Basic Repair and Maintenance Course

Lesson 1 • Organizing a Maintenance Workspace

Addresses workbench layout, parts organization, and cleanliness standards. An organized workspace reduces errors and speeds every repair procedure.

Lesson 2 • Reading Technical Diagrams

Teaches interpretation of exploded-view diagrams, schematics, and parts lists. Builds the visual literacy needed for every repair task ahead.

Lesson 3 • Core Tool Identification and Use

Introduces hand tools, power tools, and measuring instruments. Students match each tool to its correct application and safe handling method.

Lesson 1 • Removing Damaged Fasteners

Addresses stripped screws, seized bolts, and broken studs. These techniques are essential before any disassembly can proceed safely.

Lesson 2 • Torque Specifications and Tools

Teaches use of torque wrenches and torque sequences. Correct torque prevents both under-tightening failures and over-tightening damage.

Lesson 3 • Adhesives, Sealants, and Gaskets

Introduces thread-locking compounds, RTV sealants, and gasket materials. Proper sealing prevents leaks and vibration-induced loosening.

Lesson 1 • Belts, Chains, and Drive Systems

Addresses tension measurement, alignment, and replacement of drive belts and chains. Correct drive system setup prevents premature wear and power loss.

Lesson 2 • Seals, O-Rings, and Leak Diagnosis

Teaches leak tracing, seal selection, and installation technique. Eliminating leaks is critical to system reliability and environmental compliance.

Lesson 3 • Identifying Wear, Fatigue, and Damage

Teaches recognition of surface wear, cracks, corrosion, and deformation. Accurate damage classification guides the correct repair or replacement decision.

Lesson 4 • Bearings, Bushings, and Rotating Parts

Covers inspection and replacement of bearings and bushings in rotating assemblies. These components are frequent failure points in mechanical systems.

Lesson 1 • Lubricant Types and Properties

Explains viscosity grades, additive packages, and lubricant compatibility. Choosing the wrong lubricant accelerates wear and voids equipment warranties.

Lesson 2 • Hydraulic Fluid and Cooling System Service

Addresses hydraulic reservoir service and coolant flush procedures. Contaminated hydraulic or cooling fluid causes rapid system degradation.

Lesson 3 • Oil Change and Filter Service

Teaches drain, flush, refill, and filter replacement procedures for engines and gearboxes. Proper oil service is the single highest-impact preventive maintenance task.

Lesson 1 • Reading Wiring Diagrams and Schematics

Builds ability to trace circuits on wiring diagrams and locate components. Diagram literacy cuts diagnostic time and prevents incorrect repairs.

Lesson 2 • Wiring Repair and Connector Service

Covers wire splicing, terminal crimping, and connector replacement. Proper wiring repairs restore full circuit integrity without creating new faults.

Lesson 3 • DC Electrical Fundamentals

Covers voltage, current, resistance, and Ohm's Law in practical terms. These concepts underpin every electrical diagnosis task in the course.

Lesson 4 • Using a Multimeter for Diagnosis

Teaches voltage, continuity, and resistance measurement with a digital multimeter. Accurate meter use is the foundation of all electrical fault-finding.

Lesson 1 • Work Orders and Maintenance Records

Teaches work order creation, completion, and filing for traceability. Accurate records support warranty claims, audits, and future PM improvements.

Lesson 2 • Maintenance Scheduling Techniques

Covers calendar-based, meter-based, and condition-based scheduling methods. Matching the schedule type to equipment use patterns maximizes PM effectiveness.

Lesson 3 • Preventive vs. Reactive Maintenance

Contrasts planned preventive maintenance with reactive breakdown repair. Understanding the cost difference motivates disciplined PM program adherence.

Lesson 1 • Pre-Disassembly Planning and Documentation

Covers photographing assemblies, marking parts, and creating reassembly notes. Thorough pre-disassembly documentation prevents costly reassembly errors.

Lesson 2 • Component Cleaning and Inspection

Addresses solvent cleaning, parts washing, and post-clean inspection. Clean components allow accurate measurement and reveal hidden defects.

Lesson 3 • Reassembly and Alignment Procedures

Covers assembly sequence, alignment verification, and pre-lube steps. Correct reassembly sequence prevents interference fits and premature failures.

Lesson 4 • Post-Repair Testing and Quality Checks

Teaches functional run-in, leak checks, and performance verification after reassembly. Structured post-repair testing confirms the repair meets specification before return to service.

Lesson 1 • Failure Pattern Recognition

Teaches analysis of maintenance records to spot recurring failure patterns. Pattern recognition enables proactive design or procedure changes before failures recur.

Lesson 2 • Communicating Diagnostic Findings

Covers writing clear fault reports and presenting findings to supervisors. Effective communication ensures corrective actions are approved and implemented promptly.

Lesson 3 • Structured Troubleshooting Methodology

Introduces divide-and-conquer and symptom-isolation diagnostic frameworks. A structured method prevents random part replacement and reduces diagnostic time.

Lesson 4 • Root Cause Analysis Techniques

Covers 5-Why analysis, fishbone diagrams, and fault tree construction. Identifying root causes prevents recurrence and drives lasting corrective action.