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Student Note T2 – T12 Bracken Ridge Electrical

1. 00 38 Marking Out Equipment cccccceees 38 Marking Off Table ccecseeeeeeeeeeees 39 Scribing Block Surface gauge 0 40 Cente PINON saccsrnsoreni a 41 Emery Paper see usveornctnccuseaetecsoactuectaemsssevanesa 50 De burring Tool essssssssssseseeeeeesssssssssssese 50 File Safety serssriorrsossrsnseasiirneei sonores 50 Handsaws ccccceccccceesccccessccceesececeeseseeenees 51 Hacksaw ccccccceseccceesecccessccceesecsceeseceeenees 51 Junior hacksaw ccccccceseccceeseccceeeeceeeeees 55 Pad Handle ccccceccccceseccceesececeeseseeenees 55 COping SAW sess secorsassacesneanncassgaacereaereantaanncs 55 Keyhole SAW ec orcicenandessaaancaseancncersanaucartasancs 56 Hand Saw Wood c cceecccceesececeeeeeeeees 56 HOLE SIW areno 57 Py CU e E E ETET 57 Wad Punti entension 57 Metal Punch Chassis Punch 58 E102A Notes T2 T12 Version 4 BG doc 23 January 2014 CONCISE ries ha ctsaciensinsnctss taint lantxbindenntnientantindes 58 Wood Chisels cceceeeeeeeseeessseesseeeseeeeees 60 Bolster CIN SE lis nncnsnnosscnnaconadnctiantanesecanenesanenes 60 SIDI T EEA T 60 TIN SMPS waasiareensanoccarsenaaadacianscaeeeeonehseen cquuael 61 C LIMPS ene E 62 G Clapie aia 62 Adjustable Vice Grips cccccccccsssssseeeeeees 63 Multi Grip Pliers or Slip Joint Pliers 63 E i a A AE 63 Footprint Pipe Wrench
2. ccccccccceeeeeeeeeeeees 178 Section 3 Verification and Testing 179 a 182 Sheet Metal Work Safety eeeee 182 Sheet Metal Characteristics cccccccee 183 Types of Sheet Material used in Electrotechnology cccccccccceccseessseeeeeees 183 Electrotechnology Sheet Metal Tasks 184 Sheet Metal Work Hand Tools 185 Sheet Metal Work Power Tools 189 Sheet Metal Work Plan Activities 203 Safe Handling of Materials 203 Makir Obecna mre tre retro nr ss 204 Cutting Sheet Metal eee 206 Making a Lap Joint centres 206 Folding Sheet Metal eens 208 Self Secured JOMtS ccesssssesseeeeeeeees 212 Job Inspection enesessssssseesseeeeesesssssssss 212 OG AM UD e E 212 Joining Lengths of Cable Duct 213 Making a Turn Down 214 Mitres or Angle Joints cceeseeeees 216 Making Tee Joints cccececcceeeeeeeeeeeees 218 Drilling and Cutting Holes In Sheet Metal219 Sustainable Energy Work Practices 220 Vernier Calliper Vernier Gauge 222 Outside Micrometer ccseeeeeeeeeeees 228 Large Purpose Micrometetfs 00006 231 Page 3 of 254 Digital Micrometer cceceeeeeeeeeees 22 Inside Micrometer c sscsscoscesesceess 234 Depth Micrometer 0sssseeeeeeeeees 235 Care of Micrometers ccces
3. Safety When Changing a Saw Blade Always follow manufacturer s instruction if they are available on how to change a blade If instructions not available then follow the guide below e Always turn off the saw s power switch and remove the power cord s plug from the mains socket outlet Bring the plug end of the saw s lead very close to you so that it cannot be accidentally reinserted into an outlet while you are changing the blade e Slide up the protective blade guard to expose the blade and lay the saw down ona sturdy bench top e Note which way the saw s teeth are pointing prior to removal e Most circular saw models are equipped with a blade lock feature that can be employed to stop blade movement e Attach the supplied spanner or socket to the circular saw blade retaining bolt in the centre of the blade This bolt attaches the blade to the saw s spindle e NB This bolt will undo in the opposite direction to the saw s rotation Most probable it will be a left hand thread Remove the bolt and set aside e Remove the saw blade and place the new blade with the teeth direction as before in its place e Replace the blade bolt and tighten securely to the saw E102A Notes T2 T12 Version 4 BG doc Page 174 of 254 23 January 2014 Heat Gun Ref http Awww productreview com au A heat gun is a tool used to emit a stream of hot air They are superficially similar in shape and construction to a hair dryer though they
4. NO O D N oo pa Operational Safety Checks Never leave the lathe running unattended 2 Before making adjustments or measurements switch off and bring the machine to a complete standstill Do not attempt to slow stop the chuck or revolving work by hand Avoid letting swarf build up on the tool or job Stop the machine and remove it Always remove the chuck key from the chuck Do not store tools and parts on top of the machine eS Lathe Maintenance Switch off the machine and reset all guards to a fully closed position Leave the machine in a safe clean and tidy state Potential Hazards e Flying objects chuck key left in chuck e Cutting tool injury when cleaning filing or polishing e Rotating machine parts entanglement e Metal splinters swarf e Eye injuries Don ts x Do not use faulty equipment Immediately report suspect machinery x Do not try to lift chucks or face plates that are too heavy for you E102A Notes T2 T12 Version 4 BG doc Page 77 of 254 23 January 2014 x Never leave the machine running unattended x Do not attempt to slow or stop the chuck or revolving work by hand x Do not attempt to feel the work piece while it is spinning x Do not leave equipment on top of the machine Abrasive Saw An abrasive cut off saw cuts material by means of a high speed thin abrasive wheel It can cut most materials to close tolerances including glass ceramics and many metals but not alumini
5. PLANISHING CHIPPING HEAVY WORK SELECTING THE CORRECT HAMMER BALL PEIN HAMMER FEATURES OF A HAMMER DERN A A n Af Riveting block ENGINEER S HAMMER Page 116 of 254 Cross Pein Hammer The pein end of this hammer can be used to stretch metal By supplying a number of light sharp blows to the concave side of a bent bar it is possible to straighten the bar The pein end can also be used for working in confined spaces such as channels corners and recesses where the striking face will not fit NB The difference between a cross pein hammer and a straight pein hammer is shown below lt Powection of metal spread Claw Hammer This tool is used to either fix timber pieces together or nail accessories to timber i e wall brackets pin clips or nails etc The claw end is used for removing nails from timber or for levering nails and galvanized iron roofing etc They are available in a range of head weights from 0 5kg to 1 25kg Note Do not use a claw hammer general engineering work or for hitting hard objects such as masonry nails cold chisels etc as the face is likely to chip Lump Hammer Mash or Masons Club Hammer A lump hammer ranges in size from 1 to 2 kg but only a short handle It is used in conjunction with the following tools strike e Bolster chisels for cutting bricks concrete and pavers etc e Seaming coursing or plugging chisels to remove b
6. 7 Agood magnifying glass is helpful when reading a vernier but when one is not available hold the vernier so that you are looking at the scale at an angle and in line with the graduated line As shown to the right 8 Move into a position where the light strikes from the back of the vernier scale at about the same angle as your line of sight Look along rather than at the line E102A Notes T2 T12 Version 4 BG doc Page 225 of 254 23 January 2014 Characteristics of a Vernier Calliper An advantage of a vernier calliper over a micrometer is that the standard tool may measure from zero up to the length of the main scale often 250 millimetres or more INTERNAL JAWS Also the base tool can measure both outside a inside and depth readings EXTERNAL JAWS The disadvantage of a vernier is its accuracy is only O 02mm compared to a micrometer s accuracy of 0 01mm Dial Type Vernier Callipers This design of calliper has an attached dial face reading device which replaces the vernier scale They will measure to the same accuracy as other SORDE l Jaw adjusted verniers The dial gives the advantage of quick by thumb and easy reading The dial is graduated to represent a proportion of the main scale division One complete turn of the pointer around the dial represents a distance of one main division on the main scale NB Verniers which incorporate a digital readout are also manufactured One com
7. witness marks should be placed on adjacent sections prior to dismantling For an electric motor witness marks are best made with a centre punch on both end shields and the frame Typically one mark at the drive end and two marks at the non drive end Polling means that the motor s revolving rotor is rubbing against the stationary stator core On a closely fitted motor polling could be as a result of either worn bearings or a misalignment of the motor s end shields during reassembly Polling is synonymous with a machine which has close fitting parts For many other machines witness marks could simply be a mark from a permanent felt marker drawn across a key joint such that the two pieces can be realigned precisely as before Fine Tolerances Gaps between close fitting parts may need to be adjusted to within tolerance through the use of feeler gauges This tool discussed earlier can accurately measure very small clearance gaps Therefore when disassembling certain types of equipment it may be necessary to measure and record air gaps Temperature Variations Machine parts undergo physical changes due to ambient temperature variations This should be taken into account during reassembly For example a bearing may not fit on to a motor s shaft if the temperature of the shaft to too high The shaft may need to be cooled with compressed air or a refrigerant spray prior to assembly Alter
8. 1 7 Tools equipment and measuring devices needed to carry out the work are obtained and checked for correct operation and safety 1 8 Cutting tools such as drills and chisels are sharpened to suit the material on which they are to be used 2 Dismantle and assemble utilities industry apparatus 2 1 Established OHS risk control measures and procedures for carrying out the work are followed 2 2 Circuits machines plant are checked as being isolated where necessary in strict accordance OHS requirements and procedures 2 3 Appropriate tools are selected and used correctly and 2 4 Manufacturer apparatus dismantling and assembling guides are used where applicable 2 5 Components are marked or tagged during the dismantling to help ensure correct and efficient reassembly 2 6 Dismantled components and parts are stored to protect them against loss or damage 2 Apparatus is dismantled and assembled efficiently without waste of materials and energy and or damage to apparatus and the surrounding environment or services 2 8 Procedures for referring non routine events to immediate supervisor for directions are followed 2 9 Routine quality checks are carried out in accordance with work instructions 2 10 OHS risk control work completion measures and procedures are followed E102A Notes T2 T12 Version 4 BG doc Page 6 of 254 23 January 2014 2 11 Work site is cleaned and made safe in accordance with established procedures 2 12 Work supervisor
9. All hinged joints of tools to ensure that they move freely Any part of a tool where the safety or efficiency has been impaired through use eg Hammer handles Measuring tools such as Tapes and rules verniers and micrometers Inspect O O O O O Clean O Sharpen Grind O O O O O O Lubricate O O Recondition O Calibrate O O Ensure the accuracy of squares and protractors E102A Notes T2 T12 Version 4 BG doc Page 244 of 254 o Tension wrenches to ensure indicators are valid Storage o Ensure that all tools stored will not be damaged by their proximity to other tools and or they will not harm workers when they are retrieved o Ensure all tools which have pointed tips or sharp edges are well guarded when placed in storage o Ensure that before being stored tools are stripped down to their base form le Remove taps from its tap wrench the die from the stock and even the blade from a hack saw etc o Ensure that the jaws of tools are not stored fully closed as this can cause strain and long term damage Discard o All tools that are beyond repair must be discarded to ensure that they are not accidentally used But before disposal render them totally unusable to ensure that they are not salvaged by an unsuspecting person Log o Maintain records for hand tools such as the brand supplier purchase date disposal date and other relevant details etc This data will ensure that future tool purchases are mo
10. Nb It is important to note that the welding of structural support members can only be done by a person suitably trained and certified Advantages gt Equipment is cheap versatile simple and portable gt Can be used indoors or outdoors as it does not use shielding gas FILLET WELD E102A Notes T2 T12 Version 4 BG doc Page 141 of 254 23 January 2014 gt Welds in any position Disadvantages Fumes are prejudicial to health Electrode selection is crucial The weld length is limited by the length of the fixed size electrode Hydroscopic electrodes absorb moisture Need to remove slag immediately after welding Weld quality depends largely on the operator skill VVVVVV Safety MMAW can be a dangerous and unhealthy practice if proper precautions are not taken The open electric arc presents a risk of burns which are prevented by personal protective equipment in the form of heavy leather gloves and long sleeve jackets Additionally the brightness of the weld area can lead to a condition called arc eye in which ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes Welding helmets face mask with dark face plates are worn to prevent this exposure and in recent years helmet models have been produced that feature a face plate that self darkens upon exposure to high amounts of UV light To protect bystanders especially in industrial environments translucent welding curtains shou
11. O 5 10 15 20 25 30 35 40 45 VERNIER SCALE e The main scale divisions are one millimetre long The vernier scale divisions are 0 98 of a millimetre long This means that the Divided into 50 parts Each part vernier scale divisions are 0 02 of a Lat Adena OOB cin millimetre shorter than the main scale 50 divisions METRIC VERNIER SCALES o 1mm 0 98 mm 0 02 mm e From the sketch note that each vernier division is progressively displaced by 0 02 of a millimetre from its corresponding main scale visioni MAIN SCALE NB The key reading is the point where the two scales become aligned Reading a Metric Vernier Read a metric vernier with an accuracy of 0 02mm as follows e Read the main scale to the left of zero of the vernier in millimetres VERNIER SCALE e Now look at the vernier scale l e Note which one of the vernier divisions is opposite a line on the main scale e Each of the lines on the vernier scale represents a division that is 0 02 of a millimetre shorter than those of the main scale Multiply the number of the line on the vernier scale by 0 02 and add the result to the reading of the main scale e The sketch shows the reading on a vernier e There are 37 full divisions on the main scale to the left of the zero This equals 37 millimetres E102A Notes T2 T12 Version 4 BG doc Page 223 of 254 23 January 2014 Note The thirty third line on the vernier scale IS Opposite a line on the main scale
12. SkillsTech Australia Industry s right hand UEENEEE102A Fabricate assemble and dismantle utilities industry components Student Note T2 T12 Bracken Ridge Electrical Version 4 February 2013 Student Name SkillsTech www skillstech tafe qld gov au Queensland AUSTRALIA Government Table of Contents Machine guards cccccssssssssssseeeeeeseeeeeees 17 Work ARC dics tics cacsesumnmansetnncsevesesnedetaneaannasenas 17 Care in the Use of Hand Tools 17 Risk ASSCSSMEM1 cccccccsssseseeseeeeeeeeeeees 18 Materials Used In The Electrotechnology TUG I eee E 18 Planning Process cccccccssssssessssseeeeeeeeees 18 Safe Work Method Statement 19 A r eoaee ome E E E E 20 Measurement cceccsccccceeeesseeeeeeeeeeeeeees 20 SEET RUTO oc ncn paseseatanenouconetenucopceebucoeecemeceeets 24 Ref http www tractorsupply com 25 Rule Depth Gauge sssssosseeeeeessssssssssseee 26 Marking Out Tools c cc ccssseesesseeeeeeeeeees 21 Types of Marking out Lines 00 28 Engineer s Scriber ecciesia 32 Protractor and Bevel Gauges 0666 33 PROM ACIONS ccwnscidsienexctencnanceasencnctssetaaiiineueartone 33 Engineer s Square or Tri Square 34 COMBINATION Sel sesent anaE 35 Date e kc ene mer crn eer e ere are 36 Jenny Ge iit ole eee ee mere ee cere re eee 37 Outside and Inside Callipers
13. Tool Post This is available in many designs and its role is to firmly hold the lathe cutting tool Shown immediately below is a view of the saddle cross slide and tool slide The control wheels are used to accurately position the cutting tool against the work piece The sketch at the bottom is of the tailstock A centre inserted in the tailstock is used to support work material that extends a long distance out from the spindle Tool Post Cross Slide T y Top or Tool Slide Aprori Handwheel Feed Dial Crosetfeed Handwheel Tailstock Centr L acscrew Leatiscrew Ranger Bearing E102A Notes T2 T12 Version 4 BG doc Page 75 of 254 23 January 2014 Basic Operation of a Lathe The material to be machined is held in the chuck three or four jaws and rotated by Chuck the main drive motor which is threaded onto Be the spindle The rotational speed of the chuck is controlled either electronically or on older designs by pulleys or gears Material A specially shaped hardened steel lathe tool is held by the tool post which in mounted on the top slide mechanism The top slide is in turn mounted onto the cross slide which in turn is mounted onto the saddle Tools for a Lathe There are various types of the cutting tools available Three common types are shown to the right a Side tool b Cutting off tool
14. arms until the point is in the center of the shaft 4 Tighten the forcing bolt slowly and carefully onto the shaft Check that the puller is not going to slip off center or off the pulley Readjust the puller if necessary 5 If the forcing bolt and puller jaws remain in the correct position tighten the forcing bolt E102A Notes T2 T12 Version 4 BG doc Page 243 of 254 and pull the part off the shaft Ref http Awww forums woodnet net The image below illustrates a three limb bearing puller being used to remove a bearing from the rotor of an electric motor Care and Maintenance of Hand Tools All tools should be serviced as part of a routine maintenance plan All regulatory requirements for testing and calibration of instruments must be met Summary of hand tool maintenance requirements All tools especially hammer handles for signs of defects Never put a tool back into store or in a toolbox if it requires repair Faulty tools should be tagged or marked so they are not used while faulty The insulation of tools used by electricians eg Pliers and screwdrivers PPE for signs of defects All tools to ensure that dirt and grease is not affecting their effectiveness and safety Scribers and caliper points Chisels and screwdrivers Saw blades where possible Drills The heads of chisels and punches etc for signs of mushrooming Other cutting tools The surfaces of metal tools to ensure that they do not rust
15. cceeeeeeeeeees 64 Torque Wrench Tension Wrench 64 BCCI VIC agru 65 MIO JAWS cere ecenctonthaneqanteananesteateannteancaesceaeae 66 Workshop Equipment c ssssssseeeeeeees 66 Off Hand Grinding cccccceeeeeeeeeeeeeees 67 Pedestal grindetr ccccccceeeceeeeeeeeseeeeeees 68 Bench Grint ica scsisicaseacseccsatcenccddacbeccsandwncs 69 Truing and Dressing a Griding Wheel 70 Hand Tool Maintenance ccccsseeeeeeees 71 Sharpen Centre Punches and Scribers 71 Sharpen Cold Chisels sssseeeeeeeees 72 Engineering Lathe cccccccccceeeeeeeeeeeeees 74 Abrasive Saw cccccccccccccccccccccccccccccceceeees 78 Cold er ee ere ee ee eee 79 Vertical Band Saw ssciesastoacesnatuncoternccuees 81 POW Cl HACKS AW wscccseespstcnct uecasecenntedeetnaastns se 82 eee 84 Drills and Drilling Techniques 84 Twist Drill or Drill Bit 2 0 ee 84 Twist DA Spoed eni 87 Lubricant and Cutting Fluids 88 Sharpening a Twist Drill suitable for Drilling Brass Or PerspeX ccccccssssesseeeeeeeeeaeeneeeees 91 Possible Faults Due to Incorrect Drill SHEL PSNIN Gs ssssjavecsvecahawaressshedvancdvaseecsaveteceabed 91 Countersink Bit cecccccccccceeeeeeeeeeeeeees 92 Preparing Work for Drilling 0000000000000 92 Conte D e 93 Masonty DIM va csncessseveosensieueassactinactenctensesness 93 SPadE Dils sssr Ee EE 94
16. you will have no way of knowing that you are still on course The crossing point is then marked with a centre punch indent The punch mark forms a small seat to locate the drill point thus ensuring accuracy Without the punch mark the drill may have a tendency to wander off its intended location AIT center Punches have before it begins to cut hardened polnts E102A Notes T2 T12 Version 4 BG doc Page 86 of 254 23 January 2014 Twist Drill Speed Select the correct cutting speed and appropriate cutting lubricant The Correct drilling speed is very important as it prevents the drill from over heating As shown in the table below drilling speed criteria is based on the size of the drill and the type of work material Generally larger diameter drills require a lower cutting speed Operating speeds RPM Accessory Softwood Hardwood Acrylic Brass Aluminium Steel Shop Notes wist drill bits Imm 5mm 3000 3000 2500 3000 3000 3000 Lubricate when cutting 6mm 10mm 3000 1500 2000 1200 2500 1000 steel Use centre punch 11mm 16mm 1500 750 1500 750 1500 600 on all holes to prevent drill 17mm 25mm 750 500 NR 400 1000 350 from wandering Holding the Work Piece For safe drilling operation the work piece must be held firmly by some mechanical means such as a machine vice or V block and clamps Be sure to also securely fasten the machine vice or v block to the drill press table Pil
17. Long and loose hair must be times in work areas contained Sturdy footwear must be worn at all times in work areas Rings and jewellery must not be S wom Pre Operational Safety Checks 1 Ensure fixed guards are in place to prevent hands or other parts of the body from entering the trapping space 2 Guards or safety devices must never be removed or adjusted except by an authorized person for maintenance purposes Working parts should be well lubricated and free of rust and dirt The area around the machine must be adequately lit and kept free of materials which might cause slips or trips 5 Be aware of other personnel in the immediate vicinity and ensure the area is clear before using equipment Familiarize yourself with and check all machine operations and controls Ensure cutting table is clear of scrap and tools Faulty equipment must not be used Immediately report suspect machinery Close fitting protective clothing must be worn Gloves must not be worn when using this machine Pp P a i a Safety Checks Do not attempt to cut material beyond the capacity of the machine Never attempt to cut rod strap or wire with this machine Use correct lifting procedures when handling large sheets of material Take extreme care during the initial feeding of the work piece into the machine The work piece should always be held sufficiently far back from the edge being fed into the guillotine Ensure fingers and limb
18. The flat washer is the most A spring or split washer with A star washer with internal common style of washer used internal teeth is used to teeth is used to prevent nuts to prevent nuts and bolts from prevent nuts and bolts from and screws bolts from backing out and to spread the loosening loosening forces over a bigger area A star washer with external A six sided machine nut Also A Nyloc or locking nut teeth is used to prevent nuts referred to as a finished which has a nylon insert and and bolts from loosening Itis hexagonal nut is used to prevent it loosening often used in switchboards to due to vibration ensure a good electrical contact to a metal panel for earthing studs E102A Notes T2 T12 Version 4 BG doc Page 128 of 254 23 January 2014 Castle nuts are similar to An acorn nut with a domed A wing nut is used for hand slotted nuts but with the slots top is used mainly for tightening and for quick in a rounded section above decorative purposes removal by hand the main nut Used to prevent loosening Head Driving Types http Awww jamesglen com au DocPath driving methods amp The drive type on a screw fastener is the feature through which rotational torque is applied All threaded fasteners will have a drive feature or a retention feature to prevent rotation whilst the securing part is rotated Eg nut Machine screws are available in
19. Working over the top of an oiled filled transformer 9 When requiring high torque on a fastener always select a ring spanner rather than an open ended spanner D O cae E102A Notes T2 T12 Version 4 BG doc Page 122 of 254 23 January 2014 Tightening Lock Nuts A locknut is a supplementary nut which is tightened upon the primary nut to prevent it from shaking loose This technique is commonly used in the electrotechnology industry to ensure busbars joints remain firmly connected To tighten a locknut bolting arrangement e First ensure the primary nut Nut B in the illustration is tightened to the required tension e Add the lock nut Nut A in the illustration e Place an open end spanner on the primary nut and it hold firm e Use a second spanner to tighten the lock nut against the primary nut e When tighten to the required tension remove both spanners Jows thrust fully on to nut Care when using Spanners It is important for spanner jaws to fit fully on the nut or bolt head The jaws should also fit centrally on the hexagon flats as shown in the diagram which also shows how a spanner will be damaged as a result of failure to fit it properly onto a nut Damage to both the spanner and nut can be avoided by correctly placing the spanner on the nut before applying any force The handle length of an open ended spanner has been designed to enable a
20. bending as there is no stretch or compression at this point The problem is that the position of the neutral axis difficult to fix as there are many variables The roe neutral axis is located near the centre of the ee Ft metal for a gradual bend and closer to the a FA inside edge for a tight bend The position Aia a N NEUTRAL AXIS of the neutral axis with respect to the 7 MIGRATION material thickness is known as the K ahi rs factor In practice K is between 0 25 and 0 50 The length of the bend measured along the line of the neutral axis is called the bend allowance The cut length of the material becomes the length of the two flat sections plus the bend allowance BEND The Bend Allowance can be calculated from the ALLOWANCE following formula 22 A R KT pa NA 360 Where BA Lengthof bend allowance L A B BA A Angle in deg rees i _ where R Bend radius mm L is the total flat length K Neutral axis offset K Factor A and B are shown in the illustration BA is the bend allowance value T Thickness of material mm E102A Notes T2 T12 Version 4 BG doc Page 210 of 254 23 January 2014 The problem with the theoretical approach is that K and the bend allowance calculation is NOT an exact science and for critical tasks the best method is to always use a trial piece of material in the same bender and then accurately measure t
21. carbon in contact with metals and exposed to moisture creates an electrolytic galvanic reaction leading to corrosion of the metal For this reason black lead pencils should never be used for marking out on metals exposed to the weather When working on site ie on the job marking out will invariably require the use of tools capable of measuring much greater distance without loosing accuracy Tape rulers and a chalked string line can be useful when marking long lines on sheet metal Eg Marking fixing lines on the tops of large switch boards This method leaves a line that is easy to see is easily removed and leaves the sheets undamaged Ref http www cnccookbook com CCMillWayCovers htm miT ey Cm ATD le E 2 7 E102A Notes T2 T12 Version 4 BG doc Page 204 of 254 23 January 2014 Marking Out From a Datum Edge or Datum Line It is difficult to achieve a high level of accuracy when cutting metal from a large sheet To overcome this the piece of metal should be marked out and cut slightly oversize This will allow the metal to be accurately marked to size from a datum edge or datum line A datum edge is a perfectly straight edge to be used as a measurement reference It should run down the Retaisnes full length of the piece of metal and Edge is used to mark out the job A sce second datum line should then be drawn at right angles to this datum edge which can also be used as a side reference All job di
22. is the same as for the trays except that what is right and left on trays is reversed for covers Only the lap on top of covers is required E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 217 of 254 Making Tee Joints lf commercial tees are not available it is relatively simple to make them Note that the end of one tray is made to fit into the side of the other To make such a tee joint gt Vv Vv WV WV Mark the spot where the joint is to be made Measure the width X of the cable tray base Transfer this measurement to the sides of the end of the tray piece that will form the branch Mark off the measurements with a scriber Cut away the sides but leave the base as shown Remove any burrs with a file Slide the tray end under the base of the other tray where the branch is to fit and mark the outline of the branch tray on the side of the other tray Remove the branch tray then halve the distance between the two marks just made and mark this centre with a scribed line Cut through this centre line and along the back of the tray sides to the two lines that mark the outline of the branch t ray Line of joint _ MARKING AND REMOVAL OF SHADED PARTS I HORIZONTAL TEE JOINT Cut MAKING TEE JOINTS Fold down each flap at 90 along the marked lines Remove burrs and sharp edges Slide the branch tray into the gap made in the other tray Clamp drill and rivet the t
23. of the file s teeth The longer the file the further the teeth are apart which means that longer files are coarser than short ones The common grades used are flat smooth flat second cut and flat bastard Note A bastard file is a file whose teeth configuration is rougher than a second cut file and is ideal for quickly removing excess metal on a surface File Shapes Ref http www pferdusa com products 201a 201a15 201a1503P html Hand file The hand file has the same cross sectional dimensions as the flat file shown further below but has a blunt end shape as the flat file has a tapered end Hand files are parallel in width but do taper in thickness to the end They are somewhat thicker than flat files This type is double cut and normally has one safe edge uncut which permits filing one surface without affecting an adjoining one They are used for general filing work PAA RRA aii nih Flat File i d My i Nt ii i i NN Hi WK nh i a Nt iN va it am iti Y Vy NN iJ May Ur Wy Le ca NAR NN WR a a i A n AN W i Tapered in width at the point and slightly tapered in thickness at the point Flat files are double cut on both sides and are single cut on the edges Flat files are general purpose files E102A Notes T2 T12 Version 4 BG doc Page 45 of 254 23 January 2014 Mill File This type has two square e
24. or three jaws in the set that can be used on a puller They are designed to work either externally around a pulley or internally The forcing bolt has a very long very fine vee thread and is directed to the center of the drive shaft When the forcing bolt is rotated with the aid of a spanner its very fine screw action enables the puller to exert great force between the end of the shaft and the object to draw it off the shaft Safety check e Always wear eye protection when using a bearing puller e Make sure that the puller is located correctly on the work piece If the jaws cannot be fitted correctly on the part then select a more appropriate puller e Do not use a puller that does not fit the job Process 1 Examine the puller you have selected for the job Identify the jaws there may be two or three of them and they must fit the part you want to remove The cross arm enables you to adjust the diameter of the jaws The forcing bolt should fit snugly onto the part youre removing Finally select the right size spanner to fit the nut on the end of the forcing bolt 2 Adjust the jaws and cross arms of the puller so that it fits tightly around the part to be removed The arms of the jaws should be pulling against the component at close to right angles 3 Use the appropriate spanner to run the forcing bolt down to touch the shaft Check that the point of the forcing bolt is centered on the shaft If not adjust the jaws and cross
25. run at much higher temperatures They are used in the electrotechnology industry to apply heat shrink tubing to colour code electrical conductors Other uses include rapidly drying paint and in the electronics field to de solder circuit board components Output air temperatures range from 100 950 C with some hotter models running around 760 C Heat guns can have nozzles which deflect the air flow for various purposes Most have a heating element based on electrical resistance and a fan increases and focuses the air flow for convection heating Other devices used for similar purposes include focused infrared heaters Electric Soldering Iron These tools come in many sizes and wattage ratings Some have almost instantaneous heat while others require some time to reach correct temperature Some are temperature controlled Application e Joining electrical conductive wires e _ Soldering small conductors to circuit boards Safety The main soldering iron hazards are receiving personal burns and setting fire to combustible materials Never leave a soldering iron unattended If the iron must be left on for a protracted period to retain heat place a guard around the hot areas to prevent accidents E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Cc MEDIUM LIGHT DUTY TYPES OF ELECTRIC SOLDERING IRONS Page 175 of 254 Portable Power Tool Safety Never use any power tool with the manufacturer s gua
26. storage tank It is essential that all impurities are removed from the compressed air and the pressure controlled if pneumatic tools are to operate efficiently and effectively Points To Remember When Using Compressed Air Compressed air is widely used in engineering to operate pneumatic tools such as torque wrenches drills grinders sanders and other equipment Compressed air is piped around many work areas Australian Standard ASNZ1345_1995 Identification of the contents of pipes conduits and ducts Table 1 sets the colour coding of pipes supplying compressed air as Light Blue E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Air filter Automatic pressure Ps regulator eer f 4 u Compressor SSi Check 3 gt i RY y hos a sie valve NE ET Ly M SE ka a Motor AA JRE Air release NSSE cock TED Safety ANA N xA Pressure gauge valve Storage tank Drain valve COMPRESSED AIR UNIT Y connector Exhaust UY Thread Inlet and thread MAKE SURE TOOLS ARE IN GOOD CONDITION Clamp secure Hose condition ZA Coupling secure Outlet ducts ae clean and clear Pad and disc _ secure INSPECT EQUIPMENT BEFORE USE Page 165 of 254 Safety Air Compressor DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working with a Compressor Safety
27. tags are shown to the right Note that the test date and the date of the next test are both listed TAG PLACED BY DEPARTMENT DATE Note Prior to use always inspect the tool s tag and if the Test Due date has passed then this item MUST NOT be used under any circumstances Any faulty equipment should be tagged with a suitable danger tag and reported to the supervisor E102A Notes T2 T12 Version 4 BG doc Page 181 of 254 23 January 2014 Introduction Sheet Metal work or Metal Fabrication is the working of metal by cutting bending and assembling processes gt Cutting is done by sawing shearing or chiselling all with manual and powered variants torching with handheld torches such as oxy fuel torches or plasma torches and via CNC Computer Numerical Control cutters using a laser mill bits torch or water jet gt Bending is done by hammering manual or powered or via a pan brake press brake or similar tools gt Assembling joining of the pieces is done by welding binding with adhesives riveting threaded fasteners or even yet more bending in the form of a crimped seam Structural steel and sheet metal are the usual starting materials for fabrication along with the welding wire flux and fasteners that will join the cut pieces As with other manufacturing processes both human labour and automation are commonly used Fabrication tasks overlap the various metalw
28. 10 A L N i 23 4 5 7 8 Mutluay laolalta Main Scale 28mm E nny Verner Scale 0 6rninm 0 02mm 0 62 rm Vernier Divisions Total Reading 28 0 0 62 26 62mm NB In this example the vernier scale is graduated from 0 to 10 which means you can use a direct vernier scale reading e Inthe sketch above the number of whole millimetres of the main scale immediately to the left of the vernier scale s 0 point is 28mm e Next the division of the vernier scale which aligns best with a main scale graduation is 62 meaning that the decimal fraction component is 0 62mm e Therefore the full reading is becomes 28mm 0 62mm 28 62mm Using a Vernier Calliper The procedure for using a vernier calliper is as Light direction follows 1 Move the sliding jaw to the approximate position required 2 Lightly tighten the locking screw on the fine adjustment clamp 3 Adjust the sliding jaw by means of the knurled fine adjustment nut until with the instrument square to the work piece the jaws contact the work piece with a sensitive feel 4 Lightly tighten the locking screw on the sliding jaw 5 In general the precautions against strain misuse and faulty storage applying to micrometers given below are also essential for vernier callipers 6 The next task is to determine which division of the vernier scale aligns best with a division on the main scale
29. 119 Open End Spannetr ccseeeeeeeeeees 120 Ring Spanner eeecceecccscssssssessseeseeeeeees 121 Adjustable Spanner 0ssseeeeeeeeees 121 Socket Spanner sescasc sccsssessncenapaontessaanegseadads 122 Tightening Lock Nults ccccceeeeeeeees 123 Reversible Ratchet Spannet 124 Tube Spanner or Box Spannet 124 ee 125 Types of Machine Screws and Nuts 125 Machine Screw Applications 06 126 Common Screw Head Types 0 128 Washers and Nut Types cccceeeeeeees 128 Head Driving Types cccseeeeeeeeeees 129 Machine Screw Threads Types and Sizes 130 ISO Metric Thread Designation 131 Machine Nuts ccccceeeeeeeeeeeeeeeeeeeeeeeeees 131 Various Nut Types c ssssssssseeeeeeeeees 131 Machine Screws and Tapped Holes 132 Nut Inserts 5c car aeereanceat ve setaitanesteonconenmiasraas 132 CASS INU ea inne eeasueien 133 Spring Steel Captive Nuts cceeeeeee 134 Lock mi enpara E 134 Nylon Insert Locknut Nyloc Nut 134 Serrated Flange Locknuts cccccsseeee 135 Washer Applications cccceeeeeeeeees 135 Machine Screw JOints cc cccceeeeeeeeees 136 Selecting Fasteners soscotcsonssdivncdcnasinacdionevriies 137 Metallurgical Bonding Processes 138 W E a A nen rere 138 Manual Metal Arc ceeeeessssseeeeee
30. 3J 1 33 l elimination equipment 1 Elimination of the hazard is the most effective means of hazard control as it involves the physical removal of the hazard Eg If employees are required to work high above the ground the hazard can be eliminated by moving the piece they are working on to ground level to eliminate the need to work at heights 2 Substitution involves removing something that produces a hazard similar to elimination but replacing it with something that does not produce a hazard An example of substitution is replacing an existing chemical cleaner with a less toxic type 3 Engineering controls do not eliminate hazards but rather keep people isolated from hazards Examples are better guards on machines etc 4 Administrative controls are changes to the way people work Examples of administrative controls include procedure changes employee training and installation of signs and warning labels Administrative controls do not remove hazards rather limit or prevent people s exposure to the hazards Eg Completing a task out of hours when all electrical power can be isolated 5 Personal Protective Equipment PPE is the least effective way to control hazards PPE is the method of last resort because of the high potential for the PPE to become ineffective due to damage or aging etc Wear Appropriate PPE Personal Protective Equipment It is essential to safety that you always wear the approp
31. BG doc EEE ame ea Cleaned area covered with silicone Gland plate FIXING A GLAND PLATE Hole diameter T DT Box wall No burrs on Cross section hole edges of seal WEATHERPROOF SEAL Page 251 of 254 system increases its sealing properties radlal spring pressure They are constructed from an elastomer compound and typically have an internal metal radial or garter spring which helps the sealing lip compensate for lip wear and elastomer changes The sealing lip has a point contact with the shaft formed by two angles with the air side angle usually less than the liquid side angle seer alr The garter spring is positioned such that axially the centre line of the spring is biased to the air side of the lip contact point Installation The sealing lip is critical and it should be closely inspected to make sure there are no nicks or tears at any point around its circumference Ensure that the lip is not turned back as a torn or turned lip will quickly fail in service Make sure that the garter spring has not been displaced out of its groove as a result of handling and the seal s outside diameter should be free of damage such as cuts dents or scores If there is any sign of damage then do not use it New seals should be wiped clean prior to installation The shaft surface should be inspected to ensure there are no nicks or burrs which could damage the seal lip Re
32. D and shall have a measured resistance of the protective earth circuit or the protective earthing conductor which does not exceed 2 3 3 2 Testing of insulation Insulation shall be subject to a leakage current test or an insulation resistance test in accordance with Appendix E When an insulation resistance test is performed in accordance with Appendix E the insulation resistance values obtained shall be not less than those specified in Table 2 Partial extract shown below E102A Notes T2 T12 Version 4 BG doc Page 180 of 254 23 January 2014 TABLE 2 Insulation resistance limits l Minimum insulation Insulation test resistance MQ Class Measure between live parts and 10 accessible earthed parts Class II Measure between live parts and any 10 accessible metal parts PRCDs with FE Measure between live parts and the 0 05 functional earthing conductor Cord extension sets cord Measure between live parts and the 10 sets EPODs and PRCDs protective earthing conductor Ref http www haineselectrical com au Summary The testing requirements for equipment to be used on a construction site in terms of frequency of tests must be in accordance with ASNZ3012_ 2010 as this standard is directly referenced in the Queensland Electrical Safety Regulation 2013 NOLLNW3 ASNZ3012_ 2010 in tun directly Auco ne p gt SERVICE references standard ASNZ3760 for electrical specifications for the tests DO NOT OPERATE Sample
33. Notes T2 T12 Version 4 BG doc Page 147 of 254 23 January 2014 Potential Hazards e Electric shock Fumes Radiation burns to eyes or body Flying sparks Fire Don t J e e Body burns due to hot or molten materials J J gt Do not use faulty equipment Immediately report suspect equipment gt Never leave the welder running unattended This SOP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references It is designed as a guide to be used to compliment training and as a reminder to users prior to equipment use Spot Welding Resistance Welding Spot welding is a resistance welding method used to join overlapping metal sheets Spot welding involves work pieces being clamped together under pressure exerted by two heavy copper alloy electrodes The electrodes concentrate high welding current into a small spot while simultaneously holding the sheets together at the point of the weld A large current is then passed through the spot thereby melting the contact metal area and forming the weld As current is passed from one electrode to the other metal clamped between them acts as a low value resistor This causes a build up of heat that melts the two pieces of metal thus welding them together It is also known as resistance spot welding because the amount of heat delivered to the spot is directly related to the r
34. The head is held onto the handle by a metal wedge driven into the end of the handle after the head has been fitted The head of the hammer has both its face and pein end hardened and tempered Hold the hammer handle near its end Do not choke the hammer by placing your hand near the head as the face will be at the wrong angle to the work surface It will allow you to apply more force Safety A moving hammer can concentrate a large amount of kinetic energy into a small area where it can splinter material on impact and cause chips to fly off dangerously Always wear goggles when hammering if there is a possibility of chips flying Selecting the Correct Hammer Hammering varies from light tapping to hard striking The heads of hammers can be swung with significant force As it strikes an object it changes the position or the shape of that object E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Head in section HEAD WEDGED ON HANDLE Make sure all is clear behind Use safety goggles when chipping USE SAFE WORKING PRACTICES Page 115 of 254 When a hammer is being selected the mass of its head is as much a factor as the work piece Light hammers are easy to control but are not suitable for applying heavy blows Likewise heavy hammers are tiring to use and it is difficult to strike light accurate blows with them Handle Characteristics e Length and shape of
35. and with adequate protection Australian Standards set the guidelines ASNZ1788 1_ 1987 Abrasive wheels Design construction and safeguarding ASNZ1788 2_ 1987 Abrasive wheels Selection care and use To safeguard the operator always adhere to the following precautions e Always handle and store the wheels correctly e Acompetent person should be assigned to the care inspection and mounting of grinding wheels e Before mounting check all wheels for possible damage in transit e Check maximum operating speed established for the wheel against machine s speed e Check the mounting flanges are at least one third the diameter of the wheel and relieved around the hole E102A Notes T2 T12 Version 4 BG doc Page 67 of 254 23 January 2014 e Use the mounting blotters supplied with the wheels NB A blotter is a paper ring that helps buffer mounting pressures between the wheel and the flange e Ensure that the work rest is correctly adjusted On off hand grinding machines work rests must be kept within 2mm of the wheel face e Always use a guard covering at least one half of the grinding wheel e Allow newly mounted grinding wheels to run at operating speed with the guard in place for at least one minute before commencing grinding e When first turned on always stand to one side of the machine and not directly in front of it in case the wheel shatters e Always wear safety goggles or an approved type of eye protectio
36. are almost unnoticeable E102A Notes T2 T12 Version 4 BG doc Page 137 of 254 23 January 2014 If possible do not bring dissimilar meals in direct contact When this is not practical materials should be selected that will not create high levels of corrosion through electrolysis le Select materials that are close to each other on the Noble Scale Metallurgical Bonding Processes The metallurgical attachment of one metal to another can be accomplished three basic ways 1 Welding 2 Brazing and 3 Soldering The most significant difference between these methods is the process temperature Welding Welding is a process in which the base metal is melted during the joining process and the molten parts flow together and when allowed to cool they solidify to form a permanent bond The process typically involves the bonding high melting temperature metals such as steel to steel The process can be performed with or without the addition of a filler metal If a filler metal is used then it should have metallurgical properties that match the properties of the adjoining materials The welding process requires very high heat which can be provided by an AC or DC arc welder or an oxygen acetylene gas torch Common types of welding processes include MMAW Manual Metal Arc Welding Was called Stick Welding MIG Metal Inert Gas welding also called GMAW Gas Metal Arc Welding TIG Tungsten Inert Gas welding also called GTAW Gas Tun
37. as for digital images sketch any aspect which will assist with correct assembly Create witness or alignment marks with a felt tip pen in positions where they will not show on the final assembled product Label each wire that is to be removed if it is possible to swap them during reassembly Group fixing screws from each area under a piece of adhesive tape to ensure that they are returned to the precise locations from where they originated If the machine is slot mounted which could give a slight variation to the position trace feet outlines or witness mark it to ensure that it is returned to its original position Record DOR direction of rotation prior to removal If mounting bolts may have been tensioned and machine documentation is not available record each bolt s tension as it is removed Measure and record the precise position of any fans pulleys on motor shafts Storing Parts during Disassembly 1 2 Store all parts in suitable containers so that they are not lost or damaged Parts should NEVER be left on the floor or loose on a work bench The fragility and cost of each component will dictate the security level of its storage If possible attempt to stack the parts in an order which will expedite the reassembly E102A Notes T2 T12 Version 4 BG doc Page 249 of 254 process 3 Store fixing screws with their own part 4 Serviceable bearings should be stored such that they are not affected by dirt etc If they ar
38. be used in conjunction with other references It is designed as a guide to be used to compliment training and as a reminder to users prior to equipment use Ref http bolty net wp content uploads 20 10 11 solder_1 jpg E102A Notes T2 T12 Version 4 BG doc Page 161 of 254 23 January 2014 Portable Power Tools Portable power equipment is essential to the electrotechnology industry both within the workshop and in the field This section deals with the most commonly used portable electric hand tools e Pistol drill e Jigsaw e Hammer drill e Sabre saw e Angle grinder e Circular saw e Disc sander e Hand shear e Straight grinder e Nibbler e Vertical grinder e Heat gun e Die Grinder Portable power tools can be operated using three types of power sources e Electrically mains operated via a power lead e Battery operated e Pneumatically air operated NB Not every type of portable power tool is available in all three power modes Portable Tool Safety Safety when using power tools is very important Always Keep the work area clean When not in use store tools in dry high or locked places e Use the right tool Do not force a small tool to do the job of a heavy duty tool It will do the job better and more safely at the rate for which it was designed e Wear protective clothing Loose clothing or jewellery will get caught in moving parts Rubber gloves and footwear are recommended for outdoor work e Yo
39. c Insulated screwdrivers Rated to 1000v are used by electricians as their blades are sheathed in insulation to avoid contact with live parts Selecting the Correct Size Screwdriver Tip Various widths of tip are available and each width is available in different length blades Thickness of a tip typically varies in proportion to the length of the blade Width of Tip It is important to always select the size of tip carefully The width of the tip should almost equal the length of the bottom of the slot e Too wide a tip could damage the work Insulated handle Handles shaped for grip m Length of blade or shank Width of tip Insulated handle Insulating sheath Farallel tip LIGHT DUTY SCREWDRIVER e Tips that are too narrow exert their turning force too close to the screw axis Check that the blade axis is lined up with the screw axis The wrong alignment causes turning pressure to damage the tip and the screw rather than turn the screw E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 110 of 254 Thickness of the Tip It is important to always select the size of tip carefully The width of the tip should almost equal the length of the bottom of the slot Correct width e Too wide a tip could damage the work e Tips that are too narrow exert their turning force YY too close to the screw axis Check that the blade UMMA WC axis is lined up with the sc
40. compromised and the continued use of the tool will result in faulty work Tape Rule or Tape Measure A measuring tape consists of a flexible blade of i i a 2 White or yellow steel housed in a metal or plastic case flexible 9 blade Long Tape This instrument is used to measure very long Hard plastic or stainless steel casing lengths typically up to30m but longer designs up THE LONG STEEL TAPE to 50m are available An application could be measuring the route length for a conduit or cable duct run an 6 7 8 of 4 2 34 56 7 8 9k The flexible tape may be made of either nylon coated steel or fibre glass The measuring tape is returned into the case by operating a turning mechanism with a handle as shown to the right On some designs the handle can be folded away when not in use An example is shown to the right laa bin mulelialaaul al im Ref http Awww surveyequipment com Steel Tape This tape is used to measure shorter lengths up to about 8 to 10 metre lengths Tape rules have a power return spring which automatically returns the tape blade into the housing Do not allow the tape to return in an uncontrolled fashion as the tip hook will break off A lock button is usually included to secure the blade in the open position as well as slow its return into the case Lock button Danger Because steel is an excellent conductor of Scale Retaining electricity NEVER use a steel tape in close screw pr
41. convenient height for the person marking out They are constructed from either heavy cast iron or granite which is then machined and ground perfectly flat The table should be located so that there is adequate lighting and freedom from obstructions from all sides The marking off table is used in conjunction with specialized marking out equipment such as an angle plate vee blocks or a scribing block to perform precision fitting work Care e The table s surface is to be used for precision work only and you should never use it for hammering or welding or any rough work etc e Replace the protective cover over the table when it is not in use e Always protect the surface of a metal table against rust machined square Angle Plates The working surface of angle plates are machined at right angles to their adjacent surfaces in order that work pieces may be held at right angles to the surface of a marking off table Cast iron is the most likely material from which angle plates are made Clamps To allow the marking out process to take place without any movement clamps can be used to secure work to the angle plate Light work may be clamped by using toolmaker s clamps The size of the work piece determines whether to use one or more clamps Only light clamping forces are normally required Nb Magnetic clamps are also available for this task E102A Notes T2 T12 Version 4 BG doc Page 39 of 25
42. cramp them with locking pliers G cramps or similar Drill holes for fasteners at a suitable spacing Remove cramps clean up swarf from drilling E102A Notes T2 T12 Version 4 BG doc Page 206 of 254 23 January 2014 lf water proofing is required for a joint apply a continuous narrow bead of sealant over the centre line of the drill holes Re form the lap then insert the fasteners Apply additional sealant to fasteners to seal them Wipe off excess sealant squeezed from the joint Pop rivet Riveter a Sealant bead Rivet sealed e Excess sealant a its vD Joints by Soldering Soldering can be used to join some sheet metals Solder is an alloy that can be melted E and then it solidifies after cooling thereby L a bonding the two materials together For effective jointing the solder must have a melting Direction of run point lower than the materials to be joined Sometimes the joints to be soldered should be a Pe a fastened with rivets prior to sealing with the Ly solder eee face flat on seam Soldering cannot be used to join all sheet metal e types The common materials that can be soldered include zinc galvanised steel zinc sheet as well as copper and brass sheets Joints in materials such as Zincalume Colorbond and aluminium must be screwed riveted or joined with a sealant such as silicone When soldering sheet metal the preferred type of solder is 50 50 It is an alloy conta
43. diagrams Application of the Unit Not Applicable Licensing Regulatory Information 1 2 License to practice During Training Competency development activities are subject to regulations directly related to licencing occupational health and safety and where applicable contracts of training such as apprenticeships In the workplace The application of the skills and knowledge described in this unit require a license to practice in the workplace where work Is carried out on electrical equipment or installations which are designed to operate at voltages greater than 50 V a c or 120 V d c Other conditions may apply under State and Territory legislative and regulatory requirements Pre Requisites Prerequisite Unit s 2 2 1 Competencies Granting competency in this unit shall be made only after competency in the following unit s has have been confirmed UEENEEE101A Apply Occupational Health and Safety regulations codes and practices in the workplace 2 2 Further Information For the full prerequisite chain details for this unit please refer to Table 2 in Volume 1 Part 2 Employability Skills Information Employability Skills 3 This unit contains Employability Skills The required outcomes described in this unit of competency contain applicable facets of Employability Skills The Employability Skills Summary of the qualification in which this unit of competency is packaged will assist in identifying Employability Skill requi
44. edge of the material Draw the gauge along the edge to scribe a parallel line These are both precision measuring tools typically used for fitting type applications They are used in one of two ways e The calliper ends are preset to a definite measurement using a steel ruler as reference and then the calliper is compared to the work surface or e The calliper is set to the spacing of the work surfaces and then compared to the graduations on the ruler Use To adjust a calliper to a scale dimension first one leg of the calliper should be held firmly against one end of the ruler and the other leg adjusted to the desired dimension To adjust a calliper to the work open the legs wider than the work spacing and then bring them down to the work very gently Caution Never place a calliper on work that is revolving in a machine such as a lathe Marking Out Equipment The following basic equipment is used for marking out The marking off table Angle plates Clamps Vee blocks Parallel strips Marking medium Care Always keep these tools well oiled to prevent rust build up and protect the needle point against damage E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 38 of 254 Engraved setting Flat out lines machined Marking Off Table The function of the table is to provide an accurate flat surface that becomes a datum surface with respect to the work piece It also supports the work at a
45. foot pedal The folding beam is the front gate like cast plate of the tool and is hinged It is controlled by a handle which is lifted to force roll the sheet around the edge of the fingers to form the bend The bends can be to any angle up to a practical limit of about 120 degrees E102A Notes T2 T12 Version 4 BG doc Page 196 of 254 23 January 2014 Folding A metal bending machine can be used to form bends or folds in sheet metal It consists of two jaws to clamp the sheet metal in place and a hand operated bending leaf To use the bending machine Clamp the metal in place with the fold line aligned with the outer edge of the top jaw Lift the bending wind leaf up until the desired angle of fold is achieved Lower the bending leaf to its starting position Release the jaws and remove the metal Check angle VVV WV Ref http toolboxes flexiblelearning net au demosites series12 12 04 toolbox1204 re sources 03workshop 10sheet_metal 05folding htm E102A Notes T2 T12 Version 4 BG doc Page 197 of 254 23 January 2014 Adjusting the Bend Radius on a Pan Brake Folder The bend radius of the folded edge is controlled by lowering or raising the bending wing in relation to the top of the clamp bar If the radius is too tight it will crush the metal and possibly weaken it The cross section view of the bar folder illustrated below left side shows the wing raised to produce a very sharp fold and o
46. glasses must be worn at all Long and loose hair must be times in work areas a contained Appropriate footwear with Close fitting protective clothing must substantial uppers must be worn be worn Rings and jewellery must not be Ensure all flammable materials are worn safely stored DGO Pre Operational Safety Checks e Ensure no slip trip hazards are present in workspaces and walkways Locate the compressor in a suitable location for safe operation Lock the wheels on the base of the compressor to prevent movement Check that all fittings and connections are in good condition prior to starting Check all fittings are securely connected prior to being pressurised Faulty equipment must not be used Immediately report suspect machinery Locate and ensure you are familiar with the operation of the ON OFF starter ae Safety Checks Start the compressor noting pressure increase and cut out cut in pressure e Listen for any air leaks from any flexible airlines and immediately report if any leaks are observed e Adjust pressure regulator to suit work requirements e Check the compressor at regular intervals Ending Operations and Cleaning Up e Switch off machine e Leave the machine hose and work area in a safe clean and tidy state Potential Hazards x Unsecured hoses whipping under pressure x Compressed air is very dangerous when used for anything but the correct purpose Pressures of 690 kilopascals kPa or more are quite c
47. grease oil and any flammable materials Ensure gas hoses are in good condition and do not create a tripping hazard Before lighting up check all equipment for damage Check that the area is well ventilated Start the fume extraction unit before beginning to weld Ensure the unit is fitted with working flashback arresters e Ensure work return earth cables make firm contact to provide a good electrical connection Pressure Setting e Check that the oxygen and acetylene regulator adjusting knobs are loose e Check that both blowpipe valves are closed e Slowly open the cylinder valves on each cylinder for half a turn only e Screw in the regulator adjusting knobs slowly until the delivery pressure gauges register 70kPa e Purge and check for constant oxygen gas flow o Open the oxygen blowpipe valve for 2 seconds and check the delivery gauge o If necessary re adjust the oxygen regulator to achieve a 7OkPa pressure o Close the oxygen blowpipe valve e Purge and check for constant acetylene gas flow o Open the acetylene blowpipe valve for 2 seconds and check the delivery gauge o If necessary re adjust the acetylene regulator to achieve a 7OkPa pressure o Close the acetylene blowpipe valve Lighting Up e Open the acetylene blowpipe valve slightly and light the blowpipe with a flint lighter e Continue to slowly open the acetylene valve until the flame no longer produces soot e Slowly open the oxygen blowpipe valve until a neutral f
48. gt Helps ensure the safety of workers and equipment gt Ensures that quality assurance requirements will be met gt Ensures that the type of tools and equipment needed to complete the tasks are identified and are available gt Ensures that the types of personal protective equipment needed for safe working are identified Task Scheduling Time management and the amount of materials required for the job are key elements of the planning process The practical difficulties of estimating times are considerable The important point to consider is that the time allocated to each activity should be realistic rather than desirable In practice the estimation of times for each activity for a small job or a large project is derived from a person or persons with previous experience in performing or managing similar tasks Alternatively the duration of particular activities may be extracted from records concerning similar tasks carried out in the past Each individual task must be allocated an appropriate amount of time suitable equipment and materials required and a work method statement and risk analysis Safe Work Method Statement Work method statements detail how each work related activity can be carried out safely They are required for all work related tasks from the most basic task such as using an electric drill to a more difficult task such as the use of a lathe Besides the process they also detail the Personal Protective Equipment
49. has two wings that when compressed allow the cage to be inserted into a standard square hole in the equipment rack When the wings are released they hold the nut in position behind the hole There is a small amount of movement to enable hole alignment Using cage nuts mounted in square holes provides several benefits over threaded holes directly in the cage First one has the flexibility to choose the size of nuts and bolts at a time after the cage is installed They are easily replaceable In contrast to a pre threaded cage where if the threads are stripped it becomes more difficult to make use of the hole A A RAR The nut is usually slightly loose in the cage to allow for minor adjustments in alignment The gap between the two wings determines thickness of material that will hold nut in correct position without pulling it from the base material The size of square hole will also govern the position of nut If size of hole is too large it will still pull out from base material E102A Notes T2 T12 Version 4 BG doc Page 133 of 254 23 January 2014 Spring Steel Captive Nuts http export rsdelivers com product rs r0504 525 082 znpt spring steel captive nut m4 0525082 aspx Captive nuts are manufactured from spring steel and are used for inaccessible areas where the securing nut is positioned close to a finished edge ie lt 25mm First a clearance hole for the screw is drilled or stamped in the sheet ba
50. insert The insert is placed at the outer end of the nut and the insert s inner diameter is slightly smaller than the major diameter of the screw The insert deforms elastically over the thread of the screw The thread is not cut into the nylon The nylon insert locks the nut in two ways First it forces the bottom face of the screw threads against the top face of the nut threads increasing the friction between the two to prevent loosening Second the nylon applies a compressive force against the screw itself It is used in applications where vibration can cause loosening E102A Notes T2 T12 Version 4 BG doc Page 134 of 254 23 January 2014 Serrated Flange Locknuts http www apexfasteners com fasteners nuts locking nuts Fine thread serrated hex flange lock nuts have a built in washer with serrations on the bearing or mating surface The angled serrations help to prevent the nut from loosening and will resist severe vibrations The large flange has the added advantage of covering up oversized and messy drill holes Serrated flange nuts actually require more torque to loosen the nut than is needed to tighten Washers A washer is a thin plate typically disk shaped with a hole typically in the middle that is normally used to distribute the load ii of a threaded fastener such as a screw or nut Other uses are as a spacer spring Belleville washer wave washer wear pad preload indicating device locking device and to reduce vi
51. is 0 5mm x K Sight up in line with each edge of the work in turn To achieve reading accuracy and reduce parallax error when reading this tool always align the eye carefully with the point or edge of the work piece where the measurement is being taken POSITIONING THE RULE and then look closely at the rule graduations Positioning the Rule e Correct use of steel rules is necessary for accurate reading Proceed as follows e Place yourself and the article to be measured in the best reading light e Position the rule at right angles to your line of sight e Make certain the rule that you use has fine clear graduations cut right to the edge E102A Notes T2 T12 Version 4 BG doc Page 24 of 254 23 January 2014 Edge of Rule Method If the steel rule is worn on the end then the following method is suggested e Steady the work with your left hand e Hold the rule with your right hand and steady it with your right thumb against the work e Place the end of the rule on the surface so that the face of the rule is at right angles to the work e Place the edge of the rule on the surface so that the face of the rule is at right angles to the work and square across it e Sight up the first numbered graduation with the left hand edge of the work e Sight up the nearest graduation in line with the right hand edge of the work and take the reading NB Remember to subtract the first number graduation from you
52. le We have taken a guess which is imprecise An engineering tolerance is the predefined permissible limit s of variation in a physical dimension etc eg The tolerance of a job may be given as 1mm which means 1mm more or 1mm less than the originally set value It is the client or the nature of the task which defines the tolerance to which you are to work For example if you are required to fit a bearing to the shaft of an electric motor then the tolerance may be stated as 0 01mm The accuracy of measuring equipment defines its ability to take an exact reading The degree of closeness of the measurement to the quantity s actual or true value reflects the accuracy it can achieve The bigger the difference the more inaccurate it is The accuracy of measuring equipment is determined by the smallest unit available to it Eg The accuracy of a standard engineering ruler is 0 5mm or 0 1mm a vernier O 02mm and a micrometer 0 01mm Measuring Tools The process of measuring is one of aligning an unknown physical quantity the work piece against a known standard ie the measuring tool and gauging the size The graduated measuring instruments typically used by a tradesperson are a tape and steel rule and depth gauges High precision measuring tools such a vernier and micrometer are covered in a later topic Care of Measuring
53. learning assessment environment Note Where simulation is considered a suitable strategy for assessment conditions for assessment must be authentic and as far as possible reproduce and replicate the workplace and be consistent with the approved industry simulation policy The resources used for assessment should reflect current industry practices in relation to dismantling assembling and fabricating utilities industry components Method of assessment 9 4 This unit shall be assessed by methods given in Volume 1 Part 3 Assessment Guidelines Note Competent performance with inherent safe working practices is expected in the Industry to which this unit applies This requires that the specified essential knowledge and associated skills are assessed in a structured environment which is primarily intended for learning assessment and incorporates all necessary equipment and facilities for learners to develop and demonstrate the essential knowledge and skills described in this unit Concurrent assessment and relationship with other units 9 5 For optimisation of training and assessment effort competency development in this unit may be arranged concurrently with unit Range Statement RANGE STATEMENT 8 This relates to the unit as a whole providing the range of contexts and conditions to which the performance criteria apply It allows for different work environments and situations that will affect performance This unit shall be demons
54. masonry etc It can be used in situations where a masonry drill is not available Turn 30 every hit E102A Notes T2 T12 Version 4 BG doc Page 60 of 254 23 January 2014 Chisel Safety Precautions e Always wear safety glasses Grind off e Never chip towards yourself and protect others with screens e Do not use a chisel that has a crack ora flaw e Check that the hammer is in good condition HH e Make sure your hands the chisel and GEROUS hammer are clean and dry and free from CONDITION grease e Watch the cutting edge of the chisel not its head when hammering e Make sure that the size of the chisel and its ___ Blade cutting angle is correct for the job Rivet or bolt e Never use a chisel with a mushroomed pee head as it can easily chip and splinter and __ Stops become a hazard The mushroomed O Benia section should be ground back using a bench grinder to an approximate shape as i shown to the right Tin Snips This tool is used for cutting light gauge materials A such as sheet metal They are typically used in the electrotechnology industry for installing cable tray J and metal duct Tin snips will cut slightly heavier gauges of soft metals such as aluminium alloys or copper sheet Cutting line The linkage of compound action type tin snips increases the mechanical advantage without increasing the length of the snips Tin snips are made with either straight univers
55. may have EXTRA DEEP e Six 6 points and be a normal TYPE hexagonal shape This is known as a single hex socket e Twelve 12 points and be a double hexagonal shape This is known as a double hex socket e Sockets typically have a square drive hole at the other end IMPACT TIPE SOCKETS NB Common socket spanner accessories include a Speed brace Extension bar Universal joint Handles Adjustable offset handle L bar handle Sliding tee handle Correctly using a spanner 1 The spanner must be the correct size for the nut or bolt head If it is a loose fit it may round off the corners of the nut or bolt head 2 Do not use a metric spanner on an imperial B bolt or vice versa 3 If possible always pull the spanner towards your body This way you are far more balanced then when pushing away Pulling the spanner GSN will also reduce the likelihood of the nut ar suddenly cracking open and injuring your eee ie knuckles z 4 If pushing the spanner is required then use the heel of your palm to avoid hurting your a knuckles t Never use a spanner on moving machinery Do not hammer on to a spanner or extend the handle for additional leverage Use a larger design of spanner The spanner must be in good condition with no cracks or worn jaws If you are working in an area where the spanner could be dropped into a hazardous position then use a wrist strap to secure it ie
56. of risk put control measures in place to reduce the risk level The risk level is determined by the consequences if it does occur and the probability that it will occur A safe work plan means listing all of the control measures needed to either eliminate the identified hazards or at least reduce the risk to an acceptable level Note Workshop and tool safety is such an important topic some of the points discussed above will be reinforced in each of the topic areas Materials Used In The Electrotechnology Industry Materials used in the electrotechnology industry can be grouped under three main categories gt Electrical conductors gt Electrical insulators gt Equipment construction and support Electrical Conductors Most conductors are metals because they have a relatively low resistance to current flow While silver and gold are the best conductors their high cost makes them unsuitable for most practical applications Copper aluminium and brass are the most commonly used materials due to their good conductivity and cost Copper and aluminium are used for both general circuit conductors and for large capacity busbars Brass is used for its hardness when is used for neutral and earth links in switch boards Electrical Insulators There are many insulating materials available that can be used as electrical insulators Electrical insulation is used in an electrical system to prevent unwanted flow of electric current to the e
57. of the tool along the edge of the work piece to form a small bevel and make the edge smooth This model works equally well for curved surfaces File Safety e Always wear eye protection when filing e Never use a file unless it is equipped with a tight fitting handle A file without a handle could result in the tang being driven into your hand The file handle also will also give you better control and a more accurate cut e Never use a file with a loose handle as it may come off while in use e Never use a file as a lever or hammer The hardened steel is very brittle and will snap and this could cause personal injury E102A Notes T2 T12 Version 4 BG doc Page 50 of 254 23 January 2014 Handsaws There are a number of different types of hand saws used in the electrotechnology industry Listed below are the more common ones Hacksaw The basic hacksaw is used to hand cut most solid materials including metals and other dense non metallic materials Eg Plastics and Perspex They are not effective when used to cut timber ADJUSTABLE A hacksaw consists of a flexible hardened steel blade and an adjustable frame with the blade held under tension Wooden Saw blades are made of carbon steel or high speed So os handle molybdenum more expensive The teeth of the ee saw are hardened while the back of the blade is just annealed HINGED FRAME i Parts of a hacksaw Most hacksaws have an adjustable frame so it may Pist
58. on centre wandered the fault can be corrected by chipping a groove on prick punch the 4 the side towards the erecting pornta direction the drill has chip a groove with a Hell lad re be ly to move with a round round nose chisel prick punch marks will nose chisel or even a be half visible centre punch can be used The cutting force can now push the drill over into the groove and back on centre It may be necessary to repeat this procedure several times A ame Bene Steet Parea al EPa This correction procedure should be started when the drill has entered about half way down the point It must be finished before the body of the drill enters the work piece because once the drill is cutting to its full diameter it s not possible to make any further corrections Masonry Drill These drills have a cutting tip of tungsten carbide that allows them to drill all forms of masonry materials They are designed for use with a drilling machine equipped with a rotary impact hammer drilling action Applications e Drilling ceramic tiles to secure a socket outlet e Drilling brickwork for plugs to secure an outside light fitting weatherproof switch etc e Drilling concrete to secure motors or other machines Tungsten carbide tip teed pe a ee oN ee et ia te 3 i Oa a Soo ta Se Leta ents hoa ee jeg ha PR aed ie ta erat My ie ail pe Be th ca ISSO sss MGS Shee NON aU coal ea a Note Do not use drills in the impac
59. or the coating is too thick or too conductive then the molten area may extend to the exterior of the work pieces escaping the containment force of the electrodes This burst of molten metal is called expulsion and when this occurs the metal will be thinner and have less strength than a weld with no expulsion The common method of checking a weld s quality is a peel test Safety Spot Welder DO NOT use this machine unless you have been instructed in its safe use and operation and have been given permission Personal Protective Equipment Safety glasses must be Long and loose hair Leather gloves must worn at all times in work must be contained be worn when areas handling hot metal Sturdy footwear must Close fitting protective Rings and jewellery be worn at all times in LF clothing must be worn must not be worn work areas Pre Operational Safety Checks Check workspaces and walkways to ensure no slip trip hazards are present Check switchgear and cable are in sound condition Check electrode points are in good condition and meet exactly Ensure electrodes are securely mounted and clean from contaminants Set pressure on clamps to hold work securely without damaging work Preset weld time under your supervisor s direction if timer fitted Use gloves to position and hold work Operational Safety Checks e Ensure the spot welder has cooled before making any adjustments e Avoid prolonged use as this can cause heat
60. perform a task that it was not designed for eg A circular saw with timber rip cut blade must NOT be used to cut masonry products Special brick cutting blades are manufactured to fit circular saws The two saw blades below are both designed to fit a circular saw but the products differs significantly The saw blade below is suitable for cutting The saw blade below is suitable for cutting Wood Engineered Wood Products Ceramic Bricks Pipes Floor amp Wall Tiles Hardboard Chipboard Particle Board Terracotta Roof Tiles Clay and Mud Plywood Softwoods Hardwoods Picture Products Concrete Blocks Bricks Frames Timber Planks and Weather Board Pavement Pavers Pipes E102A Notes T2 T12 Version 4 BG doc Page 164 of 254 23 January 2014 Pneumatic Power Tools A pneumatic tool is one operated by compressed air This makes safer than electrically powered in many applications ie Damp Each tool is somewhat lighter than the equivalent powered by an electric motor Unlike an electrically powered tool they are not damaged when stalled Air compressor An air compressor is a machine that pumps and stores air at a pressure which is high enough to operate pneumatic tools and equipment Most compressors are fitted with a regulator to control the correct pressure in the storage tank a filter to remove impurities from the air and a drain valve to remove water that has condensed inside the
61. safety glasses must be worn E102A Notes T2 T12 Version 4 BG doc Page 59 of 254 23 January 2014 Wood Chisels These are designed to cut timber or other soft materials These are made in a variety of types and sizes They have either a wood or plastic handle plastic being the more suitable material for use with a steel hammer The blade has parallel sides and tapers in thickness Blade widths from 6mm to 50mm are available Some uses include e Cutting recesses for architrave dimmer switches e Cutting recesses in skirting for socket outlets etc e Cutting rebates in studs or noggings to accommodate cables Safety Precautions for Wood Chisels e _ Replace cracked or split handles e Never use a wood chisel as a lever e _ Make sure the work is braced or supported e _ Never place your hand where it could be cut if the chisel slipped Always cut away from your person e Use a sheath to protect the tip while it is being stored Bolster Chisel A brick layers bolster chisel is designed to cut masonry bricks in two It is commonly used in conjunction with a lump hammer It has a blade 65mm wide Star Drill Classified as a chisel because of its impact cutting action when struck with a hammer the star drill finds its main use in cutting round holes in concrete or brick work Brackets supporting switchboards motors and cable tray can be secured to fixing devices that have been inserted into the concrete or
62. sheet metal less than 1 6 mm thick A selection of these joints is shown Of these the wy following are the most cee n ER IE Inside lock or widely used are Knocked up bottom joint Knocked up side seam Cashbox seam wd r Slip joint gt The grooved seam gt The paned down joint gt The knocked up joint Job Inspection gt Finished joints need to be cleaned and inspected to ensure that the materials are correctly aligned and sealed gt When inspecting completed joints check that all laps have been completely closed by the joining method When using fasteners like rivets or screws check the spacing between fasteners to ensure that they meet the job specifications gt Check the sealant in the joint to ensure that it has completely sealed any gaps and that leaks will not occur Check all open style rivets to make sure that the sealant has been applied in a way that ensures that they will be watertight if necessary gt When checking soldered joints ensure that all areas of the joint have been effectively sealed and that rivets have been sealed with solder Check that all traces of flux have been removed gt If joints are meant to be watertight it is normal to expose them to water and check for leaks Inspections should be done carefully as leaking installations will require repairs later on This is both expensive and embarrassing gt lf faults are discovered during inspections use appropri
63. then the underlying steel will be exposed to the environment and the sheet will rust very quickly E102A Notes T2 T12 Version 4 BG doc Page 183 of 254 23 January 2014 Galvanized metal can be bent without the zinc peeling away Also it solders well but welding is complicated by the fact that the zinc gives off toxic fumes and a residue which makes the weld more difficult In addition welding destroys the coating on the sheet and for this reason it is rarely used where welding applications are required Because of the zinc coating galvanized sheets will measure slightly thicker than uncoated sheets The difference is so slight that the gauge numbers for the sheet remain the same as for the solid sheets Electrical cable tray and cable duct are generally constructed of galvanized steel Zincalume Trademark BlueScope This is steel sheeting protected against corrosion by an aluminium zinc coating Typical uses include electrical appliances white goods switchboards etc Zincalume sheets are often painted using a special process in which the painted finish is baked onto the surface This is commonly known by the trade name Colorbond Many colours are available Solid Sheet Metal Un coated Stainless steel The term Stainless Steel refers to a general class of metals rather than to one particular type and there are a number of different types of stainless steels available Each type is designed to meet a particular need
64. to the thimble e Endeavour to develop a light constant feel e Do not put a micrometer down ina position where it could be knocked or dropped e Replace any attachments such as extension rods in their box immediately after they have been used e Do not attempt to make adjustments to micrometers unless you have been trained to do this e Have micrometers checked regularly over their range of size e When you have finished using the micrometer it must be wiped clean oiled with suitable protective oil and stored in a protective box Clean and replace micrometer and extensions immediately after use Maintenance and Storage Measuring Tools All measuring tools should be cleaned free of dust and grit after use If damp they should be dried with a clean rag and the blade returned into the case passing through an oil saturated cloth This equipment should be carefully stored in a tool box or drawer E102A Notes T2 T12 Version 4 BG doc Page 236 of 254 Dismantle and Assembly A common task that an electrician is expected to perform is dismantling and reassembling electrical electronic equipment and accessories Because there are innumerable variations to these products an electrician must always include a range of suitable tools in the kit The following are some of the more commonly used tools needed to perform this task Pliers Pliers are gripping tools used to hold small components that would otherwise be difficult t
65. warning labels on the packaging and always read the SDS for all chemical products Soldering http www smex net au Reference SilverSolderingO1 htm Soldering is a process in which two or more parts are joined by melting a relatively low melting point filler metal into a joint The bond established is not as strong as the base metal The two main type of soldering are soft soldering and silver soldering also Known as hard soldering Soft soldering is a process in which two or more parts are joined by melting and flowing filler metal into the joint with the filler which has a relatively low melting point below approx 420 C The bond between the materials is by wetting action Wetting refers to the behaviour of a liquid when it contacts a solid surface Liquids with poor wetting ability tend to form droplets while liquids with good wetting ability tend to spread out evenly over the solid surface area A good soft soldered joint has adequate strength but good electrical conductivity and is typically water tight Silver soldering also Known as hard soldering is a process in which two or more parts are joined by melting and flowing filler metal into the joint The melting point of the filler metal is above 420 C and flows into the joint by capillary action Capillary attraction is the ability of a liquid to flow in narrow spaces without the assistance of and in opposition to external force
66. wear goggles or safety glasses Long Nose Pliers Long Taper Nose Long nosed pliers are sometimes called needle nose pliers This tool is useful for holding small objects and reaching into confined spaces and for making delicate adjustments to equipment E102A Notes T2 T12 Version 4 BG doc Cutting edge diagonal to axis DIAGONAL CUTTING PLIERS Pulling out cotter pin e cotter C Ke ae ga USING SIDE CUTTERS TO MOVE COTTER PINS LONG TAPER NOSE PLIERS Page 238 of 254 Wire Strippers This tool is used to cut back the insulation from electrical wire without damaging nicking the copper wire strands When using this type of tool always make sure that it is correctly adjusted before attempting to strip the insulation Once the adjustment is made a steady squeezing and pulling action will strip a wire There are a number of designs made including the three are shown below Wire nine gripped __ Sess AUTOMATIC STRIPPERS Ref htto www sparksdirectsupplies co uk products item kew technik automatic wire stripper ws 250 Maintenance and Storage Moving parts of tools should be tight and kept oiled and cutting edges free of gaps and sharp Tools should be stored in a suitable container or on a shadow board Tools will begin to rust very quickly if exposed to the weather E102A Notes T2 T12 Version 4 BG doc Page 239 of 254 Circlip Pliers Circlip or snap r
67. when a person looks into the beam unintentionally for a brief moment Nevertheless as with the sun one should not look directly into sources of bright light and NEVER direct the laser beam toward persons E102A Notes T2 T12 Version 4 BG doc Page 23 of 254 23 January 2014 Steel Rule Engineer s Rule Steel rules are designed to accurately measure lengths in the range between 0 to 300mm to 2000mm For lengths longer than 2m then a steel tape is used An example of a steel rule is shown below io 20 30 40 5f so 70 80 90 JOQ no 12 The ends and edges of the rule form important reference points as it is from these surfaces that accurate measurements are to be taken If the rule were to be used as a Scraper a screwdriver a lever or as a piece of packing then the resultant damage would make it unreliable as a reference tool for future accurate measuring Errors in measurement can occur from any or a combination of the following Face at 90 to work e Wear on the end of the rule e Graduation errors in the manufacture of the rule e Poor light conditions e Rule not held parallel or at right angles to the work piece e Parallax error which is a displacement or difference in the apparent position of an object when viewed along two different lines of ae sigut against work An engineer s rule is graduated in 1mm increments on one side and 0 5 mm increments on the other This means its accuracy
68. work to be measured Check carefully that the locating face on the end of the thimble and the shoulder of the extension rods are clean Insert the rod into the thimble and push it down to the locating face Replace the knurled clamping cap Tighten the clamp to a firm finger tight pressure Measuring the depth of a recess E102A Notes T2 T12 Version 4 BG doc CHECKING THE screwed down ZERO SETTING until anvil touches surface Frame held firm on flat machined surface DEPTH MICROMETER Unscrew and remove cap Page 235 of 254 Care of Micrometers Micrometers are precision instruments Their accuracy depends upon the way they are used and stored Some points to be considered when using micrometers are e Clean the face of the spindle and anvil before using the micrometer e Check the zero reading e See that the work is clean and dry before measuring e Donot attempt to measure over rough surfaces e Make sure the work is stationary before attempting to take a reading e Make sure the spindle clamp has Protect micrometer from damage been loosened before turning the during use thimble e Do not screw the spindle beyond the barrel scale e Never place the micrometer where it can come in contact with dirt or cutting fluids e Handle the micrometer as little as possible and never allow it to be exposed to heat e Keep the micrometer square to the work during readings e Never apply excessive force
69. 00mm and then release USE OF THE CHALK LINE This action should ensure a crisp line is produced e The chalk will gradually disappear E102A Notes T2 T12 Version 4 BG doc Page 42 of 254 23 January 2014 Plumb Bob This tool is used to vertically align two points in space The tool is weighted object commonly brass with a pointed tip that is attached to a string line The force of gravity causes the weighted line to hang vertically or plumb Plumb bobs are made in different weights Always take care when using it outdoors as their accuracy is affected by the wind To mark a vertical line on a wall e Hang a plumb bob from a chalk coated string almost against the wall ideally with a tiny gap Secure the string at the top point near the wall with a nail e Steady the weight by hand until it stops swinging and twirling e Leave the weight to find its final position e Hold the weight against the wall and snap the string against the wall to create a vertical chalk line e Remove the chalk line when no longer needed Applications There are many applications including e Vertical conduit runs e The centring of lighting point to be located above a dining table Spirit Level A spirit level or bubble level is an instrument designed to indicate whether a surface is horizontal level or vertical plumb Levels are made in many shapes sizes and materials to suit the different trades They have in common a small gl
70. 00mm apart Stand in front of the machine and slightly left of the grinding wheel Sieh Fe e Hold the drill at about one quarter of its length from the point between the thumb and first finger of the right hand e Support the hand on the tool rest with the other fingers Cutting edge e Hold the shank of the drill between the thumb and iti oom fingers of the left hand to wheel face e Keep both elbows against your sides Position yourself by moving your feet so that the drill makes an angle of 59 to 60 to the wheel face CORRECT POSITION OF DRILL E102A Notes T2 T12 Version 4 BG doc Page 89 of 254 23 January 2014 Hold the drill level Twist it until one cutting edge is horizontal and parallel to the wheel face Swing the shank of the drill slightly downwards and to the left with the left hand Support the right hand on the tool rest Roll the drill to the right by turning it between the thumb and finger as you swing the left hand down Watch the cutting edge against the wheel Note that as the shank swings down the cutting edge will come slightly upwards and away from the wheel face Sharpen the second cutting edge using the same amount of drill movement as before When these actions are carried out carefully the drill will be sharpened with equal cutting angles Check these angles with a drill gauge NB The three key criteria to be used when sharpening twist drills are 1 Equal drill point an
71. 014 Jig Saw This is a portable reciprocating saw which means it cuts with an alternating back and forth blade Single or dual speed switch movement This tool is used to cut out holes and i openings in sheet metal timber or plaster board etc It is ideal for curved work in the field where band saws are unavailable By selecting a suitable type blade it can be used to cut most thin materials from cardboard to steel Always allow the tool to reach full speed before bringing its cutting surface to the job This prevents overloading of the motor and serious damage Single Hand Jig Saw If the tool has multi speed control then use the low setting when cutting sheet steel and the high setting for wood or aluminium Circles may be cut by gt Guiding the saw freehand gt Using a circle guide which is ideal for repeating work Cutting Action Cutting is done on the up stroke only Most jig saws have reciprocating up and down action only This tends to cause drag on the down stroke Some saws have the blade canted forward at the bottom to give clearance on the down stroke and some saws have an adjustable roller support to lessen the unsupported length of the blade Work i Always keep the base plate in contact with the work adi SEE Never exceed the capacity of the saw The blade must have sufficient clearance below the work to prevent fouling HOLDING THE WORK Display A E Cut out for instrument
72. 02A Notes T2 T12 Version 4 BG doc Page 76 of 254 23 January 2014 Lathe Safety A lathe is potentially a very hazardous piece of machinery It can rotate at a high speed and due to its gearing has a very high torque The lathe operator is required to work very close to the cutting tip while the work piece is turning at high speed with few protective guards in place Safety Metal Lathe DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on a Lathe Safety glasses must be worn at all a Long and loose hair must be times in work areas contained Sturdy footwear must be worn at all times in work areas Rings and jewellery must not be S wom Pre Operational Safety Checks Check workspaces and walkways to ensure no slip trip hazards are present Locate and ensure you are familiar with the operation of the ON OFF starter and Emergency Stop if fitted Ensure all guards are in place Check that the job is clamped tight in the chuck Remove all tools from the bed and slides of the machine Ensure correct speed for machining process is selected Remove the chuck key before starting the lathe Do not try to lift chucks or face plates that are too heavy for you Faulty equipment must not be used Immediately report suspect machinery Close fitting protective clothing must be worn Gloves must not be worn when using this machine
73. 203 of 254 23 January 2014 needs to be pulled to free it use locking pliers or similar tools to grip the sheet instead of your hands Marking Out Sheet metal must be correctly and accurately marked out according to the job specifications In workshop situations marking out is best done with a scriber and steel rule A metal blade tape measure can be used for larger jobs Marking gauges designed for metal work are useful for marking small measurements which need to be repeated such as folding allowances for seams or laps A range of engineering squares and adjustable bevels are available that will help when marking out sheet metal materials The use of pencils ball point pens or felt tip markers is not recommended for sheet metal work as these produce lines that are too wide for accuracy Also the marks made by these methods are sometimes difficult to see on the shiny surface of the sheets or rub off during handling of the material When pre finished materials like Colorbond are being used a fine line felt tip pen could be used to eliminate the scratches left by scribers These pens should not be used for marking out after the tip has been worn to the point where it leaves wide lines on the material Pens of this type have a limited life as marking instruments for sheet metal and so their use should be restricted to those tasks where they are the only viable option NB Black lead pencils are made from a mixture of graphite and clay Graphite
74. 23 January 2014 only if both parts of the joint are clean and at an equal high temperature Sometimes it may appear that there is direct metal to metal contact but there may a thin film of oxide on the surface that insulates the two parts This will produce a dry joint which may have a high resistance This will then lead to system failure The surface of the soldering iron tip should always be clean and not pitted Clean the tip surface by wiping it on the cleaning pad as shown above A cleaning pad can be an abrasive wire type or a wet sponge is also suitable NB After cleaning always wait a few seconds for the soldering iron to reach its correct operating temperature before re use Technique When the soldering iron is up to temperature e Apply some solder to the flattened working end at the end of the bit and wipe it ona piece of damp cloth or sponge so that the solder forms a thin film on the bit This is called tinning the bit e Melt a little more solder on to the tip of the soldering iron and position the tip so it contacts both parts of the joint It is the molten solder on the tip of the iron that allows the heat to flow quickly from the iron into both parts of the joint If the iron has the correct amount of solder on it and is positioned correctly then the two parts to be joined will reach the solder s melting temperature in a couple of seconds e Next apply the end of the solder to the point where both p
75. 4 23 January 2014 Rocking bar Vee Blocks Vee blocks are used to hold circular work when marking out or setting up for machining They are manufactured in pairs from cast iron or steel hardened A variety of sizes are available Some vee blocks are fitted with a clamp to hold work securely in position There are also magnetic vee blocks where clamps are not required These provide the option of securing flat plate at 90 degrees to working surface or locating round bar for marking out Scribing Block Surface gauge are a pair in This consists of a solid base machined flat on the this set up bottom A vertical column attached to the base includes a scriber which is located in a moveable Vee blocks supporting a shaft clamp Its most common purpose on the marking off for marking out and drilling table is to scribe lines on a work piece parallel to the table surface It may also be used for e Setting up work for machining e Checking work for parallel e Finding the centre of work Square head of Turn curved combination set point downwards Have work well ny as height bs supported i gauge Keep Sleeve Scriber COl TT clamping clamp vertical screw Fine adjusting Make fine adjustment with screw Make one clean T gt stroke with scriber gt A Ei trailing oe n ee Locating eee pin a ee Ds Ld es Lin Wyte f Doira Uf BAA Ye Machined surface or marking off table When using a surface gauge it is
76. 5 1 5 16 5 1 5 18 5 1 5 20 5 2 0 22 0 1 5 23 5 1 5 30 5 1 5 38 5 1 5 48 5 Metric Conduit Spark Plug WHIT Form E102A Notes T2 T12 Version 4 BG doc Page 109 of 254 23 January 2014 Screwdrivers A screwdriver is a twisting tool with a long blade fitted to a handle and is designed to install screws and like The tip of the blade is shaped to fit into the head of a screw and when turned will either tighten or loosen the screw There are two groups of hand held screwdrivers a Standard types with tips to slotted heads and b Special types with tips to suit recessed headed screws NB Screwdriver tips are made to be used in conjunction with drill braces and power tools etc Warning A screwdriver should NEVER be used as a chisel or as a lever This will damage the blade and could result in a hazardous situation Standard Screwdrivers These are made with a Round blades or square shanks for use with spanners to loosen stubborn screws b Handles made of metal wood or molded plastic c The thickness of the blade is based on the width of the tip and the blade length Standard screwdrivers are specified in size by length of shank blade and width of the tip eg 200mm by 6mm Variations of the standard screwdriver include a Stumpy stubby or dumpy screwdriver which is about 40mm by 6mm for use where there is limited room b Light duty screwdrivers with small tips
77. 9 Finished joint riveted CUTTING OUT AND ASSEMBLING A STOP END Page 215 of 254 Mitres or Angle Joints Mitres or single joints are required at corners and are External mitres for external corners Internal mitres for internal corners External Mitres Right Angled gt gt gt Vv Vv Y Y VW V WV EXTERNAL MITRE lf commercially produced mitres are not available it will be necessary to make them to suit the job To make a right angled mitre VA INTERNAL MITRE Measure the distance against the wall between MITRES the cable tray end and the edge of the wall corner Transfer this measurement to the cable tray to the side that will be against the wall and mark the spot with a scriber A Place the tray upside down for the marking but take care to identify which side goes towards the wall before marking Remember you are marking upside down j Cable Grat Measure the width of the base of the cable tray e g 100 mm Le side Mark on the wall side of the cable tray 100 mm from the corner mark B and 200 mm from corner mark C Place the stock of a try square against the tray wall side Draw from mark B a line across the base of the tray with a scriber to D Draw lines from A and C and D using ruler and scriber This forms a triangle with a top angle of 90 at D 25 mm lap VIEW AT WALL SIDE Allow for a 25 mm lap as shown MAKING AN EXTERNAL MITRE Cut away excess metal with tins
78. A Notes T2 T12 Version 4 BG doc 23 January 2014 ry td Incorrect pitch E S fine pitch ne chip clearance teeth clogged Pa Pa Pe ee Pe Pe a Faa Pan i ki l fine pitch no chip clearance teeth clogged P T coarse pitch siraddles work stripping teeth de coarse pitch straddles work Page 52 of 254 Place blade in frame Fitting a blade NB A hacksaw blade should be inserted into the frame with its teeth points facing forward to enable it to cut on the forward stroke le Teeth point away from the handle e Set the frame to the correct length to suit the blade e Hold the handle in one hand and check that both pins face the same direction e Hold the front of the blade in the other hand with the teeth facing towards the front of the frame Thumbs press blade e Fit the blade on the pin near the handle and steady it against flats eo with your thumb then fit the blade on the other pin e Use your thumbs to press the blade hard against the flats of the blade holders and tension the blade with the wing nut Take up the slack then give three full turns on the tensioning nut _ Fingers tighten e Check the tension the blade should ring sharply ja ree MU when the back of the blade is plucked with your thumb nail If the blade flexes sideways when cutting more FITTING A BLADE tension is needed e The saw blade may break if it is too loose in the frame or if the work pie
79. APED AND RESTORED Page 113 of 254 Hexagon Socket Wrench These are more commonly known as Allen keys these are hexagonal bars of tool steel bent to an L shape They are designed to turn hexagonal headed fixing screws be 1 Allen keys are available in both metric imperial sizes When using these keys a Make sure socket and keys are clean before use b Use the correct size c Insert to full depth d Do not attach an additional lever to the end of the key as this may cause it to strip or break Note Discard a key if the ends become worn or rounded as shown in the image to the right Socket screw otherwise it is likely to slip under load Shown below is an Allen key being used to fix a component E102A Notes T2 T12 Version 4 BG doc Page 114 of 254 23 January 2014 Hammers Hammers are heavy impact tools widely used by tradespeople They impart a force either directly through impact or indirectly through a punch or chisel to change the shape or position of materials Hand hammers are manufacture in a wide variety of shapes and sizes They are graded by the weight of their head They have handles made of wood steel or fiberglass The type of material used to construct the head classifies them into one of two groups Hard or Soft face Hammer A hard hammer has a steel head fastened to a handle which can be made of timber fibreglass or steel
80. Adjustable O A popular commercial front Ses 1 f gauge Foot l SSA Off on guillotine is the hydraulic wich Savini quite lZ buttons powered design which has a variable cutting length With these machines it is possible to adjust the rake angle and the clearance gap as well as being able to set front and back stops ELECTRO HYDRAULICALLY OPERATED GUILLOTINE NB Due to their blade design guillotines are designed for straight line cutting only Also they cannot be used to cut half way along a piece of metal It must be a full cut or no cut Bottom Blade Blade Gap E102A Notes T2 T12 Version 4 BG doc Page 194 of 254 23 January 2014 The principle of operation is that an upper blade which is offset slightly from the horizontal plane descends vertically towards a fixed bottom blade which is fitted to the bed of the machine thus shearing off the metal along a line where the two blades pass The distance between the cutting edges of top and bottom blades is termed the blade gap or clearance gap and this distance should be adjusted to suit the thickness of metal being cut using feeler gauges Safety Metal Cutting Guillotine A guillotine is potentially a very hazardous piece of machinery DO NOT use this machine unless you have been instructed in its safe use and operation and you have been given permission Only one person may operate this machine at any one time Safety glasses must be worn at all R
81. Arc welding may be performed using direct current DC with the electrode either positive or negative or alternating current AC The choice of current and polarity depends on the process the type of electrode the arc atmosphere and the metal being welded Fuses Mains isolator switch Welding machine near power source a Primary power cable connection Electrode holder Insulated hook a Work cable Chipping hammer shield away from bench connection Connect welding cables first Steel top welding bench EQUIPMENT SET UP Welding Circuit A basic arc welding circuit is illustrated to the right The design uses a low voltage high current power source which can be either AC or DC and is fitted with whatever controls may be needed to control the current Basic AC welders typically use a step down transformer which incorporates a magnetic bridge to create the conditions necessary for welding The welder s output terminals are connected by the work cable to the metal work piece and by a second welding cable to the electrode holder which makes an electrical contact with the welding electrode An arc is created across the gap when the energized circuit and the electrode tip touches the work piece and is slightly withdrawn Welding lead cable Electrode Return lead cable Power Supply AC or DC E102A Notes T2 T12 Version 4 BG do
82. Equipment Measuring tools are precision instruments and are easily damaged They should be stored in locations or containers where they will be protected from corrosion dirt contact and also from harmful contact with heavier tools such as hammers chisels and files The best way to ensure they are not damaged is to return them to their protective cases when they are not in use Also never leave the jaws of the instrument firmly closed as they will stretch and loose accuracy They should always be stored with the jaws slightly apart to allow for physical changes due to temperature variations While the equipment is in use you should always guard against E102A Notes T2 T12 Version 4 BG doc Page 20 of 254 23 January 2014 Dropping the instrument Dropping other equipment onto the measuring instrument Allowing it to come into contact with filings grinding grit or dirt Taking measurements whilst the machinery is still running To protect instruments from corrosion they should be cleaned and lightly coated with suitable oil at the completion of the day s work At regular intervals these instruments should be dismantled cleaned checked and if necessary re calibrated Folding handle Graduations are in folds away millimetres If contact surfaces are scored or burred if numerals are spindles are bent or if the frames are strained A Usually marked ZAL in centimetres then the accuracy of the instrument can be pe and metres
83. Fixed Drilling Machines ccceeeeeceees 94 Always select the most suitable drilling machine for a given task as it makes the task much easier more accurate and much safer Honahi OE O E AA A A AE eee 94 Bench Dri sa incccatecencnsedeseswanveannstancnndeasneseanes 95 Pillar Drilling Machine eee 98 Radial Arm Drilling Machine 99 101 Tapping and Tap Wrenches 6 101 Threads and Terminology 00000ee 104 Thread Identification cccceecssssceseeeeeees 104 PPS WICC E T E E mecaeeans 104 Cutting External Threads ee 105 Page 2 of 254 SCLOW EXUWACLON rrsan EE 107 CAG MAG LUG EEE 107 Pipe Cutter or Tube Cutter 108 BUE Is CAMel saat ccs namo nenasancnae 108 Tana Di E TAAL e 109 E 110 SCREW CN VETS osuin acatat aa 110 Screwdrivers for Recessed Head Screws 111 Totx DIV CE o vetsiariveonencinenttanisertiveaeakeeonne 112 Angle Screwdrivers sssssseeeeeeeeeeees 112 Impact Screwdriver ssseeeseseeeeeeeeees 113 Hexagon Socket Wrench cccceceeees 114 Ball Pein Hammet 00eeseeeeeeeeees 116 Peining Hammers sseeeesseeeeeeeeees 116 Claw Hammet cccccccccccccccsssssssseeeeeeeees 117 Lump Hammer Mash or Masons Club Hammer jcn 117 Sledge Hammer ccccccccccccsssssseeeeeees 118 Soft Faced Mallet ce cccceeeneeeeees 118 Types of Soft Face Mallets
84. ING LIP sharpen the drill point and cutting T a lips Ls es m To sharpening a twist drill you will require a suitable bench grinder with a fine flat abrasive wheel Access to coolant will ensure that the drill tip does not overheat and soften as it is sharpened CHISEL EOGE Note the two key angles depicted in the illustration above Adjust tool Lp rest correctly PLP j P N Z Fingers p L 4 gt supported A against rest wy e Drill point angle 118 e Lip Clearance angle 8 to 12 Manual sharpening in this way is an exacting technique to master and requires much practice Drill diameters in the range from about 8 to 10mm are generally the easiest size bits to manipulate and you should select a drill bit in this range when practising the sharpening technique Hold drill The following criteria are of greatest importance when 1 4 length from point grinding in twist drills YTL XK A SUPPORT THE DRILL CORRECTLY e Create equal and correctly sized drill point angles e Create equal length cutting lips g e Create correct clearance angle behind the cutting lips and correct chisel edge angle l l Drill held level To successfully sharpen a twist drill on a bench supported at grinder use the following method this point by finger e Wear a well fitted pair of safety glasses Tool rest e Stand in a comfortable position with the feet about 4
85. NDERS Page 169 of 254 Operating an Angle Grinder e Before beginning a grinding operation make sure that the material to be ground is firmly clamped in a vice or to a bench e The operator must be in a comfortable well balanced position with a clear view of Wear face shield and goggles the material e Always check that the wheel is properly secured Warning Always check that the machine is switched in the OFF position before connecting the power supply e Point the grinder downwards when starting it up Hold it firmly because of a possible kick back e Use a backwards and forwards motion across the surface being ground GRINDERS Warning e Do not over speed grinding wheels e When using the angle grinder keep both hands on the machine e Do not remove the guard e Never put the machine down until the wheel has stopped rotating e When the grinding operation has been completed switch off the machine and place it on the bench top with the disc facing upwards Safety Many industrial accidents occur with this type of power tool Discs can explode Beware of hot work USING A PNEUMATIC ANGLE GRINDER TO GRIND DOWN A WELD BEAD E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 170 of 254 Straight Grinder Straight grinders are portable hand held machines designed for industrial level grinding They have long thin bodies with the grinding wheel fitted on the end of the drive s
86. NG PLIERS Page 237 of 254 Warning e Never cut wires that are under tension until you have made sure that the ends cannot fly dangerously Always wear safety glasses for this type of application e Grip small round objects at right angles to the flat jaws for greatest control Diagonal Cutting Pliers This tool is designed to neatly cut wires They are especially useful for cutting copper wires Another name for diagonal cutting pliers is side cutters These cutters are made with the jaws cranked or offset That is they are set at an angle which allows wire to be cut close to a surface or in confined spaces They are also available with insulated handles for electrical work Note Never cut electrical wires unless you are certain that the electrical power has been first disconnected NB If in doubt always use an electrical tester multimeter device to confirm that the cable is de energized prior to cutting If you are working near the middle section of a cable which cannot be traced out use a non contact electrical tester to confirm that the cable is de energized Remember Always orove test prove when using an electrical tester to test for de energization Warning Short ends of wire particularly steel wire are liable to fly considerable distances when cut Guard against this Cut with the free end of the wire pointing away from you and aimed into a closed receptacle such as a bin Always
87. PPE which will be required for each task For example e safety helmets safety shoes safety glasses respirator gloves ear plugs ear muffs wet weather gear sun protection fall arrest systems back braces etc E102A Notes T2 T12 Version 4 BG doc Page 19 of 254 23 January 2014 Measurement The system of measurement in use in Australia and in most countries of the world is the SI System International Metric system The metre is the standard unit for length with sub divisions and multiples of the metre being based on the decimal system All engineering measurements however are made in millimetres and all dimensions shown on engineering drawings are given in millimetres There are 1000 10 millimetres ina metre The abbreviation for metres is the lower case m and the abbreviation for millimetres is lower case Gh 7 mm Precision Tolerance and Accuracy of Measurement The precision of a measurement system also called reproducibility is the degree to which repeated measurements under unchanged conditions show the same results In practical terms this equates to the minimum size unit being used to take a measurement The smaller the unit used the more precise the final measurement eg If we attempt to go beyond the base unit of measurement and attempt to estimate by using just a part of the smallest graduation then there is a high probability that the reading cannot be repeated
88. Some are extremely resistant to corrosion while others are not Some will resist certain chemicals better than others Others are designed for special qualities i e weld ability ease of machining and work hardening A small change in one of the constituent alloys will change the characteristics of the steel Stainless steel is classed by type number e g type 304 There are a large number of grades of stainless steel available and full details can be found in a metal handbook Eg Type 304 is used for applications where possible corrosion is mild Type 316 is used in highly corrosive environments such as electrical fittings located in marine or toxic environments such as chemical plants etc Both 304 and 316 grade stainless steels are termed austenitic meaning they are non magnetic Aluminium Is light weight non magnetic and highly corrosion resistant Sheet aluminium weighs approximately one third as much as sheet steel and is just as strong and can be folded and welded effectively It is however more expensive than steel Aluminium is used in place of steel for many outdoor applications such as electrical switchboards and connection boxes etc Because aluminium is so low in the Noble table it is highly susceptible to galvanic corrosion if it is placed in direct contact with a metal of another type Copper Is easily recognized by its reddish colour It offers high resistance to corrosion and good electri
89. Starting hole Circle guide CUTTING WITH THE JIG SAW CUTTING CIRCLES E102A Notes T2 T12 Version 4 BG doc Page 190 of 254 23 January 2014 The Kerf refers to the width of the cut It is the slot made by a cutting tool when parting material For a jig saw this is the width of the blade plus the set of the teeth The kerf width is lost when a cut is made and should always be considered especially when determining the number of blanks that can be cut from a stock sheet The kerf for a jig saw is always much less than that for a nibbler A jigsaw kerf is approximately 2mm whereas the kerf of a typical hand held nibbler is about 6 mm Safety Always wear appropriate PPE and clamp the material down securely to prevent it from moving or falling while cutting Also carefully control the position of the tool s power lead to ensure that it is not accidentally cut Two Handed Jig Saw Sabre Saw This is a portable jig saw designed for two handed operation It is designed for heavy duty use When in use it is usually pulled towards the operator Cutting is usually done on the up stroke but some are designed to cut on the down stroke also Always check with the manual It can be used to cut steel pipe or heavier gauge sheet metal Hand Shear Portable hand shears are a time saving machine because they quickly cut along lengths of sheet metal They are faster than jig saws They are
90. Vise A pipe vice is a clamp used to securely hold round bar or pipe such as metal conduit or water pipe while it is being cut or threaded There are a number of designs available including the two types shown below The chain vice on the left is very flexible and can accommodate large diameter cylindrical objects The bench yoke vice on the right has a slightly faster locking action START Wrap Hold tube chain over tube_ horizontal Handle and leadscrew Quick release h P bolt fits either link in slot tighten to grip chain Lift handle horizontal and D turn to tighten PIPE VICE USING A CHAIN PIPE VICE E102A Notes T2 T12 Version 4 BG doc Page 104 of 254 23 January 2014 Cutting External Threads A cutting tool called a die is secured in a handle and frame known as a stock and rotated by hand in a clockwise direction to cut a right hand external thread There are Knurled three main types of dies adjustable half handig dies button and die nuts External threads are used on metal conduits water pipes or solid fixing rods There are many variations to the basic design for stocks and dies Locking and adjusting screws Leading face of die Parts of a Stock The stock is the tool used to hold and turn STOCK the die when making an external thread by hand e The locking screws hold the die in position while the adjusting screw alters t
91. a tri square being used to check the squareness of a face This test should be also carried out frequently so that even during the roughing down stage the surfaces will be kept reasonably square with each other and you will maintain control of the work Practical Uses for a Tri Square i Guide a scriber when marking out lines at right angles to the edge of work ii Determine if two surfaces are at right angles to each other iii Check the flatness of surfaces E102A Notes T2 T12 Version 4 BG doc Page 34 of 254 23 January 2014 Square head Combination Set This is a multi function tool comprised of a ia Centre blade a square head a protractor head head and a centre head i The square head has one face that forms a right angle 90 with the blade and another face which forms a 45 angle with the blade The square head and blade can be used as a e Depth gauge to measure from the square face to the end of the blade e Height gauge by setting the square Protractor face flush with the end of the blade COMBINATION SET e Square to set work at right angles e Bevel gauge to set work at 45 The protractor head allows the blade to be set at an angle to the flat face It is used for setting up or measuring angles The centre head is designed to allow one edge of the blade to pass through the centre of two faces which are at right angles It can also be used to f
92. a wide assortment of driver head types including standard slotted Phillips head hex socket head for use with Allen keys Torx six pointed star square drive socket head and security heads which are easily driven in but very difficult to remove Sketch Drive Type Uses Tightening Tool Commonly found on woodscrews Flat bladed common and machine screws in domestic screwdriver applications or where field Slot retightening or removal may be required Most suitable for hand operated tools Oldest and simplest drive form Phillips Commonly found on self tapping Ideal for power Recess screws and machine screws operated tools and Type 1 particularly where they can be hand tools X Recess power assembled eg ona Cross Recess production line for domestic appliances POZIDRIVE As above but is less prone to Power operated RECESS cam out when drive tools are Pozidrive Tools and Type Il Or IA worn Pozidrive hand tools X Recess Tri Wing Security applications usually Special 3 bladed confined to screw products drivers both power and particularly in aircraft public hand transport fittings and electrical appliances where fieldwork should only be carried out by E102A Notes T2 T12 Version 4 BG doc Page 129 of 254 23 January 2014 authorized service personnel Principally used in high torque applications such as automotive heavy equipment tool die sets Commonly associated with cap screw
93. ach is best utilised in Apprenticeship programs and reduces assessment intervention It is the industry preferred model for apprenticeships However where summative or final assessment is used it is to include the application of the competency in the normal work environment or at a minimum the application of the competency in a realistically simulated work environment It is recognised that in some circumstances assessment in part or full can occur outside the workplace However it must be in accordance with industry and regulatory policy Methods chosen for a particular assessment will be influenced by various factors These include the extent of the assessment the most effective locations for the E102A Notes T2 T12 Version 4 BG doc Page 9 of 254 23 January 2014 assessment activities to take place access to physical resources additional safety measures that may be required and the critical nature of the competencies being assessed The critical safety nature of working with electricity electrical equipment gas or any other hazardous substance material carries risk in deeming a person competent Sources of evidence need to be rich in nature to minimise error in judgment Activities associated with normal everyday work have a bearing on the decision as to how much and how detailed the data gathered will contribute to its richness Some skills are more critical to safety and operational requirements while the same skills may be m
94. al and fabrication tools Vv Vv VY VV WV T11 Low tolerance measurement encompassing tolerance techniques in using vernier callipers techniques in using micrometers using vernier callipers to measure engineering components using micrometers to measuring engineering components VVVV WV T12 Dismantling and assembly techniques encompassing tools used in dismantling and assembling electrotechnology equipment Spanners screwdrivers bearing pullers etc procedures for ensuring the safe treatment of dismantled components dismantling electrical electronic instrumentation or refrigeration air conditioning piece of equipment using correct procedures assembling electrical electronic instrumentation or refrigeration air conditioning piece of equipment using correct procedures Vv VV WV EVIDENCE GUIDE 9 The evidence guide provides advice on assessment and must be read in conjunction with the Performance Criteria Required Skills and Knowledge the Range Statement and the Assessment Guidelines for this Training Package The Evidence Guide forms an integral part of this unit It must be used in conjunction with all parts of the unit and performed in accordance with the Assessment Guidelines of this Training Package Overview of Assessment 9 1 Longitudinal competency development approaches to assessment such as Profiling require data to be reliably gathered in a form that can be consistently interpreted over time This appro
95. al cutting jaws bent or Straight cutting snips are used to cut ina straight line and wide curves e Right snips will cut straight and in a tight curve to the right e Left snips will cut straight and in a tight curve to the left e Universal snips cut will cut in both directions These different cutting styles are necessary because metal is stiff and heavy and does not move out of the way readily when cutting around a curve The respective styles move the material out of the way when cutting in the direction they are designed for The blades are usually serrated to prevent material slippage when cutting UNIVERSAL CURVED STRAIGHT TINSNIPS E102A Notes T2 T12 Version 4 BG doc Page 61 of 254 23 January 2014 Use Grip the handles between the thumb and the first finger and allow first and second fingers to curl around the lower handle Place the third and small fingers between the handles but rest them on top of the lower handle This gives good control to open and close the cutting jaws Application Cutting large cable entry holes for switchboards notching cable tray and cable duct during installation Clamps A wide variety of clamping tools are used in a metal workshop Each clamp has a variety of uses in situations which require the holding or aligning of materials in readiness for drilling riveting screwing or welding G Clamps A C clamp is designed to temporary
96. amount of lift of the clamping beam is important It should be sufficient to allow the fitting and use of special clamping blades fingers and to give adequate clearance for previous folds 2 Folding Care must be taken to ensure that the folding beam will clear the work Particularly when making second or third folds for a piece of metal Some folding machines are designed to fold radii above the minimum either by fitting a radius bar or by adjustment of the folding beam 3 Removal of work Care must be taken when folding to ensure that the work can be easily removed on completion of the final bend Get this wrong and the material becomes trapped inside the folder The sequence of folding must be carefully planned The lift of the clamping beam is important when removing the work Some folding machines known as universal folders have swing beams Here the work may be folded completely around the beam which is swung out to facilitate removal of the work Clamping beam Beam operating cam Bead Beam operating AW End frame lever Radius adjusting SC he vy Folding beam Pedestal Folding handle The folding action of the tool is illustrated in the images shown below The brake consists of a flat surface onto which the material is placed and a clamping bar fingers which are forced down on the bend line to hold the material firmly in place during the bend This clamping action may be manual automatic or operated using a
97. an is necessary in cool clean water Sharpen a cold chisel by grinding e Wear a protective face shield or safety glasses and stand in a comfortable position to the front of the wheel e Hold the chisel firmly in both hands and lay it on the tool rest keeping your fingers behind the tool rest e Incline the chisel upwards and bring it into contact with the grinding wheel to form an angle with the face of the wheel that is half the required cutting angle e Move the chisel slowly back and forth across the grinding wheel face Quench the chisel in ae Transparent cool water when it becomes heated aed A safety PCR screen e Turn the chisel over and grind the second facet when the first is finished NB The sketch below shows a general purpose cutting angle Keep fingers behind tool rest Incline chisel upwards Maximum of 2mm between tool rest and wheel CORRECT POSITION FOR GRINDING CHISEL E102A Notes T2 T12 Version 4 BG doc Page 72 of 254 23 January 2014 Safety Off Hand Grinder DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on a grinder Safety glasses must be Long and loose hair Hearing protection worn at all times in work must be contained must be used areas Sturdy footwear must Close fitting protective Rings and jewellery be worn at all times in Ly clothing must be worn must not be worn work a
98. and c Boring bar The lathe tool is adjusted so that the cutting tipis 8 Side Tool in line with the centre axis of material Cutting principle e The cutting edge is the intersection of two surfaces the rake surface and the clearance surface e The rake surface is shaped and or angled to provide an escape path which guides and forms the chip into a manageable shape as it leaves the cutting edge e The clearance surfaces enable the cutting edge to penetrate the work surface with a minimum of rubbing TOOL POST Tool Geometry CUTTING The shape of the cutting tool edge is an important TOOL HOLDER factor in determining the cutting properties of a tool TOOL BIT e The tool should be ground so that it is sharp enough to force its way into the work e t must also retain sufficient material behind the cutting edge to make the tool strong enough to withstand the pressure imposed upon it when cutting and to dissipate the heat generated when cutting e The cutting operation the tool performs also determines its shape e The effectiveness of any metal cutting tool is determined by its normal rake and inclination e The tool or tool bit must be of the correct cross section size to fit the tool holder you intend to use The material from which the tool bit is made is referred to as High Speed Steel HSS Tool bits are usually produced in square section Other shapes available are rectangle round and come in a variety of sizes E1
99. and a greater speed of filing NB A file with a safe edge is commonly used to ensure that material from an adjacent surface is not removed while filing close by HEAVY FILING LIGHT FILING FINISHING GRIPS FOR FILING E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Slight bend at yoe f both feet Feet apart E STANCE FOR FILING Page 48 of 254 Draw Filing Draw filing is a technique that can be used as a final finishing process on parts that are longer than they are wide This method is only used when the work is nearly flat and close to its final size It produces a smooth even surface with all the file marks running in one direction To draw file use the following procedure e Balance the file across the work at right angles to its length e Grip the file with both hands as close as possible to the work with your thumbs on the rear edge and your fingers on the front edge e Make sure you keep the file level and move both hands at the same time e Make the cutting stroke by moving the file directly forward using light pressure e Don t use heavy pressure on the file on the return stroke e Continue at a speed suited to the job Fitting the File Handle Two methods can be used when fitting wooden file handles e An axial hole is first drilled in the handle with a drill that has a diameter equal to the width of the tang at its mid point e The tank is then inserte
100. ange Meters Ref www ehud engel co A laser distance meter uses a laser beam to determine the distance from a fixed starting point to another object The distance is measured along a laser beam emitted by the tool to the point at which the beam strikes a reflective surface The target from which the measurement is taken is clearly identified by the red laser measuring spot The range of the tool depends on the reflectance and structure of the target surface from which measurements are taken Measurements taken through glass or from plastic foam materials such as polystyrene foam or from highly reflective surfaces mirrors glass etc may produce inaccurate results The most common form of laser meter operates on the time of flight principle by sending a laser pulse in a narrow beam towards the object and measuring the time taken by the pulse to be reflected off the target and returned to the sender This measuring principle permits highly accurate and reliable measurement of distances to objects without need for special reflectors The specifications for these devices vary between manufacturers but the Hilti PD42 as shown above will measure from 0 05m to 200m with an accuracy of 1mm Laser Safety Depending on the model purchased generally these tools comply with Laser Class 2 in accordance with IEC825 1 2003 EN60825 1 2003 and may be used without need for further protective measures The eyelid closure reflex protects the eyes
101. are controlled with the aid a windlass handle Depth Gauge A depth gauge may be provided to allow the drilling of holes to precise depths This allows accurate repetitive boring NB Safety considerations when using a pedestal drilling machine are 1 the shape of drill tip to be used 2 that the drill bit fits securely in the spindle 3 the use a suitable vice or clamps to secure the work piece and 4 the drill speed setting Pillar Drilling Machine This is a heavier duty floor mounted drilling machine suitable for medium scale work They have a drill capacity up to about 65mm and are either belt or gear driven This design greatly increases the potential vertical height thereby enabling larger objects to be drilled The throat depth is generally not much more than that of a bench drill It has a very wide range of available spindle speeds Dial or lever selection of speed is often provided A range of automatic feeds is often available in addition to both coarse and fine hand feeds Complex work tables that may swivel and tilt may be provided In large machines the table may be operated by a separate elevating motor E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Speed control levers Coarse feed hand lever Fine feed hand wheel Work table PILLAR DRILLING MACHINE Page 98 of 254 Radial Arm Drilling Machine Ref I TEE http www sundamachin Radial Arm SrA TEAS eto
102. arlier U E102A Notes T2 T12 Version 4 BG doc Page 208 of 254 23 January 2014 pon cJ Accurate folding is a fairly complex task and every folder exhibits different characteristics In addition the bending characteristics will always change slightly as the machine and its edges begin to wear Before attempting any new bending task always use a piece of scrap material to determine the current bending characteristics of the machine to be used This will ensure the best accuracy and the least amount of material waste When using a metal folder it is important to gt Set the machine to suit the metal thickness to be bent gt Never bend beyond the capacity of the machine as this strains the machine and will shorten it life span and reduce the quality of the folds produced gt Never bend materials for which it was not designed When removing or inserting the fingers of the machine take care not to get your own hand or fingers squashed Always follow the SOP for the machine Grooved seam The main specifications of folding machines are as follows 1 The maximum length and thickness to be bent For example the capacity of the machine may be 1 5 m times 1 62 mm This means that the machine is capable of folding a metal sheet 1 5 m wide and of 1 62 mm thick 2 The lift and shape of the clamping beam The smallest width B in the sketch below of bend is typically 8 to 10 times the metal thickness The mi
103. arse pitch to give ample chip clearance e Hard material use a fine pitch to give sufficient cutting points in contact with the work e Thin sections use the finest pitch to ensure a minimum of three teeth in contact with the work Note Blade manufacturers supply precise tables of the type and pitch of blade to suit specific Keep workpiece close to the materials vice jaw for rigidity when hacksawing Cutting Techniques Acut ona work piece should be started with only light cutting pressure with the thumb or fingers on one hand acting as a guide for the blade e Sometimes it helps to start a blade ina small vee notch filed into the work piece e When a work piece is supported in a vice make sure that the cutting is done close to the vice jaws for a rigid setup free of chatter e Work should be positioned in a vice so that the saw cut is vertical This makes it easier for the saw to follow a straight line At the end of a saw cut just before the pieces are completely parted reduce the cutting pressure or you may be caught off balance when the pieces come apart and cut your hands on the sharp edges of the work piece e To saw thin material sandwich it between two pieces of wood for a straight cut e Avoid bending the saw blades because they are likely to break and when they do they usually shatter in all directions and could injure you or others nearby Blade Tooth Breakage Common causes e Work insecurely clamp
104. arth or between phases An insulating material must be mechanically strong have a high dielectric strength to withstand the voltage stresses high insulation resistance to prevent leakage current to the earth and it must also be free from unwanted impurities The physical as well as electrical properties must be independent of temperature changes There are many materials in common use including PVC Polyvinyl Chloride Nylon Porcelain Mica Fibre glass Perspex Bakelite Densified wood and Insulpanel Phenolic resin impregnated paper base laminated sheet used in switchboard construction Each material is application specific Equipment Construction and Support Materials used for construction and support are extremely varied Materials include steel mild and stainless aluminium brass and copper are well as a full range of plastics etc Planning Process Planning a job correctly involves coordinating all of the tasks from start to finish Information can be derived from plans and specifications quality assurance requirements and occupational health and safety requirements This understanding enables problems to be avoided and also helps Increase workplace safety Reduce damage to tools and equipment Reduce costly mistakes Avoid processes which do not comply with the job plans or specifications Australian Standards or codes of practice VVVV E102A Notes T2 T12 Version 4 BG doc Page 18 of 254 23 January 2014 Planning
105. arts of the joint and the soldering iron are all touching one another The solder will melt immediately and flow around all the parts that are at or over the melting part temperature e After a few seconds remove the iron from the joint Make sure that no parts of the joint move after the soldering iron is removed until the solder is completely solidified This can take quite a few seconds with large joints If the joint is disturbed during this plastic period it may become seriously weakened APPLY SOLDER TO THE JOINT The finished surface of a properly made joint should have a smooth shiny appearance and if the wire is pulled it should not pull out of the joint In a properly made joint the solder will bond the components very strongly It is important to use the correct amount of solder both on the iron and on the joint Too little solder on the iron will result in poor heat transfer to the joint Too much will cause the solder to form strings as the iron is removed causing splashes and bridges to other contacts Too little solder applied to the joint will give the joint a half finished appearance a good bond where the soldering iron has been and no solder at all on the other part of the joint Safety Soft Soldering DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission Personal Protective Equipment Approved safety Long and loose hair Appropriate footwear glas
106. ary 2014 Safety and tools Small hand tools should be kept clean and tidy Always return hand tools back to their storage area when they are no longer required They should be used correctly and maintained in good condition Larger tools should be kept under control and not scattered about Keep equipment out of aisles and working spaces where they would become a hazard Use of machines Before using any machine know how it works Always check the SOP Standard Operating Procedure for the machine which should be clearly displayed beside the machine It is important to carry out checks and minor maintenance before a machine is used so that it always remains in a serviceable condition Always keep your hands away from moving parts When using a machine tool NEVER attempt to feel the finished surface with the machine still in operation Machines should be completely stopped before any checks or measurements are made Machine guards Guards should be fitted to machines that have external moving parts If the guard is missing from a machine then it MUST NOT be used The guards are there to protect the operator who should make sure that the guards are correctly in place Eg Grinders should have covers over the grinding wheels to prevent grindings from being thrown towards the operator The tool rests should always be adjusted close to the edges of grinding wheels This will prevent an article that is being ground from jamming between the too
107. ass bulb filled with a liquid which has a small air bubble When the bubble is located precisely between the two set marks then the surface is level or plumb Applications The are countless applications including checking that switchboards socket outlets or a conduit or ducting run is mounted level or vertical Sustainable work practice involves e Maintaining and repairing tools and equipment so that it can operate at high efficiency and effectiveness e Reducing waste products e Re using and recycling materials e Responsibly disposing of waste products E102A Notes T2 T12 Version 4 BG doc Page 43 of 254 23 January 2014 The electrotechnology industry covers a vast array of tasks and as such there are many types of hand and power tools that you are expected to recognize know the characteristics and use safely and efficiently The tools shown in this note are the more common types but as you progress through the industry you will undoubtedly encounter many other specialized tools Files Files are tools used to accurately shape materials by abrading away some part of its surface This may be to make the stock match the measurements from an engineering drawing or to reduce the size of one metal part so that it will fit into or around another Sometimes filing is used to remove rough tool marks left by chipping or machining and produce a high quality finished surface Files are made of high grade carbon tool steel There are ma
108. asuring around curved surfaces E102A Notes T2 T12 Version 4 BG doc Page 22 of 254 23 January 2014 Distance Measuring Wheel Ref http www laserlevel tripod com A distance measuring wheel also called a surveyor s wheel is an excellent tool for measuring longer distances with reasonable accuracy They are ideal when measuring the route length of underground cable or aerial cable runs such as when estimating costs or cable quantities etc Each revolution of the wheel measures a specific distance such as a metre and as the revolutions are automatically counted with a device attached to the wheel it measures the total distance directly The design will provide reasonable accuracy on a smooth surface such as pavement but on rough terrain wheel slippage and bouncing can reduce the accuracy somewhat Soft sandy or muddy soil can also affect the rolling of the wheel As well obstacles in the way of the path may have to be accounted for separately When using keep track of any circumstance on the path that can influence the accuracy of the distance measured and either measure that portion with an alternative technique such as a measuring tape or make a reasonable estimate of the correction to apply To use the device first reset the counter and locate the wheel at the point you want to start measuring and roll in a straight direction to the stopping point then read distance travelled directly off the counter Laser R
109. ate techniques to fix any problems This may involve additional fasteners sealant or solder and check the joints again Clean up gt Always allow clean up time Cleaning up includes clearing the work site of debris and unused materials and stacking materials to aid good site management gt Sheet metal off cuts will result from cutting and joining of these materials Off cuts that are large enough to be used for other projects should be stored for future use In workshops storage racks are usually provided to contain part sheets and large off cuts This material should be stored as soon as possible to keep work areas clear and prevent damage to the material If working on site locate suitable storage areas for this material gt Smaller off cuts should be disposed of as soon as practicable Sharp edges make this material dangerous to handle Gloves should be worn to protect workers hands during disposal operations E102A Notes T2 T12 Version 4 BG doc Page 212 of 254 23 January 2014 gt In some organisations small sheet metal off cuts are separated from other waste material and sent to recyclers Check the operating procedures in the workplace before disposing of waste gt All off cuts swarf from drilling or cutting operations rivet stems etc must be cleaned up at the end of each day If this material is left on a finished surface it will stain and can lead to corrosion gt Tools and equipment used during the installation sh
110. ation with a fixed main scale to obtain high precision Eg A vernier gauge can be used to accurately measure a motor shaft and housing diameter to identify a suitable bearing type E102A Notes T2 T12 Version 4 BG doc 23 January 2014 VERNIER CALIPER Jaw thickness added to Vernier reading SLA Measuring an internal diameter Page 222 of 254 A vernier gauge consists of two scales e Main scale e Vernier scale The base tool is designed in such a way that the one instrument is able to take external internal and depth measurements and can be used in locations such as narrow slots that are inaccessible to micrometers A vernier is an expensive high precision instrument and as such requires great care When not being used it is essential that it is wiped clean very lightly MAIN SCALE divided into millimetres oiled with suitable protective oil and stored in its each 10th being numbered protective case a1 mm Principle of the Metric Vernier The principle of a standard metric vernier with an accuracy of 0 02mm is as follows ae 49 Millimetres e The main scale is graduated into millimetres pone with each tenth millimetre being numbered e The vernier scale is made 49 millimetres long and divided into 50 equal parts e The length of each division is therefore one fiftieth of the total length of 49 millimetres e 1 50 of 49 mm 0 98 of a millimetre
111. ave one moveable jaw They tend to slip and are only used when a full kit of set spanners is not available Movable jaw ye jaw Adjustable spanners range in length from 100mm to 760mm The type illustrated has its jaws set at an angle to the handle They are not meant to replace fixed spanners which are more suitable for heavy service In general adjustable spanners are not recommended in the metal industry It is important to keep adjustable spanners clean and moving parts should be lubricated regularly PARTS OF AN ADJUSTABLE SPANNER Right Wrong E102A Notes T2 T12 Version 4 BG doc Page 121 of 254 23 January 2014 Double Thin hexagonal 7 wall Socket Spanner Socket spanner sets generally include a wide variety of handles adapters ratchets breaker Double hexagonal ces Socket bar speed handles universal joints and size hl _Drive extensions which significantly decrease the end time taken to loosen or tighten nuts and bolts Rubber STANDARD insert TYPE A socket is a cylindrical shaped tool made from chrome plated alloy steel One of its ends has Double a square recess with an internal groove to SPARK PLUG hexagonal accommodate a drive bar Its other end is TYPE recessed to suit a particular nut or bolt head i Thin wall The dimension of the socket is measured across the flats of the square recess Single hexagonal The nut or bolt head recess
112. ave a pilot drill bit approximately 6mm diameter at their center to keep the saw teeth from walking during the cut Sometimes there is a coil spring located around the drill bit to expel the core material from the saw after the hole is completed Most hole saws have a fairly short aspect ratio of diameter to depth which means they are used to cut through relatively thin work pieces Because of their high peripheral speed it is important to use a lubricant to stop the teeth from over heating when cutting sheet metal Safety Always wear appropriate PPE especially safety glasses Applications They are many applications including mounting indicating lights push buttons and instruments for switchboard panels They are also used to cut large diameter holes in a variety of materials to facilitate cable or conduit entry etc Fly Cutter Circle Cutter This tool is designed to cut very large diameter holes in flat materials such as sheet metal or plastic etc It is ideal for hole sizes greater than can be cut using a hole saw A fly cutter is composed of a spindle horizontal bar with a securing screw for a lathe tool bit A clearance hole must be drilled to enable the spindle to rotate freely in the stock material As the entire unit rotates extremely slowly the tool bit takes a broad shallow cut The material to be drilled must be clamped flat and very secure and the spindle rotated at the slowest possible speed This tool is o
113. be used to remove a 3 screw with a left hand thread a broken press fitted stud ie interference fit a broken tap or a badly rusted screw Be aware of how deep the broken screw or stud is drilled so as to avoid expanding the broken piece and become tighter in the hole NB Extractors are very brittle and they can break very easily if too much force is applied Thread Inserts If an internal thread becomes damaged or stripped it can be repaired by the use of a thread insert kit The damaged internal thread is drilled out and re tapped to take a special high tensile spring of screw thread section This screw thread section known as the insert is then screwed into the tapped hole thereby restoring the original thread size E102A Notes T2 T12 Version 4 BG doc Page 107 of 254 23 January 2014 Pipe Cutter or Tube Cutter The main function of this tool is to neatly cut a pipe to a specific length It is designed with a hardened steel cutting wheel and two rollers There are many sizes and designs of pipe cutters available to suit a large range of pipe sizes and material types To cut tubing place the tube cutter with the cutting wheel exactly on the mark where the cut is to be made Move the cutting wheel into light contact with the tubing Turn the cutter in the direction as shown on the diagram As you rotate the handle you should feel the wheel cut a little for each revolution Gradually s
114. below The main difference between a machine screw and a bolt image shown to the right is the primary tightening method A machine screw is usually tensioned by turning the head of the screw as opposed to a bolt which is tensioned by turning the nut while holding the head stationary WASHER NUT Compared to a bolt which has an unthreaded shank section the uniform thread on a machine screw makes it more susceptible to shear loads slicing across for its size A machine screw it about equivalent when taking tension loads down the long axis E102A Notes T2 T12 Version 4 BG doc Page 125 of 254 23 January 2014 Machine screws are available in a wide array of head configurations and sizes When determining the screw diameter and the number of fixing screws required for a particular task it is best to follow the manufacturer s pre formed mounting holes as a guide Manufacturer s typically design a suitable safety margin into their product fixing arrangements and it is unwise to deviate from this Eg A large contactor may have four mounting holes available a small contactor or relay may have two mounting holes and a fuse base may only have one mounting hole The key point is to completely use all of the available fixing holes unless experience or circumstances suggests otherwise Machine Screw Applications Machine screws are versatile in the number of types of joints the
115. ble Insulated Class II Equipment Class Il equipment is either double insulation or reinforced insulation With double insulated equipment the basic protection is afforded by the first layer of insulation If the basic protection fails then Shorten lead to supplementary protection is provided by a protect conductor wires second layer of insulation preventing contact with live parts Tape minor damagen Shorten lead to remove major NB Class II equipment is NOT earthed damage le It has no PE connection SAFETY ALL ELECTRICAL WORK TO BE The symbol for Class II DONE BY A QUALIFIED equipment consists of two ELECTRICIAN concentric squares is shown to the right REPAIRING DAMAGE Legislative Requirements A workplace is a much harsher environment than a domestic environment In addition it is normal that staff share access to the organisation s tools and equipment To ensure that each portable tool is maintained there is a strict standards of inspection and testing While these regulations do not extend to private domestic appliances individual house owners may request a similar level of inspection and testing Legislative framework for in service safety inspection and testing of electrical equipment The Electrical Safety Act 2002 and Electrical Regulation 2013 provides the legislative framework in Queensland for prescribing and regulating the requirements for in service safety inspection and testing of elect
116. bolt iJ a F P Fa af Fa P F Pa y Fi f PRR F a i PRR i Pa Faj f F F EEF Pi Pa fF Fa Fa a r PFA OEP RRERRER ERRER EOE EE POPES eG i 7 es Fi Fa Pa PEPER RRF FF F 7 HFA Ao A ote fo oe f ve F EF Fa FF F RRR RE FF E102A Notes T2 T12 Version 4 BG doc Page 124 of 254 23 January 2014 Types of Machine Screws and Nuts There is no one fastener that is right for every r application and selection from the vast array of m shapes sizes materials available can be a p m daunting task Consideration must be given to the application orientation ambient temperature corrosion vibration fatigue and many other variables C Length Machine screws also called metal threads and set screws are uniformly threaded screws where the thread extends all of the way from the tip to the head It has a nominal diameter measured across the threads and is made to be threaded into a matching nut or threaded hole for the purpose of assembling equipment Uniform threads maintain the same diameter throughout the entire length of the threaded section as opposed to tapered threads which have a pointed end such as that used for wood screws Wood screws are designed to cut their way into the soft wood Machine screws are generally considered to be smaller than bolts although there is no hard and fast rule Most machine screws are typically less than 10mm nominal diameter A typical machine screw is shown
117. borne Exposure to dusts eg wood asbestos silica gases eg carbon monoxide fumes eg metal fume vapours eg Solvents mists eg acids solvents Skin contact absorption Contact with eg Pesticides corrosive substances eg acid alkali solvents photosensitisation eg Creosote affected skin exposed to sunlight allergic eg nickel epoxy Biological microbial substances Exposure to bacterial fungal viral parasitic Mechanical Refers to being caught between struck by or against mobile or fixed plant and vehicles powered equipment tools and appliances non powered hand tools appliances and equipment Psychological hazards Those situations that cause stress to a worker This kind of hazard troubles an individual to an extent that their general well being is affected Identifying Workplace Hazards Study workplace injury and illness records Stay current on WHS trends Analyse all new work procedures for WHS Investigate all workplace incidents and near misses Conduct regular safety audits and inspections e Improve consultation and feedback procedures Hazard Control Measures to Reduce Risk There are five categories of control measures E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Close fitting s high buttoned overall Close fitting cuffs No rings or watch Cuffless trousers Reinforced footwear Dress safely wear suitable protective clothing Page 14 of 254
118. bration rubber washer Washers usually have an outer diameter OD about twice the width of their inner diameter ID Washers are made of metal plastic rubber or fibre Washers can be used to prevent galvanic corrosion such as insulating the steel screws from aluminium surfaces Washers are manufactured in a wide variety of designs range of materials dimensions and finishes A washer size is designated by the diameter size of the fastener with which it is to be used Washer Applications Washers have been designed to perform particular functions in particular types of applications These may be locking load spreading decorative tension indicating sealing or a combination of these functions Some of the most common types of washers are shown in the charts following Sketch Name Uses Flat Common general purpose basic washer can come in various dimensional standards quality levels materials hardness grades and finishes Often used in conjunction with a split spring washer Split Spring Common locking washer Come in a variety of thicknesses and sectional ratios Available in various materials throughout a wide size range Used to resist vibration loosening Will damage surfaces it contacts Internal Tooth Used with machine screws to resist vibration Causes Lock Washer minimal damage to surface Star washer External Tooth Same as above except slightly more damaging to surface Lock Washer Sometimes used to ensure elec
119. c 23 January 2014 Page 139 of 254 The current path is from the welder out through the welding lead and through the electrode holder the electrode rod and into the work piece and then it returns back via the work lead to the welder The electric arc produces a temperature of about 6500 F at the tip which is sufficient to melt both the base metal and the rod electrode thereby producing a pool of molten metal sometimes called a crater The crater solidifies behind the electrode as it is manually moved along the joint The result is a fusion bond Basic arc welders consist of a variable transformer earth clamp insulated electrode holder attached to the electrode lead and a consumable flux coated welding electrode Current settings and choice of welding electrodes depends on e The type and size of the material to be welded e The type and size of the welder to be used Electrode holder Loop cable over forearm to take weight off wrist PROTECTIVE GAS FROM ELECTRODE COATING MOLTEN WELD METAL SLAG SOLIDIRED WELO METAL COMFORTABLE WORKING POSITION POSITION ELECTRODE DIRECTLY ABOVE STARTING POINT E102A Notes T2 T12 Version 4 BG doc Page 140 of 254 23 January 2014 Process characteristics of MMAW welding e Uses a electrode rod that is quickly consumed Uses equipment that is simple inexpensive and highly portable Uses an electrode that provides and regulates its own flux Pro
120. cal conductivity Copper sheet is expensive costing about three times the price of galvanized iron Copper that has been work hardened can be annealed by heating to a cherry red and then cooling in water or leaving to cool in the open air Sheet copper has some applications in electrotechnology due to its malleability le It is able to be hammered or pressed permanently out of shape without breaking or cracking Eg Capping for wooden power poles Brass Sheet brass is commonly used for electrical cable earthing gland plates mounted on electrical switch boards and connection boxes Brass sheet is used for its strength and for its good electrical conductivity Electrotechnology Sheet Metal Tasks TERS EE ESS Ta Small electrical switchboards and connection boxes Cleaned area covered with mastic etc are generally mass produced and the metal work used to construct large switchboards is typically done by specialized sheet metal workers The main type of sheet metal work performed by electrical workers is cutting cable access holes in switchboards and the installation of metal cable tray cable troughing or duct The main focus of this note is therefore Gland plate directed towards developing the techniques needed FIXING A GLAND PLATE E102A Notes T2 T12 Version 4 BG doc Page 184 of 254 23 January 2014 to install metallic cable ways But it is important to understand that the sheet metal skills developed here are t
121. can be used to cut larger diameter curves Shears can replace hand snips but they are only suitable for cutting sheet metal to a maximum thickness of SABRE SAW 1 6mm They cut with a shearing action similar to a guillotine This means that the kerf thickness is almost zero The lower cutting blade is fixed while the top blade moves up and down to cut the material It should be noted that the material on one side of the cut becomes distorted as it is cleared to make the cut Note Do not use shears beyond their cut capacity le Material thickness Most shears have their maximum capacity written on the body amy ee forward Hold top blade a PORTABLE HAND SHEARS On off switch Offcut curves down Blades Cutting table PARTS OF HAND SHEARS CARE WHEN CUTTING E102A Notes T2 T12 Version 4 BG doc Page 191 of 254 23 January 2014 Hand Nibbler A nibbler is a tool for cutting sheet metal with minimal distortion Much less than hand shears One type operates much like a punch and die with a blade that moves in a linear fashion against a fixed die removing small bits of metal and leaving a kerf approximately 6 mm wide While the shear cuts the metal with a scissor cutting action the nibbler punches a narrow slot in the metal The swarf section removed is in the form of small half moon sections called a slug and these are forced out through the top of the tool An advantag
122. cceceeceecess 236 Diagonal Cutting Pliers ccccceeee 238 Long Nose Pliers Long Taper Nose 238 Wire StripPers cccccccssssssssssseseeeeeeeeeeees 239 Ceip PICT sesa 240 Crimping Tool ccccccssssseeeseeeeeeeeeees 241 Parallel Pin Punches ccceeeeeeeeees 242 Feeler GaU SC ii ncesincvenerancanuavbostesatvoeraensaacsien 242 Bearing Puller ceessesssssseeeeeeeeeeees 243 Care and Maintenance of Hand Tools 244 Disassembly Sequencing ccccceeees 246 Disassembly of an Electric Motor 247 Reassembly of a MOtot ccccceeeeeees 248 Importance of marking labelling and storing PD AIEUS AEE A 249 Storing Parts during Disassembly 249 Machines with Close Fitting Parts 250 Temperature Variations cccccceeeeees 250 GSAS KC 5555 26 sass gasonssnn ase sace jasenssogasesoseensensc6ee 253 E102A Notes T2 T12 Version 4 BG doc Page 4 of 254 23 January 2014 Modification History Not Applicable Unit Descriptor Unit Descriptor 1 1 1 Descriptor This unit covers basic fitting and fabrication techniques as they apply in the various utilities industry work functions It encompasses the safe use of hand fixed and portable power tools cutting shaping joining and fixing using metallic and non metallic materials dismantling and assembling equipment basic mechanical measurement and marking out and reading drawings
123. ce slips in the vice while sawing Too much pressure may also cause the blade to break e A badly worn blade one which the set has been worn down will cut too narrow a kerf which will cause binding and perhaps breakage of the blade NB If you are forced to use a new blade to finish a cut turn the work piece over and start with the new blade from the opposite side and make a cut to meet the first one The set on the new blade will be wider Forcing the new blade into an old cut will immediately ruin it by wearing the set down Cutting with a hacksaw Holding the hacksaw At all times control the hacksaw with both hands and keep it straight and upright Do not allow the blade to twist or move sideways HOLDING THE HACKSAW Stance e Stand in a comfortable well balanced position approximately 400 500mm behind the vice with the right foot perpendicular to the line of the cut e Allow the body to rock forward and back with each stroke keeping the right arm close to the body with the forearm in line with the blade e Atthe beginning of each stroke most of the pressure will be directed from the left hand e Gradually transfer the pressure to the right hand by the end of the stroke SAWING STANCE E102A Notes T2 T12 Version 4 BG doc Page 53 of 254 23 January 2014 NB Both the type of material and the section to be cut are general factors to be considered in selecting the pitch of blade required e Soft material use a co
124. chine s spindle The flattened section at the very bottom of the Morse taper is called the tang It is used to remove the drill from the spindle of the drill press To insert a Morse taper drill bit first place it into the spindle hole of the drilling machine twisting and pushing upward until it is snug Place a block of wood on the table and force the tapered bit point against the wood until the bit is firmly positioned into the spindle E102A Notes T2 T12 Version 4 BG doc Page 85 of 254 23 January 2014 To remove the tapered shank drill from the spindle Place a timber block under the drill so that it cannot fall too far No greater than 25mm Then force a tapered steel bar through the spindle hole to wedge onto the tang Shown to the right Drill Sizes Twist drills are made in various sizes from about 1mm up to about 75mm in diameter They are manufactured using a range of materials i fi flp Je depending on the substances to be drilled High speed caer d LASEN L steel HSS drill types can be used to drill metal ae or hve oi 25 2151 hardwood plastics etc i Ref http www machinemart co uk shop product details cht38 ona tye 3 19pce cobalt steel drill bit se LE Using Drill Bits When drilling metals there are several steps to be followed First always mark the exact location of the hole with a scribed cross A marked dot will instantly disappear as the drill starts turning and
125. cking plate material and the captive nut is slid into place over the hole from the edge of the backing plate The clip is held in place by spring action They are relatively inexpensive and are commonly used in electrical switchboards for joining parts They do not require special assembly tools and are easily replaceable Lock nuts http www designworldonline com hard lock nuts resist loosening Locknuts are used in conjunction with a standard nut to prevent loosening due to vibration If a full nut and a half nut are to be used then the half nut is installed first This is shown in the diagram to the right HATA mull He e Tension the half nut to its set value Ue ACA e Next apply the standard nut thick and YA tension it to snug tight NS e Next hold the thin nut with a spanner to prevent rotation and then tighten the standard nut against it to full design tension In effect the two nuts are now working in opposite directions and are locked against each other The amount of actual clamping force applied to the joint is set by the inner half nut The outer full nut has to carry the combined load and therefore has to be the thicker of the two These nuts will remain locked even if tension in the assembly is lost Nylon Insert Locknut Nyloc Nut http www weifeng fastener com Nylon Insert Lock Nut 76 html A Nyloc nut or nylon insert locknut is a nut that includes a nylon
126. clamp two or more objects together Its main body is drop forged from high quality steel in the form of a G The top of the G forms the fixed upper jaw while the lower jaw is adjusted by turning the threaded shaft Depending on the way it is turned it will either increase or decrease the pressure between the jaws C clamps are available in a variety of sizes ranging from 50 mm to about 300 mm capacity They are also made in different weights and strengths for general purpose medium or heavy duty Warning Do not increase the pressure between the jaws by applying a greater leverage than the clamp is designed to take as this will distort and damage the clamp Other Types of Clamps Apart from the G clamp many other clamps are available some designed for specific uses Below is a list of these clamps Toolmaker s clamp shown to the right Sash clamps Spring clamps Adjustable Vice grips gt Vice grip pliers gt Vice grip welding clamps gt Flat nose vice grips E102A Notes T2 T12 Version 4 BG doc Page 62 of 254 23 January 2014 Adjustable Vice Grips These pliers form an adjustable portable clamp with serrated jaws designed to hold narrow objects It is adjusted by the knurled screw located at the end of the handles Application This tool can be used as a temporary clamp a wrench or a portable vice to hold items for drilling grinding and welding etc Multi Grip Pliers or Slip Jo
127. com Nut 20insert 20tool Atm If the backing plate material is too thin to successfully tap then nut inserts provide a simple method of inserting a captive threaded nut into sheet metal Inserts also known under various trade names such as Blind Rivet Nut Nut Inserts or Crimp Nuts and are designed to provide a strong threaded joint in relatively thin sheet metal They are called Blind as they can be installed from one side of the assembly even if there is no access from the backside They should not damage the parent surface of previously finished plated coated components sub assemblies Blind Nut Inserts can be installed by means of a custom crimp tool The technique is to drill a neat correctly sized hole in the metal backing and the insert is placed into the hole with the custom tool shown over page The handle is squeezed to compress the back of the insert and lock it in place The action is similar to a pop rivet gun E102A Notes T2 T12 Version 4 BG doc Page 132 of 254 23 January 2014 When installed the Blind Nut Insert body is designed to undergo controlled deformation wherein the non threaded portion crimps creating a firm 360 rib which grips the underside of the mounting surface Cage Nut http docs oracle com cd E19657 01 E29153 z4000e8e1010292 html A caged nut also called a captive or clip nut consists of a square nut in a spring steel cage which wraps around the nut The cage
128. contact to provide a good electrical connection e Take care to avoid flashes Ending Operations and Cleaning Up e Switch off the machine and fume extraction unit when work completed e Close the gas cylinder valve e Hang up welding gun and welding cables e Leave the work area in a safe clean and tidy state Potential Hazards e Electric shock Fumes Radiation burns to eyes or body Body burns due to hot or molten materials Flying sparks Don t gt Donot use faulty equipment Immediately report suspect equipment gt Never leave the welder running unattended E102A Notes T2 T12 Version 4 BG doc Page 145 of 254 23 January 2014 This SOP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references It is designed as a guide to be used to compliment training and as a reminder to users prior to equipment use TIG Tungsten Inert Gas or GTAW Gas Tungsten Arc Welding This type of welding process uses a non consumable tungsten electrode to establish an arc to the base metal The heat of the arc melts the base metal and produces a weld pool If filler wire is to be used then it is added to the weld pool separately by the operator GTAW welding employs an inert FILLER gas similar to GMAW which ROD shields the weld area to prevent oxidation of the tungsten electrode the molten weld puddle and the heat affected T zone adjacent to the weld bea
129. crew in the adjustment as you turn Different wall thicknesses types of materials and diameters of metallic tubing require different feeds The feed pressure is correct when it keeps the wheel cutting but does not flatten the tubing Continue cutting until the tube is cut The final severing tends to happen suddenly so do not take your hand off the cutter during the process as it may fall Note Pipe cutters produce a very sharp internal burr of the pipe and should NEVER be used for cutting metallic conduit For other types of pipes use a reamer or a file to remove the burr Burr Reamer This is a tool used to remove the burrs from inside of a metal pipe so that the wires are not damaged when they are pulled through BURR REAMER E102A Notes T2 T12 Version 4 BG doc Page 108 of 254 23 January 2014 Tap Drill Chart Charts like the ones shown below are commonly displayed in most engineering workshops It lists the standard thread types and sizes and the recommended drill size to suit Many styles of charts are in circulation and due to differences in how the information is arranged and thus read it is suggested that you make yourself familiar with those in your work surrounds BSW BRITISH STANDARD WHITWORTH 55 Tapping Drill ig ISO METRIC FINE 60 Tapping Drill M ISO METRIC COARSE 60 Tapping Drill Size mm 0 5 l 0 5 i 0 75 1 0 i 1 0 1 25 i 1 25 J 1 5 1 25 A 1 5 12 5 1 5 14
130. ction The metal is cut with a round blade in a Circular saw or a straight blade such as in a Jig saw or Sabre Saw Single or dual speed switch eS A EEN a EAN Al eer ce Housing N C3 i Plunger li Ww E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Moving blade Fixed blade or anvil NIBBLING ACTION Abrasive wheel a Circular saw SAWING ACTION CUTTING ACTIONS Page 163 of 254 Using Portable Tools To get the best results from any portable tool Clamp the material down to prevent it from moving or falling Always allow the tool to reach full speed before bringing it to the job This prevents overloading the motor and serious damage Lift tools such as grinders clear of the work before switching the machine off Stopping tools under load that is when they are still working on the job is not good for the motor Jig saws may need to be switched off while on the job LISTEN FOR SOUND CHANGES Keep the cutting edges of tools sharp Dull or damaged cutting edges give a poor finish and overload tools If the tool must be forced through the work the cutting edges need sharpening Listen to the sound of the motor for changes in pitch or tone Most tools must run at full speed for top efficiency A droning or slowing motor sound means an overloaded tool If this occurs sharpen the cutters or readjust the depth of cut NEVER use a tool s cutting to
131. d ELECTRODE WORKPIECE Because GTAW welding uses an inert gas it means that its atomic structure does not allow it to chemically react with metals or other gases Commonly used MOLTEN POOL shielding gases include argon helium or an argon helium mixture ARC SHIELDING GAS Ref http www advantagefabricate dmetals com tig welding html http www streetchopperweb c om Argon operates at a higher arc voltage which makes the arc start more easily and is commonly used to weld mild steel aluminum and titanium Helium is generally added to increase heat input increase welding speed or weld penetration and is used for high speed welding of mild steel and titanium Helium offers a smaller heat affected zone and therefore penetrates metals deeply It also can increase the welding speed Helium is also commonly used to weld stainless steel and copper The argon helium combination gas is used for a hotter arc when welding aluminum and aluminum alloys GTAW welding is a high quality precision welding process and is ideal for welding thin gauge metals It requires higher operator skill than other forms of welding and is suitable for a range of metals including mild steel stainless steel titanium aluminum and aluminum alloys GTAW welding is a slower process than GMAW MIG but it produces a more precise weld and can be used at lower amperages for thinner gauge metal GTAW welding using DC creates an elect
132. d also STARTING THE TAP E102A Notes T2 T12 Version 4 BG doc Page 102 of 254 23 January 2014 eases the cutting load by distributing the cutting action over several threads e Hold the tap wrench with both hands close to the centre of the tap wrench by pressing downwards and turning in a clockwise direction at the same time the tap will start to form a thread e After completing approximately one to two turns the squareness of the tap to the work surface must be checked This is carried out by removing the tap wrench from the tap and placing the blade of a try square against the tap checking in two positions at right angles to each other e Replace the tap wrench on the tap and continue to press down on the tap as it is turned At the same time gently bear sideways if it is necessary to correct any errors found via the check that was made If strong resistance is felt back the tap off free it a small amount to break the chip then continue to turn clockwise Tapping a Blind Hole le A blind hole is one that does not penetrate completely through to the other side of the material e The tapered tap is used to start cutting the thread in the hole e The intermediate tap is then used to consolidate the thread to a point where the plug tap may access enough threads for stability e The plug tap is used to cut the thread all the way to the bottom of the blind hole e By the time the tap has made 3 or 4 turns and i
133. d cut These files are used for filing internal angles more acute than the right angle Three corner files triangular have a triangular cross section which gradually tapers Some files taper all the way to a point especially small ones They are used for many cuts such as cutting angles less than 90 degrees They are often employed to sharpen the teeth of wood saws Dr me tire terre sink a ae as i Be ae Th a j Tee a TARRAT oes Sa poi 7 rr m Pey T E102A Notes T2 T12 Version 4 BG doc Page 46 of 254 23 January 2014 Rasp Rasp files are tanged for blacksmith type work They are flat with a rasp cut on one side upstanding teeth arranged in rows with curved cutting edges of generally pyramidal shape and have a cutting face with a positive rake or slope and a double cut file on the reverse side They are used for removal of soft materials such as wood Dreadnought File Dreadnought files typically have very coarse curved teeth They are used for rapidly removing large quantities of material from thick aluminium alloy copper or plastic epoxy filler materials NB A tradesperson s toolkit is not complete unless it contains an assortment of file types Jeweller s Files Kits of small files often called Swiss Pattern or Jeweller s files are used to fit parts of delicate mechanisms and for filing work on instruments Always handle these small files carefully because they break easily Round Li ee Square
134. d definitions that apply to wording in the document Procedures for Inspection and Testing Section 2 of AS3760 outlines the frequency of inspection and testing types of inspection and tests to be undertaken required test results actions to occur as a result of the test results and required documentation In Queensland the requirement of the Electrical Safety Act and Regulation 2013 takes precedence over the requirements of AS NZS 3760 What this means is that you must firstly ensure you meet the requirements of electrical safety legislation If the standard has additional requirements then they can be addressed as an add on Extracts from AS NZS 3012 2010 Electrical installations Construction and demolition sites Section 3 Verification and Testing Construction wiring and electrical equipment shall be inspected and tested as follows 3 5 RCDS RCDs shall a be successfully operated by means of their in built test facility push button and b be subject to and comply with a test for operating time of RCDs in accordance with AS NZS3760 3 6 Other Electrical Equipment on Site 3 6 1 General All other electrical equipment on site including power tools flexible cords cord extension sets and portable socket outlet assemblies shall be tested in accordance with Clauses 3 6 2 and 3 6 3 aS appropriate and inspected in accordance with the methods of AS NZS 3760 before being put into service and thereafter at intervals not exce
135. d into the hole of the handle With one hand hold the body with the file upright Steady the file with the other hand e Bring down the handle sharply on a solid bench top e Alternatively a small diameter pilot hole is drilled axially in the handle Then the tang is heated while the blade is protected by a wet cloth e When the tip of the tang is red hot it is pushed into the handle to a depth of three quarters of its length and then withdrawn e Once the tang is cool it is reinserted into the hole and firmly fixed in the handle Inserting a file in a plastic handle e File three grooves in the tang e Heat the tang until it is cherry red e Push it into the plastic handle The heat will melt the plastic into the grooves and solidify when it cools File Storing and Safety Files are fine cutting tools To cut well they must be kept clean Because they are tempered and hard they are also very brittle and easily damaged E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Light downward force Forward movement DRAW FILING GRIP ALTERNATIVE POSITION Hold the file body Bench top CORRECT INCORRECT INSERTING THE TANG IN THE HANDLE Page 49 of 254 To care for files ensure that you follow these rules e Keep files clean and dry Never put oil on the teeth of a file Never strike a file on a solid metal surface or strike it with a metal object it could shatter Never bend a file or exert excessive pre
136. d screwdrivers be used for Pozidriv screws nor Pozidriv screwdrivers for Phillips head screws since the recess is easily damaged E102A Notes T2 T12 Version 4 BG doc Page 111 of 254 23 January 2014 Identification of recessed screws and screwdrivers Because Pozidrive screwdrivers are unsuitable for use with Phillips recess fasteners you should be able to identify both types of tip Comparing tips of the same size Both types have 53 end angles formed by the wings and there is a second taper that gives the extreme end a blunted appearance The top image to the right is Phillips and at the bottom is Pozidriv Their differences are listed below Phillips tips have e wings that taper e shallow two faceted flutes between the wings Pozidrive tips have e Wings that have straight sides e Small ribs or projecting flutes between the wings Screwdrivers Safety e Select the correct type and size of screwdriver for the task e Check that the tip is in good condition and is a good fit in the screw slot or recess e For electricians check that the handle is free of defects and that the handle is well insulated e Keep your hand away from where it could be injured by a slipping screwdriver blade e Keep the axis of the blade in line with the axis of the work e Never use a screwdriver as a chisel lever pry or punch bar Torx Driver Torx pronounced torks is a special type of screw head characte
137. dges Mill files are tapered in both width and thickness One edge has no teeth le Safe edge Mill files are used for smoothing work draw filing and other fine precision work Mill files are always single cut Warding File This file can be used for narrow slotting and working on intricate shapes It is double cut parallel in thickness tapered in width and quite thin Like a hand or flat file that comes to a point on the end Used for flat filing work Round Also called a Rat Tail file This file is used for enlarging circular holes or rounded grooves that are too small for a half round file It tapers toward the point making it adaptable for use on various size holes Round files are gradually tapered and are used for many tasks that require a round tool Half Round File This file is used for filing out concave surfaces and crevices and for rounding out holes The spiral cut enables them to remove metal rapidly and leaves a smooth finish Some half round files taper in width and thickness coming to a point and are narrower than a standard half round file Square File This file is used for filing slots Keyways and rectangular as well as square holes and for surface work this file has four equal sides Double cut it tapers toward the point Triangular Three Square or Three Cornered File Three square files are triangular in cross section and are double cut and have fairly sharp corners that are slightly set an
138. ds adjustment E102A Notes T2 T12 Version 4 BG doc Page 99 of 254 23 January 2014 Safety Vertical Drill DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on a Vertical Drill Safety glasses must be Long and loose hair mn Gloves must not be worn at all times in work must be contained vi worn areas Sturdy footwear must Close fitting protective Rings and jewellery T be worn at all times in F clothing must be worn must not be worn work areas Pre Operational Safety Checks e Locate and ensure you are familiar with all machine operations and controls e Ensure all guards are fitted secure and functional Do not operate if guards are missing or faulty Check workspaces and walkways to ensure no slip trip hazards are present Ensure the chuck key if used has been removed from the drill chuck Follow correct clamping procedures to ensure work is secure Erect a barricade if the job obstructs the walkway Adjust the spindle speed to suit drill or cutter diameter APETA ee Safety Checks Before making adjustments or before cleaning swarf accumulations switch off and bring the machine to a complete standstill e Feed downwards at a sufficient rate to keep the drill cutting e Feed with care as the drill breaks through the underside of the work e Use a safe working posture Ending Operations and Cleaning Up e Switch off the machine when
139. ds and forms the metal by pressing it into a specially shaped V die The size of the die of the press brake can be changed to suit the task le Gauge and type of metal The press brake is a high volume production machine That is it is better suited to doing a large number of repetitive operations rather than doing many different operations Generally machine stops are set to suit the task and then the process can be repeated exactly many times over for a production run Press brakes are made in various sizes with a 3 metre wide bed model being common NB Typically a knife edged shape blade is forced down onto the sheet forcing it into a V shaped die This produces a folding action on the metal The distance that the blade travels vertically downwards creates the bend angle E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 200 of 254 NB This type of folder can produce multiple folds very close together if required Unlike the pan brake folder the gain or stretch which occurs during the bend is distributed either side of the fold line gt Always wear appropriate PPE as designated in the SOP when using this machine gt Always ensure that all guards are in place prior to use as your hands may get squashed between top and bottom tooling Also fingers may get trapped between machine and work piece gt The work piece may fly up when bending and strike operator
140. e drill This greatly reduces the included angle of the cutting lip This will give the drill a scraping action necessary for brass rather than the cutting action used for steel This scraping action will significantly reduce the likelihood of the drill grabbing when drilling brass stock NB Once the drill has been backed off in this fashion to suit brass it cannot be used to drill mild steel in this form Typically a small number of drill bits are sharpened in this fashion and are then retained solely for drilling brass Drilling Perspex The drill bit sharpened as above to suit brass can also be used to drill holes in Perspex sheet This material is very brittle and highly susceptible to grabbing and shattering A drill with the face backed off in this fashion scrape through the Perspex Important To further reduce the probability that the drill will grab and crack when drilling Perspex always use a fresh piece of timber packing material immediately behind the Perspex and in line with the axis of the drill When drilling multiple holes always relocate the packing piece to a fresh area for each new hole to be drilled Possible Faults Due to Incorrect Drill Sharpening Typical chip pattern e Lip lengths unequal lip heights unequal drill point off centre Result Oversize hole uneven swarf from each flute reduced cutting efficiency e Unequal angles ch
141. e models have selectable hammer action for light duty masonry drilling Some models have variable speed control Pistol grip drills are designed for single hand eee Dutton operation and are mainly used for drilling small diameter holes Power lead The size of a portable drill is established by the PISTOL maximum twist drill diameter that its chuck will ee accommodate For portable drills sizes range from 6 5 10 to 13mm Eg A 10mm drill will take up to a 10mm twist drill When using a portable electric drill always wear suitable eye protection and ensure that drill test tag indicates that it has been tested to verify that it is in safe working order Cordless Drill These use a rechargeable battery as energy source They are used as a drill and as a power screwdriver if they have a reversing switch fitted The cordless design offers increased flexibility of movement Some models have drill bit capacities up to 12mm hammer action and variable speed There is a range of rechargeable battery types available with 18V Lithium ion types commonly used trade model They weigh up to about 2kg Variable speed allows you to match the speed with the size of the drill bit It also allows you to start drilling slowly then increase the speed as required without burning out the motor Heavy Duty Drill These are used for drilling larger diameter holes The side handle prevents injury to the operator if the drill bit jam
142. e amount of off cuts which invariably is wasted When performing the calculation on usage always consider the cut wastage kerf For example a guillotine has a shear action which has virtually no loss but a saw will have a loss of about 2 3mm for each cut If the job pieces are small and there are many cuts to be made then this loss can be significant If the job length is small always pre determine if the stock material can E102A Notes T2 T12 Version 4 BG doc Page 220 of 254 23 January 2014 be safely secured after it has been reduced to a small size That is can you safely make the final cut s or does this section become waste also The method used to mark out a sheet will depend on whether it is a one off task or a large production run For a one off task always attempt to use up an off cut from a previous job if possible and avoid cutting a new sheet For a production run involving a full sheet always consider how the sheet is to be cut For example a guillotine will only make complete cuts across the sheet but a gas cutter or laser cutter can cut virtually any length or shape If using a guillotine common edge cutting is a more efficient method as the one action can produce a number of pieces But it may also lead to wastage Computer controlled machines are able to obtain the optimum cut from a sheet Other techniques include nesting small parts in cut out holes and making use o
143. e joint and applying the alloy FOR WELDING Types of Braze Joints oe The best brazed joints are those which have a capillary joint le close fitting gap into which the molten filler metal can flow The most common type of joint used for brazing is the lap joint or the sleeve joint in the case of tubular components The main criteria for a lap joint are the joint gap and the degree of overlap It is these two parameters that determine the ultimate joint strength rather than the properties of the filler metal Safety Brazing alloys and fluxes contain elements which if overheated produce fumes which may be harmful or dangerous to health Brazing should be carried out in a well ventilated area with operators positioned so that any fume generated will not be inhaled Adequate ventilation to prevent an accumulation of fumes and gases should be used Where fume levels cannot be controlled below the recognized exposure limits use local exhaust to reduce fumes and gases In confined spaces without adequate ventilation an air fed breathing system should be used and outdoors a respirator may be required Special precautions for working in confined spaces should be observed Apart from fume hazards flux can be irritating to the skin and prolonged contact should be avoided Before use E102A Notes T2 T12 Version 4 BG doc Page 155 of 254 23 January 2014 always read all the manufacturer s instructions Refer to the
144. e of the nibbler is that it will cut tighter bends than can be achieved by shears and it does not distort the material ELECTRIC NIBBLER either side of the cut The disadvantage is the very wide kerf NB Nibblers are designed to suit a maximum material thickness Do not use a tool on material that is thicker than the machine s capacity Always refer to the manufacturer s instructions prior to use NB Sheet metal workshops often have a fixed nibbler Pierced section of sheet NIBBLING Sanding Machine This hand held machine can be either electrical or air powered It has a flexible rubber pad onto which the abrasive sanding disc is fastened by means of a centre nut This tool is used in a sheet metal workshop for weld removal on metal panels cabinet corners etc prior to painting E102A Notes T2 T12 Version 4 BG doc Page 192 of 254 23 January 2014 Electric Angle Grinder Wear face shield The main use of an angle grinder in the sheet metal shop is for removing excess weld metal on welded joints flanges frames and general fabrication work prior to painting With the aid of a cutting disc sheets angles flat bar etc can be cut to size It is a heavier duty than a sander Changing Grinding Discs The method of changing a grinding disc on the different sizes of angle grinder is very similar On most grinders the grinding disc is secured by a locknut The removal of the disc requires a two pronged
145. e open or partially open types then cover them with a plastic bag to ensure that are safe 5 An idle electric motor should be rotated by hand approximately 10 for each calendar month to ensure that the bearings are not affected by false brinelling 6 Link sub assemblies temporarily together to better protect components Eg Electronic circuit cards are susceptible to ESD Electrostatic Discharge and are safer if they are reinserted back in their connecting slots Surface Mounted Devices SMDs are less likely to suffer mechanical damage if the cards are relocated back in their slots 7 Store electronic circuit boards in specially designed anti static bags NB One of the keys to successful disassembly and assemble is to always be patient and methodical Machines with Close Fitting Parts As manufacturers of electrical equipment are forced to meet government Minimum Energy Performance Standards MEPS they are engineering their products to much closer tolerances Appliances such as electric motors etc have much reduced air gaps and spacings Eg Electric pumps which require seals to prevent liquid leaks also operate on very fine tolerances Other equipment which has close fitting parts includes those rated for flame proof or explosion proof operation Witness Marks Due to the fine tolerances there may be rotational clearance only when the machine is assembled in one of the possible ways Key alignment marks called
146. e position of the outlines as they may become obliterated Witness marks are especially important when the marking medium eventually rubs off due to handling Witness marks are light uniform indents made with a fine prick punch and punched accurately on the line work indicating the outlines When the required fitting or machining has been completed only one half of each witness mark should remain visible Once the witness marks have been completed the centre marks used for drilling are deepened at this stage prior to commencing drilling operations NB Examples of the placing and spacing of witness marks are shown below Edge to be machined Edge to be filed Hole to be drilled Hole to be filed At every change in direction Spaced to accurately indicate the shape Sustainable energy work practices related to reducing waste when marking out Stock materials are sold in standard sizes Efficient ordering means purchasing stock sizes so as to obtain the maximum number of job pieces blanks out of a stock length The key is to eliminate the amount of off cuts which invariably is wasted When performing the calculation on usage always consider the cut wastage For example a guillotine has a shear action which has virtually no loss but a saw will have a loss of about 2 mm for each cut If the job pieces are small and there are many cuts and this loss can be significant If the job length
147. ead types maintain a slightly higher profile to various degrees The screw head shape is chosen to fit the application Larger heads can be used to cover large mounting holes and spread the mechanical forces over a bigger area a b C d Profile Legend a pan b dome button c round d truss mushroom tank e flat countersunk f oval raised head The advantages offered when joining materials using machine screws are e Ease of disassembly e No heat distortion e Nodisruption to painted surfaces The main disadvantage of machine screw fixings it that they may become loose under severe vibration This however can be overcome by using special locking nuts or washers or a chemical thread locker product such as Loctite 243 Ref http www hirespares com sealants adhesives thread lock c 68 71 html E102A Notes T2 T12 Version 4 BG doc Page 127 of 254 23 January 2014 Overview of Machine Screws http www boltdepot com fastener information T ype Chart aspx Machine Screws with uniform Socket Headed Machine Hexagonal Headed Screw threads for use with anut ora Screws also known as Allen for use with a nut or tapped tapped hole head are fastened with a hex hole Allen wrench ss DD Common Screw Head Types There is a large number of screw heads available but the common types are shown below Slotted head Truss Tank Oval head Pan head ly Washers and Nut Types
148. eal for large work The work is clamped directly to the machine table The packing must be the same height as the work or slightly higher The clamping bolt should be as close to the work as possible Soft metal strip Packing to make clamp Diaken pan acc a parallel to table N Smali N Machined surface Job tends to move towards clamp Washer Gi ie apie Bolt closeto work E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 97 of 254 Tapered Shank Drill bits can be purchased with a No 2 Morse taper shank to match the Morse taper in the machine spindle A steel wedge is typically used to remove the drill bit from the spindle This allows the fitting of bits without using a chuck The shank of the drill and the hole in the driving shaft sleeve are identically tapered The bit is pushed firmly into the sleeve Drilling increases the pressure onto the taper thereby creating a more positive grip Qe Safety Ensure that the power to the drill is effectively isolated before changing the belt position The pulleys are very sharp and could easily sever fingers NB Some newer type pedestal drills are fitted with electronic variable speed controls Feed Control A simple hand lever with two or more spokes is usual If using a machine for the first time gauge the feel and the range of movement of the lever Work Table Note how it is adjusted and how it can be fixed Some tables
149. eave the machine running unattended Do not bend down near the machine while it is running Never force the work piece against a wheel x xXx KK XK E102A Notes T2 T12 Version 4 BG doc Page 73 of 254 23 January 2014 Engineering Lathe The main function of the engineering lathe is to hold and rotate the work piece to perform a machining operation Machining operations include facing turning drilling reaming form threading boring Knurling and more The work material is securely held in an attachment to the rotating spindle such as a chuck or a face plate While the work piece is spinning a specially shaped cutting tool which is attached to the tool post takes a precise cut across the surface of the work piece In this way the work piece is machined down to the required size This tool has many applications in the electrotechnology industry including truing or skimming the surface of a copper commutator or brass slip rings and also to machine electric motor shafts and bearings Main Parts of a Lathe As shown in the image below a lathe is comprised of a number of parts The main parts that you should be aware of are listed below Tool Post Tailstock Headstock Spinde Carriage compound Slide AS hr i Bed Ways E tar a Coo Nee SS of a E Lead Screw Change Box Feed Screw CENTRE LATHE MAJOR PARTS Bed This is the base for the whole
150. ece from warping due to over heating The coolant minimizes friction which reduces heat buildup and allows the heat to better flow away from the job and the drill bit Cutting lubricants are typically needed for steel and wrought iron but cast iron aluminium brass and other soft metals may be drilled dry The lubrication list below suggests suitable lubricants Lubrication Chart WIG CAI anaa aaa Fluids Aluminum Alloys c 0000 Kerosene lard oil soluble oil Brass Bronze cisienctcearesetddnites Dry Kerosene lard oil soluble oil for deep holes Magnesium Alloys 0008 Mineral lard oil kerosene or dry CONDE conics roaa Mineral lard oil and kerosene soluble oil or dry Mild Steel ceeccceeeeeeeeees Mineral lard oil High Tensile Steel Soluble oil Stainless Steel ccceceee Soluble oil TANU aone Soluble oil PIASTICS aisa ntlaenaas Soapy water Hard RUDDET cinse Dry Warning Cutting fluids have been associated with skin rashes dermatitis and some serious diseases Care should be taken to avoid inhaling any vapours or mist resulting from the use of cutting fluids and precautions should be taken to avoid skin contact E102A Notes T2 T12 Version 4 BG doc Page 88 of 254 23 January 2014 Sharpening a Twist Drill for Steel and Aluminium All twist drills eventually become spe ea a mut ts oF blunt after continued use sea ANGLE Therefore it is necessary to CUTT
151. ed e Pitch of saw too coarse too few teeth in contact with work Incorrect tension on blade Starting a cut on a corner Pressure too great Failure to reduce pressure at the finish of a cut Twisty or jerky sawing action Using new blade to finish a cut started with worn blade Correct E102A Notes T2 T12 Version 4 BG doc Page 54 of 254 23 January 2014 Safety Considerations e Always wear safety glasses to avoid chips entering eyes Ensure the blade is correctly tensioned and that the teeth point away from the handle Clamp the job close to the saw line to avoid excessive vibration Support the over hang as the cut is nearly completed When cutting always have in your mind that the blade could shatter at any time and your balance is the only thing preventing your knuckles from injury Junior hacksaw A junior hacksaw is used to cut light gauge metal or rigid plastic such as PVC conduit etc This is a small steel framed tool in which the spring tension of the frame itself holds Junior Hacksaw the blade in place The blade must be fitted with the points of the teeth facing forward away from the handle so it will cut on the forward stroke Pad Handle Pad Handle A pad handle is made of a light alloy or a rigid plastic and has a securing nut designed to hold a piece of a standard hacksaw blade It is used to make a cut in tight confined spaces or situations where you are unable to access the space in behind t
152. ed to create internal holes E102A Notes T2 T12 Version 4 BG doc Page 253 of 254 The gasket is made from a material that is yielding so it can deform and tightly fill the voids Eg Rubber neoprene cork etc The gasket material must be compatible with the substances being contained le Temperature pressure acidity etc Some gaskets require an additional liquid or paste sealant to enhance its sealing properties Always check with manufacturer s specifications before using unknown sealants When installing the gasket is clamped between two solid surfaces with sufficient force so that the pressure is resisted by the stored energy within the gasket A gasket has to react to the forces generated by the bolts and therefore the work and energy imparted to the bolted joint becomes stored within the gasket itself Installing a New Gasket e Remove all foreign material and debris from the seating surfaces fasteners bolts or studs nuts and washers e Examine flange surfaces for warping radial scores heavy tool marks or anything prohibiting proper gasket seating Replace components if found to be defective If in doubt seek advice e Examine the gasket to ensure it is free of defects e Carefully insert gasket between flanges Do not use jointing compounds or release agents on the gasket or seating surfaces unless it is specified by the gasket manufacturer Bring flanges together ensuring the gasket isn t pinc
153. ed to suit the strength of its jaws The following spanners are common to an engineering workshop e Open end spanner Ring spanner Socket spanner Ratchet spanners Adjustable spanners Torque wrench Tube or Box Spanner Most spanners are purchased as part of a set suitable for the bolt types and sizes likely to be encountered Common set types include metric BSW and AF Spanner Size Both Metric and AF across flats nuts and bolts are measured across the flats measurement A opposite of the hexagon In millimetres for metric and fractions of an inch for AF Fixed Size Parallel Jaws _ Stamped BSW British Standard Whitworth spanner sizes ae are based on the diameter of the bolt and not the is dimension across the flats of the head There are a m instances where different sizes of bolt from different l j __ _ thread types have the same size head and aa E 4 X therefore fit the same spanner Never use a lt Shank spanner from one thread system on another thread system Open End Spanner These spanners are open at both ends so they can SIDE VIEW be placed around nuts or bolts They are very OPEN END SPANNER useful where you are unable to place the spanner over the bolt head or nut because something is in the way Standard spanners have a length about ten times the width of the jaw Extending this will strain the jaws of the spanner strip the thread shea
154. ed to the spindle By tightening the nut on the spindle the punch and die are gradually pressed together until the hole is clearly punched through Holes made with these punches are suitable for fixing meters gland fittings and light sockets etc USING A METAL PUNCH METAL PUNCH E102A Notes T2 T12 Version 4 BG doc Page 219 of 254 23 January 2014 Fly Cutter A fly cutter consists of a lathe cutting tool secured to an adjustable arm This in turn is secured to a holder the spindle of which is clamped into a drill chuck Very large diameter holes can be cut with this tool and the cutting is done at the lowest speed possible Large radial drilling machines are typically used as they offer accurate control and very low rotational speeds The plate or sheet to be cut with this process must be clamped very securely against rotation and held absolutely flat on the work lil Cutting bar table Suitable cutting fluid must be provided during the cutting operation Cutting a Rectangular opening To cut out a rectangular opening in an electrical switchboard gt Mark out the cut out outline with a ruler scriber and try square etc NB If the switchboard is already painted then it is best to use masking tape to shield the cut out area against scratches and mark the cut out on the Pilot drill masking tape with a pen or pencil gt Drilla clearance hole suitable for the saw blade to be USE OF FLY CUTTER used in diagonall
155. edge Set odd leg callipers to the required width Mark to the required width by moving the odd leg callipers along the datum line VV VVVWV E102A Notes T2 T12 Version 4 BG doc Page 205 of 254 23 January 2014 Cutting Sheet Metal To form the job the sheet metal needs to be cut accurately using appropriate cutting tools and in accordance with safety requirements In workshop situations large sheets typically need to be cut into smaller pieces blanks to produce the required components for fabrication This is typically done with a guillotine As shown above large guillotines are usually power driven while smaller types are manually operated usually by a foot pedal or bar All guillotines have limits with respect to the type and thickness of materials they can cut Always read the SOP to obtain user instructions for the safe and correct use of a guillotine before starting Never exceed the rated capacity of the guillotine This could result in expensive damage to the machine or injuries to workers In addition to a guillotine there are a number of hand held power tools available that can be used for cutting sheet metal although non will achieve the same level of precision as a guillotine The hand held tools include Power shears Nibblers Circular saws fitted with metal cutting blades Angle grinders fitted with metal cut off discs VVVV Always read and follow the instructions given in the SOP for each tool and wear the PPE a
156. edge s or surface s A datum edge is a straight edge running the length of the material It provides the starting or reference position to begin marking out The marking out for a job can originate from one or more datum points lines or surfaces The datum may be a manufactured edge of the stock material or if the existing edges on the material are too rough the datum may be scribed line s that are drawn near the edges In some situations the datum point may two intersecting lines established to locate an important feature such as a centre lines for a hole The images below show three examples of how a datum enables the marking out process to proceed Datum Edge 6 mm p a Datum Edge Insert Datum Point Datum Lines Datum Line E102A Notes T2 T12 Version 4 BG doc Page 28 of 254 23 January 2014 Centre Lines Centre lines are often scribed at required distances from the datum features to establish the positions of holes slots radii and other details Holes and radii centres require two centre lines Centre Lines et 40 mm Outlines Outlines show the dimensions of the work piece and indicate the location and amount of metal to be removed Lengths widths thicknesses angles diameters and radii are outlines which determine the finished shape Finally carefully check all dimensions against the drawing Remember Measure twice and cut ONCE NB If an error in the marking out is f
157. eding those listed in Table 3 of this Standard TABLE 3 PERIODIC VERIFICATION INTERVALS Transportable structures Class I earthed conductive parts and Residual current devices Class II doubled insulated RCDs electrical equipment Transportable Pushbutton test Operating time Environment Structures fixed by user RCD tester and transportable Portable equipment and equipment Non i Non construction Portable portable Portable portable fixed fixed wiring including switchboards Construction 6 3 After l 3 12 and months months connection to a month months months demolition socket or sites in before accordance connection of with equipment and Clause 1 1 at least once every day in use E102A Notes T2 T12 Version 4 BG doc Page 179 of 254 23 January 2014 3 8 2 Non compliant equipment Where inspection or testing identifies equipment that fails to comply with the criteria given in this Standard the equipment shall be a withdrawn from service immediately have a label attached to it warning against further use and b sent for repair disposal or destruction by an authorized repair agent or service personnel 3 8 3 Compliant equipment New equipment after inspection and tests shall be fitted with a durable non reusable non metallic tag Construction wiring switchboards fixed RCDs fixed and transportable electrical equipment need not be tagged 3 10 Documentation Reco
158. ee O Threa Squere LC oee Hali Round em py Flat Warding Ee Knife y LL Ln EE EEee Hane i Doce OE E EEEEEEEre Crossing nT A Barrette q Round Edge oint lt Queene Slitting 0 a Pippin a E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 47 of 254 File Handles The tang of a file is designed to fit tightly into a suitably sized file handle It is designed as a tapered fit The file handle is typically made of strong high impact material contoured to fit the hand for straight or draw filing Each file must be fitted with a handle for two reasons 1 To prevent the sharp long tang from piercing the hand 2 To give better control over the pressure and direction of the file Both wooden handles and plastic handles are common Long files require a long handle and vice versa The handle must fit firmly onto the tang and must not be loose How to use a File Cross filing Use long steady strokes of medium pressure made at about 40 to 50 strokes per minute If the pressure is too light or the file speed too great then the file tends to slip over the work without cutting Slipping damages the file s teeth Always use enough pressure so that you feel the file cutting Use drill of rg this diameter DRILL HANDLE TO SUIT TANG For heavy filing increase the pressure and decrease the speed of filing If the work is very soft or its surface very narrow use less pressure
159. eees 138 MIG Metal Inert Gas 143 TIG Tungsten Inert Gas 0 0 eeeeee 146 Spot Welding ccccccceecccceeceeeeeeeeeeeees 148 Oxygen Acetylene Welding 151 Brazio enoni Ei 154 SOLJEN sonini 156 Silyer Solde essri 156 E102A Notes T2 T12 Version 4 BG doc 23 January 2014 CUNT TOO e ener me tenn emer ttee 163 Pneumatic Power Tools ccccceeeeeeeees 165 Electric Powered Tools 168 Portable grinding machines 168 Angle Grinde s cccccceeeeeeeeeeeeeeeeeees 168 Straight Grinder ccccccesseseessseeeeeeeeeeeees 171 Die GANGET srecrnsuiaca aanbeakes 171 Sanding Machines sssssssseseeeeeeeees 171 Portable Mains Powered Drill 172 Cordless Drill c ccccccceceeeeeeeeeeeeeeeeeeeeaes 172 Heavy Duty Drill eee 172 Power Saw Circular Saw cc cceeeees 174 Heal Nise Oe 175 Electric Soldering Iron eee 175 Portable Power Tool Safety 08 176 Care and Maintenance Portable Power Tools E ope deni EE E 176 HazafdS srt snodatensnocahesbaeaatanestagtacnnensinensasents 177 Portable Power Tool Insulation 177 Single Insulated Class I Equipment 177 Double Insulated Class I Equipment 178 Legislative Requirements cccccseeeee 178 Type of electrical equipment to be inspected and tested includes sscsseeeeeeeeeeeees 178 Construction Work
160. emover are available to remove surplus rosin flux as they leave no residue that could cause tracking E102A Notes T2 T12 Version 4 BG doc Page 158 of 254 23 January 2014 Soldering Techniques Soldering is normally achieved with the aid of either a gas torch or a soldering iron A butane gas torch has its own gas supply and reaches correct soldering temperature very quickly The unit shown is self igniting through piezo ignition light weight portable and has an output temperature of 1300 C Its disadvantage is that a naked flame can be very dangerous in some environments as it can burn electrical insulation and surrounding parts because it is difficult to localize the flame Also the flame is adversely affected by the wind Despite this electrical contractors typically use these types of units to make solder connections during installations Ref http www getprice com au A soldering iron provides a more precise form of soldering The heat energy can be directed to an exact location A soldering iron must supply heat to melt the solder so that it can flow into the joint between the work pieces It is comprised of a heated metal tip normally copper and an insulated handle Heat energy is obtained by passing an electric current supplied via an electrical cord or battery supply through a resistive heating element in contact with the tip Some portable irons are heated by a gas flame Solderi
161. ent capacity bar type wrenches available T Handle Tee Tap Wrenches Tee T tap wrenches are used for tasks where there is insufficient room to turn a bar type wrench These wrenches have a small adjustable two jaw chuck on the end of a stem with a handle There are different capacity tee T type tap wrenches available The largest capacity takes taps up to 13mm in size NB A large tap wrench fitted to a small tap significantly increases the chances of snapping the tap Hand Taps Taps are normally used in sets of three to allow progressive cutting of the threads There are many thread pitch types and tap sizes manufactured and this must exactly match the mating thread characteristics Each tap set consists of a e Taper tap i Use only e Intermediate tap F i ona hand e Plug tap or bottoming tap P to turn Each tap in a set has identical length and thread characteristics Only their tapered leads are different See image over page 1 T TYPE i TAP WRENCH E102A Notes T2 T12 Version 4 BG doc Page 101 of 254 23 January 2014 The long taper of the tapered tap is designed to start cutting the thread When tapping materials which are reasonably thin approx 6 12mm and the hole passes completely through to the other side of the work material then the tapered tap can also complete the cutting Tap wrench wy grips squared m part of shank Ml Zi Start with taper Z E i of s
162. er e Insert the rod into the body of the micrometer with the curved anvil outwards e Press the locating face against the end of the micrometer e Tighten the clamping screw to hold the rod in position e Check the zero setting of the inside micrometer by measuring it with an outside micrometer of the same size Radius anvil Push extension rod against micrometer Tighten clamp Measuring a large bore using an Inside Micrometer with an extension rod fitted Check overall size with reading at zero Zero reading Fe a C6 te E E es EE ee Radius ends on anvils to clear hole Minimum measuring range of micrometer E102A Notes T2 T12 Version 4 BG doc Page 234 of 254 Depth Micrometer Depth micrometers are special micrometers used to measure e Depths of holes e Depths of grooves or recesses e Heights of shoulders or projections e The measuring range of depth micrometers can be increased by using interchangeable extension rods Change the extension rod of a depth micrometer as follows Hold the lower portion of the knurl on the thimble firmly between the thumb and first finger of your left hand Use the thumb and finger of your right hand to loosen the knurled clamp by turning it anti clockwise Unscrew the clamp completely from the thimble Remove the existing rod by pulling it completely out of the thimble and place it in the protective box Select a suitable length extension rod for the
163. er which will evenly distribute the pressure around the bearing Store ALL parts to ensure they are not lost Connecting box Fan end shield Stator winding Fan cover Cage rotor Bearing Shield and flange on shaft end side Replacement or Repair A common question when a machine fails is should it be replaced or should it be repaired This decision is sometimes difficult to make Considerations include Is a suitable replacement available and what will be the cost and time frame for both options Will the repaired machine be as reliable and efficient as a new one NB Rewound electric motors are not required to meet government MEPS Minimum Energy Performance Standards Age of the machine How long will the repairs take Will a repaired item void any warranty considerations E102A Notes T2 T12 Version 4 BG doc Page 247 of 254 Reassembly of a Motor 1 2 When installing new bearings absolute cleanliness is essential Ensure that the inner bearing cap is in place before fitting a new bearing Most bearings are now of the sealed type which are pre lubricated The use of a hydraulic press is recommended If no other means are available the bearing may be driven onto the shaft by gentle taps with a hammer or mallet A piece of tubing of metal or brass called a drift should be used a mounting sleeve of a shaft The drift must only contact the inner race of the bearin
164. er point angle of 60 or less and it is used to make only small marks on a reference line or outline of a work piece E102A Notes T2 T12 Version 4 BG doc 23 January 2014 May have square head to prevent rolling Prick punch witness marks Hole position with heavy centre punch mark Line up vertically Page 41 of 254 Chalk Line A chalk line is a piece of string or cord that is heavily coated with a coloured chalk The line is stretched tightly between two points and then snapped to release a chalky line onto the target surface The unit shown is a self chalking line A mechanical self chalking line is a container with the line on a reel The container is filled with coloured chalk powder The line is automatically chalked each time it is pulled out and can be 20 to 30m long Ref http www toolstop co uk stanley 0 47 681 fatmax chalk line set p42363 Application This is a tool commonly used by an electrical mechanic during installation work Applications include e Marking out fixing points for a cable run e A straight line guide when installing long rows of light Pull out fittings or and e Levelling duct or cable tray release Technique e Stretch a taut string line between the ends of the proposed run by using suitable means of fastening eg nails or existing fixings This ensures a straight line is produced e Pull the line perpendicular ee ae ae away from surface about 1
165. er use make sure that Tools are disconnected On off__ e first turn off the air supply at the control switch valve e Then disconnect the coupling holding it Wheel _ firmly to prevent the hose from whipping guard around Hoses are not kinked cutting off the air supply Reinforced e This is dangerous and could cause the resinoid wheel coupling to come off e t may damage the hose e The tool is clean PNEUMATIC VERTICAL GRINDER E102A Notes T2 T12 Version 4 BG doc Page 167 of 254 23 January 2014 e Do not attempt to clean yourself or your clothing with compressed air This is a dangerous practice e Do not use compressed air to clean off equipment It can cause you or other workers near by serious eye injury e When finished ensure that the tool and leads are packed away in a safe place for protection Electric Powered Tools When using an electrically power tools there is always the inherent risk of receiving an electric shock As a result there must be very strict safety checks These are discussed later If an electric powered tool stalls for a length of time then the current drawn by the motor will increase substantially This may cause the motor to burn out and it could cause a fire Grinding and Sanding Machines Grinding and sanding operations are used to prepare or finish many goods Many different types of machines are available however their operating principles are similar Por
166. es T2 T12 Version 4 BG doc Page 136 of 254 23 January 2014 Tensile Load Top image previous page Where the load is acting to separate the fastened components along the shank length it is referred to as a tensile load Tensile loads try to elongate the fastener Shear Load Bottom image previous page Where the load is acting to separate the fastened components across the shank diameter it is referred to as a Shear load Shear loads try to slice the fastener in two The load carrying capability of a fastener is somewhat less in shear than in tensile and will further vary if the shear plane is across the threads rather than the plane shank ie Bolt Some applications will exert a combination of tensile and shear loads Selecting Fasteners Calculating fixing sizes is beyond the level of this competency Fortunately manufacturers mostly provide engineering advice on the minimum fastener size when mounting their products If this information is not available then as a rule of thumb select the largest fastener that will fit through the manufacturer s standard mounting hole If replacing an existing fastener then replace like with like unless there is an obvious reason not to When choosing the length of fastener screws after allowing for all intervening layers of materials there should always be a minimum of two 2 full threads protruding out of the securing nut or tapped surface etc Dissimilar Metals Choose the most appropr
167. es and fabricating dismantling assembling of utilities industry components The knowledge and skills shall be contextualised to current industry standards technologies and practices KS01 EE102A Hand and power tools and their application Evidence shall show an understanding of hand and power tools and their application to an extent indicated by the following aspects T1 Mechanical drawing interpretation and sketching encompassing gt drawing standards and conventions used in drawings of mechanical components as specified in AS1100 gt basic abbreviations and symbols used in drawing of mechanical components gt interpretation of mechanical drawings commonly used in the electrotechnology industry orthogonal projection third angle detail and assembly drawings pictorial views gt laying out a drawing of mechanical components using engineering drawing convention gt freehand drawings of mechanical components showing all information needed for its manufacture fabrication T2 Workshop planning and materials encompassing gt methods used to work safely in an industrial work environment gt typical non electrical hazards in the workplace gt control measures for dealing with hazards identified E102A Notes T2 T12 Version 4 BG doc Page 7 of 254 23 January 2014 gt Conducting a risk assessment on a given work environment documenting and assessing the risks identified gt type of metallic and non metallic materials used
168. esistance between the electrodes the amplitude of the current and the duration of the applied electric current The current required for such applications is produced by a step down transformer which lowers the voltage and increases the current output The voltage between the two electrodes rarely exceeds 1 5 volts except for when there is no galvanic connection between the two when the voltage increases to between 5 10 volts The electric current can reach very high values le Hundreds of amps The E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Resistance to passage of current at contacting surface causes fusion under pressure ANAANAANANANNSNAS 8 EV gh GSPSTPLTIALLSA 82 00 0AHSIAIATTAASALAASLS Copper electrode SPOT WELDING Electrode holder pinch bolts Hinged top arm accuated by foot pedal Tee slots to give varying positions for lower arm _ Foot control pedal SAFETY Ensure isolator switch is OFF before making any adjustments Page 148 of 254 spot welder electrodes and the work metal form the secondary circuit of the device E102A Notes T2 T12 Version 4 BG doc Page 149 of 254 23 January 2014 Advantages e Efficient energy use Limited work piece deformation High production rates Easy automation No filler materials required Disadvantage If excessive heat is applied or applied too quickly or if the force between the base materials is too low
169. ety Gaskets used in the past for high pressure steam systems and like may contain asbestos If the presence of asbestos is suspected DO NOT access this existing gasket but immediately seek expert advice and assistance on its safe removal and disposal OOOOOOQOOQOQOOOOOO0O0 0000 E102A Notes T2 T12 Version 4 BG doc Page 254 of 254
170. f http www bargroup com au hollow_shaft_parts html Both the seal lip and the shaft should be lubricated typically with the same oil or grease that is being sealed prior to installation of the seal This makes installation easier and less damaging to the seal It also helps protect the seal during the initial break in period Continued lubrication minimizes wear and maximizes service life of the seal Running a machine with the seal dry can quickly ruin the seal y Care must be taken to install the seal facing the correct direction When replacing an existing seal always note the direction in which the old seal faced Ensure that the seal is installed straight and not skewed such as that shown in the image Use a suitable drift to ensure it is inserted straight in the housing Seal Installation Checklist Is the seal in good condition Is the spring properly in place or has it been displaced during handling Have you carefully wiped the seal clean so as not to damage it Have you made sure there are no nicks scratches or spiral grooves on the shaft surface Have you pre lubricated the seal s lip for initial break in N KAKRA E102A Notes T2 T12 Version 4 BG doc Page 252 of 254 Are you installing the seal with the lip facing in the right direction Are you installing the seal at a right angle to the centerlines of the bore and shaft Have you taken measures to keep the lip from being damaged when passing
171. f suitable off cuts where possible Always re check all marking out measurements prior to cutting to ensure no error wastage Always remember the saying measure twice and cut ONCE E102A Notes T2 T12 Version 4 BG doc Page 221 of 254 23 January 2014 Tolerance Engineering tolerance is the maximum permissible limit or limits of variation in a physical dimension a measured value Eg It could be the space between a bolt and a hole etc Dimensions properties or conditions may vary within certain practical limits without significantly affecting functioning of equipment or a process Tolerances are specified to allow reasonable leeway for imperfections and inherent variability without compromising performance A variation beyond the tolerance is said to be non compliant rejected or exceeding the tolerance regardless of if this breach was of the lower or the upper bound If the tolerance is set too restrictive resulting in most objects being rejected it is said to be intolerant A primary concern is to determine how wide the tolerances may be without affecting other factors or the outcome of a process Vernier Calliper Vernier Gauge NB A calliper is an instrument designed to measure the distance between two points A vernier calliper is a precision tool used to obtain very accurate measurements for machined components A vernier is a small movable graduated scale used in combin
172. f the lower handle Squeeze the hand closed and note that handles and blade close Open the hand and note that the handles part and the blades open ready for cutting Place the sheet metal to be cut into the blades with the junction of the blades on the marking line Squeeze the hand closed and note the cutting action Open the hand and move more metal into the blades Alternatively push the snips further into the metal Repeat the steps above until the cut is complete Avoid closing the blades completely as this causes distortion of the metal immediately ahead of the snips VVVVV V V V WV Pop Rivet Tool Gun This tool is used to install a fixing rivet in a pre drilled hole located within thin materials such as sheet metal for the purpose of joining Pop rivets are manufactured from aluminium alloy mild steel or copper alloy http www htsalescompany com E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 __Rivet or bolt a Sto p 5 Handle Metal curls up CORRECT USE OF TINSNIPS Page 187 of 254 They are supplied with a domed or countersunk head in diameters of 2 8mm 3 2mm 4 0mm 4 8mm and 6 0mm Rivets are made in various lengths to accommodate different thicknesses of materials The hole size to be pre drilled is typically the nominal size of the rivet NB Always check manufacturer s details Riveting Tool A typical hand riveting tool with grip handles is shown above This tool is su
173. f the screw should be slightly longer than the conjoined pieces so as to ensure that a nut etc can be secured to the end The length of the fully tightened screw should be such that the screw tip should protrude beyond the securing thread or nut by at least two full threads There are many head types commercially available such as slotted Phillips and Torx head The head type must match the available tightening tools Eg Battery drill tip or hand screwdriver etc Machine screws are prone to snapping if over tightened A tool such as a screwdriver or battery drill and screw bit offer a large mechanical advantage to the user Always match the size of the tightening tool to the size and type of screw Nb Brass screws tend to snap very easily and tend to give little warning that they are about to break Choosing between the different screw heads normally comes down to the tool available and whether you want a screw that has better torque Phillips head or more driving force slotted head Hex heads can take more stress than the slotted types and are better for heavy duty projects Torx heads are sometimes used to restrict unauthorised access to a part There are a number of different head profiles and shapes The common machine screw head profiles are shown below e A flat countersunk head has a completely flat top and is normally used for projects where the screw head must be flush with the top of a surface All of the other h
174. for special applications Rigid nylon is used if an insulator is required Each type of material has different characteristics of strength and corrosion resistance The key is to select a screw type to fit the application and the environment Always consider factors such as metal fatigue due to vibration and electrolytic corrosion if dissimilar metals are to be direct contact within a moist environment Gland plate Zinc plated mild steel screws are used in benign environments such as a dwelling or factory etc Stainless steel and brass are best used for outdoor applications and for corrosive marine environments where ordinary mild steel even plated types would quickly corrode Brass Part B is often used for its good electrical Machine Screw conductivity and nylon screws are used for their electrical insulating properties Hex Nut When choosing a machine screw first consider the pieces to be joined A and the thickness of the substrate a and then select a screw that is long b y Flat Washer enough to pass completely through d Y The diameter of the screw should be Part A Lock Washer E102A Notes T2 T12 Version 4 BG doc Page 126 of 254 23 January 2014 thick enough to resist the forces that will attempt to separate the fixing and its load Screw diameter is normally determined both by the material that the screw is made from and the stresses that it will encounter during its life The length o
175. ften used with a radial arm drill Wad Punch Because the leading edge is very sharp it enables this tool to cut neat holes in soft sheet material such as plastic fibre felt or lead This makes it suitable for making gaskets Wad punches are produced with hole sizes ranging from 5mm to about 40mm using high grade steel To use a wad punch first place a piece of soft timber as backing behind the sheet material and align it with the point of contact Align the wad punch carefully with the centre line cross and strike the end of the punch cleanly with a hammer If sharp it should cleanly remove the centre section from the material E102A Notes T2 T12 Version 4 BG doc Page 57 of 254 23 January 2014 Metal Punch Chassis Punch This tool is used to cut neat holes up to about 40mm diameter in sheet metal or gasket material with a thickness not greater than 1 6mm This tool is often used to cut conduit access holes in the sides of electrical switchboards First drill a clearance hole for the bolt Locate the cutting head on the inside and the recessed section on the outside Thread the bolt through and begin to tighten using an Allen Key or ring spanner depending on the design When the cutting head passes through the metal it leaves very little burr Because it produces little heat it does not affect painted surfaces Cold Chisel Cold chisels are designed to cut thick sections of metals such as steel but
176. g gas system is not suited to outdoor applications in the wind Vine spool 7 B amp G Regulates a Wire Feeler r Cas Shiekh Ui wekl shiekling gas A Gronni Cabbe The GMAW process is versatile and is capable of Splid wire joining most types of metals eleclrode and it can be performed in fy Shielding gas in most positions Itis suitable if for many metal types including aluminum mild Trave steel cast iron magnesium and stainless steel Current conductor Wire euide and eontact tube rT Tag nozzle molidfied PT EAN Ref weld metal ie 2 ehielding gag http www burnsstainless co ia m During GMAW welding the thin wire electrode melts within the arc and becomes deposited as filler material The wire feed unit supplies the continuous electrode to the work driving it through the conduit lead and on to the contact tip Basic models provide the wire at a constant feed rate only but more advanced machines can vary the feed rate in response to the arc length and voltage setting The wire feed rate sets the arc length and is one of the most important settings on a MIG welder needed to obtain quality welds Holen weld metal E102A Notes T2 T12 Version 4 BG doc Page 144 of 254 23 January 2014 Safety Gas Metal Arc Welding The shielding gases used for MIG welding do not support human life so it is very important that the welding area is well ventilated Do not to weld i
177. g in the electrotechnology industry Safety The Workplace Health and Safety WHS Act 2011 requires the PCBU Person conducting a business or undertaking to ensure the health and safety of workers so far as is reasonably practicable In addition while at work workers are required to take reasonable care for their own health and safety and that of others who may be affected by their actions or omissions They must also cooperate with any reasonable instruction given by the PCBU and any reasonable policy or procedure of the PCBU to comply with the WHS Act 2011 and WHS Regulation 2011 This means that you have a responsibility to ensure that any decisions or actions on your part do not put yourself or others at risk This means e Avoid unsafe practices e Follow your supervisor s instructions e Use correct methods Workplace injuries can be caused by many factors including e Poor design of factories equipment and work areas Poor management and organisational practice Lack of instruction provided on safe use of equipment Failing to provide or failure to use personal protective equipment PPE Using tools and equipment incorrectly Distracting others from their work Individual unsafe practices such as fooling around in workshop areas Hazards in the Workplace Hazard is a term used to describe something that has the potential to cause harm and a risk is a measure of the possibility of a specific harmful effect in g
178. g so that no stress is placed on the bearings Contact with the outer race would destroy the bearing NB This is illustrated below If the motor has open bearings they may be evenly heated in an oil bath to between 80 C and 90 C and then the expanded bearing may be carefully slipped over the shaft An open bearing needs to be packed up to 50 full of grease but no more Place the rotor within the stator taking care not to damage the windings Place a piece of copper wire into an inner bearing cap thread hole so that you may easily locate the other holes later Screw an end shield on to the stator evenly tightening the bolts Place the other end shield on the shaft and evenly tightening the bolts this will evenly pull the end shield over the bearings If there is a need to force the end shields over the bearing always use a soft faced mallet and never a steel ball pein hammer as this tool would damage the end shields You should now be able to rotate the motor shaft by hand After repairs on a motor always perform an Insulation Resistance and Earth Continuity Test on the motor a Join all live conductors together set Insulation Resistance and Earth Continuity Tester to the 500V scale place one lead on the joined actives and the other probe on the metal frame of the motor Test result must be 1 Megohm or greater Disconnect the active conductors b Fora three phase 400 Volt motor Set Insulation Resistance and Ear
179. giving o 33x 0 02 which equals 0 66 mm Now add 0 66 mm to the main sale reading of 37 mm to give a total reading of 37 66 mm Another type of vernier scale is commonly used apart from the one shown in the above example This design still has a vernier scale 49 mm long but each fifth graduation of the vernier scale is numbered from 1 to 10 ie There are still 50 minor division as before Because each division on the vernier scale still represents 0 02 mm then the fifth line representing 5 x 0 02 which equals 0 1 mm is actually marked number 1 le 1 corresponds with 0 1mm and 2 corresponds with 0 2mm and so on This makes it easier to read as you do not have to multiply as shown earlier You can directly read the decimal fraction off the vernier scale In the example to the right the O 5 10 15 20 25 30 35 40 45 LIN ey MAIN SCALE 60 mm 9 10 1 it tiny ITNT TT Alli 1 KEN niii HTH 9 Total reading 60 56 whole millimetres from the main scale are 60mm and the decimal fraction from the vernier scale is 0 56mm giving a total of 60 0 56 60 56mm le The principle is identical to that shown earlier as it still has 50 divisions but the renumbering of the vernier scale means the user does not have to multiply to get the reading E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 224 of 254 Example 2 7 0 1 2 3 4 Re 8 9
180. gles 2 Cutting lips of equal length 3 Correct clearance behind the cutting lips Check angle and length of edge f A Retain grip with f right han CHECK CUTTING ANGLE WITH DRILL GAUGE E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Point moves up T Roll drill clockwise Swing down and to left Cutting edge comes BZ up and away from A wheel face p f Move drill slightly forward to grind flank Yor N All movements Ty controlled by left hand Co ordinate these three slight movements Page 90 of 254 Sharpening a Twist Drill suitable for Drilling Brass or Perspex Ref http www listoftools com grinding operations sharpening twist drill drilling brass html If a drill bit that has been sharpened to cut steel is then used to drill brass it will tend to grab viciously and lock the spindle of the drilling machine This can be very dangerous and could cause injury to the drill operator To prevent this the cutting tips of the drill need to be modified slightly To grind a drill tip suitable for drilling brass hold the cutting lip against the right side of the wheel as shown in the sketch to the right NB It is not normally recommended that the side of the wheel be used for grinding But for this application only the pressure exerted on the wheel is so light that it should not cause a problem Very gently grind the flute slightly flat in line with the axis of th
181. gsten Arc Welding Oxy Acetylene Welding Spot welding Resistance Welding VVVV WV Manual Metal Arc Welding MMAW Also called Shielded Metal Arc Welding SMAW or Stick Welding Ref http www weldinginfocenter org basics ba_05 html MMAW is one of several fusion processes for joining metals By applying intense heat a metal joint is melted and caused to intermix directly or more commonly with an intermediate molten filler metal Upon cooling and solidification a bond is created Since the joint is a mixture of metals the final weldment potentially has the same strength as the metal of the original parts This is in sharp contrast to non fusion joining processes such as soldering and brazing etc in which the mechanical and physical properties of the base materials cannot be duplicated at the joint Arc welding uses the intense heat produced by an electric arc to melt the base metals The arc is virtually a short circuit arc as the circuit resistance is typically very low The arc is formed between the actual work piece and an electrode wire rod Once the arc forms the electrode must be manually guided along the seam of joint The electrode used for welding is a specially prepared rod or wire that not only conducts the current but also melts sacrificial and supplies filler metal to the produce the joint The consumable electrode tip melts under the heat of the arc and molten droplets are detached and transported t
182. gt Always use correct manual lifting techniques when operating this machine Sheet Metal Hydraulic Punch http www stainelec com au 2 html This tool uses an hydraulic ram action and a hardened steel punch and die combination to quickly and accurately produce holes and cut outs in sheet metal Each punched shape and size requires a dedicated punch and die combination If the edges on the die set are sharp then the hole produced by the punch is virtually free from any burrs on the reverse side This greatly speeds up high volume processing NB A burr is the leftover sharp hazardous ridge caused by a cutting process De burring is the process of removing burrs Blanking is the term used when cutting a work piece from a stock sheet in one operation The cut out piece which is wanted is called the blank or work piece and the material left behind is then the scrap Scrap skeleton Metal strip Work or blank BLANKING E102A Notes T2 T12 Version 4 BG doc Page 201 of 254 23 January 2014 The term Piercing is similar to blanking but here the cut out piece called the slug is punched from the work piece and becomes the scrap The work is the sheet with the holes in it scrap PIERCING The process of Notching involves cutting out a Corner Offcut shaped section typically in the form of a V from the wo
183. h should only be used for tightening operation and not to loosen nuts as this will affect its accuracy Common types of torque wrench include Beam Deflecting beam Click and Electronic The Click type torque wrench clicks a button when the selected torque is reached This type is shown below E102A Notes T2 T12 Version 4 BG doc Page 64 of 254 23 January 2014 Steady the wrench Locking screw Ky Graduations Contact made at correct setting say atl ey Pull only on Ch hand grip 7 Socket Hold socket Square on nut Trigger pin released TORQUE WRENCH Electronic Type Torque Wrench Ref http Awww google com au imgres This design provides a digital readout of the torque being exerted Bench Vice During disassembly work an engineer s bench vice can be used to hold parts while they are being processed A bench vice is fabricated from steel or cast iron and consists of two jaws one fixed or stationary and one moveable These are fitted into a frame with a heavy screw apparatus operated by a lever which controls the moveable jaw allowing the space between the jaws to be expanded or contracted to accommodate different sized pieces of material The size of a vice is set by the width of the jaws Common sizes range from 75mm to 150mm and with jaw openings from 100mm to 200mm As shown to the right some designs have offset jaws to enable t
184. haft There are two types of straight grinders light or heavy duty They may be electrically or pneumatically powered Small versions are sometimes called die grinders Die Grinder Also called a Pencil Grinder This tool is used for finishing operations to grind and polish contours in metals plastic or wood The grinding wheels are cemented to a shank commonly called mounted points The shank then fits into a collet in the grinder NB A collet is a holding device that forms a collar around the object to be held and exerts a strong clamping force on the object when it is tightened usually via a tapered outer collar A die grinder operates at very high speed and there is a wide selection of point abrasive wheels available to suit different applications Sanding Machines When the coarser grinding operation is completed and a smoother finish is required the work must be sanded The most popular types of sanding machines are the disc sander and the belt sander Polishing Buffs can also be fitted to an angle grinder A buff is used to give the surface of paint work a high shine DISC SANDER E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 171 of 254 Portable Mains Powered Drill Portable drills are used in the electrotechnology industry for drilling holes when installing equipment These are pistol grip rotary action drills designed for light duty operation Som
185. he stop saving the need to measure each part Blades Power hacksaw blades differ from hand hacksaw CUT OFF GAGE blades in that they heavier longer and have fewer teeth per inch Hacksaw blades are discarded when they become dull sharpening is not practical E102A Notes T2 T12 Version 4 BG doc Page 82 of 254 23 January 2014 Common pitches for power hacksaw blades range from 4 to 14 teeth per inch Soft materials require a coarser blade to provide adequate spaces between the teeth for removal of chips Hard material requires a finer blade to distribute the cutting pressure to a greater number of teeth thereby reducing wear to the blade At least three teeth must be in contact with the work piece at all times or the blade will snag on the work piece and break teeth from the blade Safety Power Hacksaw DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on a Power Hacksaw Safety glasses must be Long and loose hair Hearing protection worn at all times in work must be contained must be worn areas Sturdy footwear must Close fitting Rings and jewellery T be worn at all times in Ly protective clothing must not be worn work areas must be worn Pre fasion Safety Checks Locate and ensure you are familiar with all machine operations and controls e Ensure all guards are fitted secure and functional Do not operate if guards are miss
186. he amount of stretch and in which direction from the fold line that it occurs This trial and error should determine the current bending characteristics for this folder on this gauge and type of metal Working with Inside Measurements Before marking out always establish the level of accuracy needed for the assembled work For relatively simple low level tasks determine cut and fold measurements based on inside measurements is normally sufficient If in doubt fold small a trial piece and test the amount of stretch and make minor adjustments if necessary Inside measurements example Consider the U shaped task to the right for a material which has a nominal thickness of 1mm The dimensions given are outside dimensions which is typically given in drawings 17m Note that around the outside face the total length is 17 17 30 64 mm The inside measurements are then 30mm 16mm for each of the two side walls and 28mm for the base for a total cut length of 60mm The difference to the outer surface is made up as the metal is stretched by the bender for each of the two 90 degree bends As explained earlier each type of folder will stretch in different directions and by different 16 a0 16 amounts A pan brake folder such as that to be used in the practical exercise will stretch the metal in one direction only The metal under the clamp should not st
187. he faulty bits or those components needed to gain access to the faulty bits This approach reduces the amount of unnecessary work E102A Notes T2 T12 Version 4 BG doc Page 245 of 254 Considerations before starting dismantling 1 Analyse the results of a Risk Analysis 2 Possibility that hazardous substances may be present within the machine and the need for suitable personal protective equipment PPE 3 Analysis of Safety Data Sheets SDS Possible environmental fire or a health hazard to humans Eg Depending on its chemical composition the oil stored within a transformer tank or a large capacitor can be toxic 4 Warranty status Once manufacturer s seals are broken a machine s warranty may become void ie Invalid or not legally binding 5 Inconclusive electrical tests and you are uncertain as to the precise status of the machine 6 Prior machine history of the machine 7 Possible Electrostatic Discharge Damage ESD issues 8 The availability and quality of any support documentation 9 Personal experience with similar machines 10 Time frame available to complete the task 11 Availability and cost of a replacement machine compared to service costs 12 Location where the machine is to be disassembled eg In situ or workshop 13 Priority in terms of costs while the machine is out of service 14 Interval time between the disassembly and reassembly 15 Overt signs that the machine may be beyond repai
188. he machining and filing that you will need to perform e The stock material itself for signs of cracks flaws surface defects warps and twists etc e That this stock is the correct material for the job Marking Medium To ensure scribed lines show up clearly on the work piece the relevant area of the work should be pre coated with a suitably coloured marking off medium Commonly used marking mediums include e Chalk e Whitewash e Copper sulphate solution e Spirit based metal marking dye e White water based acrylic paint The marking off medium selected should contrast in colour with the colour of the working surface e Chalk is ideal for small areas on rough surfaces of castings e White water based acrylic paint would be more effective on larger areas of rough surfaces of castings etc e Bright steel or machined steel is best suited to spirit based marking dye An alternative to the marking dye is copper sulphate solution e Adark permanent felt marking pen is also acceptable A thin coating is more preferable than a thick coat Lines will show up sharp and clean with a thin coat NB For a small piece of stock material it is easier to coat the entire job For a large object strategically coat only those areas that are to be worked on E102A Notes T2 T12 Version 4 BG doc Page 27 of 254 23 January 2014 Types of Marking out Lines Datum Lines The word datum is used to indicate a valid starting point such as line s
189. he object to be cut A small section of hacksaw blade protruding from the handle is easier to control Coping Saw http en wikipedia org wiki Coping saw A coping saw is a type of hand saw used to cut intricate shapes in sheet materials The blades are thicker and much coarser than a junior hacksaw blade A coping saw consists of a thin hardened steel blade stretched between the ends of a square C shaped springy iron frame to which a handle is attached e A coping saw blade is removable by partially unscrewing the handle Retightening the handle tensions the blade and locks it at the desired angle relative to the frame e The blade is prevented from rotating by means of the short steady bar provided where the blade is attached e Loosening the handle also allows the blade to be rotated relative to the frame as desired T he FRAME COPING SAW _o SLOTTED PIM k Fa BLADE a cee roma e PINS POINTING TOWARDS FITT THE HANDLE COPING SAW _SLOTIED PIN a p z er adel r BLADE PIN SHAPE TO BE CUT E102A Notes T2 T12 Version 4 BG doc Page 55 of 254 23 January 2014 e Aligning the finger steady bars at the top and bottom of the blade ensures that the thin blade is straight and not twisted along its length e The direction of the cut is easy to change because of the thinness of the blade Gentle curves are achieved by slowly turning the whole frame by means of the handle w
190. he size of thread to be cut e Knurled handles hold and turn the die on the stud being threaded e The recess houses the die and holds it against the leading face Split with adjusting screw Cutting Parts of a Die The die is a round or square block of hardened steel with a hole containing threads and flutes which are the cutting Leading face of die edges LARGE BUTTON DIE e The first few teeth of the die are chamfered to allow an easy start when turning a thread am e A split in some larger dies allows the die opening to be made larger or smaller by turning an adjustment screw Before attempting to cut a thread by means of a die the end of the work material requires some preparation The end must be squaring up and a small lead chamfer formed either by machining or filing This lead surface will make it easier for the die to start cutting the thread The following procedure should be followed for cutting an external thread e Secure work appropriately in a bench vice and coat the surface where the thread will be cut with a suitable cutting compound e Hold the die holder near the centre with both hands and place the starting side of the die over the end of the rod Then by firmly pressing the die onto the rod while turning it ina clockwise direction the thread will start to be formed E102A Notes T2 T12 Version 4 BG doc Page 105 of 254 23 January 2014 e lf there is no guide in the die care mu
191. he work Bevel gauges are used mainly to transfer and to compare the angle from part to another Protractor measuring an angle Bevel gauge being used to check the cutting angles of a twist drill Note how in the illustration above it is being used to compare the drill point angles E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 33 of 254 Blade edges straight flat Engineer s Square or Tri Square and parallel This tool consists of a thick body called a stock ENGINEERS and a blade set to a true right angle 90 to the TRY stock The blade is straight flat and has parallel SQUARE edges Stock faces true flat and parallel Tri Squares are used for e Checking that surfaces are at right angles 90 to each other 96 e Setting up work square to another surface a NG O guide when scribing lines at right angles a Using a square e Before using a square it is important to remove any burrs from the work and ensure that the work surface and square are clean e Face towards a light source so the light will shine from behind the work e With your right hand hold the inside of the stock of the square against one finished edge to be tested e Leave a light gap between blade and the other edge e Lower the stock carefully until the blade comes into contact with the edge of the work e Ifthe surfaces are square all light will be excluded The adjacent illustration shows
192. hed or damaged Lubricate load bearing surfaces but use only specified or approved lubricants Apply lubricant uniformly to all thread nut and washer load bearing surfaces Ensure lubricant doesn t contaminate either flange or the gasket face When tightening always use proper tools such as a calibrated torque wrench or other controlled tensioning device Always torque nuts in a cross bolt tightening pattern e Tighten the nuts in multiple steps Step 1 Tighten all nuts initially by hand Larger bolts may require a spanner Step 2 Torque each nut to approximately 30 of full torque Step 3 Torque the nuts to approximately 60 of full torque Step 4 Torque each nut to full torque again using the cross bolt tightening pattern NB Large diameter flanges may require additional tightening passes o Step 5 Apply at least one final full torque to all nuts in a clockwise direction until all torque is uniform Large diameter flanges may require additional tightening passes O O OO Initial ce Impression O ring This is a gasket consisting of a ring of rubber or plastic used to seal a joint against pressure It is a static seal designed to provide compression on the seal across one axis They are often used on outdoor luminaires to 3 prevent the ingress of water They are Sea Unpressat zed inexpensive easy to install and are fairly reliable They can seal high pressure areas if required Saf
193. heel E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 70 of 254 A diamond dresser offers more precision than the revolving wheel type The wheel type dresser is normally pushed straight into the wheel to clear the face In contrast the diamond type dresser works best at a drag angle When using the diamond dresser revolve it to retain its sharp point EC to 7D Hand Tool Maintenance Tool sharpening is usually done on a smaller bench type grinder Safety Checks e Visually check the condition of the wheel and work rest positions before starting the machine e Check all guards are fitted to the machine e Support yourself comfortably on both feet Sharpen Centre Punches and Scribers e The grinding action of the wheel transmits any heat generated onto the solid part of the tool e Air flow carried around by the wheel is directed onto the cutting edge this helps to prevent overheating e The grinding action is down onto the cutting edge to produce a burr free surface E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Blotter discs Tool rest a ee Heat transmitted to shank Rotate to produce conical point Air stream cools point SHARPENING A CENTRE PUNCH Page 71 of 254 Sharpen Cold Chisels Carbon tool steel chisels are normally sharpened by grinding Care must be taken not eS to overheat the cutting edge or to remove more hey _ Container of metal th
194. hem to hold long lengths of stock vertically aki ste SOK iiti lt s aot AITA inii i E102A Notes T2 T12 Version 4 BG doc Page 65 of 254 23 January 2014 Vice Jaws Hard jaws are replaceable case hardened steel blocks fitted by two metal threads The gripping faces of the jaws are serrated to provide excellent grip Soft jaws are made of plastic polyurethane or aluminium and have a magnetic strip to secure them in place over the steel jaws Most workshops use soft jaws from bent L shaped inserts of aluminium These help avoid damaging the surface of soft materials or threads etc Care and Use of a Vice e Ensure that the vice is securely fixed to the work bench e Clamp the work piece evenly in the vice e Support the ends of long piece of material held in the vice e Do not use the vice as a hammering surface as it is not designed to function as an anvil The movable jaw is usually made of thin cast iron can easily crack e Heat should not be applied to work held in the jaws as the hardened insert jaws will become softened e The force of bending should be against the fixed jaw rather than the movable jaw of the vice e Bench vices should occasionally be taken apart so that the screw nut and thrust collars can be cleaned and lubricated The screw and nut should be cleaned in e Solvent and a heavy grease should be packed on the screw and thrust collars before reassembly e When it is not being used
195. hen mark with a prick punch the four points where the two centre lines cut through the circle Finally mark the centre of the circle more heavily with a centre punch so the drill point will have an easier starting spot E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Typical chip pattern Screw hole being enlarged to take screw head Countersunk head wood screw Invert the screw and lower into countersunk hole Countersunk hole Ca TESTING FOR DEPTH Head should be recessed approx 3mm below the surface for a painted finish SCREW HEAD RECESSED COUNTERSINKING Page 92 of 254 Centre Drill This specialised tool can create a very accurate starting centre hole in the face of a job Centre drills are usually double ended types with a 60 degree stepped point Because of the stepped design they are very rigid and do not wander off centre like a standard twist drill is prone to do It is common practice to start a hole with a centre drill and then use a pilot hole and then the final drill bit Centre punch mark Four points Drawing a Drill Back on Centre prick punched By taking care when setting up and by using correctly sharpened drills you can minimize the tendency for a drill to wander off centre Nevertheless surface hard spots and irregularities sometimes cause the hole to start off centre ie punch the ie ay p n must draw it back If the drill has
196. hile continuing to cut steadily e The blade can also be rotated with respect to the frame to make sharper curves in the material being cut e The teeth on a coping saw blade should normally face the handle i e face backwards as compared with most other hand saws the action of pulling the coping saw allows the frame to remain in tension and thus reduces blade breakages This technique is opposite most other saws which cut on the push stroke e Coping saws are used for cutting a range of soft materials such as wood acrylic and aluminum Pointed tapered blade Keyhole Saw a Compass Saw or Plaster Saw OE This is a long narrow and tapering rip saw designed to Screws cut sections from boards or panels IN AG Handle Cross cut teeth shape It is commonly used in the electrotechnology industry KEYHOLE SAW to cut small holes in plaster board to accommodate socket outlets and light switches It consists of a pointed 150 to 180mm tapered blade with rough pointed teeth usually with a wooden handle through The point is usually sharp enough to penetrate soft plaster board directly without the need to pre drill i to Start awe saw Safety Use extreme caution when cutting plaster ia board on an existing house as there may be live gt T conductors directly behind the plaster panel Always cee turn off the power to the area before cutting Also plaster board dust could be a health hazard Wear a 7 Sa
197. huck key to tighten it securely NB The key only needs to be placed in one key hole only to tighten all three jaws Keyless Chuck If frequent bit changing is necessary a keyless chuck as shown right is the preferred type to use This design is tightened by hand and requires a flick of the wrist to undo They tend to be hard to undo if they have been under load when driving a large bit Pedestal drill chucks have a straight shank drill bit capacity up to about 13mm but if the chuck is removed then the spindle itself will typically hold a larger diameter tapered shank drill But never exceed the manufacturer s drill capacity size Ref http www powertoolsdirect com rohm keyless chuck rv 1 2inch 20 steel single sleeve E102A Notes T2 T12 Version 4 BG doc Page 96 of 254 23 January 2014 Holding the work It is extremely important that the work piece is held securely to the machine table when drilling There are various methods used including table stops vice and direct clamping Table stops prevent the work from rotating but NOT from lifting The drill turns clockwise so the work is prevented from turning in that direction This method is only used for the drilling of small holes It has a very quick turn over rate Flat work can be held in a vice it is the simplest and most commonly used securing method For larger drill sizes the vice itself must also be clamped or bolted to the table Direct clamping is id
198. iate type of sheet metal and jointing materials to comply with the job specification Problems can arise when dissimilar metals are in direct contact When two dissimilar metals are in contact with each other and moisture is present an action known as electrolysis or galvanic corrosion begins that can lead to rapid corrosion of one of the materials This is due to a very small flow of current that is generated between the different materials when they are moist This then leads to the decomposition of one of the materials Some materials are more reactive than others The list below shows the reactivity of common materials and is known as the Noble Scale Ranking in sea water Top of table is the most noble Most Noble e Gold e Silver e Monel e Nickel e Brass e Tin e Lead e Active Stainless Steel most common type e Cast Iron e Steel e Zinc e Magnesium Least Noble Those materials near the bottom least noble are the most reactive If a material from near the bottom eg zinc is placed in direct contact with a material near the top eg copper and exposed to moisture electrolysis will occur at a rapid rate The less noble material is soon decomposed by the current flow that is generated and as a result the zinc in this example would corrode away Materials that are close to each other on this scale eg brass and copper will still create a reaction but any corrosion that occurs takes place so slow that the effects
199. ickly to a cutting process by changing the welding tip to a cutting tip e The high temperature the gas mixture attains e The use of regulators to control gas flow and reduce pressure on both the oxygen and acetylene tanks e The use of double line rubber hoses to conduct the gas from the tanks to the torch e Melting the materials to be welded together e The ability to regulate temperature by adjusting gas flow The welding tip is mounted on the end of the torch handle and the gas mixture passes through it to feed the flame Welding tips have only one hole while cutting tips have a centrally located hole with a number of smaller holes in a circular pattern Direction of welding Travel of filler rod Travel of 90 blowpipe gt Approx 60 i Approx 30 FOREHAND WELDING E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Black hose QA Red hose y7 rn im ae T a Tea it en oy a Acetylene cylinder cylinder maroon black PLANT ASSEMBLY Oxygen mY obs ef Seo n miii FETE E to Sa ns m ae Stare ee ee His NEUTRAL EQUAL QUANTITIES OF OXYGEN AND ACETYLENE _ T a ipes PE a gg niir White excess acetylene flame surrounding the rounded cone CARBURISING EXCESS ACETYLENE a Very short pointed cone and smaller flame OXYDISING EXCESS OXYGEN TYPES OF FLAME Page 151 of 254 Whe
200. ide of the curve and stretches the material on the outside of the curve However at some distance between these two there is a space r BEND RADIUS which is not affected by either force This area is known as the Neutral Line or Neutral Axis The position of the neutral axis is not fixed and will vary with material type its thickness the bend radius and even the characteristics of the folder itself The action of some folders will stretch the metal in only one direction from the fold line while other folder types stretch the metal equidistant either side of the _ THIS PART STRETCHES fold line This stretching causes small variations in the finished size of the bent parts To achieve the desired accuracy allowances must then be made for every bend to ensure the final measurements are f by ae Neutral axis accurate ij 7 Pa No change in ell Sg length when l the part is bent THIS PART SHRINKS There are two approaches that can be adopted to x determine the precise position of the fold line A ae El theoretical design based on a calculation involving the position of the neutral axis and the second is an approximation based on inside measurements and material thickness NEUTRAL AXIS The theoretical approach is based on the MIGRATES WITHIN fact that the measured length along the THIS ZONE N neutral axis will NOT change as a result of i K
201. ide blade on a cut of small radius Use relief cuts when cutting sharp curves x x xx Power Hacksaw Ref http www itlind co in hacksaw machine htm Most power hacksaw machines are similar in design to that shown to the right They are designed to cut heavy stock bar The base contains a coolant reservoir and a pump for conveying the coolant to the cutting surface There is an adjustable vice some designs can swivel located on top of the base to secure the stock material The size of a power hacksaw is determined by the largest piece of stock material that can be held in the vice and sawed A heavy steel cast frame supports and tensions the hacksaw blade which contacts the work piece on the cutting stroke only The frame lifts on the outwards stroke and cuts on the draw or back stroke This design prevents unnecessary wear on the saw blade The blades teeth should point forward on the cutting stroke aN l au Some machines feed by gravity the saw frame having weights that can be shifted to give greater or less pressure on the blade Other machines are power fed with the feed being adjustable On these B 4 machines the feed is usually stopped or reduced a A automatically when a hard spot is encountered in the WORKPIECE p material thus allowing the blade to cut through the hard spot without breaking When cutting more than one work piece it is possible to set a bar stop The material is set to t
202. ideration must be given to drilling or punching any holes prior to bending Task sequencing is important The piece that is made first should always be the piece that is wanted now and not in six weeks When planning a job it is important to minimise the amount of scrap Careful consideration as to how blanks work pieces are arranged may increase the amount produced per sheet Ifa saving on metal means extra working time involved one aspect must be weighed against the other in the final analysis Plans or Specifications Before starting a project it is important to understand the specifications of the task The plans are drawings used to specify the finished job Some complex sheet metal tasks will use a series of drawings to depict the object from a number of different angles Plans are usually drawn to a scale to allow a large area to be shown on a single plan page The scale of the plan is shown as a ratio such as 1 10 This means that the drawing is 1 10th of full size Something drawn with the size of 1 would have a size of 10 A measurement of 150mm on the drawing would really be 1500mm Many of the important measurements are written on the plan These written measurements always take precedence over a measurement that you may scale off yourself Some plans are not drawn to scale NTS and the key measurements are given in written form In Australia the dimensions will be given using the ISO International Standards Orga
203. ils e Make sure the locating face on the frame and the collar on the extended anvil are clean and free from grit e Test bars are supplied with the micrometer Always make a test reading with a test bar between the anvils before you measure with the micrometer Large micrometer supported by both hands Digital Micrometers This tool operates on a similar principle to other micrometers but gives a direct numerical reading of size on a dial in the frame The figures on the dial e Make the micrometer quick and easy to read e Ensure accurate measurement of size DIGITAL MICROMETER e Help eliminate reading errors E102A Notes T2 T12 Version 4 BG doc Page 232 of 254 Metric Micrometer Reading Class Exercise Determine the readings for the following positions and record in the box provided E102A Notes T2 T12 Version 4 BG doc Page 233 of 254 Inside Micrometer Inside micrometers are used to measure Inside diameters of holes Distances between internal parallel surfaces Other inside dimensions Inside micrometers are provided with a series of extension rods to measure a range of sizes INSIDE MICROMETER Fit an extension rod to an inside micrometer as follows e Select an extension rod suitable to cover the range required Loosen clamp e Loosen the clamping screw on the sleeve e Remove the existing extension rod and place it in its protective box e Wipe the locating faces on the new rod and micromet
204. important to ensure e The scriber point is sharp e The scriber is held as short as possible against the column and always turn the bent end down for safety e The scriber is kept in a horizontal position as this will be more accurate e To make one clean stroke across the work after setting the correct height Safety When finished with the surface gauge the scriber is clamped parallel to the column with the main point downward and the curved point inwards E102A Notes T2 T12 Version 4 BG doc Page 40 of 254 23 January 2014 Punches These are made from hardened tool steel There are two main types of punches commonly used in marking out A centre punch and a prick dot punch Centre Punch Centre punches are used to locate a centre position for a hole and make it easier to start a drill point cutting accurately at that position The centre punch has a point angle of between 60 90 and it is used for making an indent on a work piece to locate the drill point at start All enter punches have lt M hi ha rdened 0 p points A gt Pa gt Prick Punch Prick punches are used to make light witness marks to better identify scribed lines The prick punch makes it easier to e See marking out lines e Check the accuracy of centre positions before centre punching e Locate the pivot points of dividers for scribing circles of arcs Compared to the centre punch a prick punch has a sharp
205. in a position where it can be easily tripped Speed Control Vertical drills mostly use stepped pulleys to alter the rotation speed of the bit The required rotation speed is chosen by moving a V belt up or down on the pulleys Belt and pulley Chuck key Switch Table locking lever To obtain the slowest rotation speed use the smallest pulley at the motor end and the largest pulley at the drill spindle end E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 95 of 254 Changing Speeds 1 Ensure the power is isolated before commencing any speed adjustment 2 Open the belt guard 3 Unlock the belt tension knob this usually allows the motor to move toward the spindle 4 Shift the belts to obtain the required rotation speed It is important to ensure the belts are running in line with the pulleys 5 Move the motor away from the spindle to obtain the desired belt tension and lock the belt tension knob Close the belt guard Reinstate the power supply Test drill a hole in scrap material for correct rotation speed and correct belt tension 9 Ifthe speed is incorrect or if the belts are slipping repeat ee the above procedure Driver Driven Motor Machine Spindle Chucks Most bench drills i have as standard a three jaw chuck secured by a Morse 7 taper To fit a straight shank a drill bit hand tighten the chuck down to the bit size then use the c
206. in combination with a securing nut or a threaded component Mechanical Properties http www jamesglen com au training manual Most joining applications are designed to support or transmit some form of externally applied load If strength is the only criteria then screws made of carbon steel are ideal Nonferrous fasteners brass bronze nylon should be considered only when a special application is required Metals used in fastener manufacture are elastic materials which will stretch elongate under applied loads and return to their original shape when the load is removed However if sufficient load is applied the material will stretch beyond its yield point and enter a plastic zone losing its elasticity and becoming permanently stretched Further increased load on the material will stretch it to its ultimate tensile strength at which point the material will fracture The major factor in determining the load a fastener can carry is its tensile strength which is related to its hardness Tensile Strength is an expression of the maximum capacity of the material to stretch under tension load prior to failure It is normally expressed in kilo newtons kn Yield Stress Yield point is an expression of the theoretical point of stress pressure beyond which the material loses its elasticity and becomes permanently stretched Realistically this is a range rather than a single point It is expressed as N mm E102A Not
207. in the electrotechnology industry and application of the common materials gt planning process T3 Measuring and marking out encompassing gt reasons for measuring and marking out gt tools used for marking out gt measuring and marking out a project accurately following correct procedures gt sustainable energy work practices related to reducing waste when marking out T4 Holding and cutting encompassing gt common tools for holding bench vices multi grips vice grips wrenches gt common tools for cutting metallic and non metallic material hacksaws wood saws Chisels pliers files gt procedure for using a range of tools for cutting shaping and finishing metallic and non metallic materials gt safety procedures when using holding and cutting tools TS Drills and drilling encompassing gt types of drills used in the electrotechnology industry gt sharpening twist drills gt drilling metallic and non metallic components gt safe use of a bench drill T6 Tapping and threading encompassing type and size of commonly used threads used in electrotechnology work taps and tap wrenches tapping metallic and non metallic components stock and die tools threading metallic and non metallic components VVVVV T7 G eneral Hand Tools encompassing hammers used in electrotechnology work screwdrivers used in electrotechnology work spanners and sockets used in electrotechnology work pliers used in electrotechnolog
208. ind the centre of a round object or checking 45 angles The images below illustrate how the tool can be used in different applications Using the square head as a depth gauge Checking for i square and he A measuring height 2A LAc USES OF THE SQUARE HEAD The examples below illustrate of how the Centre head can be used to create an accurate centre mark for a piece round stock bar The intersection of the two lines is the centre of the bar of a turn and scribe 2nd fine Hold centre 3 4 turn for head firmly 3rd line against side E102A Notes T2 T12 Version 4 BG doc Page 35 of 254 23 January 2014 The illustration to the right shows how the tool can be used to draw parallel lines Combination Set Maintenance A combination square set is an expensive high precision tool and as such requires commensurate care and protection from rough treatment and the environment Individual parts should be regularly cleaned and returned to its case when not in use The ruler from the set should not be used as a generic measuring tool Its real value is as part of the combination with the other parts Dividers Spring Dividers and Wing Dividers Dividers are tools used to scribe circles and arcs They can also be used for marking out geometrical tasks such as dividing circles and lines and creating angles etc Another common use is to transfer and compare distances between two points Comme
209. inful burns can occur on the surface of the eye and could result in permanent eye damage The sketches below illustrate gas bottle gauges Cylinder pressure gauge indicates contents Welding pressure Welding pressure Cylinder lt pressure pressure screw i slacken when not in use Regulator Acetylene to LA pressure blowpipe LIT ASA screw LH thread W5 slacken when not a gG in use RH thread fi _ to cylinder re onde to LH thread gt Owpipe 3 H threa Gas from R H thread Gas from to cylinder cylinder enters here ACETYLENE PRESSURE REGULATOR ovinaer enters ere OXYGEN PRESSURE REGULATOR E102A Notes T2 T12 Version 4 BG doc Page 152 of 254 23 January 2014 Safety Oxy Fuel Gas Welding Safety DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission Personal Protective Equipment Welding goggles must Long and loose hair Oil free leather be worn at all times in must be contained gloves must be worn work areas Sturdy footwear must Close Rings and jewellery be worn at all times in Ly fitting protective must not be worn work areas clothing must be worn Pre Operational Safety Checks Locate and ensure you are familiar with all machine operations and controls Check workspaces and walkways to ensure no slip trip hazards are present Keep area clean and free of
210. ing pliers are designed to install and remove external or internal circlips A circlip is a form of spring used as a fastener The ring is elastically deformed put in place and allowed to snap back toward its unstressed position into a groove or recess Applications Circlips are used to secure fans onto motor shafts and locate bearings in end housings etc The size and type of circlip will dictate the tips needed on the jaws on the pliers FOR INTERNAL CIRCLIPS Circlips with a small hole at each end require round cos jaws and those with a slight bevel at each end require flat jaws FOR EXTERNAL CIRCLIPS CIRCLIP PLIERS roove in shaft roove in shaft _ A EXPANDING EXTERNAL CIRCLIP EXPANDING EXTERNAL CIRCLIP NB Where there is limited space in front of the circlip pliers with angled jaws can be used An external circlip is expanded with a pair of external circlip pliers to remove or install it An internal circlip is contracted using a pair of internal circlip pliers to remove or install it Care This is a specialized tool and should be kept in a protected location It should not normally be grouped with the common tools as the fine tips will get damaged E102A Notes T2 T12 Version 4 BG doc Page 240 of 254 Crimping Tool Crimping tools are used to crimp deform a wide variety of cable lugs and connectors used terminate electrical conductors They use compressive force to const
211. ing or faulty e Check workspaces and walkways to ensure no slip trip hazards are present e Ensure the material is tightly clamped in the work vice e Check coolant delivery system to allow for sufficient flow of coolant Operational Safety Checks e Support overhanging work and signpost if it presents a hazard e Ensure no one stands in front of the saw when it is started e Keep clear of moving machine parts e Direct coolant onto blade before starting cut J Ending Operations and Cleaning Up e Switch off machine when work completed e Before making adjustments or before cleaning swarf accumulations switch off and bring the machine to a complete standstill e Leave the machine and work area in a safe clean and tidy state Potential Hazards and Injuries e Reciprocating saw arm e Metal splinters e Sharp edges and burrs e Hair clothing getting caught in moving machine parts e Eye injuries Don ts x Do not use faulty equipment Report suspect machinery immediately x Do not cut very small items x Do not cut material other than metal x Never leave the machine running unattended Safety Always report a faulty machine to your supervisor Remember to always isolate the machine before changing belts or blades etc E102A Notes T2 T12 Version 4 BG doc Page 83 of 254 23 January 2014 Drills and Drilling Techniques Safety No matter what kind of drilling machine you are about to use your body must be protected from inj
212. ing requirements o Demonstrate an appropriate level of skills enabling employment o Conduct work observing the relevant Anti Discrimination legislation regulations polices and workplace procedures gt Demonstrated consistent performance across a representative range of contexts from the prescribed items below o Fabricate dismantle assemble of utilities industry components as described in 8 and including A Selecting and using hand tools appropriate to a task correctly and safely B Selecting and using power tools appropriate to a task correctly and safely C Sharpening at least two drill bits each for use different types of material D Interpreting mechanical drawings diagrams and instructions correctly E Dismantle and assemble an apparatus relevant to utilities industry discipline in which competency is sought E102A Notes T2 T12 Version 4 BG doc Page 10 of 254 23 January 2014 F Fabricate a component relevant to the utilities industry discipline in which competency is sought G Dealing with unplanned events Context of and specific resources for assessment 9 3 This unit should be assessed as it relates to normal work practice using procedures information and resources typical of a workplace This should include gt OHS policy and work procedures and instructions gt Suitable work environment facilities equipment and materials to undertake actual work as prescribed in this unit These should be used in the formal
213. ing teeth cut in a convex jaw The anor tess handle has inward facing teeth cut into a straight jaw Adjustment for differing dia S made by fitting the removable pin in a hole that will allow the pipe to be gripped properly without the two handles of the wrench being too far apart Application Multi grips footprints and Stillsons are used for gripping and turning pipes or conduits Note As pipe wrenches tend to bite in they will invariably mark the surface on which they are used Therefore they should not be used on polished or plated surfaces Here use a strap wrench Any burrs left on the surface should be filed off Any damaged surface of galvanized metal conduit should be refurbished with paint to avoid the onset Il of rust Torque Wrench Tension Wrench A torque wrench is used in situations where a prescribed amount of torque turning force is specified for the final tightening of a fixing bolt A torque wrench has a square drive which fits standard sockets and can be preset to release at a predetermined torque in Newton Metres Nm In the electrotechnology industry they are used to tension nuts on busbars electric motors and machinery etc The amount of force required to turn a fastener is directly related to the tensile stress within the fastener In Australia torque is measured in Newton Metres but for imported equipment torque values may be given psi Pound per square inch A torque wrenc
214. ining 50 lead and 50 tin that melts at a temperature of approximately 220 C Solder can be applied to the joint with a soldering iron The working part of a soldering iron is a copper bit which is usually square in cross section and tapered to a point The bit is heated by a gas flame or by an electrical element to a temperature hot enough to melt the solder The heat energy stored in the bit is then transferred to the materials being joined by direct contact The materials are raised to a temperature that allows the molten solder to adhere Prior to use a soldering iron needs to be tinned This is a process that allows a coating of solder to be applied to the copper bit of the soldering iron To tin a soldering iron it should be heated filed to a bright smooth finish and have solder applied while the hot iron is rubbed in flux The flux normally used for tinning soldering irons is a block of sal ammoniac or similar After heating the soldering iron it should be cleaned before applying solder to the joints This can be done by quickly dipping the iron into a pot containing water with a small amount of soldering flux added or by quickly wiping the surface on a cloth If the surface of the iron becomes oxidised by overheating re tinning will be necessary E102A Notes T2 T12 Version 4 BG doc Page 207 of 254 23 January 2014 The materials to be soldered must be thoroughly cleaned of oil grease dirt and corrosion prio
215. int Pliers This tool is used as light duty pipe wrench and is ideal for assembling metal conduit work They have a shaped pivot pin which can fit into two or more openings in the legs This gives a range of jaw openings which allows parallel gripping by the jaws ina number of positions Multi grips are designed to grip round objects such as rods and pipes and should not be used to turn hexagon headed bolts or nuts Stillson Also called Pipe Wrench This tool is used for gripping and turning metal pipes or conduits It has much greater gripping force than can be provided by multi grip pliers Fixed to the handle is a jaw with outward facing teeth Attached to this handle by a pivot pin is a spring loaded casing that carries a knurled adjusting nut This engages with a thread on the adjustable arm of a jaw with inward facing teeth Once the jaws are adjusted the spring loading keeps them in contact with the work and the toggle action causes the hardened serrations to bite into the work E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Shaped Five pivot slot pivot pin Long handles for strong y grip Thread Adjusting nut Inward facing teeth Outward facing teeth Page 63 of 254 Footprint Pipe Wrench This tool is used for gripping and turning pipes or conduits It does not have the gripping force of Stillsons but takes much less time to set up One folded steel handle has outward fac
216. is small always pre determine if the stock material can be safely secured after it has been reduced to a small size That is can you safely make the final cut or does this section become waste also E102A Notes T2 T12 Version 4 BG doc Page 31 of 254 23 January 2014 The method used to mark out a sheet will depend on whether it is a one off task or a production run For a one off task always attempt to use up an off cut from a previous job if possible and avoid cutting a new sheet For a production run involving a full sheet always consider how the sheet is to be cut For example a guillotine will only make complete cuts across the sheet but a gas water or laser cutter can cut virtually any length or shape e f using a guillotine common edge cutting is a more efficient method as the one action can produce a number of pieces But it may also lead to wastage e Computer controlled machines are able to obtain the optimum cut from a sheet e Other techniques include nesting small parts in cut out holes and making use of suitable off cuts where possible e Always re check all marking out measurements prior to cutting to ensure no error wastage Tooling The term tooling as applied to the engineering trades refers to any equipment that helps in the production of a product or any related activity It ranges from the most fundamental type of hand tool such as a file to the very complex machine tools such a
217. is notified of the completion of the work in accordance with established procedures 3 Fabricate utilities industry components 3 1 Established OHS risk control measures and procedures for carrying out the work are followed 3 2 Circuits machines plant are checked as being isolated where necessary in strict accordance OHS requirements and procedures 3 3 Appropriate tools are selected and used correctly and safely in fabricating components 3 4 Drawings and instruction for the fabrication of components are followed 3 5 Component dimensions are determined directly or by calculation from information given in job drawings and instructions 3 6 Components are fabricated efficiently without waste of materials and energy and or damage to the surrounding environment or services 3 Procedures for referring non routine events to immediate supervisor for directions are followed 3 8 Routine quality checks are carried out in accordance with work instructions 3 9 OHS risk control work completion measures and procedures are followed 3 10 Work site is cleaned and made safe in accordance with established procedures 3 11 Work supervisor is notified of the completion of the work in accordance with established procedures Required Skills and Knowledge REQUIRED SKILLS AND KNOWLEDGE 7 This describes the essential skills and knowledge and their level required for this unit Evidence shall show that knowledge has been acquired of safe working practic
218. isel which is used for cutting oil grooves in bearing surfaces and also for drainage channels Cutting Edge End View Fi The diamond point chisel is grooves and sharp corners m as well as for preparing Cross Cut Diamond Point Danger Always wear safety glasses when using a metal chisel as pieces of metal can a become projectiles i L Round Mose Cutting Angle on Flat Chisels The cutting angle cutting edge is usually formed by two bevels or facets equal in angle and width The average cutting angle is 65 but may be varied from 55 to 85 to suit the metal to be cut The harder the metal to be cut the stronger and larger must be the cutting angle Commonly used cutting angles are Brass Mild Steel Cast Iron 50 60 60 70 70 80 Sharpening a Chisel A chisel made of carbon tool steel is normally sharpened on a grinding wheel Care should be taken not to apply too much pressure nor to keep it against the wheel for too long before cooling it eg Water If the chisel is overheated where its tip changes to a blue colour then the temper of the steel will be drawn and the chisel will be too soft to use Always wear safety glasses when using a grinder Chisels should be ground on the front face of the wheel Always point the chisel facing upwards towards the wheel estimating the required angle The wheel should be fitted with a spark guard and
219. isel edge off centre lip heights equal Result Oversize hole uneven swarf from each flute E102A Notes T2 T12 Version 4 BG doc Page 91 of 254 23 January 2014 e Lip clearance insufficient Result The drill will rub on the heel of the drill e Lip clearance excessive Result This will weaken the cutting edge e Unequal angles lip heights unequal Results Hole oversize stepped diameters uneven swarf i from the flutes Countersink Bit This tool is sometimes called a rose drill and is used to set a screw head flush or slightly below the surface of the materials being secured The bits range in size from 10 to 25mm and they come in a variety of shank sizes some types are suitable for timber only while others can be used on either timber or metal The bit shown is suitable for metal and has four cutting edges which are taper ground to the angle marked on the body When using this tool remove only enough metal to set the screw or rivet head flush with the material If you remove too much material the top of the hole will enlarge and weaken the work Preparing Work for Drilling The location of a hole is marked by the intersection of two centre lines To ensure that the hole is drilled in the prescribed position the intersection point of the centre lines is prick punched and a circle equal in diameter to the required hole is drawn with the point of intersection of the centre lines as its centre T
220. it can also be used to cut products such as masonry bricks and concrete They are made of carbon tool steel or of alloy tool steel They are forged to the shape and size required then hardened and tempered They METAL PUNCH Allen key USING A METAL PUNCH should be tough enough to withstand the impact of a heavy blow yet sufficiently hard to maintain their sharp cutting edge A cold chisel could be used to chip away excess metal or to split a piece of metal that can not be cut by hand with a saw or grinder Common Types of Chisels Chisels designed to cut metals are usually classified by the length of the stock the width of the cutting edge and the type Examples are 180 x 25 mm flat chisel and the 150 x 6 mm cross cut chisel E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Head chamfered and left relatively soft Body or stock shaped for good grip Cutting angio tempered Cutting edge gt y Bevel or facet COLD CHISEL Page 58 of 254 Types of metal chisels The most common is the flat chisel which is used for chipping flat surfaces trimming cutting thin sections of metal General applications include cutting off rivet heads and bolt heads and splitting nuts when dismantling machinery Less common chisel types include The cross cut chisel which is used for cutting key ways and grooves requiring a flat bottom and CHIP _ Square walls f amm The round nose ch
221. it over splines threads or burrs on the shaft Have you inspected the bore to make sure there are no burrs or scratches Have you ensured proper protection for the seal during painting or cleaning operations Is adequate ventilation provided for internal pressure in the seal area Have you made sure that assembly components do not rub and that any vents are not clogged NANNN NAAN NB The assembly drawing shown below illustrates the parts for an AC Alternating Current electric motor Both bearings have a seal located either side to prevent grease seeping into the motor stator and to prevent contaminants from the outside affecting the bearing Bearing cover Seal Pol Bearing i Centrifugal washer 6 Front housing Seal p Locking ring Centrifugal washer Bearing OX 7 Bearing cover A os Gasket Ref http en wikipedia org wiki Gasket A gasket is a flat static mechanical seal which fills the voids Spaces between two or more mating surfaces generally to prevent leakage from or into the joined objects while under compression Gaskets allow less than perfect mating surfaces to form a seal as it compresses to can fill the irregularities They are commonly produced by cutting a specific shape from a sheet Complex gaskets are typically commercially made but simple shapes can be custom made A custom gasket is cut using a sharp knife and wad punches are us
222. ith the use of hand and power tools are v Examine each tool for visual signs of damage before use v Check that the guards are present and secure v Check the wheels and blades for cracks v Visually check electrical cords and plugs v Al portable tools that are damaged should be removed from use and tagged Do Not Use v Keep tools sharp and clean v Follow instructions given in the user s manual for lubricating and changing accessories v Maintain tools according to the manufacturer s specifications v Replace vibration mountings before they are worn out v Check rotating parts for balance and replace them if necessary Hazards Hazards associated with portable electric tools used on a construction site include Electric shock electrocution burns Heat sparks fire Cuts abrasions punctures Dust flying particles arc flash eyes Entrapment of clothing etc Sprains and strains wrist hand arm shoulder Noise hearing Vibration Portable Power Tool Insulation Electric shock is the most significant of the potential hazards listed above Electric shock caused by indirect contact is typically due to by insulation failure An appliance in a safe condition is expected to have a very high insulation resistance ie gt 1MQ between its active conductors and any exposed external conductive surface But if the insulation resistance was to decrease due to a failure of the insulation then this could result in a
223. ith your fingers Light pressure Allow them to slip on the knur against work of the thimble Work passes between anvils Spring loaded ratchet Micrometer Advantages The main advantage of the micrometer over a base level vernier or other measuring instruments is the accuracy of 0 01mm Its disadvantage is the inherently low range that it has Eg As stated earlier the range is typically only 25mm The scope of measurements can be extended by using larger frames and extended anvils as shown below These enable it to measure from Omm up to about 100mm but for every 25mm block the anvil must be changed Large Purpose Micrometers This tool is used to obtain very accurate and precise measurements of objects which are larger than can be accommodated by a standard micrometer Locating face and pin th f i Anvil e Large outside micrometers with interchangeable extended anvils make it possible to measure over a range of sizes i Adjusting nuts e The micrometer consists of the normal barrel i Clamping nut E102A Notes T2 T12 Version 4 BG doc Page 231 of 254 spindle and thimble with a larger frame e The anvil in the frame can be removed by undoing a clamping nut that holds it in position e By selecting suitable anvils it is possible to take measurements progressively larger from zero to the maximum range of the micrometer frame e Care must be taken when changing anv
224. iven circumstances It is important to know the difference between these two terms Types of workplace hazards include Electrical Exposure to electrical energy from direct contact with exposed conductors or indirect contact with a faulty piece if equipment Gravity Falls trips and slips of a person struck by falling objects Kinetic energy Hitting objects with a part of the body or being hit by moving objects Radiation ionising and non ionising Exposure to ultraviolet UV radiation arc flashes infrared radiation microwaves and lasers etc Vibration Exposure to whole of body vibration or vibration to parts of the body only such as hands E102A Notes T2 T12 Version 4 BG doc Page 13 of 254 23 January 2014 Noise Exposure to single sudden sound or long term exposure to sound Chemical Exposure to products such as solvents glues cleaning agents thinners etc Body stressing Muscular stress while lifting carrying or putting down objects muscular stress while handling objects other than lifting carrying or putting down or muscular stress with no objects being handled repetitive movement low muscle loading Ergonomics Fatigue or workplace design causing stress causing errors Substances Single contact with chemical or substance or long term contact with chemicals or substances reptile insect or spider bites and stings other unspecified contact with chemical or substance fire and explosion Air
225. k as it makes the task much easier more accurate and much safer PILLAR DRILLING MACHINE E102A Notes T2 T12 Version 4 BG doc Page 94 of 254 23 January 2014 Bench Drill Also called Pedestal Drill A typical pedestal drill is shown to the right It is used for small scale drilling tasks The size of the work piece Is limited in both depth and height This design is usually belt driven via two pulleys The spindle speed ranges from a few hundred revolutions per minute to a few thousand As a rule of thumb the larger the drill bit diameter the lower the rotational speed If in doubt about a drill soeed setting always err on the low speed side This drilling machine is hand fed via the chuck feed lever It is made more sensitive by balancing the weight of the spindle by means of a return spring The main advantage of a fixed drill over a portable drill is its ability to keep the drill bit plumb right angle to the material surface This very difficult to achieve when using a portable drill Machine Characteristics Motor Controls Normally this type of machine is a simple start stop push button control Full control details are given by standard AS60204 1 2005 Safety of machinery Electrical equipment of machines General requirements Safety Features The design always includes a guard covering the drive belts and pulleys and emergency mushroom style stop button typically located
226. kage make sure that the work has a suitable clamping arrangement to prevent the work piece from coming loose Twist Drill or Drill Bit Drills and bits likely to be encountered in the electrotechnology industry are Twist drill Masonry drill Auger bit Spade bit A twist drill is a tool used to make cylindrical holes in solid materials The word drill can be confusing as it may also refer to either the drilling machine itself or the drill bit which is inserted into the drilling machine E102A Notes T2 T12 Version 4 BG doc Page 84 of 254 23 January 2014 A twist drill consists of a cylindrical piece of hardened steel with two spiral grooves called flutes The body is the penetration length of the drill One end of the drill is pointed while the other end called the shank is shaped so that it may Ta be secured tightly by the drilling machine r BOOT SHANK The point of a drill is the entire cone shaped L LAND FLUTE surface at the end of the drill and the dead MARGIN centre is the sharp edge at the extreme tip of POINT the point This is formed by the intersection of the cone shaped surfaces of the point and CHISEL POINT df ay E should always be in the exact centre of the axis ANGLE ee d of the drill Vig 195 fF A EDGE The web is the metal wall running the entire length of the body which separates the flutes and forms the bac
227. kbone of the drill The web s thickness increases towards the shank end DEAD CENTER _ The two lips or cutting edges one for each FLUTE CLEARANCE flute are sharply ground The lip clearance of a drill is the surface of the point that is ground away or relieved just back of the cutting edge DRILL POINT LIF The thin strip along the inner edge of the body is ANGLE CLEARANCE called the margin The distance across the two ANGLE margins represents the full diameter of the drill and CUTTING LIP this extends the entire length of the flute The diameter of the margin at the shank end of the drill is pt designed to be slightly smaller than the diameter at the point This feature allows the drill to revolve without binding when drilling deep holes MARGIN E i The shank is that part of the twist drill which fits into the spindle or chuck of the drilling machine or drill press Different drill shank types are manufactured A E Straight shank drill are used for diameters up p to about12mm SSS Si Straight shanked drills are normally held in a Standard three jaw chucks are tightened with a Straight shank chuck key Keyless chucks are tightened by hand requiring a flick of the wrist to tighten and undo Large diameter drills commonly have a standard Morse taper shank The Morse taper fits into a matching taper inside the drilling ma
228. l for straight line cutting or trimming of sheet material The maximum width of the cut is given by its bed base cutting area size measurement A treadle guillotine sometimes called a foot operated squaring shear is common to most workshops as they are ideal for cutting light gauge metal up to 1 2mm thickness and about 1 2 metres in length Because of the shearing action the kerf of the cut is normally zero Some of these machines do not have sheet clamps If the machine does not have sheet clamps then to achieve optimum accuracy always cut with the edge of the metal against the left or right hand side squaring gauge of the guillotine Safety Ensure nearby people are clear of foot pedals Do not over exert when trying to cut metal Do not exceed the capacity of machine Ensure your own feet and legs are clear of the foot pedals Take care when handling the sheet itself Only one sheet should be cut at a given time Never cut wires rods or seams etc VVVVVV V Z _ Power Guillotine Bed Counter in out N control Guillotines vary in shape and Extension size from the small treadle a os foot operated type shown 2 o aTe above which is ideal for cutting SASN cd light gauge sheet metal to the heavy duty mechanical or hydraulic powered types shown to the right which can be used to cut heavy gauge steel plate to a length of about 3 metres y
229. l rest and the grinding wheel This could easily injure the operator damage the wheel or ruin the article being ground Work Area A clean and tidy area is safer than an untidy work area Practice good housekeeping in your work area by keeping the area clean ordered and tidy Always immediately report any damaged worn or inoperative items or any unsafe conditions Care in the Use of Hand Tools Hand tools can cause injuries when an incorrect improvised or defective tool is used It is important to observe and carry out the following points e Make sure you select the correct type and size of tool for the job Replace each tool as you e Check the condition of any tool before you finish using It use It e Do not use tools that are worn out or damaged e Maintain tools in good condition and remember that cutting tools need to be sharp to be safe e Make sure that you use each tool in the correct manner e Store and carry your tools safely Put oily waste in bin E102A Notes T2 T12 Version 4 BG doc Page 17 of 254 23 January 2014 Risk Assessment A risk assessment must be completed before commencing any practical task Its purpose is to discover the realistic risks to be managed and then prioritize the risks inherent in the task This usually involves walking around the intended work zone imagining the task to be performed and determining what could be reasonably expected to cause harm Then based on the level
230. lame is produced Shutting Off Blowpipe e Close the acetylene blowpipe valve first e Then close the oxygen blowpipe valve Ending Operations e Close down both cylinder valves Open oxygen blowpipe valve to allow the gas to drain out When oxygen gauges read zero unscrew regulator adjusting knob Close oxygen blowpipe valve Turn off acetylene cylinder valve E102A Notes T2 T12 Version 4 BG doc Page 153 of 254 23 January 2014 e Open acetylene blowpipe valve and release gas e When acetylene gauges read zero release regulator adjusting knob e Close acetylene blowpipe valve Cleaning Up e Hang up welding blowpipe and hoses e Switch off the fume extraction unit e Leave the work area in a safe clean and tidy state Potential Hazards e Burns Radiation damage to eyes Flying sparks Combustible materials Fumes Explosion by gas leakage Flashbacks Oil and grease Don t gt Do not use faulty equipment Immediately report suspect equipment gt Donotlight the blowpipe with matches or lighters gt Do not use oil grease or other hydrocarbons gt Do not use oxygen as a substitute for compressed air This SOP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references It is designed as a guide to be used to compliment training and as a reminder to users prior to equipment use Brazing Brazing is a lower temperature process than welding It does
231. ld be downwards towards the work rest The spindle rotation must always be such as to tighten the nuts holding the wheel Stand facing the machine The spindle on the left should have a left hand thread and the spindle on the right should have a right hand thread This will ensure that both nuts will be tightened by their respective blade rotation Truing and Dressing a Griding Wheel Grinding wheels like all other cutting tools require frequent reconditioning of cutting surfaces to enable them to perform efficiently Dressing means to clean the periphery front face of grinding wheels Cleaning breaks away any dull abrasive grains and smoothes the front face so that there are no grooves Truing means the removal of material from the cutting face of the wheel so that it runs true rotates perfectly round with the spindle axis Dressing Tools A revolving wheel type dresser is shown to the right to speed Set the wheel dresser on the rest as shown and bring it in firm contact with the wheel Move the dressing tool back and forth across the face of the wheel until the surface To dress a wheel run the grinder up 1 i Wheel rotation Work rest WHEEL ROTATION HOLDS WORK DOWN ON REST Turning effect of wheel tightens nut a Left hand thread tightens anticlockwise LEFT HAND SIDE SAFETY HOOD J La WHEEL DRESSER is clean and approximately square with the sides of the w
232. ld always be in contact with the work surface while cutting If a coarse blade is used on a thin section then the teeth will straddle the work making cutting difficult and cause the teeth to break Eg This is very common when cutting thin walled pipe But if the tooth pitch is too fine then the blade cannot clear the material as it is removed It will become clogged and will not cut efficiently Recommended Pitch Usage NB TPI Teeth per Inch Pitch 1 inch 14 teeth e 14TPI Use for machine cold rolled or structural steel e 18 TPI Use for solid stock aluminium tool steel high speed steel cast iron and the like e 24TPI Use for angle iron brass copper iron pipes etc e 32 TPI Use for conduit and other thin tubing and sheet metal work Hand hacksaw blades are generally 12mm wide and 0 7 mm thick The kerf is wider than the blade s thickness because of the set of the teeth NB The kerf is the width of cut groove or incision made by the blade The set of a blade refers to the offset of teeth outward from the blade itself Two kinds of sets are found on hand hacksaw blades the straight alternate set and the wavy set Correct pitch plenty of chip clearance aa plenty of chip clearance i two or more teeth On section Fa ea a so a Fia Pa ra two or more toerh on section A wavy set is found on most fine tooth hacksaw blades E102
233. ld or twist metal into shape Use in preliminary work only Pop Rivet Tool Used to quickly join then gauge sheet metal Hand saws Hacksaws to cut most metals and junior hacksaws to cut lighter gauge materials http www graysonline com a r P Scrber Dividers T Odd leg calipers Center and Dot Punches Combination Set E102A Notes T2 T12 Version 4 BG doc Page 185 of 254 23 January 2014 Snips Tin snips or snips are used to cut sheet metal There are many designs of snips in use The ones shown below are quite common The main problem when using snips is that the material on one side of the cut deforms curls The cut should be arranged so that the deformed section is the off cut and not needed for the finished product They are manufactured in a variety of styles for different cutting operations The two main types are Universal Top image and Aviation Bottom The type of snip required for a task depends on the thickness of metal type of metal and the type of cut e g straight line curved or notch Straight snips can have a combination blade or straight back blade The handle on these snips are set in line with the blade Not cranked They are used for straight line cutting notching and outside curves Cranked snips have their handle set at an angle to the blade This enables the operator s hand to clear the sheet for safe and easier operation Ref http w
234. ld surround the welding area These curtains made of a polyvinyl chloride plastic film shield nearby workers from exposure to the UV light from the electric arc but should not be used to replace the filter glass used in helmets In addition the vaporizing metal and flux materials expose welders to dangerous gases and particulate matter The smoke produced contains particles of various types of oxides The size of the particles in question tends to influence the toxicity of the fumes with smaller particles presenting a greater danger Additionally gases like carbon dioxide and ozone can form which can prove dangerous if ventilation is inadequate Some welding masks are fitted with an electric powered fan to help disperse harmful fumes Safety Manual Metal Arc Welder DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PERSONAL PROTECTIVE EQUIPMENT Safety glasses must be Long and loose hair Oil free leather worn at all times in must be contained gloves must be worn addition to welding mask Respiratory protection A welding mask with Close Ca devices may be O correct grade lens for fitting protective required MMAW must be worn clothing to cover arms and legs must be worn Sturdy footwear with rubber soles must be worn Rings and jewellery must not be worn Pre Operational Safety Checks Locate and ensure you are familiar with all machine opera
235. le hazards associated with all machine tools as part of their operation and use To reduce the level of risk it is essential that you e Are suitably trained in its correct use and that you DO NOT perform any task that is outside the scope of your training e Are supervised closely when new to a machine e Wear all PPE Personal Protective Equipment that is deemed necessary for the task e Strictly follow ALL of the safety guidelines Off Hand Grinding Off hand grinding is the term used in engineering to describe the process where the work is held by hand and surplus material is removed using an abrasive grinding wheel This type of grinding is carried out in the workshop to e Dress metal Rough shape parts Remove excess metal Prepare plates for welding Smooth surfaces Off hand grinding is also used for sharpening cutting tools such as e Twist drills e Chisels and scrapers e Punches and scribers e Lathe cutting tools Safety Always wear safety goggles or an approved type of eye protection when performing any grinding operations Important Leather gloves must NOT be worn when sharpening small tools such as drills or tool bits where fingers and hands are in close proximity to the abrasive wheel There is significant risk that the gloves may get caught in the spinning wheel which could cause severe injuries Safe Use of Grinding Wheels Grinding wheels are fragile and they must be handled mounted and used carefully
236. ls use staged pilot holes 8 Ensure that the drilling speed is correctly set 9 Gently lower the drill and allow the bit to cut If too much force is required then the drill is not sharp enough 10 Raise the drill and ensure that the cone drilled thus far is centred correctly If the cone is not centred then using a chisel place a groove on the side that the drill needs to be closer to This process can be repeated 11 Complete the hole raising the bit as required to remove swarf Always apply pressure on a line which goes straight through the axis of the drill Side pressure will only enlarge the hole and can break the drill Keep the drill steady and apply enough pressure to keep it cutting Too much pressure will overload the motor and too little pressure will merely cause the drill to polish instead of cut This will quickly dull the cutting edges of the drill You will know the pressure is correct when the drill bites continuously without overloading the drill motor Lubricant and Cutting Fluids Drilling generates heat and as a result the drill tip may be overheated Blue point Lubrication is often required to reduce the friction caused by drilling Excessive heat build up can cause distortion of the hole or the material being drilled and or cause permanent damage to the cutting edges of the drill bit Lubrication increases the life of the drill by preventing overheating The cooling also prevents the work pi
237. machine and supports the headstock tailstock and carriage in alignment The normally Vee shaped finely machined tracks on the bed are called the ways and these are used by the carriage and tailstock as a slide Headstock This is clamped rigidly to the bed and holds all of the drive mechanisms gears or pulleys that turn the drive spindle and its attachments Headstock Spindle This is the main drive line The end of the headstock spindle is usually machined so that it can carry a faceplate chuck drive plate internal or external collets or even special attachments designed for particular jobs In turn these attachments hold the work piece that is going to be machined Tailstock This slides along the bed as required and holds a steel centre that supports the end of the rotating work piece Carriage The assembly of parts that slides up and back on the ways It is comprised of the Saddle front Apron Top and Cross Slides Carriage movement is controlled by the lead screw This is the threaded rod that runs the length of the lathe Saddle This is the part of the carriage that fits onto the top of the bed and slides along on the ways E102A Notes T2 T12 Version 4 BG doc Page 74 of 254 23 January 2014 Compound Slide Consists of the Cross Slide and Top Slide The compound slide rest moves across the top of the saddle which in turns glides the length of the bed
238. mensions should then be measured and drawn from these two references NB Sometimes unsuitable stock material can be prepared for a datum edge as follows gt Rule a straight line with a rule and a scriber i z gt Carefully cut along the line with tin snips or a guillotine gt Test for straightness with a rule straight edge gt Mark the edge with a datum edge mark Reference Point If the metal is too thick to be cut with snips gt Scribe a straight line close Edge to the edge of the metal gt Carefully file down to the line gt Draw file the edge and test for straightness with a rule gt Mark with a datum edge mark ie V NB If it is not possible to form a datum edge on the stock material an Datum Batumidge alternative method is to draw a straight datum line down the full length of the material usually close to the bottom edge and mark this as a datum V mark Near the bottom left hand side of the stock draw a second datum line at right angles to the first which will also be used as a dimension reference When marking to size all markings should be made from the two datum edge as follows Place the stock of the try square firmly against the datum edge Scribe a line close to the edge of the metal Use a rule and a scriber to mark off the length of the job Hold the stock of a try square firmly against the datum edge and scribe a line through the mark and square to the datum
239. metal surfaces such as pipes and metal objects etc Non corrosive fluxes are used for soldering electrical electronic connections and for other work that must be free of any trace of corrosive residue Rosin is the most commonly used non corrosive flux In its solid state rosin is inactive and non corrosive When heated it melts and provides some fluxing action Rosin core solder is a tubular hollow form of solder The voids in the solder are filled with a non corrosive rosin flux This helps to keep the work piece clean during the soldering process and facilitates the bond between the metals and the solder Rosin core solder is the recommended solder when working with electrical wiring and metals including copper and tin This type of solder is available in different diameters for different purposes Precise work with electronics is typically best suited for solder type with thinner diameter Other types of solder fluxes are listed in the table shown below Metal Fluxes Brass copper ti cccceeeceseeeeeeeseeeess Rosin EEA anette cg turer tretlan Ot auscet ta ik caaat at Tallow rosin WON SLCC ecstasy at Borax sal ammoniac Stainless steel and other nickel alloys Phosphenic acid Galvanized ION uraan A Zinc chloride LO a A TE Zinc chloride AMINO Minaa neneeren eter Stearine special flux NB When soldering is complete always clean any remaining traces of the flux from the joint Special alcohol based flux r
240. mselves melted they are not warped or otherwise distorted and retain their original metallurgical characteristics e Because brazed joints have a very clean well finished appearance it is often the preferred bonding process for manufacturing plumbing fixtures tools heavy construction equipment and high quality consumer products e The process is well suited for joining dissimilar metals which gives the assembly designer more material options e Complex assemblies can be manufactured in stages by using filler metals with progressively lower melting points e Brazing is relatively fast and economical requires relatively low temperatures and is highly adaptable to automation and lean manufacturing initiatives In the electrotechnology industry an oxy Acetylene torch is used for brazing small assemblies and low volume applications A neutral flame with a bluish to orange tip a well defined bluish white inner cone and no acetylene feather works the best a flame with a colorless tip can cause oxidation The quality of the Oxidizing flame joint is largely dependent on operator skill and consistency is I sometimes an issue this technique requires only a small investment and is used extensively Ref http www theiiwmumbai 8m com brazing4 html The six fundamental points of brazing are 1 Joint design 2 Choice of filler metal 3 Pre cleaning of the parent materials 4 Fluxing 5 Removal of flux residues and 6 Heating th
241. n NB When preparing to use a sealant always carefully read the Safety Data Sheet for the product and use all recommended PPE Weatherproofing is a typical application for sealants in the electrotechnology industry Outdoor items such as switchboard cable entry junction boxes and light fittings etc must be made waterproof if the electrical system is to be made reliable The cable gland plate shown to the right is a typical example A mechanical seal is a physical device which helps join systems or mechanisms together by preventing leakage A static weatherproof seal is shown to the right It is made of rubber or plastic and is designed to fit into standard sized holes in sheet materials ranging from 12 5mm up to about 50mm It can be inserted or removed with the aid of screwdriver and is typically to seal off spare cable or conduit entries into switchboards A rotary shaft seal is a more complex design and is commonly used to seal between a moving surface eg motor shaft and a fixed surface eg motor end housing It can be used to prevent water chemicals oil or grease etc passing from one side of the seal to the other A common shape is shown to the right The design is pressure energising This means that the compression load on the seal is initially just sufficient to resist low pressure but when machine is operating the inherent pressure within the E102A Notes T2 T12 Version 4
242. n electric shock Safety When using mains 230V powered equipment always perform a visual inspection just prior to use to ensure that there are no overt signs of faults to the tool s case power lead or plug In the workplace you should also Two pin plug D check the test date marked on the test tag a En he gate O affixed to the power lead This date ensures that the tool is not past mandatory test date DOUBLE INSULATED EQUIPMENT Australian Standard AS NZ 3000 Wiring MUST NOT BE EARTHED Rules introduces classes of electrical equipment based on the type of protection that they employ For portable tools the two most important are Class and Il Single Insulated Class I Equipment Class equipment employs a protective earth PE conductor The basic means of protection is the insulation between live parts and exposed conductive parts such as the metal enclosure In the event of a fault that would otherwise cause an exposed conductive part to become live the supplementary protection i e the protective earth comes into effect E102A Notes T2 T12 Version 4 BG doc Page 177 of 254 23 January 2014 Additional protection is also provided for Class equipment when it is plugged into a socket outlet via a mandatory RCD Residual Current Device If an insulation failure ie drop in resistance causes the leakage current flowing to earth to exceed 30mA then the RCD will trip and de energizing the circuit Dou
243. n an enclosed space where you could become asphyxiated DO NOT use this type of machine unless you have been instructed in its safe use and operation and have been given permission Personal Protective Equipment Safety glasses must A welding mask with Oil free leather gloves be worn at all times in correct grade lens for and spats must be addition to welding GMAW must be worn worn mask Sturdy footwear with Long and loose hair Rings and jewellery rubber soles must be a must be contained must not be worn worn 20 Respiratory protection Close fitting protective devices may be clothing to cover arms required and legs must be worn Pre Operational Safety Checks Locate and ensure you are familiar with all machine operations and controls Check workspaces and walkways to ensure no slip trip hazards are present Ensure the work area is clean and clear of grease oil and any flammable materials Keep the welding equipment work area and your gloves dry to avoid electric shocks Ensure your gloves welding gun and work leads are in good condition Ensure other people are protected from flashes by closing the curtain to the welding bay or erecting screens e Start the fume extraction unit before beginning to weld e Ensure work leads do not create a tripping hazard Operational Safety Checks e Ensure machine is correctly set up for current voltage wire feed and gas flow e Ensure work return earth cables make firm
244. n and you have given permission Beware of swinging counter balance weights and bottom leaf bed of machine Do not use improper manual handling techniques when using machine or moving metal in or out of benders This machine can put great strain on your back Beware of blade crush when using machine or especially changing blade NB Only one person at a time should control this machine Never use another person to operate the clamp while you attempt to align the fold line This action will result in pinched fingers Yours E102A Notes T2 T12 Version 4 BG doc Page 198 of 254 23 January 2014 Safety glasses must be worn at all times in work areas Long and loose hair must be contained Sturdy footwear must be worn at all times in work areas Rings and jewellery must not be worn Close fitting protective clothing must be worn Gloves must not be worn when using this machine 00O Pre Operational Safety Checks 1 Guards or safety devices shall never be removed or adjusted except by an authorized person for maintenance purposes 2 Working parts should be well lubricated and the jaws and fingers free of rust and dirt 3 Ensure no slip trip hazards are present in workspaces and walkways 4 Be aware of other personnel in the immediate vicinity and ensure the area is clear before using equipment 5 Familiarise yourself with and check all machine operations and controls 6 Faulty equipment must n
245. n the right side it is lowered to suit thicker gauge material which needs a larger bend radius As a rule of thumb the wing should be set to a minimum of one material thickness below the top of the clamp block This is measurement x in the lower sketch To adjust the bender in our workshop there are six bolts 3 either side which can be loosened slightly Two further lower bolts then act as grub screws to enable fine adjustment of the wing When the setup is complete re tighten the six wing bolts Wing SHARP FOLD ROUNDED FOLD NB Clamp pressure can be adjusted by turning the two lower knurled nuts on the clamp adjustment bolts Located towards the top ofthe bender Weil The top two knurled nuts are to Bending wing gt lock the setting Clamp Block Also the fingers can be spaced to suit the task x A restriction with a pan brake Folding arm style of folder is the minimum distance it requires between folds There must always be sufficient clearance to enable the previous fold to fit so that it does to come it contact with the finger clamping mechanism The brake press style of bender shown below can create bends much closer together Safety Using a Pan Brake Folder A pan brake folder is potentially a very hazardous piece of machinery DO NOT use this machine unless you have been instructed in its safe use and operatio
246. n welding the flame produced by the combination of the gases melts the metal faces of the work pieces to be joined causing them to flow together A filler metal alloy is then normally added to fill the void Characteristics of the oxy acetylene welding process include gt The use dual oxygen and acetylene gases stored under pressure in steel cylinders gt Its ability to switch quickly to a cutting process by changing the welding tip to a cutting tip gt The high temperature the gas mixture attains gt The use of regulators to control gas flow and reduce pressure on both the oxygen and acetylene tanks ACETYLENE FEATHER gt The use of double line rubber hoses to conduct the gas WELOING TORCH TR INE Roe from the tanks to the torch i E aE gt Melting the materials to be SOUDFIED e t welded together WELD METAL Me Ss SSS See A EERE EE EEE EEE Ti ts gt The ability to regulate temperature by adjusting gas flow Pa ee Safety The molten metal has a tendency to pop and splatter as heat is applied and oxygen reacts with the superheated metal It is critical when using this process that you wear suitable gloves and approved safety goggles or face shield The goggles and or face shield protect the eyes from sparks and flying hot metal particles Also the goggles or face shield use special lenses to protect the eyes from light damage If protective eye shielding is not used pa
247. n when operating the grinding wheel Do not use a wheel that has been dropped Do not use mounting flanges on which the bearing surfaces are not equal clean or flat Do not excessively tighten the mounting nut Do not start the machine when the wheel guard is not in place Do not stand directly in front of the wheel when the grinder is started Do not grind material for which the wheel is not designed Do not wear gloves when working close to the wheel Care and Storage of Grinding Wheels The following details must be observed so that a grinding wheel will function safely and efficiently e During the handling don t roll wheels or allow them to bump together Keep them free from oil e Store wheels on edge preferably in racks They must be kept dry and not subjected to extreme pressure e Do not overload the wheel or repeatedly jab the wheel into the work e Donot make sudden or heavy loadings on the wheel especially if the wheel is new or when starting work on a cold morning e Make sure that the wheel is dressed regularly Procedure shown below Protective Equipment e Wear suitable clothing such as close fitting overalls buttoned up to the neck No loose sleeves or business ties Safety goggles must be worn on all grinding operations Wear safety boots shoes Wear hearing protection Types of Off Hand Grinding Machines There are several types of machines used for off hand grinding Types include e Pedestal flo
248. natively a motor s end housings may need to be placed in an oven to expand them to a point where they can accommodate the bearing E102A Notes T2 T12 Version 4 BG doc Page 250 of 254 Seals and Gaskets The word seal used as verb can mean to seal something in thereby preventing something from escaping or to seal something off thereby isolating the area As a noun a seal is a device or substance that is used to join two things together so as to prevent them either from coming apart or to prevent something seeping between them Eg This could be the passage of solids liquids or gases etc A sealant is a material compound which has both the adhesive and cohesive properties necessary to form a seal NB Adhesive means to ability to adhere stick to some surface and cohesive means its ability to hold together and not dissolve There are countless substances available that can be used as sealants with silicone and polymers being common The sealant is selected on the characteristics of what is to be resisted the surface in contact with the sealant eg metal ceramic wood plastic etc the environmental conditions such as pressure and temperature range etc and whether the sealant is required to cure or be non curing NB Cure means to set hard whereas non curing means remains flexible which allows for expansion and contractio
249. nd spanner or for small grinders an Allen key to remove the locknut To change a grinding disc on either angle grinder the procedure is as follows Safety Turn off the power supply and remove the plug from the power point e Select the correct spanners to loosen the locking nut The Allen key and two pronged spanner for the small grinder and the open end spanner and two pronged spanner for the large grinder e Position the Allen key in the centre of the drive shaft of the small grinder or the open end spanner below the grinding disc holding the drive shaft on the large grinder e Place the two pronged spanner into the holes of the locking nut and turn anti clockwise to loosen it e Remove the old grinding disc Place the new disc in position then replace the locking nut putting the two pronged spanner into the locking nut holes Tighten in a clockwise direction to fasten the grinding disc in position e Plug the lead into the socket and switch on The grinder is now ready to use Note Using a small grinder to do work that is too large or requires too much pressure will end up in burning out the motor E102A Notes T2 T12 Version 4 BG doc 23 January 2014 __ New disc Lock nut Two pronged spanner Open end spanner ACESSORIES TO CHANGE GRINDING DISC Two pronged spanner Allan key SPANNERS FOR SMALL GRINDERS Open end spanner Two pronged spanner SPANNERS FOR LARGE GRI
250. nder Work rests Adjustable work rests are provided for steadying and guiding the work The rest should be positioned with a maximum gap not more than 2mm from the wheel surface The top of the tool rest BENCH TYPE GRINDER should be slightly below the horizontal centre line of the grinding wheel As an abrasive wheel is reduced in diameter due to wear the work rest must be adjusted inwards towards the wheel surface Warning Make adjustments to the work rest only when the wheel is stationary Wheel guards Off hand grinding machines must not be used unless the wheel guards are securely in place They are there for several reasons PEDESTAL including Solid guards e Retain the fragments of wheel if it breaks i e Protect the operator from coming into firmly fixed in place contact with the rotating wheel WH e Prevent the fitting of a wheel that is to BEE GUARDS large for the machine s capacity e Helps prevent accidental damage to a stationary wheel E102A Notes T2 T12 Version 4 BG doc Page 69 of 254 23 January 2014 Wheel Speed Manufacturers specify the maximum safe speed for all sizes of abrasive wheel Do not exceed this speed Do not fit a wheel that is larger than the one designed to fit the machine nor increase the spindle speed This is very dangerous It will cause the wheel to run at a higher surface peripheral speed and it may fly apart Wheel Rotation The rotation of the grinding machine shou
251. ng irons are available in various ratings from 15W to a few hundred watts The advantage of a high wattage iron is that it can provide sufficient heat energy to quickly solder a joint This is important when there is a quite a large volume of metal to be heated A smaller iron would take a longer time to heat the joint up to the correct temperature during which time there is a danger of the electrical insulation becoming damaged A small iron is used to make joints for miniature electronic components which are easily damaged by LIGHT DUTY excess heat TYPES OF ELECTRIC SOLDERING IRONS Temperature controlled soldering irons operate at a set temperature Temperature control can range from special magnetized soldering tip based on the Curie point and a magnetic switch to a Abrasive cleaning pad highly sophisticated electronically controlled NA eee soldering station These are used to solder ta igo ea ia printed circuit boards The soldering iron s heat capacity must always TEL be matched to the size of the task When Ti Bit should heating large masses the temperature drops Re be replaced too quickly drops and does not melt the solder i But too much heat capacity on very small jobs can affect the surrounding parts When soldering the solder will flow evenly to make a good electrical and mechanical joint bit can be filed back to shape CARE OF BITS E102A Notes T2 T12 Version 4 BG doc Page 159 of 254
252. nimum inside corner radius of the bend is typically 1 times the metal thickness NB Dimension B refers to the smallest width a which will clamp securely in the machine If B LR is smaller than 8 to 10 times metal thickness it yi may slip out from under the clamp The three main steps in folding work are These are repeated from earlier in the note 1 Clamping In clamping the amount of lift of the clamping beam is important It should be sufficient to allow the fitting and use of special clamping blades or to give adequate clearance for previous folds 2 Folding Care must be taken to see that the folding beam will clear the work particularly when making second or third folds Some folding machines are designed to fold radii above the minimum either by the fitting of a radius bar or by adjustment of the folding beam 3 Removal of the work Care must be taken in folding to ensure that the work may be easily removed on completion of the final bend The sequence of folding must be carefully studied The lift of the clamping beam is important here Some folding machines known as universal folders have a swing beam The work may be completely folded around this beam which is then swung out to allow removal of the work E102A Notes T2 T12 Version 4 BG doc Page 209 of 254 23 January 2014 Metal Folding When metal is folded the bending action stresses the sheet The folding force compresses the material on the ins
253. nips Fold the tray along the fold line and ensure the lap is inside the base Clamp together then drill and rivet the tray together Fix the tray securely to the wall E102A Notes T2 T12 Version 4 BG doc Page 216 of 254 23 January 2014 Internal Mitres Right Angled If commercially produced mitres are not available it will be necessary to make them to suit To make a right angled internal mitre gt Vv Y V WV gt Measure the distance against the wall between the cable tray end and the internal corner Transfer this measurement to the cable tray to the side that will be against the wall and mark the spot with a scriber A Place the tray upside down for the marking Remember that right is now left and vice versa Using a try square and a scriber draw a line from that mark to the outer edge of the tray B Measure the width of the base of the tray 2 g 75 mm Mark off 75 mm on each side of B giving points C and D S Brackets Wall side Fold line lt a 2 90 ra a VIEW AT WALL SIDE MAKING AN INTERNAL MITRE Join C and D to A to complete the right angled triangle Mark the 25 mm laps for the base and on the side opposite the fold line Cut away excess metal with tinsnips shaded areas Clamp drill and rivet the tray edges together Fix the tray securely to the wall Cable Tray Covers The general procedure for making external and internal mitres right angled
254. nization measurement system This means that all dimensions are in millimetres mm or metres m A specification provides details of a job that are not found on the plan Some of the things detailed in the specification may include gt Materials type including type eg steel zinc aluminium grade eg Grade 316 Stainless steel G250 steel sheet thickness finish coatings Eg Galvanised Zincalume or Colorbond etc Joining methods such as welded screwed or riveted Fastener types and spacing Sealing methods and types sealant types eg solder silicone mastic and sealant specifications YYY NB Always check the SDS Safety Data Sheets before using any chemical sealants Safe Handling of Materials When moving heavy or awkward loads the safety of workers in the area must be ensured Sheet metal materials are often slippery due to oil coatings applied during manufacture Ifa sheet slips through your hands it can cause serious cuts Two people working as a team should move full sheets of metal Large bundles of sheets need to be moved with a forklift or other lifting devices If materials become jammed in equipment such as folders or guillotines etc you should never pull at it to remove it If it is stuck then your hands may slip along the edges and cause serious cuts Always find out why it is jammed and free it without pulling with your hands If the sheet E102A Notes T2 1T12 Version 4 BG doc Page
255. not involve melting of the substrate surfaces but rather depends on the formation of inter metallics to provide adhesion It uses a bronze or brass filler rod coated with flux together with an oxygen acetylene gas torch to join the pieces of metal Ref http www magnagroup c om pressarea Content2 a sp Uid 6 Brazing takes place at the melting temperature of the filler e g 870 C to 980 C for bronze alloys which is lower than the melting point of the base material e g 1600 C for mild steel i A bead of filler rod material reinforces the joint Brazing fluxes are required to remove oxides from the filler material and mating pieces and to promote good flow of the molten filler Typically brazing fluxes contain borates and fluorides and are considered corrosive The joint area is heated above the melting point of the filler metal but below the melting point of the work piece metals being joined The molten filler metal flows into the gap between the other two metal pieces by capillary action and forms a strong metallurgical bond as it cools E102A Notes T2 T12 Version 4 BG doc Page 154 of 254 23 January 2014 e Brazing is very versatile and the joints have great tensile strength and are often stronger than the two metals being bonded together Brazed joints repel gas and liquid withstand vibration and shock and are unaffected by normal changes in temperature Because the metals to be joined are not the
256. nut EEA or bolt to be adequately tightened without poste by spreading the jaws of the spanner lower jaw in this position What happens v Never use a pipe or other device to increase leverage on the spanner mab Jaws worn sprung and rounded Crack E102A Notes T2 T12 Version 4 BG doc Page 123 of 254 23 January 2014 Reversible Ratchet Spanner A ratchet spanner is used in conjunction with sockets and T variety of socket accessories It oggle selects significantly speeds up the drive direction turning motion when tightening and loosening nuts and bolts It is also used in tight spots where the turning arc is small A socket drive is the square section that clips in to the top of the socket r i Handle length designed to ommon socket sets have l si T drives sizes of either 1 2 drive give nominal safe torque or 4 inch REVERSIBLE RATCHET DRIVE NB The half inch drive is a common general use size Unless the socket set is equipped with a drive converter the drive dimensions mean that often individual sockets are not interchangeable between sets Tube Spanner or Box Spanner Tube or box spanners are used to tighten bolts and nuts that are located in deeply recessed or confined spaces These tools are sold in sets with a range of sizes suitable most standard sized bolts The lever or Tommy bar is used to provide additional torque Nut in recess Projecting
257. ny types in use with each suited to a specific application Parts of a File The diagram below illustrates the principal parts of a file Ref httos www dlsweb rmit edu au toolbox electrotech toolbox1204 resources 03workshop 05hand tools O8files htm Shoulder Edge Face Point Classification of Files Files are classified by the following features Length Type of cut Grade of cut Longitudinal shape Cross sectional shape Its most common use Length of a File This is measured from the point to the shoulder and does not include the tang which is inserted into the handle See image above Common types are made in various lengths ranging from about 150mm up to about 300mm depending on the usage E102A Notes T2 T12 Version 4 BG doc Page 44 of 254 23 January 2014 Cut Types Single cut files have their teeth formed by a single set of parallel chisel cuts Each tooth runs the full width of the side of the file at an angle to its edge These files are used with lighter pressure than double cut files and give a smoother finish Double cut files have their teeth formed by a double set of parallel chisel cuts that cross each other diagonally eee ITT This gives a series of small diamond shaped Pr a i De teeth Dreadnought cut files have very coarse curved teeth and are used for cutting soft metals such as aluminium lead and fibre glass Grades of Cut The grade of cut is indicated by the pitch or size
258. o grasp and control Pliers are also used for shaping and bending light sheet metal as well as bending twisting and cutting small diameter wires Combination Pliers Standard engineers pliers are also called combination pliers because of their versatility These pliers combine the function of a number of types of pliers and therefore have a wide variety of uses in the electrotechnology industry Combination pliers are available in sizes from 150 to 230mm Applications e The flat jaw tips are serrated for general gripping bending and twisting etc e The pipe grip is serrated for gripping cylindrical objects e Two joints cutters are provided for shearing off steel wires e Side cutting jaws are for cutting softer wires e g copper etc or stripping cables Note Stripping electrical cables with this tool so as not to damage the copper conductors requires a great deal of practice e To cut harder steel wires use only the joint cutters These have strong 90 shearing edges and are placed to have greater mechanical advantage than the side cutting jaws e Tocut open the pliers wide until the cutter grooves in adjacent jaws line up Insert the wire with the short end facing away Squeeze to cut E102A Notes T2 T12 Version 4 BG doc Flat grip Pipe grip Side cutters Joint cutters Insulated handles on standard electricians pliers Fulcrum pin Reverse side of jaws FITTING SPLIT PIN USI
259. o the work through the arc column Arc welding systems in which the electrode is melted off to become part of the weld are described as metal arc The open circuit voltage ie before the arc is struck produced by a welding machine must be low enough so as not to be hazardous to the user le Typically between 50 and 80 Volts But this open circuit welding voltage is then not high enough to cause a discharge when the electrode tip is held off the work le The voltage is not high enough to arc across the normal airgap The arc must be established by first touching the electrode tip to the work this produces a high current flow in the circuit and then the operator must withdraw the electrode tip by a small distance as the contact zone becomes heated An electric arc is then formed which lonizes the air which in turn enables the air to readily conduct current across the small gap The E102A Notes T2 T12 Version 4 BG doc Page 138 of 254 23 January 2014 key point is that an arc cannot form by passing a cold electrode over the work piece The arc must be ignited by the user Once the arc is struck the welder design causes the terminal voltage to drop to between 17 and 40 volts but at a constant current level le Up to hundreds of amps depending on the size of the welder and materials to be welded Arc welding uses the low voltage high current power to produce the heat energy necessary to melt the parent metals and the filler rod
260. ol grip accommodate blades of different lengths of blades handle A set screw or catch allows the bow to be set in different positions in the handle TYPES OF HACKSAWS Hacksaw blades General purpose blades are made in lengths of 230mm 250mm and 300mm Tension adjusting nut and washer The number of teeth per inch 25mm also varies for each application This ranges from 18 to 32 teeth per inch Square hole in end of b When choosing a blade for a task as a rule of pipet id thumb there should be at least two teeth in contact with the cut surface at all times When cutting employ long steady slow strokes using as many teeth as is possible to do the cutting Short fast strokes with uneven pressure will only result in a dulled or broken blade The cut is made on the forward stroke only and NOT on the backward stroke Therefore when cutting mild steel with a hand hacksaw you should apply downward pressure on BLADE HOLDING PIECE MAY BE the forward stroke only SET IN ANY OF FOUR POSITIONS HACKSAW FRAME Do not twist or bend the blade when cutting because this could cause it to break E102A Notes T2 T12 Version 4 BG doc Page 51 of 254 23 January 2014 Selecting Blade Pitch The blade pitch for different types of work is shown below The blade s teeth should be flat across the work A blade with the correct number of teeth will provide chip clearance As general rule two or more teeth shou
261. ols com a Column This design is suitable for very large diameter drills used on large sized work pieces They are used in Arm up down tool rooms and fabrication work shops for tasks that are too big for the previous types of drilling machines On Off The radial arm can move i pivoted horizontally and move vertically which gives it great flexibility to locate the drill head over the drill point Radial drilling machines have very low rotational speed settings which is very effective for large diameter drills and fly cutters Care of Drilling Machines There are two main requirements for the continued efficient operation of drilling machines e They must be used correctly e They must be given regular cleaning lubrication and maintenance to prevent rust build up The main precautions to be observed in using a drilling machine are Do not overload the machine e By using drills of excessive diameter e By using feeds so heavy that the drilling head is deflected appreciably Do not subject the machine to shock e By ramming the drill into the work e By allowing the spindle to jar on the back stroke The following are indications that adjustments or repairs are necessary The spindle wobbles e The worn bearings need to be replaced The spindle has excessive end play e The feed mechanism must be adjusted to avoid backlash Holes are not being drilled at right angles to the work surface e The work table nee
262. ommon E102A Notes T2 T12 Version 4 BG doc Page 166 of 254 23 January 2014 Safety Precautions for Compressed Air Tools Always inspect equipment before use to make sure that everything is in correct working order Before use make sure that e Hoses are not cut or split e Hose couplings are fastened tightly to the end of the hose e Tool exhaust outlet ducts are clean and clear so that pressure will not build up inside the tool e The pad and disc is securely attached to the spindle if using a portable sander or grinder e The machine is in good working order If not report it e Label the tool stating its fault and send it out for repairs e Only the correct working pressures as specified by the manufacturer are used for the equipment e Incorrect pressures can cause serious injury and also damage the equipment When using make sure that e Tools are used as directed by the manufacturer e Use the correct stance and grip you will know if you are standing correctly if you feel well balanced and comfortable e You take care not to damage anything or injure yourself e When using portable cutting and grinding tools you must wear approved eye protection e You do not play around with compressed air e Do not point the hose at anyone it can cause serious injuries Warning Remember air under pressure is dangerous many lives have been lost through thoughtless and careless acts with compressed air Aft
263. on of the joint where the solder material bonds the component to a surface The key steps when making a silver soldered joint are form the joint clean it flux it apply heat and solder cool it clean and inspect Silver Soldering Safety e Silver soldering produces fumes and you should avoid breathing these A mask is preferred Solder only in a ventilated area but not so ventilated that the breeze cools the job Stand back from the work not over it e Goggles and gloves are essential These parts get hot Don t be tempted to touch anything even with gloves on unless you are sure it really is cold Always lay down sticks of solder with the hot end away from you e Be careful of stray naked flame It is very easy to concentrate on the job in hand in front of you and wave the flame elsewhere and possibly set the workshop alight e Be careful with any of the chemicals involved and thoughtful disposal of the pickle solution is recommended e The heat from soldering a large item can be overpowering and exhausting so be aware and be careful Dehydration and heat stress can and does occur e The propane torch should be complete with a burst hose protector flash back arrestor for connecting to the gas bottle Soft Soldering Solder is a fusible metal alloy used to join together metal work pieces and having a melting point below that of the work piece s There are different types of solder used by industry including bars wires and solde
264. on to their own work area Always think safety E102A Notes T2 T12 Version 4 BG doc Page 182 of 254 23 January 2014 Sheet Metal Characteristics Sheet metal refers to material types such as steel stainless steel aluminium brass copper etc produced as standard sized flat sheets or as coiled a strip of metal The major feature of sheet metal is called gauge which refers to the thickness of the metal sheet Standard gauges may vary from about 3 6 073mm to 38 0 152mm Note that the higher the gauge number the thinner the metal Today sheet identification is by thickness in mm rather than by a gauge number Typical sheet thickness range from a thin 0 4mm to about 3mm depending on the metal type Commonly available thicknesses are 0 4 mm 0 55 mm 0 75 0 70 mm 0 90 0 95 mm 1 15 1 20 mm 1 55 1 60 mm 1 95 mm 2 5 mm and 3 0 mm Available sheet sizes depend on the gauge and material Common sheet steel sizes in mm include 900x1800 900x2400 1200x1800 1200x2400 1200x3000 and 1500x2400 Electrotechnology applications for sheet metal are extensive as it can be cut and bent into a variety of different shapes Common applications in the electrotechnology industry include electrical switchboards busways connection boxes cable tray and cable duct trough Images of cable troughing and an electrical busway are shown Ref Busway http expor
265. ool with a handle similar to a multi bladed pen knife which holds multiple blades of hardened steel that are ground or rolled to an accurate and constant thickness e Each individual blade is stamped with its thickness measurement in millimetres 0 40 e The blades can be used singly or in combination to accurately measure the spacing between two surfaces or points e Feeler gauges are only used to measure very small clearances e With the correct clearance the feeler gauge should slide snugly between the two parts with a slight resistance e The drawing above illustrates a set of metric feeler gauges Feeler Gauge ranging from 0 05 mm to 0 60 mm e The sketch shows a feeler gauge being used to measure clearance Pinion Bearing Spacer Gauge Screw E102A Notes T2 T12 Version 4 BG doc Page 242 of 254 Bearing Puller This tools main function is to remove components such as a gear pulley or bearing etc from a drive shaft When first assembled these components would have been press or shrink fitted to secure them to their drive shaft and it typically requires considerable force to remove them during disassembly Bearing puller sets are made up of a range of interchangeable parts of various sizes and shapes all designed for perform specific applications They consist of three main parts e Jaws e Cross Arm e Forcing Bolt Normally there will be two
266. or type e Bench type e Portable Pedestal grinder A pedestal or floor type grinder is a heavy duty machine grinder and consists of a heavy base supporting the drive motor The main drive spindle is belt driven from the motor There is usually an abrasive wheel mounted on each end of the spindle The grinding wheels range up to around 300 mm PEDESTAL TYPE GRINDER diameter and 50 mm thick E102A Notes T2 T12 Version 4 BG doc Page 68 of 254 23 January 2014 The machines have a roughing wheel at one end and a finer finishing wheel at the other end The grit of the roughing wheel is larger than the grit of the finishing wheel and the grade of the finishing wheel is usually a little softer Because the wheel must run at a surface speed of 7s Maximum about 1700m min there is always some risk of the A wheel shattering It is important therefore that Lis 2mm the wheel be enclosed in a steel guard Vee A pedestal grinder is mostly used for coarse operations rather than tool sharpening although they can be used to sharpen larger tools such as drills etc WORK RESTS Bench Grinder A bench grinder is a light duty grinder which may be mounted directly on a work bench or on a vertical stand fixed to the floor Abrasive wheels are fitted directly to the ends of the motor shaft The grinding wheels range up to around 200 mm in diameter and about 25 mm thick The bench grinder is mostly used for light grade tool sharpening Gri
267. ore or less frequently practised These points are raised for the assessors to consider when choosing an assessment method and developing assessment instruments Sample assessment instruments are included for Assessors in the Assessment Guidelines of this Training Package Critical aspects of evidence required to demonstrate competency in this unit 9 2 Before the critical aspects of evidence are considered all prerequisites must be met Evidence for competence in this unit shall be considered holistically Each element and associated performance criteria shall be demonstrated on at least two occasions in accordance with the Assessment Guidelines UEEOQ7 Evidence shall also comprise gt A representative body of work performance demonstrated within the timeframes typically expected of the discipline work function and industrial environment In particular this shall incorporate evidence that shows a candidate is able to o Implement Occupational Health and Safety workplace procedures and practices including the use of risk control measures as specified in the performance criteria and range statement o Apply sustainable energy principles and practices as specified in the performance criteria and range statement o Demonstrate an understanding of the essential knowledge and associated skills as described in this unit It may be required by some jurisdictions that RTOs provide a percentile graded result for the purpose of regulatory or licens
268. orking specialties Eg Fabrication shops and metal machine shops have overlapping capabilities but fabrication shops generally concentrate on metal preparation and assembly as described above By comparison machine shops also cut metal but they are more concerned with the machining of parts using machine tools such as a lathe or a milling machine Sheet Metal Work Safety Sheet metal work has a number of inherent hazards The metal has very sharp edges especially thin gauge and the associated machines and tools all present a different set of hazards Never operate any tool or machine unless you have been specifically trained in its use and have been given permission to use it Always follow the SOP Safe Operating Procedure list which must be situated adjacent to the machine Ensure all machine guards are in place and there are no visible signs of machine defects before use Always wear appropriate personal protective equipment PPE as directed by the SOP Eg gt Appropriate clothing gt Eye protection gt Feet protection gt Hands gt Ears Good housekeeping is an important element in accident prevention and begins with planning As stated above edges of sheet metal can be very sharp and represent a significant hazard in the work area All materials especially sheet metal should be neatly stacked and off cuts placed in storage bins Any spillages of oil or grease should be cleaned up immediately Each person should pay attenti
269. ot Holes A pilot hole is a much smaller diameter initial hole which is drilled prior to drilling the final hole The advantage of a pilot hole is that it reduces drilling forces around the centre of the hole and it should also lead to a more accurately positioned hole The effectiveness of a pilot hole is dependant on the size of the pilot relative to the larger twist drill size that will follow As a rule of thumb the diameter of pilot hole should be about one quater of the diameter of the final hole E102A Notes T2 T12 Version 4 BG doc Page 87 of 254 23 January 2014 Drilling Process The drilling process is pointless unless you have the drill mark in the correct position Always remember measure twice and drill once Ensure you have correctly marked out the hole with a cross Now check it again Centre punch the desired location of the hole Use dividers to scribe a circle inside the final size of the hole Set up the job on the drill table Secure the job to the drill table or vice Ensure neither the table nor the drill vice can move under the force of the drill Drill a pilot hole first Any drill size above about 6mm should have a pilot hole TO SNS Note The pilot hole is made to ensure that the final hole is on the mark It is quite difficult to centre a large diameter drill bit on a small centre punch mark The pilot hole also reduces the load on the drill bit For very large final dril
270. ot be used Immediately report suspect machinery Operational Safety Checks 1 Never use pan brakes for bending metal that is beyond the machine s capacity with respect to thickness shape or type 2 Never attempt to bend rod wire strap or spring steel sheets in a pan brake 3 Remove the pan brake fingers that are in the way use only the pan brake fingers required to make the bend 4 Ensure the pan brake fingers that are not removed for an operation are securely seated and firmly tightened before the machine is used 5 Ensure fingers and limbs are clear before operating the pan brake 6 Lower finger clamps to work do not drop 7 Check work piece is secure 8 Keep clear of moving counterweight where fitted AWARNING Housekeeping Watch for pinch 1 Lower finger clamps to a safe position points on this 2 Return all accessories to storage racks equipment This 3 Leave the work area in a safe clean and tidy equipment has state many moving parts which may cause serious injury to yourself or others around the equip gt Squash crush and pinch points ment gt Impact from counterweight Not on some types Potential Hazards gt Sharp edges and burrs E102A Notes T2 T12 Version 4 BG doc Page 199 of 254 23 January 2014 Brake Press Folding Machine This is much larger type of machine for bending sheet metal This operation of this machine is quite different from the Pan Brake folder because it ben
271. ot be worn work areas Pre Operational Safety Checks e Locate and ensure you are familiar with all machine operations and controls e Ensure all guards are fitted secure and functional Do not operate if guards are missing or faulty Check workspaces and walkways to ensure no slip trip hazards are present Ensure push stick is available Lower the blade guide and guard to full effect Start the dust extraction unit before using the machine a lala Safety Checks Keep hands away from the blade and cutting area e Feed the work piece forward evenly and hold it firmly on the table to ensure effective control during cutting while keeping hands in a safe position e Use a push stick when feeding material past the blade e Before making adjustments switch off the saw and bring the machine to a complete standstill e Stop the machine before attempting to back the work away from the blade e Stop the saw immediately if the blade develops a click Report it to your supervisor E102A Notes T2 T12 Version 4 BG doc Page 81 of 254 23 January 2014 Ending Operations and Cleaning Up e Switch off the machine when work completed e Reset all guards to a fully closed position e Leave the machine in a safe clean and tidy state Don ts x Do not use faulty equipment Immediately report suspect machinery Attempt to cut very small items Cut cylindrical or irregular stock Never leave the machine running unattended Do not force a w
272. ould be cleaned to remove oil grease dirt sealant etc After cleaning they should be checked for damage or wear If tools require maintenance report this to the work supervisor Tools requiring maintenance should be tagged to prevent other workers using them before repairs are carried out REDUCTIONS Flare or_reductions FLARED OR REDUCED sr qa Joining sleeve TYPES OF STRAIGHT TRAYS Cable duct is a common cabling system used in both industrial and commercial applications Joining Lengths of Cable Duct There are three types of cable trays gt Straight tray Tapered with reductions gt Straight tray Flared at one end gt Straight tray No reductions but with joining sleeves Straight Tray with Reduction gt Generally there is a difference of 1 5 mm between one end of the tray and the other gt Slide the narrow end into the larger one of the next tray for approximately a 50 mm lap gt Either notch or rivet the ends together gt Mount the assembled length on the brackets or on the wall R Straight Tray Reduced or Flared hal mema gt Atone end of the cable tray a step inwards or l lof gi Leave outwards is made during production gt Slide the narrow end into the manufactured end gt Notch or rivet together to secure the parts JOINING TRAYS WITHOUT REDUCTIONS Straight Tray with Joining Sleeves gt Depending on manufacture sleeves are mounted inside or out
273. ound after the fitting operations have commenced the probable consequences are wasted time and wasted material Outlines R 13 mm E102A Notes T2 T12 Version 4 BG doc Page 29 of 254 23 January 2014 Marking Out from a Datum Edge If the stock material supplied has an existing Datum mark true edge which can be used as a datum then the development can proceed directly from this edge as shown to the right If there is no true edge then e A datum edge may be a ruled line on the material as shown above or e Create a true edge by either o Cutting a straight edge using tin Snips for thin gauge sheet metal or o Filing an edge straight for thicker materials Once the datum has been established e An engineer s tri square is used to project a vertical datum line line at right angles 90 e A steel ruler is then used to develop from this scribed line e A Jenny calliper is used in the bottom sketch to develop parallel lines NB The key point is that development of the work piece cannot proceed until firm datum edges or lines have been established NB The V mark is typically used to denote the datum line MARKING OUT FROM DATUM EDGE E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 30 of 254 Permanent Outlines Once the marking out and the checking of dimensions is complete it is usually necessary to lightly prick punch fine witness marks to permanently indicate th
274. ower end touch against the bottom of the recess e Tighten the locking screw e Lift the gauge carefully out of the recess and away from the work e Turn the gauge into a position where you can read the depth of the recess directly from the rule scale MEASURING THE DEPTH OF A RECESS MEASURING IN FROM AN EDGE E102A Notes T2 T12 Version 4 BG doc Page 26 of 254 23 January 2014 Marking Out Tools Marking out is the preliminary work needed to establish the guide lines and centre marks required for cutting drilling and machining It is necessary to ensure that the finished job precisely meets the job specifications For manual tasks an engineering drawing is typically provided which contains the details necessary for the tasks to follow For automatic tasks the marking out is first created as a drawing using Computer Aided Drawing CAD software and the custom designed program is then used to direct appropriate machines to perform the engineering tasks to follow Marking Out Procedure Marking out or lining is the process of placing accurate lines on metal surfaces in order to establish limits for the work le File cut and drill etc Marking out also establishes definitively if the work piece will accommodate the intended task Inspection of the Work Prior to Marking Out Begin by checking e The physical size of the raw stock material to be certain that it will accommodate the finished size following all of t
275. own into the work Provision is sometimes made for the blade to be tilted or the vice swivelled or both for angular cutting The blade is sharpened to eliminate the jamming effect of the thickening chip in the cut Alternate teeth are chamfered and the un chamfered have a smaller diameter Liquid coolant is pumped through a hose and Metal sparks Noise Sharp metal burrs Contact with rotating disc Eye injuries Burns from hot work pieces Do not use faulty equipment Immediately report suspect equipment Do not grind on the side of abrasive cut off wheels Do not cut wood or wood products Do not hold a work piece by hand as it will become very hot while being cut Do not use a length stop on the free off cut end of a clamped work piece Do not have any part of your body in line with the path of the abrasive disc Do not force the tool into a cut Do not attempt to remove cut material while disc is moving directed onto the blade when cutting takes place The blade makes straight cuts only and is used to dock off stock materials E102A Notes T2 T12 Version 4 BG doc Page 79 of 254 23 January 2014 Safety Cold Saw DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on a Cold Saw Safety glasses must be Long and loose hair Hearing protection worn at all times in work must be contained must be worn areas Stu
276. oximity to live electrical terminals Length stamp Tape Maintenance Thin spring steel Correctly maintained steel tapes and tape rules will l last for many years Follow these steps Curved across width e Keep the blade free from grit and moisture STEEL TAPE E102A Notes T2 T12 Version 4 BG doc Page 21 of 254 23 January 2014 e Slide the blade between a slightly oiled rag when returning it into the case e Avoid leaving the blade exposed to the direct rays of the sun as this can buckle it Using Tapes Tapes can be graduated in either all metric or a combination of metric and imperial feet and inches measurements ey start at inside edge TYPICAL TAPE ENDS Hook folds up HAHEI HHHH i ity TTT y 4 5 6 7 13 44 15 NR End hook compensates for metal thickness when taking inside or outside measurements End hook measuring overall End hook hooks butted into an internal corner Internal corner measurement External corner measurement TAPE RULE APPLICATIONS A steel tape can be used in most situations but it is best used for on site setting out and for taking on site measurements The fixed end hook on a steel tape can move to compensate for the thickness of the metal when taking inside or outside measurements so it is important to place it correctly in position The tape rule is used for all types of measuring and setting out tasks within its length Its flexibility enables it to be used for me
277. p electrode leads around yourself NB This SOP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references It is designed as a guide to be used to compliment training and as a reminder to users prior to equipment use Arc Shielding Joining metals requires more than moving an electrode along a joint Metals at high temperatures tend to react chemically with elements in the air Eg Oxygen and Nitrogen When metal in the molten pool comes into contact with air oxides and nitrides form which destroy the strength and toughness of the weld joint Arc shielding is a process of covering the arc and the molten pool with a protective shield of gas vapour or slag This shielding prevents or minimizes contact of the molten metal with air MIG Metal Inert Gas or GMAW Gas Metal Arc Welding OXIDE http www advantagefabricatedmetals WIRE _ com brazing html ELECTRODE GMAW is a welding process in which an electric arc forms between a consumable SHIELDING wire electrode and the metal work piece s which heats the work pieces metals causing them to melt together The welding cable pipe coming from the welder to the welding gun contains the continuous thin wire electrode a shielding gas line and the control wires from the welding gun s trigger switch The trigger switch on off controls the power electrode feed
278. partially close up the jaws but not fully tightened NB Ifa vice is left too tight any expansion or contraction due to temperature change could crack the frame Workshop Equipment A fixed machine tool refers to a power driven machine mounted in a permanent location Most fixed workshop equipment is electric powered Be aware if an electric powered tool stalls for a length of time then the current drawn by the motor will increase substantially This may cause Close fitting Wear the motor to burn out and it could cause a fire overalls buttoned well fitting Workshop tools function by to the neck rm safety ey goggles e Holding the material to be cut Hands kept clear e Holding the cutting tool or tools Safety shield e Moving or rotating the work the tool or both so that the parent material is yourself removed to enable e Controlling the speed magnitude and rate _ Ne required of the cut pressure to be applied The word machining means the cutting away of material by means of a power driven machine tool Typical fixed workshop machine tools include a e Pedestal or Bench grinder e Bench Pedestal Pillar or Radial fixed drilling machine e Metal Lathe e Abrasive saw e Cold saw Safety boots Keep area clear SUPPORT YOURSELF COMFORTABLY ON BOTH FEET E102A Notes T2 T12 Version 4 BG doc Page 66 of 254 23 January 2014 e Vertical Band saw e Power hacksaw Safety There are identifiab
279. plete turn of dial equals one division on scale Vernier Height Gauge The vernier height gauge is a development of the standard vernier calliper The graduated frame is held in a vertical position by being attached to an accurately ground base The base is commonly a magnetic design to enable it to firmly attach to a magnetic surface The vernier is read in the same way as the standard vernier calliper except in this case the reading is taken from the movable jaw to the base This tool is commonly used in conjunction with a surface plate or table and is designed for accurate marking out or checking heights VERNIER HEIGHT GAUGE E102A Notes T2 T12 Version 4 BG doc Page 226 of 254 23 January 2014 Metric Vernier Reading Class Exercise Determine the readings for the following positions and record in the box provided 7 E102A Notes T2 T12 Version 4 BG doc Page 227 of 254 23 January 2014 Outside Micrometer An outside micrometer is a high precision measuring tool used to obtain accurate measurements of machined parts The principle of the micrometer is based on the movement of a precision cut screw rotating through a mating nut The scales on the micrometer provide a means of counting the revolutions of the screw and converting them into a length measurement ANVIL SPINDLE SPINDLE LOCK SLEEVE THIMBLE RACHET FACE FACE NUT Metric micrometers measure to an accuracy of 0 01mm The
280. pplied with interchangeable jaws to suit different diameter rivets This tool automatically severs the mandrill from the rivet when the set tension point is reached When selecting a suitable rivet for a task always be sure to replace like with like Common rivets are made of aluminium but stainless steel types are also made for harsh environments Installation Process gt Pre drill a hole to the specified diameter at the precise location for the rivet gt Ensure that the rivet tool s jaws are suitable for the size of rivets to be used NB The jaws are interchangeable Hex head spanner gt Insert the mandrill in the jaws of the riveting tool gt Using the rivet tool as support force the head of the rivet through the predrilled hole until the rivet head is seated flush gt Squeeze the riveting tool s handles together which causes the mandrill to pull through the head causing the rear of the rivet to flare out Ensure rivet oa lt is pulled hard against nose piece LY gt Ata predetermined point the mandrill will sever leaving the rivet clamping the two surfaces tightly together E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 188 of 254 Pop River Characteristics Pop rivets are installed from one side of a work piece in one simple operation without damage or distortion to the structure This is very useful when you cannot access the rear section To remove a pop ri
281. present Ensure the depth stop is properly adjusted Keep table and work area clear of all tools and off cut material Operational Safety Checks e Ensure all adjustments to machine are secure before making a cut e Use the vice to clamp the work and properly support the over hanging portion of the work piece level with the base of the machine e Allow the machine to reach full speed before contacting the work piece e Ease the abrasive disc against the work piece when starting to cut e Keep hands away from the blade and cutting area e After finishing the cut release the switch hold the saw arm down and wait for the disc E102A Notes T2 T12 Version 4 BG doc Page 78 of 254 23 January 2014 to stop before removing work or off cut piece Before making any adjustments disconnect the plug from the power source and bring the machine to a complete standstill Cleaning Up Remove foreign material from in and around ventilation openings and switch levers Leave the machine in a safe clean and tidy state Potential Hazards and Injuries Don ts x x xXx xXxXXXX Cold Saw A cold saw cuts with a slow speed blade Itis a true chip forming action like a milling cutter unlike the high speed abrasive saw above Small machines use blades from 200mm diameter to cut light sections Large machines are capable of cutting up to 600mm square stock They are of a swing frame type where the blade and drive is pivoted and manually pulled d
282. program is maintaining a log for each power tool recording full manufacturer and an accompanying list of the parts needed for normal service and major repairs Eg Bearing and brushes etc The maintenance program will establish the frequency of inspections for each tool in addition to the mandated electrical test and tag program set Australian standards This is discussed in the next section Portable tools must be checked e Before the tool is put into use for the first time e After servicing and changing parts e At regular intervals appropriate for each tool Checks include tests for e Less than normal output e Malfunctioning safety devices such as on off switches emergency buttons protective covers or guards etc Over temperature Severe noise or vibration Cracked or broken grinding wheels or faulty cutting blades Cracked or broken case overt flaws in the power lead Faulty electrical insulation or faulty earthing system Constant care and adequate maintenance and storage are essential for the safe use of portable tools in the workplace In practice this involves visual inspections aimed at detecting signs of possible fault Early detection may be able to correct a small problem before it becomes a major problem Items requiring attention should be reported and recorded in the maintenance log E102A Notes T2 T12 Version 4 BG doc Page 176 of 254 23 January 2014 Some basic procedures to prevent hazards associated w
283. quare Li WZ Pim Tt Threads at cutting face must be sharp Through thread Use second tap after taper Cutting face a Flute HAND TAP Lead or chamfer z F J _ ur _ 5 g i F INTER MEDIATE JL 7 E Using a Tap Wrench y y First the hand tap must be securely clamped in the jaws of a tap wrench Bottoming completes thread in blind hole Se NB The pre drilled drill hole size must always have a smaller diameter than the tap size A comprehensive tapping chart is shown on the pages below It is important to stress that the tap and tap wrench must be matched in terms of physical size to reduce the probability of breaking the tap If a large tap wrench is used with a small tap then there is a good TAP SET chance the tap will snap Especially when tapping into copper UU The tap wrench has two handles to provide a balanced driving force to control and reduce the chance of breaking the tap e The work should be firmly held in a vice or clamped from moving and the hole should be aligned to an upright position e Obtain a supply of suitable cutting lubricant and apply to the tap thread e Grip the tap in the wrench The taper tap is used first because the taper lead allows the tap to better enter the hole This helps to guide the tap an
284. r eg Burn odour peripheral case burning or overt physical damage 16 Recovery value of possible salvageable parts Disassembly Sequencing This is a detailed step by step approach to disassembly Typically the sequence may give the precise order that is to be followed and could be supported by detailed assembly drawing or images Criteria used to establish such a sequence is 1 Worker safety 2 Reducing the risk of any potential environmental damage due to spillage or gas leaks etc 3 Elimination of damage to the components during the disassembly process 4 Fastest approach which reduces the disassembly time 5 Component separation where one component must pass beside or through another component 6 A sequence which will give service personnel access to the zones which have a high probability of component failure without the need to completely disassemble the entire machine Eg For a washing machine this may include the main controller area the valves and the electric motor etc Example Sequence Dismantle and Assemble Electrical Equipment and Removal of the Electric Motor A disconnection procedure is as follows Notify all concerned persons of the isolation and removal of the motor Find an effective earthing point within the electrical system From this point check that the frame of the motor is not LIVE Check the direction of rotation of the motor if possible and record details Locate the circuit isolato
285. r to starting as these contaminants prevent good adhesion of the solder to the surfaces being joined The joints need to be chemically cleaned with a flux to remove any surface oxide layer from the material The flux also prevents the formation of oxides while the molten solder is flowing into the joint A range of commercial fluxes are available These are normally identified by the manufacturer s trade name on the container Instructions on the container explain the suitability of these fluxes for particular applications Most fluxes are corrosive Take care when handling and working with fluxes Read the manufacturer s SDS for the product prior to starting work Always use appropriate PPE and work in well ventilated areas After soldering the flux residue must be removed from the affected surfaces with a clean wet cloth If this is not done corrosion of the joints and or the surrounding areas will occur Other materials which can be soldered include copper brass stainless steel and tinplate Each material requires its own special flux GELLEYS Joining with Sealants Due to the difficulty of soldering some metal products alternative methods of joint sealing have been developed Chemical sealants such as silicone are e Be now in common use Many different types of sealants are available from trade SEALANT suppliers and specialist adhesive manufacturers It is important to select an appropriate sealants for the task Sometimes
286. r EZA safety face mask when performing this task i z USING A KEYHOLE SAW Hand Saw Wood Cross Cut or Rip Saw Types This type of hand tool is designed to cut mainly timber based products The teeth of rip saws are designed to cut timber of medium thickness with the grain and the teeth of cross cut saws are designed to cut timber across the grain and also general cutting Start a cut by slowly drawing the saw up a few times to make a notch Once started the saw blade itself assists guiding the blade straight for the remainder of the cut Uses in the electrotechnology industry include cutting battens used for clipping cable cutting out studs to mount air conditioners and making noggins to support ceiling mounted light fittings Blade length 550m to 700mm Tooth size Six points per 25mm is recommended for general purpose applications E102A Notes T2 T12 Version 4 BG doc Page 56 of 254 23 January 2014 Hand Saw Maintenance e Keep the surface of the saw coated with a light lubricant to ensure that it does not rust e Ensure that the teeth do not contact other steel based tools as this will damage them Hole Saw This tool is designed to cut neat round holes in variety materials of diameters larger than is possible with a normal twist drill Typical sizes range from diameters of about 18mm up to about 75mm in diameter A hole saw is a circular shaped saw blade that is used in a powered drill They typically h
287. r and isolate the power supply to the motor via the circuit break and motor isolator Pre test the test device test the terminals of the motor and then retest the test device on a Known supply 7 Attach a personal danger tag and lock out the isolating switch to prevent accidental reconnection of supply to the motor 8 Disconnect the live conductors carefully marking and recording their position for reconnection Disconnect the earth conductor last Make the conductors safe both ol SS D E102A Notes T2 T12 Version 4 BG doc Page 246 of 254 10 11 12 mechanically and electrically Record all motor nameplate details Remove all holding bolts and nuts on the motor base coupling etc Remove the motor from its mounting using safe lifting procedures le Manual method straight back bent knees etc lf using mechanical lifting devices care must be taken to use the correct size sling Disassembly of an Electric Motor 1 2 Place the motor on a sturdy clean bench Witness mark both the stator and the end shield for accurate realignment on reassembly A common method is to use a centre punch NB Witness marks are explained in Part c below Undo the central bearing cover metal threads Carefully lever the end of shield from two positions on opposite sides of the motor to evenly space the pressure on the bearing taking care not to damage the windings To remove bearings you must use the correct bearing pull
288. r final reading to obtain the accurate measurement required Other Uses for the Steel Rule A steel rule can also be used as a e Guide to draw or scribe a straight line e Straight edge to test the accuracy of a flat surface e Scale for setting dividers and other marking out tools Ref http www tractorsupply com E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Any wear on corner Graduation in line would introduce with edge is error the reading Measurement EDGE OF RULE Page 25 of 254 Rule Depth Gauge Knurled nut A depth gauge is a measuring tool developed from a steel rule Depth gauges are used to measure e Depths of holes e Depths of recesses and slots e Distances in from the edges of work Millimetre graduations The depth gauge consists of a narrow graduated steel rule fitted with a sliding frame that may be clamped along the rule Narrow rule Using a Depth Gauge Use a depth gauge to measure the depth of a RULE DEPTH GAUGE recess as follows e Hold the frame of the depth gauge between the thumb and finger of one hand e Loosen the locking screw with the thumb and first finger of your other hand e Hold the frame base firmly down on the surface across the recess of the work to be measured e Hold the gauge square to the work by steadying the rule with the first finger of one hand e Use the first finger of your other hand to press the sliding rule down until you feel the l
289. r paste Wire solder which has an internal flux core is typically used in the electrotechnology industry The most common type of solder is an alloy of tin and lead It is compatible with most types of fluxes and it has good corrosion resistance and excellent electrical properties It can be used for joining most metals including copper wires By convention the solder s tin content percentage is always stated first For example electrical 60 40 solder means it contains 60 tin and 40 lead ferniperkne C femiperive C Plumber s solder is normally 50 50 400 which means 50 lead and 50 tin AE EE which liquid NB The symbol for tin is Sn and 10 Maay 5 e solidification starts for lead is Pb ert ii aren The ratio of tin to lead sets the 250 Pann solder s melting characteristics The greater the tin concentration the i greater the solder s tensile and shear 150 strength Tin also increases the i solidus wetting ability and lowers the ae cracking potential of the solder fomperaiund al which solidification is a0 f completa Wetting produces an inter metallic bond Poor wetting tends to form x Y s 2 v u OT Onw Increasing percentage by mass oliin Sn droplets while good wetting ability E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 157 of 254 tends to spread out evenly over the solid surface area 60 40 Tin lead solder i
290. r the bolt or possibly cause an accident Maintenance and Storage All spanners should be selected carefully for the application planned and inspected prior to use to ensure where applicable e Jaws are square e Hexagon shoulders are not worn and e Moving parts are in good repair e All spanners when not in use should be cleaned and stored in a suitable roll or tool chest E102A Notes T2 T12 Version 4 BG doc Page 120 of 254 23 January 2014 Ring Spanner Ring spanners are available with offset or angled shanks Because it is in the form of a ring spreading of the spanner jaw cannot occur and greater force may be applied making these spanners better for removing difficult or frozen heads Clearance The offset shank provides clearance for for knuckles knuckles while the angled shank is to provide R R JJ WJIJWWWJIJJZJIMW clearances above obstructions Angled shank Combination Ring and Open End Spanner When the combination ring and open end spanner is used the ring spanner loosens the nut and the open end is then used to quickly undo the nut Vise iy f Aff Af Aff JS AA PLS pf 7 Jf 7 tt LTT tify MJ PWJJJ WJ A AA AGAO GGG RING SPANNER This spanner has open jaws at one end and a 12 point double hexagon ring at the other end Adjustable Spanners These are also called a shifting spanner or an adjustable wrench Adjustable spanners are similar to open end spanners but they h
291. ransferable to other sheet metal working tasks Sheet Metal Work Hand Tools Quality tools must be used with care and for the correct purpose where they will provide years of useful service requiring only minor attention such as sharpening Tools used incorrectly or for the wrong application or handled carelessly quickly become blunt damaged or broken Sheet metal work tasks for electrotechnology will typically require the use of the tools listed below Full details of the tools are explained elsewhere in this note Steel rule Used for measuring ruling straight lines testing for straight edges and flat surfaces Engineer s square and Combination square Used for marking lines at specific angles to an edge and for testing right angles Scriber Used for marking of lines Centre punch Used for marking the centre of holes prior to drilling Dividers Used for marking circles and curves stepping off equal divisions along a line transferring measurements Odd leg Jenny callipers Used for marking lines parallel to an edge Mallet Wooden or rubber can be used to bend and shape sheet metal Ball Pein Hammer Used for general work Snips Tin snips They are used mainly for notching metal sections prior to bending Available in straight right or left hand versions Soldering iron Can be used for general soldering applications such as joining of metals or electrical cable joints Pliers Can be used to fo
292. rate and the rate of gas flow GMAW is generally a constant voltage DC power source and the electrode flow rate through the gun sets the value of welding current The higher the wire feed rate the higher the welding current Nb Constant current AC is also available on some GMAW welders The shielding WORKPIECE E102A Notes T2 T12 Version 4 BG doc Page 143 of 254 23 January 2014 gas prevents atmospheric contamination for the weld and protects the weld during solidification The shielding gas also assists with stabilizing the arc which provides a smooth transfer of metal from the weld wire to the molten weld pool The process can be semi automatic or fully automatic There is different metal transfer processes available with GMAW depending on the type of welds required Each method has its own advantages and disadvantages Characteristics of GMAW e Uses a continuous consumable wire electrode that is fed from a spool which makes it a very fast method of welding e Uses a shielding gas usually argon argon 1 to 5 oxygen argon 3 to 25 CO gt z and a combination argon helium gas depending on the type of metal welded Provides a uniform weld bead Produces a slag free weld bead which needs little cleanup Produces less heat and distortion of the material being welded than MMAW Allows welding in all positions Requires less operator skill than TIG welding Allows long welds to be made without starts or stops The shieldin
293. rcially they are available in lengths ranging from 100mm up to about 300mm depending on the design Smaller sizes are used for smaller dimensions A spring divider upper image consists of two sharp points at the end of straight legs held apart by a spring and threaded rod and adjustment is by a knurled nut A wing type divider bottom image has a steel bar that separates the legs a lock nut for setting a rough measurement and an adjustment screw for fine adjustments Use e Set the desired radius on the dividers using the appropriate graduations on a rule e When setting dividers against a rule the points should be kept parallel to the edge of the rule and set to the centre of the required graduation e When scribing a circle or arc lean the dividers in the direction of movement and scribe the circle by revolving the dividers Maintenance e Keep dividers clean and dry e Regularly oil to ensure that it does not rust E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Page 36 of 254 e Protect the points against damage e Store dividers where they will not become bent or broken e Keep the hardened points sharp and care must be taken to keep the two legs at an equal length Jenny Calliper Also called odd leg calliper This tool is commonly used to measure and scribe a development line onto a job surface from an adjacent edge It consists of one divider leg and one in
294. rd removed Before using any power tool read the operating instructions carefully _ Always wear safety glasses when using power tools _ Use a face or dust mask if the cutting operation is dusty _ Wear ear protection for noisy operations _Do not use power tools in explosive atmospheres _ Never carry a tool by the cord or tug the cord to disconnect it _ Protect cords from heat oil and sharp edges _Do not expose power tools to rain _ Do not force a small tool or an attachment to do the job of a heavy duty tool _ Disconnect tools when not in use before servicing or when changing accessories such as blades e Maintain tools with care Keep tools sharp and clean at all times for best and safest performance Follow instructions on lubricating and changing accessories e _ Avoid accidental starting Do not carry a plugged in tool with a finger on the switch Be sure the switch is off before plugging in e _ When using the tool at a considerable distance from the power source an extension cord of adequate size must be used for safety and to prevent loss of power and overheating e _ Before using cords inspect them for loose or exposed wires and damaged insulation e Ensure any needed repairs are made or replacement before using your power tool Care and Maintenance Portable Power Tools A maintenance programme integrates workplace health and safety inspection reporting and record keeping procedures A key part of the maintenance
295. rds of inspection and tests shall be kept All the following should be recorded A register of all equipment Arecord of formal inspection and tests A repair register A record of all faulty equipment i Visual inspection date checklist as per AS NZS 3000 checklist ii Continuity of earthing system values obtained for main earth bonding earth and protective earth iii Insulation resistance value iv Polarity checklist v Correct circuit connections checklist vi RCD values for trip time Extract from AS NZS 3760_ 2010 In service safety inspection and testing of electrical equipment SECTION 2 INSPECTION AND TESTS 2 3 3 Testing The purpose of testing is to detect the unobservable faults not found by the visual inspection process and forms an integral part of the inspection testing process 2 3 3 1 Earthing continuity To confirm that the resistance of the protective earth circuit is sufficiently low to ensure correct operation of the circuit protecting device the continuity of the protective earthing conductor from the plug earth pin to accessible earthed parts of Class equipment shall be checked The continuity of the protective earth conductor between the earth pin of the plug and the earth contact and every outlet s of cord sets cord extension sets EPODs and PRCDs portable residual current device shall be checked Such equipment shall be tested in accordance with Appendix
296. rdy footwear must Close fitting protective Rings and jewellery be worn at all times in Lh clothing must be worn must not be worn work areas Pre Operational Safety Checks e Locate and ensure you are familiar with all machine operations and controls e Ensure all guards are fitted secure and functional Do not operate if guards are missing or faulty Check workspaces and walkways to ensure no slip trip hazards are present Ensure saw blade is in good condition Check the operation of the work vice Check coolant delivery system to allow for sufficient flow of coolant Operational Safety Checks e Ensure the work piece is securely held in the work vice e Support overhanging work Signpost if it presents a hazard e Listen for any unusual noises during the sawing process Ending Operations and Cleaning Up e Switch off the machine when work completed e Before making adjustments or before cleaning swarf accumulations switch off and bring the machine to a complete standstill e Clean up and absorb any coolant spills immediately e Leave the machine in a safe clean and tidy state Potential Hazards and Injuries e Possible skin irritation from coolants e Eye injuries e Sharp edges and burrs metal splinters e Noise Don ts x Do not use faulty equipment Immediately report suspect equipment x Do not cut very small items x Do not cut materials other than metal x Never leave the machine running unattended x Never force the
297. re reliable Assemble and Dismantle Machines Electrical equipment must be dismantled for a variety of reasons including routine maintenance fault finding and repair and sometimes during the initial installation phase Preparation Always attempt to obtain all available information regarding the machine prior to dismantling This can be obtained from the machine s nameplate product manuals maintenance logs form other maintenance staff and the operator In particular you are looking for recurring faults or locations where persistent wear may occur A three phase motor is a piece of equipment that an electrotechnology tradesperson is required to both assemble and disassemble A typical motor name plate and winding connections are shown below Ref http www electricneutron com TEC EPACT EFFICIENCY 3 PHASE INDUCTION MOTOR ove cA NO eS ae LourpuT HP KW FRAME r Poes INS e ASE 3 HsH eo al Y N Inr i l J045MOOUTMIEZIT s i SS a ea ae bega PR ws SB oesion as a0 a E NENA NOMLEFF NEWA MIN EFE RATING CONT een 1s cams sone en USABLE ON V NETWORK AT AMF O TECO Elec amp Mach Co Ltd When dismantling a machine the two possible approaches are 1 Completely disassemble it without any detailed component inspection and then make a full diagnosis when all parts have been removed This is a very quick disassembly 2 Inspect and diagnose each component and only remove t
298. reas Pre Operational Safety Checks e Locate and ensure you are familiar with all machine operations and controls e Ensure all guards are fitted secure and functional Do not operate if guards are missing or faulty Check workspaces and walkways to ensure no slip trip hazards are present e Ensure the wheels do not touch the work rest and that the gap between wheel and rest is no greater than 2mm e Check that the wheels are running true and are not glazed or loaded e Check for cracks in the wheel and report any you find Operational Safety Checks Stand to the side of the wheels when starting up Let the wheels gain maximum speed before starting to grind Only one person may operate this machine at any one time Slowly move the work piece across the face of the wheel in a uniform manner Ending Operations and Cleaning Up e Switch off the machine when work completed e Clean up and absorb any coolant spills immediately e Leave the machine in a safe clean and tidy state Potential Hazards and Injuries Hot metal Sparks Noise Sharp edges and burrs Hair clothing getting caught in moving machine parts Wheels run on after switching off Eye injuries Don ts x Do not use faulty equipment Immediately report any suspect machinery Do not hold work piece with gloves cloth apron or pliers Do not grind non ferrous metals Do not grind on the side of the wheel Do not hold small objects by hand Never l
299. rely cause any problems but too little can ruin the work as it prevents the capillary action of the solder into the joint or fails to remove the oxides properly when heated Heating of the job should be done reasonably quickly to prevent exhausting the flux A propane heating torch is suitable and provides gentler broader heating as compared to an oxy acetylene flame which can be too hot and concentrated and should be avoided unless skilled in it s use Choose a burner of sufficient capacity for the job size Heating should be even for the whole job and ALL parts of the assembly should be at or about the same temperature E102A Notes T2 T12 Version 4 BG doc Page 156 of 254 23 January 2014 Allow the joined parts to cool naturally to room temperature Remember that some base materials may change their properties after being heated to the red heat required for silver soldering After soldering always clean any accumulated flux from the job and clean by pickling or emery paper Nb Pickling means to use a liquid solution eg water acid etc to clean surfaces of flux residues Check the joint from both sides where possible to ensure that all joints are soldered correctly If not it is usually possible to re flux the work and repeat the soldering process after cleaning Make sure that the solder has fully penetrated the joint and there is a small fillet of solder in the corners Nb A fillet is the rounded concave secti
300. rements E102A Notes T2 T12 Version 4 BG doc Page 5 of 254 23 January 2014 Application of the Unit 4 4 1 General Application This unit applies to persons entering work in utilities industry and may be used in school based vocational programs 4 2 Importation RTOs wishing to import this unit into any qualification under the flexibility provisions of NQC Training Package Policy Elements and Performance Criteria Pre Content 6 Elements describe the essential outcomes of a unit of competency Performance criteria describe the required performance needed to demonstrate achievement of the Element Assessment of performance is to be consistent with the evidence guide Elements and Performance Criteria 1 Prepare for dismantling assembling and fabrication work 1 1 OHS procedures for a given work area are obtained and understood through established routines and procedures 1 2 Established OHS risk control measures and procedures in preparation for the work are followed 1 3 Safety hazard not previously identified are reported and advice on risk control measures is sought from the work supervisor 1 4 The nature of the work is obtained from documentation and from work supervisor to establish the scope of work to be undertaken 1 5 Advice is sought from the work supervisor to ensure the work is coordinated effectively with others 1 6 Materials required for the work are obtained in accordance with established routines and procedures
301. retch but the section under Fingers the wing will stretch as it is rolled around the ae A radius at the front of the fingers under the clamp when making both bends That is parts A and B will protrude over the wings This will ensure that the stretch in the two walls is equal and the two side walls will be equal in length Just how accumulate it will be can be x determined by a small test piece This means that when folding a U section shown it is important that the base section is Wing The radius of the bend created by aL a pan brake folder can be Bending wing gt adjusted by setting the height of Clamp Block the wing The amount of gap required between the clamp block and the clamp fingers determines the bend radius If the wing is raised to it highest point where it is Folding arm flush then the bend will be very sharp small radius When the wing Is lowered it created a bigger bend arc and the radius is greater E102A Notes T2 T12 Version 4 BG doc Page 211 of 254 23 January 2014 Self Secured Joints These joints are formed by folding and interlocking thin sheet metal edges together in such a manner that they are made secure P A o d e without the aid of any aned down bottom joint additional jointing nn eee process Their use is confined to fabrications or Grooved seam components constructed with light gauge
302. rew axis The wrong TIP ALMOST AS alignment causes turning pressure to damage the AS BOTTOM OF SLOT tip and the screw rather than turn the screw Shape of the Tip TIP TOO WIDE The shape of the tip is also important The tip edge must DAMAGES WORK be straight If the tip is badly worn arc or incorrectly Narrow tip damages screw amp tip ground it will tend to jump out of the slot Correct Safety when using a screwdriver thickness e Ensure the correct sized tool for the screw e Check the tool is in good working condition e Ensure the screwdriver fits correctly into the recess of the screw e Keep your hands free of the tip when operating as the screwdriver may slip and injure Fe eye Ree BRR e Keep axis of shaft aligned with the screw Screwdrivers for Recessed Head Screws A wide variety of recessed head screws are used in the electrotechnology industry These screws and their IO drivers tips are preferred over slotted screws because wa they are unlikely to slip and damage the work piece The image to the left is a Phillips head and the right side image is a Pozidrive head TIP TOO THIN BLADE TWISTS Rounded end DO NOT USE in Phillips recess Rounded WORN AND DANGEROUS SELECTING THE CORRECT SIZE TIP Pozidriv screwdrivers are similar to Phillips head screwdrivers but they are made to fit Pozidriv screws which have a deeper recess NB It is not recommended that Phillips hea
303. riate personal protective equipment assigned to the task you are performing This may include some of the following items Suitable clothing Safety shoes or boots Safety glasses Goggles Hair net or cap Hearing protection Gloves Breathing apparatus Clothing Suitable clothing should always be worn in the workshop Loose sleeves and other loose clothing can easily catch on parts of a vehicle or tangle in E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 substitution engineering controls administrative controls and personal protective Chin in head erect Back straight Leg muscles do lifting Firm secure grip Hands diagonally opposite Hair and eyes unprotected Page 15 of 254 workshop equipment Rotating parts such as fans belts and drills are particularly dangerous as these could catch a loose sleeve and quickly pull a hand into a moving part Long hair that is not under control can become tangled in rotating parts This can cause severe personal injury Always tie back long hair or wear a cap or other headgear such as a hair net NB An example of an unsafe work practice is an operator with long hair using rotating machinery without using some form of a hair protector Footwear Boots and shoes should be of stout safety design Safety footwear is designed with reinforced toecaps to provide some level of protection against some falling objects Safet
304. rical circuit that flows only one way This leads to a constant polarity of arc charge DC is used for welding ferrous metals such as stainless steels GTAW welding using high frequency AC creates an arc which switches polarity in regular cycles This polarity switching removes surface oxidation from the weld area and is used for welding aluminum E102A Notes T2 T12 Version 4 BG doc Page 146 of 254 23 January 2014 TIG Summary e Uses a non consumable tungsten electrode during the welding process Uses a number of shielding gases including helium He and argon Ar Can be applied to thin gauge materials Produces very high quality weld dependant on operator skill Welds can be made with or without filler metal Provides precise control of welding variables i e heat Welding yields low distortion Leaves no slag or splatter Safety The clear atmosphere around the GTAW arc can cause up to twice the amount of infrared and UV rays compared to normal arc welding Any exposed skin will be burned similar to extreme sunburn Safety Gas Tungsten Arc Welding DO NOT use this machine unless you have been instructed in its safe use and operation and have been given permission Personal Protective Equipment Safety glasses must be Long and loose hair Oil free leather gloves worn at all times in must be contained O and spats must be addition to welding worn mask Sturdy footwear with Close fitting protective Rings and jewellery r
305. rical equipment Type of electrical equipment to be inspected and tested includes 1 Portable equipment mains operated portable appliances connected to supply by flexible cords 2 Cord extension sets and electrical portable outlet devices 3 Portable and Non portable Residual Current Devices RCD s including electrical portable outlet devices incorporating RCD s Construction Work The Electrical Safety Regulation 2013 Subdivision 3 requires that all electrical portable equipment used for Construction work must comply with the requirements of Australian standard AS NZS 3012 2010 Electrical Installations Construction and demolitions site AS NZS 3012_2010 in turn references Australian Standard ASNZS 3760 2010 In service safety inspection and testing of electrical equipment to define the test procedures for inspecting electrical equipment to be used for construction work AS NZS 3760_2010 In service safety inspection and testing of electrical equipment This standard specifies the procedures for safety inspection and testing of electrical equipment operated by single or polyphase low voltage supply and which is entered into service for the first time or which is already in service or is available for hire or resale The scope of the standard is outlined in Section 1 as well as the type of electrical equipment the procedures E102A Notes T2 T12 Version 4 BG doc Page 178 of 254 23 January 2014 cover an
306. ricks from walls etc E102A Notes T2 T12 Version 4 BG doc Page 117 of 254 23 January 2014 Sledge Hammer This is the heaviest of the hammers with head weights from 3 to 10kg They have a long wooden handle for extra leverage and are used for heavy duty tasks Eg Heavy steel work or smashing concrete etc Hammer Safety Before using any hammer use a clean dry cloth to wipe your hands the handle and the head of the hammer Oil grease and dampness can cause the handle to slip from your hand or the striking face to slip from the work Feel if the head is firmly fixed to the handle and that the wedge is tight Check that the head is square and in line with the handle If the handle is loose refit the head and have it re wedged Caution Hammer heads flying from poorly fitted or broken handles can inflict serious injuries Inspect the striking faces of the head and discard any split or badly chipped heads Have any burrs or tiny chips ground off making sure the faces are smooth bright clean and dry Inspect the handle and replace if it is cracked or split Smooth any splinters with sandpaper and make sure that the handle is clean and dry free from oil grease or dampness Never hit two hammer faces together as the faces may split and chips would fly dangerously Never hit any hardened metal directly Always use a piece of soft metal between the hammer and hard steel to cushion the impact Soft Faced Mallet Malle
307. rict or deform a specially designed connector or cable lug Crimping tools fall into two basic categories small hand operated types for smaller sizes and large hydraulic powered types for very large high current electrical connections NB The automatic crimping tool to the right is a hand operated tool for small cable lugs It is purpose built where the different cable lug sizes are colour matched to the jaw position The tool shown at the bottom right is a hydraulic crimper typically used to crimp very large cable lugs and connectors Adjusting screw Setting marks ADJUSTABLE CRIMPER E102A Notes T2 T12 Version 4 BG doc AUTOMATIC PRESET CRIMPER CRIMP TOOLS HYDRAULIC CRIMPER Page 241 of 254 often substituted in situations where the Parallel Pin Punches Pin punches are made from hardened steel and are often used as a drift to remove or insert locking pins dowels and rivets etc during assembly and disassembly Nb A hand made copper or brass drift is j A lf machine part being disassembled could get l gt damaged by a hardened steel drift Safety As for all punches always keep the head of the punch free from burrs and ensure that the punch is squarely struck with the hammer NB Wear eye protection when using punches as chips may fly and keep you fingers away from the striking and point areas Feeler Gauge A feeler gauge is a fine measuring t
308. rized by a 6 point star shaped pattern Torx screws are commonly found on electrical appliances Because the screwdriver bits were not widely available torx screws were used by manufacturers to reduce the level of tampering by non professionals Access to a Torx screwdriver set is essential when dismantling many types of electrical electronics equipment Angle Screwdrivers An angle screwdriver is used to loosen and tighten screws located in very confined spaces These cannot be accessed by a normal type screwdriver An angle or offset screwdriver has its blades set at an angle to its shank STANDARD TYPE The standard type may have its blades set at 0 45 90 or 135 degrees to a plane which is at right angles to the shank RECESSED TYPE ANGLE SCREWDRIVER E102A Notes T2 T12 Version 4 BG doc Page 112 of 254 23 January 2014 a Rounded end Maintenance of Screwdrivers J Screwdriver tips constantly wear with use Worn tips tend to slip dangerously so it is important to inspect screwdriver tips regularly If a tip becomes worn or rounded restore it to the correct shape by dressing it to shape with a file After dressing the tip must be symmetrical about the axis of the blade All corners must be square The end must be at right angles to the axis in both planes The tip thickness must be correct The faces of the tip must Rounded be parallel for a distance equal to just over half the width of the
309. rk piece This is usually done prior to folding Notching can be done by hand using snips but is much easier and faster when using a specialized tool called a notcher Hand type shown below Hand Operated Sheet Metal Corner Notcher This is typically a hand operated bench or floor mounted tool with a capacity of about 100mm x 100mm x 90 fixed angle cut for sheet up to about 1 0 mm It has a Die set sized cutting blade and die and is designed to cut a perfect 90 V section out of a piece of thin sheet metal Typically this is done usually prior to folding If necessary a second cut can be made into the V for angles greater than a right angle A hand notching tool has a long handle to give the operator sufficient leverage to force the blades through the metal Power operated notchers are also available and are used for larger production runs NOTCHING Ref http www advancecutting com E102A Notes T2 T12 Version 4 BG doc Page 202 of 254 23 January 2014 Sheet Metal Work Plan Activities Careful planning of work activities is essential when performing sheet metal tasks safely and effectively It is important to think a job through before starting work Factors such as Joint design Welding screws or rivets Type of material Thickness and type of finish Cutting efficiency to avoid wastage Cut lengths and bend lines VVVV Always consider the bend sequence the order of work cons
310. s The most common drive on bolt products very versatile in drive torque range economical to produce Hexagon Recess Hexagon Internal Torx Gives very high driving torque capability with low risk of cam out Usually found in high production applications Hexagon socket key Allen key and hexagon power drivers Hand driven ring and open ended spanners hand or power driven with socket drivers Normally power driven with special drive bits or hand driven with a Torx key particularly automotive and appliance industries Usually restricted to screw products Usually associated with screw products Is useful where it can be power driven on the assembly line and removed or adjusted in service with a blade screwdriver Usually head is indent hex and sometimes x recess is also added Power driven with hexagon socket Hand adjusted with blade screwdriver Hexagon Slot Combination Machine Screw Threads Types and Sizes The most common machine screw thread type used in Australia is ISO Metric International Organization of Standardization but imperial sizes le in inches such as BSW British Standard Whitworth BA British Association UNC Unified Coarse UNF ze Unified Fine and BSF British Standard Fine may also be M23 la encountered in older types of equipment me 19 A screw size can be identified by measuring its nominal me 2 diameter and it
311. s Some have closed D pistol grip handles or breastplate or both and additional side handles for extra grip and pressure As a general guide drill bit diameters over 8mm should be used in a machine with the additional side handle These tools have large chuck capacity with heavy duty motor and bearings They usually have a dual function and can be switched to operate as impact drills for masonry or concrete work Breast plate E102A Notes T2 T12 Version 4 BG doc Page 172 of 254 23 January 2014 Hammer drills A hammer drill has a spring or pneumatically driven floating hammer which adds percussive force to the rotary action This offers the advantages of faster drilling and reduced operator fatigue Hammer drills are more efficient than impact drills when drilling into masonry or concrete Mostly are used in rotary plus hammer mode but can be switched to rotary mode only The hammer action must not be used to drill products such as timber of steel Never use hammer action on ceramic tiles as it may cause them to crack Angle Head Drill Ideal for drilling in tight corners or in confined spaces It has a small chuck capacity Operating a Drill e Select the correct drill bit e Carbide tipped bits are used for stone concrete brickwork ceramic tile and fibrous cement They need slow speed and high feed pressure e Insert the drill bit e Most drills have a three jaw key tightening chuck Hand tighten the chuck and
312. s specified in the SOP Most powered tools are very noisy and noise protection is recommended especially if a large amount of cutting is required Chips and sparks from these tools can cause eye damage if safety glasses or face shields are not worn Only operate these tools if you have had instruction in their safe use Some tools such as saws and grinders may leave a burred edge which are sharp and can make the blanks dangerous to handle Also the burred edge of mild steel materials will corrode badly if exposed to weather The burr can be removed with a suitable file Unsightly rust stains and corrosion of the sheet will result if fine chips known as swarf are left in contact with the sheet surface and then exposed to weather Swarf from nibblers and dust from jig saws etc must be completely removed from the surfaces when cleaning up Angle grinders produce very hot chips of metal that can burn into the surface of materials like Colorbond Making a Lap Joint A lap joint is an overlapping joint between two pieces of metal It must be made using appropriate tools and equipment 2 Lap joints can be fastened by welding rivets or even self tapping screws AE 25 mm lap If using screws or rivets for the join first cut the material to size after allowing for a lap of about 25 mm Next ensure that surfaces are clean dry and free of contaminants Mark laps on material to help with alignment Lap the materials and
313. s a computer controlled machines The basic hand tools include Engineer s Scriber Tape measure and Steel rule Square Protractor and Bevel gauge Combination square Dividers and Jenny callipers scribing block Vernier height gauge Hammers Centre punch and prick punch Engineer s Scriber This tool is designed to scribe scratch very fine marking out lines on to a metal i work piece in preparation for fitting DOUBLE EDGE tasks Itis made from hardened tool ENGINEERS SCRIBER steel which has been ground to a needle sharp point The scriber s point should be frequently restored so that all marking out lines are sharp and clear When a grinding wheel is used to sharpen a scriber care must be taken because if temper colours are raised due to overheating the point will be softened Protecting cork It is better to use an oil stone to sharpen a scriber to avoid spoiling the hardness of the scriber s point A scriber is generally used in combination with a rule square or straight edge to draw a single firm line Correct Use The steps in the correct use of the scriber are as follows 1 Hold the straight edge firmly in the required position e g steel rule square etc 2 Incline the scriber away from the straight edge to bring the sharp tip as close to the straight edge as possible 3 Incline the scriber slightly toward you in the direction of the stroke 4 Draw the scriber toward you in one firm stroke E102A No
314. s a small specially shaped piece of metal used to strengthen a joint E102A Notes T2 T12 Version 4 BG doc Page 214 of 254 23 January 2014 Make a Stop end To make a stop end gt gt gt Scribe a vertical line at each side of the tray where it is to be turned up lines A B and C D If possible this should be done with the tray temporarily positioned From points B and D scribe two lines angled at about 15 20 from the vertical marks and towards the end of the tray lines B M and D N Depth Discard pieces A M Pe ae a AS i Equal to depth N ra N y N 10 e S TRIMMING EXCESS LENGTH Check that the distance from points B and D to the end of the tray is equal to the depth of the tray If this distance is greater than the depth of the tray trim off the excess length Leave the bottom piece projecting by approximately 10 mm if a reinforcing top edge is required Trim off the top of the tray sides between points M and N and the end leaving a 20 mm lap Turn the 10 mm allowance on the bottom piece up at 90 to form a stiffening fold if so required Turn up the end of the tray vertically The lapping allowances should be on the inside of the tray sides Drill and rivet into position E102A Notes T2 T12 Version 4 BG doc 23 January 2014 End of tray SCRIBING THE TRAY Discard pieces p 2 allowance 10 mm lap left on Stiffening edge turned 9 89
315. s action is referred to zeroing the micrometer and is always carried out just prior to use to ensure the accuracy of measurement If the scales do not zero then the barrel needs to be adjusted with the supplied C spanner For micrometers larger than 0 25mm an appropriate test piece is used between the anvils so the specific micrometer can be checked zero Datum line 0 5 mm Graduations Graduated 0 to 25 mm 5 5 5 5 O O 45 45 Note relative positions of sleeve graduations E102A Notes T2 T12 Version 4 BG doc than this reading 45 Anvil touching n Both scales show O L 50th of a complete turn Anvils will be open 0 01 mm a 45 10 divisions of thimble 1st minor graduation visible One complete turn anvils open 0 5 mm ist major graduation visible Two turns anvils open one full millimetre 1 00 mm Page 229 of 254 Note the micrometer below with its C spanner adjusting tool Reading a Metric Micrometer 1 Read from the sleeve or barrel scale the number of whole millimetres that are completely visible In the sketch to the right this is 4mm 2 Add any half millimetres that are completely visible on the sleeve NB The key words are completely visible Here you must be careful as some instruments begin to partially display a sleeve scale graduation even though the thimble scale has not rotated past the
316. s are clear before actuating the guillotine Hold material firmly to prevent inaccurate cutting due to creep When cutting ensure feet are positioned to avoid contact with the foot operated lever oe on oO Housekeeping Remove all off cuts and place them in either in the storage rack or waste bin Leave the work area in a safe clean and tidy state Potential Hazards gt Sharp edges and burrs gt Crush and pinch points gt Manual handling sheets E102A Notes T2 T12 Version 4 BG doc Page 195 of 254 23 January 2014 Pan Brake Folder There are a number of different types of commercial folding machines available A pan brake is a manually operated tool used for bending thin gauge sheet metal It consists of a clamping bar to hold the material firmly during the bending process This clamping bar has removable fingers blocks to enable the bending of box shapes or partially formed pieces The bending is preformed by a bending beam which is hinged at the front of the equipment Some pan brakes utilize a counterweight to assist with the bending action A pan brake can be used for sheet thicknesses up to approximately 1 62 mm in thickness A typical manually operated folding machine is shown below The smallest width of bending is 8 to 10 times the material thickness and the minimum inside corner radius of the bend is about 1 5 times the metal thickness Characteristics of a sheet metal folding machine 1 Clamping In clamping the
317. s commonly used for soldering electrical connections It melts at 188 C and it transitions between a liquid and a solid very quickly le It has very short pasty stage which means that the electrical joint is less likely to fail Eutectic solder is a 63 37 Tin lead combination transitions directly from a solid to liquid state at a temperature of 183 C le It has no plastic stage It is often used for soldering electronic components as it has the lowest melting point of all the tin lead alloys NB Eutectic is the proportion of constituents in an alloy that yields the lowest possible complete melting point In all other proportions the mixture will not have a uniform melting point some of the mixture will remain solid and some liquid At the eutectic the solidus and liquidus temperatures are the same Flux Rust and oxides form on most metal surfaces when exposed to air and any heating will only accelerate this formation Solder will not adhere to or wet flow over the metal unless these pollutants are first removed Fluxes are special chemical compounds used to clean and maintain the metal surfaces during the soldering process They also decrease the surface tension of the solder making it a better wetting agent Fluxes are manufactured in cake paste liquid or powder form and are classified as either corrosive or non corrosive Corrosive fluxes are used when soldering large
318. s like gravity A silver soldered joint is a sandwich of different layers each metallurgically linked to the surface of the joined parts and is very strong le Much stronger than soft soldering It is called silver soldering because the filler material often contains silver Although soft soldering and silver soldering both introduce a filler material solder into the joint with soft soldering the solder only adheres sticks to the surface With hard silver soldering the metallurgy of the surface is changed and the joints are metallurgically linked and become part of the underlying metal surface This is why a silver soldered joint is considered much stronger joint than one that is soft soldered Silver Solder This is not a gap filling process It does require a very small gap of about 0 001mm for proper capillary action during joining of parts which means that items need to be matched to close tolerances for best effect The best joint design is one where there is an overlap of the components in the form of a lap or sleeve join Silver solder will join most metals eg brass bronze copper steel cast iron etc but not aluminium FILLER METAL A flux is used to clean the surface of the metals by removing oxides TROR from the metals to be joined and prevent further oxidization during the heating process Flux is an essential part of silver soldering and usually applied as a thick paste Too much flux will ra
319. s thread type can be determined by using a MS 25 thread gauge to measure its thread pitch The thread pitch ya 39 is the distance from one thread groove to the next measured from crest to crest Ms 34 MILO 40 Wil 2 46 Thread gauge Fs ALAALA AALA AATA AA TTA ALTA T p NNDOODDAANUUODOAANOOD E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 130 of 254 ISO Metric Thread Designation A metric ISO International Standardization Organization screw thread is designated by the letter M followed by the value of the nominal diameter D and the pitch which is expressed in millimetres and separated by the multiplication sign x e g M8 x1 25 If the pitch is the common coarse pitch listed in ISO 261 or ISO 262 it can be omitted e g M8 Where the ISO metric thread pitch is the measured distance per thread in millimetres imperial standards such as BSW are designated by how many threads occur per a given distance Thus inch based threads are defined in terms of threads per inch TPI Right and Left Hand Threads The vast majority of fixing screws are tightened by clockwise rotation which is termed a right hand thread A common mnemonic for remembering this when working with screws and bolts is lefty loosey righty tighty Screws or bolts with left hand threads are mainly used for rotating parts to ensure that the forces do not cause the fa
320. saw into the work piece Use a slow and even feed rate E102A Notes T2 T12 Version 4 BG doc Page 80 of 254 23 January 2014 Control Tension panel adjustment Vertical Band Saw A vertical band saw can be used for docking off stock material but its main use is in cutting curved shapes due to the narrow blades that can be fitted Each blade is one continuous piece New replacement blade material is purchased in a roll Each new blade must be custom made To form a new blade the material is first cut to length and the ends are tapered for joining The two ends are then braised together by a special seam butt welder A custom designed saw band welder and a blade grinder is normally attached to the front side of the machine The table is horizontal and the blade is driven downwards forcing the material being cut downwards onto the table surface ie Blade teeth downwards The operator s hands control the work piece and Worktabie safety is a high priority when using this type of machine Safety Band Saw DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on a Band Saw Safety glasses must be Long and loose hair Hearing protection worn at all times in work must be contained may be required areas Sturdy footwear must Close fitting protective Rings and jewellery be worn at all times in F clothing must be worn must n
321. sealants may be specified for the job and this information is typically in the plans or specification for the job A common type of sealant is shown to the right Ref http www bunnings com au NB Always check the SDS Safety Data Sheets before using any chemical sealants Electrolysis or Galvanic Corrosion As shown earlier corrosion can occur when dissimilar metals are placed in direct contact with each other in the presence of moisture Electrolysis or galvanic corrosion can then lead to rapid corrosion of one the least Noble of the materials This is due to a very small flow of electric current that is generated between the different materials when they are wet This current flow leads to the decomposition of one of the materials Some materials are more reactive than others in this type of situation Galvanic corrosion can be overcome by the use of chemical sealants as they form an insulating barrier between the two metals Folding Sheet Metal Folding or bending is one of Pa ll GQ the most fundamental sheet on ted a S oe yy al r P metal work tasks Folding is Ls A AA used to fabricate products and also to make joints oe Be E between associated pieces a Zz oe og E ee While folding can be a achieved manually with the SE A s a aid of ahammer and a straight edge it is generally best done with the aid ofa purpose built machine such as the Pan Brake folder or the larger Brake Press discussed e
322. ses must be worn must be contained with substantial uppers at all times must be worn E102A Notes T2 T12 Version 4 BG doc Page 160 of 254 23 January 2014 Respiratory protection Close fitting protective Rings and jewellery Ca devices may be CY clothing to cover arms must not be worn required and legs must be worn Pre figs load Safety Checks Examine the tools power lead and machine for obvious damage e Check condition of the soldering tip Replace if damaged Ensure tip is tinned and free from waste build up Wipe tip on damp sponge to clean once iron has warmed up Ensure that the cord does not create a slip trip hazard Ensure the workspace is well ventilated Use a fume extraction unit if available Leave soldering iron in the stand when warming up Never leave the soldering iron unattended when turned on or still hot Leave unplugged when not in use Operational Safety Checks e Never operate a faulty Power Tool Always report faults to your supervisor Ending Operations and Cleaning Up e Switch off the soldering tool and fume extraction unit when work is completed e Ensure soldering iron has sufficiently cooled before storing Potential Hazards e Electric shock e Fumes e Body burns due to hot or molten materials e Fire Don t Do not use faulty equipment Immediately report suspect equipment This SOP does not necessarily cover all possible hazards associated with this equipment and should
323. side calliper leg designed to pivot about a point The tightness of the two arms is set by a metal thread and flat nut This is used to adjust tension the arms Practical Uses Examples are illustrated in the images below 1 To set distances from an edge or Offset leg shoulder A 2 For marking out lines parallel to an Firm joint Locking nut edge fi 3 For finding the centre of circular work Setting up Jenny Callipers Replaceable 1 Hold the inward curving leg with ne y scriber one hand and place it against the ig _ point end of the rule 2 With your other hand position the scriber point in the required graduation 3 Make sure the ends of both legs are at equal lengths Keep leg and point in line Care parallel to edge Always keep the tool well oiled to prevent rust build up and protect the needle point SETTING JENNY CALIPERS against damage E102A Notes T2 T12 Version 4 BG doc Page 37 of 254 23 January 2014 Marking or Scratch Gauge Ref http toolboxes flexiblelearning net au Practical uses To set distances from an edge or shoulder and marking out lines parallel to an edge Using a marking gauge gt Loosen the lock screw on the headstock Hold the headstock with one hand against the end of the rule Move the scriber point to the required graduation on the rule Lock the screw on the headstock YYY WV WV Outside and Inside Callipers Hold the headstock against the reference
324. side the tray Butt the ends of the cable tray together Place the joiner either inside or outside the join Align the joiner centrally on the join and mark its rivet hole positions Clamp the joiner to the tray ends to avoid misalignment of parts during drilling Drill the holes and rivet joiner sleeve and tray ends together Vv Vv VV WV NB The use of a rivet gauge is helpful in achieving a neat and consistent appearance of each joint See illustration RIVET GAUGE E102A Notes T2 T12 Version 4 BG doc Page 213 of 254 23 January 2014 Making a Turn Down A change of direction gt Place the tray in position gt Scribe vertical lines on the sides of the gutter at the points where the turn down is to be made gt Cut along the scribe lines using a hacksaw and scribe lines tinsnips gt Bend the gutter down to the required angle and check with a bevel SCRIBING FOR A TURN DOWN sate of turn down Pal 30 50mm ue Same height as tray side CHECKING THE ANGLE OF BEND 1a A of Gussets riveted in place Make a template from paper or from cardboard in the shape and to the size of the gussets required Cut a pair of gussets from scrap material to cover the gaps in the sides of the tray FINISHED TURN DOWN Insert the gussets to the sides of the tray and secure them temporarily with clamps Check the angle again then drill and rivet the joints Y V V WV NB A gusset is this case i
325. spanner and an open end spanner for a large grinder For GRINDERS smaller type grinders an Allen key and a spanner is used to remove the locknut Operating an Angle Grinder Before beginning a grinding operation make sure that the material to be ground is firmly clamped in a vice or to a bench The operator must be in a comfortable well balanced position with a clear view of the material Always check that the wheel is properly secured and not damaged prior to use Safety Always wear appropriate PPE when operating this tool as it can be extremely dangerous __ New disc Reinforced Ss resinoid Two pronged ANGLE GRINDER wheel spanner _ z Sy 7 Open end vy _ Spanner Flexible DISC SANDER disc DIFFERENCE BETWEEN AN ANGLE GRINDER AND A DISC SANDER ACESSORIES TOCHANGE Two pronged spanner Allan key Open end j spanner i pian a E r de ree Ep cies n z oF tie a m hat PDA i n r al Tir r j yc a fi f J F Two pronged spanner SPANNERS FOR t SPANNERS FOR SMALL GRINDERS LARGE GRINDERS E102A Notes T2 T12 Version 4 BG doc Page 193 of 254 23 January 2014 Treadle Guillotine A guillotine is a device for cutting or trimming sheet material such as sheet metal It consists of a hardened steel blade inclined at a small angle such that that it descends onto the sheet with a shearing action A treadle type guillotine is small manually powered foot operated too
326. ssure on it File Card Pinning Scratching occurs when particles of metal or other material become wedged in between the teeth of a file These particles stand higher than the teeth and cause scratches in the work surface The effects of pinning can be minimized by rubbing soft teacher s chalk into the face of the file prior to starting filing Pinning commonly occurs when too much pressure is applied to a new file If pinning is occurring then the pins can be removed from the file s teeth by using a small stiff brush known as a file card Brush ina direction parallel with the teeth for best results Emery Paper To achieve an extra smooth finished surface after filing place a piece of emery paper abrasive cloth length ways under the file with its rough side out Then use the file such that the work surface grain is directed in one direction To finish reverse the emery paper ie smooth side out and burnish polish the surface De burring Tool Ref http www rapidonline com Tools Equipment Deburring Tool with Spare Blade 302092 Store files separately from each other and from other tools ie Wrap in cloth or paper to The tool shown to the right is designed to de burr the edge of a hole after filing or drilling It has a solid protect cutting teeth e Make sure that file handles are sound and firmly fitted carbide blade The technique is to run the cutting edge
327. st a known voltage source Reconnect the conductors as per the diagram Always connect the earth conductor first Having warned all relevant persons remove your lock and danger tag etc turn the circuit breaker and isolating switch on Test the motor for operation and correct rotation Importance of marking labelling and storing parts Marking or labelling each component as it is removed from a complex machine is critical Especially when you are not familiar with this machine or if no servicing documentation is available While you may easily recall the correct reassembly sequence at the time of disassembly you may be compelled to wait for an extended period of time for replacement parts and in the interim you will soon forget the sequence It is quite common that a different staff member may be required to reassemble machine at a later time and only detailed documentation and comprehensive labelling will ensure a smooth reverse process There are a number of documentation techniques that you should consider 1 9 Take high resolution digital still images showing the key views before each component is removed Focus mainly on any orientation aspects such as cable colours cable connections pin plug orientations physical orientation physical alignments clearances direction of rotation le Anything that could go back more than one way If photos are not possible then make suitable sketches showing key details before removal Just
328. st be taken to keep the die square with the work Sighting from two positions at right angles to each other can check this Bearing downwards on one side of the die makes corrections e Continue to turn the die but when resistance builds up back the die off a part of a turn to break the chips and then continue forward again e When the end of the work comes through the other side of the die remove the die and check the size of the new thread with a nut If necessary alter the setting of the button die to increase or reduce the size of the thread e Continue cutting for the full length of the thread e Remove any burrs with a file Applications e Cutting external threads on conduits e Threading rod of circular bar for light drops or cable supports Wrap chain over Hold tube horizontal Fit closest link in slot Lift handle horizontal and turn to tighten USING A PIPE VICE Thread Cutting Lubricants A cutting lubricant is used for e Cooling e Lubricating e Chip removal It must also be e Non corrosive e Non injurious to the operator e Non inflammable at normal temperatures e Reasonably cheap and in plentiful supply Examples Material Lubricant Steel eee e eee Neatsfoot oil or sulphur based oil Stainless Steel Neatsfoot oil or sulphur based oil Brass and copper Kerosene and lard oil Cast iron annonae Kerosene or soluble oil AluMINIUM nanana Kerosene and ligh
329. stener to loosen Eg The securing bolt for the blade on a circular saw and screw securing fan blades etc are typically left hand threads Machine Nuts The primary function of the nut in a threaded assembly is to act as the instrument through which the tension is induced into the screw and to retain that tension by clamping the load to the assembly The vast majority of nuts have hexagon drive faces although some tank screws often use nuts with square drive faces The material used for the nut should be the same as that for the screw to avoid corrosion due to electrolytic action le dissimilar metals Common materials range from carbon steels stainless steels brass aluminium nylon Finishes would normally include plain zinc galvanized and chrome The correct combination of screw and nut should ensure that the nut is capable of tensioning the mating bolt to breaking point rather than the nut stripping NB A broken screw is clearly evident but a stripped nut may not be Various Nut Types Plain hexagon The standard form general purpose nut and may be used with various washer types Also available in a thin or half nut version May also come with full bearing or washer face when machined Hexagon castle The groove is aligned with a small through hole in the screw to insert a cotter pin which is then spread to lock the nut Hexagon flange Special serrations on the flange face resist loosening in serra
330. t mineral oil Plastics eee eee Soap solution E102A Notes T2 T12 Version 4 BG doc 23 January 2014 hee cutting compound en ats the thread Sa somal 20 Keep overhang under 150 mm Chamfer depth N koja to pitch sA E Short reverse _ turn to break chips CUTTING THE THREAD Page 106 of 254 Die Nut A die nut has cutting teeth and relief holes to enable it to clean or recondition a damaged thread or to remove thick paint etc from inside a thread A die nut is not designed to create new threads as it has no guide The hexagonal shape of a die nut allows it to be F rotated by means of a spanner or suitable socket TYPICAL DIE NUT Screw Extractor Also called Easy outs Screw extractors are used to extract remove broken screws and studs from threaded holes To remove a broken screw or stud first drill a hole to the recommended size in the exact centre of the broken end of the bolt This is not an easy task Next using a tap wrench to support the extractor bit turn the extractor bit in an anticlockwise direction for right hand screw threads The extractor does not have to be hammered in because it takes a quick and positive grip It feeds itself into the predrilled hole and should start the most stubbornly embedded part and turn it out on its own threads leaving the original thread in the hole undamaged j A screw extractor should not
331. t mode on hollow or brittle materials eg ceramic tiles E102A Notes T2 T12 Version 4 BG doc Page 93 of 254 23 January 2014 Spade bit A spade bit is commonly used by electricians to drill through parts of the timber frame of houses when roughing out Sometimes long extension pieces are added to the spade bit to enable it to extend down from the top plate to drill through a horizontal noggin to enable a cable to be installed in a panelled wall This type of bit has either a round or hexagonal shank and is used with an electric drill Drill head b C Column Base table BENCH DRILLING MACHINE Fixed Drilling Machines Workshops have various types of fixed drilling machines The type of machine used for a job depends on the size of the drill to be used and the physical dimensions of the work piece to be drilled As shown to the right key considerations are the throat depth measurement b which limits the distance from the edge of the work piece to the centre of the hole and the vertical height measurement c which limits the height of the object to be drilled plus the length of the drill bit Note that the main advantage of the pillar machine shown right is the drill height that it offers Common drilling machines available in Drill head workshops are e Bench or Pedestal Drill e Pillar Drill e Radial Arm Drill Always select the most suitable drilling machine for a given tas
332. table grinding machines A portable grinding machine is a machine that is fitted with a non flexible reinforced abrasive wheel This can rotate at speeds between3000 and 48000 rpm The three basic types are Angle Grinders An angle grinder appears similar to a disc sander but is different in that it has a non flexible reinforced grinding wheel mounted on its drive shaft Angle grinders are for heavy duty grinding which includes e Remove welding bead deposits e Cut mild steel panels e Remove brackets that have been welded on etc The grinding wheel can be used on its edge On off switch Side handle Wheel guard Reinforced resinoid wheel ELECTRICAL ANGLE GRINDER Reinforced Z resinoid ANGLE GRINDER wheel Flexible DISC SANDER disc DIFFERENCE BETWEEN AN ANGLE GRINDER AND A DISC SANDER e This makes it particularly useful for grinding in awkward areas e t can also be used to clean out small dents in sheets before filling them Applications e Cutting off metal strips tube and angle iron e Chasing concrete and brickwork e Grinding welded joints flat E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 168 of 254 Changing Grinding Discs The method of changing a grinding disc on either sized angle grinder is very similar On most grinders the grinding disc is secured by a locknut The removal of the disc requires a two pronged spanner and for large grinders an open e
333. ted lock nut vibration applications Also available as a plain flange to whiz lock span a large hole or slot or spread the clamp load E102A Notes T2 T12 Version 4 BG doc Page 131 of 254 23 January 2014 Hexagon nylon A nylon insert on top of the nut creates a prevailing insert lock nut torque resists loosening and allows reuse after several removals without significant performance loss Hexagon acorn or Either machined with a closed domed end or capped in domed a secondary process after tapping or cap nut Used in decorative applications or for protection from protruding threads Usually chromed or polished Coupling nuts Similar to the deep nut above except longer deeper joining Used for connecting lengths of all thread Machine Screws and Tapped Holes It is common for electrical equipment to be mounted onto sheet metal backing plate within the switchboard In many cases rear access behind this panel is not possible This means that it is not possible to secure the components with a clearance hole machine screw washer and a nut If the backing plate is made sufficiently thick it can be drilled and tapped with a suitable thread The thickness of the backing plate should be such as to support at least 3 full threads For electrical switchboards and motor control panels this is generally the fastest and cheapest method of mounting smaller sized electrical equipment Nut Inserts http www mightyboyev
334. tes T2 T12 Version 4 BG doc Page 32 of 254 23 January 2014 Scriber Safety e Never use a scriber as a substitute for a centre punch e Any hand tool which has sharp points or a sharp edge should be guarded when the tool is stored in the tool storage area Use either a hardened pouch sheath or a cork or similar soft object to protect both the tool and the person who retrieves it Protractor and Bevel Gauges Angular measurement is closely associated with linear straight line measurement Parts that are manufactured may have angles or tapers that are required to fit accurately into mating parts Various measuring tools have been designed to measure angles or tapers in degrees or even parts of a degree Protractors Protractors have a dial face graduated in degrees with a straight blade that can be swivelled to a specific angle and then locked in position They are used for e Setting work to an angle e Testing angles e Marking out the position of holes Because they are graduated only in degrees protractors have limited accuracy Bevel Gauges A bevel gauge consists of a body with an adjustable sliding blade that may be set and clamped at an angle to the body of the work piece Use a bevel gauge as follows e Set the blade of the gauge to the angle required e Lock the blade to the body with the clamping screw e Transfer the gauge on to the work e Compare the setting of the gauge against the angle on t
335. th Continuity Tester to the 1000V scale Check the insulation resistance between each phase winding and the other two windings Test result must be 1 Megohm or greater c Set Insulation Resistance and Earth Continuity Tester onto the OHM scale one probe to the motor s earth terminal and the other probe to the metal frame in few a few positions Test result must be less that 0 10 on the fixed part of the frame or E102A Notes T2 T12 Version 4 BG doc Page 248 of 254 10 11 12 13 14 15 16 less than 1Q for moving parts of the frame Bench test the motor on full voltage in the workshop before re installing it Check the no load current against the name plate current Typically the no load current is between 60 rated current on very small machines and 20 of rated current on large machines Before reconnecting the motor it is essential to check that all circuit breakers and switches and danger tags are still in place If it is safe to continue inform all concerned persons that you are going to re install the motor Bolt the motor to its mountings taking care to align the couplings or belts Test all of the conductors for LIVE with a non contact circuit tester and then test your tester on a Known voltage source Take the tape off the conductors treating them as if they were alive Once bare test the conductors using a pre tested voltmeter and the effective earth as a reference Always retest the tester again
336. the handle e Material has good elasticity e Centre line of the handle should be at right angles to the head e Shape is important because it depends upon the feeling of flexibility and power which should go with each hammer blow e Most new hammers have a wooden wedge inserted lengthwise and a steel wedge inserted crosswise This is to make sure that the handle end completely fills the head Head Shape The shape and contour of the face must be suitable for the task e Marking off hammers usually have a flat face with slightly rounded edges e Hard hammers and sledge hammers usually have a convex face so that they will not mark the plate severely Types of Hammers Ball Pein Hammer This tool is most suitable for general bench fitting type work It has a flat or slightly convex curved out face for general work and a hemispherical ball pein at the other end They range in size from 100 grams to approximately 1 5 kilograms It is used to strike chisels punches or the work piece itself while the ball pein is used for doming or shaping rivets An example is shown to the right Peining Hammers The two main types are the cross pein and straight pein A cross pein type is shown to the right and a straight pein type has its pein offset by 90 degrees NB Peining means to strike with the end of the hammer opposite to the face E102A Notes T2 T12 Version 4 BG doc 23 January 2014
337. then finish with the key e For drilling which needs many drill changes a keyless chuck is useful This is tightened by hand pressure E102A Notes T2 T12 Version 4 BG doc 23 January 2014 Depth gauge HAMMER DRILL Knurled surfaces for _7 gripping by hand TYPES OF CHUCK Page 173 of 254 Safety NB Chuck keys must not be attached to leads with metal wires because of the danger of an electrical short circuit if the lead is faulty Never lower any portable tool such as a portable drill or saw etc to the ground from a height via its power lead as this could cause a hazard Power Saw Circular Saw This is a rotary saw originally designed to cut timber With the introduction of special blades or discs it is now capable of efficiently cutting a wide variety of materials Note the arrow direction on the drawing to the right A circular saw s blade typically turns counter clockwise as you face the blade side of the saw The saw blade s teeth except in rare instances always point in the direction of blade rotation The securing bolt should be unscrewed in the direction opposite of the blade s rotation For the majority of saw brands this makes it a left hand thread Applications Electricians commonly use a circular saw fitted with a carbide type blade to make parallel cuts in masonry walls for the purpose of running conduits inside the wall render etc This technique is known as chasing
338. tions and controls Check workspaces and walkways to ensure no slip trip hazards are present Ensure the work area is clean and clear of grease oil and any flammable materials Keep the welding equipment work area and your gloves dry to avoid electric shocks Ensure electrode holder and work leads are in good condition Start the fume extraction unit before beginning to weld Ensure other people are protected from flashes by closing the curtain to the welding bay or by erecting screens E102A Notes T2 T12 Version 4 BG doc Page 142 of 254 23 January 2014 Operational Safety Checks e Keep welding leads as short as possible and coil them to minimise inductance e Ensure work return earth cables make firm contact to provide a good electrical connection e Ensure the electrode holder has no electrode in it before turning on the welding machine e Ensure current is correctly set according to electrode selection Ending Operations and Cleaning Up e Switch off the machine and fume extraction unit when work is completed e Remove electrode stub from holder and switch off power source e Hang up electrode holder and welding cables Leave the work area in a safe clean and tidy state Potential Hazards e Electric shock Fumes Radiation burns to eyes or body Body burns due to hot or molten materials Flying sparks Fire Don t gt Do not use faulty equipment Immediately report suspect equipment gt Do not use bare hands and never wra
339. tip WORN AND DANGEROUS If it is necessary to grind the tip take care not to overheat it Grind only a little and then allow the tip to cool each time An overheated tip will be too soft for use and would have to be hardened and tempered again Impact Screwdriver This is a special heavy duty screwdriver designed to remove very tight screws that will not turn when using a conventional screwdriver Body e Some designs have Drive end interchangeable bits to accommodate slotted or Phillips SCrews e Some designs also include a forward reverse rotation selector e The object machine which contains the screw must first be securely held in place as the forces applied during the process are substantial e It may be necessary to spray a penetrating liquid onto the screw to assist with the process e Insert the screwdriver tip in the head of the screw and rotate the handle in the direct to loosen the screw to load up the internal tapers e Use a heavy headed lump hammer to strike the end of the driver The opposing tapers located on the drive train inside the driver s head impart substantial torque on the screw Bit Safety Always wear safety glasses when using this tool as it probable that chips may fly Also it is advisable to wear a protective glove on the driver hand to protect it from slippage E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Right angle corners O on end TIPS CORRECTLY SH
340. to build up in the electrodes and arms e When holding work be aware of the heat created during welding process e Ensure work return earth cables make firm contact to provide a good electrical connection Ending Operations and Cleaning Up e Switch off the machine when work completed e Leave the work area in a safe clean and tidy state Potential Hazards e Electrodes become hot with continued use Burns Hot metal Spitting metal or flying sparks Eye injuries E102A Notes T2 T12 Version 4 BG doc Page 150 of 254 23 January 2014 Don t gt Do not use faulty equipment Immediately report suspect machinery This SOP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references It is designed as a guide to be used to compliment training and as a reminder to users prior to equipment use Oxygen Acetylene Welding Also called Oxy Fuel Gas Welding This is a common welding process for sheet metal panels The combination of oxygen and acetylene gases produces a flame that burns at up to about 3500 C which is hot enough to melt most commercial metals To weld the two metal work pieces are brought together with their edges touching and are melted by the flame with or without the addition of filler rod Characteristics of the process include e The use dual oxygen and acetylene gases stored under pressure in steel cylinders e ts ability to switch qu
341. to position MIMS cable in place Using Hammers Safely To avoid injuries when using a hammer z S Plastic insert e Always wear appropriate PP when using hammers Replace worn inserts e Never use a hammer with a split badly chipped or loose head e Replace any handle that is cracked or split e Make sure the handle and striking faces are clean and dry and free from grease e Never hit two hammer faces together e Use a piece of soft metal between a hammer and hard steel e Make sure it is clear behind and above before you swing a hammer e Strike the heads of chisels and punches etc squarely SOFT FACED MALLETS Maintenance and Storage e Hammers should be selected carefully for the job in hand e Hammers fitted with wooden handles should be inspected prior to each use to ensure that the handle is tightly fitted full depth in the head and securely wedged e Hammers should be stored in a tool box or hung on a shadow board when not in use E102A Notes T2 T12 Version 4 BG doc Page 119 of 254 23 January 2014 Spanner Spanners are used to apply a twisting force torque to tighten or release a nut bolt or threaded fastener Spanners are made with jaws or openings that fit square or hexagonal shaped nuts and bolts They are made of high tensile or alloy steel drop forged and heat treated for strength They are given a smooth surface finish to make them easier to grip The length of a spanner is design
342. trated in relation to installation fault finding maintenance repair or development work functions in any of the following disciplines Electrotechnology Disciplines Gas industry Disciplines ESI Transmission Distribution and Rail Disciplines ESI Generation Disciplines VVVV Generic terms used throughout this Vocational Standard shall be regarded as part of the Range Statement in which competency is demonstrated The definition of these and other terms that apply are given in Volume 2 Part 2 1 E102A Notes T2 T12 Version 4 BG doc Page 11 of 254 23 January 2014 Unit Sector s Not Applicable Competency Field 2 3 Literacy and numeracy skills Participants are best equipped to achieve competency in this unit if they have reading writing and numeracy skills indicated by the following scales Description of each scale is given in Volume 2 Part 3 Literacy and Numeracy Reading 3 Writing 3 Numeracy 3 2 3 Literacy and numeracy skills Competency Field 5 Utilities industry E102A Notes T2 T12 Version 4 BG doc Page 12 of 254 23 January 2014 Introduction Tools are designed to make a job easier and enable you to work more efficiently and safely Without the proper tools and the knowledge of how to use them a tradesperson wastes time reduces efficiency and may even cause themselves an injury The aim of this note is to explain the function the correct and safe use and proper care of the tools you will use while workin
343. trical earth continuity Shake Proof between two joined metal surfaces Wave Available as full circle or split Is used in place of spring washers where surface damage is to be avoided Also used where some pressure is required on a free element of an assembly Usually confined to small diameters Similar products are crinkle washers E102A Notes T2 T12 Version 4 BG doc Page 135 of 254 23 January 2014 Curved Generally confined to light applications similar to above where only very light pressure is required Screw Cup Used under a countersunk screw where a decorative or Cup appealing finish is required Normally would be nickel or chrome plated or in stainless material Structural A hardened steel washer used in conjunction with structural bolts in heavy construction applications The washer spreads the load The three external tabs identify it as a structural washer Load Indicating Used in the structural industry to provided evidence that Washer Coronet the required tension has been achieved The raised protrusions will crush in relation to the load applied providing a permanent witness that required tension was achieved Machine Screw Joints Machine screws are 7 i versatile in the number of types of joints they can Pd a fasten Typically they are a butt joint used to make lap and T joins and are generally not suitable for butt and corner joins As shown they can be used
344. ts alignment has been corrected it will be firmly held by the thread it is cutting and will be automatically drawn deeper into the hole as it is turned e Every 2 or 3 turns free the tap by reversing it for a quater turn and then continue cutting e Normally a through hole can be completely cut with a taper tap but if the cutting load becomes too heavy the taper tap should be reversed out of the hole for the intermediate tap to be substituted e Remember taps are hard and brittle and are very easily broken The user must learn to exercise good judgment with regards to the degree of force applied to the tap e Care must be taken to keep the blind hole clear of chips otherwise the tap will be prevented from entering to the full depth Be extra careful when the tap hits the bottom of the blind hole as this is when Check with try square Apply steady turning pressure TURNING THE TAP of ak Aaa r Ti mitina z E PETANAN the tap is most likely to break Quarter reverse turn when necessary Complete clockwise turn Check with rule Test position 90 apart FREEING THE TAP BRUSH CHIPS FROM TAP AND WORK E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 103 of 254 Threads and Terminology A screw thread is helical ridge of uniform section formed on the surface of a cylinder or cone that advances uniformly along the length of the cylinder or cone There are many thread
345. ts or soft faced hammers are used to apply force to surfaces without damaging any soft or brittle parts The force of the blow is distributed over a larger area than a hard hammer and any stretching or marking of the metal is reduced or even eliminated A blow from a steel hammer can damage or mark parts made of copper aluminium or light alloys etc Mallets have wide flat heads which are made from materials like wood rubber soft metal and plastic E102A Notes T2 T12 Version 4 BG doc 23 January 2014 i Feel that head iA is tight SAFETY CHECK Chips Splits or burrs Splinters DO NOT USE HAMMERS WITH ANY OF THESE FAULTS DO NOT USE HAMMERS WITH ANY OF THESE FAULTS Page 118 of 254 Types of Soft Face Mallets Rubber Mallets A rubber mallet has a cylindrical head made from solid rubber moulded to a wooden handle Correct use of this mallet will prevent damage to surfaces which may have been painted plated or finely machined Other Soft Faced Mallets Materials used in the heads of soft head hammers include brass copper aluminum lead wood rubber plastic and rawhide If possible set the work piece in a vice as rebound can be a problem when using mallets For example use e Copper to drive steel parts into position e Rawhide to seat insulated coils in an electric motor armature e Plastic to strike a finished metal surface e Lead to avoid damage due to rebound e Rubber
346. tservices com au bus_ducts php Types of Sheet Material used in Electrotechnology Steel is an ideal material because it is strong easily worked relatively cheap and is available with special coatings suitable for various environments Sheet metal is rolled into thin and flat s pieces It is the main sheet material used and can be cut and bent into a variety of y different shapes Countless Z Y objects associated with p electrotechnology are constructed of the material Thicknesses can vary significantly although extremely thin thicknesses are considered as foil or leaf and pieces thicker than 6mm are considered to be plate Sheet steel is made in both coated or uncoated form Uncoated ferrous iron based sheets are susceptible to rust and corrosion and are not commonly used Coating of various types are applied to either to prevent corrosion or for aesthetics appearance Coated sheets include galvanized and zincalume while stainless steel aluminium brass or copper are referred to as solid sheets Individual sheet types can be identified by visual appearance or by manufacturer s marks Galvanized Steel This has a zinc coating and can be recognized by its typical spangled appearance A zinc coating is highly resistant to corrosion as long as it remains intact on the sheet However if the surface coating is damaged in any way by welding grinding or bending
347. types but the most common is the vee thread named because of its shape j j Minor sar e Screw threads are used for general fastening Diameter for 50 purposes thread e They are uniform in diameter unlike a wood screw which is tapered e n some applications screw threads are used for the transmission of power and controlled motion e The thread pitch is the distance from one thread groove to the next It is measured from crest to crest ie Peak to peak Major diameter External Commonly used Vee Threads e Metric is currently the most commonly used thread form in the electrotechnology industry e British Standard Whitworth BSW thread form was once a widely used general purpose thread in Australia There will still be remnants of these bolts and nuts in older switchboards and machines e Various other types of threads are used in imported machines Thread Identification A tradesperson is frequently called upon to mate a nut with an existing bolt Here the type of thread and the pitch must be determined precisely To make an accurate identification of a thread type a tool known as a thread pitch gauge is used The graded teeth of the gauge are placed into the teeth of the thread and this then identifies the pitch of the thread Measure the major diameter of the bolt to determine the thread size Pipe Vice Sometimes spelt as Pipe
348. ubber soles must be CY clothing to cover arms S must not be worn worn and legs must be worn A welding mask with Respiratory protection devices may be required GTAW must be worn correct grade lens for Pre Operational Safety Checks Locate and ensure you are familiar with all machine operations and controls Check workspaces and walkways to ensure no slip trip hazards are present Ensure the work area is clean and clear of grease oil and any flammable materials Keep the welding equipment work area and your gloves dry to avoid electric shocks Ensure your gloves welding torch and work leads are in good condition Ensure other people are protected from flashes by closing the curtain to the welding bay or erecting screens Start the fume extraction unit before beginning to weld Ensure work leads do not create a tripping hazard Operational Safety Checks e Ensure machine is correctly set up for current voltage and gas flow e Ensure work return earth cables make firm contact to provide a good electrical connection e Strike the arc before placing the tip of the filler wire in the weld zone Turn off the power while changing tungsten electrodes e Take care to avoid flashes Ending Operations and Cleaning Up e Switch off the machine and fume extraction unit when work completed e Close the gas cylinder valve e Hang up welding gun and leads e Leave the work area in a safe clean and tidy state E102A
349. um zinc or other soft metals The blade makes straight cuts only and is used to dock off stock materials The abrasive wheel on this type of machine is the same type that can be fitted to circular saws and angle grinders This saw does not use liquid coolant Safety Abrasive Saw DO NOT use this equipment unless you have been instructed in its safe use and operation and have been given permission PPE guidelines when working on an Abrasive Saw Safety glasses must be Long and loose hair Hearing protection worn at all times in work a must be contained must be worn areas Sturdy footwear must Close fitting protective Rings and jewellery be worn at all times in clothing must be worn must not be worn work areas Pre Operational Safety Checks e Locate and ensure you are familiar with all machine operations and controls e Ensure all guards are fitted secure and functional Do not operate if guards are missing or faulty e Ensure the saw is properly secured to a worktable by bolts clamps at approximately hip height e Ensure the saw is operated on an RCD residual Current Device protected circuit e Use abrasive cut off wheels with the correct size arbor hole Use abrasive cut off wheels with a maximum safe operating speed greater than the no load RPM marked on the machine s nameplate Inspect the cut off wheel for chips and cracks Check workspaces and walkways to ensure no slip trip hazards are
350. ur own equipment should include e protective goggles e gloves e ear protection e protective clothing e Avoid dangerous environments In a gaseous or explosive atmosphere sparks from an electric tool may ignite fumes Do not expose tools to rain or wet conditions e Use the correct tool Never carry the tool by the cord or pull it to disconnect the plug Make sure the tool is switched off before plugging in the cord e When using a tool at a long distance from the power source an approved extension cord must be used for safety and to prevent loss of power and overheating e Before using cords inspect them for loose or exposed wires and damaged insulation Have any necessary repairs done by a qualified electrician before using your power tool E102A Notes T2 T12 Version 4 BG doc Page 162 of 254 23 January 2014 Cutting Tools Among the range of portable power tools available are cutting tools Each type of cutting tool relies on a different cutting action Types of Cutting Actions Shearing action The metal is cut in a similar way to tinsnips The blades slice but no metal is removed An electric hand shear tool is shown below On off switch Finger guard Blades Cutting table PARTS OF HAND SHEARS Nibbling action The metal is punched out in a half moon shape The kerf is much wider than that produced by a saw blade Abrasive action The metal is cut in a similar way to a grinding action Sawing a
351. ury by using the following equipment e Safety glasses e Work type pants and shirt made from industrial quality material e Industrial quality work boots or shoes with steel toe caps e A hair net if you have long hair e Ear muffs if you are working in a high noise level area Hazards Drilling machines can be dangerous so you must observe safety precautions and watch out for the following e sharp swarf particles NB The term Swarf refers to the shavings and chips of metal debris resulting from metalworking operations Also the term Kerf refers to the width of the cut groove or incision made by some type of saw or blade e the work piece spinning because there is not enough clamps used on the job for the size of the cutting forces e loose clothing or hair becoming entangled in the rotating spindle e dermatitis from the cutting fluids being used e burrs on drilled holes Additional advice to avoid injuries e Do not wear gloves while using a drilling machine The gloves may become caught and drag your hand into the cutter e Never try to remove tangled swarf from the cutting tool while it is still revolving Always stop the machine and then use pliers to remove the swarf NOT YOU RE HANDS e When changing the spindle speed via the belt and pulley make sure that the machine cannot be suddenly started to avoid fingers getting nipped between belt and pulley e To avoid damage to the cutting tool and possible brea
352. vet use a drilling machine with a twist drill the same size as was used to install originally This means that a new rivet can be re installed back in the same hole with no loss of integrity Sealed rivet Range of Riveting Tools RININI http www rivetwise co uk productrange tools asp section po Grooved rivet hollow pset_rivet_hand_tools 2 78 TYPES OF RIVETS A hand small hand riveter is suitable for small jobs only For tasks where many rivets are to be installed larger tools are available A selection of manually operated tools are shown below Sheet Metal Work Power Tools There are a number of hand held power tools suitable for sheet metal work The more common types are as shown below Safety when using power tools is very important Keep the work area clean gt Always wear appropriate protective clothing for the task Never wear loose clothing or jewellery as they may get caught in moving parts Always inspect the tool prior to use to ensure there are no visible defects When not in use store tools in dry high or locked places Use the right tool Do not force a small tool to do a task for which it was not designed If the task is too heavy for this tool then a heavy duty tool will do the job better and more safely at the rate for which it was designed VVV WV Ref http www jalopyjournal com forum showth read php t 381458 E102A Notes T2 T12 Version 4 BG doc Page 189 of 254 23 January 2
353. vides all position flexibility Is less sensitive to wind or drafts Yields a weld with a variable quality and appearance based on operator skill Electrodes and Flux sr 7 Sy Ref http patelpowertools com viewmenu P Gra s php id 26 gape The electrode is used to conduct current through to the work piece It consists of a metal rod of various diameters gauge which is covered by a flux coating of mineral or organic materials A P As the weld is laid the flux coating of e H the electrode evaporates giving off vapors and a layer of slag The molten slag covers the filler metal METAL as it travels from the electrode to the weld pool Once part of the MOLTEN weld pool is formed the slag floats on the surface and protects SOLIDIFIED SLAG the weld from atmospheric contamination as it solidifies Once hardened the slag should be chipped away using a chipping hammer to reveal the finished weld ARC METAL AND SLAG Wein GASEOUS WORKPIECE Flux coated electrodes are available in many core wire diameters and lengths The electrode core must be matched to the properties of the base materials to be welded Commercial electrodes types include those BUTT JOINT suitable for mild steel stainless steel aluminum bronze bronze and nickel Typical manual welded joints are shown to the right Manual welding is a process that LAP JOINT requires a large amount of practice to achieve proficiency
354. wo parts together E102A Notes T2 1T12 Version 4 BG doc 23 January 2014 Page 218 of 254 Drilling and Cutting Holes In Sheet Metal Making holes in sheet metal can be done with gt Drills gt Hole saws gt Metal punches gt Fly cutters Drills To drill thin metal below 1 6 mm in thickness it is best to use a DRILLING THIN METAL specially prepared sheet metal drill for holes over 6 mm in WITH A DOWELLING DRILL diameter Such a drill resembles the dowelling drill used by carpenters and joiners Drills with a 140 point angle can also be used satisfactorily to drill thin sheet metal The outer corners must be cuttin Standard drills 120 point angle are satisfactory for use on yh ee aay thicker material Holes drilled with these drills are suitable for bolts and for entry of cables Hole Saws These can be used to cut larger holes in sheet metal Their sizes range from 15 to 150 mm in 2 mm diameter increments When using a hole saw make sure to use an adequate supply of cutting fluid to cool the blade and to reduce friction Holes made with hole saws are suitable for meters and gland fittings etc Metal Punches The punches for smaller holes 6 to 15 mm in diameter are usually pushed or punched through the metal For holes of 16 mm and larger the matched punches and dies are pressed through the metal A pilot hole to accommodate the punch spindle is drilled HOLE SAW first and then punch and die are assembl
355. work completed e Leave the machine in a safe clean and tidy state Potential Hazards and Injuries e Hair clothing getting caught in moving machine parts e Eye injuries e Flying swarf and chips e Sharp edges and burrs Don ts x Do not use faulty equipment Immediately report suspect equipment x Never leave the machine running unattended x Do not hold the item being drilled with your hands Use a clamp E102A Notes T2 T12 Version 4 BG doc Page 100 of 254 23 January 2014 Tapping and Tap Wrenches A tap wrench is designed to securely hold and rotate a thread tap which is used to cut an internal thread in a pre drilled hole Always choose a suitably sized and type of tap wrench for the tap and the location If a tap wrench is too large it will increase the probability of snapping the tap Types of Tap Wrenches Bar Tap Wrenches Bar tap wrenches have a flat centre section containing jaws shaped to grip the squared end of the tap One sliding jaw is adjusted by a screw operated by turning one of the handles about its axis The ends of the two handles are knurled p Adjust jaw opening 4 by twisting handle BAR TAP WRENCH Always choose the smallest capacity wrench that will grip the tap firmly Check that the handles of the tap wrench can be turned without striking nearby parts A small bar type tap wrench can hold taps ranging Chuck to from 3mm to13 mm in size There is a range of adjust size differ
356. ww toolstop co uk Ref http www powertoolsdirect com Aviation Snips This design has a compound action universal blade and the cutting edge is serrated to prevent slipping Tin snips are designed to cut curves in one direction only Waste material ga tothe left There are three cutting styles straight cutting left cutting and right cutting Straight cutting snips generally have yellow coloured soft grips cut in a straight line and wide curves left cutting snips usually red will cut straight and in a tight curve Se annen mignGhanted to the left right cutting snips usually green will cut straight and in a tight curve to the right Care of snips gt Only use snips for the material they were designed to cut gt Never use snips to cut wire as the cutting edge will be nicked and further clean cuts will be impossible to make gt Keep the cutting edges in good condition by lightly honing with an abrasive stone or by re grinding on a bench grinder gt The pivot point should be kept lightly oiled and in good adjustment so that the faces of the blades slide together firmly with minimum clearance E102A Notes T2 T12 Version 4 BG doc Page 186 of 254 23 January 2014 Correct Use of Snips gt Grip the handles between thumb and first finger and allow first and second fingers to curl around the lower handle Place the third and small fingers between the handles but rest them on top o
357. y are available in various frame sizes including 0 25mm 25 50mm 50 75mm 75 100mm 100 125mm 125 150mm and beyond Metric models have a 0 25mm measuring range which is limited by the length of the thread on the spindle While larger frame sizes enable sizes enable them to measure longer lengths the SPINDLE measurement range does not increase LOCKS The principal parts of the micrometer are gt Frame manufactured from drop forged steel to minimise distortion and determines the size of the micrometer gt Spindle made with an accurate screw thread one end hardened ground and lapped gt Lock Nut in which the spindle thread turns gt Sleeve Accurately graduated and clearly marked gt Thimble provides equally marked divisions and is fixed to the spindle gt Ratchet to ensure even pressure of the spindle so as to provide exact repetitive readings gt Anvil built into the frame in exact alignment with spindle E102A Notes T2 T12 Version 4 BG doc Page 228 of 254 23 January 2014 Principle of a Micrometer A standard metric micrometer measures to an accuracy of 0 01mm This is achieved through the combination of two scales The sleeve or barrel scale which is graduated into millimetre and half millimetre graduations and the thimble scale which is graduated into 50 equal parts If the anvils are cleaned and then adjusted to touch each other both scales should show 0 Thi
358. y can secure They can be used for fastening electrical accessories with through holes and a nut behind or into a tapped hole They can be passed through two or more components and then threaded into the rearmost component which acts as the securing nut for the joint Machine screws can be threaded into metallic inserts cast into soft materials such as plastic or light alloy Two opposing machine screws can be used with a standoffs to separate plates by set distances Conductive machine screws brass can be used as part of an electrical connection neutral or earth link and nylon screws are commonly uses as insulators to separate panels which contain different potentials Machine screws are commonly used to fasten electrical gland plates to switchboards and cableways to facilitate cable entry They are called machine screws because their primary role is to assemble machine components such as for tools manufacturing equipment electrical and electronic a EE EA Cleaned area covered equipment of every description In the electrotechnology witenhpoara with mastic industry machine screws are used in switchboard construction to secure internal equipment such as contactors relays and protective devices fuses and circuit breakers to back panels Machine screws are made using a variety of materials Most are metallic steel including mild and stainless or brass but some exotic materials such as titanium are also used
359. y glasses and shields Eyes need special protection Clear safety glasses should be worn when using a grinding wheel or for any workshop job where dust or metal particles are prevalent a yM WLAS Manual Handling Manual tasks can contribute to injuries affecting all parts of the body particularly the back shoulder and wrist These are commonly called musculoskeletal disorders Extra care is needed when performing manual tasks If the task is beyond your capabilities then either e Seek help e Use a mechanical lifting aid eg bar HOISTS USED FOR e Use a mechanical lifting device eg LIFTING HEAVY EQUIPMENT Crane ines i Over time damage can build up in your body through things such as e Handling loads frequent lifting with the back bent and or twisted or pushing or pulling loads e Repetitive work using the hand or arm or gripping tools or loads tightly e Static work of the whole body working in a fixed position with the back bent continuous sitting or standing or driving vehicles for long periods e Static work of the upper limb working with the neck shoulders and arms in a fixed position such as using tools and handling heavy loads e Vibration using tools or coming into contact with vibrating surfaces while undertaking manual tasks such as sitting on a large machine Use aids to lift awkward material E102A Notes T2 T12 Version 4 BG doc Page 16 of 254 23 Janu
360. y opposite inside corners of the cut out area Make sure to stay well within the marked outline gt Cut from a drilled hole through the material to the next corner with a jig saw sabre saw or a hacksaw blade and pad handle Use the saw to trim close but not to the line gt File the rough edges to the marked outline and remove sharp edges and burrs Finally remove the masking tape and paint edges to protect metal gt Thin material can be cut with tin snips Sustainable Energy Work Practices Sustainable work practices involve Working safely with electro technology Reduce energy usage where possible but switch off electrical systems when not in use Maintaining and repairing tools and equipment Reducing waste products Reusing and recycling materials Responsibly disposing of waste products VVVVVV All waste whether it is the materials or energy represents loss of resources and loss of money Reducing waste can help Reduce operating costs Reduce waste disposal costs Reduce long term liability Help sustain environmental quality Project a positive public image for an organization VVVV WV Sheet metal stock materials are sold in standard sizes This means set lengths for bars rods and pipes and set length and breadth for sheet materials Efficient ordering means purchasing stock sizes so as to obtain the maximum number of job pieces blanks out of a stock length or sheet area The key is to eliminate th
361. y work assembling components applicable to electrotechnology industry using a variety of hand tools VVVVV T8 Joining techniques encompassing types of machine screws and nuts forms of welding Oxy acetylene electric arc welding forms of brazing and hard soldering process of soft soldering joining components using machine screws joining components using welding brazing or soldering techniques VVVVV WV T9 Portable electric power tools encompassing gt portable electric power tools grinders drills jigsaws Saws gt applications of portable electric power tools used in the electrotechnology work gt using portable power tools E102A Notes T2 T12 Version 4 BG doc Page 8 of 254 23 January 2014 gt fabricating components using power tools drills grinders T10 Sheet metal work encompassing types of sheet metal materials used in the electrotechnology work names and applications of the types of fabrication materials tools used with sheet metals in electrotechnology work hacksaw tinsnips guillotines punches notching tools folding machines techniques used in fabricating sheet metal cutting bending drilling punching joining cutting mitres marking out cutting bending drilling and or cutting and or punching holes joining and cutting mitred joints using sheet metal sustainable energy work practices to reducing waste when fabricating using sheet metal gt fabricating components using sheet met
362. zero point If in doubt about a sleeve scale graduation take a lead from the position of the thimble scale In the example to the right the half scale does show and this adds 0 5mm to the total 3 Note the number of graduations on the thimble scale that is level with the datum line and add to the previous values In this example this adds a further O 05mm Each major division on barrel is 1mm Readingis 4 4 mm Plus additional minor divisions Reading is 1 0 5 mm Each thimble division is 0 01 mm Reading is 5 0 05 mm Total Reading 4 55 mm The total reading is 4mm 0 5mm 0 05mm 4 55mm E102A Notes T2 T12 Version 4 BG doc Page 230 of 254 Using Outside Micrometers Excessive pressure during adjustment will give inaccurate readings and cause strain on the thread and possibly distort the frame To avoid this micrometers are fitted with a spring loaded ratchet that will ensure constant adjusting pressure on the component being measured provided the micrometer is kept square to the work When using the micrometer try as much as possible to have the graduations on the barrel scale towards you If the frame cannot be supported by the left hand and only one hand can be used to hold the micrometer support the frame on the lower centre of your palm using the little finger to hold the frame to the palm Keep the first finger and thumb free to adjust the knurled thimble Develop the feel w

Student Note T2 – T12 Bracken Ridge Electrical

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Student Note T2 &ndash; T12 Bracken Ridge Electrical

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Student Note T2 – T12 Bracken Ridge Electrical