DL254
3 Detailed maintenance advice on workshop machines
3.1 Disc and belt sanding machines
Daily check
· Clean any dust not removed by the extraction system.
· Check condition of sanding belt/disc and replace if torn/worn.
· Check fit of sanding table to disc/belt (it should be as close as possible, normally no greater than 2 mm).
· Check that quadrant guard is in the correct position.
Weekly check
· Clean filters in dust-extraction system, if fitted.
· Empty dust-collection tray/bag if fitted.
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts, if fitted. Replace if worn.
· Lubricate if necessary.
· Check operation of dust-extraction system.
· Check bearings for wear.
3.2 Drilling machine
Daily check
· Check that the chuck guard is clean, functions correctly and is not cracked/broken.
· Make sure that the guard over the driving belt fits correctly and that the interlock or securing device is in place and working correctly.
Weekly check
· Make sure that the chuck key fits correctly and is not worn.
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
· Make sure that the drill head clamping bolts are tight and the head locking ring is in place.
· Make sure that the table clamp functions correctly.
· Check condition of drill bits. Sharpen as required. Replace twist drills that have worn shanks.
· If wooden blocks are used under the work piece, replace those that are worn.
Termly check
· Check condition of motor, drive system and drive belts. Replace if worn.
· Lubricate if necessary. Machines with gears running in an oil bath should have the oil level checked.
· Check bearings for wear.
· Check that machine vices and hand vices function correctly and are not worn or clogged with waste materials.
3.3 Bench-mounted jig saw
Daily check
· Clean any dust not removed by the extraction system.
· Check condition of blade and replace if blunt.
· Check that blade guard is correctly set.
· Where fitted, check that machine ‘foot’ functions correctly.
Weekly check
· Clean filters in dust-extraction system, if fitted.
· Empty dust-collection tray/bag, if fitted.
· Visually check condition of electrical switches, conduit, cable, etc.
· If fitted, check fit of table insert and replace if required.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts, if fitted. Replace if worn.
· Lubricate if necessary.
· Check operation of dust-extraction system.
· Check bearings for wear.
3.4 Band saw
Daily check
· Clean any dust not removed by the extraction system.
· Check condition of blade; replace if blunt or if welded joint on blade is suspect.
· Check that blade guard is correctly set.
· Check that machine braking system functions correctly.
Weekly check
· Clean filters in dust-extraction system, if fitted.
· Empty dust-collection tray/bag, if fitted.
· Visually check condition of electrical switches, conduit, cable, etc.
· If fitted, check fit of table insert to blade and replace if required; (the gap between the insert and the blade should be no greater than 4 mm).
· Check blade guides and thrust wheel for wear and adjust/replace as required.
· Check tracking setting and condition of rubber tyres on blade wheels, if fitted. Replace if required.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts, if fitted. Replace if worn.
· Lubricate if necessary.
· Check operation of dust-extraction system.
· Check bearings and blade guards for wear and replace if necessary.
3.5 Circular saw
Daily check
· Clean any dust not removed by the extraction system.
· Check condition of blade and replace if blunt.
· Check that top or crown guard is correctly set and connected correctly to the extraction system, if the latter is fitted.
· Check that machine braking system functions correctly.
Weekly check
· Clean filters in dust-extraction system, if fitted.
· Empty dust-collection tray/bag, if fitted.
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts, if fitted. Replace if worn.
· Lubricate if necessary.
· Check operation of dust-extraction system.
· Clean the inside of the machine using an industrial vacuum cleaner.
· Check fit of table insert, if fitted, and replace if required.
· Check bearings and replace if necessary.
· Check condition of crown guard and replace if necessary.
3.6 Planing machines for wood:
overhand planer, thicknesser, combined planer / thicknesser
Daily check
· Clean any dust/shavings not removed by the extraction system.
· Check that all guards are correctly set.
· Check that machine braking system functions correctly.
Weekly check
· Clean filters in dust-extraction system, if fitted.
· Empty dust-collection tray/bag, if fitted.
· Check condition of blades and replace if blunt.
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts. Replace if worn.
· Check condition of feed roller drive, clean, overhaul and lubricate as required.
· Lubricate if necessary.
· Check operation of dust-extraction system.
· Check bearings and blade guards for wear and replace if necessary.
3.7 Radial arm saw
Daily check
· Clean any dust not removed by the extraction system.
· Check that blade guard and side-protection guards are correctly set and function as required.
· Check that machine braking system functions correctly.
Weekly check
· Clean filters in dust-extraction system, if fitted.
· Empty dust-collection tray/bag, if fitted.
· Visually check condition of electrical switches, conduit, cable, etc.
· Check condition of rear timber support and replace if necessary.
· Check condition of blade and replace if blunt.
· Lubricate if necessary.
Termly check
· Check condition of motor and drive system.
· Lubricate as necessary.
· Check bearings and blade guards for wear and replace if necessary.
3.8 Wood-turning lathe
Daily check
· Clean any dust not removed by the extraction system, where fitted.
· Check functioning of electrical interlock for top guard on headstock, or mechanical fixing as appropriate.
· Check that foot switch or other emergency-stopping device functions correctly.
· Check that mandrel nose guard for unused spindle nose is in place.
Weekly check
· If fitted, check functioning of dust-extraction system.
· Visually check condition of electrical switches, conduit, cable, etc.
Termly check
· Check condition of motor, drive system and drive belts. Replace if worn.
· Lubricate as necessary.
· Check operation of dust-extraction system.
· Check bearings wear and replace if necessary.
3.9 Metal-turning lathe
Daily check
· Clean chuck guard and any chip screens if fitted.
· Check functioning of electrical interlock on chuck guard.
· Check that cover plate on outer end of hollow mandrel is in place.
· Check functioning of electrical interlock on change wheel guard.
Weekly check
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts. Replace if worn.
· Lubricate as necessary, including slideways.
· On machines with geared headstock, check oil level in gearbox.
· Check bearings for wear and replace if necessary.
· If fitted, check coolant pump and system; clean if required.
Yearly check
· If a coolant pump is fitted, drain the coolant, flush out the system with clean water and replace the coolant every 12 months.
3.10 Milling machine - horizontal/vertical
Daily check
· Clean all cutter guards.
· Check sharpness of milling cutters; take out of use any that are blunt or damaged.
Weekly check
· Visually check condition of electrical switches, conduit, cable, etc. This should include any separate motors used for power feeds.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts. Replace if worn.
· Lubricate as necessary, including slideways.
· Check bearings for wear and replace if necessary.
· If fitted, check coolant pump and system.
Yearly check
· If a coolant pump is fitted, drain the coolant, flush out the system with clean water and replace the coolant every 12 months.
3.11 Power hacksaw
Daily check
· Check condition of blade and replace if blunt, or damaged.
· Check that machine functions correctly.
Weekly check
· Clean machine of swarf/metal dust.
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts, if fitted. Replace if worn.
· Lubricate as necessary, especially sliders of saw arm.
· Check bearings for wear and replace if necessary.
· Check functioning of dash pot and pressure-relief system.
· If fitted, check coolant pump and system.
Yearly check
· If a coolant pump is fitted, drain the coolant, flush out the system with clean water and replace the coolant every 12 months.
3.12 Mortising machine
In most schools this machine is used infrequently. Therefore, the checks below should be made before use, rather than on a regular basis.
Before use
· Check condition of chisel and auger bit; replace or sharpen if blunt or damaged.
· Check that the vice functions correctly.
· Check that all guards are in place, including the guard around the auger chuck.
· Visually check condition of electrical switches, conduit, cable, etc.
· Lubricate if necessary.
Termly check
· Check condition of motor, drive system and drive belts, if fitted. Replace if worn.
· Lubricate as necessary, especially sliders of motor frame.
· Check bearings for wear and replace if necessary.
3.13 Double-ended, high-speed grinding machine
Weekly check
· Clean eye screens and check that they are in the correct position.
· Check position of tool rest and adjust if required; (the tool rest should be as close as possible to the grinding wheel, normally within 3 mm).
· Check condition of grinding wheels.
· Visually check condition of electrical switches, conduit, cable, etc.
3.14 Polishing/buffing machine
Weekly check
· Check position of spindle guards and adjust if required.
· Check condition of polishing mops.
· Visually check condition of electrical switches, conduit, cable, etc.
4 Detailed maintenance advice on metal-heating equipment
4.1 Gas safety system
Most school workshops that have several items of heat-treatment equipment will have a gas safety system which will not allow gas to flow through the system if a leak or other fault is detected, and which will stop the flow of gas if the electrical power is stopped, for example, if an emergency-stop button is operated. Where there is only one item of equipment, then the safety system is often built into the equipment itself.
The gas installation should be checked by a qualified gas engineer (ie, CORGI-registered) every 5 years. A record of the check should be kept.
The functioning of the gas safety system itself can be checked by normal operation. Normally a warning light will indicate the presence of a fault. Any faults should be rectified by a qualified, CORGI-registered gas engineer. The system and equipment connected to it should not be used until any faults have been corrected.
A gas shut-off valve should be installed in every room where there is a gas supply. This should be located in an accessible position and should be labelled. It should be standard practice to turn off the gas supply at the end of the school day, or earlier if the room is not used in the last period of the day. This leaves the room in a safe condition and serves as a check that the valve is working.
A shut-off valve should be fitted in the supply pipe to each item of equipment. This should be turned off when the equipment is not in use, and at the end of the school day.
In order to meet the requirements of the COSHH Regulations, the LEV system for heat-treatment equipment should be checked every 14 months.
4.2 Brazing hearth and/or chip forge
Weekly check
· Check condition of air and gas flexible hoses.
· If fitted, check functioning of spark igniter.
· Check function of gas shut-off valve.
· Visually check extraction system.
4.3 Crucible furnace
Note In most schools this equipment is used infrequently. Therefore the checks below should be made before use, rather than on a regular basis.
Before use
· The crucible should be inspected for damage or cracks. Any crucible showing signs of damage should be immediately discarded.
· Check condition of all personal protective equipment.
· Eye protection/face shields should be free of scratches and fit the user properly.
· Gloves should be of an appropriate size, sufficiently flexible to use and free of holes.
· The buckles on aprons should fasten correctly.
· Spats should fasten correctly.
· If a tilting type of crucible furnace is used, check that the tilt mechanism functions correctly.
· If the crucible is lifted out of the furnace and placed in a pouring ring, check that the lifting tongs and pouring ring are a good fit on the crucible.
· If fitted, check functioning of spark igniter.
· Check function of gas shut-off valve.
· Visually check fume-extraction system.
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School D&T Department
EQUIPMENT REGISTER AND MAINTENANCE LOG
Type of equipment …………………………. Serial No. ………………………………………. Location …………………………………………
Make ………………………………. If electrical, details of phase/ power, etc. ……………………………………………………………………
DATE OF SERVICE AND INSPECTION / REPAIR/SERVICING WORK REQUIRED/CARRIED OUT AND REMARKS / SIGNATURE OF PERSON CARRYING OUT SERVICE/ INSPECTION / DATE WORK WAS DONE / SIGNATURE OF PERSON CARRYING OUT WORK REQUIRED1