MECHANICAL EXAM REVIEW

VERSION B

Look at the exam paper(Q&A) to see how specific objects look

1. state one responsibility of the employer under the HASWA when carrying out
maintenance operation (1)
Provide PPE, provide a safe working environment

2. List 3 hazards that may be encountered during the routine maintenance of a large
compressor. (3)
-Oil and grease
-Damaged fittings
-Fractured supply lines

3. Name the current standards for all engineering drawings. (1)

BS 8888

4. Name 2 types of technical specifications. (2)

Design specification and test specification

5. Identify the colors of the following items (2)

a) warning signs - black and yellow
b) fire extinguishers - predominantly red and white

6. State the difference between routine and emergency breakdown maintenance. (2)
Routine maintenance is carried out on a system at specified intervals based on the effective
service life of the component.
Emergency breakdown maintenance is the immediate response to repair or replace a part of an
equipment that has stopped or malfunctioned.

7. State an application for catalogue numbers as an identification system. (1)

For similar items that have the same name but come in a range of sizes or capacities e.g. fuses,
circlips

8. Describe 2 fault location techniques. (4)

Half split technique - Christmas tree lights
Unit substitution - by removing components sequentially and replacing with a known functioning
item until normal operation

9. Identify 3 sources of sensory information. (3)

Any 3 of Sight, Sound, smell, touch
10. State one mandatory requirement when working on scaffolding. (1)
Not to use in strong winds or with broken or missing parts

11. Name the lifting device shown in Figure 1 below. (1)

Packing case grabs(clamps)

12. Describe what the value accompanying the letters 'SWL' stamped on a lifting device
are specifying. (2)
The maximum permissible load that the device is capable of lifting safely.

13. State 2 lifting machines that should only be used by a certified competent person. (2)
Fork lift truck, cranes. (overhead, jib or derrick)

14. Describe a suitable application for the use of rollers. (2)

To maneuver and relocate a heavy flat based item of equipment or machine.

15. State the correct application of a:

a) pipe wrench - has self adjusting jaws that grips the outside walls of the pipe when force is
applied.
b)torque wrench - a spring calibrated socket wrench with multiple sockets that can be set to
apply specific tightening force that prevents over-tightening and damaged to the threaded
fasteners.

16. Figure 2 below shows a pair of long(snipe) nose pliers. Sketch how Universal pliers
differ from the Long nose pliers. (3)
Universal pliers have shorter/thicker nose

17. State a suitable instrument for measuring each of the following quantities
a) 0.4mm - micrometer
b)10ohms - multimeter
c)290mm - steel rule

18. a) State the reason for checking the calibration of an instrument before use. (1)
To ensure consistency and accuracy when measuring a number of components

b) State 2 advantages of using a laser in the checking of alignments. (2)

Higher level of precision can be achieved
Faster and easier to mount and use

19. Describe the difference between a gasket and seal. (2)

Seals are used to prevent leakages in moving components whiles gaskets are fitted between
flat surfaces and does not allow for movements.
20. State 2 possible reasons for the loss of properties in an oil based lubricant. (2)
Excessive heat during operation, contamination

21.Describe the method of proof marking during a maintenance operation. (2)

Proof marking is used during the dismantling process where component features are marked
simultaneously in the same place at a joint interface so they can be reassembled in exactly the
same position.

22. a) Sketch a parallel key. (2)

b) State an application for a parallel key. (1)

Parallel square keys are used for smaller shafts and rectangular faced keys are used for shaft
diameters over 170mm.

23. State a different situation during a maintenance operation where each of the following
should be used.
a) Manual press - Press in a bearing or bush
b) Drift - aligning holes with 2 interlocking components
c) Pullers - Extracting shafts

24. Describe the difference between a set screw and a blot. (2)
A set screw is threaded up to the head but a bolt is threaded for a given percentage with the
remainder up to the head as a plain shank.

25. Name in each case, the gear systems shown in figure 3.(2)
A - spur
B - bevel drive

26. Name 2 components that would normally be re-used during maintenance operation.
(2)
Any 2 of: Un-blown fuses, undamaged keys, castellated nuts

27. State 3 activities that should be taken to restore the work area on completion of a
job.(3)
Cleaning the work area
putting tools and equipment into safe storage
leave the work area free of unused consumables

28. State 3 things that will be on a scheduled maintenance work order.(probably the
question)(3)
Any 3 of:
Date of maintenance operation
notes on wear of parts
Name of maintenance personnel
order reference number