Machine Maintenance

Electrical Troubleshooting

Troubleshooting electronics and diagnosing machinery using testing devices.

Skills should include:

• Reading electrical schematics
• Using multimeters and voltmeters
• Diagnosing power issues
• Replacing:
• Contactors
• Relays
• Proximity switches
• Limit switches
• Sensors
• Timers
• Motor troubleshooting
• VFD (Variable Frequency Drive) basics
• 24
  
  VDC and 480V industrial controls

A technician must be capable of disassembling, repairing, and rebuilding equipment.

Skills include:

• Bearing replacement
• Gearbox maintenance
• Chain and sprocket replacement
• Belt alignment and tensioning
• Coupling replacement
• Lubrication systems
• Machine alignment
• Vibration identification

Many fabrication machines utilize hydraulics.

Skills include:

• Reading hydraulic schematics
• Replacing hoses and fittings
• Cylinder repair
• Valve troubleshooting
• Leak identification
• Pressure testing
• Preventing contamination

Used throughout fabrication equipment and automation.

Skills:

• Air preparation systems
• Solenoid valves
• Pneumatic cylinders
• FRLs (Filter-Regulator-Lubricators)
• Leak detection
• Air compressor fundamentals

Computer-controlled machinery and CNC programs.

Maintenance personnel should understand:

• Basic CNC controls
• Machine homing procedures
• Servo systems
• Encoder feedback
• Safety interlocks
• Alarm diagnostics
• Parameter backups

For Amada-style laser equipment and similar cutting systems.

Skills:

• Lens maintenance
• Nozzle replacement
• Beam alignment awareness
• Assist gas systems
• Chiller systems
• Cut quality troubleshooting

Brake and folding machine operations.

Skills:

• Backgauge adjustments
• Hydraulic troubleshooting
• Tooling alignment
• Ram calibration
• Sensor inspection

Skills:

• Weld power source troubleshooting
• Wire feed systems
• Grounding systems
• Gas delivery systems
• Fixture repair

Competencies should include:

• Developing PM schedules
• CMMS or PM tracking systems
• Equipment inspections
• Lubrication programs
• Root cause analysis
• Failure trend analysis
• Spare parts management

Maintenance technicians should understand:

• Metal fabrication processes
• Material flow
• Machine capabilities
• Tooling systems
• Drawings and blueprints
• Measuring instruments

The production documentation also emphasizes familiarity with:

• Lasers
• Punches
• Brakes
• Material gauges
• Tooling
• Forklift operation

• Analyzing machine error messages
• Diagnosing equipment problems
• Reviewing operator feedback
• Testing equipment performance

• Perform root cause analysis
• Use a logical troubleshooting process
• Interpret machine alarms
• Read manuals and technical documentation
• Create corrective actions
• PM completion
• Basic mechanical repairs
• Safety procedures
• Lubrication
• Hand and power tools
• Basic electrical testing
• Electrical troubleshooting
• Hydraulic systems
• Pneumatic systems
• CNC diagnostics
• Welding equipment repair
• PM program execution
• Laser maintenance
• Press brake maintenance
• Servo systems
• Control wiring
• Root cause analysis
• Advanced diagnostics
• PM program ownership
• Capital equipment installation
• Contractor management
• Spare parts strategy
• Reliability engineering
• Maintenance KPI management