Maintenance Schedule For Cage Systems - · PDF fileVersion 1A – Last Updated September...

Ve r s i o n 1 A – L a s t U p d a t e d S e p t e m b e r 1 1 , 2 0 0 6

Maintenance Schedule For Cage Systems

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Table of Contents:

Section 1: Notes Section 2: Recommended Daily Maintenance Section 3: Recommended Weekly Maintenance Section 4: Recommended Monthly Maintenance Section 5: After Each Flock Recommended Maintenance Section 6: Recommended Maintenance by Category

When performing maintenance or repairs make sure the local control switch is OFF and the

main electrical power control panel is OFF and tagged “DO NOT OPERATE”

ALL Guards are for your personal safety and protection. “DO NOT OPERATE” the machinery without the Guards in the

manufacture’s intended positions. Always replace and/or close the Guards before restoring

the electrical power to the machinery.

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Section 1: NOTES We would like to start by THANKING YOU for purchasing our products. Within this document you will find many recommendations for maintaining the equipment that you have purchased. It is strongly recommended that you follow the recommendations listed within this document, but it should be noted that maintenance cycles are very dependent on the environment were your facilities are located. NOTE: We strongly recommend that you follow the manufacture’s recommended maintenance schedules for any and all equipment in your facilities. We have provided our recommendations for both Val-Co products as well as products that are typically in a poultry laying or pullet facility. For equipment that comes with specific maintenance recommendations or is made by another manufacturer, their recommended maintenance schedules supersede the recommendations listed in this document. NOTE: For all roller chains in the cage system we recommend that you use a SAE 30 or lighter weight oil, at least once very month (Oiling the roller chains will also lubricate the sprockets where the chain comes into contact with the sprocket). Using a heavier weight oil on the roller chains, is not recommended because the oil will not necessarily lubricate the internal components of the roller chains. NOTE: Oil corners: If your corners have oil cups check the level of the oil in the cups; SAE 80 weight oil should be used in the oil cups. If you do not have oil cups on your corners you should oil the corner every two months with SAE 10 weight oil. NOTE: Please refer to your Val Watering Installation, Part List Operations and Maintenance Instruction Book. Frequency of cleaning and flushing the drinker line does depend on the water quality at your facility. We also recommend that you clean and flush drinker lines after each medication. NOTE: Clean the cage system between flocks either wet or dry. If wet cleaning, make sure that all the feed is out of the trough (if wet feed gets into the barrel(s) of the chain and dries it can cause cracks and/or break the chain, when it goes through the corners). After wet cleaning turn the ventilation on maximum to speed up the drying thus minimizing corrosion. During cleaning, protect electric appliances such as motors and switch boxes from damage by direct splash water. It is not recommended to use cleaning agents. NOTE: Wash (remove the I-Beams if you are going to wash them) or clean off I-Beams as dirt build up effects the performance of the collector; If the elevator chain is bouncing the chain needs to be either oiled or it is to tight, thus if the chain still has lubrication on it decrease the tension by loosening the chain take-up. NOTE: The tension on all of the chains should be checked weekly. NOTE: The egg belt should be tightened until there is 35 and 40 lbs of pressure on it. This should be done when the slack is being removed from the egg belt. The slack in the egg belt should be removed if the egg belt take-up’s, take-up is exhausted or if there is more than 6 inches of slack between the guide brackets.

When performing maintenance or repairs make sure the local control switch is OFF and the main electrical power control panel is OFF and

tagged “DO NOT OPERATE”

ALL Guards are for your personal safety and protection. “DO NOT OPERATE” the machinery without the Guards in the

manufacture’s intended positions. Always replace and/or close the Guards before restoring the electrical power to the machinery.

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Section 2: Recommended Daily Maintenance

Category Recommended Maintenance Checked Water Supply Check the birds’ water consumption and record it. Check the water column inside the transparent hose at the beginning and end of each

cage row.

Check the nipple drinkers. Immediately clean any that are leaking or not working properly. If the problem persists replace the nipple drinker(s).

Feed Chain Make sure that the feed chain is always lying flat in the feed trough. If it buckles during operation immediately switch off the drive. Check whether the feed chain is caught somewhere, if it is, correct the problem.

Feed Chain Drive Unit

Check the shear pin that connects the sprocket and hub. If the pin is sheared, replace the shear pin but, before replacing the sheared off pin, correct the problem that caused the shear pin to break.

Feed Hopper Check the feed level at the feed level slide. Remove feathers and other foreign matter.

Corners Check all of the feed chains and the corner wheels to make sure they are operating correctly; the corner wheels should be rotating trouble-free. Remove any foreign objects that may be caught in the feed corners, do this after shutting off the electrical power.

Manure Belt Drive

Clean the manure scrapers at the drive and check for proper operation before or after each manure removal. Check the manure scrapers, if they are badly worn rotate or replace them.

Check whether the belts are operating without slipping, assuming that the belt is not overloaded. If there is damage, check for the possible reason(s) and repair the damage. If no problem can be detected, increase the compression force of the rollers as necessary (NOTE: tighten within reason).

Manure Belt Idler Unit

Check the manure belt idler take-up, if the take-up is completely exhausted; move the take-up back to its original location then remove the excess belt and re-weld the belt

Manure Belts Check the alignment and tension during each manure removal and readjust if required. If a manure belt gets torn under any circumstance immediately repair the torn place.

Cages Use an inspection cart for checking etc. Do not step on the feed troughs! Replace any damaged component parts as necessary.

When performing maintenance or repairs make sure the local control switch is OFF and the main electrical power control panel is OFF and tagged

“DO NOT OPERATE”

ALL Guards are for your personal safety and protection. “DO NOT OPERATE” the machinery without the Guards in the manufacture’s intended positions. Always replace and/or close the Guards before restoring the

electrical power to the machinery.

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Egg Belt Check all cages for dead birds; remove all the dead birds before gathering the eggs to prevent trouble during the collection of the eggs. In areas where the eggs are not washed we also recommend that all cracked and shell-less eggs be removed before gathering the eggs to prevent eggs from getting dirty.

Inspect belt for any fraying, if there is fraying fix any tracking problems and/or repair/replace any parts that the belt is rubbing on.

Egg Belt Idler Units

Check the belt operation at all idler/take-up points or cleaners for proper function and immediately correct any damage.

Egg Belt Drives Clean egg transfer area and egg counters. Immediately correct any damage that has occurred.

Clean drive rollers and compression rollers as well as the egg belt idler units or cleaners and check for proper functionality.

Adjust compression rollers if any slippage occurs under heavy egg loads.

Egg Collection Cross-Conveyor

Check the oil level in the reservoirs of the transport chain lubrication system and check their function. If required immediately add oil. Use a light oil such as SAE 10.

Clean egg transfer area and check the conveying chain or the transport belt for trouble free operation. Readjust if required.

Finger Belt Collector

Check the fingers make sure that they are in sufficient condition to handle the eggs. If not replace any fingers that are damaged or missing.

Check whether the egg belts are operating without slipping. If there is damage, check for possible reason(s) and repair the damage. If no problem can be detected, increase the tension on the compression rollers (within reason).

Check whether the finger belts are operating without slipping. If there is damage, check for possible reason(s) and repair the damage. If no problem can be detected, increase the tension on the belt (within reason) using the take-up.

Clean egg transfer area. Immediately correct any damage that has occurred.

I-Beam Collector

Clean egg transfer areas. Immediately correct any damage that has occurred.

Check all chains, if any chain is lose then adjust its take-up.

Feed Augers and Silo/Bin

Check the sensor for proper function

Fans Check all blades for proper function. Check all control devices for proper function.

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Section 3: Recommended Weekly Maintenance

Category Recommended Maintenance CheckedFeed Chain Check the feed chain tension, first the chain should be pulled tight then the chain should

be relaxed. Once the chain is relaxed the following formula should be used for determining the amount of chain that should be removed: X = (Total length of chain for the given tier) * 0.045 / (# Drives). Upon start up the chain should rise up two or three inches and then lay down flat quickly before this slack enters the first feed corner.


Clean the V-scrapers/Auger and idler roller scrapers and check for proper function. For trouble-free operation, the return circuit of the belt always has to be clean.

Cross Manure Removal

Clean the scraper at the drive and the idler unit.

Cages

Ensure that the cages are in good condition and make certain that there aren’t any foreign objects that could injure the birds.

Egg Belt In areas where the eggs are not washed we recommend that the part of the cage bottoms which are underneath the feed troughs be cleaned to prevent eggs from getting dirty.

Egg Belt Drives Empty the dirt collecting boxes then clean the egg collection areas with high-pressure air.

I-Beam Collector

Empty the dirt collecting boxes then clean the egg collection areas with high-pressure air.

Check if the take-up on the elevator chain is exhausted. If so release tension, then remove 5 inches (2 I-Beams) reconnect chain and re-tension the chain.

Fans Clean the wire mesh guard. Debris significantly decreases efficiency of the fans.

Alarm System Check the alarm signal for proper operation with respect to both the water supply and the temperature aspects (both excessively high and low temperatures).

Emergency Power Generation

Check the emergency power unit for proper function by means of a test run and, in any case, refer to the manufacture’s maintenance instructions.





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Section 4: Recommended Monthly Maintenance

Category Recommended Maintenance CheckedWater Supply Clean and flush the drinker line especially in hot weather. (NOTE: frequency of cleaning

and flushing the drinker line does depend on the water quality at your facility)


Check the drive sprocket and power shoe to assure they are in proper working condition. If they appear to be excessively worn, rotate the parts and install them using the opposite side or order new parts to replace the worn ones.

Check the feed chain to make sure that it is running straight through the drive, between the drive wheel and the power shoe.

Corners Remove caked feed remains. Check the bearings, chain guide rails and guiding clips in the corner bottom to be certain that they are not too worn. Replace worn parts if necessary.

Oil corners: If your corners have oil cups check the level of the oil in the cups; SAE 80 weight oil should be used in the oil cups. If you do not have oil cups on your corners you should oil the corner every two months with SAE 10 weight oil.

Manure Belt Drive

Clean the drive unit and lubricate all roller chains and sprockets; we recommend SAE 30 weight oil.


Clean the drive unit and lubricate all roller chains and sprockets; we recommend SAE 30 weight oil.

Cages

Check whether the systems including drive end sets are properly aligned and are not displaced. If necessary, correct misalignment.

Egg Belt Check egg belts for excess stretching. The egg belt should not sag more than 6 in or 15 cm between two brackets for returning egg belt.

Egg Belt Drives Lubricate the roller chains and sprockets with SAE 30 weight oil.

Egg Collection Cross-Conveyor

Lubricate the roller chains and wheels at the drive


Lubricate the roller chains and sprockets with SAE 30 weight oil.

I-Beam Collector

Lubricate the roller chains and sprockets with SAE 30 weight oil. We do offer an optional chain lubricator setup for the elevator chains. If you have this system, turn on the oilers while the collectors are running.


Check the tension of the V-belt.

Fans If existing, check the tension of the V-belts.

Alarm System Check the batteries.





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Section 5: After Each Flock Recommended Maintenance

Category Recommended Maintenance CheckedWater Supply Clean and flush drinker lines.


Check the gap between the power shoe and the sprocket; it should be .05 inches or less.

Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s recommended maintenance schedule.

Feed Hopper Adjust all feed level slides to the same level; to prevent feed losses set the feed level low. Check the remix wheel for wear, replace any damaged or worn components

Manure Belt Drive



Release the tension on the manure belt, if the house temperature is going to drop below 60ºF (15.5ºC)

Manure Belts Check the weld joints of the manure belts.


Clean the entire conveying system and replace any corroded parts.

Cages

Clean the cages between flocks either wet or dry. If wet cleaning, make sure that all the feed is out of the trough (if wet feed gets into the barrel(s) of the chain and dries it can cause cracks and/or break the chain, when it goes through the corners). After wet cleaning turn the ventilation on maximum to speed up the drying thus minimizing corrosion. During cleaning, protect electric appliances such as motors and switch boxes from damage by direct splash water. It is not recommended to use cleaning agents.

Egg Belt Idler Units

Check plastic cleaner, if it is badly worn rotate or replace it.

Egg Belt Drives Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s recommended maintenance schedule.



I-Beam Collector






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Check for rain/moisture leaks in both the silo/bin and the boot/un-loader. If there are areas that are leaking repair/replace the parts that are functioning improperly.

Lubricate the un-loader/boot bearing. Replace excessively worn parts. Clean the inside of the silo thoroughly. Follow manufactures safety procedures. Check the silo/bin lid for proper operation; if the lid is not operating correctly

repair/replace the parts that are functioning improperly.

Check the feed tubes for wear. If the wear is excessive replace the worn parts.

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Section 6: Recommended Maintenance by Category

D Daily maintenance W Weekly maintenance

M Monthly maintenance AF After each flock maintenance

Water Supply [NOTE: Please refer to your Val Watering Installation, Part List Operations and Maintenance Instruction Book; we recommend that you clean and flush drinker lines after each medication] D Check the birds’ water consumption and record it. D Check the water column inside the transparent hose at the beginning and end of each cage row. D Check the nipple drinkers. Immediately clean any that are leaking or not working properly. If the

problem persists replace the nipple drinker(s). M Clean and flush the drinker line especially in hot weather. (NOTE: frequency of cleaning and flushing the

drinker line does depend on the water quality at your facility) AF Clean and flush drinker lines.

Feed Chain [WARNING: Shut off electrical power and wait for all motion to stop before doing any maintenance dealing with the chain feeding system] [NOTE: The tension on all of the chains should be checked weekly] D Make sure that the feed chain is always lying flat in the feed trough. If it buckles during operation

immediately switch off the drive. Check whether the feed chain is caught somewhere, if it is, correct the problem.

W Check the feed chain tension, first the chain should be pulled tight then the chain should be relaxed. Once

the chain is relaxed the following formula should be used for determining the amount of chain that should be removed: X = (Total length of chain for the given tier) * 0.045 / (# Drives). Upon start up the chain should rise up two or three inches and then lay down flat quickly before this slack enters the first feed corner.





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Feed Hopper [WARNING: Rotating parts, shut off electrical power and wait for all motion to stop before removing any foreign matter in the hopper] D Check the feed level at the feed level slide. Remove feathers and other foreign matter.

AF Adjust all feed level slides to the same level; to prevent feed losses set the feed level low. AF Check the remix wheel for wear, replace any damaged or worn components

Feed Chain Drive Unit [WARNING: Rotating parts behind the guard, shut off electrical power and wait for all motion to stop before removing guard] D Check the shear pin that connects the sprocket and hub. If the pin is sheared, replace the shear pin but,

before replacing the sheared off pin, correct the problem that caused the shear pin to break. M Check the drive sprocket and power shoe to assure they are in proper working condition. If they appear to

be excessively worn, rotate the parts and install them using the opposite side or order new parts to replace the worn ones.

M Check the feed chain to make sure that it is running straight through the drive, between the drive wheel

and the power shoe. AF Check the gap between the power shoe and the sprocket; it should be .05 inches or less. AF Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s

recommended maintenance schedule.

Corners [WARNING: Rotating parts behind the guard, shut off electrical power and wait for all motion to stop before removing guard] D Check all of the feed chains and the corner wheels to make sure they are operating correctly; the corner

wheels should be rotating trouble-free. Remove any foreign objects that may be caught in the feed corners, do this after shutting off the electrical power.

M Remove caked feed remains. Check the bearings, chain guide rails and guiding clips in the corner bottom

to be certain that they are not too worn. Replace worn parts if necessary. M Oil corners: If your corners have oil cups check the level of the oil in the cups; SAE 80 weight oil should

be used in the oil cups. If you do not have oil cups on your corners you should oil the corner every two months with SAE 10 weight oil.

Manure Belt Idler Unit [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] D Check the manure belt idler take-up, if the take-up is completely exhausted; move the take-up back to its

original location then remove the excess belt and re-weld the belt W Clean the V-scrapers/Auger and idler roller scrapers and check for proper function. For trouble-free

operation, the return circuit of the belt always has to be clean. AF Release the tension on the manure belt, if the house temperature is going to drop below 60ºF (15.5ºC)

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Manure Belts D Check the alignment and tension during each manure removal and readjust if required. D If a manure belt gets torn under any circumstance immediately repair the torn place. AF Check the weld joints of the manure belts.

Manure Belt Drive [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] D Clean the manure scrapers at the drive and check for proper operation before or after each manure

removal. Check the manure scrapers, if they are badly worn rotate or replace them. D Check whether the belts are operating without slipping, assuming that the belt is not overloaded. If there

is damage, check for the possible reason(s) and repair the damage. If no problem can be detected, increase the compression force of the rollers as necessary (NOTE: tighten within reason).

M Clean the drive unit and lubricate all roller chains and sprockets; we recommend SAE 30 weight oil. AF Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s


Cross Manure Removal [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] [NOTE: Follow manufacture’s recommended maintenance schedule] W Clean the scraper at the drive and the idler unit. M Clean the drive unit and lubricate all roller chains and sprockets; we recommend SAE 30 weight oil. AF Clean the entire conveying system and replace any corroded parts.

Cages D Use an inspection cart for checking etc. Do not step on the feed troughs! D Replace any damaged component parts as necessary. W Ensure that the cages are in good condition and make certain that there aren’t any foreign objects that

could injure the birds. M Check whether the systems including drive end sets are properly aligned and are not displaced. If

necessary, correct misalignment. AF Clean the cages between flocks either wet or dry. If wet cleaning, make sure that all the feed is out of the trough (if

wet feed gets into the barrel(s) of the chain and dries it can cause cracks and/or break the chain, when it goes through the corners). After wet cleaning turn the ventilation on maximum to speed up the drying thus minimizing corrosion. During cleaning, protect electric appliances such as motors and switch boxes from damage by direct splash water. It is not recommended to use cleaning agents.

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Egg Belt [NOTE: The egg belt should be tightened until there is 35 and 40 lbs of pressure on it. This should be done when the slack is being removed from the egg belt. The slack in the egg belt should be removed if the egg belt take-up’s, take-up is exhausted or if there is more than 6 inches of slack between the guide brackets.] D Check all cages for dead birds; remove all the dead birds before gathering the eggs to prevent trouble

during the collection of the eggs. In areas where the eggs are not washed we also recommend that all cracked and shell-less eggs be removed before gathering the eggs to prevent eggs from getting dirty.

D Inspect belt for any fraying, if there is fraying fix any tracking problems and/or repair/replace any parts

that the belt is rubbing on. W In areas where the eggs are not washed we recommend that the part of the cage bottoms which are

underneath the feed troughs be cleaned to prevent eggs from getting dirty. M Check egg belts for excess stretching. The egg belt should not sag more than 6 in or 15 cm between two

brackets for returning egg belt.

Egg Belt Idler Units D Check the belt operation at all idler/take-up points or cleaners for proper function and immediately correct

any damage. AF Check plastic cleaner, if it is badly worn rotate or replace it.

Egg Belt Drives [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] D Clean egg transfer area and egg counters. Immediately correct any damage that has occurred. D Clean drive rollers and compression rollers as well as the egg belt idler units or cleaners and check for

proper functionality. D Adjust compression rollers if any slippage occurs under heavy egg loads. W Empty the dirt collecting boxes then clean the egg collection areas with high-pressure air. M Lubricate the roller chains and sprockets with SAE 30 weight oil. AF Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s


Egg Collection Cross-Conveyor [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] [NOTE: Follow manufacture’s recommended maintenance schedule] D Clean egg transfer area and check the conveying chain or the transport belt for trouble free operation.

Readjust if required. D Check the oil level in the reservoirs of the transport chain lubrication system and check their function. If

required immediately add oil. Use a light oil such as SAE 10. M Lubricate the roller chains and wheels at the drive.

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Finger Belt Collector [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] D Clean egg transfer area. Immediately correct any damage that has occurred. D Check whether the egg belts are operating without slipping. If there is damage, check for possible

reason(s) and repair the damage. If no problem can be detected, increase the tension on the compression rollers (within reason).

D Check whether the finger belts are operating without slipping. If there is damage, check for possible

reason(s) and repair the damage. If no problem can be detected, increase the tension on the belt (within reason) using the take-up.

D Check the fingers make sure that they are in sufficient condition to handle the eggs. If not replace any

fingers that are damaged or missing. M Lubricate the roller chains and sprockets with SAE 30 weight oil. AF Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s


I-Beam Collector [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] [NOTE: Wash (remove the I-Beams if you are going to wash them) or clean off I-Beams as dirt build up effects the performance of the collector; If the elevator chain is bouncing the chain needs to be either oiled or it is to tight, thus if the chain still has lubrication on it decrease the tension by loosening the chain take-up] D Clean egg transfer areas. Immediately correct any damage that has occurred. D Check all chains, if any chain is lose then adjust its take-up. W Empty the dirt collecting boxes then clean the egg collection areas with high-pressure air. W Check if the take-up on the elevator chain is exhausted. If so release tension, then remove 5 inches (2 I-

Beams) reconnect chain and re-tension the chain. M Lubricate the roller chains and sprockets with SAE 30 weight oil. We do offer an optional chain

lubricator setup for the elevator chains. If you have this system, turn on the oilers while the collectors are running.

AF Check the oil level in the gear reducer. If low add proper lubrication as specified by the manufacture’s


Fans [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] [NOTE: Follow manufacture’s recommended maintenance schedule] D Check all blades for proper function. D Check all control devices for proper function. W Clean the wire mesh guard. Debris significantly decreases efficiency of the fans. M If existing, check the tension of the V-belts.

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Feed Augers and Silo/Bin [WARNING: Rotating parts behind the guards, shut off electrical power and wait for all motion to stop before removing guards] [NOTE: Follow manufacture’s recommended maintenance schedule] D Check the sensor for proper function. M Check the tension of the V-belt. AF Clean the inside of the silo thoroughly. AF Lubricate the un-loader/boot bearing. Replace excessively worn parts. AF Check the feed tubes for wear. If the wear is excessive replace the worn parts. AF Check the silo/bin lid for proper operation; if the lid is not operating correctly repair/replace the parts that

are functioning improperly. AF Check for rain/moisture leaks in both the silo/bin and the boot/un-loader. If there are areas that are

leaking repair/replace the parts that are functioning improperly.

Alarm System [NOTE: Follow manufacture’s recommended maintenance schedule] W Check the alarm signal for proper operation with respect to both the water supply and the temperature aspects (both

excessively high and low temperatures). M Check the batteries.

Emergency Power Generation [NOTE: Follow manufacture’s recommended maintenance schedule] W Check the emergency power unit for proper function by means of a test run and, in any case, refer to the

manufacture’s maintenance instructions.

When performing maintenance or repairs make sure the local control switch is OFF and the main electrical power control panel is OFF and

tagged “DO NOT OPERATE”

ALL Guards are for your personal safety and protection. “DO NOT OPERATE” the machinery without the Guards in the manufacture’s

intended positions. Always replace and/or close the Guards before restoring the electrical power to the machinery.

Maintenance Schedule For Cage Systems - · PDF fileVersion 1A – Last Updated September...

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Transcript of Maintenance Schedule For Cage Systems - · PDF fileVersion 1A – Last Updated September...