TTC Skilled Trades Training - UAW-Chrysler.com

SKILLED TRADES: 

APPLIED INDUSTRIAL 

TECHNOLOGY 

1

Applied Industrial Technology: 

CATIA V5 FUNDAMENTALS (CAT 101) 

Course Description 

The participant will understand the fundamentals of the CATIA V5 Computer Aided Design 

software and understand the basic philosophy of the software, as well as the Sketcher and 

Part Design Workbenches. 

Learning Outcome 

Upon completion of this course, participants should be able to: 

1. create new part files in the CATIA V5 software; 

2. understand the basic philosophy of the CATIA V5 software; 

3. create, constrain, and edit 2D sketches; 

4. understand the various CATIA V5 solid-modeling commands; and 

5. obtain necessary part information. 

2 hours 

Course Objective 

To provide the participant with the skills necessary to create, constrain and edit a solid model 

using the CATIA V5 software. 

Major Topics Covered 

• Creating Sketches 

• Pad & Shaft Features 

• Pocket & Groove Features 

• Dress-Up Features 

• Feature Duplication 

• Rib & Slot Features 

• Constraining Sketches 

• Feature Techniques 

• Feature Management 

• Multi-Profile Sketches 

• Part Information 

• Loft Features 

Prerequisites 

None 

Class Size 

9 

Course Duration 

40 hours 

2


ELECTRICAL CONTROLS & SCHEMATICS (EST 100) 


This course provides participants with the skills to understand and use graphic representations 

by preparing detailed electrical drawings. Participants will demonstrate the use of lines, 

schematic drawings and interconnections, and wiring and terminal diagrams to display 

electronic and electrical circuits. 



1. demonstrate an understanding of basic electrical theory as it relates to schematics and 

prints; 

2. read and understand title blocks, drawing notes and revision systems; 

3. read electrical symbols; 

4. demonstrate an understanding of electrical print standards (ANSI, IEEE, JIC, NMTBA, 

NEMA, etc.); and 

5. recognize and use different types of electrical prints. 


To provide the knowledge and skills required to read and understand electrical schematics 

and prints commonly found in a plant environment. 


• Review of electrical theory 

• Introduction to electrical schematics and prints 

• Interpretation of electrical symbols 

• Interpretation logic and gate symbols 

• Interpretation of electronic symbols 

• Recognition and use of electrical prints 

• Power distribution drawings 

• Industrial control prints 

Prerequisites 

None 

Class Size 

12 


40 hours 

2 hours 

3


MECHANICAL SCHEMATICS (MST 100) 


This course provides participants with the necessary skills to read, understand, and interpret 

assembly drawings and diagrams to plan projects. Emphasis will be placed on how to 

interpret mechanical working drawings, read intermediate blueprints and schematics, and 

use construction specifications focusing on floor plans. 



1. identify various industrial drawings; 

2. read and understand title blocks, drawing notes and revision systems; 

3. identify the various types of lines and views; 

4. demonstrate an understanding of basic geometric dimensioning & tolerancing; and 

5. demonstrate an understanding of basic building drawings. 


To provide the knowledge and skills required to read and understand mechanical schematics 

and prints commonly found in a plant environment. 


• 3rd angle projection (American drawings) 

• 1st angle projection (German drawings) 

• German to English translation of drawings 

• Welding symbols 

• Pipe symbols and drawings 

• Industrial drawings 

• Title block 

• Drawing notes 

• Drawing revision system 

• Sketching 

• Multi-view drawings 

• Section views 

• Pictorial drawings 

• Geometric Dimensioning & Tolerancing (GD&T) 

• Building drawings 

Prerequisites 

None 

Class Size 

12 


40 hours 

4 

2 hours


GEOMETRIC DIMENSIONING & TOLERANCING FOR 

MANUFACTURING (GDT 100) 

2 hours 


This 40-hour class will provide an overview for Skilled Trades, Design, and Engineering 

personnel whose responsibilities include the process of reading and interpreting blueprints 

or tube drawings. The course will present methods in the proper interpretation of blueprint 

drawings used in the manufacturing and inspection of parts and assemblies. 



1. check parts using Geometric Dimensioning and Tolerancing; 

2. recognize and sketch part views; 

3. apply and interpret symbology, dimensioning, and tolerancing part features in order 

to provide a more thorough understanding; 

4. be able to interpret drawings quicker; and 

5. identify more useable parts 


To understand how Geometric Dimensioning and Tolerancing is used in the manufacturing 

and inspection of parts and assemblies. 


• Geometric Dimensioning and Tolerancing symbology 

• Dimensioning part features 

• Tolerancing part features 

• Interpreting drawings 

• Review the use of precision measuring instruments 

• Checking parts using Geometric Dimensioning and Tolerancing principles 

• Using Geometric Dimensioning and Tolerancing as an international standard 

• ISO and ASME y14.5M 1994 Dimensioning and Tolerancing Standards 

Prerequisites 

Participants should have a general knowledge of blueprint reading, be able to recognize part 

views and know how to apply and interpret symbology. 

Class Size 

10 


40 hours 

5


DIE MAKING TECHNOLOGY (MDT 100) 


Industrial die making technology has undergone trermendous changes. This course updates 

participants with the current skills and techniques used in the die making industry. 


Upon successful completion of this course, participants will learn the latest technologies used 

in the die making field during the entire die construction process. Methodologies include 

lecture, discussion, lab exercises, demonstration, and computer activities. 


To train participants in the current and new technologies directly affecting the die making 

industry at Chrysler Corporation. 


• Role of the Die Maker 

• CATIA (V5 CATIA) 

• SMIRT 

• Metallurgy for Die Makers 

• Rigging for Die Makers 

• Welding technology 

• Die making in Asia 

• Next generation die making 

• Super plastic forming 

• The future of metal forming 

Prerequisites 

A general understanding of automation and computers is helpful. 

Class Size 

8 


40 hours 

2 hours 

6


FUNDAMENTALS OF METALLURGY (WLT 200) 


The participant should be able to identify common metals used in auto plants; determine a 

metal’s repair characteristics for welding or machining; quench and flame harden metals; 

perform hardness tests; and prepare metal for repair welding procedures. 



1. identify common metals used in auto plants; 

2. determine a metal’s repair characteristics for welding or machining; 

3. quench and flame harden metals; 

4. perform hardness tests; and 

5. prepare metal for repair welding procedures. 


The participant should acquire metallurgical knowledge and understand the processes 

regarding the manufacturing, processing, and utilization of six important metals that are used 

in the automotive industry. 


• Properties of metals 

• Metal identification 

• Material specifications 

• Crystal structures 

• Effects of plastic deformation and heat treatment 

• Applications of tool steels, cast irons, stainless steel, copper alloys, and aluminum 

Prerequisites 

None 

Class Size 

6 


40 hours 

2 hours 

7


ADVANCED METALLURGY-HEAT TREATING (WLT 300) 


This course should give the participant the knowledge and skills to select various steels, 

perform heat treating operations on steel, and strengthen and anneal aluminum. 



1. select carbon, low alloy or tool steels for specific applications; 

2. perform hardening or strengthening heat treating operations to specifications; 

3. case harden low carbon and alloy steel; 

4. anneal hardened steel; 

5. normalize and stress relieve steel; 

6. anneal aluminum for formability; and 

7. strengthen annealed aluminum. 


The participant will perform basic heat treating operations on carbon steel, alloy steel, tool 

steel and aluminum. 


• Microstructural analysis 

• Quenching and tempering 

• Normalizing and stress relieving 

• Aluminum heat treating and case hardening 

Prerequisites 

Fundamentals of Metallurgy (WLT 200). Participants should bring their book and WLT 200 course 

material, as these will be the basis of the written training material. 

Clothing Requirements 

This hands-on class will require participants to perform some machining, grinding, and other 

shop-related tasks. Work clothing and safety shoes are required. 

Class Size 

6 


40 hours 

2 hours 

8


PUNCH DIE FINISHING (PUT 100) 

THIS COURSE IS CURRENTLY UNDER 

DEVELOPMENT 

9


INDUSTRIAL AUTOMATION 

10

Industrial Automation: 

CNC SETUP & OPERATION FOR MILLS (CNT 120) 


This course covers the programming and operation fundamentals of the Bridgeport EZ-Trak 

CNC mill. Hands-on training emphasizes writing CNC programs for the mill, machine setup, 

setting and adjusting tool offsets, and troubleshooting programs. CNC-operated Bridgeport 

mills and EZ-Trak software are available for hands-on use. 



1. manually program and edit basic parts on the Bridgeport EZ-Trak CNC mill; 

2. understand setup and operation techniques for CNC mills; 

3. startup and grid, jog, program upload and download, set datum, set tool offsets, and 

run parts on the Bridgeport EZ-Trak CNC mill; 

4. set and change tool offsets to compensate for changes caused by cutter wear; 

5. operate the Bridgeport EZ-Trak CNC mill control; and 

6. understand the Cartesian coordinate system and basic mathematics used for CNC 

programming. 


The participant should gain the knowledge and skills required to set up, operate, and write 

basic programs for the Bridgeport EZ-Trak CNC mill. 


• Bridgeport EZ-Trak mill hardware 

• Coordinate systems 

• CNC mill operation 

Prerequisites 

Training participants must be able to operate a milling machine. 

Class Size 

8 


40 hours 

2 hours 

11


PROTOTRAK MILL PROGRAMMING & OPERATION (CNT 130) 


This course covers the programming and operation fundamentals of the ProtoTrak CNC mill. 

Hands-on training emphasizes writing CNC programs for the mill, machine setup, setting 

and adjusting tool offsets, and troubleshooting programs. CNC-operated ProtoTrak mills and 

ProtoTrak CNC mill software are available for hands-on use. 



1. manually program and edit basic parts on the ProtoTrak CNC Mill; 

2. understand setup and operation techniques for CNC Mills; 

3. start-up and grid, jog, program upload and download, set datum, set tool offsets, and 

run parts on the ProtoTrak CNC Mill; 

4. set and change tool offsets to compensate for changes caused by cutter wear; 

5. operate the ProtoTrak CNC Mill Control; and 

6. understand the Cartesian coordinate system and basic mathematics used for CNC 

programming. 


The participant should gain the knowledge and skills required to set up, operate, and write 

basic programs for the ProtoTrak CNC mill. 


• ProtoTrak CNC mill hardware 

• Coordinate systems 

• CNC mill operation 

Prerequisites 

None 

Class Size 

8 


40 hours 

2 hours 

12


ALLEN-BRADLEY CONTROLLOGIX PROCESSOR FAMILY 

USING RSLOGIX 5000 SOFTWARE (BAT 175) 

2 hours 


Using Rockwell Software RSLogix 5000, the participant will learn how to install, set up, and 

troubleshoot the A-B ControlLogix system family of programmable controllers. 


Upon completion of this course through use of the A-B ControlLogix trainer, participants 

should be able to: 

1. install and set up ControlLogix 5000 family processors; 

2. activate RSLogix 5000 and RSLinx software; 

3. prepare and edit instructions; 

4. develop fundamental ladder logic circuits; 

5. set up the computer for processor communications; and 

6. search and perform program back up and restore procedures. 


To provide the participant with the knowledge and skills to install, set up, and troubleshoot 

the A-B ControlLogix processor and software. 


• Understanding Logix 5000 systems 

• Navigating RSLogix 5000 software 

• Saving and restoring programs 

• Identifying system components 

• Searching ladder logic 

• Comprehending data storage and organization 

• Understanding timer and counter instructions 

• Communicating with the controller 

• Learning and reviewing bit level instructions 

• Using documentation 

Prerequisites 

Participants should have a knowledge of electrical sequence control systems and a working 

knowledge of the electrical control of machines. 

Class Size 

8 


40 hours 

13


TROUBLESHOOTING ALLEN-BRADLEY CONTROLNET (CRT 300) 


This course provides participants with the skills and knowledge to maintain and troubleshoot 

both hardware and software for A-B ControlNet. Emphasis is placed on effective maintenance 

and troubleshooting of the ControlNet hardware and software. 



1. lay out and install an A-B ControlNet network; 

2. understand and use PLC5 Memory; 

3. successfully navigate through RS NetWorx software for ControlNet; and 

4. troubleshoot the ControlNet network. 


To provide the knowledge and skills required for effectively maintaining and troubleshooting 

a ControlNet network. 


• PLC5 memory layout 

• Message instruction with the PLC5 

• Building an online network 

• Error codes 

• Data mapping 

• Creating/modifying a scanlist 

• Peer to peer scheduled and unscheduled ControlNet communications 

Prerequisites 

Participants should attend two weeks of training on A-B PLC5 Programmable Controllers 

and be familiar with RSLogix 5 Software. 

Class Size 

10 


40 hours 

2 hours 

14


TROUBLESHOOTING ALLEN-BRADLEY DEVICENET (DNT 300) 


This course provides participants with the skills and knowledge to maintain and troubleshoot 

both hardware and software for A-B DeviceNet. Emphasis is placed on effective maintenance 

and troubleshooting of the DeviceNet hardware and software. 



1. understand A-B DeviceNet components and how DeviceNet differs from other 

networks; 

2. understand and use the PLC5 Memory; 

3. successfully navigate through RS NetWorx software for DeviceNet; and 

4. successfully troubleshoot a DeviceNet network. 


To provide the knowledge and skills required for effectively maintaining and troubleshooting 

a DeviceNet network. 


• Block transfer instruction 

• DeviceNet hardware and cabling 

• Building an online network 

• Error codes 

• Data mapping 

Prerequisites 

Participants should attend two weeks of training on A-B PLC5 Programmable Controllers 

and be familiar with RSLogix 5 Software. 

Class Size 

10 


40 hours 

2 hours 

15


INTERMEDIATE CONTROLLOGIX WITH CONTROLNET (BAT 275) 


This core program is intended for personnel who are migrating from the PLC-5 and SLC 

500 controllers to ControlLogix. Participants should be those whose responsibilities include 

programming, program editing, and troubleshooting faults in applications using program 

instructions. 


The successful completion of this course should enable the participant to efficiently navigate 

a ControlLogix system using a Windows based terminal. 


• ControlNet Communications 

• Unscheduled Network Communication 

• Messages & Remote IO 

• RS Networks for ControlNet 

• Scheduled Network Communication 

Prerequisites 

Participants should have a completed a ControlLogix Fundamentals (BAT 175) or Introduction 

program, and have working experience with the basic instructions and operations of a 

programmable logic controller. 

Class Size 

8 


40 hours 

16


ALLEN-BRADLEY PANELVIEW 1400E (BAT 310) 


The participant should be able to install, program, edit, troubleshoot, and repair the PanelView 

1400e operator control panel using RS Linx software. 



1. set up the PLC5 communication; 

2. configure PanelView hardware and software; and 

3. use PanelBuilder software to develop and edit programs including objects, screens, 

and addresses. 


To provide participants with the skills needed to set up a PLC5, configure PanelView hardware 

and software, and use PanelBuilder software to develop and edit programs. 


• PanelView hardware 

• Hardware overview 

• Interconnections 

• PanelView configuration 

• Review A-B 6200 software 

• PanelBuilder software 

• Loading and pass through communications 

• Data highway 

• Remote I/O and disk operations 

Prerequisites 

Participants must have completed Allen-Bradley PLC5 Family/6200 Software (BAT 105) OR have 

equivalent work experience with the PLC5 programmable controllers. 

Class Size 

8 


40 hours 

2 hours 

17


RSLOGIX 5 SOFTWARE FOR ALLEN-BRADLEY SLC 500 (BAT 320) 


The participant will learn RSLogix 500 software to develop programs; carry out basic 

functions, including the development of fundamental ladder logic circuits; use the Tag editor; 

communicate with Remote I/O; and diagnose and troubleshoot. 



1. activate RSLogix software; 

2. develop and edit instructions; 

3. develop fundamental ladder logic circuits; and 

4. demonstrate an understanding of Forcing. 


To provide participants with the skills needed to develop programs for A-B SLC-500 using 

RSLogix 500 software. 


• Basic review of DOS-based software 

• Introduction to Windows 95 

• Basics of RSLogix 

• Program development 

• Program storage, retrieval, and printing 

• Troubleshooting 

Prerequisites 

Participants must have completed Allen-Bradley SLC 500 Processor Family Using ICOM Software 

(BAT 115), OR the former TTC course Allen-Bradley SLC 500 Family Using 6200 Software (BAT 

100), OR have had equivalent formal training on A-B SLC 500 equipment. 

Class Size 

8 


40 hours 

2 hours 

18


RSLOGIX 5 SOFTWARE FOR ALLEN-BRADLEY PLC5 (BAT 330) 


Participants will learn to use A-B RSLogix 5 software to develop programs; carry out basic 

functions, including the development of fundamental ladder logic circuits; communicate with 

Remote I/O; and diagnose and troubleshoot. 



1. activate A-B RSLogix software; 

2. develop and edit programs; 

3. develop fundamental ladder logic circuits; and 

4. demonstrate an understanding of Forcing. 


To provide the participant with the skills needed to develop programs for the A-B 

PLC5 using RSLogix 5 software. 


• Basic review of DOS-based software 

• Introduction to Windows 95 

• Basics of RSLogix 

• Program development 

• Program storage, retrieval, and printing 


Prerequisites 

Participants must have completed Allen-Bradley PLC5 Family/6200 Software (BAT 105) OR have 

equivalent formal training on A-B PLC5 equipment. 

Class Size 

8 


40 hours 

2 hours 

19


ALLEN-BRADLEY PLC5 PROCESSOR FAMILY/RSLOGIX 

SOFTWARE (BAT 335) 

3 hours 


Participants will gain the theory and principles of operation of the A-B PLC5 Processor Control 

System, which will enable them to edit ladder logic programs, troubleshoot and repair PLCs, 

set up computer terminals for communication with processors, and troubleshoot major faults 

on the A-B SLC 500 family of programmable controls. 



1. use RSLogix 5 software and the PLC5 Controller to install and set up PLC5 family 

processor; 

2. troubleshoot and repair the PLC5 Processor control system; 

3. edit ladder files using RSLogix 5 software; 

4. perform corrective action to isolate and repair faults; 

5. set up computer for PLC5 processor communications; and 

6. perform program backup and restore procedures. 


To provide participants with the knowledge and skills to install, set up, and troubleshoot the 

PLC5 Controller using RSLogix software. 


• Power supply 

• Processor board 

• 1771 series I/O 

• Fundamental programming 

• Display modes 

• Editing 

• Basic MS-DOS commands 

• Backing up programs 

• Introduction to the PC terminal 

Prerequisites 

Participants should have a knowledge of electrical sequence control systems and a working 

knowledge of the electrical control of machines. 

Class Size 

8 


80 hours 

20


ADVANCED CONTROLLOGIX (BAT 375) 


This course is intended for participants who are migrating from PLC-5 and SLC 500 controllers 

to the ControlLogix. Participants attending should be those whose responsibilities include 

programming, program editing, and troubleshooting the controller and ControlLogix 

networks. 


The successful completion of this course should enable the participant to efficiently navigate 

a ControlLogix system using a Windows based terminal. 


• Ethernet Communications IP Configuration 

• Advanced Instructions 

• IO Buffering 

• Messages & Message Types 

• Faults and Fault Codes Power Up Routines 

• Trends 

• Analog IO 

Prerequisites 

Participants should have a completed a ControlLogix Fundamentals (BAT 175) or Introduction 


programmable logic controller. 

Class Size 

8 


40 hours 

21


ALLEN-BRADLEY 1394 MOTION CONTROL OPERATIONS 

& MAINTENANCE (BAT 410) 

2 hours 


This course provides the knowledge and experience needed to install, program, troubleshoot, 

and repair A-B 1394 motion control systems using GML software. 



1. install, program, troubleshoot, and repair A-B 1394 motion controls; 

2. understand power and motor wiring, digital and analog input wiring, power loss, 

bus under and over voltages, and motor parameters (i.e., stall, overload, over 

temperature); 

3. understand programming and display panels such as operating display, fault display, 

speed output display, special and other displays; 

4. understand local or remote control programming; and 

5. understand theory of operation, speed source priority, operational modes, and 

programming of parameters. 


The participant should gain the ability to operate and troubleshoot A-B 1394 motion control 

systems utilizing both the GML software and installed indicators. 


• Servo basics 

• AC servo motors 

• 1394 motion control system physical components 

• Test equipment use 

• GML programming language introduction 

Prerequisites 

A basic knowledge of electrical controls. 

Class Size 

8 


40 hours 

22


IN-PLANT CONTROL SYSTEMS TROUBLESHOOTING (BAT 420) 


This course provides the participants with the skills and knowledge to identify and isolate 

specific problems found in overall plant control systems. Although this course will use Allen- 

Bradley family components and software, the course focus is on troubleshooting techniques, 

skills and applications to efficiently locate and solve problems regardless of the system 

used. 


The successful completion of this course should enable the participant to: 

1. Understand I/O communications and typical in-plant hardware (e.g., remote racks, 

drives, PanelViews, etc.) as controlled with a PLC. 

2. Understand and use various Allen-Bradley software packages to troubleshoot each 

device type, both as a single device and as an integral system. 

3. Successfully navigate, for troubleshooting purposes, using the A-B RSLogix 5, 

PanelView, Drive Manager, Drive Tools, and RSLogix 500 software. 

4. Successfully troubleshoot multi-device/ plant control systems. 

Course Objectives 

To provide the knowledge and skills required to effectively communicate with, maintain and 

troubleshoot various in-plant systems and remote hardware devices with an emphasis on 

Allen-Bradley components. 


• Combined in-plant systems 

• PLC5 - PanelView, A/C Drive, Communications setup and troubleshooting 

• PLC5 – Remote I/O configuration and troubleshooting for each device individually 

and all devices as a remote I/O system 

• System and device Error and Fault recognition and troubleshooting 

• Troubleshooting techniques 

Prerequisites 

Participants should have completed Allen Bradley RSLogix 5 (BAT 330 or 335) and/or Allen 

Bradley PanelView (BAT 300 or 310) or AC drive (BAT 400) training OR other similar training 

such as Telemecanique, Siemens, or others. 

Class Size 

8 


40 Hours 

2 hours 

23


DEVICENET WITH CONTROLLOGIX (BAT 475) 


This course is intended for personnel who are migrating from the Rockwell Automation PLC-5 

controller to the ControlLogix architecture. Participants should be those whose responsibilities 

include programming, program editing, and troubleshooting faults in applications using 

program instructions and hardware. 



1. return a malfunctioning DeviceNet network to normal operation and complete basic 

hardware and software maintenance tasks with minimum downtime; 

2. verify proper network installation and perform both hardware and software-based 

tasks used to isolate network problems; 

3. efficiently add and replace network devices; and return a malfunctioning DeviceNet 

network to normal operation to minimize downtime. 


• Scanner module numeric and alphanumeric codes 

• Scanner module and device status indicators (LEDs) 

• RSNetWorx for DeviceNet 

• RSLogix 5000 software 

• RSLinx 

Prerequisites 

Participants should have a completed a ControlLogix Fundamentals (BAT 175) or an introduction 


programmable logic controller (PLC). 

Class Size 

8 


40 hours 

24


ROBOTICS: ABB S4C/C+ PROGRAMMING LEVEL 1 (BBT 100) 

2 hours 


This course is designed to prepare each participant to operate and program the ABB S4 C/C+ 

Robot Controller and Manipulator. 



1. follow all robotic safety and lock out procedures; 

2. locate and identify components of the robot system; 

3. identify and use of the teach pendant buttons, menus, function keys, and indicators; 

4. jog the robot using different coordinate systems to quickly obtain desired motion; 

5. set up and verify TCP and Work Object (User frame); 

6. select programs for test cycling forward and backward for touch up of positions; 

7. utilize all program edit functions; 

8. utilize and move offset instructions; 

9. use and manipulate most commonly used program instructions; 

10. program and manipulate all commonly used I/O types; and 

11. file utilities for program backup, and restore. 


• General safety guidelines 

• Communications 

• Basic teach pendant functions 

• Jogging the robot 

• File utilities 

• Program creation, edit, mod pos 

• Inputs and outputs 

• Controller and manipulator components 

• TCP/Wobj creation and use 

• Program selection and test cycling 

Prerequisites 

A general understanding of automation and computers. 

Class Size 

6 


40 hours 

25


ROBOTICS: ABB S4C/C+ ELECTRICAL MAINTENANCE & 

TROUBLESHOOTING LEVEL 2 (BBT 200) 


This course is designed to prepare each participant with the necessary skills needed to 

troubleshoot the ABB S4, S4C and S4C+ style controllers and manipulators. For users of the 

ABB M-2000A M6600 Robot, please see BBT 250. 




2. locate and identify function of all electrical and mechanical components and schematics 

of the robot system; 

3. locate, identify, and use the teach pendant buttons 

4. jog the robot to perform maintenance and troubleshooting; 

5. mastering, calibration, and rev. counter updating of the robot; 

6. file utilities for program backup, loading, and software restoration; 

7. connect, troubleshoot, and replace all components of the robot system; 

8. use of position screen, alarms screen, status screens, LED’s and indicators for 

troubleshooting; 

9. locate robot inputs and outputs screen to determine system or equipment status; and 

10. motor removal, replacement, and recovery of robot system. 


To provide the participant with the skills necessary to electrically repair the ABB S4 robot 

controller and manipulator. It includes the local and remote I/O on the robot and to the cell 

controller where high incidents of faults can occur, to aid in minimal downtime. 


• Main CPU • Remote I/O Modules • Relays K1, K2 and K3 

• Expansion Memory • Robot Wiring & Safety Circuits • Teach Pendant 

• Main Power Supply • Connector Unit/Backplane • Floppy Disc Drive 

• Robot Computer • Serial Measurement Board • Axis Board 

• Fuses • Ethernet Communication • Manipulator Motors 

• DC Link 

• File Utilities Software reload 

• Servo Amplifiers • Panel Unit & System Board 

Prerequisites 

Participants should have completed Robotics: ABB Operations and Programming Levels 

(BBT 100) and have a general understanding of automation, computers, and electrical 

troubleshooting. 

Class Size 6 

26 

Course Duration 40 hours


ROBOTICS: ABB M2000A, IRB 6600 S4C/C C+ ELECTRICAL 

MAINTENANCE & DCX PROGRAMMING STANDARDS LEVEL 2 (BBT 250) 


This course is designed to prepare each student to perform electrical maintenance and 

electrically troubleshoot the M2000A ABB S4C+ robot controller and 6600 series manipulator 

and use advanced user instructions and DCX Programming Standards. 




2. understand and troubleshoot fault diagnostic messages; 

3. electrical schematics and component fault led diagnostics; 

4. controller component troubleshooting and replacement; 

5. robot calibration and rev. counter updating; 

6. robot manipulator motor troubleshooting and replacement; 

7. robot system software download through Rob Install; 

8. DCX Robot programming software standards; 

9. advanced user instructions used in DCX ABB Robot Programs 

10. robot screen viewer for changes monitoring status in Auto Operation Mode; and 

11. use screen Viewer and Production screen to hot edit production programs. 


To provide the participant with the skills necessary to apply troubleshooting techniques 

including the manipulator, local and remote I/O on the robot and to the cell controller where 

high incidents of faults can occur, to aid in minimal downtime. 


• Controller Fault Diagnostics • Controller Component Replacement 

• Controller Troubleshooting • Robot System Software Reload 

• Robot Calibration and Rev Counters • DCX Robot Programming Standards 

• DCX-ABB Special Instructions • Robot Controller Electrical Schematics 

• Robot Motor Troubleshooting • DCX Screen View and Production Menus 

and Replacement 

Prerequisites 

Participants should have completed Robotics: ABB Operations and Programming Level 1 (BBT 100) 

and have a general understanding of automation, computers, and electrical troubleshooting. 

Class Size 


6 40 hours 

27


ROBOTICS: FANUC RJ2-RJ3 OPERATION & 

PROGRAMMING (FRT 300) 

2 hours 


This program prepares the participant with the skills necessary to operate and program the 

Fanuc RJ2 or RJ3 Robot Controller and Manipulator. 




2. locate and identify components of the robot system; 

3. locate, identify, & use the teach pendant buttons, menus, function keys, & indicators; 

4. jog the robot using different coordinate systems to quickly obtain desired motion; 

5. select programs for test cycling forward and backward for touch up of positions; 

6. use and understand macros, manual function screens and abort all features; 

7. utilize all program edit functions; 

8. use and manipulate most commonly used program functions; 

9. demonstrate advanced program shift and adjust features; 

10. program and manipulate all commonly used I/O types; and 

11. file utilities for program backup, loading and software restoration. 


To provide the participant with the skills needed for the operation and programming of the 

Fanuc RJ2 or RJ3 Controller and Manipulator. 


• General safety guidelines 

• Controller and manipulator components 

• Basic teach pendant functions 

• Jogging the robot 

• Program selection and test cycling 

• Program creation, edit, and touch up 

• Communications 

• Inputs and outputs 


• File utilities 

Prerequisites 

A general understanding of automation and computers. In addition, this course serves as a 

prerequisite for Fanuc RJ2-RJ3 Electrical Maintenance and Troubleshooting (FRT 350). 

Class Size 

6 


40 hours 

28


ROBOTICS: FANUC RJ2-RJ3 ELECTRICAL 

MAINTENANCE & TROUBLESHOOTING (FRT 350) 

2 hours 


This course prepares participants with the necessary skills needed to troubleshoot the Fanuc 

RJ2 and RJ3 style controllers, and Fanuc Manipulators. 



1. locate and identify the functions of all electrical and mechanical components of the 

robot system teach pendant buttons and jog the robot; 

2. connect, troubleshoot, and replace all components of the robot system; 

3. use position, alarms, and status screens, and indicators for troubleshooting; 

4. locate robot inputs and outputs screen to determine equipment status; remove motor, 

replace master and calibrate the robot system; and 

5. file utilities for program backup, loading and software restoration. 


To provide the participant with the skills to diagnose, troubleshoot, and carry out electrical 

maintenance on the Fanuc RJ2 and RJ3 robotic equipment. 


• Robotic Basics Review: Safety guidelines, fault recovery, power up controller using 

various methods, jogging the robot using different methods for troubleshooting. 

• Robot Setup: Zero position and single axis mastering and calibration, Tool Center 

Point (TCP), Application specific setup screens and Inputs and Outputs. 

• Communication: Robot Communications to peripheral equipment. 

• Component Identification, removal and replacement: Install, remove, and identify 

the functions of all robot system components. 

• Troubleshooting: Position, alarm and status screens, LEDs, robot inputs and outputs 

screen location, PLC to robot communications, common electrical components issues, 

and UOP input and output utilization. 

• File Utilities: Robot Core Software files and configuration, Teach pendant programs, 

application programs and system variables. 

Prerequisites 

Fanuc RJ2-RJ3 Operation and Programming (FRT 300) or training that includes a general 

understanding of automation, computers and electrical troubleshooting. 

Class Size 

6 


40 hours 

29


ROBOTICS: NACHI OPERATION/PROGRAMMING 

FOR THE AR 11/AR 52 CONTROLLERS (RNT 320) 

2 hours 


Upon successful completion of this course, the participant should be able to effectively operate 

and program the AR 11 and the AR 52 Nachi controllers. 



1. understand robot safety; 

2. use control cabinet operations and panel functions; 

3. perform pendant operation and functions; 

4. use manual and automatic robot motion control; 

5. perform I/O and programming; 

6. manipulate memory files; and 

7. display and recover from errors. 


To provide the participant with the skills needed for operation and programming of the Nachi 

AR 52 robot. 


• Operations 

• Programming systems 

• Screen displays 

• Mode selections 

• Practical applications 

• Error reporting/recovery 

• Writing/editing robot programs 

• Fundamental robot concepts 

• Communication with external equipment 

Prerequisites 

Participants should have completed a basic robot course or have equivalent industrial 

manufacturing work experience. 

Class Size 

6 


40 hours 

30


ROBOTICS: NACHI OPERATION/PROGRAMMING FOR THE 

AW11 CONTROLLER (RNT 330) 

2 hours 


This course covers the programming and safe and effective operation of the AW11 Controller 

and robot arm. 



1. use the operation panel and teach pendant; 

2. set up operation modes; 

3. program the robot’s motions; 

4. perform error recovery; and 

5. manipulate memory files. 


To provide participants with the knowledge and skills to operate and program the Nachi 

AW11 Controller and robot arm. 


• Robot safety 

• Operation panel functions 

• Teach pendant operation 

• File manipulation 

• Robot programming 

• Operation modes and codes 

• Robot motion and associated attributes 

Prerequisites 

Participants should have completed a basic robot course or have equivalent industrial 

manufacturing work experience. 

Class Size 

6 


40 hours 

31


ROBOTICS: NACHI AR 52 ELECTRICAL MAINTENANCE (RNT 360) 


This course covers the safe maintenance, operation, and troubleshooting of the Nachi AR 52 

robot arm and control cabinet. 



1. understand robot safety and safety devices; 

2. understand basic operation and major robot system components, including control 

systems and power supply distribution; 

3. understand the robot encoder system, servo drive system analysis, 

schematic diagram analysis, and PC board description/function; 

4. perform troubleshooting, including error code troubleshooting and hands-on 

troubleshooting; 

5. monitor and maintain a control cabinet and replace cabinet components; 

6. replace and adjust the power supply; and 

7. perform robot arm wiring. 


The participant should attain the knowledge and experience necessary to diagnose, 

troubleshoot, and carry out electrical maintenance and repair on the Nachi AR 52 robot arm 

and control cabinet. 


• Operation of major robot systems 

• Robot safety and devices 

• Robot encoder system 

• Writing/editing programs 

• Error reporting/recovery 

• Control cabinet functions 

• Robot arm wiring 

Prerequisites 

Participants should have completed Nachi AR 52 Operation/Programming (RNT 310) or Nachi 

Operation/Programming for the AR 11/AR 52 Controllers (RNT 320) or have equivalent industrial 

manufacturing work experience. Use of a digital voltmeter and prior machine control 

troubleshooting experience is required. 

Class Size 

6 


40 hours 

2 hours 

32


ROBOTICS: NACHI AW 11 ELECTRICAL MAINTENANCE (RNT 375) 


This 40-hour Electrical Maintenance course is intended for Skilled Trade and Engineering 

personnel whose responsibilities are electrical maintenance and repair of the Nachi robot. 


The successful completion of this course should enable participants to: 

1. utlize robot safety procedures; 

2. understand the basic operation; 

3. utilize the robot encoder system; and 

4. repair the base AW Nachi control cabinet and Nachi robot arm. 


To provide the participant to effectively maintain, diagnose, troubleshoot, and repair the base 

AW Nachi control cabinet and Nachi robot arm. 


• Major robot system components 

• Control system overview 

• Power supply distribution 

• Servo drive system analysis 

• PC board description and functions 

• Schematic diagram analysis 

• Error code troubleshooting 

• Control cabinet monitoring 

• Cabinet component replacement procedure 

• Power supply replacement and adjustments 

• Hands-on troubleshooting 

• Robot arm wiring 

• Motor replacement procedure 

• Control cabinet maintenance 

Prerequisites 

Participants should have completed a Nachi AW Operation/Programming course or have 

equivalent work experience with the AW controller. Work experience with a digital volt 

meter and prior machine control troubleshooting is recommended. 

Class Size 

6 


40 hours 

2 hours 

33


ROBOTICS: NACHI AX OPERATION PROGRAMMING (RNT 500) 


This 40-hour Operation/Programming course is intended for skilled trades personnel 

whose responsibilities are operation, programming, program modifications, and repair or 

maintenance of the AX Controller and Robot arm. 


The successful completion of this course should enable the participant to effectively operate 

and program the Nachi robot arm. 


• Robot Safety 

• Online HELP Message Review 

• AX Cabinet Operation Panel & Functions 

• Display Units Layout & Function 

• Manual Robot Motion Control 

• Program Step Attributes 

• Program Modifications 

• Cycle Time Monitoring & Modification 

• Step Function Operation & Programming 

• Operations Code Menus & Selection 

• Step Function Modifications 

• Verifying Program Files for Modification 

• Safety Devices 

• Teach Pendant Operation & 

Functions 

• Controller Operation Modes 

• Automatic Robot Motion Control 

• Recording Programs 

• External Control Selections 

• Input and Output Operation & 

Programming 

• Memory File Manipulation & 

Backup Operation 

• Interface Panel Operation 

• Error Display & Recovery 

• Operation Levels 

Prerequisites 

Participants scheduled for this course should have completed a basic robot course or have 

equivalent industrial manufacturing work experience. 

Class Size 

6 


40 hours 

34


ROBOTICS: NACHI AX ELECTRICAL MAINTENANCE & 

TROUBLESHOOTING (RNT 550) 


DEVELOPMENT 

35


INTRODUCTION TO TELEMECANIQUE (TMT 100) 


The participant should be able to enter, edit, and troubleshoot the Telemecanique TSX 57 

system using the PL7 JR software. 



1. monitor, troubleshoot, and replace TSX 57 system hardware; 

2. search, edit, save and restore existing logic diagrams with PL7 JR software; 

3. restore and backup existing logic programs with PL7 JR software; and 

4. install components properly and safely, identify problems, and demonstrate the 

appropriate corrective procedures. 


To provide the participant with the skills necessary to apply troubleshooting techniques 

including interpretation of status indicators, understanding diagnostic messages, and using 

the terminal to isolate faults and take corrective action. 


• Identify control system components 

• Monitor, troubleshoot, and replace TSX 57 hardware 

• Configure and program Telemecanique TSX 57 Controllers 

• Connect and establish communication 

Prerequisite 

A basic knowledge of electrical sequence control panels and Windows software, as well 

as a working understanding of the electrical control of machines and Programmable Logic 

Controllers. 

Class Size 

8 


40 hours 

3 hours 

36


ADVANCED TELEMECANIQUE (TMT 200) 


The participant will gain hands-on experience in both troubleshooting and maintenance 

techniques for rapid fault isolation and correction with a TSX-57 Premium Controller, Magelis 

HMI, FIPWAY Communications, and the CAY-21 Linear Axis Control module. 



1. monitor a ladder logic program; 

2. troubleshoot the Modicon Premium system; 

3. replace Premium system hardware; 

4. edit existing logic programs with the PL7 Pro software; and 

5. identify the proper procedures for replacing Premium system components safely. 


To provide the participant with the skills necessary to use the TSX Premium PLC PL7 Pro 

programming software and the Magelis HMI programming software. 


• GRAFCET programming 

• CAY Servo Module (Linear Axis Control) 

• SMOVE Instructions for the CAY Module 

• Troubleshooting and fault Isolation 

• Safety techniques 

• FIPWAY communications 

• Tying all system components together 

Prerequisite 

All participants must have successfully completed Introduction to Telemechanique (TMT 100). 

Class Size 

8 


40 hours 

1 hour 

37


INDUSTRIAL MAINTENANCE 

38

Industrial Maintenance: 

TROUBLESHOOTING AC MOTORS (ACT 100) 


The course provides participants with the knowledge to troubleshoot and repair AC motor 

drives. 



1. Know the effect of Volts, Hertz and electronic fundamentals on motor operation; 

2. Troubleshoot Power Control Devices such as inverter components, transistors, SCRs, 

and GTOs; 

3. Identify three-phase bridge operation and faults; 

4. Know the different types of motors with an emphasis on three-phase field rotation; 

5. Identify failures in converters and inverters; and 

6. Troubleshoot AC drives (VVVF and PWM drives) to the board level. 


To provide the participant the skills necessary to troubleshoot AC motor faults, determine 

the root cause and decide upon a plan of action for AC motor repair. The participant will be 

able to perform routine maintenance on various AC motors. 


• AC motor theory, AC advantages, magnetic principles, synchronous speed, three-phase 

motor control, rated torque, horsepower curves 

• Motor control, AC motor operations, three-phase measurement, inverters, power 

circuits, control circuits, troubleshooting tips 

Prerequisite 

Electrical/Electronic Fundamentals (IET 105) or a demonstrated knowledge of the fundamentals 

of electrical and electronic troubleshooting and repair procedures. 

Class Size 

12 


40 hours 

2 hours 

39


REFRIGERANT TRANSITION & RECOVERY CERTIFICATION (AIT 100) 


This course provides participants with a good working understanding of air conditioning. 

Upon completion of this course, the participant should have all of the necessary tools to 

successfully complete the Air Conditioning Contractors of America (ACCA) standards for 

A/C Refrigeration Reclamation Certification. 



1. have a solid understanding of A/C components; and 

2. troubleshoot units using drawings by applying their relationship to the various stages 

of the electrical/mechanical functions in the manufacturing environment. 


To provide the participant with the knowledge of BTU, proper system size, forced air principles, 

duct size and location, pipe size, basic electrical controls, and safety in air conditioning 

reclamation. 


• Refrigerant chemistry and applications 

• Refrigerant oils and their applications 

• Legislative and proposed regulations 

• Safe handling and transport of refrigerants 

• Ozone depletion 

• Recovery, recycling and reclaim 

• Waste oil 

• Conservation – servicing and testing 

Certification 

Upon completion of this course, each student will be tested for a certification from ACCA. 

This rating will give the student a universal refrigeration certification. 

Class Size 

8 


40 hours 

2 hours 

40


INDUSTRIAL AIR LOGIC (ALT 101) 


This course covers air logic control systems, including fundamentals of compressed air, the 

operation of air logic circuits, and troubleshooting procedures and techniques. 



1. match circuit functions of air logic components to their symbols; 

2. fabricate, operate, and analyze various air logic circuits; and 

3. identify basic air logic circuits and the sequence of operation of the system. 


The participant will gain knowledge and skills in the application and troubleshooting of air 

logic control systems. 


• Ladder diagrams 

• Fundamentals of compressed air 

• Power valve symbology 

• Comparison of electrical relays 

• Pneumatic air logic components and functions 

• Troubleshooting procedures and techniques 

Prerequisites 

Participants should have a working knowledge of pneumatics, or have completed a 40-hour 

pneumatics course within the last year. 

Class Size 

10 


40 hours 

2 hours 

41


PRINCIPLES OF REFRIGERATION & AIR CONDITIONING (ART 100) 


This 40-hour course introduces participants to fundamental concepts and theories of 

refrigeration and air conditioning systems and provides training and testing of proper safety, 

handling and application of the new R-410A refrigerant (replacement for R-22). 


The successful completion of this course should enable the participant to properly use tools 

associated with refrigeration and air conditioning. 


• Basic physics 

• Pressure/temperature relationships to various refrigerants 

• Major component functions 

• Gas laws 

Prerequisites 

None 

Class Size 

8 


40 hours 

42


INDUSTRIAL BEARING PREDICTIVE MAINTENANCE (BMT 100) 


This course provides the skills and experience to carry out preventive maintenance on bearings, 

troubleshoot, repair, and prevent future failures. It will also cover bearings fundamentals 

such as bearing types, mounting, dismounting, and monitoring. 



1. install, remove and lubricate bearings; 

2. monitor roller bearing to prevent catastrophic failure; 

3. troubleshoot bearing failures; 

4. read and interpret troubleshooting charts for bearings; 

5. understand the basics of root cause analysis; 

6. identify different types of bearings; and 

7. be familiar with predictive maintenance techniques such as infrared thermography, 

ultrasound, and oil analysis. 


To provide the participant with an introduction to different types of bearings, the ability to 

diagnose the root cause of bearing failure, and the skills to properly repair failed bearings. 


• Bearing Fundamentals 

• Root Cause Analysis 

• Oil Analysis 

• Conveyors 

• Bearing Failures 


• Bearing Types 

• Ultrasound, Infrared Thermography 

• Lubrication 

• Mounting & Dismounting 

• Bearing Monitoring 

Prerequisites 

None 

Class Size 

8 


40 hours 

43


INDUSTRIAL CONDUIT INSTALLATION (ICT 200) 


The participant should be able to gain practical knowledge of conduit bending as well as 

hands-on experience. 



1. identify the size and type of electrical conduit; 

2. find and use take-up, gain, travel, shrink, and shrinkback; 

3. bend (in rigid conduit) accurate 90° bends, 90° bends with a kick, back-back bends, 

offsets, combination bends, 3 point saddle, predetermined 4 point saddle; and 

4. use the code book to find wire size area, size conduit using same and different size 

wires, box sizing and box fill. 


To provide the participant with the knowledge required to identify electrical conduit and 

carry out various electrical conduit bends effectively. 


• Sizes and types of electrical conduit 

• Identification and use of take-up, gain, travel, shrink, and shrinkback 

• Rigid conduit bending 

Prerequisite 

None 

Class Size 

12 


40 hours 

2 hours 

44


ELECTRICAL TROUBLESHOOTING (ETT 200) 


DEVELOPMENT 

45


ELECTRICAL/ELECTRONIC FUNDAMENTALS (IET 105) 

2 hours 


This course is designed for Skilled Trades workers who need to understand electrical 

and electronic fundamentals, as well as for Electricians coming from a non-industrial 

background. 



1. identify resistors, diodes, and rectifiers; 

2. recognize and understand the uses of input/output devices; 

3. comprehend basic control protection and principles of AC, DC, and servo electrical 

motors using Ohm’s Law; 

4. use NEMA and IEC electrical standards; 

5. work with machine controls; 

6. identify components in schematic and ladder diagrams; and 

7. hook up and use transformers, power supplies, and surge protectors. 


To provide participants with the knowledge and understanding of electrical and electronic 

fundamentals. 


• Electrical safety 

• Electrical testers 

• Transformers, electric motors 

• Power supplies, drives 

• Electronic circuits 

• Input/output devices 

• PLCs/PanelViews 

• NEMA vs. IEC components 

• Machine control diagrams 

• Positioning devices for CNC 

• Electrical measurement and formulas 

• Troubleshooting control circuits 

• Control and protection of motors 

• European wiring and disconnect switches 

• Surge protection and power conditioning 

Prerequisites 

None 

Class Size 

8 


40 hours 

46


GROUNDING & BONDING (IET 210) 


This course focuses on the grounding requirements related to installation, testing, and 

inspection for commercial and industrial power systems. Based on Article 250 of the 2002 

National Electrical Code, the course addresses the rules for minimizing the risk of electric 

shock, fires, and explosions. The instructor-guided presentation provides answers to the 

common elements for clearing ground faults, and the conventions for low-impedance and 

high-impedance systems. 



1. properly ground circuits; 

2. properly bond industrial electrical connections; and 

3. practice safe procedures. 


To enable the participant to know, understand, and implement proper electrical bonding and 

grounding procedures. 


• Proper grounding of circuits 

• Equipment and facilities 

• Understanding and applying the provisions of Article 250 of the 2002 National Electrical 

Code 

• Proper bonding of electrical connection in industrial circuits 

• Use of test equipment to monitor performance 

Prerequisites 

None 

Class Size 

12 


40 hours 

2 hours 

47


TRANSFORMERS & FEEDERS (IET 215) 


The participant should be able to work safely with transformers and feeders through knowledge 

of circuitry and connections and measuring the size of feeder services. 



1. understand the principles of transformers and feeders, circuitry of transformers and 

three-phase circuits; 

2. hook up delta and zig-zag transformer connections; and 

3. know how to calculate the size of feeder services. 


The participants will understand the principles and circuitry of transformers and feeders and 

how to hook up and test transformers using different configurations. 


• Principles and circuitry of transformers 

• Delta connections 

• Zig-zag transformer connections 

• Feeder and conduit sizing 

Prerequisites 

None 

Class Size 

12 


40 hours 

2 hours 

48


FIBER OPTIC & COPPER COMMUNICATIONS CABLING 1 (FOT 110) 


The participant should learn D/C LAN and EIA/TIA 568 network concepts, and the basic 

skills to install and terminate both copper and optical fiber communications cabling. 



1. identify the elements of D/C LANs and 568 networks, and their terminology; 

2. recognize cable markings and correct installation procedures; 

3. understand the concept of bandwidth and how it is applied in LANs; 

4. terminate both multimode fiber and Category 5e copper cabling; 

5. use the OTDR, OLTS, wire mapper, and other test equipment; and 

6. install, test, and troubleshoot a simple fiber cable plant. 


To provide the participant with the knowledge required to select and pull both copper and 

fiber optic network cabling, and perform simple tests to evaluate cable performance. 


• Fundamentals of network architecture 

• Bandwidth: Why copper? Why fiber optics? 

• Cabling safety 

• Cable markings and pulling precautions 

• Basic termination procedures 

• Cable testing for loss, length, and wiring errors 

• Restoration of service by splicing 

• Circuit documentation required by D/C 

Certification 

All participants who complete the course will be: 

1. 3M products certified. 

2. After successful completion of a voluntary test, participants will be certified as a Fiber 

Optic Technician from the Fiber Optic Association. 

Prerequisites 

None 

Class Size 

8 


40 hours 

2 hours 

49




The participant should be able to explain the purpose and functioning of the elements of both 

fiber optic and copper communications networks; develop skills in terminating Cat 3, Cat 5e, 

and 50 and 62.5 micron cabling; and develop a deeper understanding of test protocols called 

for in the network standards. 



1. correctly select and install both fiber and copper cabling and the appropriate 

connectors; 

2. demonstrate a working knowledge of D/C LAN standards; 

3. install both ST and SC fiber optic connectors on multimode fiber; 

4. correctly terminate copper network cabling, both UTP and coax; and 

5. correctly use test equipment, including the Fluke DSP-4000, to troubleshoot cabling. 


To provide more detailed knowledge and hands on skills required to install and test fiber and 

copper network cabling per the D/C LAN standards. 


• Review of network requirements and cabling performance capabilities 

• Safe working with fiber cabling and light sources 

• Cross connects and punchdowns on 66 and 110 blocks 

• Advanced OTDR and OLTS testing and troubleshooting techniques 

• The 16 UTP parameters tested by the Fluke DSP-4000 

• Common failures in both fiber and copper wiring 

• Restoration splicing 

• Building, testing, troubleshooting and documenting a four terminal LAN, per D/C 

standards 

Certification 

All participants who complete the course will receive a certificate of achievement as 

Communications Cabling Specialists from Lincoln Trail College. 

Prerequisites 

Participants must have completed Fiber Optic & Copper Communications Cabling 1 (FOT 110). 

It is recommended that a participant have some hands-on plant experience with fiber optic 

cable after FOT 110 before taking FOT 310. 

Class Size Course Duration 

8 40 hours 

50 

2 hours




The participant will bring together skills developed in the preceding two courses. Participants 

will deepen understanding of the 568 and D/C network standards, and install, test, troubleshoot 

and document a four terminal LAN, particularly observing all the precautions of the D/C 

LAN Handbook and the National Electrical Code. 



1. install and test a working plant network communications system comprised of copper 

and fiber media; 

2. demonstrate a working knowledge of the fiber/twisted pair/coax/wireless hybrid 

infrastructure and their installation standards; 

3. install and test CAT 5e, CAT 6, and fiber optic connectors onto appropriate cables; 

4. construct a simulated plant network consisting of a fiber hub and cable, media 

converters, and CAT 5e cabling to work area outlets linking computers together; and 

5. demonstrate the proper use of fiber and copper test equipment. 


To provide the knowledge and hands-on skills needed to install and test plant communications 

networks consisting of optical fiber, twisted pair copper, and coax cable media. 


• The physical layer of networks 

• Bandwidth capability and application of fiber and copper cabling 

• Safety considerations with fiber and copper 

• Wireless applications and characteristics 

• D/C and TIA 568 cabling standards 

• Troubleshooting network cabling 

• Installation of a complete four terminal copper to fiber LAN. 

• Proper documentation of cable plant 

Certification 

All participants who complete the course will receive a certificate of achievement as Network 

Specialists from Lincoln Trail College. 

Prerequisites 

Participants must have completed Fiber Optic & Copper Communications Cabling 1 (FOT 110) and 

Fiber Optic & Copper Communications Cabling 2 (FOT 310). It is recommended that a participant 

have some hands-on plant experience with fiber optic cable after FOT 110 and FOT 310 before 

taking FOT 400. 

Class Size Course Duration 

8 40 hours 

2 hours 

51


FIRE SYSTEMS TRAINING (FST 100) 


The participant should be able to describe the components of fire protection systems. 

Participants will work with installation and resource compliance requirements including 

inspection and testing. 



1. describe the purpose of fire protection systems; 

2. define occupancy classifications; 

3. list the components of a fire protection system; 

4. state basic hydraulic properties; 

5. identify code and resource material; 

6. locate specific installation and compliance requirements; and 

7. determine design considerations and inspection and test procedures. 


To upgrade and provide a sound foundation for Skilled Trades personnel with respect to fire 

protection systems. 


• Purpose of fire protection systems 

• Occupancy classifications 

• Water sources 

• System components 

• Hydraulics 

• Maintenance 

• Code requirements 

• Basic design 

• Sprinkler heads 

• Inspection and testing 


Prerequisites 

None 

Class Size 

8 


40 hours 

2 hours 

52


HYDRAULIC COMPONENT TECHNOLOGY & TROUBLESHOOTING 

CERTIFICATION (HCT 200) 


This course is intended for participants involved in ongoing maintenance and repair of 

hydraulic machinery. Participants will be qualified to analyze, troubleshoot, and implement 

long-term solutions to hydraulic machine failures. 


The successful completion of this course should enable the participant to obtain in-depth 

knowledge of: 

1. fluid handling and system filtration requirements; 

2. component operation, interaction and adjustments; 

3. circuit analysis and hydraulic print-reading; 

4. component and system failure modes and corrections; 

5. maintenance techniques, preventative maintenance program and support requirements; 

and 

6. systematic troubleshooting techniques and failure prevention. 


• Safety 

• Directional Controls 

• Flow Controls 

• Proportional Servo Valves 

• Maintenance 

• Pumps 

• Actuators 


• Circuits 

• Pressure Controls 

• Accumulators 

• Failure Analysis 

Certification Test 

A certification test will be administered on the last day of the class. Participants achieving at 

least 70% will receive a numbered certificate from Macomb Community College. 

Prerequisites 

Participants must have completed a basic hydraulics course (HYT 100) or have a fundamental 

knowledge of hydraulic technology. 

Class Size 

8 


80 hours 

53


INDUSTRIAL HYDRAULICS TECHNOLOGY (HDT 100) 


This course introduces participants to hydraulic theory, operation, safety, components, and 

circuits. 



1. understand and demonstrate proper safety procedures for working on hydraulic 

equipment; 

2. read hydraulic schematics and symbols; 

3. identify and understand the operation of common hydraulic components; 

4. understand the basic requirements for fluids, fluid handling, and machine failure 

prevention; 

5. obtain the basic requirements of safe, cost-effective machine operation and preventive 

maintenance techniques; 

6. use a proactive approach to machine repair and effective troubleshooting; 

7. understand the fundamental requirements for hydraulic machine maintenance and 

repair; and 

8. know and implement the procedures for hydraulic trainers (HTU-00). 


Participants will know fundamental hydraulic theory and how to troubleshoot problems with 

hydraulic equipment safely using hydraulic schematics, knowledge of hydraulic components, 

and hydraulic power circuits. 


• Safety procedures with hydraulic equipment 

• Hydraulic schematics 

• Hydraulic components 

• Hydraulic power circuits 

Class Size 

8 


40 Hours 

2 hours 

54


ADVANCED INDUSTRIAL HYDRAULICS 

TECHNOLOGY (HDT 300) 

2 hours 


This course emphasizes advanced learning of hydraulic components, circuitry, component 

failure modes, hydraulic machine troubleshooting and its requirements, proportional and 

servo-valves, basic electricity, and ladder logic. 



1. interpret complex circuitry to enhance troubleshooting skills; 

2. reinforce fundamental principles of hydraulic machine functions; 

3. recognize the operation and purpose of sub-circuits; 

4. understand the maintenance requirements (record keeping) for machines using effective 

predictive maintenance; 

5. recognize the symbols, function, requirements, application and theory of operation of 

proportional valves, servo valves, and slip-in cartridge valves; 

6. understand basic electrical principles and ladder logic; and 

7. troubleshoot circuits on an active hydraulic simulator (test stand). 


• Reading hydraulic schematics for troubleshooting 

• Variety of valves (directional, relief, check, multiple valve manifolds) 

• Actuators 

• Pressure controls 

• Flow and directional controls 

• Fluids 

• Filtration 

• Hydraulic and fluid power formulas applied to industrial settings 

• Hydraulic and fluid power graphical symbols 

Class Size 

8 


40 Hours 

55


LASER ALIGNMENT (LZT 100) 


This course provides participants with the knowledge and experience to identify types of 

alignment systems through the safe application of laser devices, such as Hamar Laser’s 

Geometry, Spindle, and Shaft alignment systems in a simulated machine build experience. 



1. utilize laser safety; 

2. identify and describe equipment and functions of each alignment system; 

3. correctly set up and have a basic knowledge of the Hamar Geometry, Spindle, and 

Shaft systems; 

4. identify necessary aspects of alignment and procedures required for machine repair; 

5. install and use proper alignment; and 

6. use Plane5, Spindle8, Read8 and Couple4 Windows-based software. 


To provide the participant with the skills necessary to apply the proper alignment practices 

needed. 


• Terminology of laser alignment definitions 

• Foundation prep and utilization of Unisorb AK Fixator System 

• Set-up of the simulated transfer line utilizing the Hamar Laser Geometry System 

• Alignment of machining spindles to master parts to simulate drilling, tapping and 

reaming operations as in a transfer line application 

Class Size 

8 


40 hours 

2 hours 

56


LASER LEVELING (LAT 100) 


This course covers how to work safely with laser leveling equipment. Participants will gain 

knowledge and hands-on experience in setup and operation of transits and laser and optical 

instruments for leveling industrial machinery, layout of building perimeters, and use of laser 

instruments to set piping. 



1. understand all safety aspects of working with laser leveling equipment; 

2. use appropriate math to calculate corrections using lasers and optical instruments; 

3. set up and operate laser and optical instruments; 

4. set up a transit; 

5. level industrial machinery; 

6. shoot grades and slopes; 

7. layout building perimeters; and 

8. use laser instruments to set piping. 


The participant will have a practical knowledge of laser leveling necessary to install and 

maintain industrial equipment and machinery. 


• Laser safety 

• Laser operation 

• Setting benchmarks 

• Correcting existing equipment 

• Methods for machine alignment 

• Methods for leveling 

Prerequisites 

None 

Class Size 

8 


40 hours 

2 hours 

57


INDUSTRIAL PNEUMATIC TECHNOLOGY (IPT 200) 


This course provides participants with the knowledge and skills required to install, maintain, 

troubleshoot, repair, and set up pneumatic systems in industrial settings. 



1. match the pneumatic components name with its schematic symbol; 

2. solve pneumatic calculations such as those dealing with force, pressure, and area, and 

convert readings to pneumatic units; 

3. approximate the change in actuator speed given different situations; 

4. identify the characteristics of direction control valves; 

5. match the applications to flow control valves (ball, globe, need, fixed orifice) 

6. Identify metering circuits in pneumatic systems 

7. Identify different applications of check valves; 

8. Safely connect, operate and analyze the operation of circuits using available gages; 

and 

9. use plant equipment drawings to identify the proper name and function of all pneumatic 

components, circuit action in component failure, select indicators and manual valve 

operators to isolate failed component and identify possible danger with two-position 

dented valves. 


• Safety procedures with pneumatic equipment 

• Pneumatic schematics 

• Pneumatic systems 

• Compressors 

• Aftercoolers, driers, receivers and air distribution systems 

• Check valves, cylinders and motors 

• Directional control valves 

• Flow control valves, silencers and quick exhausts 

• Regulators, excess flow valves, boosters and sequence valves 

• Air preparation 

Class Size 

12 


40 Hours 

2 hours 

58


UNIVERSAL PUMP TECHNOLOGY (UPT 200) 


DEVELOPMENT 

59


REBUILDING & REPACKING STEAM VALVES & TRAPS (SVT 200) 

2 hours 


Participants will learn to repair and maintain steam valves and traps that distribute steam, 

water, air, gas, and vacuum. Participants will also learn to troubleshoot and safely rebuild, 

repack and test steam valves and traps. 



1. understand the operation and utilization of basic steam traps used in steam systems; 

2. diagnose faults within steam trap operation; 

3. repair, rebuild, and replace basic steam traps; 

4. understand the safety precautions required when inspecting, rebuilding/repacking, 

and testing steam traps and valves; 

5. determine if the position of valves ensures operation within manufacturer’s 

specifications; 

6. detect leaks in steam systems, traps, and valves; and 

7. identify the various types of steam traps. 


To provide participants with the ability to troubleshoot and repair valves and traps used in 

industrial mechanical/steam systems. 


• Review basic physics concepts 

• Vaporization and condensation 

• Properties of saturated steam 

• Pressure reducing valves 

• O, S & Y valves 

• Non-return valves 

• Relief valves 

• Safety valves 

• Check valves 

• Vacuum breakers 

• Formulas 

• Strainers 

• Safety 

• Inverted bucket traps 

• Float and thermostatic traps 

• Thermostatic traps 

• Float traps for air systems 

• Troubleshooting techniques 

Prerequisites 

None 

Class Size 

12 


40 hours 

60


INDUSTRIAL RIGGING (IMT 300) 


This course covers the use of rigging gear such as hooks, nylon slings, wire rope, wire rope 

slings, fiber rope, chains, chain slings, hoist chains, and metal mesh slings. Participants will 

utilize the TTC’s 20-ton crane for rigging exercises. 



1. inspect various equipment for safety; 

2. determine safe load limits; 

3. figure balance point of loads; and 

4. apply the techniques of a skilled rigger. 


To train the participant involved in rigging to do so efficiently and, above all, safely. 


How to inspect, select, and safely use: 

• Hooks 

• Nylon slings 

• Wire rope slings 

• Wire rope 

• Chains 

• Chain slings 

• Hoist chain 

• Metal mesh 

• Metal mesh slings 

Prerequisites 

None 

Class Size 

12 


40 hours 

2 hours 

61


THERMOGRAPHY (THT 200) 


The participant will learn how to use a Heat Imaging Camera to successfully locate and 

diagnose heat problems throughout the plant. The knowledge given is applicable to all trades 

because heat can be a problem in all types of industrial machinery and power supplies. 



1. correctly operate an Infrared Heat Thermography Camera; 

2. identify hot spots in rotating equipment; 

3. determine if there are hot spots in hydraulic equipment; 

4. locate electrical problems that are causing excessive heat; 

5. perform a building scan to find areas of heat loss in roofs and walls; 

6. search out and find overloaded circuits that create a heat problem; and 

7. use the camera correctly to find sources of overload in power supplies. 

2 hours 


To give participants the ability to correctly use an Infrared Camera in a variety of situations 

to identify, measure, and troubleshoot heat-related problems in equipment and facilities. 


• Safety 

• Buss scans 

• Gear boxes 

• Fluids 

• Pumps 

• Electrical scans 

• Circuit breakers 

• Mobile equipment 

• Molding equipment 

• Hydraulic scans 

• Steam valves 

• Wiring 

• Chemical 

• Emissivity 

• HVAC 

• Electric motors 

• Misalignment 

• Rotating equipment 

• Machining equipment 

• Building heat loss 

Prerequisites 

There are no prerequisites for this course, however, all participants from each trade must 

come to class with a desire to participate and learn how Heat Thermography can help them 

with their specific trades. 

Class Size 

8 


40 hours 

62


INTRODUCTION TO AIRBORNE ULTRASOUND (UST 100) 


This course introduces the basic principles of Airborne Ultrasound and demonstrates the 

proper usage of the equipment in plant predictive maintenance applications. 



1. integrate Ultrasound with other predictive maintenance technologies; 

2. understand how airborne ultrasound detection works; and 

3. properly use airborne ultrasound by covering principles, theory and practical 

applications conforming to the American Society of Non-Destructive Testing (ASNT) 

Standards. 


• Maintenance of the equipment 

• Ultrasound wave transmission and effects 

• Leak detection in: pneumatic systems, 

heat exchangers, underground pipes, 

closed vessels, chillers, condensers, and 

vacuum systems 

• Electrical Inspection: Detecting Arcing, 

and Corona 

• Theory of sound 

• Perform an Ultrasonic inspection 

• Mechanical Inspection: valve 

blow-by, circulation pumps, 

bearing wear, pump cavitations, 

steam traps, and lubrication 

Prerequisites 

None 

Class Size 

8 


40 hours 

63


VIBRATION ANALYSIS, ALIGNMENT, & BALANCING (VAT 100) 


The participant should be able to diagnose and measure vibration problems, use various tools 

and techniques to adjust alignment, and perform correct balancing. 



1. diagnose vibration problems; 

2. measure phase and vibration; 

3. analyze a spectrum; 

4. choose transducers; 

5. use spike energy; 

6. determine resonance; 

7. do reverse indicator alignment; 

8. compensate for thermal growth; 

9. determine balance weight; and 

10. perform correct balancing. 


To provide the participant with the ability to troubleshoot vibration problems encountered 

in rotating equipment using vibration analysis as well as how to properly align and balance 

rotating equipment. 


• Basic vibration concepts as they relate to problems with rotating equipment 

• Single channel FTT analysis 

• Proper alignment procedures 

• Single and dual plane balancing 

Prerequisites 

None 

Class Size 

12 


40 hours 

2 hours 

64


WELDING 

65

The UAW-Chrysler 

Technology Training Center 

is a proud member of the 

American Welding Society (AWS) 

ABOUT THE WELDING TRAINING LAB 

The Welding Training Lab is jointly operated by the UAW-Chrysler Technology Training 

Center and Chrysler Advanced Technical Training Services (ATTS). Its goal is to provide 

Chrysler workers with the opportunity to upgrade their workmanship and technical knowledge 

of the welding processes related to their respective trades. 

ABOUT THE WELDING COURSES 

✚ Since safety is a major concern, please be aware that Welding Safety & Overview of Processes 

(WPT 100) is a prerequisite for all other welding classes. This course, the former TTC course 

Welding & Cutting Safety (WST 050), or another documented welding safety course must be 

completed in order to register for ANY of the welding classes in this catalog. 

66

Welding: 

WELDING SAFETY & OVERVIEW OF PROCESSES (WPT 100) 

2 hours 


Designed for Skilled Trades workers, this course will provide participants the ability to safely 

set up and operate oxy-fuel cutting and electric arc welding equipment. 


Successful completion of the course should provide the participant with the knowledge of: 

1. related hazards and safety precautions; 

2. proper set up and adjustment of pressure gauges, regulators, and check valves; 

3. a step-by-step start-up and shutdown procedure of the oxy-fuel gas equipment; 

4. acetylene versus MAPP or propylene-based fuel gases; 

5. safe operation of electric arc welding and cutting equipment; 

6. plasma arc cutting ferrous and non-ferrous metals; 

7. oxy-fuel gas cutting and heating with an understanding of: the process, types of 

industrial gases, setup and adjustment of equipment, preparatory procedures, and 

check valve maintenance; 

8. flux cored and gas metal arc welding with an understanding of: the process, types of 

equipment, shielding gases, electrode wires, variables, safety procedures, and handson 

applications; 

9. gas tungsten arc welding with an understanding of: the process, types of equipment, 

shielding gases, electrodes, filler materials, process variations, applications, and quality 

welding; and 

10. shielded metal arc welding, and AC/DC equipment electrode selection. 


The participant should acquire a general understanding of manual and semi-automatic 

welding processes used in metal working industries. In addition, the course will prepare the 

participant to safely operate oxy-fuel gas and electric arc welding equipment per Chrysler 

MTI SMI-116. 


• Related hazards and safety precautions 

• Proper setup of oxy-fuel gas and electric 

arc welding equipment 

• Shielded metal arc welding 

• Gas metal arc welding 

• Gas tungsten arc welding 

• Plasma arc welding 

• Oxy-fuel gas cutting 

Prerequisites 

A basic understanding of the welding process and some previous welding experience are 

strongly recommended, but not required. 

Class Size 

12 


40 hours 

67

Welding: 

WELDING ALUMINUM ALLOYS (WAT 200) 


The participant should be able to select the appropriate welding process for aluminum, select 

the appropriate filler metal, set up and adjust the welding equipment, and produce acceptable 

quality welds on aluminum alloys. 


The successful completion of this course should give the participant a working knowledge of 

welding aluminum alloys, including: 

1. types and uses of aluminum materials, work hardenable alloys, heat treatable alloys, 

and cast alloys; 

2. physical characteristics of aluminum, including: melting temperature ranges, thermal 

conductivity, and the refractory oxide scale; 

3. welding preparation and problem areas, including: safety procedures, operation 

sequences, and weld quality problems; and 

4. hands-on applications using Gas Metal Arc and Gas Tungsten Arc Welding processes, 

including: process variations, equipment, and weld quality inspection. 


The participant should have the skills necessary to weld aluminum alloys using recommended 

welding processes and filler metals. 


• Introduction to welding aluminum 

• Physical characteristics of aluminum 

• Preparation for welding 

• Gas metal welding 

• Tungsten arc welding 

Prerequisites 

Participants should have some previous welding experience using MIG & TIG on steel alloys. 

In addition, participants must meet ONE of the following: completion of Welding Safety & 

Overview of Processes (WPT 100), equivalent welding safety training at a community college, 

or certification from a welding safety course. 

Class Size 

6 


40 hours 

2 hours 

68

Welding: 

BASIC STICK WELDING (SMAW) (WBT 200) 


The participant learns what the requirements are to produce quality welds using the Shielded 

Metal Arc Welding (SMAW) process. Commonly referred to as “stick welding,” SMAW is the 

oldest, but still the most common of the electric arc welding processes. 



1. describe the types of power sources commonly used for SMAW; 

2. identify the different kinds of welding rods; 

3. prepare the metal for welding; 

4. produce quality welds on steel in the flat and horizontal welding positions; and 

5. visually inspect welds and identify problems. 


To provide participants with the ability to produce quality welds on steel using the shielded 

metal arc welding process. 


• Types of welding power sources 

• SMAW electrode selection 

• American Welding Society recommended practices for welding joint design 

• Hands on welding experience 

• American Welding Society recommended practices for visual weld inspection 

Prerequisites 

Participants must meet ONE of the following: completion of Welding Safety & Overview of 

Processes (WPT 100), equivalent welding safety training at a community college, or certification 

from a welding safety course. 

Class Size 

6 


40 hours 

2 hours 

69

Welding: 

GAS METAL ARC (MIG) WELDING PROCESS (WET 200) 


This course covers safe procedures for equipment set-up; fundamentals of gas metal arc 

welding; and gas, electrode, and filler metal selection. 



1. set up and adjust gas metal arc welding equipment; 

2. select the correct shielding gas, electrodes, and filler metal; and 

3. weld fillet, groove, and surfacing welds using the MIG welding process. 


The participant should be able to successfully produce quality fillet, groove, and surfacing 

welds on materials ranging from sheet metal to structural steel using the MIG welding 

process. 


• Welding safety 

• Equipment setup 

• Fundamentals of gas metal arc welding and its applications 

• Gas electrode wire and filler metal selection 

Prerequisites 

To obtain the maximum benefit from this training, participants should possess a fundamental 

knowledge of fusion welding. In addition, participants must meet ONE of the following: 

completion of Welding Safety & Overview of Processes (WPT 100), equivalent welding safety 

training at a community college, or certification from a welding safety course. 

Class Size 

6 


40 hours 

1 hour 

70

Welding: 

GAS TUNGSTEN ARC (TIG) WELDING PROCESS (WVT 200) 


The participant should be able to safely use metal arc welding equipment, recognize process 

variations, and carry out appropriate fillet and square groove welds on steel using the TIG 

process. 



1. set up and adjust gas metal arc welding equipment; 

2. select the correct shielding gas, electrodes, and filler materials; 

3. identify the process variations and applications; and 

4. weld fillet and square groove welds on carbon and stainless steel using the TIG welding 

process. 


The participant should be able to successfully produce quality fillet and square groove welds 

on carbon and stainless steel using the TIG welding process. 


• Welding safety 

• Process variations 

• Fundamentals of gas, metal gas, electrode, and filler metal selection 

Prerequisites 

To obtain the maximum benefit from this training, participants should possess a fundamental 

knowledge of fusion welding. In addition, participants must meet ONE of the following: 



Class Size 

6 


40 hours 

2 hours 

71

Welding: 

PIPE & TUBE WELDING (WXT 200) 

3 hours 


Upon arrival on the first day of class, participants will be asked to designate a process (GMAW/ 

MIG, SMAW, or GTAW) and training will be provided in that area. 

Overall Course Objective 

The participant should acquire the skills necessary to produce acceptable quality welds on 

pipe and tubing. 

MIG: WXT 200 


Upon successful completion of this course, the participant should be able to prepare, fit and 

tack weld pipe joints; weld pipe in all positions using the MIG process; and inspect completed 

welds for quality. 


• Setup and adjustment of MIG equipment for welding pipe 

• Manual techniques to perform quality welds in the 2F, 5F, IGR, 2G, 5G and fixed 

positions 

• Review of pre-qualified welding procedure specifications 

Description 

The participant will be able to prepare, fit, and tack weld pipe joints; weld pipe in all positions 

using the MIG process; and inspect completed welds for quality. 

Prerequisites 




SMAW: WXT 201 


Upon successful completion of this course, the participant should be able to prepare, fit, and 

tack weld pipe joints; weld pipe in all positions using the gas metal arc welding (GMAW) 

process; and inspect completed welds for quality. 

72 

Continued Next Page ➙

(Pipe & Tube Welding Continued From Previous Page) 


• Setup and adjustment of shielded metal arc equipment for welding pipe 

• Manual techniques to perform quality fillet and grove welds in the 2F, 5F, IGR, 2G, 5G 

positions 

Description 


using the stick process; and inspect completed welds for quality. 

Prerequisites 

Participants must have sucessfully completed Advanced Sturtcural Steel Welding (WTT 300). 

GTAW: WXT 202 


Upon successful completion of this course, the participant should be able to prepare, fit, and 

tack weld pipe joints; weld pipe in all positions using the gas tungsten welding process; and 

inspect completed welds for quality. 


• Review of the TIG welding process and electric arc safety 

• Welding codes and specifications 

• Joint designs and variables that affect quality 

• Manual techniques to perform quality welds in the IGR, 2G, 5G and 6G positions 

Description 


using the TIG process; and inspect completed welds for quality. 

Prerequisites 

To obtain maximum benefit from this training, participants should already be qualified to 

weld “V” groove butt joints on plate materials in all positions. In addition, participants must 

meet ONE of the following: completion of Welding Safety & Overview of Processes (WPT 100), 

equivalent welding safety training at a community college, or certification from a welding 

safety course. 

Class Size 

6 


80 hours 

73

Welding: 

TROUBLESHOOTING ROBOTIC & AUTOMATIC WELDING SYSTEMS 

(WWT 200) 


Designed for Skilled Trades workers, this course will provide participants with the skills 

necessary to troubleshoot robotic and automatic welding systems. This course is intended 

to improve welding efficiency and product quality. Emphasis will be placed on gathering 

information required for identifying weld quality problems, locating the root cause of the 

problem, and making the necessary repairs or adjustments to the welding system. 



1. describe the safety requirements specific to welding and cutting operations that use 

high-speed automated welding equipment; 

2. describe the operating characteristics of gas metal arc and flux cored arc welding; 

3. describe what welding parameters affect weld quality; 

4. describe how welding fixtures and tooling can affect weld quality; 

5. describe the effect of travel direction and cycle speed on weld penetration and 

contour; 

6. destructively inspect welds for fusion, penetration, and contour; and 

7. use Chrysler welding specifications to determine the capability of a robotic or automatic 

welding system to produce quality production welds. 


To provide participants with the ability to troubleshoot robotic and other dedicated highspeed 

production welding systems. 


• Gas metal arc welding principles of operation 

• Flux cored arc welding principles of operation 

• Welding procedures development. 

• Visual and destructive weld examination 

• Troubleshooting welding equipment 

• Chrysler welding specifications 

Prerequisites 

None 

Class Size 

6 


40 hours 

74 

1 hour

Welding: 

STRUCTURAL STEEL WELDING (WTT 200) 


The participant should be able to prepare structural steel for welding; set up and adjust 

welding equipment; and weld structural steel in horizontal positions. 


Upon completion of this course, participants should have a thorough understanding of: 

1. Shielded Metal Arc (GMAW) and Flux Cored Arc Welding (FCAW) fundamentals; 

2. welding safety; 

3. setup and adjustment of arc welding machines; 

4. electrode classifications and selection; and 

5. the hands-on skills needed to produce welds in horizontal positions. 

(Note: Vertical and overhead position welding are not offered in this course.) 


To enable the participant to produce acceptable quality welds on structural steel using the 

shielded metal arc and flux cored welding processes. 


• Material specification 

• Weld joint design 

• Tacking and fit up 

• Filler metal selection 

• Welding techniques 

• Storage of low hydrogen electrode 

• Setup and adjustment of equipment 

Prerequisites 




Class Size 

6 


40 hours 

2 hours 

75

Welding: 

ADVANCED STRUCTURAL STEEL WELDING (WTT 300) 


The participant welds structural steel in all welding positions using the Shielded Metal Arc 

and Flux Cored Arc welding processes. 



1. set up and adjust shielded metal arc welding equipment; 

2. set up and adjust flux cored arc welding equipment; 

3. prepare structural steel for welding; 

4. weld structural steel in all welding positions; and 

5. weld complete penetration fillet and groove welds in the vertical and overhead 

positions. 


To provide participants with the ability to produce quality welds on structural steel in all 

welding positions. 


• Electrode selection for welding structural steel with the SMAW process 

• Self shielded and gas shielded electrode wires for FCAW welding on structural steel 

• Techniques for groove welds with and without backing 

• Visual and destructive weld examination 

Prerequisites 

All participants should have completed Structural Steel Welding (WTT 200). In addition, all 

participants must meet one of the following requirements: completion of Welding Safety & 

Overview of Processes (WPT 100), equivalent welding safety training at a community college, 

or certification from a welding safety course. 

Class Size 

6 


40 hours 

2 hours 

76

Welding: 

WELDING TOOL & DIE STEELS (WDT 200) 


This course covers the skills and knowledge needed to select and apply approved welding 

procedures on various tool and die steels. Hands-on performance objectives and technical 

discussions relating to the weldability of each type of steel should ensure applications. 


The successful completion of this course should enable the participant to: 

1. identify various tool steels; 

2. select proper filler metals; 

3. apply the appropriate preheats; 

4. weld repair worn or broken tools; and 

5. apply the appropriate post-weld heat treatment. 


The participant will successfully repair weld tool and die steels using approved welding 

processes and procedures. 


• Hardness testing 

• Material identification 

• Preheat and postheat schedules 

• Preparation of material surfaces for welding 

• Welding repair procedures for tool steels and cast die materials 

Prerequisites 

All participants should have a working knowledge of gas metal arc (GMAW), flux cored arc 

(FCAW), shielded metal arc (SMAW), and gas tungsten arc (TIG) welding, as well as oxy-fuel 

gas heating tips and accessories. In addition, participants must meet ONE of the following: 



Class Size 

6 


40 hours 

2 hours 

77

Welding: 

QUALIFICATION/CERTIFICATION OF… (WQT 400-WQT 407) 

Upon arrival, training participants will be asked to designate a specific area of certification. Each area 

of certification is its own specific course (topics covered are summarized below). 

• A participant may be certified in any or all of them as long as each course’s prerequisites 

are met. 

• Each course has its own set of prerequisites that must be met before registration is 

allowed. Prerequisites may be met through TTC courses or other equivalent formal 

training. 

Overall Course Objective 

The participant will demonstrate welding skills by completing welder qualification test(s) 

as specified by the American Welding Society, American Society of Mechanical Engineers, 

and/or the Canadian Welding Bureau. 

The specific topics covered in each certification are as follows: 

Welding Skills For Structural Steel (WQT 400) 

The participant must pass a visual inspection and a bend test or fillet break test. 

2 hours 

Welding Skills for Structural Aluminum (WQT 401) 

Includes a review of welding procedure specifications, variables that affect weld quality, 

and preparation of metal coupons for destructive testing. The participant must pass a visual 

inspection and a bend test or fillet break test. 

Welding Skills for Steel Pipe (MIG) (WQT 402) 

Includes a review of welding codes and qualifications, safe practices, material preparation 

and fit up of joint details. The participant must pass a visual inspection and a bend test or 

fillet break test. 

Welding Skills for Steel Pipe (GMAW) (WQT 403) 

Includes a review of welding codes and qualifications, safe practices, and material preparation 

for welding of steel pipe needed to meet industrial welding code requirements. The participant 

must pass a visual inspection and a bend test or fillet break test. 

Welding Skills For Pipe & Tube (TIG)(GTAW) (WQT 404) [80 hours] 

Includes a review of welding codes and qualifications, safe practices, and material preparation 

for welding of steel pipe and tube needed to meet industrial welding code requirements. The 

participant must pass a visual inspection and a bend test or fillet break test. 

78 

Continued Next Page ➙

(WQT 400-WQT 407 Continued From Previous Page) 

Welding Skills For Tool & Die (WQT 405) 

Includes a review of allowable repairs, problem solving exercises, and acceptance criteria per 

Chrysler Die Engineering processes standards needed to repair tool and die materials. The 

participant must pass a visual inspection, a cross-section and etch test, and a die penetrant 

test inspection. 

Welding Skills for Sheet Metal, Steel, & Stainless (WQT 406) 

Includes a review of welding codes and specifications; material preparation and joint fit-up; 

distortion control; and selection of electrodes, filler metals, and shielding gases. The participant 

must pass a visual inspection and a bend test or fillet break test that meets AWS Sheet Metal 

Welding Code D9.1 requirements. 

Welding Skills for Sheet Metal Aluminum (WQT 407) 

Includes a review of welding codes and specifications; material preparation and joint designs; 

distortion control; and selection of electrodes, filler metals, and shielding gases. The participant 

must pass a visual inspection and a bend test or fillet break test that meets AWS Sheet Metal 

Welding Code D9.1 requirements. 

Class Size 

6 


40 hours (except for WQT 404—80 hours) 

Important Information Concerning the Qualification & Certification Courses 

The TTC offers eight different types of Welding Qualification/Certification. Each one has been 

designed to meet specific welding needs. (See previous page for a brief description of each.) 

• You may be certified in any or all of them as long as you meet each course’s 

prerequisites. 

• Each course has its own set of prerequisites that must be met before registration is 

allowed. 

• Prerequisites may be met through TTC courses or other equivalent formal training. 

• A complete list of prerequisites for each type of certification may be obtained from a 

Local Technical Training Committee Member, your Local Joint Training Coordinator, 

or Plant Training Coordinator. 

79

INDEX 

1394 Motion Control Operations & Maintenance, Allen-Bradley (BAT 410) ...........................22 

AC Motors, Troubleshooting (ACT 100) ......................................................................................39 

ABB M2000A, IRB 6600 S4C/C C+ Electrical Maintenance & 

DCX Programming Standards Level 2, Robotics: (BBT 250) ............................................27 

ABB S4C/C+ Programming Level 1, Robotics: (BBT 100) ..........................................................25 

ABB S4C/C+ Electrical Maintenance & Troubleshooting Level 2, Robotics: (BBT 200) ........26 

Air Logic, Industrial (ALT 101) .......................................................................................................41 

Bearing Predictive Maintenance, Industrial (BMT 100) ..............................................................43 

CATIA V5 Fundamentals (CAT 101) ...............................................................................................2 

Conduit Installation, Industrial (ICT 200) .....................................................................................44 

Advanced ControlLogix (BAT 375) ................................................................................................21 

ControlLogix Processor Family Using RSLogix 5000 Software, Allen-Bradley (BAT 175) ....13 

ControlLogix with ControlNet, Intermediate (BAT 275) ............................................................16 

ControlNet, Troubleshooting the Allen-Bradley (CRT 300) .......................................................14 

Control Systems, Troubleshooting In-Plant (BAT 420) ...............................................................23 

DeviceNet with ControlLogix (BAT 475) ......................................................................................24 

DeviceNet, Troubleshooting the Allen-Bradley (DNT 300) ........................................................15 

Die Making Technology (MDT 100) .................................................................................................6 

Electrical/Electronic Fundamentals (IET 105) ..............................................................................46 

Electrical Controls & Schematics (EST 100) .....................................................................................3 

Electrical Troubleshooting (ETT 200) ....................................................................................................45 

Fanuc RJ2-RJ3 Electrical Maintenance & Troubleshooting, Robotics: (FRT 350) .....................29 

Fanuc RJ2-RJ3 Operation & Programming, Robotics: (FRT 300) ...............................................28 

Fiber Optic & Copper Communications Cabling 1 (FOT 110) ...................................................49 



Fire Systems Training (FST 100) .....................................................................................................52 

Geometric Dimensioning and Tolerancing for Manufacturing (GDT 100) ................................5 

Grounding & Bonding (IET 210) .....................................................................................................47 

Hydraulic Component Technology & Troubleshooting Certification (HCT 200) ...................53 

Hydraulics Technology, Industrial (HDT 100) .............................................................................54 

Industrial Hydraulics Technology, Advanced (HDT 300) ..........................................................55 

Laser Alignment (LZT 100) ..............................................................................................................56 

Laser Leveling (LAT 100) .................................................................................................................57 

Mechanical Schematics (MST 100) ....................................................................................................4 

Metallurgy, Fundamentals of (WLT 200) ........................................................................................7 

Metallurgy-Heat Treating, Advanced (WLT 300) ..........................................................................8 

Mill Programming & Operation, ProtoTrak (CNT 130) ..............................................................12 

80

Mills, CNC Setup & Operation for (CNT 120) ..............................................................................11 

Nachi AR 52 Electrical Maintenance, Robotics: (RNT 360) .........................................................32 

Nachi AW 11 Electrical Maintenance, Robotics: (RNT 375) ......................................................33 

Nachi AX Operation Programming, Robotics: (RNT 500) ..........................................................34 

Nachi AX Electrical Maintenance & Troubleshooting, Robotics: (RNT 550) ..........................35 

Nachi Operation/Programming for the AR 11/AR 52 Controllers, Robotics: (RNT 320) .....30 

Nachi Operation/Programming for the AW11 Controller, Robotics: (RNT 330) ...................31 

PanelView 1400e, Allen-Bradley (BAT 310) ..................................................................................17 

PLC5 Processor Family/RSLogix Software, Allen-Bradley (BAT 335) .....................................20 

Pneumatic Technology, Industrial (IPT 200) .................................................................................58 

Pump Technology, Universal (UPT 200) ..............................................................................................59 

Punch Die Finishing (PUT 100) .........................................................................................................9 

Qualification/Certification of Welding... (WQT 400-WQT 407) .......................................... 78-79 

Refrigerant Transition & Recovery Certification (AIT 100) ........................................................40 

Refrigeration & Air Conditioning, Principles of (ART 100) .......................................................42 

Rigging, Industrial (IMT 300) ..........................................................................................................61 

RSLogix 5 Software for Allen-Bradley PLC5 (BAT 330) ..............................................................19 

RSLogix 5 Software for Allen-Bradley SLC 500 (BAT 320) .........................................................18 

Steam Valves & Traps, Rebuilding & Repacking (SVT 200) .......................................................60 

Telemecanique, Advanced (TMT 200) ...........................................................................................37 

Telemecanique, Introduction to (TMT 100) ...................................................................................36 

Thermography (THT 200) ................................................................................................................62 

Transformers & Feeders (IET 215) ..................................................................................................48 

Ultrasound, Introduction to Airborne (UST 100) .........................................................................63 

Vibration Analysis, Alignment, & Balancing (VAT 100) .............................................................64 

Welding Aluminum Alloys (WAT 200) .........................................................................................68 

Welding Safety & Overview of Processes (WPT 100) ..................................................................67 

Welding Systems, Troubleshooting Robotic & Automatic (WWT 200) ....................................74 

Welding Tool & Die Steels (WDT 200) ...........................................................................................77 

Welding Training Lab, About the ..................................................................................................66 

Welding, Pipe & Tube (WXT 200) ............................................................................................ 72-73 

Welding, Advanced Structural Steel (WTT 300) ..........................................................................76 

Welding, Structural Steel (WTT 200) ..............................................................................................75 

Welding Courses, About the ...........................................................................................................66 

Welding Process, Gas Metal Arc (MIG) (WET 200) .....................................................................70 

Welding Process, Gas Tungsten Arc (TIG) (WVT 200) ................................................................71 

Welding (SMAW), Basic Stick (WBT 200) .....................................................................................69 

81

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