Performing preventive & corrective maintenance

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Course: Machining
Unit of competency: Perform preventive & corrective maintenance
Perform preventive & corrective maintenance
Module: At the end of the session, learners should be able to:
Learning outcomes:

Duration: 1. Perform inspection of machine
Situating Learning: 2. Perform cleaning & lubricating of machines
3. Perform minor machine repair & adjustment
4. Maintain hand tools
16 hours
You are a newly hired employee in JCA fabrications Inc. at Carmelray
Industrial Park in Canlubang, Laguna. The first task that was assigned to
you is to perform preventive and corrective maintenance in the lathe and
milling machine area. As a newly hired employee, you will be observed
carefully by your immediate supervisor. Your performance in this first task
will give you a big plus factor on your evaluation that will be used later on for
your promotion as a regular employee.

In order to accomplish the job at hand, you need to inspect the machines
individually and see to it that minor repairs & adjustments are made, clean
and lubricate the parts that need cleaning and lubricating and put tools in
their proper storage to ensure that machines are in their tip top shape at all
times and reduce the down time of the operation.

After finishing each machine, let your immediate supervisor check the
machine you have inspected to ensure the following:

1. Correct alignment and tightness of belts and gears are
correct

2. Machine has been cleaned and necessary parts are
lubricated

3. Hand tools are maintained & kept in their proper storage.

Assessment Criteria: 1. Perform inspection of machine
2. Perform cleaning and lubricating of machine
3. Perform minor machine repairs and adjustments
4. Maintain hand tools

Pedagogical Training in Instructional Design & Delivery for TVET -- ABILLADA, Joseph --

© 2010, Institute of Technical Education, Singapore Page 1

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning documents
1) Prepare work area (Documents
Shop safety practices (Brief description of
2) Perform inspection are observed referenced by each
of machines Tools and equipment strategies, sequence learning activity)
are prepared.
. of lesson, evaluation) 1.1.1. Information sheet
Safe shop
Different components 1.1 Read Shop safety practices.
of the lathe & milling practices
machine are correctly a) Handling of tools 2.1.1 Information sheet
identified b) Operating the - Kinds of Belts,
machine correct alignment &
c) Personal tension.
protective
equipment 2.1.2 Information sheet
d) Standard - kinds of gears &
operating correct clearance
procedures in
shop.
e) Preparation of
tools.

2.1 Identifying different
Belts, gears, and
its function.
Identify each and
state the following:

a. Correct tension
b. Correct alignment
c. Correct clearance

 Answer worksheet
2.1.4

3) Perform inspection Inspection of lathe & 1. Assigned to a  Read and carry out
of machines milling machines is particular machine, procedures in
done according to inspect the different operation sheet
specification. components listed 3.1.1 (checklist)
on the operation
sheet.

4) Perform minor repair Minor repair & 1. Given the Operation Read and execute
sheet, carry out minor procedures on
and adjustment adjustments are carried repair & adjustments operation sheet
4.1.1
out according to

specifications.

Pedagogical Training in Instructional Design & Delivery for TVET -- ABILLADA, Joseph --

© 2010, Institute of Technical Education, Singapore Page 2

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning documents
(Brief description of (Documents
strategies, sequence
of lesson, evaluation) referenced by each
learning activity)

5) Perform cleaning & Different parts of the Read the following 5.1.1 Information sheet
lubricating of machines lathe & milling machine topics: - Diff. Oils and its
are identified that need Use.
to be lubricated and a. Different oils and - Correct oil level
cleaned. its uses - Parts of the
machine that
b. Parts of the need to be
machine that lubricated &
need to be cleaned
cleaned and
lubricated. 5.1.4 Worksheet
- Identification of
diff. oils and its use.
- Identification of
proper waste
disposal
-Identification of
parts that need
lubrication &
cleaning

6) Perform cleaning & 1. Lathe & milling Read procedures on 6.1.1 operation sheet
lubricating of machines machine are cleaned operation sheet - Cleaning and
and lubricated. lubrication of
machine

7) Maintain hand tools Hand tools are 7.1.1 Information sheet
maintained and kept in - Maintaining hand
their appropriate storage Tools
area.

Pedagogical Training in Instructional Design & Delivery for TVET -- ABILLADA, Joseph --

© 2010, Institute of Technical Education, Singapore Page 3

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning documents
(Brief description of (Documents
strategies, sequence
of lesson, evaluation) referenced by each
learning activity)

Pedagogical Training in Instructional Design & Delivery for TVET -- ABILLADA, Joseph --

© 2010, Institute of Technical Education, Singapore Page 4

Information Sheet 1.1.1: Safe Shop practices

Learning outcomes:
1 Prepare work area
Learning Activity:
1.1 Explain shop safety practices and prepare work area.

A. INTRODUCTION TO SAFETY

There has never been more meaningful saying than
“Safety is Everyone’s Business. “ To become a skilled
craftsman, it is very important for you to learn to work
safely, taking into consideration not only your own
safety but also the safety of your own fellow workers.
In general, everyone has a tendency to be careless
about safety at times. We take chances every day by
not wearing seat belts, walking under ladders,
cluttering the work area, and doing many other
careless and unsafe things. It seems that people tend to feel that accidents always happen
to others. However, be sure to remember that a moment of carelessness can result in an
accident, which can affect you for the rest of your life. A loss of eyesight due to not wearing
safety glasses or the loss of a limb due to loose clothing caught in a machine can seriously
affect or end your career in the machine tool trade. THINK SAFE, WORK SAFE, and BE
SAFE.

THE NEED FOR ACCIDENT PREVENTION

Industrial accidents are a serious community problem. Every year, hundreds of thousands
of people are kept away from work for at least one day and almost a million working person
per week are lost. Government and safety organizations are carrying out research on
accident causes and are promoting safe working practices.

Some of the findings of research apply particularly to the engineering worker. Research
shows that:

 Young workers and people new to their jobs are more
likely to have accidents.

 Overall, about one worker in every 34 has an accident
in the course of a year, which keeps them away from
work for more than a week.

 These are average figures. In some industries the
probability of having an accident is much higher than in
others. You can reduce the risk of having an accident
by learning to work safely.

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Information Sheet 1.1.1: Safe Shop practices

Two accidents out of three result people hurting themselves by straining, falling, slipping,
tripping, stumbling, being struck by moving or falling objects, or stepping on, or striking
against stationary objects.

By using common sense and obeying general safety rules you can save yourself and others
from being hurt.

Be a safe worker
 Think safely.
 Know the procedures for your job.
 Develop safe working habits.
 Set a good example for fellow workers.
 Continually try to improve your working habits.

CAUSES OF ACCIDENTS

An accident often has more than one cause. Accident can be prevented by removing their
causes. Finding out what caused an accident is important. It can help in planning how to
prevent similar accidents.

There are two causes of accidents:
 Unsafe acts
 Unsafe conditions

The person who gets hurt does not always cause the accident. However, accidents
happened if some person failing to act safely or to correct an unsafe condition causes
accidents.

Think about these examples of unsafe acts:
 Using equipment without having received proper training in its use.
 Using tools or equipment the wrong way.
 Not using personal protective equipment, such as goggles, when the job
requires it.
 Fooling around and playing about.
 Hurrying and taking dangerous short cuts through the workshop or on the job.
 Distracting others from their work, or allowing yourself to be distracted.

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Information Sheet 1.1.1: Safe Shop practices

Consider these examples of unsafe conditions for the worker:

 Lack of instruction in safe methods.
 Lack of training.
 Unsuitable clothing for the task to be done.
 Physical defects, like poor eyesight, or defective hearing.
 Long hair near rotating machines.
 Lack of safeguards on machines.

CARE IN THE USE OF MACHINES

Machine tools can cause serious injuries when they are used incorrectly, or when persons
accidentally come into contact with moving parts. It is essential that you only use those
machines for which you have been trained and are authorized to use.

Never be afraid to say that you do not know how to use a machine. Failure to do this has
cost lives. Always keep your fingers away from moving parts an keep the following rules:

 Any machine guard that is damaged, not in place or working correctly, must
be reported immediately. The machinery must be labeled as unsafe and not
be operated until its guards are correctly in place.

 Never remove any machine guards unless you are told to do so in order to
clean, oil, set, adjust, or repair the machine.

 When guards are removed for the maintenance or adjustment of the machine,
they must be replaced before the machine is restarted.

 Guards and safety devices must never be made or left inoperative.
- Some machines can only be started by pressing two start buttons at
the same time. This is to make sure that the operator has both hands
clear when the machine is starting.

 Work to be drilled must be held in a safe way in a vice or a jig. Never try to
hold it still with your hand, even on a small drill.

 Never try to remove cutting chips from a machine with your hands. Use a
brush or a hook, and only when the machine is stationary.

 Switch off any machine at the machine switch, not at the supply point.

 When carrying out maintenance the machine must be electrically isolated and
clearly labeled DO NOT USE – MAINTENANCE IN PROGRESS

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Information Sheet 1.1.1: Safe Shop practices

 Try not to get the tool wet and take extra care in damp situations.
- Do not let leads drag through the water.
- Wear rubber-soled shoes and rubber gloves.

 Consider the safety of others when using tools.
- Check behind partitions before drilling through them.
- Make use that others will not be hit by flying sparks, hot metal, etc.
(use screens)
- Do not leave an unattended power tool plugged in.

 It is your responsibility to avoid unsafe acts. You must, for your own sake and
that of others, learn to work safely. Any silly act that could cause danger to
yourself, or others, is irresponsible. Follow your supervisor’s instructions.
Always use the correct working methods.

B. SHOP SAFETY PRACTICES IN THE SHOP.

BEHAVIOR IN THE WORK AREA

Behavior that may be enjoyable on the playing field can be extremely dangerous on
concrete floors, or near sharp steel edges and moving machinery.

 Do not trip, or wrestle another person in your work area.
 Walk; don’t run along corridors, driveways or on staircases or anywhere in the

workplace.
 Do not play practical jokes
 Do not play with fire, electricity, compressed air or water- hoses (Death can

occur)
 Never throw things about your workplace.
 -It is especially dangerous to throw soiled rags or cottons waste. Although

they are light, they may contain metal filings or other sharp pieces that can cut
or cause serious eye injuries.
 Concentrate on the job you are doing, but be aware of what is happening
around you.
 Take notice of signs and barriers, which have been built to mark off unsafe
areas or conditions.
 Get to know your work area thoroughly.
 Do not distract anyone who is concentrating on his or her own job.

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Information Sheet 1.1.1: Safe Shop practices

CLOTHING AND SAFETY EQUIPMENT

It is your employer’s responsibility to provide a safe working environment, which includes a
risk- free work area and the provision of the necessary protective clothing and equipment
for your work.

 Always wear safety glasses, goggles, or face shields designed for the type of
work when operating the machine.

 Wear clothing suited for the job. Wear shoes with thick soles- safety shoes if
heavy work is being done.

 Do not wear rings, watches, bracelets, or other jewelry that could get caught
in moving machinery.

 Do not wear neckties or loose or torn clothing of any kind
 Wear shirts with short sleeves. Roll long sleeves above the elbows.
 Always remove gloves before turning on or operating any machine. If material

is rough or sharp hand gloves must be worn.
 Always wear Personal protective equipment while doing your job.

HOUSEKEEPING

 Aisles should be clear at all times to avoid tripping or other accidents.
 Keep floors free of oil, grease, or any other type of liquid. Clean up spilled

liquids immediately; they are slipping hazards.
 Keep the floor clear of metal chips and scrap pieces. Put them in the

containers provided for them. Scrap pieces are tripping hazards, and chips
may cut through a shoe and injure the foot.
 Place all scrap pieces in the correct containers.
 Store materials in such a way that they cannot become tripping hazards.
 Put tools away when not in use.
 Do not leave tools or work on the table of a machine even if the machine is
not running. Tools or work may fall off and cause toe or foot injury.
 Always keep the machine and hand tools clean.
 Always use a brush and not a cloth to remove any chips.
 Never placed tools or materials on the floor close to machine where they will
interfere with the operator’s ability to move safely around the machine.
 Return bar stock to the storage rack after cutting off the required length.

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Information Sheet 1.1.1: Safe Shop practices

C. GENERAL SHOP SAFETY

Sometimes a safety rule is repeated because it may be applicable in more than one area.

 Always wear SAFETY GLASSES in the shop.
 Do not set up or operate any machinery unless an instructor is in the shop.
 Do not operate any machine unless authorized to do so by an instructor or

under an instructor's supervision.
 Use the proper tool for the job. Many cuts in the shop occur because a

wrench slips and a hand hits a sharp cutting tool.
 Check tools before use to assure they are safe to use.
 Do not leave tools or work on the table of a machine even if the machine is

not running. Tools or work may fall off and cause a toe or foot injury.
 Put tools away when not in use.
 Place all scrap pieces in the correct containers.
 Never handle chips with your hands or fingers. Chips are extremely sharp and

can easily cause cuts.
 Use a brush to remove chips -- not hands, fingers, or rags.
 Never wear gloves or use rags to clean the work piece or any part of a

machine that is running. Rotating tools or parts can grab gloves and rags and
pull you into the machine.
 Never use compressed air to clean any machine.
 Never use compressed air to clean your clothes or yourself.
 If using compressed air to clean a part, point the air hose down and away
from yourself and other persons.
 Even after the power is off, do not leave the machine until it has stopped
running. Someone else may not notice that it is still in motion and be injured.
Do not leave a machine until it has come to a complete stop.
 Do not try to stop the machine with your hands or body.
 Always see that work and cutting tools on any machine are clamped securely
before starting to work.
 All set- screws should be of the flush or recessed type. If they are not, move
with caution when near them. Projecting set- screws are very dangerous
because they may catch on sleeves or clothing.
 Only one person should operate the machine or switches.
 Do not lean against the machine (s).
 Always remove gloves before turning on or operating any machine. If material
is rough or sharp and gloves must be worn, place or handle material with the
machine turned off.

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Information Sheet 1.1.1: Safe Shop practices

 Get first aid immediately for any injury.

Get help for handling large, long, or

heavy pieces of material or machine

attachments.

 Follow safe lifting practices; lift with your leg

muscles, not your back. If you do not

know how to lift safely, ask an instructor to

show you.

 Be sure you have sufficient light to see

clearly. Check with an instructor if you do not have enough.

 Do not walk behind a person operating a machine; you may bump him/her by

accident or startle them and cause an accident

D. WORKING WITH CHEMICALS

Thousands of chemicals are used in industry for a great variety of purposes and each year
many new chemicals are introduced. Many have toxic, corrosive, irritant, flammable or other
dangerous properties. Solid, dust, liquids, gases, vapors, mists and fumes can all be
dangerous.

All chemicals should be treated as HAZARDOUS.

The hazards associated with the use of the chemical should be on the label, and are
outlined in the Material Safety Data Sheet (MSDS) which is supplied with each chemical.

All unnecessary contact with chemicals must be avoided.

 Read the label before handling any chemical.
- Make sure that you fully understand all instructions.

 Where possible substitute safer chemicals for ones which are known to be
very dangerous.

 Make sure there is good ventilation if you must work with chemicals.

What you can do yourself

 Do not smoke, drink or eat in the workplace.
 Wash your hands before eating, drinking, or using toilet, especially after

working with chemicals.
 Avoid breathing vapors, Use a respirator which is in good condition.
 Use the correct type of protective clothing.
 Use protective creams to protect your hands.
 Use safe mixing procedures for chemicals.

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Information Sheet 1.1.1: Safe Shop practices

Chemicals can be:

 Poisonous or toxic. They can be absorbed through lungs, skin or gut.
 Explosive or flammable, especially when exposed to air.
 Corrosive, to your skin.
 Irritants or sensitizers. Long term effects from chemical irritants are serious.

Chemical spills should be dealt immediately. Check with your supervisor the appropriate
clean-up procedures.

Chemical storage should be in proper storeroom. Poisonous chemical should be locked
away. Flammable chemicals should be stored separately. Containers should be clearly
labeled.

KNOW YOUR HAZCHEM (Hazardous Chemicals) SIGNS

PREPARE THE WORK AREA

1. Remove all your jewelries before you enter the work area
2. Clean the machine before you use.
3. Prepare the materials needed for the activity – tools and PPE
4. Check if the tools are in good working condition.
5. Place tools needed on the working table.
6. Prepare the required PPE for the activity.
7. Wear the proper PPE.

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ALT723307 maintenance May 12, 2010 June 20, 2010

Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

Learning outcomes:
1 Perform inspection of machines
Learning Activity:
1.1 Identify different components of drive mechanism of the lathe and milling machine.

Components of the drive mechanism of a machine are possibly the most important part of any
machine. Because it is the part that drives the moving parts to perform its function. Knowing
the function and specification to standards of each part is essential to be able to maintain and
carry out minor adjustments and correction.

BELT Fig 1.1
Belts are used for power transmission between
shafts. It is the cheapest and simplest way of
transmitting power. They run smoothly and with little
noise, and cushion motor and bearings against load
changes, although with less strength than gears or
chains. Belt size, normally found on the outer side of
the belt refers to its cross-sectional area. Standard
belt with large cross sectional area are meant for
heavy duty of high horsepower drives while the
standard ones are for light or small horsepower

Types of belts

A. FLAT BELT Fig 1.2

Flat belts, in the form of leather belting, served as the
basic belt drive from the beginning of the Industrial
Revolution. Not only they can be installed easily, they
can transmit large amounts of power at high speeds
as well. Flat belts find their widest application where
high-speed motion, rather than power, is the main
concern. Flat belts are very useful where large center
distances and small pulleys are involved.

Flat belt drives are now mostly used for low power
high speed applications in specialized industries
including the textile, paper making, and in office machinery.
Flat belts are also used for conveyor applications.

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Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

B. VEE-BELT Fig 1.3

V-belts are the basic power-transmission belt,
providing the best combination of traction, operating
speed, bearing load, and service life. The belts are
typically endless, with a trapezoidal cross section
which runs in a pulley with a V-shaped groove. The
wedging action of the belt in the pulley groove
allows V-belts to transmit higher torque at less width
and tension than flat belts. V-belts are far superior
to flat belts at small center distances and high
reduction ratios. V-belts require larger pulleys than flat belts
because of their greater thickness.

CATEGORIES (based on size)

1. Standard – size is designated by the letters A to E and the included angle
of the belt is 40o

Fig 1.4

2. High Capacity – is designated as 3V, 5V and 8V. It is used for high
horsepower or loading conditions. It has a reduced section from the
standard belt which allows it to fit into the smaller space.

Fig 1.5

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Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

3. Light Capacity – is designated by 2L,to 5L. which have similar cross-sectional
area as standard belts. They can also be designated by 3M, 5M, 7M and 11M
which have similar cross-sectional area as the high capacity belt.

Fig 1.6

Flat & Vee belt drive arrangements

a. Quarter turn belt drive

In this kind of set-up, the other pulley is perpendicular to the other. In effect, the
axis of power transmitted is changed, from horizontal to vertical or vice-versa.

Figure 1.7

b. Parallel belt drive
In this kind of set-up both shafts are parallel and rotate in the same direction..

Figure 1.8

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Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

C. TIMING or SYNCHRONOUS BELT Fig 1.9

Timing belts have evenly spaced teeth on their bottom
side which mesh with grooves cut on the outer side of
the pulley to produce a positive, no-slip, constant-
speed drive. They are often used to replace chains or
gears, reducing noise and avoiding the lubrication
bath or oiling system requirement.

Timing belts have also found widespread application in
miniature timing applications and machines. Timing
belts, known also as synchronous or cogged belts,
require the least tension of all belt drives and are
among the most efficient.

Fig 1.10

GENERAL GUIDELINES IN MAINTAINING BELTS
1. Maintain correct tension
Correct tension applied to the belt will decrease the occurrence of
slippage of the belt from the sheave of the pulley.

2. Maintain alignment of pulleys & shafts
The correct alignment of the shafts and pulleys is vital to the
operation of a V-belt drive

3. Keep belts clean
If dirt is allowed to build up on the belts, it will cause a lack of
friction.

4. Keep it away from lubricants.
Lubricants will make the belt lose its traction from the pulley, thus
affecting its efficiency to transmit power.

5. Replace belts
Should you see any deformity and crack on the belts replace it
immediately to prevent accidents and avoid down time.

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Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

Correct alignment of belts
Since belts fit snugly on the pulley, you can check its alignment by using a straight rule and
putting it on the sheave of the pulley. Aligned belts should have no gaps between the sheave
and the straight rule.

Pulley
No space

Straight rule

Fig 1.11 Correct Alignment

Space
Fig 1.12 Parallel misalignment
Space

Fig 1.13 Angular misalignment

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Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

Correct belt tension

The proper tension for V-belt drive is the lowest tension at which the belts won't
slip under peak load conditions. This normally is default required tension in
machines as stated in the manual.
If tension is insufficient then the belt will slip and overheating and wear will result,
if the belt is too tight it will cause overheating as well as damage to bearings.

Common problems and causes of belt malfunctions

Symptom Causes

Belt slippage  Any tendency to slip will lead to rapid wear and premature
Belt squeal failure.
Belt ticking or
slapping  The common causes of belt slippage are insufficient
Belt whipping tension, drive overload and the presence of oil or grease
on the belt.
Belts turned over
 Squealing often accompanies belt slippage and is also
Belt breakage caused by overload and insufficient tension.

 It may also occur when the arc of contact between belt
and pulley is insufficient.

 When the operation of a belt drive is accompanied by
ticking or a slapping sound this is often evidenced that
some form of mechanical interference is taking place.

 This may be due to poorly aligned guards or contact with
other machine parts.

 If a V-belt starts to whip it is likely to jump out of the pulley
groove or to roll over and become damaged.

 Whipping may be the result of the drive centers being too
far apart or due to wobbling pulleys.

 Sometimes pulsating load will also cause belt whip, in
which case the suitability of the drive should be used.

 If the cords in the belt are broken during installation by
levering the belt on to the pulley then the belt will stretch
excessively and lose strength.

 Lack of tension may also allow a belt to roll over and this
may be overcome by installing a spring loader idler pulley.

 Once a belt has turned over it will be damaged and should
be automatically discarded or replaced.

 If a V-belt breaks immediate action is clearly required.
 Breakage may occur due to overloading in the form of

shock loads or heavy starting loads but if the belt has
been properly selected this should not occur.
 A belt that has been weakened by being levered on the
pulley is likely to break prematurely.
 The presence of foreign objects or materials may also
damage the belt sufficiently for it to break.

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Information Sheet 2.1.1 : Kinds of belts, correct alignment and tension of belt

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Information Sheet 2.1.2 : Kinds of gears and clearance

Learning outcomes:
1 Perform inspection of machines
Learning Activity:
1.1 Performing inspection of machines

GEARS
A gear is a rotating machine part having cut teeth, or cogs,
which mesh with another toothed part in order to transmit
torque. Two or more gears working in tandem are called a
transmission and can produce a mechanical advantage
through a gear ratio and thus may be considered a simple
machine

TYPES OF GEARS
1. SPUR
Are the most common type of gears. They have
straight teeth, and are mounted on parallel
shafts. Sometimes, many spur gears are used at
once to create very large gear reductions.

These gears are used for the purpose of making
variations in the force and speed of rotating
axles. Simple use of this is in your wrist watch
and washing machines.

2. HELLICAL GEAR
The teeth of these gears mesh at an angle to
create optimum thrust load. The name helical is
due to their teeth, which are curved along a helical
path or resemble a helix.

It can comfortably carry heavy loads due to the
enhanced surface contact with teeth and
operates relatively quiet. It is for this reason
you can find it in the gear box of cars.

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Information Sheet 2.1.2 : Kinds of gears and clearance

3. BEVEL GEARS
The conical shaped gears the teeth perfectly mesh
together. They are usually mounted on shafts that
are 90 degrees apart, but can be designed to work at
other angles as well.

These gears are useful when there is a change
required in the direction of the shaft's rotation

4. WORM GEARS
Are used when large gear reductions are needed. It is
common for worm gears to have reductions of 20:1, and
even up to 300:1 or greater.

Worm gears have an interesting property that no other
gear set has: the worm can easily turn the gear, but the
gear cannot turn the worm. This feature is useful for
machines such as conveyor systems, in which the
locking feature can act as a brake for the conveyor
when the motor is not turning.

5. RACK AND PINION
Is a pair of gears which convert rotational
motion into linear motion. The circular pinion
engages teeth on a flat bar – the rack.
Rotational motion applied to the pinion will
cause the rack to move to the side, up to the
limit of its travel.

It is used to convert rotation into linear motion.
A perfect example of this is the steering system on many cars. The steering
wheel rotates a gear which engages the rack. As the gear turns, it slides the
rack either to the right or left, depending on which way you turn the wheel.

CORRECT CLEARANCE OF GEAR

CLEARANCE – is the distance from the tip of a
tooth to the circle passing through the bottom of the
tooth space with gears in mesh.

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
ALT723307 maintenance Aug 15, 2003
June 30, 2010 2

Worksheet 1.2.3 : Perform inspection of machine

Learning outcomes:
1 Perform inspection of machine
Learning Activity:
1.2 Inspecting of machines

Match column A to the statements or picture at column B.

Write the letter at the space provided.

__________1. Belt a. It is used for transmission of power
between shafts.

__________2. Flat belt b.
__________3. Timing belt

__________4. Vee-belt c. It is a kind of belt that is normally used
__________5. Standard Capacity where high-speed motion, rather
__________6. High Capacity than power is required
__________ 7. Light Capacity
__________8. Quarter turn belt drive d. It is a kind of belt with a trapezoidal
__________9. Parallel misalignment cross section that provides the best
combination of traction, operating
speed, bearing load, and service life.

e.

__________10. Angular misalignment f. It is a category of Vee-belt that is
designated by the letters A to E which
has an included angle of 400

g. It is a belt drive arrangement where the
other pulley is perpendicular to the
other pulley.

h.

i. It is a category of Vee-belt that is
designated by 2L to 5L.

j. It is a kind of belt that has evenly spaced
tooth on its bottom side which mesh
Perform inspection of machine with grooves on the outerside of the
pulley.

Code No. Date: Developed Date: Revised Page #
ALT723307
April 29, 2010 1

Worksheet 1.2.3 : Perform inspection of machine

Code No. Perform inspection of machine Date: Developed Date: Revised Page #
ALT723307
April 29, 2010 2

Operation Sheet 1.2.1 : Perform Inspection of Machines

Learning outcomes:
1 Inspect machines according to specifications
Learning Activity:
1.2 Inspection of machines

1. Make sure the machine has no electrical supply by turning the circuit breaker to off
position.

NOTE: When inspecting machines run by electricity, it is a must to turn off its electrical supply
to prevent electrocution and eliminate the risk of accidentally turning the machine on during
inspection.

2. Open the drive mechanism box or belt guard.
3. Locate and identify what parts of the drive mechanism that will be inspected.

A. DRIVE BELTS

CORRECT TENSION – correct tension is determined by the
amount of deflection of the belt using a tension gauge. The
amount of deflection should not be more than or less than
2% of the center distance of the pulleys. Use this formula:

Deflection= 2 x Center distance of pulleys
100

1. Measure the distance between two centers of the pulleys.
2. Use the formula given to determine the setting on the

belt tension gauge.

 Write down the Tension of the belts that need to be
adjusted on the chart at the end of this operation sheet.

B. PULLEYS

ALIGNMENT OF PULLEYS – use a straight rule to
determine the alignment of pulleys.

1. Put the straight rule on the sheaves of each pulley.
2. Check if there are gaps between the sheaves and the

straight rule.
3. If there is a gap, it means the pulleys are not aligned.
 Identify the pulley that needs adjustment and write it on the chart below.

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Operation Sheet 1.2.1 : Perform Inspection of Machines

C. GEARS

a. CLEARANCE – is the distance from the tip of a tooth to the
circle passing through the bottom of the tooth space with gears
in mesh.
1. Check each gear that is in mesh.
2. Check its clearance.
3. Identify the gears that need adjustments in terms of clearance and write it
on the chart below this operation sheet.

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Operation Sheet 1.2.1 : Perform Inspection of Machines

INSPECTION DATA SHEET
Machine name/number: __________________________ Date: ____________________
Inspected by: ________________________________________

BELTS Distance between Amount of Deflection Remarks
Belt # center
(Needs correction or
not)

PULLEYS Remarks (aligned or misaligned)
Pulley #

GEARS Remarks ( correct clearance or not)
Gear #

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
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Operation Sheet 1.2.1 : Perform Inspection of Machines

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
maintenance June 10, 2010 June 20, 2010 4

Operation Sheet 4.1.1 : Perform minor machine repair and adjustments

Learning outcomes:
1 Perform minor machine repair and adjustments
Learning Activity:
1.1 Performing minor machine repair and adjustments.

1. Make sure the machine has no electrical supply by turning the circuit breaker or switch
to “ OFF” position.
NOTE:
When inspecting machines run by electricity, it is a
must to turn off its electrical supply to prevent
electrocution and eliminate the risk of accidentally
turning the machine on during inspection.

2. Open the drive mechanism box or belt guard.
3. Using the data gathered from the operation sheet on the inspection of machines,

perform the necessary repair and adjustments on the machines.

CORRECT BELT TENSION AND ADJUSTMENT

BELT TENSION
To determine whether a belt has the correct tension, we can use belt
tension gauge. This tool measures the amount of deflection of the
belt in relation to the center distance of the pulleys. An O-ring is
attached to its graduated shaft to indicate the correct amount of
deflection required.

Belt tension gauge

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Operation Sheet 4.1.1 : Perform minor machine repair and adjustments

The amount of deflection should not be more than or less than 2% of the center distance of
the pulleys. To determine the correct tension, use this formula:

Deflection= 2 x Center distance of pulleys Center distance = 300mm
100 Example 1.1

Example 1.1

where: 300mm
( CD )Center distance of each pulley = 2/100

2% =

Solve:
Deflection= 2 x Center distance of pulleys

100
= 0.02 x 300mm
Deflection= 6 mm

In this case, the amount of deflection to be set on the
tension gauge is 6mm. Should the belt tension gauge deflect
over or under than 6mm, the belt has to be adjusted to its
correct tension.

ADJUSTMENT AND REPLACEMENT OF BELTS
To adjust the tension of the belt, follow these basic steps:

1. Turn off the electrical supply

2. Loosen the clamping bolts of the motor.

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Operation Sheet 4.1.1 : Perform minor machine repair and adjustments
3. Raise the motor by turning the adjusting screws

located at the base of the motor

4. Remove the belts form the sheaves in a rotating
Motion. Carefully transferring the belt to another
sheave until it reaches the outermost sheave.

5. Clean the sheaves and check for cracks

6. Install new belts. Using a circular motion,
transfer the belt form sheave to another until it
reaches the innermost sheave.

7. Lower the motor by turning the adjusting screws
located at the base of the motor

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Operation Sheet 4.1.1 : Perform minor machine repair and adjustments

8. Use a steel bar as a fulcrum to add tension
on the belt.

9. Check tension of the belt regularly until the
desired tension is met.

10. Tighten the clamping bolts of the motor

11. Turn On the machine to check operation of
the belts.

ALIGNMENT OF PULLEYS

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Operation Sheet 4.1.1 : Perform minor machine repair and adjustments
Alignment of pulleys are essential to the smooth operation of the machine is as much as it is
here where belts rest. Misaligned pulleys mean misaligned belts.
To check the alignment and adjusting the pulleys, follow these steps:

1. Loosen the grub screw before alignment.

2. Using a straight rule, press it against the sheaves of the
pulleys. No gap will appear if pulleys are aligned
properly.

3. Should there be a gap, adjust the pulley by using a soft
faced hammer. Make sure you hit it just by the right
amount of force; otherwise it can cause a bigger
misalignment.

4. Tighten the grub screw after alignment.

CORRECT CLEARANCE OF GEARS

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Operation Sheet 4.1.1 : Perform minor machine repair and adjustments

CLEARANCE – is the distance from the tip of a tooth to the
circle passing through the bottom of the tooth space with gears
in mesh.

1. Check each gear that is in mesh. Correct clearance between teeth

2. Check its clearance.
3. Should the clearance be too big, adjust the gear

by loosening the bolt of the driven gear to get it
closer to the driver, and adjust accordingly.

Code No. Performing preventive & corrective Date: Developed Date: Revised Page #
ALT723307 maintenance June 15, 2010
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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

Learning outcomes:
1 Perform lubrication and cleaning of machines
Learning Activity:
1.1 Performing lubrication and cleaning of machines

LUBRICATION

Lubrication is basically applying a substance that will provide a smooth and slippery
surface between two or more moving parts. This substance known as the lubricant
separates the two moving parts to allow smooth passing of one another with a minimum
amount of friction.

Purpose of Lubrication

The basic purposes of lubrication are to:
 Reduce friction.
 Reduce wear.
 Help dampen shock.
 Cool moving parts.
 Prevent corrosion.
 Seal out dirt and other contaminants.

1. Basic Properties of Lubricating Oil

1.1 Viscosity

Viscosity is defined as a measure of the fluid’s resistance to flow. A high viscosity is
desirable for maintaining sealing between mating surfaces.

Too high a viscosity increases friction, resulting in:
 High resistance to flow.
 Increased power consumption due to frictional loss.
 High temperature caused by friction.
 Increased pressure drop because of the resistance.

And should the viscosity be too low:

 Internal leakage increases.
 Excessive wear.
 Increased temperature result from leakage losses.

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

The units of viscosity can be expressed as centipoise (cP), centistokes (cST), or
Saybolt Universal Seconds (SUS), depending on the actual test method used to
measure the viscosity.

1.1.1 Viscosity Index

Viscosity index is the arbitrary measure of a fluid resistance to viscosity change with
temperature changes. Thus, viscosity is affected by temperature changes. As
temperature increases, the viscosity of a liquid decreases.

A fluid that has a relatively stable viscosity at temperature extremes has a high viscosity
index. A fluid that is very thick when cold and very thin when hot has a low viscosity
index.

Viscosity index can be classified as follows:
 Low VI - below 35;
 Medium VI - 35 to 80;
 High VI - 80 to 110;
 Very high VI - above 110.

1.2 Pour Point

The pour point of oil is the lowest temperature at which the oil will barely flow from a
container. Oil will solidify at a temperature below the pour point. Lube oils used in cold
weather operations must have a low pour point. The pour point is closely related to the
viscosity of the oil. In general, an oil of high viscosity will have a higher pour point than
an oil of low viscosity.

1.3 Flash Point and Fire Point

The flash point of oil is the temperature at which enough vapor is given off to flash when
a flame or spark is present. The temperatures of the oils are always far below the flash
point under normal operating conditions.

The fire point of oil is the temperature at which the oil will continue to burn when it is
ignited.
The flash and fire points are useful in determining a lubricant’s volatility and fire
resistance. The flash point can be used to determine the transportation and storage
temperature requirements for lubricants.

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

1.4 Demulsibility

The demulsibility, or emulsion characteristic, of an oil is its ability to separate cleanly
from any water present. This is an important factor in forced-feed systems.

1.5 Acid Number / Neutralization Number

The acid or neutralization number is a measure of the amount of potassium hydroxide
required to neutralize the acid contained in a lubricant. Acids are formed as oils oxidize
with age and service. The acid number for an oil sample is indicative of the age of the
oil and can be used to determine when the oil must be changed.

The organic acids which, if present in sufficient concentrations, will cause deterioration
of alloy bearings at elevated temperatures, galvanized surfaces, and demulsibility of
the oil with respect to fresh water and salt water.

ISO Grade: 68
SAE Number Grade: 20W20

API Gravity: 30
Flash Point COC, ºC(ºF): 240 (464)

Pour Point, ºC(ºF): -30 (-22)
cSt @ 40 ºC (104 ºF): 67
cSt @ 100 ºC (212 ºF): 8.7

SUS @ 100 ºF: 347
SUS @ 210 ºF: 56
Viscosity Index: 101
Fig. 1 Typical properties of a lubricating oil

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

TYPES OF LUBRICANTS
The types of lubricant in common use are oil and grease. Each type has a different
grade depending on the particular application. If a specified grade is not available,
choose another from an equivalent table.

1. Lubricating Oil
 Light Oil - is thin and is only effective where light working loads are involved, eg.

Spindle bearings. The viscosity at cSt@ 40 ºC is in the range between 10 to 100.

Figure 2 Light oil
 Medium Oil - is used in crankcases of machinery and engines and provides efficient

lubrication of main bearings and other stressed moving components. The viscosity
at cSt@ 40 ºC is in the range between 100 to 250.

Figure 3 Medium oil

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

 Heavy Oil - is thick and is used mainly for gearing and other components used in
power transmission systems. The viscosity at cSt@ 40 ºC is in the range between
250 to 1000.

Figure 4 Heavy oil

SELECTING THE RIGHT TYPE OF LUBRICANT

It is important to select the right type of lubricant as the wrong type might cause wear
and even seize up the equipment. Proper lubrication ensures long service life of the
machine components by containing the wear process. It also helps in conservation of
energy required for operation of the equipment by reducing frictional losses in the
system. It is also important that the equipment must get the right lubricant in right
quantity at right place in right time. Selection of lubricant for a system is mostly dictated
by the service demands it poses on the lubricant. The effects of any or all of four
conditions influence the choice of a lubricant are as follows:

a. Load
Load is the amount of work the lubricant has to do. It also means the pressure or weight
the lubricant is going to have to work against.

b. Speed
As the operating speeds of equipment increase, the lubricated surfaces will also tend to
wear faster. To help slow down the rate of wear of two fast moving surfaces, the
lubricant chosen must be able to take the extra punishment which such applications
hand out.

c. Temperature
Temperature has a definite and considerable effect on both oils and greases. A low
temperature will thicken oil and grease, while high temperatures will thin them down.

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

d. Environment
The surroundings, or environment, of an application can be of considerable
importance when choosing a lubricant. If, for example, oil is used in a system,
which is likely to contain water, it will have to be one with good demulsifying
properties, especially if the oil will be subject to much churning or splashing
action.

METHODS OF LUBRICATION

There are many different methods of supplying lubricant to the moving parts. The
method employed depends on:

 The accessibility of the moving parts.
 The loads imposed.
 The speed of the moving parts.

a. Manual Lubrication

Manual lubrication is usually done with an oil can, grease cup or grease gun.

a.1 Oil Can

The oil can is used where the lubrication point can be seen and the can is able to reach
it.

Figure 5 Oil cans

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines
a.2 Spring Operated Grease Cup
Grease held in the cup is continuously forced under spring pressure to the bearing. This
type of cup is suitable only for the thinner grades of grease, and for short direct feed
ducts or pipes.

Figure 6 Spring operated grease cup
a.3 Screw Operated Grease Cup
Grease is forced through the feed duct or pipe by the operation of a screw cap. This
type of cup is suitable for thicker grades of grease and for longer feed ducts or pipes.
The disadvantage with this type of grease cup is that the feed is intermittent and
controlled by manual adjustment of the screw.

Figure 7 Screw operated grease cup

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

Grease Gun

A grease gun is used to pump grease through a non-return nipple. After greasing, the
nipple may be left in position, or replaced by a screwed blanking cap. Take care to
ensure adequate lubrication by this method.

Figure 8 Grease gun

i. Gravity Lubrication
Gravity lubrication is also known as drip-feed oiling.

a. Drip Feed Cup Oiler
These may be used to supply a controlled feed to a bearing. The covered cup
containing oil is connected to a duct or pipeline leading to the bearing. A needle valve is
used to regulate the flow of oil.

Figure 9 Drip feed cup oiler

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines
b. Wick Feed Oiler
Components requiring a low rate of oil supply are often lubricated by wick feed. One
end of the wick is suspended in oil bath and siphon action feeds oil to the part to be
lubricated. Alternatively, a lubricating pad, usually of felt, is pre-soaked in oil before use
and held in contact with the part to be lubricated.

Figure 4.9 Wick feed oiler

c. Vibrating Pin Oiler
A small rod extends through the oiler and rides on a rotating shaft. The vibrating motion
of the pin allows oil to be admitted to the shaft and bearing.

Figure 4.10 Vibrating pin oiler

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines
b. Natural Lubrication

This form of lubrication includes the various types of Splash or Bath and Ring type of
oilers. Moving parts are immersed in an oil sump and as they move or rotate, the
lubricant is being transported to areas that need to be lubricated.

Oil Bath
This type of lubrication will only be efficient at low speeds and may be used to lubricate
such items as worm gears and gearboxes. Oil bath seals must be well maintained to
prevent leakage.

Figure 4.11 Oil bath lubrication
Splash Lubrication
The moving components are inside a protective housing. During operation, components
dip into an oil bath and carry oil to the other components.

Figure 4.12 Splash lubrication

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

Ring, Chain and Collar Oiler

These methods may be used to lubricate plain bearings in low and medium speed
machinery. A ring or endless chain mounted loosely on the shaft rotates with it carrying
oil from a reservoir below the bearing. Alternatively, the shaft may have an integral
collar from which the oil is scraped when it reaches its highest point of travel.

Figure 4.12 Chain oiler

Pressure Lubrication

Pressure lubrication is also known as force-feed lubrication is a system that requires an
oil sump at the base of the machine. There are basically two types:

Wet Sump

Oil is drawn from the sump by an internally or externally mounted oil pump. Then oil is
pressurized and distributed to the various lubricating points whether through external
pipes or internally drilled oil passages or both.

PUMP

Figure 4.13 Wet sump forced-feed lubrication

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

Dry Sump
Oil sump and pump are not included in the machine but located close by. This system is
used where the machine has insufficient space to have an oil sump.

Figure 4.14 Dry sump forced-feed lubrication

a. Importance of Lubricants Cleanliness

The most important aspect for ensuring maximum machine and lubricant life is choosing
the correct lubricant for a particular application. The next most important is keeping the
oil clean and dry as foreign material and water contamination can have devastating
effects on machine and lubricant life.

The foreign substance in lubricants is the ambient dust and dirt. In general, dust and dirt
will contain materials such as silicon oxides and aluminum oxides. Elemental indicators
of dirt ingression would be silicon (Si), aluminum (Al), and in some cases calcium (Ca)
and magnesium (Mg). These materials are the same as those used as the abrasive
media in sandpaper and are typically much harder than materials used in most
machinery components.

If the particle is larger than the clearance between two machine surfaces, the particle
will grind against them, removing metal from the machine surfaces. The resultant wear
particles can cause a chain reaction by increasing the total number of harmful particles
in the lubricant. These newly generated wear material can get broken into smaller
particles and become harder due to the process of work-hardening.

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

Moisture contamination can have numerous direct effects on machine condition. The
most obvious effect of water is to cause rust and corrosion of iron and steel surfaces.
Most lubricants are somewhat acidic by nature and the addition of certain additives can
make lubricant more acidic. Water presents in lubricant will combine with the acids in
the oil to increase the corrosive attack on ferrous and nonferrous metals. This corrosive
attack will result in the removal of metal from the component surface, typically in the
form of ferrous oxides. Ferrous oxides, or rust particles, are abrasive and together with
other wear debris and abrasive particles, they can cause further corrosion on fresh base
metal.

CLEANING OF MACHINE

Keeping the machine clean is an essential part of maintaining it. Aside from the fact
that it will make it work more smoothly, it can also prevent accidents happening.

As a general rule, anything that is out place in the machine should be removed and
cleaned before and after using it. Such as hand tools, metal chips and machine tools.
Anything that is not in these pictures is out of place.

Lathe machine Milling machine

 Remove metal chips cut from the operation using a plastic brush or a chip hook,
never use your bear hands in removing metal chips, it can cut your skin.

 Never use compressed air to remove metal cuttings from the bed, instead use a
rag to wipe it off.

 Dispose of all the metal chips collected on the metal chip tray beneath the lathe
bed on a container designated for the particular waste material.

 When removing cutting tools, use a rag or cotton gloves to prevent cuts.
 Wipe off dirt and grease from hand wheels.

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Information Sheet 5.1.1 : Perform lubrication and cleaning of machines

Code No. Perform preventive and corrective Date: Developed Date: Revised Page #
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Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

Learning outcomes:
1 Perform lubrication and cleaning of machines
Learning Activity:
1.2 Performing lubrication and cleaning of machines

1. Turn off the machine before lubricating and cleaning.

Note: Below is a standard oil level sight glass that can normally be found on machines.
There are two lines, the lower line indicating the lowest level allowable for the
machine to operate smoothly, while the upper line indicates the maximum level of
the lubricant.

Maximum level
Minimum level

Oil level sight glass

FOR LATHE MACHINES
2. Check Oil level sight glass of the following:

2.1 HEADSTOCK

2.1.1 Should the oil level fall lower the minimum
level, top it off through the Oil filler plug located on
the top of the headstock of a lathe.

Oil filler plug

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Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines
2.2 GEARBOX
When the lathe is off, oil should be visible at
all times in the gearbox oil sight window

Oil Sight

2.2.1 should the oil level fall lower the
minimum level, top it off through the
filler elbow behind the end cover of the
headstock.

Filler Elbow

2.3 APRON
Oil sight glass can be seen on the side of
the apron. Normally located at the side
facing the headstock.

Oil Sight

2.3.1 should the oil level fall lower
the minimum level, top it off
through the apron filler plug.

Apron filler plug

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Operation Sheet 6.1.1 : Perform lubrication and cleaning of machines

General Lubrication Chart

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