Basics of Industrial Maintenance
Course Number: 707
Covering safety, electricity, hydraulics, pneumatics, lubrication, and systems maintenance and related topics, this is our most comprehensive offering in this area. Also suitable as a general overview or per-requisite for industrial technology/maintenance programs with an electromechanical slant.
Recommended Contact Hours - 23
Chapter 1: Introduction to Safety
Topics: Responsibility for safety; Unsafe acts and conditions; Recognizing hazards; Types of accidents; Investigation; Handling emergencies
- Define the terms accident and hazard.
- Name and define the four main types of hazards.
- List and define various types of accidents.
- Compare meanings of the terms unsafe act and unsafe condition.
- Name the three ways in which a toxic substance can enter your body.
- List ways in which a company must plan for emergencies.
- Tell the main reason for prompt accident investigation.
Chapter 2: Principles of Electrical Safety
Topics: Importance of electrical safety; Lockout; Power equipment and portable power-tool safety; Personal precautions; Working on electric circuits; Switches; Fuses; Working around motors and other equipment; Protection against accidental grounding; Eye injuries; Fire prevention
- Explain the difference between low voltage and safety low voltage.
- Demonstrate what to do if a person suffers a severe electric shock.
- Explain how to fit an older tool with a three-wire cord.
- List the precautions that apply to personal safety in electrical work.
- List safety devices and apparel to use when working on conductors that may be energized.
Chapter 3: Electrons in Atoms
Topics: Structure of matter and atoms; Electron shells; Transferring charges; Electrical forces and terms
- Describe the structure of an atom.
- Tell the difference between a compound and an element.
- Explain how electrical forces cause objects to attract or repel other objects.
- Describe electron flow.
- State the definition of a cell.
Chapter 4: Current Electricity
Topics: Electric current and energy; Electricity from chemical action; Primary and secondary cells; Batteries; Electricity from electromagnetism
- List the main methods of producing potential difference.
- State the main difference between a primary cell and a secondary cell.
- Explain how to connect cells in parallel and in series.
- Describe how a photoelectric device works.
- Identify potential hazards when recharging batteries.
Chapter 5: Current, Resistance, and Voltage
Topics: Electric current, resistance, and potential difference; Ohm's Law; Resistance and voltage drop; Electrical measurement
- State the characteristics of an electrical conductor and an electrical insulator.
- State the definition of electric current.
- Explain the relationship of potential difference to the flow of electric current.
- State the definition of Ohm's Law.
- Identify the purpose and parts of an ammeter.
Chapter 6: Principles of Hydraulics
Topics: Force, weight, mass, pressure, work, power, and energy; Incompressibility; Nondiffusion; Hydrostatic pressure; Pascal's Law; Fluid power transmission; Bernoulli's principle
- Explain the difference between absolute and gauge pressure.
- Demonstrate how power is calculated.
- Explain Pascal's Law.
- Describe the difference between laminar and turbulent flow.
- Name the main components of a hydraulic system.
Chapter 7: Hydraulic Diagrams
Topics: Definition, kinds, and characteristics of schematics; Lines; Symbols; Flow patterns; Tracing a circuit; Sequence valve circuit
- Name three basic types of hydraulic diagrams, and explain the purposes of each.
- Describe how a valve symbol is constructed.
- List the steps to follow when reading a schematic diagram.
- Identify common hydraulic symbols.
Chapter 8: Maintaining Hydraulic Systems
Topics: Inspections; Maintenance requirements; Fluid level; External leaks; Operating pressure; Fluid quality; Filter maintenance; Reconditioning
- List the major categories of hydraulic system maintenance.
- Name and describe the six essential items in a maintenance file.
- List the steps involved in reconditioning a hydraulic component.
- Explain how to set up a maintenance plan for a typical hydraulic system.
Chapter 9: Principles of Pneumatics
Topics: Fluid power systems; Force, weight, and mass; Pressure; Work and energy; Diffusion and dispersion; Compressibility; Laws of pneumatics; Leverage; Air properties and flow; Bernoulli's Law; Components
- Explain how force is transmitted in a pneumatic system.
- Calculate force and work.
- List two factors that affect the results of pressure calculations.
- Explain pneumatic leverage.
- Briefly explain the physical laws affecting the behavior of a confined gas.
Chapter 10: Pneumatic Systems
Topics: Air supply system; Reciprocating and rotary compressors; Cooling; Compressor maintenance; Air-line filters and lubrication
- Explain the operation of linear actuators-cylinders-in a typical pneumatic circuit.
- Describe the various types of compressors and how they work.
- Define intercooling and aftercooling.
- Describe basic preventive maintenance procedures for compressors.
- List the components of an effective delivered-air system and explain how they work together.
- Describe the three main types of air-line lubrication.
Chapter 11: Systems Maintenance
Topics: Control system maintenance; Cylinder maintenance; Tool maintenance; Logs and records; Automatic recorders and recording charts
- Explain the concept of planned maintenance.
- Describe the basic procedures for maintaining the compressor and other important components in a pneumatic system.
- Describe the maintenance of industrial control circuit components.
- Explain the proper maintenance of pneumatic tools.
- Discuss the various types of maintenance logs and explain what kind of information is recorded in each.
Chapter 12: Bearings and Shafts
Topics: Bearing classification and selection; Shaft materials and stresses; Vibration; Critical speed; Fits and clearances
- Name the two main categories of bearings and cite their advantages.
- Identify bearings by the kind of support they provide.
- Describe the three kinds of stresses acting on shafts.
- Explain natural frequency of vibration and critical speed.
- Name and describe three classes of fits.
Chapter 13: Ball and Roller Bearings
Topics: Ball and roller bearing design; Single-row radial, single- and double-row angular contact bearings; Two-piece, inner-ring bearings; Roller bearings
- Name the three basic ball bearing designs and describe their characteristics.
- Explain the purposes served by the basic roller bearing shapes and their variations in typical applications.
Chapter 14: Principles of Lubrication
Topics: Lubricant classification; Friction; Cooling and sealing action of lubricants; Corrosion prevention; Preventive maintenance
- Define lubrication and describe the four forms of lubricants.
- Discuss the characteristics of static, kinetic, fluid, and rolling friction.
- Explain how a lubricant reduces wear and dampens shock.
- Discuss the cooling action of lubricants and explain how they prevent corrosion.
- Explain the importance of a lubricant's sealing action, and explain how it works.
Chapter 15: Lubrication Management
Topics: Lubrication control; Establishing oiler routes; Coding lubrication points; Computer-managed programs; Installation; Computer reports
- Explain the importance of good lubrication management practices and describe seven different kinds of information that should be included on an equipment lubrication survey form.
- Explain how to set up an oiler route and how to color-code the lubrication points.
- Discuss the considerations involved in establishing and installing a computerized lubrication program.
- Describe the purposes of several types of basic computer lubrication forms and list advantages of expanded programs.