Performing preventive & corrective maintenance

Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines
3. FOR MILLING MACHINES

3.1 SPINDLE
Check the oil level in the spindle reservoir by
stopping the machine and checking the level on
the oil level gauge.

Oil level gauge

3.1.1 If needed, add oil to the spindle reservoir
through the filler cap at the back of the
machine. The reservoir holds the oil that
lubricates the spindle drive, the spindle
drive gearbox and the pulley bracket.

Spindle filler cap

3.2 KNEE
The knee lubrication system lubricates the knee drive, feed distribution box, feed and rapid
traverse drive brackets, column and knee ways, and the elevating screw. The Filler Cap is
located just above the level gauge

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Nov. 28, 2003 June 30, 2010 4

Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

3.3 SLIDEWAYS Hand pump

The way surfaces of the machine are oiled through the filler cap
Oil reservoir
lubrication pump located on the knee of the machine.

 The pump maintains constant pressure to the lubrication

system. As the oil in the system gets used, the pump allows
more oil to flow. The pump handle should be actuated
initially until the handle no longer reaches the bottom of
its stroke.

 The reservoir can be filled through the filler cap on the top of

the reservoir.

There are many miscellaneous components on the horizontal
milling machine which need to be oiled by hand using filler cups

Filler cups are positioned at numbers 5,6,7,8,9,10 in Figure 1. Oil filler cup
These filler cups need to be filled every day.

Figure 1

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Nov. 28, 2003 June 30, 2010 5

Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Nov. 28, 2003 June 30, 2010 6

Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Nov. 28, 2003 June 30, 2010 7

Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

MEASURING OF Iceo (Leak Current) FOR TRANSISTOR
1. Adjust 0 by setting the range selector knob to a proper
range from X1~X1k.
2. For NPN transistor, apply a black test pin to the collector
and the black one to the emmiter.
3. Determine the leak current by Iceo scale indicated on the
scale plate. (Unit in A, mA)

MEASURING OF DIODE (Including LED)

1. Adjust 0 by setting the range selector knob to a proper
range from X1 (150mA)~ X100k (1.5A).
2. Apply the black test pin to anode side and the red one to
cathode side when measuring IF (forward current). Apply the
black test pin to cathode side and the red one to anode side
when measuring IR (reverse current).
3. Read the indicated value by LI scale. (The pointer
moves to a considerable extent for IF, and little extent for IR)
4. Value indicated on LV scale during the measurement is the forward voltage of diode.

Note: Additional information is available in the supplemented Learning Element entitled
"Measuring Electrical Voltage Using a Multimeter".

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Nov. 28, 2003 June 30, 2010 8

Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

SCALE READINGS

Range Multiplied Range Multiplied
DCV 10 X1
 X 100K X 100K 4 DCV 1000 X100
ACV 1000 X100
X1k X1k 5 ACV 10 X1
1 6 C (F) X1
150mA at X1 X10 (mA)
X10 X10 15mA at X10 X1 (mA)
7 X10 (A)
X1 X1 15A at X1k X0.1 (A)
1.5A at X100k X1
DCV 250 X1 8 LV X1
9 hfe X1
DCV 2.5 X0.01 ACV 10 14dB added
ACV 50 28dB added
DCV 0.25 X0.001 10 40dB added
ACV 250
2 ACV 250 X1 ACV 1000

DCA 0.25 X0.001

DCA 25m X0.1

DCA 2.5m X0.01

DCV 50 X1

3 ACV 50 X1

DCA 50 X1

4 DCV 0.1 X0.01

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Nov. 28, 2003 June 30, 2010 9

Information Sheet 7.1.1 : Maintain Hand tools

Learning outcomes:
1 Maintain hand tools
Learning Activity:
1.1 Maintaining hand tools

HAND TOOLS
Hand tools have been designed to apply one or more principles of the science of mechanics to
make tasks easier.

Cleaning and maintaining hand tools will prolong its life service, it will also keep it on its tip-top
shape, ready to be used anytime. Hand tools are categorized as follows:

1. Fastening tools
a. Spanners
b. Wrenches
c. Screwdrivers
d. Keys

Maintenance and storage rule:
 Keep fastening tools free from any lubricant and dirt.
 Segregate spanners according to its type for easy identification and access.
 If possible, use a tool cabinet.
 Keep screwdriver tips dressed.
 Replace worn out or cracked fastening tools with new ones.

2. Gripping and clamping tools
a. Pliers
b. Clamps
c. Vice grips
d. Vices

Maintenance and storage rule:
 Keep gripping tools free form any lubricant and dirt.
 Lubricate joints of gripping tools
 Put in a tool cabinet and segregate it according to its type
 Keep the jaws of clamping tools clean.
 Replace worn out or cracked tools with new ones

Code No. Perform reventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Aug 15, 2003
Mar 01, 2006 1

Information Sheet 7.1.1 : Maintain Hand tools

3. Impact tools
a. Hammers
b. Mallets
c. Punches

Maintenance and storage rule:
 Keep impact tools free form oil and dirt, specially the handle.
 Replace any cracked or broken handle to ensure safety
 Never hung impact tools to prevent accidents

4. Cutting tools
a. Chisels
b. Files
c. Hand snips
d. Saws
e. Drills
f. Tap

Maintenance and storage rule:
 Keep cutting tools dressed.
 Replace any cracked or broken cutting tool.
 As much as possible do not let each cutting tool get in contact with each
other during storage, because it can damage other cutting tools.
 Keep in a dry storage.
 Never hung impact tools to prevent accidents

Code No. Perform reventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Aug 15, 2003
Mar 01, 2006 2