Maintenance Technician Training Path

Ohm's law, series and parallel circuits, schematics and control power, then a first meter measurement. Every unit in this milestone is free.

• FreeVoltage, current, resistance and power (15 min)
• FreeSeries and parallel circuits (12 min)
• FreeReading a simple schematic (12 min)
• FreeControl power: 24 V DC or mains (10 min)
• FreeMultimeter lab: measure 24 V DC (12 min)

Why machines are guarded, how stops and light curtains work, the lockout/tagout sequence and electrical hazards, finishing with a graded knowledge check.

• FreeWhy machines are guarded (12 min)
• FreeE-stop circuits (15 min)
• FreeLab: dual-channel E-stop into a safety relay (14 min)
• FreeLockout/tagout (16 min)
• ProSafety relays and light curtains (16 min)
• ProElectrical hazards (14 min)
• ProIndustrial safety knowledge check (12 min)

Meters used safely, relays and contactors, motor nameplates, overload protection, grounding and a worked three-wire start/stop circuit.

• ProMeters done safely (15 min)
• ProRelays and contactors (12 min)
• ProMotors: single-phase, three-phase and the nameplate (15 min)
• ProOverload protection: fuses and breakers (15 min)
• ProGrounding and bonding (12 min)
• ProCapstone: read a three-wire start/stop circuit (20 min)

The half-split method, what an input LED and a voltage reading each prove, and graded fault labs on reversed sensors, a broken supply wire, a blown fuse and a tripped overload.

• FreeThe half-split troubleshooting method (15 min)
• FreeReading the symptoms: LEDs, tags and meter readings (15 min)
• FreeFault 1: Photoeye polarity reversal (8 min)
• FreeFault 4: Broken +24 V supply wire to the PLC (6 min)
• ProFault 9: Blown 24 V control fuse (10 min)
• ProFault 11: Thermal overload trip (12 min)
• ProFault 5: Broken 0 V return wire on the contactor coil (7 min)

P&ID symbols and instrument tags, the four electrical drawing types, wire numbers and cross-references, and using a drawing to decide where to measure.

• FreeWhat a P&ID is, and what it is not (14 min)
• FreeInstrument tags: reading FIC-101 and friends (15 min)
• FreeFollowing a loop from sensor to valve (18 min)
• ProFour drawings of the same circuit (12 min)
• ProLabels, terminals and cross-references (14 min)
• ProTroubleshooting from drawings: where do you measure? (18 min)

Gear trains, belts and chains, couplings, bearings and lubrication, vibration clues and a symptom-to-cause drill for mechanical faults.

• FreeGears and gearboxes (18 min)
• ProBelts, chains and pulleys (16 min)
• ProShafts, keys and couplings (15 min)
• ProBearings and lubrication (16 min)
• ProAlignment, vibration and condition clues (17 min)
• ProMechanical troubleshooting (20 min)

Choosing an actuator, pneumatic circuits and cylinder sensors, and a symptom-to-cause drill for sticking cylinders and slow axes.

• FreeChoosing the actuator (15 min)
• FreePneumatics basics (18 min)
• FreePneu 01 — Single cylinder (6 min)
• ProCylinder sensors and sequencing (15 min)
• ProTroubleshooting a sticking cylinder or slow axis (15 min)

Just enough ladder logic to follow a rung: what a PLC is, the scan, normally closed stop buttons, seal-in latches and timers, with two repair labs.

• FreeWhat is a PLC? (3 min)
• FreeThe scan cycle (5 min)
• FreeLadder logic = relay logic (4 min)
• FreeNC contacts and stop buttons (4 min)
• FreeThe latch (self-holding circuit) (5 min)
• FreeTimers (TON) (5 min)
• FreeFix 01: Motor won’t hold (4 min)
• FreeFix 02: STOP is ignored (5 min)

One carton sorter cell, five graded steps: size the drive, size the pusher and the supply, safeguard it, write the PLC cycle and commission it.

• FreeCapstone 1: size the conveyor drive (15 min)
• ProCapstone 2: size the pusher and the electrical supply (20 min)
• ProCapstone 3: safeguard the pusher station (18 min)
• ProCapstone 4: write and test the PLC cycle (25 min)
• ProCapstone 5: commission and document the cell (20 min)