General Maintenance Technician Course

Lesson 1 • Shop Organization and Material Handling

Covers 5S workplace organization, proper lifting techniques, and material storage. Creates efficient, clutter-free work habits that reduce accidents and downtime.

Lesson 2 • Power Tools: Operation and Safety

Introduces electric, pneumatic, and cordless power tools with emphasis on safe operation. Prepares students for efficient, injury-free use in all maintenance tasks.

Lesson 3 • Personal Protective Equipment and Hazard Awareness

Covers PPE selection, donning procedures, and hazard recognition in maintenance environments. Anchors all subsequent hands-on work in a safety-first mindset.

Lesson 4 • Reading Work Orders and Technical Documents

Trains students to interpret work orders, parts lists, and basic schematics. Connects documentation literacy to accurate, accountable maintenance execution.

Lesson 1 • Precision Measurement Instruments

Teaches use of calipers, micrometers, and dial indicators to achieve precise readings. Measurement accuracy directly supports correct part fitting and quality control.

Lesson 2 • Fastener Types and Thread Standards

Identifies bolts, screws, nuts, and washers by grade, thread pitch, and drive type. Ensures correct fastener selection to prevent joint failure in maintenance work.

Lesson 3 • Torque Application and Fastener Installation

Covers torque wrench types, torque sequences, and thread preparation techniques. Proper torque application prevents loosening, stripping, and component damage.

Lesson 1 • Belt Drive Systems

Covers V-belt, flat belt, and synchronous belt drives including tensioning and sheave alignment. Belt drive knowledge is foundational to maintaining the majority of rotating equipment.

Lesson 2 • Chain and Sprocket Drives

Teaches roller chain selection, lubrication, and sprocket alignment for industrial drives. Chain drives appear in conveyors, hoists, and machinery requiring positive engagement.

Lesson 3 • Couplings and Shaft Alignment

Covers rigid, flexible, and fluid coupling types with emphasis on precision shaft alignment. Misalignment is a leading cause of bearing and seal failure in rotating machinery.

Lesson 4 • Gear Systems and Gearboxes

Introduces spur, helical, bevel, and worm gear types along with gearbox servicing. Students identify gear failure modes and perform oil changes and seal replacements.

Lesson 1 • Hydraulic System Fundamentals

Introduces Pascal's law, hydraulic circuit components, and fluid power principles. Hydraulic systems power lifts, presses, and actuators across all industrial sectors.

Lesson 2 • Hydraulic System Maintenance and Troubleshooting

Teaches filter changes, seal replacement, and systematic fault isolation in hydraulic circuits. Students restore system pressure and flow to manufacturer specifications safely.

Lesson 3 • Lubricant Types and Properties

Explains viscosity grades, base oil types, and additive packages for oils and greases. Lubricant knowledge enables correct product selection for each application and environment.

Lesson 4 • Pneumatic System Maintenance

Covers air preparation units, cylinder servicing, and valve maintenance for pneumatic systems. Pneumatic maintenance skills complement hydraulic knowledge for complete fluid power competency.

Lesson 1 • Electrical Safety and Lockout Procedures

Teaches arc flash hazards, shock prevention, and electrical lockout/tagout procedures. Electrical safety is non-negotiable and must precede any hands-on wiring work.

Lesson 2 • Multimeter and Electrical Testing

Trains students to use multimeters and clamp meters to measure voltage, current, and resistance. Test instrument proficiency is essential for diagnosing faults in all electrical systems.

Lesson 3 • Wiring Devices and Panel Components

Identifies switches, receptacles, breakers, fuses, and terminal blocks used in control panels. Component recognition enables accurate diagnosis and correct part replacement.

Lesson 4 • Conduit, Cable, and Wire Installation

Covers wire sizing, conduit bending, pulling techniques, and termination best practices. Proper installation ensures code-compliant, reliable wiring in maintenance projects.

Lesson 1 • AC and DC Motor Types and Nameplate Data

Identifies single-phase, three-phase, and DC motor types and interprets nameplate specifications. Nameplate data guides correct motor selection, protection sizing, and replacement.

Lesson 2 • Variable Frequency Drive Operation

Introduces VFD operating principles, parameter programming, and energy-saving applications. VFDs are standard on modern equipment and require dedicated commissioning skills.

Lesson 3 • Motor Troubleshooting and Testing

Applies winding resistance, insulation, and vibration tests to diagnose motor faults. Systematic motor testing reduces mean time to repair and prevents misdiagnosis.

Lesson 4 • Motor Starter and Control Circuit Wiring

Covers full-voltage, reduced-voltage, and reversing starter circuits with control logic. Students wire and verify motor control circuits from ladder diagrams.

Lesson 1 • Preventive Maintenance Planning and Scheduling

Covers PM task development, frequency setting, and CMMS-based scheduling workflows. A structured PM plan is the backbone of any reliability-centered maintenance program.

Lesson 2 • Thermography and Infrared Inspection

Teaches infrared camera operation, thermal pattern interpretation, and report generation. Thermography identifies electrical hot spots and mechanical friction before failures occur.

Lesson 3 • Reliability Metrics and Continuous Improvement

Introduces MTBF, MTTR, OEE, and root cause analysis tools for maintenance improvement. Metrics-driven improvement transforms maintenance from a cost center into a reliability function.

Lesson 4 • Vibration Analysis Fundamentals

Introduces vibration measurement, frequency spectra, and common fault signatures in rotating equipment. Vibration data enables early detection of imbalance, misalignment, and bearing defects.

Lesson 1 • Repair Planning and Parts Management

Covers repair scope definition, parts procurement, and downtime minimization strategies. Effective repair planning reduces mean time to repair and controls maintenance costs.

Lesson 2 • Structured Troubleshooting Process

Teaches a repeatable six-step fault isolation process applicable to any system or equipment type. A structured approach eliminates guesswork and reduces diagnostic time significantly.

Lesson 3 • Electrical Fault Diagnosis Scenarios

Applies test instruments and ladder logic to isolate open circuits, shorts, and control faults. Electrical fault diagnosis integrates wiring, motor, and control knowledge from prior chapters.

Lesson 4 • Post-Repair Verification and Handover

Teaches functional testing, safety checks, and formal handover procedures after repairs. Proper verification confirms the repair is complete and the equipment is safe to operate.