Вы находитесь на странице: 1из 32

Test, Measurement, and Diagnostic Equipment 63B33E01 / Version MOSC 01 Oct 2004

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported

ADMINISTRATIVE DATA
Course Number Version Course Title

091-63B30-MOSC

MOSC

Wheel Vehicle Mechanic BNCOC

Task Number

Task Title

091-63B-3401 (*) 091-63B-3402 (*) 091-63B-3407 (*)

Perform Diagnostic Procedures On Wheeled Vehicle's Electrical System Perform Diagnostic Procedures on Wheeled Vehicle's Diesel Engine Perform Diagnostic Procedures on Vehicle's Hydraulic System
Task Title

Reinforced Task(s)

Task Number

091-63B-3400 091-63B-3410 091-63B-3414 091-63B-3417 091-63B-3418 091-63B-3421 091-63B-3422

Perform Diagnostic Procedures on Wheeled Vehicle's Fuel System Perform Diagnostic Procedures on Wheeled Vehicle's Air System Perform Diagnostic Procedures on Wheeled Vehicle's Central Tire Inflation System Perform Diagnostic Procedures on Wheeled Vehicle's Fuel Injection System Perform Diagnostic Procedures on Automatic Transmissions Perform Diagnostic Procedures on Wheeled Vehicle's Engine Air Induction System Perform Diagnostics Electrical Interface System

Academic Hours

The academic hours required to teach this lesson are as follows:


Resident Hours/Methods

Test Test Review Total Hours: Test Lesson Number

4 hrs 2 hrs 6 hrs 0 hrs 0 hrs 12 hrs


Hours

/ Conference / Discussion / Demonstration / Practical Exercise (Performance)

Lesson No.

Testing
(to include test review)

2 hrs 8 hrs 25 mins

63B33E10 version MOSC 63B33E11 version MOSC

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions

Lesson Number

Lesson Title

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. FD5. This product/publication has been reviewed by the product developers in coordination with the CASCOM-TD foreign disclosure authority. This product is releasable to students from all requesting foreign countries without restrictions.

References

Number

Title

Date

Additional Information

EM 0103

TM 11-6625-3199-14

TM 9-2320-364-20-1 TM 9-2320-364-20-2 TM 9-2320-365-20-1

TM 9-2320-365-20-2

TM 9-2320-366-20-1

TM 9-2320-366-20-2

TM 9-6625-SPORT/CTS, Interactive Electronic Technical Manuals for Test Set, Electronic Systems, AN/PSM-80, Test Set Electronic System, AN/PSM95 (This Product Includes the Following Items) TM 9-6625-229812&P (010430) TM 9-6625-229830&P Operators, Unit, Intermediate Direct Support, and General Support Maintenance Manual for Digital Multimeter AN/PSM-45A (NSN 662501-265-6000) Unit Maintenance Manual, Volume I for Palletized Load System Model M1074/M1075 Unit Maintenance Manual, Volume I I for Palletized Load System Model M1074/M1075 Maintenance Instructions for Unit Maintenance M1078 Series, 2 1/2Ton, 4X4 Light Medium Tactical Vehicles (LMTV) Truck, Car., LMTV, M1078W/WN, W/O WN; Truck, Van, LMTV, M1079 W/WN, W/O WN; Truck, Chas, LMTV, M1080; Truck, Car., LMTV, Air Dr Maintenance Instructions Unit Maintenance M1078 Series, 2 1/2Ton, 4X4, Light Medium Tactical Vehicles (LMTV) Vol. No. 2 of 5 for Truck, Car., LMTV, M1078 W/WN, W/O WN; Truck, Van, LMTV, M1079 W/WN, W/O WN; Truck, Chas, LMTV, M1080; Truck, Maintenance Instructions Unit Maintenance M1083 Series, 5-Ton, 6X6, Medium Tactical Vehicles (MTV) for Truck, Car., MTV, M1083 W/WN, W/O WN; Truck, Car., MTV, W/Material Handling Equipment (MHE), M1084; Truck, Car., MTV, LWB, M1085 W/WN, W/ Maintenance Instructions Unit Maintenance for M1083 Series, 5Ton, 6X6, Medium Tactical Vehicles (MTV) Vol. No. 2 of 5 Truck, Car., MTV, M1083 W/WN, W/O WN; Truck, Car., MTV, w/Material Handling Equipment (MHE), M1084; Truck Car., MTV, LWB,

Apr 2001

Dec 1988

Aug 1999 Aug 1999 Jun 1998 Change 1

Jun 1998

Change 1

Sep 1998

Change 1

Sep 1998

Change 1

Student Study Assignments

None

Instructor Requirements

One instructor per group, during CO.

Additional Support Personnel Requirements Equipment Required for Instruction

Name

Stu Ratio

Qty

Man Hours

None
Id Name Stu Ratio Instr Ratio

Spt

Qty

Exp

2320-01-304-2278 TRUCK, PALLETIZED LOADING 2320-01-354-4528 TRUCK, WRECKER 2320-01-360-1898 TRUCK, CARGO 4910-00-357-5342 TABLE, WORK, AUTOMOTIVE MAINTENANC 4910-01-343-3508 TESTER, INTERNAL COMBUSTION ENGIN 6625-01-265-6000 MULTIMETER 6625-01-445-0085 TEST SET, ELECTRONIC SYSTEMS 6625-01-493-8984 TEST SET, ELECTRONIC SYSTEMS *70032N Monitor, Television, Color *P16312 Light PRO Projector *ZX7022 Industry Standard Laptop (Toughbook)

1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:6 1:12 1:12 1:12

No No No No No No No No No No No

0 0 0 0 0 0 0 0 0 0 0

No No No No Yes No No No No No No

Materials Required

Instructor Materials: Overhead Projector w/Computer/Video Projector Video Tape 63B33E01, Supplement 1b and 2b Instructor's Guide 63B33E01, Supplement 1c and 2c Practical Exercise Checklist Student Materials: 63B33E01, Supplement 1a and 2b, Student's Guide References listed above

Classroom, Training Area, and Range Requirements Ammunition Requirements Instructional Guidance

General Instruction Building Vehicle Maintenance Instructional Building, 1600 SF, 12 Person

Id

Name

Exp

Stu Ratio

Instr Ratio

Spt Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material. Print out the power point slides as hand outs (3 per sheet) and hand them out to students. Encourage them to take notes.

Proponent Lesson Plan Approvals

Name

Rank

Position

Date

Deilus, John

GS-12

Military Analyst

01 Jul 2004

SECTION II.

INTRODUCTION

Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:18 Time of Instruction: 5 mins Media: Large Group Instruction
Motivator

In order for supervisors to properly diagnose problems, they must know how to properly perform diagnostic procedures on particular pieces of equipment. You have computerized test equipment at your disposal that is capable of diagnosing faults on computer controlled vehicles.
NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action: Conditions:

Terminal Learning Objective

Use TMDE In a classroom/shop environment, given an AN/PSM-45A Multimeter, Diagnostic Data Reader Prolink 9000, SPORT, MSD, M1074,M1098 and M1078 vehicles, and the necessary references. IAW applicable TMs

Standards:

Safety Requirements

Inform students of the following safety precaution: 1. Remove jewelry and observe shop safety procedures. 2. Wear hearing protection while operating vehicles. 3. Ensure vehicle is properly chocked. 4. Remember that electrical shorts can cause severe burns or fire. 5. Improper connection of electrical leads or test equipment can cause injury to personnel and damage to the equipment. 6. Never use a multimeter to measure resistance on live circuits.

Risk Assessment Level Environmental Considerations

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction.
NOTE: It is the responsibility of all soldiers and DA civilians to protect the environment from damage.

Adhere to the safety evacuation plans.


Evaluation

In lesson 63B33E10 you (the students) will have 1 hour and 30 minutes to take a Job Knowledge Test and Review on the material presented in this lesson. We are now ready to begin our instruction on the latest TMDE.

Instructional Lead-In

SECTION III.

PRESENTATION

NOTE: A.

Inform the students of the Enabling Learning Objective requirements. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS:

Identify TMDE components In a classroom or shop environment, given a Digital Multimeter, Pro Link 9000, SPORT, MSD and assistance IAW applicable references without causing damage to equipment or injury to personnel.

STANDARDS:

1.

Learning Step / Activity 1. Discuss the characteristics of the AN/PSM-45A Digital Multimeter Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:12 40 mins Large Group Instruction

NOTE:

Show slide 1 through 4 a. Multimeter, Digital (Fluke 27/FM)

NOTE:

Show students the actual components as they are discussed. (1) Purpose - measures resistance, ac and dc voltage, and ac and dc current. (2) Major components and descriptions: (a) Carrying case - rigid case that protects components inside. (b) Can measure up to 5,000 v AC or DC with high voltage probe. (c) Has a current shunt that extends range of multimeter to 10 amps AC or DC. (d) Pushbutton power, function, and range switches simplify operation.

NOTE: NOTE:

Show slides 5 and 6 This voltage refers to the Fluke Multimeter (e) High voltage probe - extends voltage range to 6000 volts ac or dc. (f) Test leads - one black and one red lead, to test circuit under test. (3) Operators controls: (a)Function selector rotary switch with 11 positions, including off.

NOTE:

Show slide 7

NOTE:

Explain symbols around rotary switch. (b) Range - select voltage desired voltage range. 1. 2. Meter is auto-ranging at all times. Can be changed to manual ranging with this switch.

(c) Relative mode - shows difference between two readings. (d) Minimum/maximum - shows minimum and maximum readings during test. NOTE: Show slide 8 (e) Hold- holds current measurement. (f) Volt, Ohms, Diode test terminal: 1. 2. NOTE: Show slide 9 (g) mA and A input - connects red test lead for ac and dc current measurements. 1. 2. NOTE: Show slide 10 (h) Com. input - connects black lead for all measurements. (i) Buzzer - sounds tone for pulse detection and continuity functions when this function is selected on the rotary switch. NOTE: 2. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Identify Prolink 9000 Components Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: NOTE: Show slides 11 and 12 a. Pro-Link 9000 - DDR (Diagnostic Data Reader). The (DDR) diagnostic data reader receives information from the vehicle on board computer, or ECM, through a connector called the (DDL) display data line. NOTE: Show slide 13 Conference / Discussion 1:12 1 hr Large Group Instruction mA scale - up to 320 mA. A scale - up to 10 A (20A for 30 seconds). Connects red test lead for volt and ohms testing. This terminal is also used for diode testing.

(1) Power source - from vehicle being tested. (a) Powered by the vehicle J1708 port or cigarette lighter adapter. (b) Gathers vehicle data. (c) Used with vehicle that have (DDEC) or (ATEC) systems. (2) Protector circuit - internal fuse. NOTE: Show slides 14 and 15 (3) Removable cartridges. (a) DDEC. (b) ABS. (c) ATEC. NOTE: Show slide 16 (4) Supporting systems TMDE. (a) Pushbutton - Cylinder cutout test manual. (b) Data Readout - Identifies from ECM what system DDEC II or III. (c) The Pro-Link has to function selection menu: [ENGINE] or [PRO-LINK]. NOTE: Show slide 17 (d) Engine Functions. 1. 2. 3. 4. 5. 6. 7. 8. 9. NOTE: Show slide 18 (e) Diagnostic Codes. Diagnostic Codes. View Calibration. Fuel Injector Information. Engine/Trip Data. Calibration Change. Switch/Light Statistics. Activate Outputs. MID's Received. Reset Components.

1. 2. 3. 4. NOTE:

Active Codes. Inactive Codes. Clear Codes. Diagnostic Code Description Option.

Show slide 19 (f) View Calibration. 1. 2. 3. 4. 5. 6. 7. Engine Configuration. VSG Configuration. Engine Protection. Idle Shutdown. Cruise Control. ECM's Ins/Outs Progress Shift.

NOTE:

Show slide 20 (g) Fuel Injector Information. 1. 2. 3. 4. Cylinder cutout. Response Times. Calibration Update. Change Date.

NOTE:

Show slide 21 (h) Sub-menus that follow 1. 2. 3. 4. 5. 6. Engine Trip Data. Calibration Change Switch/Light Statistics Activate Outputs MIDs Received Reset Components

NOTE:

Conduct a check on learning and summarize the learning activity.

3.

Learning Step / Activity 3. Identify AN/PSM95 SPORT Components Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:12 1 hr Large Group Instruction

NOTE:

Switch PowerPoint for the SPORT. Use actual AN/PSM-95 and associated components during the discussion. Show Power Point slides 1 through 6. a. Purpose. (1) The SPORT equipment was designed to aid the mechanic in troubleshooting and fault isolation in automotive equipment. (2) The SPORT equipment is designed to be used as a diagnostic tool on electronically controlled and non-electronically automotive equipment. b. Components and characteristics.

NOTE:

Use actual SPORT equipment; and the SPORT CDA connected to a monitor/TV to project the CDA screen images so that all students can see illustrations of components. Click on SPORT Training Icon on the CDA screen desktop; and then click on the inventory section. Discuss components as they are shown. (1) Controller Diagnostic Aid (CDA)

NOTE: NOTE:

Inform students that the SPORT CDA is a rugged, compact, lightweight portable computer with Windows 95 operation system and Pentium processor. Show slides 7 through 12 (a) Weight-Approximately 10 lb. (b) Physical dimensions- 12W X 3 X 9.38D (c) Processor-Pentium 120 MHz (d) 64 MB RAM (e) 4 GB hard drive (f) Keyboard-standard phone-pad style located on face of CDA (g) Keyboard-external (2) Connectors-standard: Serial RS232, Parallel, Small Computer System Interface (SCSI), Video Graphic Adapter (VGA), Auxiliary Universal Interface (AUI). (3) CD-ROM Used to run Electronic Technical Manuals (ETMs) and (IETMs). (4) Personal Computer Memory Card International Association- PCMCIA Drive-Use to run special function PCMCIA Cards.

NOTE:

The SPORT CDA was issue with a flash ram and modern card.

(5) Power connector-Use to connect the external power supply/charger. (6) Ground Connector-Used to attach a ground cable to the CDA. (7) Power requirement-Internal battery 12V or 18-32V DC to the supply/charger or 115-230V AC to Supply/Charger. c. Power Supply/Charger. NOTE: Show slides 13 through 16. Double click on SPORT training icon on desktop screen; then click on SPORT in the displayed menu. Next click on the power supply/charger icon and discuss the Supply/Charger. (1) DC input connector-Used to attach the NATO cable for DC power from a vehicle. (2) AC input connector-Used to connect an AC power cable to the Supply/Charger. (3) DC Output cable-This cable is attached to the Power supply/charger and connects to the CDA power connector. (4) Battery Compartment-Use to charge the extra battery. The battery is charged whenever the power supply/charger is connected to an external power source (AC or DC). (5) Battery Status Indicator-Illuminate to indicate that the extra battery is being charged. NOTE: The internal battery is designed to operate the CDA for 1.5 hours. The battery LED on the power supply/charger and the CDA illuminates green when the internal battery has sufficient charge to operate the CDA. (a) DC power indicator-Illuminates to indicate DC power is applied to the power supply/charger. (a) AC power indicator-Illuminates to indicate AC power is applied to the power supply/charger. (6) Adapter Kit, Internal Combustion Engine (ICE) Test. NOTE: NOTE: Double click on the SPORT Training icon on CDA desktop screen; then optional equipment; ICE Test kit and inventory. Discuss components as they are shown. Show slides 17 through 21 (a) ICE Box- a junction box for connections between the SPORT CDA and a vehicle under test. NOTE: The ICE box must receive external DC power for it to function. A power selector switch on the ICE box must be set to the NATO or DCA position. (b) W1 0R Diagnostic Connector Assembly (DCA) cable- this cable connects the ICE Box (J1Connector) to the 52 pin DCA connector on the vehicle under test. (c) W4 or TK1 and TK2 Cables-These cables are use to connect the ICE box to the transducers.

10

(d) Adapter Set ICE Kit- The kit contains transducers and fitting needed to perform TK testing. (e) Volt/Ohm Cable- This cable connect to the CDA and attaches the to the circuit test point. (f) Probe Set-The Probe set contains cables, two sizes of probes, spade lugs, and alligator clips that are necessary to make voltage and resistance diagnostic measurements. (g) DMM 224 PCMCIA card with data/power cable- the card converts signals from the vehicle under test, which are routed through the ICE box, into signals useable by the SPORT CDA. NOTE: Show slides 22 through 35 d. Kit Data Bus. NOTE: The kit contains components necessary for monitoring J1708 data on Detroit Diesel Electronically Controlled (DDEC) equipped vehicles. The kit is stored in the ICE kit container. (1) J1708 Adapter- An adapter that is connected to the Diagnostic Data Link (DDL) on a Detroit Diesel Electronically Controlled (DDEC) equipped vehicle. (2) Dearborn Protocol Adapter (DPA)- An adapter that is connected between the SPORT CDA and to the J1708 Adapter. (3) Serial Cable- This cable connects to the SPORT CDA RS232 port and to the DPA. (4) Special Purpose Cable-This cable is use to connect the DPA to the ICE Box. This cable would be used only if there was a problem with the DDL connector on the vehicle. e. Power sources for the CDA NOTE: Discuss the different modes of supplying power to the CDA. (1) Battery internal, in the CDA (2) External DC power through the W1 DCA cable to the ICE box that connects to the CDA. (3) External DC power using power supply/charger- Connects the NATO cable to the vehicle and to the power supply/charger; and connect the power supply/charger to the CDA. (4) External DC power directly from vehicle- Connect the NATO cable Adapter to the NATO cable; and the cable adapter to the CDA. (5) External AC power (115V to 230V) with power supply/charger- Connect the AC power cord to power supply/charger; and connect power supply/charger DC output cable connector to the CDA power input connector.

11

g. Setting up SPORT equipment for DCA mode testing. (1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in the CDA PC card drive slot. NOTE: Install the card in the slot closest to the compartment door opening. Insert the card with labeled side facing toward front of CDA. (2) Connect the P3 end of the data/power cable to the power connector on the CDA. Align red dots on cable connector and CDA connector. (3) Connect the ground connector (P4) on the data/power cable to the ground lug on the CDA. (4) Connect the P1 end of the data/power cable to the ICE box J6 connector. NOTE: Place the power selector switch on the ICE box to the off position before making any connections (5) Connect the W1 cable to the ICE box and the vehicle DCA connector. P1 end of the cable connects to the J1 connector on the ICE box; and the P2 end connects to the DCA connector on the vehicle. (6) Position the power selector switch on the ICE box to the DCA Position. NOTE: Power can be supplied to the CDA through the ICE box when using the (W1) DCA cable. For TK testing, the NATO cable must be used to transfer power from the vehicle through the ICE box to the CDA. h. Setting up SPORT equipment for TK mode testing (1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in the CDA PC card drive slot. NOTE: Install the card in the slot closest to the compartment door opening. Insert the card with labeled side facing toward front of CDA. (2) Connect the P3 end of the data/power cable to the power connector on the CDA. Align red dots on cable connector and CDA connector. (3) Connect the ground connector (P4) on the data/power cable to the ground lug on the CDA. (4) Connect the P1 end of the data/power cable to the ICE box J6 connector. (5) Connect the W4 (transducer) cable(s) P1 end, to J2 or J3 on the ICE box. (6) Connect a selected transducer to the P2 end of the W4 cable. NOTE: A transducer is connected directly to a test point on a vehicle for test measurements. (7) Connect the NATO power cable to the ICE box J5 connector. (8) Position the power selector switch on the ICE box to the NATO position. i. Setting up SPORT equipment for J1708 Data bus testing

12

(1) Connect the NATO cable to the power supply charger DC input connector. (2) Connect the power supply/charger DC output cable connector to the CDA power input connector. NOTE: Power can be supplied to the CDA using the NATO cable and NATO cable adapter, connected directly to the CDA input power connector.(For J1708 data bus test and measurement)However, the extra battery in the power supply charger would not be charged if the power supply/charger were not used. (3) Connect the SPORT serial cable to the Controller Diagnostic Aid RS232 serial port and to a port on the Dearborn Protocol Adapter. (One end to the CDA and the other to the DPA). NOTE: There are two ports or connectors on the DPA. One port on each end. The serial Cable can be connected to only one of the ports, and the J1708 Adapter connects to the other. (4) Connect the J1708 Adapter to a port on the DPA. (5) Connect the J1708 Adapter to the Diagnostic Data Link (DDL) on the DDEC equipped vehicle. j. Operation. (1) Power up Controller Diagnostic Aid (CDA) (2) Connect an external power source to the CDA or use internal battery (a) Press the ON/OFF button (3) Performing a test using the SPORT using CDA (a) Connect the CDA to the vehicle (b) Power up the CDA (c) Use the track ball to move the pointer over the Self Test icon for the desired test to be performed, i.e. ICE or J1708. (d) Follow the instruction on the screen. Step-by-step instructions are shown along with illustrations. k. Care of the AN/PSM-95/SPORT. (1) Inspect CDA carrying case and ICE equipment container for damage. (2) Open containers and inspect components. Ensure port connectors and cables are clean and that the pins are not bent, burned, broken or missing. Check receptacles for similar damage. (3) Perform before and after operation PMCS IAW with electronic technical manual. Conduct an inventory IAW the ETM. (4) Store all components in their original containers and store cases in a controlled environment.

13

NOTE: 4.

Conduct a check on learning and summarize the learning activity. Learning Step / Activity 4. Identify AN/PSM95B MSD Components Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:12 1 hr Large Group Instruction

NOTE: NOTE:

Show Slide 1 TO THE INSTRUCTOR; THE COMPONENTS FOR THE MSD ARE THE SAME AS THE SPORT EXCEPT FOR A FEW CHANGES LISTED, SO YOU ONLY HAVE FIVE SLIDES TO THE STUDENTS HOW THE MSD LOOKS LIKE. Switch to the MSD for the PowerPoint. Use actual AN/PSM-95A and associated components during the discussion. Show slides 2 through 4 a. Purpose, Components, Characteristics, Operation, and CarePurpose (1) The MSD equipment is a Field Ready configuration, which provides a comprehensive maintenance and diagnostic system, utilized as a on system test set in support of all U.S. Army weapon platforms. (2) The MSD allows maintenance and operations manuals to be transported and utilized electronically versus the need to maintain reams of paper and volumes of manuals at the forward site. b. Components and characteristics

NOTE: NOTE:

NOTE:

Use actual MSD equipment and connected to a monitor/TV to project the screen images so that all students can see illustrations of components. Click on MSD Training Icon on the screen desktop; and then click on the inventory section. Discuss components as they are shown. Inform students that the MSD is a rugged, laptop portable computer with Windows 2000 Pro operation system and Pentium processor. show slides 5 through 7 (1) CPU (a) Weight-Approximately 13 lb. including batteries. (b) Physical dimensions- 13W X 12 D X 4H (c) Processor-Pentium 1.3 GHz (d) 512 MB SDRAM

NOTE: NOTE:

14

(e) 40 GB removable hard drive (f) Keyboard-standard and environmentally sealed (g) Hula point mouse (2) Connectors-standard: Two Serial RS-232, Parallel, Small Computer System Interface Controller (SCSI), Video Graphic Adapter (SVGA), Auxiliary Universal Interface (AUI). (3) DVD / CD-RW Used to run Interactive Electronic Technical Manuals (IETMs). (4) Personal Computer Memory Card International Association- Two type II PCMCIA Card Slots Drive-Use to run special function PCMCIA Cards. NOTE: The MSD was issued with a flash ram and modern card. (5) Power connector-Use to connect the external power supply/charger (6) Ground Connector-Used to attach a ground cable. (7) Power requirement-Internal battery 12V or 18-32 VDC to the supply/charger or external power adapter 110-220 VAC to Supply/Charger. c. Power Supply/Charger (1) DC input connector-Used to attach the NATO cable for DC power from a vehicle. (2) AC input connector-Used to connect an AC power cable to the Supply/Charger. (3) DC Output cable-This cable is attached to the Power supply/charger and connects to the power connector. (4) Battery Compartment-Use to charge the extra battery. The battery is charged whenever the power supply/charger is connected to an external power source (AC or DC). (5) Battery Status Indicator-Illuminate to indicate that the extra battery is being charged. NOTE: The internal battery is designed to operate for 2.75 hours at 25 degrees Celsius. The battery LED on the power supply/charger and illuminate green when the internal battery has sufficient charge to operate. (a) DC power indicator-Illuminates to indicate DC power is applied to the power supply/charger. (b) AC power indicator-Illuminates to indicate AC power is applied to the power supply/charger. (6) Adapter Kit, Internal Combustion Engine (ICE) Test (a) ICE Box- a junction box for connections between the MSD-ICE and a vehicle under test.

15

NOTE:

The ICE box must receive external DC power for it to function. A power selector switch on the ICE box must be set to the NATO or MSD position. (b) W1 0R MSD cable- this cable connects the ICE Box (J1Connector) to the 52 pin MSD connector on the vehicle under test. (c) W4 or TK1 and TK2 Cables-These cables are use to connect the ICE box to the transducers. (d) Adapter Set ICE Kit- The kit contains transducers and fitting needed to perform TK testing. (e) Volt/Ohm Cable- This cable connect to the MSD and attaches the to the circuit test point. (f) Probe Set-The Probe set contains cables, two sizes of probes, spade lugs, and alligator clips that are necessary to make voltage and resistance diagnostic measurements. (g) DMM 224 PCMCIA card with data/power cable- the card converts signals from the vehicle under test, which are routed through the ICE box, into signals useable by the MSD-ICE. d. Kit Data Bus

NOTE:

The kit contains components necessary for monitoring J1708 data on Detroit Diesel Electronically Controlled (DDEC) equipped vehicles. The kit is stored in the ICE kit container. (1) J1708 Adapter- An adapter that is connected to the Diagnostic Data Link (DDL) on a Detroit Diesel Electronically Controlled (DDEC) equipped vehicle. (2) Dearborn Protocol Adapter (DPA)- An adapter that is connected between the ICE and to the J1708 Adapter. (3) Serial Cable- This cable connects to the MSD RS-232 port and to the DPA. (4) Special Purpose Cable-This cable is use to connect the DPA to the ICE Box. This cable would be used only if there was a problem with the DDL connector on the vehicle. (3) External DC power using power supply/charger- Connects the NATO cable to the vehicle and to the power supply/charger. (4) External DC power directly from vehicle- Connect the NATO cable Adapter to the NATO cable. (5) External AC power (110V to 220V) with power supply/charger- Connect the AC power cord to power supply/charger; and connect power supply/charger DC output cable connector to the power input connector. e. Setting up MSD equipment for DCA mode testing (1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in the MSD PC card drive slot.

16

NOTE:

Install the card in the slot closest to the compartment door opening. Insert the card with labeled side facing toward front of MSD. (2) Connect the P3 end of the data/power cable to the power connector on the MSD. Align red dots on cable connector and MSD connector. (3) Connect the ground connector (P4) on the data/power cable to the ground lug on the MSD. (4) Connect the P1 end of the data/power cable to the ICE box J6 connector.

NOTE:

Place the power selector switch on the ICE box to the off position before making any connections. (5) Connect the W1 cable to the ICE box and the vehicle MSD connector. P1 end of the cable connects to the J1 connector on the ICE box; and the P2 end connects to the DCA connector on the vehicle. (6) Position the power selector switch on the ICE box to the DCA position.

NOTE:

Power can be supplied through the ICE box when using the (W1) DCA cable. For TK testing, the NATO cable must be used to transfer power from the vehicle through the ICE box. f. Setting up SPORT equipment for TK mode testing (1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in the PC card slot.

NOTE:

Install the card in the slot closest to the compartment door opening. Insert the card with labeled side facing toward front of MSD. (2) Connect the P3 end of the data/power cable to the power connector on the MSD. Align red dots on cable connector and MSD connector. (3) Connect the ground connector (P4) on the data/power cable to the ground lug on the MSD. (4) Connect the P1 end of the data/power cable to the ICE box J6 connector. (5) Connect the W4 (transducer) cable(s) P1 end, to J2 or J3 on the ICE box. (6) Connect a selected transducer to the P2 end of the W4 cable.

NOTE:

A transducer is connected directly to a test point on a vehicle for test measurements. (7) Connect the NATO power cable to the ICE box J5 connector. (8) Position the power selector switch on the ICE box to the NATO position. g. Setting up MSD equipment for J1708 Data bus testing (1) Connect the NATO cable to the power supply charger DC input connector. (2) Connect the power supply/charger DC output cable connector.

17

(3) Connect the MSD serial cable to the RS232 serial port and to a port on the Dearborn Protocol Adapter. NOTE: There are two ports or connectors on the DPA. One port on each end. The serial Cable can be connected to only one of the ports, and the J1708 Adapter connects to the other. (4) Connect the J1708 Adapter to a port on the DPA. (5) Connect the J1708 Adapter to the Diagnostic Data Link (DDL) on the DDEC equipped vehicle. h. Operation. (1) Power up MSD-ICE (2) Connect an external power source to the MSD or use internal battery (3) Press the ON/OFF button (4) Performing a test using the MSD-ICE (a) Connect the MSD-ICE to the vehicle (b) Power up the MSD-ICE (c) Use the track ball to move the pointer over the Self-Test icon for the desired test to be performed, i.e. ICE or J1708. (d) Follow the instruction on the screen. Step-by-step instructions are shown along with illustrations. i. Care of the AN/PSM-95B MSD (1) Inspect MSD carrying case and ICE equipment container for damage. (2) Open containers and inspect components. Ensure port connectors and cables are clean and that the pins are not bent, burned, broken or missing. Check receptacles for similar damage. (3) Perform before and after operation PMCS IAW with electronic technical manual. Conduct an inventory IAW the ETM / IETM. (4) Store all components in their original containers and store cases in a controlled environment. NOTE: NOTE: Show slides 8 through 11 Conduct a check on learning and summarize the learning activity.

18

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO. B. ENABLING LEARNING OBJECTIVE
ACTION: CONDITIONS:

Set-up Test Measurement, and Diagnostic Equipment In a shop environment, given an A?PSM-45A multimeter, Prolink 9000, Sport, MSD, selected wheeled vehicles and references IAW applicable references

STANDARDS:

1.

Learning Step / Activity 1. Demonstrate Set-up Procedures Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Demonstration 1:6 2 hrs Large Group Instruction

NOTE: The instructor will demonstrate TMDE Hook up and setup procedures on selected equipment. NOTE: Instructor will demonstrate various testing procedures on each TMDE. NOTE: 2. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Set-up TMDE Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Performance) 1:6 6 hrs Large Group Instruction

19

NOTE:

Restate safety precautions that are listed in the introduction. Ensure that all necessary training materials listed in lesson plan are available. Divide class into groups and assign an assistant instructor as necessary. Assign groups to vehicles in the shop area and rotate when tasks are completed. Throughout the exercise, use Supplement 1, Practical Exercise Checklist, to check the progress of the students to ensure they are accomplishing the tasks.

20

SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:18 Time of Instruction: 5 mins Media: Large Group Instruction

Check on Learning

Determine if students have learned the material presented by -a. Soliciting student questions and explanations.

b. Asking questions and getting answers from the students. c. Correcting student misunderstanding. QUES: On the SPORT, what cables are use to supply power to the power supply/charger? ANS: NATO and AC power cables.

QUES: What are the tests that can be performed with the multimeter? ANS: Voltage, continuity, current.

QUES: How much voltage can be measured with the high voltage probe on the Fluke 27/FM multimeter? ANS: CDA? ANS: 1.5 hours QUES: How many types of analog test is the MSD-ICE capable of performing? ANS: 50 types
Review / Summarize Lesson

6000 volts.

QUES: On the SPORT, how long will the internal battery operate the

21

SECTION V. Testing Requirements

STUDENT EVALUATION NOTE: Describe how the student must demonstrate accomplishment of the TLO. Refer student to the Student Evaluation Plan. In lesson 63B33E10 you (the students) will have 1 hour and 30 minutes to take a Job Knowledge Test on the material presented during Annex E.

Feedback Requirements

NOTE: Feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

22

63B33E01 JUN 04 Suppl 1a

PRACTICAL EXERCISE SHEET 63B33E01PE1


Title Lesson Number / Title Terminal Learning Objective

J1708 Test with the MSD or SPORT 63B33E01 version MOSC / Test, Measurement, and Diagnostic Equipment
NOTE: The instructor should inform the students of the following Terminal Learning Objective covered by this practical exercise. At the completion of this lesson, you [the student] will: Action: J1708 Test Conditions: In a classroom/shop environment, given an SPORT or, MSD, and Standards:

the necessary references. IAW applicable TMs

Safety Requirements Risk Assessment

None Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. None In lesson 63B33E10 you (the students) will have 1 hour and 30 minutes to take a Job Knowledge Test and Review on the material presented in this lesson. None
Student Materials:

Environmental Considerations Evaluation

Instructional Lead-In Resource Requirements

63B33E01, Supplement 1a Student's Guide References listed above

Special Instructions

None

63B33E01 Suppl 1a

Procedures: 1. 2. NOTE: 3. NOTE: CAUTION: 4. 5. 6. 7. 8. Click on the J1708 icon on the desktop. Self-test will run Turn ignition switch to accessories then click OK. If a fault is in the vehicle a warning note will appear. Click OK and exit from warning to continue test. Go to function, then DDEC II options, then cylinder cut out. Read all screens carefully before performing test. Read all cautions carefully Select auto, 1000 rpms, and number of cylinders for vehicle and click start. (Test will run) Annotate cylinder cutout test results. Click cancel; go to function, DDEC II options, injector response time. Annotate IRTs results Exit back to desk top

END OF TASK
Feedback Requirements

63B33E01 Suppl 1a

63B33E01 JUN 04 Suppl 1b PRACTICAL EXERCISE INSTRUCTORS GUIDE Title References Enabling Learning Objective TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT Number ACTION: CONDITION(S): STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. Title Date Page No. Add'l Info

J1708 Test with the MSD or SPORT In a classroom with assistance, given a MSD or SPORT applicable references. IAW appropriate references without causing damage to equipment or injury to personnel.

Keep clear of the engines moving parts when the engine is running. Remove all jewelry (watches, rings, ID tags). No horseplay in the shop or classroom. Use caution when handling any training aid. Sharp edges, moving parts, and electrical components can cause injury. Disconnect power source from circuits when measuring ohms. Pay special attention to all safety procedures listed in technical manuals when using electronic TMDE. Use caution with electrical sources; 50 volts or more can cause loss of life. Use extreme care while walking around the vehicle while TMDE wires are connected. Tripping over wires can cause injury to personnel and severe damage to testing equipment.

Risk Assessment Level Environmental Considerations

Low. (See Appendix A) Exhaust system must be used when engines are running. Hearing protection must be worn when operating equipment. Ensure appropriate containers are available to collect any engine fluids. Clean all spills immediately. Wash your hands if you come in contact with POL products. 1. Verify students have performed inventory and PMCS on the MSD or SPORT. Direct students to perform setup procedures. 2. Verify students have performed setup procedures IAW Reference guide. Direct students to power-up the equipment and prepare it for testing. 3. Verify students have Selected the J1708 test. 4. Verify students have Correctly conduct the J1708 test. 5. Verify students have received historical and active codes from equipment being tested. 6. Verify students have interpreted codes END OF TASK

Procedures

63B33E01 Suppl 1b

63B33E01 Jun 04 Suppl 1c PRACTICAL EXERCISE CHECKLIST COURSE: SUBJECT: REFERENCES: WHEEL VEHICLE MECHANIC (BNCOC) 63B30 TEST J1708 Students handout

DIRECTIONS TO THE INSTRUCTOR: 1. 2. Complete page 2 of this form as the group performs the task. Once the group has correctly performed a step, place a check in that column. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands-on steps of the task. Have students rotate between stations once the task is completed. If a safety violation occurs, stop the group, correct on the spot and restart the group. If a student misses the practical exercise or a group needs remedial training for longer then the PE allows, then conduct this remedial training at earliest opportunity.

3. 4.

STUDENT NAMES: _________________________ _________________________

CLASS NUMBER:____________ DATE: ___________________ START TIME:______________

_________________________ STOP TIME:_______________ _________________________ TOTAL TIME:______________ _________________________ _________________________ _________________________ ______________________________ INSTRUCTOR'S SIGNATURE

63B33E01 Suppl 1c

5. Conduct a detailed review to ensure that each student can accomplish the following performance measures: a. b. c. d. Observe maintenance discipline and safety procedures. Select and properly interpret references. Prepare MSD or SPORT for operation correctly. Properly conduct the J1708 test. (1) (2) e. f. g. _____ Cylinder cutout. Injector response time. Annotate corrective action on DA Form 2404 correctly. Complete task without injury to personnel or damage to equipment. Return all tools, equipment and references to proper location.

63B33E01 Suppl 1c

63B33E01 Jun 04 Suppl 2a PRACTICAL EXERCISE SHEET 63B33E01PE2


Title Lesson Number / Title Terminal Learning Objective

SPORT ICE TEST 63B33E01 version MOSC / Test, Measurement, and Diagnostic Equipment
NOTE: The instructor should inform the students of the following Terminal Learning Objective covered by this practical exercise. At the completion of this lesson, you [the student] will: Action: SPORT ICE TEST Conditions: In a classroom/, given an SPORT ICE and the necessary references. Standards: IAW applicable TMs

Safety Requirements Risk Assessment

None Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction. None In lesson 63B33E10 you (the students) will have 1 hour and 30 minutes to take a Job Knowledge Test and Review on the material presented in this lesson.

Environmental Considerations Evaluation

Instructional Lead-In Resource Requirements Student Materials:

63B33E01, Supplement 2b, Student Guide References listed above

Special Instructions

None

Procedures

1. 2. 3. NOTE: 4. 5. 6. NOTE: 7.

Click on the ICE testing on the desktop. Click number 1, select vehicle then click OK. Go to function, then DDEC II options, then cylinder cut out . Self-test will run and pass test. Click OK Read directions carefully (make sure ICE TEST OFF SET switch is on. Click OK, test will run. If a fault code show up click cancel then OK and turn off STE ICE OFF SET switch. Engine will be on for this test.

63B33E01 Suppl 2a

8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Enter test number 12, then click OK, click run, test number 10 will show up, click enter Clicks run, ACCEL will appear, have partner press accelerator to the floor until DECEL shows up Click OK and annotate results from test number 12. Click enter, then enter test number 10, click OK, click RUN, click enter and annotate test results. Click enter and enter test number 24, click OK then turn off engine. Click run, and annotate results. Enter test number 67, click on Run 2nd test, and then click OK. Enter 2nd test number 68, then click OK. Click Ready, select run, then crank engine without starting for about 2 seconds, annotate results. Click enter and enter test number 72, then click OK. Read caution and click OK, click Ready read info, click RUN, then crank engine without starting for 2 seconds, press enter, annotate results from test number 72,73,74 and 75. Exit back to desktop and shut down computer.

18.

END OF TASK

Feedback Requirements

63B33E01 Suppl 2a

63B33E01 Jun 04 Suppl 2b PRACTICAL EXERCISE INSTRUCTORS GUIDE Title References Enabling Learning Objective TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT Number ACTION: CONDITION(S): STANDARD: Safety Requirements 1. 2. 3. 4. 5. 6. 7. 8. Title Date Page No. Add'l Info

SPORT ICE TEST In a classroom/, given an SPORT ICE and the necessary references. IAW applicable TMs

Keep clear of the engines moving parts when the engine is running. Remove all jewelry (watches, rings, ID tags). No horseplay in the shop or classroom. Use caution when handling any training aid. Sharp edges, moving parts, and electrical components can cause injury. Disconnect power source from circuits when measuring ohms. Pay special attention to all safety procedures listed in technical manuals when using electronic TMDE. Use caution with electrical sources; 50 volts or more can cause loss of life. Use extreme care while walking around the vehicle while TMDE wires are connected. Tripping over wires can cause injury to personnel and severe damage to testing equipment.

Risk Assessment Level Environmental Considerations

Low. (See Appendix A) Exhaust system must be used when engines are running. Hearing protection must be worn when operating equipment. Ensure appropriate containers are available to collect any engine fluids. Clean all spills immediately. Wash your hands if you come in contact with POL products. 1. Verify students have performed inventory and PMCS on SPORT ICE. Direct students to perform setup procedures. 2. Verify students have performed setup procedures IAW Reference guide. Direct students to power-up the equipment and prepare it for testing. 3. Verify students have Selected the SPORT ICE test. 4. Verify students have Correctly conduct the SPORT ICE test. 5. Verify students have received historical and active codes from equipment being tested. 6. Verify students have interpreted codes END OF TASK

Procedures

63B33E01 Suppl 2b

63B33E01 Jun 04 Suppl 2c PRACTICAL EXERCISE CHECKLIST COURSE: SUBJECT: REFERENCES: WHEEL VEHICLE MECHANIC (BNCOC) 63B30 SPORT ICE TEST Students handout

DIRECTIONS TO THE INSTRUCTOR: 1. 2. Complete page 2 of this form as the group performs the task. Once the group has correctly performed a step, place a check in that column. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands-on steps of the task. Have students rotate between stations once the task is completed. If a safety violation occurs, stop the group, correct on the spot and restart the group. If a student misses the practical exercise or a group needs remedial training for longer then the PE allows, then conduct this remedial training at earliest opportunity.

3. 4.

STUDENT NAMES: _________________________ _________________________

CLASS NUMBER:____________ DATE: ___________________ START TIME:______________

_________________________ STOP TIME:_______________ _________________________ TOTAL TIME:______________ _________________________ _________________________ ______________________________ INSTRUCTOR'S SIGNATURE

63B33E01 Suppl 2b

5.

Conduct a detailed review to ensure that each student can accomplish the following performance measures: a. b. c. d. Observe maintenance discipline and safety procedures. Select and properly interpret references. Prepare SPORT ICE for operation correctly. Properly conduct the SPORT ICE test. (1) e. f. g. _____ Cylinder cutout. Annotate corrective action on DA Form 2404 correctly. Complete task without injury to personnel or damage to equipment. Return all tools, equipment and references to proper location.

63B33E01 Suppl 2b

Вам также может понравиться