IMMT 211 Principles of Mechanical Maintenance - LAB MANUAL

IMMT 211
PRINCIPLES OF MECHANICAL
MAINTENANCE
Lab Manual
MECHANICAL SKILLS DEPARTMENT

(MSD)
Year: June 2022
1
Table of Contents
Laboratory
Topic Page No.
Exercise
1 HAND AND POWER TOOLS 4
2 MAINTENANCE PROCEDURE OF EQUIPMENT 10
3 LIFTING EQUIPMENT 23
4 LUBRICATION 33
5 INSPECTION AND MAINTENANCE OF BEARINGS 45
6 ASSEMBLY/DISASSEMBLY OF SEALS AND GASKETS 59
7 COUPLINGS AND GEAR DRIVES 71
8 CHAIN AND BELT DRIVES 102
9 MECHANICAL EQUIPMENT INSTALLATION AND LEVELING 133
10 SERVICING MECHANICAL EQUIPMENT 141
Bibiography 162
IMMT 211
HAND AND POWER TOOLS
LAB EX - 1
Lab - 1 Hand and Power Tools
LABORATORY EXERCISE: 1
HAND AND POWER TOOLS
Learning Objectives Of This Laboratory Exercise:

After completing this exercise, the student technicians will be able to:
 Insure safe practices in the maintenance laboratory.
 Identify the tool type and function.
 Perform the proper handling procedures of the hand and power tools.
Key Words:
Holding, fastening, striking, aisle, guard, dismantle, nozzle, plugges,
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Yanbu Technical Institute 4
1.1 APPARATUS
 Hand and Power Tools
1.2 SAFETY PRECAUTIONS

 Read and follow instructional manual.
 Use handles for lifting the item.
 Ensure all the parts are secured firmly.
1.3 INTRODUCTION
The purpose of any hand tool is to extend and multiply the capabilities of the human body.
Hand tools can be divided into five categories.
1) Holding tools
2) Fastening tools
3) Cutting and Shaping tools
4) Striking tools
5) Measuring and Marking tools.
In this Lab all of the tools are discussed in general terms including description use and
safety precautions.
Safety when using tools is always important. The united states department labor estimates
that 130,000 injuries each year are caused by defective hand tools or their improper use.
Each of these accidents is costly to the plant, but more important, to the injured persons
themselves; costly, not only in pain and suffering, but frequently in lost pay, and sometimes
loss of lib or sight Key points for using hand tools.
The following four basic rules apply to the proper uses and care of all types of hand tools:
1) Select the proper tool for the job.

2) Inspect tools before using them.
3) Use tools correctly.
4) Store tools in such a way as to preserve their condition.
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1.4 MAINTENANCE OF LABORATORY SAFETY GUIDELINES
1) Shoes must completely cover the foot. No sandals are allowed.

2) Never work in the laboratory alone, always have another qualified person in the area
wearing an "ipod" or other device that interferes with hearing is not allowed.
3) Do not use any equipment unless you are trained and approved as a user by your instructor
or staff. Ask questions if you are unsure of how to operate something.
4) Perform only those experiments authorized by the instructor. Never do anything in the
laboratory that is not called for in the laboratory procedures or by your instructor.
5) Carefully follow all the instructions, both written and oral. Unauthorized experients are
prohibited.
6) Don’t eat, drink, or smoke in the laboratory.
7) Don’t yell, scream, or make any sudden loud noises that could startle others who are
concentrating on their work.
8) If any laboratory equipment is malfunctioning, making strange noises, sparking,
smoking, or smells "funny,” get an instructor or staff immediately. It is imperative that the
instructor or staff knows of any equipment problems.
9) All accidents, no matter how minor, should be reported to the faculty/staff member
supervising the laboratory immediately.
10) Keep aisles clear and maintain unobstructed access to all exits, fire extinguishers, electrical
panels, emergency showers, and eyewashes.Do not use corridors for storage or work areas.
11) Avoid using extension cords whenever possible. Extension cords should not go under
doors, across aisles, be hung from the ceiling, or plugged into other extension cords.
12) When using compressed air, uses only approved nozzles and never direct the air towards
any person.
13) Guards on machinery must be in place during operation.
14) No painting in laboratories or in the building (except in an approved designated area)
15) When you are done with your project, all components must be dismantled and returned
to proper locations. You are responsible for disposal of all unwanted materials.
16) Please report any unsafe behavior or condition to the instructor or staff.
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EXERCISE 1:
1. Select the required tool

2. Identify the Assigned Tools.
3. Write its function.
4. Perform how do you use the tool in a proper way.
Tool Selection Name of the Performance % Return of

# Function
(From 5 categories) tool (Identify) (Use in proper way) tool
1 Y/N
2 Y/N
3 Y/N
4 Y/N
5 Y/N
6 Y/N
7 Y/N
8 Y/N
9 Y/N
10 Y/N
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Tool Selection Name of the Performance % Return of

# Function
(From 5 categories) tool (Identify) (Use in proper way) tool
11 Y/N
12 Y/N
13 Y/N
14 Y/N
15 Y/N
16 Y/N
17 Y/N
18 Y/N
19 Y/N
20 Y/N
LAB Performance Grade: /20
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IMMT 211
MAINTENANCE PROCEDURE
OF
EQUIPMENT
LAB EX - 2
Lab - 2 Maintenance Procedure of Equipment
MAINTENANCE PROCEDURE OF EQUIPMENT

(MAINTENANCE PROCEDURE for Disassembly and Reassembly of equipment in pumping station)
After completing this exercise, the student technicians will be able to:
 Understand the essence of work order and job report

 Inspect and analyze the required maintenance work
 Learn equipment specification
 Construct work order and job report
 Perform the equipment safety isolation and TAGOUT/LOCKOUT procedure in
preparation for disassembling/ reassembling of equipment on the system
 Perform the dismantling/ reassembling of equipment
Key Words:
PPE, component, tagging, preliminary, efficiency, plant, investigate, workorder,
jobreport, analyze.
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2.1 APPARATUS
 Pumping Station

 Read and follow the MAINTENANCE OF LABORATORY SAFETY GUIDELINES
 Use all the PPE.
 Ensure all the electrical conections are disconnected before the lab exercise.
2.3 INTRODUCTION
All plants contain mechanical and electrical components and maintenance of equipment is
essential for the plant to keep operating. Proper operation of ail equipment is required to
meet three important criteria.
*Quality * Efficiency * Safety. A good maintenance system help to achieve them, so ail plants
have procedures designed to help the worker do the job more effectively not ail plants operate
the same way, so not ail plants use the same procedure. There are, however, maintenance
practices that are common to all plants.
These include.
1. The correct use of procedure
2. Advance planning for maintenance tasks
3. Tagging
4. Safety during maintenance work
5. General rules for assembling and disassembling equipment. Documents
require for good maintenance procedure and preparation.
2.4 WORK ORDER OR JOB REQUEST
When a problem is discovered in a plant, a maintenance supervisor makes a preliminary

investigation to determine whether the problem must be corrected immediately or later.
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2.5 ADVANCE PLANNING FOR MAINTENANCE TASK
Fig 2.1
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2.6 PERMIT TO WORK (P.T.W) AND TAGGING
When the plant maintenance engineer has been planned work order. They request for P.T.W.
from plant operation through the planning department.
Before issuing the P.T.W. the operation department will isolate the equipment or system and
they put the tag on that. Tagging insure that equipment is in proper position to protect
personnel and equipment. Tags tact worn workers not to operate equipment see Figure are
called danger tags safety tags "or hold tags".
2.7 EXERCISES FOR PUMPING STATION:
Fig 2.2: Pumping Station
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1. Inspections of pumping station and determination of required maintenance work

construction of work order.
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1 Performance of equipment Safety isolation and TAGOUT/LOCKOUT

a. List the equipment safety isolation activities.
i.________________________________________________________
ii.________________________________________________________
iii.________________________________________________________
iv.________________________________________________________
v.________________________________________________________
vi.________________________________________________________
vii.________________________________________________________
viii.________________________________________________________
ix.________________________________________________________
x.________________________________________________________
2 Tools and area preparation for dismantling (gate valve / pump)

3 Understanding of disassembling and reassembling procedure
There are standard rules for disassembly
i. Doing things by procedure

ii. Keeping track of parts that are removed
iii. Using proper bolting and unbolting techniques
iv. Especial care when handling fragile parts or easily damaged parts
v. Using witness marks
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4 DISASSEMBLING OF :
a. GATE VALVE
i. Filled up Work Order
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ii. Gather Tools required. Construct table for tools

iii. Dismantle the gate valve following the correct procedure
iv. Identification and function of parts. Construct table. For parts
v. Inspection of parts use table
vi. Remarks for each part whether – good, for repair, or for replacement; Construct
table. For parts analysis
Tools Required:
Parts and remarks of the gate valve:
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b. CENTRIFUGAL PUMP
i. Filled up Work order
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ii. Gather Tools required. Construct table for tools

iii. Dismantle the gate valve following the correct procedure
iv. Identification and function of parts. Construct table. For parts
v. Inspection of parts use table
vi. Remarks for each part whether – good, for repair, or for replacement; Construct
table. For parts analysis
Tools Required:
Parts and remarks of the gate valve:
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5. Reassembling of:
a. GATE VALVE
i. Cleaning of parts
ii. Lubrication of parts that needs lubrication
iii. Reassemble the gate valve with correct procedure
iv. Construct the job report
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b. CENTRIFUGAL PUMP
i. Cleaning of parts
ii. Lubrication of parts that needs lubrication
iii. Reassemble the centrifugal pump with correct procedure
iv. Construct the job report
6. Gather the tools

7. Clean the area.
LAB Performance Grade: /20
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IMMT 211
LIFTING EQUIPMENT
LAB EX - 3
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Lab - 3 Lifting Equipment
LIFTING EQUIPMENT

After completing this exercise the student technicians will be able to:
 Identify the lifting and rigging equipment.
 Calculate the weight of the load.
 Perform knotting operations.
 Perform the basic rigging and lifting operations.
Key Words:
Volume, width, object, weigh, bowline, clove, hitch, load, rigging, sling, knot, material.
APPARATUS
 Hoisting, Lifting Rigging
SAFETY PRECAUTIONS
 Be sure to establish the weight of the load.

 Determine the proper type of hitch based on the type of load.
 Understand the relationships between angles and tension as they pertain to slings and
hardware. If you don’t understand the relationships, or if you have any questions,
check with your supervisor before you proceed.
 Make sure that you select the right sling for the job based on the type of load to be
lifted.
 Also, select the right hardware based on the type of load and the type of sling or slings
that will be used for the lift.
 Inspect each sling before you use it. Never use a defective sling. Take defective slings
out of service immediately and follow your company’s procedure for handling
defective equipment.
 Inspect all rigging hardware before you use it. Never use defective hardware. Take
defective hardware out of service immediately and follow your company’s procedure
for handling defective equipment.
 As you rig the load, protect slings from cuts and tears.
 Determine the load’s center of gravity.
 Pay close attention to detail at the time of the lift.
Taks 1: Identify the Lifting and Rigging Equipment:
Fig 3.1
Fig 3.2
Task 2: Calculate the weight of Load:
Step 1:
Volume formulas:
• Rectangle/square: Volume = Length x Width x Height
• Hollow cylinder: Volume = 3.14 x Length x Wall thickness x (Diameter wall
thickness)
Task 3: Perform the following knots with the given ropes:
1. Bowline knot
The most useful knot, simple & stronge, very useful and can be used to make a
stnding loop in the end of the line.
2. Clove Hitch
 Great because it is quick and easy to tie.
 Not so great because it can slip or unwind if not under tension.
3. Half turn and 2 half hitches

 This is a very versatile knot and is best used for fastening a line around a
ring, hook, rail, bollard.
4. Double sheet bend

 Ideal for joining two ropes of different thicknesses thgether.
5. Double sheet bend

 Used as a stopper knot to prevent a rope running through a car.
Lifting Sling Colour Code
Whether you opt for the web or round version of the lifting sling, these handy hoists
typically come in a variety of colours.
This isn’t simply a vibrant design choice: the colour coding system is a universally recognised
method of determining how much weight a sling can handle – so it’s important to get well
acquainted.
The typical lifting sling colour code is as follows:
Purple Lifting Slings
Capable of lifting up to one tonne of weight max.
Green Lifting Slings
Capable of lifting up to two tonnes of weight max.
Yellow Lifting Slings
Capable of lifting up to three tonnes of weight max.
Grey Lifting Slings
Capable of lifting up to four tonnes of weight max.
Red Lifting Slings
Capable of lifting up to five tonnes of weight max.
Brown Lifting Slings
Capable of lifting up to six tonnes of weight max.
Blue Lifting Slings
Capable of lifting up to eight tonnes of weight max.
Orange Lifting Slings
Capable of lifting between 10 tonnes and 20 tonnes, depending on the chosen strength.
Task 4: Perform the the rigging and lifting operation for the given job:
a) Determine the sling angles for the given values of H and L, and write the nearest sling
angle according to the table below.
b) Find the load of the given bar.

c) Determine the load of each sling for the given angles, following the rule below.
Calculations:
IMMT 211
LUBRICATION
LAB EX- 4
Lab - 4 Lubrication
LUBRICATION

 Identify type of lubrication system and lubricants.
 Check the lubrication systems and lubricants.
 Select the right lubricant for the right application.
 Perform lubrication on different equipment and machine tools.
Key Words:
Viscometer, lubrication, coupler, grease, dirt, centistrokes, transmit, apron, lathe, pillow,
chain, universal.
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Lab - 4 Lubrication
APPARATUS
 Viscometer, grease gun, grease coupler, pint oil can, chain, machine tools.
SAFETY PRECAUTIONS
INTRODUCTION
The primary purpose of lubrication is to reduce wear and heat between contacting surfaces in
relative motion. While wear and heat cannot be completely eliminated, they can be reduced to
negligible or accepted levels. Lubrication is also used to reduce oxidation and prevent rust; to
provide insulation in transformer applications; to transmit mechanical power in hydraulic fluid
power applications; and to seal against dust, and dirt, and water.
Taks 1: Viscosity measurement of a SAE 30 oil at room temperature.
Procedure
1. Perform the Safety Procedures.

2. Identify the instrument shown in Fig 4.1, and explain its function.
Fig 4.1. Viscometer.
Viscosity Measurement:
3. Take a container of SAE 30 oil, a thermometer, a Zahn 3 viscometer, an empty container,
and a stopwatch.
4. Measure the temperature of the oil.
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Lab - 4 Lubrication
Oil temperature:
5. Using the Zahn 3 viscometer and the stopwatch, measure the oil flow time three times
and calculate the average.
Time1: Time2: Time3:
Average flow time:

6. Determine the oil viscosity in centistokes (cSt) using the following formula:
V = 11.7 T - 87.8
where V is the viscosity in centistokes
T is the time in seconds.
Viscosity: cSt. at ⁰F
Storage and Cleaning

7. Pour the rest of the oil contained in the viscosity cup and the container back to its original
container using a funnel.
8. Clean the viscosity cup with a solvent.
Note: Never clean the orifice with a metal tool, abrasive cloth, or paper since nicks or wear at
the orifice will affect the accuracy of the cup. Ask your instructor for solvent disposal
procedures.
9. Store the viscometer in its cardboard tube with the red cap in place over the orifice.
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Lab - 4 Lubrication
Taks 2: Pillow block bearing Lubrication
Procedure
Fig 4.2. Grease Gun
3. Explain why it is important to clean the grease coupler of the instrument.
4. Pump grease into a pillow block bearing to lubricate it as shown in Fig 4.3.
Fig 4.3. Lubrication of a pillow block bearing.
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Lab - 4 Lubrication
Task 3: To lubricate a chain.
Procedure
1. Perform the Safety Procedures
Fig 4.4. Chain oiler.

Fig 4.5 Universal base setup.
3. Set up a chain drive with the No. 40 chain as shown in Fig 4.5. Install a 20-tooth
and a 30-tooth sprocket on the shafts
4. Fill the chain oiler with SAE 30 oil, and place a clean rag under the chain to
collect the surplus oil.
5. On which part(s) of the chain should oil be applied?
6. Lubricate the chain.
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Lab - 4 Lubrication
Task 4: Read the MSDS AND LUBRICATION CHART
To interpret a material safety data sheet and a lubrication chart.
Procedure
MATERIAL SAFETY DATA SHEET

1. Read the following material safety data sheet
Assessment marks for
MSDS 1: ______________________
MSDS 2: ______________________
MSDS 3: ______________________
MSDS 4: ______________________
MSDS 5: ______________________
MSDS 6: ______________________
MSDS 7: ______________________
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Lab - 4 Lubrication
Task 5: Lathe Lubrication
Proper lubrication of machine tools is the responsibility of the operator. In order to ensure that
the machine runs properly and maintains its accuracy, regular lubrication is required.
Before operating the lathe, make sure that all lubricants are at their proper levels. Being that all
lathes are different, it is impossible to cover the lubrication schedule for all of the types of lathes
found in the machine shop. Use the chart below as a guide for the proper lubrication points
found on most types of lathes.
HeadStock:
Spindle bearings, headstock gearing, and shafts are lubricated continuously from a distributor
tank located beneath the headstock top cover. The oil is supplied either by a pump or an oil
slinger found in the headstock. Evidence of supply is shown in an oil sight glass located on the
headstock front face (Fig 4.6).
Fig 4.6
If the machine is equipped with a pump, oil should be visible when the motor is running. If the
machine is equipped with a slinger, oil should be visible in the headstock reservoir sight glass.
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Lab - 4 Lubrication
The oil filler tube is typically found behind the

headstock end guard cover.
Ensure that the oil level in the system is kept

topped off. On lathes with an oil pump, oil is
usually added through a filler tube in the oil tank
located behind the headstock end guard cover.
(Fig 4.7).
Fig 4.7
On lathes with an oil slinger, oil is usually added

through a filler plug on the headstock cover. (Fig
4.8).
Oil filler plug located on the top of the headstock

of a lathe equipped with an oil slinger lubrication
system
Fig 4.8
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Lab - 4 Lubrication
Some types of lathes are

equipped with both a
reservoir sight glass and
an oil flow sight glass (Fig
4.9). The reservoir sight
glass is located on the
lower half of the
headstock while the flow
sight glass is located near
the top of the headstock.
Lathe headstock
equipped with both flow
and reservoir sight glasses
Fig 4.9
Gearbox:
Gears in the gearbox are splash lubricated from
an oil tank that is part of the gearbox. An oil
sight window is typically situated on the front or
side face of the gearbox (Fig 4.10).
When the lathe is off, oil should be visible at all

times in the gearbox oil sight window.
Fig 4.10
To top off or fill the gearbox, find the filler elbow

behind the headstock end cover (Fig 4.11).
Typical filler elbow found behind the end cover

of the headstock.
Fig 4.11
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Lab - 4 Lubrication
Apron:
The apron gears are splash lubricated from

an oil tank that is part of the apron. On new
style lathes, the apron oil tank is also the
reservoir for the manually operated pump
(Fig 4.12) that lubricates the bedways, cross
slide ways, and nut.
Fig 4.12
When the oil level falls below the level on The system can be filled through the filler
the site glass on the apron (Fig 4.13) plug found on the saddle (Fig 4.14).
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Lab - 4 Lubrication
1. Grease each week - rack and end train gears (change wheels) Shell Alvania RA.
- Chuck (manual) Molycote"D".
2. Oil each week - Tailstock, Leadscrew, Endgear, Bushes and Topslide, Shell Tellus T37
(ISO VG37)
3. Apron. Check level and top up each week - Shell Tonna TX68 (ISO VGT 68) Total
capacity 1.2 litres.
4. Headstock. Check level and top up each week - Shell Tellus T37 (ISO VG37) Total
capacity 16 litres.
5. Gearbox. Check level and top up each week - Shell Tellus T 37 (ISO VG 37) Total
capacity 2.6 litres.
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IMMT 211
INSPECTION AND
MAITENANCE OF BEARINGS
LAB EX-5
Lab - 5 Inspection and Maintenance of Bearings
INSPECTION AND MAINTENANCE OF BEARINGS
 Identify the category and type of bearings.
 Identify materials of bearings.
 Mount and dismount the bearings following the right procedures.
 Diagnose defected bearings, deduce the causes of defects, expected operation
symptoms and propose the remedy.
Key Words:
Appendix, sleev, install, plain, axial, radial, groove, surface, porus, bearing, install, mandrel,
tendem.
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5.1 APPARATUS
 Bearings

Task 1: PLAIN BEARINGS
To install and remove a sleeve bearing into housing using an arbor press and a hammer.
PROCEDURE
1. Perform the Safety Procedures listed in Appendix.
2. Identify, in Table. 5.1, the three plain bearings shown in Fig. 5.1.
Safety Procedures
https://rb.gy/rrq2lr
Fig 5.1. Plain bearings.
PLAIN BEARING TYPE

1
2
3
Table.5.1. Plain bearings.
3. Explain the difference between a radial load and an axial load.
4. Identify, in Table.5.2, the load(s) that each plain bearing can support.
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LOAD
PLAIN BEARING
RADIAL AXIAL
Sleeve
Flange
Thrust
Table.5.2. Plain bearings and corresponding load(s).
5. Explain the function of the grooves in the grooved sleeve bearing.
6. Take the plain thrust bearing and drag it between your fingers. Explain why the bearing
has a porous and oily surface.
7. As opposed to the sleeve, grooved sleeve and thrust bearings, the flange bearing of
your trainer is not impregnated with oil. Since lubrication is necessary, explain how
lubricant can be supplied to the bearing.
8. Slide the one-dot shaft back and forth into the sleeve bearing to verify that it slides
freely.
9. Using an arbor press and the mandrel 2 from the Bearings 2 panel, insert the sleeve
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bearing in the one-dot housing as shown in Fig.5.2.
Fig.5.2. Insertion of the sleeve bearing in the one-dot housing.
10. Slide the one-dot shaft back and forth in the sleeve bearing. Does it
slide as easily as before? If not, explain why.
11. Using an arbor press, remove the sleeve bearing from the housing.
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12. Repeat the sleeve bearing insertion using a dead blow hammer.
13. Using an arbor press, remove the sleeve bearing from the housing.
14. Which of the hammer or the arbor press is the most recommended tool for inserting
a sleeve bearing? Explain why
BALL BEARINGS
Task: To install a ball bearing on a shaft using a hammer and a mandrel. To remove a ball
bearing using a puller. To install a ball bearing to a shaft by heating the bearing.
PROCEDURE
2. Identify, in Table.5.3, the five ball bearings shown in Fig.5.2.
Fig 5.2. Ball bearings.
BEARING NAME
1
2
3
4
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5
Table.5.3 . Ball bearings.
3. Explain the main differences between open, shielded and sealed bearings.
4. Identify, in Table.5.4 , the load(s) that each ball bearing can support best.
LOAD
BALL BEARING
RADIAL AXIAL
Open, shielded and
sealed deep groove
Angular
Thrust
Table.5.4 . Ball bearings and corresponding load(s).
5. Identify, in Table.5.5 , the parts of the ball bearing shown in Fig.5.3.
PART NAME
1
3
4
Table.5.5 . Parts of a typical ball bearing.

Installation and Removal of an Open Ball Bearing
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6. Using a dead blow hammer and the mandrel 1, install the open ball bearing on the
two-dots shaft.
Note: Never directly hit a bearing with a hammer.
7. Remove the bearing from the shaft using a puller as shown in Fig.5.3 .
If the forcing screw blocks, lubricate it.
Fig.5.3 . Removal of an open ball bearing using a puller.
Note: Make sure you do not pull on the outer ring of the ball bearing.
8. Using a bearing heater, heat the open ball bearing.
Note: Never heat a bearing above 250 F.
9. Install the bearing on the two-dots shaft.
10. Explain why a heated bearing is easier to install.
11. What precaution should you take when installing a bearing with a mandrel.
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12. Install the shaft and bearing assembly into the two-dots housing. Make sure you
install all the required elements.
ANGULAR BALL BEARINGS
Task: To install two angular ball bearings in a tandem arrangement. To preload two
angular ball bearings in a tandem arrangement.
PROCEDURE
2. Take a radial ball bearing and an angular ball bearing from the Bearings 1 panel,
and note two differences.
3. Explain when is an angular ball bearing preferred to a radial ball bearing?

An angular ball bearing is shown in Fig. 5.4.
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Fig. 5.4. Angular ball bearing.
4. Name two of the most common applications for angular ball bearings.
G 5. Identify the bearing arrangements shown in Fig. 5.5 .
Fig. 5.5. Bearing arrangements.
1. 2. 3.
6. Two angular ball bearings installed in a tandem arrangement cannot support an axial load
with a varying direction. Explain why.
7. Explain why two opposed angular ball bearings or a combination of more
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than two, must be installed on a shaft.
8. Explain how the rigidity of a tandem angular ball bearing arrangement can be increased?
Installation of two Angular Ball Bearings in a Tandem Arrangement
9. Install the four-dots shaft and angular ball bearings into the four-dots housing as shown in Fig.5.6
. Make sure the bearings are installed in tandem. Make sure you install all the required elements
including the wave disc spring, sleeve, locknut and lock washer.
Fig.5.6 . Shaft and housing assembly.
10. What is the function of the wave disc spring?
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ROLLER BEARINGS
Task: To install two tapered roller bearings in a back-to-back arrangement.
PROCEDURE
2. Identify, in Table.5.6, the load(s) that each type of roller bearing shown in Fig.5.7 can
support.
Fig.5.7. Three types of roller bearings.
LOAD
ROLLER
RADIAL AXIAL
Tapered (1)
Needle (2)
Thrust (3)
Table. 5.6. Three types of roller bearings.
3. Explain why the cone and cup of tapered roller bearings are generally separable.
4. Give two reasons why a roller bearing is sometimes preferred to a ball bearing.
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5. Give a common application in which tapered roller bearings are used.
Installation of two Tapered Roller Bearings in a Back-to-back Arrangement
6. Install the three-dots shaft and tapered roller bearing assembly into the three-dots housing
as shown in Fig.5.8. Make sure you install all the required elements. Make sure the
bearings are installed back-to-back.
Fig.5.8. Shaft and housing assembly.
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BEARING LUBRICATION
Task: To lubricate a tapered roller bearing.
PROCEDURE
2. List two lubricants that can be used to lubricate a bearing.
3. Are bearings always lubricated by the manufacturer before shipping?
4. Give a consequence of over greasing.
5. Lubricate a tapered roller bearing with grease using a bearing packer as in Fig.5.9.
Fig.5.9. Lubrication of a tapered roller bearing
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IMMT 211
ASSEMBLY/DISASSEMBLY
OF SEALS AND GASKETS
LAB EX - 6
Lab - 6 Assembly/Disassembly of Seals and Gaskets
ASSEMBLY/DISASSEMBLY OF SEALS AND GASKETS
 Prepare a gasket. You will also install a gasket between two mating surfaces.
 Remove and install an O-ring.
 Install and remove a lip seal.
 Install a mechanical seal.
 Recognize types of and functions of gaskets and seals.
 Practice studying of operation condition of gaskets in mechanical equipment.
 Practice selecting the correct types of materials of gaskets for specific conditions
and applications.
 Practice cutting gaskets for required geometry.
 Practice replacing gaskets and seals.
Key Words:
Gasket, scissors, punch, lip seal, lubricant, manipulate, mechanical seal.
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APPARATUS
SAFETY PRECAUTIONS
1. GASKETS
Task: To describe gaskets. To cut and install a gasket.
Procedure
2. Describe the function of a gasket similar to the one shown in Fig.6.1 .
Fig.6.1. Gasket used in a pump.
3. Are gaskets designed to be installed between mating surfaces that move relative to
one another?
a) Yes b) No
4. List two common materials from which gaskets are made.
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5. Name three important factors that must be considered when choosing a material for a
gasket.
Cutting a Gasket from Cork
8. Use scissors, a punch and a hammer to prepare a gasket for installation between seal hub
1 and seal hub 2 found on the Seal Hardware panel as shown in Fig.6.2 .
Fig.6.2. Preparation of a gasket for seal hub 1 and 2.
Note: Cut the cork with care to avoid tears, and place the gasket on a wood plate when
punching the holes.
7. Install the gasket between the two mating surfaces of seal hub 1 and seal hub 2.Fig.6.3
Note: Make sure the mating surfaces are free of dirt and burrs before installing the gasket.
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Fig.6.3. Gasket flange
8. Complete the assembly by inserting the four 5/16-18 x 1 1/8-in. HHCS through the hubs
Fig.6.4.
Note: Use a criss-cross pattern when tightening the screws. Do not over tighten the
screws to avoid damaging the gasket.
Fig.6.4. Criss-cross pattern.
9. If you have the Bearings system, model 46617, cut gaskets for the three- dots housing as shown in
Fig.6.5, and install them
Fig.6.5. Gaskets for the three-dots housing.
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2. O-RINGS
Task: To describe O-rings. To install and remove an O-ring.
Procedure
2. Describe the function of an O-ring similar to the one shown in Fig.6.6.
Fig.6.6.Typical O-ring.
3. List two common materials from which O-rings are made.
4. Describe the consequences of excessive and insufficient mechanical squeeze

on an O-ring installed between two surfaces?
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O-ring Installation and Removal
5. Install an O-ring on the seal hub 1 as shown in Fig.6.7.
Fig.6.7. Installation of an O-ring.
Note: Make sure the surface is free of burrs and dirt before installing the O-ring.
6. Remove the O-ring from seal hub 1 using a flat screwdriver.

Note: Manipulate the screwdriver with care to avoid damaging the O-ring.
7. If you have the Gear Drives 2 system, model 46614-10, dismount the gearbox and inspect
the O-ring.
8. Determine whether the O-ring installed in the gearbox is used for a static or a dynamic
application.
Application:
9. Install the O-ring and complete the gearbox assembly.
3. LIP SEALS
Task: To describe lip seals. To install and remove a lip seal.
Procedure
2. Explain the function of a lip seal as the one shown in Fig.6.8.
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Fig.6.8. Typical lip seal.
3. Inspect the lip seal from the Seal Hardware panel. What is the function of the
spring?
4. Are all lip seals spring-loaded?
a) Yes b) No
5. Which of the open or closed side of the lip seal should face the lubricant?
Side:
6. Identify in Table.6.1 the parts of the lip seal shown in Fig.6.9.
Fig.6.9. Parts of a lip seal.
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PART NAME
1
2
3
Table.6.1 . Parts of a lip seal.
Lip Seal Installation and Removal
7. Using the lip seal tool and a hammer, install the lip seal on the seal hub 2 as shown in
Fig.6.10 . Make sure you leave enough space between the external edge of the lip seal and
the interior of the hub to be able to remove the lip seal.
Fig.6.10.. Installation of the lip seal using the lip seal tool.
Note: Do not directly hit the lip seal with the hammer.
8. Using a flat screwdriver and a hammer, remove the lip seal from the seal hub 2.Fig.6.11.
Note: Manipulate the screwdriver and hammer with care to avoid damaging lip seal
Fig.6.11. Removal of the lip seal.
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4. MECHANICAL SEALS
Task: To describe mechanical seals. To install a mechanical seal.
Procedure
2. Identify in Table.6.2. the parts of the mechanical seal shown in Fig.6.12.
Fig.6.12 Parts of a mechanical seal.
PART NAME
Table.6.2 Parts of a mechanical seal.
3. Which part of a mechanical seal turns with the shaft?
Part: ________________________________________
4. Name an application in which mechanical seals are commonly found.
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Application:
5. Explain how the primary seal is achieved in a mechanical seal similar to the one supplied
with your trainer.
6. What happens if the spring holds the mating flat faces with an excessive force?
Installation of the Mechanical Seal

7. Take the seal hub 3, shaft, and mechanical seal parts from the Seal Hardware panel.
8. Lubricate the shaft on which the seal head will be installed.
Note: Make sure to apply a film of lubricant that is compatible with the seal
material.
9. Slide the seal head, spring, holder, and retaining parts on the shaft.
Note: Manipulate the seal head carefully, and avoid touching the sealing surfaces.
If the seal head does not slide easily on the shaft, add lubricant.
10. Insert the seat in the seal hub 3 as shown in Fig.6.13.
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Fig.6.13. Insertion of the seat in seal hub 3.
11. Complete the assembly as shown in Fig.6.14
Fig.6.14 Mechanical sel assembly.
Note: Make sure there is no dirt between the sealing faces of the seat and the seal head.
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IMMT 212
COUPLINGS
AND GEAR DRIVES
LAB EX - 7
Lab - 7 Couplings and Gear Drives
COUPLINGS AND GEAR DRIVES
 Align two shafts and install a flange coupling
 Align two shafts and install a flexible sleeve coupling
 Aalign two shafts and install a chain coupling
 Align two shafts and install a gear coupling.
 Align two shafts and install a grid coupling.
 Install a double universal joint.
 Install the components of a two-helical gear drive.
Key Words:
Gear,
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APPARATUS
 Couplings
 Gear Drives
SAFETY PRECAUTIONS
7.1 FLANGE COUPLINGS
Lockout/Tagout Procedure
1. Perform a lockout/tagout procedure as described in Job Sheet 1.

Note: The Universal Base should be set up from Job Sheet 1.
Repeat Job Sheet 1 if necessary.
Rough Alignment
2. Align the shafts using the straightedge and feeler gauge method. Refer to the manual titled
Introduction to Mechanical Drive Systems, p/n 36737-20 if necessary.
Coupling Installation
3. Take the flange coupling from the Couplings 1 Panel.
4. Perform the following steps if the bushing are not assembled into the coupling hubs:
 Slide a 5/8-in. bore, size H split taper bushing into both hubs. The
 bushing should slide freely. If not, install it on the opposite side of the hub.
 Line up the unthreaded bushing holes with the threaded holes on the hubs.
 Slide and hand-tighten the capscrews to lock the bushings into the hubs.
5. Install a key into each shaft keyseat.
Note: The edges of the keyseats are sharp.
6. Slide hub 1 and hub 2 on the shafts as shown in Fig.7.1. leaving a gap between the two
hubs.
7. Tighten the pillow block bearing setscrews on the flat surface of the shaft.
8. Tighten the pillow block bearing screws to the extrusions.
9. Tighten the mounting base screws to the extrusions.
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Fig.7.1. Installation of the hubs on the shafts.
10. Tighten the motor screws to the mounting base.

Precision Alignment
11. Align the shafts using the dial indicator method (refer to Job Sheet 1) or the reverse
indicator method (refer to Job Sheet 2).
Start-up Procedure
12. Connect the motor to the built-in AC outlet on the frame of the universal base.
13. Ensure that all screws, setscrews and capscrews are tightened.
14. Install the safety panels.
15. Ask your instructor to inspect the setup.
16. Ask each person to remove their padlock from the lockout device.
17. Remove the lockout/tagout device.
18. Ensure that the output voltage selector is set to FlXED.
19. Set the disconnecting switch to ON.
20. Start the motor by pressing the Start button on the Start/Stop push-button station.
System Operation
21. Let the motor run for a few seconds.
22. Check to see whether the drive produces unusual vibrations. If this is the case, perform
the following steps:
Stop the motor by pressing the Stop button on the Start/Stop pushbutton station.
Set the disconnecting switch to OFF.
Perform a lockout/tagout procedure.
Remove the safety panels.
Ensure that the alignment is adequate. If not, realign the shafts.
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Perform a start-up procedure.

23. Stop the motor by pressing the Stop button on the Start/Stop push-button station.
24. Set the disconnecting switch to OFF.
25. Perform a lockout/tagout procedure.
26. Remove the safety panels.
27. Dismount the coupling but leave the rest of the setup as shown in Fig.7.2
Fig.7.2. Current universal base setup.
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7.2. FLEXIBLE SLEEVE COUPLINGS
Rough Alignment
3. Take the flexible sleeve coupling from the Couplings 1 Panel.
5. Slide a coupling hub on the motor shaft.
6. Align the hub with the end of the shaft.
7. Tighten the hub setscrew.
8. Insert the sleeve in the hub.
9. Slide a coupling hub on the shaft supported by the pillow block bearings.
10. Align the hub with the end of the shaft.
11. Tighten the hub setscrew.
4. Tighten the motor screws on the mounting base. Precision Alignment
Coupling Assembly
16. Loosen the pillow block bearing setscrews and slide the driven shaft toward the motor
shaft until the coupling hub mate with the sleeve.
17. Tighten the pillow block bearing setscrews on the flat surface of the driven shaft.
Start-up Procedure
18. Perform a start-up procedure as described in Job Sheet 3
System Operation
20. Check to see whether the drive produces unusual vibrations. If this is the
case, perform the following steps:
 Stop the motor by pressing the Stop button on the Start/Stop
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push-button station.
 Set the disconnecting switch to OFF.
 Perform a lockout/tagout procedure.
 Remove the safety panels.
 Ensure that the alignment is adequate. If not, realign the shafts.
 Perform a start-up procedure.
24. Ask the instructor to check your work.
26. Dismount the coupling but leave the rest of the setup as shown in Fig.7.3.
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7.3 CHAIN COUPLINGS

Note: The Universal base should be set up from Job Sheet 1.
Rough Alignment
3. Take the chain coupling from the Couplings 2 Panel.

4. Disassemble the coupling by removing the screws using a 1/4-in. slot screwdriver.
5. Slide the seals on the shafts as shown in Fig.7.4.
Fig.7.4. Installation of the seals on the shafts.
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7. Slide the sprockets on the shafts.
8. Align the sprockets with the end of the shafts.
9. Tighten the sprocket setscrews
11. Position the motor mounting base so that the gap between the sprockets is
approximately 0.325 in., as shown in Fig.7.5.
Fig.7.5. Relative position of the sprockets.

Precision Alignment
Coupling Assembly
15. Make sure the gap between the coupling hubs is 0.325 in. If not, correct it.
16. Wrap the No.40-2 chain around the sprockets.
17. Attach the ends of the chain with a connecting link. Refer to the manual titled Chain Drives
1, p/n 36892-20 if necessary.
18. Slide the seals onto the sprockets.
Note: Use the cover to determine the position of the seals on the sprockets.
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19. Install one half of the cover and the gaskets under the coupling as shown in Fig.7.6.
Fig.7.6. Cover installation
20. Fix the other half of the coupling cover with the screws.
Note: Normally, grease would be inserted in the coupling
assembly through grease fittings installed on the periphery of the cover.
Start-up Procedure
21. Perform a start-up procedure (refer to Job Sheet 3 if necessary).
System Operation
 Stop the motor by pressing the Stop button on the Start/Stop push-button station.
 Perform a lockout/tagout procedure
 Ensure that the chain is properly lubricated. If not, lubricate it using the oiler and the
SAE 30 oil from the Lubrication Package.
29. Dismount the coupling but leave the rest of the setup as shown in Fig.7.7
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7.4. GEAR COUPLINGS
1. Perform a lockout/tagout procedure (refer to Job Sheet 1 if necessary).

Repeat Job Sheet 1 if necessary
Rough Alignment
2. Align the shafts using the straightedge and feeler gauge method as
described in the manual titled Introduction to Mechanical Drive Systems, p/n 36737-20.
3. Take the gear coupling from the Couplings 1 Panel.
5. Slide the coupling hubs on the shafts as shown in Fig.7.8.
Fig.7.8. Disposition of the hubs on the shafts.
6. Tighten the driving hub setscrew.

7. Slide the nylon sleeve on the driving hub.
8. Slide the driven hub so that it does not touch the sleeve.
9. Tighten the driven hub setscrew.
12. Tighten the motor screws on the mounting base.
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Precision Alignment
Coupling Assembly
14. Make sure the dimension shown in Fig.7.9. is approximately 3.295 in.
Fig.7.9. Dimension.
15. Tighten the driven hub setscrew.

Start-up Procedure
System Operation
18. Check to see whether the drive produces unusual vibrations. If this is the case,
perform the following steps:
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24. Dismount the coupling but leave the rest of the setup as shown in Fig7.10.
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7.5. GRID COUPLINGS
1. Perform a lockout/tagout procedure (refer to Job Sheet 1 if necessary).
Note: The Universal base should be set up from Job Sheet 1.
Repeat Job Sheet 1 if necessary.]
Rough Alignment
2. Align the shafts using the straightedge and feeler gauge method as described in the manual
titled Introduction to Mechanical Drive Systems, p/n 36737-20.
3. Take the grid coupling from the Couplings 2 Panel.
4. Disassemble the coupling by removing the capscrews using a 3/16-in. hexagonal key.
5. Slide the seals on the shafts as shown in Fig.7.11., 7.11.1.
Fig.7.11. Installation of the seals on the shafts.

7. Slide the hubs on the shafts.
8. Align the hubs with the end of the shafts.
9. Tighten the hub setscrews.
10. Tighten the pillow block bearing setscrews on the flat surface of the shafts.
11. Position the motor mounting base so that the gap between the hubs is approximately
0.125 in.
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Fig.7.11.1. Relative position of the hubs.

Precision Alignment
Coupling Assembly
15. Make sure the gap between the hubs is 0.125 in. If not, correct it.
16. Install the grid around the hubs. Use a rubber hammer if necessary.
17. Slide the seals onto the hubs.
Note: Use the cover to determine the position of the seals on the hubs.
18. Install one half of the cover and the gaskets under the coupling as shown in Fig.7.12
Fig.7.12. Cover installation.
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19. Fix the other half of the coupling cover with the capscrews. Make sure the marks on the
two halves of the cover are aligned as shown in Fig.7.13 ,7.13.1
Fig.7.13 Alignment of the marks.
Note: Normally, grease would be inserted in the coupling assembly through grease fittings
installed on the periphery of the cover.
Start-up Procedure
System Operation
 Ensure that the lubrication is adequate. If not, apply grease to the hub slots. Use the
grease cartridge from the Lubrication Package.
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28. Disassemble the setup and return the components to the storage location.
Fig.7.13.1 Current universal base setup.
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7.6. UNIVERSAL JOINTS
1. Perform a lockout/tagout procedure as described in Job Sheet 1. Universal Base Setup

2. Fix three T-slotted extrusions to the universal base, as shown in Fig.7.14.
Fig.7.14. Universal base setup.
3. Install four pillow block bearings to the extrusions. Do not tighten the screws.
4. Slide a 9-in. shaft through each pair of pillow block bearings. Do not tighten the setscrews.
5. Slide a universal joint on the driving shaft and another on the driven sha as shown in Figure
8-4. Do not tighten the setscrews.
6. Slide a 9-in. shaft between the two universal joints.
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7. Slide a 3-in. D. sheave on the driving shaft as shown in Fig.7.15.
Fig.7.15. Current universal base setup
8. Tighten the sheave setscrew on the flat surface of the shaft.

Note: Make sure the sheave can rotate without interfering with the universal base.
Universal Joint Installation
9. Tighten the screws of the pillow block bearings that support the driving shaft.
10. Slide the universal joints and the shafts until the ends of the three shafts are flush with
the grooves machined on the periphery of the two universal joints.
Note: The shafts could interfere with the center block of the universal joints if this condition is
not met.
11. Rotate the universal joints until the assembly is positioned as shown in Fig.7.16.
Fig.7.16. Universal joint installation.
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12. Tighten the universal joints and pillow block bearing setscrews on the flat surface of the
shafts.
Universal Joint Alignment
13. Lay a straightedge on the periphery of the driving universal joint.
14. Measure the distance between the straightedge and the driven universal joint at two
different points using a rule as shown in Fig.7.17.
Fig.7.17. Alignment of the universal joints.
15. Move the pillow block bearings that support the driven shaft until the two measurements
are the same
16. Tighten the pillow block bearing screws to the extrusions.

System Operation
17. Rotate the sheave a few turns.
 Ensure that the tip of the shafts do not interfere with the center block of the universal
joints.
 Ensure that the shafts are parallel. If not, realign the shafts.
 Rotate the sheave a few turns.
20. Disassemble the setup and return the components to the storage location
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7.7. GEAR POWER TRANSMISSIONS
Task: To assemble a parallel-axis gear drive, and a right-angle axis gear drive
using a set of helical gears.
Procedure
1. Perform the Safety Procedures .
2. Take the three helical gears from the Gear Hardware panel. A helical gear is shown
in Fig.7.18. , 7.18.1.
Fig.7.18. The two possible hands for a helical gear. Fig.7.18.1

7.7.1 Helical gear.
3. Identify the left-handed helical gear in Fig.7.18.1
Left-handed helical gear:
4. Determine whether the helical gear combinations found in Table.7.1. mesh

correctly.
DO THE GEARS MESH CORRECTLY?

HELICAL GEAR AXIS
COMBINATION CONFIGURATION
YES NO
Parallel
Right hand with
right hand
Perpendicular
Parallel
Right hand with left
hand
Perpendicular
Table 7.1. Helical gear combinations.
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5. Explain why helical gears are often preferred to spur gears for parallel axis
gear drives.
6. Is it possible to use helical gears to transmit power between shafts that are not
parallel or perpendicular?
a) Yes b) No
7. What type of lubricant should be applied to helical gears? Type of lubricant:
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Parallel-axis Helical Gear Drive

8. Set up the parallel-axis helical gear drive shown in Fig.7.18.2
Fig.7.18.2. Parallel-axis helical gear drive.
9. Determine whether the helical gears of the setup you assembled are of the same or
opposite hand.
Hand:
10. Align the gears.
11. Adjust the backlash.
12. Manually operate the parallel-axis helical gear drive to verify that the gears rotate
without interference. Repeat the alignment and/or backlash adjustment
procedure(s) if necessary.
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Right-angle axis Helical Gear Drive

13. Set up the right-angle axis helical gear drive shown in Fig.7.18.3.
Fig.7.18.3.Right-angle axis helical gear drive.
Note: Use an arbor press and the mandrel from the Gear Hardware panel to insert the bronze
sleeve into one of the helical gear.
14. Determine whether the helical gears of the setup you assembled are of the same
or opposite hand.
Hand:
15. Adjust the backlash.
16. Manually operate the right-angle axis helical gear drive to verify that the gears
rotate without interference. Repeat the alignment and/or backlash adjustment
procedure(s) if necessary
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7.7.2 WORMS AND WORM GEARS

Task: To assemble a non-intersecting axis right-angle gear drive using a worm and a
worm gear.
Procedure
2. Perform the Lockout/Tagout Procedure.
3. Count and record the number of thread(s) of the worm. A worm is shown in Fig.7.19 ,
7.19.1
Number of thread(s): _____________________
Fig.7.19 Fig.7.19.1
4. Determine whether the worm is right- or left-handed.
Worm hand:
5. Is it possible to mesh a worm and a worm gear with different hands? A worm gear is
shown in Fig.7.19.
a) Yes b) No
6. Which of the worm or the worm gear is most commonly the driving component?
Driving component:
7. What is one of the most common applications in which worm gear drives are found?
Most common application:
8. Set up the worm gear drive shown in Fig.7.20
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Fig.7.20. Worm gear drive.
Note: Use an arbor press and the mandrel to insert the bronze sleeve into the worm gear.
9. Perform the Start-up Procedure for the Variable Speed Motor.
10. Verify that the worm and worm gear rotate without interference.
11. Determine the speed ratio (n1/n2) of the worm gear drive if n1 is the speed of the
worm, and n2 is the speed of the worm gear.
Speed ratio (n1/n2):
12. Stop the motor by pressing the Stop button on the Start/Stop pushbutton station.
14. Determine what would be the speed ratio if the worm is replaced with one having
two threads, or starts.
15. Disengage the variable speed motor by removing the jaw coupling. Try to turn the
worm gear by hand and determine whether the gear drive is self- locking?
a) Yes b) No
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7.7.3 MITER GEARS

Task:To assemble an intersecting-axis miter gear drive using a set of miter gears.
PROCEDURE
3. Explain the difference between miter gears and bevel gears. A miter gear is shown in
Fig7.20.
Fig.7.20.. Miter gear.
4. Count the number of teeth in each miter gear and record the value.
Number of teeth:
5. Is it possible to build a speed reducer using the miter gears provided with your
trainer?
a) Yes b) No
6. What is the main function of miter gears?
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7. Set up the gear drive shown in Fig.7.21.
Fig.7.21. Intersecting-axis miter gear drive.
8. Roughly align the miter gears so that they are approximately perpendicular.
9. Adjust the miter gear mounting distance.
10. Perform the Start-up Procedure for the Variable Speed Motor.
11. Verify that the miter gears rotate without interference. Repeat the mounting
distance adjustment procedure if necessary.
12. Stop the motor by pressing the Stop button on the Start/Stop push button station.
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7.8 GEARBOXES
Task: To disassemble a gearbox and determine its characteristics. To install a gearbox
on a C-face constant speed motor.
Procedure
3. Disassemble the gearbox and identify the type of gears used.
Type of gears:
4. ount the number of teeth of each gear shown in Fig.7.22.
Fig.7.22. Gears enclosed in the gearbox.
N1: N2:
N3: N4:
5. Determine the speed ratio of the gearbox using the number of teeth of each gear.
Speed ratio:
6. Determine the speed of the output shaft if the motor shaft rotates at 1725 r/min.
Speed:
7. Identify the two types of seals installed in the gearbox.
8. Identify the type of lubricant required for this gearbox.
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Lubricant:
9. Fix the gearbox to the C-face constant speed motor as shown in Fig.7.23
Fig.7.23. Gearbox mounted on the C-face constant speed motor.
10. Perform the Start-up Procedure for the Constant Speed Motor.
11. Measure the speed of the output shaft and record the value.
Speed:
12. Stop the motor by pressing the Stop button on the Start/Stop push button station.
14. Does the speed of the output shaft corresponds to the calculated value?
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IMMT 211
CHAIN AND BELT DRIVES
LAB EX - 8
Lab - 8 Chain and Belt Drives
CHAIN AND BELT DRIVES
 Identify a chain, calculate its length, and break it.
 Align a two-sprocket chain drive. You will check for angular and parallel
misalignment, and execute the required adjustments.
 Measure and adjust chain sag on a two-sprocket chain drive.
 Calculate the speed of a driven sprocket from the driving sprocket speed and sprocket
teeth ratio.
 Measure the speed of a sprocket using a photo-reflective tachometer.
 Identify probable causes of faulty chain drive operation.
 Align, and tension a wedge V-belt drive and a notched wedge V-belt drive.
Key Words:
Chain, calliper, pitch, sprocket, barrel, extrusion, setscrew, bubble, alignment,
puller, needle.
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APPARATUS
 Chains
 Belts
SAFETY PRECAUTIONS
Procedure

Chain Pitch and Type

1. Take a chain from the tool box.
2. Using a dial calliper, measure the center-to-center distance between two adjacent
rollers as shown in Fig.8.1 to determine the chain pitch.
Chain pitch:
Fig.8.1. Pitch measurement.
3. Name the chain according to the measured pitch, chain type, and number of strands.
Chain designation:
4. Read the chain designation on a plate of the chain. Is your answer the same?
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Chain Length
5. Given the following parameters and the chain pitch you measured in the previous
section, calculate the required chain length for a chain drive having 15.25 in. between
the shaft centers, a 15-tooth driving sprocket, and a 30-tooth driven sprocket.
Breaking a Chain
6. Take the short chain No. 40 (p/n 36985-01) from the tool box.
Note: The 42-in. long chain (p/n 36985) must not be broken.
7. Install the chain breaker on a chain pin and snug the inner barrel against the chain
link as shown in Fig.8.2. Remove the center pin by screwing.
Fig.8.2. Breaking a chain.
Note: The chain of your training system is of the standard type.
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SPROCKET INSTALLATION
Objectives
In this lab, student will set up a two-sprocket chain drive. You will install the motor, pillow
block bearings, driven shaft, and sprockets.
Procedure
Universal Base Setup
3. Fix three T-slotted extrusions to the universal base as shown in Fig.8.3.
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4. Fix the constant speed motor mounting base to the extrusions.
Note: Make sure the tension adjustment screw on the motor mounting base is oriented as
shown in Fig.8.3
5. Fix the constant speed motor to the mounting base.
6. Place a shaft key into the motor shaft keyseat.
7. Slide the 15-tooth sprocket on the motor shaft as shown in Fig.8.4. The sprocket hub
must be on the motor side.
Note: Make sure the sprocket and motor shaft key are in line with the end of the motor shaft.
Fig.8.4. Driving sprocket installation.
8. Tighten the sprocket setscrew.

9. Install two pillow block bearings on the extrusions.
Do not tighten the screws now.
10. Slide a 9-in. shaft through one pillow block bearing.
11. Place a shaft key in the driven shaft keyseat.
Note: Because chain drives transmit high torque levels, it is preferable to use a key
instead of tightening the sprocket setscrew directly on the flat surface of the shaft.
____________________________________________________________________________________________________
13. Slide the 30-tooth sprocket on the shaft. Make sure the sprocket hub is on the motor
side.
14. Slide the shaft through the other pillow block bearing.
15. Center the driven shaft, then tighten the pillow block bearing setscrews.
Note: Always tighten the setscrews on the flat surface of the shaft. Tightening a setscrew
on the curved surface can damage the shaft.
16. Approximately align the sprockets (without instruments) and tighten the driven
sprocket setscrew.
SPROCKET ALIGNMENT
Procedure
Angular Alignment
3. Verify the vertical angular alignment by laying a combination square against the face
of the driving sprocket as shown in Fig.8.5. Note the position of the bubble.
Fig.8.5. Vertical angular alignment.
4. Lay the combination square against the face of the driven sprocket and note the
position of the bubble.
____________________________________________________________________________________________________
5. Adjust the vertical angular alignment so that the position of the bubble on the driven
sprocket coincides with its position on the driving sprocket. Insert shims under the
pillow block bearings as required.
Note: The bubble does not need to be centered. It must be at the same position on both
sprockets.
6. Verify the horizontal angular alignment by laying a straightedge on the face of both
sprockets.
7. Adjust the position of a pillow block bearing as shown in Fig.8.6.until the distances A
and B are equal.
Fig.8.6. Horizontal angular alignment.
8. Tighten the pillow block bearing screws.
Parallel Alignment
9. Lay a straightedge against the face of both sprockets and move the driven sprocket
until the four reference points of the sprockets are in contact with the straightedge
as shown in Fig.8.7.
Fig.8.7. Parallel misalignment.
____________________________________________________________________________________________________
13. Tighten the driven sprocket setscrew on the driven shaft key.
CHAIN INSTALLATION
Procedure

Note: The Universal Base should be set up from Job Sheet 3. Repeat Job Sheet 3 if necessary.
Chain Puller Method
3. Install the chain on the sprockets and hold the two free ends together with the chain
puller as shown in Fig.8.8. Turn the adjustment screw until the chain puller retains the
chain without your help.
Fig.8.8. Chain puller method.
4. Install a connecting link by inserting a plate with links and a side plate.
5. Install a locking clip using a needle nose plier as shown in Figure 9.
____________________________________________________________________________________________________
Sprocket Method
6. Dismount the connecting link using a needle nose plier as shown in Fig.8.9 ,8.9.1
Fig.8.9. Locking clip installation. Fig.8.9..1. Connecting link dismantlement.
Note: A connecting link should not be reused. This is done here for pedagogical purposes.
10. Install the chain with the two free ends on the driven sprocket as shown in Fig.8.10.
Fig.8.10. Sprocket method.
11. Install the connecting link.
Note: The locking clip must be assembled so that its closed end faces the direction of travel.
____________________________________________________________________________________________________
CHAIN TENSIONING
Procedure
Note: The Universal Base should be set up from Job Sheet 4. Repeat Job Sheet 4 if
necessary.
Allowable Sag
3. Using a tape rule, measure the center-to-center distance between the driving shaft and
driven shaft.
Distance:
4. Calculate the amount of allowable sag by multiplying the center-to-center distance by

4%.
Allowable sag:
Sag Adjustment
5. Lay a straightedge on the top side of the chain.
6. Transfer the slack on the top of the chain and measure the sag at chain midspan with a
rule as shown in Fig8.11.
Fig.8.11. Sag measurement
____________________________________________________________________________________________________
7. Add tension as required by turning the tension adjustment screw on the motor
mounting base.
SPEED, TORQUE, AND SPROCKET RATIOS
Procedure
Note: The Universal Base should be set up from Job Sheet 5. Repeat Job Sheet 5 if necessary.
Sprocket Speed Calculation
6. Calculate the teeth ratio (N2/N1) and driven sprocket speed of a two-sprocket chain
drive using the following parameters:
Driving sprocket speed = 1725 r/min

Number of teeth on the driving sprocket = 15
Number of teeth on the driven sprocket = 30
Teeth ratio:
Driven sprocket speed:

7. Make sure that a reflective tape is present on both sprockets as shown in Fig8.12.
Fig.8.12. Piece of reflective tape applied on a sprocket.

Start-up Procedure
____________________________________________________________________________________________________
8. Connect the motor to the built-in AC outlet on the frame of the universal base.
9. Ensure that all screws and setscrews are tightened.
10. Install the safety panels.
11. Ask your instructor to inspect the setup.
12. Ask each person to remove its padlock from the lockout device.
13. Remove the lockout/tagout device.
14. Ensure that the voltage output selector is set to FlXED.
15. Set the disconnecting switch to ON.
16. Start the motor by pressing the Start button on the Start/Stop push-button station.
Driving Sprocket Speed
17. Point the light beam of the photo-reflective tachometer toward the reflective tape on
the driving sprocket and measure the speed as shown in Fig8.13.
Driving sprocket speed (n1):
Fig.8.13. Speed measurement.

Driven Sprocket Speed
18. Measure the speed of the driven sprocket (n2) using the photo-reflective tachometer.
Driven sprocket speed (n2):
____________________________________________________________________________________________________

22. Using your measured speed values, calculate the speed ratio (n1/n2).
Speed ratio:
____________________________________________________________________________________________________
Driving Sprocket Replacement
Loosen the chain by turning the tension adjustment screw on the motor mounting base.
24. Unwrap the chain from the driving sprocket
25. Dismount the driving sprocket from the motor shaft and replace it by the 20-tooth
sprocket.
Note: Make sure the sprocket hub is on the motor side.
26. Tighten the driving sprocket setscrew.
27. Align the sprockets as described in Job Sheet 3.
28. Install the chain as described in Job Sheets 4 and 5.
29. Make sure that a reflective tape is present on both sprockets.
30. Calculate the teeth ratio (N2/N1):

Teeth ratio:
31. Perform a Start-up procedure.
32. Measure the speed of both sprockets using the photo-reflective tachometer: Driving
sprocket speed (n1):
Driven sprocket speed (n2):
33. Stop the motor by pressing the Stop button on the push-button station.
35. Using your measured speed values, calculate the speed ratio (n1/n2).
Speed ratio:
36. Does this ratio corresponds to the teeth ratio (N2/N1) you calculated?
a)Yes b)No
____________________________________________________________________________________________________
SPROCKET AND CHAIN MAINTENANCE
Procedure
Associate, with each symptom, all probable causes of faulty operation by checking the
appropriate boxes:
PROBABLE CAUSES
SYMPTOMS
Dirt in chain Excessive sag Chain rides
Shock Misalignment
joints too high
Broken link plates
Tight joints
Excessive noise
Deformed rollers
____________________________________________________________________________________________________
BELTS INSTALLATION
WEDGE AND NOTCHED WEDGE V-BELTS
Task: To assemble a wedge V-belt drive and a notched wedge V-belt drive.
PROCEDURE

2. Perform the Lockout/Tagout procedure.
3. Give an advantage wedge V-belts have over conventional V-belts.
4. Which of wedge V-belts or notched wedge V-belts have the greater tolerable degree of
bend?
V-belt:
Determine the length of a 5VX1500 V-belt.
Length: _________________________________
INSTALLATION
1. Set up a belt drive with the 3V400 V-belt as shown in Figure 1. Install the 3.30-in. D. single
groove wedge pulley on the motor shaft and the 4.45-in. D. single groove wedge pulley on
the driven shaft. Install a 5/8-in. bore, size H split taper bushing in each pulley.
2. Align the wedge pulleys.

3. Tighten the split taper bushing screws up to 95 lbAin.
4. Refer to Table.8.1 and determine the required belt deflection force.
____________________________________________________________________________________________________
Required deflection force:
RECOMMENDED
SMALL SMALL PULLEY DEFLECTION FORCE
BELT CROSS SPEED
PULLEY SPEED lb
SECTION RATIO
DIAMETER r/min
MINIMUM MAXIMUM
in.
2.65 to 2.80 1200 to 3600 3.0 4.3
3.00 to 3.15 1200 to 3600 2.00 3.3 4.8
3V 3.35 to 3.65 1200 to 3600 to 3.7 5.4
4.12 to 5.00 900 to 3600 4.00 4.4 6.4
5.30 to 6.90 900 to 3600 4.8 7.1
2.35 to 2.50 1200 to 3600 3.2 4.7
2.65 to 2.80 1200 to 3600 2.00 3.5 5.1
3VX 3.00 to 3.15 1200 to 3600 to 4.00 3.8 5.5
3.35 to 3.65 1200 to 3600 4.1 6.0
4.12 to 5.00 900 to 3600 4.8 7.1
5.30 to 6.90 900 to 3600 5.8 8.6
Table.8.1. Recommended deflection force for 3V and 3VX belts.

5. Adjust the tension of the belt.
6. Perform the Start-up Procedure for the Constant Speed Motor described in Appendix F.
9. Perform the Lockout/Tagout Procedure described in Appendix E.
10. Remove the belt from the drive but leave the rest of the setup.
11. Take a shaft, the 3V400 and 3VX400 belts.
12. Wrap the 3V400 belt around the shaft.
13. Force the belt to contour the shape of the shaft as shown in Fig.8.15
14. Repeat the same procedure with the 3VX400 belt.
15. Which of the 3V400 or 3VX400 belt contours more easily the shape
of the shaft?
Belt:
Fig.8.15. The 3V400 belt wrapped around a shaft.
____________________________________________________________________________________________________
16. Repeat the wedge V-belt installation procedure using the 3VX400 belt.
18. Disassemble the pulleys and belt from the universal base but leave the rest of the
setup as shown in Fig.8.16.
____________________________________________________________________________________________________
2. MULTIPLE-BELT DRIVES
Task: To assemble a multiple-belt drive.
PROCEDURE

3. Explain why using belts from different manufacturers in a multiple-belt drive is not
recommended.
4. Explain why all belts should be replaced at the same time when one of the belt breaks
in a multiple-belt drive.
INSTALLATION
1. Setup a multiple-belt drive with two 3V400 V-belts as shown in Fig.8.17. Install the 3.35-
in. D. double groove wedge pulley on the motor shaft and the 5-in. D. double groove
wedge pulley on the driven shaft. Install a 5/8-in. bore, size SH quick disconnect
bushing in each pulley.
2. Align the pulleys.
3. Refer to Table 5B-1, and determine the required belt deflection force.
____________________________________________________________________________________________________
5 .Perform the Start-up Procedure for the Constant Speed Motor described in Appendix F.
Fig.17. Universal base setup.

9. Disassemble the pulleys and belts from the universal base but leave the rest of the setup
as shown in Fig.8.18.
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3.MULTIPLE-SPEED BELT DRIVES
Task: To assemble a multiple-speed belt drive.
PROCEDURE
3. Which pulleys from the Pulleys 1 panel can be used in multiple-speed belt drives?
Pulleys:
INSTALLATION
1. Setup a multiple-speed belt drive with a 4L500 V-belt as shown in Fig.8.19. Install a
step-cone pulley on each shaft.
3. Refer to Table.8.2, and determine the required deflection force. Required deflection
force:
____________________________________________________________________________________________________
RECOMMENDED DEFLECTION
SMALL PULLEY PITCH
V-BELT CROSS- FORCE
DIAMETER RANGE
SECTION lbf
in.
MINIMUM MAXIMUM
2-3 2,4 3,6
A (4L) 3.1 - 4 2,8 4,2
4.1 - 5 3,5 5,2
Table.8.2. Recommended deflection force.
5. Make sure that a piece of reflective tape is present on both pulleys, and perform the Start-
up Procedure for the Constant Speed Motor described in Appendix F.
6. Measure the speed of the driving step-cone pulley.
Speed (n1):
7. Measure the speed of the driven step-cone pulley.
Speed (n2):
10. Calculate the speed ratio.
Modification of the Speed Ratio

1. Determine the pitch diameter of the steps, on both step-cone pulleys, around which the
belt must be wrapped to obtain a speed ratio of approximately 0.47.Fig.8.20.
Driving step-cone pulley pitch diameter (D1):
Driven step-cone pulley pitch diameter (D2):
2. Repeat the installation procedure with the pitch diameters you determined.
____________________________________________________________________________________________________
4. Measure the speed of the driving step-cone pulley.
Speed (n1):
5. Measure the speed of the driven step-cone pulley.
Speed (n2):
8. Calculate the speed ratio.
4. VARIABLE-SPEED BELT DRIVES
Task: To assemble a variable-speed belt drive.
PROCEDURE
3. Which pulley from the Pulleys 2 panel can be used to set up a variable- speed drive?
Pulleys:
____________________________________________________________________________________________________
INSTALLATION
1. Setup a variable-speed belt drive with a 4L500 V-belt as shown in Fig.8.21.. Install
the 3-in. D. pulley on the motor shaft, and the variable- pitch pulley on the driven
shaft.
Fig.8.21. Universal base setup

.
2. Perform the following steps to adjust the pitch diameter of the variable-pitch pulley:
* Hold the variable-pitch pulley with one hand and turn the mobile half clockwise until it
touches the other half.
* Turn the mobile half counterclockwise until the setscrew is aligned with the first flat surface
on the pulley hub as shown in Fig.8.22.
* Tighten the setscrew on the flat surface of the hub. This corresponds to a pitch diameter of
approximately 4.4 in.
Fig.8.22. Adjustment of the pitch diameter.
____________________________________________________________________________________________________
4. Measure the A distance as shown in Fi.8.23. and distribute it evenly (A/2) on the sides
of the driving pulley.
A distance:
Fig.8.23. Alignment of the pulleys.
5. Refer to Table 2, and determine the required deflection force.
7. Make sure that a piece of reflective tape is present on both pulleys, and perform the
Start-up Procedure for the Constant Speed Motor described in Appendix F.
8. Measure the speed of the driving pulley.
Speed (n1):
9. Measure the speed of the variable-pitch pulley.
Speed (n2):
____________________________________________________________________________________________________
12. Using the speed values, calculate the speed ratio.
13. Loosen the belt.
14. Turn the mobile half of the variable-speed pulley five turns in the counterclockwise
direction.
15. Tighten the mobile half setscrew on the flat surface of the hub.
16. Install the 4L500 V-belt on the pulleys, and align them.
18. Measure the speed of the driving pulley.
Speed (n1):
19. Measure the speed of the variable-pitch pulley.
Speed (n2):
22. Using the speed values and the pitch diameter of the driving pulley, calculate the pitch
diameter of the variable-pitch pulley using the following formula:
Pitch diameter (D2): Fig.8.24.
____________________________________________________________________________________________________
5. SYNCHRONOUS BELT DRIVES

Task: To assemble a synchronous belt drive.
PROCEDURE
3. What is the width of a 300L075 belt. Width:

Comparison Between Conventional and Synchronous Belt Drives
1. Setup a belt drive with a 4L500 V-belt as shown in Fig.8.25. Install a step- cone pulley
on each shaft, and wrap the belt around the middle step on both step-cone pulleys.
Fig.8.25. Belt drive with step-cone pulleys.
2. Mark both step-cone pulleys with a soapstone marker as shown in Figure 5-3-12.
Make sure that the marks are aligned.
3. Manually rotate one of the step-cone pulleys five turns in the clockwise direction.
4. Are the marks on both step-cone pulleys still aligned? Explain why.
____________________________________________________________________________________________________
5. Disassemble the step-cone pulleys and belt but leave the rest of the setup.
6. Setup a synchronous belt drive with a 367L050 belt as shown in Fig.8.26.
Install a 18-tooth timing belt pulley on each shaft.
Fig.8.26. Synchronous belt drive.
7. Align the timing belt pulleys.
8. Mark both timing belt pulleys with a soapstone marker. Make sure that the marks are
aligned.
9. Manually rotate one of the timing belt pulleys five turns in the clockwise direction.
10. Are the marks on the timing belt pulleys still aligned? Explain why.
11. Determine the value of each of the following parameters, and calculate the deflection
force.
Belt span (S): Belt length (L):
Tension (T): Constant (K):
Deflection force (F):
____________________________________________________________________________________________________
14. Ask your instructor to check your work.
17. Disassemble the pulleys and belt from the universal base but leave the rest of the
setup as shown in Fig.8.27.
____________________________________________________________________________________________________
6. HIGH TORQUE SYNCHRONOUS BELT DRIVES
Task: To assemble a high torque synchronous belt drive.
PROCEDURE
3. What is the pitch of a 9608M20 belt?
Pitch:
INSTALLATION
1. Setup a high torque synchronous belt drive with a 9608M belt as shown in Figure 6-1. Install
the 24-tooth HTD timing belt pulley on the motor shaft, and the 30-tooth HTD timing belt
pulley on the driven shaft. Install a 5/8-in. bore, size JA quick disconnect bushing in the 24-
tooth pulley bore, and a 5/8-in. bore, size H split taper bushing in the 30-tooth pulley bore.
Fig.8.28
Fig8.28. Universal base setup.
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IMMT 211
MECHANICAL EQUIPMENT
INSTALLATION AND
LEVELING
LAB EX - 9
Lab - 9 Mechanical Equipment Installation and Leveling
MECHANICAL EQUIPMENT INSTALLATION AND LEVELING
 Practice applying the safe and right rules of equipment installation including:
o Position selection
o Equipment outline for interference check,
o obstruction, trapping
o Service requirement
o Equipment mounting and fixing
o Site preparation
o Mounting preparation
o Installation with leveling.
 Practice checking the right application of installation techniques. Procedure For the
assigned equipment and following the right rules of equipment installation:
o Check the position and dimensions of the equipment.
o Check floor strength.
o Check outline.
o Check mounting of the equipment.
o Perform the required modifications.
o Prepare a "Work Order" for the required work
o Report your work
Key Words:
Pressure, rigid, indicator, alignment, fluid, concrete, precision, strain, suction, vibration,
catastrophic, extreme.
____________________________________________________________________________________________________
APPARATUS
 Pumps
SAFETY PRECAUTIONS

1. PUMP INSTALLATION AND START UP

2. 1. Read and understand the instruction
manual.
3. 2. Use a proper foundation. The foundation
should be rigid, level and clean of debris.
4. 3. Install the base on the foundation.
5. 4. Install the pump and the driver on the
baseplate.
6. 5. Add the proper oil to the proper level in
the bearing housings (pump, gear reducers,
etc.)
7. 6. Check initial alignment.
8. 7. Ground the base to the foundation. 15. Complete the pre-startup check
9. 8. Install piping. Read piping guidelines procedure; fill and vent the pump and
below. system, and check the system valve and
10. 9. Complete a second alignment check, and component "lineup".
readjust piping as needed. 16. Recheck alignment to ensure that fluid
11. With the coupling element removed, weight in the piping didn't cause a
complete a rotational check of the driver. change in the alignment.
12. Verify correct pump settings. 17. Start the unit.
13. Install ancillary equipment. 18. Check for proper indicators such as
14. Install coupling and/or insert. pressures, flows, temperature, vibration
and noise.
19. Recheck alignment. Perform "hot
alignment" if fluid is above 200°F.
____________________________________________________________________________________________________
FOUNDATION
The success to pump longevity begins with

a strong foundation. In general, a pump
should be mounted on a strong baseplate
and supported by a strong concrete
foundation. The pump should be properly
aligned to the motor as well as to the piping
system.
The concrete foundation must be Ensure that the baseplate's machined

substantial enough to absorb any vibration mounting surfaces are horizontal, flat and
and form a permanent rigid support for the parallel. To prevent stress and distortion of
baseplate. The anchor bolts are usually of the equipment, all surfaces in the same
sleeve type—or the "J" type—shown above plane must be within 0.002" overall.
and must be located in accordance with the
certified outline drawing of the baseplate. When the baseplate is level, check that all
support wedges or shims are in full contact
The entire surface of the foundation should with the foundation and baseplate. Tighten
be leveled by chipping away any defective the foundation anchor bolts evenly and
concrete, leaving it rough, but level. The double check the level.
surface must then be freed of all oil, grease
and loose particles. While individual The temperature of the baseplate, grout
practices vary throughout industry, there is and foundation should be kept between 40°
a tendency in most leading companies to F and 90° F during grouting—and for a
remove the pump and driver from the period of at least 24 hours afterwards.
baseplate prior to installation. This When using cement-based grouting, follow
facilitates leveling of the base and in the grout supplier's instructions in detail
removing any distortion. and ensure that the grout placement is
done quickly and continuously to prevent
The baseplate should be supported on cold joints and voids under the baseplate.
leveling screws, shims or metal wedges with The grout should be allowed to harden in
a small taper located close to the accordance with the manufacturer's
foundation bolts. All leveling screws and instructions.
other areas that require protection from
grout spatter should then be covered with a
wax to prevent the grout from adhering to
them. Check the machined mounting
surfaces on the baseplate by adjusting the
leveling devices and using a precision level.
____________________________________________________________________________________________________
SHAFT ALIGNMENT
Proper shaft alignment is critical to the

equipment's life. This means that the pump
and motor shaft are collinear across both
horizontal and vertical planes. In order to
maintain proper shaft alignment, you should
begin with proper pipe alignment and
support.
PROPER PIPE SUPPORT
Both the suction and discharge piping should

be aligned and independently supported so
that the pipe doesn't create any undesired
strain against the fluid connections of the
pump. Pipe strain is a leading factor in
causing shaft misalignment. Pipe support
should be balanced so that when fluid is
introduced, there is no movement that
would cause pipe strain on the pump.
SUCTION PIPING
As a rule of thumb the suction side with a

straight pipe run, in a length equivalent to 5
to 10 times the diameter of that pipe,
between the suction reducer and the first
obstruction in the line. This will reduce
turbulence into the pump, which reduces
unwanted vibration.
____________________________________________________________________________________________________
SHAFT ALIGNMENT CHECKS

A second alignment should be performed after piping installation and prior to start-up. While
some shaft couplings can compensate for some slight shaft misalignment, it is still
recommended to align equipment to the manufacturer's specifications and not the coupling's
specifications.
Shaft misalignment can lead to premature seal and bearing failure and often caused by the
following:
 Improper mounting/shimming of the equipment.
 Pipe strain caused by improper alignment to the pump's fluid connections
 Pipe strain cause by improper support of the pipe.
ROTATION DIRECTION
Prior to starting the equipment, it is extremely important that you uncouple the pump before
you check rotation of the driver. Running a pump in reverse rotation for even short time
periods can cause catastrophic failure. Some pumps utilize threaded impellers, which can
unscrew if run in the opposite designed direction. Even pumps with keyed impellers and lock
nut can also hydraulically loosen in time.
PRE-STARTUP CHECK & STARTUP PROCEDURE

Fill and vent the pump and system. Check the system valve "lineup". Review and verify the
preceding steps were accomplished. Remember, you cannot vent a running pump; the fluid
will come out, but the air trapped in the center of the machine will remain. The fluid has more
mass and will be flung to the outside.
Start the unit. Be prepared to stop the unit immediately if anything does not seem right.
Check for proper pressures, flows, temperature of oil and bearings, vibrations, and noise. It is
good practice to recheck the alignment after the pump has been operating for a short time.
If the pumped fluid is very hot (above 200° F), it is also good practice to perform a "hot
alignment."
____________________________________________________________________________________________________
2. MECHANICAL EQUIPMENT INSTALLATION STEPS
____________________________________________________________________________________________________
INSTALLATION REPORT:
____________________________________________________________________________________________________
IMMT 211
SERVICING MECHANICAL
EQUIPMENT
LAB EX - 10
Lab - 10 Servicing Mechanical Equipment
SERVICING MECHANICAL EQUIPMENT
 Disassemble and reassemble the gate valve and pneumatic valve.
 Understand RT 395 trainer.
 Perform Functional test of BUTTERFLY Valve with Pneumatic Drive.
 Perform Functional test of Pneumatic control valve with electro-pneumatic
Positioner.
 Perform Functional test of - Pressure reducer (Gas pressure control valve))
Key Words:
Valves, pumps, compressors, pneumatic, electropneumatic, analogue, fluctuates, socket,
extraction.
____________________________________________________________________________________________________
APPARATUS
 Valves
 Pumps
 Compressors
SAFETY PRECAUTIONS

Task 1: Disassemble the assigned gate valve and Identify and List the maintenance issues
in it.
Task 2: Disassemble the assigned pneumatic valve and Identify and List the maintenance
issues in it.
142
VALVES
THE RT 395 TRAINER
Maintenance of Valves and Fittings and Actuators - facilitates training on large and heavy industrial
valves.
The unit consists of a strong work bench with a wooden work surface and a switch panel. The switch
panel provides the student with the necessary electrical and pneumatic setting options for testing
and calibrating the valves. In addition, it contains measuring instruments that display the pneumatic
pressures and electrical variables such as voltage and current. There is a vice on the work bench for
assembly work.
The unit enables the student to connect various valves and to understand their function and
behaviour.
The four valves to be studied are as follows:
1. Pneumatic butterfly valve
2. Pneumatic ball valve
3. Pneumatic control valve with electropneumatic positioner
4. Pressure reducer
To operate, the unit requires an electrical power supply and a compressed air connection.
Fig.10.1 Valve work bench

10.1 UNIT DESCRIPTION
____________________________________________________________________________________________________
1 Butterfly valve with slewing gear 14 DC power supply 24V / 2A

2 Pneum. control valve with electro-pneum. 15 Compressed air maintenance unit
positioner 16 Master switch
3 Pressure reducer 17 Mains electricity connection
4 Fine pressure regulator 18 Spherical segment valve with slewing gear
5 Pressure gauge 0...6 bar 19 Adjustable current source 0...20 mA
6 Self-closing pressure gauge connections for 7 20 Digital voltmeter 0...20 VDC
7 Pressure gauge 0...2.5 bar 21 Digital ammeter 0...20 mA
8 Pressure gauge 0...1.6 bar 22 Fine pressure regulator
9 Self-closing pressure gauge connections for 10 23 Adjustable compressed air output 0...1.6 bar
10 Pressure gauge 0...1.0 bar 24 Compressed air changeover switch for 25
11 + pressure connection for 13 25 Switchable compressed air output
12 - pressure connection for 13 26 Adjustable compressed air output 0...6 bar
13 Differential pressure gauge 0...10 kPa
Fig.10.2 Maintenance on RT 395 Valves and Actuators
____________________________________________________________________________________________________
10.2 PRESSURE GUAGE:
In the upper section of the switch panel are three large analogue dial pressure gauges with different
measuring ranges.
– Differential pressure gauge (left)
Measuring range: 0...10kPa
Resolution: 1 Scd* = 0.1 kPa
– Pressure gauge for pressure relative to atmosphere
Measuring range: 0...1 bar (centre)
Resolution: 1 Scd = 0.02 bar
Accuracy: Class 1.0
– Pressure gauge for pressure relative to atmosphere
Measuring range: 0...2.5 bar (right)
Resolution: 1 Scd = 0.02 bar
Accuracy: Class 0.6
The smallest of the three pressure gauges is a differential pressure gauge. The connections for the
pressure (top) and intake side (bottom) are located
on the right next to the display. The other two pressure gauges measure the excess atmospheric
pressure or pressure relative to the atmosphere in bar. The connections in the switch panel are two
connecting sockets connected in parallel. The connecting sockets are self-closing, i.e. when the
corresponding connectors are removed, the sockets close. As the sockets are self-closing, it is possible
that when the sockets are closed and the atmospheric pressure fluctuates the indicator will fall below
zero. Briefly opening the socket corrects the pressure.
10.3 Compressed air extraction connections and changeover switch for sudden
____________________________________________________________________________________________________
pressure changes
In the lower right-hand area of the switch panel are three different compressed air extraction
connections, each with two self-closing connecting sockets. For the two outer connections numbered
“1" and ”2", the pressure can be adjusted with the fine regulator valve above. The small pressure
gauge above the fine regulator valve displays the set pressure. Connection “1" has an adjustment
range of 0...1.6 bar and connection ”2" has an
adjustment range of 0...6 bar.
Between the two compressed air extraction points “1" and ”2", there is a further extraction point
“½", which provides the pressure from ”1" or “2" at the central connection, depending on the position
of the changeover switch. This output ”½" is used to easily create sudden pressure changes.
Fig10.3: Compressed air extraction connections with changeover and adjusting function
10.4 Adjustable current source
____________________________________________________________________________________________________
Fig.10.4 : Electrical control panel 1 - Power supply 2 - Adjustable current source 3 - Voltmeter 4 - Ammeter
Below the three pressure gauges to the left of the air supply is the electrical valve testing unit. The
upper of the three digital displays is an adjustable current source with a range of 0...20 mA. To set a
current, a consumer with an ohmic load must first be connected to the right of the display. The ohmic
load can be a maximum of 500 Ohm.
CAUTION! Above 500 Ohm, the range automatically switches to 0...10 V. The current setting is made
using the arrow keys on the unit. Pressing the up arrow key increases the current. Pressing the down
arrow key reduces the current.
Ammeter and voltmeter with digital display Below the adjustable current source are two digital
displays, each with connecting sockets on the right hand side. Right at the bottom is the display for
the ammeter with a measuring range of 0...20 mA. The central digital display is for a voltmeter with
a measuring range of 0...20 VDC.
NOTE: Do not change the functions of the keys. 2.6 Power supply The power supply provides a 24 V
DC voltage and
is suitable for a maximum load of 2 A.
The power supply output on the switch panel takes the form of four 4 mm signal jacks. These jacks
are located to the left of the adjustable current source.
____________________________________________________________________________________________________
10.5 Compressed air maintenance unit
The compressed air maintenance unit

allows the pressure of the compressed
air supply to be reduced and kept
constant with a valve. The air is also
filtered and all condensate is removed.
Any condensate is collected in the gas
tank and can be drained by loosening the
lower knurled screw. To adjust the
pressure, the adjusting knob should be
slightly lifted. To prevent unintentional
adjustment, the adjusting knob should
be lightly pressed down again after
Fig.10.5. Compressed Air Maintenance adjusting the pressure.
Unit
Commissioning
Connect unit to the compressed air supply. The connection is made using the compressed air
maintenance unit on the left-hand side of the switch panel. The initial pressure on the
maintenance unit should be set to approx. 8 bar. In addition, the electrical power supply should
be connected.
Maintenance / Care
The unit is maintenance-free to a large extent. However, the maintenance unit should be drained
of any condensate.
SAFETY:
DANGER! Caution when opening switch housing, and when making
changes to all other electrical circuits. There is a risk of electric shock.
Always remove the mains connector beforehand. Work should only be
carried out by specialist personnel.
CAUTION! Before dismantling pneumatic experimental layouts, first
set the pressure regulator to zero (Fig. 2.1-Pos. 4/22) and then loosen
the rapid action couplings directly on the switch panel.
ATTENTION! Do not connect valves actuated with the 0...20 mA
current interface to the 24 V DC supply.
ATTENTION! For experiments with compressed air, do not exceed the
measuring ranges of the pressure gauges.
____________________________________________________________________________________________________
Task 3: Functional test of BUTTERFLY Valve with Pneumatic Drive.
 Switch on master switch

 Ensure compressed air supply is
connected
(8 bar)
 Use the two fine regulator valves
and the
pressure gauge to set the output
pressures
(e.g. 1 bar / 5 bar)
 Connect compressed air connection
on butterfly valve to a compressed
air line and then
connect the other end of the
compressed air
line to the switchable compressed
air output
marked “½".
 Use the changeover switch to test
the function of the butterfly valve
 Supply butterfly valve with 1 bar
 Check position of valve
Fig.10.6: Pneumatic butterfly valve
 Valve is closed
(spring readjustment) A - Compressed air
 Supply butterfly valve with 5 bar
connection B - Position display
 Check position of valve
 -> Valve is open
Function
Turning the valve shaft (right/clockwise)
closes the
fitting. The maximum swivelling range is
90°.
ATTENTION! When dismantling the
experiment, first of all disconnect the
compressed air line from the self-closing
output on the switch panel.
____________________________________________________________________________________________________
Task 4: Functional test of Pneumatic control valve with electro-pneumatic

positioner
Function
In the positioner, the I/P
transducer (currentpressure
converter) converts the DC control
signal
in the range 4...20 mA coming
from the control
device into a proportional pressure
signal. This
pressure signal pe creates an
adjusting force at a
measuring diaphragm, which is
compared with the
force of a spring. The lever
transmits the movement of the
measuring diaphragm to the
double
cone of the amplifier, so that a
corresponding
operating pressure pst is initiated.
Fig.10.7. Pneumatic control valve with The operating pressure pst is the
electro-pneumatic positioner reference variable that determines
0...20 mA the flow in the valve by way of
A - Connection for pneumatic the adjusting drive, the drive rod
auxiliary power and the valve
cone. The stroke can be read off
on the drive rod.
See also appendix - “Installation
and operating
instructions for electro-pneumatic
positioner”
ATTENTION! When dismantling the

experiment, first of all disconnect
the compressed air line from the
self-closing output on the switch
panel.
____________________________________________________________________________________________________
 Ensure compressed air supply is connected (8 bar)
 Use the fine regulator valve and the pressure gauge to set the output pressure for
the valve auxiliary power (e.g. 3 bar)
 Attach a compressed air hose to the valve compressed air connection and then
connect to the compressed air output, e.g. at 3 bar.
 Create the electrical connection between the positioner and the adjustable current
source. Connect a red signal lead to the red (+) socket and a blue signal lead to the
blue (-) socket.
 Use the keys for the adjustable current source to change the position of the valve
and then check the valve position.
 Actuating signal: Iout = 0 mA
 >Valve closed
 >Valve closed
 >Valve ½ closed
 >Valve open
ATTENTION! When dismantling the experiment,

first of all disconnect the compressed air line from
the self-closing output on the switch panel.
ATTENTION! Do not connect the valve’s electrical
connection lead to a 24 V supply.
Task 4: Functional test of - Pressure reducer (Gas pressure control valve)
____________________________________________________________________________________________________
Function
The valve controls the output pressure

depending on the set pre-tension of the
spring. This directly controlled proportional
valve for pressure regulation is referred to as
a pressure reducer. The drive diaphragm
converts the pressure into a force acting in
the cone closing direction. The force from
the pre-tensioned spring is transmitted to
the spindle through the cross pin and
coupling and is opposed to the diaphragm
force and thus acts in the opening direction
of the cone. If the two forces are of equal
magnitude, there is equilibrium and the
minimum pressure set using the adjusting
plate (5) is corrected. When the minimum
pressure is changed, the cone is adjusted in
Fig.10.8. Pressure reducer the relevant direction “open” or “close”.
1. Compressed air connection at

pressure reducer input
2. Compressed air branch at output to

allow extraction of compressed air
for connection of drive diaphragm.
3. Valve with silencer to allow

adjustment of the air flow through
the pressure reducer
4. Compressed air connection to allow

the drive diaphragm to be supplied
with compressed air.
5. Adjusting plate for the spring
____________________________________________________________________________________________________
 Ensure compressed air supply is connected (8 bar)
 Use the right-hand fine regulator valve and the pressure gauge to set the output
pressure for the valve auxiliary power to 6 bar.
 Connect compressed air output (Fig.4.19- 2) before the manual valve to the
compressed air connection on the diaphragm unit Fig. 4.19- 4).
 Attach a compressed air hose to the input on the valve and then connect to the
compressed air output on the switch panel at 6 bar.
 Open manual valve at pressure reducer output.
 Relive the spring in the pressure reducer by turning the adjusting plate to the left. The
pressure reducer closes.
 Now pre-tension the spring by turning the adjusting plate to the right, until a
minimum pressure of approx. 0,8-2,5 bar is attained.
The size of the pressure reducer with a nominal diameter of 15 makes it very difficult
to
check the control function with a 6 mm compressed air line. In the range from
0,8-2,5 bar, it is only possible to identify the
control function in a very narrow range. Raising the valve seat by a few tenths of a
mm is
enough to allow more compressed air to
pass than the air supply can deliver.
 Adjusting the manual valves before or after the pressure reducer should allow a
response from the pressure reducer to be observed.
ATTENTION! When dismantling the experiment,
first of all disconnect the compressed air line from
the self-closing output on the switch panel.
PUMPS
____________________________________________________________________________________________________
SERVICING OF PUMP STATION
Performance objectives
Upon completion of the lab exercise, the student technician will be able to:
1. Identify pumping systems, components and types of pumps.
2. Check the installation of pumps.
3. Check pumps for:
a) Leakage
b) Noise and vibration
c) Condition of impeller
d) Wearing rings and clearance
4. Check pipeline for:
a) Leakage
b) Condition and leakage of valves
c) Condition, leveling and installation of pipes
5. Perform measuring major dimensions of the system.
6. Layout the system.
Procedure
For the assigned pumping system
1. Identify category and uses of the system.
2. Identify type(s) of pump(s).
3. Check the installation of pump(s).
4. Check the pump.
5. Check the pipeline.
6. Perform the major dimensions of piping system.
Pumping system:
____________________________________________________________________________________________________
Technical Specifications:
Operation Symptoms:
INSPECTION OF PUMPS
____________________________________________________________________________________________________
Component Condition Service Needed
 Casing
 Impeller
 Packing & SB
 Wearing ring
 Shaft
 Gaskets
 Bearings
 Coupling
INSPECTION OF PIPELINES
 Pipes
 Gaskets &
Joints
 Valves
____________________________________________________________________________________________________
____________________________________________________________________________________________________
COMPRESSORS
SERVICING OF COMPRESSOR STATION
PERFORMANCE OBJECTIVES
Upon completion of the laboratory exercise, the student technician will be able to:
1. Identify compressed air systems, components and types of compressors.
2. Check the installation of compressors and components.
3. Check compressors for:
a) Condition of suction and discharge valve.
b) Noise vibration.
c) Alignment of compressor.
d) Condition of piston and piston rings, bearings, cylinder, connecting rod and
crankshaft.
4. Check pipeline for:
a) Gasket leakage.
b) Condition and leakage of valve.
c) Noise and vibration of pipeline.
5. Perform measuring major clearances between the components.
PROCEDURE
For the Assigned Air Compressor System

1. Identify category and uses of the system.
2. Identify type(s) of compressor(s).
3. Check the installation of compressor(s).
4. Practices dismantle the compressor.
5. Check the pipelines.
6. Perform the major dimensions.
7. Layout the system
____________________________________________________________________________________________________
Technical Specifications:
Compressor
 Type:
 Power:
 Capacity:
 Pressure:
 No. of Cylinder:
 Cylinder arrangement:
 No. of Stages:
 Cooling System:
 Power Transmission System:
 Operating Symptoms:
Inspection of Components
 Piston
 Piston rings
 Cylinder
 Piston rod
 Connecting
rod
 Crankshaft
 Suction and
discharge valve
 Bearings
____________________________________________________________________________________________________
Inspection of Pipelines
 Pipes
 Gasket and joint
 Valves
____________________________________________________________________________________________________
____________________________________________________________________________________________________
Bibliography
1. Lab view manuals

2. https://savree.com/en/3d-models/centrifugal-pump-cross-section
3. https://www.engineeringtoolbox.com/pumps-parallel-serial-d_636.html
4. https://www.quincycompressor.com/tips-for-working-safely-with-compressed-air/
35T 35T
5. https://eparts.bitzer.de/index.php/m/spc/index/catalog/BITZER/path/%2C0%2C1
35T
6. https://www.bitzer.de/shared_media/html/matrix/enGB/matrix.html?P=/html/matrix/e
n-GB/&N=matrix.html
7. https://www.wisc-online.com/LearningContent/mtl10702/MLT10702.html
8. https://www.phonenixpumps.com/pump-installation-guide-checklist.html

IMMT 211 Principles of Mechanical Maintenance - LAB MANUAL

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IMMT 211 Principles of Mechanical Maintenance - LAB MANUAL

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IMMT 211

MECHANICAL SKILLS DEPARTMENT

Year: June 2022

HAND AND POWER TOOLS

HAND AND POWER TOOLS

Learning Objectives Of This Laboratory Exercise:

1.2 SAFETY PRECAUTIONS

1) Select the proper tool for the job.

1.4 MAINTENANCE OF LABORATORY SAFETY GUIDELINES

1) Shoes must completely cover the foot. No sandals are allowed.

1. Select the required tool

Tool Selection Name of the Performance % Return of

Tool Selection Name of the Performance % Return of

LAB Performance Grade: /20

MAINTENANCE PROCEDURE OF EQUIPMENT

Learning Objectives Of This Laboratory Exercise:

 Understand the essence of work order and job report

2.2 SAFETY PRECAUTIONS

2.4 WORK ORDER OR JOB REQUEST

When a problem is discovered in a plant, a maintenance supervisor makes a preliminary

2.5 ADVANCE PLANNING FOR MAINTENANCE TASK

2.6 PERMIT TO WORK (P.T.W) AND TAGGING

2.7 EXERCISES FOR PUMPING STATION:

Fig 2.2: Pumping Station

1. Inspections of pumping station and determination of required maintenance work

1 Performance of equipment Safety isolation and TAGOUT/LOCKOUT

2 Tools and area preparation for dismantling (gate valve / pump)

There are standard rules for disassembly

i. Doing things by procedure

ii. Gather Tools required. Construct table for tools

Parts and remarks of the gate valve:

ii. Gather Tools required. Construct table for tools

Parts and remarks of the gate valve:

6. Gather the tools

LAB Performance Grade: /20

Learning Objectives Of This Laboratory Exercise:

 Be sure to establish the weight of the load.

Taks 1: Identify the Lifting and Rigging Equipment:

Task 2: Calculate the weight of Load:

Task 3: Perform the following knots with the given ropes:

3. Half turn and 2 half hitches

4. Double sheet bend

5. Double sheet bend

Lifting Sling Colour Code

The typical lifting sling colour code is as follows:

Purple Lifting Slings

Capable of lifting up to one tonne of weight max.

Green Lifting Slings

Capable of lifting up to two tonnes of weight max.

Yellow Lifting Slings

Capable of lifting up to three tonnes of weight max.

Grey Lifting Slings

Capable of lifting up to four tonnes of weight max.

Red Lifting Slings

Capable of lifting up to five tonnes of weight max.

Brown Lifting Slings

Capable of lifting up to six tonnes of weight max.

Blue Lifting Slings

Capable of lifting up to eight tonnes of weight max.

Orange Lifting Slings

b) Find the load of the given bar.

Learning Objectives Of This Laboratory Exercise: