Revision C&G 4510
Unit 225 Engineering Maintenance
• Name 2 actions before removing guards to service a machine
• Give the method to braze together 2 pieces of steel
• Before using a Mains powered hand drill give 2 checks to make sure
the drill is safe to use
• Explain how 2 basic guages can give the fluid level in a machine
• What information needs to be provided to obtain a permit to work
• How could you use a log of previous repairs to help repair a machine
• Name 2 actions before removing guards to service a machine
• Barriers in place to prevent others coming into the area
• Work on the machine must be stopped to prevent getting tangled in the
machine
• Isolate the machine and lock off to prevent electric shocks
• Clean the machine to remove danger from swarf or contamination
• Give the method to braze together 2 pieces of steel
• Clean surfaces to ensure good contact with braze
• Assemble joint
• Apply flux
• Heat using appropriate method (flame or induction)
• Add filler metal
• Allow to cool
• Before using a Mains powered hand drill give 2
checks to make sure the drill is safe to use
• Visual inspection for cracks etc
• No exposed wiring or damaged insulation
• If using screwdriver bits make sure they fit the
fasteners
• Check unit is earthed or double insulated
• If using drill bit make sure it is not damaged
• Explain how 2 basic guages can give the fluid level in a machine
• Flow meters showing the flow of fluid in or out of machine
• Graduated scale on a clear tube external to machine
• Window in the side of the machine with marks for high low
• Manometers external to machine
• What information needs to be provided to obtain a permit to work
• What is to be done
• How is the work to be carried out
• Who is going to do the work
• Time frame for the work
• Precautions for safety
• How could you use a log of previous repairs to help repair a machine
• Helps identify repeated faults quicker
• Shows trends (things getting worse)
• Dates to show external influences e.g. certain operators
Revision 2nd session
• Explain fault finding using the input output method
• What is the meaning of hazard in risk assessments
• What is the meaning of risk in risk assessments
• What is the meaning of control measure in risk assessments
• What types of fault can be found by carrying out alignment checks
• Explain how to splice (join) 2 electrical cables together
• Explain how to re-assemble a machine after someone else has
replaced a part.
• Explain fault finding using the input output method
• You have a known input coming in
• Check that the output is as you would expect
• What is the meaning of hazard in risk assessments
• Something that can cause injury
• What is the meaning of risk in risk assessments
• Impact of the hazard when it occurs e.g. fragments in the eyes leading to
blindness.
• What is the meaning of control measure in risk assessments
• How you will eliminate, mitigate or reduce the risk from happening
• What types of fault can be found by carrying out alignment checks
• Linear misalignment
• Angular misalignment
• Parallel or vertical or horizontal misalignment (called offset)
• Damage in coupling leading to misalignment from looseness.
• Explain how to splice (join) 2 electrical cables together
• Ensure cables are isolated from power
• Remove insulation from 30mm at end of each cable
• Slide heatshrink onto one end of wire
• Twist wires together
• Use soldering iron and solder to apply heat and melt solder onto wires
• Shrink heatshrink over the join to insulate
• Strip insulation from ends of wires
• Push the stripped wires into a crimp connector and crimp with crimping tool
• or push stripped ends into Wago connector and close the levers to join wires
• Explain how to re-assemble a machine after someone else has
replaced a part.
• Identify parts to be refitted, make sure they are clean
• Look for proof marks for orientation and location
• Rebuild all sub-assemblies before rebuild
• Replace “lifed” parts
• Set the relative position of parts e.g. gaps, end float, clearance etc.
• Re attach access panels
• Check all fixings and retaining devices are tight and secure
• Check all moving parts can move e.g. rotate or slide
