Mechanical Installation

Table of Contents

Chapter 1: Wrenches and Screwdrivers

Topics: Wrenches-open-end, box-end, combination, socket, adjustable, torque; Screwdrivers-standard, cross-slot, spiral, ratchet, offset; Driving and removing screws; Restoring a blade

Learning Objectives:

• Identify types of materials used for making wrenches.
• Identify open-end, box-end, socket, socket-head, adjustable, torque, and striking-face wrenches.
• Describe two sizes that are important in identifying a socket wrench.
• Identify standard, Phillips, offset, and spiral-ratchet screwdrivers.
• List the steps to follow when driving a screw.

Chapter 2: Fasteners

Topics: Threaded fasteners; Screw threads; Types of nuts; Washers; Safety wiring; Keys and pins; Rivets

Learning Objectives:

• Identify seven major types of threaded fasteners.
• Read and interpret common screw thread and threaded fastener specifications.
• Describe the three actions in a manual riveting operation, and explain why each action must be done properly.
• Demonstrate the proper technique for safety wiring a group of threaded fasteners.
• Identify three kinds of washers.

Chapter 3: Introduction to Industrial Rigging

Topics: Rigging tools; Determining weight and center of gravity; Vertical and horizontal force; Slings; Hooks; Hoist hooks; Special-purpose rigging hooks

Learning Objectives:

• Identify the tools used in rigging and explain the purpose of each.
• Give examples of three methods of calculating the weight of a load.
• Explain center of gravity and its importance in rigging a load.
• Describe four common sling arrangements and the relation between sling angle and horizontal force.
• Name five types of hooks frequently used in rigging and explain the purpose of each.
• Discuss proper hook use and cite four reasons for removing a hook from service.

Chapter 4: Wire Rope and Wire-Rope Slings

Topics: Wire rope construction, classification, and strength; Seizing, cutting, and splicing; Wire-rope slings; Inspection

Learning Objectives:

• Identify the component parts of wire rope and describe its construction and classification.
• Identify and discuss the factors that affect wire rope strength.
• Describe the basic single-leg and multiple-leg slings and the calculation of their allowable loads.
• Enumerate the signs of damage that would probably cause a wire rope to be removed from service.

Chapter 5: Chain and Metal-Mesh Slings

Topics: Welded-link chain; Chain grades and strength; Chain slings; Inspecting slings; Metal mesh slings; Sling materials

Learning Objectives:

• Identify the different grades of chain and name some of their applications.
• Define the terms working load limit, proof test, and minimum breaking force.
• List and discuss four factors that affect the strength of chain slings.
• Describe three types of damage you might see in a daily inspection of chain slings that would lead you to set the sling aside for more thorough examination.
• Describe the two standard types of end fittings for metal mesh slings and the hitches for which each can be used.
• Name several advantages of, and applications for, metal mesh slings.
• List the visible signs of damage that would cause you to recommend a sling's removal from service.

Chapter 6: Fiber Rope and Webbing Slings

Topics: Natural and synthetic-fiber rope; Sling strength; Whipping rope ends; Splicing fiber rope; Synthetic webbing; Inspecting slings

Learning Objectives:

• Identify the grades of manila rope that can be used for overhead lifting.
• Name the three commonly used synthetic-fiber ropes and list three of their advantages over manila.
• Discuss the factors that affect the strength of fiber rope.
• Name the signs of wear or damage that would warrant setting a fiber-rope sling aside for more detailed inspection.
• Describe an encased polyester fiber sling.
• Explain the construction of synthetic-web slings and name four of the basic types.
• List examples of visible damage that should cause a synthetic-web sling to be removed from service.

Chapter 7: Industrial Hoists and Cranes

Topics: Overhead manual chain, power, and wire-rope hoists; Side pull; Overload limit device; Underhung and top-running cranes; Jib cranes; Inspection

Learning Objectives:

• Describe the characteristics of the various kinds of overhead hoists.
• Explain the differences between single and double reeving.
• Explain the proper function and operation of an upper limit switch and an overload limit device.
• Describe and contrast the construction of top-running and underhung cranes.
• Identify the three basic types of jib cranes.
• Describe what the rigger's daily visual inspection should include.
• List examples, from the additional criteria given in this Lesson, of conditions that should warrant removal of wire rope or hoist load chain from service.

Chapter 8: Operating Practices

Topics: Hoist and crane operation; Special heavy lifts; Pulling, setting, and turning a load; Eyebolts; The thought process of rigging

Learning Objectives:

• Enumerate the general operating practices that apply to all tools of rigging.
• Explain the 11 operating practices that apply to slings.
• Discuss nine operating practices that should be observed when using a hoist or crane.
• Detail the special circumstances under which a hoist or crane may be used to pull a load or lift a load heavier than the equipment's rated capacity.
• Describe three methods of turning a load.
• Discuss the eight questions that a rigger must answer in the thought process that should precede any lift.

Chapter 9: Scaffolds and Ladders

Topics: Types of scaffolds; Guy lines; Accessories; Ladders; How to raise and inspect a ladder; Life belts; Scaffold and ladder safety

Learning Objectives:

• Explain the construction of pole and suspension scaffolds and lift platforms, and the safety measures that apply to them.
• Name several scaffolding accessories and explain their use.
• Discuss recommended usage and inspection of the three common types of ladders.

Chapter 10: Building Drawings

Topics: Buildings and building sites; Symbols and conventions; Plat, site, and floor plans; Working drawings

Learning Objectives:

• Name building materials, given their standard symbols.
• Explain how to find useful information on a flow diagram.
• Explain how to find useful information on an industrial plat.
• List the contents of a set of building drawings.
• Describe the purpose of a structural drawing.

Chapter 11: Preparing the Site

Topics: Relocating underground piping, wiring, and cables; Barricading the work area; Removing excavated materials; Foundations and footings; Reinforced concrete; Safety precautions for excavating

Learning Objectives:

• Tell who plans the installation of new equipment and list the steps involved.
• Define the terms foundation and footing.
• Tell which type of ground will support the most weight.
• Explain how steel rods are held in position when pouring a concrete footing.
• Name the best materials for filling around a foundation.
• Explain how to protect concrete that might come into contact with oil or chemicals.
• Tell how long new concrete must sit before equipment is installed on it.

Chapter 12: Vibration Control and Anchoring

Topics: Selecting anchors and isolators; Isolator mounts; Anchor bolts; Using power hammers; Grouting

Learning Objectives:

• Define vibration and tell how it enters and leaves equipment.
• Tell what type of isolation is best to use on sensitive testing instruments.
• Explain how to isolate anchor bolts when mounting equipment on pads.
• Tell what type of wrench to use for tightening anchor bolts.
• Name the best tool for drilling anchor bolt holes in concrete.
• Tell why the bases of production and processing equipment should be grouted.
• Explain why you must not use a concrete mix to grout anchor bolts.

Chapter 13: Moving and Setting

Topics: Uncrating; Relocating; Lifting; Raising with jacks and slings; Crowbars; Making the move; Personal safety

Learning Objectives:

• Explain the procedures involved in relocating existing equipment.
• Tell two things you must know before lifting equipment with a hoist.
• List three things to consider when selecting a jack.
• Explain the operation and uses of a roller skid.
• Tell where to find a floor's allowable load.

Chapter 14: Leveling and Aligning

Topics: Leveling devices; Wedges and shims; Checking alignment; Aligning equipment on the foundation; Alignment screws; Aligning machine tools

Learning Objectives:

• Explain the correct way to handle a master precision level.
• Explain how to check the accuracy of a level.
• Name the greatest enemy of precision tools.
• Explain how to level V-shaped ways.
• Tell which leveling device is used most often on small equipment.
• Name three tools commonly used to check alignment.
• Tell how to set an alignment screw to prevent its movement.

Chapter 15: Checking and Test Running

Topics: Electric, hydraulic, and pneumatic connections; Coolant systems; Safety devices; Settings and adjustments; Making the test run; Safety

Learning Objectives:

• Explain how to test for the presence of moisture in electrical equipment.
• Tell what device is commonly used to prevent excessive pressure in a hot water heater.
• Explain the function of a pressure regulating valve.
• List the steps to take before initial equipment startup.
• Tell the usual cause of excessive temperature during equipment startup.

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