fundamentals of maintenance by osama mohammed elmardi suleiman khayal

1. 1
‫ك‬‫ـــ‬‫تاب‬
‫أساس‬‫ـــ‬‫الص‬ ‫يات‬‫ـــ‬‫يانة‬
‫إع‬‫ـ‬‫أس‬ /‫داد‬‫ـ‬‫حم‬ ‫اوة‬‫ـ‬‫امل‬ ‫ىد‬‫ـ‬‫سميى‬ ‫رضي‬‫ـ‬‫ان‬
‫النين‬ ‫وادي‬ ‫جاوعة‬ ،‫والتكنية‬ ‫اهلندسة‬ ‫كمية‬ ،‫امليكانيكا‬ ‫قشي‬ ،‫وشاعد‬ ‫أستاذ‬

2. i

3. ii
i.e.

4. iii
5112

5. iv
i
ii
iv
vi
1 11
1 52
1 111
1 112
5 151
5 551
5 155
5 151
5 251
1 111
1 113
1 515
2 111
2 511

6. v
3 111
3 513
3 115
3 121
3 221
3 321
4 122
4 522
4 122
4 123
4 224
5 126
5 526
5 131
5 131
5 231
6 136
6 544
6 151
11 154
11 555

7. vi
‫اهل‬‫ـ‬‫ون‬ ‫دف‬‫تدريص‬:‫املكرر‬
1
5
1
5
1
1

8. vii
2
3
4
5
6
11
11
15
11

9. 1
‫األوه‬ ‫الفصن‬
‫الصناع‬ ‫اإلدارة‬‫ـ‬‫ية‬Industrial Management
i.e.
Organized
corporations
1.1‫الك‬‫ــ‬‫اله‬Fatigue
Nervous Fatigue
Organisms
impulses
i.e.

10. 5
physiological or organic equilibrium
Nature of fatigue
Studies of fatigue
ergograph
i.e.
ergograph

11. 1
ergograph
1
amplitude
511
1
1
2i.e.
3
4
5
Signs of fatigue
(Monotony)
(Boredom)

12. 1
(Monotony)
Boredomdepression
(Brain Lock)
Indirect measures of fatigue
Environmental conditions affecting fatigue
Noise
1Noise and Industrial music
5illumination

13. 2
1Temperature and humidity
1Ventilation
Direct measures of fatigue
1.1‫الص‬‫ــ‬‫يانة‬Maintenance
1i.e.
5i.e.
1
1
2
1
5

14. 3
1Operation department
5Electrical department
1Building and construction department
1Mechanical department
2(Production department)
3
4Sub- contractorsi.e.
1i.e.
5
1i.e.
1

15. 4
Maintenance Objectives and Types
iObjectives of maintenance
1
5
1
1
2i.e.
3
4
5
iiTypes of maintenance
1 1

16. 5
(Maintenance)
(Corrective maintenance)(Preventive maintenance)
(Overhaul)(Repair)
(Shutdown maintenance)
1 1
1
5
1
1
2
3

17. 6
4
5
6
The characteristics & basic features
1
5
1
1
2i.e.
3
Log book
Organizing maintenance departments
iCentralized organization

18. 11
1i.e.
5i.e.
1
1
5i.e.
1i.e.
iiDecentralized organization
1
5i.e.
1

19. 11
1i.e.
1i.e.
5i.e.
1
1
(Relation between maintenance & production departments)
1
5
1.‫تصن‬‫ـ‬‫املع‬ ‫يف‬‫ــ‬‫الصناع‬ ‫دات‬‫ــ‬‫ية‬
Classification of Industrial Equipment
iGeneral purpose machines
:
(Advantages & limitations of general purpose machines)
1Versatile machines

20. 15
5
1
1
2
3
4
iiSpecial purpose machines
(Advantages & limitations of special purpose machines)
1
5
1
1

21. 11
2
3
:(Replacement of machines)
1
5
1
(Policies of replacement of machines)
1
5
1
(Costs)
ii.e.
ii

22. 11
1
2
3
4
5
6
11
11
Organizing maintenance equipment
i:Maintenance Programming
1
5
iiPlanning preventive maintenance

23. 12
1i.e.
5
1
1
1.1‫الشالو‬‫ــ‬‫و‬ ‫ة‬‫األو‬‫ــ‬‫الصناع‬ ‫ن‬‫ــ‬‫ي‬Industrial safety and security
1661
11
(Importance of industrial security)
1
5
1
(The objectives of the industrial security law)
1

24. 13
5
1
1
2
(The relation between industrial security & production)
iThe human element
1
5
1
1
2
3

25. 14
iiMachines and equipment
iii:Raw materials
iv:Enlightenment and training
1(Symposiums)(Forums)(Workshops)
(Lectures)
5
v
(Guidance inspection & preventive procedures)
1

26. 15
5
i.e.
i.e.
(Industry Injuries)
i(Direct cost)
1
5
1
1
ii(Indirect cost)
1
5

27. 16
1
1
2
:Industrial safety requirements
1
5
1
1
2
1i.e.
5

28. 51
1
1
2
3
4
5
6
11
11(Leaflets and booklets)

29. 51
‫ا‬‫لفص‬‫ـ‬‫الثان‬ ‫ن‬‫ـ‬‫ي‬
‫التآك‬‫ــ‬‫ن‬Corrosion
1.1‫تع‬‫ــ‬‫ريف‬‫التآك‬‫ــ‬‫ن‬:(Definition of corrosion)
1.1‫احمل‬‫ــ‬‫االقتص‬ ‫ددات‬‫ــ‬‫لمتآك‬ ‫ادية‬‫ــ‬‫ن‬(Economical limitations of corrosion)
1
5Maximization of Design Materials
1
1(shut – down
maintenance)
2

30. 55
3deficiency
4
5
6
1.‫احمل‬‫ــ‬‫االجتىاع‬ ‫ددات‬‫ــ‬‫لمتآك‬ ‫ية‬‫ــ‬‫ن‬(Social limitations of corrosion)
1
5
i.e.
1

31. 51
1.1‫ص‬‫ـــ‬‫التآك‬ ‫ور‬‫ـــ‬‫ن‬
1
5
1
1.2‫أن‬‫ـــ‬‫التآك‬ ‫واع‬‫ـــ‬:‫ن‬(Types of corrosion)

32. 51
1Homogeneous and Galvanic corrosion
i.e.

33. 52
5 1
1Erosion corrosion

34. 53
(Corrosion)
(Local corrosion)(Homogeneous corrosion)
(Microscopic corrosion)(Macroscopic corrosion)
1(Inter – granular corrosion)1(Galvanic corrosion)
1(Stress corrosion cracking)1(Erosion corrosion)
(Crevice corrosion)
1(Pitting corrosion)
2(Exfoliation corrosion)
3
(Selective leaching corrosion)
1.1

35. 54
Crevice corrosion
i
ii
iii
iv

36. 55
(Stainless steel)(Titanium)
1:Pitting corrosion
.
i.e.

37. 56
2Exfoliation and selective leaching corrosion
3Inter – granular corrosion

38. 11
4Stress corrosion cracking

39. 11
‫الثالث‬ ‫الفصن‬
‫الصيانة‬ ‫يف‬ ‫اهلندسي‬ ‫التصىيي‬ ‫دور‬
The role of engineering design in maintenance
.1‫خط‬‫ــ‬‫إج‬ ‫وات‬‫ــ‬‫التصى‬ ‫راءات‬‫ــ‬‫يي‬
1recognition of need
(Necessity
is the mother of invention)
5brain storming
1
ii.e.
iii.e.
i.e.
i.e.
i.e.

40. 15
i.e.
(Ergonomical
factors)i.e.
iii
i.e.
i.e.
Permanent Joint
iv
i.e.

41. 11
(major and minor
parts)
v
1i.e.1
2
i
ii
iii

42. 11
3
i.e.
4i.e.
5
i
ii
iiiLife expectancy
i.e.i.e.

43. 12
ivNature of market
i.e.
v
1
5
1
1i.e.
2i.e.
3

44. 13
‫الرابع‬ ‫الفصن‬
‫اهلندسية‬ ‫لمىظروعات‬ ‫الفنية‬ ‫اجلدوى‬ ‫دراسة‬
Technical Feasibility Study Of Engineering Projects
1.1‫امل‬‫ــ‬‫واصف‬‫ــ‬‫ات‬Specifications
1(Site selection)
i
iiAvailability of basic infrastructure
iii

45. 14
iv
I
II
III
IV
v
1:Climate study
i
ii

46. 15
iii
ivCorrosion
:Future Expansion
i
By – products)i.e.
ii
1.1‫التص‬‫ـ‬‫ـ‬‫ىيي‬Design
i.e.

47. 16
I
II
i
ii
iii
iv

48. 11
‫اخلاوص‬ ‫الفصن‬
‫دراس‬‫ـ‬‫اجل‬ ‫ة‬‫ـ‬‫اهلندسية‬ ‫لمىظروعات‬ ‫االقتصادية‬ ‫دوى‬
Economical Feasibility Study Of Engineering Projects
2.1‫التك‬‫ـ‬‫امل‬ ‫ييي‬‫ـــ‬‫الي‬(Financial evaluation)
1
5
i
ii
1(Annual profits and losses)
2.1‫التك‬‫ـ‬‫االقتص‬ ‫ييي‬‫ــ‬‫ادي‬(Economical evaluation)
1. (Net annual profit)
5(Payback period)

49. 11
1Annual rate of return
111
1Break Even Point
2 1
2.1
2External rate of return
Future Worth
Profit
Cost
B.E Point
Revenues
Loss
Annual
revenues and
annual cost
Quantities produced per year

50. 15
3Internal rate of return

51. 11
‫الشادض‬ ‫الفصن‬
‫تريوتكنولوج‬‫ــ‬‫يا‬
Terotechnology
3.1‫و‬‫ــ‬‫دخ‬‫ـ‬‫ن‬:(Introduction)
1(Industrial and services price structure)
5(Industrial relations)
1(Innovation)
1(Technology methods developments)
2

52. 11
3
i
ii
iii
iv
v
Price, quality and utility
i.e.

53. 12
1643
1i.e.
5reliabilitymaintainability
iperformance
iicapital cost
iiirunning cost
1
1Commissioning
2
Wear and Fatigue

54. 13
3
4
3.1‫امل‬‫ـ‬‫واصف‬‫ــ‬‫ات‬( :Specifications)
1
ii.e.
iii.e.
iiii.e.
ivi.e.
v
vi
5
i

55. 14
iii.e.Cooling and
Lubrication systems
iiii.e.
PLANPower =
C
PLANC
mass of air
combustion
i5212
ii1305m152.5m
iii1 3
15mm
iv
corrosion

56. 15
1:Future expansions
i
ii
I5111
II61
III11 3
351 3
3.‫ورح‬‫ــ‬‫التص‬ ‫مة‬‫ـ‬‫ىيي‬Design Stage
1material selection
i
ii
5Load Factor
Continuous ratingIntermittent rating

57. 16
1Safety
Supposing Knowledge for the design stage
1
5
1
Dynamic nature
i
ii

58. 21
Failure and its prevention
1ductile failure
5Brittle failure
1creep failure
1fatigue failure
2wear
3corrosion
3.1‫ورح‬‫ــ‬‫التص‬ ‫مة‬‫ـ‬‫والرتك‬ ‫نيع‬‫ــ‬‫يب‬Manufacturing and installation
3.1.1
iQuality Assurance
iiMaintainability
iiiDesign Faults
1

59. 21
5Quality control
i:visual examination
ii:macro - examination
iii:micro - examination
iv:micro structure
1

60. 25
3.1.1
(Foundations)
icritical vibration
ii
Concrete foundation
151G : S : C
size, distribution
consistency
shrinkage
porosity
Soil mechanics
5 55

61. 21
Concrete block movement
periodical recoverable
i
ii
iii
3.2‫التظغ‬‫ــ‬‫التج‬ ‫ين‬‫ــ‬‫رييب‬:Commissioning
1
5
1
1
2
3

62. 21
4
3.3‫التظغ‬‫ــ‬‫ين‬(Operation)

63. 22
‫الشابع‬ ‫الفصن‬
‫نظ‬‫ـ‬‫التزي‬ ‫ي‬‫ـ‬‫األ‬ ،‫يت‬‫جه‬‫ـ‬‫واإلج‬ ‫زة‬‫ـ‬‫راءات‬
4.1‫ودخ‬‫ـ‬‫ـ‬‫ن‬(Introduction)
4.1‫التك‬‫ـ‬‫ييي‬Evaluation
4.‫الوس‬‫ـ‬‫املعط‬ ‫ائن‬‫ـ‬‫لمتزيي‬ ‫اة‬‫ـ‬‫ت‬The means provided for lubrication

64. 23
Hand Pressure Grease Guns
1111
2000 psi
(Tribology)(Wear, Friction
and Lubrication)
1111112000 psi
(i.e. Heavy trucks, Loaders, Bulldozers, Excavators)
Power guns
100 lb
Oil mist
4.1‫أف‬‫ــ‬‫التزي‬ ‫راد‬‫ــ‬‫يت‬Lubrication Personnel

65. 24
1
5
1
1
211
3
4
5
6
11
11
15
11
4 2‫فظ‬‫ـ‬‫ـ‬‫التزيي‬ ‫ن‬‫ـ‬‫ـ‬‫ت‬Lubrication failures
1

66. 25
5
1
1
2
(Under lubrication)
Over lubrication

67. 26
‫الفصن‬‫الثاون‬
‫قابم‬‫ــ‬‫التب‬ ‫ية‬‫ـ‬‫اده‬Interchangeability
5.1‫تع‬‫ــ‬‫قابم‬ ‫ريف‬‫ــ‬‫الت‬ ‫ية‬‫ــ‬‫باده‬Definition of Interchangeability
1611
i.e.
i.e.
5.1‫قابم‬‫ــ‬‫التب‬ ‫ية‬‫ــ‬‫واإلنت‬ ‫اده‬‫ــ‬‫التج‬ ‫اج‬‫ـ‬‫اري‬Interchangeability and mass production

68. 31
5.‫خ‬‫ــ‬‫ال‬ ‫دوة‬‫ش‬‫ــ‬‫واحمل‬ ‫يارات‬‫ــ‬‫ركات‬Automobiles and Automotive service
1measuring
Linear Measurements
USCS
United States Customary System
SI
.
(Angular measurements)
1Disassembly

69. 31
Machining
1Installing new parts
2Reassembly
3Adjustments
5.1‫خ‬‫ــ‬‫احمل‬ ‫دوة‬‫ــ‬‫ركات‬(Auto – motives service))‫الصىاوات‬ ‫وآلية‬ ‫الصىاوات‬(
1Cleanliness

70. 35
1Valves troubles
rocker arm
valve stemvalve guide
pre-ignition
valve sticking
over heating
eccentric seatsi.e.cocked spring
i.e.
5 15 1

71. 31
Fig. 8.1 Cam on a camshaft. Note positions of
the toe and heel.
Fig. 8.2 Valve train on an engine using a pair
of gears to drive the camshaft. The cam lobe
has pushed the push rod up so the valve is
opened.
Fig. 8.3 Valve train of previous picture,
showing how the valve closes when the cam
lobe moves out from under the valve lifter.
Fig. 8.4 Intake stroke. The intake valve (at
left) has opened. The piston is moving
downward, drawing in a mixture of air and
gasoline vapor into the cylinder.

72. 31
5.2‫أجه‬‫ــ‬‫اخ‬ ‫زة‬‫ـ‬‫احمل‬ ‫تبار‬‫ــ‬‫رك‬Engine Testing Instrument
1Tachometer
rev/min
rev/min135
r.p.m
1Cylinder Compression tester
diaphragm
5 2

73. 32
1000 rev/min
i.e.
Fig. 8.5 Using cylinder-compression tester.
(Chevrolet Motor Division of General Motors Corporation)
1
i.e.
Diesel Engine Compression Test

74. 33
15
41
1.892 kpai.e.1 565
1Results of the compression test
i
ii

75. 34
iii
iv
v
vi
vii
2Cylinder – Leakage Tester
TDC
whistle
1
adapter
5 35 4
51
i.e.tail pipe

76. 35
Fig. 8.6 Cylinder – leakage tester. The whistle is used to locate TDC in cylinder No. 1
(Sun Electric Corporation)
Fig. 8.7 How the Cylinder – leakage tester works. It applies air pressure to the cylinder through
the spark – plug hole with the piston at TDC and both valves closed. Points where air is leaking
can be pinpointed. (Sun Electric Corporation)

77. 36
‫التاسع‬ ‫الفصن‬
‫تظخ‬‫ـ‬‫أعط‬ ‫يص‬‫ـ‬‫احمل‬ ‫اه‬‫ــ‬‫رك‬
Engine Trouble Diagnosis
6.1‫األعط‬‫ــ‬‫العاو‬ ‫اه‬‫ــ‬‫ة‬(General troubles)
1engine will not turn over
i
ii
iii
iv
1Engine turns over slowly but doesn't
start
i
ii
iii
(Engine turns over at normal
speed but doesn’t start)
i
ii

78. 41
iii
iv
v
vi
vii
1Engine runs but misses on
one cylinder
i
iii.e.
iii
iv
v
vi
vii
viii
2(Engine turns but misses
on different cylinders)
i

79. 41
ii
iii
iv
v
vi
vii
3
(Engine lacks power, acceleration, or high speed performance, hot or cold)
i
ii
iii
iv
v
vi
vii
viii
4Engine overheats
i

80. 45
ii
iii
iv
v
vi
vii
viii
ix
5Rough idle
i
ii
6Engine stalls cold or as it warms up
i
ii
iii
ivsolenoid
v
vi

81. 41
11
(Engine stalls after idling or slow speed driving)
i
ii
iii
iv
vthrottle solenoid
11Engine stalls after high speed driving
i
ii
iii
ivPCV valve
v
11Engine back fires
i
ii
iii
iv
v
vi

82. 41
vii
viii
ix
1
Too much HC and CO in exhaust)
i
ii
iii
iv
vTCS
viDefective catalytic converters
11Smoky exhaust
i
ii
iii
12Excessive oil consumption
iseals
ii

83. 42
iii
13Low oil pressure
i
ii
iii
ivrelief
valve
14Excessive Fuel Consumption
ijackrabbit starts
ii
iii
iv
v
vi
vii
viii
ix
x
xi
xii

84. 43
xiii
xiv
xv
xvi
xvii
xviii
xix
15Engine is noisy
i:regular clicking of valve and its follower:
ii(ping or chatter on load or
acceleration)
iiiLight knockcrank
pin
iv

85. 44
v
vi
vii
(Dull, heavy, metallic knock under load or acceleration, especially
when cold).
clutch engagement
viiiaccessories
alternator
6.1‫خ‬‫ـ‬‫نظ‬ ‫دوة‬‫ـ‬‫حك‬ ‫ي‬‫ـ‬‫الوقـ‬ ‫ن‬‫ـ‬‫فـ‬ ‫ود‬‫ـ‬‫حمـ‬ ‫ي‬‫ـ‬‫البنـ‬ ‫رك‬‫ـ‬‫زين‬(Servicing Gasoline Engine Fuel
Injection Systems)
1
I
i
ii

86. 45
iii
iv
v
II
vacuum leaks
i
ii
III
ileakage
iikinks
(2.81kg/ ) 41psi
1Preliminary Diagnosis
visual inspection

87. 46
iEngine cranks but will not start
iiHard starting
iiipoor fuel economy
ivEngine stalls after start
vrough idle
viprolonged fast idle
viiNo fast idle
viii(Engine hesitates or stumbles on
acceleration)
ix
6 1
1
accelerator pump)Throttle position switch
5
Fast idle camElectric fast idle valve
1
floatFuel pressure regulator

88. 51
1
Power valve/ metering rodsmanifold absolute pressure sensor
2
metering jets and idle fuel system
(Injection valves, electronic control
unit (ECU))
6.1
.
Trouble Diagnosis Chart
1
i
ii12v
iii
(ECU)

89. 51
iv
5
Engine will not start, fuel pump runs
i
ii
iii
1Engine starts cold but stalls
i
iitrigger contacts defective
iii
1
Engine cuts out when driving (usually preceded by mis- firing)
i
ii
iii
2:
Engine works irregularly, one cylinder not firing, exhaust white

90. 55
ione injector sticking
ii
3:
Engine misfiring, not caused by ignition system
4Engine not reaching full power
i
ii
iii
5Fuel Consumption too high
iECU
ii
iii
611111800 r.p.m
Engine hunts excessively at idle speed between 1000 and 1800 r.p.m)
i

91. 51
ii
iii
11:
Engine misfires when accelerating
11:
Too high idling speed, idling speed cannot be adjusted
i
ii
iii
6.‫خ‬‫ــ‬‫حم‬ ‫دوة‬‫ــ‬‫ال‬ ‫رك‬‫ــ‬‫ديزه‬(Diesel Engine Service)
Diesel Engine Trouble Chart
1
(Engine cranks normally but does not start)
i
iisolenoidGlow plugs
iii
iv

92. 51
v
1Engine starts but stalls on idle
i
ii
iii
iv
(Engine starts, idles rough without abnormal noise or smoke)
i
ii
1
i
ii
2Engine misses one cylinder
i
ii
iii

93. 52
3
(Engine misfires above idle but idles okay)
i
ii
iii
4Loss of power
i
ii
iii
iv
v
vi
vii
viii
ix
5
Rap like a rod- bearing knock from one or more cylinders)
i

94. 53
ii
6Combustion noise with black smoke
i
ii
iii
11Engine runs with key off
Solenoid.

95. 54
‫العاطر‬ ‫الفصن‬
‫أس‬‫ــ‬‫ف‬ ‫ئمة‬‫ـ‬‫املك‬ ‫ي‬‫ــ‬‫رر‬
11.1‫أس‬‫ــ‬‫ف‬ ‫ئمة‬‫ـ‬‫وك‬ ‫ي‬‫ــ‬‫أساس‬ ‫رر‬‫ــ‬‫الص‬ ‫يات‬‫ــ‬‫يانة‬
1
5
1
1
2
3
4
5
6
11
11
15
11
11
12

96. 55
11.1‫أس‬‫ــ‬‫وإج‬ ‫ئمة‬‫ــ‬‫منوذج‬ ‫ابات‬‫ــ‬‫ف‬ ‫ية‬‫ـ‬‫وك‬ ‫ي‬‫ــ‬‫أساس‬ ‫رر‬‫ــ‬‫الص‬ ‫يات‬‫ــ‬‫يانة‬
1
Itransitional energy
IIstored energy
i
ii
iii
iv
v
vi
5
i
ii
iii
iv
v
vi

97. 56
vii
viii
I
i
ii
II
i
ii
iii
iv
III
i
ii
iii
IV
i
ii

98. 61
V
i
ii
iii
VI
i
ii
VII
i
ii
iii
iv
vv
VIII
i
ii
1
i
ii

99. 61
iii
iv
v
vi
vii
viii
1
i
iiTDC
iii
ivBDC
vCompression ratio
2
iB.H.P
Dynamometer

100. 65
iiI.H.P
3
if.h.p
iib.s.f.c
bsfc = (kg/kwh)
iii)
4
i.e.131

101. 61
.i
.ii
.iii
.iv
v113
i
.ii

102. 61
iii
iv15
5
i
ii
N = nN =
n
iii
iv
v
vi
vii
6
i
ii
iii
iv

103. 62
v
vipins
viii.e.
11
i
ii
iii
iv
v
11
icompression rings
iioil rings
15Fly wheel

104. 63
i
ii
iii
iv
11
i
ii
iii
iv
v
vi
11
i
ii
iii
iv
v
12

105. 64
iViscosity
ii
iii
iv
v
vi
vii
viii
13

106. 65
14
15

107. 66
30- 40 N/
16
51
51

108. 111
i
ii
iii
iv
v
55
i
i.e.)
i.e.
ii
iii
iv
51
i
ii
iii
iv
v

109. 111
vi
51
52
18 N/
53
75 – 85 c
54
i

110. 115
ii
55Anti- freeze solutions

111. 111
‫امل‬‫ـ‬‫راج‬‫ــــ‬‫ع‬
‫الك‬‫ـ‬‫وامل‬ ‫تب‬‫ـ‬‫راج‬‫ــ‬‫الع‬ ‫ع‬‫ـ‬‫ربي‬‫ــ‬‫ة‬
1
5
1644
11651
1
2
5111
35112
‫الك‬‫ـ‬‫وامل‬ ‫تب‬‫ـ‬‫راج‬‫ــ‬‫ع‬‫اإلجنليزية‬
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112. 111
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