Prepared by:

Mr. Roslan bin Hashim

Mechanical Engineering Department
Ungku Omar Polytechnic
 COURSE LEARNING OUTCOMES
(CLO)
 Upon completion of this course, students should be
able to:

 CLO 1 : Apply the concept of mechanical components

to solve related problems. ( C3 , PLO 1 )

 CLO 2 : Organize appropriately experiments in

groups according to Standard Operating Procedure.
( P4 , PLO 5)

 CLO 3 : Perform the troubleshooting on mechanical

component failure and damage ( P4 , PLO 4 )
TOPIC 1.0 MAINTENANCE &
TROUBLESHOOTING PRINCIPLES AND
PROCEDURES
1.1 Understanding of maintenance.
The Meaning Of Maintenance.
 maintenance is a set of organised
activities that are carried out in order to
keep an item in its best operational
condition with minimum cost acquired.
 Maintenance History
-Term terotechnology
introduced
(replacement &
Development of

removal)
Maintenance

-Recognition of need
to present equipment
failures. -Increased awareness of:
-Models for -Environment
preventive -Safety
Fix the equipment maintenance -Quality
when it breaks developed. -Need for reliable equipment.
-Reduction in costs.

Time
Pre-World War II Post-World War II 1980 Onwards
 Maintenance Objectives
 Maintenance objectives should be consistent with and
subordinate to production goals.

 The relation between maintenance objectives and production

goals is reflected in the action of keeping production machines
and facilities in the best possible condition.
 Maintenance Objectives
1. Maximising production or increasing facilities availability at
the lowest cost and at the highest quality and safety
standards.
2. Reducing breakdowns and emergency shutdowns.
3. Optimising resources utilisation.
4. Reducing downtime (periods when a system is unavailable (offline)) .
5. Improving spares stock control.
6. Improving equipment efficiency and reducing scrap rate.
7. Minimising energy usage.
8. Optimising the useful life of equipment.
9. Providing reliable cost and budgetary control.
10. Identifying and implementing cost reductions.
Maintenance Objectives
PLANT

Maximising Production Reduce Breakdowns

M
A
I
Minimising Energy N Reduce Downtime
Usage
T
E
N
Optimising Useful Life Improving Equipment
of Equipment
A Efficiency
N
C
Providing Budgetary E Improving Inventory
Control Control

Optimising Resources Implementing Cost

Utilisation Reduction
Advantages Of Implement
Maintenance.
1. Improved Efficiency. The overall efficiency of your
system will be improved, helping save on energy
costs. Many experts believe that regular
maintenance will help a system retain up to 95% of
its original efficiency rating.
2. Fewer Repairs. Small problems can often be
detected before they become large problems with
expensive repairs.
3. Extended Equipment Life. The life of your system
will be extended over what you can expect from a
system that is not regularly maintained.
4. Lower utility bills. A neglected HVAC system
consumes up to 25% more energy which means
unnecessarily high power bills.
Advantages Of Implement
Maintenance.
5. Identify Problems Early. Potentially hazardous conditions
can be identified.
6. Anticipate Failures. Many unexpected failures can be
prevented that could result in breakdowns during extreme
temperatures when operating systems are under maximum
workload.
7. Fewer “emergency” calls. Emergencies can be expensive
and frustrating. Your unit will be maintained and
emergencies can be avoided.
8. Added comfort and peace of mind. Know that your system
is being taken care of and that your unit is functioning
properly.
1.2 Cost consideration in
maintenance
Types of cost in maintenance
Costs associated with maintenance are:
1. Downtime cost due to equipment breakdown.
2. Cost of spares and other material used for repairs.
3. Cost of maintenance labour and overheads of maintenance
department.
4. Losses due to inefficient operations of machines.
5. Capital requirement for replacement of machines .

 The term downtime is used to refer to periods when a system

is unavailable (offline). Downtime or outage duration
(Maintenance Duration) refers to a period of time that a
system fails to provide or perform its primary function.
Explanation of all types of
maintenance cost related
 Because of breakdowns, both the
machinery as well as the manpower are left
idle, per force.
 This results in production, delay in
schedules and emergency repairs.
 The downtime costs generally exceed the
preventive maintenance costs of
inspection, service and scheduled repairs.
 Maintenance Costs
Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Costs
Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Costs
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Costs
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Optimal Maintenance
Commitment
1.3 UNDERSTANDING OF TROUBLESHOOTING.
The Meaning Of Troubleshooting.
• Troubleshooting is a form of problem solving, often applied
to repair failed products or processes on a machine or a
system.

• It is a logical, systematic search for the source of a problem

in order to solve it, and make the product or process
operational again

• Troubleshooting is needed to identify the symptoms

• Determining the most likely cause is a process of

elimination—eliminating potential causes of a problem.

• Finally, troubleshooting requires confirmation that the

solution restores the product or process to its working state.
THE METHODS OF TROUBLESHOOTING
The Troubleshooting Process Steps Are As Follows:
 Identify the problem.
 Establish a theory of probable cause.
 Test the theory to determine the cause.
 Establish a plan of action to resolve the problem and
implement the solution.
 Verify full system functionality and, if applicable,
implement preventive measures.
How do you troubleshoot
mechanical equipment?
 Step 1: Identify the symptoms.
 Step 2: Isolate the problem to a
particular component.
 Step 3: Test the suspected component.
 Step 4: Repair or replace the component.
 Step 5: Test the system.
1.4 WORKPLACE SAFETY.
1.4 Workplace Safety.
The benefit clean and safe working environment
1. Reduced handling to ease the flow of materials
2. Fewer tripping and slipping accidents in clutter-free
and spill-free work areas
3. Decreased fire hazards
4. Lower worker exposures to hazardous substances (e.G.
Dusts, vapours)
5. Better control of tools and materials, including
inventory and supplies
6. More efficient equipment cleanup and maintenance
7. Better hygienic conditions leading to improved health
more effective use of space
8. Reduced property damage by improving preventive
maintenance
9. Less janitorial work
10. Improved morale
11. Improved productivity (tools and materials will be easy
to find)
Poor housekeeping can be a cause of
accidents, such as:
1. Tripping over loose objects on floors, stairs and platforms
being hit by falling objects.
2. Slipping on greasy, wet or dirty surfaces.
3. Striking against projecting, poorly stacked items or misplaced
material.
4. Cutting, puncturing, or tearing the skin of hands or other parts
of the body on projecting nails, wire or steel strapping.
5. To avoid these hazards, a workplace must "maintain" order
throughout a workday. Although this effort requires a great
deal of management and planning, the benefits are many.
The important of Personal Protection
Equipments (PPE)
What is PPE?
Equipment that workers wear to protect themselves
from hazards in their work environment.
Examples:
 hearing protection
 respirators
 hard hats (safety helmets)
 safety goggles
 safety glasses
 safety shoes
 gloves
The important of Personal Protection
Equipments (PPE)
 When hazards can not be eliminated through
engineering and/or administrative controls, PPE
must be used to protect the eyes, face, head,
feet, hands, arms, body, ears, and lungs.
 Preventable Injuries:
 Chemical burns to the eyes
 Chemical irritation to the eyes and skin
 Particulate matter in the eye
 Heat burns
 Slips, trips, and falls
 Cuts and abrasions
VIDEO LOGOUT AND TAGOUT
1.3.3 Use lock-out and tag-out
when needed.
 .Log-Out and Tag-Out (LOTO)
This practice helps safeguard employees from
hazardous energy while they are performing service
or maintenance on machines and equipment. E

 The OSHA standard 29 CFR §1910.147, identifies

the practices and procedures necessary:
 a written program and lockout procedures,
 shut down and lockout or tagout of machines and
equipment,
 employees training in their role in the lockout/tagout
program, and
 periodic inspections conducted to maintain or
enhance the energy control program.
1.3.3 Use lockout and tag-out
when needed.
What are lockout devices?
 Lockout device: Any device that uses a
positive means, such as a lock, blank
flanges and bolted slip blinds, to hold an
energy-isolating device in a safe position,
thereby preventing the energizing of
machinery or equipment.

Valve Devices What are Energy-Isolating devices?

Plug out
 Energy-isolating device: A mechanical device
that physically prevents the transmission or
release of energy, including but not limited to
the following: A manually operated electrical
circuit breaker; a disconnect switch; a line
valve; a block; and any similar device used
to block or isolate energy. Push buttons,
selector switches and other control circuit
type devices are not energy isolating
devices.
Circuit Breaker Device
1.3.3 Use lockout and tag-out when
needed.
When needed LOTO?
 before begin any servicing or maintenance
activities where the unexpected energization,
(start-up or release of stored energy) could
cause injury.
 Procedures for locking out equipment and
machinery are attached at the control panel.
 Information in the procedure:
1. will provide the location of energy sources,
2. the magnitude of energy, the isolation
A good rule of thumb is: whenever the devices, and
guarding is removed, or by-passed, or
any part of your body can come in
3. the sequence required to shut down and
contact with the working parts during restart the machine or equipment.
service/maintenance lockout must be
done!
 The organization that governs the safety of
hazardous material.
1. The Department of Occupational
Safety and Health (DOSH)

A department under the Ministry of Human Resources. This department is responsible for
ensuring the safety, health and welfare of people at work as well as protecting other people
from the safety and health hazards arising from the activities sectors which include:
 Manufacturing
 Mining and Quarrying
 Construction
 Hotels and Restaurant
 Agriculture, Forestry and Fishing
 Transport, Storage and Communication
 Public Services and Statutory Authorities
 Utilities - Gas, Electricity, Water and Sanitary Services
 Finance, Insurance, Real Estate and Business Services
 Wholesale and Retail Trades

As a government agency, the department is responsible for the administration and

enforcement of legislations related to occupational safety and health of the country, with a
vision of becoming an organisation which leads the nation in creating a safe and healthy
work culture that contributes towards enhancing the quality of working life.
2.

 To develop the capacity and capability of the

construction industry through the enhancement of
quality and productivity by placing great emphasis on
professionalism, innovation and knowledge in the
endeavour to improve the quality of life.
3. National Institute of Occupational Safety and
Health (NIOSH)

 NIOSH is committed to ensure a safe and healthy working

environment to all employees and others involved in or affected by its
operation taking into account statutory requirement and relevant
national and international standards and codes of practices.
 NIOSH will ensure that adequate resources, training and time are
made available.
 Safety and Health management systems and programmes will be
regularly reviewed to ensure continuous improvement.
 Humanistic approach will be adopted by NIOSH to promote a safe and
healthy work culture which employer and employees share the
common responsibility of creating a better work environment for all.
 HAND TOOLS
 Hand Tools - Tools that
are manually operated
and powered by human
force such as screw
drivers, pliers, wrenches,
and cutting shears, etc.
 Wrenches:
 Choose a wrench that properly fits the
fastener that is to be turned. Using the
correct size reduces the chances of
wrench slippage.
Wrench
 Avoid using a length of pipe or other
extension to improve the leverage of a Set
wrench. Manufacturers design wrenches
so that the amount of leverage obtained
with the handle is the maximum safe
application.
 Use socket wrenches for hard-to-reach
areas.
Ring
 Always try to pull on a wrench (instead of
pushing) in case the fastener suddenly Ratchet
loosens. Wrench Set
 Inspect wrenches periodically for damage
such as cracking, severe wear, or
distortion.

Adjustable
Socket Wrench
Wrench
Set
 Pliers:
 Do not increase the handle length
of pliers to gain more leverage.
Use a larger pair of pliers or bolt
cutters.
 Do not substitute pliers for a
wrench when turning nuts and
bolts. Pliers cannot grip these
items properly and will slip.
 Never use pliers as a hammer or
hammer on the handles. Such
abuse is likely to result in cracks
or breaks.
 Cut hardened wire only with
pliers designed for that purpose.
 Always cut at right angles. Never
rock from side to side or bend the
wire back and forth against the
cutting edges.
 Hammers:
 Do not use a hammer if the handle is
damaged or loose.
 Never weld, heat, or regrind a
hammer head.
 Remove from service any hammer
exhibiting signs of excessive wear
such as cracks, chips, or a
mushroomed head.
 Match the proper type of hammer to
the job it is designed to perform.
 Do not strike the surface at an angle.
The hammer face should contact the
striking surface squarely. Glancing
blows made with a hammer often
lead to injury.
 Screwdrivers:
 Never use a screwdriver as a
pry bar, chisel, punch,
stirrer, or scraper.
 Always use a screwdriver tip
that properly fits the slot of
the screw.
 Throw away screwdrivers
with broken or worn
handles.
 Use magnetic or screw-
holding screwdrivers to
start fasteners in tight
areas.
 Never use pliers on a
screwdriver for extra
leverage. Only use a wrench
on screw drivers specifically
designed to accept them.
 POWER TOOL
 Power Tools - Power tools
that are hand held,
manually operated, and
powered by electricity, air,
gasoline, diesel, or
explosion, such as circular
saws, sanders, drills,
reciprocating saws, air
wrenches, air grinders, air
fasteners, chainsaws,
Ramset guns & etc.
 IMPORTANT OF INDICATING
POWER TOOL
 The two most common hazards associated with the use of
hand tools are misuse and improper maintenance.
 Misuse occurs when a hand tool is used for something
other than its intended purpose. (An example would be
using a screwdriver as a chisel. This may cause the tip to
break and strike someone).
 Improper maintenance allows hand tools to deteriorate
into an unsafe condition.
 (Examples would include cracked wooden handles that
allow the tool head to fly off or mushroomed heads that
can shatter upon impact).
 Specially designed tools may be needed in hazardous
environments. (Always use non-sparking tools in the
presence of flammable vapours or dusts. Insulated tools
with appropriate ratings must be used for electrical work).