CE 004 177 Hall, Eugene J.; Turner, Raymond C. An … · Simple machines used to gain mechanical...

DOCUMENT RESUME

ED 107 964 CE 004 177

AUTHOR Hall, Eugene J.; Turner, Raymond C.TITLE An Analysis of the Industrial Mechanics

Occupation.INSTITUTION Ohio State Dept. of Education, Columbus. Div. of

Vocational Education.; Ohio State Univ., Columbus..Trade and Industrial Education InstructionalMaterials Lab.

SPONS AGENCY Office of Education (DHEW), Wishington, D.C.PUB DATE [75]NOTE 150p.; For related documents, see CE 004 160-176, CE

/ 004 178-206, CE 004 263 -268, and CE 004 425-427

EDRS PRICE MF-$0.76 HC-$6.97 PLUS POSTAGEDESCRIPTORS Communication Skills; Equipment Maintenances; *Job

Analysis; Knowledge Level; *Machine RepairsMachinists; Mechanical Equipment; *Mechanical kills;*Occupational Information; Safety;'Skill Analysi,Skill Development; Skilled Occupations; *TaskAnalfsis; Task Performance; Work Attitudes

IDENTIFIERS *Industrial Mechanics

ABSTRACTThe general purpose of the occupational analysis is

to provide workable, basic information dealing with the many andvaried duties performed in the industrial mechanics occupation. Areview of the -contents will provide a guide for designing andorganizing a curriculum for teaching skills, and knOwledge essentialto an industrial mechanic. The document opens with a briefintrotuction followed by a job description. The bulk of the documentis presented in table fora. Twenty-two duties are broken down into anumber of tasks and for each task a two-page table is presented, .

showing on the first page: tools, equipment, materials, objects actedupon; performance knowledge (related also to decisions, cues anderrors); safety--hazard; and on the second page:,science;Latimrnnsber systems; and communications (performance modes,examples, and skills and concepts)..The duties involve instllation;repair, and maintenance of machinery and.equipment used in t eproduction, transportation,:and storage of all types of indutrialmaterials. The document concludes with an outline of an industrial.mechanics responsibilities and frequency/of some preventative'maintenance procedures, and a list of personal tools needed byemployees. (BP)

_ .

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* materials not available from other sources. ERIC makes every effort ** to obtain'the best copy available. nevertheless, items of marginal *

* reproducibility are often encountered and this affects the quality *

* of the microfiche and hardcopy reproductions ERIC makes available *

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13

AN ANALYSIS OF THE INDUSTRIAL MECHANICS OCCUPATION

Developed By

Eugene J. HallInstructor, Combination WeldingPaul C. Hayes Technical SchoolGrove City, Ohio

Raymond C. TurnerConsultantRetired Industrial MechanicNorth American RockwellColumbus, Ohio

Occupational AnalysisE.P.D.A. Sub Project 73402

June 1, 1973 to December 30, 1974Director: Tom L. Hindes

Coordinator: William L. Ashley

The Instructional Materials LaboratoryTrade and Industrial Education ,

The Ohio State University

3

"The activity which is the subjectof this report was supported inwhole or in part by the U.S. Officeof Education, Department of Health,Education, and Welfare. However,the opinions expressed hereill donot reflect the position or policyof the U.S. Office of Education,and no official endorsement by theU.S. Office of Education should beinferred.

TABLE OF CONTENTS

Foreword

Preface vii

Acknowledgment ix

Job Description xi

DutiesA Inspecting, Repairing, and Maintaining Chain Drive- 1

B Inspecting, Repairing, and Maintaining Direct Drive 9

C Inspecting, Repairing; and Maintaining Flat Belt. 17.

D Inspectingl,Rapairing, and Maintaining Gear Drive. 25

E InspectineRepairing, and Maintaining Gear Box Drive 33

F Inspecting, Repairing, and Maintaining Rack and Pinion Drive 41

G Inspecting, Repairing, and Maintaining Ring and Pinion Drive 49

H Inspecting, Repairing, and Maintaining Variable Speed Drive 57

I Inspecting, Ripairing, and Maintaining Vee Belt Drive 65

J Inspecting, Repairing, and Maintaining Centrifugal Clutch 73

K Inspecting, Repairing, and Maintaining Pneumatic Clutch and Brake 81

L Inspecting, Repairing, and Maintaining Acme Feed Screw. , 89

Inspecting, Repairing, and Maintaining Ball Nut Feed Screw . 97

N Inspecting, Repairing, and Maintaining Fluid Feed Screw. 105

0 Inspecting, Repairing, and Maintaining Anti Friction Bearings. 113

P Inspecting, Repaiting, and Maintaining Control Systems-. 121

Q Inspecting, Repairing, and Maintaining Hydraulic, Pneumatic, and Vacuum 129

Components and SystemsR Inspecting, Repairing, and Maintaining Installation Machinery 137

Inspecting, Repairing, and Maintaining Service Bearings. . . \.., ... 141

T Inspecting, Repairing, and Maintaining Weld Shaft 'Padding 145

U Inspecting, Repairing, and Maintaining Harden Solder 149

V Inspecting, Repairing, and Maintaining Bending Pipe 155

Index 1 159

Index 2 161

Index 3 163

FOREWORD

The occupational analysis project was conducted by The Instructional Materials

Laboratory, Trade and Industrial Education, The Ohio State University in con-

junction-with the State Department of Education, Division of Vocational Educa-

tion pursuant to a grant from the U.S. Office of Edudation.

The Occupational Analysis project was proposed and conducted to train voca-

tional educators in the.techniques of making a comprehensive occupational

analysis. Instructors were selected from Agriculture, Business, Distributive,

Home Economics and Trade and Industrial Education to gain experience in

developing analysis documents for-sixty-one different occupations. Represen-

tatives from Business, Industry, Medicine, and Education were involved with

the vocational instructors in conducting the analysis process.

The project was conducted in three phases. Phase one involved the planning

and development of the project strategies. The analysis process, was based

on sound principles of learning and behavior. Phase two was the identifica-

tion, selection and orientation of all participants. The training and work-

shop sessions constituted the third phase. Two-week workshops were held

during which teams of vocational instructors conducted an analysis of the

occupations in which they had employment experience. The instructors were

assisted by both occupational consultants and subject matter specialists.

The pr ject resulted in producing one hundred two trained vocational instruc-

tors c pable of conducting and assisting in a comprehensive analysis of

variou occupations. Occupational analysis data were generated for sixty-one,

occupations. The analysis included a statement of the various tasks performed

in each occupation. For each task the following items were identified:

tools and equipment; procedural knowledge; safety knowledge; concepts and

skills of mathematics, science and communication needed"for successful per-

formance in the occupation. The analysis data provided a basis for generating

instructional materials, course outlines, student performance objectives,

criterion measures as well as identifying specific supporting skills and

knowledge in the academic subject areas.

gt,

PREFACE _

The scope of the following analysis was designed to cover the work activities of installation,repair, and maintenance of various types of industrial equipment and machinery.. The informatireported for each task follows a generalized procedure for performing that type of workactivity involved. A review of the contents will provide a guide for designing and organizinga curriculum for teaching the skills and knowledge essential to an industrial mechanic.

7

ACKNOWLEDGMENT

We wish to-acknowledge the valuable assistance rendered by the followingsubject matter specialists. They provided input to the vocational instruc-

tors in identifying related skills and concepts of each respective subject

matter area and served as training assistants in the analysis process duringthe two-week workshops.

Rollin M. Barber, PsychologyThe Ohio State UniversityColumbus, Ohio

Jodi Beittel, CommunicationsColumbus, Ohio

Diana L. Buckeye, MathetaticsUniversity of MichiganAvon-Lake, Ohio

Rick Fien, ChemistryThe Ohio State UniversityBeachwood, Ohio

N.S. Gidwani, ChemistryColumbus TechniciVInstituteColumbus, Ohio

Bruce A. Hull, BiologyThe Ohio State UniversityColumbus, Ohio

Donald L. Hyatt, PhysicsWorthington High SchoolWorthington, Ohio

-Glenn Mann, CommunicationsColumbus, Ohio

Jerry McDonald, Physical SciencesColumbus Technical InstituteReynoldsburg, Ohio

Colleen Osinski, PsychologyColumbus Technical InstituteColumbus, Ohio

David Porteous, CommunicationsUniversity of Connecticut,Colchester, ConnecticUt

i

James A. Sherlock, CommunicationsColumbus Technical InstitUte '

Columbus, Ohio

Jim VanArsdall, MathematicsWorthington High SchoolWorthington, Ohio

Lillian Yontz, BiologyThe Ohio State UniversityCaldwell, Ohio

Acknowledgment ii.extended to the following I.M.L. staff members for their rolein conducting the workshops; editing, revising, proofing and typing the analyses.

Faith Justice Research AssociateS4eila Nelson Administrative AssistantMarsha Opritza Editorial ConsultantRita Buccilla npistPeg Bushelman TypistCarol Fausnaugh TypistMindy Fausnaugh TypistRita Hastings TypistCarol Hicks TypistSue Holsinger TypistBarbara Hughes TypistCarol Marvin TypistPatti Nye TypistKathy Roediger TypistMary Salay Typist

JOB DESCRIPTION

An Industrial Mechanic is a skilled worker involved in the installation, repair, andmaintenance of machinery and equipment used in the production, transportation, and

storage of all types of industrial materials. The industrial mechanic follows manufacturers'

specifications and instructions and performs to exact standards.

4

Duty A Inspecting, Repairing, and Maintaining Chain Drive

1 Inspect chain drive2 Repair chain drive3 Maintain chain drive

r

11

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Flashlight

Socket head wrenches

Wiping cloth

Remove inspeCtion plate

Operate hand crank

Observe chain

Observe sprocket teeth

land check chain tension

Hand crank and feel operatior -

Listen for unusual sounds

410

DfXAMINS

Determine repairs needed

CU

ES

Cnndition at chain drive

Unusual sounds

Safety glasses

ER

RO

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Machine failure under-load

(TA

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INSPECT CHAIN DRIVE

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'.

Simple machines used to gain mechanical advantage[sprocket]

Work input, work output, friction and efficiency in

simple

machines (work output)

[Effects of lubrication]

Fluids under Pressure [pressures,

correct lubrication]

Inertia and momentum

.

.

,

'

Operating dimensions

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SKILLS/CONCEPTS'

Reading__

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Sreaking

Viewinl

Listening

Touching

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Inspection order

-

Tnstrnction to operator

Inspect equipment-

Operating equipment

.

Surface and parts

-:..-

.

.

.

.

Comp -

tzsion, detail/inference, trade

teL

Irlog,'

Trade terninololy, enunciation, clarity

of expression, logic

Visual,analysis, describing, logic,

detail / inference

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Auditory discrimination, concentration,

noise discrimination

Shape, texture, movement, tension

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TOOLS, EQUIPMENT, NUMERALS,

OBJECTS

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iminosser

PERFORMANCE KNOWLEDGE

_

SAFETYHAZARD

,

..,.

Ball peen hammer

Remove protective cover

Safety glast--

Crescent wrench

Remove broken chain

Observe pincL ,aints

Ratchet,wrench and sockets

-Remove broken sprocket

All files to have handles

Flashlights-

Weld toothon sprocket

[Smoking not permitted where

Wiping cloth

Hand file to dress tooth

flammable liquids, and'paint are

Socket heXd'wre4es

Repair chain (repair links)

-being used/store or posted]

Wood-blocking

Clean or, foreign materials

[Report all injuries]

Pliers

Instal& repaired sprocket

Box end wrenches

.Loosen valve block

Files, flat, rat tail, bastard,-3

Install chain

cornered

Adjust tension on chain

New cotter keys

Align sprockets

4

Oil

Tighten valve block

-Replace cover

Fill_ with proper oil

,-

Run and check

./

/

.

-emmeomIii

.

,

DECISIONS

CU

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.

Determine whether repair or replace

Condition and life span of parts

......._

Machine failure under load

sprocket)

Foreign object present

Determine whether to repair broken

chain

.

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Simple machines used to gain mechanical -advantage [sprocket]

Work input, work output, friction and efficiency in simple

machines (work output) [Effects of lubrication]

.

Fluids under pressure foil pump fluids under pressure]

Read and interpret charts, tables-and/or graphs


Motion resulting from two or more forces acting on a point

in a body

'motion from a fixed Point]

Arrangement of molecules, atoms and ions and the effect

on

structure and strength of materials

.

I

.

Measures of length

-_

Measure'with the Metric and English system and convert

between them

_Operating Dimensions

.

..

a.,

.

.--

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Vi4Jing

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Repair service order

Parts and repair manual

Instructions to operator

Reouisition for parrs

Equipment

Comprehension, detail/inference, trade

terminology

Description of mechanism, definition,

instructions

Trade terminology, enunciation, clarity

expression, logic

Penmanship, spelling, classification,'

terminology

Visual analysis, describing, logic,

.

detail /inference

.

5

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MAINTAIN CHAIN DRIVE

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Ratchet and sockets

SoCket head wrenches

Hammer

Wiping cloth

Remove cover

Align sprockets

Adjust chain tension

Clean oil sump

Replace cover

Safety glasses

Pinch points

011 spills

Slips and fills


flammable liquids and paint are

being used/stored or posted]

[Report all injuries]`

_D

EC

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NS

Determine maintenance services to

perform

CU

ES

Standard preventltive maintenance

schedule

ER

RO

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AAINTAIN (WAIN DRIVE

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..._

Simple machines used to gain mechanical adyantage[sprocket]


machines (work output)

[Effects of lubrication]

Fluids under pressure [pressures, correct lubrication]


.


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Preventative maintenance


Equipment

_

Comprehension, detail/inference,

description of mechanism, trade

terminology



Visual analysis, decribing, logic,

detail/inference

.

Duty B Inspecting, Repairing, and Maintaining Direct Drive

Inspect direct drive coupling2 Repair direct drive coupling3 Maintain direct drive coupling

(TA

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!INSPECT DIRECT DRIVE

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OBJECTS

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Flashlight

.

Wiping cloth


Socket wrenches

Screwdrivers

_.

Remove inspection plate

observe while running

Listen for unusual noise

Feel vibration

Try to achieve harmonics of coupling

(Adjust speeeto remove)

Stop machine, feel heat of couplings

Observe lubrication

Safety glasqes

.

Caution - moving ?arts

Crease or oil mills


flammable liquids Nand paint are

being used/storea-nr -posted]


DE

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S.

CU

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Determine repair= needed

Condition of equipment, vibration, heat

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Hookes Law


machines [Effects of lubrication]

-

Resistance of materials-to-cbinge in shape [twisting,

bending]

----'

Harmonies (vibiation noise factor)

Relationship of force to distortion in an elastic body

.


CO

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EXAMPLES

SKILLS /CONCEPTS

Reading

Speaking

Viewing

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Touching

Inspection order

Instructions of operator

Inspect equipment

Operating equipment

Surface and parts

_y

....

.,


terminology




detail/inference




.-

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REPAIR DIRECT DRIVE COUPLING

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Ratchet and sockets


File

Two dial indicators

Aviation snips

Shim stock (brass)

-Electric drill motor and drills

Extension cord

Reamer

Flashlight

Inspection mirror

Straight edge

Grease (if required)

Grease gun

Taper pins

Lock out main switch

Remove guard

Remove-motor mount bolts

' Loosen coupling set screws

Slide motor` back

k

RemoVe coupling

Deburr shafts

Align motor shaft with gear box shaft

Drill and ream two opposing corners

for taper pins

'

Move motor back

Realign motor

Install taper pins and mounting bolts

Install coupling

Lubricate as _required

Install guard')

Run and check

Safety glasses

File-handle on all files


Smoking not permitted where flamma-

ble liquids and paint are being

used or stored or where posted

Report all injuries

Check for pinch points

Ear plugs to be worn in a high noise

level area

DE

CIS

ION

S

Determine whether to repair or

replace worn coupling

CU

ES

Mis

alig

nmen

t:lack of lubricant, -

condition and life span of parts

ER

RO

RS


0'

(TA

SK

ST

AT

EM

EN

T)

SC

IEN

CE

MA

TH

NU

MB

ER

SYSTEMS

Work input, work output, friCtiOn and efficiency in simple

machines [Effects of lubrication]


Resistance of materials to change in shape [twisting,

and bending]

Peifect elasticity (Hookes Law)

,Harmonies

Measureof length

Measure of time and speed


.

CO

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UN

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RF

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g1(421gP

Repair

serviceorc1/,;


Instruction to operator

Requisition for paits

::',.

Equipment

.

.

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EP

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Reading

.

Speaking

Writing

:

Viewing

,

,


terminology

Description of mechahism, definition,

instructions



.

Penmanship, spelling, classification,

terminology

---__


detail/inference

.

21E

IS

(TA

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TO

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QU

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UP

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SA

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Ratchet and sockets

Screwdrivers

Flaih light

Grease gun

Grease


Remove guard

.

Tighten motor mountscrews and gear box

screws

Tighten coupling set screws

Tighten coupling cover screws

Lubricate coupling

1

Install guard

Run and 'check

,

Safety glasses

Lockout main switch

Watch for pinch points_

Oil, grease or'debris on floor





,

..-

DE

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SC

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RR

OR

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Standard preventative maintenance

perform

schedule

.......,

.

.

,

.


.

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Hookes,Law


Resistance of materials to change in shape [twisting

and bending)

Harmonies

Effects of lubrication

Measure of speed and time [speed and RPM]


.

.

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Preventative maintenance schedule

,

.


Equipment

.

Colkprehension, detail/inference, des-

criOtion of mechanism, trade term-

inology

.




detail/inference

.-----

----

.P ...

24.

15

DutY'C Inspecting, Repairing, and Maintaining Flat Belt

1 Inspect flat belt drive2 Repair flat belt drive3 Maintain flat belt 4rive

(TA

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INS

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Flashlight

.

,

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Check-lagging on head pully

Check...belt tension

Check wear on belt

Check alignment

,t.

Check mounting bolts

Check idler bearings

Check for vibration

Check grease in motor bearing

Check shaft bearing

Check driven shaft for whip

.

Check take-up adjustment

---

Safety glasses

Grease on floor

Debris on floor

[Smoking not permitted,where flamma-


used/stored or posted]

port all injuries)

S

..

.

DE

CIS

ION

S-

CUES

cE

RR

OR

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Condition of equipment, vibration,

tension, alignment

.,,

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.


.

.

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Simple machines used to gain mechanical advantage [belts

and-pulleys]


machines jfriction]

Effect of heating and cooling on expansion of materials

[change of dimension]

Composition of matter, including protons, neutrons,

electrons, atoms,-molecules, elements [composition of

matter]


[elastic body].

,

Resistance of materials to change in shape [stretching]

_

Measures of length, width, thickness

,


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Listening

.

Touching

lInspection order

Instructions.to operator

Inspect equipment

Operating equipment

Surface and parts

Comprehension; detail/inference, trade

terminology*




detail/inferenie

.



Shape, texture, movement, terdon

2.

19

(TA

SK

ST

AT

EM

EN

T)REPAIR FLAT BELT DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

.9)4

Belt clamps

Come-a-long

Square

Belt knife

Hammer

Lacing

Crescent wrenches

Side cuts

Release tension on idler roll

Remove lacing pin from belt

Fasten belt-clamps to belt.

Ingage come-a-long to overlap belt

Mark belt to desired length

Square both ends

Cut belts to remove excess

Install new lacing

Operate come-a-long to install pin

Release come-a-long

Remove belt clamps

Adjust take up idler

Run and check belt

Safety glasses

No finger rings or watches

To protect one's self from mo4Ing

equipment, rope off or barricade

area around machine

Observe pinch points

[Smoking not permitted where flamma-

ble liquids and paint give being

Used/stored or posted]


DECISIONS

Determine if belt is slipping

Tension

CU

ES

Stretched belt

ER

RO

RS

(TA

SK

ST

AT

EM

EN

T)

SC

IEN

CE

t

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [pulleys

and belts]


machines [friction]

Effect of heating and cooling on-expansion of materials

[change of dimension]

Composition of matter, inclOding protons, neutrons,

electrons, atoms, molecules, elements [composition of

matter]



Measures of length, wIdth.and thickness


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Writing

Viewing

EXAMPLES

Repair service order_


Instructions to operatbr

Requisition for parts

Equipment

SK

ILLS

/CO

NC

EP

TS

Comprehension, detail/inference, trade,

terminology-


instructions

Trade terminology, enunciation, clarity.



terminology


detail/inference

21'

Co c,

(TA

SK S

TA

TE

ME

NT

)MAINTAIN FLAT BELT DRIVE

TO

OL

S, E

QU

IPM

EN

T, M

AT

ER

IAL

S,O

BJE

CT

S A

CT

ED

UPO

NPE

RFO

RM

AN

CE

KN

OW

LE

DG

Eno

SAFE

TY

- H

AZ

AR

D

Grease

Grease gun

Crescent wrench

Lacing pin

..

..

-

Replace belt lacing pin

Adjust take-up

Adjust alignment

Lubricate idler

,

..

Safety glasses

Observe pinch

points

Apply crescent wrench

to prevent jaws from

[Smoking not permitted

ble liquids and paint



_

.

in proper manner

spreading

where flamma-

are -being

.

DE

CIS

ION

SC

UE

SE

RR

OR

S-

.Determine maintenance services to


perform

,____schedule

'

,,..

.-.

.-


.,

..

<.,

(TA

SK S

TA

TE

ME

NT

).

..

SCIE

NC

E-

MATH

NU

MB

ER

SY

STE

MS

Resistance of materials to change in shape

Accommodation of materials to change in shape

.,.

_

Measures of length, width, and thickness

Operating dimensions ..,

CO

MM

UN

ICA

TIO

NS

PER

FOR

MA

NC

E M

OD

ES

EX

AM

PLE

SSK

ILL

S /C

ON

CE

PTS

Reading

,Speaking

Viewing


Instruction's to operator

Equipment



terminology



Vihual analysis, describing, logic,

detail/inference

.,.

WV . i. I

23

Duty D Inspecting, Repairing, and Maintaining Gear Drive

1 Inspect open gear drive2 Repair open. gear drive3 Maintain open gear drive

(TA

SK S

TA

TE

ME

NT

)IN

SPE

CT

OP

EN

GE

AR

DR

IVE

TO

OL

S, E

QU

IPM

EN

T, M

AT

ER

IAL

S,O

BJE

CT

S A

CT

ED

UPO

NPE

RFO

RM

AN

CE

KN

OW

LE

DG

ESA

FET

Y ,

HA

ZA

RD

Work jlatform

Install work platform

Safety glasses

Ratchet wrench and socket

Remove guard

Pinch potnts

Ball peen hammer

Run continuously

No "make shift" defective

Flashlight

Listen fbr knocks

Scaffolds, rigging or staging


Observie bull gear for wobble

[Smoking not permitted where 21zurmva-

Observe pinion shaft for whip


Check bearings for heat


Observe pinion gear wobble


Inspect taper

keys

for looseness

Hammer blows for cracked gear

Hammer blows for cracked shaft

Verify correct grease

.

.

DE

CIS

ION

SC

UE

SE

RR

OR

Ss

.


Condition of gear drive:sound


,, -

-------..z_-;-

.

(TA

SK

ST

AT

EM

EN

T)

INS

PE

CT

OP

EN

GE

AR

DR

IVE

SC

IEN

CE

-,

MA

TH

--N

UIW

3ER

SY

ST

EM

S

Arrangement of molecules, atoms, ions, and the effect on


Effect of heating and cooling on state of matter


-Measure length, width and thickness


..

CO

MM

UN

ICA

TIO

NS

-i

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Viewing

TouChing

.

Inspection order

7


_

Inspect equipment

Surface and parts

.

Comprehension, detail/inferenc e, trade

terminology





Shape, texture, movement, torsion,-

.

:14

27

(TA

SK

ST

AT

EM

EN

T)

REPAIR OPEN GEAR DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

;"4,

5

Ratchet wrenches and sockets


Ball peen hammer (medium).

Brass rod

Flashlight

File

Emory cloth

Gear puller

Center punch

Open gear lubricant

Putty knife

Work platform

Feeler gauges

Determine if key is sheared

Properties of open gear lubricant

Place work platform

Remove guard

Remove key

Remove pinion-gear

Inspect shaft damage

Deburr shaft

Acquire'new key

Install pinion gear on shaft, adjust

clearance

Align keyways

Match "wituias" marks

Install new wedge key,

Lubricate gears

Replace guard

Unlock switch-check operation

Safety glasses

Secure main switch (lock out)

No horse play

Watch for fork trucks

Check for pinch points

Handle for file





(TA

SIK

ST

AT

EM

EN

T)

REPAIR OPEN GEAR DRIVE

SCIENCE

, MATH

NU

MB

ER

SY

ST

EM

S



machines [friction]

Effects of friction on work processes and product quality

Arrangement of molecules, atojns, ions and the effect on


Hook's Law, Electrolysis

Shear modulus or the coefficiency of rigidity is the ratio

of the stress to strain for the case of a shear or a

twist; it the shearing stress divided by the fractional.

shear

Effects of heating and cooling on state of matter-1ga

ets]

Resistance of materials to change in shape [to torque].

Effects of eccentric loading; of wear'on gear

Transfer of heat from one body to another [heat on mate-

rials]

.

Effect of lubrication; of severe vibration on materials

Relationship of force to distortion in an.elastic body

Torque (inch-pounds) = force pounds x radius (inches)

Simple machines used to gai. n mechanical advantage [gears]

Operating dimensiOns

.

.

CO

MM

UN

ICA

TIO

NS

.

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

SIReading

Speaking

Writing

Viewing

.


.

-._

Parts and repair Manual

.



.

Equipment


trade terminology


instructions

Trade terminology, enunciation,

clarity of expression, logic


terminology

Visual analysis, describing, logic.

detail/inference

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN OPEN GEAR DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OBJECTS ACTED UPON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

EP

ER

FO

RM

AN

CE

SA

FE

TY

HA

ZA

RD

,:1

Ratchet and socket

Place work platform

_Safety glasses

Ball peen hammer

,Remove guard

Pinch points

File

Clean pinion and bull gear

[Smoking not permitted whereflamma-

Work platform

Adjust clearance between teeth


Flashlight

Deburr teeth pinion and bull gear


Open gear lubricant

Set wedge keys firmly


Putty knife

-Lubricate

.

Replace guard

DE

CIS

ION

SC

UE

SE

RR

OR

S

Determine-maintenance services to

per-

Standard rreventative maintenance sched-

_


form

ule

-

.

., .

..

-.

!\\

1,cr

ASK

ST

AT

EM

ETrMAINTAIN OPEN GEAR DRIVE

AS

CIE

NC

E,

_MA

TH

NU

MB

ER

SY

ST

EM

S

Effects of fri4i

Torque

Effects of lubric

..

_

.

n. on work processes and product quality

tion

1 1

.,

Measure of length,width and'thickness

,


.

.

.

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

ENKMDES.

EXAMPLES

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Viewing

.



Equipment

1 ! 1.

/Comprehension, detail/inference,

,

description of mechanism,trade

terminology'


of"expression, logic


detail/inference

31

Inspecting, Repairing, and Maintaining Gear_ Box Drive_-__

1-- Inspect, gear-box.--drive

2 Repairgear box drive3 Maintain gear box drive

33

_ffir

(TA

SK

ST

AT

EM

EN

T)

INS

PE

CTGEAR BO

DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,'

OB

JEC

TS

AC

TE

D U

PO

N

Flashlftht

Wiping cloth

'Socket head cap screw wrenches

Eye bolt

Nylon sling

Chain hoist

Ladder

;ft line

\,

DE

CIS

ION

S


PE

RF

OR

MA

NC

EK

NO

ZG

E

Listen to gear box run

Feel for heat.

Smell for unusual odor

Vibration factor

Chedk oil level leaks

Shat off

\Secure safety switch

\Chick mounting screws, external

ReMove cover plate andsecure

Inspect gears (visual)

Inspect bearings feel end play

Inspect shafting

Inspect breather (clean)

Inspect oil residue, sludge

Inlpect oil seals and gaskets

Replace cover

T

SA

FE

TY

HA

ZA

RD

Safety\

Oil api

Falls frgl'asses

ls\ mAladder

uld cause

Smoking,c

fire

.[Smoking not

where flamma-



'

. [Report -al/ injuries]

1C

UE

S.

Unusual noises, temperature, odor,

vibrations

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

. SC

IEN

CE

.M

AT

HN

UM

BE

R S

YS

TE

MS

1

..---

Effect of heating .4,41 cooling-on state of matter [gaskets]

Simple machines used to gain mechanical advantage

,-

Work input, work output, friction and efficiency it simple

machines

Resistance to torque

..

Effect of wear on gear

/

Transfeiof heat from one body to another

Effect of severe vibration on materials

Effect of eccentric loading

\,

Effect of heat on materials

Relationship of force to distortio

in an elastic body

Arrangement of molecules, atoms an

ions and the effect on

structure and strength of maters

s

Resistance of materials to change i

shape


-

Liquid and dry measures [liquid measures]


_

r,...

-.

.

CO

MM

UN

ICA

TIO

NS

-.

i

..--

PE

RF

OR

MA

NC

E M

OD

ES

.

EXAMPLES

/SKILLS/CONCEPTS

Reading

Speaking

,.

Viewing

Listening

Touching

°

.

.

.

Inspection order

fustructions to operator

,--

.

Inspect equipment

-

Operating equipment

Surface and parts

.


terminology


of eipression, logic

Visual analysis, deacribikg, logic,

detail/inference

.



-

Shape, texture, movement, torsion

di,

35

(TA

SK

ST

AT

EM

EN

T)

REPAIR GEAR BOX DRIVE

-,.,

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

,.

SA

FE

TY

- H

AZ

AR

D. .

Rem

ove

cover plates

.


Drain oil

Inspect gears and bearings

Safety glasses

Oil on floor

Persuader( -inch pipe, 12-inch long)

Remove broken parts (teeth)

,

Operator shut off machine and secure

Drain pan

-----,,,Removeshaft with broken gear

Never pour flammable liquids in

Wiping cloth

Remove shaft with companion gear

sewers or drains

Work bench

Fluakand clean box

iUse caution when working on machines

Ball peen hammer

Wipe dry

that are jammed

Brass rod

Replace gear and mating gear.

-[Smoking not permitted where

File

'Flush and blen box

flammable. liquids and paint are

Flashlight

Wipe dry

...',

being used/stored or pbsted]

Stoddard solvent

Replace gear and Mating.gear in bb-x


Lubricants

Reinstall gear train -and bearings

-Reinstall retainer cap

Reinstall cover plate

Fill with proper oil to des11-3,level

Run and check for operatic

>-

.

Know properties and addition of oil =

.

..

_______

.

DE

CIS

ION

SC

UE

S.

ER

RO

RS

'?

.

Determine-if the trains locked

Defecttvey gear



Conditic\ and life span of parts

replace parts

.

.-

(TA

SK

ST

AT

EM

EN

T)

REPAIR GEAR BOX DRIVE

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Lubricants

r

Arrangement of molecules, atoms and ions and the effect on


Work Input, work output, friction and efficiency in simple

machines

.

,,


Simple machines used to-gain mechanical advantage

Effects of lubricants

'.

-

Liquid measure

Operating dimensiond

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Writing

Viewing


.




.

Equipment

_


terminology


instructions

-.




terminology


detail/inference

37

(TA

SK

ST

AT

EM

EN

T)

MA

INT

AIN

GE

AR

BO

X D

RIV

E44

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OE

IJE

CT

S A

CT

ED

UP

ON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

Y 7

-- H

AZ

AR

D,

Flashlight

Check oil level

Safety glasses

Wiping cloth

Check for leaks

Whenever more than one employee is


Check for hot bearings

,working on the same equipment, each

Small screwdriver

Check for odor of hot oil

employee should attach safety

Large screwdriver

Check for loose cap screws

lock to the switch, and.remove it onl

Lubricants

Listen for noise

when job is completed

Feel for vibration

No spitting on floor or equipment

Properties of lubricant




[Report all ,injurios]

,

,

\

.

_

,

.

DE

CtS

ION

SC

UE

SE

RR

OR

S




perform

schedule

.

.

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN GEAR BOX DRIVE

.

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S



electrons, atoms, molecules, elements

.,



Amount of oil too much/too little

Oil grooves,

Effects of lubricants,

..

Liquid and dry measures


.- '

CO

MM

UN

ICA

TIO

NS

.

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

S-S

KIL

LS/C

ON

CE

PT

S

.'

Reading

Speaking

Viewing.

Preventative maintenance sche4ule


Equipment



terminology


of expression, logic -


detail/inference

39

Duty F Inspecting, Repairing, and Maintaining Rack and-Pinion Drive

1 Inspect rack and pinion drive2 Repair rack and pinion drive3 Maintain rack and'pinion drive

41

4,

(TA

SK

ST

AT

EM

EN

T)

TOOLS, EQUIPMENT, MATERIALS,

OBJECTS ACTED UPON

PERFORMANCE KNOWLEDGE

SAFETY

HAZARD

flashlight

Wiping cloth

Lubricants

.

-

'Lock out main switch

Wipe and clean rack and pinion

Inspect for burrs

Inspect for bent or broken teeth

Hand operate for smooth operation

Relubricate gears

.

Safety glasses

Oil spills

.



used /stored or-posted)


A

,t

1111

1111

1=11

11,

DE

CIS

ION

SC

UE

S

Bur

rsC

ondi

tion

and

life

span

of p

arts

.

ER

RO

RS



(TA

SK

ST

AT

EM

EN

T)

......

.. ...

......

... ..

....."

--.

......

SC

IEN

CE

.M

AT

HN

UM

BE

R S

YS

TE

MS

.

Simplemachines used to gain mechanical advantage [gears]

Mork input, work output, friction and efficiency in simple

machines


.


-




--

,

.

._

Measures of 31Ingth, width and thickness


.

.

.

.

-1

.

,

.C

OM

MU

NIC

AT

ION

S,

PE

RF

OR

MA

NC

EMODES

L

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

,

Speaking

Viewing

Listening

Touching

Inspection order


Inspect equipment I

Operating equipment

Surface and parts

.


terminology



,Visual analysis, describing, logic,

detail/inference

..



Shape, texture, movement, torsion

43

LIR

(TA

SK

ST

AT

EM

EN

T)

REPAIR RACK AND PINION DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OBJECTS ACTED UPON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E,

SA

FE

TY

HA

ZA

RD

_


'Lock out main switch

Safety slaises

Ratchet wrench and sockets

Remove hand crank

.Pinch

points

Hamm4i

Remove, shaft bearing assembly

Handle for file

Flashlight

Remove, broken pinion


Gear puller

Install new pinion on shaft


File

Reinstall, assembly in saddle


Lubricants

Reinstall hand crank

Operate hand crank for smooth operation


Lubricants

n/e

- -

,

.

/

DE

CIS

ION

SC

UE

S.

ER

RO

RS

Determine whether to repair or replace


Carraige lock.

pinion gear and rack

Unreleased, machine failure under load

,

.

.,

.

,

(TA

SK

ST

AT

EM

EN

T) *

SC

IEN

CE

L

MA

TH

NU

MB

ER

SY

ST

EM

S.

Simple machines used to gain mechanical advantage [gears]


Lachines

Inertia. and momemtull [body at rest, =body in notion]

Arrangement of molecules, atoms and ions and tfie effect on

structure and strength of Materials [strength of

material]



Measure of length [pinion dimensions]

Wrench dimensions

..

,-.

CO

MM

UN

ICA

TIO

NS

EX

AM

PLE

S_

_---

----

-fS

KIL

LS/C

ON

CE

PT

SPE

RFO

RM

AN

CEMODES

Reading

Speaking

Writing

Viewing

t





.

Equipment

-

Comprehension,.detail/inf

ce, trade

terminology

Descirption of mec .. am, definition,

instructions

Trade to

ogy, enunciation, clarity

of exp

asion, logic

-

Pe hip, spelling; classification,

erminology


detail/inference

.

45

(TA

SK

ST

AT

EM

EN

T)

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS, -

-O

BJE

CT

SACTED UPON

-P

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

N1

Brush

Stoddard solvent

Wiping cloth

,

Flashlight

File

Lubricants

,.

.

Lock out main switch,'

rack and pinion with small brush

and solvent

Wipe dry

Deburr rack and pinion

Wipe clean

.

Lubricate

Check for smooth operation

Safety glasses

'

File handle on file

[Smoking not permitted where flemma..




mmememensr.

\D

EC

ISIO

NS

_C

UE

SE

RR

OR

S


.

, ...

,

.

.

.


perform

.

Y.

-


schedule

..

.,

,

(TA

SK

ST

AT

EM

EN

T)

SC

IEN

CE

-

I\

MA

TH

l'.1!

111

R S

YS

TE

MS

iSimple machines used to gain mechanical advantage [gears];


machines

Inertia and momentum.

Arrangement of molecules, atoms and ions ancithe effect on


Resistance of

materials to change

in shape


,.

.

Wrench dimensi4

Operating dimen'Aons

.

,

\

1, ' ,

k

.

..

-C

OM

MU

NIC

AT

ION

S,

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

S

Comprehension,\detail/Anf

descrilieion

termin

Trade to

of exp

Visual

detail

,

hS

KI L

LS/C

ON

CE

PT

S"

1

clarity ,

..5

Reading

Speaking

Viewing


.


Equipment

/

',1

rence,

of mechanism trade

ogy

nologY, enunciat on,

elision, logic

alysis

describing, logic,

inerenCe,

1\

i } 1

/47

Duty G Inspecting, Repairing, and Maintaining Ring and Pinion Drive

-4---TORC't ring and pinion drive of vertical lathe2 Repair ring and pinion drive of vertical lathe3 Maintain ring and pinion drive of vertical lathe

340

(TA

SK

ST

AT

EM

EN

T)

INS

PE

CT

RIN

G A

ND

PIN

ION

DR

IVE

OF

VE

RT

ICA

LLATHE

41111

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TO

3 U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

SA

FE

TY

HA

ZA

RD

Flashlight

Wiping cloth

Feeler gauges

Raise rail to extreme position

Remove inspection

ate in chuck

Check retaining u

Reinstall pla

Check ring and pinion for burrs,

teeth, wear

Listen to operation

Feel for vibration

Check lubrication

broken

Safety glasses

Caution - moving machinery

-





DE

CIS

ION

S


CU

ES

Burrs, broken teeth; unusual-sounds and

vibrations; condition and lifespan of

parts

ER

RO

E

Machine failire under lok

v'T \Pt

\1.

(TA

SK

ST

AT

EM

EN

T)

il'7S

PE

CT

RIN

G A

ND

PIN

ION

DR

IVE

OF

VE

RT

ICA

L LA

TH

E

SC

IEN

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MA

TH

NU

MB

ER

SY

ST

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S

TiSimplemachines used to gain

114 'lark inp:-, work output,

machines

Fluids under pressure -

Transfer of-energy from



mechanical advantage [gears)

friction and

lubricants

one form to

efficiency in simple

another


Operating clearances

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Viewing

Listening

Touching

EX

AM

PLE

S

Inspection order


Inspect equipment

Operating equipment

Surface and parts

SK

ILLS

/CO

NC

EP

TS

Comprehengion, detail/inference, trade

terminology




detail/iaerence

Auditory discrimination, concentration;


Shape, texture,- movement, tension

.51

tri

(TA

SK

ST

AT

EM

EN

T)

REPAIR RING AND PINION DRIVE OP VERTICAL

LATHE

TO

OLS

,_E

QU

IPM

EN

T.N

UV

rELI

ALS

,O

BJE

CT

S A

CT

ED

UP

ON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Ratchet wrench and socket extension


Torque wrench

Raise rail, move heads to extreme

position

Lock outzmain switch

_

Safety glasses

Pinch points


Feeler gauge

Remove inspaction place in chuck


Wiping rags

Remove retaining nut

used/stored or posted

Flashlight

Install three pick-up clamps on chuck

Report all injuries

Oil can, oil

Lift off chuck

Pick-up clamps

Lay chuck on block - inverted

Eye bolt

/Remove pinion gear and gear box

Three-legged chocker

Remove broken ring gear on chuck

'Fork truck or overhead crane

Install new ring gear on chuck

Remove pinion gear and shaft

Install new pinion gear, shaft, and

bearings

.

.Reinstall pinion gear, gear box, and

chuck

Tighten retaining nut (torque)

Adjust pinion gear to ring gear, use

.

feeler gauge

Lubricate, run and check

,

Replace inspection plate in chuck

,

DE

CIS

ION

SC

UE

SE

RR

OR

S


Condition and life span o£. parts


replace parts

.

,

(TA

SK

ST

AT

EM

EN

T)

REPAIR RING AND PINION DRIVE OF VERTICAL LATHE

SC

IE1'

,ICE

..,

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [gears

Work input, work output, friction and efficency in simple

machines

Fluids under pressure

Transfer of energy from one form to another


Torque



,.

.

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

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ON

CE

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Reading

Speaking

,,

:2--

Writing2

Vi'ewing'


Instructions to operatOr

Requisition for. parts

Equipment

,

detail/inference, trade

terminology

Trade terminology,-enunciation, clarity

of expression


terminology'


detail/inference

57 4111

153

(TA

SK S

TA

TE

ME

NT

)MAINTAIN RING AND PINION DRIVE OF VERTICAL LATHE

dim

m.

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

l'ON

_

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Flashlight

Raise rail to extreme height

Safety glasses

Feeler gauge


Pinch points

Ratchet wrench, sockets and extension



Wiping

clot

hAdjust retaining nut if required


'Reinstall plate

used/stored or posted)

Check and adjust gear tooth clearance


*Deburr teeth

-gear and pinion

Lubricate as required

Run and check

I.

-DE

CIS

ION

SC

UE

SE

RR

OR

S

vDetermine maintenance services to per-



form

schedule

,,,

(TA

SK

ST

AT

EM

EN

T)

VE OF VERTICAL LATHE

_

SC

IEN

CE

_

'MATH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [gears]


machines

FluLis unc',r pressure [lubricants]

Transfer of energy from one form ro another



.

Basic math skills

Feeler gauge


COMMUNICATIONS

PE

RF

OR

MA

NC

EMODES

-E

XA

MP

LES

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Viewing



Equipment

"


description-of mechanism, trade

terminology




detail/inference

.

55

Duty H Inspecting, Repairing, and Maintaining Variable Speed Drive

1 Inspect variable speed drive2 Repair variable speed drive3 Maintain variable speed drive

(TA

SK

ST

AT

EM

EN

T)

INSPECT VARIBLE SPEED DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

Ratchet and sockets


Safety glasses

Flashligtv-

Observe belt


Wipifig cloth

Listen for belt slap

.Do not talk to any operator while

Hand feel for vibration on motor

operating a machine

Inspect all mounting bolts-

Ordinary prescription glasses do not

Inspect variable pulleys

protect the eyes

.

Wear safety caps if employee has long

hair





.,

DE

CIS

ION

S.

CUES

ER

RO

RS


Unusual sounds or vibrations; condition

of equipment

Machine failure ender load

..

>

a

.

(TA

SK

ST

AT

EM

EN

T)

INSPECT VARIBLE SPEED DRIVE

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage (pulleys]


machines

Inertia and momentum [inertia]


[distortion]


I stretching]


Measure.of time and speed [speed-RPM]

FPM = Diameter x RPM x .262


CO

MM

UN

ICA

TIO

NS

PE

R F

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KI L

LS/C

ON

CE

PT

S.

Reading

Speaking

Viewing

Listening

Touching

Inspection on order


Inspect equipment

Operating equipment

Surface and parts


trade terminology



Visualy analysis; describing, logic,

detail/inference




59

(TA

SK

ST

AT

EM

EN

T)

REPAIR VALIABLE SPEED DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

-KN

OW

LED

GE

SA

FE

TY

- H

AZ

AR

DR

fl



Snap ring wrench

Flashlight

Hammer

Feet per minute meter

Lock out master switch

Remove guard and conveyor belt

from

variable drive

Retract motor to relax spring

in drive

pulley; loosen motor from base'

Remove belt

from driver and driven

pulley, spring loaded pulley

from

shaft, snap ring from sheave,

and

spiral spring cartridge and

nylon key

Install new spiral spring cartridge

and

key; lube shaft

Install snap ring to shaft and new

belt

Align motor and bolt down

Rotate by hand to equalize belt

Start motor for operational check

Install conveyor belt

Run conveyor-operational check

Adjust pulley pitch to required

feet

per minute

Reinstall guard

Safety glasses

Never climb or walk over conveyors

Never use defective hammers,

punches

or wrenches

Never strike togethermaterial of

equal hardness

,

Smoking not permitted whereflamma-

liquids and paint are being


Report all injuries

DE

CIS

ION

SC

UE

SE

RR

OR

S


replace broken spring




replace damaged belt

(TA

SK

ST

AT

EM

EN

T)

REPAIR VARIBLE SPEED DRIVE

.

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [pulleys],


machines



Resistance of materials to,change in shap..

[stretching]

Hooks Law


-_

Measure of time and speed [RPM)

PPM = Diameter (inches) x RPM x .262

-Operating dimensions

r

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

trade

clarity

.

logic,

Reading

Speaking

Writing

Viewing





Equipment

.:


terminology


instructions




terminology

Visual analysis, describing,

detail/inference

61

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN VARIBLE SPEED DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

-`-

---.

...

SA

FE

TY

HA

ZA

RD

iGrease gun

Flashlight

;)

Wiping cloth

Grease all fittings

,

Operate fast and slow for

proper

operation

Snug up all mounting bolts

Safety glasses





[Report all injuries)

DE

CIS

ION

SC

UE

SE

RR

OR

S


perform


schedule

.

._

Mac

hine

failu

re u

nder

load

---

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN VARIBLE SPEED DRIVE

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [pulleys]


machines

Inertia and momentum [inertia]


[distortion]

Resistance of materials to change in shape (stretching]


Measure of time and speed Ispeed - RPM]',

FPM = Diameter x RPM x .262


COMMUN ICATIONS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Viewing

EX

AM

PLE

S



Equipment

SK

ILLS

/CO

NC

EP

TS



terminology


of expression,- logic

Visual anlaysis, describing, logic,

.

detail/inference

63

Dtity I Inspecting, Repairing, and Maintaining Vee Belt Drive

1 Inspect vee belt drive

2 Repair vee belt drive

3 Maintain vee belt drive-

065

(TA

SK

ST

AT

EM

EN

T)

IT

OO

LS, E

QU

IPM

EN

T, M

AT

ER

IALS

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

Belt tension meter

Straight edge

.

Open door

Check sheaves alignment and wear

Check belt tension

Check for cleanliness

Inspect belts for wear

.

Check for vibration

Che

ckmounting bolts

.

Safety glasses

[Smoking not permitted where fiamma-




DE

CIIN

S

Determine belt condition

Determine if area needs cleaning

CU

ES

Con

ditio

n of

equ

ipm

ent;

tens

ion,

vibration

Noise

v

.E

RR

OR

S


(TA

SK

ST

AT

EM

EN

T)

.INSPECT VEE BELT DRIVE

SC

IEN

CE

...V

advantagefpulleys]

in simple

of materials

product quality

an elastic body

,

MA

TH

NU

MB

ER

SY

ST

EM

S

Relation of force to distortion

an elastic body [belt

deflection under pressure]


..,

.

.

Simple machines used to gain mechanical

Work input, work output friction and efficiency

machines [friction]

,

Effeci of heating and cooling on expansion


Effect of friction on work processes and

(friction]

Relationship of force to distortion in



CO

MM

UN

ICA

TIO

NS

P

PE

RF

OR

MA

NC

E M

OD

ES

............

EX

AM

PLE

SS

K IL

LS/C

ON

CE

PT

S

Reading

Speaking

Viewing

Listening

Touching

Inspection order.

Iii*tructions to operator

Inspect equipment

Operating equipment

-

Surface and parts


trade terminology

Trade Leminology, enunciation, clarity


Visual analysis, .deecribing, logic,

detail/inference




67

C9

(TA

SK

ST

AT

EM

EN

T)

REPAIR VEE BELT DRIVE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

AM

&

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Set of new matched belts

Adjustable wrench (crescent)

Flashlight

Stoddard solvent

Wiping cloths

Knife

Wire brush

Debris pan


Belt tension meter

Sheave groove and belt guage

Select-o-matic V-belt measuring device,

Hammer

Open inspection door

Release

belt tension

Remove old belts

Determine length, size, quantity of

belts and obtain clean sheaves

Inspect sheaves

Bell ring sheaves

Check sheave retaining screws

Check alignment of sheaves and adjust

Install new belts

Adjust tension

Close door

Run and check

Safety glasses

Debris on floor

Oil on floor

Never roll or pry belts on sheave

"(pinch point)

,Clean up all rags and material from

floor upon completing assignment

While working overhead, never carry

tools in pockets

Never use kerosene to clean parts or

assemblies

Auxiliary start button lock out

Wrenches must never be used as hammer




[Report all iOuries]

DE

CIS

ION

S

Determine when to replace worn belts

CU

ES

Misalignment, grit and dirt, normal

wear

Cracked sheaves (pulleys) do not ring

1

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

REPA,IR VEE BELT DRIVE

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S



machines [friction]

Effects of heating and cooling on expansion of materials



[friction]

Relationship of force to distortion in an elagtic body


Measures of length

Matching length

Matching belts

,Chart

Matching width

Relationship of force to distortion in an;elastic body

[deflection under pressure]


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Writing

Viewing

EX

AM

PLE

S





Equipment

SK

I LLS

/CO

NC

EP

TS

Com

preh

ensi

on, d

etai

l/inf

eren

ce,

trad

e te

rmin

olog

yD

escr

iptio

n of

mec

hani

sm, d

efin

ition

,instructions




terminology


detail/inference

69

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN VEE BELT DRIVE

TO

OLS

, EQ

UIP

ME

K'T

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

72

Stoddard solvent

Open inspection door

Safety glasses-

Wiping cloth

Clean belts (solvent)

Pinch points

Flashlight

Clean sheaves and area

No finger rings

Adjustable wrench

Adjust belt tensi


Straight edge

Check and correct sheave alignment


Hammer

Close and secure door

used/stored or'posted]

Socket head wrenches (Allen)


Belt

tension meter

DE

CIS

ION

SC

UE

SE

RR

OR

S

Determine belt condition



Determine sheave condition

schedule

; \

\ ,1 1

1

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN VEE BELT DRIVE

SC

IEN

CE

MA

TH

NU

MB

ER

telavos

Simple machines used to gain mechanical advantage (pulleys]


machines [friction]

Effects of heating and cooling on expansion of materials


Effec*

of friction on work processes and product quality

Ef

,:tion]

Relationship of force to di$

-tion in an elastic body

Resistance of materials to

cge in shape (stretching]

c.)


CO

MM

UN

ICA

TIO

NS

.._

PE

RF

OR

MA

NC

E .

MO

DE

SE

XA

MP

LES

i*

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Viewing



Equipment



terminology




detail/inference

.71

Duty J Inspecting, Repairing, and Maintaining Centrifugal Clutch

1 Inspect centrifugal clutch2 Repair centrifugal clutch3 Maintain centrifugal clutch

73

(TA

SK

ST

AT

EM

EN

T)

INSPECT CENTRIFUGAL

U H

c

TOOLS, EQUIPMENT, MATERIALS,

OBJECTS ACTED UPON

PERFORMANCE

KNOWLEDGE

SAFETY '-- HAZARD

Flashlight

-

Strobotac

Two indicators

Inspection mirror

Wiping cloth

,

Run system

Check with strobotac (slippage)

Check alignment

Safety glasses





DECISIONS

CU

ES

ER

RO

RS



\N

\

Condition of equipment, slippage,

alignment, heat, smoke

(TA

SK

ST

AT

EM

EN

T)

INSPECT CENTRIFUGAL CLUTCH

SCIENCE

MATH

NUMBER SYSTEMS

Newto& laws of motion (1-3)

Centrifugal forces developed by bodies in rotation



'---

Operating condition

,

.

COMMUNICATIONS

_.

PERFORMANCE MODES

EXAMPLES

SKILLS /CONCEPTS

Reading

Speaking

Viewing

Listening

Touching

Inspection order


Inspect equipment

Operating equipment

Surface and parts'

Comprehension, detail/inference,trade

terminology



Visual analysis,,describing, logic,

detail/inference




..

P7G

75

(TA

SK

ST

AT

EM

EN

T)

REPAIR CENTRIFUGAL CLUTCH

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE


Flash light

Wiping cloth

Strobotac

Friction tape

Feeler gauges

Lock and secure main switch

Loosen set screws on rim

Slide rim toward motor and shaft

Remove old drive blocks

Align clutch driver and clutch

Install new matched blocks in pairs at

180° /

Return rim and secure

Run and check for slippage

Dispose of all parts

SA

FE

TY

HA

ZA

RD

Safety glasses

Pinch points





DE

CIS

ION

S


worn blocks

CU

ES

Slip

page

Fatigue of block

Hot rim clutch

Life span of equipment

Smoke

ER

RO

RS

Machine failure ,under load

'(TA

SK

ST

AT

EM

EN

T)

REPAIR CENTRIFUGAL CLUTCH

SC

IEN

CE

)_

MA

TH

NU

MB

ER

SY

ST

EM

S

Newton's Laws of motion (1-3)




Effects of friction on work processess and product quality

ifriction)

.

Measure of time and speed

Measure of weight

Measures of temperature


)

.

,,,--

COMMUNICATIONS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

S,

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Writing

Viewing




Requisition of parts

.

Equipment


terminology


instructions




terminology.


detail/inference'

777,

4

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN CENTRIgiaggiagra

IT

OO

LS, E

QU

IPM

EN

T, M

AT

ER

IALS

,O

BJE

CT

S A

CT

ED

UP

ON

ill=

111=

1111

1p

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D.,(

4


Flashlight

Air hose

Blow gun

Strobotac

Lock and secure main switch

Remove flange

Blow out dust and dirt

Check blocks, (must be free)

Check and tighten set screws

Install flange

Run and check for slippage

Safety glasses-

Goggles

Flying dust from compressed air

[Smoking not permitted where flamma


used/stored or pos ed]

[Report all injurif! A

DE

CIS

ION

S

Determine-maintenance services to per-

form

er

CU

ES


schedule

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

MAINTAIN CENTRIFUGAL CLUTCH

SC

IEN

CE

,

MA

TH

NU

MB

ER

SY

ST

EM

S

Newton's Laws of Motion

.




Friction makes heat and debris

,

-

.

Operating conditions

,

$

r

.

:

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E N

KN

DE

SE

XA

MP

LES

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Viewing



Equipment

$



,terminology




'detail/inference

I

-------

-!

79

Duty K Inspecting, Repairing, and Maintaining Pneumatic Clutch and Brake

1 Inspect pneumatic clutch and brake

2 Repair pneumatic clutch3 Maintain pneumatic clutch

(TA

SK

ST

AT

EM

EN

T)

INSPECT PNEUMATIC CLUTCH AND BRAKE

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

mommmilm1.111MW

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D.

Flashlight

Wiping cloth

Belt tension tester

Air gauge

-

Shut-off machine

Observe for excessive grease

Frayed wiring

Inspect air hose, and air valve

Check belts through inspections hole

for wear and tension

Inspect clutch and brake pads for wear

Check lubrication

Request operator to "dry run" machine

Look and listen for faulty operation

Check limit switches

Examine air hose with pressure

Check air pressure

Safety glasses

Caution - moving machinery

Caution - slips and falls

Grease spills





.,

DE

CIS

ION

SCUES

ER

RO

RS


.Cond'tion of equipment


..

(TA

SK

ST

AT

EM

EN

T)

INSPECT PNEUMATIC CLUTCH AND BRAKE

SC

IEN

r:M

AT

HN

UM

BE

R S

YrT

EM

S

Simple machines used to gain mechanical advantage°Ipulleys]

Work input, woxkout put, friction and efficiency of simple

machit Js [filction kinetic and potential]

Effects of friction on work processcs'and product quality

!effects of friction on wear process]


Newtont Laws of motion

Lubricants

Gas under pressure



Resistance of materials to change in_shape [stretching]


PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Viewing

Listening

Touching

CO

MM

UN

ICA

TIO

NS

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Inspection order

Comprehension, detail/inlerence,

trade terminology


Trade terminology, enunciation, clarit

of expression

Inspection equipment

"Visual analysis, describing, logic,

detail/inference

Operating- equipment



Surfrce and parts


83

-4*

(TA

SK

ST

AT

EM

EN

T)

REPAIR PNEUMATIC CLUTCH

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

Ratchet extension and sockets


Ball peen hammer

New brake pads

Nev clutch pads

Grease gun

Grease

Wiping cloth

Flashlight

Extension cord and light

Timber and blocking

.Sling and hoist

Air pressure'gailge

DE

CIS

ION

S


replace clutch parts

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D


Remove cover plate

Block ram

Shut off air supply

Remove rotating air valve, solenoid

valve, pad mounting housing, clutch

pads, brake housing, and brake pads

Bell ring disc and housing

Install brake pads, brake housing,

clutch pads, clutch housing, rotating

'air valve, and solenoid valve

°Lubricate bearings

Check air pressure

Turn or. air

Remove blocking

Run and check operation

Install cover plates

'

CU

ES


Safety glasses

Grease, spills

Pinch points

Slips or falls

Caution on compressed air




Report all injuries

ERRORS

Lack of transmitted power

Ram drifts

Weak ram thrust

Machine failure Puler load

(TA

SK

ST

AT

EM

EN

T)

REPAIR PNEUMATIC

SC

IEN

CE

MA

TH

7N

UM

BE

R S

YS

TE

MS

Simple machines used to gain mechanical advantage 'pulleys]

Work input, work output, friction and efficiency in simple'

,/

,gyp erating dimensions

-

machines [friction kinetic and potential]


.Inertia and momentum

Newton's Laws of Motion

Lubricants

Gas under pressor:

Arrangement of molecules, atoms and, ions and the effect on


Resistance of materials to/Change in shape Ictretching]


.:

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

LS /C

ON

CE

PT

S

Reading



terminology



instructions

Speaking




Writing


Penmanship, spelling, classification

terminology

Viewing

Equipment


detail/inference

S5

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN PNEUMATIC CLUTCH

14;

IT

OO

LS, E

QU

IPM

EN

T, M

AT

ER

IALS

,O

BJE

CT

S A

CT

ED

UP

ON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Grease gun

Grease

Flashlight

End wrenches

Air pressure gauge


Lubricate bearings

Check and adjust limit switches

Check air pressure

Safety glasses

Grease spills

Pinch points

Slips or falls



used/stored -or posted]


DE

CIS

ION

S

Determine maintenance services to per-

form

CU

ES


schedules

ER

RO

RS

Machine failure under stress

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN PNEUMATIC CLUTCH

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage 'pulleys]


machines [friction, kinetic and potential]


Newton's Law of Motion

Lubricants

Gas under pressure




1


.

x

1

.,..

1

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

S

/

,/

,

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Viewing

i


Instructions to opeator

Equiptent

..



terminology




detail/inference

...--

.

37

Duty L Inspecting, Repairing, and Maintaining Acme Feed Screw

1 Inspect acme feed screw

2 Repair acme. feed screw (milling machine)

3 Maintain acme feed screw (milling machine)

R9

Rf9

(TA

SK

ST

AT

EM

EN

T)

INS

PE

CT

AC

NE

FEED SCREW

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

Flashlight

- Wiping cloth

1

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

Doo

R9

Stop machine lock out

Inspect lubrication

Hand crank table to center

Work -crank back and forth to denote

loOseness

Inspect screw for burrs and roughness,

sharp corners

Check end play of screw

Safety glasses





DE

CIS

ION

S

Determine if repairs are needed

CU

ES

Con

ditio

n of

equ

ipm

ent

Rough finish out of tolerance on

machined part

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

INSPECT ACME FEED SCREW

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S


Work input, work output, friction and efficiency in

simple

machines


%Inertia and momentum [body at rest - body

in motion]



(resist to

twisting, bending]


,

.

Dimensicnal tolerance


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

S-

..---

----

SK

ILLS

/CO

NC

EP

TS

Reading

Speaking

Viewing

Listening

Touching

,

Inspection order

.


Inspect equipment

Operating equipment

Surface and parts


terminology




detail/inference




.

90I

91

(TA

SK

ST

AT

EM

EN

T)

REPAIR ACME FEED SCREW

ILLING MACHINE)

91

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NM

M.


Socket head set

Oil

Flashlight

Screwdrivers

A-frame on wheels

Sling

Pick up clamps

Stoddard solvent

Wiping cloth

End wrenches

Face spanner

enches

New feed scr

New feed nut

New feed screw bearings

4111

11S.

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D


Crank knee down

Craak saddle out

Remove tooling from table

Remove end brackets cranks, feed dials

and bearings

Remove feed screw

Remove table gib

Remove table

Remove feed nuts

Install new feed nuts

Replace table

Install gib and adjust

Install new feed screw and bearings

Adjust feed nuts

Lube screw and check operation

Safety glasses

Pinch points

Only operator to load or unload

machine





DE

CIS

ION

S

Determine whether to install new parts

or repair

CUES

Feed, screw and nuts


ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

REPAIR ACME FEED SCREW (MILLING

MACHINE).

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage ;linear

motion to rotary motion]


machines [friction]

Fluids under pressure Ilubricant]

Centrifugal forced developed by bodies in rotation [body at

rest - body in motion]



Wrench dimensions

Measures of length (measurement)

Operating eimensions

CO

MM

UN

ICA

TIO

NS

.....

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Writing

Viewing

,.


Parts and repair uanual



Equipment

,


terminology


instructions




terminology


detail/inference

93

(TA

SK

ST

AT

EM

EN

T)

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NSocket head wrench

Screwdriver

Wiping cloth

Flashlight

DE

CIS

ION

S

Determine maintenance service to

perform

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E


Adjust screw linear looseness (end play,

Hand crank table to extreme right

Adjust feed nuts

Hand crank table to extreme left

Check feed nuts

Assure lubrication

SA

FE

TY

HA

ZA

RD

Safety glasses



used /stored or posted]


CU

ES

Standard, preventative maintenance

schedule

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

MAINTAIN ACME FEED SCREW (MILLING MACHINE)

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S



machines

Fluids under pressure [lubricants]

Inertia and momentum [bodies at rest - bodies in motion]




Wrench dimensions

Measures of length (measurement]


--,

,C

OM

MU

NIC

AT

ION

S

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Viewing



Equipment

CoMprehension, detail/inference,

discription of mechanism, trade

terminology




detail inference

95

,./

Duty M Inspecting, Repairing, and Maintaining Ball Nut 'Feed Screw

r /

.,

1 Inspect ball screw nut feed2 Repair ball screw looseness3 Maintain ball screw

9s

97

r

--'

(TA

SK

ST

AT

EM

EN

T)

INSPECT BALL SCREW NUT FEED

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

rP

ER

FO

RM

AN

CE

KN

OW

LED

GE

OB

JEC

TS

- A

CT

ED

UP

ON

SA

FE

TY

HA

ZA

RD

Flashlight


Safe0, glasses

Lint free wiping cloths

Wipe screw thread, clean of oil and dirt

Clean lint free wiping cloth

Indicator

Inspect screw thread for wear and


roughness


Indicate table for linear motion


Inspect mounting screws


Hand crank table end to end, feel for

'smooth operation

Listen for unusual 'sounds

(grinding)

Check lubrication

..

DE

CIS

ION

S-,

.C

UE

SE

RR

OR

S


Unusual sounds, condition of equipment


i t,'

.

.

_....--

(TA

SK

ST

AT

EM

EN

T)

INSPECT BALL SCREW IUT FEED

SC

IEN

CE

\MATH

- N

UM

BE

R S

YS

TE

MS

Work input, work.output, friction and efficiency in simple

machines


(change of dimensions)

Fluids under pressure foil under pressure]

Composition of matter, including protons, neutrons, elec-

trons, atoms, molecules, elements [composition of matter:


,


Effect of friction -1... 'fork processes and product quality



?

..-

Plus and minus on indicator-


.\

___

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Viewing

Listening

Touching

Inspection order


Inspection of equipment

Operating equipment

,

/

Surface and parts

//

.

Comprehension, detail/inference, tract,

terminology



isual analysis, describing, logic,

detail/inference

Auditory discrimination, concentratio



9'7

.

99

(TA

SK

ST

AT

EM

EN

T)

REPAIR BALL SCREW LOOSENESS

TO

OLS

, .E

QU

IPM

EN

T, M

AT

ER

IALS

,O

BJE

CT

S A

CT

ED

UP

ON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

Y =

HA

ZA

RD

Flashlight

Wiping cloth (lint free)

Ratchet and sockets


Indicator with magnetic base

Screwdrivers

Hammer

Horses (wood topped)

Micrometer outside 0"-1"

Depth micrometer

Wire

DE

CIS

ION

S

Determine adjustment

Loose ball screw


Remove oil motor drive, driving cou-

pling from screw, table end brackets

Secure ball nut on ball screw (wire,

cloth)

Remove ball nut bolts from table, assem

bly of screw and ball nuts, and bolts

from nut halves and.remove dowels

Move slightly to remove spacer

Grind spacer to desired thickness

Reinstall spacer, dowles and bolts

Use dial indicator to verify looseness

Remove all looseness by regrinding

spacer; reinstall screw assembly

and

end brackets

Remove one bearing thrust plate and

grind to desired length; reinstall

and check for end play of screws

Reinstall oil motor

Manually operate automatic lubricator

Check for operation

CU

ES


Safety glasses

Slips from oil spills

Handle assembly carefully

Secure ball nut or it will windmill

(mashed fingers)

No rings

Clean, lint-free wiping cloth



used /stored or posted

Report all injuries

ER

RO

RS

Wear from usage

(TA

SK

ST

AT

EM

EN

T)

REPAIR' BALL -SCREW LOOSENESS

SC

IEN

CE

MA

TH

- N

UM

BE

R S

YS

TE

MS


machines


!heat, change of dimensions]

Fluids under pressure Foil under pressure]



(hardness]

Transfer of energy from one form to another [from oil

pressure

linear measurement]


Effects of friction on work

processes and product quality


structure and strength of materials Tstructure rearrange-

ment]



Measures of length [decimal]

Wrench dimensions

Operating dimension

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Writing

Viewing

EXAMPLES




---Retinisitign of parts

Equipment

SK

ILLS

/CO

NC

EP

TS


terminology


instructions




terminology.

VfiViii-inalysis, describing, logic,

detail/inference

101

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN BALL

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

Flashlight

Wiping cloth (lint free)



1111

1111

1111

=11

1111

11M

ir

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D


Wipe screw clean

Adjust lubricator

Tighten ball nut mounting screws

Tighten end plate mounting screws

Safety glasses

Slips on oil spills

Clean lint free wiping cloth




(Report all injuries]

DE

CIS

ION

S

Determine maintenance services to per

form

CU

ES


schedulolt

ty

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

MAINTAIN BALL SCREW

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S


Wrench dimensions

machines



[change of dimensions]

Liquids under pressure (oil under pressure]

Composition of matter, including protrons, neutrons,


Transfer of energy

from one form to another




CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Viewing

EX

AM

PLE

S

Preventative maintenage schedule


Equipment

SK

I LLS

/CO

NC

EP

TS



terminology

Trade terminology, enunciation, clari


Visual analysis, deScribing, logic,

detail/inference

103

Duty N Inspecting, Repairing, and Maintaining Fluid Feed Screw .

1 Inspect fluid feed screw (oil cylinder)2 Repair fluid feed screw oil cylinder (milling machine)3 Maintain fluid feed screw (oil cylinder) milling machine

105

(TA

SK

ST

AT

EM

EN

T)

INSPECT FLUID FEED SCREW (OIL CYLINDER)

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

Wiping cloth

Flashlight


Socked head wrenches (Allen)

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E

Remove both aprons

Operate table from end to end

Inspect for leaks

Inspect piston

for scores and nicks

Inspect hold down bolts

SA

FE

TY

HA

ZA

RD

Safety glasses





DE

CIS

ION

S


CUES

Condition of equipment, leaks, scores,

nicks

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

INSPECT FLUID FEED SCREW (OIL CYLINDER)

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Work input, work output, friction and efficiency insimple

machines


Forces acting on a body immersed or floating in a

liquid


Inertia and momentum [Pascals Law]


Wrench dimensions


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Speaking

Viewing

Listening

Touching

EX

AM

PLE

S

Inspection order


Inspect equipment

Operating equipment

Surface and parts

SK

ILLS

/CO

NC

EP

TS


terminology



Visual-analysis, describing, logic,

detail/inference

Auditory discrimination, concentration



107

(TA

SK

ST

AT

EM

EN

T)

REPAIR FLUID FEED SCREW OIL CYLINDER (MILLING MACHINE)

1T

OO

LS, E

QU

IPM

EN

T, M

AT

ER

IALS

,O

BJE

CT

S A

CT

ED

UP

ON


End wrenches

Tubing box wrench

Screwdrivers

Wiping cloths

Spedi-dri

Flashlight

Cylinder rod seal

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E

ry

SA

FE

TY

HA

ZA

RD

Remove table apron - rod end

Move table to expose piston rod and

cylinder end

Lock out main'switeh

Unbolt piston rod from bracket on frame

Loosen fitting on hydro line on

opposite end of cylinder

Push piston red clear of bracket

Remove seal gland and oil seal

Install new seal

Reinstall gland

Reinstall piston rod in end bracket

Tighten loosened oil Una fitting

Start machine

Operate machine end to end

Blead air from cylinder - both ends

Start machine check for operation,

leaks

Reinstall table apron

Safety glasses

Caution - working on moving machinery

Slips from oil spills or leaks

Do not attempt to take dimensions

while machine is in motion

When using knives, screwdrivers

or

any cutting tool do not direct the

strain toward self or another

employee

Do not use screwdrivers as chisels or

pry bars





DE

CIS

ION

S

Determine whether to install new seal

CUES

Condition and lifespan of parts

ER

RO

RS

Constant usage

.

Leakage


(TA

SK

ST

AT

EM

EN

T)

REPAIR FLUID FEED SCREWOIL CYLINDER

(MILLING MACHINE)

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S


machines


Forces acting on a body immersed or floating in a liquid



Pascal's Law


,

Wrench dimensions

Number of oil seal


'CO

MM

UN

ICA

TIO

NS

.

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

S,

SK

ILLS

/CO

NC

EP

TS

_

Reading

Speaking

.

Writing

Viewing


Parts and repair manuals

I



Equipment


trade terminology


instructions

Trade terminology, enunc4ation,

.clarity of expression, logic


terminology

.


detail/inference

ilit4:

109

(TA

SK

ST

AT

EM

EN

T)

MA

INT

AIN

FLU

ID F

EE

D S

CR

EW

(O

IL C

YLI

ND

ER

) M

ILLI

NG

MA

CH

INE

-...

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

10.7

SA

FE

TY

HA

ZA

RD



Flashlight

Wiping cloth

Operate table end to end

Remove apron on both ends

Observe'for leakage

Stop leaks

Tighten hold down bolts

Reinstall aprons

DE

CIS

ION

S

Determine maintenance service to per-

form

Safety glasses





CU

ES

Sta

ndar

d pr

even

tativ

e m

aint

enan

ceschedule

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

MAINTAIN FLUID FEED SCREW (OILCYLINDER) MILLING MACHINE

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

\Work input, work output, friction'and efficiency in simple

machines


Forces acting on a body immersed or floating in a liquid



Pascal's Law

Effects of lubricant

Wrench dimensions


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

.

Reading

Speaking

Viewing

7/

.


-.


Equipment

Comprehension, detail/inferenCe,

'description of meChanim, trade

terminology




'detail/inference

111

Duty 0 . Inspecting, Repairi4, and Maintaining Anti Friction Bearings

1 InSpect anti fri6tion bearing (roller or ball)2 Repair anti friction bearing (roller or ball)3 Maintain anti friction bearing (roller or ball)

113

(TA

SK

ST

AT

EM

EN

T)

INSPECT ANTI-FRICTION BEARING (ROLLER OR BALL)

TO

OLS

,. E

QU

IPM

EN

T, M

AT

ER

IALS

,O

BJE

CT

S A

CT

ED

UPON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E

d.

SA

FE

TY

HA

ZA

RD

-Flashlight

,Wiping cloth

\

Contact thermometer

Aligning bar (straight edge)

,.

Inspect lubrication

Check for excessive fleet

.

Check for excessive vibration

Check for excessive noise

Safety glasses

Crease on floor

Caution: rotating shaft

[Smokint. not permitted where flamma-



[Report all inju. ies]

arassmasommollir--..

DE

CIS

ION

SC

UE

S,

"RR

OR

S


Condition of equipment, temperature,

noise, vibration

.

Machine fai

re under load

.

INSPECT

___

____

_

SC

IEN

CE

MA

TH

- N

UM

BE

R S

YS

TE

MS


Basic math skills (read thermometer)



machines [friction]


Fluids under pressure flube]




CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EXAMPLES

.S

KIL

LS/C

ON

CE

PT

S

Reading

Inspection order


terminology

Speaking




Viewing

Inspect equipment


detail/inference

Listening

Operating equipment


-noise discrimination

Touching

Surface and parts


.1

TTNPFCT ANIT- FRICTION RFARTNC (ROLLER OR BALL)

115

111

....

(TA

SK

ST

AT

EM

EN

T)

REPAIR ANTIFRICTION BEARING (ROLLER OR BALL)

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

vim

iser

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

Di1

2


Socket bead wrenches

Flashlight

Wiping cloth

Stoddard solvent

Jack

Timber

File

Emory cloth

Oil

Surface thermometer

Lock out main switch'

Jack up bearing shaft and block

Remove bearing

Clean and inspect bearing for possible

reuse

Reinstall old bearing if possible to

reuse

Lower shaft,"secure bearing mount

Check and adjust alignment

Lubricate

Run and check operation

Feel for heat

Feel for-vibraticine


Safety glasses

Pinch points

Splinters from timber (wear gloves)





DE

CIS

ION

S

Determine whether to reuse or replace

bearing

CU

ES

Dirty, noisy, heat

Lack of lube

Life span of'parts

Expense of bearing

ER

RO

RS


Unnecessary expense

REPAIR ANTIFRICTION BEARING (ROLLER OR BALL)

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [pulley]


machines

Effect of heating and cooling an expansion of materials

[expansion due to heat]

Fluids under pressure [proper lube]




Wrench dimensions

Measures of length

Measures of temperature [bearings]

Liquid and dry measures [oil]


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Writing

Viewing





Equipment


terminology


instructions




terminology

Visual analysis,describing,

logic,

detail/inference

117

(TASK ST

TE

11/E

NT

)MAINTAIN ANITFRICTION BEARING (ROLLER OR BALL)

./

11M)

,E

QU

IPM

EN

T, M

AT

ER

IALS

,E

CT

S A

CT

ED

UPON

PE

RF

OR

MA

NC

EKNOWLEDGE

SA

FE

TY

HA

ZA

RD

Flashlight

Wiping cloth

Lubricant



.


Wip off axterior

Lubricate bearing

,-

Loosen bearing bolts

Align bearing

Tighten mounting bolts

Run and check

.

.

Safety glasses

Grease on floor

/ [Smoking not permitted where flamma-


used/stored Or posted]


DECISIONS

CUES


schedule

.ERRORS

Determine maintenance services to per-

form


MAINTAIN ANTI FRICTION REARING ,DATTVD OR UATTN

.....

......

......

. ....

.....

%...

......

SC

IEN

CE

..,..

......

.,

MA

TH

NU

MB

ER

SY

ST

EM

S

r

Simple machines used to gain mechanical advantage [pulley]

Work input, work output,--friction and efficiency in simple

machines

Effect of heating and cooling on expansion of material

[expansion due to heat]

Fluids under pressure [lube]




Wrench dimensions


,

8

.

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KILLS/CONCEPTS

Reading

____---

_

Speaking

Viewing

,"

.

.


r


Equipment

,



terminology




detail/inference

.

tit

119

Duty P Inspecting, Repairing, and Maintaining Control Systems

1 Inspect control system (linkage and levers)

2 Repair control systems (linkage and levers)

3 Maintain control system (linkage and levers)

121

(TA

SK

ST

AT

EM

EN

T)

INSPECT CONTROL SYSTEM LINKAGE AND LEVERS

IT

OO

LS, E

QU

IPM

EN

T, M

AT

ER

IALS

,O

BJE

CT

S A

CT

ED

UP

ON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D1;

1; 7

Flashlight

Wiping cloth

i

Shut off machine

Hand operate levers

Feel for looseness

Visually inspect pins, levers for

deformations (wear, twist, bends)

Start machine

Feel for looseness

Listen for vibrations and rattles

.

Safety glasses


ble liquids and paint are

being

stored/used or posted]


1

0

DE

CIS

ION

SCLUES

ADmOition of equipment

ER

RO

RS


.


".

TA

TE

ME

NT

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Sipple machines used to gain mechanical advantage (levers

and linkage]


Basic math skills


CO

MM

UN

ICA

TIO

NS

PERFORMANCE MODES

EXAMPLES

SKILLS/CONCEPTS

Reading

Speaking

Viewing

-Listening

Touching

Inspection order


Inspect equipment

Operating equipment

Surface and parts

.


terminology



Visual analysis, describing, logic, --__

detail/inference




.

..... --.

123

(TA

SK

ST

AT

EM

EN

T)

REPAIR CONTROL SYSTEMS

(LINKAGE AND LEVERS)

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

Flashlight



Electric drill

High speed drills

Reamers (rose type)

Pliers

Ball peen hammer

Oil can

Oil

Anvil or steel plate

Cotter keys

Oversize linkage pins

DE

CIS

ION

S

Determine whether to repair or place

parts

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E


Dismantle levers, pins, linkage, fork

and bar shifter and pinions gears,

and quadrant gear shifter

Drill and ream levers and linkage

Install oversized pins and cotter keys

Straighten shifting levers

Linkage and

Replace sleeve'beArings-as-required---

Check spring, de tent tooth and slot

CUES

Condition and lifespan of parts

SA

FE

TY

- H

AZ

AR

D

Safety glasses

Pinch points

Report all injuries


ble liquids and paint are being used/

stored or posted]


ER

RO

RS


......

......

......

.....

----

-- -

--

__ _

__,

MA

TH

- N

UM

BE

R S

YS

TE

MS

SC

IEN

CE

Sim

ple

mac

hine

s us

ed to

gai

n m

echa

nica

l adv

anta

ge fl

ever

s,linkage]

, ,

Composition of matter, including protons. neutrons,


Transfer of energy from one form toanotner [spring]


[detent]

Relationship of force to distortion

in An elastic body

[spring]

.

Resistance of materials to change in shape (spring com-

pression]

Effects of lubricant

/Basic math skills

Wrench sizes dimensions

.brill sizes

Reamer sizes


I 1

CO

MM

UN

ICA

TIO

NS

i

PE

RF

OR

MA

NC

E, M

OD

ES

E C

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Writing

Viewing


' -Parts and repair - ..manual



.

,-

Equipment


terminology


instructions




termindlogy.


detail/inference

1 WI

125

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN CONTROL SYSTEM (LINKAGE AND LEVERS)

TO

OLS

; EQ

UIP

IVtE

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

1121

Flashlight

Oil can

Oil

Wiping cloth

Shut off machine

Lubricate linkage and pins

Start machine and actuate lever in all

positions

Check for correct operation: linkage

pins, cotter keys

Safety glasses

Oil spills

Slips and falls

Pinch points





DE

CIS

ION

S


perform

CU

ES


schedule

ER

RO

RS


(TA

SK

ST

AT

EM

EN

T)

sys.a.4"."...1

,,,,Avyays.4.0

,O4../.....o"

401.

&..

ZIA

VI,

'S

CIE

NC

E

Yy

&

MA

TH

NU

MB

ER

SY

ST

EM

S.

Simple machines used to gain mechanical advantage !levers

and linkage]


electrons, atoms, molecules, elements (hardness]


Basic math skills


/

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

trade clarity

logic,

.

,41

92

Reading

Speaking

Viewing

.



Equipment

.


description of mechanism,

terminology



Visual analysis, describing,

detail/inference

127

Duty Q

Inspecting, Repairing, and Maintaining Hydraulic, Pneumatic, and VacuuM Components and Systems

1Inspect hydraulic, pneumatic, vacuum components and systems

2Repair hydraulic, pneumatic, vacuum components and systems

3Maintain hydraulic, pneumatic, vacuum components and systems

129

(TA

SK

ST

AT

EM

EN

T)

INSPECT HYDRAULIC. PNEUMATIC VACUUM COMPONENTS AND SYSTEMS

IDO

LS, E

QU

IPM

EN

T, M

AT

ER

IALS

,P

ER

FO

RM

AN

CE

KN

OW

LED

GE

SA

FE

TY

HA

ZA

RD

OB

JEC

TSACTED UPON

Flashlight

Operate system, at full capacity

Safety glasses

Wiping cloth

Inspect flow and pressures

[Smoking not permitted where flan

Fox boro recor'er

Inspect ft-sr leaks


Inspect hose for wear


Inspect safety cables on high pressure


hoses and lines

-

Inspect all fittings

Inspect drive belts

Inspect pulleys for

wear

Inspect lubricants

,

Inspect for smooth operation

Hand check for vibration

Check hold down bblts

Check hour meters time factor


,-

Check vacuum systems

(AMMEMOMMNEW

DE

CIS

ION

SC

UE

S.

ER

RO

RS


Condition of equipment


.

..

(TA

SK

ST

AT

EM

EN

T)

INSPECT HYDRAULIC

PNEUMATIC; VACUUM COMPONENTS AND SYSTEMS

SCIENCE

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage (gears

pulleys]

Conversion of pressure of fluids and gases to linear or

rotary motions


Basic math skills


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS /C

ON

CE

PT

S

Reading

Speaking

Viewing

Listening

Touching

Inspection order


Inspection of equipment

Operating equipment

Surface and parts


trade terminology




detail/inference

Auditory descrimination, concentration,



i Si

131

(TA

SK

ST

AT

EM

EN

T)

REPAIR HYDRAULIC, PNEUMATIC, VACUUM COMPONENTS

AND SYSTEMS

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TSACTED UPON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D 1

7g

Test gauges (master)


Safety glasses

Flow meter

Remove cover plate from reservoir

Pinch points

Miss hardware (pipe fittings, etc.)

Clean interior; clean and/or replace

Oil spills

Filter elements

filter; check and replace as required:

Caution:

high pressure on air and

0-rings

all tubing, piping and fittings

oil lines

Ratchet wrench set

Replace cover

.

Smoking not permitted where flame-

Socket head wrench set

Remove and dismantle valves; replace


End wrench set

defective parts; reassemble and

used/stored or pasted

Screwdrivers

install valves

Report all injuries

Ball peen hammer

Remove pump and disassemble; replace

Tube cutter

defective parts; reassemble and

Hack saw

.

Putty knife

install

Calibrate pressure gauges

Stoddard solvent

Refill lubrication system and hydraulic

Wiping cloths

system, if required; bleed air from

Emergy cloth

hydraulic lines; run; system and check

Sealant

flow and pressures; visually check

Taper pin

accumulators, actuators, seals, safe-

Oil can and oil

ty controls, receivers, mufflers,

fans

Fox boro recorder

fittings, drive and general conditions

Air hose and blow gun

Blow out heat exchanger and Check systen

111

V

DE

CIS

ION

SC

UE

SE

RR

OR

S


Ireplace defective parts

"Hour meter, dust, dirt, normal wear,

leaks


Imme

,,

i

4...

....

.,....

....

..___

___

.....

__.

..--.

....-

.....-

.... -

-...-

--.._

SC

IEN

CE

.-

-

MA

TH

NU

MB

ER

SY

ST

EM

S

Simple machines used to gain mechanical advantage [levers,

gears, pulleys]

Work input, work output, friction and efficiency

in simple

machines


Transfer of energy from one form

to another

Transfer of heat from one body to another


Effects of friction on workprocesses and product qgglity


Basic math skills

Wrench-dimensions


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Writing

Viewing





Equipment


trade terminology


instructions

'trade terminology, enunciation,


.


terminology


detail/inference

1127

133

VACUUM COMPONENTS AND SYS

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

DO

BJE

CT

S A

CT

ED

UPON NN

Flashlight


Safety glasses

Wiping cloth

Remove, clean or replace external filter

Pinch points

End wrenches

Check belt drives


Hydraulic oil

Adjust tension


Lube oil

Lube variable belt adjustments


Grease gut

Check all fittings


Fox boro recorder

Check all hose

Test gauges (master)

Tighten as required

Check pressure gauges, correct errors

Check flows, correct erross

Check all valves, replace packing

Check oil for viscosity

Check oil for contaminants

Refill hydraulic oil if required

Check vacuum for leaks

Bleed air from hydraulic system

DE

CIS

ION

SC

UE

SE

RR

OR

S

.

Determine maintenance service to



perform

.

(TA

SK

ST

AT

EM

EN

T)

MAINTAIN hYDRALIC

.PNEUMATIC

_

(TA

SK

ST

AT

EM

EN

T)

II 4 HYDRAULIC

_

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

.....,

Simple machines used to gain mechanical advantage [levers,

gears, pulleys and belts]

Work input,

machines


Fluids under pressure [transfer of pressure]

Transfer of energy from one form to another [gas under

pressure]

.


.

.Effects of friction on work processes and product quality

Relationship of force to distortion in ar. elastic body

[packing and 0-rings]



Basic math skills


.

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Speaking

Viewing



Equipment



terminology




detail/inference

135

-I 2

'4

Duty R Inspecting, Repairing, and Maintaining Installation Machinery

1 Install machinery

137

(30

(TA

SK

ST

AT

EM

EN

T)

INSTALL MA'

INERY

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

,

SA

FE

TY

HA

ZA

RD

.

tfti

Theramiter (contact)

Uncrate machine, assist setting on

Safety glasses

Levels (spirit)

foundation; clean exterior


Plumb bobs

Level machine with spirit level and/or


Broneon or Wild optical transit

optical transit


Snips

Cut shim stock

Report all injuries

Shim stock

Tighten hold down bolts

.

Stoddard solvent

Recheck for level, adjust accordingly

Wiping cloth

Lubricate machine; check all movements

Putty knife

and for missing parts (bill of lading)

Adjust tension on drive belts

Start machine, run four hours at me

medium speed

Check bearings for heat, gear box oil,

for all tools, for parts manual, for

operators manual, and for smooth

-

operating conditions

Operate at speeds and feeds

Check all trips and stop dogs, automatic

movement reversals and automatic

lubers

Check for safety features

DECISIONS

DUES

-

ERRORS

Determine adjustments needed

Operation of machinery


NM

E Y

TM

ipe mcie sd t

an mcaia datg ga,

Oeaig dmnin

ees

ok nu, wr

upt rcin ad efcec

n sml

ahns

Efcs o

etn

noln

n epnin o

aeil

lis udr pesr

,

Efcs o

urcns

CM

UIA

IN...

._P

R F

RA

C-

MD

S--

-E

AP

EK

LS C

NE

Tedn

ntlain odr

Cmrhnin ealifrne

-tae triooy

Prs ad oeaos mna

ecito

f mcaim eiiin

ntutos

Sekn

ntutos t

prtr

Tae triooy nnito,

caiy o

xrsin oi

iwn

npc qimn

iul aayi, dsrbn, lgc

ealifrne

Lseig

Oeaig eupet

Adtr iciiain ocnrto

os iciiain

Tuhn

ufc

nat

hp, txue oeet eso

NTL AHNR

1

Duty S Inspecting, Repairing, and Maintaining Service Bearings

1 Replace bearing (sleeve)

03141

(TA

SK

ST

AT

EM

EN

T)

REPLACE BEARING

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

N

SLEEVE

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Scrapers

Oil stone

Hi-spot prussian blue

Oil

Timber

Ratchet wrench

Wiping cloth

Secure drive mechanism

Loosen bolts in bearing block

Raise shaft slightly

Remove bearing block

Remove sleeve from block

Place prussian blue on shaft

Slide new bearing on shaft

Lower shaft

Rotate shaft

Remove bearing and scrape, clean shaft

Clean bearing

Lube shaft and bearings

Reassemble

Run and check

DE

CIS

ION

S


bad bearing

cuE

S,

Excess oil leakage

Looseness

Vibration

Safety glasses

Caution - 'sharp tools

Pinch points

Do not use cotton waste or dirty cloths

to wipe bearings

Do not use incorrect kind of lubricant





ER

RO

RS


(TA

SIK

ST

AT

EM

EN

T)

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Lubricant

SaeNumbers and meanings


Effects of friction on work processes and, product quality


Measures of length [length ID and OD]


-C

OM

MU

NIC

AT

ION

S

PE

RF

OR

MA

NC

EMODES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Reading

Writing

Viewing

c.)

'Repair service order



Equipment


trade

terminology


instructions


terminology

Visual analysis, describing, logic.

detail/inference

11ftS

143

Duty T Inspecting, Repairing, and Maintaining Weld Shaft Padding

1 Weld-build up shaft by padding

/,145

(TA

SK

ST

AT

EM

EN

T-I

WELDBUILD UP SHAFT BY PADDING

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TSACTED UPON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

E

11-4

-

SA

FE

TY

HA

ZA

RD

Arc welder

Clean shaft

Safety glasses

Helmet

Position shaft on vee blocks

r.

Leaeher gloves

Electrodes

Acquire type of metal of shaft

Protective clothing

.

Chipping hammer

Acquire correct electrode

Always pour acid into water

Wire brush

Set proper .amperage

Keep welding stubs off floor

Vee blocls

\

Weld in proper sequencq

Check for flammable material before

Chip eldg and brush each bead of weld

welding

Overlap each bead 1/3

Have water type extinguisher

Check oorosity, visually inspect

Curtain to protect others from arc

tch with dilute solution of nitric acid

rays

Machine welded sections b4ck to original

Faceshield, rubber gloves and apron

dimen:ions

when handling acid



used/stored or nosted]

DE

CIS

ION

S.

CU

ES

ER

RO

RS

Determine if surface is worn

Frozen bearing

Machine failure

,

..

(TA

SK

ST

AT

EM

EN

T)

WELDBUILD UP SHAFT BY PADDING

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Effect of heating and cooling on expansion of maierial



C,mposition of matter,including protons, neutrons,


Electrode: tensile strength, yield point, elongation,

melt off rate

Cohesion

Adhesion

Measurement of length

Read and interpret charts, tables, and/or graphs [charts

for amperage settings]


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Writ ing

Viewing

EX

AM

PLE

S




Equipment

SK

ILLS

/CO

NC

EP

TS


.

trade terminology

Description of mechanism,definition,

instructions


terminology


detail/inference

147

Duty U Inspecting, Repairing, and Maintaining harden Solder

1 Sharpen drill

2 Silver solder joint

149

(TA

SK

ST

AT

EM

EN

T)

SHARPEN DRILL

TOMS,

EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TSACTED UPON

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Grinding wheel (water cooled)

Drill grinding gage

Stone dresser

Goggles

.

Dress face of stone

Readjust tool rest

Lip clearance 8° to 120

High speed drill

High carbon

Carbide tip

Safety glasses

Disconnect power supply when changing

grinding wheels

Stand to one side when dressing grind-

ing wheel

Never "dig" into the side of a grind-

ing wheel.

It will throw wheel out

Of balance

Tool rests to be adjusted to 1/8 inch

or less from face of stone


ble liquids aid paint are being

-,used/stored or posted]

[Report all injuries].

DE

CIS

ION

SC

UE

SE

RR

OR

S

Determine if the drill is dull

Length and angle of tips

Dull cutting edge'

(

.

.

No lubricant and/or coolant

Drill failure,

-=.

ITA

SK

ST

AT

EM

EN

T)

DU

..---

ST

AT

EM

EN

T)

SC

IEN

CE

MA

TH

NU

MB

ER

SY

ST

EM

S

Effect of friction on work processes and product quality

Index drill calibration

1




Motion resulting from two or more forces acting on a point

in a body [motion]

Composition of stone

Use of coolant to absorb heat during grinding

CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

EX

AM

PLE

SS

KIL

LS/C

ON

CE

PT

S

Viewing

drill

_Visual analysis, describing, logic,

detail/inference, recognize

symbol

codes and emblems

Jail

(TASK

ST

AT

EM

EN

T)

SILVER SOLDER JOINT

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TSACTED imam

PE

RF

OR

MA

NC

E K

NO

WLE

DG

ES

AF

ET

YH

AZ

AR

D

Emory cloth

Clean surface

Safety glasses

Silver solder

Check silver content of solder

Goggles

Flux

Identify correct flux

Gloves

Oxy-acetylene torch

-Adjust properflame on torch

Report all injuries to your foreman

Goggles

Melting point of solder

Check fire extinguisher

Flint lighter

Melting point of copper

Dispose of scrap material in scrap

File

hopper

Deburrer

All files must have handles

Copper - tubing

Check for flammable material

Copper elbow

Never use cigarette or match to light

Pliers

torch

Hack saw

.Relieve pressure on pipe before start -

Fire extinguisher

ing job

.

Empty pipe completely before soldering





DE

CIS

ION

SC

UE

SE

RR

OR

S

Determine whether to use silver solder

Vibration factor

_or soft solder

Weld does not, hold

(

(TA

SK

ST

AT

EM

EN

T)

SILVER SOLDER JOINT

SCIENCE

Effects of heating and cooling on

expansion of material


Arrangement of molecules, atoms, ions and the effect

on


Theory of attraction of unlike metals

Cohesion

Adhesion

MA

TH

NU

MB

ER

SY

ST

EM

S

Measures of length, OD and ID

CO

MM

UN

ICA

TIO

NS

.

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Writing

Viewing

EXAMPLES




Equipment

SK

ILLS

/CO

NC

EP

TS


trade terminology


instruction


terminology


detail/inference

Duty V Inspecting, Repairing, and Maintaining Bending Pipe

1 Wrinkle bend pipe to 90°

Isty

(TA

SK

ST

AT

EM

EN

T)

WRINKLE BEND PIPE TO 900

TO

OLS

, EQ

UIP

ME

NT

, MA

TE

RIA

LS,

OB

JEC

TS

AC

TE

D U

PO

NP

ER

FO

RM

AN

CE

KN

OW

LED

GE

SAFETY

HAZARD

Pipe

Oxy-acetylene torch

Goggles

Flint lighter

Rule

Soap stone

Large vise

Chalk line

Framing square

Fire extinguisher

Layout

Adjust torch

Observe critical temperature

Apply bending force

Time heat belts

Check for accuracy

Safety glasses

Goggles

Burns and radiation

Gloves

Fire extinguisher

Check area for flammable,miterial

Never use cigarette or match to light

tore'

[Smokille: not permitted where flamma-




DE

CIS

ION

S

Determine size of pipe

Determine radius size

CRIES

Type of machinery

ER

RO

R$

Inaccurate measurement

(TA

SK

ST

AT

EM

EN

T)

WRINKLE BEND PIPE TO 900

SCIENCE

MA

TH

NU

MB

ER

SY

ST

EM

S

Effects of heating and cooling on expansion of material

Resistance of materials to change in shape [bending]

Melting point of liquid oxygen

Acetone

Conditions of metals-stages:

Alpha, Beta', Gamma and Delta

Composition of metals

Effects of heat on metals

Hardening or annealing

Elongation and/or expansion of metals per degree of heat

Measure of length [measurements]

Use of arcs or chord in determining facts about a circle

or its parts

Determination of facts involving sectors of a circle

Determination of facts involving lines tangent to circles


CO

MM

UN

ICA

TIO

NS

PE

RF

OR

MA

NC

E M

OD

ES

Reading

Writing

Viewing

EX

AM

PLE

SRepair service order


Requisition for parts.

Equipment

SK

ILLS

/CO

NC

EP

TB

/-Comprehension, detai

inference,

trade terminolo

Description o

mechanism, definition,

instruc

ns

Penman

ip, spelling, classification,

inology

_,,-Visual analysis, describing, logic,

detail/inference

INDEX 1

INDUSTRIAL MECHANICS RESPONSIBILITIES

1 wear eye protectionI arrive promptly on service -all3 contact operator, have machine shut off and secured

4 have operator explain nroblem as seen5 before attempting work - pull master switch off and secure switch

6 attempt to acertain repairs required7 lay plan of action

8 make repairs9 reverse procedings 3 and 510 have operator accept as OK11 return to maintenance for new assicnment

151 7

INDEY 2

FREQUENCY OF SOME PREVENTATIVE MAINTENANCE PROCEDURES

1 adjust belts,clean and inspect year

2 check feed screws and adjust as required ---1 year

3 adjust auto Tubers ---1 year

4 check sight glass oil levers (operator) ---daily

5 lube non-shielded motor ball bearings ---1/2 year

6 check vibration amplitude all electric motors ---1 year

7 adjust gibs and examine alt machines except the gibs on grindersyear

8 adjust gibs and examine on grinders ----1/4 year

9 deburr machine ways ---1 year

INDEX -3

EMPLOYEES PERSONAL TOOLS

1 crescent wrench 6 inch1 crescent wrench 10 inch1 crescent wrench 3 inch1 small proxyln hammer 10 inch handle1 standard small ball peen hammer 10 inch handle1 standard medium ball peen hammer 14 inch handle

1 standard set 14 inch drive English socket wrenches1 standard set 11 inch drive English socket wrenches

4 standard set pin punches4 standard set center punches4 standard set steel cut chisels6 standard set screwdrivers1 standard adjustable hack saw1 set open end wrenches to 1 inch

1 set box end wrenches to 1 inch

1 standard small pliers1 standard medium pliers1 standard large pliers2 channel lock pliers 61/4 inch-91/4 inch

1 standard scriber1 standard combination square (Starret or equivalent)1 standard 0-1 inch outside micrometer (Starret or equivalent)1 standaid 1-2 inch outside micrometer (Starret or equivalent)1 standard 0-3 inch depth micrometer (Starret or equivalent)'1 standard good pocked knife1 standard set phillips drive screwdrivers1 standard needle nose',pliers small1 standard needle nose pliers medium

INDEX 3 (CON'T)

1 set socket heed wrenches to 3s inch (Allen type)

1 persuader 1.1 inch galvailized pipe 10 inch long

1 pair 61/2 inch vise 'grip's

1 pair 9.11 inch vise grips

1 outside caliper 4 inch1 inside caliper 4 inch1 divider caliper 4 inch1 rubber mallet1 scale 6 inch1 burring tool1 set jewelers screwdrivers1 magnifying glass 3 inch1 safety 2 cell flashlight1 pipe wrench 10 inch1 ice pick in sheath3 pencils1 tablet1 dental type mirror1 machine hand book latest edition1 drill and tap size chart1 straight edge x 1 x 24 inches1 straight edge 14 x 2 x 48 inches

1 small tool box1 large tool box

CE 004 177 Hall, Eugene J.; Turner, Raymond C. An … · Simple machines used to gain mechanical...

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Transcript of CE 004 177 Hall, Eugene J.; Turner, Raymond C. An … · Simple machines used to gain mechanical...