Industrial Mechanical Maintenance Course

Lesson 1 • Introduction to Engineering Drawings

Explains orthographic views, section cuts, and dimension notation used in mechanical drawings. Drawing literacy enables technicians to plan repairs and order correct parts.

Lesson 2 • Workplace Safety Fundamentals

Covers hazard recognition, personal protective equipment, and lockout/tagout procedures. Safety compliance underpins every hands-on task in this course.

Lesson 3 • Reading Technical Documents

Teaches interpretation of equipment manuals, parts lists, and maintenance schedules. Accurate document reading reduces errors during all subsequent repair tasks.

Lesson 4 • Hand Tools and Measuring Instruments

Introduces correct selection, use, and care of common hand tools and precision measuring devices. Proper tool use is prerequisite to all mechanical repair work.

Lesson 1 • Shafts, Keys, and Couplings

Examines shaft design, keyway fits, and coupling types used to connect rotating components. Correct assembly prevents misalignment and premature wear.

Lesson 2 • Clutches and Brakes

Describes friction clutch and industrial brake designs, adjustment methods, and wear indicators. These components control start-stop cycles and must be maintained for safe operation.

Lesson 3 • Gear Drives and Gearboxes

Introduces spur, helical, bevel, and worm gear geometry along with gearbox inspection procedures. Gear knowledge enables accurate diagnosis of noise and wear patterns.

Lesson 4 • Core Mechanics for Technicians

Reviews force, torque, work, and power as applied to industrial machinery. These principles form the analytical basis for diagnosing mechanical problems.

Lesson 1 • Bearing Types and Load Ratings

Classifies rolling-element and plain bearings by geometry, load direction, and speed capability. Correct bearing selection prevents premature failure under operating loads.

Lesson 2 • Bearing Failure Analysis

Identifies spalling, brinelling, corrosion, and misalignment damage patterns on failed bearings. Root-cause analysis prevents repeat failures and guides corrective action.

Lesson 3 • Bearing Installation Techniques

Demonstrates cold-press, heat-mounting, and hydraulic methods for safe bearing installation. Proper technique prevents damage to raceways and rolling elements during fitting.

Lesson 4 • Bearing Fits and Tolerances

Explains interference and clearance fits for inner and outer rings on shafts and housings. Correct fits prevent creep, fretting, and premature race wear.

Lesson 1 • Static Sealing Methods

Covers gasket materials, O-ring groove design, and flange face preparation for leak-free joints. Static seal integrity is foundational to safe pressurised system operation.

Lesson 2 • Dynamic Shaft Seals

Examines lip seals, mechanical face seals, and labyrinth designs for rotating and reciprocating shafts. Proper installation prevents lubricant loss and contaminant ingress.

Lesson 3 • Seal Failure Diagnosis and Prevention

Identifies causes of seal failure including shaft runout, contamination, and improper installation. Systematic diagnosis reduces repeat seal failures and unplanned downtime.

Lesson 1 • Reciprocating Compressor Maintenance

Addresses valve inspection, piston ring replacement, and cylinder bore measurement for reciprocating compressors. Proper valve and ring condition directly controls compression efficiency.

Lesson 2 • Positive-Displacement Pump Maintenance

Covers gear, vane, and piston pump designs with inspection and clearance-setting procedures. These pumps require precise clearances to maintain volumetric efficiency.

Lesson 3 • Centrifugal Pump Fundamentals

Explains impeller action, pump curves, and system head to predict pump operating points. Understanding pump-system interaction is essential for diagnosing flow and pressure problems.

Lesson 4 • Pump and Compressor Troubleshooting

Applies systematic fault-tree analysis to diagnose low flow, excessive noise, and overheating in fluid machines. Structured troubleshooting reduces mean time to repair.

Lesson 1 • Laser Alignment Systems

Covers laser-optic alignment tool setup, data entry, and live move guidance for coupled machines. Laser systems improve speed and accuracy over dial indicator methods.

Lesson 2 • Alignment Fundamentals and Terminology

Defines parallel, angular, and combined misalignment and their effects on machinery components. Clear terminology enables accurate communication of alignment conditions.

Lesson 3 • Thermal Growth Compensation

Explains how operating temperature changes shaft centre-lines and how to apply pre-set offsets. Thermal compensation ensures alignment is maintained at operating conditions.

Lesson 4 • Dial Indicator Alignment Methods

Teaches rim-and-face and reverse-dial indicator setups for measuring and correcting misalignment. Dial methods remain widely used and build foundational measurement discipline.

Lesson 1 • Hydraulic and Pneumatic Troubleshooting

Applies pressure and flow testing with gauges and flow meters to isolate faults in fluid power circuits. Systematic testing reduces diagnostic time and prevents unnecessary component replacement.

Lesson 2 • Hydraulic Component Maintenance

Covers inspection and service of hydraulic pumps, directional valves, cylinders, and accumulators. Component-level maintenance restores system performance and prevents catastrophic failure.

Lesson 3 • Pneumatic System Maintenance

Addresses air preparation units, directional valves, cylinders, and flow controls in pneumatic circuits. Clean, dry, regulated air is the foundation of reliable pneumatic operation.

Lesson 4 • Reading Hydraulic Circuit Diagrams

Teaches ISO symbol recognition and circuit tracing for pumps, valves, actuators, and lines. Diagram literacy is required before any hydraulic troubleshooting can begin.

Lesson 1 • Vibration Analysis Fundamentals

Introduces vibration measurement units, frequency spectra, and common fault signatures for rotating machinery. Early vibration detection prevents catastrophic bearing and gear failures.

Lesson 2 • Oil and Lubricant Analysis

Explains viscosity testing, particle counting, and wear metal analysis to assess lubricant and machine condition. Oil analysis detects internal wear before external symptoms appear.

Lesson 3 • Maintenance Strategy Overview

Compares reactive, preventive, predictive, and reliability-centred maintenance strategies by cost and effectiveness. Selecting the right strategy for each asset optimises maintenance investment.

Lesson 4 • Infrared Thermography Applications

Covers thermal camera operation, emissivity settings, and interpretation of hot spots in mechanical and electrical equipment. Thermography identifies friction, overload, and insulation faults non-invasively.