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v1.1

Minor Versionm

by Plant Manager

Introduction

Note: This guide is an example of how standard work instructions are presented through the Dozuki format.

If you hear a popping noise coming from the waycovers, it’s time to complete the maintenance items in this Guide. The video below gives an overview of the symptom we will resolve.

Video Overview

  1. Start by pulling the waycovers back. Inspect the rails for loose fasteners by wiggling the rails. There should be no play in the rail.
    • Start by pulling the waycovers back.

    • Inspect the rails for loose fasteners by wiggling the rails.

    • There should be no play in the rail.

  2. Tighten the fastener bolts using a hex wrench. Apply a thin coat of red grease to the guide rails.
    • Tighten the fastener bolts using a hex wrench.

    • Apply a thin coat of red grease to the guide rails.

    • If the seals and waycovers are in good condition, this concludes the maintenance and should fix the popping noise.

  3. If the waycovers show signs of damage, or the wiper seals are allowing lubricant to leak into the housing, they should be replaced Wipers will often show small cracks as they have reached end of life.
    • If the waycovers show signs of damage, or the wiper seals are allowing lubricant to leak into the housing, they should be replaced

    • Wipers will often show small cracks as they have reached end of life.

  4. Jog the X-Aaxis to the end of travel by rotating the Handle Jog counter clockwise. Press the Emergency Stop button. Press the Emergency Stop button.
    • Jog the X-Aaxis to the end of travel by rotating the Handle Jog counter clockwise.

    • Press the Emergency Stop button.

  5. Collapse the waycover and lift it from the end of the guide rail Remove the waycover from the machine and place it upside down on a work surface. Manually separate each section
    • Collapse the waycover and lift it from the end of the guide rail

    • Remove the waycover from the machine and place it upside down on a work surface.

    • Manually separate each section

    • Sections can be separated by hand simply by lifting up and pulling apart.

  6. Wipe excess grease from the rubber wiper gaskets. Locate and remove the small philips screw that secures the wiper blade.
    • Wipe excess grease from the rubber wiper gaskets.

    • Locate and remove the small philips screw that secures the wiper blade.

  7. Using a flathead screwdriver slide the retaining strip towards the opposite end of the waycover to disengage from the standoffs. Pry the retaining strip up away from the standoffs. Remove the damaged wiper.
    • Using a flathead screwdriver slide the retaining strip towards the opposite end of the waycover to disengage from the standoffs.

    • Pry the retaining strip up away from the standoffs.

    • Remove the damaged wiper.

  8. Cut the new wiper to exact length The old wiper can be used as a reference point for length and to make sure holes are aligned. The old wiper can be used as a reference point for length and to make sure holes are aligned.
    • Cut the new wiper to exact length

    • The old wiper can be used as a reference point for length and to make sure holes are aligned.

  9. Prior to installation, clean any remaining grease from the waycover Apply a light coat of red grease to the new wiper. Place the new wiper onto the waycover.
    • Prior to installation, clean any remaining grease from the waycover

    • Apply a light coat of red grease to the new wiper.

    • Place the new wiper onto the waycover.

  10. Install the retainer over the top of the wiper. Make sure the retainer captures all of the standoffs.
    • Install the retainer over the top of the wiper.

    • Make sure the retainer captures all of the standoffs.

  11. With one hand, apply downward pressure to the retainer. Use a flathead screwdriver to slide the retainer into the locked position on the standoffs. Verify the  standoffs and retainer are locked together.
    • With one hand, apply downward pressure to the retainer.

    • Use a flathead screwdriver to slide the retainer into the locked position on the standoffs.

    • Verify the standoffs and retainer are locked together.

    • Put the waycover sections back together.

  12. Remove any remaining chips or debris from the linear guides. Remove the used gasket and sealant from the table mounting surface. Apply a thin coat of grease to the waycover guide bars
    • Remove any remaining chips or debris from the linear guides.

    • Remove the used gasket and sealant from the table mounting surface.

    • Apply a thin coat of grease to the waycover guide bars

  13. Install the waycover over the guide bars. Attach the waycover end panel to the waycover bracket with the fasteners. Fully extend the waycover one leaf at a time.
    • Install the waycover over the guide bars.

    • Attach the waycover end panel to the waycover bracket with the fasteners.

    • Fully extend the waycover one leaf at a time.

    • Make sure the sections do not separate.

  14. With the largest leaf of the cover away from the table: Put a bead of rtb silicone on the way cover Put the new gasket on the face of the waycover
    • With the largest leaf of the cover away from the table:

    • Put a bead of rtb silicone on the way cover

    • Put the new gasket on the face of the waycover

  15. Extend the waycover to the table Install the fasteners. Wipe away any excess silicone.
    • Extend the waycover to the table

    • Install the fasteners.

    • Wipe away any excess silicone.

  16. Release the E-Stop by pulling the Emergency Stop button outwards. Press the "Reset" button multiple times until all alarms are cleared.
    • Release the E-Stop by pulling the Emergency Stop button outwards.

    • Press the "Reset" button multiple times until all alarms are cleared.

  17. Apply a light coat of oil to all sections of the e-cover. Manually jog the X-Axis slowly to make sure none of the leafs bind.
    • Apply a light coat of oil to all sections of the e-cover.

    • Manually jog the X-Axis slowly to make sure none of the leafs bind.

  18. Dozuki can help improve your:

Quality Manager

Member since: 05/12/2020

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