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MECHANICAL
MAINTENANCE
BASIC
HYDRAULIC MAINTENANCE
BASIC
BEARING MAINTENANCE
BASIC
CENTRIFUGAL PUMPS
GEAR
REDUCTION UNITS
LUBRICATION
MECHANICAL
COUPLINGS AND ALIGNMENT
SEALS
AND GASKETS
VALVES
AND VALVE MAINTENANCE
BELT
AND CHAIN DRIVES
Title:
BASIC HYDRAULIC MAINTENANCE
Code: BHM:
Produced by Tech AV
Series content: 3
x Video tapes 1x Instructors' manual 1x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Maintenance Personnel.
BHM - 1: OVERVIEW
OF HYDRAULICS & HYDRAULIC SYSTEMS
Training objectives:
Describe the
principles of energy or power transmission through fluids.
Identify by name,
the principle components that comprise a typical light industrial
pre-pack unit.
Describe the basic
operating functions of the principle components.
Describe and
explain the need for filters and strainers.
BHM - 2:
MAINTENANCE PROCEDURES ON TYPICAL SYSTEMS
Training objectives:
Describe the
procedures for working with hydraulic oil (identifying and handling
of hydraulic oil).
Check and top up
oils in hydraulic systems.
Renew pressure
line filters, return line filters, return line filters.
Renew and/or clean
suction strainers.
Perform general
maintenance procedures.
BHM - 3: FAULT
DIAGNOSING & READING CIRCUIT DIAGRAMS
Training objectives:
Identify and
report on system faults.
Read a (basic)
circuit diagram for an industrial system.
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Title:
BASIC BEARING MAINTENANCE
Code: BBM:
Produced by Tech AV
Series content: 5
x Video tapes, 1x Instructors manual, 1x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians.
BBM-1: AN OVERVIEW
OF BEARINGS AND BEARING MAINTENANCE
Training objectives:
Recognise and
describe the commonly used bearings.
Describe the
general principles of maintenance on bearings.
BBM-2: PLAIN
BEARINGS (BUSHINGS)
Training objectives:
Remove and replace
plain bushings.
Remove and replace
automotive shell type bearings.
Check running clearance.
BBM-3: REMOVAL AND
REPLACEMENT OF ANTI-FRICTION BEARINGS
Training objectives:
Demonstrate the
removal and replacement procedures of a single race ball or roller
type bearings
using the
following methods:
Mechanical pullers.
Hydraulic press.
Hammers, drifts or drivers.
Thermal devices
for mounting.
BBM-4: SERVICING
Training objectives:
Replace a set of
taper roller bearings in a wheel hub.
Adjust tolerances
using a typical procedure.
BBM-5: BEARING
FAULT DIAGNOSIS
Training objectives:
Identify common
bearing faults by analysing certain wear or damage.
Describe possible
corrective methods.
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Title:
BASIC CENTRIFUGAL PUMPS
Code: BCP:
Produced by Tech AV
Series content: 4
x Video tapes, 1x Instructors manual, 1x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians,
Maintenance Personnel.
BCP-1: AN OVERVIEW
OF CENTRIFUGAL PUMPS
Training objectives:
Describe the
operating principles of centrifugal pumps.
Identify pump types.
Describe basic
pumping principles.
Describe basic
maintenance and operator principles.
BCP-2: DISMANTLING
AND RE-ASSEMBLING SINGLE STAGE PUMPS
Training objectives:
Describe parts and
functions of a typical single stage centrifugal pump.
Dismantle, inspect
and re-assemble a typical CZ or AZ type pump.
BCP-3: DISMANTLING
/ COMPONENT INSPECTION MULTI-STAGE PUMPS
Training objectives:
Dismantle and
inspect a multi-stage centrifugal pump of Sulzer HPL design.
BCP-4: ASSEMBLING
MULTI-STAGE PUMPS OF HPL DESIGN
Training objectives:
Assemble a
multi-stage pump of Sulzer HPL design.
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Title:
GEAR REDUCTION UNITS
Code: GRU:
Produced by Tech AV
Series content: 3
x Video tapes, 1 x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians,
Maintenance Personnel.
GRU - 1: AN
OVERVIEW OF GEARED REDUCTION UNITS
Training objectives:
The purpose of reducers.
How the reduction
of speed in rpm is controlled by using gears.
How gears can be
arranged in stages to achieve high reduction .
Identify gear
types (spur, single-helical, double-helical, straight bevel gears,
spiral bevel gears and worm) and the most commonly encountered gear
reduction units in industry.
GRU - 2: ROUTINE
SERVICING PROCEDURES
Training objectives:
Routine procedures
normally carried out by plant maintenance personnel on typical gear
reduction units.
Oil level checks,
topping up of oil and prevention of oil related problems.
Preventive
maintenance inspection of reduction unit.
Safety procedures.
Replacement of a
rotary shaft oil seal (in-situ replacement and on-bench replacement).
GRU - 3: WORM
DRIVE UNIT OVERHAUL
Training objectives:
Dismantling a
single reduction worm drive reducer of the Radicon type.
Inspection procedures.
First stage
re-assembling procedure.
Tooth contact
adjustment and final assembly procedure.
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Title:
LUBRICATION
Code: LUB:
Produced by Tech AV
Series content: 4
x Video tapes, 1 x Trainee workbook.
Suitable for:
Basic Engineering Students Plant Operators Maintenance Workers.
LUB - 1: WHAT IS LUBRICATION?
Training objectives:
Describe friction
and the need for lubrication.
Explain different
types and grades of lubrication used for different applications.
Explain how to
find out what types and grade of lubrication to use.
Explain the
importance of using the correct / recommended lubricants.
LUB - 2: SAFETY
AND HANDLING OF LUBRICANTS
Training objectives:
Apply relevant
hand protection agent.
Describe safe
methods for manipulating heavy drums.
Describe safe
handling methods for grease.
Describe safe
"house keeping" for lubrication areas.
LUB - 3:
LUBRICATION EQUIPMENT
Training objectives:
Identify by name
and describe the function of typical lubrication dispensing and
disposal equipment.
Prepare greasing
equipment for use.
Prepare oil
dispensing equipment for use.
LUB - 4:
LUBRICATION PROCEDURES
Training objectives:
Perform an oil change.
Perform a grease service.
Pack a bearing.
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Title:
MECHANICAL COUPLING AND ALIGNMENT
Code: MCA:
Produced by Tech AV
Series content: 4
x Video tapes, 1 x Instructors manual 1 x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians,
Maintenance Personnel.
MCA - 1: OVERVIEW
OF MECHANICAL COUPLINGS & ALIGNMENT PRINCIPLES
Training objectives:
Identify commonly
used linear couplings.
Describe the
principles of machinery alignment.
Perform an
alignment preparation.
MCA - 2:
"BIBBY" COUPLINGS (STEEL GRID COUPLINGS)
Training objectives:
Identify components.
Dismantle a coupling.
Re-assemble the coupling.
Perform axial and
radial alignment using the two clock gauge method.
MCA - 3:
"FENNA-FLEX" COUPLINGS
Training objectives:
Dismantle the coupling.
Inspect for wear / damage.
Assemble a
flexible coupling.
Align a typical
unit using vernier and inside callipers, as well as a steel rule or
straight edge.
Adjust a
taper-lock assembly.
MCA - 4:
ALTERNATIVE ALIGNMENT PROCEDURES
Training objectives:
Effect an
alignment procedure on a Bibby or a similar coupling using "Taper
Gauge" and "Feeler Gauge" method
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Title:
SEALS AND GASKETS
Code: S&G:
Produced by Tech AV
Series content: 4
x video tapes, 1 x Instructors manual, 1 x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians,
Maintenance Personnel
S&G - 1:
ROTARY SHAFT OIL SEALS
Training objectives:
Describe the basic
principles of oil seals and identify commonly used designs / types.
Replace an oil
seal correctly ensuring a leak free joint.
S&G - 2:
STATIC SEALS
Training objectives:
Describe the
necessity for a gasket.
Identify gasket material.
Maintain gaskets
in typical industrial environments.
S&G - 3: GLAND PACKINGS
Training objectives:
Replace gland
packings in a typical piece of equipment, for example, a centrifugal
pump or gate / globe valve.
S&G - 4:
MECHANICAL SEALS
Training objectives:
Describe the
fundamental principles of mechanical seals.
Identify o-ring,
wedge and bellow s type seals.
Describe important
maintenance aspects of mechanical seals.
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Title:
VALVES AND VALVE MAINTENANCE
Code: VVM:
Produced by Tech AV
Series content: 3
x video tapes, 1 x Instructors manual, 1 x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians,
Maintenance Personnel
VVM - 1: OVERVIEW
OF VALVES AND VALVE MAINTENANCE
Training objectives:
Identify valve
types used commonly in general industry.
Describe basic
valve operating principles.
VVM - 2: SERVICING
AND PACKING
Training objectives:
Describe parts and
functions of gate and globe valves.
Demonstrate the
procedures for replacing gland packings.
VVM - 3: SERVICING
A GATE VALVE
Training objectives:
Demonstrate parts
and functions of a gate valves.
Demonstrate
procedures for dismantling, inspecting and assembling a typical gate valve.
Describe typical
hydro-static testing procedures.
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Title:
BELT AND CHAIN DRIVES
Code: BCD:
Produced by Tech AV
Series content: 3
x video tapes, 1 x Trainee workbook.
Suitable for:
Modern Apprenticeships, NVQ Trainees, Operators, Trainee Technicians,
Maintenance Personnel
BCD-1: AN OVERVIEW
OF BELT AND CHAIN DRIVES
Training objectives:
Identify and
describe principle features of vee and wedge belts, roller chains and
associated drive components.
Describe basic
maintenance procedures.
Describe mandatory
safety procedures for working with rotating equipment.
BCD-2: VEE / WEDGE
BELT MAINTENANCE
Training objectives:
Demonstrate the
procedures for a safe belt replacement.
Select correct
size / type of belt.
Correctly adjust
belt tension.
BCD_3: BASIC
ROLLER CHAIN MAINTENANCE
Training objectives:
Describe isolation
and safety procedures of chain drives.
Remove and clean
roller-chains on a typical drive unit.
Inspect sprocket
wheels for wear, damage or run-out.
Use methods of
calculating / determining chain stretch.
Select correct
replacement chains.
Describe and
perform procedures for chain installation and replacement.
Achieve correct
chain tension.
Correct
mis-alignment of chain drives.
Describe purpose
and function of chain tensioners, and perform basic installation /
adjusting procedures with fitted tensioners.
Describe
importance of lubrication / perform three methods of chain lubrication.
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