Day 1: Introduction to Electric Motors & Safety Protocols

• 1. Introduction to Electric Motors
• o Types of electric motors: DC, AC, Induction, Synchronous, Universal
• o Components of an electric motor
• o Functioning and basic operation principles
• 2. Safety Protocols
• o Electrical hazards and personal protective equipment (PPE)
• o Lockout/tagout procedures
• o Emergency response and first-aid basics
• 3. Basic Motor Maintenance
• o Importance of regular maintenance
• o Common failure causes: Electrical, mechanical, environmental

Day 2: Motor Diagnosis and Fault Analysis

• 1. Motor Faults and Troubleshooting
• o Common faults in electric motors: Insulation failure, bearing failure, electrical imbalances, etc.
• o Using diagnostic tools: Multimeter, insulation resistance tester, vibration analysis
• o Interpreting motor performance data (current, voltage, power factor)
• 2. Vibration Analysis and Bearing Checks
• o Identifying mechanical faults through vibration analysis
• o How to check for bearing wear, misalignment, and imbalance
• 3. Motor Testing Methods
• o Stator and rotor testing
• o Continuity testing and insulation resistance testing
• o Electrical load testing and operational checks

Day 3: Motor Disassembly and Inspection

• 1. Motor Disassembly Process
• o Proper techniques for dismantling motors
• o Handling motor parts with care to avoid damage
• 2. Inspection of Motor Components
• o Inspecting the stator, rotor, windings, bearings, and shafts
• o Identifying signs of wear, corrosion, and overheating
• o Checking the condition of electrical connections
• 3. Documenting and Reporting
• o Creating service reports and documentation
• o Parts ordering and inventory management

Day 4: Overhauling and Reassembly of Electric Motors

• 1. Rewinding and Replacing Motor Components
• o Techniques for rewinding stators and armatures
• o Bearing replacement and lubrication
• o Rotor balancing and reconditioning
• 2. Reassembly Techniques
• o Correct reassembly sequence
• o Aligning rotor and stator
• o Reconnection of electrical components and wiring
• 3. Testing After Overhaul
• o Conducting initial tests after reassembly
• o Vibration, insulation, and operational tests

Day 5: Motor Alignment, Testing, and Troubleshooting Post-Overhaul

• 1. Final Alignment and Installation
• o Proper alignment of motor and driven equipment
• o Checking shaft couplings, pulleys, and belts for correct tension
• 2. Final Motor Testing and Performance Evaluation
• o Load testing and monitoring of motor performance
• o Troubleshooting any remaining issues post-overhaul
• o Identifying signs of improper reassembly
• 3. Preventive Maintenance and Motor Care
• o Best practices for long-term motor care
• o Preventive maintenance schedules and checklists
• o Motor storage and preservation techniques