102: NCA's Monthly Inspection

Date *

Ensure all warehouse fire extinguishers are in place and tagged properly *

Pass

Fail

N/A

If other, precise:

Inspect all dock plates, remove debris, ensure proper function *

Pass

Fail

N/A

If other, precise:

Visually inspect parts inventory and0 update list with parts used and parts ordered *

Pass

Fail

N/A

If other, precise:

Inspect all fire extinguishers, emergency exits, and emergency lighting for proper tagging, function and location *

Pass

Fail

N/A

If other, precise:

Monthly Checklist *

	Pass	Fail	N/A	Refer to Notes
Clean all photo cells and reflectors with a mild dishwashing detergent (like Dawn)
Roller Deck Maintenance: Check roller-chain for excessive sag, rust, discoloration and drive slack chain (chain should be snug, not tight). Replace roller chain if necessary (chain stretch under 14 mm)
Roller Deck: Check the condition of roller-chain sprockets. Sprocket alignment is incorrect if one-sided wear of sprocket.
Roller Deck: Check for any axial roller displacement. Align rollers if necessary (maximum 0.5-0.7 mm misalignment)
Roller Deck: Check rollers for eccentricity (max 2-3 mm) in the center and both tube ends
Friction Drive Maintenance: Check for loose friction drive chain, and gear wheel alignment
Friction Drive: Check drive chain (max. Elongation 2%)
Running Gear Maintenance: Check tread
Running Gear: Check for, and retighten, loose fasteners
Running Gear: Check side rollers
Hoist and Carriage Maintenance: Check wire rope lubrication, wire rope terminations for any irregularities, inspect wire rope in accordance with requirements
Hoist and Carriage: Check drives
Hoist and Carriage: Check gearbox (oil level and temperature)
Hoist and Carriage: Check drum
Hoist and Carriage: Check sheaves and pulley. Check for, and retighten, loose fasteners. Check groove for excessive wear
Hoist and Carriage: Check tread for cleanliness and smoothness
Hoist and Carriage: Check surface of rollers and beams for burrs, sharp edges, etc.
Hoist and Carriage: Check bearings for tight fasteners and smooth turning

If other, precise:

Elevating Transfer Vehicle (ETV) System Checklist *

	Pass	Fail	N/A	Refer to Notes
Visually check ETV rail and end stops. Ensure all rail clipps are properly tightened.
Visually check each of the storage conveyors. Make sure there is no damage to the rollers, bearings, or ratchet locking device.
Visually inspect the ETV for any damage, broken parts, broken welds, etc.
Visually inspect the rack containing the ET positioning equipment and slowdown sensors. Also, check the power rail trolley and associated power rail bus.
Run the ETV back/forth the full loength of the aisle-checking for unusual noise or vibration.
Run the ETV up/down the full vertical travel-checking for unusual noise or vibration.
Check for forced slowdown/stop at each end of rail trvel. Do same for vertical travel of hoist.
Check positioning at each horizontal location. Do same for each vertical location.
Run the extractor out at each storage location and power location. Check for proper function.
Check aisle obstruction E-Stop function-in both directions.
Check load overhang photo cell function.
Test all pilot light bulbs via the "press to test" function.
Move a test load/pallet onto and off of the ETV deck. Check for proper operation. Does the conveyor sound okay?
Test the E-stop function-check all E-stop buttons for proper operation.
Check to make sure the warning horns and warning lights are functioning properly.
Check operator cabin doors to ensure ETV won't run with doors open.

If other, precise:

Workstation Lift Units Checklist *

	Pass	Fail	N/A	Refer to Notes
Visually inspect "above ground" portion of workstation lift unit. Record/log any apparent damage to conveyor, rollers and lift side skirts.
Remove any individual roller/wheel cover plates that have been damaged. (When enough plates have been damaged and removed, a date should be scheduled where these plates are replaced on each of the drive-over conveyor units in the facility.)
Remove maintenance pit cover and climb down into lift pit area. Visually inspect for hydraulic leaks. Check all hose connections for both high pressure and low pressure return lines.
Check hydraulic pump fluid level when lift is in the up position. Add replacement fluid as required.
Visually check hydraulic pump unit for leaks or potential problems.
Run lift unit up/down several times with both unloaded condition and loaded condition. Check for any unusual noise or vibration.
Check lift for automatic positioning at conveyor transfer level.
Check lift for automatic lock-up at floor drive-over level.
Check lift safety photo cell to ensure that lift cannot be lowered significantly below floor level without pallet or load on lift.
Test E-stop function on associated operator's console.
Test all pilot lights on adjacent console via the "press to test" funtion.
Check photo cell at south end of workstation lift conveyor deck to ensure that load stops properly, even when operator maintains joystick in direction of travel.
Place measured weight on conveyor deck-check for accurate scale read-out.

If other, precise:

Truck Doc (TD) Lift Unit Checklist *

	Pass	Fail	N/A	Refer to Notes
Visually inspect "above ground" portion of truck dock lift unit. Record/log any apparent damage to conveyor, rollers, and lift side skirts.
Climb into lift pit area. Visually inspect for hydraulic leaks. Check all hose connections for both high pressure and low pressure return lines.
Check hydraulic pump fluid level when lift is in the up position. Add replacement fluid as required.
Visually check hydraulic pump unit for leaks or potential problems.
Run lift unit up/down several times with both unloaded condition and loaded condition. Check for any unusual noise or vibration. Return to home position.
Run conveyor deck sideways in both directions-return to home position. Check for any unusual noise.
Check lift for automatic positioning at conveyor transfer level.
Check winch unit for proper operation.
Check ram protection photo cell to ensure that lift cannot be moved when truck is against ram unit (PC blocked).
Test E-stop function on associated operator's consoles.
Test all pilot lift faults on adjacent console via the "press to test" function.
Check photo cell at south end of truck dock lift conveyor deck to ensure that loads stops properly, even when operator maintains joystick indirection of travel.
Put measured weight on TD lift scale conveyor. Check for accurate read-out of weight.

If other, precise:

Power Conveyors Checklist *

	Pass	Fail	N/A	Refer to Notes
Visually check all powered conveyors for any apparent damage. "Walk" all powered conveyors and "flag' each ULD/pallet photo sensor to determine that it works properly. Check to make sure there is the proper safety margin on the photo cell range by monitoring the "red" 2X pilot light on the photo cell unit.
Manually run each conveyor (without load). Listen for unusual noise or vibration.
Manually run pallet/ULD through all powered conveyor units to confirm that each conveyor work properly under load. Side shift pallets on Heliroll decks. Rotate pallets where appropriate.
With the doors in the closed position, run pallet in direction of door. Check to make sure that pallet stops before hitting door.
Test E-stop functions on operator's station associated with power conveyors.
Test by-=pass line automatic accumulation function. ensure that amber warning lights are turned on whenever automatic accumulation function is in operation.
Test electrically operated pallet stops to ensure proper operation. Make sure they are not binding in either the down or up direction.

If other, precise:

General PM Items Checklist *

	Pass	Fail	N/A	Refer to Notes
Check maintenance log book to review problems that occurred since the last maintenance.
Talk with supervisory personnel (and equipment operators) about the system pprformance during the last operational period.
Review with supervisory and operational personnel the procedure for getting "on call" maintenance service.
Impress upon NCA operating personnel the importance of maintaining an accurate maintenance log book.

If other, precise: