Lesson 1: Introduction to Troubleshooting

Topics

Troubleshooting skills, duties, aids; Mechanical and electrical troubleshooting; Maintenance organizations and personnel; Scheduling

Learning Objectives

• Tell why efficient troubleshooting is important in a production plant.
• Name the four common troubleshooting aids.
• List the steps in troubleshooting a machine.
• List the steps in troubleshooting a system.
• Describe a typical maintenance organization.

Lesson 2: Working with Other People

Topics

Communication; People skills; Aids to communicating; Differences of opinion; You and your supervisor; Upgrading your skills

Learning Objectives

• Tell why good communication between plant personnel is needed.
• List the ways a person usually sees himself/herself.
• Explain the communication cycle.
• Explain the correct method of delivering a written message from your supervisor to another person.

Lesson 3: Troubleshooting Techniques

Topics

Job responsibilities; Recognizing normal operations; Testing and observation; Reducing downtime; Routine and emergency repairs

Learning Objectives

• List the steps to recognizing normal machine operations.
• List the questions you should ask yourself when a machine fails.
• List the signs of a machine in need of service.

Lesson 4: Aids to Troubleshooting

Topics

Drawings, blueprints, and sketches; Manufacturer’s literature; Service reps; Planned-maintenance records; Work orders; Test equipment

Learning Objectives

• Describe a blueprint.
• List the information that should be recorded in a machine equipment record.
• Identify calibration standards.
• Identify a multimeter (VOM).
• Identify different troubleshooting test equipment.

Lesson 5: Preparing for Troubleshooting

Topics

Tools, parts, and supplies; Safety rules; Using charts and diagrams; Correcting malfunctions; Keeping records

Learning Objectives

• List the information you must know about mechanical or electrical systems before you can troubleshoot them successfully.
• Name the commonly used items that should be carried in every troubleshooter’s tool box.
• List the steps to follow in reading a pneumatic or hydraulic schematic.
• List the responsibilities of a troubleshooter.

Lesson 6: Using Schematics and Diagrams

Topics

Piping, compressor, and engine schematics; Hydraulic, pneumatic, and electrical schematics; Lighting diagrams; Troubleshooting charts

Learning Objectives

• Discuss how to use schematics when troubleshooting.
• Identify differences in schematics.
• Explain how to use a troubleshooting chart.

Lesson 7: Solving Mechanical Problems

Topics

Bearing, pump, and piping problems; Compressed-air, refrigeration, and pollution-control equipment; Hydraulic systems; HVAC

Learning Objectives

• Identify bearing wear problems.
• Identify pump failure problems and solutions.
• Identify types of hosing.
• Identify different plant equipment and their problems.

Lesson 8: Solving Electrical Problems

Topics

Generation and distribution; Feeders and branch circuits; Fuses and circuit breakers; Testing for continuity; Safety; Troubleshooting

Learning Objectives

• State the definition of switchgear.
• Identify current voltage characteristics of wire.
• List the safety rules to follow when working with electrical equipment.
• Identify a pictorial diagram, a block diagram, and a schematic diagram.
• Explain how to troubleshoot an electric problem.

Lesson 9: Breakdown Maintenance

Topics

Work-order procedures; Preparing for emergencies; Skills for emergency work; Using downtime

Learning Objectives

• Explain what to do if you are the first member of the emergency crew.
• Explain the spare parts requisition form.
• Discuss the four main parts of practical machine maintenance.

Lesson 10: Planned Maintenance

Topics

Frequency and benefits; Unscheduled maintenance; Keeping records, Lubrication charts and tags

Learning Objectives

• State the definition of planned maintenance.
• List the information that should be included on record sheets or file cards as part of the machine inventory.
• List the benefits to be accrued from an effective lubrication program.
• Describe the proper sag in a drive chain.
• Explain how to service a battery properly.