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Mechatronics & Industrial Maintenance

Validated by Industry . . .

The JobMaster® Training Program

A Critical Moment Gives Birth to a Program Delivering Critical Skills

Industrial Manufacturing. Green Technology. New and Emerging Industries.

The 1979 accident at the Three Mile Island nuclear power plant in Pennsylvania was the most serious in U.S. commercial nuclear power plant operating history. Though no one was injured or killed, it brought about sweeping changes to many areas of nuclear power plant operations, including reactor operator training.

Employers in all sectors, from traditional manufacturing to emerging industries, need qualified workers to meet the increasing demands of a changing world. Advancing technologies and global competition put new demands on the workforce. The shortage of qualified workers is felt whether searching for highly-skilled candidates or entry-level candidates with basic skills. The JobMaster® Training programs provides an effective solution to this critical need. JobMaster® training delivers the critical skills needed by industries of all sectors, and for trainees of all types. Whether implemented in high school and community college programs, or in industrial training programs to equip existing employees with new skills, JobMaster® provides a scalable training program custom-fit to your needs. With a comprehensive skill list developed in tangent with many industries, students obtain skills that will serve in careers today and well into the future.

To implement these new policies, teams of industrial engineers from Technical Resource Group, the parent company of JobMaster®, created detailed job task analyses on every task necessary for plant operation. A sophisticated algorithm was developed to measure the safety risk, difficulty level, frequency, and time spent for each technical task. The results were used to define training programs and assessment for plant operators and successfully implemented at nuclear power plants around the country. With that success, the company offered these same benefits to the industrial market. The same Job Task Analysis was used to implement industrial training programs for Fortune 1000 companies such as: JobMaster® covers the following topics

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Basic Foundation Skills Precision Measurement Basic Power Electricity Electrical Control Systems Industrial Power Electronics Mechanical Systems Hydraulics Pneumatics Electromechanical Maintenance Cell Capstone Project and more!

„„ Caterpillar

„„ General Motors

„„ DuPont

„„ Ford

„„ General Electric

„„ U.S. Steel

Today, JobMaster® has documented and developed programs for over 50,000 specific skills. This same combination of skill requirements validated and funded by industry forms the JobMaster® Mechatronics and Industrial Maintenance program. Now JobMaster® is supercharged with intelitek’s LearnMate® online E-learning technology. This enables online delivery, student tracking, reporting, valid assessment and certification, making JobMaster® an industrial maintenance program unlike any other!

. . . powered by LearnMate® JobMaster® is powered by LearnMate®, intelitek’s flagship blended learning solution. This online Learning Management System (LMS) is successfully deployed in over 500 LearnMate® labs worldwide. Developed to meet the specific needs of technical classrooms, LearnMate® puts powerful content delivery and classroom management capabilities into the hands of instructors.










LearnMate® enables your industrial training to be accessible, flexible and measurable. Easily enroll users, set up groups and permission levels, track progress and deliver online assessments. Import any set of competencies or create your own and map these competencies to the activities. Produce robust custom reports to document and validate what your program is accomplishing as measured against these standards. Students can access content anytime, anywhere, and proceed at their own individualized pace. Robust simulations, interactive animations and videos - all correlated to the JobMaster® training hardware - ensure relevant instruction keeps trainees engaged. Tests and quizzes with multiple question types identify skills gaps for focused training. With over 2,500 hours of content in Automated Manufacturing, ComputerAssisted Design (CAD), Computer-Assisted Machining (CAM), Computer Numerical Control (CNC), Robotics, Flexible Manufacturing Systems (FMS) Computer Integrated Manufacturing (CIM) and more, LearnMate® offers a complete solution to your mechatronics training needs.


„„ Secure assessments

„„ Deliver consistent content across multiple organizations

„„ Create, deliver and track computer-based assessments

„„ Compatible with ANY SCORM (Sharable Content Object Reference Model)-compliant content

„„ Evaluate student progress

„„ AICC (Aviation Industry CBT [Computer-Based Training] Committee)-compliant

„„ Pinpoint skills gaps

„„ Content authoring with LearnMate® Author „„ Create your own SCORM-compliant, AICC-compliant, 508c capable curriculum, tests and assignments

„„ Easy-to-use classroom management „„ Quickly and easily set up users, groups and permissions „„ Track student and class progress „„ Create student portfolios and certifications „„ Produce customizable multi-level reports

„„ Standards and competency mapping „„ Map program and student performance to any set of standards - even organization-specific competencies you create

„„ Establish any portion of content as an assessment

„„ Certifications and scalable accountability „„ Track data on student outcomes, competencies, and learning gaps at multiple levels „„ Provide a valid record of achievements with certifications

„„ Online learning community „„ Provide a dynamic environment for learning, including forums, real-time chat and e-mail „„ Students can engage in group discussions and projects and interact with instructors „„ Instructors can post assignments, create daily topics, get instant feedback from students „„ Share resources and collaborate (800) 221-2763


Modular Hardware & Relevant Content . . . JobMaster® provides a superior blended learning solution for mechatronics and industrial maintenance training by combining industrial-grade components with engaging e-learning content. No other training system provides exposure to industry-standard practices like JobMaster®. The three hardware platforms comprising the JobMaster® system the modular JobMaster® Learning Station, the Mechanical Training Bench, and the 1600 Electromechanical Maintenance Cell - consist of industry standard components:

„„ All JobMaster® curriculum is skill-based, developed by industry experts from Fortune 1000 companies across a wide range of sectors.

„„ All components are the same as used in industry, from VFDs to solar-voltaic cells. „„ All wiring is terminated with crimped ferrules, like those found in industry. „„ The JobMaster® learning station includes frame-mounted industry-standard conduit, allowing students to learn effective wiring practices when wiring from panel to panel.

JOBMASTER® MOBILE LEARNING STATION The ultimate flexibility in skills training JobMaster® Learning Station

JobMaster® FlexPonent™ Panels The JobMaster® Two-Sided Mobile Learning Station is the hardware foundation of the JobMaster® Electrical Training Courses. This sturdy anodized aluminum learning station provides the mounting points for the Flexponent™ panels provided with the JobMaster® courses. Each side of the learning station can hold 15 standard Flexponent™ panels and accommodates two students. Students can quickly and easily mount and remove panels to configure their work area for each individual skill.

The versatile learning station facilitates classroom organization. Lockable swiveling casters and the 32” (81 cm) depth enables easy mobility through standard facility doorways. For additional panel storage a Portable Storage Unit is available, which holds up to 50 standard JobMaster® panels.

JOBMASTER® MECHANICAL TRAINING BENCH All-in-one solution for mechanical training The JobMaster® Mechanical Systems mobile training station presents the operating principles of power transmission using the same industrial-strength components used in factory environments. Guided by skill-based e-learning curriculum, students work with basic machines, machine statics and dynamics, shafts and keys, bearings, belt drives, chain drives, speed reducers, electric brakes and gear drives. Optional add-ons include vibration analysis and laser alignment. With the optional two-student add-on, the mechanical training bench can accommodate a total of four students.


Once you have equipped your program with the appropriate learning stations to accommodate your students, simply choose the courses that cover the skills and concepts needed in your training program. In addition to content, each JobMaster® series of courses includes all the necessary FlexPonent™ panels for use on the learning station, along with any additional tools and hardware used in the skill-based activities, such as meters and scopes. All Flexponent™ panels are constructed of non-conductive, high density polyethylene with industry-standard recessed and insulated terminal strip connections.

Mechanical Systems


Electromechanical Maintenance Cell

Industrial training tour-de-force. The JobMaster® 1600 Electromechanical Maintenance Cell is the ultimate capstone to any industrial maintenance or mechatronics program. The Maintenance Cell provides a relevant and robust simulation of the workplace and valid delivery of career skills. Students assemble, wire, maintain, and troubleshoot electromechanical systems just as if they were in the industrial environment. This results in the most effective authentic assessment of a trainees ability to succeed in the field of mechatronics or industrial maintenance. In a footprint of 60 square feet (5.6 square meters), the Maintenance Cell includes electrical power distribution and controls, wire and cable tray, wireways, conduit and equipment housings. Add-on sub-systems include conveyor drives and controls, industrial lighting, three-phase motor controls, pneumatics, DC motor drives and variable frequency drives. Using industry-standard work orders, standard operating procedures, schematic diagrams and manufacturers technical manuals as resources, students assemble and wire the Maintenance Cell. Once constructed, instructors can remotely insert over 130 documented faults in the system for trainees to develop troubleshooting skills in a relevant, engaging manner. Each task includes validated industry standards providing measurable criteria for assessing students’ performance.

“The 1600 is the ultimate test for students. Any students that can assemble and troubleshoot the JobMaster® 1600 cell as part of a team would be prime candidates for employment.” Plant Supervisor, BAE Systems

SKILL-BASED E-LEARNING CONTENT Core concepts are taught through self-paced e-learning curriculum. Each course teaches fundamental concepts and reinforces concepts by guiding students through skill-based activities using the JobMaster® hardware. All the necessary resources, including printable instructions and wiring diagrams are available online, ready for use at the JobMaster® Learning Station. Instructors are also provided comprehensive resources, including a detailed instructors’ guide. Teachers’ versions of schematics as well as tips and tricks are all one click away.

FOUNDATION SKILLS COURSES Success in today’s workforce requires more than just technical skills. Intelitek’s Foundation Skills courses provide job ready skills for lifelong success.. Add Foundation courses to your JobMaster® program to deliver essential skills for success in the workforce!

Foundations courses include:

Foundation Skills courses deliver vital skills for technical careers, including blue print reading, applications of hand and power tools and safety. Foundations courses also focus on 21st Century skills like critical thinking, problem solving and collaboration. By including 21st Century skills education, learners obtain communication skills, work ethics and career focus that lead to personal growth and success in the work environment.

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Employability Industrial Safety: Lockout/Tagout Mathematics for Technicians 1 & 2 Blueprint Reading Hand Tools & Power Tools Mechanical Fasteners Lubrication for Technicians Mechanical Measurement and „ Quality Control „„ and more!

The Foundation Skills Program makes an excellent add-on to industrial training programs.

„„ Foundations courses are 100% virtual on-line courses, accessible anywhere, anytime. „„ Some courses have optional hardware available

(800) 221-2763


Certified & Qualified . . . Funded and validated by industry, the JobMaster® Program is an industrial standard. JobMaster® Certification measures the students skills against specific tasks. JobMaster® certifications provide trainees validation of the specific skills they possess, enabling employers to evaluate new candidates and measure training programs. Maintenance Technician - Level I

Foundation Skills

Maintenance Technician - Level II

Maintenance Technician - Level III

Employability (3097)

Mechanical Systems

Introduction to Advanced Manufacturing (3096)

Laser Alignment (ME11)

Electrical Control Systems

Industrial Safety - Lockout/Tagout (LOTO)

Vibration Analysis (ME12)

Programmable Logic Control - MicroLogix (EA18)

Mathematics for Technicians I (BA01A)

Bearing Maintenance (ME13)

Electrical Control Systems

Programmable Logic Control -Allen-Bradley SLC 500 (EA20)

Mathematics for Technicians II (BA01B) Blueprint Reading (BA02)

Electric Circuit Protection & Monitoring (EA02)

Basic Maintenance Cell (ZA01)

Lubrication for Technicians (BA03)

Transformers (EA03)

Conveyor, Drive & Controls (ZA02)

Mechanical Fasteners (BA04)

Electric Motors (EA04)

Part Manipulation (ZA03)

Hand Tools (BA05)

Electromagnetic Motor Starters (EA07)

Industrial Lighting Circuits (ZA04)

Power Tools (BA06)

Relays, Timers, & Time Delay Relays (EA08)

Adjustable Frequency Drive (ZA05)

Precision Measurement

Pilot Devices (EA09)

DC Motor Drive (ZA06)

Precision Measurement & Quality Control (8014)

Solid-State Reduced Voltage Starters (EA11)

Mechanical Systems

Fault Insertion System (ZA07)

Variable Frequency Drives (VFDs) (EA12)

Basic Mechanical Drive Components (ME01)

Solid-State Drive & DC Motor Control (EA16)

Machine Statics & Dynamics (ME02)

Industrial Power Electronics

Machine Shafts & Keys (ME03)

Oscilloscope (EB01A)

Bearings (ME04)

Digital Multimeter (EB01B)

Belt Drives (ME05)

Hand Held Digital Oscilloscope (EB01C)

Chain Drives (ME06)

DC Power Supplies (EB02A)

Machine Shaft Couplings (ME07)

Single-Phase & Three-Phase Power Supplies (EB02B)

Machine Gear Drives (ME08)

Thyristor Electric Motor Drives (EB03)

Speed Reducers (ME09)

Electronic Timers (EB04)

Electric Brakes (ME10)

Stepper Motor Drives (EB05)

Basic Power Electricity

Servo Motor Drives (EB06)

Electrical Circuits (EA01A)


Resistors & Conductors (EA01B)

Pneumatics 2: Advanced (8069)

LCR Circuits (EA01C)

Pneumatics 3: Electro-Pneumatics (3039)

Motors & Generators (EA01D)


Electromechanical Maintenance Cell


Hydraulics 2: Electro-Hydraulics (3025)

Pneumatics 1: Fundamentals (8068)

Hydraulics Hydraulics 1: Fundamentals (8008)

In-Demand Green-Tech Skills!

Demand is high for skilled workers in the green technology sector! Industries involved in harnessing renewable energy sources, conserving natural resources & reducing pollution face a shortage of qualified entry-level candidates possessing critical skills. These “in-demand” jobs include: solar photovoltaic (PV) system installers, wind-turbine technicians and clean-energy production technicians. JobMaster® certification provides the critical skills needed to fill this demand!


. . . for In-demand and Emerging Careers

Level I Careers

Level II Careers

The Level 1 Maintenance Technician Certification serves as a strong foundation for a rewarding career in industrial maintenance. Upon completion, trainees possess the skills to qualify for entry level quality control, electrical & mechanical technician positions. Some sample careers include Position* Industrial Maintenance Assistant Assembly Technician/ Inspector Electric Equipment Assembler Quality Control / Test Technician Wind Turbine Service Technician Repair Technician Mechanical Maintenance Technician Tool Repair Technician Machinery Maintenance Technician Security Installation Technician Field Service Technician Solar Photovoltaic Installer Industrial Maintenance Mechanic

Key: i Increased Demand Green occupation e Enhanced Skills Green occupation n New & Emerging Green occupation Per the US Bureau of Labor Statistics

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Level III Careers

With more advanced fluid power & motor control skills, the Level II certification leads to rewarding positions in automation, instrumentation & control, & power plant operations. This Certification builds a foundation in motor installation, maintenance & control & delivers indemand skills in system automation with programmable logic controllers. Sample career choices include: Position Motor Control Assembler Installation Technician Telecommunications Line Installer Electric Motor Repair Technician Instrument & Controls Technician Heavy Equipment Technician Marine Electrician Process Control Technician Fluid Power Technician Motor Control Technician Hydroelectric Plant Technician Mechanical Engineering Technician Industrial Electrician Electrical Engineering Technician Telecommunications Technician


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The Level III Technician Certification is the highest level certification available in Industrial Maintenance program. Covering full plant installation, maintenance & troubleshooting, Level III Technicians possess all the skills necessary for full plant operations. Certified trainees can obtain high level positions leading to supervisory & management careers: Position Environmental Engineering Technician Industrial Engineering Technician Electromechanical Technician Millwright Electrical Lineworker Avionics Technician Maintenance Supervisor PLC Programmer / Controls Engineer Engineering Technician Solar Energy Installation Manager Power Plant Operator Instrument & Control Technician Industrial Safety & Health Engineer Industrial Engineer Industrial Production Manager Quality Control Systems Manager Wind Energy Operations Manager

(800) 221-2763

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JobMaster® Course List & Skills Standards Foundation Skills Employability


Industrial Safety - Lockout/Tagout

Lesson 1: Time-Management Techniques Lesson 2: Personal Qualities Desirable for the Workplace Lesson 3: Interpersonal Communication Lesson 4: Conflict Resolution Lesson 5: Teamwork Lesson 6: Problem-Solving Techniques & Decision-Making Skills Lesson 7: Proper Business & Personal Ethics Lesson 8: Business Etiquette & Ethical Computer Behavior Lesson 9: Employer-Employee Relationships Lesson 10: Proper Communication with Diverse Populations Lesson 11: Career Goals Lesson 12: Resumés & Cover Letters Lesson 13: Job Applications Lesson 14: Potential Employer Interviews Lesson 15: Interviewing Skills

Skill 1: Acquiring Lockout/Tagout Basics Skill 2: Attaching Lockout Devices Skill 3: Completing & Attaching Tagout Devices Skill 4: Conduct Energy Control Analysis Skill 5: Performing a Lockout/Tagout Skill 6: Perform Lockout/Tagout Release

Introduction to Advanced Manufacturing

Skill 1: Working with Arithmetic & Algebra Skill 2: Working with Whole Numbers Skill 3: Working with Fractions Skill 4: Working with Decimals Skill 5: Working with Percentages Skill 6: Working with Ratios & Proportions Skill 7: Working with Systems of Measurement Skill 8: Working with Geometry Skill 9: Working with Trigonometry


Understanding the Definition of Manufacturing Understanding the History of Manufacturing Considering Career Choices Conducting a Job Search Preparing a Resume Writing a Cover Letter Planning & Staffing a Manufacturing Company Understanding Product & Strategy Selection Identifying Manufacturing Processes Understanding CAD, CAE, CAM, CNC Understanding Statistical Process Control Understanding Forecasting Software & Computer Simulation Modeling Understanding the Role of Automation in Manufacturing Understanding the Role of Flexible Manufacturing Systems Understanding Computer Integrated Manufacturing Understanding the Role of Quality Control


Introduction to Lean Manufacturing


Lesson 1: Definition Lean Manufacturing Lesson 2: Understanding Waste Lesson 3: Designing the Manufacturing Workplace Lesson 4: Designing Lean Production Processes (1) – Concept Lesson 5: Designing Lean Production Processes (2) – Method Lesson 6: Designing a Lean Production Scheduling System Lesson 7: Problem Solving Tools

Mathematics for Technicians I

Mathematics for Technicians II



Skill 1: Working with Conversion Formulas Skill 2: Applying Mechanical Principles Skill 3: Calculating Drive Ratios Skill 4: Calculating Speed Reducer Service Factor Skill 5: Using Ohm’s Law in Series & Parallel Circuits Skill 6: Converting Binary, Binary Coded Decimal, Hexadecimal & Decimal Numbers Skill 7: Calculating Pressure, Force, Head & Flow Skill 8: Calculating Shim Requirements Skill 9: Selecting Pipe Size

Precision Measuring Precision Measurement & Quality Control Identify precision & semi-precision measuring tools Demonstrate proper care of precision measuring tools Identify calibration requirements of various precision instruments Identify the Imperial & Metric systems of measurement Calculate area & volume Use fractions, decimals, & rounding Convert measurements Use scaled measurement tools Measure with direct measuring instruments Measure with comparison measuring instruments Measure with steel rules Measure with line gradated rule Measure with protractor Demonstrate parallax Measure using calipers Measure using vernier Measure outside dimensions Measure inside dimensions Measuring depth dimensions Measure a step dimension Measure with micrometers Use height gauges & dial indicators Align work pieces using height gage & dial indicators Measure with dial indicator Measure a close tolerance dimension


Blueprint Reading


Skill 1: Identifying Lines & their Functions Skill 2: Single, Multiple & Auxiliary View Skill 3: Reading & Locating Blueprint Dimensions Skill 4: Determining Tolerances Skill 5: Identifying Thread Dimensions Skill 6: Identifying Tapers & Machine Surfaces Skill 7: Cutting Plane & Sections Skill 8: Geometric Dimensioning, Wear Limits & Assembly Drawings Skill 9: Identifying Welding Symbols Skill 10: Reading Plot Plans Skill 11: Reading Footing, Foundation & Floor Plans Skill 12: Reading Reinforced Concrete & Structural Steel Prints

Lubrication for Technicians


Skill 1: Lubrication Fundamentals Skill 2: Lubrication Terms Skill 3: Identifying Lubricating Oils Skill 4: Identifying General Purpose Greases Skill 5: Identifying Special Purpose Greases Skill 6: Applying Lubricating Oils Skill 7: Applying Lubricating Greases Skill 8: Bearing Lubrication Skill 9: Setting Up a Lubrication Schedule Skill 10: Selecting Synthetic Lubricants Skill 11: Grease Guns Skill 12: Bearing Packers Skill 13: Grease Lubricators Skill 14: Drop Feed Oilers Skill 15: Electric Chain Oilers

Mechanical Fasteners

Hand Tools

Power Tools



Skill 1: Practicing Shop Safety Skill 2: Reading Rulers & Tape Measures Skill 3: Using Calipers & Feeler Gauges Skill 4: Working with Squares & Levels Skill 5: Cutting with Knives Skill 6: Scribing & Punching Materials Skill 7: Using Work Holding Devices Skill 8: Using Hammers Skill 9: Using Chisels Skill 10: Cutting with Saws Skill 11: Working with Pliers Skill 12: Identifying & Using Cutters Skill 13: Filing & Deburring with Hand Tools Skill 14: Working with Drivers Skill 15: Identifying & Using Hex Keys Skill 16: Identifying & Using Wrenches Skill 17: Identifying & Using Socket & Torque Wrenches


Skill 1: Practicing Shop Safety Skill 2: Operating a Power Drill Skill 3: Setting Up & Operating a Drill Press Skill 4: Operating a Rotary Tool Skill 5: Setting Up & Operating a Jigsaw Skill 6: Setting Up & Operating a Reciprocating Saw Skill 7: Setting Up & Operating a Circular Saw Skill 8: Adjusting & Operating a Table Saw Skill 9: Setting Up & Operating a Bandsaw Skill 10: Setting Up & Operating a Sander Skill 11: Adjusting & Operating a Bench Grinder Skill 12: Adjusting & Operating an Angle Grinder

Skill 1: Identifying Screws & Bolts Skill 2: Selecting Threaded Fasteners Skill 3: Applying Thread Standards Skill 4: Creating & Repairing Threads Skill 5: Identifying Nuts Skill 6: Installing Fasteners with a Torque Wrench Skill 7: Removing Fasteners with a Bolt Extractor Skill 8: Identifying Washers Skill 9: Installing Rivets Skill 10: Selecting Adhesives Skill 11: Attaching Hook & Loop Fasteners Skill 12: Connecting Cable Ties

Basic Power Electricity 8014

Measure with fixed gages Identify & use sine bar & sine plate Measure small dimensions with gage blocks Find the center of a hole with a plug gauge Use transfer measurement tools Transfer measurement using outside caliper Use an inside caliper Use statistical analysis Apply concepts of statistics, mean, median, standard deviation & sample size to a population Calculate the mean Calculate the extreme spread Use statistical process control Demonstrate understanding of normal distribution Measure, interpret & record SPC data Identify nominal dimensions Identify tolerances Perform an inspection Complete an inspection report Identify & use in-process inspection

Electrical Circuits


Skill 1: Performing Lockout/Tagout Skill 2: Connecting a Basic Circuit Skill 3: Identifying Switches Skill 4: Connecting a Momentary Switch Skill 5: Connecting a Toggle Switch Skill 6: Identifying Sources of Electricity Skill 7: Measuring DC Voltage Skill 8: Constructing a Series Circuit Skill 9: Constructing a Parallel Circuit Skill 10: Applying DC Voltage Principles Skill 11: Testing an Electrolytic Cell Skill 12: Testing a Battery Skill 13: Testing a Thermocouple Skill 14: Testing a Solar Cell

Resistors & Conductors Skill 1: Measuring Resistance Skill 2: Measuring Resistance in Series Skill 3: Measuring Resistance in Parallel Circuits Skill 4: Drawing & Reading Resistor Symbols Skill 5: Testing an Adjustable Resistor Skill 6: Measuring Wire Size Skill 7: Applying Resistance & Wire Size Skill 8: Calculating Wire Size Skill 9: Determining Losses in a Conductor

LCR Circuits


Skill 1: Discharging a Capacitor Skill 2 : Testing a Capacitor Skill 3: Determining Capacitance Skill 4: Applying Capacitance Principles Skill 5: Applying Magnetic Principles Skill 6: Inducing a Magnetic Field Skill 7: Assembling an Electromagnet Skill 8: Applying Electromagnetic Principles Skill 9: Inducing Voltage Skill 10: Inducing DC Voltage Skill 11: Assembling & Operating Transformers Skill 12: Applying Inductance Principles Skill 13: Operating Electromagnets Skill 14: Drawing Inductance Symbols


Motors & Generators


Skill 1: Operating a PMDC Motor Skill 2: Operating a DC Generator Skill 3: Operating an AC Generator Skill 4: Operating a Series Motor Skill 5: Demonstrating Principles of Reactance & Impedance Skill 6: Applying Phase Relationship Principles Skill 7: Illustrating Three-Phase Power Skill 8: Measuring AC Voltage

Electrical Control Systems Electric Circuit Protection & Monitoring


Skill 1 Drawing & Reading Circuit Protection Symbols Skill 2 Sizing Fuses Skill 3 Installing Fuses Skill 4 Testing & Replacing Fuses Skill 5 Performing Preventive Maintenance & Troubleshooting Fuse Blocks Skill 6 Sizing Circuit Breakers Skill 7 Testing & Resetting a Circuit Breaker Skill 8 Sizing & Installing an Overload Heater Skill 9 Adjusting & Testing the Overload Relay Skill 10 Installing & Setting Up a Three-Phase Monitor



Skill 1 Apply Transformer Principles Skill 2 Draw & Read Transformer Symbols Skill 3 Install a Control Transformer Skill 4 Install a Station Transformer Skill 5 Troubleshoot Transformer Skill 6 Connect Transformer as an Auto Transformer for Buck & Boost Operation Skill 7 Connect Transformers in Delta & Wye Skill 8 Inspect & Service a Transformer Skill 9 Size a Transformer

Electric Motors


Skill 1: Connecting & Operating a Split-Phase Motor Skill 2: Connecting & Operating a Capacitor-Start Motor Skill 3: Connecting & Operating a Shaded-Pole Motor Skill 4: Connecting & Operating a DC Motor Skill 5: Connecting & Operating a Three-Phase Motor Skill 6: Performing Visual Inspections Skill 7: Lubricating a Motor Skill 8: Performing DMM & Motor Megger Tests Skill 9: Troubleshooting a Split-Phase Motor Skill 10: Troubleshooting a Capacitor-Start Motor Skill 11: Troubleshooting a Shaded-Pole Motor Skill 12: Troubleshooting a DC Motor Skill 13: Troubleshooting a Three-Phase Motor Skill 14: Testing Motors with Adjustable Loads

Electromagnetic Motor Starters


Skill 1: Connecting a Control Relay Seal-In Circuit Skill 2: Connecting, Adjusting & Operating a Single Magnetic Starter Skill 3: Testing & Resetting Overload Protection Skill 4: Connecting, Adjusting, & Operating a Three-phase Reversing Starter Skill 5: Connecting & Operating a Magnetic Starter for Jogging Skill 6: Troubleshooting a Three-phase Motor Control Circuit Skill 7: Troubleshooting a Reversing Three-phase Motor Control Circuit Skill 8: Performing Preventive Maintenance on Magnetic Starters

Relays, Timers, & Time Delay Relays


Solid-State Drive & DC Motor Control

Skill 1: Connecting, Programming, & Operating Analog On-Delay & Off-Delay Relays Skill 2: Using Analog Relays & Motors Skill 3: Connecting, Programming, & Operating Digital Interval, Repeat Cycle, & 1-Shot Relays Skill 4: Using Digital Relays & Motors Skill 5: Connecting & Operating Electric Timers Skill 6: Using Electric Timers & Motors Skill 7: Troubleshooting Relays Skill 8: Performing Preventative Maintenance on Relays

Skill 1: Demonstrate DC Drive Principles Skill 2: Connect, Set Up, & Operate DC Drive Skill 3: Connect & Operate Braking Controls Skill 4: Test DC Drive Skill 5: Troubleshoot DC Drive Skill 6: Perform Preventive Maintenance Skill 7: Connect & Operate SCR Speed Control Skill 8: Connect & Operate TRIAC Speed Control

Pilot Devices

Skill 1: Draw & Read PLC Ladder Diagrams Skill 2: Convert Binary, Binary Coated Decimal, & Decimal Numbers Skill 3: Apply Boolean Logic Skill 4: Connect PLC Modules Skill 5: Connect Input Devices Skill 6: Connect Output Devices Skill 7: Program a PLC Skill 8: Program a PLC with a Personal Computer Skill 9: Debug & Troubleshoot a PLC Skill 10: Perform Preventive Maintenance on a PLC


Skill 1: Connecting & Operating a Photoelectric Detector Skill 2: Connecting & Operating a Photoelectric Sensor with Fiber Optics Skill 3: Connecting & Operating a Capacitive Proximity Switch Skill 4: Connecting & Operating an Inductive Proximity Switch Skill 5: Connecting & Operating a Limit Switch Skill 6: Connecting & Operating a Pressure Switch Skill 7: Connecting & Operating Liquid Level Switches Skill 8: Connecting & Operating a Magnetic Reed Switch

Solid-State Reduced Voltage Starters


Skill 1: Apply Solid State Starter Principles Skill 2: Connect & Operate a Solid State Starter Skill 3: Adjust a Solid State Starter Skill 4: Test Solid State Starters Skill 5: Troubleshoot Solid State Starter

Variable Frequency Drives (VFDs)


Skill 1: Applying VFD Principles Skill 2: Connecting & Operating a Variable Frequency Drive Skill 3: Adjusting VFD Operating Parameters Skill 4: Testing VFD Resistance Skill 5: Reading Voltage & Current on the VFD Skill 6: Troubleshooting the VFD

Programmable Logic Control (MicroLogix)

Programmable Logic Control (Allen-Bradley SLC 500)




Skill 1: Draw & Read PLC Ladder Diagram Skill 2: Convert Binary, Binary Coded Decimal, & Decimal Numbers Skill 3: Apply Boolean Logic Skill 4: Connect PLC Modules Skill 5: Connect Power, Input, & Output Circuits Skill 6: Assign Addresses & Parameters in a Ladder Logic Program Skill 7: Create a Test Program Skill 8: Create an Operating Program Skill 9: Debug & Troubleshoot a PLC Skill 10: Perform Preventive Maintenance on a PLC

Industrial Power Electronics Oscilloscope


Skill 1: Oscilloscope Screen Skill 2: Oscilloscope Controls Skill 3: Setting Up & Operating the Oscilloscope Skill 4: Adjusting Probe Compensation Skill 5: Performing AC Voltage Calculations Skill 6: Measuring AC Voltage & Frequency Skill 7: Performing DC Voltage Calculations Skill 8: Measuring DC Voltage

Digital Multimeter Skill 1: Digital Multimeter Safety Skill 2: DMM Controls & Features Skill 3: Locating & Reading DMM Icons & Symbols Skill 4: Reading the Liquid Crystal Display Skill 5: Setting Up the DMM for Reading AC Voltage Skill 6: Measuring AC Voltage Skill 7: Calculating & Converting AC Voltage Skill 8: Measuring DC Voltage Skill 9: Measuring Resistance Skill 10: Discharging a Capacitor Skill 11 Measuring Capacitance Skill 12: Testing Capacitors Skill 13: Measuring Current Skill 14: Measuring DC Millivolts Skill 15: Performing Continuity Tests Skill 16: Testing Grounds & Bonds Skill 17: Measuring Frequency

Hand Held Digital Oscilloscope


Skill 1: Reading the Oscilloscope Screen Skill 2: Identifying & Using Oscilloscope Controls Skill 3: Setting Up & Operating the Oscilloscope Skill 4: Performing AC Voltage Calculations Skill 5: Measuring AC Voltage & Frequency Skill 6: Performing DC Voltage Calculations Skill 7: Measuring DC Voltage Skill 8: Storing & Recalling Screen Displays


DC Power Supplies Skill 1: Power Supply Block Diagram Skill 2: Schematic Symbols Skill 3: Testing a Transformer Skill 4: Locating Diodes & Symbols Skill 5: Testing a Diode Skill 6: Drawing a Half-Wave Rectifier Skill 7: Connecting & Operating a Half-Wave DC Power Supply Skill 8: Confirming Full-Wave DC Power Supply Operation Skill 9: Connecting & Operating a Full-Wave DC Power Supply Skill 10: Confirming Single-Phase Bridge Rectifier Operation Skill 11: Connecting & Operating Single-Phase Bridge Rectifier


Single-phase and Three-phase Power Supplies EB02B

Electronic Timers

Skill 1: Drawing Filter Schematic Diagrams Skill 2: Connecting and Operating a Power Supply Skill 3: Drawing Zener Schematic Symbols Skill 4: Connecting & Operating a Zener Diode Voltage Regulator Skill 5: Locating an IC Voltage Regulator Skill 6: Connecting & Operating a DC Power Supply with an IC Voltage Regulator Skill 7: Connecting & Operating a Bleeder Resistor Skill 8: Connecting & Operating a Voltage Divider Skill 9: Troubleshooting a DC Power Supply Skill 10: Confirming Three-Phase Bridge Rectifier Operation Skill 11: Testing a Three-Phase Bridge Rectifier Skill 12: Connecting & Operating a Three-Phase Bridge Rectifier Skill 13: Troubleshooting a Three-Phase Bridge Rectifier

Skill 1: Locating Timer Pins Skill 2: Verifying a Monostable Timer Circuit Skill 3: Connecting and Operating a 555 Timer in Monostable Mode Skill 4: Verifying an Astable Timer Circuit Skill 5: Connecting and Operating a 555 Timer in Astable Mode Skill 6: Verifying a Pulse Train Circuit Skill 7: Connecting and Operating an Electronic Pulse Train

Thyristor Electric Motor Drives Skill 1: Locating an SCR & Drawing the Schematic Symbol Skill 2: Testing an SCR Skill 3: Connecting & Operating an SCR Skill 4: Confirming Full-Wave SCR Control Skill 5: Connecting & Operating a Full-Wave SCR DC Motor Drive Skill 6: Troubleshooting a Full-Wave SCR DC Motor Drive Skill 7: Locating the TRIAC & drawing the TRIAC Symbol Skill 8: Testing a TRIAC Skill 9: Demonstrating TRIAC Control Principles Skill 10: Locating a DIAC & Drawing the Schematic Symbol Skill 11: Connecting & Operating a DIAC-Controlled TRIAC AC Motor Drive Skill 12: Connecting & Operating a Schmitt TriggerControlled TRIAC AC Motor Drive Skill 13: Troubleshooting a TRIAC Motor Drive Skill 14: Demonstrating PWM Principles Skill 15: Connecting & Operating a PWM DC Motor Drive



Stepper Motor Drives


Skill 1: Identifying Detent Torque Skill 2: Confirming Stepper Motor Step Angle Skill 3: Demonstrating Stepper Motor Principles Skill 4: Confirming Stator Winding Connections Skill 5: Demonstrating Unipolar Stepper Motor Drive Skill 6: Installing, Connecting and Monitoring a Stepper Motor Drive Skill 7: Testing and Troubleshooting a Basic Stepper Motor and Drive

Servo Motor Drives


Skill 1: Demonstrating Closed-Loop Servo Motor Control Principles Skill 2: Demonstrating Closed-Loop Servo Motor Principles Skill 3: Demonstrating Servo System Feedback Device Principles Skill 4: Demonstrating Analog and Digital Servo Motor Drive Principles Skill 5: Installing, Connecting and Monitoring a Basic Servo Motor Drive Skill 6: Testing and Troubleshooting a Basic Servo Motor Drive

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JobMaster速 Course List & Skills Standards, continued Pneumatics

Mechanical Systems Basic Mechanical Drive Components


Perform lockout/tagout Identify mechanical drive components Calculate torque, friction, power & horsepower Install adjust & align colinear shaft system

Machine Statics & Dynamics


Identify stress, strain & combined stresses Identify material fatigue & fatigue stress points Identify fatigue failure & failure modes

Machine Shafts & Keys

Machine Speed Reducers

Electric Brakes ME03

Laser Alignment


Vibration Analysis


Belt Drives


Select belt drives Install & align single belt drive Tension single belt drive Measure belt drive speed Install, adjust & align adjustable-speed sheaves Install & adjust variable-speed drive Install & align positive drive timing belt Perform preventive maintenance Troubleshoot belt drive system Install, connect & operate DC motor

Chain Drives Break chain Install & align chain drive Measure & adjust chain slack Perform preventive maintenance Lubricate chain Troubleshoot chain drive

Machine Shaft Couplings


Identify types of couplings Identify shaft misalignment Identify & measure soft foot Calculate shim requirements Measure vertical & parallel misalignment Install & align rigid coupling Install & align two-piece chain coupling Install & align universal joint

Machine Gear Drives Install & align spur gear drive Measure gear backlash Install gear train & idler Install bevel gear & right-angle drive Install worm gear & right-angle drive Install & operate right-angle helical gear drive Install & align a perpendicular offset shaft system Calculate drive ratios Perform preventive maintenance Troubleshoot gear drives




Laser align sheaves Laser align pulleys Laser align v-belt drives Laser align couplings Checking for soft foot using a laser tool Fill out an alignment report


Identify machine vibration sources Measure shaft speed with vibration tachometer Measure vibration effects of speed Measure vibration from rotational imbalance Measure vibration from misalignment Use vibration severity charts & vibration tolerances Read & complete maintenance logs Identify displacement, velocity, & acceleration of vibration Identify RMS Trace vibration to source Isolate vibration Troubleshoot vibrating equipment Troubleshoot misalignment vibration Troubleshoot bent shafts Troubleshoot resonance & sympathetic vibrations Fix imbalance

Bearing Maintenance



Identify electric brakes Identify fail-safe operation

Measure shaft run-out Measure & fabricate keys from keystock Measure with a feeler gauge, spirit level & dial indicator Identify shafts, keys & splines Identify shaft tolerances Identify causes of shaft failure Perform shaft failure analysis Select bearings using bearing number system Determine housing & shaft tolerances Install pillow blocks Measure bearing clearance Identify plain, anti-friction & self aligning bearings Identify radial ball bearings & thrust ball bearings Identify angular contact bearings Identify parts of a ball bearing Identify parts & configurations of a roller bearings Identify bearing seals & housings Perform preventive maintenance on mounted bearings Perform bearing failure analysis Troubleshoot bearings


Identify types of speed reducers Install & operate right-angle speed reducer Install & operate in-line speed reducer Perform preventive maintenance Lubricate speed reducers Troubleshoot speed reducers


Select bearings using bearing number system Identify bearing standards Determine housing & shaft tolerances Identify needle bearings Identify plain, anti-friction & self aligning bearings Identify radial ball bearings & thrust ball bearings Identify angular contact bearings Identify parts of a ball bearing Identify roller bearing configurations Identify parts of a roller bearing Identify bearing seals & housings Install pillow blocks Dismount bearings Press fit bearings Measure bearing clearance Operate an arbor press Install & remove bushings Operate bearing pullers Operate a cone heater Operate a grease gun Pack bearings Analyze bearing failure Perform preventive maintenance on mounted bearings Lubricate bearings Perform bearing failure analysis Troubleshoot bearings

Pneumatics 1: Fundamentals


Perform lockout/tagout on pneumatic equipment Adjust filter / regulator / lubricator (FRL) units Identify the path of flow through a pneumatic circuit Demonstrate the principles of pressure & flow Draw & read pneumatic symbols (ANSI & ISO) Layout pneumatic plumbing system Identify air compressor components Adjust an air compressor pressure switch Measure air pressure & flow Connect & operate air compressor Connect shop air supply Test compressor safety valve Connect & operate single-acting cylinder Adjust cylinder speed Connect & operate double-acting cylinder Test cylinders Verify cylinder installation & alignment Adjust exhaust flow rate Identify causes of pressure & flow rate drops in pneumatic circuit Connect, test & operate flow-, pressure-, directional- & pilot-operated-control valves Connect & operate a 3/2 Valve Control a piston with PBs Implement a 5/2 valve in a pneumatic circuit Implement a 5/2 valve into a pneumatic circuit Measure pressure with U-tube manometers Demonstrate the effect of changes in air temperature on pressure Implement a 3/2 air-spring valve in a pneumatic circuit Connect & operate a control circuit Connect & operate roller-operated, spring-returned valve Connect & operate a semi-automatic system Perform preventive maintenance Locate leaks in a pneumatic system Assess air filtration needs Perform bubble testing leak detection Interpret fluid power data book charts Form a troubleshooting strategy using a troubleshooting map

Pneumatics 2: Advanced


Demonstrate logic constants & logic variables Implement logic control in a pneumatic circuit Connect & operate semi-automatic & automatic control systems Implement a toggle valve into a pneumatic circuit Connect & operate fully automatic control systems Synchronize cylinders Connect & operate sequential control with a timed delay Connect & operate time delay circuit Draw a timing diagram Using a single pilot valve to prevent opposing control signals

Pneumatics 3: Electro-Pneumatics


Identify electric control vs pneumatic control Understand ladder diagrams Connect & operate a basic electrical circuit Connect & operate cylinder position sensing device Draw & read electro-pneumatic control diagrams Connect & operate electric solenoid control valve Connect wire electric control circuit Connect & operate 5/2 solenoid-solenoid valve Connect & operate magnetic switches Connect & operate a fully-automatic electro-pneumatic circuit Activating a control system from two locations Connect & operate a sequential control system Implement a relay in a basic electrical circuit Latch & unlatch a relay Connect & operate a fully automatic circuit Connect & operate proximity switch Implement a timer into an electro-pneumatic control system Connect & operate a counter in a pneumatic feeder system

Hydraulics Hydraulics 1: Fundamentals


Understand OSHA regulations for hydraulic equipment Release residual pressure in a hydraulic system Understand the principles of pressure & flow Read fluid power diagrams Draw & read hydraulic symbols (ANSI & ISO) Use a pressure gauge to measure pressure & flow Purge air from the hydraulic system Lubricate & adjust hydraulic pistons Measure power in a hydraulic system Read a flow meter Connect & operate hydraulic power unit Connect & operate hydraulic motor Connect, operate & test hydraulic cylinders Determine & adjust cylinder speed Synchronize cylinders Identify causes of pressure & flow rate drops in a circuit Inspect a flow control valve Connect & operate bi- & uni-directional flow control valves Connect hydraulic hoses using QD connector Connect & operate a 4/3 closed-center valve Measure pressure drops across a component Demonstrate power transformation using a double-acting cylinder Connect & operate a double-acting cylinder Adjust relief valve set point pressure Control piston location Perform preventive maintenance on a hydraulic power system Locate leaks in a hydraulic power system Assess hydraulic fluid filtration needs Troubleshoot hydraulic system

Hydraulics 2: Electro-Hydraulics


Demonstrate electrical control versus manual & hydraulic control Read & understand ladder diagrams Connect & operate a solenoid valve Connect & operate a basic electro-hydraulic circuit Connect & operate a sequential operation Understand efficient versus inefficient systems Integrate a relay into an electro-hydraulic circuit Connect & operate a circuit with latched relays Implement a timer into an electro-hydraulic circuit Connect & operate a circuit based on sequential operation

Electromechanical Maintenance Cell Basic Maintenance Cell


CELL FRAME Work Order 1: Assemble the Base Work Order 2: Assemble & Install the Conveyor Mount Support Assembly Work Order 3: Install Pull Box, End & Feeder Tube Supports Work Order 4: Install Crossbars & Top Members Work Order 5: Inspect & Align Completed Frame ENCLOSURES Work Order 6: Install Load Center Work Order 7: Install Cable Trays Work Order 8: Install Wireway Work Order 9: Install Pull Boxes Work Order 10: Install Equipment Enclosures Work Order 11: Install Safety Disconnects Work Order 12: Install Fuse Box & Station Transformer CONDUIT & FITTINGS Work Order 13: Cut & Ream Conduit Work Order 14: Install Flexible Metal Conduit Work Order 15: Install EMT Conduit LOW VOLTAGE & CIRCUIT PROTECTION Work Order 16: Wire & Connect Main Power Cord Work Order 17: Install & Connect Circuit Breakers Work Order 18: Install Equipment Grounds Work Order 19: Wire Fuse Box Work Order 20: Wire Station Transformer Work Order 21: Perform Megohmmeter Tests

Conveyor, Drive & Controls


CONVEYOR Work Order 1: Install Conveyor Work Order 2: Install Conveyor Drive Components Work Order 3: Install & Align Conveyor Drive Chain Work Order 4: Install Conveyor Drive Safety Guard CONVEYOR CONTROLS Work Order 5: Install & Connect Conveyor Drive Controls Work Order 6: Install Emergency Stop Circuits Work Order 7: Perform Circuit Continuity Tests Work Order 8: Megger Test Conveyor Drive Work Order 9: Test & Troubleshoot Conveyor Drive PREDICTIVE/PREVENTIVE MAINTENANCE Work Order 10: Lubricate Conveyor Drive Work Order 11: Verify Conveyor Alignment Work Order 12: Verify Drive Chain Alignment Work Order 13: Obtain Vibration Profiles

Part Manipulation

PAINT, BAKE & COOL TUNNEL Work Order 4: Install Paint Bake Heaters Work Order 5: Install Tunnel Work Order 6: Install Paint Nozzles Work Order 7: Install Cool Down Blower Work Order 8: Install Part Count Sensor Work Order 9: Install Paint Tunnel Status Indicators

INDUSTRIAL POWER CIRCUITS Work Order 9: Install Wiring Devices Work Order 10: Rough-In Wiring Device Circuits Work Order 11: Megger Test Power Circuits Work Order 12: Wire Lighting & Lighting Control Work Order 13: Install & Test GFCI Circuit Work Order 14: Troubleshoot Lighting & Power System

PROGRAMMABLE LOGIC CONTROLLER (PLC) Work Order 10: Install PLC Work Order 11: Rough-in PLC power Work Order 12: Program PLC Work Order 13: Connect PLC input Sensor Circuits Work Order 14: Connect PLC Output Device Circuits Work Order 15: Troubleshoot Paint, Bake & Cool System

Variable Frequency Drive

Industrial Lighting Circuits


PART MANIPULATION Work Order 1: Install Part Stacker & Feeder Tray Work Order 2: Install Part Kicker Work Order 3: Install Stacker Part Sensor


INDUSTRIAL LIGHTING CIRCUITS Work Order 1: Install Fluorescent Task Lighting Work Order 2: Install Low Bay Lighting Work Order 3: Install High Bay Lighting Work Order 4: Install Flood Lighting Work Order 5: Install Hazardous Location Lighting Work Order 6: Install Emergency Lighting Work Order 7: Rough-In Lighting Circuits Work Order 8: Megger Test Lighting Circuits


Work Order 1: Install Drive Work Order 2: Rough-in Drive Wiring Work Order 3: Megger Test VFD Wires Work Order 4: Program & Test Drive

DC Motor & Drive


Work Order 1: Measure & Remove AC Motor Work Order 2: Install DC motor Work Order 3: Install DC drive Work Order 4: Rough-in DC Drive Wiring Work Order 5: Set Up & Test DC Drive (Manual - jumpers) Work Order 6: Finalize Drive Wiring & Installation Work Order 7: Troubleshoot DC Drive System

Fault Insertion System


Work Order 1: Install fault insertion sub panel Work Order 2: Rough-in power circuit Work Order 3: Rough-in fault insertion wiring Work Order 4: Install & configure triggered faults Work Order 5: Test triggered fault system

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Sustainable resources we provide: „„ Lab installation and configuration „„ Annual professional development classes „„ Real-time toll-free phone support „„ A network of trained local distributors „„ Customized training

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At intelitek, we are committed to the long-term success of every program we implement. With over $275 million of equipment installed in Industry and Education, we know what it takes to make our customers successful. We provide installation service, comprehensive on-site training and an ongoing Professional Development program to ensure the sustainability of your program.

To keep you program running smoothly, intelitek is ready to assist you through free phone support, online support, and our network of factory trained distributors.

intelitek’s Professional Development program for instructors and trainers is the key to unlocking the full potential of your program. Through annual training at intelitek’s facilities, instructors can be as effective as possible in the classroom in implementing JobMaster® curriculum, courseware and the LearnMate® LMS. By demonstrating features step-by-step, outlining best practices using LearnMate® in the classroom and tailoring the training to meet your specific needs, our professional development program can produce amazing results. Customized and individualized training is also available tailored to your programs specific needs.

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