Maintenance Mechanic Course

Lesson 1 • Hand Tools and Measuring Instruments

Introduces wrenches, screwdrivers, hammers, and precision measuring tools. Proper selection and care of tools directly affects repair quality and safety.

Lesson 2 • Reading Technical Documents

Teaches interpretation of equipment manuals, parts lists, and basic engineering drawings. Document literacy is required for every repair and PM task ahead.

Lesson 3 • Shop Safety and Hazard Awareness

Covers lockout/tagout, chemical handling, and fire prevention in a maintenance environment. Safety compliance underpins every hands-on task in the course.

Lesson 4 • Fasteners, Threads, and Fits

Explains bolt grades, thread standards, and tolerance fits used in mechanical assemblies. Understanding fastener specifications prevents failures during reassembly.

Lesson 1 • Chain and Sprocket Drives

Explains roller chain construction, lubrication, and sprocket alignment techniques. Chain drives require precise alignment and lubrication to achieve rated service life.

Lesson 2 • Shaft Alignment Techniques

Teaches dial indicator and laser alignment methods for parallel and angular misalignment correction. Precise shaft alignment is the single greatest factor in bearing and seal longevity.

Lesson 3 • Shafts, Keys, and Couplings

Covers shaft materials, keyway cutting, and rigid versus flexible coupling types. Proper coupling selection and installation reduce vibration and extend component life.

Lesson 4 • Gearboxes and Speed Reducers

Covers gear types, oil fill procedures, seal replacement, and backlash measurement. Gearbox maintenance directly affects torque transmission reliability in driven equipment.

Lesson 1 • Lubrication Programmes and Methods

Covers grease and oil selection, application intervals, and contamination control practices. A structured lubrication programme is the most cost-effective reliability improvement available.

Lesson 2 • Seals and Packing

Explains lip seals, mechanical seals, O-rings, and compression packing selection and installation. Proper sealing prevents lubricant loss and contaminant ingress in rotating equipment.

Lesson 3 • Bearing Installation and Removal

Covers press-fit, heat-mount, and puller-based removal methods with proper tooling. Incorrect installation is the leading cause of early bearing failure in the field.

Lesson 4 • Bearing Types and Selection

Compares ball, roller, tapered, and thrust bearings by load capacity and application. Selecting the correct bearing type is the first step in achieving design service life.

Lesson 1 • Motors and Motor Starters

Covers three-phase induction motor construction, nameplate data, and starter circuit components. Motor and starter knowledge allows mechanics to identify faults before calling electricians.

Lesson 2 • Reading Ladder Logic Diagrams

Introduces ladder diagram symbols, rung logic, and tracing power flow through control circuits. Ladder diagram literacy allows mechanics to verify control circuit operation during troubleshooting.

Lesson 3 • Electrical Safety and Lockout

Covers arc flash hazards, approach boundaries, and electrical lockout/tagout procedures. Electrical safety compliance is mandatory before any measurement or wiring task is performed.

Lesson 4 • DC and AC Circuit Basics

Explains Ohm's law, series and parallel circuits, and the difference between AC and DC systems. Circuit fundamentals enable mechanics to interpret measurements and understand control logic.

Lesson 1 • Valves and Actuators

Explains directional, pressure, and flow control valves plus cylinder and motor actuators. Valve function directly controls force, speed, and direction in hydraulic circuits.

Lesson 2 • Hydraulic System Troubleshooting

Applies a structured diagnostic process to no-pressure, slow-speed, and overheating faults. Systematic troubleshooting reduces downtime and prevents unnecessary component replacement.

Lesson 3 • Hydraulic Principles and Fluid Properties

Reviews Pascal's law, flow, pressure, and the role of fluid viscosity and cleanliness. Fluid fundamentals govern every component selection and troubleshooting decision in hydraulics.

Lesson 4 • Hydraulic Schematics and Circuit Reading

Teaches ISO hydraulic symbols and circuit tracing for common industrial systems. Schematic literacy is essential for systematic fault isolation in complex hydraulic machines.

Lesson 1 • Pneumatic Valves and Actuators

Addresses solenoid valves, manual valves, cylinders, and rotary actuators in pneumatic circuits. Valve and actuator condition determines cycle speed, force output, and positioning accuracy.

Lesson 2 • Pneumatic Circuit Troubleshooting

Uses schematic reading and systematic testing to isolate leaks, slow cycles, and valve faults. Structured diagnosis minimises production downtime and avoids unnecessary part replacement.

Lesson 3 • FRL Units and Distribution

Explains filter, regulator, and lubricator function, adjustment, and element replacement. FRL maintenance ensures clean, regulated air reaches every downstream component.

Lesson 4 • Compressors and Air Treatment

Covers reciprocating and rotary screw compressor maintenance, dryers, and aftercoolers. Proper air treatment prevents corrosion, valve sticking, and actuator seal degradation.

Lesson 1 • Ultrasound and Oil Analysis

Covers airborne and structure-borne ultrasound for leak and bearing detection plus oil analysis sampling. These technologies extend PM intervals while maintaining confidence in equipment condition.

Lesson 2 • Vibration Analysis Basics

Introduces vibration measurement, frequency spectra, and common fault signatures for rotating machinery. Early vibration detection allows bearing and imbalance faults to be corrected before failure.

Lesson 3 • Thermography and Infrared Inspection

Explains infrared camera operation, emissivity settings, and thermal anomaly interpretation for electrical and mechanical assets. Thermal imaging detects overloaded connections and friction hotspots non-invasively.

Lesson 4 • CMMS and Maintenance Records

Teaches work order creation, history recording, and KPI tracking within a computerised maintenance management system. Accurate records enable trend analysis and justify maintenance budget decisions.

Lesson 1 • Root Cause Analysis Methods

Covers the 5-Why technique, fishbone diagrams, and fault tree analysis for maintenance failures. Identifying root causes prevents recurrence and drives lasting equipment reliability improvements.

Lesson 2 • Pump and Compressor Overhaul

Guides disassembly, inspection, parts replacement, and reassembly of centrifugal and positive displacement pumps. Overhaul competency reduces reliance on OEM service and shortens repair turnaround time.

Lesson 3 • Repair Planning and Execution

Covers job hazard analysis, parts staging, repair sequencing, and post-repair functional verification. Structured repair planning reduces errors, rework, and safety incidents during complex maintenance jobs.

Lesson 4 • Welding and Fabrication Basics

Introduces MIG and stick welding techniques for bracket repair, pipe patching, and fabricating simple parts. Basic fabrication skills allow mechanics to create repair solutions without waiting for outside contractors.