CONDUCTIX wampfler Programs 0365, 0380 Checklist for Motorized Festoon System Instructions
- June 3, 2024
- Conductix Wampfler
Table of Contents
Programs 0365, 0380 Checklist for Motorized Festoon System
Maintenance Instructions Checklist for motorized festoon systems Programs 0365
0380
This Checklist does not replace the information given in the Operating
Instructions for your system! It is a supplement to the Mounting Instructions.
Recommended inspection interval
– Every 3 months
Assembly
Component
End clamp + towing clamp/ Buffer unit towing trolley + catenary
(Previous version, produced before 2009)
Indication of wear
Recommended measures
· Piston rod bent · tilting of the buffer plate · loose buffer plate
Replace complete buffer units on end clamp, towing clamp and towing trolley latest after 4 years of operation
or when 4 years of operation have been reached
Recommended inspection interval – Every 3 months
Assembly
Component
End clamp + towing clamp/ Buffer unit towing trolley + catenary
(Previous version, produced before 2009)
WV0300-0052b-EN www.conductix.com
Indication of wear
Recommended measures
· Bushing expanded or
Replace complete buffer units on end clamp, towing clamp and towing
broken
trolley latest after 4 years of operation
· piston rod tilting downwards
or when 4 years of operation have been reached
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Page 1 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – Every 3 months
Assembly
Component
End clamp + towing clamp/ towing trolley + catenary
(Current version, produced 2009 or later)
Buffer unit
Indication of wear
Recommended measures
· Piston rod bent · tilting of the buffer plate · loose buffer plate
Replace complete buffer units on end clamp, towing clamp and towing trolley latest after 4 years of operation
or when 4 years of operation have
been reached
Replace buffer
· Buffer damaged
Recommended inspection interval – Every 3 months
Assembly
Component
End clamp + towing clamp/ towing trolley + catenary
(Current version, produced 2009 or later)
Buffer unit
Indication of wear
Recommended measures
· Bushing expanded or
Replace complete buffer units on end clamp, towing clamp and towing
broken
trolley latest after 4 years of operation
· piston rod tilting downwards
or when 4 years of operation have been reached
WV0300-0052b-EN www.conductix.com
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Page 2 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Component
End clamp + towing clamp/ towing trolley + catenary
Anti-lift plate
Indication of wear
Recommended measures
· Visible material wear/Gap Replace anti-lift plate between I-beam and anti-
lift plate > 8mm
· Mounting screws touch I-beam
Recommended inspection interval – Every 3 months
Assembly
Component
End clamp + towing clamp Buffer unit
Indication of wear
· Loose fasteners on the track beam
· Strong corrosion on the fastening screws
Recommended measures Tighten all fasteners Replace fastening screws
WV0300-0052b-EN www.conductix.com
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Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Towing trolley/ catenary
Component Towing device
Indication of wear
Recommended measures
· Rubber plate in towing area Replace rubber plates worn out or missing
· Deformation or cracks on Replace complete towing trolley/catenary the towing
area
· cracks at the weld joints
Recommended inspection interval
– Every 3 months
Assembly Cable trolley
Component Centre plate
Indication of wear
Recommended measures
· Deformation or cracks on Replace complete cable trolley (Investigation for root course is
the centre plate
mandatory)
· Cracks at the weld joints
WV0300-0052b-EN www.conductix.com
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Page 4 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly Cable trolley
Component Side shield
Indication of wear
Recommended measures
· Side shield bent or touching Replace side shield or complete running gear (Investigation for root
track beam
course is mandatory)
· grooves on the side shield
Recommended inspection interval – After 300 hours of operation or every month
Assembly Cable trolley
Component Rollers
Indication of wear
Recommended measures
· Strong wear marks/ visible damage
Replace rollers with spare rollers
· Cracks, embrittlement or loose
bandage from the core
· Increased bearing clearance
due to worn out ball bearing
· High leakage of lubricants,
rollers sluggish.
WV0300-0052b-EN www.conductix.com
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Page 5 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Component
Clamping bar + cable Clamping bar support
Indication of wear
· Loose clamping bar · cables out of place or
damaged
Recommended measures
Check cables for damage Tighten all fasteners on clamping bar If appropriate
replace clamping bar and cables
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Component
Clamping bar + cable Cable support support
Indication of wear
Recommended measures
· Loose cable support
Check cables for damage
· Early indications of fatigue
as cracks on supports
Tighten all fasteners on clamping bar
· Loose riveting nut
If appropriate replace cable support, clamping bar and cables
· Not provide sufficient
clamping for the cables
WV0300-0052b-EN www.conductix.com
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Page 6 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – Every 3 months
Assembly Cables
Component Cables
Indication of wear
· Wire, shielding or jacket breakage
· Corkscrews have formed
Recommended measures Replace worn cables
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Component
Damping device and shock cords
Shock cords/ console and fasteners
Indication of wear
Recommended measures
· Severe constrictions in the shock cords
Replace of shock cord
· The mantle of the shock cord is If appropriate replace console and fasteners.
even partially torn
· Fraying strands on the shock
cord
· Mechanical deformations on
the shock cord brackets
WV0300-0052b-EN www.conductix.com
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Page 7 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly Towing ropes
Component
Steel ropes + shackle and fasteners
Indication of wear
Recommended measures
· Loose steel rope
Tighten fastening screws
· Immovable shackle
· Cracks on shackle, breaks Lubricate shackle
and embrittlements on steel Replace steel rope and shackle
rope
Recommended inspection interval – After 300 hours of operation or every month
Assembly Buffer
Component Rubber or cell buffer
Indication of wear
· Cracks, breaks and embrittlements on the buffer
Recommended measures Replace buffer
WV0300-0052b-EN www.conductix.com
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Page 8 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly Cable clamps
Component
Round cable clamps/ flat cable clamps
Indication of wear
Recommended measures
· Fasteners heavily corroded/corrosion
Replace cable clamps/Check cables for damage
protection has failed
· Cracks and embrittlements
in clamping rubber
· No sufficient clamping on
the cables
WV0300-0052b-EN www.conductix.com
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Page 9 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – Every 3 months
Assembly
Component
Motorized cable trolleys Protective cover (Previous version, produced before 2011)
Indication of wear
Recommended measures
· Missing or damaged
Mount new fastening screws (apply thread-locker!)
fastening screws
· Heavy corrosion or cracks Replace protective plate and fastening screws
on the plate
Recommended inspection interval – Every 3 months
Assembly
Component
Motorized cable trolleys, Silent block (Previous version, produced before 2011)
Indication of wear
Recommended measures
· Corrosion · Metal starting to loosen
from rubber
Replace silent blocks with motor mounting kit after 6.000 operational hours or 4 years of operation
or when 6.000 operational hours or 4 years of operation have been reached – whatever comes first
WV0300-0052b-EN www.conductix.com
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Page 10 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Component
Motorized cable trolleys Tooth belt/tooth belt
(Previous version,
tension
produced before 2011)
Indication of wear
Recommended measures
· Tooth belt slipping or over tensioned
· Tooth belt porous/cracked
or when 6.000 operational hours or 4 years of operation have been reached –
whatever comes first
Check belt tension/Check belt for damage/Adjust tooth belt tension as per
manuals
Replace tooth belt after 6.000 operational hours or 4 years of operation.
Adjust tooth belt tension as per manual
Recommended inspection interval
– Every 3 months
Assembly
Component
Motorized cable trolleys Tooth disk (Previous version, produced before 2011)
Indication of wear
Recommended measures
· Tooth belt slipping
Check belt tension/Check belt and disk for damage
·
Thickness of the flange at the tooth disk decreased
Replace tooth disk and belt/Adjust tooth belt tension as per manuals
· flange or tooth disk missing
WV0300-0052b-EN www.conductix.com
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Page 11 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – Every 3 months
Assembly
Component
Motorized cable trolleys (Current version, produced 2011 or later)
Protective cover
Indication of wear
Recommended measures
· Missing or damaged
Mount new fastening screws (apply thread-locker!)
fastening screws
· Heavy corrosion or cracks
on the plate
Replace protective plate and fastening screws
Recommended inspection interval – Every 3 months
Assembly
Component
Motorized cable trolleys; (Current version, produced 2011 or later)
silent block
Indication of wear
Recommended measures
· Corrosion · Metal starting to loosen
from rubber
Replace silent block with motor mounting kit after 6.000 operational hours or 4 years of operation
or when 6.000 operational hours or 4 years of operation have been reached – whatever comes first
WV0300-0052b-EN www.conductix.com
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Page 12 of 14
Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Recommended inspection interval – After 300 hours of operation or every month
Assembly
Component
Motorized cable trolleys (Current version, produced 2011 or later)
Tooth belt/tooth belt tension
Indication of wear
Recommended measures
· Tooth belt slipping or over tensioned
· Tooth belt porous/cracked
or when 6.000 operational hours or 4 years of operation have been reached –
whatever comes first
Check belt tension/Check belt for damage / Adjust tooth belt tension as per
manuals
Replace tooth belt after 6.000 operational hours or 4 years of operation.
Adjust tooth belt tension as per manual
Recommended inspection interval
– Every 3 months
Assembly
Component
Motorized cable trolleys (Current version, produced 2011 or later)
Tooth disk
Indication of wear
Recommended measures
· Tooth belt slipping
Check belt tension / Check belt and disk for damage
· Thickness of the flange at Replace tooth disk and belt / Adjust tooth belt tension as per manuals the tooth disk decreased
· flange or tooth disk missing
WV0300-0052b-EN www.conductix.com
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Maintenance Instructions Checklist for motorized festoon systems Programs 0365 0380
Conductix-Wampfler GmbH Rheinstraße 27 + 33 79576 Weil am Rhein – Märkt
Germany
Importer for the United Kingdom: Conductix-Wampfler Ltd. 1, Michigan Avenue
Salford M50 2GY United Kingdom
Phone: +49 (0) 7621 662-0 Fax: +49 (0) 7621 662-144 [email protected]
www.conductix.com
Phone: +44 161 8480161 Fax: +44 161 8737017 [email protected]
www.conductix.com
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