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.