Preparing electrical power and hydraulic tools

Operation Sheet 2.2.3 : Bending pipe using hydraulic pipe bender
4. Place the Bending Die onto the jack and make sure it is seated properly.

5. If needed, adjust the Rollers for the size of pipe you want to bend:
A. Remove the Hitch Pins and set aside.

B. Remove a Roller Shafts and move the Roller to the desired hole in the Frame.

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Operation Sheet 2.2.3 : Bending pipe using hydraulic pipe bender
6. Slide the pipe you want to bend through the pipe bender on top of the bending die and

below the rollers. Make sure the pipe being bent is long enough to be fully supported by the
Rollers and will not suddenly push past the Rollers during the bending process.

7. Make sure the top of the pipe rests against the bottom of the Rollers.
8. Using the slotted end of the handle or pliers, tighten the bottle jack Release Valve by

turning it clockwise.

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Operation Sheet 2.2.3 : Bending pipe using hydraulic pipe bender
9. Insert the Handle into the Bottle Jack.

Warning: Do not place hands or fingers near the die area while the unit is in use.

10. Pump the Handle up and down to raise the Bottle Jack and bend the pipe. Do not exceed
90 degrees.

11. After bending the pipe to the desired shape, remove the Handle from the Bottle Jack and
loosen the Release Valve by turning it counterclockwise. The ram of the bottle jack will
lower.

12. After the ram is lowered, carefully remove the pipe from the pipe bender.

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Job Sheet 2.2.4 : Bending Rigid Conduit

Learning outcomes:
1 Hydraulic tools are identified and selected in accordance with the job specification
Learning Activity:
1.2 Bending rigid conduit using hydraulic pipe bender correctly.

Equipment / Resources:

 Hydraulic pipe bender
 5 feet of 1-inch rigid galvanized conduit
 Tape
 Marking pencil

At the end of these learning activities you should be able to bend 90 degrees using hydraulic
pipe bender correctly.

Bending rigid conduit Using a Hydraulic Pipe Bender

Name ________________________________________ Date ________________

Instruction: When you are ready to perform this task, ask your Instructor to observe
the procedure and rate your performance using the below criteria.

1. Using the hydraulic pipe bender and materials bend the 1” pipe to the following
figure; see picture below. Follow procedure in operating hydraulic pipe bender
correctly.

90 degree bend -It is required when run
conduit over joint and when you want
to enter a ceiling or wall outlet on the
floor below, or from an exposed ceiling
running to a box on the wall.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 2.2.4 : Bending Rigid Conduit

Offset bend – It is needed at the end of the conduit if it is running through an outlet
box for connection of lighting fixture, convenience outlets, and similar others.

Assessment Criteria Rating
Appropriate equipment and materials are gathered and
used in line with the job requirements.
The procedure is safely performed.
The procedure is followed in chronological order.
Work area is cleaned.

Remarks:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 2.2.5 : Drilling and Grinding

Learning outcomes:
1 Electric power tools are identified and selected in accordance with the job specification
Learning Activity:
1.2 Drilling and grinding metal using electric power tools correctly.

Equipment / Resources:

 Hand drill
 Grinder
 ¼”x3”x2” metal plate
 Marking pencil

At the end of these learning activities you should be able to drill and grind correctly.

Drilling and Grinding using electric power tools

Name ________________________________________ Date ________________

Instruction: When you are ready to perform this task, ask your Instructor to observe
the procedure and rate your performance using the below criteria.

1. Using the hand drill and materials, drill a hole 3/16”, ¼”, 5/16” respectively.
See drawing below. Follow procedure in operating hand drill correctly.

15mm 15mm

3/16” ¼” 5/16”
Hole dia. Hole dia. Hole dia.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 2.2.5 : Drilling and Grinding
2. Using the grinder and materials, grind the metal plate as shown below. Follow
procedure in operating grinder correctly.

45 degrees inclination

Assessment Criteria Rating
Appropriate equipment and materials are gathered and
used in line with the job requirements.
The procedure is safely performed.

The procedure is followed in chronological order.

Work area is cleaned.

Remarks:

___________________________________________________

___________________________________________________

___________________________________________________

___________________________________________________

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Worksheet 3.1.1 : Signs, symbols and data

Learning outcomes:
3 Analyze signs, symbols and data

Learning Activity:
3.1 Determined sign, symbols and data according to classification or as appropriate in
drawing.

SELF-CHECK

I. Direction: Inside the box, draw what symbol is being asked.

Incandescent Light Outlet Power/Convenience Outlet

Air Conditioning Unit Panel board

2-gang Switch Service Entrance

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Worksheet 3.1.1 : Signs, symbols and data

II. Direction: Give the meaning of the following electrical sign. Write your
answer on a separate sheet of paper.

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Operation Sheet 4.2.1 : Interpret technical drawing

Learning outcomes:
4 Interpret technical drawings and plans.
Learning Activity:
4.2 Identifying equipment according to the plan

Planning and preparing for work.

1. Obtain the technical working drawing (electrical plan) form the concerned personnel
(instructor) then examine the nature of the work. See sample

Three lamps (A,B and C) controlled by 3gang switch

4X4 junction box

200mm 200mm

250 mm ABC

6 branch panel 500mm
board
350 mm
RSC pipe ½
diameter

350 mm 250 mm

2x4 utility box

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Operation Sheet 4.2.1 : Interpret technical drawing

2. List down the needed materials, PPE’s, Tools and Equipment needed in performing a
task. Use requisition form and barrowers form. See sample.

Technical Education and Skills Development Authority
Agusan del Sur School of and Trades

Requisition Forms Date: Sept 20, 2010_
Obtain from: Electrical workshop

Others; Specify _______________

Item Qty Unit Description
No.

1. 1 length RSC pipe ½ diameter.

2. 4 pcs Junction box 4X4 metal

3. 1 pcs Utility box 2X4 metal

4. 1 set Panel board 6 branch

5 40 pcs Wood screw ¾”

6 14 pair RSC lock nut and bushing
7 10 pcs Two hole strap ½” dia.

I acknowledge receipt of items describe above in good order and condition.

___________________________________
Borrower’s Printed name and signature

__________________________________
Instructor’s Printed name and signature

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 4.2.1 : Interpret technical drawing

Technical Education and Skills Development Authority
Agusan del Sur School of and Trades

Borrower’s Slip Date: Sept. 20, 2010
Obtain from: Electrical workshop

Others; Specify _______________

Item Qty Unit Description
No.
1. 1 set PPE ( hard hat, goggles, gloves )
2. 1 set Hydraulic pipe bender
3. 1 unit Grinder 4”dia.

I acknowledge receipt of items describe above in good order and condition. I assume full
responsibility over them, and in case of failure to return any item/items due to loss or other
reasons, I agree to replace such item/items

___________________________________
Borrower’s Printed name and signature

__________________________________
Instructor’s Printed name and signature
3. Present filled up requisition and barrowers form to the instructor for approval.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 4.2.1 : Interpret technical drawing

Learning outcomes:
4 Interpret technical drawings and plans.
Learning Activity:
4.2 Identifying equipment according to the plan

Planning and preparing for work.

1. Obtain the technical working drawing (electrical plan) form the concerned personnel
(instructor) then examine the nature of the work. See sample

Three lamps (A,B and C) controlled by 3gang switch

4X4 junction box

200mm 200mm

250 mm ABC

6 branch panel 500mm
board
350 mm
RSC pipe ½
diameter

350 mm 250 mm

2x4 utility box

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
CON724308 Tools Sept. 20, 2010 1

Operation Sheet 4.2.1 : Interpret technical drawing

2. List down the needed materials, PPE’s, Tools and Equipment needed in performing a
task. Use requisition form and barrowers form. See sample.

Technical Education and Skills Development Authority
Agusan del Sur School of and Trades

Requisition Forms Date: Sept 20, 2010_
Obtain from: Electrical workshop

Others; Specify _______________

Item Qty Unit Description
No.

1. 1 length RSC pipe ½ diameter.

2. 4 pcs Junction box 4X4 metal

3. 1 pcs Utility box 2X4 metal

4. 1 set Panel board 6 branch

5 40 pcs Wood screw ¾”

6 14 pair RSC lock nut and bushing
7 10 pcs Two hole strap ½” dia.

I acknowledge receipt of items describe above in good order and condition.

___________________________________
Borrower’s Printed name and signature

__________________________________
Instructor’s Printed name and signature

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 4.2.1 : Interpret technical drawing

Technical Education and Skills Development Authority
Agusan del Sur School of and Trades

Borrower’s Slip Date: Sept. 20, 2010
Obtain from: Electrical workshop

Others; Specify _______________

Item Qty Unit Description
No.
1. 1 set PPE ( hard hat, goggles, gloves )
2. 1 set Hydraulic pipe bender
3. 1 unit Grinder 4”dia.

I acknowledge receipt of items describe above in good order and condition. I assume full
responsibility over them, and in case of failure to return any item/items due to loss or other
reasons, I agree to replace such item/items

___________________________________
Borrower’s Printed name and signature

__________________________________
Instructor’s Printed name and signature
3. Present filled up requisition and barrowers form to the instructor for approval.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 4.2.2.: Interpret Technical Drawing

Learning outcomes:
1 Interpret technical drawings and plans.
Learning Activity:
1.2 Identifying equipment according to the plan.

Equipment / Resources:

 Technical drawing
 Requisition form
 Borrowers form
 Power tools and hydraulic tools
At the end of these learning activities you should be able to interpret technical drawings and
plans

Interpreting technical drawings and plans

Name ________________________________________ Date ________________

Instruction: When you are ready to perform this task, ask your Instructor to observe the
procedure and rate your performance using the below criteria.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 4.2.2.: Interpret Technical Drawing

1. Use the requisition form and borrower form in listing the materials, tools, PPE and
equipment. Refer to the technical drawing below.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 4.2.2.: Interpret Technical Drawing

2. Use the requisition form and borrower form in listing the materials, tools, PPE and
equipment. Refer to the technical drawing below.
One lamp (A) controlled by 1gang switch, and two lamps (B and C) controlled
by 2gang switch

4X4 junction box

250 mm 250 mm 250 mm

ABC

300 mm

6 branch panel
board

IMT pipe ½
diameter

300 mm

250 mm

350 mm 250 mm 250 mm

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Job Sheet 4.2.2.: Interpret Technical Drawing Rating

Assessment Criteria
Appropriate equipment and materials are listed in line
with the job requirements.
The procedure is safely performed.
The procedure is followed in chronological order.
Work area is cleaned.

Remarks:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________

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Operation Sheet 5.1.1 : Step to Test (trouble shooting guide) electric power tools.
Learning outcomes:
5 Maintain electrical power and hydraulic tools.
Learning Activity:
5.1 Checking condition of electric power tools.

Procedure in checking condition of electric power and hydraulic tools:

When and how should you inspect powered hand tools?
 Inspect tools for any damage prior to each use.

 Check the handle and body casing of the tool for cracks or other damage.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 5.1.1 : Step to Test (trouble shooting guide) electric power tools.
 If the tool has auxiliary or double handles, check to see that they installed securely.

 Inspect cords for defects: check the power cord for cracking, fraying, and other signs of
wear or faults in the cord insulation.

Damage cord

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 5.1.1 : Step to Test (trouble shooting guide) electric power tools.
 Check for damaged switches and ones with faulty trigger locks.

 Inspect the plug for cracks and for missing, loose or faulty prongs

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 5.1.1 : Step to Test (trouble shooting guide) electric power tools.
 Basic trouble shooting

Symptom Possible causes Corrective Action
No power
 Defective cord  Replace cord
Noisy  Defective plug  Replace plug
 Defective carbon  Replace carbon

brush brush
 Defective switch  Replace switch
 Defective bearing  Replace bearing
 Not lubricated  Lubricated bearing

bearing  lubricated gear
 Not lubricated gear

Damage gear due to poor lubrication

What should you do if you find a tool defective?
 If a tool is defective, remove it from service, and tag it clearly "Out of service for repair"
or “Defective DO NOT USE”.
 Do not use defective tools "temporarily".

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 5.2.1 : Step to Test (trouble shooting guide) hydraulic tools.

Learning outcomes:
5 Maintain electrical power and hydraulic tools.

Learning Activity:
5.2 Checking condition of hydraulic tools.

Procedure in checking condition of hydraulic tools:

When and how should you inspect hydraulic tools?

 Inspect tools for any damage prior to each use.

 Follow basic trouble shooting

Symptom Possible causes Corrective Action
Cylinder will not extend
 Release valve not  Ensure release
tightly closed valve tightly closed

 Overload condition  Remedy overload
condition
Cylinder *bleeds off after lift  Release valve not
tightly closed  Ensure release
Cylinder will not lower after valve tightly closed
unloading  Hydraulic unit
malfunction  Replace ram and/or
pump
 Reservoir overfilled
 Ram damage  Drain oil to proper
level
Poor performance  Oil level low
 Air trapped in  Replace ram
 Ensure proper oil
system
level
Will not lift to full extension  Oil level low  With ram fully

retracted, remove oil
filler screw to let
pressurized air
escape, then re
install oil filler screw
 Ensure proper oil
level

* Bleed off means that the ram begins to slowly retract than maintain position.
What should you do if you find a tool defective?

 If a tool is defective, remove it from service, and tag it clearly "Out of service for repair".

 Do not use defective tools "temporarily".

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 5.3.1 : Checking condition of electric power and hydraulic tools

Learning outcomes:
5 Maintain electrical power and hydraulic tools.
Learning Activity:
5.2 Checking condition of electric power tools.

Equipment / Resources:

 Hydraulic pipe bender
 Hand drill
 grinder

At the end of these learning activities you should be able to determine the condition of power
and hydraulic tools

Checking condition

Name ________________________________________ Date ________________

Instruction: When you are ready to perform this task, ask your Instructor to observe
the procedure and rate your performance using the below criteria.

I. Given the electric power tools and hydraulic tools, check the condition using
the table below.

Name of electric power and Conditions Remarks

hydraulic tools Good Bad

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 5.3.1 : Checking condition of electric power and hydraulic tools

Assessment Criteria Rating
Appropriate equipment and materials are gathered and
used in line with the job requirements.
The procedure is safely performed.
The procedure is followed in chronological order.
Work area is cleaned.

Remarks:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Information Sheet 6.1.1 : Types of lubricants and cleaning materials

Learning outcomes:
6 Identify types of lubricants and cleaning materials

Learning Activity:
6.1 Identifying types of lubricants and cleaning materials.

BASIC LUBRICATION

The function of a lubricant is simple - reduce friction between moving metal surfaces. A
lubricant coats surfaces and resists being displaced by 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:

 Oils cover a broad class of fluid lubricants, each of which has
particular physical properties and characteristics, see figure 1.
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 machinery.

 In figure 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.

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Information Sheet 6.1.1 : Types of lubricants and cleaning materials

 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.

 Rust remover A rust remover is used mainly to dissolve rust, but it is
also makes an excellent cleaner. For example, to remove a rusted bolt,
spray remover directly on the bolt, wait for approximately five minutes
and unscrew. WD-40 in one of the many brands of rust removers on
the market.

 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 for use on rubber, car door gaskets, handsaws, miter
saw, saw sliders, window sashes, etc. It can also be used on balky
wooden drawers, but cabinetmakers usually prefer floor wax because
it is more durable. JIG-A-LOO is a brand of dry lubricant.

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.

 Penetrating lubricant. You can find on the market a penetrating
lubricant, the PL-100 which is thick and very efficient. 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, etc., as it does not hold dirt and
dust.

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. Certain classifications are
friendlier to elastomers, seals and O-rings that might come in contact with the lubricant.

 Synthetic oils are used to lubricate instrument bearings, hydraulics, air compressors, gas
and steam turbines and other applications. They generally have excellent viscosity-
temperature characteristics, good resistance to oxidation and an extremely wide operating
temperature range.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Information Sheet 6.1.1 : Types of lubricants and cleaning materials

 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 nonflammable up to
1,200° F.

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

Solutions are homogeneous mixture of two or more components; these 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.

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/are soluble in water; while nonpolar solvents are solvents which do not
dissolve/are insoluble in water.

Solvents usually used for cleaning in automotive shops are: water, gasoline, kerosene,
thinner and detergent soap.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Information Sheet 6.1.1 : Types of lubricants and cleaning materials
The table below shows the kinds of cleaning solvent based on their solubility in water.

Cleaning Solvents Solubility in Water Polar Nonpolar
soluble x
a. water insoluble X
b. gasoline insoluble x X
c. kerosene insoluble x
d. thinner soluble
e. detergent

soap

Properties of Cleaning Solvents

A useful generalization much quoted is that “Like dissolves like”. More specifically, high
solubility occurs when the molecules of the solute are similar in structure and electrical
properties to the molecules of the solvent.

When there is a similarity of electrical properties; e.g. high dipole element between
solute and solvent, the solute-solvent attractions are particularly strong. When there is
dissimilarity, solute-solvent attractions are weak. For this reason, a polar substance such as
H2O usually is a good solvent for a polar substance such as detergent soap but a poor solvent
for a nonpolar substance such as gasoline.

Uses of Cleaning Solvents

Cleaning Solvents Uses
1. Gasoline
2. Diesoline - It is used to wash oil/greasy tools/
equipment.
3. Kerosene
4. Thinner - It is used to wash oil engine, transmission
5. Soap and water and other parts of the vehicle.

- It is used to remove dust, grease oil, paint,
etc.

- It is used to remove spilled paint on the floor,
walls and tools.

- It is used to wash/clean upholstered furniture
such as seats, tables, cabinets, etc.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Worksheet 6.1.2 : Types of lubricants and cleaning materials

Learning outcomes:
6 Identify types of lubricants and cleaning materials

Learning Activity:
6.1 Identifying types of lubricants and cleaning materials.

Directions: Read the instructions in each letter carefully. Write your answer on a separate
sheet of paper.

A. Classify the following cleaning solvents whether they are Polar or Non-polar. Write P for
polar and NP for non-polar.
1. water

2. gasoline

3. kerosene

4. diesoline

5. thinner

6. detergent soap

B. Identify the cleaning solvents used in the following substances.
1. Polar substances
a. dust
b. mud
2. Nonpolar substances
c. oil

d. grease oil

C. Match the cleaning solvents at the right with their uses at the left. Write only the letter of

your answer.

Uses Cleaning Solvents

1. It is used to clean upholstery and other furniture. A. alcohol

2. It is used to wash out spilled paint on the floors B. diesoline
and walls as well as on the tools/ equipment.

3. It is used to wash oil, greasy tools and equipment. C. gasoline

4. It is used to remove dust, grease and oil. D. kerosene
E. soap and
5. It is used to clean oil engine, transmission and
other parts of the vehicle. water

F. thinner

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Operation Sheet 7.1.1: Lubricating power tools

Learning outcomes:
7 Inspect and replaced auxiliary part of power and hydraulic tools.
Learning Activity:
7.1 Lubricating power tools

When used in a gearbox the lubricant provides two primary benefits: to lubricate
the teeth and to remove heat generated from the gear operation. The lubricant is also
often used for lubricating the various bearing found in the gearbox. If the correct lubricant
is selected for use in a gear system it will provide slip-free power transmission at high
mechanical efficiency, with good reliability, low maintenance, and long life.

Surface fatigue occurs when the lubricant film on the gear wheel teeth is insufficient to
protect the surfaces from the stress, resulting in pitting forming in the contact region.
Scuffing can result if the lubricant film is not maintained, with the consequent increase in
temperature causing distress and wear of the material surface.

Procedures in cleaning, lubricating, and storing portable grinder:

1. Lay rugs on the working table.
2. Put the portable grinder and clean the casing using rugs and brush.

See picture below

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Operation Sheet 7.1.1: Lubricating power tools
3. Remove the grinding wheel using lock nut wrench

Shaft lock

Lock nut wrench
4. Open the gear box using a star (Phillip) screw driver.

5. Wipe the old grease in the gear box.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.1.1: Lubricating power tools
6. Put new grease in the gear box; be sure not to excess the lubricants.

7. Close the gear box tightly using an appropriate tool.

8. Clean the casing by using rugs.
9. Press the shaft locks firmly so that the spindle cannot revolve then fit the wheel on over the

inner flange and screw the lock nut onto the spindle. Then use lock nut wrench to tighten
clockwise direction.

10. Plug the cord to the outlet and test. Note. Do not test without the presence of the instructor.
11. Unplug the portable grinder.
12. Clean work area, and returned equipment and materials to proper storage.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.1 : Replacing power cord

Learning outcomes:
1 Inspect and replaced auxiliary part of power and hydraulic tools.
Learning Activity:
1.2 Replacing damage power cord

Replace a damage power tool cord

Power cord can be damage due to constant twisting, rubbing, dragging, pinching and pulling
and eventually crack or wear away the outer lining of the cord. This can damage the wires
inside, and expose the tool operator to severe danger.

Procedure in replacing power cord

1. Start with a clean, uncluttered work bench area.
2. Uncover the wire terminals: The cord for most power tools connects directly to the tool

switch through a wire terminal.

Most switches are located in the handle of the tool. First remove the plate to the tool to expose
the inside of the tool.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.1 : Replacing power cord

You may have to remove more than one plate (for example on many tools, you may also have
to remove the handle)

3. Disconnect the wires from the terminals: Loosen the wire terminal screws with a
small screwdriver and pull the wires out of the terminal. At this point, it is very important
to note the route that the wires follow out of the terminal to connect to the plug. You
need to route the new wires back in the same way or you may pinch the wires when you
replace the handle.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.1 : Replacing power cord

Once the wire terminals are loose, mark each wire with masking tape to ensure that the correct
wires will be connected with the new cord.

4. Taking out the old cord: Most tools have a retaining bracket that keeps the power cord
secure and fastened in place. Remove the retaining bracket (most need to be
unscrewed) and remove the old cord.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.1 : Replacing power cord

The old cord will have the wires market with masking tape, so keep it nearby to help with
positioning the new wires.

5. Installing the new cord: Power cords are different for many types of tools, based on
the amperage and the voltage (even the length of the cord is important).

If the new cord already has the wires stripped, you are ready to install it in directly. (Go on
to step 6)

6. Put in the New Replacement Cord: Check the masking tape labels on the old cord, to
make sure that the wires are connected correctly. Place the wires in the correct path to
avoid pinching the wires when the tool case in put back in place. Secure the power cord
back in place with the retaining bracket.

7. Check the Tool for Safety: The last step is to make sure that the tool is safe to use. A
bad electrical connection can pass electrical current through the metal housing of the
tool - this is a serious danger for operation. A multitester is the best way to ensure that
the tool is safe. (A multitester measures the resistance and current in electrical circuits.
With the multitester set to RX1 put one end to the plug and the other end to the outside
housing of the tool. There should be no connection between the two.

8. Plug the cord to the outlet and test. Note. Do not test without the presence of the
instructor.

9. Clean work area, and returned equipment and materials to proper storage.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.2 : Replace carbon brush
Learning outcomes:
7 Inspect and replaced auxiliary part of power and hydraulic tools.
Learning Activity:
7.2 replacing carbon brush.
Replacing carbon brushes

Remove and check the carbon brushes regularly. Replace when they wear down to the
limit mark. Keep the carbon brushes clean and free to slip in the holders. Both carbon brushes
should be replace at the same time. Use only identical carbon brushes.

Carbon brush
spring

Limit Mark

Procedure in replacing carbon brush Makita angle grinder
1. Use flat screw driver to remove the brush holder caps.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.2 : Replace carbon brush
2. Take out the worn carbon brushes.

3. Replace with new carbon brush; make sure they are the same part number with the
older one.

4. Insert the new carbon brush and secure the brush holder caps.

5. Check the Tool for Safety: The last step is to make sure that the tool is safe to use. A
bad electrical connection can pass electrical current through the metal housing of the
tool - this is a serious danger for operation. A multitester is the best way to ensure that
the tool is safe. (A multitester measures the resistance and current in electrical circuits.
With the multitester set to RX1 put one end to the plug and the other end to the outside
housing of the tool. There should be no connection between the two.

6. Plug the cord to the outlet and test. Note. Do not test without the presence of the
instructor.

7. Unplug the portable grinder.
8. Clean work area, and returned equipment and materials to proper storage.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
CON724308 Tools Sept. 20, 2010 2

Operation Sheet 7.2.3 : Replacing hydraulic oil

Learning outcomes:
7 Inspect and replaced auxiliary part of power and hydraulic tools.
Learning Activity:
7.2 Replacing / adding hydraulic oil

When it's time to work pipe bending using hydraulic pipe bender, usually it involves
problems in hydraulic jack, it will not lift high enough, or will not lift at all due to low on oil. To fix
the problem, you need to add or replace oil to the jack, which isn't complicated to do; you just
have to know where to add the oil. In case, for different hydraulic pipe bender jack, but the
process is similar for other jacks as well. See picture below for different types of hydraulic pipe
bender.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 7.2.3 : Replacing hydraulic oil

Replacing oil

1. Remove oil filler screw of the hand pump.
2. Turn pump over and drain oil out through oil filler screw hole. Dispose oil in accordance

with local regulation.
3. Fill until oil is 3/8” of the filler screw hole opening, re install oil filler screw.

Note: Do not allow dirt or other foreign materials to enter the hydraulic system when filling.

4. Storage After refilling, remove air from system by opening release valve and rapidly
pumping handle several times. Reinstall oil filler screw when done.

Lubrication
A coating of light lubrication oil to pivot points, axles and hinges section every 3 months will
help to prevent rust.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 7.2.4 : Maintain electric power and hydraulic tools

Learning outcomes:
5 Maintain electrical power and hydraulic tools.
Learning Activity:
5.2 Replacing auxiliary part of electric power and hydraulic tools.

Equipment / Resources:

 Hydraulic pipe bender
 Hand drill
 Grinder
 Carbon brushes
 Power cord

At the end of these learning activities you should be able to replace carbon brush, power cord
and change hydraulic oil in hydraulic tools.

Replace carbon brush, power cord and change oil in hydraulic tools.

Name ________________________________________ Date ________________

Instruction: When you are ready to perform this task, ask your Instructor to observe
the procedure and rate your performance using the below criteria.

I. Given the defective electric power tools (damage cord and carbon brush),
replace parts by following the procedure in replacing carbon brush and
power cord.

Assessment Criteria Rating
Appropriate equipment and materials are gathered and
used in line with the job requirements.
The procedure is safely performed.
The procedure is followed in chronological order.
Work area is cleaned.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 7.2.4 : Maintain electric power and hydraulic tools

Remarks:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 8.1.1 : Storing electric power and hydraulic tools

Learning outcomes:
8 Store electrical power and hydraulic tools.
Learning Activity:
8.2 Storing electrical power and hydraulic tools.
Storing electrical power and hydraulic tools

A. Storing electrical power tools

Power tools are the key ingredients for a successful building project. With proper care these
tools can last a long time. While each power tool is different, the same general care
procedures work for all of them. Always read and follow the manufacturer's directions for each
particular power tool. Each brand is different and some may require special treatment. Always
unplug your tools before cleaning as well.

Instruction

1. Inspect your power tools when you complete your task. Make sure the power cord has
no exposed wires. Follow procedure in checking condition of electric power tools.

2. Clean your power tools after each use. Take care to use the proper cleaning materials.
In most instances you can simply brush or blow the dust off the tool. Remember to wipe
it off when you finish.

3. Lubricate any parts that require it. Make sure all parts are moving smoothly. Consider
using oil or a product such as WD40 to prevent rust on exposed blades. After oiling the
metal part, wipe away any excess oil. Follow procedure in lubricating electric power
tools.

4. Sharpen blades as necessary with the proper files and sharpening stones. If you aren't
sure how to do it, then take the blade to a professional.

5. Store your tools properly. Using procedure below.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Operation Sheet 8.1.1 : Storing electric power and hydraulic tools

B. Storing hydraulic tools

Rust prevention

Check cylinder every 3 months for any sign of rust or corrosion,. Clean as needed and wipe
with an oil saturated cloth. When not in use, always leave the cylinder plunger fully retracted,
Keep in dry, protected area, do not expose to corrosive vapor, dust or other harmful elements.

1. Keep cylinder retracted and release valve open when not in use.
2. Keep equipment clean.
3. Lubricate moving parts on pump handle
4. Avoid sharp kinks in hose.
5. If hydraulic oil is required, refill at oil filter screw hole until oil is in 3/8” of the oil filler

hole, reinstall oil filter screw.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
CON724308 Tools Sept. 20, 2010 2

Operation Sheet 8.1.1 : Storing electric power and hydraulic tools
PROCEDURE IN ARRANGING AND STORING TOOLS AND EQUIPMENT

1. Classify the tools and equipment according to their types.

2. Arrange the tools by their types in the shelves/racks.

3. Place equipment in designated places or location.

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CON724308 Tools Sept. 20, 2010 3

Job Sheet 9.1.1: Select, identify, maintain and store electric power and hydraulic tools

Learning outcomes:
1 Select, identify, maintain and store electric power and hydraulic tools
Learning Activity:
1.2 Selecting, identifying, maintaining and storing equipment according to the plan.

Equipment / Resources:

 Technical drawing
 Requisition form
 Borrowers form
 Power tools
 Hydraulic tools

At the end of these learning activities you should be able to select, identify, maintain and store
electric power and hydraulic tools in line with the job requirements.

Select, identify, maintain and store electric power and hydraulic tools

Name ________________________________________ Date ________________

Instruction: When you are ready to perform this task, ask your Instructor to observe the
procedure and rate your performance using the rating sheet 9.1.2.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Job Sheet 9.1.1: Select, identify, maintain and store electric power and hydraulic tools

I. Given the technical drawing below, prepare materials, the correct power tools and its
accessories and hydraulic tools needed for the job.

Service entrance 3
wire system

300mm 200mm 100mm 100mm 200mm 300mm

100mm M

300mm

6 branch
Panel
board

1 gang 3 gang 3 way 3 way
switch switch switch switch

300mm

GFCI outlet 2 gang outlet 2 gang outlet

LEGEND:

PVC pipe ½ dia
CPC pipe ½ dia
IMT pipe ½ dia
RSC pipe 1" dia

II. Maintain and store the tools and materials in problem number 1.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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Rating Sheet 9.1.2: Select, identify, maintain and store electric power and hydraulic
tools

ASSESSMENT PLAN

Unit of Competency: PREPARE ELCTRICAL POWER AND HYDRAULIC TOOLS

Module Title: Preparing Electrical Power and Hydraulic Tools

Assessment Methods

Assessment Criteria Demonstration
with oral

questioning

LO 1. Prepare electrical power tools x
x
1. Parts of electrical power tools are identified in x
accordance to manufacturer’s manual.
x
2. Electrical power tools are inspected for damage in line x
with a prescribed checklist. x

3. Defective parts /components/accessories are replaced x
according to manufacturer’s specification. x
x
LO 2. Prepare hydraulic tools x

1. Parts and functions of hydraulic tools are identified in
accordance to manufacturer’s manual.

2. Hydraulic tools are inspected for damage in line with a
prescribed checklist.

3. Defective parts /components/accessories are replaced
according to manufacturer’s specification

LO 3. Store electrical power and hydraulic tools

1. Electrical and Hydraulic tools are stored in line with the
manufacturer’s requirements.

2. Safety procedure in storing tools is strictly followed
according to manufactures standards

3. Tools are properly kept to their classification

4. Damaged tools are reported.

Code No. Prepare Electric Power and Hydraulic Date: Developed Date: Revised Page #
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