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Training Outline for Model 3600 Roll Brake Test Machine
Mechanical - Electrical - Controls

Overview of Mechanical Training

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) System Overview
* Machine system overview
* Operator input devices
* Theory of operation

4) Mechanical System Description
* Mechanical components and locations
* Major control systems
- Pneumatic
- Lubrication

5) Machine Start-Up and Checkout
* Start-up procedure
* Checkout procedure

6) Machine Setup
* Calibration procedure
* Retaining roller adjustment
* Wheelbase position setup

7) Maintenance and Troubleshooting
* Mechanical system repair and replacement
- Drive belts
- Bearings
- Roll brakes
- Encoders
* Pneumatic system repair and replacement
- Cylinders
- Solenoid valves
* Lubrication system repair and replacement
- Blow-out disk
- Purging
* Machine adjustment
- Drive Belts
- Retaining rolls
- Roll brake mounting angle
- Flow control valves
- Retaining roll and wheelbase disc brakes
- Cylinder cushion
* Preventive maintenance
* Operational checkout
* Troubleshooting

8) Questions and Answers
The above training program is based on using the existing machine manual as
a resource. Individual training manuals will be supplied for each pupil. The
training will include 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 pneumatic machine service and repair procedures. 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. Note: All times
shown are approximate



Overview of Electrical Training (back to top)

Optimum Class Size: 8 people
Maximum Class Size: 10 people
Course Length: 12 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) System Overview
* Mechanical and Electrical System Overview
* Operator Input Device Review

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

5) Machine Start-Up and Checkout
* Machine Start-Up and Checkout
* Start-up procedure
* Checkout procedure
* PLC Control Switch Settings

6) Machine Setup
* Test Parameter set-up
* Calibration procedure
* Wheelbase position setup
* Linear position transducer calibration
* Roll motor and wheelbase drive setup

7) Machine Operation (for Drivers)
* Test sequences
* Test driving techniques
* Test result analysis

8) Control System
* PLC5/VME system description
* Operator interface
* Use of pendant
* Microprocessor specifications
* Calibration
* Simulated calibration and brake test
* Hardware description
* Front panel display
* Operator display
* Parameter list and operation of it
* General test sequence
- Reverse Gear
- Cruise Control
- Service Brake Sequence
- Anti-lock Sequence
- Traction Control
- Emissions
- DTRL
- Low Tire Sensing
* Test result analysis

9) Baldor Drive
* Manufacturer's specifications
* Interface and I/O
* Drive parameter entry
* Test point voltages
* Operation

10) Maintenance
* Electrical component replacement
- PLC boards
- VME boards
- Encoders
- Switches
- Sensors
* Machine adjustment
- Limit switch adjustment
- See no. 6 for other adjustments

11) Troubleshooting and Diagnostics
* Troubleshooting
- More Faults Display
- Troubleshooting procedures (using chart covering 100 + problems)
including stop posts, air door, exhaust door, motor disconnect, motordrives,
wheelbase drive, system air pressure, lube system level and pressurepanel
overtemperature, plc modules, power supplies, and test failures as time and schedule permits
- Machine faults using standard fault list (contains 100+ faults)
* Debugging of simulated machine failures

12) Questions and Answers
The above training program is based on using the existing 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 standard electrical machine
service and repair procedures and will be familiar with Allen-Bradley PLC-5 machine controllers.
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.


 Control Operation 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 (written)

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

4) Machine Start-Up and Checkout
* Machine start-up and checkout
* Test parameter set-up
* Calibration procedure
* Wheelbase position setup

5) Control System - Brake Evaluator
* Operator interface
* Use of pendant
* Microprocessor specifications
* Calibration
* Simulated calibration and brake test
* Hardware description
* Front panel display
* Operator display
* Parameter list and operation of it
* General test sequence
- Reverse Gear
- Cruise Control
- Service Brake Sequence
- Anti-lock Sequence
- Traction Control
- Emissions
- DTRL
- Low Tire Sensing
* Test result analysis

6) Troubleshooting and Diagnostics
* Troubleshooting
- More Faults Display
- Troubleshooting procedures (using chart covering 100 + problems)
including stop posts, air door, exhaust door, motor disconnect, motor
drives, wheelbase drive, system air pressure, lube system level and pressure, panel overtemperature,
plc modules, power supplies, and test failures as time and schedule permits.
- Machine faults using standard fault list (contains 100+ faults)
* Debugging of simulated machine failures

7) Questions and Answers
The above training program is based on using the existing 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 standard electrical machine service
and repair procedures and will be familiar with Allen-Bradley PLC-5 machine controllers.
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.
 

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