SPEO2/019 Maintaining Mechanical Devices and Equipment

Candidate Name: Christopher Redfern Class: Wind Turbines Systems A

Exercise Instructions:

The candidate is to dismantle, inspect, repair, maintain, rebuild and test a mechanical devices; tasks must
include dimensional inspection, axial clearances and proper alignment of assemblies.

During this exercise the candidate will.

1. Identify and source any reference material.

2. Carry out a risk assessment for the task.

3. Complete a sequence of operations for the safe dismantling and rebuilding of the unit.

4. Identify tools and equipment needed for removal/dismantling.

5. Carry out an initial survey of components and identify any obvious faults.

6. Complete a “permit to work.”

7. Dismantle components and complete survey report, including dimensional inspection, particularly if
wear is evident.

8. Identify materials required and prepare components to rebuild.

9. Rebuild, setting all clearances.

10. Align assemblies to the given tolerance.

11. Carry out an operational test of the system.

The above named candidate was observed carrying out the work to an appropriate standard.

Job Risk Permit Survey Dimensional Clearance/Alignment Question

Plan Assessment to Work Report Inspection Report Paper

Exercise achieved: COMPETENT / NOT YET COMPETENT

Lecturer Signature:____________________ Date: _______________________________

Comments:________________________________________________________________

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Job Plan
Safety Considerations

Heavy objects
Slips, trips, and falls
Manual handling
PPE
Barrier creams
Pinching / crushing
Oil spill / contamination

Tools/Equipment

Socket sets
Torx & E torx sets
Spanners (various sizes)
Allen keys
Feeler gauge
Vernier gauge
Dial gauge / magnetic blocks
Nylon mallet
Screwdrivers
Pliers // circlip pliers

Materials/Consumables

Penetrating oil
Disposable gloves
Barrier cream
Rags/cleaning materials

Reference Materials Used

Mechatronics manual
Manufactures manuals and service guides.

COSHH Data References

Safety Data Sheets: what a liquid, gas and solids consist of i.e. harmful to health; how to deal with
contamination and spills

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Risk Assessment
(1) ASSESSMENT OF RISK FOR: (2) LOCATION OF TASK (3) RECORD NUMBER (6) ASSESSMENT UNDERTAKEN BY

The hazard and probability ratings are detailed on the help sheet and are. 1- low 3- high. The risk rating is 1- low 9- high
A B C D E F G H
Hazard Existing or required Additional control measures
Hazard and Effect Probability Risk control measures e.g. Residual Risk required e.g. PPE,
No Effect Who is at Risk rating rating CxD guards, isolation etc. (Yes/No) supervision etc.
1 Heavy Objects All those involved in Training, appropriate PPE
handling. 2 1 2 (Safety Boots) Y Lifting aids

2 Tripping & Everyone in the working Look for hazard and put Supervision of the classroom
Falling environment. the necessary signage tidiness. Everyone’s
2 1 2 N
and store equipment responsibility.
correctly.
3 Crushing & Everyone in the working Training. Check gears PPE, Supervision
Pinching environment. and moving parts are
3 1 3 N
locked into position to
avoid movement.
4 Pressurised Everyone involved in the Depressurise systems in PPE, disconnection of power
Systems work area. 3 1 2 the correct steps. Y source/isolation.

REVIEWER SIGNATURE DATE ASSESSOR SIGNATURE DATE

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Permit to Work

Section A is to be completed by all persons in the working party, Section B is to be completed by the
COMPETENT PERSON/S in charge of the working party.

SECTION A

WORK LOCATION: PLANT IDENTIFICATION:

Room G22A Various

Has the system been: De-pressurised: Yes Drained: Yes

Has the system been locked out: YES

Have all caution notices been affixed at ALL POINTS OF ISOLATION: Yes

I / WE CONFIRM THE INFORMATION GIVEN IN SECTION A IS CORRECT

SIGNATURE/S: DATE:

SECTION B

I have confirmed with the control persons:

________________________________________________________________________

that the precautions stated above have been carried out and that the control persons will maintain
these until this permit for work is cancelled.

COMPETENT PERSON System Lock Out: KEY NUMBER: -

Signed: ____________________ being the COMPETENT PERSON

Date: ____________________

All work has been successfully completed. This work permit is now cancelled.

Signature: __________________ being the COMPETENT PERSON

Date: _________________

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Sequence of operations: Yaw Drive

RAMS: Risk Assessment Method Statement

Make sure of full use of correct PPE required for the activity.
Correct tools for the activity, make sure tools are in good working order with visual inspection (no
electric tools required).

1. Check gearbox is drained of oil, using the sight level as an aid to assist.

2. Loosen and remove the bolts or fasteners securing the yaw drive motor to the yaw drive
base.

3. Carefully remove the motor from the yaw drive assembly.

4. Loosen and remove the bolts securing the yaw drive gearbox to the yaw drive base.

5. Carefully remove the gearbox from the yaw drive assembly, same applies to planetary gears.

6. Inspect the yaw drive components for wear and tear, paying close attention to the gears,
bearings, and seals.

7. Carry out all dimensional checks and record correctly in supplied data sheets.

8. Replace any damaged or worn components as necessary.

9. Reinstall the yaw drive gearbox onto the yaw drive base and secure it with bolts.

10. Reinstall the yaw drive motor onto the gearbox and secure it with bolts.

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Yaw Drive Survey Report

Faulty Component
(Include Part Number Fault Identified and Action/Remediation Required
if Appropriate)

Oil Check quality of oil. Oil within manufacturers guidelines, no need for
replacement. If out with scope, will be replaced as per recommendations.

Gaskets Replaced as per manufactures guidelines on every maintenance task.

Fasteners Some show signs of oxidation, wear, and tear. Replaced as per
manufacturers guidelines.

‘O’ rings Replaced as per manufactures guidelines on every maintenance task.

Planetary Gears Checked clearance between housing of main gear, holding 3 planetary
gears with Feeler Gauge. Spacing within recommended clearance
guidelines. No action required.

Planetary Bearings Checked with Vernier Gauge, within limits. Cleaned and regreased. No
action required.

Yaw Drive Housing Overall, in good condition. Only recommendation is drive will require fresh
coat of protective paint.

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Dimensional Inspection 1st stage

Pin and Idler Clearances A

The pin and idler are to be measured at 2 points: A & B B

For any of the three planetary gears (beware of the needle bearings collapsing)

Nominal Size mm

Tolerance + 0.05mm - 0.05mm

Allowable Clearance MAX 0.1mm

MIN 0.01mm
A: 20.30mm
Pin
B: 20.30mm
A: 28.40mm
Gear (internal)
B: 28.40mm

A: 28.20mm
Bearing
B: 28.20mm

All Torque Settings (Nm)

Bolts Part Number Quantity Torque Setting

End Cap / 1 35Nm

Allen key (stage 1) / 8 35Nm

Allen key (stage 2) / 16 45Nm

Allen key (stage 3) / 3 45Nm

Top Cover / 1 25Nm

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Clearance/Alignment Report
1st Stage planetary gear float clearance (0.525mm +/-0.02mm)

Gear 1
0.530MM
Gear 2
0.530MM
Gear 3
0.530MM

2nd Stage dimensional alignment results

Gear teeth ‘top land ‘results

Gear 1 OK

Gear 2 OK

Gear 3 OK

3rd Stage planetary gear float clearance (0.865mm +/-0.02mm)

Gear 1 0.700MM

Gear 2 0.700MM

Gear 3 0.700MM

Relubrication

Grease quantity (grams)

10 grams
Gearbox oil level (comment) Filled as per manufactures instructions.

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Question Paper

1. How do you identify defects and wear characteristics?

Visual inspection: Conduct a visual inspection of the system to identify any visible signs of defects or
wear, such as cracks, corrosion, or excessive wear.

Dimensional inspection: Use measuring tools such as callipers, micrometres, or dial indicators to
measure the dimensions of the components and compare them to the specifications provided by the
manufacturer.

Vibration analysis: Conduct vibration analysis of the system to identify any abnormal vibration or
noise that may indicate worn or damaged components.

Lubricant analysis: Analyse the lubricant used in the yaw drive system to identify any contamination
or abnormal wear particles.

Performance testing: Conduct performance testing of the system to ensure that it is operating within
the expected range of performance parameters.

Wear characteristic identification: Become familiar with the wear characteristics of the specific
components in the yaw drive system. For example, knowing the typical wear patterns for bearings or
gears can help identify potential issues before they become critical.

By using these methods, maintenance professionals can identify defects and wear characteristics on
a yaw drive system and take appropriate action to address them. It is important to have a thorough
understanding of each method and to apply them appropriately for the specific components being
checked. Regular maintenance and inspection of the yaw drive system can help prevent equipment
failure and prolong the life of the wind turbine.

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2. What are the methods and techniques of fitting keys and splines?

Determine the correct size and type of key/spline to use based on the torque and load requirements
of the yaw drive.

Clean and inspect the keyway in the shaft and hub to ensure it is free from debris and damage.
Apply a light coating of lubricant to the key/spline and keyway to aid in assembly.

Insert the key/spline into the keyway, ensuring it is fully seated and aligned with the hub and shaft.
Use a hydraulic press or a suitable tool to carefully drive the hub onto the shaft, taking care not to
damage the key/spline.

Check the alignment of the key/spline and hub to ensure they are properly aligned with the shaft.
Tighten the fasteners to the manufacturer's recommended torque specifications.

Verify that the key/spline is fully engaged and cannot rotate or move within the keyway/splineway.
Perform a visual inspection of the key and keyway to ensure there are no signs of damage or wear.

Perform regular maintenance and inspection of the yaw drive and key/spline to detect any potential
issues before they become critical.

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3. How do you identify, use, fit and remove different types of gears?

When dismantling a gearbox, it is crucial to consider the specific type of gearbox as this will
determine the appropriate dismantling process. For instance, gear pullers, circlips and other locking
devices may need to be employed to remove certain parts of the gearbox. Similarly, if the gearbox
contains spring loaded elements such as detent locks, specialist tools may be required for their
removal.

To ensure a safe and successful dismantling process, it is vital to always follow the manufacturer's
guidance and recommended procedures. This includes using the appropriate tools, adhering to the
correct sequence of steps, and taking any necessary safety precautions.

By carefully considering the gearbox type and following the manufacturer's guidance, you can
effectively dismantle the gearbox without causing damage to its components or compromising its
performance. This will allow for efficient repairs or maintenance to be carried out, ensuring the
gearbox can continue to operate reliably and effectively over the long term.

4. What types of gear/drive mechanisms were identified within the yaw drive?

Worm drive and planetary gears identified.

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Sequence of operations: ENGINE 1

RAMS: Risk Assessment Method Statement
Make sure of full use of correct PPE required for the activity.
Correct tools for the activity, make sure tools are in good working order with visual inspection.

Sump – Removal

1. Drain the engine oil, then clean and refit the engine oil drain plug, tightening it to the
specified torque wrench setting. Although not strictly necessary as part of the dismantling
procedure, owners are advised to remove and discard the oil filter, so that it can be renewed
with the oil.
2. Removed the starter motor.
3. Removed the auxiliary drivebelt cover.
4. Unplugged the electrical connector(s) to disconnect the oxygen sensor.
5. Unscrewed the nuts to disconnect the exhaust system front downpipe from the manifold,
then either unhook all the system’s rubber mountings and withdraw the complete exhaust
system from under the vehicle or remove only the downpipe/catalytic converter.
6. Unscrewed the sump-to-transmission bolts, also any securing the engine/transmission lower
adapter plate.
7. Progressively unscrewed the sump retaining bolts. Break the joint by striking the sump with
the palm of the hand, then lower the sump and withdraw it with the engine/transmission
lower adapter plate (where fitted); note the presence of any shims between the sump and
transmission.
8. Removed and discarded the sump gasket; this must be renewed as a matter of course
whenever it is disturbed as per manufacturers guidelines.
9. While the sump is removed, removed the oil pump pick up/strainer pipe and cleaned it.

Cylinder Head Cover – Removal

1. Removed the air inlet hose and inlet duct.

2. Disconnected the accelerator cable from the throttle linkage.
3. Removed the timing belt upper cover.
4. Disconnected the crankcase breather hose from the cylinder head cover union.
5. Unplugged the HT leads from the spark plugs and withdraw them, unclipping the leads from
the cover.
6. Working progressively, unscrewed the cylinder head cover retaining bolts, noting the spacer
sleeve and rubber seal at each, then withdrew the cover.
7. Discarded the cover gasket; renewed also. Checked that the sealing faces are undamaged,
and that the rubber seal at each retaining bolt is serviceable; renewed any worn or damaged
seals.
8. On refitting, cleaned the cover and cylinder head gasket faces carefully, then fitted a new
gasket to the cover, ensuring that it locates correctly in the cover grooves.
9. Refitted the cover to the cylinder head, then inserted the rubber seal and spacer sleeve at
each bolt location. Started all bolts finger-tight, ensuring that the gasket remains seated in its
groove.

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10. Working in a diagonal sequence from the centre outwards, and in two stages, tightened the
cover bolts to the specified torque wrench setting.
11. Refitted the HT leads, clipping them into place so that they are correctly routed; each is
numbered, and can also be identified by the numbering on its respective coil terminal.
12. Reconnected the crankcase breather hose and refitted the timing belt upper cover.
Reconnected and adjusted the accelerator cable, then refitted the air inlet hose and duct.

Timing Belt Covers- Removal

Upper Cover

1. Unscrewed the cover’s two mounting bolts and withdrew it.

2. Refitting is the reverse of the removal procedure; ensured that the cover edges engaged
correctly with each other and noted the torque wrench setting specified for the bolts.

Middle Cover

1. Unscrewed the nut securing the power steering pipe support clip to the stud at the rear of
the middle cover. Lifted the power steering fluid reservoir upwards out of its mounting
bracket and move it clear, as far as the hoses will allow, for access. If insufficient clearance is
obtained, disconnected the fluid unions as necessary, and collected the fluid in a suitable
container. Plug or cover any disconnected unions.
2. Slackened the water pump pulley bolts.
3. Removed the timing belt upper cover.
4. Removed the auxiliary drivebelt.
5. Unbolted and removed the water pump pulley.
6. Unscrewed the middle cover fasteners (one bolt at the front, one at the lower rear, one stud
at the top rear) and withdrew the cover.
7. Refitting is the reverse of the removal procedure. Ensured that the cover edges engage
correctly with each other and noted the torque wrench settings specified for the various
fastener.
8. If the power steering hoses where disconnected, bleed the system after reconnection.

Lower Cover

1. Removed the crankshaft pulley.

2. Unscrewed the cover’s three securing bolts and withdraw it.
3. Refitting is the reverse of the removal procedure; ensured the cover edges engage correctly
with each other and noted the torque wrench settings specified for the various fasteners.

Inner shield

1. Removed the timing belt, its tensioner components, and the camshaft toothed pulleys.
2. The shield is secured to the cylinder head by two bolts at the top, and by two studs lower
down; unscrewed these and withdraw the shield.
3. Refitting is the reverse of the removal procedure; noted the torque wrench settings specified
for the various fasteners.
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Timing Belt – Removal

1. Slacken the water pump pulley bolts.

2. Removed the cylinder head cover.
3. Removed the spark plugs, covered their holes with clean rag, to prevent dirt or other foreign
bodies from dropping in.
4. Removed the auxiliary drivebelt.
5. Rotated the crankshaft clockwise until the second pair of notches in the pulley rim align with
the edge of the sump mark, so that Nos 1 and 4 cylinders are at TDC.
6. Unbolted and removed the water pump pulley and the auxiliary drivebelt idler pulley.
7. Rotated the crankshaft through one full turn clockwise.
8. With the camshaft aligning tool remaining in place, removed the crankshaft pulley. Using
locking technique.
9. Removed the timing belt lower and middle covers.
10. With the camshaft-aligning tool still in place, slackened the tensioner bolt, and used an Allen
key inserted into its centre to rotate the tensioner clockwise as far as possible away from the
belt; retightened the bolt to secure the tensioner clear of the timing belt.
11. Renewed the belt due to stretching. Checked the toothed pulleys for signs of wear or damage
and ensure that the tensioner and guide pulleys rotate smoothly on their bearings; renew any
worn or damaged components.
12. On reassembly, temporarily refitted the crankshaft pulley, checked that the pulley notches
and sump rib are aligned as per manufacturers guidelines, then ensure that both camshafts
are aligned at TDC by the special tool.
13. Used holding tool to prevent the camshaft toothed pulleys from rotating while their bolts are
slackened and retightened; used one of the following obtain Ford service tool 15-030A / a
fabricated substitute. This is used to prevent rotation while the camshaft toothed pulley bolts
are slackened or tightened; the risk of damage to the camshaft concerned and to the cylinder
head is far too great. Used only a forked holding tool applied directly to the pulleys, as
described by manufacturers guidelines.
14. Screwed the timing belt tensioner spring retaining pin into the cylinder head, tightening it to
the specified torque wrench setting. Unbolted the tensioner, hooked the spring on to the pin
and the tensioner backplate, then refitted the tensioner, engaging its backplate on the
locating peg.
15. Slackened the tensioner bolt and used an Allen key inserted into its centre to rotate the
tensioner clockwise as far as possible against spring tension, then retightened the bolt to
secure the tensioner.
16. Fitting of the timing belt.
17. Fit the belt is in place, slackened the tensioner bolt gently until the spring pulls the tensioner
against the belt; then tensioner retained correctly against the timing belt inner shield and
cylinder head, making sure it is free to respond to changes in belt tension.
18. Tightened both camshaft toothed pulley bolts (or check that they are tight, as per
manufacturers guidelines) and then removed the camshaft-aligning tool. Temporarily refitted
the crankshaft pulley and rotated the crankshaft through two full turns clockwise to settle and
tension the timing belt, returning the crankshaft (pulley notches) to the desired position. Refit
the camshaft aligning tool.

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19. Without disturbing the pulley’s new position on the camshaft, tightened the pulley bolt to its
specified torque wrench setting. Removed the camshaft-aligning tool, rotated the crankshaft
through two further turns clockwise, and then refitted the tool to check that it now fits as it
should.

20. When the timing belt has been settled at its correct tension, tightened the tensioner bolt to
its specified torque wrench setting. Fitting the forked holding tool to the spokes of each pulley
in turn, checking that the pulley bolts are tightened to their specified torque wrench setting.
Removed the camshaft-aligning tool, rotating the crankshaft through two further turns
clockwise, and then refitted the tool to make a final check that it fits as it should.
21. The remainder of the reassembly procedure is the reverse of removal, ensuring that all
fasteners are tightened to the specified torque.

Timing Belt Tensioner and Toothed Pulleys

1. Released the tension from the timing belt.

2. Unscrewed the tensioner bolt and withdraw the tensioner, unhooking the spring, if fitted.
3. On reassembly, screwed the timing belt tensioner spring retaining pin into the cylinder head,
tightening it to the specified torque wrench setting. Hooked the spring onto the pin and the
tensioner backplate, then refitted the tensioner, engaging its backplate on the locating peg.
4. Used an Allen key, inserted into its centre to rotate the tensioner clockwise as far as possible
against spring tension, then tightened the bolt to secure the tensioner.
5. Reassembled, checking the camshaft alignment (valve timing) and setting the timing belt
tension.

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Engine Maintenance Survey Report

Faulty Component
(Include Part Number Fault Identified and Action/Remediation Required
if appropriate)

Bearing shell 4 out of 5 bearing shells are in good condition, the 5th did show signs of
wearing. Replaced as per manufactures instructions.

Gaskets Replaced as per manufactures guidelines on every maintenance task.

Fastener Some fasters did show signs of oxidation (white substance), replaced as per
instructions.

Spark Plugs Signs of water contamination, signs of rust and flaking in spark plug bay
and on spark plug.

Camshaft Camshaft gear out by one tooth. Measured with Vernier gauge. Removed
timing belt, realigned using the correct process. Fit new timing belt.

Timing belt Timing belt was loose when fitted prior to removal. Overstretch beyond
tightening process using engine tensioner. Advised to replace as per
manufactures guidance.

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Timing / Camshaft Report

Results

Spark plug gap 0.45mm

Camshaft lobes (actual) 39.95mm

Camshaft lobes (measured) 40.00mm

Camshaft bearing journal diameter (INLET) 39.50mm

Camshaft bearing journal diameter (OUTLET) 35.90mm

Camshaft end float INLET 0.20mm

Camshaft end float OUTLET 0.20mm

Installation Results
OK
TDC to camshaft(s)
OK
Independent Camshaft alignment
OK
Cam and crank alignment
55Nm
Tensioner torque
OK
Belt tension
8mm
Maximum Vertical alignment: mm (Belt)
2mm
Maximum Horizontal alignment: mm (Belt)

Lubrication
Comment: As per manufactures guidelines

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Engine Maintenance Question Paper

1. How do you obtain and interpret the documents needed in the maintenance process? Such
as: drawings, specifications, manufacturer’s manuals, other documents.

Obtaining and interpreting documents needed for vehicle engine maintenance involves sourcing and
analysing various types of information, including drawings, specifications, manufacturer's manuals,
and other relevant documents. These materials are essential for carrying out maintenance tasks
according to the required standards and specifications. In this task, I have documents given to me by
my class lecturer and also researched online through a variety of sources, which of some, was shared
with the class. Other sources are discussed below.

Drawings: These are graphical representations of the engine components and their relationships to
one another. They help maintenance teams understand the layout, assembly, and disassembly
processes. You can usually obtain drawings from the vehicle manufacturer, either in printed form or
as digital files.

Specifications: Written documents that define materials, processes, and requirements for
manufacturing and maintaining vehicle engines. Specifications provide information on material
properties, tolerances, and other technical details necessary for proper maintenance. They can be
found in manufacturer's manuals or separate documents provided by the manufacturer.

Manufacturer's manuals: Containing comprehensive information on the design, operation, and

maintenance of the vehicle engine, manufacturer's manuals provide step-by-step procedures for
various maintenance tasks, safety guidelines, and troubleshooting advice. These manuals are usually
provided with the vehicle or can be obtained from the manufacturer or authorised dealers.

Other documents: These might include service bulletins, regulatory compliance documents, and
modification records, offering additional information on maintenance history, updates, and best
practices. These can be sourced from the vehicle manufacturer, regulatory authorities, or third-party
service providers.

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2. What methods are used to check that removed components are fit for purpose?

When dismantling and maintaining vehicle engines, it's crucial to ensure that removed components
are fit for purpose before reassembling the engine. Several methods are employed to check the
condition and functionality of these components:

Visual inspection: A thorough visual examination can reveal signs of wear, damage, or corrosion on
engine components. Inspectors look for cracks, deformations, discolouration, and other indications
that a component may not be suitable for reuse.

Measurement: Using measuring tools such as callipers, micrometres, and feeler gauges, technicians
can check the dimensions and tolerances of engine components to ensure they meet the
manufacturer's specifications. This process helps identify excessive wear or deformation that may
affect the component's performance.

Functional testing: In some cases, components can be tested for functionality and performance
outside of the engine assembly. This may involve testing for leaks, pressure, or electrical continuity,
depending on the component in question.

Material analysis: Material testing techniques, such as hardness testing and metallurgical analysis,
can be used to assess the material properties of engine components. This process can help identify
potential material degradation or determine if a component has undergone an inappropriate heat
treatment process.

Manufacturer's guidelines: Always follow the manufacturer's recommendations for inspecting and
assessing the condition of engine components. These guidelines provide specific criteria for
determining the serviceability of parts based on their design and intended use.

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3. How and when is measuring equipment used? Such as: micrometres, verniers, run-out
devices and other measuring equipment.

Measuring equipment, such as micrometres, Vernier callipers, run-out devices, and other tools, play
a crucial role in servicing and maintaining vehicle engines. They are used to accurately measure
dimensions and tolerances of engine components to ensure they meet the manufacturer's
specifications. Here's how and when these measuring tools are typically used during engine
maintenance:

Micrometres: These precision measuring instruments are used to measure small dimensions, such as
the thickness of shims, the diameter of bearings, or the dimensions of other small components.
Micrometres are typically used when precise measurements are needed, as they offer a higher
degree of accuracy compared to other measuring tools.

Vernier callipers: Vernier callipers are versatile measuring tools used to measure a wide range of
dimensions, such as the length, width, and depth of engine components. They can be used to
measure the thickness of gaskets, the diameter of cylinders, and the dimensions of various engine
parts. Vernier callipers are particularly useful for measuring external, internal, and depth dimensions
with a single tool.

Run-out devices: Run-out devices, such as dial indicators, are used to measure the radial and axial
run-out of rotating engine components like crankshafts, camshafts, and flywheels. They help
determine whether a component is bent, warped, or misaligned, which can affect engine
performance and cause excessive wear on related parts.

Other measuring equipment: Various other measuring tools, such as feeler gauges, straight edges,
and depth gauges, may be used to check clearances, flatness, and depths in different engine
components. For example, feeler gauges are used to check valve clearances, and straight edges can
be used to inspect the flatness of mating surfaces.

These measuring tools are typically employed during the inspection and reassembly phases of engine
maintenance. Technicians use them to check the condition of components and verify that they meet
the required specifications before reassembling the engine. Accurate measurements help to ensure
the longevity and reliability of the engine, as well as optimal performance.

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4. How do you make adjustments to components/assemblies to ensure they function correctly?

Such as: setting working clearances, setting travel, setting backlash in gears, preloading
bearings.

To ensure that components and assemblies function correctly in engine dismantling and
maintenance, it's essential to make appropriate adjustments to various parameters, such as working
clearances, travel, backlash in gears, and preloading bearings. Here are some general guidelines for
making these adjustments:

Setting working clearances: Working clearances refer to the gap between two mating parts, which
allows for their proper operation. For example, valve clearances, piston ring gaps, and bearing
clearances are critical for engine performance. To set the correct working clearances, follow the
manufacturer's specifications and use appropriate measuring tools, such as feeler gauges or
plastigauge, to check the clearances.

Setting travel: Travel refers to the movement or displacement of a component within its operational
range. For example, the throttle valve's travel ensures it can open and close correctly. To set the
travel, follow the manufacturer's guidelines and use measuring tools like a Vernier calliper or a depth
gauge to verify the correct travel range.

Setting backlash in gears: Backlash is the clearance or play between meshing gear teeth, which is
necessary to prevent binding and allow for thermal expansion. To set the correct backlash, follow the
manufacturer's recommendations and use dial indicators or feeler gauges to measure the clearance
between gear teeth. Adjust the gears' position as needed to achieve the desired backlash.

Preloading bearings: Preloading bearings involves applying an initial load to the bearing to remove
internal clearance, ensuring proper operation and reducing noise and vibration. To preload bearings,
follow the manufacturer's specifications for the required preload force or torque. This can be
achieved by using shims, spacers, or specific adjustment techniques, depending on the bearing
design. Use appropriate measuring tools, such as torque wrenches or dial indicators, to verify the
preload.

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Sequence of operations: Air-Conditioning Compressor

RAMS: Risk Assessment Method Statement

Make sure of full use of correct PPE required for the activity.
Correct tools for the activity, make sure tools are in good working order with visual inspection.

Preparation: Before dismantling the air compressor, it is important to make sure that the compressor
is turned off and disconnected from the power source. Also, make sure to wear appropriate safety
gear, such as gloves and eye protection.

Removal of air lines: The first step in dismantling the air compressor is to remove the airlines that are
connected to the compressor. This can be done by using a wrench to loosen the fittings that connect
the lines to the compressor.

Removal of mounting bolts: Once the airlines have been removed, the next step is to remove the
mounting bolts that hold the compressor in place. These bolts are typically located at the base of the
compressor and can be removed using a socket wrench.

Separation of compressor from engine: After the mounting bolts have been removed, the
compressor can be separated from the engine. This may require some gentle prying or tapping with a
rubber mallet to loosen any stuck parts.

Disassembly of compressor: With the compressor removed from the engine, it can now be
disassembled. This may involve removing the compressor cover, taking apart the various
components, and cleaning any debris or build-up that may have accumulated inside.

Inspection of parts: As each component of the compressor is removed, it should be inspected for
signs of wear or damage. Any parts that are found to be damaged should be replaced before
reassembling the compressor.

Reassembly of compressor: Once all parts have been inspected and cleaned, they can be
reassembled in the reverse order of disassembly. Make sure to follow any manufacturer's guidelines
or torque specifications for tightening bolts and fittings.

Reinstallation of compressor: After the compressor has been reassembled, it can be reinstalled onto
the engine. Make sure to reconnect any air lines and mounting bolts, and check for proper operation
of the compressor before use.

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Air-Conditioning Compressor Survey Report

Faulty Component
(Include Part Number Fault Identified and Action/Remediation Required
if Appropriate)

Valve body corroded Replace with new / possibly machine resurfacing

External metal gasket Replace with new

damage

Valve plate corroded Replace with new

‘O’ ring perished Replace with new

Circlip bent Replace with new

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Air-Conditioning Compressor Test Documentation

Compressor I/D Number or Description: Sanden Compressor

Clutch I/D Number or Description: 400378-12

Component Identification Number or Description: 6570355

Working Pressure: 7 bar

Test Pressure: 10 bar for 10 minutes

TEST PRESSURE ACHIEVED: YES

Test Equipment Identification Number: 1204

Pressure Gauge Serial Number: M230025

Calibration Due Date: May 2024

On completion of the test has the compressor been dried out and the open ends sealed: YES

I hereby certify that the information given above is correct.

Operator Signature: _______________ Date: _______________

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Air-Conditioning Compressor Question Paper

1. What are the hazards associated with carrying out mechanical maintenance activities and
how can they be minimised? Such as: handling oils, greases, stored energy/force, misuse
of tools, using damaged or badly maintained tools and equipment, not following laid-down
maintenance procedures.

Mechanical maintenance activities can be hazardous if not carried out with the necessary care and
attention. Here are some of the hazards associated with mechanical maintenance activities and how
they can be minimised:

Handling oils and greases: Oil and grease can be slippery and pose a slip and fall hazard. To minimise
this risk, use appropriate personal protective equipment such as gloves, and ensure that spills are
cleaned up immediately.

Stored energy/force: Many mechanical systems store energy, which can be released suddenly and
cause injury. Before carrying out maintenance activities, ensure that all stored energy has been safely
discharged or isolated.

Misuse of tools: Misuse of tools can lead to serious injuries such as cuts, lacerations, and fractures.
Always use tools for their intended purpose and ensure that they are properly maintained.

Using damaged or badly maintained tools and equipment: Damaged or poorly maintained tools and
equipment can be hazardous and increase the risk of injury. Regularly inspect tools and equipment
and replace or repair any damaged or worn parts.

Not following laid-down maintenance procedures: Failing to follow laid-down maintenance

procedures can result in errors and accidents. Always follow the correct procedures and work
instructions and seek clarification if unsure.

To minimise the risks associated with mechanical maintenance activities, it is essential to carry out a
risk assessment before beginning work. This should identify any hazards and outline the steps
necessary to mitigate them. In addition, training and instruction on safe working practices should be
provided to all personnel involved in mechanical maintenance activities. By following safe working
practices and adhering to appropriate procedures and guidelines, the risks associated with
mechanical maintenance activities can be minimised.

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2. What methods and techniques are used to dismantle/assemble mechanical equipment?

Such as: release of pressures/force, proof marking, extraction, pressing, alignment.

Dismantling and assembling mechanical equipment requires careful planning and attention to detail
to ensure that the process is carried out safely and effectively. Here are some of the methods and
techniques used:

Release of pressures/force: Before dismantling equipment, it is essential to release any stored

pressure or force to prevent sudden or unexpected movement that could cause injury or damage.
This can involve the use of valves, drains or other safety devices to safely release pressure.

Proof marking: Proof marking is a technique used to ensure that parts are reassembled in their
correct position. This involves marking or numbering the parts before disassembly to ensure that
they can be reassembled in the correct sequence.

Extraction: Extraction is a technique used to remove parts that are tightly fitted or stuck in place. This
can involve the use of a puller or extractor to carefully apply force and remove the part without
causing damage.

Pressing: Pressing is a technique used to fit parts together that require a tight fit, such as bearings or
gears. This can involve the use of hydraulic or mechanical presses to apply a controlled force to the
parts to ensure a proper fit.

Alignment: Alignment is a critical step in reassembling mechanical equipment to ensure that all parts
are properly aligned and will operate correctly. This can involve the use of laser alignment tools or
manual measurement techniques to ensure precise alignment.

By following these methods and techniques, mechanical equipment can be safely and effectively
dismantled and reassembled. It is essential to follow the manufacturer's recommendations and
guidelines for the specific equipment and to ensure that appropriate tools and personal protective
equipment are used at all times.

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3. How do you check tools and equipment are free from damage or defect and are in a safe
and useable condition?

Visual inspection: Conduct a visual inspection of the tool or equipment to check for any visible signs
of damage or wear such as cracks, chips, or deformations.

Functionality test: Test the functionality of the tool or equipment to ensure that it is working as
intended. This can involve testing the various functions or features of the tool or equipment to
ensure that they are operating properly.

Calibration check: Check the calibration of measuring tools such as torque wrenches or micrometres
to ensure that they are accurate and reliable.

Lubrication check: Ensure that moving parts are properly lubricated and that there are no signs of
excessive wear or corrosion.

Electrical safety checks: For electrical equipment, ensure that the insulation is intact and that there
are no exposed wires or damaged plugs or cords. Also, check for the correct earthing.

Certification and records: Keep records of inspections and certifications of tools and equipment and
ensure that they are up to date.

By following these steps, you can ensure that tools and equipment are in a safe and useable
condition. It is essential to conduct regular inspections of tools and equipment, and to replace or
repair any damaged or worn parts immediately to prevent further damage or injury.

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4. How do you check tools and equipment are within calibration and are configured correctly
for the intended purpose?

Check the manufacturer's recommendations: Refer to the manufacturer's recommendations and

guidelines for the specific tool or equipment to understand the correct configuration and calibration
procedure.

Inspect the tool or equipment: Conduct a visual inspection of the tool or equipment to check for any
visible signs of damage or wear, which could affect its performance.

Calibration check: Use a calibration device or procedure to check the accuracy of measuring tools
such as torque wrenches or micrometres. Check the calibration of the tool or equipment against a
known standard.

Functional check: Test the functionality of the tool or equipment to ensure that it is working as
intended. This can involve testing the various functions or features of the tool or equipment to
ensure that they are operating properly.

Verify settings: Check the settings of the tool or equipment to ensure that they are correctly
configured for the intended purpose. This can involve checking the adjustment of settings or
programming to ensure that they are accurate.

Documentation: Keep records of calibration checks and verify that the tool or equipment has been
calibrated within the manufacturer's recommended schedule.

By following these steps, you can ensure that tools and equipment are calibrated and configured
correctly for their intended purpose. It is essential to conduct regular calibration checks and to
replace or repair any damaged or worn parts immediately to prevent further damage or errors.

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5. Why is it important to complete maintenance documentation and/or reports following the

maintenance activity?

Completing maintenance documentation and/or reports following a maintenance activity is essential

for several reasons:

Record keeping: Documentation and reports provide a record of the maintenance activity, including
what work was carried out, any issues or problems encountered, and any parts that were replaced or
repaired. This information can be used for future reference and can help to identify trends or
recurring issues.

Compliance: Completing documentation and reports can help to ensure compliance with regulatory
requirements, industry standards, and best practices. This can be particularly important for industries
such as aerospace, oil and gas, and healthcare, where maintenance activities must be carried out to
strict standards.

Accountability: Documentation and reports provide a way to hold individuals and organisations
accountable for maintenance activities. If a problem or issue arises in the future, the documentation
can be used to determine who carried out the maintenance activity, and whether it was carried out
correctly.

Cost control: Completing documentation and reports can help to control costs by identifying
maintenance requirements and trends. By monitoring the types of maintenance required, and the
frequency of maintenance activities, organisations can identify opportunities to reduce costs and
improve efficiency.

Safety: Documentation and reports can help to improve safety by ensuring that maintenance
activities are carried out correctly, and that any issues or problems are identified and addressed
promptly.

By completing maintenance documentation and reports, organisations can ensure that maintenance
activities are carried out correctly, in compliance with regulations and standards, and with a focus on
safety and efficiency.

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6. What are the problems associated with the mechanical maintenance activity, and how can
they be overcome?

Mechanical maintenance activities can encounter various problems that can impact their safety,
efficiency, and success. Here are some of the problems associated with mechanical maintenance
activities, and how they can be overcome:

Lack of maintenance planning: Lack of maintenance planning can lead to disorganised work
schedules and improper allocation of resources. To overcome this problem, it is essential to plan
maintenance activities in advance, allocate necessary resources, and follow established procedures.

Unforeseen problems: Mechanical maintenance activities can encounter unforeseen problems such
as worn-out parts, difficult-to-access components, and equipment malfunctions. To overcome this
problem, it is essential to conduct regular inspections, monitor equipment performance and identify
issues proactively.

Unsafe working conditions: Mechanical maintenance activities can involve working in hazardous
environments or conditions. To overcome this problem, appropriate safety procedures should be
followed, protective equipment and clothing should be worn, and only qualified and experienced
personnel should be allowed to conduct maintenance activities.

Inefficient use of resources: Inefficient use of resources can lead to delays in completing
maintenance activities, increased costs and reduced productivity. To overcome this problem, it is
essential to optimise the use of resources such as personnel, tools, and equipment, and to carry out
maintenance activities in a planned and organised manner.

Lack of documentation: Lack of documentation can lead to a lack of accountability and compliance
issues. To overcome this problem, it is essential to document all maintenance activities, including
inspections, repairs, and replacement of parts, and ensure that records are maintained according to
regulatory requirements and industry standards.

By being aware of these problems, and taking steps to address them proactively, mechanical
maintenance activities can be carried out safely and efficiently, resulting in improved equipment
reliability and performance.

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Sequence of operations: Gear Pump

RAMS: Risk Assessment Method Statement
Make sure of full use of correct PPE required for the activity.
Correct tools for the activity, make sure tools are in good working order with visual inspection.

Turn off the power: Before beginning the removal process, ensure that the power supply to the wind
turbine and the surrounding equipment is turned off.

Lock out/tag out: Lock out/tag out the power source to prevent it from being accidentally turned
back on while work is being carried out.

Identify and mark hydraulic lines: Identify and mark the hydraulic lines that connect to the gear
pump to make it easier to reassemble the system later.

Disconnect the hydraulic lines: Disconnect the hydraulic lines from the gear pump using appropriate
tools and techniques to avoid damage to the lines or the pump.

Remove the fasteners: Remove any fasteners or screws that secure the gear pump to the mounting
plate.

Lift the pump assembly: Carefully lift the gear pump assembly away from the mounting plate, taking
care not to damage the pump or any surrounding equipment.

Inspect and clean the parts: Inspect and clean all parts of the gear pump and remove any debris or
contamination.

Replace or repair any damaged parts: If any parts of the gear pump are damaged or worn, replace or
repair them before reassembling the pump.

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Gear Compressor Survey Report

Faulty Component
(Include Part Number Fault Identified and Action/Remediation Required
if Appropriate)

Wear on the lower half of the housing, on both the idle and driven sides.
Housing Replace housing

Drive shaft Damage to the keyway; full drive shaft replacement needed.

Drive shaft Wear indicated where the oil seal sits; replacement required.

Idler bearing Slight wear causing a polished finish, not excessive.

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Dimensional Inspection Report

A
Pin and Idler Clearances
B

The pin and idler are to be measured at 2 points: A & B

Gear drive shaft: Nominal Size 19.06mm

Tolerance + 0.02mm - 0.02mm
Idler shaft: Nominal Size 19.08mm
Tolerance + 0.02mm - 0.02mm
MAX 0.09mm
Allowable Clearance
MIN 0.03mm
A: 19.10mm
Gear shaft
B: 19.12mm

Idler shaft A: 19.12mm

B: 19.12mm

Carrier bearing internal diameter (driven) 19.30mm

Carrier bearing internal diameter (idler) 19.30mm

Space between gear teeth 0.10mm

Torque Settings (Nm)

Bolts Quantity Torque Setting

Pump Cover 8 20Nm

Intermediate Casing 8 20Nm

Top Cover 8 20Nm

Pump Casing Drain 1 15Nm

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Gear Pump Question Paper

1. How and when is measuring equipment used?

Bearing clearances: Measuring equipment such as micrometres or dial gauges can be used to
measure the clearance between the gear pump bearings and their journals. This ensures that
bearings are correctly fitted and have the required clearance to operate correctly.

Gear backlash: Gear backlash is the amount of play between the teeth of the gears. Measuring
equipment such as dial gauges or feeler gauges can be used to measure the amount of backlash and
ensure that it is within the manufacturer's recommended range.

Shaft alignment: Proper shaft alignment is critical for the smooth operation of gear pumps.
Measuring equipment such as laser alignment tools can be used to ensure that the pump shafts are
aligned correctly and within tolerance.

Torque: Measuring equipment such as torque wrenches can be used to ensure that bolts and
fasteners are tightened to the correct torque specification. Over-tightening or under-tightening can
cause damage or failure to the gear pump.

By using measuring equipment during gear pump maintenance, parts can be adjusted or replaced to
their correct specifications, ensuring that the gear pump operates safely and efficiently. Measuring
equipment should be properly calibrated and checked for accuracy before use to ensure reliable and
consistent measurements.

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2. When aligning a gear pump to its drive shaft, certain types of misalignments may occur,
what are these and how can they be avoided?

When aligning a gear pump to its drive shaft, certain types of misalignments may occur, which can
cause operational problems, equipment damage, and premature failure. Here are some types of
misalignments and how they can be avoided:

Parallel misalignment: This occurs when the shafts are not parallel, causing the gears to operate at an
angle. To avoid parallel misalignment, it is essential to ensure that the shafts are parallel during
installation.

Angular misalignment: This occurs when the shafts are not in the same plane, causing the gears to
operate at an angle. To avoid angular misalignment, it is essential to ensure that the shafts are in the
same plane during installation.

Axial misalignment: This occurs when the shafts are not aligned on the same axis, causing the gears
to operate at an angle. To avoid axial misalignment, it is essential to ensure that the shafts are
aligned on the same axis during installation.

Shaft runout: This occurs when the shaft is not straight, causing the gears to operate unevenly. To
avoid shaft runout, it is essential to ensure that the shaft is straight and free of any bends or warping
during installation.

To avoid misalignment, it is essential to follow the manufacturer's recommendations and guidelines

for installation, and to use appropriate tools and techniques. The use of laser alignment tools or
manual measurement techniques can be used to ensure precise alignment. It is also essential to
check for any signs of misalignment during routine maintenance and to correct any issues
immediately to prevent further damage or failure.

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3. What tools / instruments are used for alignment of mechanically driven devices?

Laser alignment tools: Laser alignment tools use laser beams to measure and adjust the alignment of
rotating machinery. They can accurately measure misalignment and help to adjust it to the correct
level.

Dial indicators: Dial indicators are precision instruments that measure minute distances and angles.
They are used to measure shaft runout, alignment, and deflection.

Straight edges: Straight edges are used to measure the straightness of machine parts, such as the
alignment of motor shafts and coupling faces.

Feeler gauges: Feeler gauges are used to measure gaps and clearances between machine parts, such
as bearings and coupling faces.

Torque wrenches: Torque wrenches are used to ensure that bolts and fasteners are tightened to the
correct torque specification. Over-tightening or under-tightening can cause misalignment or damage
to the equipment.

Optical alignment tools: Optical alignment tools use optical principles to measure and adjust
alignment. They are useful for aligning large or complex machinery.

Vibration meters: Vibration meters are used to measure and analyse the vibration levels of
machinery. High vibration levels can indicate misalignment or other problems that need to be
addressed.

By using these tools and instruments, accurate alignment of mechanically driven devices can be
achieved, ensuring that the equipment operates efficiently and safely. It is essential to follow the
manufacturer's recommendations and guidelines for alignment and to ensure that appropriate tools
and personal protective equipment are used at all times.

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RAMS: Risk Assessment Method Statement

Make sure of full use of correct PPE required for the activity.
Correct tools for the activity, make sure tools are in good working order with visual inspection.

Turn off the power: Before beginning the dismantling process, ensure that the power supply to the
pump and the surrounding equipment is turned off.

Release stored pressure: Release any pressure in the oil filter and associated equipment to avoid any
sudden or unexpected movement.

Oil: Drain oil within the system into correct containers prior before next step of removing parts.

Remove the filter housing: The first step is to remove the filter housing that surrounds the gear
pump.

Disconnect the suction and discharge lines: Disconnect the suction and discharge lines from the
pump to allow for easier access to the pump itself.

Remove the fasteners: Remove any fasteners or screws that secure the gear pump to the oil filter
assembly.

Lift the pump assembly: Carefully lift the gear pump assembly away from the oil filter, taking care not
to damage the pump or any surrounding equipment.

Disassemble the pump: Disassemble the gear pump by removing the end plates, gears, shafts and
bearings.

Inspect and clean the parts: Inspect and clean all parts of the gear pump and remove any debris or
contamination.

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Oil Filter Survey Report

Faulty Component
(Include Part Number Fault Identified and Action/Remediation Required
if Appropriate)

Filter Housing In relatively good condition. No action required.

Filter Element Filter looks that it has recently been installed. No action required.

Seals & Gaskets All Replaced as per manufacturers guidelines.

Bypass Valve No debris or blockages witnessed. No action required.

Pressure Gauge Tested and in good working order. No action required.

Hydraulic Pipes & Tested. In good working order. No action required.

Fittings

No wear and tear on worm gear etc. All in good working order. Seals / ‘O’
Gear Pump Rings replaced as per manufacturers guidelines.

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Dimensional Inspection Report

Pin and Idler Clearances A

The pin and idler are to be measured at 2 points: A & B B

Pin Nominal Size 4.85mm

Tolerance + 0.02mm - 0.02mm
Idler Nominal Size 4.85mm

Tolerance + 0.02mm - 0.02mm

MAX 0.10mm
Allowable Clearance
MIN 0.05mm
A: 4.82mm
Pin
B: 4.80mm
A: 4.88mm
Idler
B: 4.86mm

Torque Settings (Nm)

Bolts Quantity Torque Setting

Pump Cover 4 20Nm

Pressure Switch 1 15Nm

Motor - Pump 3 12Nm

Casing Drain 1 30Nm

Hose – Pump; coupling 1 40Nm

Hose – Tank; coupling 1 40Nm

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Clearance/Alignment Report

Pressure Switch Results

DO NOT ADJUST THE PRESET

Connectors 1 - 2 N.C L.P.

N.O H.P.
Connectors 1 - 3 N.C L.P.
N.O H.P.

Results

Filtration elements (comment) Clean (visually)

Pressure relief v/v (comment) Functioning (spring loaded, small)

Drain v/v function/type Ball v/v, no leaks

Pressure gauge (comment) Plastic cover broken

Motor Wiring (comment) N/A

Relubrication

All moving parts as per manufactures

Grease (comment) instructions

Oiling (comment) Filter drained (needs primed)

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Oil Filter Question Paper

1. How can oil contamination be minimised?

Use clean oil: Ensure that the oil used in the compressor is clean and meets the manufacturer's
recommendations and specifications. Regularly test the oil to ensure that it remains within the
specified cleanliness level.

Regular oil changes: Regularly change the oil according to the manufacturer's recommendations to
prevent the build-up of contaminants in the oil.

Use quality oil filters: Use high-quality oil filters that are designed to remove contaminants from the
oil and have a high filtration efficiency.

Clean or replace air filters: Ensure that the air filters are clean and working properly to prevent the
entry of contaminants into the compressor.

Use proper maintenance procedures: Follow proper maintenance procedures when carrying out
maintenance activities on the compressor, including using proper tools and techniques, wearing
protective clothing, and ensuring that the work area is clean.

Monitor the compressor: Regularly monitor the compressor for signs of oil contamination, including
changes in oil colour, unusual odours or noises, or reduced performance.

By following these steps, oil contamination in an oil filter compressor can be minimised, ensuring
that the compressor operates safely and efficiently. It is essential to follow the manufacturer's
recommendations and guidelines for maintenance and to ensure that appropriate tools and personal
protective equipment are always used.

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2. What are the minimum requirements of an oil analysis?

Oil sample collection: The oil sample should be collected using a clean and dry sampling method to
avoid contamination.
Identification: The oil sample should be labelled and identified clearly to ensure that it is accurately
tracked and analysed.
Laboratory analysis: The oil sample should be analysed by a certified laboratory to check for various
parameters such as viscosity, contaminants, wear metals, and acidity.

Results interpretation: The results of the analysis should be interpreted by a qualified and
experienced professional to identify any trends or issues that require attention.

Trend analysis: The results of the analysis should be compared with previous samples to identify any
trends or changes in the oil condition or equipment performance.

Report: A comprehensive report should be provided that includes the results of the analysis, the
interpretation of the results, and any recommendations for corrective action.

By following these minimum requirements, oil analysis can be used to identify potential problems
before they become serious, prevent equipment failure, and extend the life of the equipment. It is
essential to follow the manufacturer's recommendations and guidelines for oil analysis and to ensure
that the oil analysis is carried out regularly as part of a comprehensive maintenance program.

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3. When replacing WTG gearbox oil what would paperwork you expect to receive?

An analysis certificate must be delivered together with the ordered oil and include at least
the following items:

• Visual inspection
• Viscosity @ 40◦C
• Density
• Total Acid Number of finished product
• Air bubble separation time
• Contaminants, gravimetric or ISO cleanliness code

For wind turbine oils, foaming at 50°C could be included.

4. Within a full flow system if the inline filter is not changed regularly what may happen?

Within a full flow system, if the inline filter is not changed regularly, it can cause several problems,
including:

Reduced flow rate: Over time, the filter can become clogged with contaminants, reducing the flow
rate of the fluid through the system. This can cause a reduction in the performance of the system
and can lead to overheating or other problems.

Increased pressure drop: A clogged filter can increase the pressure drop across the filter, reducing
the system pressure and affecting its performance. This can cause problems with the operation of
the system and can lead to equipment failure.

Contamination: A clogged filter can allow contaminants to pass through, increasing the level of
contamination in the system. This can lead to damage to the equipment and can reduce its lifespan.

Equipment damage: A clogged filter can cause damage to the equipment by allowing contaminants
to enter the system, causing wear and tear on the components. This can lead to equipment failure
and costly repairs or replacement.

Reduced oil life: A clogged filter can reduce the life of the oil by allowing contaminants to circulate
through the system, leading to increased oxidation, reduced lubrication, and reduced oil life.

Regularly changing the inline filter is essential to ensure the proper functioning of the system and to
prevent the above-mentioned problems. It is essential to follow the manufacturer's
recommendations and guidelines for changing the filter, and to ensure that appropriate tools and
personal protective equipment are used at all times.

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K&U

1. Describe the health and safety requirements, and safe working practices and procedures
required for the mechanical maintenance activities undertaken.

Personal protective equipment (PPE): Wear appropriate PPE such as gloves, eye protection, and a
dust mask to prevent exposure to harmful substances and prevent injuries.

Proper ventilation: Ensure that the workspace is well-ventilated to prevent the accumulation of
harmful gases or chemicals.

Tools and equipment: Use the right tools and equipment, and ensure they are in good condition
before using them. Faulty tools can lead to accidents and injuries.

Work area: Maintain a clean and organized work area, free from clutter and hazards, to prevent
accidents.

Proper lifting techniques: Use proper lifting techniques when moving heavy parts to avoid straining
or injuring yourself.

Emergency procedures: Familiarise yourself with emergency procedures, such as the location of first
aid kits and fire extinguishers, in case of an accident.

Training: Ensure that you have received adequate training on how to safely disassemble a car
engine before beginning the task.

Respect for others: Be respectful of others working in the same area and ensure that you are not
creating hazards for others.

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2. Describe the procedure for obtaining drawings, job instructions, related

specifications, replacement parts, materials, and other consumables necessary for the
maintenance activities.

When undertaking mechanical maintenance activities, it is important to have all necessary

information, instructions, and materials to ensure the job is carried out correctly and safely. The
following procedure can be used to obtain the required information and materials:

Drawings and job instructions: Consult the manufacturer's manuals or relevant technical publications
to obtain drawings and job instructions for the specific task.

Related specifications: Check the specifications of the parts to be replaced or serviced, including their
size, material, and tolerances. This information can be found in technical publications or by
consulting with a knowledgeable supplier.

Replacement parts: Determine the replacement parts needed based on the specifications and
drawings obtained in step 1 and 2. These can be obtained from a supplier or manufacturer's
authorised dealer.

Materials and other consumables: Determine the materials and consumables required for the job,
such as lubricants, solvents, or gaskets. These can be obtained from a supplier or manufacturer's
authorised dealer.

Health and safety requirements: Ensure that any materials or consumables used meet health and
safety requirements and are compatible with the materials being worked on.

Budget constraints: Ensure that the cost of the required materials and consumables is within budget
constraints.

Record keeping: Maintain accurate records of the parts, materials, and consumables used for the
maintenance activity for future reference.

By following this procedure, I can ensure that I have all the necessary information and materials to
safely and efficiently carry out the required mechanical maintenance activities.

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3. Describe the various maintenance diagnostic techniques and aids that can be used (such
as fault reports, visual checks, measuring, movement and alignment checks, testing)

To effectively maintain mechanical equipment, it is important to have a range of diagnostic

techniques and aids at your disposal. The following are some examples of techniques and aids that
can be used:

Fault reports: Analyse any fault reports generated by the equipment, such as computer diagnostics
or error messages, to identify the source of the problem.

Visual checks: Conduct visual checks of the equipment to identify any visible signs of damage, wear,
or misalignment. This can include checking for leaks, corrosion, cracks, or other damage.

Measuring: Use measuring tools such as callipers, micrometres, or dial indicators to identify any
variations or deviations from the specified measurements.

Movement and alignment checks: Check the movement and alignment of the equipment, such as
checking for proper rotation or alignment of shafts, belts, or pulleys.

Testing: Conduct functional testing of the equipment, such as testing for vibration or noise, to
identify any abnormal behaviour.

Non-destructive testing (NDT): Use NDT techniques such as ultrasonic testing, radiography, or
magnetic particle inspection to detect internal defects or damage that may not be visible during
visual checks.

Performance monitoring: Monitor the performance of the equipment, such as measuring output or
energy consumption, to identify any changes that may indicate a problem.

By using a combination of these techniques and aids, maintenance professionals can accurately
diagnose problems with mechanical equipment and take appropriate corrective actions to ensure
safe and efficient operation.

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4. Describe the various fault location techniques that can be used, and how they are applied
(such as half‐split, input‐to‐output, function testing, unit substitution, and equipment
self‐diagnostics)

When diagnosing faults in mechanical equipment, there are various fault location techniques that
can be used. The following are some examples of techniques and how they are applied:

Half-split technique: This involves dividing the equipment into two halves, such as a gearbox or
engine, and testing each half to determine which side of the equipment the fault is located on.

Input-to-output technique: This involves testing the input and output of the equipment, such as
checking the voltage or current at each point, to determine where the fault is located.

Function testing: This involves testing the equipment's function, such as checking for proper
operation or response to control signals, to identify any abnormalities or malfunctions.

Unit substitution: This involves replacing the suspect unit with a known-good unit to see if the
problem is resolved. This can help to isolate the faulty unit and determine the location of the fault.

Equipment self-diagnostics: Many modern mechanical equipment is equipped with self-diagnostic

features that can help to identify faults and their location. These features may include onboard
sensors, computer systems, or error codes that can be accessed by the maintenance team.

By using these techniques, maintenance professionals can accurately locate faults in mechanical
equipment and take appropriate corrective actions to ensure safe and efficient operation. It is
important to have a thorough understanding of each technique and to apply them appropriately for
the specific equipment and fault being diagnosed.

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5. Describe a sequence to be adopted for the dismantling/re‐assembly of various types of

assemblies.

When dismantling and re-assembling mechanical assemblies, it is important to follow a systematic

sequence to ensure that the process is carried out correctly and safely. The following is a general
sequence that can be adopted for the dismantling and re-assembly of various types of mechanical
assemblies:

Preparation: Ensure that all necessary tools, equipment, and materials are available and ready for
use. This includes any personal protective equipment (PPE) required for the job.

Inspection: Conduct a visual inspection of the assembly to identify any visible signs of damage or
wear, such as cracks, corrosion, or worn-out components.

Disconnection: Disconnect any electrical, hydraulic, or pneumatic connections, as well as any

mechanical fasteners, such as nuts, bolts, or screws.

Labelling and marking: Label and mark all components and fasteners to ensure that they can be
easily identified during re-assembly. This can be done using tags, markers, or a digital camera.

Dismantling: Remove any components or sub-assemblies in the correct sequence, following any
relevant manufacturer's instructions or technical publications. This may involve using specialized
tools, such as pullers or extractors.

Cleaning: Clean all components and surfaces thoroughly, removing any debris, dirt, or contaminants
that may have accumulated during use.

Inspection and repair: Inspect each component for signs of damage or wear, and repair or replace
any faulty components as necessary.

Re-assembly: Re-assemble the components and sub-assemblies in the reverse order of dismantling,
following any relevant manufacturer's instructions or technical publications. Ensure that all fasteners
are tightened to the correct torque settings and any electrical or hydraulic connections are
reconnected.

Final checks: Conduct final checks, such as testing for proper operation, fluid levels, or alignment, to
ensure that the assembly is functioning correctly.

Documentation: Document the dismantling and re-assembly process, including any repairs or
replacements made, for future reference.

By following this systematic sequence, maintenance professionals can ensure that the dismantling
and re-assembly process is carried out correctly and safely, minimizing the risk of damage to the
assembly or injury to personnel.

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6. Describe the methods of checking that components are fit for purpose, and how to
identify defects and wear characteristics.

Checking that components are fit for purpose is an important part of mechanical maintenance
activities. The following are some methods that can be used to check components and identify
defects and wear characteristics:

Visual inspection: Conduct a visual inspection of the components to identify any visible signs of
defects or wear, such as cracks, corrosion, or excessive wear.

Dimensional inspection: Use measuring tools such as callipers, micrometres, or dial indicators to
measure the dimensions of the components and compare them to the specifications provided by
the manufacturer.

Non-destructive testing (NDT): Use NDT techniques such as ultrasonic testing, radiography, or
magnetic particle inspection to detect internal defects or damage that may not be visible during
visual inspection.

Performance testing: Conduct performance testing of the components to ensure that they are
operating within the expected range of performance parameters.

Material testing: Conduct material testing to determine the composition and properties of the
materials used in the components and ensure that they are suitable for the intended purpose.

Wear characteristic identification: Become familiar with the wear characteristics of the specific
components being checked. For example, knowing the typical wear patterns for bearings or gears
can help identify potential issues before they become critical.

By using these methods, maintenance professionals can ensure that components are fit for purpose
and identify any defects or wear characteristics that may need to be addressed. It is important to
have a thorough understanding of each method and to apply them appropriately for the specific
components being checked.

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7. Describe the identification, application, fitting, and removal of different types of

bearings (such as roller, ring, thrust)

Bearings are an essential component of many mechanical systems and come in a variety of types.
The following are some general guidelines for the identification, application, fitting, and removal of
different types of bearings:

Roller bearings: Roller bearings are designed to support heavy radial loads and are commonly used in
applications such as conveyor systems, vehicle wheels, and machine tools. They consist of cylindrical
or tapered rollers that are arranged in a cage or retainer. To fit or remove a roller bearing, a bearing
puller or press can be used. During installation, ensure that the bearing is properly aligned and
seated in the correct position. When removing a roller bearing, use a puller or press to avoid damage
to the bearing or surrounding components.

Ring bearings: Ring bearings are designed to support heavy radial and axial loads and are commonly
used in applications such as wind turbines, cranes, and large vehicles. They consist of an inner and
outer ring with a set of rolling elements, such as balls or rollers, in between. To fit or remove a ring
bearing, a bearing puller or press can be used. During installation, ensure that the bearing is properly
aligned and seated in the correct position. When removing a ring bearing, use a puller or press to
avoid damage to the bearing or surrounding components.

Thrust bearings: Thrust bearings are designed to support axial loads and are commonly used in
applications such as machine tool spindles, automotive transmissions, and marine propeller shafts.
They consist of a set of rolling elements, such as balls or rollers, that are arranged in a cage or
retainer. To fit or remove a thrust bearing, a bearing puller or press can be used. During installation,
ensure that the bearing is properly aligned and seated in the correct position. When removing a
thrust bearing, use a puller or press to avoid damage to the bearing or surrounding components.

It is important to refer to the manufacturer's instructions or technical publications for specific

guidance on the identification, application, fitting, and removal of different types of bearings.
Improper installation or removal can cause damage to the bearing or surrounding components,
resulting in equipment failure or injury.

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8. Explain how to correctly tension belts and chains.

Correct tensioning of belts and chains is critical to ensuring safe and efficient operation of
mechanical equipment. The following are some general guidelines for correctly tensioning belts and
chains:

Belts: Check the manufacturer's instructions or technical publications for the recommended tension
range for the specific belt being used.

Use a belt tension gauge or a deflection method to measure the tension of the belt.

Apply tension to the belt gradually, adjusting the tensioning device as necessary until the desired
tension is reached.

Ensure that the belt is running straight and aligned properly on the pulleys.

Chains: Check the manufacturer's instructions or technical publications for the recommended
tension range for the specific chain being used.

Use a chain tension gauge or a deflection method to measure the tension of the chain.

Apply tension to the chain gradually, adjusting the tensioning device as necessary until the desired
tension is reached.

Ensure that the chain is running straight and aligned properly on the sprockets.

It is important to note that over-tensioning can cause excessive wear on the belt or chain, leading to
premature failure. Under-tensioning can cause slippage or excessive vibration, leading to reduced
efficiency and potential damage to the equipment. It is important to regularly check the tension of
belts and chains and adjust as necessary to ensure safe and efficient operation.

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9. Describe the identification and application of different types of locking device.

Locking devices are essential for ensuring health and safety during mechanical and electrical
maintenance activities. The following are some different types of locking devices and their
applications:

Lockout tagout (LOTO): This is a system that ensures that machinery and equipment are shut off and
not able to be restarted until maintenance is complete. It involves using locks and tags to prevent
unauthorized access and ensure that machinery or equipment is not accidentally started up during
maintenance activities.

Safety interlocks: These devices are used to prevent equipment from operating when certain
conditions are not met. For example, a safety interlock may prevent a machine from operating if a
guard or cover is not in place.

Keyed switches: These devices use a key to turn the equipment on or off, preventing unauthorized
access or accidental operation.

Barrier guards: These are physical barriers, such as fences or shields, that are used to prevent access
to dangerous areas of equipment.

Padlocks: These are used to lock equipment or components in place to prevent accidental
movement during maintenance activities.

Cable locks: These are used to secure movable components or equipment during maintenance
activities.

Safety chains: These are used to secure equipment or components during maintenance activities.

It is important to identify the appropriate locking device for the specific application and to use it
correctly to ensure health and safety during maintenance activities. It is also important to regularly
inspect and maintain locking devices to ensure that they are functioning correctly and effectively.

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10.Describe the methods of checking that removed components are fit for purpose, and
the need to replace ‘lifed’ items (such as seals and gaskets)

Checking that removed components are fit for purpose is an important part of mechanical
maintenance activities. The following are some methods that can be used to check removed
components:

Visual inspection: Conduct a visual inspection of the components to identify any visible signs of
defects or wear, such as cracks, corrosion, or excessive wear.

Dimensional inspection: Use measuring tools such as callipers, micrometres, or dial indicators to
measure the dimensions of the components and compare them to the specifications provided by
the manufacturer.

Non-destructive testing (NDT): Use NDT techniques such as ultrasonic testing, radiography, or
magnetic particle inspection to detect internal defects or damage that may not be visible during
visual inspection.

Performance testing: Conduct performance testing of the components to ensure that they are
operating within the expected range of performance parameters.

In addition to checking removed components, it is important to replace ‘lifed’ items, such as seals
and gaskets, at regular intervals. These items have a limited-service life and will degrade over time,
potentially leading to leaks or equipment failure. The manufacturer's instructions or technical
publications should specify the recommended replacement interval for these items.

By using these methods and replacing ‘lifed’ items, maintenance professionals can ensure that
components are fit for purpose and identify any defects or wear characteristics that may need to be
addressed. It is important to have a thorough understanding of each method and to apply them
appropriately for the specific components being checked.

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11.Describe the importance of making ‘off‐load’ checks before running the equipment
under power.

Making 'off-load' checks before running mechanical equipment under power is an essential safety
precaution that helps to ensure safe and efficient operation. The following are some reasons why
making off-load checks is important:

Identification of defects or damage: Making off-load checks allows maintenance professionals to

identify any defects or damage to the equipment that may not be immediately apparent when the
equipment is running under power. This can include issues such as worn or damaged components,
leaks, or loose fasteners.

Adjustment of settings: Off-load checks allow maintenance professionals to adjust settings or

perform calibration procedures that may be difficult or dangerous to perform when the equipment
is running under power. This can include adjusting alignment, tension, or clearance settings.

Verification of safety features: Off-load checks allow maintenance professionals to verify that safety
features, such as emergency stops or safety interlocks, are functioning correctly and can be
activated if needed.

Prevention of accidents: Making off-load checks helps to prevent accidents or injuries that may
occur if defects or damage are present and go unnoticed during operation.

By making off-load checks before running equipment under power, maintenance professionals can
identify and address any issues that may affect safe and efficient operation. It is important to follow
any relevant manufacturer's instructions or technical publications when making off-load checks and
to use appropriate personal protective equipment (PPE) when necessary.

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