Industrial Machinery Mechanic Course

Lesson 1 • Reading Technical Documents

Teaches interpretation of schematics, parts lists, and OEM manuals. Provides the document literacy needed for all subsequent repair tasks.

Lesson 2 • Measurement and Inspection Tools

Introduces precision measuring instruments and their correct use. Accurate measurement underpins every diagnostic and repair procedure in the course.

Lesson 3 • Industrial Machine Types and Uses

Covers major categories of industrial machinery and their production roles. Builds the classification framework used throughout the course.

Lesson 1 • Gears and Gear Trains

Explains gear types, gear ratios, and load distribution in drive systems. Connects gear geometry to torque and speed calculations used in diagnostics.

Lesson 2 • Belt, Chain, and Sprocket Drives

Teaches tensioning, alignment, and wear inspection for flexible drive elements. Proper drive setup reduces energy loss and extends component life.

Lesson 3 • Bearings: Selection and Maintenance

Identifies rolling-element and plain bearing types and their load ratings. Students practice installation, lubrication, and early failure detection.

Lesson 4 • Clutches and Brakes

Explains friction, electromagnetic, and pneumatic clutch and brake mechanisms. Students adjust engagement force and inspect friction surfaces for wear.

Lesson 1 • Hydraulic Valves and Control

Explains directional, pressure, and flow control valves and their circuit symbols. Valve adjustment and sequencing are practiced through circuit exercises.

Lesson 2 • Hydraulic Principles and Fluid Properties

Covers Pascal's law, pressure, flow, and fluid viscosity selection. Establishes the physics foundation for all hydraulic troubleshooting tasks.

Lesson 3 • Hydraulic Pumps and Motors

Identifies gear, vane, and piston pump types and their performance curves. Students connect pump selection to system pressure and flow requirements.

Lesson 4 • Hydraulic Cylinders and Actuators

Covers single-acting, double-acting, and telescoping cylinder construction. Students calculate force output and inspect seals for leakage.

Lesson 1 • Air Treatment and Quality Standards

Covers filtration, regulation, and lubrication units in FRL assemblies. Clean, dry, regulated air is essential for valve and actuator longevity.

Lesson 2 • Pneumatic Valves and Actuators

Identifies directional control valves, cylinders, and rotary actuators used in automation. Students connect valve actuation methods to circuit response.

Lesson 3 • Compressed Air Generation and Distribution

Explains compressor types, receiver tanks, and distribution piping design. Proper air supply setup prevents downstream component failures.

Lesson 1 • Sensors and Feedback Devices

Covers proximity, photoelectric, and pressure sensors used in machine control. Students test sensor output and adjust sensing range for reliable operation.

Lesson 2 • Electric Motors and Drives

Identifies three-phase induction, DC, and servo motor types and their control methods. Motor nameplate data is used to verify correct application.

Lesson 3 • Electrical Safety and Basic Concepts

Covers voltage, current, resistance, and safe work practices around energized equipment. Establishes the electrical safety boundary for mechanics.

Lesson 4 • Ladder Logic and Control Diagrams

Teaches reading of ladder diagrams, wiring diagrams, and I/O lists. Diagram literacy enables mechanics to trace faults to specific control components.

Lesson 1 • Maintenance Strategy Fundamentals

Compares reactive, preventive, and predictive maintenance models and their cost impact. Students select appropriate strategies for different machine criticalities.

Lesson 2 • Developing PM Schedules and Checklists

Guides creation of time-based and usage-based PM tasks from OEM recommendations. Structured checklists ensure consistent task execution across shifts.

Lesson 3 • Thermography and Oil Analysis

Covers infrared thermography for electrical and mechanical hot spots and oil sampling for wear debris analysis. Both techniques extend machine life.

Lesson 4 • Vibration Analysis Basics

Introduces vibration measurement, frequency analysis, and common fault signatures. Early vibration detection prevents catastrophic bearing and shaft failures.

Lesson 1 • Structured Troubleshooting Methodology

Introduces a repeatable diagnostic process from symptom collection to root cause verification. A consistent method reduces mean time to repair across all machine types.

Lesson 2 • Failure Reporting and Analysis

Guides completion of failure reports, fishbone diagrams, and 5-Why analyses. Documented analysis feeds back into PM schedules and spare parts planning.

Lesson 3 • Electrical and Control Fault Diagnosis

Teaches fault tracing in motor circuits, control panels, and sensor loops using multimeters and test lamps. Students distinguish electrical from mechanical root causes.

Lesson 4 • Mechanical Fault Diagnosis

Applies diagnostic tools to noise, vibration, overheating, and excessive wear faults. Students link physical symptoms to specific mechanical failure modes.

Lesson 1 • Machine Reassembly and Commissioning

Establishes torque sequences, alignment verification, and functional testing after overhaul. Proper commissioning confirms the machine meets production specifications.

Lesson 2 • Gearbox and Pump Overhaul

Guides complete disassembly, inspection, and reassembly of industrial gearboxes and hydraulic pumps. Students verify clearances and perform run-in procedures.

Lesson 3 • Precision Fitting and Tolerances

Applies interference, clearance, and transition fits to shaft and bore assemblies. Students measure and correct out-of-tolerance conditions before reassembly.

Lesson 4 • Disassembly Planning and Documentation

Covers pre-disassembly inspection, photographic documentation, and component marking. Thorough planning prevents assembly errors and lost parts.