CLO/GSA MARKS
/20
CLO3, PLO4
DJJ50203 – TROUBLESHOOTING AND MAINTENANCE FOR
MECHANICAL COMPONENTS
CASE STUDY TOTAL /20
NAME: TIME ALLOCATION:
MATRIX NO: DATE:
PROGRAM: DKM CLASS: DKM 4A, 4B & 4C
INSTRUCTION:
This section consists of structured questions.
QUESTION 1
Calibrate gear in power transmission system.
1.1 Select the proper drive based on AGMA (American Gear manufacture Association).
1.2 Differentiate gear meshing and backlash.
1.3 Apply coupling concept into gear system.
1.4 Identify gear maintenance practice such as daily routine inspection.
1.5 Construct the maintenance procedures:
a. Gear tooth-wear and failure.
b. Lubrication contamination and incorrect lubrication.
c. Overheating. d. Low oil level, etc.
1.6 Produce a gear check list for preventive maintenance, symptoms and record observation for
preventive maintenance, etc.
1.7 Produce the gear maintenance procedure
CLO3, P4
(20 marks)
Your case study must be reported in the following format:-
1. Cover page – members, registration number, lecturers name, session
2. Executive summary
3. Table of contents
4. Content based on the above information
5. References (refer to APA format) & appendices
Case study evaluation item : Group presentation & report.
CLO/GSA MARKS
/20
CLO3, PLO4
DJJ50203 – TROUBLESHOOTING AND MAINTENANCE FOR
MECHANICAL COMPONENTS
CASE STUDY TOTAL /20
NAME: TIME ALLOCATION:
MATRIX NO: DATE:
PROGRAM: DKM CLASS: DKM 4A, 4B & 4C
INSTRUCTION:
This section consists of structured questions.
QUESTION 2
Classify belt drives in power transmission system.
2.1 List the applications of belt drives.
2.2 Classify types of belt drives and their characteristics based on their functions.
2.3 Classify belt tension and misalignment of belt drives.
2.4 Produce a check list for drive belts maintenance, failure symptoms and record observations for
preventive maintenance.
a. Premature belt failure.
b. Severe or abnormal belt wear.
c. Banded (joined) belt problems.
d. Belt noise and unusual vibration.
e. Problems with sheaves, belt stretches beyond take up.
f. V-belt turn over or jump off sheave, etc.
2.5 Produce belt drive maintenance procedures.
CLO3, P4
(20 marks)
Your case study must be reported in the following format:-
1. Cover page – members, registration number, lecturers name, session
2. Executive summary
3. Table of contents
4. Content based on the above information
5. References (refer to APA format) & appendices
Case study evaluation item : Group presentation & report.
CLO/GSA MARKS
/20
CLO3, PLO4
DJJ50203 – TROUBLESHOOTING AND MAINTENANCE FOR
MECHANICAL COMPONENTS
CASE STUDY TOTAL /20
NAME: TIME ALLOCATION:
MATRIX NO: DATE:
PROGRAM: DKM CLASS: DKM 4A, 4B & 4C
INSTRUCTION:
This section consists of structured questions.
QUESTION 3
Distinguish chain drive.
3.1.1 List the applications of the chain drive.
3.1.2 Classify the types of chains and their characteristics based on their functions.
3.1.3 Produce check list for chain drive maintenance and failure symptoms
3.1.4 Record observations for preventive maintenance.
3.1.5 Produce chain drive maintenance procedures.
Analyze friction drive, coupled shaft alignment or variable-speed drives.
3.2.1 Analyze the fundamentals of shaft alignment.
3.2.2 Demonstrate the use of the reverse dial indicator methods to correct shaft misalignment.
Perform troubleshooting on shaft failures.
3.3.1 Diagnose the shaft failures causing.
3.3.2 Troubleshoot the shaft failures causing to misalignment and wear and tear
CLO3, P4
(20 marks)
Your case study must be reported in the following format:-
1. Cover page – members, registration number, lecturers name, session
2. Executive summary
3. Table of contents
4. Content based on the above information
5. References (refer to APA format) & appendices
Case study evaluation item : Group presentation & report.
CLO/GSA MARKS
/20
CLO3, PLO4
DJJ50203 – TROUBLESHOOTING AND MAINTENANCE FOR
MECHANICAL COMPONENTS
CASE STUDY TOTAL /20
NAME: TIME ALLOCATION:
MATRIX NO: DATE:
PROGRAM: DKM CLASS: DKM 4A, 4B & 4C
INSTRUCTION:
This section consists of structured questions.
QUESTION 4
Analyze bearing concepts.
4.1.1 List the applications of bearing.
4.1.2 Classify types of bearing and their characteristics based on their function.
4.1.3 State the code number of rolling bearings.
4.1.4 Differentiate the suitable applications of bearing based on the bearing value and service life
value in hour or kilometer.
4.1.5 Apply seals, gaskets and packing concept into bearing system.
Investigate the friction, temperature and lubrication.
4.2.1 Distinguish the friction in bearing system.
4.2.2 Analyze the operating temperature with bearing friction.
4.2.3 Distinguish the principles of bearing lubrication.
Perform mounting and dismounting of bearing.
4.3.1 Apply mounting and dismounting equipment and tools.
4.3.2 Apply measuring equipment for bearing installation.
4.3.3 Apply the concept of adjusting clearance during installation.
4.3.4 Classify mounting methods likes cold mounting, temperature mounting, mounting tapered-
bore bearing, dismounting of bearing, hydraulic method.
CLO3, P4
(20 marks)
Your case study must be reported in the following format:-
1. Cover page – members, registration number, lecturers name, session
2. Executive summary
3. Table of contents
4. Content based on the above information
5. References (refer to APA format) & appendices
Case study evaluation item : Group presentation & report.
CLO/GSA MARKS
/20
CLO3, PLO4
DJJ50203 – TROUBLESHOOTING AND MAINTENANCE FOR
MECHANICAL COMPONENTS
CASE STUDY TOTAL /20
NAME: TIME ALLOCATION:
MATRIX NO: DATE:
PROGRAM: DKM CLASS: DKM 4A, 4B & 4C
INSTRUCTION:
This section consists of structured questions.
QUESTION 5
Perform analysis on bearing damage.
5.1.1 Produce a check list of bearing damage maintenance, failure symptoms.
5.1.2 Record observations for preventive maintenance:
a. Fatigue, vibration and wear
b. Corrosion damage.
c. Scuffing and sliding marks.
d. Local indentations in the raceway.
e. Faulty mounting and defective installation methods.
f. Poor lubrication and fault in design.
5.1.3 Produce bearing maintenance procedures.
Explain the bearing failures, diagnosis and troubleshooting.
5.2.1 Diagnose the bearing failures.
a. Abnormal bearing temperature.
b. Noises of rotating bearing.
c. Vibration of rotating bearing – wear and tear of bearing material.
5.2.2 Diagnose and troubleshoot the bearing failure above.
CLO3, P4
(20 marks)
Your case study must be reported in the following format:-
1. Cover page – members, registration number, lecturers name, session
2. Executive summary
3. Table of contents
4. Content based on the above information
5. References (refer to APA format) & appendices
Case study evaluation item : Group presentation & report.
CLO/GSA MARKS
/20
CLO3, PLO4
DJJ50203 – TROUBLESHOOTING AND MAINTENANCE FOR
MECHANICAL COMPONENTS
CASE STUDY TOTAL /20
NAME: TIME ALLOCATION:
MATRIX NO: DATE:
PROGRAM: DKM CLASS: DKM 4A, 4B & 4C
INSTRUCTION:
This section consists of structured questions.
QUESTION 6
Explain the pump fundamentals
6.1.1 Define the terms:
a. Head
b. Capacity
c. Power and efficiency
d. Net positive suction head (NPSH)
e. Suction specific speed
f. Pump formula
g. Pump characteristic curve
Perform diagnosis and troubleshooting of pump failures.
6.2.1 Diagnose the hydraulic failures
a. No fluid deliver
b. Low capacity output
c. Insufficient or low pressure
d. Insufficient or intermittent flow delivery
e. Improper priming – reprime pump
f. Air or vapour pocketing suction line – eliminate air / vapour pocket, rearrange piping
g. Air leak in suction line – repair or plug leak
h. Regular or frequent bearing failures / hot.
i. improper alignment – re-align pump and drive.
ii. improper lubrication – check, lubricate to suitability and level.
iii. lube cooling – check cooling system.
CLO3, P4
(20 marks)
Your case study must be reported in the following format:-
1. Cover page – members, registration number, lecturers name, session
2. Executive summary
3. Table of contents
4. Content based on the above information
5. References (refer to APA format) & appendices
Case study evaluation item : Group presentation & report.
