xiii Feature Contents THINKING GREEN Making Rope Last .............................................144 Re-Refi ning Used Oil ........................................202 Recycling Steel ................................................232 Proper Service Is Also Green Service ...................266 Choose the Proper Air Dryer ...............................325 Sizing Lines and Fittings ...................................332 Switching Power Supplies ..................................573 Variable Frequency Drives (VFDs) .......................613 Battery Recycling .............................................623 Range Adjustment ............................................671 Instantaneous Boilers ........................................695 Dirty Coils and Fans ..........................................722 PROCEDURES Job Safety Analysis (JSA) ....................................38 Tapping a Hole ...................................................90 Performing a Hand Splice ..................................146 Checklist before Operation .................................160 Manually Mounting a Bearing .............................198 Lubricating a Bearing ........................................204 Drive Train Inspection .......................................213 Runout Measurement ........................................216 Measuring and Correcting Soft Foot ....................217 Installing a Sheave ...........................................229 Removing a Sheave ...........................................230 Belt Installation ................................................231 Sheave Alignment .............................................231 Checking Chain Tension ....................................236 Backlash Measurement .....................................241 Axial Runout Measurement ................................241 Removing and Installing Oil Seals ......................241 Measuring Shaft Speed .....................................264 Changing a Filter ..............................................285 Determine the Proper Replacement Hydraulic Hose ....288 Cleaning a Hydraulic System .............................299 Power Unit Start-up ..........................................303 Preparing to Perform an Electrical Test ...............402 Three-Phase Fuse Test ......................................448 Soldering .........................................................456 Connect Transformers in Series ..........................471 Connect Transformers in Parallel ........................472 Making a Primary Delta Connection ....................478 Making a Primary Wye Connection ......................478 Preparing to Make a Secondary Connection .........479 Secondary Wye Confi guration .............................479 Secondary Delta Confi guration ...........................480 Removing and Inserting Fuses ...........................504 Finding Sources of Excess Current ......................518 Calculating Voltage Imbalance ...........................555 Testing a Transistor ...........................................581 Installing a Capacitive Sensor ............................596 Photo Sensor Adjustment ..................................599 Troubleshooting Sensors ....................................601 Programming VFD Parameters ............................610 Troubleshooting a VFD .......................................613 Changing PLC Processor Batteries ......................622 Troubleshooting Analog Modules ........................628 Checking an Input ............................................636 Checking Output and Load Wiring ......................638 Replacing I/O Modules ......................................639 HMI Troubleshooting .........................................657 Connect and Test an I/P Transducer ....................674 Calibrating a Thermostat ...................................713 Proper Cylinder Setup .......................................736 SMAW Setup ....................................................760 SMAW Operation ..............................................760 GMAW and FCAW Setup ....................................762 Performing GMAW ............................................763 Performing GTAW .............................................764 Equipment Assembly ........................................778 Cutting Operation .............................................778 Equipment Shutdown ........................................779 PAC Equipment Assembly ..................................781 PAC Cutting Operation ......................................782 Repacking a Pump ............................................800 Using a Pipe Cutter ...........................................816 Performing a Flare ............................................818 Threading Pipe .................................................819 Pipe Cutting and Threading with a Threading Machine ......................................820 Assembling a Flange .........................................822 General Soldering Technique .............................826 Adhesion Joining Plastic Pipe ............................827 Assembling Fittings ..........................................830