Industrial Chargers, Fleet Diagnostics, and Preventive Maintenance

This course delivers advanced technical training in stationary and fast-charging infrastructure, controller area network diagnostics, and fleet-wide asset management for electric material handling equipment. Technicians examine high-output switch-mode chargers, opportunity charging protocols, and AC distribution requirements, evaluating power factor and conversion efficiency through mathematical relationships such as $P = V \times I \times \text{PF}$. Instruction emphasizes diagnostic software navigation, digital multimeter isolation procedures, data logging, and telemetry interpretation to identify intermittent electrical faults, communication bus failures, and mechanical wear. Students learn to implement standardized preventive maintenance programs, execute thorough safety audits, and maintain compliance with workplace safety standards. By bridging individual vehicle troubleshooting with broad fleet reliability principles, this course enables technicians to minimize operational downtime, extend equipment service life, and ensure peak performance across diverse industrial work environments.

InstructorJacob Calhoun

Prerequisites

FLT 105 FLT 110

Course outline

Lectures, virtual labs, and graded assignments — completed in your browser.

01Lesson 1: Industrial Charging Topologies and AC Service Infrastructurelecture

02Lesson 2: Branch Circuit Protection, Power Quality, and Charging Efficiencylecture

03Lesson 3: Charger Programming, Charge Profiles, and Thermal Compensationlecture

04Hands-on Lab: Industrial Charger Output Verification and Calibrationlab

05Lesson 5: Onboard Diagnostics, Service Handhelds, and Trouble Codeslecture

06Lesson 6: Controller Area Network (CAN-Bus) Architecture and Physical Layer Testinglecture

07Lesson 7: Sensor Calibration, Interlock Logic, and Signal Tracinglecture

08Hands-on Lab: CAN-Bus Fault Isolation and Oscilloscope Signal Analysislab

09Lesson 9: Fleet Telematics, Wireless Data Logging, and Fault Historylecture

10Lesson 10: Preventive Maintenance Scheduling, Fluid Analysis, and Wear Limitslecture

11Hands-on Lab: Comprehensive Periodic Inspection and Wear Assessmentlab

12Lesson 12: Mast Assembly, Lifting Chains, and Chassis Structural Integritylecture

13Lesson 13: Root Cause Failure Analysis and Fleet Reliability Strategieslecture

14Capstone Service Project: End-to-End Fleet Diagnostics and Maintenance Auditassignment

Syllabus

["Week 1: Lesson 1: Industrial Charging Topologies and AC Service Infrastructure", "Week 2: Lesson 2: Branch Circuit Protection, Power Quality, and Charging Efficiency", "Week 3: Lesson 3: Charger Programming, Charge Profiles, and Thermal Compensation", "Week 4: Hands-on Lab: Industrial Charger Output Verification and Calibration", "Week 5: Lesson 5: Onboard Diagnostics, Service Handhelds, and Trouble Codes", "Week 6: Lesson 6: Controller Area Network (CAN-Bus) Architecture and Physical Layer Testing", "Week 7: Lesson 7: Sensor Calibration, Interlock Logic, and Signal Tracing", "Week 8: Hands-on Lab: CAN-Bus Fault Isolation and Oscilloscope Signal Analysis", "Week 9: Lesson 9: Fleet Telematics, Wireless Data Logging, and Fault History", "Week 10: Lesson 10: Preventive Maintenance Scheduling, Fluid Analysis, and Wear Limits", "Week 11: Hands-on Lab: Comprehensive Periodic Inspection and Wear Assessment", "Week 12: Lesson 12: Mast Assembly, Lifting Chains, and Chassis Structural Integrity", "Week 13: Lesson 13: Root Cause Failure Analysis and Fleet Reliability Strategies", "Week 14: Capstone Service Project: End-to-End Fleet Diagnostics and Maintenance Audit"]