General Preventive Maintenance Tasks

The tables are intended as a guideline and should not replace periodic maintenance schedules derived in the plant.

Tasks	Daily	Weekly	Monthly	Quarterly	6 Months	Yearly
Tasks	Daily	Weekly	Monthly	Quarterly	6 Months	Yearly

Verify all covers and doors are closed and secure. Guards, shields, and other mechanical safety devices: Ensure all safety devices are properly installed and fully functional.	✓
Check all limit switches for looseness, wear or malfunction.		✓
Check all hoses, piping, cylinders, valves, fittings, mufflers, and gauges for damage, wear or leaks.		✓
Loose bolts: Ensure that all bolts are tightened to specifications.		✓
Bearings, couplings: Check for excessive wear, noise, heat, vibration, binding or out of position. Grease and lubricate as specified in this manual.		✓
Check all rough locators and locating pins for wear or damage. Look for loose bolts, missing shims, and bent or distorted details. Verify that all part locators are in correct alignment and that the parts are being located correctly.			✓
Shot pins: Inspect for wear and replace if needed.			✓
Rest pads: check rest pads for wear, loose bolts and fasteners, make sure that they make even contact on the body surfaces. Clean blocks of debris and other foreign parts.			✓
Part clamping fixtures: Verify clamping fixture is clear of debris and slag. Verify that all part clamping units are in correct alignment and that the parts are being clamped correctly.			✓
Clamping parts: check for loose or missing shims on clamping details, check side plates for loose fasteners, wear and cracks. Check clamps for alignment side play and bushing wear.			✓
Check metal (part) clearance to clamps and adjust as required. Check clamping cycles for timing with metal in fixture.			✓
Mechanical safety devices: Inspect and make sure all safety devices are properly installed and fully operational.			✓

Tasks	Daily	Weekly	Monthly	Quarterly	6 Months	Yearly
Tasks	Daily	Weekly	Monthly	Quarterly	6 Months	Yearly

Verify that all safety devices are functioning properly.	✓
Check all emergency stop push buttons for function and indicator lamp illumination. Repair or replace non-functioning push buttons and lamps.	✓
Check all indicator lights on the electrical panels for burned out light bulbs.	✓
Check electrical panel for spare fuses and I/O fuses. Make sure they are not blown.		✓
Check terminals and connectors for looseness or signs of overheating. If there is evidence of overheating, termination points should be cleaned or replaced.		✓
Limit switches: Check for proper trip position, location and operation.		✓
Proximity switches: Check for presence of debris on unit. Clean proximity switches as needed to maintain system uptime. Check for loose connections and damaged housings. Tighten where needed and replace unit if defective.		✓
Wiring: Check for broken, loose, and damaged wires. Check all electrical cables for signs of damage and make sure all connections are tight and secure.			✓
Light curtains: Inspect interconnecting electrical and data cables for evidence of wear or damage. Replace if necessary. Clean the lenses using a clean soft cloth moistened with 70-100% isopropyl alcohol or an equivalent non-abrasive glass cleaner.			✓
Electrical enclosures: Wipe and clean the inside of the main electrical enclosures. Check for obvious signs of damage and repair as necessary.				✓
Wipe and clean the inside of the electrical control enclosure and all junction boxes. Check for signs of damage.				✓
Disconnect assembly: Verify the disconnect function. Check for loose, bent, or broken components.				✓
Circuit breakers: Inspect for loose or broken terminals. Check for the presence of contaminants like dirt, dust, grease, or rust. Remove dust, dirt, soot, grease, or moisture from the surface of the circuit breaker using a lint-free dry cloth, brush, or vacuum cleaner If contamination is found, look for the source and eliminate the problem.				✓
Power distribution blocks: Verify blocks are tight and free of corrosion. Check for presence of contaminants like: dirt, dust, grease, or rust.				✓
PLC and power supply units: Inspect for loose or broken terminals. Check for the presence of contaminants like dirt, dust, grease, or rust. Replace as required.				✓
Push button bases: Check the wiring insulation for heat damage, small cracks, brittleness, or sections of missing insulation. Check for oil or chemical exposure, swelling or loose terminals.				✓
Contact relays: Check for broken or shading coils, dirty magnet faces, and loose terminals. During operation, verify no excessive arcing is present. Replace if damaged.				✓
Servo Motors: Inspect servo motor for damage or overheating. Verify the motor power and feedback connectors are tight. Check for any signs of impact on the outer shaft that may indicate damage to the bearings. Blower vents on motor must be kept clear for air circulation, clean any accumulated dirt.				✓
Check that all cables, terminals, and connectors are clean, undamaged, and tightly seated.						✓
Check contacts for wear. Contacts should be replaced when silver has become badly worn. Always replace contacts in complete sets to avoid misalignment and uneven contact pressure.						✓
Check all electrical cables and connections for signs of damage or deterioration and make sure all connections are tight and secure.						✓

Tasks	Daily	Weekly	Monthly	Quarterly	6 Months	Yearly
Tasks	Daily	Weekly	Monthly	Quarterly	6 Months	Yearly

Check lines, hoses, and fittings: Check for leaks, loose fittings, and damaged or kinked lines. Replace if necessary.	✓
Drain drip leg.		✓
Check condition of air filter to see if the filter needs changing. Change filter if necessary. Drain any accumulated condensation in the filter bowls if not fitted with automatic drain.		✓
Pressure regulator: Verify the regulator valve is functioning properly.		✓
Pressure regulator: Check for correct pressure settings. Adjust according to tag setting.		✓
Pressure gauges: Verify the pressure gauge readings comply with the tags and adjust pressure if necessary.		✓
Inspect hoses and tubing for leakage due to cracks and loose fittings.			✓
Inspect fittings and couplings for looseness resulting from machine vibration.			✓
Manifolds: Check for leaks, loose manifold fittings, and broken or kinked lines. Replace or repair as required.			✓
Directional valves: Verify the valves are operational. Increase or decrease pressure according to values on tags and gauges.				✓
Cylinders: Verify seals on cylinders for leaks and inspect the cylinder rod for scoring.			✓
Flow controls: Inspect flow controls for proper settings, leaks and for proper operation.		✓
Silencers (Mufflers): Check filter element cartridge for dirt, metal chips, and other contaminates. Replace element cartridge if necessary.			✓
Pressure switches: Verify the switch is operating to set points.			✓
Pressure switches: Verify the pressure readings comply with the tags and adjust pressure if necessary.			✓
Inspect regulators and flow controls for proper pressure settings, leaks and for proper operation.			✓
Clean and inspect pressure and proximity switch mountings for security and proper placement. Check wiring for looseness, tighten or align if necessary.				✓
Check and inspect all pneumatic cylinders, pneumatic manifolds and valves for wear, leaks or other signs of deterioration.				✓

General Preventive Maintenance Tasks

Interactive Training Systems Inc.

Doug Maguffee - President

Amy Seymour - Key Account Manager

For technical questions on the Quick Response Library, please contact one of these Interactive Training Systems employees.