Basics of Industrial Maintenance

Table of Contents

Chapter 1: Introduction to Safety

Topics: Responsibility for safety; Unsafe acts and conditions; Recognizing hazards; Types of accidents; Investigation; Handling emergencies

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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

Learning Objectives:

• 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.

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