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200-Hour Dislocated Workers’
Advanced Manufacturing/
Integrated Systems Technology Curriculum
The 200-Hour Dislocated Workers’ Advanced Manufacturing/Integrated
Systems Technology (AM/IST) curriculum is organized into three
components: Electrical, Electronic and Mechanical.
Each community college participating in the AM/IST grant received more
curriculum than what is needed to complete the 200-Hour Dislocated
Workers’ AM/IST curriculum. The areas that are shaded in gray are
considered to be enhancement activities. Hence, these portions may be
completed as time allows, but should not be considered as part of the core
curriculum. They should be completed only if time permits.
1
ELECTRICAL
2
AC/DC ELECTRICAL SYSTEMS
Objectives
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Define electricity and give an application
Describe the two types of electrical current and give an application of each
Describe the function and operation of a circuit tester
Describe the function of the four basic components of an electric circuit
Describe the operation of two types of power supplies and give their schematic symbols
Describe the function of an electrical schematic
Describe the operation of a manual switch
Describe the operation of N.O. and N.C. contacts and give their schematic symbols
Describe the function of three types of manual switch operators and give an application
of each
Describe the operation of three types of manual switch operators and give their
schematic symbols
Describe the function of five types of electrical output devices and give an application of
each
Describe the operation of five types of electrical output devices and give their schematic
symbols
Skills
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Use an AC tester to check a wall outlet for electricity
Connect and operate a power supply
Connect and operate a circuit using three types of manual switches
Connect and operate an electrical circuit with a resistor
Connect and operate an electrical circuit with a buzzer
Connect and operate an electrical circuit with a solenoid
Connect and operate an electrical circuit with a motor
Objectives
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2
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5
Define voltage and give its units of measurement
Describe the function of two types of voltmeters and give their schematic symbol
Describe how to use a voltmeter to measure voltage
Describe the function of two multimeters: analog and digital
Define series and parallel circuits
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Describe the voltage characteristics in series and parallel circuits
Define current and give its units of measurement
Describe the function of two types of ammeters and give their schematic symbol
Describe how to use an ammeter to measure current
Describe the current characteristics in series and parallel circuits
Define resistance and give its units of measurement
Describe the function of two types of ohmmeters and give their schematic symbol
Describe how to use an ohmmeter to measure resistance
Describe the resistance characteristics in series and parallel circuits
Describe two methods of measuring continuity
Skills
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8
Use an analog voltmeter to measure the voltage at a point referenced to ground
Use a DMM to measure the voltage of a point referenced to ground
Use a DMM to measure voltage drops in series and parallel circuits
Use a DMM to measure the electrical current
Use a DMM to measure current in series and parallel circuits
Use a DMM to measure the resistance of a component
Measure the resistance in series and parallel circuits
Test the continuity of wires using a DMM
Objectives
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State the formula for calculating series resistance and give an application
State Ohm's Law, explain its importance and give an application
State Kirchhoff's voltage law for a series circuit and give an application
Define power and give its units of measurement
State a formula for calculating the total power used in an electrical circuit
State Kirchhoff's Current Law and give an application
State a formula for calculating total parallel resistance
Describe the function of two types of circuit protection and give an application of each
Describe the operation of a fuse and give its schematic symbol
Describe the operation of two types of circuit breakers and give their schematic symbols
Skills
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Calculate series resistance given each load's resistance
Use Ohm's Law to calculate voltage, current, and resistance in a series circuit
Calculate the total power used by a series circuit
Calculate the main line current in a parallel circuit
Calculate the total parallel resistance
Calculate the total power used in a parallel circuit
Operate a circuit using a fuse
Test and replace a fuse
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9
10
Operate a circuit using a circuit breaker
Test and reset a circuit breaker
5
Objectives
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Define electromagnetism and give an application
Describe the functions of four electromagnetic devices
Define inductance and give its units of measurement
Describe the operation of an inductor and give its schematic symbol
Describe the effect of an inductor in a DC circuit and give an application
Describe the effect of an inductor in an AC circuit and give an application
State the formulas for calculating total series inductance and inductive reactance
State the formulas for calculating total parallel inductance and inductive reactance
Define capacitance and give its units of measurement
Describe the operation of a capacitor and give its schematic symbol
Describe the functions of three types of capacitors
Describe the effect of a capacitor in a DC circuit and give an application
Describe the effect of a capacitor in an AC circuit and give an application
State the formulas for calculating total series capacitance and capacitive reactance
State the formulas for calculating total parallel capacitance and capacitive reactance
Describe the function of a fluorescent light fixture
Describe the function of an RC timing circuit in a time-delay relay
Describe the function of capacitors and inductors in electric power supplies
Skills
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Connect and operate a relay in a circuit
Calculate the total load on an AC circuit with inductors
Discharge a capacitor
Test a capacitor with a DMM
Measure the voltage across a charged capacitor
Calculate the total load on an AC circuit with capacitors
Calculate the time to charge and discharge a capacitor
Objectives
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Define a series-parallel circuit
Describe a method for identifying the series and parallel sections of a circuit
Describe the seven steps for solving a combination circuit
Describe how switches are used in combination circuits and give an application
Describe the function of a variable resistor and give an application
Describe the function of a voltage divider and give an application
Describe the operation of three types of voltage dividers
Explain the effect of a short circuit
Describe the four steps for troubleshooting a short circuit
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10
Describe the three basic steps for troubleshooting an open circuit
Skills
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2
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8
9
Trace the current path in a combination circuit
Solve a combination circuit
Connect and operate a basic lighting circuit
Connect and operate a ceiling fan circuit
Connect and operate a rheostat as a light dimmer
Design a voltage divider network
Connect and operate a voltage divider network
Locate a short circuit
Locate an open circuit
7
ELECTRICAL MOTOR CONTROL
Objectives
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Explain the importance of the equipment ground connection
List ten basic rules of electrical safety
Describe the purpose of the lockout/tagout system used in industry
Describe the operation of three-phase power
Describe the two most common three-phase voltage systems
Explain the function of neutral
Describe the operation of grounded and ungrounded systems
Describe two devices used to disconnect power to a circuit
Explain why time-delay fuses are used with motor starting circuits
Describe three important factors to consider with overcurrent protection devices.
Describe the operation of a three-phase motor
Describe the operating data on a motor’s nameplate
Define service factor and explain its importance
Explain why dual-voltage motors should always be run on the highest available voltage
Skills
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5
Perform a lockout/tagout
Use a voltmeter to verify supply voltage
Use an ohmmeter to check the condition of a fuse
Connect a dual-voltage three-phase motor for low voltage operation
Connect a dual-voltage three-phase motor for high voltage operation
Objectives
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Describe five functions of motor control
Describe the four basic requirements for a typical motor installation
Define motor controller and motor starter
Describe the functions of two categories of motor starters
Describe the functions of two types of manual starters
Describe the operation of a manual motor starter
Define low-voltage protection and describe its importance
Describe how low-voltage protection is accomplished in a manual starter
Describe the function of three types of overloads and give an application of each
Describe the operation of two types of thermal overloads
Describe the operation of a magnetic overload
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Skills
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Connect and operate a simple motor control circuit
Start and stop a motor using a manual starter
Set the trip level of a bimetallic overload
Select the correct heaters for a NEMA overload
Objectives
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Describe the operation of a transformer and give its schematic symbol
Define turns ratio and describe how it is calculated
Describe how the turns ratio determines the secondary voltage of a transformer
Describe the function of the four basic components of an electrical control circuit
Describe the function of an electrical schematic diagram
Describe the function of a control transformer
Describe the operation of a control transformer and give its schematic symbol
Describe how to test a transformer
Describe how to size a transformer
Describe the operation of a separate control circuit
Skills
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5
Calculate the turns ratio of a transformer
Calculate the secondary voltage of a transformer
Connect and operate a control transformer
Test a control transformer
Size a control transformer
Objectives
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8
Describe the function of three types of electrical control systems and give an application
of each
List and describe the three steps of a control process
Describe the function of an indicator lamp and give an application
Describe the operation of a pushbutton switch and give its schematic symbol
Describe the operation of a selector switch and give its schematic symbol
Describe the function of a ladder diagram
Describe the function of four components of a ladder diagram
Describe six rules of drawing a ladder diagram
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Describe how to determine the operation of a circuit given a ladder diagram
List six elements of control logic
Describe the operation of AND logic and give an application
Describe the operation of OR logic and give an application
Describe the operation of NOT logic and give an application
Describe the operation of NOR logic and give an application
Describe the operation of NAND logic and give an application
Skills
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Connect and operate a basic electrical control circuit which uses a pushbutton switch
Connect and operate a basic electrical control circuit which uses a selector switch
Draw a ladder diagram of a control circuit
Determine the operation of a control circuit given a ladder diagram
Connect and operate a control circuit given a ladder diagram
Connect and operate an AND logic circuit
Connect and operate an OR logic circuit
Connect and operate a NOT logic circuit
Connect and operate a NOR logic circuit
Connect and operate a NAND logic circuit
Design a multiple start/stop pushbutton station control circuit
Objectives
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Describe the function of a control relay and give an application
Describe the operation of a control relay and give its schematic symbol
Describe the operation of two types of control relays and give an application of each
Describe how detached symbology is used to show a control relay on a ladder diagram
Describe the operation of memory logic and give an application
Describe the operation of a magnetic motor starter
Describe the operation of a two-wire motor control circuit and give an application
Describe the operation of a three-wire motor control circuit and give an application
Describe the function of a push-to-test pilot light and give an application
Describe the operation of a push-to-test pilot light and give its schematic symbol
Skills
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Connect and operate a control relay in a circuit
Connect and operate a memory logic circuit
Connect and operate a magnetic motor starter connected to a three-phase motor
Connect and operate a two-wire motor control circuit
Connect and operate a three-wire motor control circuit
Design a multiple operator station three-wire control circuit
Connect and operate a three-wire control circuit with a push-to-test pilot light
10
Objectives
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Describe two levels of troubleshooting and give an application of each
Describe three methods of testing components and give an application of each
Describe how to test an indicator lamp
Describe how to test a manual switch
Describe how to test a control relay
Describe how to test a motor contactor
Describe how to test an overload relay
Describe how to test a 3-phase motor
Skills
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Test an indicator lamp
Test a manual switch
Test a control relay
Test a motor contactor
Test an overload relay
Test a 3-phase motor
Test a control transformer
Objectives
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Describe the function of four common electrical test instruments used in
troubleshooting
Describe how to select a DMM to measure voltage for a given application
Describe how to use a voltage tester (wiggy)
Describe how to use a clamp-on ammeter
Describe how to use a continuity tester
Describe a six step troubleshooting sequence
Describe the four methods of systems level troubleshooting and give an advantage of
each
Describe five types of in-circuit component tests
Describe how to test and analyze circuit signals
Skills
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Select and use a DMM to measure voltage for a given application
Select and use a voltage tester (wiggy) for a given application
Select and use a clamp-on ammeter
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Select and use a continuity tester for a given application
Perform and analyze circuit signal tests
Use the symptom and cause troubleshooting method to isolate a bad component
Use the output-back troubleshooting method to isolate a bad component
Use the half-split troubleshooting method to isolate a bad component
Use the shotgun troubleshooting method to isolate a bad component
Troubleshoot a 2-wire control system
Troubleshoot a 3-wire control system
Objectives
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State the NEMA and IEC standard for reversing the rotation of a three-phase motor
List two common control methods used to reverse a three-phase motor
Describe the function and operation of a drum switch
Describe the function and operation of a reversing magnetic motor starter
Describe the function of interlocking control and give an application
Describe three interlocking methods used in reversing motor control
Describe the function of manual and automatic modes and give an application of each
Describe the operation of two types of motor jogging circuits
Describe the operation of a Hand-Off-Automatic motor control circuit
Skills
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Connect and operate a drum switch to reverse a motor
Connect and operate a reversing magnetic motor starter to reverse a motor
Design a motor reversing circuit that uses a drum switch and a magnetic starter
Connect and operate a reversing motor control circuit with mechanical and auxiliary
interlocking
Troubleshoot a reversing motor control circuit
Design a reversing motor control circuit that uses pushbutton interlocking
Connect and operate a circuit to jog a motor
Connect and operate a forward/reverse jog control circuit
Troubleshoot a control circuit which has manual and automatic modes
Connect and operate a Hand-Off-Automatic motor control circuit
Design a Hand-Off-Automatic motor control circuit
Objectives
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Describe the functions of four types of automatic input devices and give an application of
each
Describe the operation of a limit switch and give its schematic symbol
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Describe the operation of a float switch and give its schematic symbol
Describe the operation of a pump control circuit
Describe the operation of a pressure switch and give its schematic symbol
Describe how to test an automatic input switch
Describe the function of a sequence control circuit and give an application
Describe the operation of a sequence control circuit
Skills
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Connect and operate a limit switch
Design an overhead door motor control circuit
Connect and operate a float switch
Connect and operate a pump control circuit
Connect and operate a pressure switch
Design a pump control circuit that includes H-O-A operation
Test an automatic input switch
Connect and operate a sequence control circuit
Troubleshoot a sequence control circuit
Design a sequence control circuit
Objectives
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Describe the function of a time-delay relay and give an application
Describe the function of two types of timer relays and give an application of each
Describe the operation of an On-Delay timer relay and give its schematic symbol
Describe the operation of a timer relay in an unloaded motor start circuit
Describe the operation of an Off-Delay timer relay and give its schematic symbol
Describe the function of a time-delay relay in time-driven sequencing
Describe how to test a timer relay
Skills
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Connect and operate an On-Delay timer circuit
Design a control circuit to perform an unloaded start of a motor
Connect and operate an Off-Delay timer circuit
Design a motor control circuit to perform time-driven sequencing
Test a timer relay
Troubleshoot an On-Delay timer circuit
Troubleshoot an Off-Delay timer circuit
13
ELECTRICAL CONTROL WIRING SYSTEM
Objectives
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Describe the function of an electrical print
Describe the function of electrical print mnemonics
Describe the function of notes on an electrical print
Describe how to interpret an electrical print
Describe the function of an electrical panel
Describe the function of three types of electrical panels
Describe the function of electrical terminal blocks
Describe how to select a terminal block for an application
Describe how to install a terminal block
Describe the importance of using wire number labels
Describe how to label wire numbers on an electrical print
Describe how to determine the number of wires to run between panels
Describe the function of wire color coding in electrical control
Describe how to determine the wire colors needed in an electrical panel
Skills
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5
Interpret an electrical print
Install a terminal block in an electrical panel
Label wire numbers on an electrical print
Determine the number of wires to run from a control panel to an operator station
Determine the wire colors needed for an application
Objectives
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Describe how to terminate panel wires
Describe how to install wire number labels on a wire
Describe two methods used to run identity wires which are run between panels
Describe how to hand feed wires through conduit
Describe how to splice motor wires using ring lug connectors
Describe how to tape motor leads
Describe the function of panel wire ways
Describe how to determine wire lengths inside a panel
Describe two methods to connect wires to terminal screws
Describe the function of wire bundling
Describe three common methods of wire bundling
14
Skills
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Terminate and label wires at a terminal block
Run wires between panels
Splice motor leads using ring lug connectors
Connect a wire to a terminal screw
Wire an electrical panel
Bundle wires in an electrical panel
Secure wire bundles in an electrical panel
Wire an electrical machine
15
POWER DISTRIBUTION SYSTEM
Objectives
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Describe the function of a wiring system
Describe the function of the four basic parts of a wiring system
Describe the function of conduit and list five types
Describe three methods by which conduit is cut
Describe the construction and operation of a hacksaw
Describe the function of a pipe vise and give three types
Describe the function of a pipe vise and describe three types
Describe six safety rules to follow when operating the bench vise
Describe the function of deburring conduit and give four tools that can be used
Describe the function of an electrical box and give an application
Describe the function of a conduit body and give an application
Describe the function of conduit fitting
Describe the function and operation of three types of connectors
Describe the function of coupling
Describe the function of a conduit strap and list three types
Skills
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7
Change a blade on a hacksaw
Use a bench vise to hold conduit
Cut EMT to length using a hacksaw
Deburr Conduit
Calculate conduit length given an application
Connect EMT between two boxes
Couple EMT conduit
Objectives
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2
3
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7
Describe the function of conduit bending and list three basic bends
Describe the function of a conduit bender and two methods that are used to bend
conduit
Describe four types of benders used with metallic conduit
Describe the construction and operation of a hand bender
Define the components of a 90 percent bend
Describe bender take-up and explain its importance in making a 90 percent bend
Describe the five steps used to determine bender take up
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Describe the five steps to lay out accurate leg lengths and stub lengths
Describe the components of an offset bend
Describe the four steps used to determine and locate the bend centers of an offset bend
Skills
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5
Determine the take-up of a hand bender
Lay out and bend EMT with proper leg length and stub-up
Determine the bend centers of an offset
Bend an offset in EMT conduit
Construct a raceway of EMT conduit
Objectives
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3
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8
Describe the similarities and differences between intermediate metallic and rigid conduit
Describe three tools used to cut intermediate metallic and rigid conduit
Describe two tools used to bend IMC and rigid conduit
Describe the construction and operation of a mechanical bender
Describe the method used to thread IMC and rigid conduit
Describe the connectors and couplings used with IMC and rigid conduit
Describe how flexible metal conduit is cut
Describe the connectors used with flexible metal conduit
Skills
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7
Cut intermediate metallic conduit
Change the shoes of a mechanical bender
Bend IMC with a mechanical bender
Thread rigid conduit
Connect and couple IMC given an application
Cut flexible metal conduit
Connect flexible metal conduit
Objectives
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2
3
4
5
Describe the function of a conductor and its two components
Describe five classifications of insulation and give an application of each
Describe five common classifications of insulation and give an application of each
Define conductor ampacity and describe the physical characteristics that affect it
Describe how distance affects wire selection
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Describe the function of a disconnect and give an application
Describe three commonly used types of disconnects and give an application of each
Describe how to size a disconnect
Describe the function of overcurrent protection and list two types
Describe how to size circuit protection
Skills
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2
3
Select wire size and type for an application
Select a disconnect for an application
Select circuit protection for an application
Objectives
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2
3
4
5
6
7
8
9
Describe percentage of fill and its importance in raceway selection
Describe two methods used to select raceway diameter
Describe the seven steps used to determine conduit size when conductors are of
different size and/or types
Describe why electrical codes limit the number of conductors in an electrical box
Describe how to select the correct size electrical box
Describe how conduit bodies are selected
Describe three methods used to pull conductors
Describe the function of a bus bar and give an application
Describe the function of a bus plug
Skills
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2
3
4
5
6
7
Use NEC table to select the proper size raceway for same size/type conductors
Determine conduit size when conductors are of different size and/or types
Determine electrical box size when conductors are the same size
Determine electrical box size when conductors are of different sizes
Pull conductors using fish tape
Connect a bus plug to a bus bar
Design and install a wiring system given specifications
18
ELECTRONIC
19
PROGRAMMABLE CONTROLLERS
ALLEN BRADLEY SLC500
Objectives
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Describe the function of a programmable logic controller and give an application
List six advantages of a PLC
Describe the functions of the five basic components of a PLC
Name three methods of entering a PLC program and give an advantage of each
Describe the basic operation of a PLC
Explain why PLCs use ladder diagrams
Identify and describe the function of the parts of a SCL-500 discrete address.
Describe the function and operation of input/output diagrams
Describe the operation of XIC and XIO input instructions
Describe the operation of an OTE instruction
Describe the basic operation of PLC ladder logic
Skills
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2
3
4
5
View a directory of processor files using PLC software
Restore a PLC processor file using PLC programming software
Monitor a PLC processor file using PLC programming software
Run a PLC processor file using PLC programming software
Stop a PLC processor file using PLC programming software
Objectives
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2
3
4
5
6
7
8
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10
List five types of numbering systems and explain their importance to PLCs
Describe the operation of the decimal numbering system and give an application
Describe the operation of the binary numbering system and give an application
Describe the SCL-500’s memory organization
Describe the operation of the SCL-500’s input and output data tables
Describe the function of seven types of processor files
Describe three advantages of PLC software
Describe how an input device can reference multiple input instructions
Describe how input device logic affects input instruction logic
Describe how a PLC controls multiple outputs at the same time
20
Skills
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2
3
4
5
6
7
8
Convert between decimal and binary
View the status of the SCL-500’s Input and output data tables
Create a PLC project using PLC software
Configure the I/O for a PLC project using PLC software
Enter a basic PLC program using PLC software
Save a PLC program to disk using PLC software
Edit a PLC program using PLC software
Generate and print out a ladder logic report using PLC software
Objectives
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2
3
4
5
6
7
Describe two methods by which a PLC output can control a motor
Describe how to draw a PLC output diagram for a motor application
Describe how input instructions can be controlled by PLC output instructions
Describe the function and operation of PLC seal-in logic
Describe the function and operation of a program interlock and give an application
Describe how a program interlock is used for safety
Describe the function of the PLC program documentation and give an application
Skills
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2
3
4
5
6
Design a PLC program to jog a motor
Design a PLC program to control the start/stop of a bi-directional motor
Design a PLC program to interlock two motors
Design a PLC program that uses a safety interlock to control the operation of a machine
View project documentation and use it to operate a PLC program
Document a PLC program file
Objectives
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2
3
4
5
Describe four features used to select a PLC discrete input module
List and describe the five features used to select a PLC discrete output module
Describe the effect of leakage current on an AC output module operation
Explain how to interface to a discrete electronic sensor with NPN or PNP output
Describe how to interface a PLC to a machine controller
21
Skills
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3
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5
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7
Connect and test a limit switch to a PLC discrete input module
Connect and test the operation of a solenoid valve to a PLC output
Connect and test the operation of a motor starter to a PLC
Connect and test the operation of an electronic sensor to a PLC input module
Connect and test the operation of a PLC input module to a robot output module
Connect and test the operation of a PLC discrete output module to a robot input module
Develop an interface wiring diagram to interface a PLC to a machine controller
Objectives
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2
3
4
5
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13
Describe two levels of troubleshooting and give an application of each
Describe six types of PLC faults
Describe the functions of PLC status and diagnostic indicators
Describe the operation of the PLC power supply circuit
Describe how to troubleshoot the PLC power supply circuit
Describe how to troubleshoot a PLC DC power supply module
Describe how to test PLC discrete input devices
Describe the operation of the TEST mode and give an application
Describe how to test a PLC discrete input module
Describe the Force function and give an application
Describe the function of the Force Table and its effect on the PLCs input and output data
Describe how to test a PLC discrete output device
Describe how to test a PLC discrete output module
Skills
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2
3
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5
6
7
Use PLC status indicators to determine the status of PLC operation
Troubleshoot the PLC power supply circuit
Test a PLC discrete input device
Test a discrete input module
Use the Force function to force an input or output
Use the Force function to test a PLC discrete output device
Test a PLC discrete output module
22
Objectives
1
2
3
4
5
6
7
Describe the function of the processor status file and give an application
Describe how to troubleshoot a PLC processor which controls local I/O
Describe five methods of PLC troubleshooting and give an application of each
Describe four types of PLC component tests
Describe a six-step PLC troubleshooting sequence
Describe the operation of the PLC Search function and give an application
Describe the function of a Contact Histogram and give an application
Skills
1
2
3
4
5
6
View and interpret the processor status file
Troubleshoot a processor fault
Use a six-step sequence to troubleshoot a PLC system
Troubleshoot a PLC-controlled electric motor system
Use the PLC Search function to find an instruction
Create and view a PLC Contact Histogram
Objectives
1
2
3
4
5
Define event-driven sequencing
Describe the operation of a reciprocating actuator PLC program
Describe the function of an internal output instruction and give an application
Describe the operation of a continuous cycle reciprocating program
Describe the operation of basic multiple actuator sequence program
Skills
1
2
3
Design a reciprocating actuator sequence PLC program
Design a continuous-cycle clamp and drill sequence PLC program
Troubleshoot a clamp and drill sequence PLC program
23
Objectives
1
2
3
Describe the functions of the seven steps used to design a PLC program
Describe the operation of a PLC program with manual and automatic modes
Describe three methods of stopping a PLC controlled machine
Skills
1
2
3
4
5
Design a PLC program using a seven-step design process
Troubleshoot a PLC program with manual and automatic modes
Design a motor control program which uses both manual and automatic modes
Design a PLC program which has both Halt and Cycle-Stop functions
Troubleshoot a PLC program which has both Halt and Cycle-Stop functions
Objectives
1
2
3
4
5
6
7
Describe the function of two types of timer instructions and give an application of each
Describe the operation of a retentive timer on-delay instruction
Describe the function and application of two types of non-retentive timer instructions
Describe the operation of the non-retentive timer on-delay instruction
Describe the operation of an off-delay timer instruction
Define time-driven sequencing and give three applications
Describe the operation of a time-driven sequence program
Skills
1
2
3
4
5
6
7
Enter and edit a PLC program that uses an RTO instruction
Enter and edit a PLC program that uses a TON instruction
Enter and edit a PLC program that uses a TOF instruction
Design a PLC program that provides low voltage starting of an electric motor
Design a PLC program that uses a time-driven sequence to control an actuator
Design a PLC program to control a plastic injection molding machine
Troubleshoot a PLC program which controls a plastic injection molding machine
24
Objectives
1
2
3
4
5
6
7
8
9
10
Describe the functions of two types of PLC counter instructions
Describe the operation of an up-counter instruction
Describe the operation of a down-counter instruction
Describe the operation of the BCD numbering system and give an application
Describe the function of a BCD thumbwheel switch and give an application
Describe the operation of a BCD thumbwheel switch
Describe the function and operation of the FRD instruction
Describe the function of an LED display and give an application
Describe the operation of an LED display
Describe the function and operation of the TOD instruction
Skills
1
2
3
4
5
6
7
8
9
Enter and edit a PLC program that uses an up-counter instruction
Design a PLC program to control the number of production cycles
Enter and edit a PLC program that uses an Up/Down-Counter instruction
Design a PLC program that controls a conveyor queue station
Convert between decimal and binary coded decimal
Enter a PLC program that uses an FRD instruction
Enter and run a PLC program that uses a TOD instruction
Design a PLC program that controls an adjustable counting station
Troubleshoot a PLC program which controls an adjustable counting station
25
MECHANICAL
26
BASIC HYDRAULICS
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
Define hydraulics and give an application
Describe the functions of five basic components of a hydraulic system
Define hydraulic pressure and give its units of measurement
Describe the operation of a hydraulic power unit
Describe the function of a hydraulic schematic
Describe the function of a hydraulic quick disconnect fitting and give its schematic
symbol
Describe the function of a tee and give its schematic symbol
Describe the operation of a pressure gage and give its schematic symbol
Describe the function of a hydraulic cylinder and give an application
Describe the operation of a double-acting hydraulic cylinder and give its schematic
symbol
Describe the operation of a 3-position, 4-way directional control valve (DCV) and give an
application
Describe the operation of a 3-position, 4-way directional control valve and give its
schematic
Skills
1
2
3
4
5
6
7
Read a hydraulic pressure gage
Read the liquid level and temperature in the reservoir
Operate a hydraulic power unit
Connect and disconnect a hydraulic hose that uses quick-connect fittings
Use a tee to connect two circuit branches together
Connect and operate a double-acting hydraulic cylinder using a 3-position, manuallyoperated DCV
Design a dual cylinder hydraulic circuit
Objectives
1
2
3
4
5
Define flow rate and explain how it can be measured
Describe the operation of two types of flow meters and give their schematic symbol
Describe the operation of a fixed-displacement pump and give its schematic symbol
Describe the operation of three types of fixed displacement pumps and give an
application of each
Describe the main function of a needle valve
27
6
7
8
9
10
Describe the operation of a needle valve and give its schematic symbol
Describe the function of a hydraulic motor and give an application
Describe the operation of a hydraulic motor and give its schematic symbol
Describe the operation of three types of hydraulic motors and give an application of each
Describe eight basic rules for drawing hydraulic schematics
Skills
1
2
3
4
5
6
7
Connect and read a flow meter
Connect and operate a needle valve to control the speed of an actuator
Control the speed of an actuator using a manually-operated DCV
Connect and operate a bi-directional hydraulic motor using a 3-position, manuallyoperated DCV
Draw a hydraulic schematic from the actual circuit connections on the machine
Connect a hydraulic circuit given a schematic
Design a multiple actuator hydraulic circuit
Objectives
1
2
3
4
5
6
7
8
9
Describe how to calculate the actual force output of an extending cylinder
Describe how to calculate the force output of a hydraulic cylinder in retraction (pull)
State Pascal's Law and explain its significance in hydraulics
Explain how force is multiplied using Pascal's Law
Describe two types of resistance in a hydraulic system
Explain how Delta P describes hydraulic resistance
Explain how pressure is distributed in a hydraulic system
Describe two methods of representing hydraulic pressure
Describe how oil flows on the suction side of the pump
Skills
1
2
3
4
5
6
Calculate the extension force of a cylinder given its size and pressure
Measure the force output of an extending cylinder
Calculate the retraction force of a cylinder given its size and pressure
Measure the force output of a retracting cylinder
Measure Delta P across a hydraulic component
Calculate between absolute pressure and gage pressure
28
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Describe the function of a relief valve and give an application
Describe the operation of a direct-acting relief valve and give its schematic symbol
Describe how a relief valve is used for system protection
Describe how a relief valve is used for speed control assistance
Describe the function of a check valve and give an application
Describe the operation of three types of check valves and give their schematic symbol
Describe the function of the flow control valve and give an application
Describe the operation of a flow control valve and give its schematic symbol
Describe the effect of actuator load changes on flow control valve operation
Describe the operation of meter-in flow control circuit and give an application
Describe the operation of a meter-out flow control circuit and give an application
Define independent speed control and give an application
Explain how speed control valves can be used to provide multiple speeds
Describe how to calculate the speed of a hydraulic cylinder
Describe how to calculate the retract speed of a cylinder
Describe how to calculate the stroke time of a cylinder
Skills
1
2
3
4
5
6
7
8
9
10
Connect a relief valve in a circuit to limit pressure in the system
Design a circuit to provide bypass flow
Connect and adjust a flow control valve to control speed of an actuator
Connect and operate a meter-in flow control circuit
Connect and operate a meter-out flow control circuit
Design an independent speed control circuit
Design a two-speed actuator circuit
Calculate the speed of a hydraulic cylinder given its size and a flow rate
Calculate the retract speed of a cylinder given its size and a flow rate
Calculate the cylinder stroke times given its size and a flow rate
Objectives
1
2
3
4
5
6
7
Describe the function of a pressure sequence valve and give an application
Describe the operation of a direct-acting pressure sequence valve and give its schematic
symbol
Describe the function of a by-pass check valve in a sequence valve circuit
Describe the operation of an integral check valve and give its schematic symbol
Describe the function of a two-sequence valve control circuit
Explain why a sequence valve is externally drained
Describe the function of a pressure reducing valve and give an application
29
8
9
10
Describe the operation of a direct-acting PRV and give its schematic symbol
Describe the function of a PRV’s bypass check valve
Explain why a PRV is externally drained
Skills
1
2
3
4
5
6
7
Connect and adjust the pressure setting of a sequence valve
Connect and operate a pressure sequence circuit
Design a pressure sequence circuit
Design a two-sequence valve control circuit
Connect and adjust the pressure setting of a PRV
Connect and operate a reduced pressure circuit
Design a hydraulic circuit that uses a pressure reducing valve
30
INTERMEDIATE HYDRAULICS
Objectives
1
2
3
4
5
6
7
8
9
10
Describe and explain the terms used to specify DCVs
Describe the function of a hydraulic 4/2 DCV and name one application
Describe the operation of a hydraulic 4/2 DCV and give its schematic symbol
Describe the function of a hydraulic 3/2 DCV and name one application
Describe the operation of a hydraulic 3/2 DCV and give its schematic symbol
Describe the function of a hydraulic pilot-operated DCV and name one application
Describe the operation of a hydraulic pilot-operated DCV and give a schematic symbol
Describe the function of a hydraulic cam-operated valve and name one application
List and describe the applications of two types of hydraulic cam-operated valves
Describe the operation of a hydraulic 4/2 cam-operated valve and give its schematic
symbol
Skills
1
2
3
4
5
6
7
8
9
Connect and operate a hydraulic DCV with a tandem-center spool
Select a spool option for a hydraulic DCV based on application information
Connect and operate a hydraulic 4/2 DCV
Connect and operate a 4/2 DCV to function as a 3/2 DCV
Design a hydraulic circuit using a 2-position DCV
Connect and operate a hydraulic pilot-operated DCV
Connect, adjust and operate a hydraulic cam-operated valve
Design a hydraulic sequence circuit that uses a cam-operated hydraulic valve
Design a hydraulic rapid traverse - slow feed circuit that uses a cam-operated valve
Objectives
1
2
3
4
5
6
7
8
9
Describe the operation of four types of cylinders and give an application of each
Describe the construction of two types of cylinders and give an application
Describe three common cylinder mounting styles and give an application
Describe three common cylinder feature options
Describe the principle of cylinder regeneration and name an application
Describe the operation of a basic regeneration circuit
Describe how to calculate the extend speed of a cylinder in regeneration
Describe how to calculate the extend force of a cylinder in regeneration
Describe the function of a pressure-compensated flow control valve and name one
application
31
10
11
12
13
14
15
Describe the operation of a pressure-compensated flow control valve and give its
schematic symbol
Describe the function of a double-rod cylinder and name one application
Describe the operation of a double-rod cylinder and give its symbol
Define cylinder synchronization and name three applications
Explain why cylinders do not operate in synchronization
List and describe the operation of five methods used to synchronize a circuit using flow
control valves
Skills
1
2
3
4
5
6
7
Select a cylinder mounting style for a given application
Connect and operate a basic regenerative circuit
Calculate the extend speed of a cylinder in regeneration
Calculate the extend force of a cylinder in regeneration
Connect and operate a pressure compensated flow-control valve
Set up, adjust, and operate a cylinder synchronization circuit using flow control valves
Set up and operate a synchronization circuit using series actuators
Objectives
1
2
3
4
5
6
Explain the advantage of a pilot-operated relief valve
Describe the operation of a pilot-operated relief valve and give its complete schematic
symbol
Describe the function of the vent port of a pilot-operated relief valve
Describe two methods of pump unloading and give an application of each
Describe the operation of a remote-controlled relief valve circuit
Describe multiple pressure relief valve operation and give one application
Skills
1
2
3
Connect a pilot-operated relief valve to unload a pump by venting
Connect and operate a remotely controlled p.o. relief valve circuit
Design a circuit to provide a two-pressure control with unloading
Objectives
1
2
3
Explain how actuator relaxation occurs in a multi-actuator circuit
Describe the operation of a P-port check valve circuit
Design the construction of an integral P-port check valve
32
4
5
6
7
8
9
10
11
12
13
14
15
Describe the function of a pilot-operated check valve and give its schematic symbol
Describe the operation of a pilot-operated check valve and give an application
Describe the operation of load-lock circuits using one POC valve
Describe the operation of load-lock circuits that use two POC valves
Describe the operation of a double-POC check valve
Describe the function of a prefill valve and give an application
Define POC valve pilot ratio and explain its importance
Describe how to calculate the pressure required to open a POC valve
Define pressure intensification and explain its importance
Describe how to calculate the maximum pressure in a POC valve circuit
Describe the function and operation of a POC valve with decompression poppet
List five application guidelines for POC valves
Skills
1
2
3
4
5
6
7
Connect and operate a P-port check valve circuit
Connect and operate a hydraulic pilot-operated check valve
Connect and operate a load-lock circuit using a pilot-operated valve
Measure pilot-operated check valve pilot pressure
Calculate the pilot pressure required to open a POC valve
Calculate the maximum pressure in a POC valve circuit
Design a POC valve circuit
33
BASIC PNEUMATICS
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Define pneumatics and give an application
Describe the functions of basic components of a pneumatic system
Define pneumatic pressure and give its units of measurement
Describe the function of a pneumatic schematic
Explain six pneumatic safety rules
Describe the function of a pressure regulator valve and give an application
Describe the operation of a pressure regulator and give its schematic symbol
Describe the function of an air filter
Describe the operation of an air filter and give its schematic symbol
Describe the function of a pneumatic quick connect fitting and give its schematic symbol
Describe the function of a tee and a cross and give their schematic symbols
Describe the function of a pneumatic cylinder and give an application
Describe the operation of a double-acting pneumatic cylinder and give its schematic
symbol
Describe the function of a 3-position, 5-way pneumatic DCV and give an
application
Describe the operation of a 3-position, 5-way pneumatic DCV and give its
schematic symbol
Skills
1
2
3
4
5
6
7
8
Read a pneumatic pressure gage
Connect and adjust a pressure regulator
Drain a pneumatic filter
Connect a pneumatic hose that uses quick-connect fittings
Use a tee to connect two circuit branches together
Use a cross to connect three circuit branches together
Connect and operate a double-acting pneumatic cylinder using a 3-position, manuallyoperated DCV
Design a multiple cylinder pneumatic circuit
Objectives
1
2
Describe the function of a single-acting pneumatic cylinder and give an application
Describe the operation of a single-acting, spring-return cylinder and give its schematic
symbol
34
3
4
5
6
7
8
9
10
11
12
Describe the function of a 3/2 pneumatic DCV and give an application
Describe the operation of a 3/2 pneumatic DCV and give its schematic symbol
Describe the function of a pneumatic motor and give an application
Describe the operation of a pneumatic motor and give its schematic symbol
Describe the function of a muffler and give its schematic symbol
List three common pneumatic motor designs and explain where they are used
Describe the line symbols used with fluid power circuits
Describe seven basic rules for drawing pneumatic schematics
Describe the function of pneumatic simulation software and name two applications
Describe the function of the pneumatic symbol library
Skills
1
2
3
4
5
6
7
Connect and operate a single-acting pneumatic cylinder using a 3/2 manually-operated
DCV
Connect and operate a unidirectional pneumatic motor using a 3-way, manuallyoperated DCV
Identify pneumatic symbols
Draw a pneumatic schematic from the actual circuit connections on the machine
Connect a pneumatic circuit given a schematic
Design a multiple actuator pneumatic circuit
Use software to simulate a pneumatic circuit
Objectives
1
2
3
4
5
6
7
8
9
10
11
Describe how to calculate the force output of an extending cylinder
Describe how to calculate the force output of a cylinder in retraction (pull)
State Pascal's Law and explain its significance in pneumatics
Explain how force is multiplied using Pascal's Law
Describe two methods of representing pneumatic pressure
Explain how air pressure is created in a pneumatic system
State Boyle's Law and explain its significance
Explain how a pneumatic system creates flow
Describe two types of resistance in a pneumatic system
Explain how Delta P describes pneumatic resistance and explain its importance
Describe what determines the speed of a pneumatic actuator
Skills
1
2
3
4
5
Calculate the extension force of a cylinder given its size and pressure
Measure the force output of an extending cylinder
Calculate the retraction force of a cylinder given its size and pressure
Convert between gage and absolute pressures
Use Boyle's Law to calculate changes in pressure and volume
35
6
Measure Delta P across a pneumatic component
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Describe the main function of a pneumatic needle valve and give an application
Describe the operation of a needle valve and give its schematic symbol
Define flow rate and give its units of measurement
Describe the function of a flow meter and give an application
Describe the operation of a rotameter and give its schematic symbol
Describe the function of a pneumatic check valve and give an application
Describe the operation of two types of pneumatic check valves and give their schematic
symbols
Describe the function of a flow control valve and give an application
Describe the operation of a flow control valve and give its schematic symbol
Describe the effect of actuator load changes on flow control operation
Describe the operation of a meter-in flow control circuit and give an application
Describe the operation of a meter-out flow control circuit and give an application
Describe the operation of an exhaust port speed control circuit
Describe the operation of a pressure port speed control and give an application
Define independent speed control circuit
Skills
1
2
3
4
5
6
7
8
9
10
11
Connect and operate a needle valve to control actuator speed
Convert air volumes at pressures to free air volumes
Connect and read a flow meter
Connect and operate a check valve
Connect and adjust a flow control valve to control the speed of an actuator
Connect and operate a meter-in flow control circuit
Connect and operate a meter-out flow control circuit
Connect and operate an exhaust port speed control circuit
Connect and operate a pressure port speed control circuit
Design speed control circuits
Design an independent speed control circuit
36
INTERMEDIATE PNEUMATICS
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
List four sources of compressed air contamination and explain their effect
Describe the operation of three common filter elements
Describe the function of a coalescing filter and give an application
Describe the operation of a coalescing filter and give its schematic symbol
Explain how air filter elements are rated
Describe how to select a filter for an application
Define dew point and relative humidity and explain their importance
Explain how water condenses in a pneumatic system and its effect
Describe two methods of removing water vapor from a pneumatic system
Describe the function of an aftercooler and give an application
Describe the function of a dryer and give an application
Describe the principle of operation of three types of dryers and give an application of
each
Describe the operation of a refrigeration type air dryer
Describe the function of pneumatic system trap
Describe the operation of two types of pneumatic traps and give the schematic symbol of
each
Describe the function of air lubrication and list three lubrication methods
Describe the function of a lubricator and give its schematic symbol
Describe the operation of three types of pneumatic lubricators and give an application of
each
Describe the types of oils in lubricators
Describe how pressure gages are calibrated
Describe how acrylic flowmeters are cleaned
Describe the importance of eliminating air leaks
Describe how to locate air leaks
Describe four common pneumatic component failures and their probable causes
Skills
1
2
3
4
Change an air filter element
Select an air filter for an application
Connect, fill and adjust a lubricator
Disassemble, inspect and service a pneumatic cylinder
37
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Describe the three functions of an air line
Describe the construction of pneumatic rubber hose and give an application
Describe three methods of connecting rubber hose to a fitting
Describe the construction of 3 types of pneumatic fitting threads and give an application
of each
Describe the operation of dryseal tapered pipe threads (NPTF)
Explain how to identify and specify pipe size
Describe the function of a reducing bushing and give an application
Describe how to specify the size of a reducing bushing
Describe the operation of straight threaded fittings
Describe the UNF thread size used for pneumatic fittings
Describe the function of an adapter and give an application
Describe the functions of four types of flexible plastic conductors and give an application
of each
Describe how to specify flexible tubing
Describe the function of three pneumatic tubing fittings and give an application of each
Describe the function of a bulkhead fitting and give an application
Describe the function of six fitting shapes
Describe the function of a subplate and give an application
Give five guidelines used in the construction of pneumatic circuits
Skills
1
2
3
4
5
6
7
8
9
10
11
12
Install a rubber hose onto a push-on type fitting
Install and seal tapered pipe fittings using teflon sealing tape
Identify the nominal pipe size of a fitting given an example
Install a reducing bushing to connect an oversized port
Install and seal a straight thread fitting
Connect polyurethane ether tubing to a barbed fitting
Connect tubing using a ferrule type fitting
Connect tubing using a push-on type fitting
Install a bulkhead fitting
Identify the shape, type and size of tubing connectors
Install and replace a DCV on its subplate
Size, select, and install the fittings and tubing for an application
38
PIPING SYSTEMS
Objectives
1
2
3
4
5
6
7
8
9
Describe the function of a piping system and give an application
Describe the color code system to identify pipe function
Describe the functions of the basic components of a piping system
Describe four types of piping and give an application of each
Describe five rules of safe dress for working with piping
Describe nine piping rules
List four types of metal pipe materials and give an application of each
Describe how metal pipe is specified
Describe how to calculate the head loss given pipe size and flow rate
Skills
1
2
3
4
5
Identify pipe function by color code
Identify pipe size by measurement
Identify pipe size given a specification
Write a pipe specification given its dimensions
Calculate the head loss for a given pipe size and flow rate
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Describe two methods of attaching metal pipe
Describe the functions of four categories of fittings
Describe the functions of thirteen types of fittings
Describe the construction of three types of pipe threads and give an application of each
Describe how fittings are specified
Describe how to cut metal pipe
Describe the operation of a pipe threading machine
Describe how to prepare a pipe for assembly
Describe how to assemble threaded pipe
Describe the construction of seven types of pipe hangers and give an application of each
Describe how to install a pipe hanger
Describe the function of an expansion joint and give an application
Describe the operation of an expansion joint
Describe the function of three types of pipe insulation and give an application of each
Describe the function of a piping schematic
Identify the piping fitting schematic symbols
39
17
Describe how to design a piping system
Skills
1
2
3
4
5
6
7
8
9
10
Identify fitting type and size given a sample
Use a cutoff saw to cut metal pipe
Use a pipe threading machine to create threads on a pipe
Prepare a pipe for assembly
Assemble threaded pipe and fittings
Install a pipe hanger
Install an expansion joint
Install pipe insulation
Read and interpret a piping schematic
Design and draw a piping schematic for a given application
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
Describe the characteristics of two categories of tubing and give an application of each
Describe four types of metal tubing and give an application of each
Describe the construction of metal tubing
Describe how metal tubing is specified
Describe how to cut tubing
Describe the operation of a tube bender
Describe how to determine bend locations and angles
Describe three methods of assembling metal tubing
Describe how to assemble tubing using flared and flareless fittings
Describe how to solder metal tubing
Describe how to calculate the head loss given metal tubing size and flow rate
Describe how to select and size metal tubing for an application
Describe how to maintain a metal tubing system
Skills
1
2
3
4
5
6
7
8
9
10
Identify metal tubing size by measurement
Identify metal tubing size given a specification
Write a metal tubing specification given its dimensions
Cut off tubing using a tube cutter
Use a tube bender to bend tubing to certain angles
Determine bend locations and angles given a tubing layout drawing
Assemble metal tubing using flared and flareless fittings
Solder metal tubing
Calculate the head loss for a given metal tubing size and flow rate
Select and size metal tubing for an application
40
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
Describe the characteristics of two categories of hose and give an application of each
Describe the construction of six types of rubber hose and give an application of each
Describe the construction of two types of metal hose and give an application of each
Describe three types of hose fittings
Describe how hose is specified
Describe how to cut hose
Describe three methods of attaching a fitting to a hose
Describe the operation of a hose crimping machine
Describe how to determine the length of a hose for an application
Describe how to calculate the head loss given hose size and flow rate
Describe how to select and size hose for an application
Describe how to maintain a hose system
Skills
1
2
3
4
5
6
7
8
9
10
Identify hose size by measurement
Identify hose size given a specification
Write a hose specification given its dimensions
Cut off hose using a cutoff saw
Attach screw-on fittings to hose
Crimp fittings onto a hose
Determine hose length given a layout drawing
Attach a hose
Calculate the head loss for a given hose size and flow rate
Select and size hose for an application
41
ELECTRO-FLUID POWER
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Describe the function of a power diagram
Describe the function of electro-hydraulic controls and give an application
Describe the operation of two types of hydraulic solenoids and explain the application of
each
Describe the operation of a solenoid-operated hydraulic DCV and give its schematic
symbol
Describe the function and operation of a hydraulic DCV manual override
Describe the function of electro-pneumatic controls and give an application
Describe the operation of two types of solenoid-operated pneumatic DCVs
Describe the operation of a pneumatic DCV
Describe the function and operation of a pneumatic DCV manual override
Describe the function of a control transformer
Describe the operation of a control transformer and give its schematic symbol
Describe the function of circuit protection and list two types
Describe the operation of a fuse and give its schematic symbol
Describe the operation of a circuit breaker and give its schematic symbol
Skills
1
2
3
4
5
6
7
8
9
Use the manual override of a solenoid-operated hydraulic DCV to jog a cylinder
Connect and operate a double-acting cylinder using a 4/3 solenoid-operated hydraulic
DCV
Connect and operate a double-acting cylinder using a 4/2 solenoid-operated DCV
Connect and operate a hydraulic motor using a 4/2 solenoid-operated DCV
Use the manual override of a solenoid-operated pneumatic DCV to jog a cylinder
Connect and operate a double-acting cylinder using a 5/3 solenoid-operated pneumatic
DCV
Connect and operate a single-acting cylinder using a 5/2 solenoid-operated pneumatic
DCV
Connect and operate a unidirectional pneumatic motor using a 5/2 solenoid-operated
DCV
Replace a fuse
42
Objectives
1
2
3
4
5
6
7
8
9
10
11
Describe the function of a control relay and give an application
Describe the operation of an electromechanical relay and give its ladder diagram symbol
Describe the construction of a general purpose relay and give an application
Describe how relay contacts are specified
Describe the construction of a machine control relay
Describe the operation of a relay used to energize a fluid power valve solenoid
Describe the operation of a relay to perform control logic
Describe the function of a seal-in circuit
Describe the operation of a seal-in circuit
Describe the operation of a uni-directional motor control start/stop circuit
Describe the operation of a bi-directional motor control start/stop circuit
Skills
1
2
3
4
5
6
7
8
Connect and operate a relay given a ladder diagram
Connect and operate a relay to energize a fluid power solenoid
Connect and operate a relay to perform a seal-in relay function
Design a logic circuit that uses a relay
Connect and operate a uni-directional motor control start/stop circuit
Connect and operate a bi-functional motor control start/stop circuit
Design a motor control circuit with multiple start/stop pushbuttons
Design a bi-directional motor control circuit that uses a single pushbutton
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
Describe the function of a limit switch and give an application
Describe the operation of a limit switch and give its schematic symbol
Describe how to interpret limit switch symbols
Describe the construction of a heavy duty limit switch and give an application
Describe the construction of a light duty limit switch and give an application
Describe the operation of limit switch in an event sequencing circuit
Describe the operation of a single-cycle cylinder reciprocation circuit
Describe the operation of a continuous-cycle reciprocation circuit
Describe the operation of a single-cycle reciprocation circuit with a 2-solenoid DCV
Describe the function of multiple cylinders in a machine
Describe how multiple cylinders are controlled using one limit switch and give an
application
Describe how multiple cylinders are controlled with multiple limit switches and give an
application
43
Skills
1
2
3
4
5
6
7
8
Connect and operate a control circuit containing a limit switch given a ladder diagram
Design a logic circuit that uses a limit switch to sequence an event
Connect and operate a single-cycle cylinder reciprocation circuit
Connect and operate a continuous-cycle cylinder reciprocation circuit
Connect and operate a single-cycle cylinder using a 2-solenoid DCV
Design a relay circuit to continuously cycle a cylinder using a double solenoid DCV
Design a dual cylinder sequence circuit using one limit switch
Connect and operate a dual-cylinder control circuit using two limit switches
44
HYDRAULIC TROUBLESHOOTING
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Define hydraulic troubleshooting and explain its importance
Describe two levels of hydraulic troubleshooting and give an application of each
Describe two methods of testing a hydraulic component and give an application of each
Describe six hydraulic safe dress rules
Describe eight hydraulic troubleshooting safety rules
Describe the function of a pressure-compensated pump and give an application
List two types of pressure-compensated pumps and give an application of each
Describe the operation of a pressure-compensated vane pump and give its schematic
symbol
Describe the operation of a pressure-compensated piston pump
Identify the schematic symbol of a hydraulic pressure-compensated pump
Describe how to start up a pressure-compensated vane pump
Describe how to adjust the pressure setting of a pressure-compensated vane pump
Describe how to set a pressure-compensated pump and relief valve combination
Describe the procedure to shut down a hydraulic system
Describe the function of automatic and manual modes and give an application of each
Describe the procedure to shut down a hydraulic system for maintenance
Describe the function of a maximum volume stop
Describe how to adjust the setting of a maximum volume stop
Skills
1
2
3
4
5
6
Start up a pressure-compensated hydraulic vane pump
Adjust the pressure-compensator on a pressure-compensated pump
Shut down a hydraulic system
Use manual mode to operate an actuator
Shut down a hydraulic system for a maintenance operation
Adjust the maximum volume stop on a pressure-compensated pump
Objectives
1
2
3
Describe four types of in-circuit component tests and give an application of each
Describe three hydraulic troubleshooting measurements and give an application of each
Describe the construction of three types of pressure test points and give an application
of each
45
4
5
6
7
8
9
Name the two typical locations of pressure test points
Describe three ways to use a flow meter to troubleshoot a hydraulic system
Describe two methods of measuring flow
Describe eleven symptoms of pressure-compensated pump failure
Describe how to interpret a troubleshooting chart
Describe how to inspect and troubleshoot a pressure-compensated pump
Skills
1
2
3
Use a pressure test point to troubleshoot a hydraulic system
Test a hydraulic system by measuring fluid flow
Troubleshoot a pressure-compensated vane pump using an in-circuit test
Objectives
1
2
3
4
5
6
7
8
9
Describe the function of a cylinder cushion and give an application
Describe the operation of a cylinder cushion
Describe how to adjust a cylinder cushion
Describe the function of a cylinder rod boot and give an application
Describe how to install a cylinder rod boot
Describe the causes of five symptoms of hydraulic cylinder failure
Describe how to inspect and troubleshoot a hydraulic cylinder
Describe five symptoms of motor failure and their causes
Describe how to inspect and troubleshoot a hydraulic motor
Skills
1
2
3
Adjust a cylinder cushion
Troubleshoot a cylinder using an in-circuit test
Troubleshoot a motor using an in-circuit test
Objectives
1
2
3
4
5
6
Describe six symptoms of direct-operated DCV failure and their causes
Describe how to inspect and troubleshoot a direct-operated DCV
Describe the function of DCV pilot chokes and give an application
Describe the operation of a DCV pilot chokes
Describe seven symptoms of pilot-operated DCV failure and their causes
Describe how to inspect and troubleshoot a pilot-operated DCV
46
7
8
9
Describe the x functions of a sandwich valve and give an application
Describe the operation of a sandwich valve
Describe how to adjust a sandwich valve
Skills
1
2
3
4
Troubleshoot a direct-operated DCV using an in-circuit test
Adjust and operate DCV pilot chokes
Troubleshoot a pilot-operated DCV using an in-circuit test
Adjust a sandwich valve
Objectives
1
2
3
4
5
6
7
8
9
10
Describe six symptoms of non-compensated flow control valve failure and their causes
Describe how to inspect and troubleshoot a non-compensated flow control valve
Describe the function of a dial-type pressure-compensated flow control valve and give
an application
Describe the operation of a pressure-compensated flow control valve
Describe the six symptoms of compensated flow control valve failure and their causes
Describe how to inspect and troubleshoot a compensated flow control valve
Describe four symptoms of check valve failure and their causes
Describe how to inspect and troubleshoot a check valve
Describe five symptoms of pilot-operated check valve failure and their causes
Describe how to inspect and troubleshoot a pilot-operated check valve
Skills
1
2
3
4
5
Troubleshoot a non-compensated flow control valve using an in-circuit test
Adjust and operate a dial-type pressure-compensated flow control valve
Troubleshoot a compensated flow control valve using an in-circuit test
Troubleshoot a check valve using an in-circuit test
Troubleshoot a pilot-operated check valve using an in-circuit test
47
Objectives
1
2
3
4
5
6
7
8
9
Describe the construction of an R-series pressure control valve
Describe how to change the pressure control setting of a pressure control valve
Describe how to change the function of an R-series pressure control valve
Describe nine symptoms of relief valve failure and their causes
Describe how to inspect and troubleshoot a relief valve
Describe ten symptoms of sequence valve failure and their causes
Describe how to inspect and troubleshoot a sequence valve
Describe ten symptoms of pressure reducing valve failure and their causes
Describe how to inspect and troubleshoot a pressure reducing valve
Skills
1
2
3
4
Identify the functions of the two pressure taps on an R-series pressure control valve
Change the pressure control setting of a pressure control relief valve
Troubleshoot a relief valve using an in-circuit
Troubleshoot a pressure reducing valve using an in-circuit test
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Describe three categories of hydraulic system faults and give an application of each
Describe how to use a troubleshooting flow chart to troubleshoot a hydraulic fault
Describe how to troubleshoot low or zero system pressure
Describe how to troubleshoot a hot hydraulic system
Describe how to troubleshoot vibration in a hydraulic system
Describe how to troubleshoot hydraulic system leaks
Describe how to troubleshoot hydraulic fluid problems
Describe how to troubleshoot an actuator that will not move
Describe how to troubleshoot an actuator that moves out of sequence
Describe how to troubleshoot an actuator that moves in the wrong direction
Describe how to troubleshoot a pressure change problem in a multiple pressure circuit
Describe how to troubleshoot a speed change problem in a multiple speed circuit
Describe how to troubleshoot erratic actuator movement
Describe how to troubleshoot slow actuator speed
Describe how to troubleshoot fast actuator speed
Describe how to troubleshoot actuator drift
Describe how to troubleshoot incorrect acceleration or deceleration
48
Skills
1
2
3
4
5
6
7
8
9
10
11
12
Troubleshoot low or zero system pressure
Troubleshoot high system pressure
Troubleshoot a hot hydraulic system
Troubleshoot an actuator that will not move
Troubleshoot an actuator that moves out of sequence
Troubleshoot a pressure change problem in a multiple pressure circuit
Troubleshoot a speed change problem in a multiple speed circuit
Troubleshoot erratic actuator movement
Troubleshoot slow actuator speed
Troubleshoot fast actuator speed
Troubleshoot actuator drift
Troubleshoot incorrect acceleration or deceleration
49
MECHANICAL SYSTEMS 1
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Describe the function of a mechanical power transmission and give an advantage
Describe five methods of rotary mechanical power transmission and give an application
of each
Describe five rules of safe dress for working with power transmission equipment
Describe eight mechanical transmission safety rules
Describe the operation of the lockout/tagout system
Describe the function of a foundation and give three types
Describe the function and construction of a bedplate
Describe the function of a spirit level and give an application
Describe the operation of a spirit level
Describe three types of motor mounts and give an application of each
Describe how fasteners are used to attach a motor mount to a bedplate
Describe how to select fastener size and type for a motor mount
Describe how to mount and level an electric motor
Describe two methods of measuring motor shaft speed and give an application
Skills
1
2
3
4
5
6
Perform a lockout/tagout
Use a spirit level to determine orientation of a surface
Select a fastener size and type for a motor mount
Mount and level an electric motor
Use a digital tachometer to measure motor speed
Mount and level an electric motor to correct for a soft foot condition
Objectives
1
2
3
4
5
6
7
8
9
Describe the function and operation of a key fastener
Describe the construction of six types of keys and give an application of each
Describe how keys and keyseats are specified
Describe how to measure the actual size of a key and key seat
Describe six types of set screws
Describe how to assemble a shaft to a hub using a key
Describe two methods of loading a mechanical drive system
Describe how to calculate rotary mechanical power
Describe how to calculate mechanical efficiency and explain its importance
50
10
11
Describe two methods of measuring shaft torque and give an application of each
Describe three methods of measuring electric motor current
Skills
1
2
3
4
5
6
7
8
9
Select a key size for a given application
Measure the actual size of a key and keyseat given a sample
Cut and file key stock to fit a keyseat
Assemble a hub to a shaft using a key fastener
Use a pony brake to measure shaft torque
Calculate rotary mechanical power
Convert between English and S.I. units of motor power
Calculate mechanical efficiency
Measure electric motor current
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Describe the function of a shaft and give an application
List four types of shaft materials and give an application of each
Describe how shafts are specified
Describe the function of a bearing and give an application
Define three types of bearing loads and give an example of each
Describe how bearings are positioned to support a load
Describe the operation of two categories of bearings and give an application of each
Describe two methods of mounting a shaft bearing and give an application of each
Describe the function of a coupling and give an application
Describe the function of four categories groups of mechanical couplings
Describe the operation of flexible jaw coupling
Describe the purpose of shaft alignment and give two types of misalignment
Describe a general procedure for shaft alignment and give four measurement methods
Describe the operation of the straight edge and feeler gage method
Skills
1
2
3
4
Identify shaft size given a sample
Install and adjust a pillow block antifriction bearing and shaft
Install a flexible jaw coupling
Align two shafts using a straight edge and feeler gage
51
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
Describe the function of the three basic components of a belt drive
Define pitch and explain its importance
Define pitch circle, pitch diameter, and pitch length and explain their importance
Describe how to calculate the pulley ratio and explain its importance
Describe how to calculate the shaft speed and torque of a belt drive system
List five types of belt drives and give an application of each
List three types of v-belts and give an application of each
Describe the operation of a fractional hp v-belt drive
Describe how to install and align a v-belt drive
Describe how to determine belt tension for an application
Describe three methods of adjusting belt tension
Describe three methods of measuring belt tension and give an application of each
Skills
1
2
3
4
5
6
Calculate pulley ratio
Calculate the shaft speed and torque of a belt drive system
Install and align a fractional HP v-belt drive with a finished bore
Determine the belt deflection force for a given application
Adjust belt tension using an adjustable mounting base
Use a belt tension tester to measure belt tension
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
Describe the function of the three basic components of a chain drive
Describe how to calculate sprocket ratio and explain its importance
Describe how to calculate the shaft speed and torque of a chain drive system
List four types of chain drives and give an application of each
List four types of roller chain drives and give an application of each
Describe the operation of a single-strand roller chain drive
Describe how to install, align and remove a roller chain drive system with adjustable
centers
Describe how to determine allowable chain sag for a given application
Describe two methods used to adjust chain sag
Describe how to measure chain sag
Describe the function and operation of a master link
Describe two methods of installing a lightweight chain which uses a master link
Describe the operation of a chain puller
52
Skills
1
2
3
4
5
6
7
8
Calculate the sprocket ratio
Calculate the shaft speed and torque of a chain drive system
Install, align and remove a roller chain drive system with adjustable centers
Determine allowable chain sag for a given application
Use a rule and straight edge to measure chain sag
Adjust chain sag to a specified amount using adjustable centers
Install and remove a chain with a master link using sprocket teeth
Install and remove a chain with a master link using a chain puller
53
MECHANICAL SYSTEMS 2
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
Describe the function of a bushing and list three types
Describe the construction and operation of a QD bushing and give an advantage
Describe the construction and operation of a conventional v-belt Drive
Describe the construction and operation of a multiple belt v-belt drive
Describe the construction and operation of a split taper bushing and give an advantage
Describe the construction and operation of a wedge v-belt drive
Describe the construction of a taper lock bushing and give an advantage
Describe the construction and operation of a notched v-belt and give an advantage
Describe the operation of a variable speed v-belt drive system and give an application
Describe how to install and align a variable speed v-belt drive system
Describe five v-belt configurations and give an application of each
Describe the function of a belt idler pulley and give an application
Describe the operation of four types of belt idler pulley configurations
Skills
1
2
3
4
5
6
7
Install and align a conventional v-belt drive system with a QD bushing
Install and align a multiple belt v-belt drive system with a split taper bushing
Install and align a wedge v-belt drive system with a taper-lock bushing
Install and align a notched v-belt drive system
Install and align a variable speed v-belt drive system
Install and align a backslide v-belt idler
Install and adjust a kiss v-belt idler
Objectives
1
2
3
4
5
6
7
8
9
Describe how v-belts are specified
Describe three methods of identifying belt size and type
Describe the function and operation of v-belt match codes
Describe how sheaves and bushings are specified
Describe how sheaves are specified
Describe how to select a v-belt, bushing, and sheave for an application
Describe preventive maintenance
Describe nine maintenance steps for v-belt drives
Describe how to troubleshoot a v-belt drive system
54
Skills
1
2
3
4
5
6
7
Use a belt code to determine the size and type of v-belt
Use a belt gage to determine belt cross section belt size
Use measurement to determine the size and type
Use a sheave gage to identify a sheave size
Identify size and type of sheave and bushing given a sample
Select a v-belt, bushing, and sheave for a given application
Troubleshoot a v-belt drive system
Objectives
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Describe the operation of four types of sprockets (No Hub, Single Hub, Double Hub, and
Bushing) and give an application of each
Describe the operation of a silent chain drive
Describe how to install and align a silent chain drive system
Describe the operation of a multiple strand chain drive
Describe how to install and align a multiple strand chain drive system
Describe the construction and operation of a taper lock busing and give an advantage
Define chain pitch, pitch circle, pitch diameter, and pitch length of a chain drive and
explain their importance
Describe how chains are specified
Describe how sprockets are specified
Describe how to select the type and size of chain and sprocket for a given application
Describe four types of chain lubrication methods (manual, drip cup, oil bath or disc, and
forced oil stream)
Describe how to select a lubrication system for a chain drive system
Describe how to select a lubrication type for a chain drive system
Describe ten maintenance steps for chain drives
Describe how to inspect and troubleshoot a chain drive system
Describe the operation of a chain breaker
Skills
1
2
3
4
5
6
7
8
Install and align a silent chain drive system
Install and align a multiple strand chain system using a taper lock bushing
Identify the characteristics of a chain and sprocket given a specification
Select a chain and sprocket for a given application
Select a lubrication system for a chain drive system
Lubricate a chain drive using a manual method
Troubleshoot a chain drive system
Cut a chain using a chain breaker
55