Before you start to work make sure of the following:
1. Clean the work area. A clean work area is a safe work area.
2. Make sure that there are no oil or water spills on the floor.
3. Store all unused tools so that they are not in the way.
4. Dispose of used parts and packaging according to regulations.
5. The working area should be free of waste and off-cuts.
6. Check plugs and power cords for any damage.
7. Make sure that work area is well ventilated and that the lighting is good.
8. Make sure lifting equipment is available and in working order when working with heavy materials.
9. Make sure lockout devices are in place where necessary.
10. Know the equipment and machines.
11. Wear the appropriate PPE. (Personal Protective Equipment)
12. Put up screens for welding.
13. Store dangerous chemicals in a safe place.
14. Make sure warning and safety signs are in place.
Step 1: select the tools and equipment that you need to finish the service.
Step 2: Inspect the parts. (before you start or even before you leave the shop.
Step 3: Arrange the component of the machine you took appart.
Step 4: Clean all the components.
Step 5: Replace the faulty parts with new parts or repare the faulty parts.
Service and record results
1. Use the manufacturers service manuel:
this manual contains a list of the parts used to built the machine.
this manual contains graphical drawings of parts and how they fit together.
this manual give step by step instructions of how parts fit together.
this manuel give you all specifications for the parts.
this manual give you all the torque settings for the nuts and bolts.
2. install the replacement parts into the component:
3. Inspect the assembly:
check the assembly for obstructions
check that the component move or rotate freely
Check that all the components is correctly aligned
4. Check torque settings:
We use a torque wrench to tighten nuts to the correct specified torque. Torque is the power that make something turn around a central point. Manufacturers provide torque specifications
the formula used is: T = F x S = NM where T = torque, F = force and S = distance. NM = Newtons meter.
5. Manually check the component for operation:
If you have replaced and reasembled parts and components, check them by hand to make sure they work propperly and smoothly.
Rotate gears and belts by hand to make sure of their alignment.
Test V-belt tension with a reliable belt tensioner
Finally start the engine and make sure there are no abnormal noise or vibrations.
6. Record service information:
When finished with the service write a report that include the following:
1. the date that service was completed
2. the parts that were replaced
3. information of the replaced parts (type, brand name, lubricants used etc.
4. reason why machine broke down or parts replaced.
5. when next service is due
6. name and signature of artisan that performed the work.
7. some firms has printed reports where you only tick off what you have done.
Example of a service report:
Date: 17 December 2016
Reason for breakdown: Because of a worn fan belt the engine overheated and the battery did not charge fully.
Parts replaced: Worn Fan belt and faulty pulley. We also replace the water in the radiator and top it up with antifreeze.
Next service: Your vehicle is due for a service at 120 000 kilometers but not later than 17 December 2018.
Name of technician: (your name and surname)
Dismantle and clean components:
Ensure that work area and conditions are free of obstacles:
1. Remove obstacles and tools from workbench to ensure you have enough room to work.
2. Pick up tools from floor and store them away.
3. Close lubricants and fluids and store them in proper storage.
4. Dispose of any waste materials (safely)
5. Remove/dispose of all components from previous job. If these components must be returned to the suppliers they should be labeled and packed.
6. Clean any fluid spills.
7. Wipe the workbench
You can control the hazard circumstances in your workplace:
1. Flammable and toxic materials and fluids must be kept sealed or closed.
2. Report poor electrical cables and connections.
3. Make sure the machine you are working on is stable and supported.
4. Make sure your work piece is secured before you start .
5. Work in well ventilated area.
6. Wear appropriate PPE
7. Make sure the lighting is sufficient.
8. Control dust and dampness.
9. Before you start working, check that the workplace, work area and machinery are clean, safe and in good working order.
Inspect your work piece/component before disassembly:
1. make sure that you know how the component fit together.
2. it will help to make a scetch of the component before you start.
3. while you are inspecting the component, make sure you know in wich order to take it appart.
4. Pre-clean the component:
5. cleaning the component make it easier to see how it fit together and to see any cracks or breakages 6. because it removes the dirt and crime that may cover the defects.
7. All cleaning agents may not suit all materials to be cleaned. Make sure you use the correct cleaning agents.
8. Consult the technical manual for correct cleaning agents.
Inspect and diagnose components:
When you dissasemble the components, you must look for signs of wear and tear, cracks or other damage.
Damage can take different forms:-
cracks
chips
change in shape
deterioration
change in size
loss of elasticity
rounding of corners.
While you are inspecting the parts, ask yourself the question if these parts are still good enough to function on the component. Will they last until the next service or will they cause untimely breakdowns. If so, replace them.
Do a final cleaning with cleaning equipment.
It is important to inspect components for defects. Defects are not always obvious. Keep the following in mind with your inspection:
a) the function of the components.
b) the conditions it must work in (hot, cold, humid, etc)
c) sort of stress put onto the parts or components.
If the component can not function properly in these conditions, determine why not and repair/ replace them.
The following conditions can influence the components:
Wear: - Sometimes the wear that took place is obvious. However, make sure that you inspect all sides of the component for wear. Then decide if the wear is af such an extend that the part must be replaced.
Assemble and test components:
Before you start you must select the tools and equipment to use for the assembly.
Some tips for assembly:
1. do not use pliers to loosen nuts and bolts.
2. do not use a hammer on a spanner or a screwdriver
3. do not extend the length of a spanner by putting a length of pipe over it.
4. do not throw tools or leave them lying around
5. do not use power tools with faulty or damaged plugs or wiring
6. use a deep penetrating solvent (Q20) to loosen tight nuts
7. Use the correct size spanner
8. Clean tools after use
9. Check tools regularly for wear and tear or damage.
Fit the components in time:
You do not want to finish the assembly and find spareparts still lying on the workbench.
Make sure that you work correct and fit everything correctly
Plan how you are going to finish the job before you start
Make drawings and know how the pieces fit together
Check the quality of your work as you proceed
Check assembly and record results:
Once the the equipment has been assembled test it by rotating it by hand.
start the machine to see if it perform as expected
While the machine is running, check for the following obvious signs:
1. overheating
2. vibrations
3. noise levels
4. component expectancy
5. kilowatt ratings up to standard
6. overall performance.
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