Attachment 2 - Basic P.M. Procedures Final Draft.docx

Attachment 2 - Basic Preventative Maintenance Procedures

Data collected from basic preventive maintenance either checked or inspected is documented for TEAD records. All the documentation should be ISO (International Organization for Standardization) controlled, and electronically transferred to a database for future comparison and historical reports.

HYDRAULIC SYSTEMS:

· Check oil levels in power unit tanks.

· Check for temperature changes in the oil.

· Check for leaks.

· Check and tighten screws and pipe clamps.

· Verify pressure gauge readings.

· Empty all valve panel drip pans.

· Check and replace filters.

· Check the condition of hydraulic hoses.

· Check the condition of all hydraulic cylinders.

· Check counterbalance.

· Check for worn or defective parts.

· Tighten pipe clamps, if necessary.

· Tighten bolts on the pumps, electric motors, valves, etc.

ELECTRICAL SYSTEM:

· Clean electrical cabinet

· Check incoming voltages

· Check DC bus voltage

· Inspect connections and terminals

· Inspect electrical ground connections

· Replace or clean filter fan

· Check safety locks

· Check axis motors and cables

MECHANICAL SYSTEM:

· Verify machine level

· VMC – verify spindle sweep

· Lathe – verify turret square to spindle face

· Check lubrication is reaching the spindle

· Inspect rotary oil level (mill)

· Inspect drive belts

· Verify gearbox/motor operation

· Inspect tool changer and lubricate

· Inspect spindle taper condition (mill)

· Inspect toolholders and grease pull studs (mill)

· Verify smooth turret indexing (lathe)

AIR & LUBRICATION SYSTEM:

· Inspect filters

· Check lubrication level and replenish if needed.

· Inspect hoses and fittings

· Grease parts thar look dry.

· Check pump operation / test

· Check/adjust pressure, spindle regulator

· Check spindle mist

· Inspect system for leaks

· Change gearbox oil (lathe only)

· Verify lube/pump operation for axes

· Inspect all lines and hoses

· Verify all pump operation

· Check incoming air supply

COOLANT SYSTEM:

· Inspect coolant hoses

· Verify all pump operation

· Inspect and clean coolant filters

· Inspect, Test and adjust coolant concentration

· Completely clean Inspect coolant tank for sediment and replace the coolant.

· Clean and replace inline air filters

· Clean the filter screen

· Inspect the coolant level.

· Inspect for coolant leaks.

· Grease coolant motor bearings

· Verify coolant refill is operating correctly

SPINDLE:

· Clean pump filter

· Inspect the hoses for cracking

· Verify the Auto Clean system is operating correctly

· Clean and lubricate the spindle taper.

· Spindle drawbar force and tension measurement.

· Inspect lubrication tank level.

· Perform Spindle Lubrication Test.

· Bearing temperature

MECHANICAL SYSTEM:

· Inspect tool holders/grease pull studs.

· Inspect the rotary oil level (Mill)

AUTOMATIC PALLET CHARGER:

· Clean debris from the APC and Receiver areas

· Clean debris from receiver pallet clamped switch.

· Grease the plunger.

· Clean the locating pins and bushings.

· Inspect the pallet wipers.

· Inspect the door for proper operation.

· Grease the door side guide rails

AUTOMATIC TOOL CHARGER:

· Clean the chips from the tool changer

· Inspect motors and mechanical sensors.

· Inspect motors and proximity sensors.

· Inspect the arm plunger and adjuster assembly.

· Clean and lubricate the pocket tool plungers.

· Clean and lubricate the track on the carousel housing that the tool pocket rollers ride on (SMTC30/50 only)

· Grease the tool changer cams.

· Grease the guide rails.

· Grease the extractor fingers.

· Inspect and replace worn pocket components: springs, plungers

AUXILIARY FILTER

· Replace the filter bag.

· Inspect the hoses for cracking.

LINEAR & ROTARY AXIS:

· Inspect grease reservoir level.

· Inspect the hoses for cracking.

· Inspect ball screws wear and backlash

· Ball bar analysis

· Replace the oil.

· Inspect the oil level.

· Inspect the A-Axis counterbalance cylinder for oil leaks.

· Replace the A-Axis counterbalance cylinder.

COUNTERBALANCE

· Inspect the counterbalance pressure.

ELECTRICAL CABINET

· Clean vector drive air vents / filter.

ENCLOSURE/SAFETY:

· Inspect safety interlock operation

· Inspect windows for damage

· Inspect way covers and wipers

· lubricate way covers

PROBE SYSTEM:

· Check the probe batteries

· Check probe calibration

GEARBOX:

· Inspect the oil level.

· Clean the oil pump inlet screen

· Replace the oil

OIL SKIMMER:

· Inspect the oil skimmer pickup tube.

PNEUMATICS:

· Inspect the spindle air regulator pressure.

· Inspect the hoses for cracking.

· Clean the Air Purge Solenoid.

CALIBRATIONS:

· Calibrate machine