Industrial Machinery Repair Part Episode 1 Part 3 ppsx

34 Maintenance Skills Assessment C. Drip lubricator. D. Oil sump. 18 A lubrication system in which the component needing lubrication rotates through an enclosed housing containing oil and carries the oil to other components is called a(n): A. Dip lubricator. B. Shot lubricator. C. Drip lubricator. D. Oil sump. 19 In a force-feed lubrication system, lubricant is moved to the component needing lubrication by a: A. Cooler. B. Pump. C. Filter. D. Bearing. 20 What is the most undesirable by-product of oil misting? A. Bearing failure B. Shaft damage C. Explosion potential D. Oil breakdown Knowledge Area: Bearings 1 The two basic categories of bearings are: A. Plain and antifriction. B. Ball and roller. C. Journal and ball. D. Pillow-block and roller. 2 Bearings: A. Are found in machines with moving parts. B. Function as guides. C. Help reduce the friction between moving parts. D. All of the above. Maintenance Skills Assessment 35 3 Thrust bearings: A. Support axial loads on rotating members. B. Support radial loads on rotating members. C. Both A and B. D. None of the above. 4 Antifriction bearings: A. Contain balls. B. Contain rollers. C. Will run hot if they are overlubricated. D. All of the above. 5 Bearing lubrication systems include: A. Lubrication by hand. B. Central grease systems. C. Pressure-feed oil systems. D. All of the above. 6 Plain bearings operate by: A. Separating the races with balls or rollers. B. Using an air gap. C. Hydraulics. D. Running on a film of lubricant. 7 Antifriction bearings operate by: A. Separating the races with balls or rollers. B. Using an air gap. C. Hydraulics. D. Running on a film of lubricant. 8 Roller bearings are used over ball bearings for which of the following situations? A. High-speed applications B. High-load applications C. Wet environments D. Mobile equipment engines 9 Bearing clearance can be described as: A. The space between the rolling elements and the races. B. The allowed difference between the shaft size and the bearing inner race. C. The allowed differences between bearing inner and outer race. D. None of the above. 36 Maintenance Skills Assessment 10 Shaft tolerance can be defined as: A. The allowed difference between the shaft size and the bearing inner race. B. The force applied during installation. C. The space between the rolling elements and the races. D. None of the above. 11 The preferred method for installing an antifriction bearing is: A. With a sledge hammer. B. To sand down the shaft until the bearing slides on. C. With a bearing heater. D. Both B and C. 12 When tightening the lock-nut on a spherical roller bearing, the preferred tool is: A. A spanner wrench. B. A bearing heater. C. A hammer and punch. D. None of the above. 13 The bearing best suited for both radial and thrust loads is a bearing. A. tapered-sleeve B. linear-motion C. needle D. tapered-roller 14 A bearing lubricated with oil is capable of speeds than the same bearing lubricated with grease. A. lower B. higher C. the same D. different 15 As you tighten the nut on a spherical-roller bearing, the space between the race and the rolling element: A. Increases. B. Decreases. C. Remains the same. D. Develops cracks. Maintenance Skills Assessment 37 16 On a metric bearing with the number 7307, the ID of the bearing is: A. 35 mm. B. 7 mm. C. .035". D. .007". 17 To convert the metric shaft size of a bearing to inches, you multiply the millimeters by: A. 5. B. 39. C. .03937. D. .05. 18 A failed bearing that has a cracked inner race probably failed because: A. the shaft was too large. B. of a lack of lubricant. C. the operator failed to do the proper inspection. D. of overlubrication. 19 An antifriction bearing can run hot because: A. of overlubrication. B. it is about to fail. C. of excessive load. D. all of the above. 20 A 20% increase in bearing load, can result in a % decrease in bearing life. A. 20 B. 100 C. 50 D. 10 Knowledge Area: Chain Drives 1 What is the maximum elongation that a roller chain can tolerate before it should be replaced? A. 10% B. 3 inches 38 Maintenance Skills Assessment C. 3% D. 3 16 inch per ft. of chain 2 What causes roller fatigue? A. Lack of lubrication B. Contamination C. Improper chain tension D. All of the above 3 What problems will chain misalignment cause? A. Side plate wear B. Sprocket wear C. Pin wear D. Chain break 4 What are the two most important factors in the life of a silent chain drive? A. Lubrication and alignment B. Lubrication and tension C. Tension and alignment D. All of the above 5 What type of machine guard limits the operator’s access to the danger zone? A. Safety chain B. E-stop C. A barrier guard D. None of the above 6 What type of machine guard prevents access to the danger zone altogether? A. An enclosure guard B. Safety chain C. Barrier guard D. None of the above 7 Name the two main groups of mechanical couplings: A. Rigid and flexible. B. Chain and gear. C. Grid and Lovejoy. D. Spring and centrifugal. Maintenance Skills Assessment 39 8 Large fans are typically powered in what way? A. Motor and belts B. Motor and chain drive C. Motor direct drive D. Motor, gearbox, and belts 9 Which type of conductivity cells are usually equipped with a safety chain to prevent the cell from blowing out? A. Immersions B. Insertion C. Flow D. Screw-in 10 Chain-linked fences should be topped with: A. Three strands of electrically energized wire. B. Barbed wire. C. A skirt of the same material that kicks back 45 degrees and extends 18 inches. D. None of the above. 11 What are the two links that make up a standard roller chain? A. Roller, rigid B. Roller, pin C. Master, half D. Offset, half 12 On a roller chain with a designation of 35, what do the 3 and the 5 designate? A. 3 is the size in inches; 5 is the duty B. 3 is the duty; 5 is the size in thousandths of an inch C. 3 is the size in eighths of an inch; 5 means a rollerless chain D. 3 is the size; 5 means heavy duty 13 What is the maximum elongation that a roller chain can tolerate before it should be replaced? A. 10% B. 3 inches C. 3% D. 3 16 inch per ft. of chain 40 Maintenance Skills Assessment 14 What causes roller fatigue? A. Lack of lubrication B. Contamination C. Improper chain tension D. All of the above 15 What problems will chain misalignment cause? A. Side plate wear B. Pin wear C. Chain break D. All of the above 16 What are the two most important factors in the life of a silent chain drive? A. Lubrication and alignment B. Lubrication and tension C. Tension and alignment D. Tension and speed 17 Name the two main groups of mechanical couplings. A. Rigid and flexible B. Chain and gear C. Grid and Lovejoy D. Spring and centrifugal 18 What type of machine guard limits the operator’s access to the danger zone? A. Safety chain B. E-stop C. A barrier guard D. None of the above 19 What type of machine guard prevents access to the danger zone altogether? A. An enclosure guard B. Safety chain C. Barrier guard D. None of the above 20 What is the tension or slack a roller chain is recommended to have? A. 10% slack between centers B. 1 2 inch slack C. 5% slack between centers D. 2% slack between centers Maintenance Skills Assessment 41 Knowledge Area: Belt Drives 1 Of the following, what are the four main types of belt drives? A. V-belt; flat belt; timing belt; ribbed belt B. Straight belt; V-belt; gear belt; ribbed belt C. Rubber; vitron; buna-n; teflon D. Round belt; dual face belt; V-belt; multibelt 2 Identify routine maintenance performed on flat belts. A. Tensioning B. Cleaning C. Dressing D. Both A and B 3 Which of the following is an acceptable V-belt installation process? A. Reduce center-to-center distance of the pulleys. B. Use a pry bar to slide the belt over the pulleys. C. Tension the belt until your hand bounces off the belt. D. All of the above. 4 Which of the following contribute to rapid belt wear? A. Oil, dirt, heat, and alignment B. Water, dirt, sunlight, and tension C. Guarding, shielding, reflection, and direction D. Sunlight, dry-rot, mold, and water 5 Why do timing or gear belts not require high tension? A. They do not require tensioning. B. The material they are made of reduces slippage. C. They provide slip-proof engagement. D. There is not load fluctuation. 6 Different speeds are required for various materials when cutting with a band saw. How is saw speed adjusted? A. Set the speed indicator to the desired rpm and start the machine. B. Adjust the belt tensioner and start the machine. C. Start the machine and adjust the speed indicator. D. Dial in the correct job selector and start the machine. 7 Belt drives are designed to transmit power between a drive unit and a: A. Conveyor belt. B. Motor. 42 Maintenance Skills Assessment C. Driven unit. D. Roller. 8 A drive belt with the designation “XL” would indicate which of the following types? A. Cogged, fractional horsepower B. Conventional V-belt C. Narrow V-belt D. Positive drive belt 9 A drive belt with the designation “C” would indicate which of the following types? A. Power band belt B. Conventional V-belt C. Narrow V-belt D. Fractional horsepower 10 A drive belt with the designation “V” would indicate which of the following types? A. Positive drive belt B. Conventional V-belt C. Narrow V-belt D. Fractional horsepower 11 A “C” belt with a nominal length of 60 inches is 4 10 " long. What identification should be marked on the belt? A. C410 B. C60/4 C. C64 D. C56 12 When replacing one of a set of belts, the mechanic should: A. Replace the worn belt only. B. Replace the worn belt and the belt closest to the drive motor. C. Replace all of the belts. D. Replace the worn belt and the belt farthest from the drive motor. 13 What criteria should be used to determine if a belt needs to be replaced? A. The belt protrudes above the top of the sheave no more than 1 16 ". B. The belt is flush with the top of the sheave groove. C. The belt is recessed more than 1 16 " into the groove sheave. D. The belt is recessed more than 1 8 " into the groove sheave. Maintenance Skills Assessment 43 14 The length of belt is determined by its: A. Pitch line. B. V-line. C. Standard line. D. None of the above. 15 When “timing” is a critical consideration with a belt, which of the following is typically used? A. Joined belt B. V-belt C. Cogged belt D. Positive drive belt 16 Regarding sheave grove angle, which of the following statements is correct? A. Smaller diameter sheaves have less groove angle than larger diame- ter grooves. B. Larger diameter sheaves have less groove angle than smaller diame- ter sheaves. C. Groove angles are not affected by sheave diameter. D. Can be compensated for by adjusting belt tension. 17 Which of the following conditions can cause excessive belt wear? A. Dirty operating conditions B. Improper sheave alignment C. Improper tensioning D. All of the above Knowledge Area: Hydraulics 1 What function does a reservoir serve in a hydraulic system? A. Stores surplus of oil B. Cools the oil C. Cleans the oil D. A, B, and C 2 Why is there a baffle in a hydraulic reservoir? A. To prevent baffling B. To assist in cleaning and cooling of the oil C. To keep the oil level the same D. To prevent overpressurization of the reservoir [...]... right/20 = Belt Drives: total right /17 = Hydraulics: total right /16 = Couplings: total right /17 = Final Score: total of the scores / 13 0 = 69% or below = Needs extensive mechanical training 70% –79% = Needs moderate mechanical training 80% –95% = Needs to review mechanical subject areas 95% 10 0% = Needs no training 4 Safety First, Safety Always Introduction As an industrial mechanic, you should always... been load tested within the last 12 months Death, injury, equipment damage, loss of equipment run time None needed 3 Score total = 8 Safety First, Safety Always 53 Risk = High/Danger Note: Task risk scale: The score for a risk is only determined once the countermeasures are followed; 1 = no risk; 2 = moderate risk; 3 = high risk (other countermeasures must be found) ANY 3 must be addressed immediately... Safety First, Safety Always WARNING: Sample Only—Table 4 .1: This table is designed to provide a maintenance person with the understanding of the risk assessment process and should not be used for any determination of risk or safety criteria Table 4 .1 Risk Assessment Worksheet Risk Assessment Worksheet Task: Replace 10 0hp Electric Motor Date: 10 /19 /02 Name of Person Performing Risk Assessment: Ricky Smith... Grease Forced air Process fluid Oil 13 Hose connections that are frequently made and “broken” would use which of the following types of couplings? A B C D Flange Push-on Quick-connect Reusable 14 KAMAG generators may use any number of drivers Which of the following coupling types are NOT recommended to tie the two together? A B C D Flexible Gear Solid Both B and C 15 A common return signal wire shared... in, direct flow D Control, directional control 10 What are the two basic types of actuators in a hydraulic system? A B C D Bladder, piston Cylinder, motor Double cylinder, single cylinder Pump, actuator 11 Which of the following are means by which a directional control valve may be actuated? A B C D Manual Solenoid operated Pilot pressure All of the above 12 The variable volume pump used most often in... liquid C A and B D None of the above 15 Component parts connected to each other by fluid lines in the hydraulic system form a: A B C D Closed center system Bypass Circuit Motor 46 Maintenance Skills Assessment 16 A needle valve in a hydraulic line provides a: A B C D Flow control orifice Pressure control orifice Relief valve Master valve Knowledge Area: Couplings 1 A major advantage of flexible couplings... mesh 10 Some centrifugal compressors use a high-speed gear-type coupling How is this type of gear attached to the compressor shaft? A B C D Bolted Welded Keyed Interference fit 11 With high-speed gear couplings, gear teeth showing a large polished area indicate which of the following? A B C D Proper gear mesh Unit operation beyond recommended capacity Gear wear Galling 48 Maintenance Skills Assessment 12 ... of imbalance, misalignment, etc., in a rotating part based on the measurement of vibration signals Sources of Vibration due to Mechanical Imbalance Two major sources of vibration due to mechanical imbalance in equipment with rotating parts or rotors are: (1) assembly errors and (2) incorrect key length guesses during balancing Assembly Errors Even when parts are precision balanced to extremely close... high-pressure systems is what type of pump? A B C D Vane Piston Gear Centrifugal 13 Basic hydraulics theory tells us that pressure: A On a confined liquid is transmitted undiminished in every direction B Acts with equal force on equal areas C Acts at right angles only on the container side walls D Acts with equal force on reduced areas 14 Hydraulics is the science of transmitting force or motion through a medium... pads may be used to prevent cutting shoulders and help reduce fatigue To lift an object off the ground, the following are manual lifting steps: Make sure of good footing and set your feet about 10 to 15 inches apart It may help to set one foot forward Assume a knee-bend or squatting position, keeping your back straight and upright Get a firm grip and lift the object by straightening your knees—not your . duty 13 What is the maximum elongation that a roller chain can tolerate before it should be replaced? A. 10 % B. 3 inches C. 3% D. 3 16 inch per ft. of chain 40 Maintenance Skills Assessment 14 . life. A. 20 B. 10 0 C. 50 D. 10 Knowledge Area: Chain Drives 1 What is the maximum elongation that a roller chain can tolerate before it should be replaced? A. 10 % B. 3 inches 38 Maintenance Skills. cracks. Maintenance Skills Assessment 37 16 On a metric bearing with the number 730 7, the ID of the bearing is: A. 35 mm. B. 7 mm. C. . 035 ". D. .007". 17 To convert the metric shaft size