PREFACE xi INDUSTRIAL MAINTENANCE SYLLABUS xxi ABOUT THE AUTHORS xv ACKNOWLEDGMENTS xxi Reem GENERAL KNOWLEDGE 1 1, Safety 3 Objectives 3 1-1. Workplace Safety 4 1-2. Hazardous Material Handling 12, 1-3 Ladders and Scatfolds 19 Summary 2 Review Questions 2B 2. Tools 25 Objectives 25 2-1 Hand Tools 26 2-2 Measuring Devices 40 2-3. Power Tools 4B Summary 47 Review Questions 48 3. Fasteners 49 Objectives 49 3-1. Threads 50 3-2. Taps and Dies 4 3-3. Fastener Types 7 3-4 Fastener Grades 58 3-5. Torque Specifications 59 3-6 Retaining Ring Fasteners 62 Summary 64 Review Questions 65 Industrial Print Reading 67 Objectives 67 4-1 Mechanical Drawings 68 4-2. Piping Symbols and Drawings 70 4-3. Hydraulic/Pneumatic Symbols and Drawings 72 4-4 Electrical Symbols and Drawings 76 4-5. Welding Symbols and Drawings 85 Summary 88 Review Questions 89 Rigging and Mecha Installations 91 Objectives 1 5-1 Formulae and Weight Estimations 92 5-2 Load Balancing 99 5-3. Synthetic Slings 101 5-4 Fiber Rope and Securing 108 5-5 Wire Rope and Wire Rope Stings 114 5-6 Chain and Chain Slings 121 5-7 Prelift Planning 126 Summary 127 Review Questions 127 nnn Bn enn pry eb ed NEvil Contents SECTION 2 MECHANICAL KNOWLEDGE 129 6. 10. Mechanical Power Transmission Objectives 6-1 Belts and Sheaves 6-2 Chainsand Sprockets 6-3 Gears and Gearboxes 6-4 Speed Calculations Summary Review Questions Bearings Objectives 74 Bearing Loads 7-2 Bearing Construction 73 Seties of Bearings 7-4 Bearing Types 7-5. Bearing Installation and Removal 76 Bearing Failures Summary Review Questions Coupled Shaft Alignment Objectives 81 Shaft Alignment 8.2 Dial Indicator Method 8-3 Reverse Dial Indicator Method 8-4 Fecler Gauge Method 8.5 Laser Shaft Aligament Summary Review Questions Lubrication Objectives 9-1 General Terms 9-2 Types of Lubricants 9.3. Methods of Application 9-4 Lubrication Schedules Summary Review Questions Seals and Packing Objectives 10-1. Packing Seals 10.2. Mechanical Secls 131 131 132 142 144 149 193 134 155 155 156 156 157 158 162 165 166 166 167 167 168 175 180 131 135 186 187 189 189 190 190 191 194 195 195 197 197 10-3 Radial Lip Seals Suromery Review Questions 11. Pumps and Compressors Objectives 11-1 Hydraulic Pumps 11-2 Pump Specifications 11-3 Pump Troubleshooting 11-4. Air Compression 11-5. Compressor Types 116 Compressor Troubleshooting Suramary Review Questions 12. Fluid Power Objectives 12-1 Fluid Power Fundamentals 122 123 Hydraulics Pneumatics 124 Valves 12.5. Linear Actuators Summary Review Questions 13. Piping Systems Objectives 13-1 Piping Tools 13-2. Piping Systems 133. Fittings 1344. Fitting Allowances 13-5 Pipe Connection Methods Surmmary Review Questions 202 203 204 205 205 206 212 214 21s 217 219 219 221 223 223 224 224 228 231 240 249 250 251 251 252 254 256 258 262 266 267 Sao) ELECTRICAL KNOWLEDGE 14, Electrical Fundamentals Objectives 141 14-2 143 144 145 ‘Atomic Structure Current Voltage Resistance Resistor Wattage Ratings and Power 269 271 271 272 274 274 276 28015. 16. 17, 18. 146 a7 Scientific Notation Engineering Notation 148 Ohm's Law 14-9, Power Law 14-10 Magnetism Summary Review Questions Test Equipment Objectives 15-1 Digital Multimeter 15-2. Clamp-On Ammater 15-3. Megahmmeter 15-4 Oscilloscope Summary Review Questions Basic Resistive Electrical Circuits Objectives 16-1. Series Circuits 16-2. Parallel Circuits 16-3 Combination Circuits Summary Review Questions Reactive Circuits and Power Factor Objectives 17-1 Inductance and Rel Circuits 17-2 Capacitance and R-C Circuits 17-3. ReL-C Series and Parallel Circuits 17-4. Power Factor Correction 17-5. Three-Phase Circuits 17-6 Three-Phase Power Factor Correction Summary Review Questions Wiring Methods Objectives 181 Conductor Selection and Sizing 18-2 Conductor Color Code 183. Raceway Selection 18-4 Raceway Sizing summary Review Questions 282 282 283 286 290 290 290 291 291 292 296 297 300 309 309 31 311 312 317 323 335 335 337 337 338 348, 360 369 373 374 377 378 379 379 380 383 385 19. 20. 21. 22. Contents Transformers Objectives 19-1. Basic Transformers 19-2. Autotransformers 19-3. Current Transformers 19-4 ‘Three-Phase Transformers 19-5. Primary Distribution Systems 19-6 Consumer Distribution System 19-7, Grounding System Summary Review Questions Electrical Machinery Objectives 20-1 DC Generators 20-2. DC Motors 20-3 20-4 Alternators Three-Phase Motors 20-5. Single-Phase Motors 20-6 Motor Maintenance Summary Review Questions Control and Controlled Devices Objectives 21-1. Pushbuttons 21-2. Rotary Switches 21-3. Limit Switches 21-4 2-5 21-6 2-7 21-8 Proximity Switches Photoelectric Switches Relays Motor Starters ‘Annunciators Summary Review Questions Motor Control Circuits Objectives 22-1 22.2 223 22-4 22.5 22-6 22.7 Two-Wire Controls Three-Wire Controls Multiple Start/Stop Controls Forward/Reverse Controls Speed Control Jog Control Miscellaneous Control 391 391 392 401 405 406 424 425 425 428 428 431 431 432 436 441 4a 446 452 454 454 455 455 456 458 460 460 462 468 47 472 474 474 475 475 476 476 478 481 484 486 487