AIT 110 - Mechanical Systems

1. Use measurement hand tools to inspect dimensions of shafts and other components.
2. Install, align, tension, and adjust: a shaft couplings, belt drives, chain drives, gear drives, pillow block, and flange block bearing.
3. Identify all lubrication points on a machine, select lubricant, and apply lubricant to machine according to maintenance schedule.
4. Apply troubleshooting techniques for shaft couplings, chain drives and belt drives.
5. Utilize effective mechanical fabrication procedures.

1. Measurement Tools (i.e. inspect dimensions of shafts and components)
   1. Metric, decimal, inch fraction rules
   2. Conversions of measurements
      1. English units
      2. Metric units
   3. Calipers
      1. Digital
      2. Dial
   4. Micrometers
      1. Digital
      2. Vernier
   5. Resolution, repeatability, and accuracy
   6. Tool selection (based on accuracy and feature to be measured)
   7. Measurement concepts
      1. Check calibration of measurement tool using a master
      2. Dial indicator or digital indicator to measure:
         1. Total Indicated Run-out (TIR)
         2. Flatness
         3. Other features
         4. Indirect measurement
2. Installing/Aligning Shaft Coupling (i.e. using rim and face, feeler gauge, and laser methods); Installing/Aligning/Tensioning: Belt Drive (i.e. single, multiple belt systems; using V-belts, timing, and HTP types) and Chain Drive (i.e. single, multiple chain systems)
   1. How to mount a motor
   2. How to correct for a soft foot on a motor
   3. How to level motors and shaft
   4. Installing flexible, flange, grid, and chain couplings
   5. Couplings identification (given a specification)
   6. Manufacturer’s documentation to locate alignment specifications of a coupling
   7. Measuring shaft speed using a tachometer
   8. Shaft alignment, using the following techniques:
      1. Feeler gauge and straight edge
      2. Rim and face
      3. Dial indicators
      4. Laser aligning equipment
   9. Installation of:
      1. Multiple V-belt drive onto a shaft with a bushing
      2. Timing belt or HTD belt onto a shaft using a bushing
      3. Split taper, QD, and taper lock bushings
   10. Identification of sheaves and V-belts specifications
   11. Identification of V-belt drive components (given a specification)
   12. Aligning V-belt drive using a straight edge
   13. Checking tension of a V-belt drive using a tension tool
   14. Tensioning V-belt drive by positioning the prime mover
   15. Interpreting specifications of sprockets and chains (given a specification)
   16. Installing chain drive using proper tools
   17. Aligning chain drive using a straight edge
   18. Checking tension of a chain drive using a straight edge and rule
   19. Tensioning a chain drive by positioning the prime mover
3. Install, Align, and Adjust a Spur Gear Drive and a Right Angle Gear Drive
   1. How gears are attached to shafts through keys and keyways
   2. Interpreting specifications of gears
   3. Identifying spur and right angle gear components (given a specification)
   4. Aligning gear drive using a straight edge
   5. How to check backlash of gears using a dial indicator per specifications
4. Install, Align, and Adjust a Pillow Block and Flange Block Bearing
   1. Interpreting specifications of pillow block and flange bearings
   2. Identifying pillow block bearings (given a specification)
   3. Install, align, and adjust pillow block and flange bearings
5. Lubrication Points on a Machine (i.e. select and apply lubricant to machine according to maintenance schedule)
   1. Importance of a lubrication plan
   2. How to identify all oil and grease lubrication points using the manual
   3. Identify/select correct lubricant given a specification from the manual.
   4. Procedure for safe handling and storage of lubricants
   5. Lubricate bearings using Zerk fittings
   6. Grease gun to lubricate a bearing
   7. How to fill an oil cup
   8. Inspecting/filling automatic lubricators
   9. What is lubrication oil
   10. What is lubricating grease; different grades/usage
   11. Purpose of vent plugs
   12. Purpose of additives and viscosity
   13. Effects of over and under lubrication of bearings
6. Troubleshooting Techniques for Shaft Couplings, Chain Drives and Belt Drives
   1. Identifying cause of wear or malfunction of a flexible coupling through visual inspection
   2. Perform troubleshooting techniques to analyze wear or malfunction of:
      1. V-belt drive
      2. Chain drive
      3. Gear drive
      4. Pillow block bearing