Machine Shop Maintenance

MACHINE SHOP MAINTENANCE
MAC03004
The Importance of Maintenance
1. It saves the money and effort that is needed if the machine is damaged.
2. It increase the productivity of the machine
3. It can avoid accidents
Different types of maintenance:

1. Corrective maintenance: it includes improvements (change in design or materials)
2. Repairs maintenance: doing the maintenance if required
3. Predictive maintenance: Identifying conditions that require corrections before a major
problem develops
4. Preventive maintenance: To prevent a major breakdown in the machine so as to interrupt
the production.
Equipment and tools used in maintenance:

A. Presses: they are used to dismantle bearings, gears and pulleys on or out of the shafts.
There are 2 main types
1. Mechanical presses
2. Hydraulic presses
1. Mechanical Presses: They are operated by hand and use the idea of rack and pinion or
screw and nut. They are simple to use and also easy to maintain.
Application:
Hydraulic Presses: They use hydraulic system for operation. They can produce big forces
with controlled displacement similar to car jack. They are more accurate than mechanical
presses but they also need more care.
B. Spirit Level: It is used to check

machine level if they are vertical or horizontal or not.
The principle relies on a curved glass tube partially filled with alcohol with air bubble
which floats to the height point of glass tube.
To use the spirit level just put it on the flat surface and move the surface to be levelled till
the bubble comes in the center.
C. Pullers: They are used to pull gears, pulleys, bushes and bearings out from shafts.
Puller can be manual or hydraulic or two jaw or three jaw. The jaws can be used to pull from
inside or outside.
Application:
D. Other hand Tools:

1. Pin Punches: They are used to drift pins of all types from holes. They are made from
toughened high carbon steel in sets to satisfy all requirements.
Application :
2. Hollow Punches: They are used to open hole in jacket materials when making a new
jacket. They are found in complete set to cut all holes.
Application:
3. Allen Key: They are used to open screw
Application:
4. Spanners: They ate used to open nut and bolts.

a. Socket
b. Open
Adjusting movement of the sliding parts
A. Method of controlling the movements.
The movements of sliding parts must be controlled to prevent any play or backlash.
The movements of sliding parts are
Carriage, cross slide, compound slide in lathe machine
Knee, saddle and table of milling machine
Ram and table of shaping and slotting machine
To control these movements a Gig, or Strip and Screw are used.
1. Gib: They are tapered strips fit between the
stationary and moving parts.
2. Strips and Screws: They are used to control the

movements of the small parts of the machine tools, it
can also be used to adjust gap between parts.
It consist of a ground parallel strips with a thickness
smaller that the gap between the 2 parts and a set of
screw used to stop and push the strip against other
moving parts.
B. Method of Adjusting
1. Adjusting linear movements such as movement of tables, cross slides, compound slides,
rams and over rams can be adjusted by using the control adjusting methods(Gibs, Strip and
screws).
By moving gib forward or backward movement can be adjusted also by tightening or
loosening the screw against the strip piece the linear movement can be adjusted then the
locking nuts are tightened to lock the screw.
2. Adjusting the Rotary movement : It can be adjusted by changing the brass nut if it is worn. If
the nut is subjected to some wear, the nut should be pushed against the spindle by inserting
a thin washer between the handle and fixed par.
3. Eliminating the Backlash: The Backlash is a no active movement of the handle or dial
caused by wear in spindle or the nut also, it happens due to missing of adjustment. It
can be Eliminated by
a. Using 2 nuts and
wedge piece
b. Using 2 nuts and moving one against the another
c. Using a worm and worm wheel

Basis of Dismantling and Reassemble
A. Methods of fastening parts together: to dismantle any parts you need to know how the
parts are fastened together.
Common method to locate or fasten parts together are
1. Bolt and threaded hole in the parts used to fasten parts together. Eg cover of an Unit
to the Unit body
2. Bolts and Nuts used to fix thin wall parts
3. Studs and Nuts used to fix small parts to the bodies of units and
machines.
4. Keys and Keyways used to locate gears, pulleys and flywheels to the shafts
5. Splines and Splines Shaft used for sliding member on

shafts such as gears and collars in gear box
6. Circular Clips used to retain parts that fits on shafts. They may be used as external or
internal retainers. Types
Application :
7. Split, tapers and straight pins: they are used to locate parts together also to fix two
parts such as collar with shafts
8. Ball and col springs: used with moving
parts to define the position of
displacement.
B. General notes on Dismantling parts of machine tools

1. Always isolate the machines electrically before dismantling any parts
2. Clean the parts that shall be dismantled
3. Never remove any safety trip guard or dog at any end of machine parts
4. Try to dismantle only required parts only, not all parts.
C. Procedure of Dismantling
1. Start with big parts, lay them in a separate place
2. Fit the bolts, pins, clips and keys in their original position to avoid loosing them
3. Put marks or numbers on the mating parts if there are not any before
4. Use the machine catalogue to see any details you may need
5. Arrange the dismantled parts in correct order on a clean place
6. If the maintenance work will takes a long time, keep the parts in a safe cupboard.
7. Clean all parts with paraffin or kerosene, dry them and make the ready for
reassembling.
D. Steps of assembling
1. Follow the instruction sheet of the machine if available
2. Assemble the parts with the same order of dismantling
3. Tight all bolts and nus for one parts completely before you start with another.
4. After assembling all parts, retighten all bolts and nuts again.
5. Try to move the parts by hand after assembling to feel the movement.
6. Be sure that the guards, safety device and auxiliary parts are in their correct positions.
7. Run the machine and check the parts.
E. Methods of Lubrications.
The main purpose of lubrication is to prevent wear of the moving parts.
The method used are
1. Wick feed Oiler: to lubricate plain
bearing and slide ways in machine
2. Ring Chain or collar oilers: To lubricate the parts of gear boxes
3. Mechanical force feed lubrications: To lubricate all parts of machine tools. It is used
for modern machines specially the big ones
4. Hand Operated force feed Lubricators: Most of the machine
tools are equipped with this type of lubricators. The machine
operator should use the lubricator daily before starting the
machine.
5. Pressure gun applications: They are used to press the grease to the sliding parts
especially to the roller and ball bearing used in machine tools.
SAFETY PRECAUTIONS
1. Wear the safety equipment (Overall, safety shoes and gloves).
2. Wash your hand and arms carefully specially when using the kerosene or paraffin for
cleaning
3. Disconnect the electrical power supply from any machine before maintenance
4. Ask for help in case of lifting or moving heavy pieces.
5. Give your jobs the maximum care and full attention to avoid any mistake.

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MACHINE SHOP MAINTENANCE

Different types of maintenance:

Equipment and tools used in maintenance:

B. Spirit Level: It is used to check

D. Other hand Tools:

4. Spanners: They ate used to open nut and bolts.

2. Strips and Screws: They are used to control the

b. Using 2 nuts and moving one against the another

c. Using a worm and worm wheel

2. Bolts and Nuts used to fix thin wall parts

5. Splines and Splines Shaft used for sliding member on

B. General notes on Dismantling parts of machine tools

2. Ring Chain or collar oilers: To lubricate the parts of gear boxes

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