Maintenance Procedure from Blow-Room to Autoconer Machines

Maintenance
Maintenance may be defined as the chronological process of systematic activities done for keeping the m\c or equipment’s at the heat level for well run or its proper services.

All the textile machinery both process and related ones are high performance machinery and they have to maintained well to ensure their high performance and efficiency. Also proper maintenance ensures their long operating life.

The following types of maintenance are carried out in the factory:
Schedule Maintenance: Here mainly all the machines are checked on the basis of a fixed schedule of time. Different machine parts are opened, cleaned, lubricated, gauged and replaced if necessary.

Predictive Maintenance: This type includes maintenance of machine parts on the basis of suspicion that they consists problem and will cause greater problem in future. It also includes the gear changes that are done to adjust count, ktex etc of machinery and overhauling.

Breakdown Maintenance: When a machine stops due to failure of machine parts, then it is called machine breakdown. The maintenance that is done to repair and make it ready to run is called breakdown maintenance.

The points that are checked during the maintenance of different machines as well as different lubricating points are given in the following section.

Blow-room:

Maintenance Points: 

Machine Name	Maintenance Point	Work to be Done
Unifloc A11	Fan Impeller	Checking .
	Inside Swivel Tower unit	Cleaning.
	Take-off Roller/Retracting Roller/Swivel Flaps	Cleaning and Checking.
	Covering belts/Ducts	Cleaning, Checking and Tension.
	All types of Belts/Rollers	Cleaning, Checking and Tension.
	All drive Chain	Cleaning, Checking, Tension and Oiling.
	Guard	Checking.
	Gear Motor of Retracting Rollers	Check Oil Level.
	Tooth Segments	Checking.
	Brake Lift Drive	Check Oil Level.
UniClean  B11/B12	Sealing Strips (Lock Roller)	Cleaning
	Grid Bar	Cleaning
	Inside of Drum and Grid adjustment	Cleaning
	Perforated sheet for dust extraction	Cleaning, Checking, Adjusting
	V-Belt for Drum Drive	Tension
	Lock rollerdrive chain	Cleaning,Checking
	Inner part of the spike feed lattice	Cleaning
Unimix  B-70/B-71	All types belts	Checking, Tension
	All drive Chain	Cleaning, checking, tension, Oiling
	Separating vanes, Exhaust air chambers	Cleaning
	Storage section inner chamber	Cleaning
	Rivets & spikes of spiked feed latice	Cleaning, checking
	Roller	Checking
	Conveyor belt	Checking, Cleaning
	Closing flap & spike feed	Checking
	Spike feed lattice bearing	Checking
	Cotton filter	Tension
	All Gear box	Check oil level
	Stripping roller	checking
Uniflex B-60	Lamella chute	Cleaning
	All drive chain	Checking, Cleaning, Oiling
	Saw tooth roller	Checking, Cleaning
	Grid Bar	Checking, Cleaning
	All Seals	Checking
Condenser A-21	Drum seal	Checking
	Stripper	Cleaning, Checking
	All types belt	Cleaning , Checking, Tension
	Perforated drum inside or outside	Cleaning
	All bearing	checking
	Take off roller	Cleaning
	Outside the m/c	Cleaning
	Material in , out and exhaust line	Checking,Cleaning

Lubrication Points:

Machine	Lubricating Points	Lubricants	Intervals
Unifloc-A11	All roller chain	Mobil Gear 632 or Chain Spary Hotemp 2000 Spary	25 to 45 Days
Unimix B-70	All roller chain	Mobil Gear 632 or Chain Spary Hotemp 2000 Spary	25 to 45 Days
Uniflex B-60	All roller chain	Mobil Gear 632 or Chain Spary Hotemp 2000 Spary	25 to 45 Days
Uniclean B-11	Chain of lock roller	Mobil Gear 632 or Chain Spary Hotemp 2000 Spary	25 to 45 Days

 

Carding: 

Maintenance Points: 

SL NO.	Maintenance Point	Work to be done
01	Carding element	Cleaning
02	All bearing condition	checking
03	Flat to cylinder setting	Checking
04	Front auto leveler surroundings	Tension,Cleaning
05	Cylinder inside	Cleaning
06	Cylinder gasket	Checking
07	Stripping knife	Checking
08	Can turntable	Cleaning
09	Card clothing condition	Checking
10	All suction points	Checking, Cleaning
11	Detaching unit	Cleaning
12	Chute	Cleaning
13	All types belts	Tension, Checking
14	Flat drive belt	Tension

Lubrication Points:  

SL NO.	Lubricating Point	Suggested Lubricating	Intervals
01	Cylinder bearing	Grease EP-2	(10-14) months
02	Bearing of the card flats,cleaning brush and cleaning comb	Grease EP-2	(10-14) months
03	Card flat drive	Kluber plex BEM34-132	(10-14) months

Unilap: 

Maintenance points:

Maintenance Area	Maintenance Points	Work to be done
Table calendar	Top cleaning device & bottom cleaning device	Clean and check its physical condition
Suction Unit	Mote knives, waste suction pipes	Clean and check suction properly
	Filter	Clean and check condition
Sliver feed frame	Sliver guide, guide rolls	Clean properly and check setting
Drafting system	Top & bottom rollers , tension bar	Clean, check gauge and reset if required
Drive units	All belts and chains	Clean, check tension, greasing and apply grease if required
Safety device	Safety switch, pneumatic switch	Check functioning
Lubrication	Drafting gear box, main gear box and all greasing point	Check oil level and put oil if required, also check greasing
Gear Units	Setting gear	Clean and check gear meshing, vibration, abnormal sound etc.
Lapping unit	Lap guide plate	Clean and check condition
	Condenser roller	Clean properly
Electrical function	Motor, electronic board, limit switch, proximity switch etc.	To be cleaned and checked by electrical persons.
Nut and bolt	Drafting gear box, main gear box, lap roller drum, lap plate etc.	Tightness check and make correct if required.
Trolley	Trolley wheel, pneumatic system	Clean the wheel and the outer surface

Comber:  

Maintenance Points:

Maintenance Area	Maintenance Points	Work to be done
Delivery Unit	Feed table, trumpet, calendar roller, table funnel	Clean and check condition, adjust if required
	Top combs, clearer rolls and flats, bearing of the bottom roller, circular comb, filter, spring assemblies	Clean and check condition, adjust if required
	Nipper, nipper lever on in-feed side, circular comb brush	Clean and check condition, adjust if required
	Feeding throats, feed roller, nipper lips, top detaching roller, fleece guide plates, top delivery roller, lap plate	Clean and check condition and gauge, adjust if required
Draft system	Stripper, Top and bottom roller	Clean properly, check physical condition
Belt tension and condition	Timing belt, flat belt, V-belt	Clean all the belt, check tension and adjust if required
Gauge points	Setting and condition of top comb, circular comb brush	Gauge check and adjust if required
	Roller, nipper feed plate, nipper gauge, bottom detaching roller gauge	Gauge check and adjust if required
Machine Side	Outer surface of the machine and condition	Clean properly
Gear Box	Oil level in gear box	Check oil level and apply oil if necessary
	All gear	Check gear condition, correct if required
Can changer	Chain tension on turn table	Clean and check condition, adjust if required
Greasing points	Bearing, bush of the top detaching roller	Clean and check, grease if required
	Drafting roller, strip nipper frame, lower delivery and table calendar	Clean and check, grease if required
	Batt tension roll axles and other greasing points	Clean and check, grease if required
Nut-Bolts	Top comber nipper, circular comb, top roller pressure, main gear box, index wheel, all pulley, can wheel, coiler wheel, lap feed plate, lap roller nut-bolt.	Check tightness and make correct if required.
Electrical parts	Motor, motor fan, photo-cell, limit switch, electronic board, connection cable	Check and clean by electrical person

 

Finisher Draw Frame: 

Maintenance Points:  

Maintenance Area	Maintenance Points	Work to be done
Auto leveler	Funnel, scanning roller, contact roller, gatherer, nail and stripper	Clean and check their condition, make correct if required
Drafting Zone	Top & bottom roller	Clean and check its gauge, reset if required.
	Pressure bar, round guide bar, top roller, weighing frame, funnel, condenser, trumpet, coiler	Clean properly, check physical condition
Suction system	Filter box, filter screen, fan blade	Clean properly and check filters and blade condition.
Can changer	Can Plate	Clean and check that it works correctly
	Gear	Clean, check meshing condition, vibration, abnormal noise etc.
	Power cylinder	Clean and check that it is working correctly.
Belt tension and condition	Flat belt, V-belt, timing belt	Clean all the belt, check tension & adjust.
Gear box	Planetary gear box	Check oil level and put oil if required
Nut-Bolt	Top roller lock, pulley nut-bolt, creel nut-bolt, drafting zone nut-bolt	Check tightness and make perfect tightness
Electrical parts	Motor, fan, limit switch, proximity switch, creel light barrier	Clean and check by electrical persons
Outer Surface	Outer surface of the whole machine	Clean properly

 

Simplex: 

Maintenance Points:  

Maintenance Area	Maintenance Points	Work to be done
Back Side	Creel	Clean and check bearing condition
	Balancing spring and chain	Clean and check greasing
	CWC	Clean and check belt tension and condition
	Creel chain	Clean and check greasing
	Grease level in the grease pump	Check grease level and apply grease if required, Check grease pump
	Photo cell	Clean by soft cloth
	Rack groove	Clean and check greasing
GE head	Belt tension and its condition	Check and adjust if necessary
	Lifter gear box, main gear box	Check oil level and filter and put oil if required
	Gear setting	Check gear meshing, observe vibration, sound etc.
	Bearing and greasing point	Check bearing condition, vibration and sound, check greasing and apply grease if required
	All nuts and bolts	Check tightness and make it correct if required
OE Head	Sensor	Clean all the sensor with soft cloth.
	Blanching chain	Clean and check greasing
Drafting Zone	Traverse bar and sliver guide	Clean, check setting
	Top & bottom roller	Clean, gauge check and adjust if required
	Condenser assembly	Clean, check assembly and make correct if necessary
	Top & bottom clearer cloth	Clean, check condition
	Neck bearing of bottom roller	Clean, check cover missing or broken, nipple missing or broken, replace if required
	Cradle unit	Clean and check functioning and wear and tear
	Pressure arm	Check height gauge and re-adjust if required
	Top & bottom apron	Clean properly with suitable detergent, check condition for replacement
Flyer rail & Bobbin rail	Bobbin Rail & Seal	Open the cover, Clean it & check the gear condition
	Flyer cap	Clean and set properly
	Flyer and its gear	Clean, check gear meshing condition
	Shaft	Clean and check condition
Outer surface	Outer surface of the machine	Clean the outer surface properly

 

Ring Frame (RX-240): 

Maintenance points:

SL NO.	Maintenance Points	Work to be done
01.	Top cot roller and cradle	Cleaning
02.	Travers track of roving guide	Checking, Adjusting
03.	Gear Bearings	Checking
04.	Top and bottom apron	Cleaning
05.	Teeth surface of all gears at head stock	Cleaning, Checking
06.	Mesh clearance of the gears	Checking
07.	Fluted roller bearings	Checking
08.	Bottom fluted roller	Cleaning
09.	Suction tube	Checking, Adjusting
10.	Top & bottom apron	Washing
11.	Gauge of traveler	Checking, Adjusting
12.	Spindle blade	Checking
13.	Ring rail height gauge	Checking, Adjusting
14.	Top roller gauge	Checking, Adjusting
15.	Ring rail position gauge	Checking, Adjusting
16.	Balloon control ring center	Checking, Adjusting
17.	Top roller arm pressure gauge	Checking, Adjusting
18.	Lappet rail height gauge	Checking, Adjusting
19.	Filter box	Checking

 

Lubrication Points:

SL NO.	Lubricating Point	Suggested Lubricants	Interval
01.	Tim pulley shaft bearing	Mobilux EP-2	(05-07) Months
02.	GE gearing	Mobil gear oil 632	(05-07) Months
03.	Spindle bolster	Mobile velocite oil 6	(05-07) Months
04.	Drive shaft bearing	Mobilux EP-2	(05-07) Months
05.	Tape tension  pulley bearing	Molilith SHC-100	(05-07) Months
06.	Screw shaft lifting gear	Mobilux EP-2	(05-07) Months
AUTO DOFFER
07.	Spar gear in the gear box	Mobilux EP-2	(05-07) Months
08.	Screw shaft in the power cylinder	Mobilux EP-2	(05-07) Months
09.	Taper roller bearing in the power cylinder	Mobilux EP-2	(05-07) Months
10.	Crank lever bracket	Mobilux EP-2	(05-07) Months

 

Auto Coner: 

Maintenance Points:

Maintenance Area	Maintenance Point	Work to be done
Waxing Device	Waxing shaft	Cleaning and checking any damaged(cut)
	Pressure fork	Cleaning and checking any damaged(cut)
	Locking flap	Remove the yarn accumulation and cleaning
	Yarn trap	Remove the yarn accumulation
	Guide Plate	Cleaning the wax properly
Splice Unit	Splice cutter	Cleaning and apply R.S. – 400
	Prism and its cover	Cleaning the prism by compressed air
	Untwist nozzle	Clean/wash by petrol & brush, checking the position
	Clamping guide	Cleaning by cloth
	Pointer	Checking the position of similarity
	Feeder arm	Checking the position
Tension Device	Rubber sleeve	Cleaning
	Sensor (Tension)	Cleaning carefully and adjust if required
	Cutter	Cleaning and apply RS-400 spray
	Lower end sensor	Cleaning the sensing area
Cradle Holder	Package adapter	Check for unobstructed rotation
	Sliding part (cradle)	Cleaning and apply silicon oil
	Cradle sensor	Check its cover and screw
Magazine	Circular magazine	Dis-assy, check, clean and refixing
	Chute door	Cleaning, centering check
	Ejector	Cleaning & movement check
	Bobbin peg	Cleaning
Conveyor belt	Deflection roller	Remove loose yarn ends from the deflection rollers
	Tensioning Device	Remove cover from the belt tensioning device of the conveyor belt and remove yarn laps / jam if required
OHTC	Rail	Cleaning
	Filter	Cleaning by compressed air
	Shifter	Cleaning and put one drop silicon oil
Suction end and Head stock		Cleaning the fly waste from head stock and suction device compartment
Checking and Gauging	Suction arm	Checking (adjust if required)
	Cradle vibration	Checking (adjust if required)
	Paper cone to drum	Checking (adjust if required)
	Bobbin peg centering	Checking (adjust if required)
	Dust collection assym. (OHTC)	Checking (adjust the alignment if required)
	EYC	Checking the sensitivity
	All kinds of nut & bolt	Nut-bolt checking, tightening if required

 

Lubrication Points: 

Lubrication Points	Used Lubricants	Intervals
Lubricate the RH package adapter	Silicon oil (S-1000)	1 month
Apply the maintenance spray (RS-400) on both splice cutter and lower yarn cutter	Maintenance spray RS-400	1 month
Lubricate the LH package adapter	Shell Alvania grease – R2	4 months
Lubricate the RH package adapter	Kluberplex BE 32-222	1 year
Lubricate the suction drive motor	Shell Alvania grease – R2	4 months
Lubricate all internal rotating parts	Lithium grease containingMos2 / Molykote spray	4 months
Lubricate all bearing points of the gear	Lithium grease containingMos2 / Molykote spray	8 months
All toothed wheel and toothed segment of central housing	Shell Alvania grease – R2	8 months
Lubricate the yarn guide drum	Shell Alvania grease – R2	2.5 years