Training Outline for Non-Contact Alignment Test Machine
Maintenance - Operators - Controls

Outline Electrical and Mechanical
Maintenance Training

Optimum Class Size: 8 people
Maximum Class Size: 10 people
Course Length: 12 hours

1) Introduction / Course Overview
* Introductions and hand out training manuals for each participant
* Review of parts of the training manual
* Basic description of the machine
* Drawings

2) Safety Issues
* Lockout procedures

3) Mechanical System Description
* Mechanical components and locations
* Pneumatic components and locations

4) Electrical System Description
* Electrical components and locations
* Computer boards and locations

5) Machine Startup and Shutdown
* Machine startup procedure
* Machine shutdown procedure
* Machine checkout

6) Machine Setup
* Test parameter set-up
* Calibration procedure
* Pre-entry bar code interface

7) Mechanical Maintenance
* Mechanical system repair and replacement
* Pneumatic system repair and replacement
   - Cylinders - Solenoid valves
* Machine adjustment
   - Flow control valves
   - Cylinder cushion
* Preventive maintenance
* Operational checkout

8) Control Overview
* Operator interface with the machine (overview)
* Cimplicity™ interface
* Alignment evaluator interface
* Torque fastening system interface
* Allen-Bradley PLC 5/40 system description

9) Wheelbase Drive
* Manufacturer's specifications
* Interface and I/O
* Drive parameter entry
* Operation

10) Electrical Maintenance
* Electrical component replacement
   - Laser Camera Replacement (See Perceptron Camera)
   - Allen-Bradly 5/40 PLC boards
   - VME boards
   - Switches
   - Sensors
* Machine adjustment
   - Proximity switch adjustment

11) Perceptron Camera/Laser
* Camera setup and calibration
* Care and maintenance of lens
* Care and maintenance of camera

12) Troubleshooting and Diagnostics
* Troubleshooting Guide
   -Troubleshooting procedures (using chart covering 40+ problems)
   -Test failures as time and schedule permits
   -Machine faults using standard fault list
   -Debugging of machine failures
* Analog Gage Tool Troubleshooting
* Laser Camera Troubleshooting
* INCS Tuning & Troubleshooting

13) Questions and Answers
The above training program is based on using the operation and maintenance manual as a resource. Individual training manuals will be supplied for each pupil. The training will utilize the manual as well as visits to the machine itself. The room allotted for training must be within 5 minutes walking distance of the machines to allow sufficient training time. It is assumed that the students will have basic knowledge of standard mechanical and electrical machine service and repair procedures and will be familiar with PLCs. It is also assumed that at least one machine will be available for training use and will not be used for production during the training class.

Training Outline Machine Operation (For Drivers and Pit Operators) (back to top)

Optimum Class Size: 8 people
Maximum Class Size: 10 people
Course Length: 8 hours

1) Introduction / Course Overview
* Introductions and hand out training manuals for each participant
* Review of parts of the training manual
* Basic description of the machine
* Drawings

2) Safety Issues
* Lockout procedures

3) Mechanical System Description
* Mechanical components and locations
* Pneumatic components and locations

4) Machine Startup and Shutdown
* Machine startup procedure
* Machine shutdown procedure
* Machine checkout

5) Machine Controls Overview
* Driver Station
* Pit Operator Controls
* Cimplicity ™ Interface
* Alignment Evaluator Interface
* Torque Fastening System Interface

6) Test Process
* Alignment Test Process (Pit Operators)
  -Wheel Alignment Concepts
  -Pit Operator Test Displays
  -Tools
  -Toe Adjustment
* Steering Wheel Angle Tool (Drivers)
* Test Procedure and Training (Drivers and Pit Operators)
* Label Printout

7) Questions and Answers
The above training program is based on using the machine manual
as a resource. Individual training manuals will be supplied for each pupil.
The training will utilize the manual as well as visits to the machine itself.
The room allotted for training must be within 5 minutes walking distance
of the machines to allow sufficient training time. It is assumed that at least
one machine will be available for training use and will not be used for
production during the training class.


Training Outline
Supervisor/Test Engineer Training (back to top)

Optimum Class Size: 8 people
Maximum Class Size: 10 people
Course Length: 8 hours

1) Introduction / Course Overview
* Introductions and hand out manuals for each participant
* Review of parts of the manual
* Basic description of the machine
* Drawings

2) Safety Issues
* Lockout procedures

3) Mechanical System Description
* Mechanical components and locations
* Pneumatic components and locations
* Lubrication components and locations

4) Electrical System Description
* Electrical components and locations
* Computer boards and locations

5) Machine Startup and Shutdown
* Machine startup procedure
* Machine shutdown procedure
* Machine checkout

6) Machine Setup
* Test parameter set-up
* Calibration procedure
* Wheelbase position setup

7) Control System
* Operator interface
* Use of pendant
* Microprocessor specifications
* Hardware description
* Vehicle Test Display
* Pit Monitor Display
* Parameter list and operation of it
* General test sequence
* Test result analysis

8) Troubleshooting and Diagnostics
* Troubleshooting
   -Troubleshooting procedures (using chart covering 40+ problems)
   -Test failures as time and schedule permits
   -Machine faults using standard fault list
* Debugging of machine failures

9) Questions and Answers
The above training program is based on using the machine manual as a resource.
Individual training manuals will be supplied for each pupil. The training will utilize
the manual as well as visits to the machine itself. The room allotted for training must
be within 5 minutes walking distance of the machines to allow sufficient training time.
It is assumed that the students will have basic knowledge of PLCs.
It is also assumed that at least one machine will be available for training use and
will not be used for production during the training class.