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Mechanical Maintenance and Systems
Length: 36 Hours

Course Number: M-326
Maximum Participants: 10 Students

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Course Description: The Mechanical Maintenance and Systems training course is designed to educate the student about various aspects of mechanical systems and their maintenance requirements. The course will be customized to address specific customer equipment and needs. Students will complete this course with a thorough understanding of maintenance management, mechanical energy transfer, vibration, fastening, bearings, speed reducers, belt and chain drives, lubrication and other mechanical processes. Each module of this course stresses to the student the importance of efficiency, cost savings and safety. This course presents a basic education in common mechanical systems. A customer requiring additional instruction in a particular module or wanting to remove a module due to specific facility requirements can be accommodated.
Prerequisites: There are no specific prerequisites for this course, however it is helpful if the student has an awareness of basic mechanical components and processes.
Course Objectives:
Students completing this course will be able to demonstrate an understanding of common mechanical systems and prove knowledge of selection, utilization and maintenance of those mechanical systems.
Outline:
  • Maintenance Management: at the completion of this module, students will have a thorough understanding of maintenance management systems including Reactive Maintenance (RTF), Preventative Maintenance (PMS) and Pro-active Maintenance (PROG).

  • Principles of Precision Maintenance: this module will expose the student to the techniques of reading and following manufacturer's service manuals, disassembly, troubleshooting and reassembling equipment, calculating operating efficiency, life expectancy and operating costs.

  • Mechanical Energy Transfer: at the completion of this module, students will have an understanding of how electrical energy is converted to mechanical energy and understand the relationship between horsepower, torque and RPM in an electric motor.

  • Precision Measuring: this module gives the student exposure and training on the use of precision measuring devices such as dial indicators, dial and digital calipers and micrometers that will be used for troubleshooting equipment problems and calculating wear.

  • Bearings: students completing this module will have a thorough understanding of radial, angular contact and thrust bearings. Topics covered include the importance of selecting the proper bearing, proper handling and installation of a bearing, identifying proper tolerances and fits, understanding the relationship between bearings and lubrication, selecting the proper lubrication and lubrication intervals and identifying bearing failures, their causes and prevention.

  • Industrial Lubrication: students completing this module will have an understanding of tribology, be able to identify the four classes of lubricants and understand how to select the proper lubrication for the application. Students will be given instruction on how to establish a pro-active lubrication maintenance program and study the importance of good housekeeping required for proper equipment operation.

  • Understanding and Measuring Vibration: completing this module will give the student a basic understanding of the causes of vibration and the damage that can result from vibration in a mechanical system. Students will study the relationships between vibration velocity, acceleration, frequency, amplitude and peak-to-peak as shown on a vibration sine wave. Students will learn how a vibration analyzer measures velocity, Gs and Bearing Damage Unit (BDU) and how to use an analyzer to identify causes of vibration.

  • Fastening and Torque: this module gives the student an understanding of the physics of how a bolt is utilized as a fastener, how the coefficient of friction affects the bolt threads and the importance of identifying each bolt’s torque rating. Additionally, students will learn the importance of proper torque and the use of a torque wrench.

  • Couplings: at the completion of this module, students will have an understanding of the application and alignment requirements of rigid and flexible couplings, the importance of the proper assembly of the coupling hub on the shaft and how to measure runouts.

  • Keys and Keyways: this module teaches the student how to properly specify and utilize a set screw and key, calculate the proper fit between the key and keyway and develop an understanding of how an incorrectly sized key can affect balance and cause destructive vibration.

  • Speed Reducers: this module teaches the student what a speed reducer is and how it functions and how the speed reducer creates a mechanical advantage or disadvantage. Students will calculate speed reducer ratios to achieve specific input and output results. Students will identify differences between gears used in parallel, intersecting and cross over shafting, study the advantages and importance of gear tooth profiles, backlash and end tooth clearance. Students will set and check gear backlash and end clearances.

  • Belt, Chain Drive and Conveyor Calculations: this module instructs the student on the differences between friction drives and positive power transmission drives, identifying broken and worn out components and completing the proper steps of belt and chain installation, alignment and tension. Students will receive instruction on the relationship between RPM, Diameter and Feet Per Minute as it relates to conveyor operation and will practice the techniques needed to modify belt speeds through mechanical changes.

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