TTC Course Descriptions Catalog - UAW-Chrysler.com

TTC Course Descriptions 

UAW-DaimlerChrysler 

Technology Training 

INTRODUCTION 

The UAW-DaimlerChrysler Technology Training Center (TTC), which is a program of the UAW-DaimlerChrysler 

National Training Center (NTC), was created by the UAW-DaimlerChrysler Joint Activities Board (JAB) in an 

effort to further improve the skills of an already world-class workforce. In 1993, the UAW and DaimlerChrysler 

negotiated a joint commitment to New Technology training (Letters 125 and 181) for the UAW-represented 

DaimlerChrysler workforce. The 2003 National Agreement includes Letters 125 and 181 which demonstrate 

the commitment of both the UAW and DaimlerChrysler to provide ongoing training. 

This joint commitment ensures: 

• A common understanding of the new and emerging technologies being introduced 

• A mutual commitment to the implementation of new technical training 

• Better acceptance of training by the UAW-represented workforce 

• Increased productivity leading to globally competitive products, job security, and profi tability 

• A common direction 

• Apprenticeship 

Another indicator of joint commitment to technical training is the formation of Local Technical Training 

Committees (LTTCs) at major manufacturing facilities. Established in 1996 through Letter 190, and updated 

in the 2003 National Agreement, LTTCs plan and coordinate local technical training and coordinate training 

activities between plants and the UAW-DaimlerChrysler Technology Training Center. 

COURSE DESCRIPTIONS CATALOG 

This catalog is your primary reference source for courses at the TTC. Periodically, course date availability will 

be sent to Local Technical Training Committee members. In addition, a full, detailed and up-to-date course 

catalog is available online at http://www.uawdcx.com/training/TOC.pdf. Any new courses or course changes 

are provided through TTC Updates to LTTC Members. 

PLEASE NOTE 

Please keep this catalog as it will be your primary 

reference for the next couple of years. 

1


ENROLLMENT PROCEDURE 

Production workers, Skilled Trades workers, and Salaried Bargaining Unit (S.B.U.) members who meet course 

prerequisites are eligible to be selected for appropriate course attendance. LTTC members may make course 

recommendations based on their knowledge of the plant’s training needs, the participants’ training backgrounds, 

and the TTC’s prerequisites for certain courses. 

The key symbol 

course. 

signifi es that training participants who are not from DaimlerChrysler may not take this 

The UAW Local President (or designee) and the Plant Manager (or designee) must sign the enrollment 

forms. 

PLEASE NOTE 

Sending in an enrollment form does not guarantee 

acceptance into a class. The participant is officially 

enrolled only when the plant receives confirmation from 

the TTC. 

Questions concerning course enrollment should be directed to the appropriate Technology Training Center 

Plant Liaison at 1-586-427-4033 or 1-586-427-4039 from 8:00 A.M. to 4:00 P.M. Eastern Time. 

ENROLLMENT MATERIALS 

The TTC will send confi rmation of class enrollment to the LTTCs. LTTC members must then notify the training 

participants and their immediate supervisors. 

QUESTIONS REGARDING REGISTRATION 

LTTC members who have questions regarding enrollment should call their Plant Liaison at the TTC at 1-586- 

427-4033 or 1-586-427-4039 from 8:00 A.M. to 4:00 P.M. Eastern Time. 

2


ENROLLMENT CANCELLATIONS 

Training participants who absolutely must cancel their TTC enrollment need to contact their LTTC member 

or Training Coordinator. 

PLEASE NOTE 

All cancellations occuring fewer than seven days 

before the scheduled start of a class will be subject to a 

cancellation fee. 

TRAVEL & ACCOMMODATIONS 

The UAW-DaimlerChrysler Technology Training Center staff will make the necessary travel and accommodation 

arrangements for participants from plants outside the Detroit area. The Travel Itineraries are sent to the LTTC 

members, who will then distribute them to the training participants. Return fl ights will not be scheduled prior 

to 2:00 P.M. (Eastern Time) on Fridays. 

TRAVEL CANCELLATIONS 

Training participants who absolutely must cancel their travel arrangements or accommodations need to contact 

the TTC as soon as possible, but no later than 3:00 P.M. (Eastern Time) on the Friday before the class is to 

start. The LTTC member, the Plant Training Coordinator, or the participant should call the Registration Desk 

at 1-800-683-8840. 

IMPORTANT! 

Anyone who must cancel after 3:00 P.M. (Eastern Time) on 

the Friday before training is to start must call the Sterling 

Inn directly at 1-800-953-1400 to cancel his/her lodging 

reservations, otherwise lodging costs will be incurred. 

The hotel staff will provide a cancellation number, which the participant should give to an LTTC member or the 

Plant Training Coordinator on the following Monday. The toll-free number is for cancellations only and other 

calls will not be taken on this line. The main telephone number for the hotel is 586-979-1400. 

Participants who cancel must also turn in their unused travel tickets to an LTTC member or the Plant Training 

Coordinator as soon as possible. This will help minimize the costs associated with cancellations. 

3


SKILL CERTIFICATION 

Some courses may offer certifi cation, which will be indicated, if available, in the “Course Description” section. 

Participation in certifi cation is purely voluntary on the part of training participants. On the fi rst day of class, the 

instructor will explain specifi c requirements and procedures needed to obtain certifi cation. (PLEASE NOTE: 

Certifi cation is NOT the same as earning college credit, which is explained in the next section.) 

COLLEGE CREDIT 

The Technology Training Center has made it possible for participants to earn transferable college credit for 

certain courses taken at the TTC. The American Council on Education’s Credit Recommendation Service 

has evaluated the TTC’s courses for compatibility with established college criteria. The amount of credit 

recommended by ACE varies from course to course. An eligible course is designated by the graduation 

cap symbol located in the top right corner of the course description. Courses being reviewed for ACE credit 

consideration are designated by the graduation cap symbol with a question mark. For specifi c course eligibility 

information, please refer to the TTC area of the NTC’s Website. 

More than 1,800 accredited degree-granting colleges and universities and 

higher education-related associations, organizations, and corporations 

have accepted ACE’s credit recommendations. All recommendations are 

subject to each individual institution’s overall policy and are based on the 

credit recommendations from the appropriate academic department. Once 

a college or university accepts the transfer of credit, that credit is applied 

toward the total number of credits needed for a particular degree. 

Credit 

Eligible 

Under 

Review 

The transfer of college credit is purely voluntary. At the beginning of each 

course, participants choose whether or not to receive the recommended college credit. In order to receive 

college credit, a minimum attendance requirement must be met, a pre-test and a post-test must be taken, 

a required lab and/or exercise completed, and a certifi cate of satisfactory completion sent to the college or 

university. Course performance scores are strictly confi dential and will only be made available to colleges or 

universities with the participant’s written permission. 

4


APPRENTICESHIP PROGRAM 

The Apprenticeship Core Skills Training Program provides new apprentices with 200 hours of formal training, 

including: 

✦ 40 hours of Generic Trade Training 

✦ 80 hours of Health and Safety Training 

✦ 80 hours of Trade-Specifi c Core Skills 

The Health and Safety Training helps apprentices value safety as an essential element in their workplace 

environment. The Generic Trade Training and Trade-Specifi c Core Skills programs give apprentices the skills 

and knowledge to make an immediate contribution upon arrival at their assigned plant. 

Generic Skills Training involves classroom lecture and discussion as well as hands-on application of 

procedures introduced in designated lab areas. Topics covered during the session include, but are not limited 

to: 

✦ History of Apprenticeship 

✦ Responsibilities of an Apprentice 

✦ English & Metric Measurement 

✦ Combination Squares 

✦ Basic Measurement & Layout Tool 

✦ Precision Measurement Instruments 

✦ Fasteners 

✦ Basic Hand Tools 

✦ Shop Machinery 

✦ Drilling, Tapping, & Reaming Holes 

✦ Applied Drawing Basics 

✦ Cables, Hoists, & Chains 

✦ Physical Properties of Metal 

✦ Hands-On Projects 

Core Skills Training provides classroom lecture, discussions, and extensive hands-on projects designed and 

taught by journeymen. Areas covered during this session by trade include, but are not limited to: 

✦ Die Makers, Machine Repair, Tool Makers & Die 

Makers, and Jig and Fixture Tool Makers learn 

to operate mills, lathes, and surface grinders. 

✦ Plumber/Pipefitters receive training on 

measuring, cutting, reaming, and threading 

pipe. They will also bend and solder copper 

pipe. Apprentices receive information on the 

National Plumbing Code. 

✦ Electricians work on basic electrical projects, 

conduit bending, ladder diagrams, PLCs, 

transformers, Ohm’s Law, codes, and other 

electrical fundamentals. 

✦ Millwrights learn to perform basic rigging, 

conveyor installation and repair, and how to 

move heavy equipment. 

5


HEALTH & SAFETY TRAINING 

Health and Safety Training includes the rules governing Health and Safety, mechanical safety, industrial 

hygiene, hazardous materials, personal protective equipment, hand tool safety, energy lockout, ergonomics, 

fall protection, confi ned spaces, and other topics. 

6

Production Worker Course Descriptions 

PRODUCTION 

WORKER 

TRAINING 

7


OVERVIEW OF THE 

MANUFACTURING PROCESS 

(OMP 100) 

Course Overview 

Participants will gain an understanding of the 

automotive manufacturing process from vehicle 

design to manufacturing. The purpose, layout, jobs, 

processes, and technologies used in DaimlerChrysler 

manufacturing plants will be explored. This course will 

also focus on the role that the Production worker has 

in increasing quality and customer satisfaction. 

Learning Outcome 

Upon completion of this course, participants will 

understand: 

1. the role and importance of Production 

workers in producing a quality product and 

the interrelationship of various operations 

performed throughout the manufacturing 

process; 

2. the defi nition and importance of quality and 

customer satisfaction; 

3. the history of automotive production and how 

it has evolved into the present system; 

4. the entire automotive production and 

manufacturing process including operations, 

jobs, and technologies; 

5. the different types of equipment used at 

DaimlerChrysler plants; 

6. the systems used in the plants that promote 

quality and reduce errors, such as Performance 

Feedback System (PFS) and MQAS; 

7. plant standard operating procedures, and how 

following these procedures directly impacts 

quality and the customer satisfaction; 

8. the importance of teamwork and communication 

within the plants, and how they can improve 

product quality; and 

9. how just-in-time (JIT) production methods play 

a role in plant organization. 

Major Topics Covered 

• Automotive manufacturing 

• The purpose, layout, jobs, processes, and 

technologies used in DaimlerChrysler 

manufacturing plants 

• Production worker responsibilities in product 

quality 

Who Should Attend 

Any Production worker 

Prerequisites None 

Class Size 14 

Course Duration 40 hours 

FUNDAMENTALS OF JOB SETTING 

(JSP 100) 

Course Description 

This course introduces the basic functions and tasks 

of a Job Setter with a special emphasis on safety, 

quality, leadership, and communication. Participants 

will be given the opportunity to apply their knowledge 

during practical hands-on activities as a way to 

increase their effectiveness as a Job Setter. 


Upon completion of this course, participants should 

be able to: 

1. describe the basic responsibilities of a Job 

Setter; 

2. identify and apply basic safety procedures on 

the job; 

3. describe the relationship between accurate 

measurement and product quality; 

4. measure parts accurately by applying basic 

math skills, and by selecting and properly using 

different measurement devices; 

8


5. maintain product quality through routine 

preventive maintenance techniques, use of 

coolants, and proper machine setup; 

6. maintain product quality through the use of 

cutting tools, cutting fl uids, workholding devices, 

and appropriate cutting conditions; 

7. effectively assess and communicate various 

machining problems; and 

8. understand and apply effective leadership and 

communication techniques to the production 

team. 

Course Objective 

Participants should acquire a comprehensive 

knowledge of the basics of measurement, machining 

processes, and safety procedures. 


• Preventive maintenance 

• Production team leadership 

• Measurement and product quality 

• Tools and devices for metal cutting 

• Communicating machining problems 

• Basic safety procedures and Job Setter 

responsibilities 


Class Size 14 


MEASUREMENT FOR 

MANUFACTURING 

(MGP 100) 

2 hours 


The participant should gain the knowledge and skills 

to use analog and digital measurement devices and 

to interpret charts, graphs, and diagrams for statistical 

quality control. 



be able to: 

1. understand the importance of Production 

workers in producing quality products; 

2. know a Production worker’s responsibility in 

the Quality Control Process; 

3. effi ciently utilize quality control tools used by 

DaimlerChrysler; 

4. apply basic math skills and quality assurance 

concepts; 

5. learn how to use and maintain several 

measurement devices including analog and 

digital indicators; and 

6. gain a basic knowledge of statistical data 

processing and how to interpret material from 

charts, graphs, and diagrams. 


This 40-hour course is designed to provide UAWrepresented 

DaimlerChrysler Production workers with 

information they can use to increase overall product 

quality. Participants will be given the opportunity to 

apply their knowledge during practical hands-on 

activities. 


• Production Worker responsibilities in product 

quality 

• Use of measurement devices in 

manufacturing 

• Interpreting statistical data 

• Applying math skills and quality concepts 

• English to metric conversions with concentration 

on microns 

• Comparing measures within the metric 

system 

• All math operations in the metric system 


Class Size 14 


9


METAL FINISHING 

(MFP 100) 

2 hours 


This course provides Reprocess Production workers 

with the knowledge and ability to detect and repair 

defects in sheet metal to a high level of quality. 

When completing this course, training participants 

should be able to locate defects, select and use tools 

appropriately, and remove various types of defects to 

create a paintable surface. 



be able to: 

1. understand the properties of sheet metal; 

2. identify and classify different types of 

damage; 

3. identify sheet metal tools and understand their 

uses; 

4. understand and perform damage removal 

techniques and procedures; 

5. demonstrate correct soldering processes; 

and 

6. understand and perform correct sanding and 

blocking techniques. 


To provide the participant with the ability to accurately 

locate, analyze, access, repair, fi ll, and sand panels 

to create a paintable surface. 


• Safety and defi nitions 

• Types of steel used in automotive exterior sheet 

metal panels 

• Working properties of steel 

• Locating, analyzing, and repairing damage 

• Proper identifi cation and use of hand and power 

tools 

• Types of solder 

• Correct soldering, sanding, and blocking 

techniques 

Prerequisites 

Basic understanding of the working properties of 

sheet metal and repair tools. 

Class Size 6 


WELDING SAFETY & OVERVIEW OF 

PROCESSES (WPP 100) 

2 hours 


Designed for production welders, participants should 

learn 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 in all 

welding and cutting operations; 

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. plasma arc cutting ferrous and non-ferrous 

metals; 

6. 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; 

7. flux cored and gas metal arc welding with 

an understanding of the process, types of 

equipment, shielding gases, electrode wires, 

and hands-on applications; 

9. gas tungsten arc welding with an understanding 

of the process, types of equipment, shielding 

gases, electrodes, filler materials, process 

variations, and applications; and 

10. shielded metal arc welding, and AC/DC 

equipment electrode selection. 

10



This course will prepare the participant to safely 

operate oxy-fuel gas and electric arc welding 

equipment per DaimlerChrysler MTI SMI-116. 


• Related hazards and safety precautions 

• Gas metal arc welding 

• Proper setup of oxy-fuel gas and electric 

• Gas tungsten arc welding arc welding 

equipment 

• Plasma arc welding 

• Shielded metal 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. 


Production workers whose job requires welding— 

particularly in the body-in-white area. 

Class Size 12 


MIG & FLUX CORED WELDING FOR 

PRODUCTION WORKERS 

(WSP 100) 

1 hour 


This course is designed to provide participants 

with the ability to safely produce quality welds on 

automotive component parts. 



be able to: 

1. Understand the importance of welding safety 

in the workplace; 

2. Understand the principles of welding; 

3. Describe the parts of a weld and the operating 

characteristics of Gas Metal and Flux Cored 

Arc Welding; 

4. Describe what welding parameters affect weld 

quality; 

5. Produce quality production welds on automotive 

sheet metal; 

6. Repair discrepant spot welds using the Gas 

Metal and Flux Cored Arc Welding Processes; 

and 

7. Use DaimlerChrysler welding specifi cations 

to determine the acceptability of production 

welds. 


To provide the participant with the skills necessary 

to produce acceptable quality welds on automotive 

sheet metal and underbody chassis components. 


• Fundamentals of welding safety 

• Fundamentals of the welding processes 

• Welding equipment 

• Shielding gases 

• Electrode wires 

• Variables that affect weld quality 

• Hands on welding practice with both MIG and 

Flux Cored Arc Welding processes 

• Visual and destructive weld examination 

Prerequisites 

None 


Production workers whose job requires welding— 

particularly in the body-in-white area. 

Class Size 6 

Course Duration 40 Hours 

11


PAINTED METAL DENT REPAIR 

(MDP 200) 


Participants learn to select and properly use color 

bump tools to repair minor damage in painted sheet 

metal to a high level of quality. 



be able to: 

1. understand the properties of sheet metal; 

2. identify and classify different types of 

damage; 

3. identify color bump tools and understand their 

uses; 

4. perform and understand damage removal 

techniques and procedures; 

5. demonstrate correct sanding and polishing 

procedures and techniques; and 

6. understand and perform correct panel 

access. 


To provide the participant with the ability to accurately 

locate, analyze, access, and repair surface defects 

with as little disruption of the painted surface as 

possible. 


• Safety and defi nitions 

• Working properties of steel 

• Correct sanding and blocking techniques 

• Analyzing, accessing, and repairing damage 

• Proper identifi cation of hand and power tools 

• Types of steel used in exterior automotive sheet 

metal panels 

Prerequisites 

A basic understanding of the working properties of 

sheet metal and repair tools. 

Class Size 6 

2 hours 

PRODUCTION WELD INSPECTION 

(WQP 200) 


Participants learn what the procedural requirements 

are to produce, inspect, and document quality welds 

on automotive component parts. 



be able to: 

1. describe the safety requirements specifi c to 

welding and cutting operations; 

2. describe the operating characteristics of gas 

metal arc and fl ux cored arc welding; 

3. describe what welding parameters affect weld 

quality; 

4. describe the parts of a weld; 

5. visually inspect production welds; 

6. destructively inspect and document welds; 

and 

7. use DaimlerChrysler welding specifi cations 

to determine the acceptability of production 

welds. 


To provide participants with the ability to inspect 

production welds on automotive component parts. 


• Welding theory 

• Gas metal arc welding principles of operation 

• Flux cored arc welding principles of operation 

• Weld nomenclature 

• DaimlerChrysler welding specifi cations 



Class Size 6 


12 

Course Duration 40 hours

Applied Industrial Technology Course Descriptions 

SKILLED TRADES: 

APPLIED INDUSTRIAL 

TECHNOLOGY 

13

14 


ELECTRICAL CONTROLS AND 

SCHEMATICS (EST 100) 

Course Overview 

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. 



be able to: 

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 


Class Size 12 


MECHANICAL SCHEMATICS 

(MST 100) 

2 hours 2 hours 


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 fl oor plans. 



be able to: 

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. 


• Industrial drawings 

• Title block 

• Drawing notes 

• Drawing revision system 

• List of materials 

• Alphabet lines 

• Sketching 

• Multi-view drawings 

• Auxiliary views 

• Section views 

• Pictorial drawings 

• Geometric Dimensioning 

& Tolerancing (GD&T) 

• Building drawings



Class Size 12 


GEOMETRIC DIMENSIONING 

& TOLERANCING FOR 

MANUFACTURING 

(GDT 100) 


The participant will learn to recognize and sketch 

part views, interpret symbology, and dimension and 

tolerance part features. 



be able to: 

1. recognize and sketch part views; and 

2. apply and interpret symbology, dimensioning, 

and tolerancing part features in order to provide 

a more thorough understanding. 


To understand how blueprint drawings are used in the 

manufacturing and inspection of parts. 


• Sketch part views 

• Symbology 

• Dimensioning part features 

• Tolerancing part features 

2 hours 

Prerequisites 

Participants should have a general knowledge of 

blueprint reading, be able to recognize and sketch 

part views, and know how to apply and interpret 

symbology. 

INTRODUCTION TO CATIA & VPM 

FOR MANUFACTURING 

(CTT 001) 


This course introduces CATIA procedures and 

concepts. Included in the course is Virtual Product 

Modeler (VPM), which allows the participant access 

to databases containing DaimlerChrysle-+r’s product 

and tooling fi les. 



be able to: 

1. manage CATIA fi les; 

2. use the REFMODEL function; 

3. identify surface wire for frames and faces; 

4. use layers and fi lters; and 

5. analyze geometry. 


To acquaint each participant with the basic functions 

of CATIA. 


• Accessing and using CATIA 

• Managing display features 

• Managing geometric content 

• Analyzing geometric content 

• Printing and plotting model fi les 

Prerequisites 

Training participants should have basic keyboarding 

and computer skills. 

Class Size 8 


2 hours 

Class Size 12 


15


CATIA FUNDAMENTALS 

(CTT 200) 


Participants will identify key hardware; log on to 

CATIA; explain and identify key elements of an active 

CATIA window; create and store a Palette; and cut a 

section using surface geometry. 



be able to: 

1. identify key hardware; 

2. log on to CATIA; 

3. explain and identify key elements of an active 

CATIA window; 

4. create and store a Palette; 

5. cut a section using surface geometry; 

6. identify and explain the difference between 

Space and Draw modes; 

7. manipulate geometry; and 

8. create, apply, analyze, and verify a Filter. 


To understand how to log on to CATIA, move around 

inside of CATIA models, view multiple CATIA models, 

cut a section, and perform simple analysis and plotting 

using CATIA. 


• Logging on to CATIA 

• Working with CATIA 

• Inside CATIA 

• Layer function 

• Creating and storing a Palette 

• Overlay tool 

• /M fi nd 

• Plotting 

• Data structure 

• Analysis function 

• Interacting with CATIA 

• Section cutting 

• REFMODEL 

2 hours 

Prerequisites 

Participants must have completed Introduction 

to CATIA & VPM for Manufacturing (CTT 001). 

All participants should also possess fundamental 

keyboarding skills along with a basic knowledge of 

blueprint reading. 

Class Size 8 


CATIA FOR DIE MAKERS (SOLIDS) 

(CTT 300) 


The participant will cut sections through VAMOS/ 

CATIA solid geometry, apply and manage dittos, use 

“Layers” and “Filters” functions to die components and 

sections, analyze die model fi le geometry, and create 

simple drawings with text and dimensions. 



be able to: 

1. cut sections through VAMOS/CATIA solid 

geometry; 

2. apply and manage dittos; 

3. use “Layers” and “Filters” functions to visualize 

die components; 

4. analyze die model fi le geometry; and 

5. create simple drawings with text and 

dimensions. 


To know how to visualize, analyze, and create simple 

dimensional drawings of stamping die components 

using VAMOS/CATIA software. 


• Analyzing solids 

• Creating drawings 

• Accessing CATIA models 

2 hours 

16


• Working with model details and dittos 

• Working with solid elements 

• Performing section cutting 

Prerequisites 

Participants must have completed Introduction to 

CATIA & VPM for Manufacturing (CTT 001) and CATIA 

Fundamentals (CTT 200). All participants should also 

possess fundamental keyboarding skills along with a 

basic knowledge of blueprint reading. 

Class Size 8 


CATIA LAYOUT & INSPECT 

(CTT 310) 

2 hours 


Metrologists should gain the tools and knowledge to 

implement procedures for programming a Coordinate 

Measuring Machine (CMM), to develop or retrieve 

CMM inspection data, and to generate reports and 

charts to display data. 


This course provides metrologists with the tools and 

knowledge necessary to implement DaimlerChrysler’s 

G.I.s: CMMDATA & CMMINSPC, and to develop 

new and/or retrieve existing coordinate measuring 

machine inspection data and CMDANA. Participants 

learn to generate off-line CMM drive paths via the 

CMMINSPC function. Other functions necessary to 

create wireframe geometry, simple surfaces, and 

simple drawings will be reviewed. There will also be 

a review of analysis, creation and use of fi lters, and 

how to overlay model fi les. Functions necessary to 

manage data will be introduced. Upon completion of 

this course, participants should be able to: 

1. review the introductory CATIA functions such 

as logon, fi le access, and plotting; 

2. utilize CATIA as a tool to create wireframe 

geometry and cutting planes; perform section 

cutting; use and manage details; analyze 

model data; use layers; create and apply 

fi lters; and create simple drawings with text 

and dimensioning; 

3. create curves on a surface using the Geodesic 

function; 

4. obtain a working knowledge of DaimlerChrysler’s 

CMM layering standards; how to prepare CATIA 

models for CMM point selection; create check 

points and paths; create and edit data logs; and 

work with sets; and 

5. generate statistical reports and output inspection 

data using CMDANA. 


To understand the procedures of programming 

inspection paths for a Coordinate Measuring Machine 

(CMM) and generate trend charts and reports to 

display inspection data. 


• Creating inspection data and programming a 

CMMDATA inspection log 

• Off-line programming of coordinate measuring 

machines using CATIA 

• Processing data analysis 

Prerequisites 



Fundamentals (CTT 200). 

Class Size 8 


CATIA FOR TOOL MAKERS 

(SOLIDS) (CTT 320) 

2 hours 


The Tool Maker should gain the skills necessary to 

visualize, analyze, plot, and create simple dimensional 

drawings of CATIA-generated tooling components, 

including process CATIA model fi les as released by 

the Tool Design Group of DaimlerChrysler. 

17



The successful completion of this course should enable 

the Tool Maker to gain dimensional and mathematical 

information to create tooling components by doing 

the following tasks: 

1. reviewing Introduction and Fundamentals 

course materials; 

2. cutting sections through CATIA solid 

geometry; 

3. reviewing and plotting CATIA drawing drafts; 

4. using layers and applying Filters to tool 

components and sections; 

5. analyzing tool model fi le geometry; 

6. creating simple drawings with text and 

dimensions; and 

7. overlaying released car part model fi les with 

tools. 


The Tool Maker should have the experience and 

skills to create simple dimensional drawings of 

CATIA-generated tooling components including 

DaimlerChrysler Tool Design Group model fi les. 


• Sections through CATIA solid geometry 

• Review and plot CATIA drawing drafts 

• Use layers and apply fi lters to tool components 

and sections 

• Analyze tool model fi le geometry 

• Create simple drawings with text and 

dimensions 

• Overlay released car parts model fi les with 

multiple and single tool models 

Prerequisites 



Fundamentals (CTT 200). All participants should also 

possess fundamental keyboarding skills along with a 

basic knowledge of blueprint reading. 

DIE MAKING TECHNOLOGY 

(MDT 100) 


Industrial die making technology has undergone 

tremendous 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 DaimlerChrysler 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 


2 hours 

Class Size 8 


18


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 

fl ame harden metals; perform hardness tests; and 

prepare metal for repair welding procedures. 



be able to: 

1. identify common metals used in auto plants; 

2. determine a metal’s repair characteristics for 

welding or machining; 

3. quench and fl ame 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 identifi cation 

• Material specifi cations 

• Crystal structures 

• Effects of plastic deformation and heat 

treatment 

• Applications of tool steels, cast irons, stainless 

steel, copper alloys, and aluminum 


Class Size 6 


2 hours 

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. 



be able to: 

1. select carbon, low alloy or tool steels for specifi c 

applications; 

2. perform hardening or strengthening heat 

treating operations to specifi cations; 

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 shoprelated 

tasks. Work clothing and safety shoes are 

required. 

Class Size 6 

2 hours 


19

Industrial Automation Course Descriptions 


INDUSTRIAL AUTOMATION 

21


BASIC OPERATOR TRAINING FOR 

THE GE FANUC SERIES 15 CNC 

(CNT 100) 


Participants should be able to select and use the 

automatic and manual modes of operation of the GE 

Fanuc Series 15 CNC. They should also demonstrate 

a working knowledge of code systems and program 

troubleshooting. 



be able to: 

1. select and use the automatic and manual 

modes of operation of the GE Fanuc Series 15 

CNC; 

2. read a parts program; and 

3. use signaling commands. 


Participants will learn how to properly operate the GE 

Fanuc Series 15 CNC controller. 


• Automatic modes such as EDIT, MEM, MDI, 

and TAPE 

• Manual modes such as JOG, INC, and DRN 

• Code systems 

• Axis operation 

• Optional skip block 

• Program troubleshooting parameters and 

diagnostics 

Prerequisites 

Participants should be aware of machine shop 

practices. 

Class Size 8 


2 hours 

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. CNCoperated 

Bridgeport mills and EZ-Trak software are 

available for hands-on use. 



be able to: 

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. 



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 

2 hours 


22


PROTOTRAK MILL PROGRAMMING 

& OPERATION (CNT 130) 


This course covers the programming and operation 

fundamentals of the ProtoTrak CNC mill. Handson 

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. 



be able to: 

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. 



required to set up, operate, and write basic programs 

for the ProtoTrak CNC mill. 


• ProtoTrak CNC mill hardware 

• Coordinate systems 

• CNC mill operation 


Class Size 8 


2 hours 

TROUBLESHOOTING THE GE 

FANUC SERIES 15 CNC 

(CNT 300) 

2 hours 


The successful completion of this course should 

enable the participant to: 

1. have the skills and knowledge to effectively 

troubleshoot and repair the GE Fanuc Series 

15 CNC (all models); 

2. have a practical understanding of the functions 

and programs; and 

3. obtain an introduction and overview of the 

GE Fanuc Series 15 CNC including: parts 

identification, power distribution, CRT and 

keyboard, data management, GE Fanuc 

ladder logic and programming, and basic 

troubleshooting skills. 



be able to: 

1. identify key terms; 

2. enter and manipulate data; 

3. identify, locate, and trace basic machine 

interface signals from external sources through 

the system; 

4. select and set machine parameters; 

5. upload and download parts programs and 

parameters with a PC; and 

6. troubleshoot. 


To make technicians profi cient troubleshooters of 

problems encountered in the GE Fanuc Series 15 

CNC Controller. 


• BMI signaling 

• Sequence programming 

• Softkey main menu screens 

• Reading and saving programs 

• Parts programming 

• Troubleshooting 

• Nomenclatures, descriptions, and functional 

relationships of printed circuit boards 

23


Prerequisites 

A good electrical background is required. Participants 

should also possess a fundamental understanding of 

relay-based machine sequence controls. 

Class Size 8 


BASIC PROGRAMMER TRAINING 

FOR THE GE FANUC SERIES 15 

CNC (CNT 400) 

2 hours 


Participants should be able to select and use the 

automatic and manual modes of operation of the GE 

Fanuc Series 15 CNC, read a parts program, and use 

signaling commands. 



be able to: 

1. determine which G code system is used in the 

GE Fanuc Series 15 CNC (all models); 

2. use the G, M, S, and T codes in parts 

programming; 

3. demonstrate the difference between initial, 

modal, and one shot G codes, and when they 

are used; 

4. use the parameter section to determine initial 

parameter settings as they apply to code 

functions; 

5. write parts programs; 

6. debug programs using program check and 

graphic areas; and 

7. appreciate the overall CNC environment. 


To learn how to properly program the GE Fanuc 

Series 15 CNC controller. 


• Practical functions and programs 

• Program operation 

• Optional block skip 

• Axis operation 

• Code systems 

• Reading and saving programs 

• Troubleshooting parameters and diagnostics 

Prerequisites 

Participants must have completed Basic Operator 

Training for the GE Fanuc Series 15 CNC (CNT 100) 

OR have two years work experience in the operation 

of CNC equipment. 

Class Size 8 


ALLEN-BRADLEY SLC 500 

PROCESSOR FAMILY USING A-B 

6200 SOFTWARE 

(BAT 100) 

2 hours 


Participants should be able to carry out the fundamentals 

of the A-B SLC 500 family of programmable controls 

using A-B 6200 software. 



be able to: 

1. install and set up SLC 500 family processors; 

2. troubleshoot and repair SLC 500 family 

programmable control systems; 

3. edit ladder fi les using A-B 6200 software; 

4. perform corrective action to isolate and repair 

faults; 

5. set up computer to SLC 500 family processor 

communications; and 

6. perform program backup and restore 

procedures. 

24




required to install, write basic ladder logic programs, 

set up communications from programming terminal 

to processor, and troubleshoot faults on the A-B SLC 

500 family of programmable controls. This course is 

designed to cover the fundamentals of A-B SLC 500 

family of programmable controls using A-B 6200 

software. 


• Introduction to programmable controllers 

• Hardware installation procedures 

• Basic instructions 

• Editing 

• Commands 

• Timers and counters 

• Branching 

• File organization 

• Documentation 

• Disk copy 

• Force modes 


Prerequisites 

A basic knowledge of electrical sequence control 

panels and a working understanding of the electrical 

control of machines are needed to fully benefi t from 

this training. 

Class Size 8 


ALLEN-BRADLEY PLC-5 

FAMILY/6200 SOFTWARE 

(BAT 105) 

4 hours 


The participant should be able to enter, edit, and 

troubleshoot PLC-5 programs using the A-B PLC-5 

Programmable Logic Controller and 6200 software. 



be able to: 

1. install, program, troubleshoot, and repair 

A-B PLC-5 Family programmable logic 

controllers; 

2. search, edit, save, and restore existing logic 

diagrams with a 1784 T50 industrial terminal 

and 6200 series software; and 

3. install components properly and safely, identify 

problems, and demonstrate the appropriate 

corrective procedures. 


Participants should learn how to program, edit, 

and troubleshoot A-B PLC-5 Programmable Logic 

Controllers. 


• Basic PLC-5 instructions using A-B 6200 

software 

• A-B hardware 

• Troubleshooting techniques 

Prerequisites 





Class Size 12 


25


ALLEN-BRADLEY PLC-5 FAMILY/ 

ICOM SOFTWARE (BAT 155) 


The participant should be able to enter, edit, 

and troubleshoot PLC-5 programs using the A-B 

PLC-5 Programmable Logic Controller and ICOM 

software. 



be able to: 

1. install, program, troubleshoot, and repair 

the A-B PLC-5 Family programmable logic 

controllers; 

2. search, edit, save, and restore existing logic 

diagrams with a 1784 T50 industrial terminal 

and ICOM series software; and 



corrective procedures. 




Controllers using ICOM software. 


• Basic PLC-5 instructions using A-B ICOM 

software 



Prerequisites 





Class Size 12 


4 hours 

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 


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 

26


Prerequisites 

Participants should have a knowledge of electrical 

sequence control systems and a working knowledge 

of the electrical control of machines. 

Class Size 8 


ADVANCED ALLEN-BRADLEY PLC- 

5 FAMILY/6200 SOFTWARE 

(BAT 205) 

2 hours 


The participant should be able to enter, edit, and 

troubleshoot PLC-5 programs using the A-B PLC- 

5 Programmable Logic Controller and advanced 

instructions of 6200 software. 



be able to: 

1. utilize block transfer with analog inputs and 

outputs; 

2. understand remote I/O, auto confi guration, and 

troubleshooting; 

3. perform message transfer and operation; and 

4. operate and control scanners and adapters. 




Controllers. 


• Advanced instructions using A-B 6200 

software 



Prerequisites 

Participants must have completed Allen-Bradley 

PLC-5 Family/6200 Software (BAT 105) OR have had 

equivalent formal training on A-B PLC-5 Family/6200 

Software equipment. 

Class Size 8 


TROUBLESHOOTING ALLEN- 

BRADLEY CONTROLNET 

(CRT 300) 

2 hours 


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. 



be able to: 

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

2. understand and use PLC-5 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. 

27



• PLC-5 memory layout 

• Message instruction with the PLC-5 

• 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 PLC-5 Programmable Controllers and be familiar 

with RS Logix 5 Software. 

Class Size 10 



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 PLC-5 Programmable Controllers and be familiar 

with RS Logix 5 Software. 

Class Size 10 


TROUBLESHOOTING ALLEN- 

BRADLEY DEVICENET 

(DNT 300) 

2 hours 


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. 



be able to: 

1. understand A-B DeviceNet components and 

how DeviceNet differs from other networks; 

2. understand and use the PLC-5 Memory; 

3. successfully navigate through RS NetWorx 

software for DeviceNet; and 

4. successfully troubleshoot a DeviceNet 

network. 

ALLEN-BRADLEY PANELVIEW 

1400E (BAT 310) 


2 hours 

The participant should be able to install, program, 

edit, troubleshoot, and repair the PanelView 1400e 

operator control panel using RS Linx software. 



be able to: 

1. set up the PLC-5 communication; 

2. confi gure PanelView hardware and software; 

and 

3. use PanelBuilder software to develop and 

edit programs including objects, screens, and 

addresses. 

28



To provide participants with the skills needed to set 

up a PLC-5, confi gure PanelView hardware and 

software, and use PanelBuilder software to develop 

and edit programs. 


• PanelView hardware 

• Hardware overview 

• Interconnections 

• PanelView confi guration 

• 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 either PLC-5 Family 

course (BAT 105 or BAT 155) OR have equivalent 

work experience with the PLC-5 programmable 

controllers. 

Class Size 8 


RS LOGIX 5 SOFTWARE FOR 


(BAT 320) 


The participant will learn RS Logix 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. 



be able to: 

1. activate RS Logix software; 

2. develop and edit instructions; 


and 

4. demonstrate an understanding of Forcing. 


To provide participants with the skills needed to 

develop programs for A-B SLC-500 using RS Logix 

500 software. 


• Basic review of DOS-based software 

• Introduction to Windows 95 

• Basics of RS Logix 

• Program development 

• Program storage, retrieval, and printing 


2 hours 

Prerequisites 


SLC 500 Family Using 6200 Software (BAT 100), 

OR Allen-Bradley SLC 500 Processor Family Using 

ICOM Software (BAT 115), OR have had equivalent 

formal training on A-B SLC 500 equipment. 

Class Size 8 


29



PROCESSOR FAMILY/RS LOGIX 

SOFTWARE (BAT 325) 

3 hours 


Participants will learn how to install, set up and 

operate a processor control system (A-B PLC-5) using 

compatible (RS Linx/RS Logix 500) communications. 

They will also learn to use an algorithmic approach 

to writing ladder logic programs, and troubleshoot 

major faults. This course is for both 6200 and ICOM 

software since ICOM must use 6200 as an interface 

for PanelBuilder. 



be able to: 

1. install, program, troubleshoot, and repair A-B 

SLC 500 Family PLCs; 

2. search, use histograms, create custom monitor 

screens, and edit, save, and restore existing 

logic diagrams with a programming terminal & 

RS Logix 500 software; and 



corrective measures. 


To provide participants with the knowledge and skills 

to install, set up, and troubleshoot the SLC-500 using 

RS Logix software. 


• SLC 500 installation 

• SLC 500 setup and troubleshooting 

• Use of Logix 500 software to develop, edit, and 

document logic programs 

• Use of RS Linx/RS Logix 500 software to set 

up communications with SLC 500 processors 

Prerequisites 


sequence systems and a working knowledge of the 

electrical control of machines. 

Class Size 8 


RS LOGIX 5 SOFTWARE FOR 


(BAT 330) 


Participants will learn to use A-B RS Logix 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. 



be able to: 

1. activate A-B RS Logix software; 

2. develop and edit programs; 


and 

4. demonstrate an understanding of Forcing. 


To provide the participant with the skills needed to 

develop programs for the A-B PLC-5 using RS Logix 

5 software. 


• Basic review of DOS-based software 

• Introduction to Windows 95 

• Basics of RS Logix 

• Program development 

• Program storage, retrieval, and printing 


2 hours 

30


Prerequisites 


PLC-5 Family/6200 (BAT 105), Allen-Bradley PLC-5 

Family/ICOM (BAT 155), OR have equivalent formal 

training on A-B PLC-5 equipment. 

Class Size 8 



PROCESSOR FAMILY/RS LOGIX 

SOFTWARE (BAT 335) 

3 hours 


Participants will gain the theory and principles of 

operation of the A-B PLC-5 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. 



be able to: 

1. use RS Logix 5 software and the PLC-5 

Controller to install and set up PLC-5 family 

processor; 

2. troubleshoot and repair the PLC-5 Processor 

control system; 

3. edit ladder fi les using RS Logix 5 software; 

4. perform corrective action to isolate and repair 

faults; 

5. set up computer for PLC-5 processor 


6. perform program backup and restore 

procedures. 


To provide participants with the knowledge and 

skills to install, set up, and troubleshoot the PLC-5 

Controller using RS Logix 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 


sequence control systems and a working knowledge 

of the electrical control of machines. 

Class Size 8 


ALLEN-BRADLEY 1336 PLUS 

FAMILY VARIABLE SPEED AC 

DRIVES (BAT 400) 

2 hours 


Participants should be able to set up, install, edit, 

and troubleshoot the 1336 Plus Variable Frequency 

AC Drive. 



be able to: 

1. install, program, troubleshoot, and repair the 

1336 Plus A-B family drives; 

31


2. understand power and motor wiring, digital and 

analog input wiring, power loss, bus under and 

over voltages, motor parameters (i.e., stall, 

overload, over temperature); 

3. understand local or remote control, programming 

and operating display panels, speed output 

display, fault display, special and other displays; 

and 

4. understand the theory of operation, programming 

of parameters, speed source priority, and 

operational modes. 


The participant will gain hands-on experience in the 

setup, installation, editing, and troubleshooting of the 

1336 Plus Variable Frequency AC Drive. 


• Manual (stand alone) drive operation 

• The HIM (Human Interface Module) 

• The Drive Manager 

• The Drive Monitor Software 

• Remote I/O (with the PLC-5 Programmable 

Controller) operation of this drive 

Prerequisites 

A basic knowledge of electrical controls. 

Class Size 8 


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. 



be able to: 

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 


32


ROBOTICS: ABB OPERATION/ 

PROGRAMMING FOR THE S3 

CONTROLLER (ABT 300) 

2 hours 


Participants should be able to understand basic robot 

safety principles, control panel operation, program 

unit operation, programming structure and language, 

and be able to create programs including function, 

positioning, and conditional programs. 



be able to: 

1. understand basic robot safety principles, control 

panel, and program unit operation; 

2. understand programming structure and 

language; 

3. create programs including function, positioning, 

and conditional programs; 

4. use subprograms and basic adaptive 

programming; 

5. perform manual functions, system set-up, and 

transfer programs to and from disks; 

6. edit programs or instructions; 

7. interpret system diagnostic messages; and 

8. clear minor operation faults. 


Participants should be able to operate and program 

the robot using the teach pendant. 


• Safety precautions used while programming 

and during program execution 

• Operating controls and indicators on the robot 

controller 

• Selecting proper menus from the program unit 

for programming and program execution 

• Positioning the robot by use of joystick 

control 

• Advanced programming principles 

• Subprogramming, reference point program 

control, storing positional locations, and 

palletizing 

Prerequisites 

Basic programming or experience with the robot 

system is helpful. 

Class Size 6 


ROBOTICS: MECHANICAL 

MAINTENANCE FOR ABB SYSTEMS 

INCLUDING WRIST REPAIR 

(ABT 315) 

2 hours 


This course provides hands-on labs and exercises to 

help the participant mechanically maintain and repair 

the robot including the wrist. The course also covers 

the mechanical components of the robot and the 

proper tools used for repair. The training is targeted 

to industrial personnel required to mechanically 

repair the robots and to perform regular preventive 

maintenance. 



be able to: 

1. perform safety precautions used while doing 

mechanical repair; 

2. properly start-up, jog, and shut down the 

robot; 

3. describe the operation of mechanical 

components; 

4. disassemble and reassemble the robot including 

the wrist; 

5. make proper adjustments to reduce backlash 

in gears; and 

6. use the manual for repairs and ordering of 

spare parts. 

33



The course goal is to teach participants how to 

properly disassemble and reassemble the IRB 6400 

robot including the wrist. It also teaches proper 

preventive maintenance procedures for this robot. 


• Proper safety precautions used while performing 

mechanical repair 

• Operation of robot control and mechanical 

unit 

• Description and operation of mechanical 

components 

• How to use the manual for repair and ordering 

of spare parts 

• Disassembly and reassembly of the robot 

including the wrist 

Prerequisites 

Participants should have mechanical background or 

experience. 

Class Size 4 


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. 



be able to: 

1. follow all robotic safety and lock out 

procedures; 

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. fi le 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 


34


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. 



be able to: 

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. fi le 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 specifi c 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 fi les 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 


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. 



be able to: 

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; 

35


5. perform I/O and programming; 

6. manipulate memory fi les; 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 


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. 



be able to: 

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 fi les. 


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 


36


ROBOTICS: NACHI AR 52 

ELECTRICAL MAINTENANCE 

(RNT 360) 

2 hours 


This course covers the safe maintenance, operation, 

and troubleshooting of the Nachi AR 52 robot arm 

and control cabinet. 



be able to: 

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. 

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 



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 

37

Industrial Maintenance Course Descriptions 


INDUSTRIAL MAINTENANCE 

39


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. 



be able to: 

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 


2 hours 

BEARING LIFE IMPROVEMENT 

(BLT 101) 


This course provides the skills and experience to 

safely and effectively determine proper sizes of shafts 

and housings, carry out preventive maintenance on 

bearings, troubleshoot and repair failed bearings, and 

prevent future failures. 



be able to: 

1. determine proper sizes of shafts and 

housings; 

2. install, remove, and lubricate bearings; 

3. monitor rolling bearings to prevent catastrophic 

failure; 

4. troubleshoot bearing failures; 

5. read and interpret troubleshooting charts for 

bearings; and 

6. prevent future failures and rework bearings. 


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. 


• Selection and types of bearings 

• Installation, removal, and lubrication of bearing 

seals 

• Keeping bearing seals, shafts, and housings 

fi t 


Class Size 12 


1 hours 

40


INDUSTRIAL CONDUIT BENDING 

(COT 100) 


This course is designed to provide participants with 

a practical knowledge of conduit bending as well as 

hands-on experience. 



be able to: 

1. identify the size and type of electrical conduit; 

2. fi nd and use take-up, gain, travel, shrink, and 

shrinkback; and 

3. bend (in rigid conduit) accurate 90º bends, 90º 

bends with a kick, back-to-back bends, offsets, 

and combination bends. 


Participants will know how to identify electrical 

conduit and carry out various electrical conduit bends 

effectively. 


• Sizes and types of electrical conduit 

• Identifi cation and use of take-up, gain, travel, 

shrink and shrinkback 

• Rigid conduit bending 


Class Size 10 


1 hour 

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. 



be able to: 

1. identify resistors, diodes, and rectifi ers; 

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 

• Machine control diagrams 

• Electrical testers 

• Positioning devices for CNC 

• Transformers, electric motors 

• Electrical measurement and formulas 

• Power supplies, drives 

• Troubleshooting control circuits 

• Electronic circuits 

• Control and protection of motors 

• Input/output devices 

• European wiring and disconnect switches 

41


• PLCs/PanelViews 

• Surge protection and power conditioning 

• NEMA vs. IEC components 


Class Size 8 


ELECTRONIC MAINTENANCE 

(IET 200) 

2 hours 



be able to understand: 

1. fundamental concepts of electricity, including: 

voltage, grounds, AC voltage, frequency, and 

load; 

2. practical applications and calculations, including 

work with: meters, signed numbers, safety, 

current, resistance, color code, conductors and 

insulators, and wire size and type; 

3. units of measurement, including: prefixes, 

technician’s triangle, head calculations, Ohm’s 

Law, power, voltage drops, safety, and ground 

faults; 

4. series and parallel circuits; 

5. voltage dividers, potentiometers, and 

rheostats; 

6. magnetic principles, including: magnetic fi elds, 

coils, transformers, and clamp-on meters; 

7. scopemeters and signal generators; 

8. power supply circuits, including: diodes, bridge 

rectifi ers, capacitors, and fi lters; 

9. fundamental circuit parts, including: power 

connections, AC wiring, 3-phase (delta and 

wye), fuses, breakers, single-line diagrams, 

switches, relays, solenoids, contactors, and 

NEMA and IEC ratings; 

10. ladder diagramming, including: ladder symbols, 

low-voltage control, motor control centers, 

motor starters, thermal breakers, proximity 

switches, & indicator lights; and 

11. AC motor drives including variable voltage, 

variable frequency, pulse width modulation and 

types of AC motor drive applications. 

Week 1 Objectives 

The participant will be able to work safely with 

electricity; use instruments to take and interpret 

electrical readings; read and interpret electrical 

drawings and ladder diagrams; identify and test 

electrical components; and understand the basic 

principles of AC and DC Motors. 

Week 1 Topics Covered 

• Fundamental concepts 

• AC motors 

• Circuits 

• Units of measurement 

• Ladder diagramming 

• Circuit parts 

• Practical applications 

• DC motors 

• Components 


The participant will be able to test equipment to 

identify which board needs to be replaced or repaired 

in an electronic system. 


• Fundamental concepts 

• Op amps 

• Solid state switches 

• Measurement techniques 

• Digital logic devices 

• Test equipment 

• Math review of relevant computational 

techniques 

• Power supplies 


• Circuits 

42



The participant will be able to identify circuit boards 

in need of replacement and use test equipment to 

identify defective components in a board. 


• Electronic concepts 

• Op amps 

• Power supplies 

• Math review of relevant computational 

techniques 


• Semiconductors 

• Circuits 

• Digital logic systems 


The participant will be able to understand three-phase 

fi eld rotation; describe the effects of volts/hertz and 

boost on motor operation; troubleshoot power control 

devices including diodes, transistors, SCRs and 

GTOs; identify three-phase bridge operation and 

faults; apply troubleshooting techniques to identify 

failures in converters and inverters; use fault codes 

and control parameters; and troubleshoot both PWM 

and UVVF drives to the board level. 


• Variable voltage and frequency 

• Pulse width modulated AC motor drive types 

• Troubleshooting and repair techniques 


Class Size 12 

Course Duration 

160 hours: Two 2 week class periods with a two week 

minimum interval at home plant between sessions. 

GROUNDING & BONDING 

(IET 210) 

2 hours 


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, fi res, and explosions. The 

instructor-guided presentation provides answers to 

the common elements for clearing ground faults, 

and the conventions for low-impedance and highimpedance 

systems. 



be able to: 

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 

43



Class Size 12 



Class Size 12 


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. 



be able to: 

1. understand the principles of transformers and 

feeders, circuitry of transformers and threephase 

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 

confi gurations. 


• Principles and circuitry of transformers 

• Delta connections 

• Zig-zag transformer connections 

• Feeder and conduit sizing 

FIBER OPTIC CABLE 

INSTALLATION, MAINTENANCE, & 

TROUBLESHOOTING 

(FOT 110) 

2 hours 2 hours 


The participant will learn to use appropriate tools on 

fi ber circuits for maintenance and troubleshooting. 

Participants will also use a variety of fi ber optic cables, 

connectors, and adapters to install and troubleshoot 

fi ber optic installations. 



be able to: 

1. identify the two modes of fiber system 

operation; 

2. understand the generation of LED and ILD light 

and the techniques involved in the installation 

of a fi ber optic network; 

3. understand IEEE and TIA/EIA cabling 

standards; 

4. splice and connectorize optical fi bers; 

5. assemble a fi ber patch panel; and 

6. install, test, and troubleshoot a complete fi ber 

network. 


To provide the participant with the knowledge required 

to design, install, and test fi ber optic communications 

systems. 

44



• Fundamentals of fi ber optics 

• Install connectors 

• Safety 

• Cable installation 

• Basic procedures 

• Fiber testing 

• Splicing 

• Circuit documentation 

Certification 

All participants who complete the course will be: 

1. 3M products certifi ed. 

2. After a voluntary test and successful completion, 

participants will be certifi ed as a Fiber Optic 

Technician from the Fiber Optic Association. 


Class Size 12 


ADVANCED FIBER OPTICS 

(FOT 310) 

2 hours 


The participant will be able to implement a fi ber optic 

data system, install fi ber optic connectors, use fi ber 

optic measurement tools, and have knowledge of fi ber 

optic cable standards. 



be able to: 

1. install and troubleshoot a fiber optic data 

system; 

2. demonstrate a working knowledge of fi ber cable 

installation standards; 

3. install fi ber optic connectors; properly utilize 

an OTDR and a light source/power meter kit 

for measurements as defi ned by the TIA/EIA 

FOSTP 14 standard; and 

4. use hand tools. 


To provide the knowledge and skills required to install 

and test fi ber optic communications systems. 


• Fundamentals of fi ber optics review 

• Cable installations 

• Safety 

• OTDR and LS/PM testing and documentation 

• Advanced procedures 

• Restoration splicing 


• Install connectors 

Certification 

All participants who complete the course will be 3M 

products certifi ed. 

Prerequisites 

Participants must have completed Fiber Optic Cable 

Installation, Maintenance, & Troubleshooting (FOT 

110). It is recommended that a participant have some 

hands-on plant experience with fi ber optic cable after 

FOT 110 before taking FOT 310. 

Class Size 8 


45


PLANT COMMUNICATIONS 

SYSTEMS (FOT 400) 


The participant will learn to use twisted pair copper and 

coax cables in networks as used in DaimlerChrysler 

plants. Participants will also identify and observe the 

National Electrical Code in testing, operating, and 

troubleshooting network installations. 



be able to: 

1. install and test a working plant network 

communications system; 

2. demonstrate a working knowledge of the fi ber/ 

twisted pair/coax hybrid infrastructure and their 

installation standards; 

3. install and test CAT 5e, CAT 6, and fi ber optic 

connectors onto appropriate cables; 

4. construct a simulated plant network consisting 

of a fi ber hub and cable, media converters, 

and CAT 5e cabling to work area outlets linking 

computers together; and 

5. demonstrate the safe use of hand tools used 

for cable and connector information. 


To provide the knowledge and hands-on skills needed 

to install and test plant networks consisting of optical 

fi ber, twisted pair, and coax cable media. 


• Fundamentals of networks 

• Categories of cabling 

• Safety 

• Installation of cabling 

• Cabling standards 


• Fiber and twisted pair testing 

• Termination of fi ber and copper cables 

2 hours 

Certification 

All participants who complete the course will receive 

a certifi cate of achievement as Network Specialists 

from Lincoln Trail College. 

Prerequisites 

Fiber Optic Cable Installation, Maintenance, & 

Troubleshooting (FOT 110) and Advanced Fiber 

Optics (FOT 310). It is recommended that a 

participant have some hands-on plant experience 

with fi ber optic cable after FOT 110 and FOT 310 

before taking FOT 400. 

Class Size 8 


FIRE SYSTEMS TRAINING 

(FST 100) 

2 hours 


The participant should be able to describe the 

components of fi re protection systems. Participants 

will work with installation and resource compliance 

requirements including inspection and testing. 



be able to: 

1. describe the purpose of fire protection 

systems; 

2. defi ne occupancy classifi cations; 

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. 

46



To upgrade and provide a sound foundation for Skilled 

Trades personnel with respect to fire protection 

systems. 


• Purpose of fi re protection systems 

• Occupancy classifi cations 

• Water sources 

• System components 

• Hydraulics 

• Maintenance 

• Code requirements 

• Basic design 

• Sprinkler heads 

• Inspection and testing 



Class Size 8 


TROUBLESHOOTING FLUID POWER 

EQUIPMENT (FLT 100) 


2 hours 

The participant should be able to read pneumatic 

schematics; identify and understand common 

hydraulic and pneumatic components; understand 

common circuit applications; troubleshoot fl uid power 

circuits; perform preventive maintenance; and remove, 

clean, and replace fl uid power components. 



be able to: 

1. read pneumatic schematics; 

2. identify and understand common hydraulic and 

pneumatic components; 

3. understand common circuit applications; 

4. troubleshoot fl uid power circuits; 

5. perform preventive maintenance; and 

6. remove, clean, and replace fluid power 

components. 


The participant will have the knowledge of how to 

effectively and effi ciently troubleshoot, repair, and 

maintain fl uid power equipment. 


• Basic concepts of compressed air 

• Hydraulics 

• Hydraulic directional control valves 

• Pressure control valves 

• Volume controls 

• Cylinder applications 

• Pumps 

• Pneumatic power supply systems 


Class Size 12 


47


FLUIDS, FLUID ANALYSIS, & 

CONTAMINATION CONTROL 

(OAT 200) 

2 hours 


The participant will understand the fundamentals of 

hydraulic machine operation and how this relates 

to the use and handling of hydraulic fl uids, fl uid 

analysis, and the requirements of fi ltration of hydraulic 

systems. 



be able to: 

1. understand the fundamental principles of 

hydraulic machine operation; 

2. recognize fl uid power components in a circuit 

based on graphic symbology; 

3. understand the operating principles and 

requirements of standard fluid power 


4. identify and relate operating parameters of 

hydraulic fl uid conveyors and fi ttings; 

5. apply fundamental fluid power formulae in 

solving circuit dynamic problems; 

6. relate the requirements of circuit design and 

component use to application dependency and 

operating parameters; and 

7. understand common symptoms of hydraulic 

failure and the probable causes. 


To provide the participant with the ability to properly 

handle and maintain hydraulic fl uids in industrial 

machinery. 


• Safety 

• Hydrostatic system fundamentals 

• Fluid conveyors 

• Fluid behavior, properties, and types 

• Fluid failure modes 

• Contamination prevention, fl uid analysis (types, 

frequency of use in PM) 

• Fluid fi ltration, construction, location options 

• Setting machine cleanliness levels, 

requirements 

• Contamination types, sources, and 

consequences 

Prerequisites 

Basic knowledge of the fundamentals of hydraulic 

machinery is helpful. 

Class Size 12 


GENERAL ELECTRIC FORKLIFT 

SEPARATELY EXCITED MOTOR 

CONTROL SYSTEMS (TZR) LX- 

100/200 SCR CONTROL SYSTEMS 

(MCT 200) 


This course is intended for Skilled Trades workers 

who need to effi ciently troubleshoot and repair both 

GE electrical SCR and transistor control systems for 

Powered Industrial Vehicles (PIVs). 



be able to: 

1. Identify electrical components, their schematic 

symbols and function; 

2. Trace the fl ow of current through the control 

and power circuits; 

48


3. Measure the voltage readings on the equipment 

using a VOM; 

4. Set the controller voltage and current parameters 

by using the hand diagnostic set; 

5. Install malfunctions in forklift truck in order to 

demonstrate fault codes using hand diagnostic 

set; and 

6. Properly maintain, troubleshoot and repair 

Powered Industrial Vehicles. 


The participant will have the knowledge and skills to 

effectively and effi ciently maintain, troubleshoot, and 

repair both GE electrical SCR and transistor control 

systems for PIVs. 


• Relevant electrical components 

• Schematic symbols 

• Voltage readings 

• Hand diagnostic set 

• Fault codes 

• Controller voltage 

Prerequisites 

Participants must have completed the course Lift 

Truck Maintenance Care Program DC Fundamentals 

for powered industrial vehicles provided by 

DaimlerChrysler’s Advanced Technical Training or 

have equivalent working knowledge. 

Class Size 6 


INDUSTRIAL GEAR BOX REPAIR 

(GRT 300) 

2 hours 



enable the participant to build gear boxes correctly, 

troubleshoot failed gear boxes, select the proper 

gear box, install a speed reducer, replace seals 

and bearings correctly, and set up a gear box using 

shims. 



be able to: 

1. analyze gear box failure; 

2. rebuild gearboxes to correct tolerances; 

3. select the proper gearbox for an application; 

4. analyze and replace seals, bearings, and 

lubricants; and 

5. axially align output with a drive shaft. 


To provide the participant with the understanding and 

skill to select, troubleshoot, and install gearboxes, 

and to rebuild and maintain gearboxes. 


• Geometry review 

• Application and characteristics of spur 

• Gearbox selection 

• Installation alignment 

• Lubrication 

• Thermal effects 

• Bearing seal performance 

• Failure analysis 

• Rebuild to specifi cations 

• Helical, ring-pinion, herringbone, planetary, 

worm, and bevel-miter gear trains 


Class Size 12 


49


TROUBLESHOOTING INDUSTRIAL 

HYDRAULIC EQUIPMENT 

(HYT 100) 


This course introduces participants to hydraulic theory 

and provides hands-on hydraulic troubleshooting 

experience. 



be able to: 

1. understand and demonstrate proper 

safety procedures for working on hydraulic 

equipment; 

2. read hydraulic schematics and symbols; 

3. identify and understand common hydraulic 

components and their operation; 

4. obtain a basic knowledge of common circuit 

applications; 

5. troubleshoot hydraulic power circuits; and 

6. know and implement the procedures for 

HU-40. 


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 


2 hours 

ADVANCED TROUBLESHOOTING 

INDUSTRIAL HYDRAULIC 

EQUIPMENT (HYT 300) 


Using prints of plant equipment, the participant 

troubleshoots hydraulic systems and identifi es the 

pitfalls of installation procedures. 



be able to: 

1. troubleshoot hydraulic systems using prints of 

the equipment found in their plants; 

2. identify the pitfalls of installation procedures; 

3. determine why proportional valves fail and how 

to prevent failure; 

4. interpret, from schematics, the operation of 

logic and cartridge technology; 

5. read and interpret schematics to aid in 

troubleshooting; and 

6. demonstrate understanding of servo valve 

technology and how to properly set up various 

types of servos. 


To provide participants with the ability to troubleshoot 

industrial hydraulic systems. 


• Safety 

• Actuators 


• Proportional valve technology 

• Formulas 

• Servo valves 

• Directional valves 

• Logic control forces 

• Rectifi er circuits 

• Pump & control technology 

• Relief valves 

• Filtration 

• Check valves 

• Fluid power graphical symbols 

2 hours 

50


• Modular stacks 

• Fluid power formulas 

• Mounting confi guration 

Prerequisites 

All participants must have completed Troubleshooting 

Industrial Hydraulic Equipment (HYT 100). 

Class Size 12 


LADDER LOGIC 

(LLT 110) 

2 hours 


This course is designed to provide a hands-on 

approach to the functions and skills needed to 

understand ladder logic and various control devices. 

Through an industrial trainer incorporating basic 

solid state relays, electro-mechanical relays, 

various switches, and programmable controllers, the 

participant should gain an understanding of ladder 

logic control devices, electrical control languages, 

and programmable controllers. 


To provide the participant with the knowledge required 

to troubleshoot and maintain basic plant electrical 

equipment and the concepts of ladder logic and 

control devices. 


• Types of wire 

• Voltage generation techniques 

• Conduits and fi ttings 

• Pilot devices 

• Solenoids 


• PC grounded/ungrounded circuits 

• Relay timers 

• A-B Micrologic 1000 

• Proper uses of test equipment 

• AC, DC, single-phase, and three-phase power 

systems 


Class Size 8 




be able to: 

1. wire electrical drops using correct wire sizes; 

2. know applications of DC, single, and threephase 

systems; 

3. identify uses for grounded and ungrounded 

control systems; 

4. use test equipment such as voltmeters, 

ammeters, and Wigginton testers; and 

5. identify the proper uses of Pilot Devices 

(Machine Control Devices) such as solenoids, 

relays, and motor control circuits. 

51


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. 



be able to: 

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 


Class Size 8 


2 hours 

LUBRICATION SYSTEMS 

(LST 100) 

2 hours 


The participant should be able to maintain and 

troubleshoot lubrication systems commonly found in 

a manufacturing environment. 



be able to: 

1. maintain and troubleshoot lubrication systems 

such as manual greasing, automatic oilers and 

Trabon systems; 

2. understand lubrication specifi cations, systems 

and applications, PLC lube controllers and 

mechanical timers; 

3. interpret viscosity and consistency ratings; 

4. operate common lubrication systems; 

5. maintain system components including pumps, 

filters, valves, reservoirs, manifolds and 

different types of seals including compatibility 

with different fl uids; and 

6. monitor lubricant levels and conditions including 

common preventive maintenance items (fi lter 

changes, sampling, inspections and their 

frequencies). 


To provide the participant with the ability to operate 

and troubleshoot automatic lubrication systems. 


• Lubrication basics 

• Lubricant properties 

• Additives 

• Component wear 

• Bearing failure analysis 

• Tribological tests 

• Divider valve operation 

• Types of lubrication systems 

• Interaction between metals and lubricants 

• Bearing and gear lubrication 

• Oil contamination and oil fi ltration systems 

operation 

• Calculation of Trabon divider block sizing 

requirements 

52



Class Size 12 


TROUBLESHOOTING MECHANICAL 

POWER SYSTEMS 

(MPT 100) 


The participant should be able to troubleshoot, 

maintain, and repair mechanical drive systems. 



be able to: 

1. understand mechanical systems, simple and 

complex machines, gear drives, belt drives, and 

applications of various industrial fasteners; 

2. troubleshoot mechanical systems; 

3. service different types of belts, chains, or gear 

driven systems; 

4. perform power measurements; 

5. provide proper lubrication; 

6. recognize a ball screw defect; and 

7. lubricate a ball screw. 


The participant will have the knowledge and 

techniques to troubleshoot, maintain, and repair 

mechanical drive systems including bearing shafts, 

pulleys, and belt chain and gear drive systems. 


• Power transmission systems 

• V-belt drives 

• Chain drives 

• Gear drives 

• Shaft drives 


Class Size 12 

2 hours 

TROUBLESHOOTING PNEUMATIC 

CONTROLS & EQUIPMENT 

(PNT 101) 


This course covers the troubleshooting, maintenance, 

and repair of pneumatic control systems and 

equipment. 



be able to: 

1. read pneumatic schematics; 

2. identify and understand pneumatic 


3. troubleshoot pneumatic control circuits and 

programmable logic controllers; 

4. read and interpret ladder diagrams; 

5. understand common circuit applications; 

6. perform preventive maintenance on pneumatic 

systems; and 

7. remove, clean, and replace pneumatic 

components. 


To provide the participant with the ability to troubleshoot 

pneumatic controls and equipment. 


• Compressed air cylinders 

• Control valves 

• Volume controls 

• Compressors 

• Plant distribution systems 

• Control circuitry 

• Ladder diagramming 

• Troubleshooting and repair techniques 


Class Size 12 


2 hours 


53


PUMP REPAIR 

(PRT 100) 


Participants should be able to install, align, 

troubleshoot, repair, and maintain centrifugal 

pumps. 



be able to: 

1. install, align, troubleshoot, repair, and maintain 

pumps with particular emphasis on system 

pumps and pumps other than hydraulic; 

2. understand bearing failure causes, cavitation, 

air entrainment, and pump corrosion; 

3. understand energy, work and break horsepower, 

variable speed pumping, specifi c speed, suction 

speed, and single and double suction; 

4. calculate energy loads and energy cost; and 

5. understand pump curves, reticulation, shaft 

deflection, mechanical loads, and affinity 

laws. 



and repair pumps. 


• Pump types 

• Centrifugal pumps 

• Positive displacement pump 

• Pump packing and seals 

• Pump alignment 

• Pump overhaul 


Class Size 12 


2 hours 

REBUILDING & REPACKING STEAM 

VALVES & TRAPS 

(SVT 200) 


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. 



be able to: 

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 

specifi cations; 

6. detect leaks in steam systems, traps, and 

valves; and 

7. identify the various types of steam traps. 



and repair valves and traps used in industrial 

mechanical/steam systems. 


• Review basic physics concepts 

• Vacuum breakers 

• Vaporization and condensation 

• Formulas 

• Properties of saturated steam 

• Strainers 

• Pressure reducing valves 

• Safety 

• O, S & Y valves 

• Inverted bucket traps 

2 hours 

54


• Non-return valves 

• Float and thermostatic traps 

• Relief valves 

• Thermostatic traps 

• Safety valves 

• Float traps for air systems 

• Check valves 



Class Size 12 


INDUSTRIAL RIGGING 

(IMT 300) 

2 hours 


This course covers the use of rigging gear such as 

hooks, nylon slings, wire rope, wire rope slings, fi ber 

rope, chains, chain slings, hoist chains, and metal 

mesh slings. Participants will utilize the TTC’s 20-ton 

crane for rigging exercises. 



be able to: 

1. inspect various equipment for safety; 

2. determine safe load limits; 

3. fi gure balance point of loads; and 

4. apply the techniques of a skilled rigger. 


To train the participant involved in rigging to do so 

effi ciently 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 


Class Size 12 


THERMOGRAPHY 

(THT 200) 

1 hour 


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. 



be able to: 

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 fi nd areas of heat 

loss in roofs and walls; 

55


6. search out and fi nd overloaded circuits that 

create a heat problem; and 

7. use the camera correctly to fi nd sources of 

overload in power supplies. 


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 

• Steam valves 

• Buss scans • Wiring 

• Gear boxes • Chemical 

• Fluids 

• Emissivity 

• Pumps 

• HVAC 

• Electrical scans • Electric motors 

• Circuit breakers • Misalignment 

• Mobile equipment • Rotating equipment 

• Molding equipment • Machining equipment 

• Hydraulic scans • 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 


VIBRATION ANALYSIS, 

ALIGNMENT, & BALANCING 

(VAT 100) 

2 hours 


The participant should be able to diagnose and 

measure vibration problems, use various tools and 

techniques to adjust alignment, and perform correct 

balancing. 



be able to: 

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. 



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 


Class Size 12 


56

Welding Course Descriptions 


WELDING 

57


The UAW-DaimlerChrysler 

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-DaimlerChrysler Technology Training Center and 

DaimlerChrysler Advanced Technical Training Services (ATTS). Its goal is to provide DaimlerChrysler 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 enroll for 

ANY of the welding classes in this catalog. 

58


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 hands-on 

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 

DaimlerChrysler MTI SMI-116. 


• Related hazards and safety precautions 

• Gas metal arc welding 

• Proper setup of oxy-fuel gas and electric arc 

welding equipment 

• Gas tungsten arc welding equipment 

• Plasma arc welding 

• Shielded metal 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 


WELDING ALUMINUM ALLOYS 

(WAT 200) 

2 hours 


The participant should be able to select the appropriate 

welding process for aluminum, select the appropriate 

fi ller metal, set up and adjust the welding equipment, 

and produce acceptable quality welds on aluminum 

alloys. 



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; 

59


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 fi ller 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 certifi cation from 

a welding safety course. 

Class Size 6 


BASIC STICK WELDING (SMAW) 

(WBT 200) 


2 hours 

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. 



be able to: 

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 fl at 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 



Class Size 6 


60


WELDING CAST IRON 

(WIT 300) 

1 hour 


The participant learns what the requirements are to 

produce quality welds on cast iron. 



be able to: 

1. describe the fi ve types of cast iron; 

2. prepare broken cast iron parts for welding; 

3. select the welding process most suitable for the 

repair; 

4. preheat cast iron; 

5. weld cast iron with both the shielded metal arc 

and oxy-fuel welding processes; and 

6. post heat and stress relieve cast iron after 

welding. 


To provide participants with the ability to successfully 

repair weld broken or worn cast iron parts. 


• Weldability of cast iron 

• Weld joint preparation for broken or worn cast 

iron parts 

• Shielded metal arc welding electrodes used on 

cast iron 

• Oxy-fuel welding repairs on cast iron 

• Preheating, inter pass temperature, postheating 

and stress relieving cast iron 

Prerequisites 




training at a community college, or certifi cation from a 

welding safety course. In addition, participants must 

have completed either Structural Steel Welding (WTT 

200) or Basic Stick Welding (WBT 200). 

Class Size 6 


GAS METAL ARC (MIG) WELDING 

PROCESS (WET 200) 

2 hours 


This course covers safe procedures for equipment 

set-up; fundamentals of gas metal arc welding; and 

gas, electrode, and fi ller metal selection. 



be able to: 

1. set up and adjust gas metal arc welding 

equipment; 

2. select the correct shielding gas, electrodes, and 

fi ller metal; and 

3. weld fi llet, groove, and surfacing welds using 

the MIG welding process. 


The participant should be able to successfully produce 

quality fi llet, groove, and surfacing welds on materials 

ranging from sheet metal to structural steel using the 

MIG welding process. 

61



• Welding safety 

• Equipment setup 

• Fundamentals of gas metal arc welding and its 

applications 

• Gas electrode wire and fi ller metal selection 

Prerequisites 

To obtain the maximum benefi t 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 

certifi cation from a welding safety course. 

Class Size 6 


GAS TUNGSTEN ARC (TIG) 

WELDING PROCESS 

(WVT 200) 

2 hours 


The participant should be able to safely use metal arc 

welding equipment, recognize process variations, and 

carry out appropriate fi llet and square groove welds 

on steel using the TIG process. 

4. weld fi llet and square groove welds on carbon 

and stainless steel using the TIG welding 

process. 


The participant should be able to successfully produce 

quality fi llet 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 

fi ller metal selection 

Prerequisites 

To obtain the maximum benefi t from this training, 

participants should possess a fundamental knowledge 

of fusion welding. In addition, participants must meet 





Class Size 6 




be able to: 

1. set up and adjust gas metal arc welding 

equipment; 

2. select the correct shielding gas, electrodes, and 

fi ller materials; 

3. identify the process variations and applications; 

and 

62


PIPE & TUBE WELDING 

(WXT 200) 


Upon arrival on the fi rst 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 



participant should be able to prepare, fi t 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 fi xed positions 

• Review of pre-qualified welding procedure 

specifi cations 

Description 

The participant will be able to prepare, fi t, and tack 

weld pipe joints; weld pipe in all positions using 

the MIG process; and inspect completed welds for 

quality. 

SMAW: WXT 201 

3 hours 


• 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 



the stick process; and inspect completed welds for 

quality. 

GTAW: WXT 202 



participant should be able to prepare, fi t, 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 specifi cations 

• Joint designs and variables that affect quality 

• Manual techniques to perform quality welds in 

the IGR, 2G, 5G and 6G positions 

Description 



the TIG process; and inspect completed welds for 

quality. 



participant should be able to prepare, fi t, and tack 

weld pipe joints; weld pipe in all positions using the 

gas metal arc welding (GMAW) process; and inspect 

completed welds for quality. 

63


Prerequisites 

To obtain maximum benefit from this training, 

participants should already be qualifi ed 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 



Class Size 6 


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 production welding 

effi ciency 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. 

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 DaimlerChrysler welding specifi cations 

to determine the capability of a robotic or 

automatic welding system to produce quality 

production welds. 



robotic and other dedicated high-speed production 

welding systems. 


• Gas metal arc welding principles of operation 

• Flux cored arc welding principles of operation 

• Welding procedures development. 


• Troubleshooting welding equipment 

• DaimlerChrysler welding specifi cations 


Class Size 6 




be able to: 

1. describe the safety requirements specifi c to 

welding and cutting operations that use highspeed 

automated welding equipment; 

2. describe the operating characteristics of gas 

metal arc and fl ux cored arc welding; 

3. describe what welding parameters affect weld 

quality; 

4. describe how welding fi xtures and tooling can 

affect weld quality; 

64


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. 



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 classifi cations 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 fl ux cored welding processes. 


• Material specifi cation 

• Weld joint design 

• Tacking and fi t up 

• Filler metal selection 

• Welding techniques 

• Storage of low hydrogen electrode 

• Setup and adjustment of equipment 

2 hours 

Prerequisites 






Class Size 6 


ADVANCED STRUCTURAL STEEL 

WELDING 

(WTT 300) 

2 hours 


The participant welds structural steel in all welding 

positions using the Shielded Metal Arc and Flux Cored 

Arc welding processes. 



be able to: 

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 fi llet 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 of structural steel 

• Techniques for groove welds with and without 

backing 


65


Prerequisites 

All participants should have completed Structural 

Steel Welding (WTT 200). In addition, all participants 

must meet one of the following requirements: 





Class Size 6 


WELDING TOOL & DIE STEELS 

(WDT 200) 

2 hours 


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. 


• Hardness testing 

• Material identifi cation 

• 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), fl ux 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 





Class Size 6 




enable the participant to: 

1. identify various tool steels; 

2. select proper fi ller 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. 

66


QUALIFICATION/CERTIFICATION 

OF… (WQT 400 - WQT 407) 

2 hours 

Upon arrival, training participants will be asked to 

designate a specifi c area of certifi cation. Each area of 

certifi cation is its own specifi c course (topics covered 

are summarized below). 

• A participant may be certifi ed 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 enrollment 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 qualifi cation test(s) as specifi ed by 

the American Welding Society, American Society of 

Mechanical Engineers, and/or the Canadian Welding 

Bureau. 

Welding Skills for... 

Structural Steel (WQT 400) 

The participant must pass a visual inspection and a 

bend test or fi llet break test. 

Structural Aluminum (WQT 401) 

Includes a review of welding procedure specifi cations, 

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 fi llet 

break test. 

Steel Pipe (MIG) (WQT 402) 

Includes a review of welding codes and qualifi cations, 

safe practices, material preparation and fi t up of joint 

details. The participant must pass a visual inspection 

and a bend test or fi llet break test. 

Steel Pipe (GMAW) (WQT 403) 


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 fi llet break test. 

Pipe & Tube (TIG)(GTAW) 

(WQT 404) 


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 fi llet break test. 

Tool & Die (WQT 405) 

Includes a review of allowable repairs, problem solving 

exercises, and acceptance criteria per DaimlerChrysler 

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. 

Sheet Metal, Steel, & Stainless 

(WQT 406) 

Includes a review of welding codes and specifi cations; 

material preparation and joint fi t-up; distortion control; 

and selection of electrodes, fi ller metals, and shielding 

gases. The participant must pass a visual inspection 

and a bend test or fi llet break test that meets AWS 

Sheet Metal Welding Code D9.1 requirements. 

Sheet Metal Aluminum (WQT 407) 

Includes a review of welding codes and specifi cations; 

material preparation and joint designs; distortion 

control; and selection of electrodes, fi ller metals, 

and shielding gases. The participant must pass a 

visual inspection and a bend test or fi llet break test 

that meets AWS Sheet Metal Welding Code D9.1 

requirements. 

Class Size 6 


67


INDEX 

1336 Plus Family Variable Speed AC Drives, Allen-Bradley (BAT 400) .................................................... 31 

1394 Motion Control Operations & Maintenance, Allen-Bradley (BAT 410) .............................................. 32 

ABB Operation/Programming for the S3 Controller (ABT 300), Robotics: ................................................ 33 

ABB Systems Including Wrist Repair (ABT 315), Robotics: Mechanical Maintenance for ........................ 33 

Air Logic, Industrial (ALT 101) ................................................................................................................... 40 

Apprenticeship Program .............................................................................................................................. 5 

Bearing Life Improvement (BLT 101) ......................................................................................................... 40 

Cancellations, Enrollment ........................................................................................................................... 3 

Cancellations, Travel .................................................................................................................................. 3 

CATIA & VPM for Manufacturing, Introduction to (CTT 001) ..................................................................... 15 

CATIA for Die Makers (Solids) (CTT 300) ................................................................................................ 16 

CATIA for Tool Makers (Solids) (CTT 320) ............................................................................................... 17 

CATIA Fundamentals (CTT 200) ............................................................................................................... 16 

CATIA Layout & Inspect (CTT 310) ........................................................................................................... 17 

Certifi cation, Skill ........................................................................................................................................ 4 

College Credit ............................................................................................................................................. 4 

Communications Systems, Plant (FOT 400) ............................................................................................. 46 

Conduit Bending, Industrial (COT 100) ..................................................................................................... 41 

ControlLogix Processor Family Using RSLogix 5000 Software, Allen-Bradley (BAT 175) ........................ 26 

ControlNet, Troubleshooting the Allen-Bradley (CRT 300) ........................................................................27 

Course Descriptions Catalog ....................................................................................................................... 1 

DeviceNet, Troubleshooting the Allen-Bradley (DNT 300) ........................................................................ 28 

Die Making Technology (MDT 100) ........................................................................................................... 18 

Electronic Maintenance (IET 200) ............................................................................................................ 42 

Electrical/Electronic Fundamentals (IET 105) ........................................................................................... 41 

Electrical Controls & Schematics (EST 100) ............................................................................................. 14 

Enrollment Materials .................................................................................................................................... 2 

Enrollment Procedure .................................................................................................................................. 2 

Fanuc RJ2-RJ3 Electrical Maintenance & Troubleshooting (FRT 350), Robotics: .................................... 35 

Fanuc RJ2-RJ3 Operation & Programming (FRT 300), Robotics ............................................................. 34 

Fiber Optics, Advanced (FOT 310) ............................................................................................................ 45 

Fiber Optic Cable Installation, Maintenance, & Troubleshooting (FOT 110) ............................................. 44 

Fire Systems Training (FST 100) ............................................................................................................... 46 

68


Fluid Power Equipment, Troubleshooting (FLT 100) ................................................................................. 47 

Fluids, Fluid Analysis, & Contamination Control (OAT 200) ......................................................................48 

Forklift Separately Excited Motor Control Systems 

(TZR) LX-100/200 SCR Control Systems, General Electric (MCT 200) .......................................... 48 

GE Fanuc Series 15 CNC, Basic Operator Training for the (CNT 100) ..................................................... 22 

GE Fanuc Series 15 CNC, Basic Programmer Training for the (CNT 400) ............................................... 24 

GE Fanuc Series 15 CNC, Troubleshooting the (CNT 300) ...................................................................... 23 

Gear Box Repair, Industrial (GRT 300) ..................................................................................................... 49 

Geometric Dimensioning and Tolerancing for Manufacturing (GDT 100) .................................................. 15 

Grounding & Bonding (IET 210) ................................................................................................................ 43 

Health & Safety Training .............................................................................................................................. 6 

Hydraulic Equipment, Advanced Troubleshooting Industrial (HYT 300) .................................................... 50 

Hydraulic Equipment, Troubleshooting Industrial (HYT 100) ..................................................................... 50 

Job Setting, Fundamentals of (JSP 100) ..................................................................................................... 8 

Ladder Logic (LLT 110) .............................................................................................................................. 51 

Laser Leveling (LAT 100) .......................................................................................................................... 52 

Lubrication Systems (LST 100) ................................................................................................................. 52 

Manufacturing Process, Overview of the (OMP 100) .................................................................................. 8 

Map, Metro Detroit ..................................................................................................................................... 71 

Map, TTC Area .......................................................................................................................................... 73 

Map, Warren Area ..................................................................................................................................... 72 

Measurement for Manufacturing (MGP 100) ............................................................................................... 9 

Mechanical Power Systems, Troubleshooting (MPT 100) ......................................................................... 53 

Mechanical Schematics (MST 100) ........................................................................................................... 14 

Metal Finishing (MFP 100) ........................................................................................................................ 10 

Metallurgy, Fundamentals of (WLT 200) .................................................................................................... 19 

Metallurgy-Heat Treating, Advanced (WLT 300) ........................................................................................ 19 

Mill Programming & Operation, ProtoTrak (CNT 130) ............................................................................... 23 

Mills, CNC Setup & Operation for (CNT 120) ............................................................................................ 22 

Nachi AR 52 Electrical Maintenance (RNT 360), Robotics: ....................................................................... 37 

Nachi Operation/Programming for the AR 11/AR 52 Controllers (RNT 320), Robotics: ............................ 35 

Nachi Operation/Programming for the AW11 Controller (RNT 330), Robotics: ......................................... 36 

Painted Metal Dent Repair (MDP 200) ...................................................................................................... 12 

PanelView 1400e, Allen-Bradley (BAT 310) .............................................................................................. 28 

PLC-5 Family/6200 Software, Allen-Bradley (BAT 105) ............................................................................25 

69


PLC-5 Family/6200 Software, Allen-Bradley, Advanced (BAT 205) ........................................................... 27 

PLC-5 Family/ICOM Software, Allen-Bradley (BAT 155) ........................................................................... 26 

PLC-5 Processor Family/RS Logix Software, Allen-Bradley (BAT 335)..................................................... 31 

Pneumatic Controls & Equipment, Troubleshooting (PNT 101) ................................................................ 53 

Pump Repair (PRT 100) ............................................................................................................................ 54 

Qualifi cation/Certifi cation of Welding... (WQT 400-407) ............................................................................ 67 

Registration, Questions Regarding ............................................................................................................. 2 

Rigging, Industrial (IMT 300) ..................................................................................................................... 55 

RS Logix 5 Software for Allen-Bradley PLC-5 (BAT 330) ..........................................................................30 

RS Logix 5 Software for Allen-Bradley SLC 500 (BAT 320) ...................................................................... 29 

SLC 500 Processor Family/RS Logix Software, Allen-Bradley (BAT 325) ................................................. 30 

SLC 500 Processor Family Using A-B 6200 Software, Allen-Bradley (BAT 100) ...................................... 24 

Steam Valves & Traps, Rebuilding & Repacking (SVT 200) ..................................................................... 54 

Technology Training Center, Introduction to ................................................................................................ 1 

Thermography (THT 200) .......................................................................................................................... 55 

Transformers & Feeders (IET 215) ............................................................................................................ 44 

Travel & Accommodations ........................................................................................................................... 3 

Vibration Analysis, Alignment, & Balancing (VAT 100) .............................................................................. 56 

Weld Inspection, Production (WQP 200) ................................................................................................... 12 

Welding Aluminum Alloys (WAT 200) ........................................................................................................ 59 

Welding Cast Iron (WIT 300) ..................................................................................................................... 61 

Welding for Production Workers, MIG & Flux Cored (WSP 100) ................................................................11 

Welding Safety & Overview of Processes (WPP 100) [Production Course] ............................................. 10 

Welding Safety & Overview of Processes (WPT 100) [Skilled Trades Course] ........................................ 59 

Welding Systems (WWT 200), Troubleshooting Robotic & Automatic ...................................................... 64 

Welding Tool & Die Steels (WDT 200) ....................................................................................................... 66 

Welding Training Lab, About the ............................................................................................................... 58 

Welding, Advanced Structural Steel (WTT 300) ........................................................................................ 65 

Welding, Pipe & Tube (WXT 200) .............................................................................................................. 63 

Welding, Structural Steel (WTT 200) ......................................................................................................... 65 

Welding Courses, About the ...................................................................................................................... 58 

Welding Process, Gas Metal Arc (MIG) (WET 200) .................................................................................. 61 

Welding Process, Gas Tungsten Arc (TIG) (WVT 200) ............................................................................. 62 

Welding (SMAW), Basic Stick (WBT 200) ................................................................................................. 60 

70


METRO DETROIT MAP 

Directions to the UAW-DaimlerChrysler Technology Training Center 

• Take I-94 EAST to I-75 NORTH. (If coming from Metro Airport.) 

• Continue on I-75 NORTH until you reach the JOHN R./ 9 MILE ROAD EXIT (EXIT #60), 

which will be on your RIGHT. 

continued next map ➙ 

DETROIT AREA 

71


WARREN AREA MAP 


• Exit the freeway and make a RIGHT (GO NORTH) at the fi rst set of traffi c lights onto 

JOHN R. ROAD. 

• Continue straight ONE BLOCK to the next set of traffi c lights and make a RIGHT (GO 

EAST) on 9 MILE ROAD. 

continued next map ➙ 

WARREN AREA 

72


TTC AREA MAP 


• Continue going STRAIGHT about 1 1/2 MILES, cross DEQUINDRE ROAD, and after 1/4 

MILE, the TTC will be on the RIGHT HAND SIDE (SOUTH SIDE) of 9 MILE ROAD. 

• You will see the ENTRANCE to the PARKING LOT and TRAINING FACILITY on the 

RIGHT HAND SIDE (SOUTH SIDE) of the STREET. 

(If you cross WARNER ROAD, you have gone too far.) 

TTC AREA 

UAW-DaimlerChrysler Technology Training Center 

2500 E. Nine Mile Road 

Warren, MI 48091 

73

TTC Course Descriptions Catalog - UAW-Chrysler.com

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