Task ID.

Daily.

Weekly.

Monthly.

3 Monthly.

6 Monthly.

Clean photo eyes, reflectors and proximity sensors

X

Inspect the fan filter in control console (if fitted).

X

Inspect proximity switch adjustments.

X

Inspect reed switches.

X

Inspect mechanical switches.

X

Inspect the PLC battery indicator.

X

Inspect wiring (visual).

X

Inspect all other switches and buttons.

X

Test 24-volt DC supplies for adjustment.

X

Procedure.

Follow this procedure to maintain Bushes and Cam Tracks.

Step.

Action.

     1.       

Remove excessive foreign material.  Use a dry lint free cloth.

     2.       

Inspect bushes and cam tracks for excessive play and/or damage.  Report excessive play or damage to your supervisor.

Procedure.

Follow this procedure to maintain a Pneumatic Service Unit.

Step.

Action.

1.

Inspect the operational condition of the equipment. Test the isolation and lockout control is functioning correctly. Report any damage or safety issues to your supervisor and replace the unit.

2.

Inspect the filter bowl is clean. Clean with a dry lint free cloth if necessary.

     3.       

Inspect the pneumatic filter for debris. Clean or replace if necessary.

     4.       

Test for pressure on the pneumatic regulator gauge. Adjust if necessary and ensure handle is returned to the locked position to prevent self adjustment resulting from vibration. Refer to Maintenance Specification for pneumatic pressure setting.

     5.       

Ensure seals are in good condition.

     6.       

Inspect all fittings and pneumatic lines, tighten if required.

     7.   

Test for leaks.

     8.       

Clean the pneumatic service unit and any spills.

Procedure.

Follow this procedure to inspect the Belts and Pulleys/Chain and Sprockets.

Step.

Action.

     1.       

Inspect for any physical wear and tear. Report any defects to your supervisor.

     2.       

Test belt tension is sufficient to avoid slippage. 

     3.       

Inspect pulleys are not slipping on the shaft and are aligned with the transmission belt and correctly tensioned.

Procedure.

Follow this procedure to tension Drive Belts.

Step.

Action.

     1.       

Check the alignment of all drive pulleys.

     2.       

Adjust belt tension by adjusting the four adjusting screws on motor mount plate.  Drive belt tension should be approximately 5 mm deflection over a 300 mm span (measured at centre of span).  Refer Fig 1.

Procedure.

Follow this procedure to tension drive chains.

Step.

Action.

    1. 

Check the alignment of all drive sprockets.

    2.

Adjust chain sag to match the table below.

Procedure.

Follow this procedure to inspect a Pneumatic Cylinder.

Step.

Action.

 1.

Inspect the nose cone seal for leaks; this is typically the first area of leakage.

 2.

Visually inspect that the cylinder operates smoothly. Inconsistent operation indicates that the cylinder requires servicing or needs to be replaced by suitably qualified personnel.

 3.

Inspect the wiring to ensure the cable is not damaged.

Procedure.

Follow this procedure to maintain a Reed Switch.

Step.

Action.

     1.       

Clean the body with a soft dry lint free cloth or soft brush. Note any setting and position.

     2.         

Test if the sensor is functioning correctly. Is the LED indication visible when the cylinder is extended or retracted? If the LED is not visible check if the reed switch is securely attached to the cylinder.

     3.         

Inspect the cylinder to determine if it is functioning correctly. If necessary, adjust the position of the reed switch until the correct setting is found. Repositioning the reed switch must be within the operating parameters of the cylinder. 

     4.      

Inspect the wiring to ensure the cable is not damaged.

     5.         

If the sensor is not responding to adjustments report the defect to your supervisor. All reed switches must be replaced by suitably qualified personnel.

Procedure.

Follow this procedure to maintain a Fasteners

Step.

Action.

    1.

Clean with soft dry lint free cloth.

    2.

Visually inspect for fatigue or stress fracture.  Inform manager if found.

    3.

Inspect for loose fasteners.  Lock tight/replace as appropriate any lose or worn fasteners.

Procedure.

Follow this procedure to maintain a Photo Electric Sensor.

Step.

Action.

     1.       

Clean the lens and body with a soft dry lint free cloth or soft brush. Note any setting and position.

     2.       

Test if the sensor is functioning correctly. Is the LED indication visible when covered or uncovered? Adjust the sensitivity of the sensor if necessary and check again until the correct setting is found. If the sensor is not responding to adjustments report the defect to your supervisor. All photoelectric sensors must only be replaced by qualified personnel.

Procedure.

Follow this procedure to secure and adjust the sensitivity of a Photo Electric Sensor.

Step.

Action.

     1.       

Adjust the sensitivity to the maximum setting by turning the sensitivity potentiometer, this is normally indicated by a ‘+’ symbol. The adjustment can usually be made either on the back or top of the unit.

     2.       

Aim the receiver unit at the sender unit until the LED indicator on the receiver unit turns [on] (light switching) or [off] (dark switching if the LED is permanently on). 

     3.       

To be certain the sensor beam is centred, sweep the sender unit across the receiver unit in the vertical plane and determine the position where the LED indicator turns [on] and then [off]. It is important to ensure that the sensor units are also aligned in the horizontal position. When in the correct position the fixings on the brackets can be tightened. Do not over tighten the fixing screws on the sensor as this will damage or impair the function of the unit.

     4.       

Reduce the sensitivity by turning the potentiometer towards the ‘–‘ symbol until the LED indicator begins to flicker or goes out completely. Slowly turn the potentiometer back in small increments in the ‘+’ direction until the LED indicator displays a solid indication.

     5.       

It may be necessary to reduce the sensitivity to a lower setting for transparent or translucent materials or to detect objects smaller than the effective beam.

     6.       

Test operation and adjust if necessary.

Procedure.

Follow this procedure to maintain a Proximity Switch.

Step.

Action.

     1.       

Clean the threaded barrel proximity switch with a dry clean lint free cloth or soft brush. Check the condition of the proximity switch and cable. If damaged report the defect to your supervisor. 

     2.       

Test the operation of the proximity switch by observing if the LED indicator alternates between on and off when using a test piece to activate it. 

     3.       

Read the information on the proximity switch. Contained in this is the part code and sensing range. Ensure you test within the sensing range of the proximity switch.

     4.

To adjust the air gap, gently slacken off the locknuts of the proximity switch.

     5.        

Set the air gap to suite the sensing range of the proximity switch. Ensure the LED on the proximity switch is visible.

      6.

Tighten the securing locknuts.

    7. 

Test the operation of the proximity switch and make further adjustments if necessary.

Procedure.

Follow this procedure to maintain and replace a Safety Interlock Switch component.

Step.

Action.

     1.    

Clean the switch head and body with a soft dry lint free cloth or soft brush. Note all settings and positions.

     2.       

Inspect the condition of the actuating head, switch body and the cable. If any damage is found report it to your supervisor.

     3.       

If the actuator or head needs to be replaced, it is important to note all positions and connections before commencing any work. Slacken off all fixing screws, and remove the damaged component. The component must be replaced with a compatible part. It is important to use the correct tools and securely tighten terminals and the component after installation.

     4.    

Secure the actuator or switch in its original position and test the operation.

     5.    

Make adjustments and fully tighten all fixings when the set-up is complete.

Procedure.

Follow this procedure to maintain a Pneumatic Energy system.

Step.

Action.

        1.       

Remove excessive foreign material from on or around tubing and equipment. Use a dry clean lint free cloth or soft brush.

     2.    

Inspect the equipment and tubing for damage. Report any defects to your supervisor.

     3.    

Tighten fittings; ensure the tubing is pushed securely into the fittings.

     4.    

Ensure restrictor locking nuts are in place and finger tight.

     5.    

Inspect all equipment and fixings are secure and tight.

     6.    

Check that the equipment and tubing identification labels are present, replace if necessary.

     7.    

Test the supply pressure and inspect sensing devices. 

     8.    

Test operation and make adjustments if necessary.  (Refer to the Maintenance Specification section)

Procedure.

Follow this procedure to maintain the PLC battery.

Step.

Action.

     1.      

Check that the service date is written on the battery cover.

       2.         

If the LED warning light indicating the battery has failed is on, replacement the battery immediately.

Under no circumstances, turn the power off to the PLC when changing the battery. If the power is turned off, the contents of the PLC will be lost.

Procedure. 

Follow this procedure to clean vacuum filters and for inspection of valves.

Step.

Action.

     1.      

Visually inspect valves for damage.  Report any damage to your supervisor.

     2.      

Visually check vacuum filter inspection window.  Remove window to clean filter.

     3.      

Remove filter elements from vacuum filter and clean/replace as required.

Procedure. 

Follow this procedure to clean vacuum cups.

Step.

Action.

    1.

Visually inspect cups for damage to the cup lips.  Inform your manager if the cups are damaged.

    2.

Blow out the holes in bottom of cups.

    3.

Clean the contact faces of the cup with an approved silicon spray on a clean lint free cloth.

Procedure. 

Follow this procedure to inspect pneumatic service units.     (Refer Detail A).

Step.

Action.

        1.

Inspect pneumatic tubing for damage, leaks, or wear.

        2.

Inspect pneumatic regulator gauges operate correctly.  Refer to “Maintenance Specification” in section 5.2 for the Pneumatic system Settings.

        3.

Inspect all fixings and connections are tight.

4.

Inspect pneumatic filters.

No.

Item.

Comments.

     1.   

On / Off Valve

Turns air off to the machine

     2.   

Filter/ Regulator

Filters small particles and regulates pressure

     3.   

Branching Module

Used for air supply that won’t be dumped on e-stop

     4.   

Monitored Safety Dump Valve

Dumps compressed to the machine