Mechanical Maintenance Course

Lesson 1 • Reading Technical Documentation

Covers interpretation of engineering drawings, parts manuals, and work orders. Technicians who read documentation accurately reduce errors and downtime.

Lesson 2 • Workplace Safety Fundamentals

Establishes hazard recognition, personal protective equipment selection, and lockout/tagout procedures. Safe work habits are the non-negotiable baseline for all maintenance tasks.

Lesson 3 • Hand Tools and Measuring Instruments

Covers proper selection, use, and care of hand tools and precision measuring devices. Correct tool use prevents equipment damage and ensures accurate measurements.

Lesson 4 • The Mechanical Technician's Role

Defines responsibilities, career paths, and performance expectations for maintenance technicians. Establishes the professional context that frames all subsequent technical learning.

Lesson 1 • Dynamic Seals and Packing

Addresses lip seals, O-rings, and mechanical packing used in rotating and reciprocating equipment. Proper seal installation eliminates leaks and extends component life.

Lesson 2 • Threaded Fastener Systems

Covers bolt grades, thread standards, and torque specifications for threaded connections. Proper fastener selection prevents joint failure and equipment damage.

Lesson 3 • Gaskets and Static Seals

Explains gasket materials, compression requirements, and surface finish standards for leak-free joints. Correct gasket installation is critical for pressure and fluid containment.

Lesson 1 • Lubrication Fundamentals

Explains viscosity, lubricant types, and the film formation that prevents metal-to-metal contact. Selecting the right lubricant is the single largest factor in bearing longevity.

Lesson 2 • Bearing Installation and Removal

Covers interference fit methods, heating techniques, and puller use for safe bearing handling. Correct installation preserves bearing geometry and rated service life.

Lesson 3 • Bearing Types and Load Ratings

Identifies rolling-element and plain bearing types, load directions, and dynamic load ratings. Matching bearing type to application load prevents premature failure.

Lesson 4 • Lubrication Application and Management

Covers manual and automatic lubrication methods, re-greasing intervals, and oil analysis programs. Systematic lubrication management reduces unplanned downtime significantly.

Lesson 1 • Rotor Balancing Principles

Covers static and dynamic imbalance, influence coefficients, and trial weight placement. Balancing eliminates vibration forces that accelerate bearing and structural fatigue.

Lesson 2 • Alignment Theory and Tolerances

Explains parallel and angular misalignment, their effects on bearings and seals, and acceptable tolerance ranges. Understanding alignment theory is prerequisite to all alignment procedures.

Lesson 3 • Thermal Growth and Pipe Strain

Addresses thermal expansion offsets and pipe-induced forces that shift alignment during operation. Compensating for these factors ensures alignment is maintained at running temperature.

Lesson 4 • Straightedge and Dial Indicator Alignment

Covers rim-and-face and reverse-dial indicator methods for coupling alignment. These foundational techniques build the manual skill base for laser alignment work.

Lesson 1 • V-Belt and Synchronous Belt Drives

Covers belt cross-sections, sheave alignment, tension measurement, and replacement intervals. Correct belt tension and alignment maximise power efficiency and belt service life.

Lesson 2 • Gear Types and Inspection

Identifies spur, helical, bevel, and worm gear geometries and their failure modes. Gear inspection skills enable early detection of pitting, scoring, and tooth breakage.

Lesson 3 • Clutches and Brakes

Addresses friction clutch adjustment, brake lining inspection, and actuator maintenance. Properly maintained clutches and brakes ensure safe and precise machine control.

Lesson 4 • Chain Drive Systems

Explains roller chain standards, sprocket wear, elongation measurement, and lubrication requirements. Chain drives require precise elongation monitoring to prevent sprocket damage.

Lesson 1 • Reading Fluid Power Diagrams

Teaches ISO symbol interpretation and circuit tracing for hydraulic and pneumatic schematics. Accurate schematic reading is essential for systematic fault isolation.

Lesson 2 • Hydraulic and Pneumatic Troubleshooting

Applies pressure testing, flow measurement, and symptom analysis to isolate fluid power faults. Structured diagnostic methods reduce mean time to repair in fluid power systems.

Lesson 3 • Pneumatic Circuit Components

Covers compressors, FRL units, directional valves, and pneumatic actuators. Pneumatic systems require clean, dry, regulated air for reliable operation.

Lesson 4 • Hydraulic Circuit Components

Identifies pumps, valves, actuators, accumulators, and filtration components in hydraulic systems. Component recognition is prerequisite to accurate circuit diagnosis and repair.

Lesson 1 • Thermographic Inspection

Covers infrared camera operation, emissivity settings, and thermal anomaly interpretation. Thermography identifies overheating in bearings, electrical connections, and refractory without contact.

Lesson 2 • Vibration Analysis Fundamentals

Introduces vibration measurement, frequency spectra, and fault signatures for common mechanical defects. Vibration data enables detection of imbalance, misalignment, and bearing faults before failure.

Lesson 3 • Preventive Maintenance Planning

Covers task identification, frequency setting, and work order creation for PM programs. A structured PM plan is the foundation of equipment reliability management.

Lesson 4 • Maintenance Records and KPI Tracking

Covers work history documentation, MTBF calculation, and maintenance cost tracking. Accurate records enable data-driven decisions that continuously improve equipment reliability.

Lesson 1 • Overhaul Planning and Execution

Addresses scope definition, parts procurement, task sequencing, and resource scheduling for major overhauls. Thorough planning minimises overhaul duration and return-to-service risk.

Lesson 2 • Commissioning and Acceptance Testing

Covers run-in procedures, performance baseline recording, and acceptance criteria verification after overhaul. Structured commissioning confirms that repaired equipment meets operational requirements.

Lesson 3 • Precision Measurement in Overhaul

Applies bore gauges, dial indicators, and surface plates to verify clearances and fits during overhaul. Precision measurement confirms that reassembled components meet design specifications.

Lesson 4 • Root Cause Analysis Methods

Covers five-why analysis, fishbone diagrams, and fault tree construction for mechanical failures. Identifying root causes prevents recurrence and reduces total maintenance cost.