Embed Size (px)
Citation preview
QUARTER 1
Electrical Installation and Maintenance
NCII
MODULE 1
Prepare Electrical and
Hydraulic Tools
Electrical and Installation Maintenance – Grade 11
Alternative Delivery Mode
Quarter 1-4 – Module 1-4
Senior High School
Republic Act 8293, section 176 states that: No copyright shall
subsist in any work of the Government of the Philippines. However, prior
approval of the government agency or office wherein the work is created
shall be necessary for exploitation of such work for profit. Such agency or
office may, among other things, impose as a condition the payment of
royalties.
Borrowed materials (i.e., songs, poems, pictures, photos, brand names, trademarks, etc.) included in this book are owned by their respective copyright holders. Every effort has been exerted to locate and seek permission to use these materials from their respective copyright owners. The publisher and authors do not represent nor claim ownership over them.
Published by the Department of Education
Secretary: Leonor M. Briones
Undersecretary:
Assistant Secretary:
Development Team of the Module
Writer: Engr. Roland V. Sindayen Jr. Content Editor: Cherry Q. Sadicon; Fe L. Dalugdug; Shiela T. Arellano Language Editor: Cleo C. Canonce Proof-reader: Marsha Liza L.
Management Team:
Chairperson: Dr. Arturo B. Bayocot, CESO III Regional Director
Co-Chairperson: Dr. Victor G. De Gracia Jr. CESO V Asst. Regional
Jonathan S. dela Peña, PhD, CESO V
Schools Division Superintendent
Rowena H. Para-on, PhD
Assistant Schools Division Superintendent Mala Epra B. Magnaong, Chief ES, CLMD
Members: Neil A. Improgo, PhD, EPS-LRMS;
Bienvenido U. Tagolimot, Jr., PhD, EPS-ADM;
Erlinda G. Dael, PhD, CID Chief;
Norberto E. Rosales, EPS (TLE-TVL) In-charge;
Celieto B. Magsayo, LRMS Manager;
Loucile L. Paclar, Librarian II;
Printed in the Philippines by __________________________________
Department of Education – Bureau of Learning Resources (DepEd-BLR)
Office Address: Zone 1, Upper Balulang Cagayan de Oro City 9000
Telefax: (088) 880-7071, (088) 880-7072
E-mail Address: [email protected]
Department of Education • Republic of the Philippines
Senior High School
QUARTER 1
Electrical Installation and Maintenance
NCII
MODULE 1
Prepare Electrical and Hydraulic
Tools
Department of Education • Republic of the Philippines
This instructional material was collaboratively developed and reviewed by
educators from public and private schools, colleges, and/or universities. We
encourage teachers and other education stakeholders to email their feedback,
comments, and recommendations to the Department of Education at
We value your feedback and recommendations.
Table of Contents
Introduction …………………………………….…….…… 1
Overview ………………………………………………… 1
Instruction ………………………………………………… 1
What to Learn ………………………………………………… 1
What I Know ………………………………………………… 2
What Is Knew ………………………………………………… 3
Definition of Terms ………………………………………………… 4
Quarter 1 Lesson 1 Identify and Prepare Electrical and Hydraulic Tools
Learning Outcome 1. Identify Electrical and hydraulic tools
Self-Check 1
Learning Outcome 2. Request tools, equipment, and materials
Self-Check 2
Performance Task
Learning Outcome 3. Safe Handling of Electrical Power and Hydraulic
Tools.
Self-Check 3
Learning Outcome 4. Operating Procedure of Electrical Power and
Hydraulic Tools
Self-Check 4
Performance Task
Learning Outcome 5. Maintain Electrical Power and Hydraulic Tools
Self-Check 5
Performance Task
Post-Assessment ………………………………………………… References …………………………………………………
Answer key …………………………………………………
1
Introduction
The content of this module will give you the opportunity to develop your skills in
Preparing Electric and Hydraulic tools with accordance to standard operating
procedures, techniques and knowledge of Electrical and Installation maintenance that
will help you acquire National Certificate Level II.
This module contains information and suggested learning activities on the
preparation of electric and hydraulic tools. It includes instructions and procedure on
how to prepare appropriate tools and materials needed in electrical wiring installation;
in storing unused and surplus electrical materials upon completion of the job; and
maintaining and soring basic tools and equipment.
Overview
This will be the source of information for you to acquire knowledge and skills in this particular trade independently and at your own pace, with minimum supervision or help from your instructor.
This module consists of two learning outcome. The learning outcome contains
learning activities with instructions sheets. Before you start, read well the discussion;
answer the pre-assessment; and work out the activities provided just to assess your
competence necessary to get a Certificate of Competency or National Certificate
Level II.
Instruction
You are required to go through a series of learning activities in order to
complete each learning outcome of the module. In each learning outcome are
Information Sheets and activity sheets. Perform these activities on your own and
answer the self-check at the end of each learning outcome. You may use another
answer sheet at the end of each module to write your answers for each self-check and
activity.
What to Learn in this Module
At the end of the lesson, you are expected to:
Identify electric and hydraulic tools
Request tools, equipment and materials
Explain how to handle safely electrical power and hydraulic tools Identify the Parts Electrical Power Tools Explain the Operating Principles of Electrical Power Tools Practice how to operate electrical power tools
Maintain electrical power and hydraulic tools
2
WHAT I KNOW?
Pre-Assessment
Direction: Select the best answer. Write the letter of the correct answer on your
answer sheet.
_____1. This is a flame retardant, moisture resistant wire used for building wiring installation in dry or wet locations.
a. thermoplastic portable cords (types SJT & ST) b. thermoplastic wire (type TW)
c. control cable (braided type)
d. flat cord (type SPT)
_____2. The appropriate tool used in cutting flexible armored cable.
a. Pliers b. Backsaw c. Hacksaw d. Knife
_____3. What do you call a plastic or metal material that is used for mounting of convenient outlets and switches on walls?
a. Junction box b. Frames c. Utility box d. fitting
_____4. It is used for branching conductors and enclosing splices.
a. Utility box b. Fastening device c. Junction box d. Adhesive
_____5. What is the safety device which automatically cuts off current that
exceeds the circuit rating?
a. Circuit b. Circuit breaker c. Conduit d. Galvanic reaction
_____6. It is a conduit fitting used to make a 90 degree change in
direction of the conduit run to a quarter bend.
a. coupling b. offset c. nipples d. elbow
_____7. It is a process of removing sharp edges or burrs left after cutting the pipe.
a. shaping b. reaming c. finishing d. smoothing
_____8. How many degrees in the direction of conduit run does a quarter
angle bend provides?
a. 45 degrees b. 90 degrees c. 135 degrees d. 180 degrees
_____9. It is a type of condulet which makes conduit turns to the right.
a. C b. LL c. LB d. LR
_____10. It is a short length conduit or tubing which is used to extend a
conduit system and also used between conduit and tubing such
as boxes or enclosures between two boxes.
a. connector b. coupling c. nipple d. condulets
3
www.google.com
Do the following activity.
Matching Type: Match the picture in Column B and Functions in Column A.
1. A handheld power tool used for cutting A.
2. Use to bend pipes using heat
3. Uses drill bit to drill holes
4. Use for polishing
5. Use to drill holes on concrete
6. Use to bend pipes except PVC conduits B.
7. Angle Grinder
8. Hand Drill
9. Hydraulic Bender
10. Heat Gun
C.
D.
What Is New
www.google.com
www.google.com
www.google.com
4
Definition of Terms
Flat Screw Driver - blade tip is wedge-shaped and resembles a negative (-) sign. This is
used to drive screws with a single slot ahead.
Philip screw driver - has a cross tip resembling a positive (+) sign. This is used to drive
screws with cross slot heads.
Claw Hammer- a hammer with one side of the head split and curved, used for
extracting nails.
Combination Pliers (Lineman’s Pliers) - is used for gripping, holding, and cutting
electrical wires and cables and even small nails.
Side Cutting Pliers - type of pliers is used for cutting medium and big wires and cables.
Long Nose Pliers - used for cutting and holding wires. This can reach tight space or
small opening where other pliers cannot reach.
Wire Stripper - A tool used for removing insulation of medium sized wires ranging from
gauge #10 to gauge #16.
Electrician’s Knife - used by linemen to remove insulation of wire and cables in low
and high voltage transmission lines.
Hacksaw - tool is used to cut metal conduit and armored cable.
Junction Box - an octagonal shaped electrical material where the connections or
joints of wires are being done.
Circuit Breaker - a protective device used to automatically blow and cuts the current
when trouble in the circuit such as short circuit or overload occurs.
Utility Box - a rectangular shaped metallic or plastic (PVC) material in which flush type
convenience outlet and switch are attached.
Stranded Wire - is made of multiple strands joined together to make a single wire.
Solid Wire - is made of a single strand of copper or aluminum wire.
Clamps- electrical materials used to hold and anchor electrical conduits in its
proper position.
Connectors- used to attach metallic or non-metallic conduit to the junction or
utility boxes.
Conduits/Pipes- electrical materials used as the passage of wires for protection and
insulation. These could be rigid metallic, flexible metallic conduit (FMC), rigid
nonmetallic (PVC), and flexible non-metallic or corrugated plastic conduit (CPC).
https://gltnhs-tle.weebly.com/lesson-12.html
5
L.O. 1. Operating Procedure of Electrical Power and Hydraulic Tools
Lesson Information 1.1 Kinds and Functions of Electrical Power and Hydraulic Tools
Learning Objectives: After Reading this discussion you must be able to identify
electrical power and hydraulic tools that is commonly used during electrical
installation.
Electrical and hydraulic tools are used to multiply manual work of humans. Tools can
be considered as extension of the human hand thereby increasing its speed, power
and accuracy.
Advantages of using proper electrical tools.
1. Efficiency of the work is met.
2. High quality of work is achieved.
3. Accomplishment of a task is faster.
4. Accuracy is obtained.
5. It is less stressful on the part of the user.
Electrical Power Tools
1. Angle Grinder - An angle grinder, also known as a side or disc grinder, is a hand held power tool used for cutting, grinding and polishing.
2. Hand Drill - A drill is a tool with a rotating drill bit used for drilling holes in various materials. The drill bit is gripped by a chuck at one end of the drill and rotated while pressed against the target material.
What Is It?
AC Power Operated Battery Operated
www.google.com
www.google.com www.google.com
6
3. A Heat Gun is a device used to emit a stream of hot air. Heat guns can be used to dry and strip paint, apply heat shrink tubing, apply shrink film, dry out damp wood, bend and weld plastic, soften adhesives, heat shrink wrap on packaging, and thaw frozen pipes, depending heavily on heat output
4. Hydraulic Bender - A hydraulic pipe bender is used for bending almost all types of pipes except PVC conduit pipes. The bending capacity of hydraulic pipe benders varies as per the strength, power and performance. The hydraulic pipe benders are designed with extra power for large jobs. They are suited for various types of bending and forming applications.
Electrical Tools and Materials 1. Pliers. Hand-operated tool for holding and gripping small articles or for bending
and cutting wire. The handle insulation is not considered sufficient protection alone. Other safety precaution must be observed. The common types of plier are:
Diagonal cutting Snap ring Long nose Combination Slip joint Side cutting
www.google.com
www.google.com
www.thespruce.com
www.thespruce.com
www.thespruce.com
www.thespruce.com
www.thespruce.com
www.thespruce.com
7
2. Screw drivers are used to drive and pull out screws. They come in various sizes and shapes and with either sharp or square tips. The width of the screw driver should match the width of the screw slot. Common types of screw drivers are:
Flat head Square head
Reed and Prince Y tip
Philip head Triangle head
3. Wire puller (fish wire) is used to pull wires into the conduit or raceway.
4. EMT bender is a tool used to bend electrical metal tubing.
www.thespruce.com www.garagetooladvisor.com
www.thespruce.com
www.garagetooladvisor.com
www.garagetooladvisor.com www.garagetooladvisor.com
www.garagetooladvisor.com www.garagetooladvisor.com
www.google.com
www.google.com www.google.com
8
5. Drilling Equipment is needed to make holes in building structure for passage of wires and conduit in both new and old installation, indoor or outdoor wiring. Common types of drilling tools and equipment are:
Electric drill Auger brace Hand drill
Gimlet Drill bits Masonry bit
6. Soldering tools are used in making splices and taps connections of wires.
Soldering iron with deluxe stand Soldering gun Blow torch
7. Hammer are used to drive and pull out nails. They are made of either hard steel or plastic. A claw hammer with fiberglass insulated handle is specially designed for electricians. Common examples of hammer are:
Claw hammer Ball peen hammer Mallet
www.google.com www.google.com www.google.com
www.google.com www.google.com www.google.com
www.google.com www.google.com
www.google.com www.google.com www.google.com
www.google.com
9
8. Measuring tools and instrument. The electricians uses the following measuring tools and devices to measure value of voltage, current and resistance, wire length, opening sizes of wire, conduit and other items.
Steel tape Wire gauge Vernier caliper
Multitester Voltmeter Ammeter
Galvanometer Clamp meter Micrometer Caliper
9. Sawing and Cutting tool. It is used to cut through material, very often wood and metal.
Hacksaw Keyhole saw
Gltnhs-tle.weebly.com Gltnhs-tle.weebly.com Gltnhs-tle.weebly.com
Gltnhs-tle.weebly.com Gltnhs-tle.weebly.com Gltnhs-tle.weebly.com
Gltnhs-tle.weebly.com Gltnhs-tle.weebly.com Gltnhs-tle.weebly.com
www.google.com
www.google.com
10
10. Wire is a single, usually cylindrical, flexible strand or rod of metal. Stranded Solid
11. Cables are composed of two or more electric conductors insulated from one another. They are larger than wires.
www.google.com www.google.com
www.google.com
11
https://studylib.net/doc/18397466/preparing-electric-and-
hydraulic-tools
Types of Wire and Cable insulation.
Insulations Letter Type
Weather Proof WP
Slow Burning SB
Slow Burning Weather proof SBW
Rubber – Code Compound R
Heat Resistant RH
Moisture Resistant RW
Moisture and Heat Resistant RH – RW
Latex (Regular) RU
Latex (Moisture Resistant) RU
Mineral (Metal – Sheated) MI
Thermoplastic Compound
Thermoplastic T
Moisture – Resistant Thermoplastic TW
Moisture and Heat Resistant Thermoplastic THW
Thermoplastic and Fibrous Outer Braid TBS
Thermoplastic and Asbestos T
Varnish Cambric
Standard Black
Heat Resisting V
Paper
Solid Type
Oil – Filled
Untreated
Treated
Asbestos
Non – impregnated A and AA
Impregnated AI and AIA
Asbestos – Varnished – Cambric
Outer Asbestos Braid AVA
Lead Covered
Cotton Braid Covered AVB
Silicon Asbestos SA
12
12. Electrical Boxes are made of steel and nonmetallic materials (plastic). Metal boxes are made of #14 heavy galvanized steel and available in four principal shapes: square, octagon, rectangular, and circular.
Utility box Junction box Square Box
Circuit Breaker Box Safety Switch box
Fuses and Circuit Breaker
Fuses and circuit breakers are electrical protective devices which are used to interrupt the flow of current when short circuit or over current occurs. They are available in different sizes and shapes and ratings. The common types are:
Cartridge Fuse Knife blade fuse Plug fuse Circuit breaker (2 pole type)
www.google.com www.google.com www.google.com
www.google.com www.google.com
www.google.com www.google.com www.google.com www.google.com
13
Switch It is an electrical device which is used to turn ON and OFF the circuit.
Flush type Tumbler type
Fittings are electrical materials which are commonly used to fit wiring devices during
wiring installation. The following are some examples of these materials:
Insulated staple wire Condulet Porcelain tubing
Electrical tape PVC fitting Sand paper
Metal clamp PVC clamp Male plug
www.google.com www.google.com
www.google.com www.google.com www.google.com
www.google.com www.google.com www.google.com
www.google.com www.google.com
www.google.com
14
Locknut and Bushing PVC and CPC Connector PVC and CPC coupling
Wire connector Terminal block
www.google.com www.google.com www.google.com
www.google.com www.google.com
15
What I Have Learned
What I Have Learned
SELF-CHECK 1.1 Direction. On your answer sheet, illustrate the following electrical materials. 1. Circuit breaker 2. Utility box 3. Philip head screw driver 4. PVC clamp 5. Male plug 6. EMT bender 7. Locknut 8. Insulated staple wire 9. Stranded wire 10. Long nose plier
SELF-CHECK 1.2 Direction. Identify the tools being describe. Write your answer on your answer sheet. 1. It is used to drive and loosen screws. 2. It is a tool used to bend electrical metal tubing. 3. It is needed to make holes in building structure for passage of wires and conduit in
both new and old installation, indoor or outdoor wiring. 4. It is used to pull wires into the conduit or raceway. 5. It is also known as a side or disc grinder, is a hand held power tool used for
cutting, grinding and polishing. 6. These are some electrical materials which are commonly used to fit wiring devices
during wiring installation. 7. It is a hand-operated tool for holding and gripping small articles or for bending and
cutting wire. 8. It is composed of two or more electric conductors insulated from one another. 9. These are electrical protective devices which are used to interrupt the flow of
current when short circuit or over current occurs. 10. It can used to bend electrical PVC pipe.
16
What Is In?
Now since you are done performing and answering the activities intended for you to identify the electrical and hydraulic tools. This time let us deepen your knowledge about electric and hydraulic tools through identifying major parts of it.
Below are the major parts of the common electric and hydraulic tools.
Lesson Information 1.2
1. Parts of Angle Grinder
2. Parts of Hand Drill
www.google.com
www.google.com
17
3. Parts of Heat Gun
4. Parts of Hydraulic pipe bender
www.google.com
www.google.com
18
What I Have Learned
SELF-CHECK 1.3
Direction: Identify the parts of a portable electric drill. Write the correct answer on
your answer sheet.
______________1.
______________2.
______________3.
______________4.
______________5.
______________6.
______________7.
______________8.
www.google.com
19
What Is In?
Before you proceed with the new lesson, take a few minutes and
write down some of the information that you’ve learned from the previous
lessons. Do this in a sheet of paper for at least 100 words.
This time you will learn new information about the process of borrowing
things and making an inventory of the things you have.
L.O. 2. Request tools, equipment, and materials
Borrow electrical tools and materials through requisition slip form.
Produce a list of electrical tools and materials using inventory form.
20
https://studylib.net/doc/18397466/preparing-electric-and-
hydraulic-tools
Lesson Information 2.1
REQUISITION SLIP FORM
Requisition slip form is a written or printed request of something that is needed. You can utilize this kind of form whenever you need to borrow something from your electrical laboratory just to accomplish your actual performance.
REQUISITION SLIP FORM (SAMPLE)
Name: Juan dela Cruz
Date:
Project: Extension wire
Location: School Campus
Classification: Electrical Installation and Maintenance NC II Purpose: For Electrical laboratory use
__________________ ____________________ Requisitioner Teacher
NO. QUANTIY UNIT DESCRIPTION UNIT COST
TOTAL COST
1 10 mtrs Flat cord wire #14 AWG
2 1 pc 3 Gang outlet (surface
type)
3 1 pc Male plug ( heavy
duty)
What Is It?
21
What I Have Learned
https://studylib.net/doc/1839746
6/preparing-electric-and-hydraulic-tools
SELF-CHECK 2.1
PREPARING REQUISITION SLIP FORM
Direction: Using the given format below, make a requisition for your electrical
project which is wiring up a small room with a lamp controlled by a switch. The activity will involve embedding a rigid conduit on the concrete wall and wooden ceiling.
REQUISITION
Slip Form Name: ________________
Project: ____________________
Location: ___________________
Classification:_______________
Purpose:____________________
No. Quantity Unit Description Unit Cost Total Cost
_________________ _________________ Requisitioner Teacher
22
https://studylib.net/doc/18397466/preparing-electric-and-
hydraulic-tools
Lesson Information 2.2
Inventory form is a list of tools, materials, property and other resources.
INVENTORY FORM (SAMPLE)
Name:Juan dela Cruz Section: ________________________ School: _________________________ Shop lab: Electricity Purpose: ________________________
Tools / Equipment
Quantity
No. of
Functional
No. of Not Functional
But Repairable
No. of Condemnable
No. of Borrowed
No. of Missing
pliers 13 12 1 0 0
power drill 5 4 1 0 0
hacksaw 11 10 1 0 0
__________________ _____________________ Requisitioner Teacher
What Is It?
23
What I Have Learned
https://studylib.net/doc/18397466/preparing-electric-and-
hydraulic-tools
SELF-CHECK 2.2
PREPARING AN INVENTORY FORM Direction: Using the given format, make an inventory of your available tools inside
your house.
Inventory Form of Tools
Name: Project: Location: Classification: Purpose:
Tools Equipment
Quantity
No. of
Functional Items
No. of Not Functional but
Repairable Items
No. of Condemnable
Items
No. of Borrowed
Items
No. of Missing Items
24
Performance Task (Individual Activity) 2.1
https://studylib.net/doc/1839746
6/preparing-electric-and-hydraulic-tools
NOTE: THIS PERFORMANCE TASK IS TO BE PERFORMED ON SCHEDULED DATE.
Direction: Using the given format below, make an inventory of your available tools inside your laboratory.
Inventory Form of Tools
Name: Project: Location: Classification: Purpose:
Tools Equipment
Quantity
No. of
Functional Items
No. of Not Functional but
Repairable Items
No. of Condemnable
Items
No. of Borrowed
Items
No. of Missing Items
25
This time you will learn new things about how to handle safely electrical power and
hydraulic tools. You need to learn safe handling before going on with the topic which
is the operating procedure of electrical power and hydraulic tools.
Tools are such a common part of our lives that it is difficult to remember that they
may pose hazards. Tragically, a serious incident can occur before steps are taken to
identify and avoid or eliminate tool-related hazards.
.
L.O. 3. Safe Handling of Electrical Power and Hydraulic Tools.
Explain how to handle safely electrical power and hydraulic tools.
Familiarize safety notices found in manuals.
What Is In?
26
Pre-Assessment
Matching Type: Match the picture in Column B and its meaning in Column A
COLUMN A COLUMN B
______1. It indicates a potentially hazardous situation which if not avoided, may result in property damage.
______2. It indicates a potentially hazardous situation which,
if not avoided, could result serious injury or death.
______3. It indicates an imminently hazardous situation
which if not avoided, may result in serious injury or
death.
______4. Read and Understand Instruction Manual.
______5. Eye Wear Protection
WHAT I KNOW?
A.
B.
C.
D.
E
.
27
Do the following activity. True or False:
Direction: Write true if the statement is correct and write false if the statement is incorrect.
_____1. Ensure that the heat gun, guard and attachments (Including handle) are secure and correctly fitted.
_____2. Keep fingers, hands and power cords clear of the tip the heat gun (heat gun tube or nozzle).
_____3. Examine the power cord, extension lead, plugs, sockets and power outlet for possible damage.
_____4. Disconnect the drill from the electrical supply when installing the bits.
_____5. Clamp stock so it will not move during the drilling operation.
_____6. Before drilling, turn the drill on to see if the bit is centered and at place.
_____7. Never grind with the portable disc grinder in an area with flammable
materials or combustible gases.
_____8. Never lay the portable disc grinder down until the disk stopped rotating.
_____9. Never disconnect the hose when it is under pressure
_____10. Keep the electrical cords and extension cords out of the way work when
grinding.
What Is New
28
Lesson Information 3.1
Learning Objectives:
After Reading this module you must be able to explain how to handle safely
electrical power and hydraulic tools.
Safe Handling and Operating Principle of Power Tools
Power tools must be fitted with guards and safety switches; they are extremely
hazardous when used improperly.
To prevent hazards associated with the use of power tools, workers should observe
the following general precautions:
2. Never carry a tool by the cord or hose. 3. Never yank the cord or the hose to disconnect it from the receptacle. 4. Keep cords and hoses away from heat, oil, and sharp edges. 5. Disconnect tools when not using them, before servicing and cleaning them,
and when changing accessories such as blades, bits, and cutters. 6. Keep all people not involved with the work at a safe distance from the work
area. 7. Secure work with clamps or a vise, freeing both and to operate the tool. 8. Avoid accidental starting. 9. Do not hold fingers on the switch button while carrying a plugged-in tool. 10. Maintain tools with care; keep them sharp and clean for best performance. 11. Follow instructions in the user’s manual for lubricating and changing
accessories. 12. Be sure to keep good footing and maintain good balance when operating
power tools. 13. Wear proper apparel for the task. Loose clothing, ties, or jewellery can
become caught in moving parts. 14. Remove all damaged portable electric tools from use and tag them: “Do Not
Use.”
What Is It?
29
Safe Handling and Operating Principle of Hydraulic Tools
15. Read and understand the entire owner's manual before attempting assembly or operation.
16. Read and understand the warnings posted on the machine and in this manual. Failure to all of these warnings may cause serious injury.
17. Replace the warning labels if they become obscured or removed. 18. Hydraulic Tools are designed and intended only if you are not familiar with
the proper and safe operation of a pipe bender, do not use until proper training and knowledge have been obtained.
19. Before operating Hydraulic Tools (Pipe Bender), remove tie, rings, watches and other jewellery, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear gloves.
20. Do not operate Hydraulic tools while tired or under the influence of drugs, alcohol or any medication.
21. Check damaged parts. Before further use of the machine, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform it is intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect it is operation. A guard or other part that is damaged should be properly repaired or replaced.
22. Provide for adequate space surrounding work area and non-glare, overhead lighting.
23. Keep the floor around the machine clean and free of scrap material, oil and grease.
24. Keep visitors a safe distance from the work area. Keep children away. 25. Give your work undivided attention .Looking around, carrying on a
conversation and “horse-play” are careless acts that can result in serious injury.
26. Maintain a balanced stance and do not overreach or us excessive force to perform any machine operation.
27. Use the right tool. Do not force a tool or attachment to do a job for which it was not designed. The right tool will do the job better and safer.
28. Use recommended accessories; improper accessories maybe hazardous. 29. Maintain tools with care and clean for the best and safest performance. Follow
instructions for lubricating and changing accessories.
30
Note:
Familiarize yourself with the following safety notices found in manuals:
This means that if precautions are not heeded or observed, it may result in minor injury and/or possible machine damage.
This means that if precautions are not heeded or observed, it may result in serious injury or possibly even death.
Always Use Proper PPE
Safety glasses must be worn at all times in work areas.
Long and loose hair must be contained.
Appropriate footwear with substantial uppers must be worn.
Close fitting/protective clothing must be worn.
Rings and jewellery must not
be worn.
Hearing protection must be worn when using this machine.
31
What I Have Learned
SELF-CHECK 3.1 True or False Direction: Write true if the statement is correct and write false if the statement is
incorrect. No Statement Answer
1 Keep the floor around the machine clean and free of scrap material, oil and grease.
2 Never yank the cord or the hose to disconnect it from the receptacle.
3 Use the right tool. Do not force a tool or attachment to do a job for which was not it designed. The right tool will do the job better and safer
4 Maintain tools with care; keep them sharp and clean for best performance.
5 Wear proper apparel for the task. Loose clothing, ties, or jewelry can become caught in moving parts.
6 Read and understand the entire owner's manual before attempting assembly or operation.
7 Avoid accidental starting. Do not hold fingers on the switch button while carrying a plugged-in tool
8 CAUTION means that if precautions are not heeded or observed, it may result in minor injury and/or possible machine damage.
9 Use the right tool. Do not force a tool or attachment to do a job for which it was not designed. The right tool will do the job better and safer
10 Remove all damaged portable electric tools from use and tag them: “Do Not Use.”
32
This time you will learn new ideas about how to operate electrical power and
hydraulic tools. Always remember that power tools can be hazardous when
improperly used. Since you are done with safe handling, the next topic you will be
guide you on how to operate electrical power and hydraulic tools.
.
L.O. 4. Operating Procedure of Electrical Power and Hydraulic Tools
Explain the Operating Principles of Electrical Power Tools Practice how to operate electrical power tools
What Is In
33
Lesson Information 4.1
Operating procedure of Electrical Power and Hydraulic Tools
Learning Objectives: After Reading this discussion you must be able to know the
operating procedures of electrical power and hydraulic tools that is commonly used
during electrical installation.
Operating Angle Grinder
Performance Objective: Given necessary tools and materials, you must be able to
operate Angle Grinder.
Operating Precaution:
1. Examine the power cord, extension lead, plugs, sockets and power outlet for possible damage
2. Ensure the grinding disc for damage, don not use damage grinding disc 3. Ensure that the grinding disc, guard and attachments (Including handle) are
secure and correctly fitted. 4. Keep fingers, hands and power cords clear of the grinding disc.
Operating Procedure:
Grinding Works
1. Attach Grinding Disc to angle grinder 2. Make sure the Disc is fully fitted with the inner flange. 3. Lock the outer flange using wrench, make sure the Disc is properly installed
and lock tightly.
What Is It?
www.academia.edu
34
4. Mark accurately the area for cutting/grinding.
5. Hold tightly the handle of the grinder and turn the power switch ON.
6. Drop the grinding disc/wheel through the marked area. (Caution: Hold tightly the grinder with both hands and put your goggles and dust mask)
7. Apply an amount of pressure while cutting/grinding. Make sure you hold the grinder with a firm grip, as there is a tendency for the grinder to want to jump out of your hands when it hits the area.
8. After grinding, remove the disc from the cut area and Turn-Off the grinder then remove the power cord,
9. Clean the grinder before storing.
Direction of Grinding
Concrete Cutting
www.academia.edu
www.academia.edu
www.academia.edu
35
Performance Task (Individual Activity)
4.1
www.academia.edu
NOTE: THIS PERFORMANCE TASK IS TO BE PERFORMED ON SCHEDULED DATE.
Direction: Perform the operating procedure of Angle Grinder.
Trainee’s Name: __________________________________ Date: ____________
Operating Angle Grinder Directions: Rate the operation in using angle grinder against each of the following criteria. Place an X on the appropriate box at the right of each item to indicate how well the given project meets the criterion.
Criteria Yes No
1. Grinding Disc/Wheel is attached properly
2. Grinding Disc/Wheel is fully fitted with the inner flange.
3. Grinding Disc/Wheel is tightly locked with outer flange using wrench
4. Area for grinding are marked before grinding
5. Operated correctly the angle grinder
6. Cleaned angle grinder before storing
Comments and Suggestions:
Name of Trainer
Name and Signature
Date:
36
www.academia.edu
Operating Hand Drill
Performance Objective:
Given necessary tools and materials, you must be able to operate Hand Drill.
Operating Precaution:
1. Examine the power cord, extension lead, plugs, sockets and power outlet for possible damage.
2. Keep fingers, hands and power cords clear of the rotating part of the hand drill and drill bit
Operating Procedure:
Drilling Works
1. Choose the size and location of the hole. (See Project 1.1-4b) 2. Base on the given project, measure and mark the location with Pencil. 3. Use center punch and make a small hole on the center of the marked area.
4. Identify the correct size of drill bit to be used (the size depends on the size of screw being used)
5. Secure the drill bit in the chuck. (Leave the hand drill unplug) open an empty chuck by twisting the outer barrel with your hand.
6. Place the bit in between the three grips and tighten the chuck. (Use chuck key to tighten)
7. Drill the hole, (Always wear proper PPE) Place the point of the bit over the marked area with small hole.
Make a small
hole using
Center Punch
Chuck Key
Insert Drill
Bit to chuck
Marked Area for drilling
www.academia.edu
www.academia.edu
37
8. Hold the hand drill perpendicular to the surface and slowly squeeze the trigger button or switch gently. (Hold firmly so it doesn’t shift once it starts turning
9. Check the depth of your hole with the screw that is going into it. (Drill deeper if necessary)
10. Unplug the drill, and remove the bit from the chuck 11. Clean hand drill before storing.
Trigger Button
(Switch)
Perpendicular
with the area
Correct Way of
Holding Hand
Drill
Depth of the
hole depends
on the screw
www.academia.edu www.academia.edu
www.academia.edu
38
Performance Task (Individual Activity) 4.2
NOTE: THIS PERFORMANCE TASK IS TO BE PERFORMED ON SCHEDULED DATE.
Direction: Drill a hole for number 6 TOX for screw. Follow the operating procedure
of Hand Drill.
39
www.academia.edu
Performance Criteria Check List
Trainee’s Name: __________________________________Date: ______________
Operating Hand Drill Directions: Rate the operation in using Hand drill against each of the following criteria. Place an X on the appropriate box at the right of each item to indicate how well the given project meets the criterion.
Criteria Yes No
1. Identified dimension and size of hole for drilling
2. Marked and punched accurately the area for drilling
3. Identified correctly the size and type of drill for drilling
4. Drill bit securely inserted to chuck and tightened.
5. Operated correctly the hand drill
6. Drilled hole accurately a. Accurate depth b. Accurate Dimension
7. Cleaned Hand Drill before storing
Comments and Suggestions:
Name of Trainer
Name and Signature
Date:
40
Operating Heat Gun Performance Objective:
Given necessary tools and materials, you must be able to operate Heat Gun. Operating Precaution:
1. Examine the power cord, extension lead, plugs, sockets and power outlet for possible damage
2. Ensure that the heat gun, guard and attachments (Including handle) are secure and correctly fitted.
3. Keep fingers, hands and power cords clear of the tip the heat gun (heat gun tube or nozzle)
Operating Procedure:
Bending Works
1. Prepare the material for heating 2. Check the nozzle to be used for heating base on the area for heating
3. Hold and Turn On (Plug the power) the switch by squeezing the switch button (Most Heat Gun has variable speed and heat) squeeze to full speed and heat if the material needs more heat and medium speed and heat if the material needs small amount of heat.
4. Point the nozzle on the area or material to be heated Note; excessive heat may damage the material heated and the distance of
the heat gun nozzle and area to be heated affects the amount of heat that hits
material or area.
5. Turn Off and let the nozzle cool down. 6. Clean heat gun before storing.
www.academia.edu
41
Performance Task (Individual Activity) 4.3
NOTE: THIS PERFORMANCE TASK IS TO BE PERFORMED ON SCHEDULED DATE.
Direction: Perform the operating procedure of Heat Gun.
Performance Criteria Check List
Trainee’s Name: ________________________________Date: ______________
Operating Heat Gun Directions: Rate the operation in using Heat Gun against each of the following criteria. Place an X on the appropriate box at the right of each item to indicate how well the given project meets the criterion.
Criteria Yes No
1. Prepared materials for heating
2. Used correct nozzle for heating
3. Identified correctly the size and type of drill for drilling
4. Operated the Heat Gun correctly
5. Heated Material not damage
6. Cleaned Heat Gun before storing
Comments and Suggestions:
Name of
Trainer
Name and Signature
Date:
www.academia.edu
42
Operating Hydraulic Bender
Performance Objective: Given necessary tools and materials, you must be able to
operate Hydraulic Bender.
Operating Precaution:
1. Check hydraulic pump for any defects before using. 2. Always observe operating precautions of the bender.
Operating Procedure:
1. Identify the size of pipe for bending to match the size of die to be used.
2. Raise the handle and the upper wing plate.
3. Select the suitable bending die for the pipe to be bent and slip it on the end of cylinder ram.
4. Select the positions of swaging blocks for the pipe. Note: For shorter pipes, position the
swaging blocks closer together to
account for the pipe shortening
during the bending process
5. Turn the swaging blocks to the notch that best fits the diameter of the pipe to be bent. (Lubricating the swaging blocks will promote ease of movement)
6. Place the pipe for bending 7. Lower the upper plate 8. Close the release valve (Turn
clockwise) 9. Pump the handle to bend the pipe 10. When the pipe bend has been made, release the pressure by opening the
release valve (Turn counter clockwise) the ram will automatically retreat. 11. Clean hydraulic bender before storing
www.academia.edu
43
Performance Task (Individual Activity) 4.4
NOTE: THIS PERFORMANCE TASK IS TO BE PERFORMED ON SCHEDULED DATE.
Direction: Perform the operating procedure of Hydraulic Bender.
Performance Criteria Check List
Trainee’s Name: _________________________________Date: ______________
Operating Hydraulic Bender Directions: Rate the operation in using Hydraulic Bender against each of the following criteria. Place an X on the appropriate box at the right of each item to indicate how well the given project meets the criterion.
Criteria Yes No
1. Prepared pipe for bending.
2. Used appropriate die for bending.
3. Swaging blocks fitted appropriately with the size of pipe.
4. Operated the Hydraulic bender correctly
5. Pipe bent without damage.
6. Cleaned hydraulic bender before storing
Comments and Suggestions:
Name of Trainer
Name and Signature
Date:
www.academia.edu
44
This time you will learn how to maintain electrical power and hydraulic tools and how to store it properly. Regular maintenance and servicing of power tools and electric tools will help to ensure that they operate with optimum efficiency at all times. This will not only help to keep tool operating costs low but it can also increase tool safety and reliability.
Electrical power and hydraulic tools are maintained and stored properly upon completion of the job in line with the manufacturer’s specification. Defective electrical power and hydraulic tools are segregated and reported to the person concerned in line with the company standards.
L.O. 5. Maintain Electrical Power and Hydraulic Tools
Prepare Maintenance Schedule for Power Tools.
Prepare Maintenance Schedule for Hydraulic Bender.
Report damaged electrical and hydraulic tools.
What Is In
45
www.academia.edu
Lesson Information 5.1 Maintaining Electrical Power and Hydraulic Tools
Learning Objectives: After Reading this discussion you must be able to maintain
and store properly the electrical power and hydraulic tools that is commonly used
during electrical installation. You must also be able to report the damaged electrical
and hydraulic tools.
Maintenance:
1. Maintenance is an action carried out to retain electrical power and hydraulic tools in an acceptable condition,
2. The principal objectives of maintenance can be clearly defined as follows:
To extend the useful life of electrical power and hydraulic tools
To assure the optimum availability of electrical power and hydraulic tools
To ensure operational readiness of electrical power and hydraulic tools
To ensure safety of personnel using electrical power and hydraulic tools
Types of Maintenance
1. Planned Maintenance – Work activities are performed as scheduled or expected
a. Preventive Maintenance –Maintenance performed to prevent or find failure before they develop into breakdown
b. Predictive Maintenance – Maintenance performed at a predetermined periods when the maintenance activity is most cost effective and before the equipment fails.
2. Unplanned Maintenance – Maintenance performed unexpectedly a. Emergency – Maintenance performed to put the item on hand
IMMEDIATELY to avoid serious consequences
What Is It?
46
www.academia.edu
Maintenance Schedule
Maintenance Schedule – Is a list allocating specific maintenance of equipment
and tools to a specific period.
Sample Maintenance Schedule
MAINTENANCE SCHEDULE
Legend
/ -Maintenance Scheduled
X –Maintenance Accomplished
Maintenance Activity
January February March April May June Remarks
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Cleaning of
power tools
/ / / / / / After Use
Lubrication x / / /
Checking of power cords
Before use
Complete listing of all Maintenance
activities to be performed
Scheduled Accomplished
47
1. Liquid
2. Solid
3. Grease
4. Paste
Lubrication
The following features contribute to safety and economic lubricating machine tools:
1. Plates on machines clearly show the grades of lubricant, quantities and
intervals are required. The machine name, type, and model should be visible.
2. Maintain the proper level of lubrication reservoirs. 3. Suitable method of lubrication should be followed to minimize or prevent
metal – to – metal contact at all times. 4. Sufficient lubricant capacity is needed to prevent overheating and
thermal distortion of machine tool structures. 5. Adequate sealing should be properly observed. Install provision for
removal of contaminant collected by the lubricant (e.g., filters). 6.
Types of Lubricant
Liquid lubricant. A lanolin or natural water repellent lanolin is derived from wool grease and a safe alternative of those common petro chemical based lubricants. These lubricants are also preventive agents against corrosion.
Water. It can also be used as a major component aside from other based oils.
Vegetable oils. These are primarily derived from plants and animals.
www.google.com www.google.com
www.google.com www.google.com
48
Purpose of Lubricating:
Lubricating performs the following key functions:
1. Keeps movable part apart 2. Reduces friction 3. Transfers heat 4. Carries away contaminant and debris 5. Transmits power 6. Protects against wear 7. Prevents corrosion
BASIC LUBRICATION
The function of a lubricant is simple. It reduces friction between moving metal surfaces. A lubricant coats surfaces and resists being displaced by the pressure keeping the metal parts separated. Lubricants also prevent corrosion, block contaminants and can serve as a coolant. A good lubricant flows easily under pressure and remains in contact with moving surfaces. It does not leak out from gravitational or centrifugal forces nor does it stiffen in cold temperatures. There are several types of lubricants:
1. Oils cover a broad class of fluid lubricants which has particular physical properties and characteristics. Petroleum oils (mineral oils) are made from naphthenic or paraffinic oils. Naphthenic oils contain little wax and their low pour point makes them good lubricants for most applications. Paraffinic oils, on the other hand, are very waxy, which makes them useful for hydraulic equipment and other machineries.
2. Ideal for lubricating bearings, gaskets, seals and other moving parts, greases consist of an oil or synthetic fluid (~80%), a thickening agent (~10%) and additives (~10%). The consistency of greases is usually ranked by their relative hardness on a scale set by the National Lubricating Grease Institute (NLGI). The softest greases are rated at 000 (which is a flowing liquid) with higher numbers indicating harder grease. Most grease falls in the range between 1 and 4.
3. Solid lubricants are usually fine powders, such as Molybdenum Disulfide (Moly), graphite and Teflon® (PTFE). They can be used alone, or as additives in grease or dispersions, or as dry film bonded lubricants. Lubricating solids can last longer than unfortified oils and greases because of their ability to form burnished films on surfaces.
49
4. Rust remover is used mainly to dissolve rust. It is also use as an excellent cleaner. For example, to remove a rusted bolt, spray remover directly on the bolt, wait for approximately five minutes; and unscrew. For a bicycle chain, apply the rust remover to clean the chain, and then apply a thick lubricant (oil or PL-100). WD-40 and Release All are two of the many brands of rust removers on the market.
5. Dry lubricant is a product that, although greasy when applied, dries
in a few minutes and leaves a protective film. Since it dries rapidly,
it doesn't attract dust, so there is no mess. This is why it is
recommended to be used on rubber, car door gaskets, handsaws,
mitre saw, saw sliders, window sashes, etc. It can also be used on
balky wooden drawers, but cabinet makers usually prefer floor wax
because it is more durable. JIG-A-LOO is the common brand of a
dry lubricant.
a. Locksmiths also use a dry lubricant, graphite, to free stuck door locks. This product, commonly found in stores, should be applied sparingly into the keyhole, as it is very messy. Graphite lubricant is composed of a fine black powder that no cleaner can remove, so it is wise to protect the door when graphite is applied.
6. Penetrating lubricant. Its lubricating properties persist even after having removed residues, as it penetrates into metal. It is ideal for door hinges, even the fridge, hard to open pliers, ski bindings, and as it does not hold dirt and dust. The PL-100 is thick and very efficient.
Synthetic lubricants cover a broad category of oils, greases, and pastes of varied properties. Synthetic lubricants are more inert, generate less waste, are capable of a wider range of temperatures and have a longer life than petroleum materials. They are even applicable to elastomers, seals and O-rings.
1. Synthetic oils are used to lubricate instrument bearings, hydraulics, air compressors, gas and steam turbines, and other applications. They have excellent viscosity-temperature characteristics, good resistance to oxidation and an extremely wide operating temperature range.
2. Synthetic greases can last a lifetime, making them very cost-effective. They are chemically inert, and their high thermal stability makes them useful for aerospace, electrical, automotive and other high-tech or industrial applications. Some of these lubricants keep their viscosity in temperatures ranging as high as 550° F and are non-flammable up to 1,200° F.
50
Silicones are very stable and very inert lubricants, which provide a wider range of operating temperatures than non-silicone synthetic lubricants. Other advantages include water repulsion and electrical insulation. Flourosilicones have a higher resistance to harsh environments and the ability to carry bearing loads. Lubricant manufacturers can provide technical data sheets on their products to advise you on the best applications of each type of lubricant.
Kinds, Uses, and Properties of Cleaning Solvents
Kinds of Cleaning Solvents
1. Solutions are homogeneous mixture of two or more components; can be gaseous, liquid, or solid. When we speak of a solution, we usually think of a solid dissolved in water. While water is the most common solvent, other liquids are frequently employed as solvents for certain substances – for example wax maybe dissolved in gasoline. The dissolved material in a solution is termed as solute (e.g. wax) while the dissolving medium is called solvent (e.g. gasoline). However, the term can be interchanged depending on which substance is of greater amount.
2. Solvent is a component of a solution that dissolves solute and is usually present in large proportion or amount. It can be classified as polar or nonpolar. Polar solvents are solvents which dissolve or are soluble in water; while nonpolar solvents are solvents which do not dissolve or are insoluble in water.
Solvents that are usually used for cleaning in automotive shops are water, gasoline, kerosene, thinner and detergent soap.
The table below shows the kinds of cleaning solvent based on their solubility in water.
Cleaning Solvents Solubility in Water Polar Nonpolar
a. water b. gasoline c. kerosene d. thinner e. detergent soap
soluble insoluble insoluble insoluble soluble
x
x
X X x
51
Uses of Cleaning Solvents
Occupational Health and Safety Practices in Handling Cleaning Solvents
Disregarding the basic precautionary measures could lead to eye injury and cuts in using cleaning solvents. You should never use compressed air to clean your clothes, hands or body. The pressure can cause the cleaning solvents and dirt particles to penetrate your skin, resulting in infection and /or blood poisoning.
Do not use compressed air to clean an object immediately after it has been removed from a hot cleaning tank. Rinse the cleaning solvents away with water. Do not use carbon tetrachloride as a cleaning solution. The fumes, when inhaled can cause serious internal injury and possibly result in death. When steam-cleaning, place the object to be cleaned on a pallet and wear a face shield and rubber gloves for protection against loose debris.
If a job or cleaning task requires the use of gloves, use the appropriate
gloves. If you have cut, nicked, or burned yourself, or something has got into your eyes, report immediately to the first-aid person.
Keep all inflammable cleaning solvents in closed tin containers and whenever possible, store them in a separate area.
5S (METHODOLOGY)
5S is a reference to a list of five Japanese words translated into English. It is a method of organizing a workplace, especially shared workplaces (like a shop floor or an office space, even in school). It is sometimes referred to as a housekeeping methodology; however this characterization can be misleading because organizing a workplace goes beyond housekeeping.
Cleaning Solvents Uses
1. Gasoline - It is used to wash oil/greasy tools/ equipment.
2. Diesoline - It is used to wash oil engine, transmission, and other parts of the vehicle.
3. Kerosene - It is used to remove dust, grease oil, and paint.
4. Thinner - It is used to remove spilled paint on the floor, walls and tools.
5. Soap and water - It is used to wash, clean upholstered furniture such as seats, tables, cabinets.
52
The key targets of 5S are workplace morale and efficiency. The assertion of 5S is, that time must not be wasted. Additionally, it is quickly obvious when something is missing from its designated location. 5S advocates believe the benefits of this methodology come from deciding what should be kept, where it should be kept, and how it should be kept. This decision making process usually comes from a concept of standardization which builds a clear understanding, among employees how work should be done. The 5S's stands for:
SEIRI: SORT (CLEAN UP)
This is the first in the 5S program: "Sorting" means to sort everything in each work area. Keep only what is necessary. Put in a separate storage area materials/tools that are not frequently used and discard the ones that are no longer functional. Sorting is the first step in making the work area tidy. It makes it easier to find the things you need. In the sorting process, you can eliminate broken equipment and tools. It frees up additional space when we discard the things that we no longer need. Obsolete fixtures, molds, jigs, scrap material, waste and other unused items/materials are disposed.
SEITON: SET IN ORDER (ORGANIZE)
This is the second step in the Five S program: Step two is to organize, to arrange or organize everything. Commonly used tools should be readily available. Storage areas, cabinets and shelves should be properly labeled. Always keep the floor clean and paint floors for you to make it easier to spot dirt, waste materials and scattered parts and tools. Outline areas on the floor to identify work areas, movement lanes, storage areas, finished product areas, etc. Put shadows on tool boards, making it easy to be located. In an office/school, there should be a designated area for bookshelves for frequently used manuals, books and catalogs. Label the shelves and books so that they can be easily found. The objective of this step is to put everything in the workplace and properly identified and labeled.
This means that there are two important parts to systematic organization. The first part is putting everything in its proper place and setting up a system so that it is easy to return each item to its proper place. The second part is where good labeling and identification practices are important. Both the equipment/tools and materials you use, as well as their proper storage locations, need to be clearly identified and labeled.
53
SEISŌ: SWEEP (REGULAR CLEANING) Step Three: requires you to do regular cleaning. Once you have everything from each individual work area up to your entire facility sorted (cleaned up) and organized, you need to keep it that condition. This requires regular cleaning or to go along with our third S, "shining" things up. Regular, usually daily cleaning is needed or everything will be returned to their original places. This can be done by regular inspection. While cleaning its needed also to inspect the machines, tools, equipment and supplies you work with.
Regular cleaning and inspection makes it easy to spot lubricant leaks, equipment misalignment, breakage, missing tools and low levels of supplies. If these minor problems are not addressed they can lead to a serious loss in production.
SEIKETSU: STANDARDIZE (SIMPLIFY) Step Four: is to simplify and standardize our actions so that it will be a habit in our routine.
The good practices developed in steps 1 through 3 should be standardized and made easy to accomplish. Develop a work structure that will support the new practices and make them into habits. As you learn more, update and modify the standards to make the process simpler and easier.
One of the hardest steps is avoiding old work habits. It is easy to slip back into what you have been doing for years. It gives comfort most of the time for this is part of your habit. Use standards to help people work into new habits that are a part of your Five S program.
Use labels, signages and banners in the workplace to make people aware of the standards being observed.
SHITSUKE: SUSTAIN Step Five: The final step is to continue training and maintaining the standards. Have a formal system for monitoring the results of your 5S program. Constant monitoring is crucial at this stage. Continue to educate people about maintaining standards. When there are changes - such as new equipment, new products, new work rules - that will effect your Five S program, make the necessary adjustments to accommodate those changes. Make needed changes in the standards and provide training that addresses those changes.
Translations and modifications Often in the west, alternative terms are used for the five S. These are "Sort, Straighten, Shine, Systemize and Sustain". "Standardize" is used as an alternative for "Systemize". Sometimes "Safety" is included as 6th S.
1. Clear out and Classify i. Clearing items no longer required ii. Tagging items that may be required and storing away from
workplace
54
2. Configure i. A specific place for specific items ii. “ A place for everything and everything in its place”
3. Clean and check
i. Identify the cleaning zones and establishing cleaning routines
4. Conformity
5. Custom and practice i. Monitoring process adherence ii. Continually validating process iii. Customer satisfaction by doing scientific training to workers iv. Continually focus on man, machine, material and method
Alternative acronyms have also been introduced, such as CANDO (Cleanup, Arranging, Neatness, Discipline, and Ongoing improvement). Even though he refers to the ensemble practice as "5S" in his canonical work, Hirano prefers the terms Organization, Orderliness, Cleanliness, Standardized Cleanup, and Discipline because they are better translations than the alliterative approximations.
Practice Good Housekeeping
Good housekeeping is one of the surest ways to identify a safe workplace.
You can tell how workers feel about safety just by looking at their housekeeping practices. Good housekeeping is not the result of cleaning up once a week or even once a day. It is the result of keeping cleaned-up all the time. It is an essential factor in a good safety program, promoting safety, health, production, and morale.
Whose responsibility is housekeeping? It is everyone's. Clean work areas and aisles help eliminate tripping hazards. Respecting "wet floor" signs and immediately cleaning up spills prevents slipping injuries. Keeping storage areas uncluttered reduces the chances of disease and fire as well as slips, trips, and falls. Accumulated debris can cause fires and clutter slows movement of personnel and equipment during fires.
Other housekeeping practices include keeping tools and equipment clean and in good shape or keeping hoses and cables or wires bundled when not in use. Broken glass should be picked up immediately with a broom and dustpan, and never with bare hands. Be aware of open cabinet drawers, electric wires, sharp corners or protruding nails. Unsafe condition should be addressed immediately.
How a workplace looks makes an impression of employee’s behavior at
work. A visitor's first impression of a business is important because that image affects the amount of business it does. Good housekeeping goes hand-in-hand with good public relations. It projects order, care, and pride.
55
Besides preventing accidents and injuries, good housekeeping saves space, time, and materials. When a workplace is clean, orderly, and free of obstruction; work can get done safely and properly. Workers feel better, think better, do better work, and increase the quantity and quality of their work.
56
What I Have Learned
SELF-CHECK 5.1 Direction: Identify the type of lubricant that is needed. Write, “RUST REMOVER”, “SOLID LUBRICANT”, “OIL”, “GREASE”, AND PENETRATING LUBRICANT” on your answer sheet . 1. Removing rust from bolts, hand tools, bicycle chain and
equipment parts.
2. Maintaining heavy structures like garage door or gate and
other related tasks.
3. Application of maintenance activity for common hand
tools, equipment and other hardware.
4. Recommended to be used on rubber, car door gaskets, and
window sashes.
_____________5. Maintenance for stock-up parts like bearing, bushing, and
heavy bolts and nuts
57
What I Have Learned
SELF-CHECK 5.2
Direction: Identify the following information by writing “ALWAYS” and “NEVER” before each number. Use separate sheet for your answers.
___________1. Perform regular check or the condition of tools, instrument and equipment.
___________2. Place electrical leads in areas where they can be damaged.
___________3. Assign competent people to repair damaged electrical leads, tools and equipment.
___________4. Decrease cost of replacement.
___________5. Test and tag electrical tools and equipment regularly.
___________6. Use damaged electrical leads, tools and equipment.
___________7. Use safety switches when using electrical tools and equipment.
___________8. Improved system reliability.
___________9. Apply preventive maintenance on tools and equipment to prevent electrocution.
___________10. Use electrical leads, tools and equipment in damp a wet condition.
58
Performance Task (Individual Activity) 5.1
NOTE: THIS PERFORMANCE TASK IS TO BE PERFORMED ON SCHEDULED DATE.
Direction: Perform the following maintenance activities for the material indicated in “A” and “B” below.
A. Hand drill, Angle Grinder and Heat Gun
Cleaning
Lubricating of Gears
Checking of power cords and plugs
Check Frayed Cords
Check power Switch
Check Tag-out B. Hydraulic Bender
Check the oil level
Check for any leaking
Lubrication
Cleaning
59
What I Have Learned
www.studylib.net/doc/18397466/preparing-electric-and-hydraulic-
tools
SELF-CHECK 5.3 Direction: Using Maintenance Schedule template prepare a Maintenance Schedule
for electrical power tools prepare maintenance schedule for electrical power and hydraulic tools.
MAINTENANCE SCHEDULE
Prepared by: ______________________ Trainer: __________________________
Maintenance
Activity
January February March April May June Remarks
60
Post Assessment
Test I – Multiple Choice
Direction: Read and analyze the statement carefully. Write the letter of the correct
answer in your answer sheet.
1. What measuring device is used by an electrician to measure value of voltage,
current, and resistance? a. Volt-Ohmmeter c. Megger
b. Multi-tester d. drilling Equipment 2. These are electrical materials in which splices and joints are being made.
a. Utility box c. Square Box
b. Junction box d. Electrical Boxes
3. What action can be carried out to retain an item or to restore it to a functional
condition?
a. repair and maintenance c. corrective maintenance
b. emergency maintenance d. maintenance
4. It is an electrical device used in controlling the flow of current in a circuit or
even the entire circuit.
a. Flush type switch c. Main switch
b. Tumbler switch d. Switches
5. Electrical conductors which is single, usually cylindrical, flexible strand or iron
rod of metal.
a. Stranded conductor b. Wires c. Cables d. Conductors
6. Which of the following should we use to keep a flammable cleaning solvent?
a. closed tin container b. plastic pail c. aluminum basin
7. As a safety precaution, which of the following safety devices should be worn in
electrical wiring?
a. Face shield b. Rubber gloves c. Apron
8. Which of the following solvents should not be used as a cleaning solution for it
poses hazards to health?
a. Gasoline b. Kerosene c. Carbon tetrachloride
61
9. What can the operator expect to happen when the wire brush attachment is
used on the portable disc grinder?
a. The grinder may be jumped out or be thrown out.
b. The grinder moves back and forth.
c. The grinder stays steady on the material being bushed.
d. The grinder performs well. 10. Why is it necessary to tighten the disk lock nut snuggly only when the disc is
replaced on the portable disc grinder?
a. The threads will be stripped on the spindle.
b. The disc may be too difficult to remove next time.
c. The natural rotation of the disc and spindle will cause the threads to
tighten.
d. The loose threads are allowed to hold some of the vibration created by
the portable disc grinder.
Test II – Identification
Direction: Identify what is being described in each of the following sentences.
Write your answer in your answer sheet.
1. It is used to drive and to pull out nails.
2. It is commonly used to make terminal loops on copper wire and can reach tight
places.
3. It is used to scrape surfaces of conductors and to remove big cables insulations.
4. It is performed in order to correct a failure.
5. It is performed in order to prevent failures before they develop into a breakdown.
6. An accident that has to be prevented when using power tools.
7. What we look at if the product has passed the quality standards?
8. What should you do when there is something wrong with the normal function of
the product after warranty period?
9. What should you do when malfunction or trouble has occurred a week after
purchasing the products?
10. It is an action carried out to retain or restore an item at an acceptable condition.
62
References:
Books
Electrical and Installation & Maintenance Learners Manual for Senior High School
Training Regulations Electrical Installation and Maintenance NCII
Technical Education & Skills Development Authority Competency Based Learning
Material
Electrical Layout and Estimate, Fajardo Max Jr.
Practical Electricity III, Azares, Efren F. and Cirilio B.
Online Resources
https://www.scribd.com/doc/101420918/Module-6-Preparing-Electrical-Power-and-
Hydraulic-Tools
https://lrmds.deped.gov.ph/detail/6205
https://studylib.net/doc/18397466/preparing-electric-and-hydraulic-tools
https://www.slideshare.net/maricrisbrandes/electrical-and-hydraulic-tools-
maintenance-procedure
https://www.csunitec.com/pdf_files/CSU-Overview-Catalog.pdf
https://www.dtwd.wa.gov.au/sites/default/files/teachingproducts/AUT034_CCBY.PD
F
https://www.researchgate.net/publication/24399412_The_WHO_modules_in_occupa
tional_safety_and_health_training_for_prevention
https://www.osha.gov/sites/default/files/2018-12/fy11_sh-22318-
11_Mod_1_InstructorNotes.pdf
https://www.academia.edu/34572518/OHSE_Trainer_training_in_Occupational_heal
th_safety_and_environment_course_Trainers_Manual_Module_1
http://sam.dgs.ca.gov/TOC/3800/386/.htm
http://electrical.about.com/od/electricaltools/tp/top16electricaltools.htm
http://gltnhs-tle.weebly.com/module.html
http://encyclopedia2.thefreedictionary.com/Electric+Power+Tool
https://www.powertoolinstitute.com
https://www.technologyinstitute.com
https://www.omnicontrols.com
https://www.wikihow.com
63
ANSWER KEY
Pre Assessment
Matching Type
64
Self-Check 1.2
Self-Check 1.3
Pre-Assessment
Matching type
65
Activity
True or False
Self-Check 3.1
Self-Check 5.1
66
Self-Check 5.2
Post Assessment
TEST I
67
Post Assessment
TEST II
