TROUBLESHOOTING AND MAINTENANCE FOR MECHANICAL COMPONENTS Amizan Yahaya bin Jamil Leanna binti Mohd Yunos CHAPTER 1
TROUBLESHOOTING AND MAINTENANCE FOR MECHANICAL COMPONENTS Chapter 1 : Maintenance & Troubleshooting Principle and Procedure Amizan Yahaya bin Jamil Leanna binti Mohd Yunos
Published : POLITEKNIK MUKAH SARAWAK KM7.5, JALAN OYA 96400 MUKAH SARAWAK TEL : 084-874001 FAKS : 084874005 www,pmu.edu.my COPYRIGHT All rights reserved. No part of this publication may be reproduced. Stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, photographs, recording, etc without the prior permission of Politeknik Mukah Author : Amizan Yahaya bin Jamil Leanna binti Mohd Yunos 1st EDITION 2023
SINOPSIS TROUBLESHOOTING AND MAINTENANCE FOR MECHANICAL COMPONENTS covers basic mechanical components needs in Industry. The topic includes maintenance & troubleshooting principles and procedures, lubrication, power transmission, bearing and pumps. This course also gives knowledge and skills regarding maintenance & troubleshooting of mechanical components and assemblies. Editor
ABOUT AUTHOR Lecturer Mechanical Engineering Department DH44 E-mel: [email protected] AMIZAN YAHAYA BIN JAMIL LEANNA BINTI MOHD YUNOS Lecturer Mechanical Engineering Department DH44 E-mel: [email protected]
TABLE OF CONTENTS 1.1 Explain the principles of maintenance and troubleshooting. 1.2 Indicate workplace safety. 1.3 Classify types of hand tools and power tools equipment 1.1.1 Define the meaning of maintenance and troubleshooting. 1.1.2 List the objectives of maintenance and troubleshooting. 1.1.3 Explain the needs and importance of maintenance and troubleshooting 1.2.1 List the benefits of clean and safe work environment. 1.2.2 Explain the importance of personal protection equipment. 1.2.3 Apply the usage of lockout and tag-out when needed. 1.2.4 Classify the organizations that regulate the safety of hazardous materials. 1.3.1 List the most common types of hand tools and power tools. 1.3.2 Demonstrate the proper use of various types of hand tools and power tools. 1.3.3 Indicate the importance of inspecting hand tools and power tools. 01 02 03 Chapter 1 : Maintenance & Troubleshooting Principle and Procedure
objective Upon completion of this course, student should be able to : Apply the concept of mechanical components to solve related problems. Organized appropriately experiments in groups according to Standart Operating Procedure Perform the troubleshooting on mechanical components failure and damage
CHAPTER 1 : maintenance & troubleshooting principles and procedures 1.1 Explain the principles of maintenance and troubleshooting 1.1.1 Define the meaning of maintenance and troubleshooting Maintenance The meaning of maintenance involves the inspection of all functions, scheduled servicing, repair or replacement of damaged tools, equipment, machinery, building infrastructure and utility support required in industrial, business and residential installations. Over time, this has covered a wide range of topics describing various cost-effective practices to keep equipment operating well; this activity occurs either before or after the damage occurs.
Troubleshooting Troubleshooting is a form of problem solving. It is often used to repair products or machines that fail to perform a process or system. It is a systematic method of identifying the cause of a problem and solving it while making a product or process operational again. Troubleshooting is required to identify the cause of the malfunction. Determining the most likely cause is a process of elimination—eliminating potential causes of the problem. Finally, troubleshooting requires verification that the restoration of the product or process to a working state. In general, troubleshooting is the process of identifying or diagnosing a "problem" in a system arrangement caused by some type of malfunction or failure. This problem is initially described as a symptom of a malfunction, and resolution is the process of determining and repairing the cause of this malfunction.
1.1.2 List the objectives of maintenance and troubleshooting Objectives of maintenance : -To increase the reliability of the production process function. -To maximize product production capacity from a certain equipment and process. -To minimize the amount of production. -To minimize the frequency of interruptions in the production process by reducing the breakdown of a machine. -To improve employee safety. Objectives of troubleshooting : -Identify common symptoms and problems associated with computer malfunctions. -Isolate the source of problem through basic troubleshooting techniques. -Identify care and service techniques and common problems with primary printer types. -Develop a preventive maintenance schedule for the computers.
Importance of maintenance : 1. Improved safety Helps identify and address potential safety hazards, reducing the risk of accidents and injuries. 2. Increased efficiency Help reduce energy consumption, increase productivity, and lower costs. 3. Extended lifespan Can extend the lifespan of equipment and systems, reducing the need for costly replacements. 4. Improved reliability Helps identify and resolve potential issues before they become major problems, reducing downtime and improving reliability. 5. Compliance with regulations Can help ensure compliance with regulations and industry standards, reducing the risk of fines and penalties. 6. Cost savings Can identify and address potential problems before they become major issues, which can save significant amounts of money in the long run. 1.1.3 Explain the needs and importance of maintenance and troubleshooting
Importance of troubleshooting : 1. Resolves Issues Quickly Helps to identify the root cause of a problem and provides a solution in a timely manner, reducing downtime and ensuring that the system is up and running as soon as possible. 2. Improves System Performance Helps to improve the overall performance of the system, ensuring that it is operating at peak efficiency. 3. Prevents Future Issues Helps to prevent future issues by identifying potential problems and addressing them before they become serious issues. 4. Enhances User Experience Helps to improve the user experience by ensuring that devices are functioning properly and providing a smooth and seamless experience. 5. Cost-Effective Helps to reduce the overall cost of ownership for a device or system.
1.2 Indicate workplace safety 1.2.1 Benefits of clean and safe work environment :
Prevent illness and sickness Germs and diseases spread much faster in a filthy environment. The health and safety of your employees is critical, and avoiding the transmission of any harmful bacteria or germs is a critical component of that. Businesses that fail to maintain a clean work environment may notice an increase in sick days and absences among employees, which can harm overall productivity. Ensures safety A polluted atmosphere not only has the ability to cause illness, but it may also cause damage! Cluttered workplaces can cause stumbles and slides, and spills that go unclean pose a severe safety risk. To avoid incidents, it is critical that you take health and safety seriously and maintain high standards in your workplace. Increases productivity A super-clean environment is one of the best ways to achieve commercial success. Your employees will be more calm and concentrated, which is the ideal mix for enhancing productivity. We are easily distracted by thoughts coming at us from all sources, but at least your employees will not be concerned about the mess!
Happier employee Employee happiness has emerged as a hot topic in recent years, and it is now more vital than ever for managers and directors to assure the satisfaction of those who work for them. Cluttered and messy circumstances can lead to stress and a lack of focus; it might be tough to concentrate when your surrounds aren't clean. Creates good impression A tidy workplace is a simple and powerful marketing tool for your guests. First impressions (and continued impressions) are critical, and if clients are greeted by an immaculately clean and tidy office, they will know they are in good hands.
What is PPE: Personal protective equipment (PPE) is any equipment or clothing that individuals wear to protect themselves from potential workplace hazards. Examples of PPE include: Hard hats for head protection Safety glasses and goggles for eye protection Earplugs or earmuffs for hearing protection Respirators for respiratory protection High-visibility clothing for visibility enhancement Gloves for hand protection Steel-toed safety shoes or boots for foot protection Face shields for facial protection Protective clothing, such as coveralls, aprons, or lab coats for skin protection 1.2.2 The importance of personal protection equipment (PPE):
Why is PPE importance?: The use of personal protective equipment (PPE) reduces the risk of injury, illness, or death in the workplace. The use of PPE can safeguard the general populace, clients, and the environment in addition to workers. For instance, PPE is worn by employees in healthcare facilities to stop the transmission of infectious diseases to patients and other people. Why is PPE importance?: To protect workers from exposure to hazardous substances such as: Chemicals Biological agents Physical hazards Heat Noise Radiation
A safety procedure called lockout/tag-out (LOTO) is used to make sure that dangerous energy sources are controlled and kept from harming anyone while performing maintenance and servicing tasks. 1.2.3 Applying the usage of Lockout and Tag-Out when needed: Lockout : Lockout is one way to control hazardous energy. In practice, lockout is the isolation of energy from the system (a machine, equipment, or process) which physically locks the system in a safe mode. The energy-isolating device can be a manually operated disconnect switch, a circuit breaker, a line valve, or a block (Note: push buttons, selection switches and other circuit control switches are not considered energy-isolating devices). In most cases, these devices will have loops or tabs which can be locked to a stationary item in a safe position (deenergized position). The locking device (or lockout device) can be any device that has the ability to secure the energy-isolating device in a safe position.
Lockout Procedure : Preparation for Shutdown – study the equipment and the source(s) of energy before tagging/locking it. Alert the operator (s) that power is going to be disconnected. 1. 2.Equipment Shutdown. Equipment Isolation – find and isolate every form of energy that the machine uses. 3. Application of Lockout Devices – apply lock and/or tags to all energy isolating equipment. Anything that might restore the flow of energy to the work area must be locked out. 4. Control of Stored Energy – after locking out/tagging out the equipment, the stored energy must be controlled by: 5. Relieving any residual energy Waiting until moving parts stop Relieving trapped pressure Installing ground wires to discharge electrical capacitors Blocking or supporting elevated equipment Verify Equipment Isolation – before starting the work, check once more if all the equipment is locked out/tagged out and free from stored energy. 6.
Tag out : Tag out is a labelling process that is always used when lockout is required. The process of tagging out a system involves attaching or using an information tag or indicator (usually a standardized label) that includes the following information: Why the lockout/tag out is required (repair, maintenance, etc.). 1. 2.Time and date of application of the lock/tag. The name of the authorized person who attached the tag and lock to the system. 3.
The following are the steps to correctly implementing lockout/tag-out procedures: 1. Determine the energy sources that must be regulated: Determine the energy sources that must be controlled, such as electrical, mechanical, hydraulic, pneumatic, and others. 2. Inform others: Inform any personnel who may be affected by the maintenance or servicing activities about the work that will be done and the lockout/tagout procedures that will be in place. 3. Isolate the energy source: Turn off the power, disconnect the device, or use a lockable energy-isolating device to disable or isolate the energy source. 4. Apply the lockout device: Attach a lockout device, such as a padlock, to the energyisolating device so that it cannot be reactivated until the device is removed by the person who applied it. 5. Check for the absence of dangerous energy: Check that the equipment or machinery has been deenergized and that there is no leftover energy present. 6. Mark the equipment as follows: Attach a tag with the employee's name and the date to the lockout device to indicate that the device is in use and that the equipment is not to be activated. 7. Perform the maintenance or servicing: Conduct the maintenance or servicing activities. 8. Remove the lockout devices: Once the work is finished and the equipment has been inspected and certified to be safe, remove the lockout devices.
Colour Code for Locks and Tags: Locks: Blue locks - equipment locks - used to protect equipment. Red locks - used for Personal Protection. Green locks - given to contractors to use on equipment. Orange Locks - control a group lockout. Locks out many pieces of equipment with only one locking device. Tags: Red tags with Red locks - used for personal protection of employees. Red tags with Green locks – used for contractor protection. Yellow tags with Blue locks – used for protection of equipment. Yellow tags without a lock – non-energized equipment out of service. The tag will tell what is wrong with the equipment.
Organization Globally: Health and safety executives Institute of Occupational Safety and Health (IOSH) NEBOSH National Safety Council National Institute for Occupational Safety and Health Health and Safety Authority Occupational safety and Health Administration (OSHA) European Agency for Safety and Health at work Safe work Australia British Safety Council Occupation Safety and Health Consultants Register National Compliance and Risk Qualification Canadian Center for Occupational Health and Safety Occupational Safety and Health Review Commission Mines safety and Health Administration State Administration for work safety Korea Occupational Safety and Health Agency Board of Canadian Registered Safety Professionals American Society of Safety Professionals 1.2.4 Classify the organization that regulate the safety of hazardous materials:
Organization in Malaysia: The Department of Occupational Safety and Health (DOSH) of the Ministry of Human Resources is in charge of regulating the safety of hazardous products in Malaysia. The DOSH is in charge of enforcing the Occupational Safety and Health Act (OSHA) of 1994 and its accompanying rules, which provide requirements for the safe handling and transportation of hazardous items in the workplace. The DOSH aims to guarantee that companies take the required precautions to protect workers' and the public's health and safety from the negative effects of hazardous materials. The Department of Occupational Safety and Health (DOSH), sometimes known as the Occupational Safety and Health Department, is a Malaysian government organization in charge of promoting and maintaining a safe and healthy workplace. The department's principal mission is to avoid workplace injuries, illnesses, and fatalities. DOSH aims to achieve this by developing and enforcing occupational safety and health rules, educating and training companies and employees, and conducting workplace inspections and investigations. The agency also provides companies with technical advice and support to assist them in identifying and addressing workplace dangers, as well as ensuring compliance with occupational safety and health requirements.
1.3 : Classify types of hand tools and power tools equipment 1.3.1 List the most common types of hand tools and power tools. Most common types of hands tools: Pliers Screwdriver Handsaw Adjustable Wrench Most common types of power tools: Angle grinder Sander Machine Compound Mitre saw Drilling machine
Hand tools: 1.Hammer A hammer is used in almost all professional and amateur construction work. The most common type is the claw hammer, where the face or the blunt part of the head is used for hammering nails and the back part or the claw is used for extracting nails. Do not use the sides of the hammer for striking nails, and ensure that you have a good, firm group on the handle before using. 2.Wire Cutters These are used to cut wires of varying materials including copper, brass, iron, aluminum, and steel. It is best to use wire cutters that have insulated handles for added protection against electric shocks; though best practice is still not to cut live wires. Wear safety goggles and or a face shield to protect from flying particles. 1.3.2 Demonstrate the proper use of various types of hand tools and power tools.
3.Pliers Different types of pliers offer different uses. Some help with gripping smooth, round surfaces such as a rod, and some can be used for twisting and even cutting certain types of wire. Wear safety goggles are a face shield to avoid flying particles that could damage your eyes. 4.Screwdrivers A hand tool for turning screws with slotted heads, screwdrivers come in a variety of sizes and tips. This hand tool should never be used for piercing since it is only designed to tighten and loosen screws. Ensure that the tip is clean and free of any material and debris so you can properly grip the screw tips and avoid slipping.
Power tools: 1.Chainsaw A mechanical saw with a sharp set of cutter teeth run by a length of chain and a motor. While popularly used to cut wood, some types of chainsaw can also cut through brick, concrete, and stone. Do not wear loose-fitting clothing and wear proper PPE that provides protection for your hands, feet, legs, eyes, face, and hearing. 2.Angle Grinder Also called side grinders and disc grinders, angle grinders are primarily used to polish, cut, sharpen, and sand a variety of materials including wood, metal, tiles, stucco, and pavers. Some angle grinders are wired, while cordless options are battery-powered. Always use both hands when operating angle grinders for maximum control and stability.
3.Power Drill Power drills are used to drill holes through wood, plastic, thin metal, and masonry. The type of drill bit to be used depends on the type of surface you are working with. After using the power drill, ensure that you clean up the dust, shavings, and other material from your work surface by using a vacuum. Do not use your bare hands since you may end up cutting yourself.
Hand tools Regular tool inspections are ideal to prevent unnecessary injuries and accidents on the job. If you notice a tool in some way is malfunctioning or broken, it should be properly noted. That way someone else doesn’t try to use it and get hurt. Common hand tools: Hammers Chisels Wrenches Screwdrivers 1.3.3 Indicate the importance of inspecting hand tools and power tools.
Power tools Equipment inspection is not just about making sure your fleet is compliant, but can save you money and time in the long run. It usually costs a lot less to have equipment repaired than replaced. Inspections help prevent major repairs, or even worse — equipment failure. With regular inspection, you make sure your equipment is in top shape and can handle the toughest jobs. A trained technician can determine if small repairs will make a big difference and can suggest repairs to help your equipment run more efficiently. An equipment inspector may point out details your team might tend to overlook. Most importantly, regular inspections ensure the safety of your workers. You can get projects done on schedule and with peace of mind, knowing your equipment is in good condition. When it comes down to it, there is no reason not to have regular inspections and get the most out of the investment you made in your heavy equipment. Still not convinced? Keep reading to learn more about inspections and why they are critical to your heavy equipment lifespan. 1.3.3 Indicate the importance of inspecting hand tools and power tools.
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