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 *
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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
=
(TA
SK
ST
AT
EM
EN
T)
INSPECT CIAIN 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
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
RS
Machine failure under-load
(TA
SK
ST
AT
EM
EN
T).
INSPECT CHAIN DRIVE
-S
CIE
NC
EM
AT
HN
UM
BE
R-S
YS
TE
MS
'.
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
z
-
.
.
-
.
_
.
k.
.
'-'
.
-
.
.
.
,C
OM
MU
NIC
AT
ION
S
PE
RF
OR
MA
NC
EMODES
-EXAMPLES
SKILLS/CONCEPTS'
Reading__
-
-
Sreaking
Viewinl
Listening
Touching
..
/
,
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
.
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
.
3
(TA
SK S
TA
TE
ME
NT
)R
EP
AIR
-CH
AIN
DR
IVE
TOOLS, EQUIPMENT, NUMERALS,
OBJECTS
AC
TE
D -
UP
ON
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
ES
ER
RO
RS
.,
o
.
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
.
)
.
._
4
(TA
SK
ST
AT
EM
EN
T)
_S
CIE
NC
EM
AT
HN
UM
BE
R S
YS
TE
MS
.
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
Inertia and momentum
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.,
.
.--
CO
MM
UN
ICA
TIO
NS
_
..
PE
RF
OR
MA
NC
E M
OD
ES
EX
AM
PLE
SS
KIL
LS7C
ON
CE
PT
SReading
!
i
S e king
Iof
Writing
Vi4Jing
1 i
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
(TA
SK
ST
AT
EM
EN
T)
MAINTAIN CHAIN DRIVE
IsimmEno
TO
OLS
, EQ
UIP
ME
NT
, MA
TE
RIA
LS,
OB
JEC
TS
AC
TE
D U
PO
N
VM
MIII
MM
UM
EM
P
PE
RF
OR
MA
NC
E K
NO
WLE
DG
ES
AF
ET
YH
AZ
AR
D
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
[Smoking not permitted where
flammable liquids and paint are
being used/stored or posted]
[Report all injuries]`
_D
EC
ISIO
NS
Determine maintenance services to
perform
CU
ES
Standard preventltive maintenance
schedule
ER
RO
RS
Machine failure under load
(TA
SK
ST
AT
EM
EN
T)
AAINTAIN (WAIN DRIVE
SC
IEN
CE
--it
MA
TH
-- N
UM
BE
R S
YS
TE
MS
..._
Simple machines used to gain mechanical adyantage[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
,
-
CO
MM
UN
ICA
TIO
NS
.
PE
RF
OR
MA
NC
E M
OD
ES
.,E
XA
MP
LES
.S
KIL
LS/C
ON
CE
PT
S
Reading
.
Speaking
Vielying
.
Preventative maintenance
Instructions to operator
Equipment
_
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
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
SK
ST
AT
EM
EN
T)
!INSPECT DIRECT DRIVE
OUPLPIC
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
- H
AZ
AR
D
Flashlight
.
Wiping cloth
Socket head wrenches
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
[Smoking not permitted where
flammable liquids Nand paint are
being used/storea-nr -posted]
[Report all injuries]
DE
CIS
ION
S.
CU
ES
.E
RR
OR
S
Determine repair= needed
Condition of equipment, vibration, heat
, __---__---
__---
e
/
'..
Machine failure under load
.
(TA
SK
ST
AT
EM
EN
T)
-,_
SC
IEN
CE
MA
TH
- N
UM
BE
R S
YS
TE
MS
Hookes Law
Work input, work output, friction and efficiency in simple
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
.
Operating dimensions
CO
MM
UN
ICA
TIO
NS
'
PE
RF
OR
MA
NC
EMODES
EXAMPLES
SKILLS /CONCEPTS
Reading
Speaking
Viewing
Listening
Touching
Inspection order
Instructions of operator
Inspect equipment
Operating equipment
Surface and parts
_y
....
.,
Comprehension, detail/inference, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
detail/inference
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
.-
2C
(TA
SK
ST
AT
EM
EN
T)
REPAIR DIRECT DRIVE COUPLING
TO
OLS
, EQ
UIP
ME
NT
, MA
TE
RIA
LS,
OB
JEC
TS
AC
TE
D U
PO
N"
PE
RF
OR
MA
NC
E,-
KN
OW
LED
GE
SA
FE
TY
HA
ZA
RD
.
Ratchet and sockets
Socket head wrenches
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
Lock out main switch
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
Machine failure under load
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]
Relationship of force to distortion in an elastic body
Resistance of materials to change in shape [twisting,
and bending]
Peifect elasticity (Hookes Law)
,Harmonies
Measureof length
Measure of time and speed
Operating dimensions
.
CO
MM
UN
CA
TIO
NS
.
PE
RF
OR
MA
NC
EMODES
g1(421gP
Repair
serviceorc1/,;
Parts and repair manual
Instruction to operator
Requisition for paits
::',.
Equipment
.
.
SK
ILLS
/CO
NC
EP
TS
Reading
.
Speaking
Writing
:
Viewing
,
,
Comprehension, detail/inference, trade
terminology
Description of mechahism, definition,
instructions
Trade terminology, enunciation, clarity
of expression, logic
.
Penmanship, spelling, classification,
terminology
---__
Visual analysis, describing, logic,
detail/inference
.
21E
IS
(TA
SK
ST
AT
EM
EN
T)MAINTAIN DIRECT DRIVE COUPLING
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
E2:
1.
SA
FE
TY
HA
ZA
RD
Socket head wrenches
Ratchet and sockets
Screwdrivers
Flaih light
Grease gun
Grease
Lock out main switch
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
[Smoking not permitted where
flammable liquids and paint are
being used/stored or posted]
[Report all injuries]
,
..-
DE
CIS
ION
SC
UE
SE
RR
OR
S,
Determine maintenance services to
Standard preventative maintenance
perform
schedule
.......,
.
.
,
.
Machine failure under load
.
,
/
(TA
SK
ST
AT
EM
EN
T)
SC
IEN
CE
._
MA
TH
NU
MB
ER
SY
ST
EM
S
Hookes,Law
Relationship of force to distortion in an elastic body
Resistance of materials to change in shape [twisting
and bending)
Harmonies
Effects of lubrication
Measure of speed and time [speed and RPM]
Operating 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
Viewing
...
,
.
Preventative maintenance schedule
,
.
Instructions to operator
Equipment
.
Colkprehension, detail/inference, des-
criOtion of mechanism, trade term-
inology
.
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
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
SK
ST
AT
EM
EN
T)
INS
TO
OLS
, EQ
UIP
ME
NT
, MA
TE
RIA
LS;
OB
JEC
TS
AC
TE
DU
PO
N.
PE
RF
OR
MA
NC
E K
NO
WLE
DG
E
71
SA
FE
TY
HA
ZA
RD
Flashlight
.
,
(.,
0
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-
ble liquids and paint are being
used/stored or posted]
port all injuries)
S
..
.
DE
CIS
ION
S-
CUES
cE
RR
OR
S
Determine repairs needed
,.
-
Condition of equipment, vibration,
tension, alignment
.,,
,..,.!,, '
.
Machine failure under load
.
.
(TA
SK
ST
AT
EM
EN
T)
,S
CIE
NC
EM
AT
HN
UM
BE
R S
YS
TE
MS
Simple machines used to gain mechanical advantage [belts
and-pulleys]
Work input, work output, friction and efficiency in simple
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]
Relationship of force to distortion in an elastic body
[elastic body].
,
Resistance of materials to change in shape [stretching]
_
Measures of length, width, thickness
,
Operating dimensions
,,
\
.
,
,
.
.
.
\ -t,
,.
,
'..,-
,,..
.
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
lInspection order
Instructions.to operator
Inspect equipment
Operating equipment
Surface and parts
Comprehension; detail/inference, trade
terminology*
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
detail/inferenie
.
Auditory discrimination, concentration,
noise discrimination
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]
[Report all injuries]
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]
Work input, work output, friction and efficiency in simple
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]
Relationship of force to distortion in an elastic body
Resistance of materials to change in shape [stretching]
Measures of length, wIdth.and thickness
Operating dimensions
CO
MM
UN
ICA
TIO
NS
PE
RF
OR
MA
NC
E M
OD
ES
Reading
Speaking
Writing
Viewing
EXAMPLES
Repair service order_
Parts and repair manual
Instructions to operatbr
Requisition for parts
Equipment
SK
ILLS
/CO
NC
EP
TS
Comprehension, detail/inference, trade,
terminology-
Description of mechanism, definition,
instructions
Trade terminology, enunciation, clarity.
of expression, logic
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
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
used/stored or posted]
[Report all injuries]
_
.
in proper manner
spreading
where flamma-
are -being
.
DE
CIS
ION
SC
UE
SE
RR
OR
S-
.Determine maintenance services to
Standard preventative maintenance
perform
,____schedule
'
,,..
.-.
.-
Machine failure under load
.,
..
<.,
(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
Preventative maintenance schedule
Instruction's to operator
Equipment
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
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
Socket head wrenches
Observie bull gear for wobble
[Smoking not permitted where 21zurmva-
Observe pinion shaft for whip
ble liquids and paint are being
Check bearings for heat
used/stored or posted]
Observe pinion gear wobble
[Report all injuries]
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
.
Determine repairs needed
Condition of gear drive:sound
Machine failure under load
,, -
-------..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
structure and strength of materials
Effect of heating and cooling on state of matter
Effects of lubrication
-Measure length, width and thickness
Operating dimensions
..
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
Instructions to operator
_
Inspect equipment
Surface and parts
.
Comprehension, detail/inferenc e, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Auditory discrimination, concentration,
noise discrimination
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
Socket head wrenches
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
(TA
SIK
ST
AT
EM
EN
T)
REPAIR OPEN GEAR DRIVE
SCIENCE
, MATH
NU
MB
ER
SY
ST
EM
S
Inertia and momentum
Work input, work output, friction and efficiency in simple
machines [friction]
Effects of friction on work processes and product quality
Arrangement of molecules, atojns, ions and the effect on
structure and strength of materials
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
.
Repair service order
.
-._
Parts and repair Manual
.
Instructions to operator
Requisition for parts
.
Equipment
Comprehension, detail/inference,
trade terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation,
clarity of expression, logic
Penmanship, spelling, classification,
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
ble liquids and paint are being
Flashlight
Deburr teeth pinion and bull gear
used/stored or posted]
Open gear lubricant
Set wedge keys firmly
[Report all injuries]
Putty knife
-Lubricate
.
Replace guard
DE
CIS
ION
SC
UE
SE
RR
OR
S
Determine-maintenance services to
per-
Standard rreventative maintenance sched-
_
Machine failure under load
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
,
Operating dimensions
.
.
.
CO
MM
UN
ICA
TIO
NS
PE
RF
OR
MA
NC
ENKMDES.
EXAMPLES
SK
ILLS
/CO
NC
EP
TS
Reading
Speaking
Viewing
.
Preventative maintenance schedule
Instructions to operator
Equipment
1 ! 1.
/Comprehension, detail/inference,
,
description of mechanism,trade
terminology'
Trade terminology, enunciation, clarity
of"expression, logic
Visual analysis, describing, 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
Determine repairs needed
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-
ble liquids and paint are being
used/stored or posted]
'
. [Report -al/ injuries]
1C
UE
S.
Unusual noises, temperature, odor,
vibrations
ER
RO
RS
Machine failure under load
(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
Effects of lubrication
-
Liquid and dry measures [liquid measures]
Operating dimensions
_
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
.
Comprehension, detail/inference, trade
terminology
Trade terminology, enunciation, clarity
of eipression, logic
Visual analysis, deacribikg, logic,
detail/inference
.
Auditory discrimination, concentration,
noise discrimination
-
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
.
Socket head wrenches
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
[Report all injuries]
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
Machine failure under load
Determine whether to repair or
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
structure and strength of materials
Work Input, work output, friction and efficiency in simple
machines
.
,,
Effect of heating and cooling on expansion of materials
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
Repair service order
.
Parts and repair manual
Instruction to operator
Requisition for parts
.
Equipment
_
Comprehension, detail/inference, trade
terminology
Description of mechanism, definition,
instructions
-.
Trade terminology, enunciation, clarity
of expression, logic
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
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
Socket head wrenches
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all ,injurios]
,
,
\
.
_
,
.
DE
CtS
ION
SC
UE
SE
RR
OR
S
Determine maintenance services to
Standard preventative maintenance
Machine failure under load
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
Simple machines used to gain mechanical advantage
Composition of matter, including protons, neutrons,
electrons, atoms, molecules, elements
.,
Arrangement of molecules, atoms and ions and the effect on
structure and strength of materials
Amount of oil too much/too little
Oil grooves,
Effects of lubricants,
..
Liquid and dry measures
Operating dimensions
.- '
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
Instructions to operator
Equipment
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic -
Visual analysis, describing, 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
.
[Smoking not permitted where flamma-
ble liquids and paint are being
used /stored or-posted)
[Report all injuries]
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
Determine repairs needed
Machine failure under load
(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
Inertia and momentum
.
Arrangement of molecules, atoms and ions and the effect on
-
structure and strength of materials
Resistance of materials to change in shape
Effects of lubricants
--
,
.
._
Measures of 31Ingth, width and thickness
Operating dimensions
.
.
.
.
-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
Instructions to operator
Inspect equipment I
Operating equipment
Surface and parts
.
Comprehension, detail/inference, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
,Visual analysis, describing, logic,
detail/inference
..
Auditory discrimination, concentration,
noise discrimination
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
_
Socket head wrenches
'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
[Smoking not permitted where flamma-
Gear puller
Install new pinion on shaft
ble liquids and paint are being
File
Reinstall, assembly in saddle
used/stored or posted]
Lubricants
Reinstall hand crank
Operate hand crank for smooth operation
[Report all injuries]
Lubricants
n/e
- -
,
.
/
DE
CIS
ION
SC
UE
S.
ER
RO
RS
Determine whether to repair or replace
Condition and life span of parts
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]
Work input, work output, friction and efficiency in simple
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]
Resistance of materials to change in shape
Effects of lubrication
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
Repair service order
Parts and repair manual
Instructions to operator
Requisition for parts
.
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
Visual analysis, describing, logic,
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..
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
mmememensr.
\D
EC
ISIO
NS
_C
UE
SE
RR
OR
S
Machine failure under load
.
, ...
,
.
.
.
Determine maintenance services to
perform
.
Y.
-
Standard preventative maintenance
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];
Work input, work output, friction and efficiency in simple
machines
Inertia and momentum.
Arrangement of molecules, atoms and ions ancithe effect on
structure and strength of materials
Resistance of
materials to change
in shape
Effects of lubricants
,.
.
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
Preventative maintenance schedule
.
Instructions to operator
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
-
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
DE
CIS
ION
S
Determine repairs needed
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
CE
MA
TH
NU
MB
ER
SY
ST
EM
S
TiSimplemachines used to gain
114 'lark inp:-, work output,
machines
Fluids under pressure -
Transfer of-energy from
Inertia and momentum
Effects of lubricants
mechanical advantage [gears)
friction and
lubricants
one form to
efficiency in simple
another
Operating dimensions
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
Instructions to operator
Inspect equipment
Operating equipment
Surface and parts
SK
ILLS
/CO
NC
EP
TS
Comprehengion, detail/inference, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
detail/iaerence
Auditory discrimination, concentration;
noise discrimination
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
Socket head wrenches
Torque wrench
Raise rail, move heads to extreme
position
Lock outzmain switch
_
Safety glasses
Pinch points
Smoking not permitted where flamma-
Feeler gauge
Remove inspaction place in chuck
ble liquids and paint are being
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
Determine whether to repair or
Condition and life span o£. parts
Machine failure under load
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
Inertia and momentum
Torque
Effects of lubricants
Operating 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
,,
:2--
Writing2
Vi'ewing'
Repair service order
Instructions to operatOr
Requisition for. parts
Equipment
,
detail/inference, trade
terminology
Trade terminology,-enunciation, clarity
of expression
Penmanship, spelling, classification,
terminology'
Visual analysis, describing, logic,
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
Lock out main switch
Pinch points
Ratchet wrench, sockets and extension
Remove inspection plate
[Smoking not permitted where flamma-
Wiping
clot
hAdjust retaining nut if required
ble liquids and paint are being
'Reinstall plate
used/stored or posted)
Check and adjust gear tooth clearance
[Report all injuries]
*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-
Standard preventative maintenance
Machine failure under load
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]
Work input, work output, friction and efficiency in simple
machines
FluLis unc',r pressure [lubricants]
Transfer of energy from one form ro another
Inertia and momentum
Effects of lubricants
.
Basic math skills
Feeler gauge
Operating dimensions
COMMUNICATIONS
PE
RF
OR
MA
NC
EMODES
-E
XA
MP
LES
SK
ILLS
/CO
NC
EP
TS
Reading
Speaking
Viewing
Preventative maintenance schedule
Instructions to operator
Equipment
"
Comprehension, detail/inference,
description-of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
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
Remove inspection plate
Safety glasses
Flashligtv-
Observe belt
Lock out main switch
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted)
[Report all injuries]
.,
DE
CIS
ION
S.
CUES
ER
RO
RS
Determine repairs needed
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]
Work input, work output, friction and efficiency in simple
machines
Inertia and momentum [inertia]
Relationship of force to distortion in an elastic body
[distortion]
Resistance of materials to change in shape
I stretching]
Effects of lubricants
Measure.of time and speed [speed-RPM]
FPM = Diameter x RPM x .262
Operating dimensions
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
Instructions to operator
Inspect equipment
Operating equipment
Surface and parts
Comprehension, detail/inference,
trade terminology
Trade terminology, enunciation, clarity
of expression, logic
Visualy analysis; describing, logic,
detail/inference
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
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
Ratchet wrench and sockets
Socket head wrenches
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
used/stored or posted
Report all injuries
DE
CIS
ION
SC
UE
SE
RR
OR
S
Determine whether to repair or
replace broken spring
Condition and life span of parts
Machine failure under load
Determine whether to repair or
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],
Work input, work output, friction and efficiency in simple
machines
Inertia and momentum
Relationship of force to distortion in an elastic body
Resistance of materials to,change in shap..
[stretching]
Hooks Law
Effects of lubricants
-_
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
Repair service order
Parts and repair manual
Instructions to operator
Requisition for parts
Equipment
.:
Comprehension, detail/inference,
terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation,
of expression, logic
Penmanship, spelling, classification,
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
Lock out main switch
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries)
DE
CIS
ION
SC
UE
SE
RR
OR
S
Determine maintenance services to
perform
Standard preventative maintenance
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]
Work input, work output, friction and efficiency in simple
machines
Inertia and momentum [inertia]
Relationship of force to distortion in an elastic body
[distortion]
Resistance of materials to change in shape (stretching]
Effects of lubricants
Measure of time and speed Ispeed - RPM]',
FPM = Diameter x RPM x .262
Operating dimensions
COMMUN ICATIONS
PE
RF
OR
MA
NC
E M
OD
ES
Reading
Speaking
Viewing
EX
AM
PLE
S
Preventative maintenance schedule
Instructions to operator
Equipment
SK
ILLS
/CO
NC
EP
TS
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
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-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
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
Machine failure under load
(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]
Operating dimensions
..,
.
.
Simple machines used to gain mechanical
Work input, work output friction and efficiency
machines [friction]
,
Effeci of heating and cooling on expansion
Inertia and momentum
Effect of friction on work processes and
(friction]
Relationship of force to distortion in
Resistance of materials to change in shape
Effects of lubricants
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
Comprehension, detail/inference,
trade terminology
Trade Leminology, enunciation, clarity
of expression, logic
Visual analysis, .deecribing, logic,
detail/inference
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
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
Socket head wrenches
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[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
Machine failure under load
(TA
SK
ST
AT
EM
EN
T)
REPA,IR VEE BELT DRIVE
SC
IEN
CE
MA
TH
NU
MB
ER
SY
ST
EM
S
Simple machines used to gain mechanical advantage [pulleys
Work input, work output, friction and efficiency in simple
machines [friction]
Effects of heating and cooling on expansion of materials
Inertia and momentum
Effects of friction on work processes and product quality
[friction]
Relationship of force to distortion in an elagtic body
Resistance of materials to change in shape [stretching]
Measures of length
Matching length
Matching belts
,Chart
Matching width
Relationship of force to distortion in an;elastic body
[deflection under pressure]
Operating dimensions
CO
MM
UN
ICA
TIO
NS
PE
RF
OR
MA
NC
E M
OD
ES
Reading
Speaking
Writing
Viewing
EX
AM
PLE
S
Repair service order
Parts and repair manual
Instructions to operator
Requisition for parts
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
Trade terminology, enunciation, clarity
of expression, logic
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
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
[Smoking not permitted where flamma-
Straight edge
Check and correct sheave alignment
ble liquids and paint are being
Hammer
Close and secure door
used/stored or'posted]
Socket head wrenches (Allen)
[Report all injuries]
Belt
tension meter
DE
CIS
ION
SC
UE
SE
RR
OR
S
Determine belt condition
Standard preventative maintenance
Machine failure under load
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]
Work input, work output, friction and efficiency in simple
machines [friction]
Effects of heating and cooling on expansion of materials
Inertia and momentum
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.)
Operating dimensions
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
Preventative maintenance schedule
Instructions to operator
Equipment
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted)
[Report all injuries]
DECISIONS
CU
ES
ER
RO
RS
Machine failure under load
Determine repairs needed
\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
Transfer of energy from one form to another
Inertia and momentum
'---
Operating condition
,
.
COMMUNICATIONS
_.
PERFORMANCE MODES
EXAMPLES
SKILLS /CONCEPTS
Reading
Speaking
Viewing
Listening
Touching
Inspection order
Instructions to operator
Inspect equipment
Operating equipment
Surface and parts'
Comprehension, detail/inference,trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis,,describing, logic,
detail/inference
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
..
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
Socket head wrenches
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
DE
CIS
ION
S
Determine whether to repair or replace
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)
Transfer of energy from one form to another
Centrifugal forces developed by bodies in rotation
Inertia and momentum
Effects of friction on work processess and product quality
ifriction)
.
Measure of time and speed
Measure of weight
Measures of temperature
Operating dimensions
)
.
,,,--
COMMUNICATIONS
PE
RF
OR
MA
NC
E M
OD
ES
EX
AM
PLE
S,
SK
ILLS
/CO
NC
EP
TS
Reading
Speaking
Writing
Viewing
Repair service order
Parts and repair manual
Instructions to operator
Requisition of parts
.
Equipment
Comprehension, detail/inference, trade
terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation, clarity
of expression, logic
Penmanship, spelling, classification,
terminology.
Visual analysis, describing, logic,
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
Socket head wrenches
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
ble liquids and paint are being
used/stored or pos ed]
[Report all injurif! A
DE
CIS
ION
S
Determine-maintenance services to per-
form
er
CU
ES
Standard preventative maintenance
schedule
ER
RO
RS
Machine failure under load
(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
.
Centrifugal forces developed by bodies in rotation
Transfer of energy from one form to another
Inertia and momentum
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
Preventative maintenance schedule
Instructions to operator
Equipment
$
Comprehension, detail/inference,
description of mechanism, trade
,terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
'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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
.,
DE
CIS
ION
SCUES
ER
RO
RS
Determine repairs needed
.Cond'tion of equipment
Machine failure under load
..
(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]
Inertia and momentum
Newtont Laws of motion
Lubricants
Gas under pressure
Arrangement of molecules, atoms and ions and the effect on
structure and strength of materials
Resistance of materials to change in_shape [stretching]
Operating dimensions
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
Instructions to operator
Trade terminology, enunciation, clarit
of expression
Inspection equipment
"Visual analysis, describing, logic,
detail/inference
Operating- equipment
Auditory discrimination, concentration,
noise discrimination
Surfrce and parts
Shape, texture, movement, tension
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
Socket head wrenches
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
Determine whether to repair or
replace clutch parts
PE
RF
OR
MA
NC
E K
NO
WLE
DG
ES
AF
ET
YH
AZ
AR
D
Lock out main switch
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
Condition and life span of parts
Safety glasses
Grease, spills
Pinch points
Slips or falls
Caution on compressed air
Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted
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]
Effects of friction on work processes and product quality
.Inertia and momentum
Newton's Laws of Motion
Lubricants
Gas under pressor:
Arrangement of molecules, atoms and, ions and the effect on
structure and strength of materials
Resistance of materials to/Change in shape Ictretching]
Effects of lubricants
.:
CO
MM
UN
ICA
TIO
NS
PE
RF
OR
MA
NC
EMODES
EX
AM
PLE
SS
KIL
LS /C
ON
CE
PT
S
Reading
Repair service order
Comprehension, detail/inference, trade
terminology
Parts and repair manual
Description of mechanism, definition,
instructions
Speaking
Instructions to operator
Trade terminology, enunciation, clarit
of expression, logic
Writing
Requisition for parts
Penmanship, spelling, classification
terminology
Viewing
Equipment
Visual analysis, describing, logic,
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
Lock out main switch
Lubricate bearings
Check and adjust limit switches
Check air pressure
Safety glasses
Grease spills
Pinch points
Slips or falls
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored -or posted]
[Report all injuries]
DE
CIS
ION
S
Determine maintenance services to per-
form
CU
ES
Standard preventative maintenance
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]
Work input, work output, friction and efficiency in simple
machines [friction, kinetic and potential]
Inertia and momentum
Newton's Law of Motion
Lubricants
Gas under pressure
Arrangement of molecules, atoms and ions and the effect on
structure and strength of materials
Resistance of materials to change in shape [stretching]
1
Operating dimensions
.
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
Preventative maintenance schedule
Instructions to opeator
Equiptent
..
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
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
Machine failure under load
(TA
SK
ST
AT
EM
EN
T)
INSPECT ACME FEED SCREW
SC
IEN
CE
MA
TH
NU
MB
ER
SY
ST
EM
S
Simple machines used to gain mechanical advantage
Work input, work output, friction and efficiency in
simple
machines
Fluids under pressure
%Inertia and momentum [body at rest - body
in motion]
Effects of friction on work processes and product quality
Resistance of materials to change in shape
(resist to
twisting, bending]
Effects of lubricants
,
.
Dimensicnal tolerance
Operating dimensions
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
.
Instructions to operator
Inspect equipment
Operating equipment
Surface and parts
Comprehension, detail/inference, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
detail/inference
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
.
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.
Ratchet wrench and sockets
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
Lock out main switch
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
DE
CIS
ION
S
Determine whether to install new parts
or repair
CUES
Feed, screw and nuts
Condition and life span of parts
ER
RO
RS
Machine failure under load
(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]
Work input, work output, friction and efficiency in simple
machines [friction]
Fluids under pressure Ilubricant]
Centrifugal forced developed by bodies in rotation [body at
rest - body in motion]
Effects of friction on work processes and product quality
Resistance of materials to change in shape [stretching]
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
,.
Repair service order
Parts and repair uanual
Instructions to operator
Requisition for parts
Equipment
,
Comprehension, detail/inference, trade
terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation, clarity
of expression, logic
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
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
Lock out main switch
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used /stored or posted]
[Report all injuries]
CU
ES
Standard, preventative maintenance
schedule
ER
RO
RS
Machine failure under load
(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
Simple machines used to gain mechanical advantage
Work input, work output, friction and efficiency in simple
machines
Fluids under pressure [lubricants]
Inertia and momentum [bodies at rest - bodies in motion]
Effects of friction on work processes and product quality
Resistance of materials to change in shape
Effects of lubricants
Wrench dimensions
Measures of length (measurement]
Operating dimensions
--,
,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
Preventative maintenance schedule
Instructions to operator
Equipment
CoMprehension, detail/inference,
discription of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
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
Lock out main switch
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
[Smoking not permitted where flamma-
roughness
ble liquids and paint are being
Indicate table for linear motion
used/stored or posted]
Inspect mounting screws
[Report all injuries)
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
Determine repairs needed
Unusual sounds, condition of equipment
Machine failure under load
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
Effect of heating and cooling on expansion of materials
(change of dimensions)
Fluids under pressure foil under pressure]
Composition of matter, including protons, neutrons, elec-
trons, atoms, molecules, elements [composition of matter:
Transfer of energy from one form to another
,
Inertia and momentum
Effect of friction -1... 'fork processes and product quality
Resistance of materials to change in shape
Effects of lubrication
?
..-
Plus and minus on indicator-
Operating 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
Viewing
Listening
Touching
Inspection order
Instructions to operator
Inspection of equipment
Operating equipment
,
/
Surface and parts
//
.
Comprehension, detail/inference, tract,
terminology
Trade terminology, enunciation,
clarity of expression, logic
isual analysis, describing, logic,
detail/inference
Auditory discrimination, concentratio
noise discrimination
Shape, texture, movement, tension
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
Socket head wrenches
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
Lock out main switch
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
Condition and life span of parts
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
Smoking not permitted where flamma-
ble liquids and paint are being
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
Work input, work output, friction and efficiency in simple
machines
Effect of heating and cooling on expansion of materials
!heat, change of dimensions]
Fluids under pressure Foil under pressure]
Composition of matter, including protons, neutrons,
electrons, atoms, molecules, elements
(hardness]
Transfer of energy from one form to another [from oil
pressure
linear measurement]
Inertia and momentum
Effects of friction on work
processes and product quality
Arrangement of molecules, atoms and ions and the effect on
structure and strength of materials Tstructure rearrange-
ment]
Resistance of materials to change in shape
Effects of lubrication
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
Repair service order
Parts and repair manual
Instructions to operator
---Retinisitign of parts
Equipment
SK
ILLS
/CO
NC
EP
TS
Comprehension, detail/inference, trade
terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation, clarit
of expression, logic
Penmanship, spelling, classification,
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)
Ratchet wrench and sockets
Socket head wrenches
1111
1111
1111
=11
1111
11M
ir
PE
RF
OR
MA
NC
E K
NO
WLE
DG
ES
AF
ET
YH
AZ
AR
D
Lock out main switch
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
(Report all injuries]
DE
CIS
ION
S
Determine maintenance services to per
form
CU
ES
Standard preventative maintenance
schedulolt
ty
ER
RO
RS
Machine failure under load
(TA
SK
ST
AT
EM
EN
T)
MAINTAIN BALL SCREW
SC
IEN
CE
MA
TH
NU
MB
ER
SY
ST
EM
S
Work input, work output, friction and efficiency in simple
Wrench dimensions
machines
Operating dimensions
Effect of heating and cooling on expansion of materials
[change of dimensions]
Liquids under pressure (oil under pressure]
Composition of matter, including protrons, neutrons,
electrons, atoms, molecules, elements
Transfer of energy
from one form to another
Inertia and momentum
Effects of friction on work processes and product quality
Resistance of materials to change in shape
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
Instructions to operator
Equipment
SK
I LLS
/CO
NC
EP
TS
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clari
of expression, logic
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
Ratchet wrench and sockets
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
[Smoking not permitted where
flammable liquids and paint are
being used/stored or posted]
[Report all injuries]
DE
CIS
ION
S
Determine repairs needed
CUES
Condition of equipment, leaks, scores,
nicks
ER
RO
RS
Machine failure under load
(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
Fluids under pressure
Forces acting on a body immersed or floating in a
liquid
Transfer of energy from one form to another
Inertia and momentum [Pascals Law]
Effects of lubricants
Wrench dimensions
Operating 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
Instruction to operator
Inspect equipment
Operating equipment
Surface and parts
SK
ILLS
/CO
NC
EP
TS
Comprehension, detail/inference, trade
terminology
Trade terminology, enunciation, clarit
of expression, logic
Visual-analysis, describing, logic,
detail/inference
Auditory discrimination, concentration
noise discrimination
Shape, texture, movement, tension
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
Socket head wrenches
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
[Smoking not permitted where flamma
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
DE
CIS
ION
S
Determine whether to install new seal
CUES
Condition and lifespan of parts
ER
RO
RS
Constant usage
.
Leakage
Machine failure under load
(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
Work input, work output, friction and efficiency in simple
machines
Fluids under pressure
Forces acting on a body immersed or floating in a liquid
Transfer of energy from one form to another
Inertia and momentum
Pascal's Law
Effects of lubricants
,
Wrench dimensions
Number of oil seal
Operating dimensions
'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
Repair service order
Parts and repair manuals
I
Instructions to operator
Requisition for parts
Equipment
Comprehension, detail/inference,
trade terminology
Description of mechanism, definition,
instructions
Trade terminology, enunc4ation,
.clarity of expression, logic
Penmanship, spelling, classification,
terminology
.
Visual analysis, describing, logic,
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
Socket head wrenches
Ratchet wrench and sockets
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
[Smoking not permitted where flamma
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
CU
ES
Sta
ndar
d pr
even
tativ
e m
aint
enan
ceschedule
ER
RO
RS
Machine failure under load
(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
Fluids under pressure
Forces acting on a body immersed or floating in a liquid
Transfer of energy from one form to another
Inertia and momentum
Pascal's Law
Effects of lubricant
Wrench dimensions
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
S
.
Reading
Speaking
Viewing
7/
.
Preventative maintenance schedule
-.
Instructions to operator
Equipment
Comprehension, detail/inferenCe,
'description of meChanim, trade
terminology
Trade terminology, enunciation,
clarity of expression, logic
Visual analysis, describing, logic,
'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-
ble liquids and paint are being
used/stored or posted]
[Report all inju. ies]
arassmasommollir--..
DE
CIS
ION
SC
UE
S,
"RR
OR
S
Determine repairs needed
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
Simple machines used to gain mechanical advantage [pulleys
Basic math skills (read thermometer)
Work input, work output, friction and efficiency in simple
Operating dimensions
machines [friction]
Effect of heating and cooling on expansion of materials
Fluids under pressure flube]
Inertia and momentum
Effects of friction on work processes and product quality
Effects of lubrication
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
Comprehension, detail/inference, trade
terminology
Speaking
Instructions to operator
Trade terminology, enunciation, clarity
of expression, logic
Viewing
Inspect equipment
Visual analysis, describing, logic,
detail/inference
Listening
Operating equipment
Auditory discrimination, concentration,
-noise discrimination
Touching
Surface and parts
Shape, texture, movement, tension
.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
Ratchet wrench and sockets
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
Listen for unusual noise
Safety glasses
Pinch points
Splinters from timber (wear gloves)
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
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
Machine failure under load
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]
Work input, work output, friction and efficiency in simple
machines
Effect of heating and cooling an expansion of materials
[expansion due to heat]
Fluids under pressure [proper lube]
Inertia and momentum
Effects of friction on work processes and product quality
Effects of lubrication
Wrench dimensions
Measures of length
Measures of temperature [bearings]
Liquid and dry measures [oil]
Operating 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
Repair service order
Parts and repair manual
Instructions to operator
Requisition for parts
Equipment
Comprehension, detail/inference, trade
terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation, clarity
of expression, logic
Penmanship, spelling, classification,
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
Ratchet wrench and sockets
Socket head wrenches
.
Lock out main switch
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-
ble liquids and paint are being
used/stored Or posted]
[Report all injuries]
DECISIONS
CUES
Standard preventative maintenance
schedule
.ERRORS
Determine maintenance services to per-
form
Machine failure under load
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]
Inertia and momentum
Effects of friction on work processes and product quality
Effects of lubricants
Wrench dimensions
Operating 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
,"
.
.
Preventative maintenance schedule
r
Instructions to operator
Equipment
,
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic,
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
[Smoking not permitted where flamma
ble liquids and paint are
being
stored/used or posted]
[Report all injuries]
1
0
DE
CIS
ION
SCLUES
ADmOition of equipment
ER
RO
RS
Determine repairs needed
.
Machine failure under load
".
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]
Effects of lubricants
Basic math skills
Operating dimensions
CO
MM
UN
ICA
TIO
NS
PERFORMANCE MODES
EXAMPLES
SKILLS/CONCEPTS
Reading
Speaking
Viewing
-Listening
Touching
Inspection order
Instructions to operator
Inspect equipment
Operating equipment
Surface and parts
.
Comprehension, detail/inference, trade
terminology
Trade terminology, enunciation, clarity
of expression, logic
Visual analysis, describing, logic, --__
detail/inference
Auditory discrimination, concentration,
noise discrimination
Shape, texture, movement, tension
.
..... --.
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
Ratchet wrench and sockets
Socket head wrenches
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
Lock out main switch
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
[Smoking not permitted where flamma-
ble liquids and paint are being used/
stored or posted]
[Report all injuries]
ER
RO
RS
Machine failure under load
......
......
......
.....
----
-- -
--
__ _
__,
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,
electrons, atoms, molecules, elements
Transfer of energy from one form toanotner [spring]
Effects of friction on work processes and product quality
[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
Operating dimensions
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
Repair service order
' -Parts and repair - ..manual
Instructions to operator
Requisition for parts
.
,-
Equipment
Comprehension, detail/inference, trade
terminology
Description of mechanism, definition,
instructions
Trade terminology, enunciation, clarity
of expression, logic
Penmanship, spelling, classification,
termindlogy.
Visual analysis, describing, logic,
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
[Smoking not permitted where flamma-
ble liquids and paint are being
stored/used or posted]
[Report all injuries]
DE
CIS
ION
S
Determine maintenance services to
perform
CU
ES
Standard preventative maintenance
schedule
ER
RO
RS
Machine failure under load
(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]
Composition of matter, including protons, neutrons,
electrons, atoms, molecules, elements (hardness]
Effects of lubricants
Basic math skills
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
S
trade clarity
logic,
.
,41
92
Reading
Speaking
Viewing
.
Preventative maintenance schedule
Instructions to operator
Equipment
.
Comprehension, detail/inference,
description of mechanism,
terminology
Trade terminology, enunciation,
of expression, logic
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
ble liquids and paint are being
Inspect hose for wear
stored/used or posted]
Inspect safety cables on high pressure
[Report all injuries]
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
Listen for unusual noise
,-
Check vacuum systems
(AMMEMOMMNEW
DE
CIS
ION
SC
UE
S.
ER
RO
RS
Determine repairs needed
Condition of equipment
Machine failure under load
.
..
(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
Effects of lubricants
Basic math skills
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
S
Reading
Speaking
Viewing
Listening
Touching
Inspection order
Instructions to operator
Inspection of equipment
Operating equipment
Surface and parts
Comprehension, detail/inference,
trade terminology
Trade terminology, enunciation, clarit
of expression, logic
Visual analysis, describing, logic,
detail/inference
Auditory descrimination, concentration,
noise discrimination
Shape, texture, movement, tension
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)
Lock out main switch
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
ble liquids and paint are being
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
Determine whether to repair or
Ireplace defective parts
"Hour meter, dust, dirt, normal wear,
leaks
Machine failure under load
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
Fluids under pressure
Transfer of energy from one form
to another
Transfer of heat from one body to another
Inertia and momentum
Effects of friction on workprocesses and product qgglity
Effects of lubricants
Basic math skills
Wrench-dimensions
Operating 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
Repair service order
Parts and repair manual
Instructions to operator
Requisition of parts
Equipment
Comprehension, detail/inference,
trade terminology
Description of mechanism, definition,
instructions
'trade terminology, enunciation,
clarity of expression, logic
.
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
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
Lock out main switch
Safety glasses
Wiping cloth
Remove, clean or replace external filter
Pinch points
End wrenches
Check belt drives
[Smoking not permitted where flamma
Hydraulic oil
Adjust tension
ble liquids and paint are being
Lube oil
Lube variable belt adjustments
used/stored or posted]
Grease gut
Check all fittings
[Report all injuries]
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
Standard preventative maintenance
Machine failure under load
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
Effect of heating and cooling on expansion of materials
Fluids under pressure [transfer of pressure]
Transfer of energy from one form to another [gas under
pressure]
.
Inertia and momentum
.
.Effects of friction on work processes and product quality
Relationship of force to distortion in ar. elastic body
[packing and 0-rings]
Resistance of materials to change in shape
Effects of lubricants
Basic math skills
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
S
Reading
Speaking
Viewing
Preventative maintenance schedule
Instructions to operator
Equipment
Comprehension, detail/inference,
description of mechanism, trade
terminology
Trade terminology, enunciation,
clarity of expression, logic
Visual analysis, describing, logic,
detail/inference
135
-I 2
'4
(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
Smoking not permitted where flamma-
Plumb bobs
Level machine with spirit level and/or
ble liquids and paint are being
Broneon or Wild optical transit
optical transit
used/stored or posted
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
Machine failure under load
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
(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
Determine whether to repair or replace
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
[Smoking not permitted where flamma
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
ER
RO
RS
Machine failure under load
(TA
SIK
ST
AT
EM
EN
T)
SC
IEN
CE
MA
TH
NU
MB
ER
SY
ST
EM
S
Lubricant
SaeNumbers and meanings
Transfer of heat from one body to another
Effects of friction on work processes and, product quality
Effects of lubricants
Measures of length [length ID and OD]
Operating dimensions
-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
Parts and repair manual
Requisition of parts
Equipment
Comprehension, detail/inference,
trade
terminology
Description of mechanism, definition,
instructions
Penmanship, spelling, classification,
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
[Smoking not permitted where flamma-
ble liquids and paint are being
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
Transfer of heat from one body to another
Effects of friction on work processes and product quality
C,mposition of matter,including protons, neutrons,
electrons, atoms, molecules, elements
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]
Operating dimensions
CO
MM
UN
ICA
TIO
NS
PE
RF
OR
MA
NC
E M
OD
ES
Reading
Writ ing
Viewing
EX
AM
PLE
S
Repair service order
Parts and repair manual
Requisition for parts
Equipment
SK
ILLS
/CO
NC
EP
TS
Comprehension, detail/inference,
.
trade terminology
Description of mechanism,definition,
instructions
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
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
[Smoking not permitted where flamma-
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
Arrangement of molecules, atoms and ions and the effect on
Operating dimensions
structure and strength of materials
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
[Smoking not permitted where flamma-
ble liquids and paint are being
used/stored or posted]
[Report all injuries]
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
Transfer of heat from one body to another
Arrangement of molecules, atoms, ions and the effect
on
structure and strength of materials
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
Repair service order
Parts and repair manual
Requisition for parts
Equipment
SK
ILLS
/CO
NC
EP
TS
Comprehension, detail/inference,
trade terminology
Description of mechanism, definition,
instruction
Penmanship, spelling, classification,
terminology
Visual analysis, describing, logic,
detail/inference
(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-
ble liquids and paint are being
used/stored or posted]
[Report all injuries)
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
Operating dimensions
CO
MM
UN
ICA
TIO
NS
PE
RF
OR
MA
NC
E M
OD
ES
Reading
Writing
Viewing
EX
AM
PLE
SRepair service order
Parts and repair manual
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