Ethiopian TVET-System

Furniture Making L-II

Based on Sept. 2012G.C. Occupational standard

Module Title: Performing Equipment Maintenance

TTLM Code: IND FMK2 TTLM 0919V1
This module includes the following Learning Guides

LG01: Prepare for work

LG Code: IND FMK2 M01 LO1-LG-01
LG02: Carry out basic routine maintenance
LG Code: IND FMK2 M01 LO2-LG-02
LG03: Complete work
LG Code: IND FMK2 M01 LO3-LG-03
 Instruction Sheet LG01: Prepare for work

This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics:
1.1. Tools and Equipment
1.2. Maintenance supplies
1.3. Basic routine maintenance
1.3.1. Dismantling and assembling
1.3.2. Testing and tightening
1.3.3. Minor adjustments and repairs
1.3.4. Routine servicing procedures
1.4. Identifying fault/unsafe machineries according to enterprise requirements
1.4.1. Standard Operating Procedures (SOPs),
1.4.2. Industry standards
1.4.3. Production schedules
1.4.4. Material Safety Data Sheets (MSDSs),
1.4.5. Work notes and plans
1.4.6. Product labels, manufacturers specifications,
1.4.7. Operators' manuals, enterprise policies and procedures
1.5. OHS requirements
1.5.1. Protective clothing and equipment
1.5.2. Use of tools and equipment
1.5.3. Workplace environment and safety
1.5.4. Handling of materials
1.5.5. Use of firefighting equipment
1.5.6. Organizational first aid
1.5.7. Hazard control and hazardous materials and substances
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 1.5.8. Safe operating procedures

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:
• Identify Tools and supplies required to carry out basic routine maintenance tasks
• Identify Faulty or unsafe machinery and equipment for repair or replacement
• Identify OHS hazards in the workplace Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described below.
3. Read the information written in the information “Sheet 1, Sheet 2, Sheet 3, Sheet 4, and Sheet
5”.
4. Accomplish the “Self-check 1, Self-check t 2, Self-check 3, Self-check 4 and Self-check 5” in
page -7, 8, 12, 17, and 25 respectively.

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 Information Sheet-1 Tools and Equipment

Tools
• Tools can be divided into two main groups: hand tools and power tools.
• Hand tools are operated by the physical strength of the user.
• Power tools require an external source of power such as electricity or compressed air to
operate.
• Each of these groups can also be divided into sub groups.
Tool and Equipment Safety Rules

• Observe and follow Student Shop Rules as posted.

• Understand and follow manufacturer operating procedures.
• Inspect the tool for damage prior to use.
• Verify all guards are in place and adjusted properly.
• Do not bypass any safety devices.
• Only use the tool when it is secured to the floor via a pedestal or work bench.
• Always stay at the machine while it is running.  Clean the tool after use.
• Report any malfunction or damage to the Shop Supervisor after tagging the tool “Out of
Service, do not use”.
• Always disconnect the plug from the power source before making any adjustments,
changing, or physically inspecting the blade.
• Never use another person as a substitute for a table extension or as additional support.
• Do not attempt to cut pieces of stock that are too small to easily hold with your hands.
Use clamping devices and/or jig fixtures instead.
• Always stand with your face and body to one side of the saw blade when making cuts.
• Never make free-hand cuts by raising the work piece into the blade.
• Never feed the saw into the work piece at a rate faster than it can accept.
• Never pull the blade beyond the point necessary to make the cut as the back of the
blade could lift the work piece and throw it over the fence.
• The saw must have a device installed which will automatically return the cutting head to
the back of the track when released from any point of its travel.
• The saw must have a mechanical limit to prevent the cutting head from traveling beyond
the front edge of the table.

Operation Sheet 1 Use hand and power tool safely

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 Steps 1- select the right tool for the job
Steps 2- keep tools in good condition
Steps 3- use tools the correct way
Steps 4- keep tools in a safe place

• Combination wrench
• Hex key
• Framing square
• Medium size flat blade screw driver

Drilling tools
 Drilling tools are used in conjunction with drill bits to drill holes in material such as
wood, steel and plastics.
 There are other added features of pistol grip drills which make them more versatile,
such as reverse rotation, torque settings making them useful as an electric screw
driver and a hammer action setting.
 All these features are available in a cordless drill.

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 Dust Collectors
 Dust collectors contribute to a cleaner more healthful workshop environment.
 We offer a wide selection of top quality dust collectors to suit all your shop needs

Grease Gun
A grease gun is used to apply grease or oil to car parts, machinery, tools, etc. through the
grease nipple. A grease gun can inject grease into areas that are difficult to reach. Using a
grease gun can be easy once you have taken it apart and loaded it. By doing this, you
immediately see how the gun works and you are ready to use it with no further directions

Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. List hand and power tool safely? (4points)
2. What is the function of grease gun? (2points)

Note: Satisfactory rating – 6 points Unsatisfactory - below 6 points

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You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet-2 Maintenance supplies

Maintenance, Repair, and Operating supply items are supplies utilized in the production process
that is not ultimately seen in the end products themselves. Maintenance, Repair, and Operating
items may include:
• Gloves
• Safety equipment
• Industrial Equipment (valves, compressors, pumps)  Consumables (cleaning,
laboratory and office supplies)

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 • Plant upkeep supplies (lubrications, Gaskets, repair tools)

Lubrication is the process or technique of using a lubricant to reduce friction and wear in a
contact between two surfaces.
Lubricants can be solids (such as Molybdenum disulfide MoS2),[1] solid/liquid dispersions (such as
grease),liquids (such as oil or water), liquid-liquid dispersions or gases

Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page: 1.
List Maintenance supplies? (3 points)

Note: Satisfactory rating – 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet-3 Basic routine maintenance

Performs routine maintenance on machine/ equipment such as lubricating, cleaning, oil,

and checking parts etc...
Basic routine maintenance
• Checking/ cleaning machine parts
• Keep the saw clean
• Keep the blades sharp
• Clean and lubricate parts
• Adjust and inspect the parts
• Changing the motor brushes
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 • replacing the drive belt
• checking/ changing the friction wheel

General requirements for equipment maintenance include:

• Obtaining a copy of the maintenance schedule recommended by the manufacturer.

• Ensuring that maintenance is performed as required.
• Ensuring that the person(s) performing the maintenance are competent (e.g. licensed
mechanic).
• Retaining records of maintenance/service conducted.
• Specifying who is responsible for overseeing equipment maintenance and where the
records are kept.
• Set up a system for removal and tagging of damaged or defective tools and equipment.

1.3.1. Dismantling and assembling

Dismantling equipment

The main stages of dismantling are;

• Dismantling proper, taking the machine parts and in a strict sequence.

• Dismantling should commence with the removal of guards, protective devices, followed by
disconnection of transmissions and withdrawal of belts, after which the machine is
brokendown into its units in a definite order.

• Cleaning can be done by kerosene and petrol

• Cleaning, washing and wiping, drying the dismantled parts.

1.3.2. Testing and tightening
All preparatory measures are carried out during the first stage;
• They include check of the quality of work performed on machine and its output, all
inconveniences; weak spots in the machine during its operation and servicing are found out.
• Second stage of the preliminary operations, consists of the following measures;
1) Removing all guards and protective arrangements of machine to facilitate access and
inspection of moving and guiding parts of the machine. Removing or loosening flexible
transmissions (belt, rope and chain drives etc.
2) Inspecting and checking the condition and position of external rubbing parts subjected to
impact loads and high stresses (tables, slides ,carriages, screws etc,)
3) Inspecting and checking the tightness and rigidity of the fixed joints on the machine.
4) Checking the radial and axial play of the movable joints.
5) Checking the smoothness of travel and positions of all moving parts directly by hand or with
levers.
6) Checking the condition and action of locking and all fastening arrangements and also the
starting, control and braking devices.
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 7) Checking the foundation bolts.

1.3.3. Minor adjustments and repairs

• Repair means responding to the breakdown of equipment and undertaking work to correct
the problem in order to return the equipment to a working condition.
• Before equipment can be repaired, you need to be aware that there is a problem! Therefore,
there should be a clearly understood system for reporting faults and breakdowns and
equipment users should be encouraged to report faults and breakdowns as soon as
possible.

 Simple repairs can be done by the in-house or external maintenance and repair team.
 More complex repairs will be carried out by specialized maintenance personnel

Basic repair operations

The operations involved in woodworking machinery can be classified into 5 basic types;

1) Local tightening up of loosened worn parts.

2) Local fastening of worn, broken parts.
3) Partial adjustment of position, interconnection and interaction between individual
parts of machine.
4) Partial restoration of broken parts.
5) Partial replacement of worn, broken or missing parts.

1.3.4. Routine servicing procedures

 Different maintenances strategy is going to be formulated; there are many maintenance
procedures that could be chosen, from sophisticated procedures to low level procedures.
 In reality there is a mix between different procedures due to the variety equipment in the
plant and because of economic consequences the equipment causes if a scheduled stop
occur.
A) Operate to break down (unplanned corrective maintenance) (O.T.B.D)
 If all maintenance jobs carried out in the plant are O.T.B.D, maintenance will result in low
availability performance and high maintenance coast.
 Coast for down time will be extremely high.
 Maintenance is controlled by the unplanned demand for maintenance.
 Maintenance effectiveness is low; maintenance work is pressing and some- times
dangerous due to the fact that safety procedures are often neglected.
 Sometime this maintenance procedure has to be practiced purposely because of economic
or technical reasons.
 But only for equipment which this procedure has been decided for. If all maintenance are
carried out are break down jobs, the maintenance strategy is completely wrong.
B) Fixed time maintenance (F.T.M)

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 Fixed-time maintenance will result in less expensive maintenance and less down-time
compared to operate to breakdown procedure.
 Fixed-time maintenance work is established for important machinery. Components whose
life-time can be estimated are replaced or reconditioned.
 Preventive maintenance base only on the fixed-time maintenance procedure will not give
the expected results since parts are having individual life time.
 Some parts will be replaced too often, and results in unnecessarily coast. Some parts will go
breakdown and creates high down time costs.
C) Condition-based maintenance, (C.B.M)
 Condition-based maintenance will result in optimized availability and maintenance cost and
is giving the best profitability.
 This maintenance procedure can be considered as just in time maintenance.
 Condition-monitoring of equipment while in operation will make possible planning corrective
maintenance and a flexible maintenance planning coordinated with production planning
production down-time due to e.g. changes of tools, changes of product etc., will be utilized
for maintenance work.
 This maintenance procedure has resulted in extremely low down-time and high availability.
D) Design out maintenance, (D.O.M.)
 This maintenance procedure means that actions are taken to design out failures
completely.
The failure newer occurs again after the design out action has been taken.
 Follow up of carried out maintenance is crucial to be able to practice this procedure.
 It must be known what is going on with the equipment in the plant, if there are any repetitive
failures and the reason there of.
 When a failure is designed out the need of maintenance will decrease and the availability
performance arise?
 When designing /procuring machinery, maintenance demands should be far more
emphasized.
 To buy the cheapest equipment will very often result in high costs for maintenance, low
availability and short technical life-time.
 High quality equipment is normally more expensive but will result in lower costs for
maintenance, better availability performance and longer technical life-time.
E). Life-time extension, (L .T .E.):-
 Life-time extension shall always be in mind of maintenance people. If the life-time of parts
can be extended by making some modification, renewal of material etc.,
 The demand for both preventive and corrective maintenance will decline. Follow up of
maintenance carried out is essential to practice the L.T E. procedure. F). Redundancy,
(R.E. D.):
 Redundancy means that a spare machine or part is installed in parallel with the original.
 This means that the spare machine or part can be stated and connected to the production
line, if the original one stops unforeseen.
 This procedure is very expensive to as it requires double function of equipment.
 If an unplanned stop create big losses or other consequences and is inevitable, the
procedure must be practiced if it is economically.
Self-Check -3 Written Test
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 Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. What are general requirements for equipment maintenance? (2 points)
2. List Routine servicing procedures? (3 points)
3. List Basic routine maintenance? (2 points)
Note: Satisfactory rating – 7 points Unsatisfactory - below 7 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet-4 Identifying fault/unsafe machineries according to

enterprise requirement

1.4.1. Standard Operating Procedures (SOPs),

 A standard operating procedure, or SOP, is a set of step-by-step instructions created by a

business to help workers carry out routine operations.
 Their purpose is to achieve efficiency, quality output and uniformity of performance, while reducing
miscommunication and failure to comply with industry regulations.

Health and safety

 Procedures are extensively employed to assist with working safely.

 They are sometimes called safe work methods statements (SWMS).

 They are usually preceded by various methods of analyzing tasks or jobs to be performed in a
workplace, including an approach called job safety analysis, in which hazards are identified and their
control methods described.
 Procedures must be suited to the literacy levels of the user, and as part of this, the readability of
procedures is important

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 1.4.2. Industry standards

 In manufacturing, a measure of excellence or a state of being free from defects, deficiencies and
significant variations.
 It is brought about by strict and consistent commitment to certain standards that achieve
uniformity of a product in order to satisfy specific customer or user requirements.

A technical standard is an established norm or requirement for a repeatable technical task. It is usually a
formal document that establishes uniform engineering or technical criteria, methods, processes, and practices.
In contrast, a custom, convention, company product, corporate standard, and so forth that becomes generally
accepted and dominant is often called a de facto standard.

A technical standard may be developed privately or unilaterally, for example by a corporation, regulatory body,
military, etc. Standards can also be developed by groups such as trade unions and trade associations. Standards
organizations often have more diverse input and usually develop voluntary standards: these might become
mandatory if adopted by a government (i.e., through legislation), business contract, etc.

The standardization process may be by edict or may involve the formal consensus[1] of technical experts.

1.4.3. production schedules

Complete, thorough, and current documentation is essential to an effective maintenance

program.
Whether you are performing preventive, predictive, or reliability-centered maintenance,
keeping track of equipment condition and maintenance performed or planned is critical.
• Maintenance recommendations contained in this report should be used as the basis for
establishing or refining a maintenance schedule.
• The maintenance recordkeeping system must be kept current so that a complete
maintenance history of each piece of equipment is available at all times.
• This is important for planning and conducting an ongoing maintenance program and
provides documentation needed for the Power.
• Regular maintenance and emergency maintenance must be well documented, as should
special work done during overhauls and replacement.
1.4.4. Work notes and plans Importance
of taking notes
 Taking notes helps you remember
 Unless you have the memory bank of a super computer, you need to take down notes to
remember things.
 Even if you‟re good at memorizing stuff, taking notes will relieve the mind of that extra task
of recalling things at the office.

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• Taking notes is your document of proof Four Tips to Take Notes Effectively
• Use pen and paper
• Learn shorthand
• Just highlight the key points
• Prepare a written report immediately after the work

Work notes and plans

Circular saw

Maintenance Timefrequents Remark

General Daily With compressed air and

cleaning of the broom
machine and
around the
machine

Cleaning of the Daily With compressed air

saw table
Cleaning of the Daily With compressed air, broom or
motor area clothe
Observing the Daily Dull and damaged saw blade
saw blade leads to unsafe operation of the
circular saw and unclear saw cut
Changing of the If dull or Dull and damaged saw blade
saw blade necessary leads to unsafe operation of the
circular saw and unclear saw cut
Control of the Daily Incorrect adjustment of the riving
adjustment of knife leads to an unsafe
the riving knife operation of the circular saw
Control of v-belt Weekly If one belt is worn both belts
tension have to be replaced

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 Creasing / oiling Four month Thin film of oil or grease have to
of the saw table be applied to prevent rust
Greasing of the Two month Saw dust will stick on the slide if
slide of sliding too much greased
table

Thickness
planner
Maintenance Timefrequents Remark

General cleaning of Daily With compressed air and

the machine and broom
around the
machine
Cleaning of the Daily With compressed air
table
Cleaning of the Daily With compressed air
cutterblock
Cleaning of the Daily With oil products, not acid
rubber rollers products
Cleaning of the motor Daily With compressed air, broom or
area clothe
Oiling of the feed Weekly
chain of the feed
rollers

Control of v-belt Weekly If one belt is worn both belts

tension have to be replaced
Observing the cutting Daily If one cutting knife is dull all
knifes cutting knifes have to be
changed
Creasing / oiling of Four month Thin film of oil or grease have to
the work table be applied to prevent rust

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 Surface planner

Maintenance Timefrequent Remark

s
General cleaning of the Daily With compressed air and
machine and around the broom
machine
Cleaning of the in-feed Daily With compressed air
and out-feed table
Cleaning of the Daily With compressed air
cutterblock
Cleaning of the motor Daily With compressed air,
area broom or clothe
Control of v-belt Weekly If one belt is worn both
tension belts have to be replaced
Observing the cutting Daily If one cutting knife is dull
knifes all cutting knifes have to
be
changed
Creasing / oiling of the Four month Thin film of oil or grease
work table have to be applied to
prevent rust

1.4.5. Product labels, manufacturers specifications,

• This information should form the basis of any inspection schedule. If this documentation
isn‟t available it may be possible to get copies from the manufacturer or supplier or
download information from the internet.
• Labels allow items to be identified and are often the first point of contact between the
customer and the product.
• This is the primary function of labels, allowing for items to be differentiated even if they
belong to the same brand.
1.4.6. Operators' manuals, enterprise policies and procedures
 Manual describes how to operate the machine properly and safely.
 Be sure to follow the safety tips and instructions stated in the manual
 Before beginning any work on the machine read and understand safety and the respective
safety guidelines.
 The operations manual is the documentation by which an organization provides guidance
for members and employees to perform their functions correctly and reasonably efficiently.
 It documents the approved standard procedures for performing operations safely to produce
goods and provide services.

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  The policies and procedures were explained in detail to each employee during their first
week of employment with the company.
 Every company has different policies and procedures. Your first day you will be given a
packet that outlines what the company expects as far as dress code, behaviors, time off and
holidays.
 It is good to keep it on hand to reference when questions arise about what the company
allows and doesn‟t allow.

Self-Check -4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page: 1.
What is an operation manual? (2 points)

Note: Satisfactory rating – 2 points Unsatisfactory - below 2 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Information Sheet-4 OHS requirements

1.5.1. Protective clothing and equipment

Woodworking workers exposes to a variety of hazards, including kickbacks, flying wood
chips, noise, wood dust, and chemical hazards. Personal protective equipment (PPE) can
help protect against these hazards

Personal Safety
 Stay alert. Watch what you are doing, and use common sense when operating a power
tool. Do not use a power tool while tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating power tools may result in serious
personal injury.
 Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair,
clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be
caught in moving parts.
 Avoid accidental starting. Be sure the Power Switch is off before plugging in. Carrying
power tools with your finger on the Power Switch, or plugging in power tools with the Power
Switch on, invites accidents.
 Remove adjusting keys or wrenches before turning the power tool on. A wrench or a
key that is left attached to a rotating part of the power tool may result in personal injury.
 Do not overreach. Keep proper footing and balance at all times. Proper footing and
balance enables better control of the power tool in unexpected situations.
 Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes,
hard hat, or hearing protection must be used for appropriate conditions.

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1.5.2. Use of tools and equipment safety

Tool safety o Do not force the tool. Use the correct tool for your application. The correct tool
will do the job better and safer at the rate for which it is designed.
o Do not use the power tool if the Power Switch does not turn it on or off. Any tool that
cannot be controlled with the Power Switch is dangerous and must be replaced.
o Disconnect the Power Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
o Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.
o Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools
with a sharp cutting edge are less likely to bind and are easier to control. Do not use a
damaged tool. Tag damaged tools “Do not use” until repaired.
o Check for misalignment or binding of moving parts, breakage of parts, and any other
condition that may affect the tool’s operation. If damaged, have the tool serviced before
using. Many accidents are caused by poorly maintained tools.
o Use only accessories that are recommended by the manufacturer for your model.
Accessories that may be suitable for one tool may become hazardous when used on
another tool.

Woodworking tools can be dangerous if not used properly.

• Only use woodworking machines that you have been trained to use properly and safely.
• Read the owner's manual carefully.
• Make sure you understand instructions before attempting to use any tool or machine. Ask
questions if you have any doubts about doing the work safely.

What safety procedures should you follow when using woodworking machines?

• Always wear safety glasses or goggles, or a face shield (with safety glasses or goggles).
• Wear dust masks when required.
• Wear hearing protection that is suitable for the level and frequency of the noise you are
exposed to in the woodworking area. If you have trouble hearing someone speak from
three feet away, the noise level from the machine is too high. Damage to hearing may
occur.
• Use gloves to protect hands from splinters when handling wood but do not wear them near
rotating blades and other machinery parts where the gloves can catch.
• Wear protective footwear when required.
• Make sure the guard is in position, is in good working condition, and guards the machine
adequately before operating any equipment or machine. Check and adjust all other safety
devices.
• Make sure the equipment is properly grounded before use.
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 • Check that keys and adjusting wrenches are removed from the machine before turning on
the power.
• Inspect stock for nails, staples, loose knots or other defects before cutting, planing, routing
or carrying out similar activities.
• Make sure that all machines have start and stop buttons within easy and convenient reach
of an operator. Start buttons should be protected so that accidental contact will not start the
machine. A collar around the button 3 to 6 mm (1/8 to 1/4 inch) above the button is
recommended.
• Ensure that all cutting tools and blades are clean, sharp, and in good working order so that
they will cut freely, not forced.
• Turn the power off and unplug the power cord (or lock out the power source) before
inspecting, changing, cleaning, adjusting or repairing a blade or a machine. Also turn the
power off when discussing the work.
• Use a "push stick" to push material into the cutting area. Jigs are also useful in keeping
hands safe during cutting procedures. Keep hands out of the line of the cutting blade.
• Clamp down and secure all work pieces when drilling, sanding, cutting or milling.
• Use good lighting so that the work piece, cutting blades, and machine controls can be seen
clearly. Position or shade lighting sources so they do not shine in the operator's eyes or
cause any glare and reflections.
• Ensure that the floor space around the equipment is sufficient to enable you to machine the
size of work piece being processed safely without bumping into other workers or
equipment.
• Use extension tables or roller supports for large work-pieces. Supports should be placed on
both sides (infeed and outfeed).
• Woodworking machines should be fitted with efficient and well-maintained local exhaust
ventilation systems to remove sawdust or chips that are produced.
• Electric power cords should be above head level or in the floor in such a way that they are
not tripping hazards.
• Keep work area free of clutter, clean, well swept, and well lit. Spills should be cleaned up
immediately. Floor areas should be level and non-slip. Good housekeeping practices and
workplace design will reduce the number of injuries and accidents from slips, trips, and
falls.
• Keep the area free from water and moisture. Do not use electrical equipment outdoors in
the rain.
• Always keep your attention on the work. For example, if you must talk to another person,
turn off the equipment first.

1.5.3. Workplace environment and safety

What should you avoid when working with woodworking machines?

• Do not wear loose clothing, work gloves, neckties, rings, bracelets or other jewellery that
can become entangled with moving parts.
• Avoid awkward operations and hand positions where a sudden slip could cause your hand
to move into the cutting tool or blade.

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 • Do not stand directly behind stock that is being cut, planed, or jointed to avoid injury from
kick-back.
• Do not remove sawdust or cuttings from the cutting head by hand while a machine is
running. Use a stick or brush when the machine has stopped moving.
• Do not use compressed air to remove sawdust, turnings, etc. from machines or clothing.
• Do not leave machines running unattended (unless they are designed and intended to be
operated while unattended). Do not leave a machine until the power off is turned off and the
machine comes to a complete stop.
• Do not try to free a stalled blade before turning the power off.
• Do not distract or startle an operator while he or she is using woodworking equipment.
• Horse play should be prohibited. It can lead to injuries.

1.5.4. Materials handling

 Facility layout should encourage an even flow of materials and keep backtracking and
crisscrossing to a minimum.
 Operators shouldn‟t have to stand in or near aisles.
 Arrange the machines so that the materials handled by the operator require minimum
movement and changes of heights.
 This applies to both incoming supply and outgoing stock.

1.5.5. Use of firefighting equipment

Classes of fires
 Class A Fires that occur in ordinary combustible materials such as wood, rags, and rubbish 
Class B Fires that occur with flammable liquids such as gasoline, oil, grease, paints, and thinners
 Class C Fires that occur in or near electrical equipment such as motors, switchboards, and electrical wiring
 Class D Fires that occur with combustible metals such as magnesium

Components of the fire triangle

 Fuel any combustible material
 Heat enough to raise the fuel to its ignition temperature
 Oxygen--Necessary to sustain combustion
(NOTE: To produce fire these three elements are necessary and must be present at the same time. If any one
of the three is missing, a fire cannot be started or, with the removal of any of them, the fire will be extinguished.)

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 Types of fire extinguishers
A. Pressurized water Operates usually by squeezing a handle or trigger; used on Class A fires
B. Soda acid Operates by turning extinguisher upside down; used on Class A fires
C. Carbon dioxide (CO) Operates usually by squeezing handle or trigger; used on Class B and C fires
D. Dry chemical--Operates usually by squeezing a handle, trigger, or lever; used on Class B, C, and D fires
(NOTE: On Class D fires, dry sand is as effective as any dry chemical other than Purple X. The cost of the Purple
X chemical places it out of reach of most shops.)
E. Foam Operates by turning extinguisher upside down; used on Class A and B fires

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1.5.6. Organizational first aid
 Make sure that you know where the first aid box is so that you can use it at once in an emergency.
 When an accident occurs, inform the person responsible for first aid immediately.
 If someone receives an electric shock, switch off the power immediately and call for medical help.
 If someone has severe bleeding from a cut, take a clean piece of cloth and press it on the cut.
When the bleeding stops, take the pat away. Gently clean the wound outwards with cotton
wool or a swap soaked in clean water. Gently dry around the wound with clean cotton wool
and apply a plaster or bandage.

1.5.7. Hazard control and hazardous materials and substances Types

of Hazardous Wastes
1. Wastes that have common hazardous properties such as ignitability and reactivity.
2. Wastes that contain leachable toxic components
Risk control of general hazards
Effective machinery and equipment risk controls reflect some or all of the following
characteristics:

• The hazard is controlled at its source

• Contact or access to the hazard is prevented
• Sturdy construction (correct materials with few points of potential failure)
• Fail-safe (failure of the control system to be effective will result in machinery shut-down)
• Tamper-proof design (as difficult as possible to bypass)
• Presents minimum impediment to machinery and equipment operator
• Easy to inspect and maintain
• Does not introduce further hazards through the risk control action.
Risk control of mechanical hazards
• Separation is a simple and effective machinery and equipment risk control and may be
achieved by distance, barrier or time.
• Distance separation means a person cannot reach the hazard due to distance.
• Barrier separation means an effective barrier or guard denies access and controls ejection
of parts, products or waste.
• Time separation means at the time of access, the machinery and/or equipment is disabled.

Risk control of non-mechanical hazards

The first step in selecting suitable and effective controls for non-mechanical hazards is to
understand the nature of emissions that can be released by machinery and equipment in
the workplace, where those emissions collect and the way they may cause harm

• Separating people from non-mechanical hazards is necessary where the emission cannot
be controlled at the source through elimination or substitution.
• Guarding may also serve to mute noise emissions through application of sound absorbing
materials.
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 • Oil leaks from machinery and/or equipment may present a serious slip hazard. By
preventing oil leaks through routine maintenance, or containing leaking oil with a drip tray or
through spill containment strategies, the risk the hazard presents is controlled.

1.5.8. Safe operating procedures

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 all guards are fitted, secure and functional. Do not operate if guards are missing or
faulty.

 Ensure all locks are securely tightened.

 Ensure table and work area is clear of all tools, off-cut timber and sawdust.  Start the dust
extraction unit before using the machine.

Self-Check -5 Written Test

Name: _________________________ Date: _______________

Directions: Answer all the questions listed below.

1. PPE A, safe and healthy equipment

2. Before Starting work B, Remove rugs within one meter of work area.

3. During Work C, Set up work area

4. At Finish the Job D, sign and avoid warning

5. machine safety E, goggle

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 6. workplace safety F, Clean up thoroughly

7. Maintain the equipment G, keep all tools clear of a work table

8. Post Warning H, Find the causes of damage

9. Furnishings I, free from dust and scratch

10, Protect Floor J, use proper hand tools to dismantle the machine

Instruction Sheet LG02: Carry out basic routine

maintenance

This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics:
2.1. Personal protective equipment
2.1.1. Overalls
2.1.2. Gloves
2.1.3. Protective eyewear
2.1.4. Hearing protection
2.1.5. Safety harness
2.2. Basic servicing of machinery and equipment
2.2.1. Importance of manufacturer‟s specifications and manuals

2.2.2. Greasing and Lubricating

2.2.3 Saw tooth Setting

2.3. Sharpening of machine blades
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 2.4. Routine adjustments and repairs
2.4.1. Tightening of bolts and screws of the machines
2.4.2. Replacement of blades and bits
2.4.3. Cleaning, lubricating, basic repairs and adjustments.
2.5. Work according to OHS requirements.

This guide will also assist you to attain the learning outcome stated in the cover page. Specifically,
upon completion of this Learning Guide, you will be able to:
• Select, use and maintain Suitable personal protective equipment according to OHS
requirements
• Perform Greasing, lubrication and other basic service
• Perform routine adjustments and repairs machinery Learning Instructions:
5. Read the specific objectives of this Learning Guide.
6. Follow the instructions described below.
7. Read the information written in the information “Sheet 1, Sheet 2, Sheet 3 and Sheet 4”.
8. Accomplish the “Self-check 1, Self-check t 2, Self-check 3 and Self-check 4” in page -5, 14,
22 and 34 respectively.
9. If you earned a satisfactory evaluation from the “Self-check” proceed to “Operation Sheet 1,
-Operation Sheet 14
10. Do the “LAP test” in page – 23 and 35 (if you are ready).

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 Information Sheet-1 Personal protective equipment

Safety glasses must be Long and loose hair must Hearing protection
worn at all times in work be contained. may be required. areas.

Sturdy footwear must be Close fitting/protective Rings and jeweler worn

at all times in work clothing must be worn. must not be worn. areas.

Safety instructions
Warning! Risk of injury! Improper maintenance can cause serious injury or
damage.
For this reason, this work may only be carried out by
authorized, trained personnel who are familiar with how to operate the
Machine and in strict observance of all safety instructions.
• Before beginning any maintenance work on the machine, switch it off and secure it against
accidentally being switched on again.
• Keep the work area orderly and clean Components and tools that are not put in their correct
place or put away may be the cause of accidents!
• Ensure that there is sufficient space to work around the machine

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• Following the maintenance work, reinstall the guards and check that they are functioning
properly.

Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. List Personal protective equipment? (2 points)
2. What are safety instructions in maintenance work? (2 points)

Note: Satisfactory rating – 4 points Unsatisfactory - below 4 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Information Sheet-2 Basic servicing of machinery and
2.2.1. equipment

Importance of manufacturer’s specifications and manuals

 This information should form the basis of any maintenance schedule.

 The maintenance activities and frequencies advised in manufacturers/suppliers manuals

should always be followed unless risk assessment of the particular circumstances of use
indicates a different approach would be more appropriate.

 For example maintenance activities are usually based on the amount of use a piece of
equipment is used. If equipment in a workshop is used a lot less frequently than indicated
in the user manual some maintenance activities could be less frequent.

 If this documentation isn‟t available it may be possible to get copies from the manufacturer
or supplier or download information from the internet. If doing the latter it is important to
use a reliable source.

2.2.2. Lubrication of Machines

 The purpose of lubrication of machine parts is to reduce friction heating and loss of power.

 Lubrication also provides the most efficient utilization of a machine but also extends service
life.

 Efficient operation of machinery largely depends not the lubricant, Selected but also on its
method of application.

 Lubricants formerly were applied by hand, but modern Machinery requires exact method
that can be precisely controlled.

 For most machinery, different methods of lubrication and types of lubricant must be
employed for different parts.

 Lubrication should ensure perfect lubrication in the range of speeds, loads and
temperatures specified for a given mechanism.

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 The selection of lubrication by
I. Geometry of contacting bodies
II. Material and finish of mating surfaces
III. Lubricate change and refreshment periods
IV. Degree contamination of the environment
V. Operating temperatures VI. Speed of rotation

 It has been found that oil has better lubricating properties than greases and with this reason
power losses are less due to friction with oils.

 Greases are more suitable for antic friction bearings and other mating parts of most units in
wood working machines.

 The use of lubricating greases does not require complicated sealing devices and provides
comparatively long service of the unit without changing of the lubricant, good protection of
the bearings against external influences, etc.

The condition under which the use of lubricating grease is in effective are:-

A). High temperature (above 70oc)

B).Below freezing (low temperature) at which grease solidifies, and increases the internal
friction.
C). Maximum ease of movement for instance in case of measuring instruments, meters etc.
D). When units cannot be dismantled for completely recuing the lubricant.
 If the bearing are to operate at high temperatures (over 70 oc) liquid lubricants (oil)will have
to be used ;
 Oil and grease are equally good for bearing working low and average peripheral speeds (up
to 1-5m/sec).
 Low viscosity oils are recommended for bearings operating at speeds above 10.000 rpm.
 Thicker lubricants are used for bearing working at low speeds.
 The load on bearing is also of great importance in the choice of lubricant.
 Bearing with considerable loads be lubricated with oils of a higher viscosity than bearing
operating under normal and small loads.
 At the temperature rises the viscosity of oil / greases decreases. Therefore a lubricant
which is satisfactory at normal temperatures may prove unsuitable at very low or high
temperatures.

Function of Lubricant
The functions of lubricant are the following:-
• To minimize mechanical friction
• Reduce the rate of wear
• Prevent dust and corrosion of the polished surfaces of the bearing.
• Dissipate some of the bearing heat and
• Act as partial seal, to prevent dirt from entering around the shaft.

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 The ideal lubrication for a sleeve bearing is one in which it is possible to maintain a state of
fluid friction between contact body(surfaces)of the metal such a condition can exist only
with high speeds and loads.

Maintenance

• Work that is done regularly to keep equipment, buildings and grounds in good condition and
working order
• All actions necessary for retaining an item, or restoring to it, a serviceable condition, include
servicing, repair, modification, overhaul, inspection and condition verification
• Increase availability of a system
• Keep system‟s equipment in working order
Objectives of maintenance General Objective

To maintain the optimum condition of physical facilities at acceptable levels and minimum
costs to satisfy the expected demands of programs and activities

Specific Objectives

1. To extend the useful life of assets.

2. To assure the optimum availability and operational readiness of installed equipment.
3. To obtain the maximum possible return of investments.
4. To ensure the safety of personnel using the facilities. Purpose of Maintenance

 Attempt to maximize performance of production equipment efficiently and regularly

 Prevent breakdown or failures

 Minimize production loss from failures

 Increase reliability of the operating systems

Principle Objectives in Maintenance

 To achieve product quality and customer satisfaction through adjusted and serviced
equipment
 Maximize useful life of equipment
 Keep equipment safe and prevent safety hazards
 Minimize frequency and severity of interruptions
 Maximize production capacity – through high utilization of facility
Problems in Maintenance
 Lack of management attention to maintenance

 Little participation by accounting in analyzing and reporting costs

 Difficulties in applying quantitative analysis

 Difficulties in obtaining time and cost estimates for maintenance works

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 Difficulties in measuring performance
Problems Exist Due To:
 Failure to develop written objectives and policy

 Inadequate budgetary control

 Inadequate control procedures for work order, service requests etc.

 Infrequent use of standards

 To control maintenance work

 Absence of cost reports to aid maintenance planning and control system Maintenance

Costs

 Cost to replace or repair

 Losses of output

 Delayed shipment  Scrap and rework

Maintenance Program

• a comprehensive list of maintenance and its incidence

• Long-term plan, covering all aspects of maintenance management which sets the direction
for maintenance management, and contains firm action plans for achieving a desired future
state for the maintenance function.

Run-to-Failure

• No Scheduled Maintenance - an Equipment Maintenance Strategy, where no routine

maintenance tasks are performed on the equipment.
• The only maintenance performed on the equipment is Corrective Maintenance, and then
only after the equipment has suffered a failure.
• Also described as a No Scheduled Maintenance strategy

Types of Maintenance
• Maintenance may be classified into four categories:
• (some authors prefer three categories- scheduled and preventive maintenances are
merged)
 Scheduled maintenance
 Preventive maintenance
 Predictive (Condition-based) maintenance
 Corrective or Breakdown maintenance

Scheduled Maintenance
 Scheduled maintenance is a stitch-in-time procedure and incorporates
– inspection
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– lubrication
– repair and overhaul of equipment‟s  If neglected can result in breakdown 
Generally followed for:
– overhauling of machines
– changing of heavy equipment oils – Cleaning of water and other tanks etc.

Preventive Maintenance

• Principle – “Prevention is better than cure”

• Procedure - Stitch-in-time

• It locates weak spots of machinery and equipment‟s

• provides them periodic/scheduled inspections and

minor repairs to reduce the danger of unanticipated
breakdown

• Schedule of planned maintenance actions aimed at the prevention of breakdowns

and failures
• Primary goal-Preserve and enhance equipment reliability
• Anything that increases life of equipment, and helps it runs more efficiently
• Preventive maintenance should be performed on most equipment as
recommended by the Manufacturer
• Examples o Oil changes o Greasing o Changing filters
o Belt tightening

Benefits of Preventive maintenance

 Increases life of equipment

 Reduces failures and breakdowns
 Reduces costly down time
 Decreases cost of replacement
Predictive Maintenance

• Techniques that help determine the condition of in-service

equipment in order to predict when maintenance should be
performed
• Primary goal – Minimize disruption of normal system
operations, while allowing for budgeted, scheduled repairs
• Predictive maintenance identifies trends and provides historical
data
• Predictive Maintenance shows condition of in-service
equipment, and predicts when corrective maintenance should be performed
• Example

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o Vibration Analysis o
Infrared Thermography o
Oil Analysis o Visual
Inspections
Benefits of Predictive Maintenance

 Provides increased operational life

 Results in decrease of downtime
 Allows for scheduled downtime
 Allows for money to be budgeted for repairs
 Lowers need for extensive parts inventory
 DOE reports
 an estimated 8-12% cost savings
 Reduction in maintenance costs – 25-30%
 • Elimination of breakdowns – 70-75%
 • Reduction of downtime- 35-45%
 • Increase in production – 20-25%
Corrective Maintenance

• Corrective or Breakdown maintenance implies that repairs are made after the equipment is
failed and cannot perform its normal function anymore

• Repair of equipment/machinery in order to bring it back to original operating condition.

• Important reminders
 Use original OEM parts
 Install per manufacturer‟s specs
 Don‟t take shortcuts
 Do it right
Disadvantages of Corrective Maintenance

 Breakdown generally occurs inappropriate times leading to poor and hurried maintenance

 Excessive delay in production & reduces output

 Faster plant deterioration

 Increases chances of accidents and less safety for both workers and machines

 More spoilt materials

 Direct loss of profit

 Cannot be employed for equipment‟s regulated by statutory provisions e.g. cranes, lift and
hoists etc..

Equipment File

• To ensure a quick and smooth planning of maintenance activities as well as the actual repair
job, it is advisable to maintain an equipment file for all equipment, used in the plant.
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• The following data should be included:
1. Specification
 Name of equipment
 Brand
 Model
 Date of installation
 Serial number
 Capacity
 Speed
 Load
2. Location 
Building
 Floor
 Department/Section
3. Spare part specifications
 Bearing
 Sealant
 Lubricant
 Drive
 Coupling

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4. History of Preventive Maintenance Activities and Repair Activities

Maintenance Schedule

• a list allocating specific maintenance to a specific period

• List of planned maintenance tasks to be performed during a given time period, together with
the expected start times and durations of each of these tasks.
• Schedules can apply to different time periods (eg. Daily Schedule, Weekly Schedule etc.)

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2.2.3 Saw tooth Setting
Correctly set teeth will cut a kerf just enough to give clearance to the blade. The kerf need
be no more than 1 ½ times the thickness of the saw blade. Only the height of each tooth is
set and the setting tool is called a saw set.
1. Secure the saw in the saw vice with the blade well exposed
2. Adjust the beveled anvil to the required amount of set for the saw
3. Start from the toe; identify the first tooth set away from you
4. Locate the hammer on that tooth and set it, using a firm, even
pressure
5. Set each alternate tooth on that side
6. Turn the saw around and repeat the setting procedure on the
unset teeth

Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. list importance of manufacturer‟s specifications and manuals (2 points

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 2. Types of Maintenance? (2 points)
3. Describe the functions of lubricant? (2 points)
4. What are Principle Objectives in Maintenance? (2 points)

Note: Satisfactory rating – 8 points Unsatisfactory - below 8 points

You can ask you teacher for the copy of the correct answers.

Name: _________________________ Date: _______________

Information Sheet-3 Sharpening of machine blades

Sharpening: One of the most important skills a woodworker can acquire is the ability to sharpen
tools easily and well. Working with hand tools can be a frustrating experience unless you have
sharp tools. The goal of this lesson is, with a minimum of equipment, is for you to be able to
produce razor sharp cutting edges on any tool blade consistently.
Sharpening hand saw procedure
The operation of sharpening, Joining, setting & filing
Jointing: - is known as topping is the process of running a file along the top the projecting
teeth of the saw until they equal of the teeth of height.
Setting: - the process of bending adjacent teeth of a saw the opposite side by saw setting
tools.
Filing: - is the process of sharpening knife proper angle

Portable Circular Saw

Keep the Saw blades Sharp
Using a dull saw blade can be extremely dangerous and provide poor cut quality.
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 Special equipment is necessary to properly sharpen a circular saw blade. An improperly
sharpened saw blade can injure the operator, destroy the saw, and damage the work piece.
 The saw blades should be sharpened regularly, and only by a qualified sharpening
service.
 Improper grinding of the carbide teeth of a saw blade can result in serious injury to the saw
operator.

Adjust and Inspect the Saw

To ensure the saw is in proper working order, periodically inspect the operation of the saw
and ensure it is properly adjusted.
 Observe the function of the saw during normal operation.
 Unusual sounds are indicative of pending problems.
 A reduction in the cut quality indicates the saw is either improperly adjusted or not
functioning properly.
 A reduction in cutting power or speed may indicate a dull blade or a motor problem.
 If any of the safety devices on the saw are inoperable or disabled, immediately stop using
the saw and have it serviced.
 Periodically inspect the wear bars for the guide rail cams for wear.

Operation Sheet 2 circular saw remove blades

 circular saw blades

 To remove the blade:-
Steps 1- Disconnect the power
Steps 2- Remove the throat plate
Steps 3- Select a wrench that fits the arbor nut.
Steps 4- Loosen the arbor nut.
Note: arbor nut is loosened in the same direction that the saw blade rotates or by
turning it in the direction the teeth are pointing

Steps 5- Remove the nut, collar and the blade.

Steps 6- blades secured (clamp)
Steps 7- Sharpe the blades by portable grinder

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 Process Type of Blade
Cross Cross cut,
Cutting Combination
Miter Cross cut,
Cutting Combination
Bevel Cross cut,
Cutting Combination
Elements of
Dadoing Dado Head
Circular Saw
Blades

Operation Sheet 3 Sharpening a circular saw blade

Sharpening a circular saw blade is something that should be done to maintain the life of the
saw blade for many years. To sharpen circular saw blade follow the following steps:- Step
One: Remove the Blade:-
 Remove the blade from a circular saw.
 This generally requires the use of an open-ended box wrench, although newer models may
have other blade releases.
Step Two: Secure the Blade down:- 
Secure the blade in a vice grip.
 The blade facing up with the teeth is towards us.
 It need to also be aware not to tighten the vice grip too hard or it will warp the metal that
holds the teeth.
Step Three: Make the Marks:-
 Make a mark at the top most point of the blade so that will be aware of when it has gone all
the way around the blade (and thus prevent double sharpening).

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 Step Four: Pay Attention to the Bevels:-
 Since the bevels appear on every other blade, skip one blade and go to the next beveled
edge.
 Repeat this process until you get around the entire blade, applying the same number of
strokes that you did with the first blade.
Step Five: Repeat on Other Side:-
 Turn the blade over when it has gone all the way around the blade, sharpening every other
point.
 This will know when it done because it will come back to the chalk mark.
 On the other side of the blade, put another chalk mark and do the something as we did to
the first side, starting with the top most point with a beveled edge.

Operation Sheet 4 Replacing the circular saw blade

Replacing the circular saw blades:

The following are the steps to be followed for replacing the circular saw blades.

Steps:

1. To replace the circular saw blades, reverse the procedures for removing

2. Make sure that the teeth of the blades point toward the operator

3. Replace the collar and tighten the nut securely.

Note: the arbor nut is tightened against, or opposite, the rotation of loosening during
operation.

4. Rotate the blade by hand to make sure that it is running clear. 5. Replace the plate or

metal insert

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 Operation Sheet 5 Changing Radial Arm Saw Blade

Changing Radial Arm Saw Blade

Steps 1- Shut off main power switch or disconnect from wall plug.
Steps 2- Select the proper type blade for the job.
Steps 3- Remove the saw guard, arbor nut and arbor collars. Remove the
blade.
Steps 4- Replace inside arbor collar with recessed face toward the blade.
Steps 5- Place the saw blade on the arbor so the teeth point in the direction of rotation.
Steps 6- Replace arbor collar and tighten the arbor nut.
Steps 7- Before replacing the guard, check the squareness of the saw blade. If out of
adjustment, consult the operator‟s manual for alignment procedures.

Sharpening/changing the standard planer knives

• Properly setting all three knives is essential to achieving accurate work results.
• Properly set knives will last longer and also keep their edge (sharpness) longer by equally
sharing the cutting workload.
• You may use the supplied knife setting gauge to help you set the knives to the correct height
whenever re-setting or changing knives.
Note: If you prefer you may also find other “aftermarket” gauges, jigs or knife
setting tools that are to your liking – ask your local tool distributor for information on
any such tools that may be available in your market.

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 Operation Sheet 6 Sharpening/changing the standard planer knives

The cutter head on this unit is supplied with

both adjustment springs and jack screws A
providing you with two options for setting the
knives. We suggest you try each method at
least once or twice and decide for yourself
which method works best and fastest for you.

1. Turn off and disconnect the machine from the

power source.
2. To give you unimpeded access to the cutter
head and knives, remove the cutter guard
and lower the tables as far as they go.
3. Remove the fence to have access to the
upper pulley and turn it by hand to rotate the
cutter head to access one of the knives.
4. Loosen (but don‟t remove) all the gib bolts B
start in the center and alternate sides (If
replacing an old or damaged knife, loosen
the bolts until the knife can be removed and
install a new sharpened knife). Then position
the gauge over the selected knife D.

5. a) To use the adjustment springs to set the knife

height: Push the knife down with the gauge so that
the edge of the knife is touching the center reference
pads on the gauge E. Hold the gauge down and
tighten the bolts B to secure the knife in place.
Repeat for the 2 other knives.

b) To use the Jack Screws to set the knife height:

Use an Allen key to turn the screws C to raise or lower the knife as needed until the ideal
position - both sets of feet of the gauge sitting flush on the cutter head and the knife barely
touching the center reference pads on the gauge E – has been achieved. Repeat for the 2
other knives.

6. Re-check the height setting on all the knives and re-

set if necessary.
7. Reset the tables and replace the fence and blade
guard.
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 IMPORTANT! After changing or resetting the knives, the out-feed (left) table height
must be re-adjusted to match the new height of the knives. Follow the instructions in
section

 Sharpening band saw blade

A band saw's job is cutting lumber, metal or meat with bone, so the abuse on the blade is
great. Sharpen a band saw when, become aware of it is no longer giving a smooth cut or it
becomes difficult to cut the material.

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 Operation Sheet 7 Sharpen the band saw blade

Steps 1- Wear safety goggles and ear plugs when you sharpen a band saw blade.
Steps 2- Remove the blade from the band saw. Follow the manufacturer's instructions.
Steps 3- Mark the blade, where to begin and stop when it sharpens a band saw
blade. Steps 4- Adjust the grinding parameter controls
and double check the teeth per inch and gullet depth
setting.
Steps 5- Set the grinding wheel depth and angle
adjustment. Make sure the grinding wheel makes
proper contact with the blade.
Steps 6- Prepared to turn the machine off when the
entire blade completes the sharpening process if it doesn't turn
off automatically. Remove the blade from the grinding machine
and put it on the band saw. Causes for band saw blade
breakage

The following factors are responsible for blade breakage. 1)

Use of defective blade caused from improper punching. Filing or welding 2)
Vibration of the upper wheel and uneven tension caused by frame.
3) Wheels out of balance. This causes uneven blade tension.
4) Too light a blade for work.
5) Twisting blade in the guides.
6) Sawing with a dull blade.
7) Improper tooth spacing for the work.
8) Blade running through worn guides.
9) Too much blade pressure on the guide thrust wheel.
10) Blade too tight in the guides.
11) Uneven blade off thickness.
12) Blade under excessive tension.
13) Throwing blade off the wheels.
14) Teeth not uniform in length.
15) Blade weaving or running back and forth across the face of the wheel.

Self-Check -3 Written Test

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Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. What are procedures for Sharpening hand saw? (2 points)

Note: Satisfactory rating – 2points Unsatisfactory - below 2 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 8 hours.
Task 1: Sharpening/changing Changing Radial Arm Saw Blade and Circular saw
Task 2: Sharpening/changing the standard planer knives

Information Sheet-4 Routine adjustments and repairs

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 Routine maintenance is the simplest but very essential form of maintenance system.
 Earlier the routine maintenance was considered about preventing failures.
 Today routine maintenance is being considered about avoiding, reducing or eliminating the
consequences of failures.
 As the name ach implies, it means carrying out minor maintenance jobs at regular intervals.
It involves jobs such as „cleaning, lubrication, inspection and minor adjustments pressure,
flow, tightness and tightening of loose parts etc. It also includes inspection of bearings,
Vbelts, couplings, jointing, foundation bolts, earthlings and protective covers etc.
 The small and critical defects, observed during such inspection, are rectified immediately
and bigger jobs are planned for rectification during next available shutdown. Such
maintenance is essential for effective scheduled preventive maintenance.
 Carrying out planned jobs regularly in simple cyclic schedule is very essential in routine
maintenance. Such schedules are simple (like check, clean, lubricate, tighten, adjust etc..
Portable Circular Saw
Dust and debris from some materials can be extremely abrasive and cause components
within the saw to wear prematurely.
It is important to keep moving parts cleared of abrasive dusts.
 As a general rule, keep the saw clean of all dust and debris. Even soft-wood dust can be
abrasive over time.
 Examine all moving parts for dust and debris.
 Keep the bevel hinges clean of dust using compressed air or cotton swabs. If the hinges
wear due to abrasive particles, the saw will not perform optimally.
 Keep the blade area and dust extraction port clean of debris. Debris can cause wear and
reduce the effectiveness of the dust extraction system.
 Periodically remove the blade cover, the blade, and the inboard arbor flange; and clean any
built up debris from the inside of the saw.

Changing the Motor Brushes

 The motor brushes are graphite bars that provide an electrical connection between the
motor controller and the rotating armature.
 When the brushes have worn past their useful length, spring loaded wear pins are exposed
that separate the brush from the armature contacts.
 This disables the motor to prevent damage. For a shorter break-in period without excessive
arcing, new brushes have ribs that quickly form to the curve of the armature.

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 Operation Sheet 8
Changing the Motor Brushes

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 Trouble shooting
Symptom Possible Causes

Motor does not  Check that the cord is properly plugged into an outlet.
start  Make sure the Plug-it connector is properly inserted and fully
tightened.
 Make sure the outlet has power. Check the circuit breaker or try
another outlet.
 The auxiliary outlet on the dust extractor has power only when
the selector is at Auto.
 Inspect the power cord (including extension cords) for damage
or missing prongs.
 The motor brushes may have worn and need replacement.
The saw makes  Make sure the guide rail gap cams are properly adjusted.
wavy cuts  Inspect the blade for damage.
 Make sure the sole plate is not rocking on the guide rail.
 Keep the blade depth consistent during the cut; don‟t raise and
lower the blade.
Saw cuts are  Make sure to use the correct blade for the material.
burning  Make sure the blade is sharp.
 Make sure the blade is installed correctly (not turning
backward).
 Reduce the motor speed.
 If possible, increase the blade depth.
 Increase your feed speed.

Operation Sheet 9 Maintaining or lubricating table saw

Table Saw
For your own safety, turn the switch OFF and remove the switch key.
Remove the plug from the power source outlet before maintaining or lubricating your saw.
Steps 1- Clean out all sawdust that has accumulated inside the saw cabinet and the motor.
Steps 2- Polish the saw table with an automotive wax to keep it clean and to make it easier
to slide the work piece.
Steps 3- Clean cutting blades with pitch and gum remover.
Steps 4- A worn, cut, or damaged power cord should be replaced immediately.
Steps 5- All electrical or mechanical repairs should be attempted only by a trained repair
technician.
Contact the nearest Sears Service Center for service.
Use only identical replacement parts. Any other parts may create a hazard.
Steps 6- Use liquid dish washing detergent and water to clean all plastic parts.
NOTE: Certain cleaning chemicals can damage plastic parts.
Steps 7- Avoid use of the following cleaning chemicals or solvents; ammonia and
household detergents containing ammonia.

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 Jointer
To prolong the service life of your jointer and to maintain optimum performance the following
basic maintenance procedures should be practiced and become part of your shop routine.
• Inspect/test the ON/OFF switch before each use. Do not operate the jointer with a damaged
switch; replay a damaged switch immediately.
• Keep the machine as well as the in-feed out-feed tables clean and free of saw dust,
woodchips, pitch or glue. Vacuum or brush off any loose debris and wipe down the machine
and the tables occasionally with a damp rag.
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• An occasional light coating of paste wax can help protect the tables‟ surface and reduce
work piece friction. Ask your local distributor for suggestions on aftermarket surface
cleaners, protectant and dry lubricants based on what is readily available in your area.
• Avoid using silicon based products that may affect or react with wood finishing products
such as oil, solvent or water-based stains, varnishes and lacquers.
• Periodically inspect the power cord and plug for damage. To minimize the risk of electric
shock or fire, never operate the planer with a damaged power cord or plug. Replace a
damaged power cord or plug at the first visible signs of damage.
• All bearings are sealed and permanently lubricated and no further lubrication is required.
The fence assembly and table ways also should not be lubricated. If you should encounter a
“sticking” problem, simply disassemble and clear away any obstructions from the ways.
• Regularly inspect jointed work pieces for
signs of knife damage or wear and replace
damaged or worn knives immediately.
• Inspect the belt regularly – To avoid
potentially costly downtime, consider
keeping a spare replacement belt on hand
for use if needed. Belts that show visible
signs of wear such as cracks or fraying at
the edges should be replaced immediately.

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 Operation Sheet 10 Checking/cleaning the kickback guards

Steps 1- Before beginning any maintenance work on the machine, switch it off and secure it
against accidentally being switched on again

Steps 2- Check if functioning: the kickback guards must fall back after having been lifted
Steps 3- Check if functioning:
• Push a planned board into the machine
• Adjust the height of the thickness table so that there is 0.5 to 1 mm gap between the board
and the cutter block‟s circle of cut
• It should not be possible to pull the board out of the machine  Push the board out of the
machine.
Steps 4- Remove any resin residue from table, kickback guards and cutter block.

Operation Sheet 11
Cleaning the feed rollers

Cleaning the feed rollers

Steps 1- Before beginning any maintenance
work on the machine switch it off
and secure it against accidentally
being switched on again Steps
2- Remove any resin residue on
the feed rollers:

! Feed rollers

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 Operation Sheet 12 Greasing the height spindle (thicknesser planing
table)

Operation Sheet Replacing the drive belt

13

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 Operation Checking/greasing the chain (transmission)
Sheet 14

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 Faults, causes and repairs

Woodturning Lathe

• Clean and oil the lathe bed so that headstock, tailstock and tool rest base will slide easily.
Clean any rust spots that may develop on the bed with a commercial rust remove

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• Use compressed air to blow out the interior of the headstock, in order to keep sawdust and
chips from accumulating on belts and sheaves. Also blow off debris that accumulates in the
motor fan and around inverter. Do not disassemble inverter to clean!
• Frequently clean out the Morse tapers on both headstock and tailstock.

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 Self-Check -4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. Define what is Routine maintenance? (3 points)

Note: Satisfactory rating – 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 15 hours.
Task 1: Identify personal protective equipment, select, use and maintain according to OHS
requirements.

Task 2: Use operator‟s manual/manufacturers specifications and supervisor's instructions for

Greasing, lubrication and other basic servicing of machinery and equipment
Task 3: Perform routine adjustments and repairs machinery and equipment according to
operators' manual/manufacturers‟ specifications and supervisors instructions
Task 4: Work is conduct according to OHS requirements and completed to supervisor's satisfaction.

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 Instruction Sheet LG03: Complete work
This learning guide is developed to provide you the nece ssary information regarding

the following content coverage and topics:

3.1. Steps in proper storing of tools

3.2. Collect, treat and dispose or recycle waste

3.3. Clean and maintain work area

3.4. Maintenance reporting procedure

3.4.1. Reports on faulty, Malfunctions, faults, and damaged tools

3.4.2. Reports on waste to be treated, disposed or recycled

This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:
• Conduct and complete the work according to OHS requirements
• Treat and dispose or recycle wastes from maintenance activities with OHS
• Report malfunctions, faults, wear or damage tools to the supervisor
• Clean and maintain work area according to OHS Learning Instructions:
11. Read the specific objectives of this Learning Guide.
12. Follow the instructions described below.
13. Read the information written in the information “Sheet 1, Sheet 2, Sheet 3 and Sheet 4”.
14. Accomplish the “Self-check 1, Self-check t 2, Self-check 3 and Self-check 4” in page -4, 6, 8
and 13 respectively.
15. Do the “LAP test” in page – 14 (if you are ready).

Information Sheet-1 Cleaning, returning and storing tools according to

manufacturer’s specifications
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Cleaning maintenance is the cleaning of equipment‟s, components, working tools, hands tool or
working gloves and workplace etc. Before taking repairs, during and after repairs is of main
importance, but is often not given due consideration.
Cleaning of components is, normally, assisted by kerosene, petrol, carbon-tetrachloride
(CTC) and many other solvents. Storing tools and equipment

Tools and equipment should be safely stored according to workplace Procedures. Generally,
this will mean returning items to their allocated place.

This could include shadow boards, cabinets, cupboards, power tool cases, cutter blocks,
drill bit containers, benches or storage racks. Tools and equipment must be put away so that
they can be easily located and accessed

Completing basic routine maintenance activities:-

 Execute regular maintenance activities according to scheduled plan.

 Maintenance procedures are followed in accordance with the manufacturers Manual and
organizational policies.

 Complex faults or repair requirements outside area of competence are reported for
specialist assistance in accordance with organizational procedures.

 responds to failed or unsafe equipment

 Maintenance and repair activities are documented and reported according to

Organizational policies.

Self-Check -1 Written Test

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 Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
3. List completing basic routine maintenance activities (4 points)

Note: Satisfactory rating – 4 points Unsatisfactory - below 4 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet-2 Collecting, treating and disposing or recycling wastes

The proper handling of the things we throw away in a manner that does not harm anyone or
anything, be it human, animals or the environment.

Waste: - Unwanted material or substance produced by human activities, which are usually
referred to as rubbish, trash, garbage or junk.

Types of Wastes

• Solid

• Liquid

• Gaseous
Proper handling: - includes the collection, transport, processing, recycling or disposal of
waste materials produced by human activity in order to reduce their negative effect on the
environment.

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 Waste Reduction: - the prevention of waste material.

3R Reuse, Reduce & Recycle Methods of Reusing and Reducing

1. Reuse of second-hand products

2. Repairing broken items instead of buying new

3. Designing products to be refillable or reusable

4. Encouraging consumers to avoid using disposable products

5. Designing products that use less material to achieve the same purpose

Self-Check -2 Written Test

Information Sheet-3 cleaning and maintaining working area

according to OHS

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. List types of Wastes? (2 points)

2. What are the Methods of Reusing and Reducing? (2 points)

Note: Satisfactory rating – 5 points Unsatisfactory - below 5 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Cleaning the work area
Safe work practices should be followed at all times. A clean work area is an important part of
having a safe work environment. On completion of each job

The assembly area should be cleaned, this includes the removal of all waste material, the
floor cleaned (swept/vacuumed) if necessary and all tools and equipment returned to their
allocated storage area.

 Cleaning up
When all the parts are assembled, your work area needs to be cleaned ready for the next
job.

In this section we will look at:

 cleaning the work area

 cleaning and maintenance of equipment

 waste disposal  Storing tools and equipment. Clean work shop site/area

 Always clean the work shop after done/ work.

 Separate workshops e.g.:- finishing machine, assembling, main store, and office &
class room.
 Remove out wastage raw material in the container.
 After using equipment & tools clean with sponge, rage, oil, turpentine & greases.
Implement Housekeeping Activities

 Regular inspections are carried out in the work area according to workplace procedures
and standards.

 Areas and amenities are cleaned and maintained in accordance with occupational Health
and Safety (OHS) and 5S procedures.

 Disposal of waste and dangerous chemicals are checked in accordance with OHS
regulations and organizational policies.

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 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. Describe the benefit cleaning and maintaining working area?

Note: Satisfactory rating – 3 points Unsatisfactory - below 3 and 4 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Information Sheet-4 Maintenance reporting procedures

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3.4.1. Reporting malfunctions, faults, wear or damaged tools

On completion of each job it is important that all the equipment you have used be cleaned
and checked for serviceability before being stored.

That Equipment is faulty or damaged should be tagged and reported to supervisor or

appropriate person. A suitable logging system should be used to identify Equipment or
materials that need to be serviced, repaired, removed, replaced or considered unsafe.
Maintenance records should include the following information:

 Name and model of equipment.

 Where equipment is usually kept.
 Unique identifier.
 Each task on the maintenance schedule.
 Frequency of each task.
 What is involved in each task.
 Result of maintenance and any actions resulting from the maintenance.
 Sign off by the person carrying out the maintenance.

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3.4.1. Reports on waste to be treated, disposed or recycled

Waste Disposal and Recycling

1. Be responsible for cleaning up workstations, tools and the shops.
2. Sort waste by category as required using approved containers.
3. Sort recyclable liquids and solids into proper approved storage container.
 Dust collection is best accomplished at the source-at the point of operation of the
equipment, if feasible. For many pieces of equipment, well-designed ducts and vacuum
hoods can collect most of the dust generated before it even reaches the operator.

 Very fine dust that manages to escape point-of-source collection can be captured from
above by general exhaust points located along the ceiling.

 These control technologies are effective for most equipment, excepting machines that
commonly produce the very finest dust or large quantities of dust.

 Good housekeeping extends to periodic hand cleaning of your entire facility, as some dust
will other Safety Hazards of Woodworking escape from even the best exhaust system and
will eventually accumulate on rafters and other out-of-the-way spots. Also, it is extremely

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 important to inspect and clean your exhaust ventilation system on a regular basis to
maintain maximum efficiency.

 Ensure the proper use and storage of flammable materials, such as paints, finishes, adhesives,
and solvents.

 Segregate tasks particularly prone to fire and explosion hazards, such as spray painting,
welding, and use of powder-actuated nail guns.

 Train employees to recognize, avoid, and correct potentially hazardous conditions and
behaviors. Train employees so that they are acquainted with the special equipment and
aspects of building design related to dealing with fires and explosions.

 Control ignition sources. This involves using electrical systems rated for the projected use and
protected by appropriate circuit breakers, grounding all equipment prone to accumulating static
electrical charges, grounding entire buildings against the possibility of lightning strikes, and
controlling and banning smoking in and around the workplace..

 Never permit blow-down of accumulated dust with compressed air. Blowing dust with
compressed air will create the very type of dust cloud that presents the greatest explosion
hazard.

 Provide continuous local exhaust ventilation on all woodworking machines. The local exhaust
systems must have a suitable collector. Dust collection systems must be located.

 Segregate combustible and flammable materials such as lumber stock and chemical solvents
from each other and from ignition sources.

 Ensure that you use equipment with a hazard classification appropriately rated for your work
environment

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 Weekly Inspection Report

Self-Check -4 Written Test

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 Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
1. What are Maintenance records should include?

Note: Satisfactory rating – 3 points Unsatisfactory - below 3 and 4 points

You can ask you teacher for the copy of the correct answers.

Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the following
tasks within 3 hours.
Task 1: Conduct and complete the work according to OHS requirements

Task 2: Treat and dispose or recycle wastes from maintenance activities with OHS

Task 3: Report malfunctions, faults, wear or damage tools to the supervisor

Task 4: Clean and maintain work area according to OHS

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 REFERENCES

 Wood working text book

 Woodworkers' Guide to Sharpening, by John English, Fox Chapel Publishing, 2008
 Illustrated Guide to Sharpening, by Thomas Lie-Nielsen, Taunton Press, 2004
 Sharpening, by Nick Engler, Rodale Press, 1994
 The Complete Guide to Sharpening, by Leonard Lee, Taunton Press, 1995
 How To Sharpen Every Blade in Your Woodshop, by Don Geary, Betterway Book machinery
component maintenance and repair

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