Explores the subject of troubleshooting and the importance of proper maintenance procedures. Covers working with others, aids in communication, and trade responsibilities. Outlines troubleshooting techniques and aids, using schematics and symbols. Focuses on specific maintenance tasks, breakdown maintenance, and planned maintenance.
Lesson 1 - Introduction to Troubleshooting
Troubleshooting skills, duties, aids; Mechanical and electrical troubleshooting; Maintenance organizations and personnel; Scheduling
– Tell why efficient troubleshooting is important in a production plant.
– Name the four common troubleshooting aids.
– List the steps in troubleshooting a machine.
– List the steps in troubleshooting a system.
– Describe a typical maintenance organization.
Lesson 2 - Working with Other People
Communication; People skills; Aids to communicating; Differences of opinion; You and your supervisor; Upgrading your skills
– Tell why good communication between plant personnel is needed.
– List the ways a person usually sees himself/herself.
– Explain the communication cycle.
– Explain the correct method of delivering a written message from your supervisor to another person.
Lesson 3 - Troubleshooting Techniques
Job responsibilities; Recognizing normal operations; Testing and observation; Reducing downtime; Routine and emergency repairs
– List the steps to recognizing normal machine operations.
– List the questions you should ask yourself when a machine fails.
– List the signs of a machine in need of service.
Lesson 4 - Aids to Troubleshooting
Drawings, blueprints, and sketches; Manufacturer's literature; Service reps; Planned-maintenance records; Work orders; Test equipment
– Describe a blueprint.
– List the information that should be recorded in a machine equipment record.
– Identify calibration standards.
– Identify a multimeter (VOM).
– Identify different troubleshooting test equipment.
Lesson 5 - Preparing for Troubleshooting
Tools, parts, and supplies; Safety rules; Using charts and diagrams; Correcting malfunctions; Keeping records
– List the information you must know about mechanical or electrical systems before you can troubleshoot them successfully.
– Name the commonly used items that should be carried in every troubleshooter's tool box.
– List the steps to follow in reading a pneumatic or hydraulic schematic.
– List the responsibilities of a troubleshooter.
Lesson 6 - Using Schematics and Diagrams
Piping, compressor, and engine schematics; Hydraulic, pneumatic, and electrical schematics; Lighting diagrams; Troubleshooting charts
– Discuss how to use schematics when troubleshooting.
– Identify differences in schematics.
– Explain how to use a troubleshooting chart.
Lesson 7 - Solving Mechanical Problems
Bearing, pump, and piping problems; Compressed-air, refrigeration, and pollution-control equipment; Hydraulic systems; HVAC
– Identify bearing wear problems.
– Identify pump failure problems and solutions.
– Identify types of hosing.
– Identify different plant equipment and their problems.
Lesson 8 - Solving Electrical Problems
Generation and distribution; Feeders and branch circuits; Fuses and circuit breakers; Testing for continuity; Safety; Troubleshooting
– State the definition of switchgear.
– Identify current voltage characteristics of wire.
– List the safety rules to follow when working with electrical equipment.
– Identify a pictorial diagram, a block diagram, and a schematic diagram.
– Explain how to troubleshoot an electric problem.
Lesson 9 - Breakdown Maintenance
Work-order procedures; Preparing for emergencies; Skills for emergency work; Using downtime
– Explain what to do if you are the first member of the emergency crew.
– Explain the spare parts requisition form.
– Discuss the four main parts of practical machine maintenance.
Lesson 10 - Planned Maintenance
Frequency and benefits; Unscheduled maintenance; Keeping records, Lubrication charts and tags
– State the definition of planned maintenance.
– List the information that should be included on record sheets or file cards as part of the machine inventory.
– List the benefits to be accrued from an effective lubrication program.
– Describe the proper sag in a drive chain.
– Explain how to service a battery properly.