1、Manufacturing Standards Ford Motor Company 1.0 INTROOUCTION 2.0 AIR SEALS 2-3 2.1 General Information 2.2 Entrance Air Seal 2.3 Exit End Air Seal PAINT BAKE OVENS CLEANING AND MAINTENANCE TABLE Of CONTENTS PAGE(S) 2 3.0 HEATING SYSTEM AND OVEN INTERIOR 3.1 Gas Fuel Supply 3,2 Filters for Make-Up and
2、 Canbustion Air 3.3 Operational Inspection, Servicing and Training Data on Direct-Gas Fired Combustion Units 3.4 Cleaning-Direct Gas Fired Combustion Chambers, Heater Fans, Interior ofSupply and Recirculating Duckor% and Oven Interior 3.4.1 Major Cleaning A. Dry Cleaning Method 8. Wet Cleaning Metho
3、d 3.4.2 Minor Cleaning 4.0 EXTERIOR 4.1 Oven Top, Exterior to suit “reach“ and accessibility requirements in the oven. Other Equipment Information It is essential that cleaning solution and rinse water be vacuumed from the floor of the oven immediately with a vacuum having adequate capacity to . rem
4、ove lfqufds,as fast as they are applied to prevent puddling and ponding and subsequent damage of insulation. Also, the vacuums should be drained to an industrial waste sewer. To expedite the cleaning process, a typical electrocoat oven requires (3) cleaner applicator units and (3) vacuums. The use o
5、f steam in oven cleaning is not recommended. Steam cleaners generate excessive moisture condensation and insulation penetration. Cleaner Application Data . Dilute WB311A(F) Paint Bake Oven cleaner 4:l to 2:l with water Pre-test oven walls to determine the amount of cleaner needed. Then dilute to sui
6、t soil and application conditions. Apply with foam unit or law pressure spray (the lower the pres- sure the greater the “hang-time“ will be on vertical surfaces). . Provide longest possible/practical contact time. Apply at ambient temperature (lOOoF is the maximum temperature l recommended) Note: Ov
7、en panels, partitions and air ducts are constructed of aluminized steel. If the aluminized surface is removed, oven interior surfaces will oxidize or rust which will generate airborne dirt for deposition on painted bodies. Since cleaners are generally alkaline, precautions must be exercised to assur
8、e that the cleaning solution selected does not affect the aluminized surface. To verify the reactivity of the cleaner with aluminum or any ques- tionable component, soak it in the appropriate cleaning solution to verify compatibility. No chemical attack should be visible. This includes bubbling, for
9、mation of non-rinsing films or pitting on the metal surface. The material recommended in this procedure is not detrimental to aluminized surfaces. Page 8 of 16 hny m U.S.A. MAINTENANCE PAINT BAKE OVENS Manufacturing Staff september , 1985 Manufacturing Standards Ford Motor Company Cleaninq Rinsing T
10、echnique . Use highest pressure possible for maxinum impingement . Hold nozzle at 45 to surface for maxim cutting action . Volume/flow rate should match extraction capacity if possible . &blent temperature should be used Other Precautions Use plastic covering on all areas susceptible to water damage
11、 such as burner unit controls, buss liner, etc. This process is not recommended for ovens with non-aluminized surfaces. B. Wet Cleaning Procedure 1. Lock out all oven controls, i.e. heating and conveyor system fans, burners, motors, etc. 2. Remove floor coverings such as aluminum foil, drip pans, et
12、c. used in the entrance part of the oven. Clean drip pans by scraping or other suitable means. If a tacky masking oil was used on the oven floor, mop clean. 3. Scrape and brush to loosen any heavy material accumulation on the interior oven surface such as the floor, walls, etc. Vacuum floor. 4. Insp
13、ect burner compartments and interior of air supply and recirculation ductwork. Scrape and brush to loosen any heavy material accumulation. Vacuum as required. 5. Spray clean the interior of the heater compartmant and the heater fans and the interior of ductwork connecting the heater to the supply an
14、d recirculating air systems. Allow material to soak for a minimum of 15-20 minutes before rinsing. Vacuum any pools of water. 6. Open hinged access doors on the supply, return and exhaust ductwork inside the oven. Spray clean oven interior including ceiling or roof, interior and exterior sections of
15、 the duct- work, nozzles, piping, conveyor gurard, etc., rail and support steel, chain. Clean side walls from bottom up. A minimum 15- 20 minute soak is desired before rinsing and vacuuming. If the loose, dusty fines are not completely removed, re-apply cleaner. Also, stubborn deposits may require a
16、 cleaner soaking period. Again, rinse and wet vacuum. Also, cleaning solution may be applied to the entire length of the oven interior prior to the rinsing and vacuuming procedure. Manufacturing Staff April, 1984 mru&A MAINTENANCE PAINT BAKE OVENS B2Gx Page 9 of 16 GED Manufacturing Standards Ford M
17、otor Company B. Wet Cleaninq Procedure Continued. 7. 8. 9. 10. 11. 12. Raise oven temperature gradually to operating temperature. Cool and reinspect (especially joints and seams). Spot clean by scraping, vacuuming and tacking off as required. Use capressed air to blow out any inaccessible areas. Che
18、ck oven lights for burned out bulbs. Replace as required. Replace floor coverings. If oven floor is oiled, use M- 99C96A. This product is not to be used in ovens operating above an ambient temperature of 350F (177CI. Product is applied with brushes, rollers, or mops. Apply material in a manner to pr
19、eclude fonning “pools“ and “puddles“. Inspect the burner. The flame rod nust be in place. Ignition rail and/or flame barrel and baffle should be in good condi- tion. Clean clogged parts. Check ignition, spark plug and clean or replace as necessary. Verify that oven controls are set properly. Raise o
20、ven temperature gradually and flln 2-3 hours at operating temperature. Cool and reinspect. Spot clean as required. Complete pre-burn cycle and continue to run oven at operating conditions for 6 to 8 hours. Again reinspect and spot clean as required. After an oven cleaning, make arrangements for the
21、oven to be started at least 2 hours before production starts. Note: If paint oven cleaning equipment or skills are not available or a time factor exists, consider the use of an outside, properly insured service contractor. Contractor should be able to reference previous automotive paint oven cleanin
22、g experience. . . 3.4.2 Minor Cleaning Suggested Cleaning Frequency: As required General Information: Between “bare metal“ or major cleanings, vacuuming and tack cloth wiping are used 1 n varying degrees as necessary to l limfnate loose particles and minimize the rate of material build-up on oven fl
23、oors, walls, burners, etc. 4.0 EXTERIOR: 4.1 Oven Top, Exterior and Adjacent Floor Areas Weekly Procedure Clean fioors between ovens. Apply M-9G29A floor finish if desired. Page 10 of 16 mmmatnu.u MAINTENANCE PAINT BAKE OVENS Manufacturing Staff April, 1984 Manufacturing Standards Ford Motor Company
24、 Quarterly Procedure BXX Check door seals for leaks. Replace seals as required. Remove debris and vacuum tops of ovens. Use Central vacuum system piped along oven or portable vacuum. Oven top cleaning may be needed more frequently in areas where dry sanding or polishing are done outside of enclosure
25、s or near operations such as cushion department. Annual Procedure Check oainted surfaces. Wash. WNCh-UD or reDaf nt as reouired. Paint Paint Paint Paint Paint Paint Clean ii&walls WI th M-425 White Enamei(aee &J50a)i tops with M-5J77A Alumqnum. ladders and handrails M-325 Yellow (see M-550). catwalk
26、s M-333 Black (see M-5J50a). burner enclosures M977A AlunHnum, rotors and fans M-5J85A Gray or M-5J94A Broua and paint floors with recommended clear epoxy. 4.2 Sealing Ovens FTPI rove e sea ing curtains over the oven entrance and exit during downtimes when oven is shut off if settled dust on vehicle
27、s presents a quality problem at start of production. Most plants use expendable material such as plastic sheets. Remove curtains from the oven vicinity prior to igniting burners. 5.0 CONTROL AND RECORDING INSTRUMENTS: 5.1 Temperature Recorders for Calibration of Paint Bake Ovens and Monitoring Metal
28、 Temperatures of Body or Paint Being Processed. General Information: As outline in the Plant Engineering Oepartment General Letters #280 and #222, oven operating curves must be obtained using a 12.point travelling temperature recorder. data is to be plotted on an &Y x 11” The paint bake oven “Oven T
29、emperature“ chart and it should be forwarded to the Divisional Plant Engineering Department for analysis and distribution to affected activities. All oven adjustments necessary to assure conformance to the specified requirements should be made before running the temperature curves. Follow manufactur
30、ers instructions for maintaining %$the instruments. Repair as required. Oven operating and temperatures nust be maintained in accordance with processing require- ments. Each plant must have personnel with the expertise to adjust, calibrate, repair and replace recorders and controllers. At least one
31、qualified tradesman must be available on each maintenance shift for servicing such equipment. Further, each plant must maintain ready access to outside assistance .from qualified service companies in the near or immediate vicinity of the plant site to assure emergency service availability. Manufactu
32、ring Staff m*LuA B2GX AprTl, 1984 MAINTENANCE PAINT BAKE OVENS Page 11 of 16 Manufacturing Standards Ford Motor Company 5.2 Oven Temperature Control and Recordinq Instruments 5.2.1 Compressed Air Filter/Dryer for Instrument Controls Weekly Procedure Drain all canpressed air filters on each air line
33、that SuDlies oven recording andcontrol instruments. The compressed air must be maintained free of water, oil and scale. The filter-dryer element aust be replace before air quality problems occur. 5.2.2 Recording Themwxneters with Pneumatic Control Weekly Procedure Check the operation of the fiber-ti
34、p pens. Replace the ink cartridge if required. (The ink color fades as the ink supply becomes marginal). Check and lubricate the chart drive hub friction spring. Lightly oil the chart drive spring, using the type of oil recaamended by the equipment supplier or equivalent high grade instrument oil. L
35、ubricate the cam drive gear train, using the type of oil recommended by the equipment supplier or equivalent high grade instrument oil. Place a drop of oil on each gear tooth of the drive gear trai n. Monthly Procedure Visually check ttk sensor (thermal bulb) at the end of the capillary tubing for a
36、ny accumulation of deposits that might affect sensi- tivity. Also, where long lengths of tubing are used, check inspection, that the protective tubing shield is not damaged. 5.2.3 Oven Burner Controls Monthly Procedure Before making any checks, make sure visually that the ground connections on the R
37、arPe detector are good. Clean the lens on the viewing window. Verify that the pilot flame adjustment is proper. Inspect all air filters on controls. Drain, clean or replace necessary. by as Visually verify that correct settings on high and low gas pressure switches and the combustion air pressure sw
38、itch are as specified for proper operation. Check to assure that the pressure switch covers are in place and that the switches are not blocked, jumpered out or damaged. Also, check for proper operation and adjust or repair as necessary, B2GX Page 12 of 16 -mtl.SA MAINTENANCE PAINT BARE OVENS Manufac
39、turing Staff April, 1984 Manufacturing Standards . Ford Motor Company B2 Monthly Procedure Continuted. Verify that the purge timer is not blocked out or jumpered out. Inspect the burner for clogged ports and clean as required. Check the ignition spark plug and clean or replace when required. Check t
40、he main exhaust blower air flaw switch for proper operation. Assure that the cover is in place and the vane is not blocked or stuck open. Verify that the high temperature limit switch is correctly set and functioning properly. Note any raw gas odor around unit. If present, notify your super- visor i
41、mmediately. 5.2.4 Gas Shut-Off Valves Annually, all lubricated type gas shut-off valves should be lubri- cated in accordance with the valve manufacturers recommendation. 6.0 MISCELLANEOUS 6.1 Fans Quarterly Procedure Inspect to detenaine that the lubricant seals are in good condition. Also, note if
42、bearing is hot, noisy or vibrating. Check condition of lubricant feeder lines where the point of lubrication is remote from the bearing. Replace worn or loose belts (in sets). Check fill level on oil type bearings. Semi-Annual to Annual Procedure Lubricate grease type fan beari-ngs with a lithium ba
43、se grease such as M-lC7B, M-lC75B, etc. Wipe off surplus grease. Follow manufacturers recommendation for type of oil and draining frequency on oil type bearings. 6.2 Motors As Required Procedure lubricate the motor bearings in accordance with the manufacturers maintenance instructions. Manufacturing
44、 Staff April, 1984 MAINTENANCE PAINT BAKE OVENS Page 13 of 16 (z!a Manufacturing Standards Ford Motor Company 6.3 Stacks Annual Procedure Check amount of build-up. Clean if build-up exceeds l/8 thickness. Loose residues can be removed by scraping, brushing and vacuuming. If stack interiors contain v
45、arnish like build-up, clean chemically. Apply material with suitable spray application equipment. For heavy build-up, cleaner is to be used undiluted. See material section for recannendation. NOTE: If stacks cannot be accessed safely by the plants normal cleaning methods, consider the use of an outs
46、ide, properly insured service con- tractor. Check guy wires and supports. Repair broken or loose guy wires. Check for evidence of corrosion and cracking. . Check access doors. Repair broken hinges and -latches. Check any stack caps for wind damage and corrosion. Repair as required. Check for corrosi
47、on on black iron stacks, wire brush exterior, prime with M6J139A Gray Primer and finish coat with M5J37 Aluminum. Check opening in stack skirts for sprinkler lines, conduit, etc. and if open, re-caulk to prevent leakage. Check draw rings around skirts and stacks for leaks and tighten or re- caulk as
48、 required to prevent leaks. 6.4 Conveyor Systems 6.4.1 Cleaning Overhead Monorail Conveyors Weekly Procedure Check trolleys, conveyor and rail for cleanliness. If required, clean by scraping, brushing and vacuuming. Obsewe operation of stationary btwsh/vacuum cleaning Unit. Change worn-out bNSheS. E
49、mpty vacuum system bag as required. On high pressure water type cleaners, check that air blow-offs or other drying devices are removing water and that the chain is being cleaned adequately (operational check). 6.4.2 Lubricating Overhead Monorail Conveyors Daily Procedure Lubricate open faced trolleys with M-99C39A oil. If an automatic lubricator is utilized, check its performance. No excess oil should be visible outside of the trolley bearing race. Adjust lubricator oil dispensing nozzle for amount and direction of lubricant. Always wipe up all excess lubricant and drip
