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Mechanical Systems Maintenance

The Mechanical Systems’ training series covers the principles of operating and maintaining most types of common equipment. Course topics begin with a thorough grounding in the elements of industrial mechanics, including working with hand tools, power tools, and fasteners. The training series continues on to explain lubricants, drive components, bearings, pumps, and piping systems. The Mechanical Systems series concludes with courses dedicated to training workers on hydraulics and pneumatics, including troubleshooting techniques for these systems.

Unit 301: Understanding Basic Mechanics ($130)

This Basic Mechanics course covers force and motion, work and energy, and fluid mechanics as applied in industrial maintenance. Explains principles of operation for simple machines, such as the lever, inclined plane, wheel and axle, pulley, and screw. Explains the basic elements of industrial machines, as well as common measurement tools used to monitor and adjust equipment. Covers hand tools, power tools and fasteners, ending with a discussion of ways to reduce friction and wear.

Lesson 1 – Forces and Motion

Lesson 2 – Work, Energy, and Power

Lesson 3 – Fluid Mechanics

Lesson 4 – Simple Machines

Lesson 5 – Machine Elements

Lesson 6 – Measurement Tools and Instruments

Lesson 7 – The Safe Use of Hand Tools

Lesson 8 – The Safe Use of Portable Power Tools

Lesson 9 – Fasteners

Lesson 10 – Friction and Wear

Unit 302: Selecting & Using Lubricants ($130)

This course covers a complete lubrication training program, including functions and characteristics of lubricants, factors in selection of lubricants, and effects of additives. Oils, greases, and other compounds used for lubrication are described, as well as their applications. Lubrication, maintenance methods, and recommended storage and handling procedures are included.

Lesson 1 – Principles of Lubrication

Lesson 2 – Lubricant Characteristics

Lesson 3 – Additives, Lub. Action, & Bearing Lub.

Lesson 4 – Oils and Their Applications

Lesson 5 – General-Purpose Greases

Lesson 6 – Special-Purpose Greases and Dry-Film Lubricants

Lesson 7 – Lubrication Systems and Methods

Lesson 8 – Automatic Lubrication Methods

Lesson 9 – Lubricant Storage and Handling

Lesson 10 – Lubrication Management

Unit 303.1: Power Transmission Equipment ($100)

Covers belt drives, chain drives, gears and gear drives, adjustable-speed drives, shaft alignment, shaft coupling devices, and clutches and brakes.

Lesson 1 – Belt Drives

Lesson 2 – Chain Drives

Lesson 3 – Gears

Lesson 4 – Gear Drives

Lesson 5 – Adjustable-Speed Drives

Lesson 6 – Shaft Alignment

Lesson 7 – Shaft Coupling Devices

Lesson 8 – Clutches and Brakes

Unit 304: Selecting & Maintaining Bearings ($130)

This course covers principles and applications of various types of bearings, including plain journal, ball, and roller bearings. Explains installation, inspection and maintenance of bearings. Deals with specialized bearings, including powdered-metal, nonmetallic, and hydrostatic bearings. Covers bearing seals, lubrication, and maintenance practices.

Lesson 1 – Bearings and Shafts

Lesson 2 – Plain Journal Bearings I

Lesson 3 – Plain Journal Bearings II

Lesson 4 – Antifriction Bearings I

Lesson 5 – Antifriction Bearings II

Lesson 6 – Ball and Roller Bearings

Lesson 7 – Specialized Bearings

Lesson 8 – Bearing Seals

Lesson 9 – Lubrication

Lesson 10 – Bearing Maintenance

Unit 305: Understanding The Operation Of Pumps ($130)

Covers typical applications of various types of pumps. Describes factors affecting pump selection. Explains operating principles of centrifugal, propeller, and turbine, rotary, reciprocating, and metering pumps. Includes special-purpose pumps, diaphragm pumps, and others designed to handle corrosive and abrasive substances. Covers pump maintenance, packing gland, seal, and bearing replacement.

Lesson 1 – Pump Development and Application

Lesson 2 – Basic Pump Hydraulics

Lesson 3 – End-Suction Centrifugal Pumps

Lesson 4 – Propeller and Turbine Pumps

Lesson 5 – Rotary Pumps

Lesson 6 – Reciprocating Pumps

Lesson 7 – Metering Pumps

Lesson 8 – Special-Purpose Pumps

Lesson 9 – Packings and Seals

Lesson 10 – Pump Maintenance

Unit 306: Piping Systems ($130)

Covers piping and tubing systems used for fluid transport in the plant: hydraulic fluids, steam, liquefied product, refrigerant, and water. Shows typical metallic and nonmetallic piping systems, pipe-joining methods, and how tubing and hoses differ from piping. Covers valves, pipe fittings, hangers, supports, and insulation, and shows how tubing is sized, fitted, bent, and joined. Explains uses of traps, filters, and strainers.

Lesson 1 – Introduction to Piping Systems

Lesson 2 – Metal Piping

Lesson 3 – Nonmetallic Piping

Lesson 4 – Tubing

Lesson 5 – Hoses

Lesson 6 – Fittings

Lesson 7 – Common Valves

Lesson 8 – Special Valves

Lesson 9 – Strainers, Filters, and Traps

Lesson 10 – Accessories

Unit 307: Understanding Basic Hydraulics ($130)

The Basic Hydraulics course covers hydraulic principles, types of hydraulic fluids and their characteristics. Describes components of the hydraulic system and their functions for maintenance procedures, including filters and strainers, reservoirs and accumulators, pumps, piping, tubing and hoses, control valves, relief valves, and actuating devices. Covers a variety of cylinders and hydraulic motors.

Lesson 1 – Principles of Hydraulics

Lesson 2 – Hydraulic Fluids

Lesson 3 – Strainers and Filters

Lesson 4 – Reservoirs and Accumulators

Lesson 5 – Hydraulic Pumps

Lesson 6 – Piping, Tubing, and Fittings

Lesson 7 – Directional Control Valves

Lesson 8 – Pressure-Control Valves

Lesson 9 – Cylinders

Lesson 10 – Hydraulic Motors

Unit 308: Developing Hydraulic Troubleshooting Skills ($130)

This course covers understanding hydraulic systems, using schematic diagrams, installation procedures, maintenance, cleanliness and safety. Includes tubing cutting, bending, and flaring, identification and selection of proper fluid, and charging the system. Discusses planned maintenance, specific repair/replacement recommendations, system diagnosis, and troubleshooting.

Lesson 1 – Hydraulic Systems

Lesson 2 – Hydraulic Schematic Diagrams

Lesson 3 – Installing Hydraulic Components

Lesson 4 – Installing Pipes and Tubes

Lesson 5 – Selecting Hydraulic Fluids

Lesson 6 – Planning System Maintenance

Lesson 7 – Troubleshooting Systems

Lesson 8 – Troubleshooting Valves

Lesson 9 – Troubleshooting Cylinders

Lesson 10 – Troubleshooting Pumps and Motors

Unit 309: Understanding Basic Pneumatics ($130)

The Basic Pneumatics course covers how work, force, and energy are applied to principles of pneumatics. Shows operating principles of reciprocating, positive displacement, rotary, and dynamic air compressors. Covers primary and secondary air treatment. Includes valves, logic devices, cylinders, and air motors.

Lesson 1 – Pneumatic Principles

Lesson 2 – Reciprocating Compressors

Lesson 3 – Rotary Compressors

Lesson 4 – Primary Air Treatment

Lesson 5 – Secondary Air Treatment

Lesson 6 – Piping, Hoses, and Fittings

Lesson 7 – Directional Control Valves

Lesson 8 – Pressure-Control Valves

Lesson 9 – Pneumatic Cylinders

Lesson 10 – Pneumatic Motors and Rotary Actuators

Unit 310: Developing Pneumatic Troubleshooting Skills ($130)

Covers pneumatic systems, schematic symbols and diagrams, installing system components, planned maintenance, system diagnosis, and troubleshooting. Includes maintenance of air compressors, control valves, air motors, electrical components, and hybrid systems.

Lesson 1 – Pneumatic Systems

Lesson 2 – Pneumatic Schematic Diagrams

Lesson 3 – Installation of System Components

Lesson 4 – System Maintenance

Lesson 6 – Troubleshooting Air Compressors

Lesson 7 – Troubleshooting Control Valves

Lesson 8 – Troubleshooting Cylinders

Lesson 9 – Troubleshooting Air Motors

Lesson 10 – Pneumatic/Hydraulic Systems