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Mechanical Training for Field Service Technicians

Preventive Maintenance

Course #: 286085
Duration: 5 hours
Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
What Students Learn: Preview
The purpose of a preventive maintenance program is to locate possible machine or equipment faults before the machine fails.

Objectives
When a student completes this study unit, he and she will be able to:

  • Describe the function of inspection and scheduled maintenance as the basis of preventive maintenance.
  • Explain why preventive maintenance is performed and how it's scheduled.
  • Identify those within industry who should be part of preventive maintenance planning and execution.
  • Discuss the causes, effects, and goals of a successful preventive maintenance program.
  • Explain how a computerized preventive maintenance program can be developed and implemented.

    Contents
    Introduction To Preventive Maintenance; Why Perform Preventive Maintenance?; Scheduling Preventive Maintenance; PM Program Personnel; PM Program Goals; Computerized PM Programs.

    • Preventive Maintenance Techniques

    Course #: 286086
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    How to implement a preventive maintenance (PM) program is just as important as the why and when of such a program. It doesn't pay to create a well thought out and scheduled PM program only to have the lubrication, inspection, or repair tasks performed improperly. The objective of this unit is to show you how to perform these tasks safely and properly. This will include showing you typical PM tasks as they are performed on common industrial equipment.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Explain how to inspect and properly maintain a belt, chain, and gearbox power transmission system.
  • Discuss why proper alignment is necessary when operating a power transmission system.
  • List the steps needed to properly maintain an AC or DC motor.
  • Explain how to perform a start-up or bump test of a motor.
  • Describe how to perform PM tasks on pneumatic systems.
  • Describe how to maintain both floor and elevated conveyor systems.
  • Identify the types of elevators and vertical lifts in your plant and the proper PM procedures for this equipment.
  • Explain how to maintain liquid and vacuum pump systems.
  • Describe how to perform a basic alignment of in-line shafts.
  • List the proper PM procedures for electronic controllers and robot systems.

    Contents
    PM Of Power Transmission Systems; PM Of Electric Motors And Controllers; PM Of Pneumatic Systems; PM Of Conveyors; PM Of Vertical Lifts; PM Of Vacuum And Fluid Pumps; PM Of Electronic Controllers; PM Of Robots.

    • Pumps, Part 1

    Course #: 286001
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Modern Centrifugal Pumps; Operating Principles of Pumps; Classifications and Types of Pumps; Fundamental Pump Terms: pressure, vapor pressure, head, losses, cavitation, net positive suction head, specific speed, viscosity; Centrifugal Pump Performance Curves; Types of Pumping System Curves.

    Special Notes:

  • This updated course replaces course 2530A.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Pumps, Part 2

    Course #: 286002
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Construction details of Centrifugal Pumps; Applications of Centrifugal Pumps; Installation and Maintenance of Centrifugal Pumps; Troubleshooting problems associated with Centrifugal Pump Operation.

    Special Notes:

  • This updated course replaces course 2530A.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Pumps, Part 3

    Course #: 286003
    Duration: 10 hours
    Course Prerequisites: Hydraulic Components: Actuators, Pumps, and Motors (286061);
    What Students Learn: Rotary Pumps: classifications, installation and operating principles; Reciprocating Pumps: classifications, installation and operating principles; Power Pumps; Applications of Rotary and Reciprocating Pumps; Troubleshooting Rotary and Reciprocating Pumps.

    Special Notes:

  • This updated course replaces course 2530B.
  • The entire course consists of study units 286001, 286002, and 286003.

    • Precision Measuring Instruments, Part 1

    Course #: 186068
    Duration: 10 hours
    What Students Learn: Purpose and Language of Measurement; Scale Instruments and Accessories; Vernier Caliper; Micrometers, Gages, and Protractors.

    Special Notes:

  • This updated course replaces course 3500A.
  • The entire course consists of study units 186068, 186069, and 3500C.

    • Precision Measuring Instruments, Part 2

    Course #: 186069
    Duration: 10 hours
    What Students Learn: Indicators; Shop Gages; Gage Blocks; Fundamentals of Trigonometry; Sine Bar and Sine Plate.

    Special Notes:

  • This updated course replaces course 3500B.
  • The entire course consists of study units 186068, 186069, and 3500C.

    • Bearings and Seals, Part 1

    Course #: 286093
    Duration: 10 hours
    What Students Learn: Preview
    Bearings of one type or another have been used since the invention of the most primitive machines. Bearings support rotating machine shafts as well as translating movement in machine components, and bearings keep the components in correct alignment.

    This study unit, will primarily discuss plain bearings. However, so that students understand the fundamental differences, it will briefly cover antifriction bearing operation. Students will get a basic understanding of the differences between plain bearings and antifriction bearings. The study unit will then discuss the various types of plain bearings and their uses in greater detail.

    Because bearings are used in such a wide range of applications, there are many factors to consider when selecting a bearing for a specific need. It is important that students understand these factors and the process for choosing the correct bearing and lubrication method for an intended application. In this study unit, students will also learn about the different techniques and tools used to properly install, lubricate, and remove bearings.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Understand what friction is and how bearings help reduce it.
  • Explain the difference between plain and antifriction bearings.
  • List the different types of plain bearings.
  • Understand the characteristics of plain bearings.
  • Know the importance of proper handling and installation of bearings.
  • Recognize the importance of proper bearing lubrication.
  • List the different materials used to make plain bearings and how material type affects their use.
  • Explain how to prevent premature bearing failure.

    Contents
    Introduction to Bearings; Journal Bearings; Other Types of Plain Bearings; Installing and Maintaining Plain Bearings; Plain Bearing Failure.

    Special Notes: This updated course replaces 2602.

    • Bearings and Seals, Part 2

    Course #: 286094
    Duration: 10 hours
    What Students Learn: Preview
    Bearings and seals are used in most every type of machine. This study unit will help you learn how to identify, lubricate, maintain, and replace antifriction bearings and seals.

    As students know, there are two types of bearings, plain and antifriction. Plain bearings use a sliding motion to reduce friction, while an antifriction bearing contacts the shaft it supports with a rolling element. This rolling motion helps reduce friction. The rolling motion produces less friction than the sliding motion produced from plain bearings. Therefore, the rotation of a shaft is smoother with an antifriction bearing.
    In this study unit, students will learn about the various types of antifriction bearings and their different parts. They will also learn about the basic characteristics of these bearings, and how to apply them to a particular shaft. The study unit will also cover proper installation and maintenance and properly applying them. An important part of proper application is correctly combining the various materials available in bearings with the material the shaft is made from.

    This study unit will also help students better understand seals. They will learn what a seal does, the different types of seals available, and how they are used. Students will also learn; the various types of material that seals are manufactured from, their advantages, the importance of maintaining bearings, and how to replace seals when they fail.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Identify the various elements used in antifriction bearings.
  • Properly identify and correct problems in antifriction bearings.
  • Choose the proper seal.
  • Choose and apply the proper lubricants for seals and antifriction bearings.
  • Understand the need for clearance and tolerances in bearings.
  • Identify the various parts of a seal.

    Contents
    Antifriction Bearings; Antifriction Bearing Replacement; Maintaining Antifriction Bearings; Installing and Maintaining Lip Seals.

    Special Notes: This updated course replaces 2602.

    • Industrial Seals

    Course #: VS62XX
    Duration: 1 hours
    What Students Learn: This course is designed to familiarize the student with the basics of various types of gaskets, packing and seals. The course includes all types and properties, inspection, installation and troubleshooting.
    Components: Industrial Seals: Types, Materials and Properties (VS6201); Industrial Seals: Gaskets and Packings; Inspection and Installation (VS6202); Industrial Seals: Mechanical Face Seals; Troubleshooting and Installation (VS6203);

    Lubrication, Part 1

    Course #: 286091
    Duration: 10 hours
    What Students Learn: Preview
    Since the development of machinery, there has been a war against friction. Friction causes machinery to vibrate excessively, sound louder, use more energy to do a given job, and, most importantly, wear out faster. To counter friction, lubricants have been developed.

    Lubricants were once basic animal fats and plant oils used on simple machines. Today's lubricants are chemical compositions specially designed for specific types of machines and their work environment. There are now hundreds of types of oils and grease to select from, each tailored specifically for the machine or an individual component of any given machine.

    This study unit is designed to give students the information they need to understand how lubricants are blended into these very special compounds and how they are selected for various applications.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Describe the various types of friction.
  • Discuss how materials wear.
  • List the various functions lubricants perform in industry.
  • Explain how lubricants reduce friction.
  • Classify lubricants depending upon their composition, properties, and additives.
  • Understand why certain lubricants are chosen for certain tasks.
  • Explain how to safely handle and store lubricants.

    Contents
    Friction and Wear; The Purpose of Lubricants; How Lubricants are Classified; How Lubricants Work; Proper Lubricant Selection; Handling and Storing Lubricants Safely.

    Special Notes: This updated course replaces 2531A.

    • Lubrication, Part 2

    Course #: 286092
    Duration: 10 hours
    What Students Learn: Preview
    Lubricating equipment is one of the most important industrial maintenance activities performed. Lubricants reduce friction, which saves on energy costs. They reduce wear, which saves on equipment maintenance costs. Proper lubrication significantly reduces machine downtime resulting from broken or worn out components. In addition, proper lubricating practices help keep a machine in tolerance for a longer period of time.

    In today's world of twenty-four-hour-a-day, seven-days-a-week, plant operation, the role of lubrication takes on even greater importance. Equipment must be lubricated on a timely schedule, in the proper amounts, and with the correct lubricants to sustain long work cycles between planned shutdowns. This study unit will show you how to properly apply lubrication and maintain lubrication systems.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Explain how to manually apply various types of lubricants in an industrial environment.
  • Describe total-loss lubrication.
  • Identify a nonloss lubrication system's components and describe their operation.
  • Explain how to maintain a nonloss lubrication system.
  • Identify the proper lubrication procedures to use for special industrial applications including sealed bearings, oil-impregnated bearings and food-processing plants.
  • Explain how lubricant-conditioning systems work and how to maintain them.
  • Describe how automatic lubrication systems work and how to maintain them.
  • List the tasks involved in preventive and predictive lubrication maintenance.

    Contents
    Manual Methods of Lubrication; Lubricating Total-Loss Systems; Nonloss Lubrication Systems; Lubrication in Special Environments; Lubrication Conditioning; Automatic Lubrication Systems; Preventive and Predictive Lubrication Maintenance.

    Special Notes: This updated course replaces 2531B.

    • Principles of Mechanics, Part 1

    Course #: 286007
    Duration: 10 hours
    Course Prerequisites: Practical Geometry and Trigonometry (5567); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Matter and Energy; Scope of Mechanics; Forms of Matter; Forms of Energy; Physical Properties of Bodies; Motion of Bodies; Velocity; Acceleration and Retardation; Weight and Mass; Work and Energy; Coordinate Systems; Precision in Computations; Newton's Laws of Motion; Uniform Motion; Variable Motion.

    Special Notes:

  • This updated course replaces course 6426A.
  • The entire course consists of study units 286007-286008.

    • Principles of Mechanics, Part 2

    Course #: 286008
    Duration: 10 hours
    Course Prerequisites: Practical Geometry and Trigonometry (5567); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Friction; Nature of Friction; Sliding Friction; Rolling Friction; Machine Elements; Levers; Inclined Plane; Wedges and Screw Threads; Wheel and Axle; Tackle; Pulleys; Gearing; Belts and Chains; Simple Harmonic Motion Centrifugal Force.

    Special Notes:

  • This updated course replaces course 6426B.
  • The entire course consists of study units 286007-286008.

    • Link Mechanisms

    Course #: 2603
    Duration: 10 hours
    Course Prerequisites: Engineering Mechanics, Part 4 (286039); Engineering Mechanics, Part 1 (286036); Engineering Mechanics, Part 2 (286037); Engineering Mechanics, Part 3 (286038); Elementary Mechanical Drawing (5434);
    What Students Learn: Definition of Terms; Plane Motion of a Rigid Body; Levers; Linkages; Quick-Return Mechanism; Straight Line and Parallel Motions; Kinematics of Link Mechanisms; Graphical Determination of Velocity; Graphical Determination of Acceleration; Kinematic Analysis.

    Gearing

    Course #: 2446
    Duration: 10 hours
    Course Prerequisites: Engineering Mechanics, Part 4 (286039); Engineering Mechanics, Part 1 (286036); Engineering Mechanics, Part 2 (286037); Engineering Mechanics, Part 3 (286038);
    What Students Learn: Rolling Curves and Surfaces; Spur Gearing; Proportions of Gear Teeth; Calculations of Spur Gears; Involute Systems; Cycloidal or Rolled-Curve System; Construction of Tooth Profiles; Helical Gearings; Spiral or Screw Gearings; Worms and Worm Gears; Bevel and Spiral Bevel Gears; Gear Cutting; Milling; Straight Hobs; Taper Hobs; Gear Finishing.

    Gear Trains

    Course #: 2604
    Duration: 10 hours
    Course Prerequisites: Gearing (2446); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: Use of Trains; Velocity Ratio of Train Gears; Compound Gearing; Speed Change Gearing; Epicyclic Gears; Planetary Gear Trains; Reversing Mechanism; Ratchet Mechanisms.

    Cams

    Course #: 2605
    Duration: 10 hours
    Course Prerequisites: Plane Trigonometry (2309A-B); Elementary Mechanical Drawing (5434);
    What Students Learn: General Classification; Uses of Cams; Types of Cams; Fundamentals of Cam Motion; Basic Curves; Combination Curves; Cam Size Determination; Cam Profiles by Calculation.

    Mechanical Power Transmission

    Course #: 286015
    Duration: 10 hours
    What Students Learn: Gears and Enclosed Gear Drives; Electric Motors; Maintenance of Gearing; Precision Chains and Chain Drives; Belt Drives; Correction for Shaft Misalignment; Clutches; Application Considerations for Mechanical Power Transmission.

    Special Notes: This updated course replaces course 2606.

    Belt Power Transmission

    Course #: 2607A-B
    Duration: 20 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (2607A). General Considerations on Belt Drives; Basic Theory of Belt Power Transmission; Types of Belt Drives; Application of V-Belt Drives; Application of Flat Belt Drives; Belt Drive Installation and Maintenance; Appendix.
    PART 2 (2607B). Application of Special Belt Drives; Additional Considerations in Belt Drive Applications; New Developments in Belt Drives.

    Hydraulic Power Basics

    Course #: 286060
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Introduction to Hydraulic Power; Physical Principles of Hydraulic Power and Energy; Pascal's Law; Bernoulli's Principle; Work and Power; Horsepower and Loss; Hydraulic Power Systems; Basic Components of Hydraulic Systems; Basic Hydraulic System Accessories; Fittings and Couplings; Characteristics of Hydraulic Systems; Comparing Power Systems; Requirements for Hydraulic Systems; Properties of Hydraulic Fluid; Fluid Storage, Handling, and Maintenance; Filters and Strainers; Heat Exchangers; Eliminating Air; Examples of Hydraulic Systems; Proportional Displacement; Hydraulic System Operation; Working Safely with Hydraulic Systems.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Components: Actuators, Pumps, and Motors

    Course #: 286061
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Actuator Design, Detail, and Operation; Linear Actuators; Hydraulic Actuator Components; Rotary Actuators; Pumping Principles; Slippage; Pump Classifications; Gear Pumps; Vane Pumps; Double Pumps; Gear and Vane Pump Lubrication and Capabilities; Piston Pumps; Screw-type Pumps; Supercharging Pumps; Variable-displacement Pump Control Fundamentals; Hydraulic Motors; Comparing Pumps and Motors; Gear Motors; Screw Motors; Vane Motors; Piston Motors; Abutment-type Motors; Losses through Fluid Motors; Deceleration and Braking.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Components: Conductors, Conditioners, and Fluids

    Course #: 286062
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Reservoirs and System Components; Types of Reservoirs; Reservoir Volume; Reservoir Components; Reservoir Interior Care and Auxiliary Tanks; Reservoir in Use; Practical Tips for Reservoir Selection and Maintenance; Conductors, Fittings, and Seals; Maintenance Tips for Conductors, Fittings, and Seals; Choice of Conductor Size and Materials; Types of Heat Exchangers; Automatic Temperature Control; Effective System Cooling Tips; Accumulators; Circuits Using Accumulators; Accumulator Safety; Hydraulic Fluids; Petroleum-based Fluids; Viscosity; Demulsibility; Oxidation Stability; Lubricating Value; Corrosion and Rust Prevention; Fire-resistant Fluids.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power System Control

    Course #: 286063
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Explain the Function of Control Components in a Typical Hydraulic System; Identify Control Valves by Pressure, Flow, or Directional Type; Explain the Operating Principles and Typical Internal Parts of Pressure, Flow, and Directional Valves; Interpret Schematic Symbols which represent Control Valve Configurations.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Interpreting Hydraulic System Schematics

    Course #: 286064
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Typical Schematic Layout; Recognizing Standard Schematic Symbols; Interpreting Control Configuration from Schematic Symbols; Evaluating System Operating Characteristics from Schematics.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Hydraulic Power System Troubleshooting

    Course #: 286065
    Duration: 10 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Introduction to Fluid Power (Block Y01);
    What Students Learn: Sizing Components to meet Requirements; Measuring and Evaluating System Operation; Assessing Motor and Pump Capacity and Performance; Special System Control including Servos and Pressure, Temperature, and Limit Switches; Performing Periodic Maintenance and Analyzing Inspection Information; Troubleshooting System Faults; Typical Hydraulic System Faults and Failures.

    Special Notes: The entire course consists of study units 286060, 286061, 286062, 286063, 286064 and 286065.

    Industrial Hydraulics

    Course #: VS63XX
    Duration: 1.18 hours
    What Students Learn: This course provides students with an understanding of hydraulic power concepts and circuits. Students receive instruction on hydraulic pumps, conductors, accessories and valves, procedures for maintenance and safety, and troubleshooting industrial hydraulic systems.
    Components: Industrial Hydraulics, Volume 1 (VS6301); Industrial Hydraulics, Volume 2 (VS6302); Industrial Hydraulics, Volume 3 (VS6303);

    Hydraulic Power Systems and Troubleshooting

    Course #: VS64XX
    Duration: 0.73 hours
    What Students Learn: This course is ideal for students employed as engineers and others who require an advanced understanding of hydraulic systems operation and maintenance. From examining basic to complex circuitry, students will learn to troubleshoot and repair hydraulic systems.
    Components: Hydraulic Power Systems and Troubleshooting, Volume 1 (VS6401); Hydraulic Power Systems and Troubleshooting, Volume 2 (VS6402);

    Pneumatics

    Course #: 6623
    Duration: 10 hours
    What Students Learn: Atmospheric Pressure; Barometers; Properties of Gases; Relative Unit Pressure; Laws Relating to Change of State; Boyle's Law; Gay-Lussac's Laws; Combination of Boyle's and Gay-Lussac's Laws; Mixtures of Gases; Pneumatic Machines and Devices; The Air Pump; Apparatus Showing Weight and Pressure of Atmosphere; Siphon; Air Compressors.

    Air Compressors, Part 1

    Course #: 286013
    Duration: 10 hours
    Course Prerequisites: Metric System (186011);
    What Students Learn: Types of Compressors; Types of Comparison; Centrifugal Compressors; Axial-Flow Compressors; Construction Details of Centrifugal and Axial-Flow Compressors; Performance Curves; Installation and Performance Tests.

    Special Notes:

  • This updated course replaces course 2626A.
  • The entire course consists of study units 286013-286014.

    • Air Compressors, Part 2

    Course #: 286014
    Duration: 10 hours
    Course Prerequisites: Metric System (186011);
    What Students Learn: Reciprocating Compressors; Cylinder and Piston Arrangements; Construction Details of Various Types; Selection, Installation, and Operation of Reciprocating Compressors; Rotary Compressors; Construction Details; Lobe Compressors; Screw Compressors; Troubleshooting Rotary Compressors.

    Special Notes:

  • This updated course replaces course 2626B.
  • The entire course consists of study units 286013-286014.

    • Pneumatics

    Course #: VS21XX
    Duration: 2.87 hours
    What Students Learn: This series is designed for skilled maintenance workers who have some knowledge of pneumatics. All of the terms used in the series are explained and defined in the workbook. Fundamental topics included in the series are compressed air power, circuitry, air processing, valves, safety, maintenance, and troubleshooting.
    Each course is introduced by identifying the specific competencies expected of the pneumatics maintenance worker. Then it explains the techniques that will result in his or her improved instruction. The emphasis is to teach the specific skills required to understand pneumatics. This series is intended to be used as an enhancement to your pneumatics curriculum.
    Components: The Power of Compressed Air (VS2101); The Pneumatic Circuit (VS2102); Processing Air (VS2103); Using Compressed Air (VS2104); Pneumatic Control Valves (VS2105); Working Safely with Pneumatic Systems (VS2106); Pneumatic Systems Maintenance (VS2107); Troubleshooting Pneumatic Systems (VS2108);

    Servomechanisms

    Course #: 2028A-B
    Duration: 20 hours
    Course Prerequisites: AC Principles (Block A22); Basic Electronic Circuits (Block B24);
    What Students Learn: PART 1 (2028A). Basic Concepts of Automatic Control Systems and Servomechanisms, Electric and Hydraulic Servo Motors and Drive Systems; Types of Servo Amplifiers; Characteristics of DC Servo Motors; Feedback Devices, such as Potentiometers, Synchros, and Resolvers; Error Detectors; Operational Amplifiers; Performance Criteria for Servo Systems.
    PART 2 (2028B). Introduction to Machines Controlled by Servos; Types of Control Operations; Performance Requirements for the Basic Applications; Drive Systems, including Input, Feedback, and Amplifying Elements; Servo Errors, Gain, Stability, Accuracy, and Linearity Requirements and Limitations; Testing and Adjusting Servos.

    Special Notes: Covers subject at an advanced, in-depth level.

    Pneumatic Instrumentation for the Technician

    Course #: 286M01
    Duration: 35 hours
    Course Prerequisites: Basic Industrial Math (Block X21);
    What Students Learn: Lesson 1 - Pneumatic Instrumentation for Industry:

  • Instrument Systems; How Fluid Power Works; Pneumatic Instruments; Link Mechanisms: Components and Adjustments; Calibration Standards, Procedures and Programs.
    Lesson 2 - Pressure and Liquid Level Measuring Instruments:
  • Principles of Pressure; Sensing Pressure; Bourbon Elements; Compensation and Calibration; Liquid-Level Instruments; Differential Pressure Instruments: Manometers, Bellows and Diaphragm Instruments, Displaces.
    Lesson 3 - Flow-Measuring Instruments:
  • Principles of Operation; Orifice Flow; Meter Types and Mechanisms; The Square-Root Problem; Integrators.
    Lesson 4 - System Components, Part 1:
  • Self-Balancing Instruments; Error Detectors; Pilot Valves; Relay Functions and Variations; Moment-Balance Pressure, Temperature and Differential-Pressure Transmitters; Moment Balance Positioners.
    Lesson 5 - System Components, Part 2:
  • True Force-Balance Instruments, Transmitters and Positioners; Motion-Balance Principle and Applications; Angle Motion-Balance Positioners; Linear Motion-Balance Instruments.
    Lesson 6 - Pneumatic System Control, Part 1:
  • Control Valve Maintenance; Control Theory and Fundamental Controllers; Gain, Feedback and Response.
    Lesson 7 - Pneumatic System Control, Part 2:
  • Controller Functions, Types and Components; Range and Gain Mechanisms; Foxboro, Honeywell, Taylor, and Fisher and Porter Controllers; Universal Controllers; Process Control.

    Special Notes: This course consists of a textbook and supplemental study guide.

    • Control Technology for Technicians

    Course #: 286M04
    Duration: 45 hours
    Course Prerequisites: Introduction to Algebra, Geometry, and Trigonometry (Block X02); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: This course introduces the fundamentals of control system components and operation. Students will learn how a control system works and how its operating characteristics can be interpreted from schematics and ladder logic diagrams. The course will explain how mechanical, hydraulic, pneumatic, electrical, and electronic components used in control systems measure parameters. These measurements are then converted into useful data or the appropriate control system response. The course discusses the use of feedback loops and their applications in real-world control systems. The student will understand how electronic systems are combined to deliver their acceptable data "signals" to computers. In conclusion, the student will learn how PLCs are used throughout industry to control complex systems.

    Part 1 (286076) . Lesson 1 - Introduction to Control Systems

  • Represent a control system with a block diagram.
  • Recognize various control system types including open loop, closed loop, analog, and digital.
  • Describe how servomechanisms work.
    Lesson 2 - Op Amps and Signal Conditioning
  • Explain how microprocessors are integrated into, and interface with, control systems.
  • Evaluate and design op-amp and related signal conditioning circuits to be used in control systems.
    Lesson 3 - Control System Switching Devices
  • Describe the operating principles of, and applications for, relays, transistors, rectifiers, triacs and other switching devices.
    Lesson 4 - Mechanical Control Systems
  • Explain how mechanical components are designed into, and operate within, control systems.
    Lesson 5 - Control System Sensors
  • Evaluate the function of sensors in a given control system.
  • Understand how sensors work to provide data in control systems.

    Part 2 (286077). Lesson 6 - DC and Stepper Motors in Control Systems
  • Explain how DC motors operate.
  • Select a motor based on mechanical and performance requirements.
  • Describe how DC motor control systems work.
  • Understand how stepper motors and their driver circuits work.
    Lesson 7 - AC Motors in Control Systems
  • Explain how AC motors operate.
  • Select a motor based on mechanical and performance requirements.
  • Describe how AC motor control systems work.
    Lesson 8 - Control System Actuators and Feedback Principles
  • Recognize the applications for, and operating characteristics of, electric, hydraulic, and pneumatic linear actuators.
  • Describe the operating principles of control valves and other components in hydraulic and pneumatic systems.
  • Differentiate between proportional, integral, differential, and fuzzy logic control systems.
    Lesson 9 - Relay Logic and PLCs
  • Explain how to tune a process control system.
  • Understand how analog and digital control circuits work.
  • Explain the operation of relays, counters, and sequencers.
  • Understand how PLCs work.
  • Interpret ladder logic diagrams.

    Special Notes: This course consists of a textbook and two supplemental study guides. We recommend the course be purchased in its entirety. However, if needed due to targeted training, study guides (Parts 1 & 2) can be purchased separately, with or without the textbook. Note that the textbook is required for the Part 1 study guide. Call Customer Service for pricing and ordering information.

    • Principles of Automatic Process Control Instruments

    Course #: 6305A-B
    Duration: 20 hours
    Course Prerequisites: Control Technology for Technicians (286M04); Electricity (4210A-C); Heat, Part 1 (686001); Heat, Part 2 (686002); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (6305A). Automation; Nature of Control Systems; Control Action; Self-Powered Controllers; Powered Controllers.
    PART 2 (6305B). Powered Controllers; Controller Settings; Failure of Automatic Control Systems; Cascade Control Systems; Glossary.

    Temperature Measuring and Control Instruments

    Course #: 6306A-B
    Duration: 20 hours
    Course Prerequisites: Control Technology for Technicians (286M04); Electricity (4210A-C); Principles of Automatic Process Control Instruments (6305A-B); Heat, Part 1 (686001); Heat, Part 2 (686002); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (6306A). Basic Concepts; Thermocouple Circuits and Connections; Thermocouple Materials and Construction, Thermocouple Measuring Instruments; Electric Interference.
    PART 2 (6306B). Types of Filled Thermal Systems; Bourdon Element; Temperature Compensation; Resistance Temperature Detectors; Radiation Pyrometry; Types of Radiation Pyrometers; Methods of Temperature Control.

    Automatic Process Control Valves

    Course #: 6307
    Duration: 10 hours
    Course Prerequisites: Control Technology for Technicians (286M04); Electricity (4210A-C); Principles of Automatic Process Control Instruments (6305A-B); Heat, Part 1 (686001); Heat, Part 2 (686002); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: Importance of Control Valves; Types and Construction Features of Various Control Valves; Types of Valve Motors; Application of Valve Motors and Control Valves; Basic Function of Valve Positioner; Applications of Valve Positioners; Definition of Control Valve Rangeability and Valve Coefficient; Sizing of Control Valves for Liquid, Gas, and Steam.

    Fluid Flow Measuring and Control Instruments

    Course #: 6308A-B
    Duration: 20 hours
    Course Prerequisites: Control Technology for Technicians (286M04); Electricity (4210A-C); Automatic Process Control Valves (6307); Principles of Automatic Process Control Instruments (6305A-B); Heat, Part 1 (686001); Heat, Part 2 (686002); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (6308A). Introduction to Fluid Flow; Standard Primary Elements; Additional Primary Elements; Measurements; Selection of Primary Elements; Proper Application of Primary Elements; Locating Primary Elements; Use of Straightening Vanes.
    PART 2 (6308B). Mechanical Flowmeters; Bellows- and Diaphragm-Actuated Manometers; Other Types of Meters; Flow Measurement.

    Process Pressure Measuring and Control Instruments

    Course #: 6309A-B
    Duration: 20 hours
    Course Prerequisites: Control Technology for Technicians (286M04); Electricity (4210A-C); Principles of Automatic Process Control Instruments (6305A-B); Heat, Part 1 (686001); Heat, Part 2 (686002); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (6309A). Pressure Measuring Considerations; Pressure Measuring Devices, such as Manometers, Draft Gages, Inverted Belts, Differential Elements, Bellows, and Diaphragm Devices; Bourdon Tube; Spiral and Helical Pressure Meters; Chemical Pressure Gages; Pressure Indicators and Recorders.
    PART 2 (6309B). Calibration Standards and Methods, including Details of Dead Weight Tester, Test Gages, and Gage Errors; Pressure Measuring and Control Instruments and Equipment; Process Pressure Application Considerations; Automatic Control of Process Pressure; Selection of Pressure Instruments for Process Pressure Applications.

    Liquid Level Measuring and Control Instruments

    Course #: 6338A-B
    Duration: 20 hours
    Course Prerequisites: Control Technology for Technicians (286M04); Electricity (4210A-C); Automatic Process Control Valves (6307); Principles of Automatic Process Control Instruments (6305A-B); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (6338A). Visual Indicators such as Sight Gages; Buoyancy Level Controllers, both of the Moving Float and Displacement Type; Static- and Differential-Pressure Level Controllers; Gamma Radiation Level Controllers.
    PART 2 (6338B). Temperature Sensitive Level Controllers and the Electrical Conductivity Type of Level Controller; Explanations of the Special Requirements of Liquid Level Control with Emphasis on Control of Hazardous Types of Liquids and Selection of Level Controls for Various Types of Process Applications.

    Properties of Materials

    Course #: 686005
    Duration: 10 hours
    Course Prerequisites: Formulas (186012); Practical Measurements (Block X22);
    What Students Learn: Effects of Forces on Materials; Stress and Deformation; Elastic Failure; Cohesive Properties of Solids; Heat and Cold Treatment; Modulus of Elasticity; Temperature Stresses; Structural Members; Tension Members; Shear; Connection of Steel Members; Members Subjected to Compound Stress; Beams; Columns; Shafts; Rope Drives; Properties of Metals, Nonferrous Metal, and Alloys.

    Special Notes: This updated course replaces course 5887.

    Predictive Maintenance

    Course #: 286087
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    Predictive technologies measure one or more characteristics of machine operation, calculate the expected life of the monitored system, and then estimate the condition of equipment and, therefore, the need for maintenance on that equipment. With this information passed along to a good preventive maintenance program, the preventive maintenance team can make informed decisions on task scheduling and make the most of its maintenance and inspection tasks.

    Vibration analysis programs are the most commonly conducted PDM efforts. By performing inspection and repairs during downtime, uptime failures of the analyzed components are all but eliminated. PDM is more than vibration analysis, however; multiple technologies, such as infrared thermography, balance, alignment, and electrical signature analysis are part of many PDM programs. Because of these technologies, plants run better and are more competitive. PDM allows maintenance departments to predict when a unit will fail and plan its maintenance during a scheduled downtime, usually when the unit is cooler, cleaner, and not needed for the manufacturing process.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Define what PDM is and how it can be used in industry.
  • Identify the various types of technologies used in PDM.
  • Explain what goals should be considered for a new and a maturing PDM program.
  • Discuss the scope of basic mechanical PDM.
  • Explain how a time waveform and a frequency spectrum can be used to identify machine faults.

    Contents
    What Is Predictive Maintenance?; Predictive Maintenance Program Goals; Basic Mechanical Predictive Maintenance; Forms Of PDM Data.

    • Predictive Maintenance: Vibration Analysis

    Course #: 286088
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    When a company decides to begin a predictive maintenance (PDM) program, the first technology usually embraced is vibration analysis. Vibration analysis allows the technicians or other specially trained personnel to perform condition monitoring of equipment. Condition monitoring is used at first as a coarse comb to pull out those programs that will imminently cause downtime. Then the program can progress beyond condition monitoring to provide scheduling services for preventive maintenance and identification of redesigns that address repetitive faults.

    This study unit will show you the basics of vibration analysis as performed with a data collector and a computer software program. These devices will be used to collect vibration measurement data and to store and display the results.

    Objectives
    When a student completes this study unit, he and she will be able to:

  • Explain how vibration measurements are taken and the systems used to identify measurement points.
  • Identify balance, looseness, and misalignment problems.
  • Discuss the techniques used to diagnose rolling-element bearing faults.
  • Explain how journal bearing condition monitoring and fault analysis is performed.
  • Identify speed reducer faults that occur in the gear sets or the internal bearings.
  • Describe how resonance can affect the operation of equipment.

    Contents
    Vibration Measurements; Analyzing Balance And Looseness Problems; Misalignment Of Inline And Overhung Drive Systems; Analyzing Rolling-Element Bearing Systems; Condition Monitoring Of Journal Bearings; Condition Monitoring Of Speed Reducers; Resonance.

    • Predictive Maintenance: Advanced Topics

    Course #: 286089
    Duration: 5 hours
    Course Prerequisites: Trades Safety: Getting Started (186001); Basic Industrial Math (Block X21); Practical Measurements (Block X22);
    What Students Learn: Preview
    Vibration analysis alone cannot perform sufficient condition monitoring to meet the needs of today's industry. Vibration analysis cannot easily find electrical faults, air leaks, electrical discharges, metal particles or contamination and breakdown of lubricants, or other important monitoring processes. Other technologies are needed for these tasks. This study unit will introduce you to these other technologies.
    In this study unit, we will investigate many different technologies that can and should often be part of a good predictive maintenance program (PDM). This course is designed to discuss these technologies at a basic level. If you're considering working with one of these technologies, it's very important to understand how to operate the equipment involved and to gain additional equipment training from the manufacturer. These actions will provide you with a safe and profitable expanded PDM program.

    Objectives
    When a student complete this study unit, he and she will be able to:

  • Explain the steps involved in performing balance and alignment on industrial machines.
  • Discuss the use and operation of ultrasonic equipment to find problems such as electrical arcing, bearing faults, and internal and external air leaks in pneumatic systems.
  • Describe the procedures used in electrical signature analysis (ESA) and how this inspection system can find motor problems.
  • Explain how oil analysis can find lubricant problems and contamination.
  • Describe how thermography can be used in a PDM environment.

    Contents
    Modern Balance And Alignment; Ultrasonic Testing; Electrical Signature Analysis; Oil Analysis; Infrared Thermography.

    • Robotics Explained

    Course #: VB05XX
    Duration: 0.33 hours
    What Students Learn: Understand how robots work and how to work safely beside them. Students will learn about the parts of the robot and the many applications they can be programmed to perform.
    Components: Robotics Explained (VB0501);

    Jigs and Fixtures

    Course #: 5099
    Duration: 10 hours
    Course Prerequisites: Basic Machining Skills (Block X08);
    What Students Learn: Types of Jigs; Examples of Jigs; Jig Parts and Accessories; Bushings; Jig Covers and Clamps; Miscellaneous Details of Jigs; Fixtures; Common Vise Fixture; Special Vise Fixture; Bolted Fixture: Combination Jig and Fixture; Trunnion Fixture; Roller Fixture; Broaching Fixture.

    Fundamentals of Tool Design

    Course #: 3535A-G
    Duration: 70 hours
    Course Prerequisites: Plane Trigonometry (2309A-B); Principles of Mechanics, Part 1 (286007); Principles of Mechanics, Part 2 (286008); Logarithms (5254); Properties of Materials (686005); Introduction to Algebra, Geometry, and Trigonometry (Block X02);
    What Students Learn: PART 1 (3535A). Design of Material-Cutting Tools; Single-Point Tools; Basic Principles of Multiple-Point Tools; Linear-Travel Tools; Axial-Feed Rotary Tools; Control of the Causes of Tool Wear and Failure.
    PART 2 (3535B). Workholding Devices; Elements and Types of Fixture Design; Evolution of Workholders; Fixture Design Summary.
    PART 3 (3535C). Design of Pressworking Tools; Power Presses; Cutting (Shearing) Operations; Types of Die-Cutting Operations; Piercing-Die Design; Blanking-Die Design; Compound-Die Design; Scrap-Strip Layout for Blanking; Commercial Die Sets; Evolution of a Blanking Die; Evolution of a Progressive Blanking Die.
    PART 4 (3535D). Bending Dies; Forming Dies; Drawing Dies; Evolution of a Draw Die; Progressive Dies; Selection of Progressive Dies; Strip Development for Progressive Dies; Evolution of a Progressive Die; Examples of Progressive Dies; Extrusion Dies; Tool Design for Forging; The Forging Process; Forging Design; Drop Forging Dies and Auxiliary Tools; Upset or Forging Machine Dies.
    PART 5 (3535E). Design of Tools for Inspection and Gaging; Workpiece Quality Criteria; Basic Principles of Gaging; Gage Types and Applications; Amplification and Magnification of Error; Gaging Positionally Toleranced Parts.
    PART 6 (3535F). Tool Design for the Joining Process; Tooling for Physical Joining Processes; Tooling for Soldering and Brazing; Tooling for Mechanical Joining Processes; Tooling for Casting; Sand Casting; Shell Mold Casting; Metal Mold Casting; Die Casting.
    PART 7 (3535G). General Considerations in Tool Design; Safety as Related to Tool Design; Tool Materials; Heat-Treating; Surface Roughness; Fits and Tolerances; Tooling Economics; Material Handling at the Workplace; Rules for Good Design.

    Special Notes: Covers subject at an advanced, in-depth level.

    Mechanical Testing of Materials

    Course #: 2608A-B
    Duration: 20 hours
    Course Prerequisites: Practical Measurements (Block X22);
    What Students Learn: PART 1 (2608A). Purpose of Testing Physical Properties of Materials; Mechanical Testing Machines; Tension Test; Compression Test.
    PART 2 (2608B). Transverse or Beam Test; Shear and Torsion Tests; Hardness Testing, Impact Testing; Miscellaneous Tests for Ductile Materials; Testing of Nonmetals.

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