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First Part Maintenance
First Part Maintenance
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1
A maintenance log records work performed on a piece of equipment. A maintenance log should be kept for _________
Machines that show signs of wear
Every machine
Two weeks following a machine failure
Machines without safety guards
2
In contrast to other types of belts, which belt is determined to be properly adjusted when belt slap is eliminated?
V-belts
O-ring belts
Flat leather belts
Multi-V belts
3
An example of preventive maintenance is ________
Scheduled replacement of minor parts that wear out quickly
Arranging for an OSHA inspection of equipment
Replacing an item that has damaged
Replacing components after they have failed
4
A _____ provides power to a hydraulic system by pumping oil from a reservoir into the supply lines
Gauge
Relief valve
Pump
Directional control valve
5
Which of the following gear types is used in machine tools like lathes, drills, and planer machines?
Spur
Rack and Pinion
Bevel
Double Helical
6
What can cause sudden movement of the machine in a hydraulic system?
Excessive steam release
Electrical restart of system
Stored energy
System pressure release
7
What is everyone responsible for?
Scheduling maintenance after equipment breakdown
Filing out corrective action reports
Keeping the work area clean of dirt, dust and debris
Completing work orders on time
8
How often the maintenance will occur is the primary consideration of what type of maintenance?
Responsive
Preventive
Reactive
Predictive
9
_________ all machine components before coupling them together will reduce the number of shims required for alignment
Polishing the shafts of
Leveling
Bolting down
Lubricating
10
The first thing you should do when discovering a building maintenance issue that negatively impacts your work area is?
Ignore the problem
Try to fix the problem
Go home until the problem is fixed
Report the situation to your supervisor
11
The gear system shown is added to a motor rotating at 200 rpm. What is the speed of the driven gear?
50 fps
800 rpm
50 rpm
200 rpm
12
A workstation designed to __________ can reduce repetitive/stress injuries.
Minimize motions
Maximize a range of motions
Increase unnecessary motions
Increase product output
13
A maintenance technician should have tools and supplies ready to perform preventive maintenance on a machine in order?
To make sure that the job is done correctly
To make sure that the machine parts are still available
To increase equipment downtime
To minimize equipment downtime
14
__________ should be replaced immediately if found to be missing during an equipment inspection.
A maintenance report
Safety guarding
A borescope
Foot rests
15
During an oil analysis, the technician finds that the oil in the reservoir has a milky color. What does this mean?
The oil temperature is too high
The oil has water in it
The oil level is too low
The oil has been agitated too much
16
A worker should lubricate equipment _____
When the equipment is going to be used
When there is spare time
At regular intervals
Only when necessary
17
Timing belts are used in which of these drive belt drive applications:
Fans, heavy industries, and pumps
Conveyor systems and machine tools like lathes and band saws
Stepper motor applications and automobile engines
Farm equipment like conveyors and balers
18
What is an accelerometer used for?
Acoustic monitoring
Temperature measurement
Vibration measurement
Oil analysis
19
Food processing equipment uses ______ for lubrication
White grease or FGL-1
WD-40
Vegetable grease only
Synthetic grease
20
Product buildup is the most common vibration problem on __________.
Cylinder pistons
Air fans
Pneumatic valves
Hydraulic pump vanes
21
When a chain's length becomes 3% longer than its original length _____
It's time to replace it
The load should be reduced
It has compeleted it's "wear in" period
It will run at optimal speed
22
Storing lubricants in the proper designated areas is an example of following _____
Correct Storage procedures
PPE requirements
Quality Policy
The leader
23
A board with tool outlines for placement is called a __________ and is a good way to ensure tools are returned
Board of tools
Storage bin
Shadow Board
Storyboard
24
What is established when operating equipment is in good condition?
Optimal order schedules for part inventory
Normal running levels for physcial characteristics
The best operator for the job
The storage of maintenance logs
25
What should a technician do before performing preventive maintenance?
Interview the oeprator
Acquire tools and supplies, then shut down the machine
Review the user manual
Make sure that the machine parts are still available
26
To calculate the speed of a gear, the speed ratio and the __________ will be needed.
Gear teeth ratio
Gear sizes
Number of gear teeth
Gear ratio
27
The shaft of a belt drive may be bent if an alignment check with a straight edge finds what condition?
4 points of contact becomes 2 points of contact after rotating the shaft
The straight edge cannot touch both of the sheaves at the same time
The straight edge scrapes the sheave
the straight edge contacts only 3 of the four points of the 2 sheaves
28
Motor shaft runout is checked to make sure of proper __________.
Alignment of mating parts
Coupling size
Motor end float
Shaft size
29
A __________ is important for a timely closure of PM work orders.
Incentive award
Computerized system
Completion date
Well-maintained machine
30
Which qualitative description corresponds with an NLGI number of 2?
Medium, like jelly
Soft, similar to hair jel
Hard, like the led of a pencil
Partly fluid, similar to honey
31
Reactive Maintenance is considered a(n) __________ activity.
Chemical-related maintenance
Planned maintenance
Unplanned maintenance
Highly responsive maintenance
32
Zerk fittings are used to lubricate _____.
Single bearings
Oil spray systems
Motor shafts
Automatic systems
33
Sensor monitoring is the most useful aspect of what program?
Preventive maintenance
Reactive maintenance
Corrrective maintenance
Predictive maintenance
34
According to proper maintenance practices, how often should oil be added to the oil reservoir?
At the beginning of each shift
As often as needed
Checking and adding oil is not necessary
According to the manufacturer's recommendation
35
The SDS sheet includes chemical properties, safety, and handling information for what material?
Lubricants
Metal stock
Wood stock
Scrap metal
36
What is the gear ratio?
Driven gear pitch diameter divided by driver gear pitch diameter
Driven gear thickness divided by driver gear thickness
Driven gear diameter divided by driver gear diameter
Driven gear teeth size drivided by driver gear teeth size
37
In some oil supply systems, an alarm is triggered when the reservoir _______
Is filled to proper level
Is in safe mode
Contains air
Is at a low oil level
38
Which of the following is not one of the 7 basic types of oils in use today?
Gear
Internal Combustion
Dispersant
Steam cylinder
39
The belt drive ratio is also used to calculate the belt drive torque. The formula is ___ proportional to the drive ratio
Differentially
Inversely
Directly
Acutely
40
Bearing seals can be damaged by what?
Shortening the run time
Proper burn-in
Excessive lubrication
Routine lubrication processes
41
What is most closely associated with repair of broken parts?
Preventive maintenance
PDCA cycles
Breakdown maintenance
Predictive maintenance
42
The level in a lubricator is normally indicated by what part?
Bowl
Level detector
Sight glass
Pressure gauge
43
Measuring a groove angle for wear is a maintenance check performed on what machine component?
Belt Drive sheave
Bearing race
End shaft chamfer
Chain sprocket
44
To reduce the time needed to clean inaccessible areas, what should operators do?
Make areas more accessible
Prevent contamination from occuring
Skip routine cleanings as needed
Only A and B
45
Perhaps the best place to store preventive maintenance records is __________.
A plastic folder attached to the equipment
In the supervisor's office
In a safe and secure location
In the maintenance office
46
What is the reading on the pressure gauge?
350 psi
320 psi
330 psi
300 psi
47
To make sure tools remain in good working order, __________.
Store them properly
Use oversized tools
Do not clean them off after use
Do not use them unless absolutely necessary
48
Sprocket sizes are determined by the _____ instead of the diamter of the sprocket
Circumference
Radius
Number of teeth
Pitch Diameter
49
In a well-organized plant, it should take a worker __________ to find the right tool.
30 seconds
10 minutes
5 minutes
1 minute
50
Misaligned chain drives have vertical angular, horizontal angular, and __________ parallel misalignments.
Crossed
Standard
Perpendicular
Horizontal
51
What is the belt drive ratio?
Driven sheave diameter divided by driver sheave diameter
Belt circumference divided by the belt diameter
Belt length divided by belt thickness
Driven sheave pitch diameter divided by the driver sheave pitch diameter
52
When opening supplies at a workstation, place excess packaging materials where?
In appropriate trash/recycle bin
In the aisle
On the floor
In the machine
53
Chain driver sprocket has 72 teeth and the driven has 24. If the driver has 1899 ft-lbs of torque? Driven torque is ____
211 ft lbs
3165 ft lbs
133 ft lbs
633 ft lbs
54
Which drive alignment method is faster and more accurate than the straight edge method?
Dial indicator method
Laser Alignment
Straight edge method
String method
55
Workers should perform an emergency shutdown of their equipment and notify their supervisor in which circumstance?
They are notified of a family emergency and need to go home
They notice that the equipment temperature is rising but still in limits
They hear a loud banging noise coming from the equipment
They detect vibration levels that are within the allowable range
56
Placing tools and equipment where they can be reached with minimal strain is a characteristic of a __________.
Pull system
Well-designed work station
Poorly designed work station
Old style workstation
57
What is an example of failure to follow preventive maintenance?
Lubricating bearings as described
Skipping a scheduled cleaning
Replacing V-belts in sets
Filter replacement
58
What is more efficient than a v-belt drive?
Compressor
Chain drive
Gear drive
Machine tool drive
59
Chain sag can be changed by __________ the sprockets.
Strengthening
Removing the chain link of
Moving
Replacing the chain of
60
What is preventive maintenance defined as?
Plan-Do-Check-Act (PDCA) cycles
Condition-based servicing
Routine servicing at predetermined intervals
Run-to-breakdown production
61
If gear X turns clockwise at a constant speed of 10 rpm, how does gear Y turn?
Clockwise at 10 rpm
Clockwise at 5 rpm
Counterclockwise at 10 rpm
Counterclockwise at 5 rpm
62
Which of the following oil levels is an indication that oil should be replenished?
When the sight glass registers at or below the bottom line
When the sight glass registers above the top line
When the sight glass registers at or below the top line
When the sight glass registers below the bottom line
63
A borescope or fiberscope can be used to __________ internal components.
Graph vibrations of
Clean and sanitize
Visually inspect
Monitor sounds of
64
The ratio of the speeds of the sprockets is the _____ of the sprocket ratio
Counter
Proportional
Inverse
Reverse
65
Chain drives deliver _____ mechanical power than belt drives
More
The Same
Less
Similar
66
The following condition is an indicator of improper v-belt alignment.
Extended belt wear
Less downtime
Excessive bearing and belt wear
Increased productivity
67
________ should be disposed of in an OSHA-approved fireproof container.
Metal scrap
Wood
Paper
Oily rags
68
Equipment should be inspected and reported to whom at the start of the production day?
Appropriate parties
The incoming shift
The auditor
All personnel
69
When a cutting tool provides unacceptable product quality results, it should be replaced and __________.
Repurposed
Resharpened
Scrapped
Reused later
70
If a machine is obviously leaking, __________.
The employee should throw some rags on the floor to soak up the leak
The employee should notify a supervisor
The employee should attempt to fix the machine
The employee should shut down the machine immediately and evacuate
71
Brooms and mops should be stored __________
In chemical cabinets
Next to the machine
In a designated area or cleaning closet
In pairs
72
Slips and falls are the worst safety hazards when __________.
Cleaning floors
Driving a tug
Lifting heavy objects
Mopping floors
73
What introduces energy to a mechanical system?
Driven device
Ball bearing
Solid bearing
Prime mover
74
What is the diameter of the driven pulley that is turning 700 rpm, when the 6-inch driver is rotating 2,100 rpm?
18 inches
24 inches
12 inches
30 inches
75
A shaft coupling may be out of round if a dial indicator shows what?
Full Range motion
Damage
Any movement
Offset
76
The accuracy of a viscometer is generally __________.
95 to 99%
85 to 90%
88 to 92%
100%
77
_________ normally include verification that the floor is clean.
Routine housekeeping inspections
Work orders
Maintenance logs
Corrective action reports
78
Gears are pre-aligned at the factory; Shafts of the gear box must be attached using a _______ device to other shafts.
Strapping
Pairing
Coupling
Welding
79
Why should grease guns be filled with a grease cartridge?
Grease cartridges do not contain dirt contaminants
Grease cartridges are better for the environment
Grease cartridges do not require special disposal
Grease cartridges are easy to load in a grease gun
80
Recurring events can be analyzed to troubleshoot problems because what is recorded in daily records?
Lubrication schedules
Completed work orders
Employee concerns
Daily maintenance
81
What fluid is the most commonly used in pneumatics?
Oxygen
Water
Oil
Air
82
Grease is classified as what kind of lubricant?
Solid
Liquid
Gas
Semisolid
83
Supply errors can be caused by relying on __________ without monitoring their performance.
Inspectors
Employees
Suppliers
Customers
84
What contains equipment histories as well as maintenance, service, and preventive maintenance records?
Equipment maintenance management software (EMMS)
Computerized maintenance management information systems (CMMIS)
All of the above
Computerized Maintenance Management Systems (CMMS)
85
What type of bearing should not be lubricated?
Ball bearing
Unsealed bearing
Block bearing
Sealed bearing
86
Daily preventive maintenance procedures, such as machine lubrication, are ________
Not really necessary and can be skipped several days in a row
Unscheduled events where workers put in OT to ensure production rates
Require a maintenance team to perform
Planned maintenance activities
87
Preventive maintenance is best described as what?
Exhausting
Flexible
Periodic in nature
Breakdown repair
88
What is a master link?
The preferred method of connecting a chain
Another name for an offset link
The first indication of a stretched chain
All of the above
89
The best way to store liquids such as paint or cleaning fluids is __________.
Under the workbench for easy access
On the workbench
Sealed and in a cabinet
Near a window for ventilation
90
The gear drive torque is __________ the gear ratio.
Indirectly proportional to
Directly proportional to
Reverse of
Inverse of
91
A gear drive has a minimum of two gears called _______
Driven and Idler
Drive and Idler
Idler and Driver
Driver and driven
92
The frequency of maintenance is usually an item found on the __________.
Warranty card
Hold card
Work order
Preventive maintenance schedule
93
Three qualities used when specifying grease are: water resistance, hardness, and _____
Boiling point
Viscosity
Freezing point
Dropping point
94
Zero defects and breakdowns is a goal of _______
WPA
TPM
FDA
UAW
95
Proper guarding, lockout/tagouts, and electrical box covers are all verified during what?
Shift changes
New operator training
Visual inspections of machines
Machine shutdown procedures
96
Corrective work is performed following preventive maintenance when ________
The PM work was performed incorrectly
Problems are discovered
The supervisor requests it
The schedule calls for it
97
Air supplied to a pneumatic system is supplied through the _____ line
Excessive steam release
Intake
Electrical restart of system
Supply
98
Which of the following is NOT a type of shaft-to-adjacent shaft power transmission?
Clutch Drive
Belt Drive
Gear Drive
Chain Drive
99
A machine was producing 100 ppm. It was designed to produce 200 ppm. The drive belt was replaced. It should produce ___
Not more than 80% of its original design due to normal wear and tear
The belt drive has no impact on ppm
200 parts per minute as designed
100 parts per minute as it was before
100
What type of bearing should be used for axial motion?
Radial bearing
Thrust bearing
Ball bearing
Solid bearing
101
The chain climbing the sprocket is a symptom of which condition?
Excessive chain tension
Excessive chain wear or sprocket wear
Excessive lubrication
Temperature of chain
102
True or false: A pillow block can only be designed as a one-piece assembly.
False
True
103
_________ should preside over housekeeping inspections or audits.
The safety team
The immediate supervisor
Unbiased auditors or inspectors
The company president
104
When temperature decreases, the viscosity of a liquid _______
Increases slightly
Decreases slightly
Stays the same
Increases substantially
105
__________ are not permitted on the floor of a workstation.
Trash cans
Non-slip mats
Extension cords
Painted lines
106
What pneumatic component provides straight line motion
Muffler
Motor
Cylinder
DCV
107
What type of lubricant is the rarest form of lubricant due to its limitations?
Liquid
Solid
Semi-solid
Gas
108
To convert absolute pressure to gauge pressure, _____
Subtract atmospheric pressure from absolute pressure
Divide atmospheric pressure by the absolute pressure
Add absolute pressure to atmospheric pressure
Multiply atmospheric pressure by the absolute pressure
109
A thorough check for a history of similar problems should occur ______
For new problems
On problems that warrant a repair
On problems that have not occured in the past
On problems that keep recurring at regular intervals
110
During an oil analysis, high oil temperature can cause what symptom?
High viscosity
Burnt or pungent odor
No odor
Good oil
111
In a spur gearing system, the small gear is called the __________.
Driven
Spline
Worm
Pinion
112
W. Edwards Deming's plan for continuous improvement is _____
Plan-Do-Check-Act (PDCA)
Design-Create-Implement-Review (DCIR)
Plan-Perform-Review-Document (PPRD)
Ask-Verify-Plan-Enact (AVPE)
113
What is often outlined and detailed in a maintenance log?
Shift leader contact information
Maintenance scheduling
Date of equipment purchase
A list of qualified operators
114
Which flange is shown with the correct tightening sequence?
D
A
B
C
115
Mechanical power transmission systems convert what type of power received from other sources into mechanical power?
Fluid
Thermal
All of the above
Electrical
116
Mineral oil is derived from ______
Cod liver oil
Soy bean oil
Synthetic components
Refining crude oil
117
When should you stop pumping grease into a pillow block bearing?
Ball bearing
Unsealed bearing
Sealed bearing
Block bearing
118
Stainless steel is a commonly used tubing material in which type of application?
Pnuematics
Hydraulics
Electrical conduit
Vacuum
119
Results of tests, inspections, and a schedule for future maintenance can be found where?
User manual
The employee break area
Statement of work (SOW)
Preventive Maintenance Log
120
what causes soft foot?
Not enough lubrication
Too much lubrication
Uneven mounting surfaces
Out-of-round shafts
121
Predictive maintenance is a type of maintenance program that does what function?
Provides startup and shutdown guidelines
Predicts the specific date when maintenance should be performed
Determines regular maintenance intervals when maintenance must be performed
Identifies machine part or component failures before a major breakdown
122
Detergent additives are used in oils ______
To decrease the oil viscosity
As a foam inhibitor
To break up and wash away deposits
As a water repellant
123
Which lubrication application method is most often used in machinery with low operating speeds?
Splash
Drip or gravity
Manual
Bath
124
What is the maximum pressure reading that the gauge could give?
1000 psi
2200 kPa
320 psi
70 kPa
125
The employee verifies that preventive maintenance is complete when __________.
Closing out a PM work order
Beginning a PM work order
Making random equipment inspections
Completing a corrective action report
126
Design failure in a production line can be apparent by repeated maintenance failures and _______
Employee turnover
Supply material used
The inability to meet performance demands
The high output achieved
127
The pressure created by any force is calculated by multiplying the total force by the total area. True or False?
True
False
128
What is the name of the clearance that allows lubricant to reach the gear teeth?
Offset alignment
Improper alignment
Backlash
Gap
129
The most harmful act a maintenance person can do to this component is to get dirt in it.
Gear
Bearing
Belt
Coupling
130
Noise, temperature, and vibration should be monitored when?
Only after a work order is submitted
Before an audit
During machinery operations
After an audit
131
A common sign of a misaligned coupling is __________.
Excessive Vibration
Excessive machine speed
Machine won't start
Excessive oil temperature
132
Too little lubrication of what component can cause seizing in a machine?
Sheaves
Bearings
Sprockets
Belt
133
What can be done after a corrective action form is completed?
The supervisor is summoned to determine whether the job is complete
The form is saved in a safe and secure place
The maintenance technician reviews the work order
Preventive maintenance should be documented as completed
134
Chain drive torque is the same as the gear ratio, meaning that when torque increases the sprocket ratio _____
Increases
Inverts
Reverses
Decreases
135
Too little lubrication of what component can cause seizing in a machine?
Belts
Bearings
Sprockets
Sheaves
