Npl 5500 Caddy Cart & Hitch

STANDARD OPERATING PROCEDURE

NPL 5500 CADDY CART & HITCH LOAD & UNLOAD PROCEDURE

I. Prepping

A. Caddy Cart 1) Put the twin hooked hanging device through the holes at the rear of the cart with the hooks facing inward. 2) Put the twin cylinder hanging device through the sleeves at the front of the cart and secure in place with the proper pins and cotter pins. 3) Cap all threaded bolts and plug all holes tightly with the proper sized caps and plugs.

Note: Holes that are not plugged on the cart will cause certain locations to fill with water and in turn cause cure failure as well as chemical runs.

4) Bottom sleeves get single cylinder cap put in, secured with pin and cotter pins after the cart is loaded onto the line securely.

Twin hooked hanging device Twin cylinder hanging device

Single cylinder sleeves

B. Caddy Hitch 1/7 (Company) TECHNICAL TRAINING DEPARTMENT 1) Put the twin hooked hanging device through the holes at the front of the hitch facing inward. 2) Slide rod through hole in beam nearest the bend, out the opening at the end of the beam and pull through the chain links hanging device back to the hole. Keep this device secured there so it can be used to attach to the hook on the line. 3) Put the steel cap in the hole on the 5/8” plate.

Note: Failure to cap this hole will result in water getting into a cavity inside the tube and causing cure failure.

4) Plug the remaining two large holes in the beam on the angled down section.

Note: There is a size difference in the gap between the hooks of the twin hook hanging devices for the cart and hitch. Make sure to use the proper one.

Twin hooked hanging device

Steel cap Chain link plate through first hole by bend in hitch

2/7 (Company) TECHNICAL TRAINING DEPARTMENT II. Loading Set Up

A. Caddy Cart 1) Put up a 30” x ¾” parallel hook off the bottom chain link of the track. 2) Skip one chain and put up a 26” x ¾” perpendicular hook.

B. Caddy Hitch 1) Put up a 1000 lb. spreader bar on the track. 2) Go to the 4th chain link after the bar and put up a regular 40” perpendicular hook with an 8” parallel hook.

III.Loading

A. Caddy Cart 1) Double wrap a 6 ft. sling around the middle of the upper beam of the cart and attach the load block of the hoist to the eyelets of the sling.

Note: Make sure hoist is centered directly above the cart to prevent any swinging once lifting has begun.

2) Bring the cart to the track using the hoist and hook the front hanging device onto the 30” hook. 3) Next, hook the rear twin hook hanging device to the 32”/16” hook combination. 4) Double check the hooks are properly attached front and rear, and then slowly lower the cart so it is suspended from the hooks on the track. 5) Remove the load block from the sling eyelets and remove the sling from the cart. 6) Put the two cylinders in the bottom sleeves and secure them in place with the pins and cotter pins.

3/7 (Company) TECHNICAL TRAINING DEPARTMENT B. Caddy Hitch 1) Double wrap an 8 foot sling around the beam of the hitch, approx. 2 ft. from the bend going towards the plate and attach the load block of the hoist to the eyelets of the sling.

Note: Make sure hoist is centered directly above the hitch to prevent any swinging once lifting has begun.

2) Bring the hitch to the track using the hoist and hook the front twin hook hanging device directly to the 1000 lb. spreader bar. 3) Attach the chain link hanging device, coming through the first hole after the bend in the beam, to the 32”/16” hook combination. 4) Double check the hooks are properly attached front and rear, and then slowly lower the hitch so it is suspended from the hooks on the track. 5) Remove the load block from the sling eyelets and remove the sling from the hitch.

4/7 (Company) TECHNICAL TRAINING DEPARTMENT IV. Unloading

A. Caddy Cart 1) Double wrap a 6 ft. sling around the top beam of the cart and attach the load block of the hoist to the eyelets of the sling.

2) Lift until you can free the front bar hanging device and the rear twin hook hanging device from the hooks on the track. 3) Set the cart down on a pallet for transport 4) Remove the load block from the sling and remove the sling from the cart. 5) Remove the hanging devices and the two cylinders from the cart. Place them all together on a pallet. 6) Get a forklift driver to transport the cart to the caddy assembly area by door 21.

5/7 (Company) TECHNICAL TRAINING DEPARTMENT B. Caddy Hitch 1) Double wrap an 8 foot sling around the beam of the hitch, approx. 2 ft. from the bend going towards the plate and attach the load block of the hoist to the eyelets of the sling.

2) Lift until you can free the twin hook hanging device from the 1000 lb. spreader bar and the chain link hanging device from hooks on the track 3) Set the hitch down on the rolling carts provided for transport. 4) Remove the load block from the sling and remove the sling from the hitch 5) Remove the hanging devices and place them on the pallet with the caddy hanging devices. 6) Bring the hitch down to the caddy assembly area near door 21. 7) Bring the pallet of caddy cart/hitch hanging devices back to their respective weld stalls for the next units to be loaded.

5500 Caddy Cart & Hitch Quality Assurance Checklist

Date: ______Time: ______am/pm

Sequence Number: ______Cart / Hitch

PRETREATMENT

Wash Operator: ______Employee ID#: ______

PREATREATMENT CONDITIONS

Inproclean 1300 H2O Rinse Cryscoat 347C H2O Rinse H2O Rinse

%: ______%: ______%: ______%: ______%: ______pH: ______pH: ______pH: ______pH: ______pH: ______temp: ______C temp: ______C temp: ______C temp: ______C temp: ______C psi: ______psi: ______psi: ______psi: ______psi: ______tds: ______tds: ______tds: ______

6/7 (Company) TECHNICAL TRAINING DEPARTMENT PRETREATMENT TESTING

Water break (visual): ______Comments: ______

Phosphate (T.S. #47): ______Comments: ______

White rag test : ______Comments: ______

Flash rust N/C: ______- ______

Chemical run N/C: ______

(All testing locations to be documented on appropriate diagram.)

Painted by: (east) ______Employee ID#: ______

Painted by: (west) ______Employee ID#: ______

CURE CONDITIONS

Oven Temp: ______Track Speed: ______ft/min.

Comments: ______

7/7 (Company) TECHNICAL TRAINING DEPARTMENT CURE TESTING

Pinholes Classification: ______Paint Mils:

Hatch Test Result: ______Minimum: ______

MEK Test Result: ______Maximum: ______

Gloss Rating: ______Average: ______

Paint non-conformance: ______

______

Repaint: NO YES Reason: ______

Inspection by: ______

Employee ID#: ______

Signed off by: ______

REPAINT RECORD

Area(s) repainted: ______

Reason: ______

Description of work: ______

Rechecked/ signed off by: ______

Employee ID#: ______

Time/Date Started: ______

Time/Date Finished: ______

Total Time to Fix: ______

8/7 (Company) TECHNICAL TRAINING DEPARTMENT 9/7 (Company) TECHNICAL TRAINING DEPARTMENT