSPECTION & MAINTENANCE

RUNNING WARM

LUBRICATION

WEAR AND TEAR

FUNCTIONAL OPERATION

POSITIONING

I
L

6.19.
2.1

Lift wagon

I
C

I
L

6.19.
2.2

Centring unit

I
C

I
L

Drop lock

I
C

TENSION

TRACKING

I
C

PLAY

DIRT

OIL LEVEL

LEAK

FASTENING

Pallet lift

NOISES

DAMAGE

OPERATION
Every 3 months

Pallet lift

SEE
PAR.

A= ADJUST R= REFILL I= INSPECT

C= CLEANING L= LUBRICATION C= CHANGE
DA= DRAIN OFF WATER

I
A

6.19.
2.3
6.19.
2.4

10-7-15

Versie 1.0.0 - 2011-08-25 rev VV 2012-01-12

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COMPONENT

FREQUENCY

MODULE

Tab. 6.5 Maintenance diagram C5000- Si / Ti

6.21

Elevator - changing chains and bearings lift shaft

See also drawing 0T.67.71A-2 (click to open)

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Maintenance

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Elevator or lift platform

10-7-15

Fig. 6.6 Overview Palletiser

6.21.1

Functional description
The lifting elevator function is integrated in the palletising function.
The lift function drive is designed for a specific maximum pallet weight of
1500 kg.
A pallet is positioned on a pallet roller conveyor.
This pallet roller conveyor is integrated on a lifting platform.
For optimal handling / energizing the unit is equipped with a guided
counterweight.
The pallet is lifted to a position under the loading platform (stripper table),
depending on the actual height of the pallet.
The loading platform opens and a layer is dropped on top of the pallet (or
pallet load).
Now the pallet(load) is lowered in high speed until the top of the pallet(load)
is under the loading platform.

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Maintenance

Then it will raise the pallet(load) in slow speed back towards the platform
for the next layer to be accepted.

6.21.2

Description
Lift construction

See drawing drawing OT.67.71A-0

The lift construction consists of:

15 Geared motor with torque support.
16 Main shaft.
17 Two bearings for shaft support.
18 Two Sprockets on the main shaft for chain 1 duplex.
19 Two chains 1D.
20 Lift platform.
21 Counter weight.

Fig. 6.7 Safety blockage lift platform

23 Safety blockage counter weight See Fig. 6.8 Safety Blockage Positions
4/5 & 29/30 .

Blocking pin

Fig. 6.8 Safety Blockage Positions 4/5 & 29/30

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22 Safety blockage lift platform See 2.1 or 7.1 or Fig 2 below

ULF 2 Procter & Gamble Product Supply UK Ltd

6.21.3

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6.21.4

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6.21.4.1

Maintenance

Safety
Warning
Improper use, faulty installation or operation, improper removal or
switching-off of safety devices and opening of protective covers without
taking safety precautions can result in serious injury or death as well as
major material damage.

Electrical installation
Warning
Work, of any nature, on the installation should be carried out by qualified
and authorised personnel only. Please read Chapter 1 ("Safety") and
take all necessary precautions.

Control cabinet
Please close the cabinet door properly always so that dust and moisture
cannot enter.
If the control cabinet is equipped with a ventilator, please check the filter
element for dirt and clean or replace when necessary. The air inlets and
outlets must remain easily accessible i.e. kept free of obstacles.

6.21.4.2

Proximity switches, limit switches and door switches

Please take particular care to check security switches and other switches
that are used now and again only.

6.21.4.3

Photo cells
Clean the lenses of photo cells and reflectors with a soft cloth.

10-7-15

The frequency of cleaning depends on environmental influences such as

dust, dirt, damp etc. You might therefore need to clean more often than
instructed.
6.21.4.4

Electrical cabling
Please ensure that cable duct do not become damaged. Please keep
cable work of the control current separate from cable work of the main
current. Loops in cables must be avoided.

6.21.4.5

Cable tracks
Depending on the application, cable tracks are used free-bearing or in
combination with cable ducts

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Maintenance

Important when inspecting and carrying out maintenance work:

6.21.5

Cable ducts may not be damaged or dirty. Bulky rubbish such as

sticky tape, packaging and product remnants, glass fragments,
wood splinters etc. must be removed immediately .

Please shut cable tracks correctly and insure that connections and
internal sections are not damaged or loose.

Cables and pneumatic hoses (if applicable) must not become

twisted or jammed. Please also ensure that there is enough play for
lengthwise movement in the cable track.

Cables and hoses must be secured with a pull relief on outer ends
of cable tracks.

Replace the lift chains and/or lift shaft bearings

Warning
The counterweight must be blocked mechanically.
For that reason a blocking provision (See Fig. 6.8 Safety Blockage
Positions 4/5 & 29/30) has been fitted on each side of the frame.
Each blocking provision has two blocking pins. ( See Fig. 6.7 Safety
blockage lift platform positions 3) In total four counterweight blocking pins
have been fitted.
Check prior to works
1 Check that the platform is empty.
(No load allowed on the conveyor.)
2 Bring the lift platform up and the counter weight down (Using the manual
control on the main operator panel)

6.21.5.1

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6.21.5.2

6-30

lift platform on high level for easier access.

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Required:

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General

Operation
Warning
The work must always be carried out by two persons.

Tools required:
-

Two padlocks.

Access to the lift drive motor.

Scaffolding and or a ladder.

Pulley wrench for motor drive removal.

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ULF 2 Procter & Gamble Product Supply UK Ltd

6.21.5.3

Maintenance

Chain
Lift chain needs to be exchanged if the elongation is more than 3 %
1 Open the door
The safety cylinders will go out (on spring actuation) and at least one of the
cylinders will be captured in the safety profile. (See Fig. 6.7 Safety
blockage lift platform)
On each side of the elevator frame a blocking provision is mounted on the
outside (see Fig. 6.8 Safety Blockage Positions 4/5 & 29/30).
2 Remove the two dummy bolts M20 positioned in the provisions (one
each) side and approx 700 mm height. holes in the elevator frame will
occur.
3 The locking pin (See Fig. 6.9 Position 2 ) can now be taken from the
blockage provision. (see Fig. 6.8 Safety Blockage Positions 4/5 & 29/
30).
Keep the pins with you for further handling.

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1 Place the dummy M20 into the (now) free slot (position) of the blocking
provision.

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2 Remove the four (4) protection plates (See Fig. 6.9 Position 2) on the
lifting mechanism inside the palletiser.

Fig. 6.9 Position 2

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Warning
The counterbalance weight must be secured!

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Maintenance

Chains must be set slack on both sides

1 Switch to manual mode (using the manual control on the main operator
panel)
-

One person to Lower the lift platform and raise the counterweight in
manual operating of the elevator.

One person on the outside of the fencing to visually check when the
bolt slot(s) become free. The counter weight must be above the bolt
slots.

2 The operator can now stop moving the elevator.

3 Mount the locking pins in the blocking provision for the counterweight
from the outside.
(See Fig. 6.8 Safety Blockage Positions 4/5 & 29/30)

4 When all four pins are installed, the operator must raise the platform
shortly and lower the counterweight onto the pins. (using the manual
control on the main operator panel)
The chains to the counterweight now become slack.
5 Open the door.
The safety cylinders will go out (on spring) and at least one of the cylinders
will be captured in the safety profile.( See Fig. 6.6 Overview Palletiser
position 7.1)

Warning
Normally we will be needing some kind of slack of the chain
In order to work safely the strong hold of the lifting platform on the lifting
chain should be eliminated!

10-7-15

Create slack on the chains to the lifting platform.

Note
See Fig. 6.6 Overview Palletiser positions 7.1 and 7.2
1 Lift by hand the brakes of the elevator drive so that the platform will drop
downwards until the lift blockage system will stop the movement.
One of the safety cylinders is now against the bottom of the hole in the
safety catching profile.

Note
The chain is to be slack on both sides!
2 Switch off the air supply.
a Make sure surplus air is let off.
b Padlock the main air valve in order to work safely.
3 Switch off the entire system electrically.
a Padlock the main switch on the related panel.
4 Secure access around the drives on higher level.

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The pin to enter into the profile of the moving area of the counterweight.

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ULF 2 Procter & Gamble Product Supply UK Ltd

Maintenance

Scaffolding or ladders are needed for access.

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Relevant safety ropes See Fig below position 22

Fig. 6.10 Position 22

5 Lift motor disconnect.
a Disconnect all cabling from the lift motor.

10-7-15

Note
The C5000 has one elevator drive.
6 Liftmotor removal/weight
a Expected weight 85 kg . Always check the actual indicated weight
on the available drive.
b Use sufficient lifting gear (hoist or crane) for safe handling of the
drive.
c Use sufficient and lifting rope(s) in combination with lifting gear .
d Only use equipment rated for the load required.

Note
Use tested and validated lifting equipment.
7 Lift rope(s)

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Maintenance

For removal of the drive the lift a rope must be tightened in such a way that
it can be shifted to one side.

Note
Make sure the drive does not drop down when it comes off the shaft!
Torque arm
After the drive is secured we can now safely remove the torque arm
support.
Note
The drive still remains on the shaft.

If you only want to exchange the drive it is not required to use the
counterweight mechanical blockage system.
1 Lift drive motor and lift chains
a Lift drive motor is to be removed from the shaft before the lift
chains can be accessed.
b Pull the drive from the shaft (Use pulley wrench if necessary).

Note
See item 8 and make sure the drive is held properly by the lifting
equipment and rope(s)!
c Replace lift chain on the drive motor side.
2 Remove the bracket (16) from the top frame on the drive motor side.
This is one of the connections between the lift frame and top part.
Now the lifting chain on the drive motor side of the elevator is free.

Warning
Mind the weight of the chain!
3 Visually check the chain for wear and tear.
If necessary exchange the chain.

Note
If chains and or bearings need to be replaced always exchange both
bearings and or chains during the stop.
a Check the status of the chain sprockets.
When chain sprockets are worn (and or if there is play between the
key connections and the chain sprocket and drive shaft) and they
need to be replaced continue with item 18.

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Note
The shaft will not start turning because the blocking mechanism prevents
the chains to move the shaft.

10-7-15

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Maintenance

b Check the following for damages;

- The drive shaft ends.
- Drive shaft fixation key and the shaft key into the connection slot.
If so continue with item 18.
-

Bearing lift shaft drive side.

To access and remove the bearings the drive shaft must be supported.
4 Support the shaft from the top frame ( See Fig. 6.10 Position 22 using
ropes and ratchet belts.

n
n

Note
Only use equipment rated for the load required.

Note
Use tested and validated lifting equipment.

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Bearing on drive side.

1 Untighten bearing and slide bearing sideways of the shaft.
2 Slide new bearing in position.
3 Tighten.
4 Loosen and remove ropes (etc) on this side.
5 On the driven side all checks are executed.
a Lift chain on the non-driven side.
Note
On the drive side the bracket is still not connected.

10-7-15

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Maintenance

Fig. 6.11 Position 24

This bracket (24) is the second of the connections between the lift frame
and top part.
Now the lifting chain at the non-driven side is free.
Note
Mind the weight of the chain!

10-7-15

a Check the chain on visual damage and on the actual elongation.

If necessary exchange the chain.

Note
Reminder if to be exchanged always exchange the pair.
b Check the status of the chain sprocket.
- When chain sprocket is worn and needs to be replaced go to item
18.
c Bearing on non-driven side.
7 Untighten and slide sideways of the shaft.
8 Slide new bearing in position.
9 Tighten.
10 Loosen and remove ropes (etc) on this side.
11 Reassemble.

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6 Remove the bracket ( See Fig. 6.11 Position 24) from the top frame at
the non- driven side.

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Maintenance

a Install bracket 24.

b Install bracket 16.
12 In case of damage to the elevator shaft or chain wheels as under 10 or
1: call CSi service (LCSI) for exchanging the shaft.
In case of damage, stop this instruction from here.
13 Re-install the lift drive.
The shaft and bushings must be greased with correct lube prior to
assembly.
(For specification see drive. Normally to be expected is that the grease is
packed separately with the drive. If drive is re-installed check and apply
grease. )
a Carefully position the drive in front of the shaft and pay attention to
the key!
b Now slide over the shaft.
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c If necessary lift the brake of the motor and turn the drive to its
position.
d Fix drive.
14 Re-install torque arm support .
a Loosen ropes etc from drive.
b Remove ropes etc from machine.
15 Connect drive.
a Connect cabling etc to the drive.
16 Power up.
17 Air up.
18 Check on safety.

10-7-15

19 Manual operation.
a Check that the installation is still in manual.
b Run lift platform down. The counterweight will now come off the
bolts.
c In this situation with all doors closed the lift platform blockage
system is now given free!
20 Stop the palletiser.
21 Remove blocking pins.
a From aside (you do not need to enter into the palletiser area)
remove the blocking pins (all 4).
b Exchange the 4 blocking pins with the 4 dummies.
c Seal the four dummies into position.
22 Back into manual.
a Run lift platform to highest position.
23 Re-install the protection plates.
a Stop palletiser. Open door (now the lift platform is automatically
blocked).

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Maintenance

b Re-install protection plates items 2 to the lifting mechanism inside

the palletiser.

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24 Reset and restart .

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