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GREAT SOUTHERN INSTITUTE OF TECHNOLOGY

AHCMOM302A - Perform machinery maintenance


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This document has been created for trainers by trainers with financial assistance from the National VET E-Learning Strategy. The content has been developed and presented with respect to the required elements of the unit and follows the required outcomes of the training package. Any lecturer or trainer is able to use all or any of the following content for their own training needs or modify all or any of the content for their training needs. All images may be used by the trainer or they may substitute for their own as needed.

For more information or clarification, please contact Andrew Morrison at the Great Southern Institute of Technology (Albany, Western Australia) by emailing [email protected] (Project Manager).


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TABLE OF CONTENTS

Element 1.1 ........................................................................................................................................................................................................................................................... 3

Element 1.2 ........................................................................................................................................................................................................................................................... 8

Element 1.3, 1.4 .................................................................................................................................................................................................................................................. 14

Element 1.5 ......................................................................................................................................................................................................................................................... 18

Element 2.1 ......................................................................................................................................................................................................................................................... 22

Element 2.2 ......................................................................................................................................................................................................................................................... 25

Element 2.3, 2.4 .................................................................................................................................................................................................................................................. 29

Element 2.5 ......................................................................................................................................................................................................................................................... 33

Element 3.1 ......................................................................................................................................................................................................................................................... 36

Element 3.2 ......................................................................................................................................................................................................................................................... 39

Element 3.3 ......................................................................................................................................................................................................................................................... 42

Element 3.4 ......................................................................................................................................................................................................................................................... 46

Element 3.5 ......................................................................................................................................................................................................................................................... 50

Element 3.6 ......................................................................................................................................................................................................................................................... 54

Element 4.1, 4.2& 4.3 .......................................................................................................................................................................................................................................... 57


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Element 1.1 Module Information

Developers Applied Quality Training Fundamentals (AQTF)

Competency This unit covers the process of maintaining machinery and equipment that is used principally in agriculture, horticulture, and conservation and land management work and defines the standard required to:

carry out engine/equipment checks according to operator manuals and enterprise requirements

carry out lubrication and replacement of oils and filters according to operator manuals

carry out transmission checks, including drive and steering clutches and oil levels

check machinery and equipment components for wear and tear, and replace, tag and report defects if necessary

dispose of replaced parts and oils according to legislation and enterprise procedures

and record all details of maintenance and requirements for monitoring

Element 1 Carry out engine/equipment checks

Criteria Criteria 1: Timed and regular engine equipment checks are carried out on specialised machinery and equipment as specified in operator manuals


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Preventative maintenance

Written Content A well thought out machinery maintenance plan extends the working life of machines by

Reducing down time and cost to do repairs

Improving efficiency by having the machines starting and working well

Keeping up resale value of machinery Maintenance Schedules and Record Keeping Keep records for each machine to make sure these maintenance procedures are being performed at the proper time. These records will also help you predict parts inventory needs. If you keep a stock of required maintenance parts, such as filters, belts and seals, you won’t be caught in a situation where important maintenance was not performed on schedule because of lack of parts.

Images

Caption: Equipment checks should be performed regularly


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Pre operational checks for a 4 stroke lawnmower

Written Content The pre-operational checks for a 4 stroke petrol engine driven lawnmower include: • Check engine oil • Check fuel level • Check Blades for damage or excessive wear • Refuel in a well-ventilated area • Inspect Air cleaner • Inspect grass Bag • Set cutting height

The maintenance schedule for each machine appears in the manual.

Images

The manual provides all manufacturers recommendations.


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Safety-identify the risk, make the changes

Written Content Prior to carrying out maintenance on any machine a risk analysis and the identification of potential hazards need to be undertaken. Potential hazards and or precautions when servicing lawnmower include:

Use precaution when lifting the machine into position for a service

Use only the correct tools for the job. Injury can occur when tools slip or break.

Fuel leaks or fuel discharge from the filler cap are a fire risk.

Oil spills and leaks may result in slips and spills.

Stop the engine and disconnect the spark plug cap: Before checking, cleaning or working on the lawn mower.

If lawn mower starts to vibrate abnormally, check immediately.

Do not change the engine governor setting or over-speed the engine.

Do not start the engine when standing in front of the discharge opening..

Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition.

Allow the engine to cool before undertaking repairs or service.

To reduce the fire hazard, keep the engine, muffler, battery compartment (if applicable) and petrol storage area free of grass, leaves or excessive grease.

Images

Caption: Potential hazards are identified checking mower blades for wear and correct fit


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Assessment Question No 1 English

Question Timed and regular checks of machines are important because: 1. You can tell if a worker is being rough on a machine 2. The machines can get stolen or lost 3. To prevent breakdowns by finding faulty parts before they cause too much damage 4. Running motors with low oil levels reduces engine life 5. All operators should be aware of the safety instructions in the manual

Answer 3,4


Question A regular check of a 4stroke petrol motor driven lawnmower would not include: 1. Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition 2. Check engine oil level 3. Remove fuel tank and drain 4. Keep the engine, muffler and petrol tank free of grass, leaves or excessive grease. 5. Walk around the mower and check for any fuel or oil spills

Answers 3


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Criteria Criteria 2: All relevant grease or lubricant points are lubricated according to manufacturer specifications


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Identifying the lubrication points

Written Content Lubrication points and grease nipples can be found by:

Checking the operation and maintenance manual

Asking your supervisor and looking on the machine.

Images

Caption: cover manual


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General properties of a lubricating oil

Written Content Viscosity indicates the resistance of a liquid to flow. It describes whether oil is thick or thin. Other properties of oils include

Flash Point

Oxidation Stability

Acidity and Alkalinity (Total Acid Number and Total Base Number)

Detergency

Anti-rust Property

Corrosion Inhibition

Anti-foaming Property

Emulsification and Demulsification

Anti-wear Property

Extreme Pressure Loading Property (EP)

Tackiness Use the recommended oil and change the oil according to the manufacturer’s instructions. Oil loses many of its lubrication qualities with age and use.

Images

Caption: Oil Properties are identified on the label


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Viscosity of oil

Written Content Viscosity indicates the resistance of a liquid to flow. SAE viscosity ratings SAE (Society of Automotive Engineers) ratings designate the oil’s viscosity; simply put, how thick or thin oil is at a certain temperature. For example SAE 30 oil is “thinner” (less viscous) than SAE 50 oil. The vast majority of carmakers specify multi grade oils which are designed to act like a thin oil when cold so that they can circulate through the engine quickly on start up, and like a thicker oil when hot, to provide the necessary engine protection. An example of a multi grade oil designation is 10W-40. The 10W (W = winter) indicates how the oil would behave when cold, while the 40 is how it acts when hot. Oil with higher viscosity is thick and can stand greater pressure without being squeezed out of the lubricating surfaces. Higher viscosity oils such as SAE 90 are used in gearboxes. Lower viscosity oil is thin and penetrates tight bearings and moving parts. Low viscosity oil have a low number (SAE 10) Low viscosity oil offers less resistance to the moving parts. It is therefore important to use lubricating oil of appropriate viscosity to achieve optimum lubrication effect. The recommended oil is stated in the machine manual. For small 4 stroke motors SAE 10W-30 is recommended for general use in Australia.

Images

Caption: Checking oil


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General properties grease

Written Content Grease is a semi-solid formed by the dispersion of a thickening agent in a liquid lubricant (base oil). Greases have advantage over oil in some applications because greases stay at the point of lubrication and will hardly be squeezed out. Sometimes, greases can also be used to seal up machine parts to prevent the entry of moisture and dust.

Images

Caption: Grease gun


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Question Which single statement about viscosity is correct: 1. Viscosity and flash point are the same thing in oils 2. Corrosion inhibition and viscosity are the most important properties of oil 3. Lawnmower motors require oils with a viscosity of 90 SAE 4. Viscosity indicates the resistance to flow of a liquid

Answer 4


Question The recommended oil for a small 4stroke motor is: 1. SAE 125 gear oil 2. SAE 10W-30 3. SAE 5

Answers 2


Question Oil loses many of its lubrication qualities with age and use True False

Answers True


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Element 1.3, 1.4 Module Information










Criteria Criteria 3: Oils and filters are changed at intervals prescribed in operator manuals Criteria 4: Hydraulic hoses and systems checked for deterioration and defects actioned in line with supervisor's instructions


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Interval for oil and air filter changes

Written Content The manual prescribes the interval for oil and air filter changes Examples The recommendations for the air cleaner for a Honda lawn mower are:

Check each use

Clean every 3 months or 50 hours and

Replace when damaged or broken The manual recommendation for the oil filter on a Briggs & Stratton 4 stroke petrol motor (Model 210000) as drives a chipper shredder is:

Replace every 50 hours of use. If the air cleaner is not serviced according to the manufacturer’s recommendation and is used clogged or dirty, damage to the motor will occur. A dirty air cleaner will restrict air flow to the carburettor, reducing engine performance. Operating the engine without an air filter or damaged filters, will allow dirt to enter the engine, causing rapid engine wear If the oil and or oil filter are not changed as frequently as recommended then the oil can

Lose its lubrication and anti-oxidation properties

Cause corrosion and wear due to acidification of the oil

Cause corrosion and wear due to impurities being carried in the oil

Images

Caption: Replace air cleaner when damaged or broken


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Hydraulic Hose Inspection

Written Content It is important to inspect hydraulic hoses regularly. They are often subject to extreme conditions such as:

Pressure differentials during operation.

Exposure to weather, sun, chemicals,

Very warm storage conditions

Mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Identify the hoses on your machine and inspect them for signs of deterioration or damage. Make sure hoses are properly routed and protected from abrasion. Before disconnecting or performing any work on hydraulic system, all pressure in the system must be relieved by stopping the engine and lowering or supporting the implement. Keep body and hands away from pinhole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and do serious damage. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

Images

Caption: Inspect hydraulic hoses regularly


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Question If the air cleaner is not serviced according to the manufacturer’s recommendation and is used clogged or dirty, the motor will: 1. continue to run well 2. overheat 3. be damaged due to reduced air flow 4. be hard to start

Answers 3


Question If the oil and or oil filter are not changed as frequently as recommended then, the oil will 1. Lose its lubrication and anti-oxidation properties 2. Cause corrosion and wear due to acidification 3. Be fine as long as it is topped up regularly 4. Cause corrosion and wear due to impurities being carried in the oil 5. Overheat and cause a fire

Answers 1,2,4.


Question Check hydraulic hoses while they are working because: 1. They do not work very often 2. It is easy to find leaks by feeling with your hands 3. It is easier to see any potential leaks 4. Never because pin hole leaks or nozzles eject hydraulic fluid under high pressure. 5. Every day things change

Answers 3


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Criteria Criteria 5: Occupational Health and Safety (OHS) hazards are identified, risks assessed and risk controls are implemented


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Occupational health and safety act 1984 and regulations 1996

Written Content Occupational health and safety act 1984 and regulations 1996 require all hazards are identified and risks assessed. Prior to operating any machine a risk analysis and the identification of potential hazards need to be undertaken. Potential hazards when using a lawnmower include: • Never operate the lawn mower with defective guards or shields. • Use extreme caution when pulling the lawn mower toward you. • Stop the engine and disconnect the spark plug cap: -

• Before clearing a blockage or unclogging the lawn mower. • Before checking, cleaning or working on the lawn mower.

• Inspect the lawn mower for damage and make repairs before restarting and operating the lawn mower. • If lawn mower starts to vibrate abnormally, check immediately. • Do not change the engine governor setting or over-speed the engine. • Start the engine carefully according to the instructions and with feet well away from the blades. • Do not start the engine when standing in front of the discharge opening. • Do not put hands or feet near or under rotating parts. Keep clear of the discharge opening at all times. • Stop the engine:

• Whenever you leave the lawn mower. • Before refuelling the lawn mower.

• Reduce the throttle setting during engine shut down and turn the fuel valve off at the conclusion of mowing. • Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. • Allow the engine to cool before storing in any enclosure. • To reduce the fire hazard, keep the engine, muffler and petrol storage area free of grass, leaves or excessive grease.

Images

Caption: Safety First


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Potential hazards

Written Content Potential hazards when using a chainsaw include:

Use caution when handling fuel. Move the chainsaw at least 10 feet (3 m) from the fuelling point before starting the engine.

Do not allow other persons to be near the chainsaw when starting or cutting with the chainsaw. Keep bystanders and animals out of the work area.

Do not start cutting until you have a clear work area, secure footing, and a planned retreat path from the falling tree.

Keep all parts of your body away from the saw chain when the engine is running.

Before you start the engine, make sure that the saw chain is not contacting anything.

Carry the chainsaw with the engine stopped, the guide bar and saw chain to the rear, and the muffler away from your body.

Do not operate a chainsaw that is damaged, improperly adjusted, or not completely and securely assembled. Be sure that the saw chain stops moving when the throttle trigger is released.

Shut off the engine before setting the chainsaw down.

Use extreme caution when cutting small size brush and saplings because slender material may catch the saw chain and be whipped toward you or pull you off balance.

When cutting a limb that is under tension be alert for spring back so that you will not be struck when the tension in the wood fibres is released.

Keep the handles dry, clean, and free of oil or fuel mixture.

Operate the chainsaw only in well-ventilated areas.

Do not operate a chainsaw in a tree unless you have been specifically trained to do so.

All chainsaw service, other than the items listed in the Owner’s Manual maintenance instructions, should be performed by competent chainsaw service personnel.(For example, if improper tools are used to remove the flywheel or if an improper tool is used to hold the flywheel in order to remove the clutch, structural damage to the flywheel could occur and could be subsequently cause the flywheel to burst).

When transporting your chainsaw, use the appropriate chain guard (scabbard). Other important safety precautions are contained in the body of the Owner’s Manual.

Images

Caption: Wear Correct PPE when using chainsaws


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Question To reduce the risk of fire when using a lawnmower you should: 1. Never play with matches 2. Keep all nuts, bolts and screws tight 3. Leave the engine running when you refuel the motor 4. Do not put hands or feet near or under rotating parts 5. Keep the engine, muffler and petrol storage area free of grass, leaves or excessive grease 6. Stop the mower if it starts vibrating abnormally

Answer 5


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Element 2 Carry out transmission checks

Criteria Criteria 1: Drive and steering clutches are checked for operation and adjustment in line with operator manual


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transmission checks

Written Content Drive clutches Ride on and self-propelled mowers may have a clutch fitted to the drive shaft. The clutch allows the operator to engage and disengage the drive. Thus the clutch allows the operating part of the machine to be disengaged without turning off the motor. You may be familiar with the reel mower pictured. This mower has a clutch. To check the clutch. Operate the mower and ensure the drive fully engages. The recommended service requirements are in the machinery manual and are as follows. The cylinder clutch lever must have a 3-5 mm spacing from the end of the clutch gate when fully engaged. The adjustment bolts are at the bottom of the rod. Slip clutches PTO driven attachments such as a slasher or rotary hoe have slip clutches. These are a safety feature designed to prevent overload and should not be adjusted under general service. The clutch should be inspected looking for worn or faulty parts.

Images

Caption: Inspecting drive clutch on a reel mower


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Question Drive clutches are useful because 1. If a mower has a drive clutch it is able to handle tougher conditions 2. When you are driving you can take fewer breaks 3. They allow the operator to engage and disengage the working parts 4. There is no need to start the motor as often 5. They provide an additional lubrication point

Answer 3


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Element 2Carry out transmission checks

Criteria Criteria 2: Transmission oil levels are checked in line with operator manual


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Transmission/gear Oil levels

Written Content If gear oil is not changed according to the manufacturers instruction excessive wear and early breakdown of gears can result Continued reliability, successful operation and long life of power transmission equipment largely depend upon the constant supply of lubrication oil of proper quantity, quality and condition. The lifeline of the gearbox is its lubrication system, critical for supporting the drive under all modes of operation. Transmission and gearboxes are either filled to the dipstick mark or have an oil level plug. Use only oils as recommended by the manufacturer. Transmission oils require good

Film strength to prevent metal contact and scoring between the gear teeth.

Lubricity to reduce friction

Adhesion to prevent throw off associated with gravity or centrifugal force. Different machines require different transmission oils. The Power take off rotary hoe transmission should be topped up with oil (SAE 140) weekly and drained flushed and filled with new oil every 500 hours. Instruction for the maintenance of the transmission of a “Parklands” ride on mower includes:

Drain and refill Transmission Oil yearly – use one pint of SAE 30

Grease all pivots daily

Images

Caption: Show oil levels


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Automatic transmission fluid (ATF)

Written Content Automatic transmission fluid (ATF) is the fluid used in vehicles with automatic transmissions. It has very low viscosity (is a thin oil) and typically coloured red or green to distinguish it from motor oil and other fluids in the vehicle. On most vehicles its level is checked by a dipstick while the engine is running. Automatic transmission fluid must not be used in gearboxes The fluid is highly specialised oil optimised for the special requirements of a transmission, such as valve operation, brake band friction and the torque converter as well as gear lubrication.

Images

Caption: Transmission oil for Automatic vehicles


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Question If gear oil is not changed according to the manufacturers instruction 1. Excessive wear and early breakdown of gears can result. 2. Owners save money because the recommendation is aimed at selling more oil 3. The gears produce a burning smell and can cause fire 4. The owners warranty is voided

Answer 1,4


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Element 2.3, 2.4 Module Information










Criteria Criteria 3: Tracks/wheels and undercarriage are checked for oil leaks and wear Criteria 4: Faulty seals or leaks are identified and corrective actions taken according to operator's instructions


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Tracks/wheels and undercarriage are checked for oil leaks and wear

Written Content When checking the undercarriage of a mini digger things to check are:

Loose bolts.

Oil leaks

Stiff or frozen track components

Tyre pressure in the wheels.

Check on the bolts to see if they are complete and tightly bolted

Make sure that the tension of the tracks is neither too tight nor too loose: refer to the manual. When checking under any machine operators must be aware of the risks of crushing if the machine falls.

Never jack up a mini-digger to check the undercarriage.

Never check under a machine with the engine running

Never walk or stand under a raised implement such as the bucket of a loader

Keep all bystanders well away from the machine while checking the undercarriage

Images

Caption: Checking Tyre pressure in the wheels


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Faulty seals or leaks are identified and corrective actions taken according to operator's instructions

Written Content Faulty seals or leaks are identified by leaking oil. The oil attracts dirt and dust and this can be easily seen. There may be a pool of oil left under the machine when parked overnight. If there appears to be a faulty seal it needs to be reported to your supervisor. The replacement of seals can be a major operation and is best undertaken by a mechanic. In most cases oil leaks need to be reported to the supervisor. In instances where the solution is simple such as, the drain plug is incorrectly fitted or loose the remedy should be undertaken immediately. Faulty seals allow water, dirt and other impurities to penetrate the bearing, transmission or engine. This will damage moving parts and cause undue wear.

Images

Caption: Check for oil Leaks


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Question Signs of faulty seals or oil leaks on a small machine include which of the following: 1. The engine vibrates excessively 2. Oil on the floor under the machine 3. The paint peels and blisters 4. The oil level requires regular top up 5. A dirt oil mixture gathers around the seal

Answer 2,4,5


Question When checking the tracks of a mini digger which of the following should be checked: 1. Are there any stiff or frozen track components 2. Drive the machine at full speed, jump off and run alongside to check everything is OK 3. Tyre pressure in the wheels. 4. All bolts to see if they are complete and tightly bolted 5. Jack the machine up and check the running of the tracks 6. Make sure that the tension of the tracks is neither too tight nor too loose

Answer 1,3,4,6


Question Which of the following is not a precaution to avoid the crushing hazard if the machine falls? 1. Never jack up a mini-digger to check the undercarriage. 2. Check on the bolts to see if they are complete and tightly bolted 3. Never check under a machine with the engine running 4. Never walk or stand under a raised implement such as the bucket of a loader 5. Keep all bystanders well away from the machine while checking the undercarriage

Answer 2


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Criteria Criteria 5: Machine is regularly cleaned as an integral part of maintenance checks


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Put a here

Written Content Washing down the machine provides the opportunity to inspect moving parts and identify leaking seals and excessive wear. Regular cleaning of the machine will be part of the maintenance schedule. Lawnmowers, rotary hoes, mulchers and other garden machines should be cleaned at the end of each day’s use. Cleaning can be done using compressed air and wiping down with a soft cloth. Pressure cleaning using degreaser and high pressure water is used on machines with heavy soiling of oil and grease. When pressure cleaning all electrical parts need to be protected as water can cause the electrics to short out. Alternators and starter motors are particularly prone to water damage

Images

Caption: Washing down the machine provides the opportunity to inspect moving parts


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Question When washing down machines with water which of the following precautions must be taken 1. Take care and wear appropriate footwear on wet surfaces 2. Cover electrical components such as the starter motor or alternator. 3. Avoid washing off oil and grease 4. Wear the following PPE, a respirator and a welding mask

Answer 1,2,


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Element 3 Maintain components and attachments

Criteria Criteria 1: Personal protective equipment (PPE) is selected, used and maintained according to procedures


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Personal protective equipment (PPE) is selected, used and maintained according to procedures

Written Content The type of personal protective equipment required varies depending on the job being done, the equipment used and the chemicals being used. Product labels are required by law to provide directions and list the PPE requirements. The product Material Data Safety Sheet (MSDS) also provides directions concerning the necessary level of protective equipment. Some workplaces will provide a worker induction and specify the requirements for PPE on each job. It is the obligation of the employer to provide a safe work environment. This includes the provision of all required PPE. If the required PPE is not available workers should not commence the task. Workers have the responsibility to work safely and to minimize danger to themselves and their fellow workers. Some workplaces provide Safe Operating Procedures information for tasks and machines. These contain information on the required PPE. If information on PPE is not available workers should consult with their supervisor before commencing the job.

Images

Caption: Safety Operating procedures


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Question Which of the following statements is/are True? 1. Product labels are required by law to provide directions and list the PPE requirements 2. If information on PPE is not available workers should do the job anyway 3. The type of personal protective equipment required varies depending on the job being done 4. If the required PPE is not available workers should not commence the task 5. Workers have the responsibility to minimize danger to themselves and their fellow workers.

Answer 1,3,4,5


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Criteria Criteria 2: Machine operational replacement wear components are checked for wear and condition


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Regular checking of machines for worn or damaged parts

Written Content Machines need to be checked regularly for worn or damaged parts A prestart check will include a visual inspection of the machine looking for worn or loose parts. A prestart inspection will also include checking fuel and oil and the air filter Parts that wear on a rotary lawnmower are the cutter blades. These need to be checked and replaced regularly.

Images

Lawnmower Maintainence.wmv

Caption: Mower Service


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Question A prestart check includes: 1. The replacement of mower blades 2. A visual inspection of the machine looking for worn or loose parts 3. Checking the fuel and oil level 4. Checking the air filter 5. Notification to the bank to pay the bearer 6. Running your hands over hydraulic hoses to check for oil leaks with the motor running

Answer 2,3,4


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Criteria Criteria 3:Worn or unserviceable replacement components are replaced as part of daily routines


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Replacing worn or damaged parts on a lawnmower

Written Content Replacing worn or damaged parts. When checking or replacing the blades on a slasher type lawnmower be aware of the following:

1. If you have removed the blade assembly, always use a torque wrench to reinstall. 2. Wear heavy gloves to protect your hands. 3. The blades can be sharpened if they are still in good condition or replaced if worn out. 4. Poor sharpening technique can lead to weakening the blades or imbalance or poor cutting. The blades must be sharpened

by trained staff, check with your supervisor. Steps to follow when checking, sharpening or removing lawnmower blades

1. Turn the fuel valve to the OFF position. 2. Disconnect the spark plug cap, then tilt the mower to the right side, so the carburettor side is up. 3. Hold the blade disc firmly and remove the blade disc holder bolt. Set a flat blade screwdriver at the engine’s bolt to

prevent the blade disc from turning when removing the blade disc holder bolt. 4. Remove the blade setting bolts, blades, spring washers, blade washers and self-lock nuts from the blade disc.

Images

Caption: Inspect blades for damage


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Lawnmower repairs – Installation of blades

Written Content Installation: 1. Clean dirt and grass from the blades, blade disc and the inside on the cutter housing. 2. Install the blade, spring washers, blade washers and self-lock nuts to the blade disc using the blade setting bolt as described

below. 3. Tighten the self-lock nuts with a torque wrench. Prevent the blade disc from turning when tightening the self-lock nuts; tighten

the self-lock nuts to the specified torque. The blade setting bolts are specially designed for the mower. Should you ever have to replace them, use only genuine parts.

4. Install the blade/blade disc, washers and blade disc holder bolts. 5. Hold the blade disc firmly and install the blade disc holder bolts. 6. After installing the blade/blade disc check that it does not interfere with the housing.

Images

Caption: Keep mower blades clean


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Question Which of the following statements is True 1. The blades can be removed with the motor running 2. The blades can be sharpened if they are still in good condition 3. Poor sharpening technique can lead to weakening the blades and/or poor cutting 4. Mower blades should only be changed every three(3) years 5. To save time do not clean out the dirt and grass from the blades

Answer 2,3


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Criteria Criteria 4: Component inspection and replacement activities are completed safely following enterprise and industry guidelines


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Safe Work Practices

Written Content The safe completion of repairs to equipment requires workers to follow the enterprise guidelines. These guidelines are provided on Safe Operating Procedures information sheets, in workshop and machinery manuals and in induction manuals. Workers should follow these three steps in all aspects of their work.

Identify the hazard

Assess the risk

Report hazard to your supervisor

Make the changes

Images

Caption: Spot the hazard, Solve the problem, Make the changes,


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Safety guidelines

Written Content To check, repair or replace lawnmower blades safely follow these guidelines:

Read and understand the Owner’s Manual.

Before using, always visually inspect to see that the blade, blade bolt(s) and mower housing are not worn or damaged. Replace worn or damaged blade and bolt(s) in sets to preserve balance.

Never pick up or carry a lawn mower while the engine is running.

Stop the engine and disconnect the spark plug cap: - Before clearing a blockage or unclogging the lawn mower. - Before checking, cleaning or working on the lawn mower. –

After striking a foreign object. Inspect the lawn mower for damage and make repairs before restarting and operating the lawn mower. –

If lawn mower starts to vibrate abnormally, check immediately.

To reduce the fire hazard, keep the engine, muffler, battery compartment (if applicable) and petrol storage area free of grass, leaves or excessive grease.

Replace worn or damaged parts for safety.

Images

Caption: Job Safety


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Question Safety guidelines covering the repairs and maintenance of machines can be found in which of the following 1. Phantom comics 2. Safe Operating Procedures information sheets, 3. Workshop and machinery manuals 4. Induction manuals. 5. Newspapers

Answer 2,3,4


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Criteria Criteria 5: Moving operational components are checked for wear and condition and adjusted to the tolerances specified in operator manuals where applicable


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Inspecting and servicing Belts

Written Content Ensure engine is shut down and all parts have stopped moving before doing any belt inspections or replacements. The maintenance schedule for belts will be outlined in the machinery manual. Some general rules are: All belts should be inspected at the prestart check Replace belts if they are badly cracked, frayed, rotten or damaged. Broken belts can result in:

A rapid increase in temperature and warning light flashing in the case of a fan belt.

Drive chain not operating in the case of a drive belt

No power steering

Images

Caption: Fan Belt


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Front tine tiller -Belt removal and replacement Page No: 3

Written Content Belt removal and replacement for a Front Tine Tiller The tiller has been engineered with belts made of special material (Kevlar Tensile). They should not be replaced with an off-the-shelf belt. Disconnect and ground the spark plug wire against the engine. 1. Remove the belt cover from the left side of the tiller as follows. 2. Remove two self-tapping screws and flat washers from the front of belt cover. 3. Remove the hex stop nut and flat washer from the side of the belt cover. Remove belt cover 4. Lift the belt off the transmission pulley 5. Remove the hex nut which secures the reverse idler pulley to the idler bracket. Slide idler pulley out and remove the belt. 6. Reassemble the new belt, following instructions in reverse order. Make certain the reverse drive belt is assembled with the wide side of the belt against the transmission and engine pulleys. Belt tension: Be certain to adjust the clutch control as instructed in the final clutch adjustment section of assembly instructions. The belt tension is adjusted on the cable attached to the tine engagement handle and carried out after the belt has been installed. Refer to your machinery manual when adjusting belt tension.

Images

Caption : belt cover


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Question Which of the following are False 1. All belts should be inspected at the prestart check 2. Replace belts if they are badly cracked, frayed, rotten or damaged. 3. All belts should be checked with the motor running 4. All belts should be as tight as possible 5. Belts should not be used to tie up pets

Answer 1,2,5


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Criteria Criteria 6: Work areas are cleaned, returned to operating condition and maintained according to enterprise and OHS requirements


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Put a here

Written Content Workshop areas must be kept clean and tidy

Put all tools in their proper place

Remove rubbish and broken or replaced parts and packaging

Wipe down benches and sweep floors

Remove any spilt oil, grease or fuel

All machines are stored in their allocated place

Machines returned to the workshop must be cleaned

Images

Caption: Clean Work Shop


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Question Which of the following are true? An untidy workshop is:

1. Efficient because tools are easier to find 2. Dangerous there are slips and trips hazards 3. More efficient when you are short of time 4. OK if you have plenty of room 5. Hard to keep clean

Answer 2,5


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Element 4.1, 4.2& 4.3 Module Information









Element 4 Record maintenance

Criteria Criteria 1: Identified faults and defects are recorded in machine record. Criteria 2: Maintenance procedures including duplicates usage are recorded in workshop record Criteria 3: Service or repair requirements are reported and actioned according to prescribed procedures


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Maintenance Records

Written Content The importance of records Maintenance records are written notes that provide documentation about the upkeep of a certain piece of equipment. These records are useful in maintenance management because

They help businesses ensure their equipment is kept in good condition.

They provide businesses with a way to manage and track repair and preventative upkeep expenses.

They can help make sure that any appropriate equipment maintenance or plant maintenance has been completed so that plant operations will run smoothly

They help avoid accidents or plant shut-downs resulting from defective equipment.

Images

Caption: Fill in Record Form


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Recording Maintenance

Written Content Machine and workshop logs need to be filled out after any maintenance or parts replacement is carried out on machinery. Check with your supervisor/workshop manager if you cannot locate logs or record books. Key components of the records include:

1. Any faults that need repair 2. Faults that have been repaired 3. Preventative service and maintenance carried out 4. Work done by each machine is recorded daily

Images

Caption: Work shop log book


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Question Maintenance records are important because they 1. Help avoid accidents 2. Provide information on the parts used 3. Can be used to check on workers 4. Provide businesses with a way to manage and track repair and preventative upkeep expenses. 5. Provide business with a way to check on poor or rough operators

Answer 1,2,4.

Documents

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