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Preventive Maintenance (Model 360/3600)

To ensure that your Roll/Brake Test Machine is continuously kept in proper operating condition, various preventative maintenance procedures, checks and services must be performed on a periodic basis.

Burke Porter Machinery offers a Preventative Maintenance / Certification Contract which affords you the opportunity to have your machine thoroughly inspected by a trained Burke Porter Service Technician twice per year. For details on this service, click on the above link.

Weekly Maintenance Items

Linear Bearings

· Check linear bearings to make sure that no scraps or miscellaneous material is present.

Inertia Rolls (4)

· Inspect inertia rollers; use roll scrapers to clean rubber buildup as necessary.

Retaining Rolls

· Inspect retaining rolls; scrape rubber buildup as needed.

Inlet Air Lubricator

· Check sight gage on lubricator. If oil is low, vent pressure from lubricator, remove cap, and fill with
  oil to fill line.

Always turn off air pressure before removing lubricator fill cap.

Monthly Maintenance Items

Ball screw

· Check ball screw to see if boots are intact.

Air-operated Components

· Check Front Scraper air pressure gage. It should register 10 PSI when energized. Adjust pressure
   as required.

· Check Rear Scraper air pressure gage. It should register 10 PSI when energized. Adjust pressure
  as required.

· Check Tire Trip air pressure gage. It should register 30 PSI. Adjust pressure as required.

· Check Front Retaining Rollers reduced air pressure gage. It should register setting specified at
  initial installation. Adjust pressure as required.

· Check Main Air Line Filter and ensure proper drainage. Refer to general cleaning and replacement
  procedure and vendor's maintenance instructions.

· Check Main Air Pressure Gage. It should register 85 PSI maximum. Adjust regulator as needed.

Quarterly Maintenance Items

Wheelbase Drive Belts

· Inspect belt on sheave for tension and wear. 

Inertia Roll Drive Belts (4)

· Inspect belt on sheave for tension and wear. Replace belt as needed. The belts used on these
  drives should be tensioned so that 23 pounds of force is required to deflect them ½-inch.

Roll Brakes (4)

· Inspect roll brake shoe lining and replace as needed. If a lining is worn to the brass screws on any
  of the brakes, it should be replaced with 3/8-inch thick brake lining material attached with contact
  cement and brass screws.

WARNING! Do not use asbestos-based brake lining material. Non-asbestos replacement lining can be obtained from Burke E. Porter.

Cylinders

· Check all cylinder seals for signs of leakage and replace if needed.

Front/Rear Air Lines Hoses

· Inspect hoses for leaks and deterioration. Remove sharp edges or relieve excessive contact
  pressure. Replace hoses if needed.

Pneumatic Solenoid Valves

· Check for proper functioning; replace if needed.

Automatic Lube Reservoir

· Check grease level in reservoir and fill to 5-pound capacity with Mobilux EP-1 grease. Be sure to
  use the bleed fitting to remove air from the reservoir.

NOTE: Some installations require the use of Molub-Alloy Grease (Product No. 860/220-1) grease in the lubrication system. 

Yearly Maintenance Items

Wheelbase Drive Motor

· If no grease fitting is available, the motor bearings are factory lubed for the life of the bearing. If
  grease fittings are available, bearings should be lubed every 15,000 hours using Chevron SRI#2 or
  equivalent. 

Preventative Maintenance / Certification* Contract (Back to Top)

Burke E. Porter Machinery offers a one (1) year Preventative Maintenance - Certification contract for Model 360 & 3600 Roll/Brake Test machines.

Preventative Maintenance contracts consist of two (2) scheduled visits per year by a BEP Service Technician to perform a comprehensive maintenance inspection and machine calibration, and provide you with a written report noting machine components, which require attention. In addition, our technician will review the report with a designated plant representative, explaining and pointing out the problem areas. The technician will also review the documentation (schematics, drawings, and program listing) available at the equipment. The scheduled visits would take place twice per year, during normal working hours: Monday through Friday, 8AM – 5PM.

The purchase of any required repair parts, along with installation labor, would be arranged after the PM visit and are not considered part of this annual contract. Any parts purchased under this type of contract would carry a “like new” warranty for up to 90 days from the time it was put into service. Warranty would vary by part type. Labor would not be included in this warranty.

The two PM visits typically include:

1. Auto-Lube System –Check condition and operation of reservoir/pump assembly. Inspect lube
    lines for damage and leaks. Verify all components on lube system are receiving lubrication.

2. Pneumatic System – Check water trap and filter; fill lubricators as required. Verify proper
    pressure settings on regulators. Check all pneumatic actuators for leaks in all positions.

3. Hydraulic System – Verify correct pressure settings. Check condition of filters. Check for leaks.
    Run system and check for adequate roll speeds front and rear.

4. Adjustable Wheelbase System – Check condition of drive belts, ways, and gibs. Ensure all
    critical fasteners are secure. Ensure rear carriage is square to front. Lubricate u-joints, as
    necessary. Check gearbox oil level. Check condition of Ryertex wear strips. Inspect condition of
    ballscrew boots.

5. Stop Posts – Verify proper operation, lubrication, and inspect general condition. Check for excessive build-up of debris under posts, which may limit travel.

6. Retaining Roll Assemblies – Verify proper operation of all retaining roller and associated
    assemblies. Inspect all bearings and door rubber. Check security of fasteners.

7. Roll Drive Trains – Check security of set-screws and taper-lock bushings. Inspect belt condition
    and tension. Check keys and keyways for wear. Inspect inter-roll and hydraulic drive train
    clutches and couplings for condition and proper operation (Model 360 machines only).

8. Air and/or Exhaust Doors – Verify proper operation and condition of screens.

9. Roll Brakes – Inspect roll brakes for proper operation, condition of pins, bushings, and brake
    pads.

10. Roll Scrapers (if applicable) – Inspect condition of blades. Verify operation and pressure setting.

11. Side-Guide Rollers – Ensure rollers turn freely and are not loose.

12. Roll Encoders – Inspect alignment. Monitor speeds for stability. Verify good cable connections
     (cross-threading is common).

13. Control Panel – Visual inspection of panel interior condition. Check operation of air conditioner
      and fan pack. Check A/C filter condition and thermostat setting. Ensure panel and operator
      station indicator lamps function.

14. Miscellaneous – Inspect condition of lines and hoses to rear carriage. 

15. Machine Certifications. This will be done on the 1st visit only.

Please note that the clutches on the model # 360’s must be in working order before the certification can be performed.

*Machine certification is suggested only every three to five years unless a physical change is made in the machine drive train system (e.g. rolls; motors; pulleys; etc). Because the machines do not have to be re-certified every year, the preventative maintenance contract for subsequent years would be at a lower cost.

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