Unit 1 : Maintenance Management

1.1 – Maintenance – Definition, Objectives, Types of Equipment Maintenance – Planned maintenance and unplanned maintenance.

1.2 – Types of Planned maintenance – Preventive Maintenance, Predictive Maintenance and Scheduled maintenance – Merits and demerits. Unplanned maintenance – Breakdown Maintenance or Emergency
maintenance – Merits and Demerits. Contract maintenance – Definition – Merits and Demerits.

1.3 – Preventive Maintenance Functions – Planning, scheduling, Repair cycles, Dispatching and Controlling.

1.4 – Safety Precautions and House Keeping – safety precautions to be followed in press area and Five steps of housekeeping (5S method).

Unit 2 : Power Transmission

2.1 – Chain Drives – Introduction, Types of Chains – Roller Chain, Silent Chain, Ewart Chain and Bead Chain, Merits and Demerits of Chain Drives.

2.2 – Belt Drives – Introduction, Types of Belts – Flat belt, Rope belt, Tooth Belt, V belt and Timing Belt, Merits and Demerits of Belt drives.

2.3 – Gear Drives – Introduction, Types of Gears – Spur gear, Helical gear, Bevel gear, Worm gears and Herringbone gear, Merits and Demerits of gear drives.

2.4 – Maintenance and Lubrication of Drive Systems – Chain Drive, Belt Drive and Gear Drive.

2.5 – Direct drive technology – Introduction, Advantages and Application in the printing field.

Unit 3 : Mechanical and Electrical Elements

3.1 – Bearings, Types of Bearings – Sliding bearings and Antifriction bearings – Ball bearings, Needle bearings and Roller bearing. Merits and Demerits.

3.2 – Cams and Follower, Types of Cams and Followers – Disk Cam, Translation Cam, Groove Plate Cam, Cylindrical Cam, Eccentric Cam and Tow Wipe Cam. Advantages of cam and Follower.

3.3 – Springs, Types of springs – Helical Spring, Conical spring, Volute Spring and Torsion Springs and its application.

3.4 – Electrical Elements – Introduction to Contactors and its types, Introduction to Limit Switches and its application, Introduction to over Load Relay Switches and its types, Thermal and Magnetic,Introduction to Sensors and Detectors and its application, Introduction to Electrical Panels.

Unit 4 : Lubrication and Reconditioning

4.1 – Lubrication – Introduction, Advantages, Types of Lubricants – Solid, Semisolid and Liquid. Lubrication Schedule, Chart and Paint Marks.

4.2 – Equipments and Tools used in Erection and Reconditioning – Cranes, Hoists, Spanner, Wrenches, Screwdriver, Spirit level, Dial Indicator with gauge, Feeler gauge, Micrometer and Vernier
Calipers, Application.

4.3 – Test Run – Types of test runs – Idle, Performance, Accuracy, Rigidity and Vibration test.

Unit 5 : Maintenance of Mechanisms

5.1 – Electrical Maintenance – Introduction to AC and DC motors, Maintenance Check list for motors, Common problems with Electricity.

5.2 – Pneumatic System Maintenance – Introduction to pneumatic system functioning, Compressor types – Reciprocating and Rotary compressor, Application in Printing Field and Check List for
pneumatic system maintenance.

5.3 – Hydraulic System Maintenance – Introduction to Hydraulic System, Application in Printing field and Check list for Hydraulic System maintenance.

5.4 – Mechatronics – Introduction and applications in Printing Field.

Text Book / Reference Book:

1. H. P. Garg, Industrial Maintenance – by S. Chand and company Ltd.
2. Reading in Maintenance – by Lewis and Tow, Cohners Book.
3. A manual for Lithographic press operation – by A.S. Porter, Lithographic Training
4. Litho Printing – by Ian Faux, Blueprint Publications.
5. Lithographers Manual – by Graphic Arts Technology Foundation, USA.
6. Design of Machine Elements – by Fairs, The Macmillan Co., London.
7. Mechanical Engineering Design – by Shirley McGrawhill.
8. “Machine Elements” – by DubrovalskyDaniel, MIR Publications.
9. Web offset press operating – by Daniel G. Wilson – GATF