Answer Keys and Theory for CL-1918-4S_053304 Automotive Lighting System Trainer CL-1918-4S_053304-91_V2025-1 © ConsuLab Educatech Inc, 2025. All rights reserved. Teacher Only CL-1918-4S_053304-91 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of contents Student Assignment Explanations 9 Circuit Construction Notes 13 Fuse Panel Explanation 15 Student Assignments Current Measurement Methods 16 CL-1918-4 Levels 1,2 & 3 Trainer Wiring Blank Template 17 Circuit Assignments SA-1 — Backup Lights Circuit 23 Circuit Explanation 23 Circuit Explanation Answer Key 24 SA-1 — Level 1 / Level 2 Assignment 25 SA-1 — Level 1 / Level 2 Assignment Instructors Answer Key 26 SA-1 — Level 1 Schematic Instructors Answer Key 27 SA-1 — Level 2 Schematic Instructors Answer Key 28 SA-1 — Level 3 Assignment 29 SA-1 — Level 3 Assignment Instructors Answers Key 30 SA-1 — Level 3 Schematic Instructors Answer Key 31 SA-2 — Hazard Lights Circuit 34 Circuit Explanation 34 Circuit Explanation Instructors Answer Key 35 SA-2 — Level 1 / Level 2 Assignment 37 SA-2 — Level 1 / Level 2 Assignment Instructors Answer Key 38 SA-2 — Level 1 Schematic Instructors Answer Key 39 SA-2 — Level 2 Schematic Instructors Answer Key 40 SA-2 — Level 3 Assignment 41 SA-2 — Level 3 Assignment Instructors Answer Key 43 SA-2 — Level 3 Schematic Instructors Answer Key 44 SA-3 — Horn Circuit (Positive Switched) 47 Circuit Explanation 47 Circuit Explanation Instructors Answer Key 48 SA-3 — Level 1 / Level 2 Assignment 50 SA-3 — Level 1 / Level 2 Assignment Instructors Anwser Key 51 SA-3 — Level 1 Schematic Instructors Answer Key 52 CL-1918-4S_053304-91 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 SA-3 — Level 2 Schematic Instructors Answer Key 53 SA-3 — Level 3 Assignment 54 SA-3 — Level 3 Assignment Instructors Answer Key 55 SA-3 — Level 3 Schematic Instructors Answer Key 56 SA-4 — Optional Circuit Horn Circuit (Ground Switched) 59 Circuit Explanation Instructors Answer Key 59 SA-4 — Level 1 Schematic Instructors Answer Key 60 SA-4 — Level 2 Schematic Instructors Answer Key 61 SA-4 — Level 3 Assignment 62 SA-4 — Level 3 Schematic Instructors Answer Key 63 SA-5 — Stop Lights Circuit 66 Circuit Explanation 66 Circuit Explanation Instructors Answer Key 67 SA-5 — Level 1 / Level 2 Assignment 68 SA-5 — Level 1 / Level 2 Assignment Instructors Answer Key 69 SA-5 — Level 1 Schematic Instructors Answer Key 70 SA-5 — Level 2 Schematic Instructors Answer Key 71 SA-5 — Level 3 Assignment 72 SA-5 — Level 3 Assignment Instructors Answer Key 73 SA-5 — Level 3 Schematic Instructors Answer Key 74 SA-6 — Tail-Park Lights Circuit (Ground Switched) 77 Circuit Explanation 77 Circuit Explanation Instructors Answer Key (3 pages) 79 SA-6 — Level 1 / Level 2 Assignment 82 SA-6 — Level 1 / Level 2 Assignment Instructors Answer Key 83 SA-6 — Level 1 Schematic Instructors Answer Key 84 SA-6 — Level 2 Schematic Instructors Answer Key 85 SA-6 — Level 3 Assignment 86 SA-6 — Level 3 Assignment Instructors Answer Key 88 SA-6 — Level 3 Schematic Instructors Answer Key 91 SA-7 — Tail-Park Lights Circuit (Positive Switched) 93 Circuit Explanation 93 Circuit Explanation Instructors Answer Key 95 SA-7 — Level 1 / Level 2 Assignment 98 SA-7 — Level 1 / Level 2 Assignment Instructors Answer Key 99 SA-7 — Level 1 Schematic Instructors Answer Key 100 SA-7 — Level 2 Schematic Instructors Answer Key 101 SA-7 — Level 3 Assignment 102 SA-7 — Level 3 Assignment Instructors Answer Key 104 SA-7 — Level 3 Student Assignment Modification Schematic 106 CL-1918-4S_053304-91 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 4 SA-7 — Level 3 Schematic Instructors Answer Key 107 SA-8 — Turn Signal Circuit 109 Circuit Explanation 109 Circuit Explanation Instructors Answer Key (3 pages) 110 SA-8 — Level 1 / Level 2 Assignment 113 SA-8 — Level 1 / Level 2 Assignment Instructors Answer Key 114 SA-8 — Level 1 Schematic Instructors Answer Key 115 SA-8 — Level 2 Schematic Instructors Answer Key 116 SA-8 — Level 3 Assignment 117 SA-8 — Level 3 Assignment Instructors Answer Key 119 SA-8 — Level 3 Schematic Instructors Answer Key 121 Headlights Circuits Notice Pertaining to CL-1918-4 Headlight Circuits 125 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification 126 Headlights and Plug Explanation 129 SA-9 — Headlights Circuit (Ground Switched) 130 Circuit Design and Operation 130 Circuit Explanation Instructors Answer Key 132 SA-9 — Level1 / Level 2 Assignment 136 SA-9 — Level1 / Level 2 Assignment Instructors Answer Key 137 SA-9 — Level 1 Schematic Instructors Answer Key 138 SA-9 — Level 2 Schematic Instructors Answer Key 139 SA-9 — Level 3 Assignment 140 SA-9 — Level 3 Assignment Instructors Answer Key 142 SA-9 — Level 3 Schematic Instructors Answer Key 144 SA-10 — Headlights Circuit (Positive Switched) 147 Circuit Explanation 147 Circuit Explanation Instructors Answer Key 149 SA-10 — All Level Assignment 152 SA-10 — All Level Assignment Instructors Answer Key 154 SA-10 — Level 1 Schematic Instructors Answer Key 156 SA-10 — Level 2 Schematic Instructors Answer Key 157 SA-10 — Level 3 Schematic Instructors Answer Key 158 Headlights Circuit (Optional Circuit Designs) 161 Assignment Explanations 161 SA-11 — Headlights Circuit — Option A 163 Student Assignment 163 CL-1918-4S_053304-91 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 5 Component Explanation Instructors Answer Key 164 SA-11 — Level 1 Schematic Instructors Answer Key 167 SA-11 — Level 2 Schematic Instructors Answer Key 168 SA-11 — Level 3 Schematic Instructors Answer Key 169 SA-12 — Headlights Circuit — Option B 172 Student Assignment 172 Component Explanation Instructors Answer Key 173 SA-12 — Level 1 Schematic Instructors Answer Key 176 SA-12 — Level 2 Schematic Instructors Answer Key 177 SA-12 — Level 3 Schematic Instructors Answer Key 178 SA-13 — Headlights Circuit — Option C 181 Student Assignment 181 Component Explanation Instructors Answer Key 182 SA-13 — Level 1 Schematic Instructors Answer Key 185 SA-13 — Level 2 Schematic Instructors Answer Key 186 SA-13 — Level 3 Schematic Instructors Answer Key 187 SA-14 — Headlights Circuit — Option D 190 Student Assignment 190 Component Explanation Instructors Answer Key 191 SA-14 — Level 1 Schematic Instructors Answer Key 194 SA-14 — Level 2 Schematic Instructors Answer Key 195 SA-14 — Level 3 Schematic Instructors Answer Key 196 SA-15 — Headlights Circuit — Option E 199 Student Assignment 199 Component Explanation Instructors Answer Key 200 SA-15 — Level 1 Schematic Instructors Answer Key 203 SA-15 — Level 2 Schematic Instructors Answer Key 204 SA-15 — Level 3 Schematic Instructors Answer Key 205 SA-16 — Headlights Circuit — Option F 208 Student Assignment 208 Component Explanation Instructors Answer Key 209 SA-16 — Level 1 Schematic Instructors Answer Key 212 SA-16 — Level 2 Schematic Instructors Answer Key 213 SA-16 — Level 3 Instructors Answer Key 214 SA-17 — Headlights Circuit — Option G 217 Student Assignment 217 Component Explanation Instructors Answer Key 218 SA-17 — Level 1 Schematic Instructors Answer Key 221 CL-1918-4S_053304-91 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 6 SA-17 — Level 2 Schematic Instructors Answer Key 222 SA-17 — Level 3 Schematic Instructors Answer Key 223 SA-18 — Headlights Circuit — Option H 226 Student Assignment 226 Component Explanation Instructors Answer Key 227 SA-18 — Level 1 Schematic Instructors Answer Key 230 SA-18 — Level 2 Schematic Instructors Answer Key 231 SA-18 — Level 3 Schematic Instructors Answer Key 232 Whole Trainer Wiring SA-19 & SA-20 — Whole Trainer Wiring 236 General Information 236 CL-1918-4 Total Jumper Wire count 236 Fuse Box Identification for Whole Trainer Wiring Assignment 236 SA-19 — Level 1 Schematic — Ground Circuits Instructors Answer Key 240 SA-20 — Level 1 Schematic— Positive Circuits Instructors Answer Key 241 SA-19 — Level 2 Schematic — Ground Circuits Instructors Answer Key 242 SA-20 — Level 2 Schematic— Positive Circuits Instructors Answer Key 243 SA-19 — Level 3 Schematic— Ground Circuits Instructors Answer Key 244 SA-20 — Level 3 Schematic— Positive Circuits Instructors Answer Key 247 Ohm’s and Kirchhoff’s Laws Assignments Ohm’s and Kirchhoff’s Laws Assignments 251 Circuit Assignments Instructions 251 SA-21 Circuit #1 — Resistances in Parallel 252 SA-21 Circuit #1 — Resistances in Parallel Instructors Answer Key 253 SA-21 — Schematic Instructors Answer Key 254 SA-22 Circuit #2 — Resistances in Series 255 SA-22 Circuit #2 — Resistances in Series Instructors Answer Key 256 SA-22 — Schematic Instructors Answer Key 257 SA-23 Circuit #3 — Combination Resistances (Series & Para) 258 SA-23 Circuit #3 — Combination Resistances in both Series and Parallel Instructors Answer Key 259 SA-23 — Schematic Instructors Answer Key 260 SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) 261 SA-24 Circuit #4 — Bulbs of Different Values in Series Instructors Answer Key 262 SA-24 — Schematic Instructors Answer Key 263 SA-25 Circuit #5 — Bulbs with Same Resistances in Series 264 SA-25 Circuit #5 — Bulbs with Same Resistances in Series Instructors Answer Key 265 SA-25 — Schematic Instructors Answer Key 266 SA-26 Circuit #6 — Different Resistance Values in Combination Series & Parallel Circuit 267 SA-26 Circuit #6 — Different Resistance Values in Combination Series & Parallel Circuit Instructors Answer Key 268 CL-1918-4S_053304-91 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 7 SA-26 — Schematic Instructors Answer Key 270 SA-27 Circuit #7 — Relay Control Circuit with High Resistance 271 SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition Instructors Answer Key 272 SA-27 — Schematic Instructors Answer Key 274 Optional Circuits SA-28 — Generic Vehicle Alarm System Circuit 276 Circuit Criteria Instructions 276 Circuit Description 276 List of Components and their Role Answer Sheet 277 SA-28 — Generic Vehicle Alarm System Circuit 278 Circuit Explanation Instructors Answer Key 278 SA-28 — Level 1 / Level 2 Assignment 282 SA-28 — Level 1 / Level 2 Assignment Instructors Answer Key 283 SA-28 — Level 1 Schematic Instructors Answer Key 284 SA-28 — Level 2 Schematic Instructors Answer Key 285 SA-28 — Level 3 Assignment 286 SA-28 — Level 3 AssignmentInstructors Answer Key 287 SA-28 — Level 3 Schematic Instructors Answer Key 288 SA-29 — Emergency Lighting System 291 Circuit Explanation 291 Circuit Explanation Answer key 292 Circuit Component Explanation Instructors Answer Key 293 SA-29 — Level 1 Schematic Instructors Answer Key 294 SA-29 — Level 2 Schematic Instructors Answer Key 295 SA-29 — Level 3 Schematic Instructors Answer Key 296 SA-30 — Removable Relay Circuit (Positive Switched Relay) 299 SA-30 — All Level Student Assignment Instructors Answer Key 301 SA-30 — Level 1 Schematic Instructors Answer Key 302 SA-30 — Level 2 Schematic Instructors Answer Key 303 SA-30 — Level 3 Schematic Instructors Answer Key 304 SA-31 — Removable Relay Circuit (Ground Switched Relay) 307 SA-31 — All Level Student Assignment Instructors Answer Key 309 SA-31 — Level 1 Schematic Instructors Answer Key 310 SA-31 — Level 2 Schematic Instructors Answer Key 311 SA-31 — Level 3 Schematic Instructors Answer Key 312 Optional Circuit Assignments 315 SA-32 — Custom Circuit #1 316 CL-1918-4S_053304-96 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 8 © ConsuLab Educatech Inc, 2025. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Made in Canada. The content of this manual is applicable to models 053304 and above. SA-32 — Level 1 Schematic Instructors Answer Key 317 SA-32 — Level 2 Schematic Instructors Answer Key 318 SA-32 — Level 3 Schematic Instructors Answer Key 319 SA-33 — Custom Circuit #2 322 SA-33 — Level 1 Schematic Instructors Answer Key 323 SA-33 — Level 2 Schematic Instructors Answer Key 324 SA-33 — Level 3 Schematic Instructors Answer Key 325 SA-34 — Custom Circuit #3 327 SA-34 — Level 1 Schematic Instructors Answer Key 328 SA-34 — Level 2 Schematic Instructors Answer Key 329 SA-34 — Level 3 Schematic Instructors Answer Key 330 SA-35 — Custom Circuit #4 333 SA-35 — Level 1 Schematic Instructors Answer Key 334 SA-35 — Level 2 Schematic Instructors Answer Key 335 SA-35 — Level 3 Schematic Instructors Answer Key 336 SA-36 — Custom Circuit #5 339 SA-36 — Level 1 Schematic Instructors Answer Key 340 SA-36 — Level 2 Schematic Instructors Answer Key 341 SA-36 — Level 3 Schematic Instructors Answer Key 342 SA-37 — Custom Circuit #6 345 SA-37 — Level 1 Schematic Instructors Answer Key 346 SA-37 — Level 2 Schematic Instructors Answer Key 347 SA-37 — Level 3 Schematic Instructors Answer Key 348 consulab.com info@consulab.com 9 CL-1918-4S_053304-91 Student Assignment Explanations Student Assignment Explanations The CL-1918-4 lighting trainer will have three separate levels of assigning student’s various assignments. It will be up to your instructor to choose which of the three levels are appropriate for each student. The three levels change in difficulty and each is explained below. Additional assignments involving circuit explanations are also included. All assignments have completed instructors answer keys. It is important to monitor student access to answer keys. LEVELS 1 & 2 – When completing a lighting circuit assignment, be sure to choose between the L1 or L2 procedure. The Level 1 assignment is identical to the Level 2 with the exception of the following : LEVEL 1 – Level 1 assignments are designed for the student with little or no previous experience with electrical lighting circuits. Your instructor may choose to assign you a completed schematic showing how the circuit is wired or may give you a complete schematic showing industry electrical symbols for the wired circuit. The Level 1 student assignment will use a picture of the trainer’s panels (Moduponents) with red and black wires shown with the completed circuit. Your instructor will choose which diagram each student uses to learn and construct the cir- cuit. There is a student answer sheet for the Level 1 assignment which is identical to the level 2. The LEVEL 1 assignments can be compared to the ASE Education Foundation (formerly NATEF) MLR Automotive Stan- dards level. See below for example of L1 schematic : REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 10 CL-1918-4S_053304-91 Student Assignment Explanations LEVEL 2 – The Level 2 student assignment will show the three panels (Moduponents) with industry standard schematic symbols in place of pictures of the connection points. You may be assigned a completed schematic or one that shows the proper hookup of the red and black jumper wires. The student answer sheet is identical to the level 1 answer sheet. The L2 assignments can be compared to the ASE Education Foundation (formerly NATEF) AST Automotive Standards level. Your instructor will choose which diagram you use to learn and construct the circuit. There is also an instructors answer key included : See below for example of L2 schematic : CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD LEVEL 3 – The Level 3 is designed for students who have some existing training or experience. Be sure to use the level 3 student assignment procedure that is different than the levels 1&2. It contains more detailed instructions and extra circuit measurements and calculations. The level 3 student assignment is structured around the student looking at the Level 3 blank two-page schematic that shows all the components used on the trainer, but without any connecting wiring. One assignment might be for students to design a specific circuit by connecting needed black and red wiring on the blank schematic, obtaining a check, then actually wiring the circuit they designed. Another option would be after the student has mastered the circuit using Level 1 or 2 schematics, they would draw out the wires of the circuit on the blank Level 3 schematic. The Level 3 schematic closely matches most OEM type schematics. There is also a student answer sheet for the Level 3 assignment and instructor’s answer key. The L3 assignments can be compared to the ASE Educa- tion Foundation (formerly NATEF) MAST Automotive Standards level : See below for exmple of L3 schematic : consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 CL-1918-4S_053304-91 Titre de la section consulab.com info@consulab.com 11 LEVELS 1&2 STUDENT ASSIGNMENT : Assignments are organized with a step-by-step procedure asking students to answer questions about the circuit being worked with or making measurements of voltage, amperage or resistance. Each assignment is accompanied with a student answer sheet and an instructor’s answer key. The assignment is designed to be accompanied with either the Level 1 or Level 2 schematic that you assigned to the student. The written assignment instructions are the same for both Levels 1 & 2, but the schematics used are different. LEVEL 3 STUDENT ASSIGNMENT : The Level 3 assignment may contain some elements of Levels 1&2 assignments, but will also have higher level of circuit assignments, questions and measurements. The Level 3 assignment also includes a student answer sheet and instruc- tor’s answer key. Level 3 assignments use the OEM style wiring schematics which are unique to Level 3 only. CIRCUIT EXPLANATION ASSIGNMENTS : Each circuit will contain a narrative explaining how the circuit operates. Your instructor may choose to distribute this document or let the students figure it out on their own. Each circuit also includes a CIRCUIT EXPLANATION assignment. This assignment measures the students understand- ing of what each component in the circuit does and how it contributes to the entire circuit. It consists of a detailed list of components and asks students to explain the function of each terminal of every component used. The assignment includes a student answer sheet and instructor’s answer key. NOTE : Many components can share a common power feed and common ground connections. For this purpose, the red and black jumper wires can be “stacked” on top of each other to join more than one wire together. Although, most wiring diagrams may show individual connections for power and ground, you may choose to “stack” jumper leads together for circuit construction purposes. When stacking jumper wires at a single connection point, do not exceed three stacked wires. or damage can occur to the wires or the socket. If you are assigned to “draw” the circuit you have constructed, you should show the exact configuration of your circuit on a blank trainer template (provided). (Level 1, Level 2 or Level 3 schematics) consulab.com info@consulab.com 12 CL-1918-4S_053304-91 Student Assignment Explanations (Instructors Version) REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date LEFT RIGHT consulab.com info@consulab.com 13 CL-1918-4S_053304-91 Circuit Construction Notes Circuit Construction Notes The CL-1918-4 lighting trainer is a very powerful teaching and learning tool for instructors and students. All of the light- ing circuits used on the trainer are “generic” in nature and do not apply to one specific vehicle or manufacturer. Howev- er, there may be many similarities to specific manufacturer circuit designs. Power Connections : When connecting red positive jumper wires to components on the trainer, be sure to follow any one of the three levels of wiring schematics that are included with the student assignments. Each red jumper wire is designed to be plugged into the appropriate circuit receptacle and most will be of a YELLOW or RED color. If the receptacle is YELLOW, po- larity is not critical. If the receptacle is RED, it must be connected to a positive source. For example, the two backup lights have two yellow receptacles each. Because these bulbs are incandescent, it makes no difference which terminal is positive and which is ground. On any light that is an LED, the receptacles are either RED or BLACK as correct polarity is essential to an LED lamp. The CL-1918-4 trainer is internally protected on all LED lights from reversed polarity con- nections and no damage with occur. If hooked up with backwards polarity, any LED lamp on the trainer will simply not operate. Many times it will be necessary to connect more than one wire at the same receptacle and to allow this, all of the jumper wires can be “stacked” on top of each other. Be sure that the stacked wires are properly seated to each other and try to avoid more than 3 or 4 stacked wires together. There are short and long red jumper wires provided with the trainer to allow access between components. Ground Connections : When connecting black ground jumper wires to components on the trainer, be sure to follow any one of the three levels of wiring schematics that are included with the student assignments. Each black jumper wire is designed to be plugged into the appropriate circuit receptacle and most will be BLACK in color. NOTE- There are no internal ground connections between the three panels. Therefore, it will be necessary to connect the ground circuits of all three panels together with black jumper wires between the 01 (top), the 02 (middle) and the 03 (bottom) panels. There are three black ground recep- tacles at both the top and bottom panels and there are six ground receptacles on the middle panel. At each panel, the ground receptacles are internally connected together from behind the panel, BUT are not connected together BETWEEN each panel. Additionally, as with the positive jumper wires, ground wires can be safely “stacked” on top of each other at the same connection receptacle in order to connect more than one wire. Fuses and Circuit Protection : Be sure to read and understand the section on the trainers fuse box in the OPERATION MANUAL. It is required that all circuits connected by students on this trainer MUST be connected through a fuse. This will prevent potential damage to components. The top three fuses (25A, 15A & 5A) are “hot all time” fuses which are fed on the right-hand side from behind the panel. The “LOAD” side of the fuses are the left-hand side of these three fuses. consulab.com info@consulab.com 14 CL-1918-4S_053304-91 Circuit Construction Notes WARNING !!! Power Supply Notes WARNING !!! As has been previously stated, the CL-1918-4 trainer power supply is capable of outputting approximately 30 amps of power within a typical voltage range of 13.00 – 13.85 volts. It is internally protected from short circuits. With the middle panel being connected to the power supply junction block located behind the middle panel, and fuses F1, F2 and F3 (hot at all times) fuses protected by fuse F9, there should be no possible way to create a “short power to ground” circuit. Fuse F9 will blow if the combined current of F1, F2 and F3 exceeds 25A. No other connections should be made to the power supply junction block mounted on the trainers frame. WARNING - THE CL-1918-4 POWER SUPPLY MUST NEVER BE USED AS A BATTERY CHARGER! POTENTIAL DAMAGE AND THE VOIDING OF THE WARRANTY CAN OCCUR IF THIS OCCURS. consulab.com info@consulab.com 15 CL-1918-4S_053304-91 Fuse Panel Explanation Fuse Panel Explanation To Circuits From Circuits MUST BE FED FROM B+ FEED EX.: IGN SWITCH F1 - F3 HOT AT ALL TIMES F4 - F8 CKT’S TO BE SWITCHED WITH B+ GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A F9 MAIN POWER PROTECTION FUSE 25A F10 POWER RELAY PROTECTION consulab.com info@consulab.com 16 CL-1918-4S_053304-91 Student Assignments Current Measurement Methods Student Assignments Current Measurement Methods NOTE – CIRCUIT AMPERAGE MEASUREMENTS : There are three acceptable methods of measuring circuit current on vehicles and on the CL-1918-4 lighting trainer. They are : DIGITAL MULTI-METER - Using the milli-amp or amp measuring function of your digital multi-meter and connecting the ammeter in series with the circuit you are measuring. Most DMM’s are protected with one or more ammeter fuses. AL- WAYS follow instructions when using this method. DIGITAL MULTI-METER CAPABLE OF DIRECT MEASUREMENT OF AMPERAGE COM TERMINAL – BLACK LEAD SELECTABLE AMP SCALE – RED LEAD AMPS or MILLIAMPS A CURRENT CLAMP connected to your digital multi-meter. This tool is a common test equipment accessory and is often used in industry. Be sure to set your DMM to read milli-volts and not amps when using this tool. It is also nec- essary to convert the displayed readings of milli-volts to milli-amps based on the selected scale of the current clamp. Follow instructions. CURRENT CLAMP USED IN COMBINATION WITH A DIGITAL MULTI-METER. READING MILLI-VOLTS & CONVERTING TO MILLI-AMPS CLAMP AMMETER - A meter with a built-in inductive ammeter is perhaps the “quickest” and easiest method of measur- ing amperage, but requires a unit that accurately measures in the milli-amp range. Using larger range inductive clamps designed for starter and alternator testing will not provide accuracy. STAND ALONE INDUCTIVE CLAMP NO DIRECT CIRCUIT CONNECTIONS REQUIRED consulab.com info@consulab.com 17 CL-1918-4S_053304-91 CL-1918-4 Level 1 Trainer Wiring Blank Template REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 18 CL-1918-4S_053304-91 CL-1918-4 Level 2 Trainer Wiring Blank Template CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4 Level 2 Trainer Wiring Blank Template consulab.com info@consulab.com 19 CL-1918-4S_053304-91 CL-1918-4 Level 3 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V CL-1918-4 Level 3 Trainer Wiring Blank Template P-1 consulab.com info@consulab.com 20 CL-1918-4S_053304-91 CL-1918-4 Level 3 Trainer Wiring Blank Template consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H CL-1918-4 Level 3 Trainer Wiring Blank Template P-2 consulab.com info@consulab.com 21 CL-1918-4S_053304-91 CL-1918-4 Level 3 Trainer Wiring Blank Template CL-1918-4 Level 3 Trainer Wiring Blank Template P-3 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 consulab.com info@consulab.com 22 CL-1918-4S_053304-91 Circuit Assignments Circuit Assignments CL-1918-4S_053304-91 SA-1 — Backup Light Circuit consulab.com info@consulab.com 23 SA-1 — Backup Lights Circuit Circuit Explanation The BACKUP lights circuit on vehicles is used to assist the driver when backing up the vehicle by providing lighting to illuminate the area. Some newer vehicles may use LED lamps instead of the traditional incandescent bulbs. In addition, many vehicles now use CAN Bus circuits to control lighting circuits. The backup lights circuit on a “traditional” vehicle consists of the appropriate fuse(s), ignition switch, backup lights switch, backup lights and the required positive and negative wiring necessary to operate the circuit. CAN Bus systems often do not use a “backup lights” switch, but use the transmission selector switch to know when the driver has selected REVERSE and a computer then turns on the backup lights. On most vehicles, the ignition switch must be in the ON position in order for the backup lights to operate. The CL-1918-4 uses the “traditional” backup lights circuit. Power for the backup lights is routed from the battery, through Fuse #1, then on to the IGNITION switch. It leaves the ignition switch when the switch is turned to the IGNITION position and is directed to Fuse #4, through the fuse, then on to the BACKUP LIGHTS switch. If the backup lights switch is closed, power then is directed to each backup light bulb and then is grounded back to the battery. consulab.com info@consulab.com 24 CL-1918-4S_053304-91 SA-1 — Backup Light Circuit SA-1 — Backup Lights Circuit Circuit Explanation Answer Key FUSE #1 – LOAD SIDE Protects the B+ circuit from battery voltage to the ignition switch BAT terminal and from the IGN terminal to fuse #4 (power side). FUSE #4 – LOAD SIDE Protects the entire backup light circuit including the switch, backup lights and connecting wiring. IGNITION SWITCH TERMINALS ACC Not used in this circuit. IGNITION This terminal is connected to the BAT terminal when the ignition switch is turned to the ignition position. START Not used in this circuit. BAT Full B+ system voltage is available at this terminal and is protected by fuse #1. BACKUP LIGHT SWITCH (a normally open switch) 1ST TERMINAL Connected to the load side of fuse #4. 2nd TERMINAL Connected to the two backup lights in parallel. BACKUP LIGHTS The two backup lights are connected in parallel and receive B+ power from the backup light switch when the switch is closed. Both backup lights are connected to system ground with black wires. GROUND CIRCUITS The ground side of this circuit consists of two black wires from each backup light which are connected to system ground. CL-1918-4S_053304-91 SA-1 — Backup Lights Circuit consulab.com info@consulab.com 25 SA-1 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the BACKUP LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the backup light components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the BACKUP LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right-hand backup light. B. Voltage drop across the left-hand backup light. C. What if the voltage drop across a backup light was 8.0V ? What does that reading tell you ? D. Total backup circuit current draw. 7. Are backup lights typically connected in series or in parallel on most vehicles ? 8. What would happen to the circuit if one backup light bulb was burned out ? 9. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 26 CL-1918-4S_053304-91 SA-1 — Backup Light Circuit SA-1 — Level 1 / Level 2 Assignment Instructors Answer Key CIRCUIT MEASUREMENTS : (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V ±) 6. A 13.50 Volts ± B 13.50 Volts ± C An 8.0 voltage drop across the backup light bulb indicates unwanted resistance located between the two volt meter test probes. This could be caused by corroded terminals, wires or connections. D 0.693 A ± or 693 mA ± 7. Parallel. 8. Because they are hooked in parallel, if one bulb was burned out, the other would still operate normally. consulab.com info@consulab.com 27 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-1 — Backup Light Circuit SA-1 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 28 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-1 — Backup Light Circuit SA-1 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-1 — Backup Lights Circuit consulab.com info@consulab.com 29 SA-1 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the backup light components. 4. Obtain instructor’s check. 5. With circuit turned OFF, measure the static resistance of each bulb with all wires disconnected. Then, reconnect circuit wires. 6. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the BACKUP LIGHT CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 7. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right-hand backup light. B. What would explain a voltage drop reading of 6.5V on the left-hand backup light ? C. Voltage drop across the left-hand backup light. D. Total backup circuit current draw. E. Measure current flow in right-hand backup light. F. Measure current flow in left-hand backup light. G. If the measured current of the left-hand backup light was significantly less than the right-hand side, what would that reading indicate might be wrong with the circuit ? 8. Now calculate the dynamic resistance of each backup light bulb. 9. Are backup lights typically connected in series or in parallel on most vehicles ? 10. What would happen to the circuit is one backup light bulb was burned out ? 11. On this specific trainer, what circuits must have the IGNITION switch turned on before operating ? 12. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 30 CL-1918-4S_053304-91 SA-1 — Backup Light Circuit SA-1 — Level 3 Assignment Instructors Answers Key CIRCUIT MEASUREMENTS : (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V ±) 5. A STATIC RESISTANCE OF RIGHT-HAND BACKUP LIGHT: 4.2 Ω ± (NOTE- If the backup lights were recently operat- ed, the static resistance will be a bit higher (2-4 Ω) but will drop to the above reading after the bulb cools down. B STATIC RESISTANCE OF LEFT-HAND BACKUP LIGHT: 4.2 Ω ± (NOTE- If the backup lights were recently operated, the static resistance will be a bit higher (2-4 Ω) but will drop to the above reading after the bulb cools down. 7. A VOLTAGE DROP ACROSS RIGHT-HAND BACKUP LIGHT: 13.5 Volts ± B Unwanted resistance somewhere in the power or ground to just that bulb. C VOLTAGE DROP ACROSS LEFT-HAND BACKUP LIGHT: 13.5 Volts ± D TOTAL BACKUP LIGHT CIRCUIT CURRENT DRAW: 0.693 A or 693 mA ± E CURRENT FLOW IN RIGHT-HAND BACKUP LIGHT: 0.348 A or 348 mA ± F CURRENT FLOW IN LEFT-HAND BACKUP LIGHT: 0.355 A or 355 mA ± G There is unwanted resistance in the positive or ground side of that bulb causing the lower current flow. 8. A DYNAMIC RESISTANCE OF RIGHT-HAND LIGHT: 13.5 ±/ 0.348 ± = 38.79 Ω ± B DYNAMIC RESISTANCE OF LEFT-HAND LIGHT: 13.5 ± / 0.355 ± = 38.02 Ω ± 9. Parallel. 10. Because they are connected in parallel, the other backup light bulb would operate normally. 11. Turn signals and backup lights. consulab.com info@consulab.com 31 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-1 — Backup Light Circuit SA-1 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 32 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-1 — Backup Light Circuit consulab.com info@consulab.com 33 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-1 — Backup Light Circuit CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit consulab.com info@consulab.com 34 SA-2 — Hazard Lights Circuit Circuit Explanation The HAZARD LIGHTS circuit on vehicles is used to warn nearby vehicles that the vehicle is experiencing some type of ab- normal condition. Examples could be a vehicle that has been disabled and is located either in or near traffic flow or the driver is experiencing hazardous road conditions, is driving very slow and wishes to warn others of this condition. This circuit is extremely important for safe vehicle operation and should be checked often during routine safety inspections. Some newer vehicles can use LED lamps instead of the traditional incandescent bulbs. The CL-1918-4 uses LED lamps for the hazard lights circuit and correct circuit hookup polarity must be followed. If the LED stop lights are hooked up backwards, no component or circuit damage will occur. On most vehicles the hazard lights circuit turns on both the front amber turn signals and the rear red stop lights (if amber turn signal lights are used at the rear, options could use either amber turn or red stop lights for the hazard circuit.). The CL-1918-4 hazard lights circuit begins with battery power flowing through Fuse #2 (hot all times) and then connects to the BAT terminal of the HAZARD FLASHER. The HAZARD FLASHER GND terminal is connected to a system ground and the SIG (signal) terminal is connected to SIG terminal of the HAZARD SWITCH. The HAZARD SWITCH GND terminal is also connected to a system ground. The LEFT terminal connects to the following lights : LEFT TURN INDICATOR, LEFT FRONT TURN, and LEFT REAR STOP lights. The RIGHT terminal connects to the following lights : RIGHT TURN INDICATOR, RIGHT FRONT TURN, and RIGHT REAR STOP lights. In addition, all six of these lights have ground circuits connected to common system ground circuits. Pushing the HAZARD SWITCH button in connects battery power through the hazard switch and on to the left and right sides front turn and rear stop lights as well as both left and right turn indicators respectively. NOTE : For purposes of consistency and learning, it is desired when constructing ONLY the hazard lights circuit, to only use wires necessary for the operation of that circuit only. It is recognized that there can be inter-connection between the hazard and turn signal circuits, but please keep them separate when wiring these circuit assignments. We believe this will enhance the student learning experience when studying individual circuits. The circuits will be connected to- gether when wiring the entire lighting system. consulab.com info@consulab.com 35 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit SA-2 — Hazard Lights Circuit Circuit Explanation Instructors Answer Key (2 pages) FUSE #2 – Protects the entire hazard lights circuit and all components in it. HAZARD SWITCH – Receives B+ power from the hazard flasher whenever the hazard switch is pushed “in” to connect SIG to LEFT, RIGHT and operate the red indicator light in the hazard switch. GND – Connects the hazard switch to system ground to operate the switch indicator light and completes the circuit to cause the hazard flasher to operate. SIG – Receives pulsing B+ power from the hazard flasher and if the hazard switch is pushed in, the LEFT & RIGHT terminals are connected which operates the hazard lights. If the hazard switch is not pushed in, there will be B+ power available at the SIG terminal. LEFT – Connects the front and rear LEFT turn signal lights to B+ power when the hazard switch is pushed in. RIGHT – Connects the front and rear RIGHT turn signal lights to B+ power when the hazard switch is pushed in. HAZARD FLASHER – This flasher provides a pulsing B+ power to the hazard switch whenever the hazard switch is pushed in. Unless the hazard switch is pushed in, the flasher will not flash, but B+ power is available on the SIG terminal at all times. BAT – Receives B+ power from fuse #2 at all times. SIG – Directs B+ power from the flasher to the hazard switch. Will not pulse unless the hazard switch is pushed in. GND – Provides a path to system ground to operate the flasher. LEFT & RIGHT INDICATORS – The left and right turn indicators are the same indicators that are operated by the turn signals. When the hazard lights are operated, both indicators will come on at the same time because of the connections to the LEFT and RIGHT terminals at the hazard switch. FRONT LEFT & RIGHT TURN LIGHTS – The left and right front turn signal lamps will operate all at the same time when the hazard switch is pushed in. They are connected to the LEFT and RIGHT terminals respectfully of the hazard switch. consulab.com info@consulab.com 36 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit REAR LEFT & RIGHT TURN LIGHTS – The left and right rear turn signal lamps will operate all at the same time when the hazard switch is pushed in. They are connected to the LEFT and RIGHT terminals respectfully of the hazard switch. GROUND CIRCUITS – The hazard switch, hazard flasher, left and right indicator lights, left and right front turn signal lights and the rear left and right turn signal lights must all be connected to system ground using parallel connected black wires. CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit consulab.com info@consulab.com 37 SA-2 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the HAZARD LIGHTS CIRCUIT, and following the schematic, correct- ly connect red and black circuit wires to the hazard light components. Please connect ONLY the necessary wires to operate JUST the hazard lights circuit and no other circuits. Be sure to use separate ground circuits for the left and right side of the vehicle. Do not combine the grounds together. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HAZARD LIGHT CIRCUIT. There should be a total of six lights operating. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are hazard lights typically connected in series or in parallel on most vehicles ? 7. As an experiment, remove the ground wire from the left front turn signal bulb. What effect did that have on the circuit ? 8. What would happen to the circuit if the right rear turn signal bulb was burned out ? 9. Measure the voltage available to the hazard lights flasher at the BAT terminal. 10. What would be the voltage reading from step 9 if fuse #2 were open ? 11. If fuse #2 was confirmed good and the voltage at the BAT terminal of the hazard flasher was zero, what could be the cause of this condition ? 12. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 38 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit SA-2 — Level 1 / Level 2 Assignment Instructors Answer Key Circuit Measurements: NOTE – All measurements may vary based on available voltage and individual component design tolerances – readings should be within 10% of stated values – answer sheet values were based on an unload- ed VOLTAGE SUPPLY OF 13.73 V ±. 6. Parallel. 7. Only the left front turn signal is inoperative because it has it own ground. 8. Only the right rear stop light bulb is inoperative because it is connected in parallel to the circuit. 9. 13.63 V ± (full system voltage). 10. Zero volts. 11. Open wire between fuse #2 and the BAT terminal of the hazard flasher. consulab.com info@consulab.com 39 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit SA-2 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 40 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit SA-2 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit consulab.com info@consulab.com 41 SA-2 — Level 3 Assignment (2 pages) Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 1. Make sure trainer is properly connected to a 120V power supply (turned OFF). 2. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the hazard lights components. Please connect ONLY the necessary wires to operate JUST the hazard lights circuit and no other circuits. Be sure to use separate ground circuits for the left and right side of the vehicle. Do not combine the grounds together. 3. Obtain instructor’s check. 4. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HAZARD LIGHT CIRCUIT. There should be a total of six lights operating. If circuit does not operate properly, go back over your work to locate the error and correct. 5. Are hazard lights typically connected in series or in parallel on most vehicles ? 6. Using proper jumper wires, set up the hazard circuit to be able to measure the total current for only the RIGHT side of the hazard circuit. You must use a jumper wire to have only the right side operate constantly to accurately mea- sure the current. Now measure the current of the right side of the hazard circuit. NOTE- You must make necessary changes to the circuit so that the right side lights stay on in order to measure total current flow. 7. Using the same procedure as step 7, repeat the current measurement for the LEFT side of the hazard circuit. 8. Add the answers from steps 7 & 8 together. What is the total hazard lights circuit current ? 9. What effect would an open wire between the GND terminal of the hazard switch and system ground cause in the hazard lights circuit ? 10. Remove the red wire connecting between the hazard flasher SIG terminal and the hazard switch SIG terminal. 11. Connect a long red wire from the SIG terminal of the hazard flasher to either terminals of the right rear marker light. 12. Connect a long red wire from the other terminal of the right rear marker light to the SIG terminal of the hazard flash- er switch. You have now inserted some unwanted resistance in the SIG circuit of the hazard lights circuits. Turn on the circuit and explain what circuit performance characteristics you notice. 13. With the circuit on, use a short red jumper wire to momentarily jump across the two terminals of the right rear mark- er light and record what you noticed happening to the circuit. CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit consulab.com info@consulab.com 42 14. Explain what conditions on a vehicle could cause this condition. 15. Using more red jumper wires, add additional side marker lights, license plate light and backup lights all in SERIES to observe what effect added resistance has on this circuit. What happens as you add more resistance into the SIG circuit ? 16. Using more red jumper wires, add additional side marker lights, license plate light and backup lights all in SERIES to observe what effect added resistance has on this circuit. What happens as you add more resistance into the SIG circuit ? 17. Remove the jumper wire and all other extra red wires and restore the circuit back to normal operating conditions. 18. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply). consulab.com info@consulab.com 43 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit SA-2 — Level 3 Assignment Instructors Answer Key Circuit Measurements: NOTE – All measurements may vary based on available voltage and individual component design tolerances – readings should be within 10% of stated values – answer sheet values were based on an unload- ed VOLTAGE SUPPLY OF 13.73 V±. 6. Parallel. 7. 0.703 A or 703 mA ± = remove the red jumper wire from the BAT terminal of the hazard flasher and connect it to the right terminal of the hazard switch. All right hand lights will come on, then measure current flow using any of the three different type of ammeters. 8. 0.693 A or 693 mA ± = Remove the red jumper wire from the BAT terminal of the hazard flasher and connect it to the left terminal of the hazard switch. All left hand lights will come on, then measure current flow using any of the three different type of ammeters. 9. 01.40 A or 1,400 mA ± 10. The circuit would be totally inoperative. 13. Adding resistance in the SIG circuit causes the led bulbs to have less brilliance but circuit will still operate. 14. As the jumper is added, the LED bulb brightness with go back to normal. 15. Any unwanted resistance in this circuit from dirt, corrosion or corroded terminals can cause dimmer than nor- mal LED lights. 16. As additional incandesent lights are added in SERIES the LED brillance will reduce until finally only a few LED elements will illuminate. consulab.com info@consulab.com 44 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit SA-2 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 45 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit consulab.com info@consulab.com 46 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-2 — Hazard Lights Circuit CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) consulab.com info@consulab.com 47 SA-3 — Horn Circuit (Positive Switched) Circuit Explanation The HORN circuit on vehicles is used to get the attention of someone near your vehicle and for other emergency type uses. The HORN circuit can consist of one or more horns of different tones to create a loud noise when operated. The specific tone of a vehicles horn will vary between manufacturers and vehicle models. The CL-1918-4 uses a low am- plitude audible tone device so that the tone is not objectionable. Vehicles use the steering wheel for locations of horn switches and the horn circuit is often connected to the keyless entry and security systems. The CL-1918-4 uses a com- mon push button switch as the horn switch. Most vehicles today use a relay to operate the horn because the horns can draw significant amounts of current which needs to be controlled by a low current control circuit. The CL-1918-4 horn circuit consists of two circuits. (LOW CURRENT CONTROL & HIGH CURRENT CONTROLLED cir- cuits) CONTROL CIRCUIT – This circuit starts at Fuse #2 (15A) (hot all times). It leaves fuse #2 and connects to one terminal of the horn switch. The other terminal of the horn switch connects to terminal # 86 of relay #4. Terminal #85 of relay #4 is connected to system ground. This is the horn circuit “control” or low amperage circuit. In this case, the horn switch supplies “positive” power to the relay coil terminal #86. Some vehicles use the horn switch as a “ground switch”. CONTROLLED CIRCUIT – This circuit starts at Fuse #3(5A) (hot at all times) and after the fuse is connected to terminal #30 of relay #4. Terminal #87 of relay #4 is connected to the RED terminal of the horn and circuit breaker. The horn is grounded from the BLACK terminal of the horn to a system ground. There is a 2mm test point between the RED and BLACK terminals of the horn for testing purposes. The circuit breaker is present for purposes of the horn fault. This is the “controlled” or high current circuit. NOTE : The CL-1918-4 uses an electronic tone device in place of a normal vehicle horn. Most vehicle horn circuits use a relay to safety handle the high current of the horn(s) so that the current doesn’t have to flow through the horn switch. In this particular case, the current draw of the “horn” is much lower than even the coil (control) circuit of the relay. It must be understood by students that this would not be the case in an actual vehicle. Pushing the horn button causes relay #4 to energize (#86 & #85) which connects power from terminal #30 to #87, which in turn causes the horn to operate. (if the circuit breaker is not open). NOTE : After you have completed first HORN CIRCUIT assignments, there is an additional assignment to setup and learn how a “ground-switched” horn circuit operates. Be sure to complete this portion of the assignment also. consulab.com info@consulab.com 48 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) SA-3 — Horn Circuit (Positive Switched) Circuit Explanation Instructors Answer Key (2 pages) FUSE #2 – LOAD SIDE “Hot at all times” on the right side and is connected to one terminal of the horn button on the load side. This provides operation of the horn at any time. FUSE #3 – LOAD SIDE “Hot at all times” on the right side and is connected to terminal #30 of relay #4 on the load side. This provides a constant supply of B+ voltage at the relay. This fuse protects the load side of the relay and the horn circuit. HORN BUTTON 1ST TERMINAL - The 1st terminal of the horn button is connected to fuse #2 and has B+ voltage waiting at this terminal at all times. 2ND TERMINAL - The 2nd terminal of the horn button is connected to terminal #86 of relay #4 and when the horn button is pushed down, B+ voltage is directed to terminal #86 of the relay which causes it to energize. RELAY #4 TERMINAL #30 - This terminal is connected to the load side of fuse #3 and is how the relay load side receives B+ voltage. B+ voltage is available here at all times. TERMINAL #87 - This normally open (N.O.) contact terminal is connected to the horn positive terminal. In the case of this trainer, it is connected to the circuit breaker which is used for fault insertion protection in the horn circuit. Terminal #87 would be “on” anytime the relay is energized. TERMINAL #86 - This terminal is the relay’s coil circuit and is connected to one side of the horn button. Pushing the horn button will energize the relay through this terminal. TERMINAL #85 - This terminal is the relay coils ground circuit and is connected to system ground. TERMINAL #87a- This normally closed (N.C.) contact is not used in the horn circuit. HORN 1ST TERMINAL - The “red” terminal of the horn is technically connected to the circuit breaker which is used for fault insertion protection in the horn circuit. consulab.com info@consulab.com 49 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) 2ND TERMINAL - This is the ground circuit for the horn and is connected to system ground. GROUND CIRCUITS - There are two ground circuits for the horn: 1. Terminal #85 of relay #4 which grounds the relay’s coil to system ground. 2. Black terminal of the horn which grounds the horn to system ground. CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) consulab.com info@consulab.com 50 SA-3 — Level 1 / Level 2 Assignment 1. Fill out the level 1&2 student answer sheet with name, class and information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the HORN CIRCUIT, and following the schematic, correctly connect red and black circuit wires to all horn components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HORN CIRCUIT. If the horn circuit does not operate properly, go back over your work to locate the error and correct. 6. What is the purpose of the horn relay in this circuit ? 7. As an experiment, temporarily remove the black wire connected to terminal # 85 of relay # 4. What happens ? What are some basic conclusions drawn from this experiment ? 8. What would happen to the horn circuit if fuse # 3 was open or defective ? 9. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) 10. Ask instructor if you are to be assigned the OPTIONAL ground switched horn circuit. If so, obtain the assignments pertaining to it. consulab.com info@consulab.com 51 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) SA-3 — Level 1 / Level 2 Assignment Instructors Anwser Key 6. The purpose of the horn relay is to control a high current circuit with a low current switch. 7. What happened to the circuit? The circuit became inoperative as the relay did not function with its ground circuit interrupted. CONCLUSIONS : Any opens or high resistance in the relay coil circuit can cause circuit performance problems. An open wire at terminals #86 or #85 will cause the relay coil to not operate. 8. An open at fuse #3 would result in no power on relay terminal #30, and even though the relay would still operate (click on and off), the horn would be function. This exercise demonstrates that most relays have two separate circuits CONTROL (low current) and CONTROLLED (high current) NOTE : Because of specific circuit designs, in this circuit with the electronic tone device being used instead of a “real” horn, the current draw of the controlled half side of the circuit is actually much less than the control circuit of the relay. This would never happen in a vehicle, but because ConsuLab chose not to use a real vehicle horn due to the volume that would have to be tolerated. consulab.com info@consulab.com 52 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) SA-3 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 53 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) SA-3 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) consulab.com info@consulab.com 54 SA-3 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the horn circuit components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HORN CIRCUIT. 6. If circuit does not operate properly, go back over your work to locate the error and correct. 7. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Current draw for the CONTROL CIRCUIT of the horn relay. B. Current draw for the CONTROLLED CIRCUIT of the horn relay. C. Measure the voltage available at both terminals of the horn switch with the push button not pushed in. D. Measure the voltage available at terminal #30 of the horn relay. 8. NOTE : Because this trainer uses a piezo type “horn” in this circuit, the amperage will be very low. Using necessary jumper wires, remove the horn from the circuit and connect the two front marker lights in parallel so that the horn relay now controls them. After confirming proper circuit hookup, measure the current flow of the new CONTROLLED CIRCUIT. 9. Describe in detail what would happen to the horn circuit if there was an open in fuse #3 ? 10. What would happen if you connected a jumper wire from a positive voltage source to terminal # 86 of relay #3 ? 11. Disconnect the ground wire from terminal #85 of relay #4. 12. Predict what the voltage would be at terminal #85 of relay #4 when the horn push button is pushed in. 13. Now, push in the horn button with a voltmeter on terminal #85 of relay #4. What is the reading ? 14. Explain why you measured the reading you did in question #12. 15. What two terminals of relay #4 are for the “low current” circuit ? 16. What two terminals of relay #4 are for the “high current” circuit ? 17. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) 18. Ask your instructor if you are to be assigned the OPTIONAL ground switched horn circuit and if so, obtain the SA-4 assignments for it. consulab.com info@consulab.com 55 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) SA-3 — Level 3 Assignment Instructors Answer Key CIRCUIT MEASUREMENTS : (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V) 7. A 146 mA ±. B 29.6 mA ± NOTE- Because trainer uses a piezo buzzer for the “horn”, the current draw is very low. C One terminal will read source voltage (±13.80V) and the other will read “0”. D 13.80 V ± (if fuse #2 is good). 8. Total current of the two front marker lights is 0.647A or 647mA ±. The typical current draw for a #194 incandes- cent bulb is in the range of 327mA ±. 9. Fuse #3 feeds terminal #30 of the horn relay and if open, the relay would still operate (click), but the horn would be inoperative. 10. Connecting a jumper wire from a positive source to terminal #86 of the horn relay would bypass the horn switch and cause the relay to energize which in turn would turn on the horn. 12. The student should predict that full system voltage would be available to relay terminal #85. This can be a good test to determine if the relay coil has continuity. 13. 3.80 V ±. 14. With the ground wire removed from terminal #85 of the horn relay, pushing the horn button will provide full sys- tem voltage to terminal #85 of the horn relay. This would confirm that the relay coil is good. 15. Terminals #86 & #85. This is the “coil” low current circuit of the relay. 16. In this case, terminals #30 & #87 are the high current circuit of the relay. consulab.com info@consulab.com 56 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) SA-3 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 57 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) consulab.com info@consulab.com 58 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-3 — Horn Circuit (Positive Switched) consulab.com info@consulab.com 59 CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Optional Circuit Horn Circuit (Ground Switched) Circuit Explanation Instructors Answer Key FUSE #2 – LOAD SIDE Connected to terminal #87 of relay #4. (same as positive switched). FUSE #3 – LOAD SIDE Connected to terminal #30 of relay #4. (same as positive switched). HORN BUTTON 1ST TERMINAL - Connected to terminal #85 of relay #4. This relay ground circuit will be controlled by the horn switch. 2ND TERMINAL - Connected to system ground. RELAY #4 TERMINAL #30 - Connected to fuse #3 load side. (same as positive switched) This circuit provides B+ voltage to the horn. TERMINAL #87 - Connected to fuse #3 load side. (same as positive switched) This circuit provides B+ voltage to the horn. TERMINAL #86- Connected to fuse #2 load side and provides B+ voltage for the relay coil (same as positive switched). TERMINAL #85- Connected to one terminal of the horn switch which will create a ground path for the relay when horn switch is pushed in. TERMINAL #87a - Not used in this circuit. HORN 1ST TERMINAL- Red terminal is connected to terminal #87 of relay #4 and is how B+ voltage is supplied to the horn. 2ND TERMINAL- Black terminal is connected to system ground. GROUND CIRCUITS- There are two ground circuits for this horn circuit: 1. The horn is connected to system ground by the BLACK terminal. 2. The #4 relay coil (terminal #85) is grounded by the horn switch, when the horn switch is pushed in. consulab.com info@consulab.com 60 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 61 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) consulab.com info@consulab.com 62 SA-4 — Level 3 Assignment In this assignment, you are going to hook up a horn circuit with the horn switch controlling the ground side of the relay. 1. Obtain a blank Level 3 schematic showing all components and circuit receptacles. Label the circuit as : “HORN CIRCUIT – GROUND SWITCHED” and fill in your name, class and date information. 2. Using your obtained knowledge, design a horn circuit where the horn switch will control the ground side of the horn relay. Draw all necessary wires on the schematic and double check your work. 3. After confirming your circuit design, hook up all necessary red and black jumper wires to the horn circuit. 4. Confirm proper horn circuit operation (ground switched) 5. Ask instructor for confirmation of your circuit design. 6. Did you construct the circuit according to the correct answer schematic ? 7. Remove all circuit wiring from the trainer. consulab.com info@consulab.com 63 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 64 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) consulab.com info@consulab.com 65 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-4 — Optional Circuit Horn Circuit (Ground Switched) CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit consulab.com info@consulab.com 66 SA-5 — Stop Lights Circuit Circuit Explanation The STOP LIGHTS circuit on vehicles is used to warn following drivers that you are either slowing down or braking your vehicle using the brake pedal. The term BRAKE LIGHT is often also used for the stop lights and there is no difference be- tween the two. This circuit is extremely important for safe vehicle operation and should be checked often during routine safety inspections. Some newer vehicles can use LED lamps instead of the traditional incandescent bulbs. The CL-1918- 4 uses LED lamps for its stop light circuit and correct circuit hookup polarity must be followed. If the LED stop lights are hooked up backwards, no component or circuit damage will occur. The stop lights will not operate with reversed polarity. On vehicles that do not have amber rear turn signals, it is com- mon to use both rear right and left turn signal bulbs for the stop lights. On vehicles with amber turn signals, there will be separate RED bulbs used only for the stop lights. Also, on newer vehicles, the CHMSL (Center High Mounted Stop Light) is used. The stop light circuit normally consists of a one or more fuses, brake light switch that closes when the driver steps on the brake pedal, brake lights in the rear of the vehicle and the required positive and negative wiring necessary to operate the circuit. Newer vehicles can use CAN Bus circuits to operate the brake lights from signals produced by the stop light switch. The stop light circuit will normally operate regardless of the position of the ignition switch. The CL-1918-4 uses LED bulbs for the stop lights circuit. Power for the stop lights is obtained from battery, then to the “hot at all times” fuse # 2. Power is then routed from the fuse to the stop lights push button switch, to the three LED stop lights (left, right and CHMSL). From the three stop lights, power is then routed through the ground circuit back to the battery. consulab.com info@consulab.com 67 CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit SA-5 — Stop Lights Circuit Circuit Explanation Instructors Answer Key FUSE #2(15A) — LOAD SIDE Connected to B+ bus on the right side of the fuse and connected to one terminal of the brake switch on the load side. This provides a constant B+ voltage to the brake switch at all times. BRAKE SWITCH 1ST TERMINAL- One terminal of the brake switch is connected to the load side of fuse #2 which provides constant B+ voltage available on this terminal. 2ND TERMINAL- The other terminal of the brake switch is connected to the CHMSL RED terminal, and both left and right rear stop lights (RED terminals). When the brake switch is closed by the brake pedal, all three lights will operate. CHMSL STOP TERMINAL- The Center High Mounted Stop Light RED terminal is connected to the brake switch and will operate when the brake switch is closed. The CHMSL is also connected to system ground at the other terminal of the CHMSL. GND TERMINAL- The CHMSL is also connected to system ground by the black GND terminal. LEFT & RIGHT REAR STOP LIGHTS STOP TERMINALS- Both the rear left and right stop lights are also connected to the brake switch at the RED terminal and will operate anytime the brake switch is closed. GND TERMINALS- Each left and rear stop lights have their own respective grounds (black GND terminals) back to system ground. GROUND CIRCUITS- The stop light circuit has the following ground connections: 1. Both rear stop lamps are connected to system ground by the black GND terminals. 2. The CHMSL is connected to system ground by the black GND terminal. CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit consulab.com info@consulab.com 68 SA-5 — Level 1 / Level 2 Assignment 1. Fill out the level 1&2 student answer sheet with name, class and information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the STOP LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the stop light components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the STOP LIGHTS CIRCUIT. There should be a total of three stop lights operating. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are stop lights typically connected in series or in parallel on most vehicles ? 7. As an experiment, correctly connect the red right rear marker light to the circuit and operate the stop light switch. What happens ? What are some basic conclusions drawn from this experiment ? 8. What would happen to the circuit if one stop light bulb was burned out ? 9. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 69 CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit SA-5 — Level 1 / Level 2 Assignment Instructors Answer Key CIRCUIT MEASUREMENTS: (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V) 6. Parallel 7. The right hand marker light comes on with the stop lights. Conclusion: All lights are connected in parallel and adding more lights simply puts more of them in the circuit. 8. Because the are connected in parallel, the rest of the bulbs would continue to be on, only the one burned out would be off. consulab.com info@consulab.com 70 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit SA-5 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 71 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit SA-5 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit consulab.com info@consulab.com 72 SA-5 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the stop lights circuit components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the STOP LIGHTS CIRCUIT. There should be three stop lights operating when the stop light switch is pushed. 6. If circuit does not operate properly, go back over your work to locate the error and correct. 7. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Total current draw for the entire stop light circuit. B. Current draw for the right hand stop light. C. Current draw for the left hand stop light. D. Current draw for the center high mounted stop light. 8. Add up the individual bulb current draws. What is the total compared with answer 7A ? What might explain any small difference between the two readings ? 9. As an experiment, add the right hand rear red marker light to the stop light circuit. What happens when you push the stop light switch button ? 10. Measure the current draw of the right rear marker light ? 11. Measure the total stop lights circuit current with the marker light included. 12. How much more current did the addition of the right hand red marker light add to the total circuit current ? 13. What conclusions can you make from this experiment regarding the current draw of incandescent bulbs compared with LED bulbs ? 14. Are stop lights typically connected in series or in parallel on most vehicles ? 15. What would happen to the circuit if one stop light bulb was burned out ? 16. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply). consulab.com info@consulab.com 73 CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit SA-5 — Level 3 Assignment Instructors Answer Key 7. A 670 mA ± B 312 mA ± C 312 mA ± D 66 mA ± 8. 690 mA ± (any difference is explained with individual LED bulb current compared to all three LED bulbs together. In this case the difference was only 19/1,000th of an amp. Not much difference. 9. The right hand marker light comes on with the brake lights. 10. 335 mA ± 11. 993 mA ± 12. About 335 mA 13. In this case, one incandescent marker light draws almost the same current as three larger and brighter LED bulbs. This demonstrates the advantage of LED bulbs. Less current equals smaller gauge wire, etc. 14. Parallel. 15. Only that one bulb would be OFF, the rest would stay ON. consulab.com info@consulab.com 74 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit SA-5 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 75 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit consulab.com info@consulab.com 76 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-5 — Stop Lights Circuit CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) consulab.com info@consulab.com 77 SA-6 — Tail-Park Lights Circuit (Ground Switched) Circuit Explanation All vehicles today use a TAIL-PARK lights circuit. It is designed to give notice to nearby vehicles that the vehicle is pres- ent. Some manufacturers use different names for this circuit. Other totally proper names that are used can be : RUNNING LIGHTS, CLEARANCE LIGHTS and others. NHTSA (National Highway Traffic Safety Association) have laws and require- ments involving vehicle lighting circuits. Most all current vehicles today must have amber colored park lights at the left and right side at the front of the vehicle and also amber colored side lights at both the left and right side of the vehicles front end. The rear of the vehicle must have a red colored tail light at both the left and right side as well as a red col- ored side lights at each side of the rear of the vehicle. Tail-park light circuits can be controlled many different ways. Some vehicles use common manual light switches, while others use some variation of “automatic” lighting switching. Most of todays vehicles use CAN Bus circuits to control the lights which allows the turning ON and OFF of vehicle lighting circuits without actual operation of a switch. This feature is utilized for security systems, vehicle locking system, keyless fob lighting control, timer circuits and many others. There are many different types of lighting circuits used on vehicles. Some can be “positive” switched while other are “ground” switched. The only difference is what circuit (positive or ground) contains the switching controls. Tail-Park Lights Circuit On the CL-1918-4 trainer, it is possible to use either a positive or ground switched tail-park lights circuit. The 3-page OEM wiring diagram uses the “ground switched” method. There will be additional assignments to have students con- struct positive switched circuits also. Tail-Park Circuit Ground Switched : Power from the battery is connected to Fuse #1 (20A) where it flows through the fuse and connects to the Tail-Park relay #3 at terminal #86. A jumper connects from terminal #86 to relay #3 terminal #30. Tail-Park Lights Low Current Control Circuit : The low current control circuit for the tail-park lights consists of the relay coil of Relay #3 (PARK-TAIL LAMPS). After leaving terminal 85, it is connected to the PARK terminal of the multi-function switch. If the multi-function switch is turned ON to the PARK position, the PARK terminal is connected to a ground path out of the “COM” terminal and on to the sys- tem GROUND which in turn causes relay #3 to energize which connects terminal #30 to #87. This is a ground-switched circuit. Tail-Park Lights High Current Circuit : The high current circuit for the tail-park lights starts at terminal #30 of relay #3. When the relay is energized by the multi-function switch, power from terminal #30 is connected to terminal #87 and on to all of the tail and park lights. CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) consulab.com info@consulab.com 78 Left-Side Tail & Park Lights Terminal #87 is connected to fuses #7 (10A) & #8 (10A). Fuse #7 connects to the left front marker light and with ad- ditional wires to the left-front park light. Another wire connects from the left front marker light to the left-rear marker light. Other wires then connect the left-rear tail and license plate light. Ground wires are connected from all of these lights to the common ground bus on all left sides of the top, middle and bottom panels. Right-Side Tail & Park Lights Fuse #8 (10A) is connected from terminal #87 of relay #3. Fuse #8 connects to the right-front marker light and will addi- tional wires to the right-front park light. Another wire connects from the right front marker light to the right rear marker light. Other wires then connect the right rear tail light. Ground wires are connected from all of these lights to the com- mon ground bus on the .left sides of top, middle and bottom panels. It is intentional to keep the left and right circuit sides electrically separate. VARIATIONS : It is acknowledged that there are many other methods of safely connecting the tail and park lights in a circuit. For purposes of reference and to as closely as possible match typical vehicle configurations, it is preferred to follow the included Level 3 OEM type wiring diagram when constructing this circuit. consulab.com info@consulab.com 79 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Tail-Park Lights Circuit (Ground Switched) Circuit Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) — LOAD SIDE Connected to the B+ bus on the right side and to terminals #30 & #86 of relay # 3. FUSE #7 (10A) — POWER SIDE Connected to terminal #87 of relay #3 on the supply side, it provides B+ voltage when relay #3 is energized. FUSE #7 (10A) — LOAD SIDE Connected to the left front side marker light. There will be B+ available only when relay #3 is energized. This is what “starts” the feed to all tail and park lights on the left side of the vehicle. FUSE #8 (10A) — POWER SIDE Connected to terminal #87 of relay #3 on the supply side and provides B+ voltage when relay #3 is energized. FUSE #8 (10A) — LOAD SIDE Connected to the right front side marker light. There will be B+ available only when relay #3 is energized. This is what “starts” the feed to all tail and park lights on the right side of the vehicle. RELAY #3 TERMINAL #86- Connected to terminal #30 and supplies B+ from fuse #1 to the relay’s coil at terminal #86. TERMINAL #85- Connected to the PARK terminal of the headlight switch and is responsible for turning on relay #3 when the headlight switch is turned to the PARK position by grounding the relay’s coil. TERMINAL #30- Connected to fuse #1 and terminal #86 of relay #3 which provides B+ at all times. TERMINAL #87- Connected to both fuses #7 and #8 on the power side. When relay #3 is energized, B+ voltage is directed to the tail-park lights with fuse #7 protecting the left side and fuse #8 protecting the right side. TERMINAL #87a- Not used in this circuit. MULTI-FUNCTION SWITCH PARK TERMINAL- Connected to terminal #85 of relay #3. Because the relay coil circuit is “ground switched”, when the multi-function switch is turned to the PARK position, PARK is connected to ground through the COM terminal and relay #3 will energize. COM TERMINAL-Connected to system ground and provides a ground path for the coil of relay #3 when the turn signal switch is in the PARK position. consulab.com info@consulab.com 80 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) FRONT LEFT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the load side of fuse #7 and is the start of the B+ feed to all left side park and tail lights when relay #3 is energized. 2ND TERMINAL- Connected to system ground and to the ground terminal of the left park-turn light. FRONT LEFT PARK LIGHT GND TERMINAL- Connected to system ground and provides the ground for the left park light. PARK TERMINAL- Connected to the left front marker light and is the source of B+ voltage when the park lights are turned on. There is also a connection from here to the left rear side marker light to supply B+ to the rear of the vehicle. FRONT RIGHT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the load side of fuse #8 and is the start of the B+ feed to all right side park and tail lights when relay #3 is energized. 2ND TERMINAL- Connected to system ground and provides the ground for the right park light. FRONT RIGHT PARK LIGHT GND TERMINAL- Connected to system ground and provides the ground for the right park light. PARK TERMINAL- Connected to the right front marker light and is the source of B+ voltage when the park lights are turned on. There is also a connection from here to the right rear side marker light to supply B+ to the rear of the vehicle. REAR LEFT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the front left marker light and connects B+ voltage to the tail and marker lights for the rear left of the vehicle. 2ND TERMINAL- Connected to system ground and provides the ground for the left rear marker light. REAR LEFT TAIL LIGHT GND TERMINAL- Connected to system ground and provides the ground circuit for the left rear tail light. TAIL TERMINAL-Connected to the left rear marker light and the license plate positive terminal. This is the supply of B+ voltage to the left rear tail and license plate light. consulab.com info@consulab.com 81 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) LICENSE PLATE LIGHT 1ST TERMINAL- Connected to the left rear tail light. This is the supply of B+ voltage for the license plate light. 2ND TERMINAL-Connected to system ground and provides the ground path for the license plate light. RIGHT REAR TAIL LIGHT GND TERMINAL- Connected to system ground and provides the ground circuit for the right rear tail light. TAIL TERMINAL- Connected to the right rear marker light and is the source of B+ voltage to operate the right rear tail light. REAR RIGHT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the right front side marker light and is the source of B+ voltage for the right rear tail and side marker lights. 2ND TERMINAL- Connected to system ground and provides the ground for the right rear marker light. GROUND CIRCUITS The tail-park light circuits have the following ground circuits: 1. The light switch provides a ground path circuit for terminal #85 of relay #3 when it is turned to the PARK posi- tion. The COM terminal of the light switch is connected to system ground. 2. Each of the side marker lights for the front and rear, left and right of the vehicle have their own dedicated ground circuit. The circuit is designed that way for the possible insertion by instructors of unwanted resistance which would affect circuit performance. This enhances the learning opportunities. 3. The left and right front park lights are connected to system ground by their GND terminals. CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) consulab.com info@consulab.com 82 SA-6 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF) and that the power supply red and black wires are connected to the trainer. 3. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the TAIL-PARK LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the tail-park lights components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right front marker light. B. Voltage drop across the left rear tail light. C. Total tail-park lights circuit current draw. 7. With the tail-park lights turned OFF, make the following voltage measurements : A. Voltage available at terminal #86 of relay #3 to ground. B. Voltage available at terminal #85 of relay #3 to ground. 8. Explain why there is voltage available on both sides of the relay coil ? 9. Are tail-park lights typically connected in series or in parallel on most vehicles ? 10. What would happen to the circuit if the right front marker light bulb was burned out ? 11. What would happen to the tail-park circuit if there was an open in the wire from terminal #85 of relay #3 and the COM terminal of the turn-signal switch ? 12. What would happen to the circuit if the wire between the right hand rear tail light GND terminal and system ground were open ? 13. What would happen to the circuit if fuse #8 were open ? 14. What would happen to the circuit if there was a constant short in the multi-function switch between the PARK and GND terminals ? 15. What would happen to the circuit if there was a short between POS and GND of the license plate light ? 16. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 83 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 1 / Level 2 Assignment Instructors Answer Key CIRCUIT MEASUREMENTS: (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V ±) 6. A 13.26 Volts ± B 13.21 Volts ± C 2.093A or 2,093 mA ± 7. A 13.78 Volts ± B 13.78 Volts ± 8. Because the relay is a “ground switched” relay, if the relay is “off”, there is no path to ground in the coil and therefore, both terminals #86 and #85 will show full system voltage. As soon as the relay is energized, the volt- age at terminal #85 will be zero. 9. Parallel. 10. Only that lamp would be out. All others would be on. 11. The entire tail-park lights circuit would be inoperative. 12. The right rear tail light and right rear marker light would be off. 13. The entire right side tail-parking lights would be inoperative. 14. The tail-park lights would be on constantly. 15. The short would blow fuse #7 and the entire left side tail-park lights would be off. consulab.com info@consulab.com 84 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 85 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) consulab.com info@consulab.com 86 SA-6 — Level 3 Assignment (2 pages) 1. Fill out level 3 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the tail-park lights components. NOTE- There are many components in this circuit. Be sure you spend suffi- cient time studying the circuit to determine the correct hookup of each component. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right front marker light. B. Voltage drop across the left rear tail light. C. Total tail-park lights circuit current draw. D. Current draw of the left rear marker light. E. Current draw of the left rear tail light. 7. Compare the differences between the current draw measured in 6D and 6E. What is the design advantage for manu- facturers to use LED bulbs ? 8. With the tail-park lights turned OFF, make the following voltage measurements : A. Voltage available at terminal #86 of relay #3 to ground. B. Voltage available at terminal #85 of relay #3 to ground. 9. Explain why there is voltage available on both sides of the relay coil ? 10. If you were to use a fused jumper wire, explain how you could energize relay #3 without having to turn on the tail- park lights switch ? This test is often performed in diagnosis. 11. Are tail-park lights typically connected in series or in parallel on most vehicles ? 12. What would happen to the circuit if the right front marker light bulb was burned out ? CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) consulab.com info@consulab.com 87 13. What would happen to the tail-park circuit if there was an open in the wire from terminal #85 of relay #3 and ground ? 14. What would happen to the circuit if the wire between the right hand rear tail light GND terminal and system ground were open ? 15. What would happen to the circuit if fuse #8 were open ? 16. What would happen to the circuit if there was a constant short in the multi-function switch between the PARK and GND terminals ? 17. What would happen to the circuit if there was a short between POS and GND of the license plate light ? 18. Now, remove the end of red positive wire that comes from the front left marker light to the left rear marker light at the left rear marker light and connect it to either terminal of the left hand backup light. Leave all other wires con- nected to the left rear marker light. 19. Connect another red positive wire from the other terminal of the backup light to the left rear marker light (red termi- nal). Now, turn on the TAIL-PARK lights circuit. 20. What happened to the tail-park lights now ? 21. Measure the voltage drop across the following lights : A. Left rear marker light B. Left rear tail light C. License plate light D. Left backup light 22. Explain what has caused the “faulted” condition that you noticed in step #20. 23. Now, remove the ground from the license plate light. Describe what the circuit is doing now. 24. Measure the voltage drops across the following lights : A. Left rear marker light B. Left rear tail light C. Left backup light 25. Explain what has caused the difference in circuit performance with the license plate light removed from the circuit. 26. Restore the circuit back to normal by removing the backup light from the circuit and confirm proper operation. 27. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 88 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 3 Assignment Instructors Answer Key (3 pages) 6. A 13.27 V ± B 13.25 V ± C 2.078 A or 2,078 mA ± D 0.320 A or 320 mA ± E 0.014 A or 14.31 mA ± 7. LED lights draw much less current than incandescent lights and are able to be of a higher brilliance. 8. A 13.78 V ± B 13.78 V ± 9. Because this is a “ground switched” relay, when the relay is not energized. there will be full B+ voltage available at terminals #86 and #85 of the relay. As soon as the circuit switch is closed, the voltage on terminal #85 will drop to zero indicating the relay coil is now energized. 10. A fused jumper wire can be used to test the relay and circuit without the need of the switch to operate. By con- necting the jumper wire to ground and touching terminal #85, the relay should operate the same as if the switch was closed. Fused jumper wires are a great tool to be used in diagnosis. 11. Parallel. 12. Only the right front side marker light would not operate. 13. The entire circuit would not operate because the relay coil would have an open circuit. 14. The right rear tail light & right rear side marker light would not operate due to the open ground. 15. All right side front and rear marker, tail and park lights would not operate due to the open fuse. 16. The relay and thus the entire tail-park circuit would stay on all the time. 17. Fuse #7 would open due to the short circuit and the entire left side of the lighting circuit would be inoperative. consulab.com info@consulab.com 89 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) 20. Backup light is on and left rear side marker light, license plate light and left rear tail light are off. 21. A 1.46 V ± B 1.45 V ± C 1.44 V ± D 11.83 V ± 22. The backup light was connected in series with left rear side marker, left rear tail and license plate light. The performance of all bulbs in this “series/parallel” branch are affected by the added resistance. The left rear marker light, left tail light and license plate are still in parallel with each other, but current has to flow through the backup light before it gets to them. Because the backup lights higher resistance caused a voltage drop of 12.31 V, there was only 1.30 V left in the parallel branch to operate the remaining three lights. This condition in a real vehicle could be caused from corroded wiring or connectors and is a “real world” problem. This would be a good opportunity to instruct your students on the disadvantage of testing “open circuit” voltage as a means of diagnosis. If they remove the wire from the backup light to the left rear side marker light and test the voltage on that wire to ground, it will read source voltage even though it is flowing through the backup light. The schematic for this faulted circuit is shown below: 23. With the ground wire from the license plate light disconnected, the left rear marker, left rear tail light and li- cense plate light now operate but more dim than normal. 24. A 7.21 V ± B 7.22 V ± C 6.10 V ± consulab.com info@consulab.com 90 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) 25. The left rear marker and left tail lights now operate but dimmer than normal. This is because the license plate bulb is no longer in the circuit. the license plate bulb draws about 0.603 A or 603 mA and thus “draws” the majority of available current from the circuit. Eliminating that bulb, now supplies more current available to the left rear marker and left rear tail light even though current is still flowing through the backup light which causes the marker and tail lights to be dimmer than normal. It is possible to “mathematically” prove out these circuit performance characteristics if instructors feels it would benefit their students. They would have to have the voltage drop and current flow through each bulb, then using Ohm’s Law, calculate the dynamic resistance of each bulb. It would prove why the lights are operating as they do in the two circuit versions. The schematic for this faulted circuit is shown below: consulab.com info@consulab.com 91 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 92 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-6 — Tail-Park Lights Circuit (Ground Switched) CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) consulab.com info@consulab.com 93 SA-7 — Tail-Park Lights Circuit (Positive Switched) Circuit Explanation All vehicles today use a TAIL-PARK lights circuit. It is designed to give notice to nearby vehicles that the vehicle is pres- ent. Some manufacturers use different names for this circuit. Other totally proper names that are used can be : RUNNING LIGHTS, CLEARANCE LIGHTS and others. NHTSA (National Highway Traffic Safety Association) have laws and require- ments involving vehicle lighting circuits. Most all current vehicles today must have amber colored park lights at the left and right side at the front of the vehicle and also amber colored side lights at both the left and right side of the vehicles front end. The rear of the vehicle must have a red colored tail light at both the left and right side as well as a red col- ored side lights at each side of the rear of the vehicle. Tail-park light circuits can be controlled many different ways. Some vehicles use common manual light switches, while others use some variation of “automatic” lighting switching. Most of todays vehicles use CAN Bus circuits to control the lights which allows the turning ON and OFF of vehicle lighting circuits without actual operation of a switch. This feature is utilized for security systems, vehicle locking system, keyless fob lighting control, timer circuits and many others. There are many different types of lighting circuits used on vehicles. Some can be “positive” switched while other are “ground” switched. The only difference is what circuit (positive or ground) contains the switching controls. In this assignment, you will learn how the “positive switched” circuit differs from the “ground switched” option. Tail-Park Lichts Circuit On the CL-1918-4 trainer, it is possible to use either a positive or ground switched tail-park lights circuit. The 3-page OEM wiring diagram uses the “positive switched” method. Tail-Park Circuit (Included OEM Schematic) Power Switched : Power from fuse F1 connects terminal #30 of relay #3 and continues on to the COM terminal of the multi-function switch. When the PARK lights are selected, power flows out of the multi-function switch on the PARK terminal which con- nects to terminal #86 of relay #3. Terminal #87 of relay #3 connects to fuse F7 & F8 which power the right park lights (F8) and left park lights (F7) Tail-Park Lights Low Current Control Circuit The low current control circuit for the tail-park lights consists of the relay coil of Relay #3 (PARK-TAIL LAMPS). Terminal #85 is connected to system ground. Terminal #86 is connected to the PARK terminal of the multi-function light switch. If the light switch is turned ON to the PARK position, B+ voltage is sent to terminal #86 of relay #3 which in turn caus- es relay to energize which connects terminals #30 to #87. This is a power-switched circuit. The COM terminal of the multi-function switch is connected to B+ from terminal #30 of relay #3. CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) consulab.com info@consulab.com 94 NOTE : CIRCUIT FUNCTION FROM THIS POINT BELOW IS THE SAME AS WITH THE GROUND SWITCHED CIRCUIT. Tail-Park Lights High Current Circuit : The high current circuit for the tail-park lights starts at terminal #30 of relay #3. When the relay is energized by the multi-function switch, power from terminal #30 is connected to terminal #87 which is then connected to the power side of both fuses #7(10A) and #8(10A). Left-Side Tail & Park Lights Fuse #7 connects to the left front marker light and with additional wires to the left-front park light. Another wire con- nects from the left front marker light to the left-rear marker light. Other wires then connect the left-rear tail and license plate light. Ground wires are connected from all of these lights to the common ground bus on the left side of the trainer. Right-Side Tail & Park Lights Fuse #8 connects to the right-front marker light and will additional wires to the right-front park light. Another wire connects from the right front marker light to the right rear marker light. Other wires then connect the right rear tail light. Ground wires are connected from all of these lights to the common ground bus on the left side of the trainer. It is intentional to keep the left and right circuit sides electrically separate. VARIATIONS : It is acknowledged that there are many other methods of safely connecting the tail and park lights in a circuit. For purposes of reference and to as closely as possible match typical vehicle configurations, it is preferred to follow the included 4-page OEM type wiring diagram when constructing this circuit. consulab.com info@consulab.com 95 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Tail-Park Lights Circuit (Positive Switched) Circuit Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) — LOAD SIDE Connected to the B+ bus on the right side and to terminals #30 & of relay # 3 and the COM terminal of the light switch section of the multi-function switch. FUSE #7 (10A) — POWER SIDE Connected to terminal #87 of relay #3 on the supply side and provides B+ voltage when relay #3 is energized. FUSE #7 (10A) — LOAD SIDE Connected to the left front side marker light. There will be B+ available only when relay #3 is energized. This is what “starts” the feed to all tail and park lights on the left side of the vehicle. FUSE #8 (10A) — POWER SIDE Connected to terminal #87 of relay #3 on the supply side and provides B+ voltage when relay #3 is energized. FUSE #8 (10A) — LOAD SIDE Connected to the right front side marker light. There will be B+ available only when relay #3 is energized. This is what “starts” the feed to all tail and park lights on the right side of the vehicle. RELAY #3 TERMINAL #86- Connected to the PARK terminal of the multi-function switch and provides B+ power to energize relay #3 when the light switch is put into the PARK position. TERMINAL #85- Connected system ground and provides a ground path for relay #3 coil. TERMINAL #30- Connected to fuse # 1 and provides B+ voltage at all times to this terminal and the COM terminal of the light switch. TERMINAL #87- Terminal #87 is connected to both fuses #7 and #8 on the power side. When relay #3 is energized, B+ voltage is directed to the tail-park lights with fuse #7 protecting the left side and fuse #8 protecting the right side. TERMINAL #87a- Not used in this circuit. consulab.com info@consulab.com 96 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) MULTI-FUNCTION SWITCH PARK TERMINAL- Connected to terminal #86 of relay #3. When the light switch is in the PARK position, B+ voltage is sent to the relay coil terminal #86 and energizes the coil, thus turning on the tail-park circuit. COM TERMINAL- Connected to terminal #30 of relay #30 which is a junction connection back to fuse #1 which provides constant B+ voltage. FRONT LEFT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the load side of fuse #7 and is the start of the B+ feed to all left side park and tail lights when relay #3 is energized. 2ND TERMINAL- Connected to system ground and to the ground terminal of the left park-turn light. FRONT LEFT PARK LIGHT GND TERMINAL- Connected to system ground and provides the ground for the left park light. PARK TERMINAL- Connected to the left front marker light and is the source of B+ voltage when the park lights are turned on. There is also a connection from here to the left rear side marker light to supply B+ to the rear of the vehicle. FRONT RIGHT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the load side of fuse #8 and is the start of the B+ feed to all right side park and tail lights when relay #3 is energized. 2ND TERMINAL- Connected to system ground and provides the ground for the right park light. FRONT RIGHT PARK LIGHT GND TERMINAL- Connected to system ground and provides the ground for the right park light. PARK TERMINAL- Connected to the right front marker light and is the source of B+ voltage when the park lights are turned on. There is also a connection from here to the right rear side marker light to supply B+ to the rear of the vehicle. REAR LEFT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the front left marker light and connects B+ voltage to the tail and marker lights for the rear left of the vehicle. 2ND TERMINAL- Connected to system ground and provides the ground for the left rear marker light. consulab.com info@consulab.com 97 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) REAR LEFT TAIL LIGHT GND TERMINAL- Connected to system ground and provides the ground circuit for the left rear tail light. TAIL TERMINAL- Connected to the left rear marker light and the license plate positive terminal. This is the supply of B+ voltage to the left rear tail and license plate light. LICENSE PLATE LIGHT 1ST TERMINAL- Connected to the left rear tail light. This is the supply of B+ voltage for the license plate light. 2ND TERMINAL- Connected to system ground and provides the ground path for the license plate light. RIGHT REAR TAIL LIGHT GND TERMINAL- Connected to system ground and provides the ground circuit for the right rear tail light. TAIL TERMINAL- Connected to the right rear marker light and is the source of B+ voltage to operate the right rear tail light. REAR RIGHT SIDE MARKER LIGHT 1ST TERMINAL- Connected to the right front side marker light and is the source of B+ voltage for the right rear tail and side marker lights. 2ND TERMINAL- Connected to system ground and provides the ground for the right rear marker light. GROUND CIRCUITS The tail-park light circuits have the following ground circuits: 1. Terminal #85 of relay #3 is the ground path for the relay. 2. Each of the side marker lights for the front and rear, left and right of the vehicle each have their own dedicated ground circuit. The circuit is designed that way for the possible insertion by instructors of unwanted resistance which would affect circuit performance. This enhances the learning opportunities. 3. The left and right front park lights are connected to system ground by their GND terminals. 4. The left and right rear tail lights are connected to system ground by their GND terminals. 5. The license plate light is connected to system ground by one of the light terminals. 6. The top Moduponent™ panel is connected to system ground by a black jumper wire connected to the middle Moduponent panel. 7. The bottom Moduponent™ panel is connected to system ground by a black jumper wire connected to the middle Moduponent™ panel. CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) consulab.com info@consulab.com 98 SA-7 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 positive switched wiring schematic that your instructor has assigned for the TAIL-PARK LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the tail-park lights components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right front marker light. B. Voltage drop across the left rear tail light. C. Total tail-park lights circuit current draw. 7. With the tail-park lights turned OFF, make the following voltage measurements : A. Voltage available at terminal #86 of relay #3 to ground. B. Voltage available at terminal #85 of relay #3 to ground. 8. Explain why there is not voltage available on both sides of the relay coil ? 9. Are tail-park lights typically connected in series or in parallel on most vehicles ? 10. What would happen to the circuit if the right front marker light bulb was burned out ? 11. What would happen to the tail-park circuit if there was an open in the wire from terminal #85 of relay #3 and ground ? 12. What would happen to the circuit if the wire between the right hand rear tail light GND terminal and system ground were open ? 13. What would happen to the circuit if fuse #8 were open ? 14. What would happen to the circuit if there was a constant short in the multi-function switch between the PARK and COM terminals ? 15. What would happen to the circuit if there was a short between POS and GND of the license plate light ? 16. Describe the difference between the ground switched and power switched TAIL-PARK light circuits. 17. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 99 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 1 / Level 2 Assignment Instructors Answer Key CIRCUIT MEASUREMENTS: (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V) 6. A 13.29 Volts ± B 13.27 Volts ± C 2.07 A or 2,075mA ± 7. A 0 Volts B 0 Volts 8. Because this is a “positive switched” circuit, terminal #85 is constantly connected to system ground and if the circuit is turned OFF, there will no voltage on terminal #86 either. 9. Parallel. 10. Because the lights are connected in parallel, only that light would be out. All others would still operate. 11. Because relay terminal #85 is connected to ground, an open in this circuit would not allow the relay to operate and thus, the entire Tail-Park circuit would not function. 12. The right rear tail and side marker lights would be inoperative. 13. Because fuse #8 feeds the right side of the vehicle, all lights on the right side would be inperative. 14. Because the COM terminal is fed from a constant supply of B+ from fuse #1 through, the tail-park lighs would be on continuously. 15. The short would cause fuse #7 to open which would result in the entire left side of the vehicles tail-park lights to be inoperative. 16. The only difference between ground switched and positive switched circuits is which terminal of the coil is switched on and off by the light switch. In a positive switched circuit, terminal #86 of the relay is switched on and off. In a ground switched circuit, terminal #85 is switched to ground to operate the circuit. The “controlled” half of both circuits are identical. It’s only in the “control” portion of the circuit that differences occur. consulab.com info@consulab.com 100 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 101 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) consulab.com info@consulab.com 102 SA-7 — Level 3 Assignment (2 pages) 1. Fill out level 3 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the tail-park lights components. NOTE- There are many components in this circuit. Be sure you spend suffi- cient time studying the circuit to determine the correct hookup of each component. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Explain the differences between a ground switched and positive switched tail-park circuit. Define what components are wired differently. 7. You are diagnosing a non-functional positive switched tail-park circuit PROBLEM DESCRIPTION : When you turn the light switch to the PARK position, no lights function. You have a voltmeter available for diagnosis. Answer the questions below : A. What is the very first component you should test ? B. How would you test the item in item A ? C. After testing the item in step A, where would go next ? D. Explain how to temporarily bypass the light switch for diagnostic purposes. E. Explain how to make the relay operate without the need of the PARK switch input. 8. The relay for the tail-park circuit does not operate. List the steps in the order you would use to diagnose this prob- lem. Use letters (A, B, C, D, etc) for your steps. Be as detailed as possible. 9. With the tail-park switch turned off, what should the voltage reading at terminal #86 of relay #3 be ? 10. With the tail-park switch turned on, what should the voltage reading at terminal #87 of relay #3 be ? 11. You are checking for voltage on terminal #30 of relay #3 and the reading is zero. What are two things that could be wrong ? CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) consulab.com info@consulab.com 103 12. With the circuit turned OFF and using the below schematic, modify the circuit to insert the right backup light bulb in series with the circuit. REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date FROM RIGHT FRONT MARKER LIGHT 13. Turn the circuit on and describe the operation of the right rear tail and side marker light. 14. Make voltage measurements between the following points : A. E to A B. E to B C. A to B D. A to C E. E to D 15. What did the reading of E to A tell you ? 16. What did the reading of E to B tell you ? 17. What did the reading of A to B tell you ? 18. What did the reading of A to C tell you ? 19. What did the reading of E to D tell you ? 20. Using a jumper wire, connect terminal D of side marker light to terminal A of backup light. Describe what happened to the circuit and why. 21. Describe a “real-world” cause of the condition you have described for this circuit modification. 22. Restore the circuit to its original operating condition. 23. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 104 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 3 Assignment Instructors Answer Key (2 pages) CIRCUIT MEASUREMENTS: (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73V) 6. 13.68 V ±. A ground switched circuit will have the circuit switch located in the ground side of the relay coil circuit. A positive switched circuit will have the circuit switch in the positive side of the relay coil circuit. 7. A Check for voltage on both sides of fuse #1. B Check for voltage to ground on both the power supply side and the load side of the fuse. Missing voltage on either side indicates either a supply voltage problem or an open fuse. C Terminal #30 or relay #3 to check to voltage available at this point. D Using a fused jumper wire, jump from the light switch COM to PARK to see if the lights come on OR It is possi- ble to use a fused jumper wire and jump between terminal #30 and #87 of relay #3 to confirm lights operation. E Using a fused jumper wire, jump from the load side of fuse #1 to terminal #86 of relay #3. The lights should operate if the relay and fuse #1 are good, the ground circuit on terminal #85 is good and if there is good connec- tions between the relay #87 terminal and all the lights. 8. (USE BACK OF ANSWER SHEET IF MORE SPACE IS NEEDED) A Check for voltage at terminals #30 (if not, fuse #1 or circuit connections are defective). B Check for voltage at the COM terminal of the light switch (if not, broken circuit between relay #30 and light switch). C Turn on light switch and check for voltage at the PARK terminal (if not, light switch is defective). D With light switch turned on check for voltage at terminal #86 of relay #3 (if not, broken wire). E If voltage is at terminal #86 of relay #3 and the relay doesn’t work. Temporarily create a known good circuit to ground on terminal #85 of relay #3. If relay works, there is a bad ground circuit. If relay doesn’t work, relay is defective. F With light switch on and relay energized, check for voltage at terminal #87 of relay #3 (if not, relay is defec- tive) (if yes, check for voltage at the power side of both fuses #7 and #8 (if not, broken wire) (if yes, check for voltage on load side of fuses #7 & #8 (if no, fuse(s) are blown) (if yes, go to step G). consulab.com info@consulab.com 105 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) G Check for voltage at left and right front marker lights (if not, broken wires) (if yes, continue checking for volt- ages at all tail-park lights and repair open circuits as discovered. H If voltages are available, check all ground circuits for opens and disconnected wires. 9. Zero Volts. 10. System voltage is 13.02 Volts ±. 11. 1- Fuse #1 is either open or not being connected to B+ bus. 2- Broken wire or connection between load side of fuse #1 and terminal #30 of relay #3. 13. Right side marker light is on but dimmer than normal and right rear tail light is barely on and right backup light is on but dimmer than normal. 14. A 13.01 Volts ± B 6.85 Volts ± C 6.14 Volts ± D 13.01 Volts ± E 6.85 Volts ± 15. That full B+ voltage is available at this testing point. 16. There is some unwanted resistance between test points A and B. (voltage drop of backup light) 17. This measurement is the voltage drop across the unwanted resistance. (back up light) 18. You are measuring B+ to Ground which equals full system voltage while circuit is ON. 19. Available voltage to operate the right left side marker light. (6.85V ±) 20. Installing the jumper bypassed the unwanted resistance and the right rear lights operate normally. 21. This condition is usually caused from corroded wires, connections or poor connections to either the positive or ground side of the affected circuit. Temporarily “overlaying” the suspect circuit with a fused jumper wire is a good method of confirming the location of the problem before disassembling any component or wiring harness. consulab.com info@consulab.com 106 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 3 Student Assignment Modification Schematic From Right Front Marker Light AB C D E consulab.com info@consulab.com 107 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 108 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-7 — Tail-Park Lights Circuit (Positive Switched) CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit consulab.com info@consulab.com 109 SA-8 — Turn Signal Circuit Circuit Explanation The TURN SIGNAL circuit on vehicles is used to warn nearby vehicles that the vehicle is going to turn either left or right. Use of turn signals by the driver is required by law in most states and provinces. The turn signals are usually command- ed by the driver. Some newer vehicles can use LED lamps instead of the traditional incandescent bulbs. The CL-1918-4 uses LED lamps for the front and rear turn signal circuit and correct circuit hookup polarity must be followed. If the LED turn signal lights are hooked up backwards, no component or circuit damage will occur. On most vehicles the turn signal lights circuit turns on both the front and rear amber turn signals. Not all vehicles use amber rear turn signals and if not, the left and right red stop lights is used for signaling turns. Most newer vehicles today use amber rear turn signals. The CL-1918-4 turn signal circuit begins with battery power flowing through Fuse #1 (20A) (hot all times) and then con- nects to the BAT terminal of the IGNITION SWITCH. From the IGNITION SWITCH, if the switch in put in the IGNITION position, power flows out of the IGN terminal and into Fuse #4 (10A). If flows out of Fuse #4 where it connects to the BAT terminal of the TURN SIGNAL FLASHER. The other terminals of the TURN SIGNAL FLASHER are SIG (signal) and GND (ground). The SIG terminal is connected to the SIG terminal of the MULTI-FUNCTION SWITCH. The GND terminal is con- nected to system ground. The purpose of the flasher to cause the circuit to come on and off when connected through the SIG terminal through a turn signal light(s) to ground. NOTE : If a 12V test light connected to GROUND was connected to SIG of either the multi-function switch or the turn signal flasher, the flasher would operate. This proves that the SIG circuit is “waiting for a connection to a load, then to ground. If a 12V test light connected to GROUND was connected to SIG of either the multi-function switch or the turn signal flasher, the flasher would operate. This proves that the SIG circuit is waiting for a connection to a load, then to ground. The purpose of the MULTI-FUNCTION switch is to direct the SIG circuit to either the LEFT or RIGHT turn signal bulbs and after the bulb, to a ground circuit. The left and right turn signal circuits are also connected to the LEFT and RIGHT INDICATOR lamps and each has its own ground circuit. The INDICATOR lights inform the driver that the circuit is functioning. CAN Bus circuits can be used with turn signals on some vehicles and not all vehi- cles are identical. The newest of vehicles do not use a turn signal flasher because electronic modules are used instead. In those cases, the normal audible “clicking” of the turn signal flasher can be artificially created by using electronics. NOTE : For purposes of consistency and learning, it is desired when constructing ONLY the turn signal circuit, to only use wires necessary for the operation of that circuit only. It is recognized that there can be inter-connection between the turn and hazard signal circuits, but please keep them separate when wiring these circuit assignments. We believe this will enhance the student learning experience when studying individual circuits. The circuits will be connected to- gether when wiring the entire lighting system. consulab.com info@consulab.com 110 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit SA-8 — Turn Signal Circuit Circuit Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) — LOAD SIDE Protects the ignition switch which feeds fuse #4. The load side of fuse #1 is connected to the ignition switch BAT terminal. The supply side of fuse #1 is connected to the B+ bus and provides B+ voltage at all times. Because fuse #1 is a higher amperage than fuse #4, the only time fuse #1 would “blow” is in the event of a short to ground between fuse #1 and the ignition switch or if the ignition switch became shorted to ground. FUSE #4 (10A) — POWER SIDE Fed from the IGN terminal of the ignition switch and provides B+ power to the turn signal flasher BAT terminal when the ignition switch is turned to the IGN position. FUSE #4 (10A) — LOAD SIDE Connected to the BAT terminal of the turn signal flasher. When the ignition switch is in the IGN position, B+ power is available to the turn signal flasher BAT and SIG terminals. IGNITION SWITCH ACC TERMINAL- Not used in this circuit. IGN TERMINAL- Connected to the power side of fuse #4 and provides B+ voltage to fuse #4 when ignition switch is in the IGN position. START TERMINAL- Not used in this circuit. BAT TERMINAL- Connected to the load side of fuse #1 and provides B+ voltage at all times to the ignition switch. MULTI-FUNCTION SWITCH (TURN SIGNAL PORTION) SIG TERMINAL- Connected to the SiG terminal of the turn signal flasher and B+ voltage is available here at all times (when the ignition switch is in the IGN position). When a connection is made to either left or right by the turn signal switch, pulsing B+ voltage from the flasher is directed to either the left or right turn signal lights. LEFT TERMINAL- The left terminal of the multi-function switch is connected to the left front turn signal light, the left turn indicator light and the left rear turn signal light and operates those lights when the multi-function lever is turned to the “LEFT” position. The turn signal switch connects its SIG terminal to the left terminal when a left hand turn is selected and the turn signal flasher will now flash on and off. consulab.com info@consulab.com 111 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit RIGHT TERMINAL- The right terminal of the multi-function switch is connected to the right front turn signal light, the right turn indicator light and the right rear turn signal light and operates those lights when the multi-function lever is turned to the “RIGHT” position. The turn signal switch connects its SIG terminal to the right terminal when a right hand turn is selected and the turn signal flasher will now flash on and off. TURN SIGNAL FLASHER GND TERMINAL - Connected to system ground by the GND terminal. SIG TERMINAL - Connected to the SIG terminal of the turn signal switch and supplies a constant B+ voltage to the turn signal switch when the ignition switch is in the IGN position. The SIG terminal will begin to pulse on and off when either a left or right hand turn is selected by the turn signal lever switch. When the turn signal switch is not selected, there is constant B+ voltage available at this point. BAT TERMINAL - Connected to the load side of fuse #4 and is the BAT supply circuit to the turn signal flasher. The ignition switch must be in the IGN position for B+ voltage to be available at this terminal. LEFT INDICATOR LIGHT - This LED light is connected to the LEFT terminal of the turn signal switch by the RED terminal and to system ground by the BLACK terminal. Being an LED bulb, correct polarity is important. RIGHT INDICATOR LIGHT - This LED light is connected to the RIGHT terminal of the turn signal switch by the RED terminal and to system ground by the BLACK terminal. Being an LED bulb, correct polarity is important. LEFT FRONT TURN LIGHT TURN TERMINAL - This LED light is connected to the LEFT terminal of the turn signal switch by the RED terminal and supplies B+ voltage to the turn signal light. Being an LED bulb, correct polarity is important. GND TERMINAL - Connected to system ground by the BLACK terminal. Being an LED bulb, correct polarity is important. RIGHT FRONT TURN LIGHT TURN TERMINAL - This LED light is connected to the RIGHT terminal of the turn signal switch by the RED terminal and supplies B+ voltage to the turn signal light. Being an LED bulb, correct polarity is important. GND TERMINAL - Connected to system ground by the BLACK terminal. Being an LED bulb, correct polarity is important. consulab.com info@consulab.com 112 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit LEFT REAR TURN LIGHT TURN TERMINAL- This LED light is connected to the LEFT terminal of the turn signal switch by the RED terminal and supplies B+ voltage to the turn signal light. Being an LED bulb, correct polarity is important. GND TERMINAL - Connected to system ground by the BLACK terminal. Being an LED bulb, correct polarity is important. RIGHT REAR TURN LIGHT TURN TERMINAL - This LED light is connected to the RIGHT terminal of the turn signal switch by the RED terminal and supplies B+ voltage to the turn signal light. Being an LED bulb, correct polarity is important. GND TERMINAL - Connected to system ground by the BLACK terminal. Being an LED bulb, correct polarity is important. GROUND CIRCUITS The turn signal circuit has the following ground circuits: 1. The turn signal flasher is connected to system ground by the BLACK terminal. Ground is needed in order for the flasher to operate. 2. The turn indicator lights (left & right) are connected to system ground by the BLACK terminals. 3. All four front and rear turn signal lights are connected to system ground by the GND terminals at the front turn signal lights and the GND terminals at the rear turn signal lights. NOTE- In reality, the individual ground circuits for each light could be “combined” and often are in vehicle systems, but for the purposes of this circuit, they are individual. This would allow for the insertion of unwanted resistances by instructors for additional student learning purposes. CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit consulab.com info@consulab.com 113 SA-8 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the TURN SIGNAL LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the turn signal lights components. Please connect ONLY the neces- sary wires to operate JUST the turn signal lights circuit and no other circuits. Be sure to use separate ground circuits for the left and right side of the vehicle. Do not combine the grounds together. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TURN SIGNAL LIGHTS circuit. There should be a total of three lights for each LEFT and RIGHT sides. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are the turn signal lights typically connected in series or in parallel on most vehicles ? 7. As an experiment, remove the ground wire from the right front turn signal bulb. What effect did that have on the circuit ? 8. What would happen to the circuit if the right rear turn signal light bulb was burned out ? 9. Measure the voltage available to the turn signal lights flasher at the BAT terminal. 10. What would be the voltage reading from step 9 if fuse #4 were open ? 11. If fuse #4 was confirmed good and the voltage at the BAT terminal of the turn signal flasher was zero, what could be the cause of this condition ? 12. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 114 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit SA-8 — Level 1 / Level 2 Assignment Instructors Answer Key CIRCUIT MEASUREMENTS : (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73V). 6. Parallel. 7. Right front turn signal does not work, but all others would operate normally. 8. Only the right rear turn signal bulb would not work, all others would operate normally. 9. 13.70 - 13.85 VOLTS ± (system voltage) 10. Zero volts. 11. Open wire between fuse #4 and the BAT terminal of the turn signal flasher. consulab.com info@consulab.com 115 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit SA-8 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 116 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit SA-8 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit consulab.com info@consulab.com 117 SA-8 — Level 3 Assignment (2 pages) 1. Fill out level 3 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the turn signal circuit components. NOTE- There are many components in this circuit. Be sure you spend sufficient time studying the circuit to determine the correct hookup of each component. For the purposes of just this assignment please hook up ONLY those wires that have to do with the turn signal circuit even though some others may be shown on schematic. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TURN SIGNALS circuit. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurement and put reading on your answer sheet. Set up your test equipment to measure the current draw of the right front turn signal. NOTE- in order to do this, you will have to separate the right front turn lamp from all other circuits and temporarily connect your ammeter in series with either the ground or the positive side) [if you are using a direct reading amme- ter and supply either a fused power or ground to the right front turn light. Record your reading on the answer sheet. NOTE- You may want to install a jumper wire from any BAT source to the right front turn signal light to allow the light to stay on all the time for easy current measurement. 7. After the measurement in step 6A, restore the entire circuit to normal operation and confirm that it works. 8. Now, using additional red wires, using the below schematic as a reference, connect the coil circuits (terminals #85 & #86) of relays #1 & #2 in SERIES with the wire coming from the RIGHT terminal of the turn signal switch AND the TURN receptacle of the right front turn light. RIGHT #85 #85#86 RELAY #1 RELAY #2 RIGHT FRONT TURN GND #86 9. Double check your connections and turn on the right turn signals. Describe the performance of the circuit. CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit consulab.com info@consulab.com 118 10. Following the same procedure as in step 6, set up the circuit to measure only the current of the modified right front turn lamp. Record your reading on the answer sheet. NOTE- You may want to install a jumper wire from any BAT source to the right front turn signal light to allow the light to stay on all the time for easy current measurement. 11. List your conclusions about why the right front turn signal lamp operated as it did with this modification. 12. With the circuit still modified, turn on the circuit and measure the voltage drop across the coil circuits of relay #1, relay #2 and the right front turn signal lamp. Record your readings on the answer sheet. A. Voltage drop across relay #1 coil circuit ? B. Voltage drop across relay #2 coil circuit ? C. Voltage drop across right front turn signal lamp ? 13. Add up all of the three individual voltage drops and record your answer on answer sheet. 14. What conclusions can you make from the reading in step 13 ? 15. Using a red jumper wire, connect terminals #85 and #86 of relay #1 together and describes what happens to the circuit. 16. Measure the voltage drop across the following components and record your readings : A. Coil circuit of relay #1 B. Coil circuit of relay #2 C. Right front turn signal lamp 17. Describe what effect unwanted resistances will have in a lighting circuit. 18. Describe the best method of diagnosing and locating the exact location of any unwanted resistance. 19. Remove the red wire connected to the TURN receptacle of the right front turn signal lamp that comes from the relay coil circuit. 20. Measure the voltage available from the end of that disconnected wire to ground and record your reading on answer sheet. 21. Explain the reading obtained in step 20. What conclusions can you make from this step regarding checking voltage drop across any electrical device ? 22. Remove all of your circuit modifications and restore the circuit back to normal functionality. Confirm that it works properly. 23. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 119 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit SA-8 — Level 3 Assignment Instructors Answer Key (2 pages) CIRCUIT MEASUREMENTS : (NOTE – ALL MEASUREMENTS MAY VARY BASED ON AVAILABLE VOLTAGE AND INDIVIDU- AL COMPONENT DESIGN TOLERANCES – READINGS SHOULD BE WITHIN 10% OF STATED VALUES – ANSWER SHEET VALUES WERE BASED ON AN UNLOADED VOLTAGE SUPPLY OF 13.73 V±.) 6. .350A - .355A or 350mA -355mA ± 9. Right front turn signal lamp is much dimmer than normal and only a few LED elements are working. 10. .032A - .033A or 32.00mA - 33.00mA ± 11. The extra resistance of the two relay coils in series with the right front LED turn lamp causes a drop in voltage which results in the LED bulb receiving less than its designed voltage resulting in dim illumination and only partial LED elements working. 12. A 2.95 - 3.00 Volts ± B 2.95 - 3.00 Volts ± C 7.60 - 7.70 Volts ± 13. 13.70 - 13.85 Volts ± 14. Normal voltage drop across any electrical device should be very close to source voltage and when it isn’t, there is unwanted resistance somewhere in the circuit. 15. The right front turn lamp got brighter because some of the unwanted resistance that was in series with the lamp was removed. 16. A 0 Volts (because the coil is bypassed with the jumper wire) B 5.3 - 5.5 Volts ± C 8.50 - 8.60 Volts ± 17. Unwanted resistances in any electrical circuit reduce the current flow and can seriously affect circuit operation or cause it to not work at all. consulab.com info@consulab.com 120 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit 18. The only accurate method of locating the exact location of unwanted resistance is to measure across two points in the circuit with a voltmeter. Making multiple measurements along the circuit will pinpoint the exact location of the resistance. 20. 13.70 - 13.75 Volts ± (this is called “open circuit voltage”). 21. The lesson here is to reinforce that when testing for unwanted resistance using voltage drop testing, the circuit must be functioning. Testing “open circuit” voltage is usually a waste of time when attempting to find unwanted resistance as the reading will always be source voltage. ADDITIONAL SUGGESTIONS FOR EXTENDED LEARNING: At this point in the lesson, it’s a great idea to have students experiment with the differences between open circuit volt- age testing (available voltage) and voltage drop testing on a live circuit with and without unwanted resistance. Have them attempt to explain to you why even though there is resistance in the circuit, the reading of open circuit voltage will al- ways equal the source voltage. This is a great time to introduce voltmeter impedance (average 20 million ohms) and why all the extra resistance does not affect circuit readings. Many students and technicians simply do not understand this concept and a successful and efficient technician must be very proficient at performing accurate voltage drop testing. consulab.com info@consulab.com 121 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit SA-8 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 122 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit consulab.com info@consulab.com 123 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-8 — Turn Signal Circuit consulab.com info@consulab.com 124 CL-1918-4S_053304-91 Headlights Circuits Headlights Circuits CL-1918-4S_053304-91 Headlights Circuits consulab.com info@consulab.com 125 Notice Pertaining to CL-1918-4 Headlight Circuits There are countless variations to properly design and build a properly operating headlight circuit on this trainer. The first circuit that will be assigned to students will be Assignment SA-9 “GROUND SWITCHED” option where the headlights are switched on and off using the multi-function switch to control the ground circuits of the relays. It is important to remember that whatever circuit options are used, at no time can any higher current than 1A be passed through the multifunction switch. If this condition is created, either one or both of the 1A replaceable fuses will blow and will need replacing. Headlight circuit designs can include any or all of the following design options : 1. Switch the ground circuits of the headlights 2. Switch the positive circuits of the headlights 3. Switch the ground circuits of the relay coils 4. Switch the positive circuits of the relay coils 5. Using 2, 3 or 4 relays in the headlight circuit Replacement 1A fuse is a T1AH 250V. CL-1918-4S_053304-91 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification consulab.com info@consulab.com 126 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification The multifunction switch on the CL-1918-3I & CL-1918-4 trainer is from an OEM 2007-2010 Hyundai Elantra. It may or may not have the optional fog light switch, but, if equipped, it is not used for this trainer. See below for the schematic of the switch. For purposes of this trainer, the multifunction switch will be used as both a positive and ground switched device for additional student learning. Therefore, using an OEM electrical schematic will not necessarily reflect actual circuit construction. Below is the electrical schematic for the switch. We have added two 1A circuit breakers or two 1A fuses in series with the COM terminals to protect the switch from high current circuits. Therefore, when constructing headlight circuits, the multifunction switch must only control relay coil current and not full headlight bulb current. The circuit breaker will trip or the 1A fuses will blow if more than one amp of current flows through the switch. The circuit breaker is resettable if tripped and the two 1A fuses are replaceable. WARNING- Do not hold down the reset button if tripped. Replacement 1A fuse is a T1AH 250V type. MULTIFUNCTION SWITCH POSITION EXPLANATIONS 1. HEADLIGHT SWITCH OFF – LEFT COM CONNECTED TO LOW – RIGHT COM NOT CONNECTED CL-1918-4S_053304-91 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification consulab.com info@consulab.com 127 2. HEADLIGHT SWITCH TO PARK – LEFT COM TO LOW – RIGHT COM TO PARK 3. HEADLIGHT SWITCH TO HEADLIGHT – LEFT COM TO LOW – RIGHT COM TO PARK & HEAD CL-1918-4S_053304-91 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification consulab.com info@consulab.com 128 4. HEADLIGHTS ON - SWITCH LEVER DOWN TO HIGH – LEFT COM TO HIGH - RIGHT COM TO PARK & HEAD HEADLIGHTS ON LOW – SWITCH UP TO FLASH-TO- PASS LEFT COM TO FLASH & HIGH HEADLIGHTS OFF – SWITCH LEVER UP TO FLASH- TO-PASS LEFT COM TO FLASH & HIGH - RIGHT COM NOT CONNECTED HEADLIGHTS OFF – SWITCH LEVER DOWN TO HIGH LEFT COM TO HIGH - RIGHT COM NOT CONNECTED LEFT COM TO HIGH HEADLIGHTS ON HIGH – SWITCH UP TO FLASH- TO-PASS LEFT COM TO FLASH & HIGH CL-1918-4S_053304-91 Headlights and Plug Explanation consulab.com info@consulab.com 129 Headlights and Plug Explanation BACK OF HEADLIGHT BULB H4656 RED - LOW YELLOW - HIGH BLACK - GND The CL-1918-4 lighting system trainer uses an H4656 sealed beam headlight. The H4656 halogen bulb complies with re- cent changes in DOT specifications regarding candlepower and filament current of headlight bulbs. It was once common that the high beam used higher current than the low beam, but that is no longer the case. The H4656 uses light prisms and refraction in the lense to direct the high beam light source to a higher level off the ground than the low beam fila- ment does. These changes result in a bulb that is very similar in current consumption on low and high beam circuits. The current of the low and high beams can vary between one bulb to another but will be within .5A total. The designed specifications of this bulb are as follows : With an available (unloaded) voltage of 13.83 V, the current draw of each element is : LOW BEAM - 2.80A-2.90A± HIGH BEAM - 2.60A - 2.70A± (Measurements taken with a FlukeTM model 88 multi-meter and each bulb was tested out of the circuit by itself) actual “in-circuit” readings might vary with changes in system voltage and how many bulbs are in the circuit.) The important factor here is to know that this bulb (and many others) uses a lower amperage “high beam” filament, but the prism de- sign inside the bulb results in a beam that is focused higher than the low beam. CL-1918-4S_053304-91 SA-9 — Headlights Circuit (Ground Switched) consulab.com info@consulab.com 130 SA-9 — Headlights Circuit (Ground Switched) Circuit Design and Operation : The headlights circuit on vehicles is used to illuminate the area in front of the vehicle so that the driver can safely see during periods of darkness, fog or low-light situations. Some vehicles also turn the headlights on (or at a reduced bright- ness) during the daytime to warn oncoming vehicles that the vehicle is in the area. Headlights on today’s vehicles come in many different types, designs, styles and control circuits. Some use (LED, Halide, incandescent, projection beam, halo, HID and xenon. Headlight systems and circuits have changed dramatically in recent years. Some components are very, very expensive and diagnosis and repair can be a high-technician level requiring special tools and equipment. Because of the above statements, the CL-1918-4 trainer uses a basic incandescent Wagner H4656 halogen sealed beam headlight system. The components used on the trainer allow the headlight circuit to be set up using many different wiring options. Students can construct the headlight circuit using ground-switched or positive switched options. With the CL- 1918-4, it is absolutely necessary to construct all headlight circuits to be controlled by relays. NEVER attempt to direct full headlight current through the multi-function switch. If this is attempted, the 1 amp protection fuse will blow. (NOTE- The protection devices are there to protect the multifunction switch contacts from excessive current). NOTE : Replace- ment 1A fuse is a T1AH 250V. NOTE : IT IS ADVISABLE TO HAVE YOUR STUDENTS READ THE EXPLANATION OF HOW THE MULTI-FUNCTION SWITCH IS WIRED AND CONNECTED INTERNALLY SO THEY WILL UNDERSTAND HOW IT CONTROLS THE PARK & HEAD LIGHTS. For purposes of educational continuity, the first headlight circuit that will be discussed will be a ground-switched circuit using two relays. Later on in this curriculum, students will be asked to build headlight circuits using other design varia- tions. Ground Switched Headlights : Circuit Description Power for the headlight circuit is obtained from Fuse #1 (20A) and connects to both COM terminals of the left and right headlights. Fuse #2 (15A) feeds terminals #86 of relays #1, #2 & #3 for the coil circuits and also to the RED terminal of the HIGH BEAM INDICATOR light. This fuse supplies B+ to all relay coils. Terminal #85 of relay #3 connects to FLASH terminal of the multifunction switch. Terminal #85 of relay #2 connects to the HEAD terminal of the multifunction switch. Terminal #85 of relay #1 connects HIGH terminal of the multifunction switch. The two COM terminals of the multifunc- tion switch both connect to system ground. Therefore, the multifunction switch controls relays #1, #2 and #3 coils ground circuits . Terminal #87 of relay #1 connects to the HIGH terminal of both the left and right hand headlights. Ter- minal #87a of relay #1 is connected to both LOW terminals of the left and right hand headlights. Terminal #30 of relay #1 is connected to terminal #87 of relay #2. The trainers top panel ground is connected to the middle panel ground with a jumper wire. Terminal #87 of relay #3 is connected to system ground. Terminal #30 of relay #3 is connected to terminal #87 of relay #1. The black wire of the HIGH BEAM INDICATOR connects to the HIGH terminal of the lefthand headlight. CL-1918-4S_053304-91 SA-9 — Headlights Circuit (Ground Switched) consulab.com info@consulab.com 131 LOW BEAM OPERATION -When the multifunction switch is moved to HEAD from the PARK position, the right-hand COM terminal of the multifunction switch is connected to the HEAD terminal which grounds the coil of relay #2 by providing a ground path and the relay turns on. With relay #2 on, terminals #30 and #87 of relay #2 are now connected. Termi- nal #87 of relay #2 is connected to the terminal #30 of relay #1. Because relay #1 if off, terminals #30 and #87a are connected with turns on the LOW beam headlights. Power flows from Fuse F1, to both headlight COM terminals, then through the LOW beam filaments to terminal #87a to terminal #30 of relay #1, then to terminal #87 and #30 of relay #2, then to system ground through terminal #30 of relay #2. The LOW terminal of the multifunction switch is not needed with this circuit design. HIGH BEAM OPERATION - When the multifunction switch is moved to HIGH, relay #1 is turned on by the connection of the left-hand multifunction switch COM to HIGH providing a ground circuit for relay #1 coil and relay #2 remains on because the right-hand COM to HEAD terminals are still connected. With both relays #1 and #2 on, the headlight HIGH beam ground circuit is from terminal #30 of relay #1 to terminal #87 of relay #1 which grounds both HIGH terminals of the right-hand headlight, over to the left-hand headlight HIGH terminal and also to the black terminal of the HIGH BEAM INDICATOR and it now turns on. This circuit controls the headlight ground circuits using relays #1 and #2. FLASH TO PASS OPERATION Whether the multi-function switch is on or off in any position, pulling the switch stalk towards you (UP) will connect the multifunction switch left-hand COM to HIGH and FLASH terminals which will turn on relay #3 and the HIGH BEAM head- lights will stay on as long as the stalk is kept “UP”. Relay #3 when on connects terminals #30 to #87 which completes the HIGH beam ground circuit through relay #1 terminals #30 to #87. Pushing the stalk downward (DOWN) connects multifunction switch terminals left-hand COM to HIGH which again turns on relay #3 and HIGH beam headlights are now on. This function will operate regardless of whether the light switch is on or off. NOTE : Some car manufacturers will turn off the LOW beam headlights when the HIGH beams are selected while others turn both LOW and HIGH beams on at the same time when HIGH is selected. Other circuit assignments in this curriculum will instruct students to build headlight circuit with many different design options. This headlight circuit design controls the ground circuits of the relay coils for relays #1, #2 and #3. The multifunction switch completes the relay coil ground circuits when LOW, HIGH and FLASH-TO-PASS circuits are selected. Relays #1 and #2 control the high current consumed by the LOW and HIGH beam headlights. Only relay coil current is directed through the multifunction switch. consulab.com info@consulab.com 132 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) SA-9 — Headlights Circuits (Ground Switched) Circuit Explanation Instructors Answer Key (3 pages) FUSE #1 — LOAD SIDE Connected to the COM terminals of both left and right headlights. This fuse provides B+ power for the headlights. FUSE #2 — LOAD SIDE Connected to terminals #86 of relays #1, #2 and #3 and the red terminal of the HIGH BEAM INDICATOR. This circuit supplies B+ to all relay coils and HIGH BEAM INDICATOR. LEFT HEAD LIGHT HIGH TERMINAL - Connected to the right-side headlight HIGH terminal, the black terminal of the HIGH BEAM INDICATOR and terminal #87 of relay #1 COM TERMINAL - Connected to the right-hand headlight COM terminal and also to Fuse F1 LOW TERMINAL - Connected to the right-hand headlight LOW terminal and also to terminal #87a of relay #1 RIGHT SIDE HEAD LIGHT HIGH TERMINAL - Connected to the left-hand side headlight HIGH terminal COM TERMINAL - Connected to the left-hand side headlight COM terminal and also to Fuse F1 LOW TERMINAL - Connected to the left-hand side headlight LOW terminal and also to terminal #87a of relay #1 RELAY #1 TERMINAL #87a - Connected to the LOW beam terminals of both left and right headlights TERMINAL #30 - Connected to terminal #87 of relay #2 TERMINAL #87 - Connected to both right-hand and left-hand headlights HIGH terminals and to the black terminal of the HIGH BEAM INDICATOR and also to terminal #87 of relay #2 TERMINAL #85 - Connected to the HIGH terminal of the multI-function switch TERMINAL #86 - Connected to terminal #86 of relays #2 and #3 and then to Fuse F2. This supplies B+ to all relay coils consulab.com info@consulab.com 133 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) RELAY #2 TERMINAL #87a - Not used in this circuit. TERMINAL #30 - Connected to system ground TERMINAL #87- Connected to terminal #87 of relay #1 TERMINAL #85- Connected to the HEAD terminal of the multi-function switch TERMINAL #86 - Connected to terminals #86 of relays #1 and #3 and then to Fuse F2 for coil B+ power RELAY #3 TERMINAL #87a - Not used in this circuit. TERMINAL #30 - Connected to terminal #87 of relay #1 for FLASH TO PASS circuit turning on HIGH beam headlights TERMINAL #87- Connected to system ground TERMINAL #85- Connected to the FLASH terminal of the multi-function switch TERMINAL #86 - Connected to terminals #86 of relays #1 and #2 and then to Fuse F2 for coil B+ power HIGH BEAM INDICATOR RED TERMINAL- Connected to terminal #86 of relay #2 (B+ power for the indicator light) BLACK TERMINAL - Connected to the HIGH terminal of the lefthand headlight DIMMER SWITCH LOW TERMINAL -Not used in this circuit COM TERMINAL - Connected to system ground HIGH TERMINAL - Connected to terminal #85 of relay #1 and turns on the HIGH beam headlights FLASH TERMINAL - Connected to terminal #85 of relay #3 and turns on the FLASH TO PASS HIGH beam headlights HEADLIGHT SWITCH PARK TERMINAL - Not used in this circuit HEAD TERMINAL - Connected to terminal #85 of relay #2 and turns on the headlights (either HIGH or LOW beams) COM TERMINAL - Connected to system ground consulab.com info@consulab.com 134 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) Circuit Operation Explanation This circuit is a “ground switched” circuit in which both the headlights and the control relays are “ground switched” by the multi-function switch and relays #1, #2 and #3. B+ power from Fuse #1 is available to both COM terminals of left and right-hand headlights. GROUND SWITCHED HEADLIGHTS – CIRCUIT DESCRIPTION : Power for the headlight circuit is obtained from Fuse #1 (20A) and is connected to both COM terminals of both headlights. Fuse #2 (15A) feeds terminals #86 of relays #1, #2 & #3 for the coil circuits and also the HIGH BEAM INDICATOR. Terminal #85 of relay #2 connected to the HEAD terminal of the multifunction switch. Terminal #85 of relay #1 connects to the HIGH terminal of the multifunction switch. The two COM terminals of the multi-function switch are connected to system ground. The LOW terminal of the multi-function switch is not used in this specific circuit. Terminal #87a of relay #1 connects to both LOW beam terminals of the headlights. Terminal #87 of relay #1 connects to the HIGH beam terminal of the left-hand headlight which also connects to the right-hand headlight HIGH terminal. LOW BEAM OPERATION: When the multifunction switch is moved to HEAD, the right-hand COM terminal of the multifunction switch is connected to the HEAD terminal which grounds the coil of relay #2 by providing a ground path through the multi-function switch and relay #2 turns on. With relay #2 on, terminals #30 and #87 of relay #2 are now connected. Both LOW beam headlight terminals are connected to terminal #87a of relay #1. Terminal #30 of relay #1 is connected to terminal #87 of relay #2 and with relay #1 off, the ground circuit for the low beam headlights is completed through terminals #87 and #30 of relay #2 with terminal #30 being connected to system ground and the LOW beam headlights turn on. The multi-function switch LOW terminal is constantly connected to the left-hand COM terminal in LOW beam operation, but is not used in this circuit HIGH BEAM OPERATION: When the multi-function switch is moved to HIGH, relay #1 is turned on by the connection of the left-hand multi-function switch COM to HIGH providing a ground circuit for relay #1 coil and relay #2 remains on because the right-hand COM to HEAD terminals are still connected. With both relays #1 and #2 on, the headlight HIGH beam ground circuit is from the HIGH beam headlights, to terminal #87 of relay #1 to terminal #30 of relay #1 and to terminal #87 of relay #2, out of relay #2 from terminal #30 and to system ground. The HIGH BEAM INDICATOR ground is also connected to the left-hand headlight HIGH terminal and the indicator light turns on. Relay #1 controls the LOW and HIGH circuits and relay #2 turns the headlight on. consulab.com info@consulab.com 135 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) FLASH TO PASS OPERATION: Whether the multi-function switch is on or off in any position, pulling the switch stalk towards you will connect the multifunction switch left-hand COM to HIGH terminal. This will turn on relay #3 which operates the HIGH beam headlights. HIGH ground circuit is from HIGH beam headlight terminal to terminal #87 of relay #1 to terminal #30 of relay #3, and with relay #3 now on, connection between terminals #87 and #30 of relay #3 is made connecting to system ground. Pushing the switch stalk down will connect multi-function switch left-hand COM to HIGH/FLASH which will again turn on relay #3 and the high beam headlights will operate. (See multi-function switch explanation diagram) CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) consulab.com info@consulab.com 136 SA-9 — Level1 / Level 2 Assignment 1. Fill out Level 1 or 2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment you were assigned by the instructor. Put the answers to all questions on this sheet. DO NOT WRITE ON THIS PAPER. 2. Make sure the trainer is properly connected to a 120V power supply and is turned OFF. 3. Obtain a Level 1 or Level 2 wiring schematic that your instructor has assigned for the correct operation of the SA-9 HEADLIGHTS CIRCUIT (GROUND SWITCHED). Using the schematic, properly connect red and black jumper wires to all components necessary for this circuit. NOTE- At this time do not connect any PARK or TAIL-LIGHTS to the circuit. ONLY the headlights. 4. Obtain instructors check at this point. 5. With instructor’s permission, turn on the power supply for the trainer and confirm the correct operation of the headlight circuit including : LOW and HIGH BEAMS, FLASH-TO-PASS and HIGH BEAM INDICATOR. If any portion of the circuit does not function correctly, go back over your work to find and correct the wiring errors. 6. Once the circuit is functioning properly, and with the headlights circuit OFF, make the following voltage measure- ments to ground where indicated and put your readings on the answer sheet. A. Voltage at terminal #86 of relay #1 B. Voltage at terminal #85 of relay #1 (Why is there voltage at both terminal #86 & #85 of relay #1 ?) C. Voltage at terminal #87 of relay #3 D. Voltage at terminal #85 of relay #3 7. What conclusions can you make from the above measurements regarding how this headlight circuit operates ? 8. With the headlights switched to LOW beam, measure the voltage between left headlight terminals COM and LOW. 9. Switch the circuit to HIGH beams. Make the following voltage measurements : A. Black voltmeter lead on to the HIGH terminal of the left headlight. B. Red voltmeter lead to the COM terminal of the left headlight. C. Measure the voltage of the HIGH beam headlights now D. What conclusions can you make when evaluating these two voltage (LOW and HIGH) measurements ? 10. By looking at a wall or flat surface in front of the headlights on the trainer, do the HIGH beam headlights appear to be located at a “higher” distance from the ground that the LOW beam headlights ? 11. With headlights turned OFF, use a black jumper wire and connect terminal #85 of relay #3 to system ground. What happens ? Why ? 12. Obtain final check from your instructor, confirm that all answers have been completed and turn in your answer sheet. NOTE- If instructed to do so, disconnect and return all wires to their storage place, turn off the trainer and unplug power cord from wall outlet. consulab.com info@consulab.com 137 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) SA-9 — Level1 / Level 2 Assignment Instructors Answer Key (2 pages) 4. INSTRUCTORS CHECK OF PROPER CIRCUIT WIRING & PERFORMANCE YOUR CHECK HERE 5. Did the FLASH-TO-PASS circuit operate properly? YES or NO 6. A 13.81 Volts ± between terminal #86 of relay #1 and ground. B 13.81 Volts ± between terminal #85 of relay #1 and ground. Answer: Relay #1 terminal #85 is not connected to ground because the relay is turned off. This test also confirms that the relay’s coil has continuity. C 0.00 Volts ± between terminal #87 of relay #3 and ground. Answer: Because relay #3 is off, there is no voltage on terminal #87 to ground. D 13.80 Volts ± between terminal #85 of relay #3 and ground. Answer: Relay #3 terminal #85 is not connected to ground because the relay is turned off. This test also confirms that the relay’s coil has continuity. 7. This circuit is “ground switched” by the multi-function switch controlling the ground circuits of all three relay’s. 8. 11.69 Volts ± between left headlight terminals COM and LOW. Voltage being measured is the voltage drop of both left and right hand low beam headlights 9. C 11.68 V ±. Explanation: voltage being measured is the voltage drop of both left and right high beam headlights D Conclusions: both low & high beam headlights draw close to the same amount of current because the voltage drops across both high and low beams are similar 10. Yes or No 11. the jumper wire grounds the coil of relay #3 and it turns on which causes the high beam headlights to come on. What happened? The high beam headlights came on as this is the FLASH-TO-PASS circuit relay. Why? The ground wire replaces the multi-function switch and temporarily tests the FLASH-TO-PASS circuit which turns on the HIGH beam headlights consulab.com info@consulab.com 138 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) SA-9 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 139 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) SA-9 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) consulab.com info@consulab.com 140 SA-9 — Level 3 Assignment (2 Pages) 1. Fill out the SA-9 Level 3 student answer sheet with name, class and date information. Put all answers to these ques- tions on the student answer sheet. DO NOT WRITE ON THIS PAPER. 2. Make sure trainer is properly connected to a 120 outlet and that the trainers power supply is turned OFF. 3. Obtain a Level 3 blank schematic (3 pages) and after studying the circuit components, draw in the red (positive) and black (negative) wires to correctly construct the ground switched headlight circuit. Following your schematic, cor- rectly connect red and black wires to the headlight components. 4. Obtain instructors check. 5. With instructors permission, turn on the trainer power supply and confirm correct operation of the HEADLIGHTS cir- cuit. Confirm that LOW, HIGH and FLASH-TO-PASS circuits all work properly. If any circuit does not operate correct- ly, go back over your work to find and correct your errors. 6. Once circuit is operating properly, and with the headlights OFF, make the following voltage measurements to system ground and put readings on your answer sheet. A. Voltage at terminal #86 of relay #1 B. Voltage at terminal #85 of relay #1 (Why is there voltage at both terminal #86 & #85 of relay #1 ?) C. Voltage at terminal #87 of relay #3 D. Voltage at terminal #85 of relay #3 7. What conclusions can you make from the above measurements regarding how this headlight circuit operates ? 8. With the headlights switched to LOW beam, measure the voltage between left headlight terminals COM and LOW. 9. Switch the circuit to HIGH beam A. Black voltmeter lead on to the HIGH terminal of the left headlight. B. Red voltmeter lead to the COM terminal of the left headlight. C. Measure the voltage of the HIGH beam headlights now. D. What conclusions can you make when evaluating these two voltage (LOW and HIGH) measurements ? 10. By looking at a wall or flat surface in front of the headlights on the trainer, do the HIGH beam headlights appear to be located at a “higher” distance from the ground that the LOW beam headlights. CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) consulab.com info@consulab.com 141 11. Properly make the indicated measurements below and record your readings on the answer sheet. A. Current draw of JUST the right headlight on LOW beam. B. Current draw of JUST the left headlight on LOW beam. C. Current draw of JUST the right leadlight on HIGH beam. D. Current draw of JUST the left headlight on HIGH beam. E. What conclusions can you make regarding the current draw of the HIGH and LOW beams ? F. Current draw of JUST the HIGH BEAM INDICATOR light ? G. Current draw of JUST the coil control current of relay #3. 12. With headlights turned OFF, use a black jumper wire and connect terminal #85 of relay #3 to system ground. What happens ? Why ? 13. Measure the voltage drop across relay #3 contacts with the HIGH beam headlights ON. 14. Obtain final check from your instructor, confirm that all answers have been completed and turn in your answer sheet. NOTE- If instructed to do so, disconnect and return all wires to their storage place, turn off the trainer and unplug power cord from wall outlet. consulab.com info@consulab.com 142 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) SA-9 — Level 3 Assignment Instructors Answer Key (2 pages) 4. INSTRUCTORS CHECK OF PROPER CIRCUIT WIRING & PERFORMANCE YOUR CHECK HERE 5. YES or NO 6. A 13.81 Volts ± between terminal #86 of relay #1 and ground. B 13.81 Volts ± between terminal #85 of relay #1 and ground.. Relay #1 terminal #85 is not connected to ground because the relay is turned off. This test also confirms that the relay’s coil has continuity. C 0 Volts ± between terminal #30 of relay #3 and ground. Because relay #3 is off, there is no voltage on terminal #87 D 13.80 Volts ± between terminal #85 of relay #3 and ground. Relay #3 terminal #85 is not connected to ground because the relay is turned off. This test also confirms that the relay’s coil has continuity 7. this circuit is “ground switched” by the multi-function switch controlling the ground circuits of all three relay’s 8. 11.69 Volts ± between left headlight terminals COM and LOW. Voltage being measured is the voltage drop of both left and right low beam headlights. 9. C 11.68 Volts ±. Explanation: voltage being measured is the voltage drop of both left and right high beam head- lights. D Conclusions: because both low & high beam voltage drops are similar, both low & high beam headlights draw close to the same amount of current. 10. A Yes or no Instructors note - your students must correctly connect the ammeter when making the below measurements. Be- cause the circuit is ground switched, it is quite easy to measure the current draw of more than one component at a time. If the readings are vastly different than the key, have them confirm where they connected the ammeter. 11. A 2.916 AMPS ± Current draw of JUST right headlight on LOW beam. B 2.930 AMPS ± Current draw of JUST left headlight on LOW beam. C 2.726 AMPS ± Current draw of JUST right headlight on HIGH beam. D 2.745 AMPS ± Current draw of JUST left headlight on HIGH beam. consulab.com info@consulab.com 143 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) E Conclusions : both low and high beam filaments on this sealed beam bulb both draw a very similar current with the low beam drawing a bit more than the high beam. The difference in the light being displayed “higher” on the wall is done with the glass refraction lenses in the bulb. This performance design is now very common in the vehicles using sealed beam headlights. F 41 milli-amps ± Current draw of the high beam indicator light. G 151.20 milli-amps ± Current draw of the relay coil current of relay #3. 12. With the black wire connecting ground to terminal #85 of relay #3, the high beam headlights come on. This test bypasses the multi-function switch and switch ground circuits and can be valuable in diagnosis and testing. This test is used for testing the flash-to-pass circuit. 13. 440mV± is voltage drop across terminals #30 and #87 of relay #3 with headlight HIGH beams both on. This test measures the conductivity of the relay contacts and if the voltage drop is too high, the contacts are in poor condition or are severely pitted. This is the ONLY way to test a relay’s ability to conduct current at its rated load. The amount of voltage drop across the relay contacts will vary with how much current is flowing through the relay. Higher current will cause higher voltage drops. Ask ConsuLab for a chart that shows acceptable voltage drop values based on the current flow. consulab.com info@consulab.com 144 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) SA-9 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 145 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) consulab.com info@consulab.com 146 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-9 — Headlights Citrcuit (Ground Switched) CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) consulab.com info@consulab.com 147 SA-10 — Headlights Circuit (Positive Switched) Circuit Explanation CIRCUIT DESIGN AND OPERATION : The headlights circuit on vehicles is used to illuminate the area in front of the vehicle so that the driver can safely see the area in periods of darkness or inclement weather conditions. Some vehicles also turn the headlights on during the day (either at full or partial brightness) to warn oncoming vehicles that the vehicle is in the area. These are often called DAYTIME RUNNING LIGHTS. Headlights on today’s vehicles are available in many different styles and designs such as LED, Halide, Xenon, Halo, HID, Projector Beam and many others. Some are extremely expensive to service and replace and often require expensive special tools and training to properly complete repairs. Because of the above reasons, the CL-1918-4 uses a basic incandescent sealed beam headlight system. The compo- nents used on the trainer allow the headlights circuit to be constructed in many different designs. Specific design charac- teristics can be ground or positive switched, 2, 3, or 4 relay controls, etc. You should have already completed “SA-9 GROUND SWITCHED CIRCUIT” previous to this assignment SA-10. This assignment will be a “positive switched” circuit using two relays. In this assignment you will be asked to insert faults into this circuit to learn “real world” symptoms and diagnostic skills. Carefully following step-by-step instructions is CRITICAL for successful completion of this assignment. POSITIVE SWITCHED HEADLIGHTS : CIRCUIT DESCRIPTION B+ CIRCUITS : Power for the headlight control circuit is taken from Fuse F2 (15A) and is connected to the right COM terminal of the multi-function switch. Another connection is made from the right COM terminal to the FLASH terminal of the multi-function switch. Power for the headlights themselves is supplied by Fuse F4 (10A) for the low beam headlights switched by relay #1 and Fuse F5 (10A) for the high beam headlights switched by relay #2. The supply side of fuses F4 (10A) & F5 (10A) are fed from fuse F1 (20A). Both fuses power relays #1 & #2 at terminals #30 for the LOW and HIGH beams. The LOW terminal of the multi-function switch is connected to terminal #86 of relay #1. The HIGH terminal of the multi-function switch is connected to terminal #86 of relay #2 and also to the positive terminal of the HIGH BEAM INDI- CATOR light. Terminal #87 of relay #1 is connected to the right-hand headlight LOW terminal and another wire connects the right-hand side to the left-hand side headlight LOW terminal. Terminal #87 of relay #2 is connected to the right-hand headlight HIGH terminal and another wire connects the right-hand side to the left-hand side headlight HIGH terminal. GROUND CIRCUITS : Relays #1 and #2 control coils are both connected to system ground from terminals #85. Both headlights are connected to system ground by wires from the COM terminals to system ground. The HIGH BEAM INDICA- TOR light is also connected to system ground. CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) consulab.com info@consulab.com 148 LOW BEAM OPERATION : The multi-function stalk switch is turned to the 2nd position which connects the B+ voltage at the right-hand COM termi- nal to the HEAD terminal. B+ leaves from the HEAD terminal and connects to left-hand COM terminal of the multi-func- tion switch. The dimmer switch section always has a connection from COM to LOW and thus, B+ leaves the multi-func- tion switch from the LOW terminal and connects to terminal #86 of relay #1. Relay #1 turns on connecting terminals #30 (Fused B+) to #87 (LOW beam headlights and both LOW beam headlights come on. HIGH BEAM OPERATION : If the stalk of multi-function is pushed down, the left COM terminal is connected to HIGH terminal and B+ leaves from the HIGH terminal of the switch and connects to the HIGH BEAM INDICATOR and terminal #86 of relay #2. This turns relay #2 on connecting terminals #30 (Fused B+) & #87 which connects both HIGH beam headlights and they both come on as well as the HIGH BEAM INDICATOR light. FLASH-TO-PASS OPERATION : If the headlights are on in either LOW or HIGH position, lifting up the stalk switch will connect left COM to both FLASH and HIGH turning on the HIGH beam #2 relay. If the headlights are off, pushing the stalk lever down will not operate the HIGH beams in this circuit. If the headlights are off, and the stalk switch is pulled UP the left COM to FLASH of the multi-function switch are connected which turns on the HIGH beams by turning on relay #2. consulab.com info@consulab.com 149 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) SA-10 — Headlights Circuit (Positive Switched) Circuit Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) — LOAD SIDE Powers the multi-function switch right-hand COM and FLASH and also powers fuses F4 and F5 on the LOAD side of fuse. FUSE #2 (15A) — LOAD SIDE Powers both relay coils #1 & #2 coil circuits (terminals #86) and the HIGH BEAM INDICATOR light FUSE #4 (10A) — POWER SIDE B+ power from Fuse F1 FUSE #4 (10A) — LOAD SIDE Powers terminal #30 of relay #1 for headlight LOW beam power FUSE #5 (10A) — POWER SIDE B+ power from Fuse F1 FUSE #5 (10A) — LOAD SIDE Powers terminal #30 of relay #2 for headlight HIGH beam power HEADLIGHT SWITCH OF MULTI-FUNCTION SWITCH COM TERMINAL- Connected to Fuse F2 and has B+ power available at all times. Also connected to the FLASH terminal of the dimmer switch and provides B+ power for the Flash-To-Pass circuit. HEAD TERMINAL- Connected to the COM terminal of the dimmer switch and if headlights are on, it will be connected either LOW or HIGH beam headlights when selected. DIMMER SWITCH OF MULTI-FUNCTION SWITCH COM TERMINAL - Connected to the HEAD terminal of the headlight switch and if headlights are turned on, it will connect to either the LOW or HIGH beam terminals of the dimmer switch. LOW TERMINAL - Connects to terminal #86 of relay #1 which when turned on will turn on LOW beam headlights. HIGH TERMINAL - Connects to terminal #86 of relay #2 which when turned on will turn on the HIGH beams. The HIGH BEAM INDICATOR positive circuit is also connected to this terminal. FLASH TERMINAL - Connects to the COM terminal of the headlight switch and provides constant B+ power to operate the Flash-To-Pass circuit regardless of whether headlights are on or off. consulab.com info@consulab.com 150 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) RELAY #1 (Relay #1 controls the LOW beam headlight circuit) TERMINAL #87a - Not used in this circuit. TERMINAL #30 - Connected to the load side of Fuse F4 and provides power for the LOW beams TERMINAL #87 - Connects to the LOW terminal of both left and right headlights. When relay #1 is on, both LOW beam headlights receive B+ power from this relay. TERMINAL #85 - Connects to system ground and provides a ground for the relay coil circuit TERMINAL #86 - Connects to LOW terminal of the dimmer switch and if the headlights are turned on, this circuit turns on relay #1 to operate the LOW beam headlights RELAY #2 (Relay #2 operates the HIGH beam headlight circuit) TERMINAL #87a - Not used in this circuit TERMINAL #30 - Connects to the load side of fuse F5 and provides B+ power for HIGH beams TERMINAL #87 - Connects to the HIGH terminal of both left and right headlights. When relay #2 is on, both HIGH beam headlights receive B+ power from this relay. TERMINAL #85 - Connects to system ground and provides a ground for the relay coil circuit TERMINAL #86 - Connects to HIGH terminal of the dimmer switch and if the headlights are turned on, this circuit turns on relay #2 to operate the HIGH beam headlights HIGH BEAM INDICATOR RED TERMINAL - Connects to the HIGH beam terminal of the dimmer switch which turns on when HIGH beams are selected. BLACK TERMINAL - Connects to system ground for the LED HIGH BEAM INDICATOR LEFT HEADLIGHT COM TERMINAL - Connected to system ground LOW TERMINAL - Connected to the right side LOW beam headlight and also to terminal #87 of relay #1 HIGH TERMINAL - Connected to the left side HIGH beam headlight and also to terminal #87 of relay #2 RIGHT HEADLIGHT COM TERMINAL - Connected to system ground consulab.com info@consulab.com 151 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) LOW TERMINAL - Connected to the left side LOW beam headlight and also to terminal #87 of relay #1 HIGH TERMINAL - Connected to the left side HIGH beam headlight and also to terminal #87 of relay #2 GROUND CIRCUITS Both left and right side headlights are connected to system ground from the COM terminals. The LED HIGH BEAM INDICATOR is connected to system ground from the black terminal. Relays #1 and #2 are both connected to system ground from terminals #85. The top panel is connected to the middle panel system ground by a jumper wire CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) consulab.com info@consulab.com 152 SA-10 — All Level Assignment (2 pages) Fill in all answers to this assignment where indicated on the student answer sheet – do not write on this paper. 1. Obtain the SA-10 HEAD LIGHTS (POSITIVE SWITCHED) either Level 1, 2 or 3 circuit schematic from your instructor and construct this circuit properly. 2. Confirm that the circuit operates properly. If it doesn’t correct any wiring errors and re-test. 3. Obtain the SA-10 — CIRCUIT EXPLANATION from your instructor and complete all of the questions in the assign- ment. Hand in your assignment when completed for instructors check. 4. Obtain the student answer sheet for SA-10 HEADLIGHTS CIRCUIT – POSITIVE SWITCHED assignment. 5. THE FOLLOWING ASSIGNMENTS REQUIRE THAT YOU HAVE A FULL UNDERSTANDING OF HOW THIS CIRCUIT OPERATES IN ORDER TO CORRECLTY ANSWER THE QUESTIONS. 6. With the circuit operating correctly, perform each of the following steps and fill in your answers for each step. 7. Remove the COM wire from the left-hand headlight and turn on the headlights to LOW beam. Describe how the cir- cuit performs on the answer sheet. 8. Using a voltmeter, measure the available voltage at the following points and answer each question. A. LOW terminal of right headlight. Is this a normal reading ? Yes or No B. LOW terminal of the left headlight. Is this a normal reading ? Yes or No C. HIGH terminal of the right headlight. Is this a normal reading ? Yes or No D. HIGH terminal of the left headlight. Is this a normal reading ? Yes or No 9. Explain why you got the reading in step 8B. 10. Explain why you got the reading in step 8D. 11. Measure the voltage to ground at the COM terminal of the left headlight. Is this a normal reading ? Yes or No 12. What does the reading in step 11 indicate ? 13. What is the voltage available to the left LOW beam headlight terminal ? 14. While measuring the voltage at the COM terminal of the left headlight, temporarily connect a jumper wire from sys- tem ground to the COM terminal of the left headlight. What is the voltage reading now ? 15. Restore the circuit to normal operation and turn the headlights off. 16. Remove the HIGH beam wire from the left headlight and connect it to either terminal of the left front marker light. CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) consulab.com info@consulab.com 153 17. Connect a red jumper wire from the other terminal of the left front marker light to the left headlight HIGH terminal. 18. Before you turn the circuit on, explain what you have just done to the circuit. 19. Make a prediction of what the circuit will do when you turn it on. 20. Turn on the headlight circuit and describe the circuit performance for each mode : A. LOW BEAM B. HIGH BEAM 21. Measure the voltage drop across the left front marker light with lights on HIGH BEAM. 22. Measure the voltage drop across the left HIGH beam headlight with the circuit on HIGH BEAM. 23. What is the operating voltage of the left HIGH beam headlight ? 24. Are the marker lights and the left HIGH beam lights connected in series or parallel ? 25. Measure the current flowing in the marker light and left HIGH beam headlight circuit. 26. Explain why the left marker light is on at full brilliance and the left HIGH beam headlight is off ? 27. Remove the wire connected to the left HIGH beam headlight and measure the voltage from that wire to system ground. 28. Explain why you got the reading you did in step 27. 29. Record the following readings while measuring the voltage drop across the left HIGH beam headlight. A. With the left marker light in the circuit. B. With a red jumper wire connected across the two terminals of the left front marker light. 30. This assignment is designed to help you understand the effect on circuit performance of unwanted resistance any- where in the circuit. The resistance could be in the positive side, the ground side OR more importantly, BOTH. With your instructors permission, you may experiment with inserting resistance in various lighting circuits. Just remem- ber to insert the resistance in SERIES and NOT in parallel. Why ? Remember that adding resistances in parallel will INCREASE the current flow in the circuit. If this is done, it is a certainly that fuses will blow. NEVER USE ANY LED LIGHTS IN THESE CIRCUIT EXPERIMENTS. The following lights all have different resistances and will cause varying degrees of negative circuit performance : A. Any side marker lights B. License plate light C. Backup lights D. Relay coil (#85 and #86) E. Headlights 31. Turn in your completed answer sheet, obtain instructors check and restore the trainer to its normal condition. consulab.com info@consulab.com 154 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) SA-10 — All Level Assignment Instructors Answer Key (2 pages) NOTE: The voltage and resistance readings will have a plus/minus tolerance based on each individual power sup- ply and differences in the headlight bulbs manufacturing tolerances. The measured reading should be CLOSE to the answer key readings but might not be EXACT. 2. DID TRAINER OPERATE PROPERLY? YES or NO 3. COMPLETE STUDENT ASSIGNMENT – CIRCUIT EXPLANATION assignment. CHECK ASSN 7. With the left COM wire removed, the left LOW beam headlight is on, but very DIM. 8. A 12.91 VOLTS ± ANSWER: YES. It should be about 12.71V± if the left LOW beam is operating properly. B 12.93 VOLTS ± ANSWER: YES. C 5.10 VOLTS ± ANSWER: NO, it should be close to zero voltage drop D 5.09 VOLTS ± ANSWER: NO, it should be close to zero voltage drop 9. Because of the operating headlights, this reading is a normal reading indicating that there is system B+ voltage available at the LOW terminal of the left headlight in REFERENCE TO SYSTEM GROUND. Therefore, the problem MUST be unwanted resistance in the ground circuit. 10. This reading indicates that there is current flowing through the HIGH beam circuit when the switch is in the LOW position. This reading should direct the student to consider an open ground in the left headlight circuit and the only way current for the LOW beam can get to ground in through the HIGH beam filament. 11. 8.96-9.24 VOLTS ± ANSWER: No, it is not normal 12. The reading indicates that there is about a 9.00 volt voltage drop in the left headlight ground circuit. Normal readings should be close to zero. 13. 12.64-12.96 VOLTS ± 14. 00.12 VOLTS ±. This is a normal voltage drop with very little resistance in the ground circuit. This also indicates a good ground circuit in the headlight. 19. PREDICTION : The left LOW beam will operate normally, but when the HIGH beam is selected, it will be OFF and consulab.com info@consulab.com 155 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) the left marker light will be on at full brilliance. 20. A LOW beam functions normally B Left HIGH beam is off and left front marker light is on at full brilliance. 21. 12.97 VOLTS ± (left front marker light) 22. 00.14 Volts ± (left high beam with switch turned to HIGH beam) 23. 00.14 Volts ± (operating voltage of left HIGH beam) 24. Series 25. 0.316 A or 316 milli-amps ± (flowing in left marker light & HIGH beam headlight circuit) 26. The left front marker light has a much higher resistance than the left HIGH beam and thus, requires a much higher voltage drop to push current through it. Because this is a SERIES circuit, with only one path for current to flow, the headlight doesn’t get enough current to operate. There is current flowing through the headlight, but not enough to cause the filament to glow. 27. 13.23 VOLTS ± (removed red wire end to ground) 28. This measurement is called “open circuit” voltage reading and is NOT a reliable method of testing for the presence of unwanted resistance in a circuit. No matter how much resistance is present in a circuit, measuring the open circuit voltage will always be equal to the source voltage. This is because the internal impedance of the voltmeter draws extremely low current from the circuit being measured. Most meters have at least 10MΩ or 20MΩ (million) of resistance and adding the resistance of 55±Ω of the headlight and the side marker light is ignored by the voltmeter. 29. A. 00.14 VOLTS or 14 millivolts ± (with left marker light in the circuit) B 12.49 VOLTS ± (with jumper wire across the two market light terminals) consulab.com info@consulab.com 156 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) SA-10 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 157 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) SA-10 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 158 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) SA-10 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 159 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) consulab.com info@consulab.com 160 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-10 — Headlights Circuit (Positive Switched) consulab.com info@consulab.com 161 CL-1918-4S_053304-91 Headlights Circuit (Optional Circuit Designs) Headlights Circuit (Optional Circuit Designs) Assignment Explanations There are countless ways to correctly wire the headlights circuits on the CL-1918-4 lighting trainer. With the headlights and multi-function being both compatible with both positive and ground switching, many different wiring designs can be created. The only critical design requirement is that at no time should any current in excess of 1A flow through any part of the multi-function switch. The switch is protected by two replaceable 1A fuses which will open if excessive current is detected. The multi-function switch on the CL-1918-4 lighting trainer must only control relay coil current to operate the headlights. This is a design change from other CL-1918-3 trainers. In addition to assignment SA-8 & SA-9, here are eight additional circuit options that can be constructed and understood by students. A brief explanation of each follows: 1. Option A – Option A is a ground switched circuit, but the relay’s control b+ power to the headlights. This circuit uses three relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 turns on the headlights by sending B+ to relay 2. Relay 2 determines whether the low or high beam headlights operate. Relay 2 is turned on by the high beam switch circuit. Relay 4 serves only to operate the “flash-to- pass” circuit if the headlights are turned off. 2. Option B – Option B is a ground switched circuit. The relay’s control the high current ground circuits of the head- lights. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 controls the low beam headlights and relay 4 controls the high beam head- lights. 3. Option C – Option C is a ground switched circuit and is very similar to option B. The relay’s control the high current ground circuits of the headlights. The main difference is how the multi-function switch connects to system ground. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and nec- essary ground circuits. Relay 3 controls the low beam headlights and relay 4 controls the high beam headlights. 4. Option D – Option D is a ground switched circuit and uses two relays to control the high current b+ power to the headlights. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indi- cator and necessary ground circuits. Relay 3 operates the high beam headlights and relay 4 operates the low beam headlights. 5. Option E – Option E is a positive switched circuit and uses two relays to control the high current B+ power to the headlights. The multi-function switch controls the B+ power to the relay’s coil current. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 operates the low beam headlights and relay 4 operates the high beam headlights. 6. Option F- Option F is positive switched circuit and uses two relays to control the high current B+ power to the head- lights. The multi-function is wired differently than option E and allows students to better understand the multi-func- tion switch operation. The multi-function switch controls the B+ power to the relay’s coil current. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 operates the low beam headlights and relay 4 operates the high beam headlights. consulab.com info@consulab.com 162 CL-1918-4S_053304-91 Headlights Circuit (Optional Circuit Designs) 7. Option G – Option G is a positive switched circuit and uses four relays to control the high current B+ power to the headlights. The multi-function is wired differently than option f and allows students to better understand the multi-function switch operation. The multi-function switch controls the B+ power to the relay’s coil current. This cir- cuit uses four relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 1 operates the left low beam headlight, relay 2 operates the right low beam headlight. Relay 3 operates the left high beam headlight and relay 4 operates the right high beam headlight. There is a relay for each headlight in this circuit. 8. Option H – Option H is positive switched circuit and uses two relays. The multi-function switch controls the B+ power to the relay’s coil current. This circuit uses two relays, headlight and dimmer switches, two fuses, two head- lights, high beam indicator and necessary ground circuits. Relay 1 supplies high current B+ power to relay #2 when the headlights are turned on. Relay 2 (if off) supplies high current b+ power from terminal 87a to the right low beam headlight which is then cross-connected to the left headlight. When relay 2 is turned on by the multi-function switch, it changes b+ connection from its 87a terminal (low beam) to terminal 87 (high beam). This assignment using eight different wiring options should consist or no more than 1 or 2 students for the completion of the circuit explanation assignment and the actual construction of each circuit. Depending on the level of your students, you may wish to assign additional learning assignments on these circuits to include: 1. Disconnect various ground circuits to either predict circuit behavior or report on what happens. 2. Adding unwanted resistances into portions of the circuit for voltage drop testing and diagnosis experience. You may use the back up, side marker lights, license plate light or any relay coil not being used. These activities will build student diagnostic abilities in learning how voltage drop testing is so critical to know. 3. Have students draw the circuit schematic on a level 1, 2 or 3 blank template. This provides great experience at hav- ing students read and understanding schematics. 4. Design other headlight circuit options or create special circuits like an emergency vehicle with a “wig-way” flashing headlight, taillight or turn/hazard lights. 5. Set up student competitions to see who can build a functioning headlight circuit the fastest, yet still operate proper- ly. CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A consulab.com info@consulab.com 163 SA-11 — Headlights Circuit — Option A At this point in your assignments, you will be given additional headlight circuit options that are different from SA-9 and SA-10 circuits. Obtain a Level 1, 2 or 3 schematic from your instructor and follow the below instructions for assignments SA-11. You will be asked to explain the operation of each component in the circuit on the student answer sheet. Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-11 HEADLIGHTS CIRCUIT (OPTION A) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-11 HEADLIGHT CIRCUIT (OPTION A) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-11 CIRCUIT EXPLANATION (OPTION A) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 164 CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A SA-11 — Headlights Circuit — Option A Component Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) Connected to terminals #30 of relays #3 and #4. FUSE #2 (15A) — LOAD SIDE Connected to terminals #86 of relays #2, #3 and #4 RELAY #2 (Used to switch from LOW to HIGH beam function) TERMINAL #86- Connected to Fuse F2 and terminals #86 of relays #3 and #4. TERMINAL #85- Connected to HIGH terminal of the dimmer switch and to terminal #85 of relay #4. TERMINAL #30- Connected to terminal #87 of relay #3 and #4. TERMINAL #87- Connected to the HIGH terminals of both HIGH beam headlight terminals. TERMINAL #87a- Connected to the LOW terminals of both LOW beam headlight terminals. RELAY #3 (Used to turn on the headlights) TERMINAL #86- Connected to terminals #86 of relays #2, #4 and Fuse F2. TERMINAL #85- Connected to system ground and is the ground for the relay coil circuit. TERMINAL #30- Connected to terminal #30 of relay #4 and to Fuse F1. TERMINAL #87- Connected to terminal #87 of relay #4 and to terminal #30 of relay #2. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to operate the Flash-To-Pass circuit) TERMINAL #86- Connected to terminals #86 of relays #2 and #3 and to Fuse F2. TERMINAL #85- Connected to HEAD terminal of headlight switch and to the FLASH terminal of the dimmer switch. TERMINAL #30- Connected to terminal #30 of relay #3 and to Fuse F1. TERMINAL #87- Connected to terminal #87 of relay #2 and to terminal #30 of relay #2. TERMINAL #87a- Not used in this circuit. consulab.com info@consulab.com 165 CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A LIGHT SWITCH COM TERMINAL- Connected to system ground. PARK TERMINAL- Not used in this circuit. HEAD TERMINAL- Connected to terminal #85 of relay #3 and turns on relay #3 with sends B+ to relay #2 to operate either LOW or HIGH beam headlights based on the position of relay #2. DIMMER SWITCH COM TERMINAL- Connected to system ground. LOW TERMINAL- Not used in this circuit. HIGH TERMINAL- Connected to terminal #85 of relay #2 which turns relay #2 on. Relay #2 switches the headlights from LOW to HIGH beam operation. FLASH- Not used in this circuit. HIGH BEAM INDICATOR RED TERMINAL- Connected to the HIGH beam terminal of the left headlight. BLACK TERMINAL- Connected to system ground. LEFT HEADLIGHT LOW TERMINAL- Connected to terminal #87a of relay #2. When relay #2 if off, the LOW beams will be on. COM TERMINAL- Connected to system ground. HIGH TERMINAL- Connected to terminal #87 of relay #2 and when relay #2 is on, the HIGH beams will be on. RIGHT HEADLIGHT LOW TERMINAL- Connected to terminal #87a of relay #2. COM TERMINAL- Connected to the left headlight COM terminal which supplies ground. HIGH TERMINAL- Connected to terminal #87 of relay #2. GROUND CIRCUITS 1. Relay #2 is grounded at terminal #85 to the HIGH terminal of the dimmer switch. 2. Relay #3 is grounded at terminal #85 to the HEAD terminal of the light switch. 3. Relay #4 is grounded at terminal #85 and terminal #85 of relay #2 and the HIGH terminal of the dimmer switch. consulab.com info@consulab.com 166 CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A 4. The dimmer switch is grounded at the COM terminal to system ground. 5. The light switch is grounded at the COM terminal to system ground. 6. Left and right headlights are both grounded from the COM terminals and the left headlight COM terminal is con- nected to system ground. 7. The HIGH BEAM INDICATOR is connected to system ground by the black terminal. 8. The top Moduponent panel is connected to system ground at the middle panel with a jumper wire. consulab.com info@consulab.com 167 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A SA-11 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 168 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A SA-11 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 169 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A SA-11 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 170 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A consulab.com info@consulab.com 171 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-11 — Headlights Circuit — Option A CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B consulab.com info@consulab.com 172 SA-12 — Headlights Circuit — Option B Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-12 HEADLIGHTS CIRCUIT (OPTION B) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-12 HEADLIGHT CIRCUIT (OPTION B) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-12 CIRCUIT EXPLANATION (OPTION B) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 173 CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B SA-12 — Headlights Circuit — Option B Component Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) Supplies B+ power to both headlights at the COM terminals and the positive terminal of the HIGH BEAM INDICATOR. FUSE #2 (15A) — LOAD SIDE Supplies B+ power to relays #3 and #4 coil circuits. RELAY #3 (Used to turn on the LOW beam headlights) TERMINAL #86- Connected to terminal #86 of relay #4 and to Fuse F2. Coil gets B+ from here TERMINAL #85- Connected to terminal HEAD of light switch. Turns on relay #3 TERMINAL #30- Connected to terminal HEAD of light switch. Turns on relay #3 TERMINAL #87- Connected to the LOW terminals of both left and right headlights. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to turn on the HIGH beam headlights) TERMINAL #86- Connected to terminal #86 of relay #3 and to Fuse F2. Coil gets B+ from here TERMINAL #85- Connected to the HIGH terminal of the dimmer switch. Turns on HIGH beams. TERMINAL #30- Connected to terminal #30 of relay #3 and to system ground. TERMINAL #87 - Connected to the right-hand headlight HIGH terminal. TERMINAL #87a - Not used in this circuit. LIGHT SWITCH COM TERMINAL - Connected to system ground. PARK TERMINAL - Not used in this circuit. HEAD TERMINAL - Connects to terminal #85 of relay #3 and grounds the relay coil turning relay on. This turns on the LOW beam headlights. consulab.com info@consulab.com 174 CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B DIMMER SWITCH COM TERMINAL - Connected to system ground. LOW TERMINAL - Not used in this circuit. HIGH TERMINAL - Connects to terminal #85 of relay #4 and turns relay #4 on. FLASH - Not used in this circuit. HIGH BEAM INDICATOR RED TERMINAL- Connected to the left-hand headlight COM terminal. BLACK TERMINAL- Connected to the left-hand headlight HIGH termanal. LEFT HEADLIGHT LOW TERMINAL- Connected to the right-hand headlight LOW terminal and also to terminal #87 of relay #3. LOW beam headlights are turned on by completing the ground circuit thru the relay. COM TERMINAL- Connected to the red terminal of the HIGH BEAM indicator and to the right-hand headlight COM terminal and Fuse F1. HIGH TERMINAL- Connected to the black terminal of the HIGH BEAM INDICATOR and to the HIGH terminal of the right-hand headlight and also to terminal #87 of relay #4. RIGHT HEADLIGHT LOW TERMINAL- Connected to the left-hand headlight LOW terminal and also to terminal #87 of relay #3. This circuit completes the ground of the LOW beams when relay #3 is turned on. COM TERMINAL- Connected to the left-hand headlight COM terminal and also to Fuse F1. HIGH TERMINAL- Connected to the left-hand headlight HIGH terminal and also to terminal #87 of relay #4. This relay turns on the HIGH beam headlights. GROUND CIRCUITS - 1. RELAY #3 Grounded by relay #3, terminal #85 through the HEAD and COM terminal of headlight switch. This relay turns on the LOW beam headlights. 2. RELAY #4 Grounded by relay #4, terminal #85 through the HIGH terminal of the dimmer switch. This relay turns on the HIGH beam headlights. consulab.com info@consulab.com 175 CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B 3. HIGH BEAM INDICATOR Grounded by relay #4 when relay is on connecting it’s black terminal to system ground through relay #4 terminals #87 to #30, then to HIGH terminal of dimmer switch to COM then to system ground. 4. DIMMER SWITCH Connected to system ground by the COM terminal (left-side). 5. LIGHT SWITCH Connected to system ground by the COM terminal (right-side). 6. LEFT HEADLIGHT Grounded either through HIGH or LOW beam terminals through relays #3 or #4 to system ground. 7. RIGHT HEADLIGHT Grounded either through HIGH or LOW beam terminals through relays #3 or #4 to system ground. consulab.com info@consulab.com 176 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B SA-12 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 177 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B SA-12 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 178 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B SA-12 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 179 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B consulab.com info@consulab.com 180 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-12 — Headlights Circuit — Option B CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C consulab.com info@consulab.com 181 SA-13 — Headlights Circuit — Option C Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-13 HEADLIGHTS CIRCUIT (OPTION C) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-13 HEADLIGHT CIRCUIT (OPTION C) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-13 CIRCUIT EXPLANATION (OPTION C) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 182 CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C SA-13 — Headlights Circuit — Option C Component Explanation Instructors Answer Key (3 pages) FUSE #1 (20A) Connected to the COM terminal of right-hand headlight and also to the left-hand headlight COM terminal and the red terminal of the HIGH BEAM INDICATOR. This circuit supplies B+ power to the headlights. FUSE #2 (15A) Connected to terminals #86 of relays #3 and #4 supplying B+ power to both relay coils. RELAY #3 (Used to turn on the LOW beam headlights (high current circuit). TERMINAL #86- Connected to terminal #86 of relay #4 and also to Fuse F2. Supplies B+ power for the relay coil circuits. TERMINAL #85- Connected to the HEAD terminal of the light switch which turns relay #3 on to operate the LOW beam headlights by grounding relay #3’s coil circuit. TERMINAL #30- Connected to terminal #30 of relay #4 and also to system ground. TERMINAL #87- Connected to the LOW terminal of right-hand headlight and also to the LOW terminal of the right- hand headlight. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to turn on the HIGH beam headlights (high current circuit). TERMINAL #86- Connected to terminal #86 of relay #3 and also to Fuse F2. Supplies B+ power for the relay coil circuits. TERMINAL #85- Connected to the HIGH terminal of the light switch which turns on relay #4 to operate the HIGH beam headlights and the HIGH BEAM INDICATOR light. TERMINAL #30- Connected to terminal #30 of relay #3 and also to system ground. TERMINAL #87- Connected to the HIGH terminal of the right-hand headlight, also to the left-hand headlight HIGH terminal. TERMINAL #87a- Not used in this circuit. consulab.com info@consulab.com 183 CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C LIGHT SWITCH COM TERMINAL- Connected to the dimmer switch COM terminal and also to system ground. This circuit grounds the coil circuits for relays #3 and #4. PARK TERMINAL- Not used in this circuit. HEAD TERMINAL- Connected to terminal #85 of relay #3 which turns on the relay turning on the LOW beam headlights. DIMMER SWITCH COM TERMINAL- Connected to the light switch COM terminal and also to system ground. This circuit grounds the coil circuits for relays #3 and #4. LOW TERMINAL- Not used in this circuit. HIGH TERMINAL- Connected to terminal #85 of relay #4 which turns on the relay to operate the HIGH beam headlights. FLASH- Not used in this circuit. HIGH BEAM INDICATOR RED TERMINAL - Connected to the left-hand headlight COM terminal. BLACK TERMINAL - Connected to the left-hand headlight HIGH terminal. LEFT HEADLIGHT LOW TERMINAL - Connected to the right-hand headlight LOW terminal and also to terminal #87 of relay #3 which turns on the LOW beams. COM TERMINAL - Connected to the red terminal of the HIGH BEAM INDICATOR and also to the right-hand headlight COM terminal which connects to Fuse F1. HIGH TERMINAL - Connected to the black terminal of the HIGH BEAM INDICATOR and connects to the right-hand headlight HIGH terminal which then connects to terminal #87 of relay #4 to turn on the HIGH beam headlights. RIGHT HEADLIGHT LOW TERMINAL- Connected to the left-hand headlight LOW terminal and also to terminal #87 of relay #3 which turns on the LOW beams. consulab.com info@consulab.com 184 CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C COM TERMINAL- Connected to the left-hand headlight COM terminal and also connects to Fuse F1 to provide B+ power for the headlights. HIGH TERMINAL - Connected to the left-hand headlight HIGH terminal and also connects to terminal #87 of relay #4 to turn on the HIGH beam headlights. GROUND CIRCUITS 1. RELAY #3 Connected to the HEAD terminal of the light switch which turns the relay on to LOW beam headlights. 2. RELAY #4 Connected to the HIGH terminal of the dimmer switch which turn the relay on to HIGH beam head- lights. 3. HIGH BEAM INDICATOR Grounded from terminal HIGH of the left-hand headlight which grounds when relay #4 is on. 4. DIMMER SWITCH Connected to the COM of the light switch and also connects to system ground. 5. LIGHT SWITCH Connected to the COM of the dimmer switch and also connects to system ground. 6. LEFT HEADLIGHT The left headlight is grounded through relays #3 and #4 depending on which relay is selected by the multi-function switch. 7. RIGHT HEADLIGHT The right headlight is grounded through relays #3 and #4 depending on which relay is select- ed by the multi-function switch. consulab.com info@consulab.com 185 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C SA-13 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 186 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C SA-13 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 187 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C SA-13 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 188 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C consulab.com info@consulab.com 189 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-13 — Headlights Circuit — Option C CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D consulab.com info@consulab.com 190 SA-14 — Headlights Circuit — Option D Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-14 HEADLIGHTS CIRCUIT (OPTION D) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-14 HEADLIGHT CIRCUIT (OPTION D) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-14 CIRCUIT EXPLANATION (OPTION D) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 191 CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D SA-14 — Headlights Circuit — Option D Component Explanation Instructors Answer Key (4 pages) FUSE #1 (20A) Connects to terminals #30 of relays #3 and #4 to provide B+ power for the high current of the headlights. FUSE #2 (15A) Connected to terminals #86 of relay #3 and #4 to provide B+ power for the relay coil circuits. RELAY #3 (Used to control the HIGH beam headlights.) TERMINAL #86- Connected to terminal #86 of relay #4 and to Fuse F2. This circuit supplies B+ power for the relay coil circuits. TERMINAL #85- Connected to the HIGH terminal of the dimmer switch which turns on relay #3 which turns on the HIGH beam headlights. TERMINAL #30- Connected to terminal #30 of relay #4 and also to Fuse F1. TERMINAL #87- Connected to the HIGH terminal of the right-hand headlight which connects to the left-hand headlight and to the red terminal of the HIGH BEAM INDICATOR. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to turn on the LOW beam headlights). TERMINAL #86- Connected to terminal #86 of relay #3 and to Fuse F2. This circuit supplies B+ power for the relay coil circuits. TERMINAL #85- Connected to the HEAD terminal of the light switch which turns on relay #3 which turns on the LOW beam headlights. TERMINAL #30- Connected to terminal #30 of relay #3 and also to Fuse F1. TERMINAL #87- Connected to the LOW terminal of the right-hand headlight which connects to the left-hand headlight LOW terminal. TERMINAL #87a- Not used in this circuit. consulab.com info@consulab.com 192 CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D LIGHT SWITCH COM TERMINAL - Connected to the dimmer switch COM terminal and also to system ground. PARK TERMINAL - Not used in this circuit. HEAD TERMINAL - Connected to terminal #85 of relay #4 which turns the relay on and operates the LOW beam headlights. DIMMER SWITCH COM TERMINAL - Connected to the light switch COM terminal and also to system ground. LOW TERMINAL - Not used in this circuit. HIGH TERMINAL - Connected to terminal #85 of relay #3 which turns on the relay and operates the HIGH beam headlights. FLASH TERMINAL - Not used in this circuit. HIGH BEAM INDICATOR RED TERMINAL - Connected to the HIGH terminal of the left-hand headlight. BLACK TERMINAL - Connected to the left-hand headlight COM terminal which is connected to system ground. LEFT HEADLIGHT LOW TERMINAL - Connected to the right-hand headlight LOW terminal and then to terminal #87 of relay #4 which when turned on, supplies a ground circuit for the LOW beam headlights. COM TERMINAL - Connected to system ground and to the left-hand headlight COM. HIGH TERMINAL - Connected to the red terminal of the HIGH BEAM INDICATOR and also to the light-hand headlight HIGH terminal and to terminal #87 of relay #3 which when turned on will operate the HIGH beam headlights. RIGHT HEADLIGHT LOW TERMINAL - Connected to terminal #87 of relay #4 and also to the LOW terminal of the left-hand headlight. COM TERMINAL - Connected to the left-hand headlight COM terminal and to system ground. HIGH TERMINAL - Connected to terminal #87 of relay #3 and to the left-hand headlight HIGH terminal and to the HIGH BEAM INDICATOR red terminal. consulab.com info@consulab.com 193 CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D GROUND CIRCUITS 1. RELAY #3 Grounded to system ground by the HIGH terminal of the dimmer switch by terminal #85. This turns the relay on to operate the HIGH beam headlights. 2. RELAY #4 Grounded to system ground by the HEAD terminal of the light switch by terminal #85. This turns on the relay to operate the LOW beam headlights. 3. HIGH BEAM INDICATOR Connected to system ground at the left-hand headlight COM terminal 4. DIMMER SWITCH Connected to system ground by the COM terminal and also connected to the light switch COM terminal. 5. LIGHT SWITCH Connected to system ground by the COM terminal and also connected to the dimmer switch COM terminal. 6. LEFT HEADLIGHT Connected to the left-hand headlight COM terminal and then to system ground. 7. RIGHT HEADLIGHT Connected to system ground at the COM terminal and also connects to the right-hand head- light COM terminal and the black terminal of the HIGH BEAM INDICATOR. consulab.com info@consulab.com 194 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D SA-14 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 195 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D SA-14 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 196 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D SA-14 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 197 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D consulab.com info@consulab.com 198 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-14 — Headlights Circuit — Option D CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E consulab.com info@consulab.com 199 SA-15 — Headlights Circuit — Option E Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-15 HEADLIGHTS CIRCUIT (OPTION E) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-15 HEADLIGHT CIRCUIT (OPTION E) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-15 CIRCUIT EXPLANATION (OPTION E) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 200 CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E SA-15 — Headlights Circuit — Option E Component Explanation Instructors Answer Key (4 pages) FUSE #1 (20A) Feeds relays #3 & #4 with B+ high current power to terminals #30 FUSE #2 (15A) Feeds B+ (low current) power to the COM terminal of the light switch and also to the FLASH terminal of the dimmer switch. RELAY #3 (Used to turn on the LOW beam headlights) TERMINAL #86- Connected to the LOW terminal of the dimmer switch and turns on relay when LOW beam headlights are selected) TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #4 and also to Fuse F1 for B+ power. TERMINAL #87- Connected to the LOW beam terminal of the right-hand headlight which is also connected to the left- hand headlight LOW terminal. This terminal turns on the LOW headlights when relay #3 is turned on. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to turn on the HIGH beam headlights) TERMINAL #86- Connected to the HIGH terminal of the dimmer switch and turns on relay when HIGH beam headlights are selected) TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #3 and also to Fuse F1 for B+ power. TERMINAL #87- Connected to the HIGH beam terminal of the right-hand headlight which is also connected to the left-hand headlight HIGH terminal. This terminal turns on the HIGH headlights when relay #4 is turned on. TERMINAL #87a- Not used in this circuit. LIGHT SWITCH COM TERMINAL - Connected to Fuse F2 which provides B+ low current power for the relay coils. PARK TERMINAL - Not used in this circuit. consulab.com info@consulab.com 201 CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E HEAD TERMINAL - Connected to the COM terminal of the dimmer switch and when HEAD lights are selected, B+ power is supplied to the dimmer switch. DIMMER SWITCH COM TERMINAL - Connected to the HEAD terminal of the light switch and receives B+ power when the headlights are turned on. LOW TERMINAL - Connected to terminal #86 of relay #3 and turns on the LOW beam headlights when LOW is selected by the dimmer switch. HIGH TERMINAL - Connected to terminal #86 of relay #4 and turns on the HIGH beam headlights when HIGH is selected by the dimmer switch. FLASH TERMINAL - Connected to the COM terminal of the light switch and supplies B+ power to operate the Flash- To-Pass light system. HIGH BEAM INDICATOR RED TERMINAL - Connected to the left-hand headlight HIGH terminal. BLACK TERMINAL - Connected to system ground. LEFT HEADLIGHT LOW TERMINAL - Connected to the right-hand headlight LOW terminal and also to terminal #87 of relay #3. When relay #3 is turned on, the LOW beam headlights operate. COM TERMINAL - Connected to system ground and also to the right-hand headlight COM terminal to provide a ground for both headlights. HIGH TERMINAL - Connected to the red terminal of the HIGH BEAM INDICATOR light and also to the right-hand headlight HIGH terminal and also to terminal #87 of relay #4. When relay #4 is turned on, the HIGH beam headlights operate. RIGHT HEADLIGHT LOW TERMINAL - Connected to the left-hand headlight LOW beam terminal and also terminal #87 of relay #3. When relay #3 is turned on, the LOW beam headlights operate. COM TERMINAL - Connected to system ground and also to the left-hand headlight COM terminal to provide a ground for both headlights. consulab.com info@consulab.com 202 CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E HIGH TERMINAL - Connected to the left-hand headlight HIGH terminal and also to terminal #87 of relay #4. When relay #4 is turned on, the HIGH beam headlights operate. GROUND CIRCUITS 1. RELAY #3 Connected to system ground from terminal #85 of relay #3. 2. RELAY #4 Connected to system ground from terminal #85 of relay #4. 3. HIGH BEAM INDICATOR Connected to system ground by the black terminal. 4. LEFT HEADLIGHT Connected to system ground by the COM terminal 5. RIGHT HEADLIGHT Connected to system ground by the COM terminal connected to the COM terminal of the left- hand headlight. consulab.com info@consulab.com 203 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E SA-15 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 204 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E SA-15 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 205 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E SA-15 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 206 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E consulab.com info@consulab.com 207 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-15 — Headlights Circuit — Option E CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F consulab.com info@consulab.com 208 SA-16 — Headlights Circuit — Option F Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-16 HEADLIGHTS CIRCUIT (OPTION F) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-16 HEADLIGHT CIRCUIT (OPTION F) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-16 CIRCUIT EXPLANATION (OPTION F) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 209 CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F SA-16 — Headlights Circuit — Option F Component Explanation Instructors Answer Key (4 pages) FUSE #1 (20A) Feeds relays #3 & #4 with B+ high current power to terminals #30 FUSE #2 (15A) Feeds B+ (low current) power to the COM terminal of the light switch for relay coil control circuit. RELAY #3 (Used to turn on the LOW beam headlights) TERMINAL #86- Connected to the HEAD terminal of the light switch and turns on relay #3 when the HEAD terminal is selected). TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #4 and also to Fuse F1 for B+ power. TERMINAL #87- Connected to the LOW beam terminal of the right-hand headlight which is also connected to the left- hand headlight LOW terminal. This terminal turns on the LOW headlights when relay #3 is turned on. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to turn on the HIGH beam headlights) TERMINAL #86- Connected to the HIGH terminal of the dimmer switch and turns on relay #3 when HIGH beam headlights are selected). TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #3 and also to Fuse F1 for B+ power. TERMINAL #87- Connected to the HIGH beam terminal of the right-hand headlight which is also connected to the left-hand headlight HIGH terminal and also to the red terminal of the HIGH BEAM INDICATOR. This terminal turns on the HIGH headlights when relay #4 is turned on. TERMINAL #87a- Not used in this circuit. LIGHT SWITCH COM TERMINAL - Connected to the COM terminal of the dimmer switch and to Fuse F2 which provides B+ low current power for the relay coils. consulab.com info@consulab.com 210 CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F PARK TERMINAL - Not used in this circuit. HEAD TERMINAL - Connected to terminal #86 of relay #3 when HEAD lights are selected, relay #3 turns on operating the LOW beam headlights. DIMMER SWITCH COM TERMINAL - Connected to the COM terminal of the light switch and is fed from Fuse F2 for relay coil control circuits. LOW TERMINAL - Not used in this circuit. HIGH TERMINAL - Connected to terminal #86 of relay #4 and turns on the HIGH beam headlights when HIGH is selected by the dimmer switch. FLASH TERMINAL - Not used in this circuit. (internally connected – see multi-function switch explanation document). HIGH BEAM INDICATOR RED TERMINAL - Connected to the left-hand headlight HIGH terminal. BLACK TERMINAL - Connected to system ground. LEFT HEADLIGHT LOW TERMINAL - Connected to the right-hand headlight LOW terminal and also to terminal #87 of relay #3. When relay #3 is turned on, the LOW beam headlights operate. COM TERMINAL - Connected to system ground and also to the right-hand headlight COM terminal to provide a ground for both headlights. HIGH TERMINAL - Connected to the red terminal of the HIGH BEAM INDICATOR light and also to the right-hand headlight HIGH terminal and also to terminal #87 of relay #4. When relay #4 is turned on, the HIGH beam headlights operate. RIGHT HEADLIGHT LOW TERMINAL - Connected to the left-hand headlight LOW beam terminal and also to terminal #87 of relay #3. When relay #3 is turned on, the LOW beam headlights operate. COM TERMINAL - Connected to system ground and also to the left-hand headlight COM terminal to provide a ground for both headlights. consulab.com info@consulab.com 211 CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F HIGH TERMINAL - Connected to the left-hand headlight HIGH terminal and also to terminal #87 of relay #4. When relay #4 is turned on, the HIGH beam headlights operate. GROUND CIRCUITS 1. RELAY #3 Connected to system ground from terminal #85 of relay #3. 2. RELAY #4 Connected to system ground from terminal #85 of relay #4. 3. HIGH BEAM INDICATOR Connected to system ground by the black terminal. 4. LEFT HEADLIGHT Connected to system ground by the COM terminal 5. RIGHT HEADLIGHT Connected to system ground by the COM terminal connected to the COM terminal of the left- hand headlight. NOTE: In this circuit, the LOW beam headlights stay on when the HIGH beam headlights are operated. This is often how some vehicles design their headlight circuits. consulab.com info@consulab.com 212 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F SA-16 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 213 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F SA-16 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 214 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F SA-16 — Level 3 Instructors Answer Key consulab.com info@consulab.com 215 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F consulab.com info@consulab.com 216 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-16 — Headlights Circuit — Option F CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G consulab.com info@consulab.com 217 SA-17 — Headlights Circuit — Option G Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-17 HEADLIGHTS CIRCUIT (OPTION G) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-17 HEADLIGHT CIRCUIT (OPTION G) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-17 CIRCUIT EXPLANATION (OPTION G) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 218 CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G SA-17 — Headlights Circuit — Option G Component Explanation Instructors Answer Key (4 pages) FUSE #1 (20A) Feeds B+ high current power to terminal #30 of relays #1, #2, #3 & #4. This power operates the HIGH and LOW beam headlights. FUSE #2 (15A) Feeds B+ low current power to terminal #86 of relays #1, #2, #3 & #4. This B+ power operates the relays coil circuits. RELAY #1 (Used to operate the left-side LOW beam headlight.) TERMINAL #86- Connected to terminal #86 of relay #2 and also to the LOW terminal of the dimmer switch. This circuit turns on the LOW beam headlights. TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #2 and also to Fuse F1. This is the high current circuit for the LOW beam headlights. TERMINAL #87- Connected to the LOW terminal of the left-hand headlight. TERMINAL #87a- Not used in this circuit. RELAY #2 (Used to operate the left-side LOW beam headlight.) TERMINAL #86- Connected to terminal #86 of relay #1 and also to the LOW terminal of the dimmer switch. This circuit turns on the LOW beam headlights. TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #1 and also to Fuse F1. This is the high current circuit for the LOW beam headlights. TERMINAL #87- Connected to the LOW terminal of the right-hand headlight. TERMINAL #87a- Not used in this circuit. RELAY #3 (Used to turn on the right-hand HIGH beam headlight.) TERMINAL #86- Connected to terminal #86 of relay #4 and HIGH terminal of the dimmer switch. This circuit turns on the HIGH beam headlights. TERMINAL #85- Connected to system ground. consulab.com info@consulab.com 219 CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G TERMINAL #30- Connected to terminal #30 of relay #4 and also to Fuse F1. This is the high current power for the HIGH beam headlights. TERMINAL #87- Connected to the left-hand HIGH beam headlight. TERMINAL #87a- Not used in this circuit. RELAY #4 (Used to turn on the right-hand HIGH beam headlight.) TERMINAL #86- Connected to terminal #86 of relay #3 and also to the HIGH terminal of the dimmer switch. This circuit turns on relay’s #3 & #4 to operate the HIGH beam headlights. TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #30 of relay #3 and also to Fuse F1. This is the high current power for the HIGH beam headlights. TERMINAL #87- Connected to the right-hand HIGH beam headlight. TERMINAL #87a- Not used in this circuit. LIGHT SWITCH COM TERMINAL - Connected to fuse F2(15A) and supplies B+ power for the relay coil circuits. It also connects to the FLASH terminal of the dimmer switch to operate the Flash-To-Pass circuit. PARK TERMINAL - Not used in this circuit. HEAD TERMINAL - Connected to the COM terminal of the dimmer switch to supply B+ coil power when the headlights are turned on. This then turns on relays #1 & #2 to operate the LOW beam headlights. DIMMER SWITCH COM TERMINAL - Connected to the HEAD terminal of the light switch to provide B+ power when the headlights are turned on. LOW TERMINAL - Connected to terminals #86 of relays #1 & #2 which turns on the LOW beam headlights. HIGH TERMINAL - Connected to terminals #86 of relays #3 & #4 which turns on the HIGH beam headlights. It also connects to the red terminal of the HIGH BEAM INDICATOR. FLASH TERMINAL - Connected to the light switch COM terminal which will operate the Flash-To-Pass headlights when the light switch stalk is pulled up. consulab.com info@consulab.com 220 CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G HIGH BEAM INDICATOR RED TERMINAL - Connected to the HIGH terminal of the dimmer switch to operate the indicator light. BLACK TERMINAL - Connected to system ground. LEFT HEADLIGHT LOW TERMINAL - Connected to terminal #87 of relay #2 which supplies B+ power to the left-hand LOW beam headlight. COM TERMINAL - Connected to system ground. HIGH TERMINAL - Connected to terminal #87 of relay #3 to supply B+ power to the left-hand HIGH beam headlight. RIGHT HEADLIGHT LOW TERMINAL - Connected to terminal #87 of relay #2 to supply B+ power to the right-hand LOW beam headlight. COM TERMINAL - Connected to system ground. HIGH TERMINAL - Connected to terminal #87 of relay #4 to supply B+ power to the right-hand HIGH beam headlight. GROUND CIRCUITS 1. RELAY #1 Connected to system ground and also to terminal #85 of relay #2. 2. RELAY #2 Connected to terminal #85 of relay #1 which then goes to system ground. 3. RELAY #3 Connected to system ground and also to terminal #85 of relay #4. 4. RELAY #4 Connected to terminal #85 of relay #3 which then goes to system ground. 5. HIGH BEAM INDICATOR Connected to system ground. 6. LEFT HEADLIGHT Connected to system ground at the top Moduponent panel which is also connected to the mid- dle Moduponent panel. 7. RIGHT HEADLIGHT Connected to system ground at the top Moduponent panel which is also connected to the middle Moduponent panel. consulab.com info@consulab.com 221 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G SA-17 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 222 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G SA-17 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 223 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G SA-17 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 224 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G consulab.com info@consulab.com 225 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-17 — Headlights Circuit — Option G CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H consulab.com info@consulab.com 226 SA-18 — Headlights Circuit — Option H Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-18 HEADLIGHTS CIRCUIT (OPTION H) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-18 HEADLIGHT CIRCUIT (OPTION H) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-18 CIRCUIT EXPLANATION (OPTION H) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 227 CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H SA-18 — Headlights Circuit — Option H Component Explanation Instructors Answer Key (4 pages) FUSE #1 (20A) Supplies B+ high current power to relay #1 terminal #30 and powers both LOW and HIGH beam headlights. When relay #1 turns on, high current power is directed to relay #2 terminal #30 for the HIGH beams. FUSE #2 (15A) Supplies B+ low current power to the multi-function switch for controlling the relay coil circuits. RELAY #1 (Turn on the headlights and power relay #2 at terminal #30.) TERMINAL #86- Connected to the HEAD terminal of the light switch and when HEAD is selected, relay #1 turns on and sends B+ power to terminal #30 of relay #2. TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to Fuse F1(20A) and is the main power for the headlights. TERMINAL #87- Connected to terminal #30 of relay #2. If #2 is off, the LOW beams will operate. If relay #2 is on, the HIGH beams will operate. TERMINAL #87a- Not used in this circuit. RELAY #2 (Used to select either LOW or HIGH beam headlights.) TERMINAL #86- Connected to terminal HIGH of the dimmer switch. When HIGH is selected, relay #2 is turned on. TERMINAL #85- Connected to system ground. TERMINAL #30- Connected to terminal #87 of relay #1. When relay #1 is turned on, relay #2 will either connect the LOW beams if it is off and the HIGH beams when relay #2 is turned on. TERMINAL #87- Connected to the HIGH terminal of the right-hand headlight which is also connected to the left-hand HIGH beam headlight terminal and the HIGH BEAM INDICATOR red terminal. TERMINAL #87a- Connected to the LOW terminal of the right-hand headlight which is also connected to the left-hand LOW beam headlight terminal. LIGHT SWITCH COM TERMINAL - Connected to Fuse F2(15A) and supplies low current power for the relay coil control circuits. consulab.com info@consulab.com 228 CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H PARK TERMINAL - Not used in this circuit. HEAD TERMINAL - Connected to terminal #86 of relay #1 and also to the FLASH terminal of the dimmer switch. When HEAD is selected, relay #1 turns on sending power to relay #2. DIMMER SWITCH COM TERMINAL - Connected to COM terminal of the light switch and also to Fuse F2(15A) for supplying low current power for relay #2. LOW TERMINAL - Not used in this circuit. HIGH TERMINAL - Connected to terminal #86 of relay #2 and when HIGH is selected, relay #2 switches from LOW (#87a) to HIGH (#87) and the HIGH beam headlights come on. FLASH TERMINAL - Connected to the HEAD terminal of the light switch. When FLASH is selected, the light switch stalk is lifted up which turns on both relay #1 and relay #2 and the HIGH beam headlights operate even if the headlights were OFF before the stalk was lifted up. HIGH BEAM INDICATOR RED TERMINAL - Connected to the left-hand headlight HIGH terminal. BLACK TERMINAL - Connected to system ground. LEFT HEADLIGHT LOW TERMINAL - Connected to the right-hand headlight LOW terminal and is how the left-hand LOW beam gets power. COM TERMINAL - Connected to system ground. HIGH TERMINAL - Connected to the HIGH terminal of the right-hand headlight, the red terminal of the HIGH and continues on the terminal #87 of relay #2. RIGHT HEADLIGHT LOW TERMINAL - Connected to terminal #87a of relay #2 and also to the left-hand headlight LOW terminal. When relay #1 turns on, power is sent to relay #2 and the LOW beams turn on. COM TERMINAL - Connected to the left-hand headlight COM terminal, then on to system ground. HIGH TERMINAL - Connected to terminal #87 of relay #2 and also to the left-hand headlight HIGH terminal. When relay #1 and #2 both turn on, power is sent to relay #2 out of terminal #87 and the LOW beams turn on. consulab.com info@consulab.com 229 CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H GROUND CIRCUITS 1. RELAY #1 Connected to system ground on top panel. 2. RELAY #2 Connected to system ground on top panel. 3. HIGH BEAM INDICATOR Connected to system ground on middle panel. 4. LEFT HEADLIGHT Connected to system ground on top panel. 5. RIGHT HEADLIGHT Connected to left-hand headlight COM terminal, then to system ground on top panel. consulab.com info@consulab.com 230 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H SA-18 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 231 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H SA-18 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 232 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H SA-18 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 233 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H consulab.com info@consulab.com 234 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-18 — Headlights Circuit — Option H consulab.com info@consulab.com 235 CL-1918-4S_053304-91 Whole Trainer Wiring Whole Trainer Wiring CL-1918-4S_053304-91 Titre de la section consulab.com info@consulab.com 236 SA-19 & SA-20 — Whole Trainer Wiring General Information The CL-1918-4 Lighting Trainer is a “generic” lighting system. There are countless different methods of wiring the entire trainer so that all circuits properly function. Each option would result in the trainer operating normally. However, when working with a group of students, and for consistency, it is advisable to follow the suggested methods included in Stu- dent Assignments SA-19 and SA-20. Due to the number of jumper wires involved in wiring the entire trainer, we have split the assignments into two halves. SA-19 will show how to connect all black ground wires and SA-20 will show how to connect all red positive wires. Below is the jumper wire count for this trainer and all connections must be made so that the connections are possible with the wire count provided. CL-1918-4 Total Jumper Wire count • 8 LONG BLACK (1 METER – 43”) (used in assignment SA-19 = 3) • 25 SHORT BLACK (58cm – 23”) (used in assignment SA-19 = 25) • 6 LONG RED (1 METER – 43”) (used in assignment SA-20 = 3) • 50 SHORT RED (58cm – 23”) (used in assignment SA-20 = 49) It will be necessary to “stack” more than one jumper wire at the same connection point. We recommend that no more than three jumper wires be stacked at any one point. Fuse Box Identification for Whole Trainer Wiring Assignment GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A Feed From Fuse 1 Relays #1 & #2 Terminals #30 HD lights and feed to Fuses 4, 5, 6 & 7 IGN Switch BAT feed Horn & Brake Lights Realy #3 Terminal #30 (Parking Lights) Realy #4 Terminal #30 (Horn) Hazard Lights Multi-Function Switch Power Turn Signals & Backup Lights (switched) Feed From Fuse 1 Feed From Fuse 1 Feed From Fuse 1 Feed From IGN SWT (IGN) CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 237 SA-19 — Level 1 / Level 2 Assignment (3 pages) The assignment of wiring the entire trainer with all lighting circuits requires a careful reading and understand of instruc- tions. Please carefully read, understand and follow the instructions you are given to complete this assignment. There are many jumper wires of both red and black that need to be installed in order to construct all of the circuits on this trainer. To avoid potential confusion, the instructions will separate the positive (power) and negative (ground) por- tions of the circuit into two different assignments. With so many wires necessary, the diagram will be somewhat compli- cated and there will be many wires routed throughout. Be sure to double check each connection with the schematic. 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the ENTIRE TRAINER WIRING, GROUND CIRCUITS (SA-19) and POWER CIRCUITS (SA-20). While carefully following each schematic, correctly con- nect red and black circuit wires according to the instructions. 3. The assignments will be in two parts : NEGATIVE (GROUND) SIDE (SA-19) and POSITIVE (POWER) SIDE (SA-20) 4. Start with the NEGATIVE (GROUND) side (SA-19). Connect black jumper wires for each of the following circuits : TOP MODUPONENT PANEL CL-1918-01A A. HEADLIGHTS B. PARK-TURN LIGHTS C. FRONT SIDE MARKER LIGHTS D. RELAYS #1 and #2 E. GROUND CONNECTION FROM TOP TO MIDDLE PANEL MIDDLE MODUPONENT PANEL CL-1918-O2A A. LEFT, HIGH BEAM and RIGHT INDICATOR LIGHTS B. HAZARD SWITCH C. RELAYS #3 and #4 D. HORN E. HAZARD FLASHER F. TURN SIGNAL SWITCH G. HEADLIGHT SWITCH H. DIMMER SWITCH CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 238 BOTTOM MODUPONENT PANEL CL-1918-O3A A. REAR SIDE MARKER LIGHTS B. REAR TURN SIGNAL LIGHTS C. TAIL-STOP LIGHTS D. BACKUP LIGHTS E. LICENSE PLATE LIGHT F. CHMSL LIGHT G. GROUND CONNECTION FROM BOTTOM TO MIDDLE PANEL 5. Continue with the POSITIVE (POWER) side (SA-20). Connect red jumper wires for each of the following circuits : TOP MODUPONENT PANEL CL-1918-01A A. HEADLIGHTS B. FRONT SIDE MARKER LIGHTS C. PARK-TURN LIGHTS D. RELAYS #1 and #2 MIDDLE MODUPONENT PANEL CL-1918-O2A A. LEFT, HIGH BEAM AND RIGHT INDICATORS B. IGNITION SWITCH C. HAZARD SWITCH D. RELAYS #3 and #4 E. FUSE PANEL F. HORN BUTTON G. HORN H. BACKUP LIGHT SWITCH I. BRAKE SWITCH J. HAZARD FLASHER K. TURN SIGNAL FLASHER L. TURN SIGNAL SWITCH CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 239 BOTTOM MODUPONENT PANEL CL-1918-O3A A. REAR SIDE MARKER LIGHTS B. REAR TURN SIGNAL LIGHTS C. TAIL-STOP LIGHTS D. BACKUP LIGHTS E. LICENSE PLATE LIGHT F. CHMSL LIGHT G. GROUND CONNECTION FROM BOTTOM TO MIDDLE PANEL 6. With instructor’s permission, turn on the power to the trainer and confirm that every circuit functions normally. If not, go back over your work to find and repair any errors. 7. List any circuits that did not properly function at first on your answer sheet. 8. If required, remove all circuit wiring and place jumper wires correctly in their storage place. 9. Submit your answer sheet to instructor for check and credit. consulab.com info@consulab.com 240 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring SA-19 — Level 1 Schematic — Ground Circuits Instructors Answer Key consulab.com info@consulab.com 241 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring SA-20 — Level 1 Schematic— Positive Circuits Instructors Answer Key consulab.com info@consulab.com 242 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring SA-19 — Level 2 Schematic — Ground Circuits Instructors Answer Key consulab.com info@consulab.com 243 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring SA-20 — Level 2 Schematic— Positive Circuits Instructors Answer Key consulab.com info@consulab.com 244 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring SA-19 — Level 3 Schematic— Ground Circuits Instructors Answer Key Page 1 consulab.com info@consulab.com 245 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 246 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 247 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring SA-20 — Level 3 Schematic— Positive Circuits Instructors Answer Key Page 1 consulab.com info@consulab.com 248 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 249 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-19 & SA-20 — Whole Trainer Wiring consulab.com info@consulab.com 250 CL-1918-4S_053304-91 Ohm’s an Kirchhoff’s Laws Assignments Ohm’s and Kirchhoff’s Laws Assignments CL-1918-4S_053304-91 Ohm’s and Kirchhoff’s Laws Assignments consulab.com info@consulab.com 251 Ohm’s and Kirchhoff’s Laws Assignments The CL-1918-4 Lighting Circuits Trainer can be utilized for the learning of Ohm’s & Kirchhoff’s Law’s and how different resistances behave in different circuits. This section uses all of the incandescent bulbs and NOT the LED bulbs. This is primarily due to the extremely high resistance of LED bulbs and the subsequent low current values. Each of the incan- descent bulbs will be “re-named” with a resistor number which makes the schematics and assignments easier to read and perform. SA-21 — Resistances in Parallel SA-22 — Resistances in Series SA-23 — Combination Resistances (Series & Para) SA-24 — Bulbs of Different Resistances (Series & Para) SA-25 — Bulbs with Same Resistances in Series SA-26 — Different Resistance Values in Combination Series & Parallel SA-27 — Relay Control Circuit with High Resistance Circuit Assignments Instructions This series of assignments are designed to demonstrate Ohm’s and Kirchhoff’s Laws covering the behavior of resistanc- es con¬nected in series and parallel circuits. Be sure to read, understand and follow each assignments instruction’s and ask your instruc¬tor if you have any questions. You will be asked to make voltage and amperage measurements for some assignments. Be sure you fully understand the proper use and hookup of volt and ammeters. All of these assignments will be constructed on the CL-1918-4 trainer. Be sure to ALWAYS use fuses to protect all cir- cuits. Fill out the Ohm’s & Kirchoff’s Law circuit assignment student answer sheet with name, class and information. Put all answers to these questions on the student answer sheet. Do not write on this paper. NOTE- The light bulbs on the CL-1918-4 will be assigned “R” numbers so that there will be clarity and consistency in constructing the circuits for these assignments. Be sure to use the correct bulb based on its “R” number. The legend is as follows : LIGHT BULB TO RESISTANCE IDENTIFICATION LF MARKER R1 R - HEADLIGHT - LOW R7 #2 RELAY COIL R13 RF PARK LIGHT R19 RF MARKER R2 R - HEADLIGHT - HIGH R8 #3 RELAY COIL R14 L TURN INDICATOR R20 LR MARKER R3 LEFT BACKUP R9 #4 RELAY COIL R15 R TURN INDICATOR R21 RR MARKER R4 RIGHT BACKUP R10 LF TURN LIGHT R16 HIGH INDICATOR R22 L - HEADLIGHT - LOW R5 LICENSE PLATE R11 LF PARK LIGHT R17 LEFT STOP R23 L - HEADLIGHT - HIGH R6 #1 RELAY COIL R12 RF TURN LIGHT R18 RIGHT STOP R24 CL-1918-4S_053304-91 SA-21 Circuit #1 — Resistances in Parallel consulab.com info@consulab.com 252 SA-21 Circuit #1 — Resistances in Parallel 1. Connect R1 & R2 side marker lights in parallel and use the backup light toggle switch to control the circuit. (See Circuit #1 schematic if needed) 2. Confirm that the circuit operates correctly. 3. Measure the voltage drop across each light. 4. Measure the voltage drop across the toggle switch. 5. What is an acceptable voltage drop across a toggle switch ? 6. What would explain an excessive voltage drop across the toggle switch ? 7. Measure the current flowing though each R1 & R2 marker light individually. 8. Add the sum of the individual current draws together. 9. Now, measure the total circuit current draw of R1 & R2 and compare with the answer in question #8. Was it very close to being the same ? 10. What would explain a voltage drop lower than expected at one of the marker lights ? 11. One can conclude that in a parallel circuit, the ? Is the same at all resistances in the circuit and the ? changes at each resistance. 12. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 253 CL-1918-4S_053304-91 SA-21 Circuit #1 — Resistances in Parallel SA-21 Circuit #1 — Resistances in Parallel Instructors Answer Key 3. R1 13.75 V ± R2 13.75 V ± 4. TOGGLE SWITCH - 70.4 millivolts or .0704 Volts ± 5. Most service information state no more than 100 milli-volts (0.100 V) per contact or connection. 6. Dirty or corroded switch contacts or loose/dirty connections to it. 7. R1 323 milli-amps or 0.3 A ± R2 323 milli-amps or 0.3 A ± 8. R1 + R2 = 645 milli-amps or 0.64 A ± 9. MEASURED TOTAL CURRENT OF R1 & R2 - 687 milli-amps or 0.7 A ± 10. There would be “unwanted” resistance in that bulb’s circuit from poor connections, bad socket, wiring or the bulb itself. 11. Voltage REMAINS THE SAME & amperage or current CHANGES AT EACH RESISTANCE. consulab.com info@consulab.com 254 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-21 Circuit #1 — Resistances in Parallel SA-21 — Schematic Instructors Answer Key R1 R2 R3 CL-1918-4S_053304-91 SA-22 Circuit #2 — Resistances in Series consulab.com info@consulab.com 255 SA-22 Circuit #2 — Resistances in Series 1. Connect the R1 & R2 marker lights in series and use the backup light toggle switch to control the circuit. (See Circuit #2 schematic if needed) 2. Confirm that the circuit operates correctly. 3. What is the first thing you notice about the brightness of the marker lights compared to Circuit #1 ? 4. Measure the voltage drop across R1 & R2 lights. 5. Measure the current flowing between the switch and the R1 marker light. 6. Measure the current flowing between the R1 & R2 marker lights. 7. Measure the current flowing between the R2 marker light and ground. 8. Disconnect the wire between the R1 & R2 marker lights. What happened ? 9. How many different paths are there in this circuit for current to flow ? 10. What would be your prediction of circuit performance if you installed another marker light in series ? 11. Install R3 in series with R1 & R2 and describe what happened to the circuit performance. 12. One can conclude that in a series circuit, the ? is the same throughout the entire circuit and the ? changes at each resistance. 13. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 256 CL-1918-4S_053304-91 SA-22 Circuit #2 — Resistances in Series SA-22 Circuit #2 — Resistances in Series Instructors Answer Key 3. Both R1 & R2 are dimmer than they were in Circuit #1. 4. R1 6.76 V ± R2 6.81 V ± 5. SWITCH & R1 - 210 mA or 0.210 A ± 6. BETWEEN R1 & R2 - 210 mA or 0.210 A ± 7. BETWEEN R2 AND GROUND - 210 mA or 0.210 A ± 8. Entire circuit shuts off. 9. Only one path. 10. All three bulbs would be on, but dimmer than with two bulbs. 11. All three bulbs are on, but dimmer than with two bulbs. 12. Current REMAINS THE SAME & Voltage CHANGES AT EACH RESISTANCE consulab.com info@consulab.com 257 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-22 Circuit #2 — Resistances in Series SA-22 — Schematic Instructors Answer Key R1 R2 R3 R4 CL-1918-4S_053304-91 SA-23 Circuit #3 — Combination Resistances in both Series and Parallel consulab.com info@consulab.com 258 SA-23 Circuit #3 — Combination Resistances (Series & Para) 1. Refer to Circuit #3 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Confirm that the circuit operates correctly. 3. There should be three branches to this circuit. R1 is connected in series with the parallel branch of R2 & R3, which is connected in series to R4. 4. Describe the performance of each bulb in the circuit. 5. Measure the voltage drop across R1, R2, R3 and R4. 6. Measure the current flow in the circuit from the backup light switch to R1. 7. Measure the current flow in the circuit from R4 to ground. 8. Measure the current flow in R2 and R3. 9. Explain why the current flow in R2 and R3 was less than R1 and R4 if all bulbs are identical ? 10. Install a jumper wire that will bypass R2 & R3 and just leave R1 & R4 in the circuit. 11. Measure the current flow in the revised circuit. 12. Measure the voltage drop across R1 & R4. 13. Explain why the readings are different than when R2 & R3 were in the circuit. 14. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 259 CL-1918-4S_053304-91 SA-23 Circuit #3 — Combination Resistances in both Series and Parallel SA-23 Circuit #3 — Combination Resistances in both Series and Parallel Instructors Answer Key 4. R1 and R4 are on dim and R2 & R3 do not appear to be on (but they are). 5. R1 5.85 volts ± R2 1.77 volts ± R3 1.77 volts ± R4 5.94 volts ± 6. 193 mA or 0.19 A ± 7. 193 mA or 0.19 A ± 8. R2 93.8 mA or 0.093 A ± R3 94.1 mA or 0.094 A ± 9. This is a three part series circuit (R1 + [R2 & R3] + R4) R2 & R3 are in parallel to each other so the amperage in the series circuit (0.213 A) (same in all parts of series circuit) enters the parallel branch, but “splits” to each bulb based on each bulb’s resistance. The currents of R2 and R3 should add up to the same as the series circuit cur- rent which is 0.213 A. So, 0.109 A (R2) plus 0.101 A (R3) equals 0.210 A which is very close to the 0.213 A of the series current. Any minute variations is based on the dynamic resistance differences in each bulb between being wired in parallel or series and how many of each is in the circuit. 11. 330 mA or 0.033 A ± 12. R1 6.83 volts ± R4 6.73 volts ± 13. Because the resistances of R2 and R3 were bypassed by the jumper wire and the remaining R1 and R4 are con- nected in series, the source voltage is split between these two bulbs. The voltage is not exactly equal due to manufacturing tolerances within each bulb. They are very close to being the same. consulab.com info@consulab.com 260 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-23 Circuit #3 — Combination Resistances in both Series and Parallel SA-23 — Schematic Instructors Answer Key R1 R2 R3 R4 CL-1918-4S_053304-91 SA-24 Circuit #4 — Bulbs of Different Values in Series consulab.com info@consulab.com 261 SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) 1. Refer to Circuit #4 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Confirm that the circuit operates correctly. 3. Describe the performance of each bulb. 4. Measure the source voltage available at the load side of the backup toggle switch to ground. 5. Measure the voltage drop across R9 & R7. 6. Measure the current flow in this circuit. 7. Explain why R9 bulb is on and R7 bulb is not on. 8. Connect a jumper wire across the terminals of R9 and explain what happens. 9. Measure the voltage drop across R7. 10. Explain why the reading is now different than it was in step #4. 11. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 262 CL-1918-4S_053304-91 SA-24 Circuit #4 — Bulbs of Different Values in Series SA-24 Circuit #4 — Bulbs of Different Values in Series Instructors Answer Key 3. The backuip light bulb is on and seems to be at full brightness. The headlight seems to be “off”. 4. 13.50 volts ± 5. R9 13.32 volts ± R7 154.4 milli-volts or 0.154 volts ± 6. 450 milli-amps or 0.450 A 7. This is a series circuit with only one path for current to flow. The backup light bulb has a much higher resistance than the LOW beam head light bulb and thus, consumes the majority of available voltage to push electrons through the circuit. This reduces the amount of voltage available to the headlight (0.110 volts) and therefore, although there is current flowing through the headlight, it is very small and is not near enough to cause the head- light to operate. 8. R9 is off and R7 is on at full brilliance 9. 12.52 volts ± 10. With R9 bypassed, full voltage is available at R7 consulab.com info@consulab.com 263 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-24 Circuit #4 — Bulbs of Different Values in Series SA-24 — Schematic Instructors Answer Key R7 R9 CL-1918-4S_053304-91 SA-25 Circuit #5 — Bulbs with Same Resistances in Series consulab.com info@consulab.com 264 SA-25 Circuit #5 — Bulbs with Same Resistances in Series 1. Refer to Circuit #5 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Confirm that the circuit operates correctly. 3. Describe the performance of each bulb. 4. Measure the voltage drop across each bulb. 5. Are most circuits in a vehicle connected in parallel or series ? 6. Now insert R14 in series with R4. Confirm that your wiring is correct. 7. Describe the operation of R4 now. 8. Measure the current flow in JUST the circuit with R4 and 14. 9. Measure the voltage drop across R4 and R14. 10. What conclusions can you make from this circuit ? 11. Using a jumper wire, jump across the two terminals of R14 and describe what happens to R4. 12. Remove R14 from the circuit. 13. Measure the total current flow of all four bulbs in this circuit. 14. Now, modify the circuit to add R14 in parallel with R1, R2, R3 & R4. 15. Measure the total circuit amperage including R14. 16. What conclusions can you make from this result ? 17. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 265 CL-1918-4S_053304-91 SA-25 Circuit #5 — Bulbs with Same Resistances in Series SA-25 Circuit #5 — Bulbs with Same Resistances in Series Instructors Answer Key 3. All the marker lights (R1, R2 R3 & R4) should be on with equal brilliance. 4. R1 13.25 volts ± R2 13.25 volts ± R3 13.25 volts ± R4 13.25 volts ± 5. Parallel. 7. R4 is barely on (difficult to see in bright room). 8. R4 + R14 = 120.6 milliamps (mA) ± 9. R4 2.31 volts ± R14 10.89 volts ± 10. The unwanted resistance of the relay coil (R14) in series with R4 causes a large voltage drop which reduces the voltage available to operate R4 properly. This extra resistance also reduces the current flow in the circuit. This could be the result of corrosion, loose wires, dirty connections or other types of resistance. 11. R4 now operates normally with the extra resistance temporarily bypassed. This testing process can be called “overlaying” a temporary wire to confirm the location of the unwanted resistance. 13. 1.250 amps or 1,250 mA ± 15. 1.41 amps or 1,410 mA ± 16. Adding more resistances in parallel increases the total circuit current flow. consulab.com info@consulab.com 266 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-25 Circuit #5 — Bulbs with Same Resistances in Series SA-25 — Schematic Instructors Answer Key R1 R2 R3 R4 CL-1918-4S_053304-91 SA-26 Circuit #6 — Different Resistance Values in a Combination Series/Parallel Circuit consulab.com info@consulab.com 267 SA-26 Circuit #6 — Different Resistance Values in Combination Series & Parallel Circuit Refer to Circuit #6 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 1. Turn on the switch and describe the performance of the circuit. 2. Measure the voltage drop at R2, R1, R7 and R5. 3. Measure the total current flow in this circuit. 4. Using a jumper wire, temporarily bypass R2 and describe what the performance of the circuit. 5. Measure the current flow in this “modified circuit”. Do you suspect that it will be higher or lower than before ? 6. Look at the circuit schematic and predict what will happen if you bypass R1 ? (Leave R2 “bypassed” for this step) 7. Using a jumper wire, temporarily bypass R1 and describe the performance of the circuit. 8. Explain why the circuit is operating as described in Step #8. 9. Measure the total circuit current flow at this point. 10. Remove the jumper wire from R1 and leave the jumper wire attached to R2. 11. Explain why the right headlight (R7) is not on and yet the left headlight (R5) is on. 12. Measure the voltage drop across R1 and R7. 13. Measure the current flow in the circuit of R1 and R7. 14. Remove the ground wire that attaches R1 bulb to ground and measure the voltage between the disconnected end and ground. 15. Explain why you got the voltage reading that you did on this wire. 16. Using jumper wires, jumper across the terminals of R1 and R2, then describe the performance of the circuit. 17. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 268 CL-1918-4S_053304-91 SA-26 Circuit #6 — Different Resistance Values in a Combination Series/Parallel Circuit SA-26 Circuit #6 — Different Resistance Values in Combination Series & Parallel Circuit Instructors Answer Key 2. R2 is on at what seems to be full brilliance and all other bulbs are off. 3. R2 13.43 volts R7 0.00 volts R1 0.11 volts R5 0.11 volts 4. 310 mA or 0.310 A ± 5. R2 went out, R7 is out, and R5 and R1 seem to both be on with full brilliance. 6. Higher 3.09 A or 3,090 mA ± 7. With R1 & R2 bypassed, all resistances other than the two headlights are “out of the circuit” and because both headlights are connected in parallel, both should come on with normal brilliance. 8. Both headlights come on with normal brilliance and both side marker lights are off. 9. With both R1 and R2 bypassed, both headlights are now connected in parallel which is how they are wired in a vehicle. They both operate at normal brilliance because there is no unwanted resistance in the circuit. 10. 5.44 amps or 5,440 mA ± 12. The ground circuit for the right headlight (R7) is connected in series with the resistance of R1. Because R1 has much more resistance than the headlight, all voltage is dropped across the marker light and not enough is left to operate the headlight. These two bulbs are connected in series. R1 represents unwanted resistance in the head- light circuit on the right-hand side. 13. R1 12.232 volts ± R7 0.17 volts ± 14. 0.300 A or 300 mA ± consulab.com info@consulab.com 269 CL-1918-4S_053304-91 SA-26 Circuit #6 — Different Resistance Values in a Combination Series/Parallel Circuit 15. 12.61 volts ± 16. This voltage measurement is calle an “open circuit” voltage test and all it reveals is that both bulbs (R1 and R7) are not burned out. The test proves that when checking for unwanted resistances in a circuit, checking open cir- cuit voltage with the component plug disconnected is a waste of time as it doesn’t tell you where the resistance is located. The only real accurate test to pinpoint unwanted resistance is to check voltage drops from one point to the next in the circuit. 17. Both headlights operate normally because all unwanted resistance has been removed from the circuit. consulab.com info@consulab.com 270 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-26 Circuit #6 — Different Resistance Values in a Combination Series/Parallel Circuit SA-26 — Schematic Instructors Answer Key R1 R2 R5 R7 CL-1918-4S_053304-91 SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition consulab.com info@consulab.com 271 SA-27 Circuit #7 — Relay Control Circuit with High Resistance 1. Refer to Circuit #7 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. In this circuit, relay #3 controls the LOW beam (R7) on the right headlight. 3. Turn on the switch and describe what happens. Leave switch on unless instructed to turn it off. 4. Measure the voltage drop across the coil of relay #3 (R14). 5. In a normal operating circuit, what should the voltage drop be across the coil of relay #3 (R14) ? 6. In a normal operating circuit, what should the voltage at the supply side of the relay coil to ground ? 7. Measure the voltage available at the power supply side of relay #3 coil (R14). 8. In a normal operating circuit, what should be voltage to ground be at the ground side of relay coil #3 (R14) ? 9. Measure the voltage from the ground side of relay #3 (R14) ground terminal to ground. 10. What does the reading from Step #9 indicate ? 11. Measure the voltage drop across the relay coil of relay #3 (R14). 12. Would a defective relay coil explain the reading measured in Step #11 ? (Yes or No) 13. Using a jumper wire, connect terminal 85 of relay #1 (R12) to terminal 85 of relay #3 (R14). Explain what happens. 14. Remove the jumper wire and explain what happens. 15. Turn the switch OFF and back ON again. Explain what happens ? 16. Reconnect the jumper wire as you did in Step 13. What happens ? 17. Measure the voltage drop across the relay coil of relay #3 (R14) with jumper still installed. 18. Measure the voltage drop from terminal #85 of relay #3 (R14) to ground. 19. Is the reading from Step 18 considered to be “normal” ? Turn the backup light switch OFF. 20. Remove the jumper wire and turn switch ON. Measure the voltage drop across each of the three relay coils. 21. Remove the wire connected from terminal #85 of relay #1 (R12) to ground and measure from the end of that wire to ground. 22. The last measurement should prove to you that when attempting to locate unwanted resistances, checking an “open circuit” voltage (a connector unplugged) will NEVER tell you where the resistance is located. The reading of an open circuit voltage will always be source voltage because there is very, very little current flowing in it. (voltmeter imped- ance only). ALWAYS use the voltage drop method of testing to located unwanted resistances. 23. Could the unwanted resistance also be in the positive side of the circuit ? 24. The purpose of this assignment is to teach you how to located unwanted resistance in a circuit using the measure- ment of voltage drop to exactly located the source of the problem. Do you understand this concept ? 25. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 272 CL-1918-4S_053304-91 SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition Instructors Answer Key (2 pages) 3. The headlight (R7) doesn’t come on. 4. 4.32 volts ± 5. Close to source voltage (13.83 volts ±) (There may be a very slight reduction from source voltage for circuit resis- tance). 6. Close to source voltage (13.00 volts ±). 7. 13.71 volts ± 8. 0.00 volts 9. 9.41 volts ± 10. There is excessive and unwanted resistance in the relay’s ground circuit. 11. 4.32 volts ± 12. No. The problem is unwanted resistance in the ground circuit of the relay #3 (R14). 13. The right headlight comes on. 14. The right headlight stays on. 15. The relay does not turn on the headlight because of the excessive resistance in the ground circuit of the relay coil. 16. The headlight comes back on because the unwanted resistance has been “jumped over” with jumper wire. If the jumper wire is disconnected, the relay will still stay on as the current required to keep the relay energized is less than the current required to energize the relay. This is an excellent teaching moment here. 17. 12.91 volts ± 18. 0.00 volts consulab.com info@consulab.com 273 CL-1918-4S_053304-91 SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition 19. Yes. 20. RELAY #3 4.63 volts ± RELAY #2 4.61 volts ± RELAY #1 4.59 volts ± 21. 13.71 volts ± 23. No, if you have source B+ voltage at terminal #86 with relay “on”, the problem is not in the positive circuit. 24. Student will answer either YES or NO. consulab.com info@consulab.com 274 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition SA-27 — Schematic Instructors Answer Key R7 R12 R13 R14 consulab.com info@consulab.com 275 CL-1918-4S_053304-91 Optional Circuits Optional Circuits CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit consulab.com info@consulab.com 276 SA-28 — Generic Vehicle Alarm System Circuit Circuit Criteria Instructions This assignment asks you to design a “generic” vehicle alarm system similar to what might be seen in common vehicle applications. You will use the trainer’s components for different applications from when they were originally designed. Be sure to carefully follow the circuit criteria explained below. Please carefully follow all of the below instructions to complete this assignment. You are allowed to use any of the components on the CL-1918-4 trainer, BUT, no additional components are permitted. Circuit Description : Using your knowledge and understanding of the CL-1918-4 trainer, design the alarm system to meet the following criteria : 1. The alarm system must NOT be able to operate anytime the ignition switch is in the IGN position. (turning on the ignition switch to IGN must disable the alarm system even though it may have been armed previously). 2. The system must be able to be armed anytime the ignition switch is turned to the OFF position. 3. There must be one “door switch” used in the system. You must choose from the switches available on the trainer. The alarm system must be “tripped” anytime the door is opened. 4. When the alarm system is tripped, both the front LOW beam headlights, both rear STOP lamps and the horn must flash on and off as long as the system remains in “alarm mode”. 5. This circuit must have an “arming switch” (most likely would be a key fob in a real vehicle) where the system can be manually turned on and off, but if the ignition switch is in the ON position, the arming switch will not be able to arm the system. On the CL-1918-4 trainer, you have to use one of the switches on the trainer for the “arming switch”. 6. All circuits must be protected by fuses. 7. Any of the components on the trainer can be used to operate this circuit. NO OTHER COMPONENTS ALLOWED. 8. Obtain a Level 1, 2 or 3 blank schematic for the trainer and draw your circuit as you design it. 9. Confirm correct circuit operation or correct any errors that are discovered. 10. Fill out the student answer sheet and explain what each component in the circuit does. 11. Upon successful completion of the circuit, turn in your completed schematic and answer sheet to your instructor. CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit consulab.com info@consulab.com 277 List of Components and their Role Answer Sheet Check every student list of components (other than wires) used to complete their alarm system. consulab.com info@consulab.com 278 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Generic Vehicle Alarm System Circuit Circuit Explanation Instructors Answer Key (4 pages) This “generic” vehicle alarm system uses three relays, the LOW beam headlights, the horn, the turn signal flasher and the following switches: 1- Backup light switch (as an arming switch), 3- Brake light switch (as a door switch), two power fuses and the necessary ground circuits for all components. FUSE #1 (20A) Fuse #1 protects the ignition switch and the coil circuit of relay #1. It also protects the control circuit of relay #3, the low beam headlights, the rear stop lights and the horn. FUSE #2 (15A) Fuse #2 protects the control circuit of relay #1, the arming switch (backup lights), the control circuit of relay #2, the door switch (brake switch), the coil circuit of relay #2, the turn signal flasher, and the coil circuit of relay #3. LOW BEAM HEADLIGHTS The low beam headlight LOW terminals are connected to terminal #87 of relay #3 and will operate anytime relay #3 is energized. Both COM terminals are connected to system ground. REAR STOP LIGHTS Both rear stop lights are connected to terminal #87 of relay #3 and will operate anytime relay #3 is energized. Both COM terminals are connected to system ground. RELAY #1 TERMINAL #30 - Connected to Fuse #1 and provides power for the arming switch (backup light) when relay #1 is NOT energized. TERMINAL #86 - Connected to IGN terminal of ignition switch and will energize relay #1 when ignition switch is turned to the IGN position. Energizing this relay will open the circuit to the arming switch and will prevent the system from being armed. TERMINAL #85- This is the ground for the coil of relay #1 and is connected to system ground. TERMINAL #87- Not used in this circuit. TERMINAL #87a - Connected to the arming switch (backup light) and will provide B+ power to one terminal of the switch whenever the ignition switch is turned OFF. Turning the ignition switch ON disconnects power to the arming switch and the system cannot be armed. consulab.com info@consulab.com 279 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit RELAY #2 TERMINAL #30- Connected to the arming switch (backup). Anytime the arming switch is closed, and if relay #1 is not energized, power will be connected to terminal 87a of relay #2 which will cause the turn signal flasher to operate and the alarm will be triggered. TERMINAL #86- Connected to one terminal of the door switch (brake) and if the door switch is held down (closed) power will be directed to the coil terminal and the relay will be energized, it will open the circuit to the turn signal flasher and the alarm system can be armed, but will not go into the alarm mode. TERMINAL #85- This is the ground for the coil of relay #2 and is connected to system ground. TERMINAL #87- Not used in this circuit. TERMINAL #87a - Connected to the turn signal BAT terminal and if the relay is not energized, the turn signal flasher will operate and the system will go into alarm mode. The closed door switch keeps the relay energized and therefore does not supply power to the flasher until the relay is not energized by opening the door switch. RELAY #3 TERMINAL #30- Connected to Fuse #1 and provides power for the headlights, horn and stop lights when the relay is energized. TERMINAL #86- Connected to the SIG terminal of the turn signal flasher. When the flasher is energized, a pulsing B+ voltage will energize relay #3. TERMINAL #85- The is the ground for the coil of relay #3 and is connected to system ground. TERMINAL #87- Connected to the positive terminals of the low beam headlights, the horn and the rear stop lights. When relay #3 is energized, all of these components will operate. TERMINAL #87a - Not used in this circuit. IGNITION SWITCH ACC TERMINAL - Not used in this circuit. IGN TERMINAL- Connected to Fuse #1 and provides B+ system voltage to this terminal at all times. START TERMINAL- Not used in this circuit. BAT TERMINAL- Connected to Fuse #1 (load side) and supplies constant B+ power at all times. consulab.com info@consulab.com 280 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit TURN SIGNAL FLASHER GND TERMINAL- Connected to system ground. SIG TERMINAL- Connected to terminal #86 of relay #3 and provides the “pulsing” circuit that turns the low beam headlights, the rear stop lights and horn on and off when the alarm is in the “tripped” mode. BAT TERMINAL- Connected to terminal #87a of relay #2 which when NOT energized, provides a B+ voltage source to the turn signal flasher. DOOR SWITCH (BRAKE LIGHT SWITCH) 1ST TERMINAL- Connected to the load side of Fuse #2 and provides B+ source of voltage when the door switch 2ND TERMINAL- Connected to terminal #86 of relay #2. When the door switch is open (up), it supplies B+ voltage to energize relay #2 and supplies B+ voltage to the BAT terminal of the turn signal flasher and causes the alarm to flash the low beam head lights, the rear stop lights and the horn. ARMING SWITCH (BACKUP LIGHT SWITCH) 1ST TERMINAL - Connected to terminajl #87a of relay #1. If relay #1 is “OFF”, B+ voltage is supplied to the BAT terminal of the turn signal flasher IF the arming switch (backup) is closed. If the arming switch is open, then terminal #30 does not have B+ voltage available and the alarm system is OFF. 2ND TERMINAL - Connected to terminal #87a of relay #1. If relay #1 is NOT energized, then B+ power is available at this terminal of the arming switch (backup). If relay #1 is energized, then B+ power is not available to the arming switch and the alarm system will stay OFF. HORN RED TERMINAL - Connected to terminal #87 of relay #3. When relay #3 is energized by the SIG circuit of the turn signal flasher, a pulsing B+ voltage will be applied to the horn (and front low beam headlights & rear stop lights) BLACK TERMINAL - Connected to system ground and provides the ground circuit for the horn. consulab.com info@consulab.com 281 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit GROUND CIRCUITS The following components are connected to system ground using black wires: 1. Relay #1 coil ground circuit (terminal #85). 2. Relay #2 coil ground circuit (terminal #85). 3. Relay #3 coil ground circuit (terminal #85). 4. Both left and right front low beam headlights. 5. Horn. 6. Both rear left and right rear stop lights. 7. Turn signal flasher. CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit consulab.com info@consulab.com 282 SA-28 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF) and that the power supply red and black wires are connected to the trainer. 3. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the ALARM CIRCUIT, and follow- ing the schematic, correctly connect red and black circuit wires to the optional alarm circuit components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the ALARM CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. What SPECIFIC action does the system arming switch perform ? How does the circuit work with the arming switch ? 7. If Fuse #2 was open, that affect would that condition have on the alarm system ? 8. According to the schematic, what would the circuit do if the connection from system ground to the left front COM terminal of the left-front headlight was open ? 9. According to the schematic, what would the circuit do if the connection from system ground to the horn was open ? 10. According to the schematic, what would the circuit do if the connection from terminal #86 of relay #2 and the door switch (brake) was open ? 11. According to the schematic, what would the circuit do if the connection from system ground to terminal #85 of relay #1 was open ? 12. According to the schematic, what would the circuit do if the terminal #86 of relay #2 was shorted to ground ? 13. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 283 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 1 / Level 2 Assignment Instructors Answer Key 6. The arming switch (backup) connects terminal #87a of relay #1 to terminal #30 of relay #2. If relay #1 if OFF, and the arming switch is closed, B+ power is connected through the closed arming switch to terminal #30 of relay #2. If the ignition switch is turned OFF, there will be B+ power connected to the BAT terminal of the turn signal flasher. Turning the ignition switch to the ON position energized relay #1 and breaks the connection of B+ power to the turn signal flasher and the alarm system can not longer be armed or turned on. 7. If fuse #2 was open, there would be no power to terminal #30 of relay #1 or to the door switch (brake). This would render the alarm system totally inoperative. 8. The left front headlight would be inoperative, but everything else would function. 9. The horn would be inoperative, but everything else would function. 10. If the system were to be armed, the circuit would be constantly in the alarm mode because the door switch (brake) would not be able to energize the coil of relay #2 which in turn supplies B+ power to the BAT terminal of the turn signal flasher. 11. Relay #1 would no longer function and thus the alarm system could not be shut off when the ignition switch is turned to IGN position. Relay #1 would not function and if the system was armed, it would be ON constantly. 12. Fuse #2 would immediately open because of the short circuit of a B+ positive source to ground. The system would be totally inoperative. consulab.com info@consulab.com 284 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 285 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 2 Schematic Instructors Answer Key CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit consulab.com info@consulab.com 286 SA-28 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF) and that the power supply red and black wires are connected to the trainer. 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the alarm circuit components. 4. Obtain instructor’s check. 5. According to the circuit schematic, what affect would an open Fuse #1 have on the alarm system ? 6. According to the circuit schematic, what affect would an open wire at terminal #87a of relay #2 have on the alarm system ? 7. According to the circuit schematic, what affect would a short circuit between the SIG and BAT terminals of the turn signal flasher have on the alarm system have on the alarm system ? 8. According to the circuit schematic, what affect would an open in the wire connected between terminal #86 of relay #1 and IGN terminal of the ignition switch have on the alarm system ? 9. According to the circuit schematic, what affect would an open circuit in the coil of relay #3 have on the alarm sys- tem ? 10. According to the circuit schematic, what affect would a short-to-ground at terminal #87a of relay #3 have on the alarm system ? 11. If you wanted to add more doors switches to this system, would you install the switches in parallel or series ? 12. Using your knowledge of the circuits construction and operation, design a modification to the circuit that would allow the front LOW beam headlights and the rear stop lamps to flash alternately when the system is in alarm mode. Include your design changes on the schematic and submit to instructor. Once approved, insert your modifications in the circuit by connecting the necessary red and black wires to the added components. 13. Does your modified circuit work as desired ? 14. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 287 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 3 Assignment Instructors Answer Key 5. With fuse #1 open, no power would be available to relay #1 or the door switch (brake) and thus, the alarm sys- tem would be inoperative. 6. No B+ power would be available to the BAT terminal of the turn signal flasher and this the system would be inop- erative. 7. The turn signal flasher would not “flash” and thus, both the front LOW beam headlights, the horn and the rear stop lights would be on all the time the alarm system is armed. 8. This would result in the alarm system being able to be armed when the ignition switch is in the IGN position and would result in the system going into alarm mode while the vehicle is being operated. 9. This would cause relay #3 to not operate which is responsible for pulsing on/off the headlights, horn and rear stop lights. Even though, the alarm system could be armed and tripped, nothing would happen. 10. A short-to-ground at terminal #87a of relay #3 would immediately “blow” fuse #1 which would render the entire alarm circuit inoportative. 11. Any extra door switches would be added in series so that the opening of any additional switch would break the circuit and cause the system to go into the alarm mode. 12. See modification schematic for correct explanation of the circuit changes necessary to accomplish this design change. Schematic is titled : “ALARM CIRCUIT – STEP #12 CIRCUIT MODIFICATION SCHEMATIC”. consulab.com info@consulab.com 288 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 289 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit consulab.com info@consulab.com 290 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-28 — Generic Vehicle Alarm System Circuit CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit consulab.com info@consulab.com 291 SA-29 — Emergency Lighting System Circuit Explanation Emergency vehicles often have an EMERGENCY LIGHTING CIRCUIT when enroute to call. Most vehicles alternately flash the high beam headlights as well as the rear stop lights. You will construct this circuit using the components on the CL- 1918-04 trainer. Circuit Description Using your knowledge and understanding of the CL-1918-4 trainer, design the emergency lighting system to meet the following criteria : 1. The emergency lighting circuit should only operate when the ignition switch is in the IGN position. 2. There needs to be a manual switch to turn the lighting system on and off. 3. The emergency lighting system needs to do the following : A. The system must flash the headlights and stop lights alternately on and off. B. The left front headlight and the right rear stop light must flash together. C. The right front headlight and the left rear stop light must flash together. D. The horn (siren) must be on constantly any the time the system is operating. E. The horn and all lights MUST be controlled by relays and must not be direct wired. 4. All current of all lights and horn must NOT flow through any relay coil circuit. 5. All circuits must be protected by fuses rated for the current of the components. Assignment 1. This assignment applies to all three levels (1,2 & 3). The difference will be what level of schematic you use to design, confirm and then draw the final circuit. 2. Obtain a Level 1, 2 or 3 blank schematic and using your knowledge of the components on the trainer, design a cir- cuit that meets the above criteria. 3. Obtain your instructor’s approval of your design, then construct your circuit design on the trainer using black and red jumper wires. Once completed, confirm proper operation of the circuit. Correct any errors that you discover. 4. Fill out the COMPONENT EXPLANATION SHEET where you explain the operation of the components you used in the circuit. Turn assignment sheet in to your instructor when completed. 5. Fill out a final Level 1, 2 or 3 schematic showing the circuit you have designed and turn in to your instructor. consulab.com info@consulab.com 292 CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit SA-29 — Emergency Lighting Circuit Circuit Explanation Answer key Power from Fuse #1 is connected to terminal #30 of relay #1. When terminal #86 of relay #1 is energized by the backup light switch, terminal #30 of relay #1 is connected to terminal #87 of relay #1 which connects to termi- nal #30 of relay #2 and the positive terminal of the horn. Fuse #2 is connected to the BAT terminal of the ignition switch. When the ignition switch is turned to the IGN position, B+ voltage is sent from the ignition switch to one terminal of the backup light switch. If the backup light switch is turned on, B+ voltage is sent to both terminal #86 of relay #1 (energizes it) and also to the BAT terminal of the turn signal flasher. With B+ voltage available at the turn signal flasher BAT terminal, the flasher begins to operate which connects the SIG terminal of the flasher to termi- nal #87a of relay #2 which causes relay #2 to operate on and off with the flasher. When relay #2 circuit is off, B+ is directed from terminal #87 of relay #1 to terminal #30 of relay #2 and out of terminal #87 to the right HIGH beam headlight and the left STOP light. This alternate operation will continue as long as the backup light switch is turned on. See Level 1, 2 & 3 EMERGENCY LIGHTS CIRCUIT schematics consulab.com info@consulab.com 293 CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit Circuit Component Explanation Instructors Answer Key HIGH BEAM HEADLIGHTS The right HIGH beam headlight is connected to terminal #87 of relay #2. The left HIGH beam headlight is connected to terminal 87a of relay #2. Both left and right headlights are also connected to system ground. REAR STOP LIGHTS The right stop light is connected to terminal #87a of relay #2 and the left stop light is connected to terminal #87 of relay #2. These connections will result in the headlights and stop lights flashing alternately on and off when relay #2 is energized. The stop lights are also connected to system ground. RELAY #1 The coil circuit of relay #1 is terminal #85 is connected to system ground and terminal #86 is connected to the one terminal of the backup light switch. Therefore, anytime the backup light switch is ON, the coil of relay #1 will energize. Terminal #30 of relay #1 is connected to fuse #1(20A) which represents system voltage at all times. Terminal #87 of relay #1 is connected to terminal #30 of relay #2. RELAY #2 The coil circuit of relay #2 is terminal #85 is connected to system ground and terminal #86 is connected to the SIG terminal of the turn signal flasher. Terminal #30 of relay #2 is connected to terminal #87 of relay #1 and also to the horn positive terminal. Terminal #87 of relay #2 is connected to the HIGH beam terminal of the right headlight and also to the left stop light. Terminal #87a of relay #2 is connected to the left HIGH beam terminal of the left headlight and also to the right stop light. IGNITION SWITCH The ignition switch BAT terminal is connected to fuse #2(15A) and brings constant system voltage to the ignition switch. The IGN terminal of the ignition switch is connected to one terminal of the backup light switch. If the ignition switch is turned to the IGN position, power is directed to the backup light switch. TURN SIGNAL FLASHER The turn signal flasher BAT terminal is connected to the backup light switch and also the same terminal as is connected to terminal #86 of relay #1. The SIG terminal is connected to terminal #86 of relay #2. Therefore, whenever the backup light switch is closed and the ignition switch is in the IGN position, a voltage signal is sent to the coil circuit of relay #1 and also to the BAT terminal of the turn signal flasher. This connection will alternately turn the relay #2 on and off with the flasher. The turn signal flasher is also connected to system ground. HORN The horn (sirens) will come on and stay on when this circuit is energized. The positive terminal of the horn is connected to terminal 30 of relay #2 and the negative terminal of the horn is connected to system ground. consulab.com info@consulab.com 294 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit SA-29 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 295 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit SA-29 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 296 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit SA-29 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 297 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit consulab.com info@consulab.com 298 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-29 — Emergency Lighting Circuit consulab.com info@consulab.com 299 CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) SA-30 — Removable Relay Circuit (Positive Switched Relay) Relay #4 on the CL-1918-4 is made to be removed for additional educational learning experiences. In addition, the ISO micro-relay was chosen as it is readily available, commonly used in vehicles, inexpensive and is usually found around most school automotive shops. During routine diagnosis of relay controlled circuits, it is often required to remove the relay and test the terminals in the socket. For this purpose, relay #4 is designed to be removed WARNING : If at any time this assignment directs you to use a jumper wire to make a connection, but sure to use ONLY a jumper wire that is routed through a fuse to protect the trainer and yourself from potential injuries Prior to completing this assignment, you should already have received the study guide showing details of relay #4, the terminal and pin identification of both the socket and relay. Be sure you understand this information before completing this assignment. Look at the below diagram and learn how the terminals are organized. This relay socket and all other standard ISO relay sockets have been standardized throughout the industry. Be aware that there are still many special use relays used by OEM manufacturers that do not follow this standardization. Assignment 1. Obtain the STUDENT ANSWER SHEET for this assignment. 2. Construct the circuit shown in REMOVABLE RELAY #4 ASSIGNMENT (POWER SWITCHED) on the trainer REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) consulab.com info@consulab.com 300 FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a 3. Confirm that the circuit works by switching the toggle switch on and off. 4. Carefully remove relay #4 and lay aside. 5. Referring to the drawing below, answer the below questions with the trainer turned OFF. Be sure to put all your answers in the STUDENT ANSWER SHEET for this assignment. DO NOT WRITE ON THIS PAPER. 6. A. What terminal of the relay socket should have B+ voltage at all times ? B. What terminal of the relay socket represents the ground for the relay coil ? C. Which two terminals of the relay socket could be jumped with a fused jumper wire to turn on the controlled device ? D. Which two terminals of the relay socket would you hook up a voltmeter to show the presence of B+ voltage at all times ? E. What would happen if you jumped across terminals #30 and #85 on the relay socket ? 7. Turn power on to the trainer with the relay still removed from the socket. Answer the below questions : A. Using a voltmeter, confirm your answer in question #5A. What terminal is the correct answer ? B. Using a voltmeter, confirm your answer in question #5B. What terminal is the correct answer ? 8. With instructor’s permission AND using a fused jumper wire, confirm the answer for #5C. Were you correct ? 9. Using a voltmeter confirm the answer to question #5D. What terminals are the correct answer ? 10. What could be the cause of a zero voltage to ground reading on terminal #30 of relay #4 socket ? 11. What could be the cause of having B+ voltage to ground on terminal #85 of the socket ? 12. If the circuit from terminal #85 of the relay socket was open, what test procedures would you to confirm that condi- tion ? 13. Insert relay #4 back into the socket and again, confirm correct circuit operation. 14. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) consulab.com info@consulab.com 301 SA-30 — All Level Student Assignment Instructors Answer Key 6. A Terminal #30 B Terminal #85. C Terminals #30 & #87. D Terminals #85 & #30. E Fuse #1 (or a fused jumper wire) would instantly “blow” and open up because this would represent a direct short to ground. 7. A YES or NO. B YES or NO. 8. YES or NO. 9. YES or NO. 10. Fuse #1 could be open or a break in the circuit between fuse #1 and terminal #30 of relay #4. 11. The only way there could be B+ voltage to ground on relay #4 socket terminal #85 is that the circuit is mis-wired. 12. A test light connected from B+ voltage should come on if the circuit from terminal #85 is good. If the test light does not come on, there is a break somewhere in the circuit. An ohmmeter could be used but it is ALWAYS better to “load” the circuit you are testing. Voltage drop testing could also be used in this diagnosis consulab.com info@consulab.com 302 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) SA-30 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 303 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) SA-30 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 304 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) SA-30 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 305 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) consulab.com info@consulab.com 306 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-30 — Removable Relay Circuit (Positive Switch Relay) consulab.com info@consulab.com 307 CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) SA-31 — Removable Relay Circuit (Ground Switched Relay) Relay #4 on the CL-1918-4 is made to be removed for additional educational learning experiences. In addition, the ISO micro-relay was chosen as it is readily available, commonly used in vehicles, inexpensive and is usually found around most school automotive shops. During routine diagnosis of relay controlled circuits, it is often required to remove the relay and test the terminals in the socket. For this purpose, relay #4 is designed to be removed. WARNING : If at any time this assignment directs you to use a jumper wire to make a connection, but sure to use ONLY a jumper wire that is routed through a fuse to protect the trainer and yourself from potential injuries. Prior to completing this assignment, you should already have received the study guide showing details of relay #4, the terminal and pin identification of both the socket and relay. Be sure you understand this information before completing this assignment. Look at the below diagram and learn how the terminals are organized. This relay socket and all other standard ISO relay sockets have been standardized throughout the industry. Be aware that there are still many special use relays used by OEM manufacturers that do not follow this standardization. Assignment 1. Obtain the STUDENT ANSWER SHEET for this assignment. 2. Construct the circuit shown in SA-24 REMOVABLE RELAY #4 ASSIGNMENT (GROUND SWITCHED) on the trainer. REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 308 CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) 3. Confirm that the circuit works by switching the toggle switch on and off. 4. Carefully remove relay #4 and lay aside. 5. Referring to the drawing below, answer the below questions with the trainer turned OFF. Be sure to put all your answers in the STUDENT ANSWER SHEET for this assignment. DO NOT WRITE ON THIS PAPER. 6. A. What terminal of the relay socket should have B+ voltage at all times ? B. What terminal of the relay socket represents the ground for the relay coil ? C. Which two terminals of the relay socket could be jumped with a fused jumper wire to turn on the controlled device ? D. Which two terminals of the relay socket would you hook up a voltmeter to show the presence of B+ voltage at all times ? E. What would happen if you jumped across terminals #30 and #85 on the relay socket ? 7. Turn power on to the trainer with the relay still removed from the socket. Answer the below questions : A. Using a voltmeter, confirm your answer in question #5A. What terminal is the correct answer ? B. Using a voltmeter, confirm your answer in question #5B. What terminal is the correct answer ? 8. With instructor’s permission AND using a fused jumper wire, confirm the answer for #5C. Were you correct ? 9. Using a voltmeter confirm the answer to question #5D. What terminals are the correct answer ? 10. What could be the cause of a zero voltage to ground reading on terminal #30 of relay #4 socket ? 11. What could be the cause of having B+ voltage to ground on terminal #85 of the socket ? 12. If the circuit from terminal #85 of the relay socket was open, what test procedures would you to confirm that condi- tion ? 13. Insert relay #4 back into the socket and again, confirm correct circuit operation. 14. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) consulab.com info@consulab.com 309 SA-31 — All Level Student Assignment Instructors Answer Key 6. A Terminal #30. B Terminal #85 C Terminals #30 & #87. D Terminals #85 & #30 E Fuse #1 (or a fused jumper wire) would instantly “blow” and open up because this would represent a direct short to ground. 7. A YES or NO. B YES or NO. 8. YES or NO. 9. YES or NO. 10. Fuse #1 would be open or a break in the circuit between fuse #1 and terminal #30 or relay #4. 11. The only way there could be B+ voltage to ground on relay #4 socket terminal #85 is that the circuit is mis-wired. 12. A test light connected from B+ voltage should come on if the circuit from terminal #85 is good. If the test light does not come on, there is a break somewhere in the circuit. An ohmmeter could be used but it is ALWAYS better to “load” the circuit you are testing. Voltage drop testing could also be used in this diagnosis consulab.com info@consulab.com 310 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) SA-31 — Level 1 Schematic Instructors Answer Key consulab.com info@consulab.com 311 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) SA-31 — Level 2 Schematic Instructors Answer Key consulab.com info@consulab.com 312 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) SA-31 — Level 3 Schematic Instructors Answer Key consulab.com info@consulab.com 313 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) consulab.com info@consulab.com 314 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-31 — Removable Relay Circuit (Ground Switch Relay) CL-1918-4S_053304-91 Optional Circuit Assignments consulab.com info@consulab.com 315 Optional Circuit Assignments SA-32 to SA-37 are custom designed circuits that must meet all of the defined circuit criteria for each assignment. Students will need to have a basic understanding of how all components on the trainer function in order to successfully build these circuits. Be sure to very carefully read the “circuit criteria” listed for each circuit, then using ONLY the components on the trainer, design and build a circuit that complies with all criteria. SA-32 — Custom Circuit #1 SA-33 — Custom Circuit #2 SA-34 — Custom Circuit #3 SA-35 — Custom Circuit #4 SA-36 — Custom Circuit #5 SA-37 — Custom Circuit #6 Each of these assignments will consist of a description of what the circuit must be designed to do. The instructor will give you either a blank Level 1, Level 1 or Level 3 schematic FOR EACH CIRCUIT for you to design the circuit on. After obtaining your instructors check, construct the circuit on the trainer and confirm normal operation. Correct any errors noticed. Upon confirma¬tion that your circuit design is correct, obtain instructors check and go to the next assignment. SA-32 — Custom Circuit #1 Design a circuit that meets the following criteria : A. When the brake switch is pushed in, all rear stop lights flash on and off. B. All circuit components and wiring must be protected by fuses. C. The circuit must function anytime the trainer is powered on. SA-33 — Custom Circuit #2 Design a circuit that meets the following criteria : A. When the light switch is turned to the headlight LOW beam position, both LOW beam headlights come on. B. When the light switch is turned to the headlight HIGH beam position, the HIGH beam headlights and the rear stop lights come on together, but the left and right sides of both headlights & stop lights will flash alternately off and on. C. All headlight current must be controlled by relays. D. All circuit components and wiring must be protected by fuses. CL-1918-4S_053304-91 SA-32 — Custom Circuit #1 consulab.com info@consulab.com 316 SA-32 — Custom Circuit #1 Design a circuit that meets the following criteria : A. When the brake switch is pushed in, all rear stop lights flash on and off. B. All circuit components and wiring must be protected by fuses. C. The circuit must function anytime the trainer is powered on. consulab.com info@consulab.com 317 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-32 — Custom Circuit #1 SA-32 — Level 1 Schematic Instructors Answer Key Optional Circuit #1 consulab.com info@consulab.com 318 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-32 — Custom Circuit #1 SA-32 — Level 2 Schematic Instructors Answer Key Optional Circuit #1 consulab.com info@consulab.com 319 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-32 — Custom Circuit #1 SA-32 — Level 3 Schematic Instructors Answer Key Optional Circuit #1 consulab.com info@consulab.com 320 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-32 — Custom Circuit #1 consulab.com info@consulab.com 321 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-32 — Custom Circuit #1 CL-1918-4S_053304-91 SA-33 — Custom Circuit #2 consulab.com info@consulab.com 322 SA-33 — Custom Circuit #2 Design a circuit that meets the following criteria : A. When the light switch is turned to the headlight LOW beam position, both LOW beam headlights come on. B. When the light switch is turned to the headlight HIGH beam position, the HIGH beam headlights and the rear stop lights come on together, but the left and right sides of both headlights & stop lights will flash alternately off and on. C. All headlight current must be controlled by relays. D. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 323 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-33 — Custom Circuit #2 SA-33 — Level 1 Schematic Instructors Answer Key Optional Circuit #2 consulab.com info@consulab.com 324 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-33 — Custom Circuit #2 SA-33 — Level 2 Schematic Instructors Answer Key Optional Circuit #2 consulab.com info@consulab.com 325 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-33 — Custom Circuit #2 SA-33 — Level 3 Schematic Instructors Answer Key Optional Circuit #2 consulab.com info@consulab.com 326 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-33 — Custom Circuit #2 CL-1918-4S_053304-91 SA-34 — Custom Circuit #3 consulab.com info@consulab.com 327 SA-34 — Custom Circuit #3 Design a circuit that meets the following criteria : A. The left front marker light is to be positive switched. B. The right front marker light is to be ground switched. C. The backup lights toggle switch is to control both lights. D. All circuit wiring must be protected by fuses. consulab.com info@consulab.com 328 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-34 — Custom Circuit #3 SA-34 — Level 1 Schematic Instructors Answer Key Optional Circuit #3 consulab.com info@consulab.com 329 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-34 — Custom Circuit #3 SA-34 — Level 2 Schematic Instructors Answer Key Optional Circuit #3 consulab.com info@consulab.com 330 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-34 — Custom Circuit #3 SA-34 — Level 3 Schematic Instructors Answer Key Optional Circuit #3 consulab.com info@consulab.com 331 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-34 — Custom Circuit #3 consulab.com info@consulab.com 332 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-34 — Custom Circuit #3 CL-1918-4S_053304-91 SA-35 — Custom Circuit #4 consulab.com info@consulab.com 333 SA-35 — Custom Circuit #4 Design a circuit that meets the following criteria : A. The normal headlight circuit must be totally functional with HIGH, LOW and HIGH BEAM INDICATOR working normally. B. Regardless of whether the headlights are on or off, turning on the toggle switch will turn on the headlights and the HIGH and LOW beams will flash from HIGH to LOW alternately. C. The circuit is to be totally independent of the headlights and no headlights should be on when the toggle switch and the headlight switch are off. D. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 334 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-35 — Custom Circuit #4 SA-35 — Level 1 Schematic Instructors Answer Key Optional Circuit #4 consulab.com info@consulab.com 335 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-35 — Custom Circuit #4 SA-35 — Level 2 Schematic Instructors Answer Key Optional Circuit #4 consulab.com info@consulab.com 336 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-35 — Custom Circuit #4 SA-35 — Level 3 Schematic Instructors Answer Key Optional Circuit #4 consulab.com info@consulab.com 337 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-35 — Custom Circuit #4 consulab.com info@consulab.com 338 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-35 — Custom Circuit #4 CL-1918-4S_053304-91 SA-36 — Custom Circuit #5 consulab.com info@consulab.com 339 SA-36 — Custom Circuit #5 Design a circuit that uses the horn to warn you that you have left your headlights on when you open the door. NOTE- Due to the design of the CL-1918-4 components, it will be necessary to use the backup lights toggle switch in the “open or off” position when the “door” is in the closed position and when you open the door, the switch will turn “on” or closed position. A. The headlights must be controlled by relays and the headlight switch. B. The “door” switch must be the toggle (backup light switch) C. Regardless of whether either the HIGH or LOW beams are left on, the horn must sound when the door is opened. D. Door opens = switch closed – door closed = switch open E. The flash-to-pass circuit must also function normally. F. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 340 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-36 — Custom Circuit #5 SA-36 — Level 1 Schematic Instructors Answer Key Optional Circuit #5 consulab.com info@consulab.com 341 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-36 — Custom Circuit #5 SA-36 — Level 2 Schematic Instructors Answer Key Optional Circuit #5 consulab.com info@consulab.com 342 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-36 — Custom Circuit #5 SA-36 — Level 3 Schematic Instructors Answer Key Optional Circuit #5 consulab.com info@consulab.com 343 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-36 — Custom Circuit #5 consulab.com info@consulab.com 344 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-36 — Custom Circuit #5 CL-1918-4S_053304-91 SA-37 — Custom Circuit #6 consulab.com info@consulab.com 345 SA-37 — Custom Circuit #6 Design a circuit to demonstrate the difference with light bulbs connected in both SERIES and parallel configurations. A. The LEFT FRONT MARKER and LEFT REAR MARKER are to be connected in SERIES on their ground side circuits. B. The RIGHT FRONT TURN, RIGHT MARKER, RIGHT BACKUP, RIGHT TURN and the RIGHT MARKER lights are to be connected in PARALLEL. C. When the toggle switch is turned on, the parallel connected circuit will turn on without the series circuit being on. D. Regardless of whether the parallel either on or off, when the HORN push button is pushed down, the series connected circuit will come on. E. In addition, when the series circuit is turned on, pushing the BRAKE switch button will temporarily connect the LEFT FRONT MARKER and LEFT REAR MARKER bulbs from series to a parallel connection. Both MARKER lights will come on a normal brilliance. F. Relays can be used if desired. G. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 346 REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S_053304-91 SA-37 — Custom Circuit #6 SA-37 — Level 1 Schematic Instructors Answer Key Optional Circuit #6 consulab.com info@consulab.com 347 CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4S_053304-91 SA-37 — Custom Circuit #6 SA-37 — Level 2 Schematic Instructors Answer Key Optional Circuit #6 consulab.com info@consulab.com 348 consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V Page 1 CL-1918-4S_053304-91 SA-37 — Custom Circuit #6 SA-37 — Level 3 Schematic Instructors Answer Key Optional Circuit #6 consulab.com info@consulab.com 349 consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H Page 2 CL-1918-4S_053304-91 SA-37 — Custom Circuit #6 consulab.com info@consulab.com 350 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 Page 3 CL-1918-4S_053304-91 SA-37 — Custom Circuit #6 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. SA-19 Level 3 Ground Circuits Instructors Answer Key Student Assignment Explanations Circuit Construction Notes Fuse Panel Explanation Student Assignments Current Measurement Methods CL-1918-4 Level 1 Trainer Wiring Blank Template Circuit Assignments SA-1 — Backup Lights Circuit Circuit Explanation Circuit Explanation Answer Key SA-1 — Level 1 / Level 2 Assignment SA-1 — Level 1 / Level 2 Assignment Instructors Answer Key SA-1 — Level 1 Schematic Instructors Answer Key SA-1 — Level 2 Schematic Instructors Answer Key SA-1 — Level 3 Assignment SA-1 — Level 3 Assignment Instructors Answers Key SA-1 — Level 3 Schematic Instructors Answer Key SA-2 — Hazard Lights Circuit Circuit Explanation Circuit Explanation Instructors Answer Key (2 pages) SA-2 — Level 1 / Level 2 Assignment SA-2 — Level 1 / Level 2 Assignment Instructors Answer Key SA-2 — Level 1 Schematic Instructors Answer Key SA-2 — Level 2 Schematic Instructors Answer Key SA-2 — Level 3 Assignment SA-2 — Level 3 Assignment Instructors Answer Key SA-2 — Level 3 Schematic Instructors Answer Key SA-3 — Horn Circuit (Positive Switched) Circuit Explanation Circuit Explanation Instructors Answer Key (2 pages) SA-3 — Level 1 / Level 2 Assignment SA-3 — Level 1 / Level 2 Assignment Instructors Anwser Key SA-3 — Level 1 Schematic Instructors Answer Key SA-3 — Level 2 Schematic Instructors Answer Key SA-3 — Level 3 Assignment SA-3 — Level 3 Assignment Instructors Answer Key SA-3 — Level 3 Schematic Instructors Answer Key SA-4 — Optional Circuit Horn Circuit (Ground Switched) Circuit Explanation Instructors Answer Key SA-4 — Level 1 Schematic Instructors Answer Key SA-4 — Level 2 Schematic Instructors Answer Key SA-4 — Level 3 Assignment SA-4 — Level 3 Schematic Instructors Answer Key SA-5 — Stop Lights Circuit Circuit Explanation Circuit Explanation Instructors Answer Key SA-5 — Level 1 / Level 2 Assignment SA-5 — Level 1 / Level 2 Assignment Instructors Answer Key SA-5 — Level 1 Schematic Instructors Answer Key SA-5 — Level 2 Schematic Instructors Answer Key SA-5 — Level 3 Assignment SA-5 — Level 3 Assignment Instructors Answer Key SA-5 — Level 3 Schematic Instructors Answer Key SA-6 — Tail-Park Lights Circuit (Ground Switched) Circuit Explanation Circuit Explanation Instructors Answer Key (3 pages) SA-6 — Level 1 / Level 2 Assignment SA-6 — Level 1 / Level 2 Assignment Instructors Answer Key SA-6 — Level 1 Schematic Instructors Answer Key SA-6 — Level 2 Schematic Instructors Answer Key SA-6 — Level 3 Assignment SA-6 — Level 3 Assignment Instructors Answer Key (3 pages) SA-6 — Level 3 Schematic Instructors Answer Key SA-7 — Tail-Park Lights Circuit (Positive Switched) Circuit Explanation Circuit Explanation Instructors Answer Key (3 pages) SA-7 — Level 1 / Level 2 Assignment SA-7 — Level 1 / Level 2 Assignment Instructors Answer Key SA-7 — Level 1 Schematic Instructors Answer Key SA-7 — Level 2 Schematic Instructors Answer Key SA-7 — Level 3 Assignment SA-7 — Level 3 Assignment Instructors Answer Key (2 pages) SA-7 — Level 3 Student Assignment Modification Schematic SA-7 — Level 3 Schematic Instructors Answer Key SA-8 — Turn Signal Circuit Circuit Explanation Circuit Explanation Instructors Answer Key (3 pages) SA-8 — Level 1 / Level 2 Assignment SA-8 — Level 1 / Level 2 Assignment Instructors Answer Key SA-8 — Level 1 Schematic Instructors Answer Key SA-8 — Level 2 Schematic Instructors Answer Key SA-8 — Level 3 Assignment SA-8 — Level 3 Assignment Instructors Answer Key (2 pages) SA-8 — Level 3 Schematic Instructors Answer Key Headlights Circuits Notice Pertaining to CL-1918-4 Headlight Circuits CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification Headlights and Plug Explanation SA-9 — Headlights Circuit (Ground Switched) Circuit Design and Operation : Circuit Explanation Instructors Answer Key (3 pages) SA-9 — Level1 / Level 2 Assignment SA-9 — Level1 / Level 2 Assignment Instructors Answer Key (2 pages) SA-9 — Level 1 Schematic Instructors Answer Key SA-9 — Level 2 Schematic Instructors Answer Key SA-9 — Level 3 Assignment SA-9 — Level 3 Assignment Instructors Answer Key (2 pages) SA-9 — Level 3 Schematic Instructors Answer Key SA-10 — Headlights Circuit (Positive Switched) Circuit Explanation Circuit Explanation Instructors Answer Key (3 pages) SA-10 — All Level Assignment SA-10 — All Level Assignment Instructors Answer Key (2 pages) SA-10 — Level 1 Schematic Instructors Answer Key SA-10 — Level 2 Schematic Instructors Answer Key SA-10 — Level 3 Schematic Instructors Answer Key Headlights Circuit (Optional Circuit Designs) Assignment Explanations SA-11 — Headlights Circuit — Option A Student Assignment Component Explanation Instructors Answer Key (3 pages) SA-11 — Level 1 Schematic Instructors Answer Key SA-11 — Level 2 Schematic Instructors Answer Key SA-11 — Level 3 Schematic Instructors Answer Key SA-12 — Headlights Circuit — Option B Student Assignment Component Explanation Instructors Answer Key (3 pages) SA-12 — Level 1 Schematic Instructors Answer Key SA-12 — Level 2 Schematic Instructors Answer Key SA-12 — Level 3 Schematic Instructors Answer Key SA-13 — Headlights Circuit — Option C Student Assignment Component Explanation Instructors Answer Key (3 pages) SA-13 — Level 1 Schematic Instructors Answer Key SA-13 — Level 2 Schematic Instructors Answer Key SA-13 — Level 3 Schematic Instructors Answer Key SA-14 — Headlights Circuit — Option D Student Assignment Component Explanation Instructors Answer Key (4 pages) SA-14 — Level 1 Schematic Instructors Answer Key SA-14 — Level 2 Schematic Instructors Answer Key SA-14 — Level 3 Schematic Instructors Answer Key SA-15 — Headlights Circuit — Option E Student Assignment Component Explanation Instructors Answer Key (4 pages) SA-15 — Level 1 Schematic Instructors Answer Key SA-15 — Level 2 Schematic Instructors Answer Key SA-15 — Level 3 Schematic Instructors Answer Key SA-16 — Headlights Circuit — Option F Student Assignment Component Explanation Instructors Answer Key (4 pages) SA-16 — Level 1 Schematic Instructors Answer Key SA-16 — Level 2 Schematic Instructors Answer Key SA-16 — Level 3 Instructors Answer Key SA-17 — Headlights Circuit — Option G Student Assignment Component Explanation Instructors Answer Key (4 pages) SA-17 — Level 1 Schematic Instructors Answer Key SA-17 — Level 2 Schematic Instructors Answer Key SA-17 — Level 3 Schematic Instructors Answer Key SA-18 — Headlights Circuit — Option H Student Assignment Component Explanation Instructors Answer Key (4 pages) SA-18 — Level 1 Schematic Instructors Answer Key SA-18 — Level 2 Schematic Instructors Answer Key SA-18 — Level 3 Schematic Instructors Answer Key Whole Trainer Wiring SA-19 & SA-20 — Whole Trainer Wiring General Information CL-1918-4 Total Jumper Wire count Fuse Box Identification for Whole Trainer Wiring Assignment SA-19 — Level 1 Schematic — Ground Circuits Instructors Answer Key SA-20 — Level 1 Schematic— Positive Circuits Instructors Answer Key SA-19 — Level 2 Schematic — Ground Circuits Instructors Answer Key SA-20 — Level 2 Schematic— Positive Circuits Instructors Answer Key SA-19 — Level 3 Schematic— Ground Circuits Instructors Answer Key SA-20 — Level 3 Schematic— Positive Circuits Instructors Answer Key Ohm’s and Kirchhoff’s Laws Assignments Ohm’s and Kirchhoff’s Laws Assignments Circuit Assignments Instructions SA-21 Circuit #1 — Resistances in Parallel SA-21 Circuit #1 — Resistances in Parallel Instructors Answer Key SA-21 — Schematic Instructors Answer Key SA-22 Circuit #2 — Resistances in Series SA-22 Circuit #2 — Resistances in Series Instructors Answer Key SA-22 — Schematic Instructors Answer Key SA-23 Circuit #3 — Combination Resistances (Series & Para) SA-23 Circuit #3 — Combination Resistances in both Series and Parallel Instructors Answer Key SA-23 — Schematic Instructors Answer Key SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) SA-24 Circuit #4 — Bulbs of Different Values in Series Instructors Answer Key SA-24 — Schematic Instructors Answer Key SA-25 Circuit #5 — Bulbs with Same Resistances in Series SA-25 Circuit #5 — Bulbs with Same Resistances in Series Instructors Answer Key SA-25 — Schematic Instructors Answer Key SA-26 Circuit #6 — Different Resistance Values in Combination Series & Parallel Circuit SA-26 Circuit #6 — Different Resistance Values in Combination Series & Parallel Circuit Instructors Answer Key SA-26 — Schematic Instructors Answer Key SA-27 Circuit #7 — Relay Control Circuit with High Resistance SA-27 Circuit #7 — Relay Control Circuit High Resistance Condition Instructors Answer Key (2 pages) SA-27 — Schematic Instructors Answer Key Optional Circuits SA-28 — Generic Vehicle Alarm System Circuit Circuit Criteria Instructions Circuit Description : List of Components and their Role Answer Sheet SA-28 — Generic Vehicle Alarm System Circuit Circuit Explanation Instructors Answer Key (4 pages) SA-28 — Level 1 / Level 2 Assignment SA-28 — Level 1 / Level 2 Assignment Instructors Answer Key SA-28 — Level 1 Schematic Instructors Answer Key SA-28 — Level 2 Schematic Instructors Answer Key SA-28 — Level 3 Assignment SA-28 — Level 3 Assignment Instructors Answer Key SA-28 — Level 3 Schematic Instructors Answer Key SA-29 — Emergency Lighting System Circuit Explanation Circuit Component Explanation Instructors Answer Key Circuit Explanation Answer key SA-29 — Level 1 Schematic Instructors Answer Key SA-29 — Level 2 Schematic Instructors Answer Key SA-29 — Level 3 Schematic Instructors Answer Key SA-30 — Removable Relay Circuit (Positive Switched Relay) SA-30 — All Level Student Assignment Instructors Answer Key SA-30 — Level 1 Schematic Instructors Answer Key SA-30 — Level 2 Schematic Instructors Answer Key SA-30 — Level 3 Schematic Instructors Answer Key SA-31 — Removable Relay Circuit (Ground Switched Relay) SA-31 — All Level Student Assignment Instructors Answer Key SA-31 — Level 1 Schematic Instructors Answer Key SA-31 — Level 2 Schematic Instructors Answer Key SA-31 — Level 3 Schematic Instructors Answer Key Optional Circuit Assignments SA-32 — Custom Circuit #1 SA-32 — Level 1 Schematic Instructors Answer Key SA-32 — Level 2 Schematic Instructors Answer Key SA-32 — Level 3 Schematic Instructors Answer Key SA-33 — Custom Circuit #2 SA-33 — Level 1 Schematic Instructors Answer Key SA-33 — Level 2 Schematic Instructors Answer Key SA-33 — Level 3 Schematic Instructors Answer Key SA-34 — Custom Circuit #3 SA-34 — Level 1 Schematic Instructors Answer Key SA-34 — Level 2 Schematic Instructors Answer Key SA-34 — Level 3 Schematic Instructors Answer Key SA-35 — Custom Circuit #4 SA-35 — Level 1 Schematic Instructors Answer Key SA-35 — Level 2 Schematic Instructors Answer Key SA-35 — Level 3 Schematic Instructors Answer Key SA-36 — Custom Circuit #5 SA-36 — Level 1 Schematic Instructors Answer Key SA-36 — Level 2 Schematic Instructors Answer Key SA-36 — Level 3 Schematic Instructors Answer Key SA-37 — Custom Circuit #6 SA-37 — Level 1 Schematic Instructors Answer Key SA-37 — Level 2 Schematic Instructors Answer Key SA-37 — Level 3 Schematic Instructors Answer Key Student Assignments for CL-1918-4S_053304 Automotive Lighting System Trainer CL-1918-4S_053304-95_V2024-2 © ConsuLab Educatech Inc, 2023. All rights reserved. CL-1918-4S_053304-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of Contents Student Assignment Explanations 7 Circuit Construction Notes 11 Student Assignments Current Measurement Methods 13 CL-1918-4 Level 1 Trainer Wiring Blank Template 14 CL-1918-4 Level 2 Trainer Wiring Blank Template 15 CL-1918-4 Level 3 Trainer Wiring Blank Template 16 Circuit Assignments SA-1 — Backup Lights Circuit 20 Circuit Explanation 20 Answer Sheet 21 SA-1 — Level 1 / Level 2 Assignment 22 Answer Sheet 23 SA-1 — Level 3 Assignment 24 Answer Sheet 25 SA-2 — Hazard Lights Circuit 26 Circuit Explanation 26 Answer Sheet 27 SA-2 — Level 1 / Level 2 Assignment 29 Answer Sheet 30 SA-2 — Level 3 Assignment 31 Answer Sheet 33 SA-3 — Horn Circuit (Positive Switched) 34 Circuit Explanation 34 Answer Sheet 35 SA-3 Level 1 / Level 2 Assignment 37 Anwser Sheet 38 SA-3 — Level 3 Assignment 39 Answer Sheet 40 SA-4 — Horn Circuit (Ground Switched) 41 Circuit Component Explanation — Answer Sheet 41 SA-4 — Level 3 Assignment 43 CL-1918-4S_053304-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 Answer Sheet 44 SA-5 — Stop Lights Circuit 45 Circuit Explanation 45 Answer Sheet 46 SA-5 — Level 1 / Level 2 Assignment 47 Answer Sheet 48 SA-5 — Level 3 Assignment 49 SA-5 — Level 3 Assignment — Answer Sheet 50 SA-6 — Tail-Park Lights Circuit (Ground Switched) 51 Circuit Explanation 51 Answer Sheet 53 SA-6 — Level 1 / Level 2 Assignment 56 Answer Sheet 57 SA-6 — Level 3 Assignment 58 Answer Sheet 60 SA-7 — Tail-Park Lights Circuit (Positive Switched) 62 Circuit Explanation 62 Answer Sheet 64 SA-7 — Level 1 / Level 2 Assignment 67 Answer Sheet 68 SA-7 — Level 3 Assignment 69 Answer Sheet 71 SA-8 — Turn Signal Circuit 73 Circuit Explanation 73 Answer Sheet 74 SA-8 — Level 1 / Level 2 Assignment 77 Answer Sheet 78 SA-8 — Level 3 Assignment 79 Answer Sheet 81 Headlights Circuits Notice Pertaining to CL-1918-4 Headlight Circuits 84 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification 85 Headlights and Plug Explanation 88 SA-9 — Headlights Circuit (Ground Switched) 89 Circuit Design and Operation : 89 SA-9 — Level1 / Level 2 Assignment 95 Answer Sheet 96 CL-1918-4S_053304-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 4 SA-9 — Level 3 Assignment 97 Answer Sheet 99 SA-10 — Headlights Circuit (Positive Switched) 101 Circuit Explanation 101 Answer Sheet 103 SA-10 — All Level Assignment 105 Answer Sheet 107 Headlights Circuit (Optional Circuit Designs) 109 Assignment Explanations 109 SA-11 — Headlights Circuit — Option A 111 Answer Sheet 112 SA-12 — Headlights Circuit — Option B 115 Answer Sheet 116 SA-13 — Headlights Circuit — Option C 119 Answer Sheet 120 SA-14 — Headlights Circuit — Option D 123 Answer Sheet 124 SA-15 — Headlights Circuit — Option E 127 Answer Sheet 128 SA-16 — Headlights Circuit — Option F 131 Answer Sheet 132 SA-17 — Headlights Circuit — Option G 135 Answer Sheet 136 SA-18 — Headlights Circuit — Option H 139 Answer Sheet 140 Whole Trainer Wiring SA-19 & SA-20 — Whole Trainer Wiring 144 General Information 144 CL-1918-4 Total Jumper Wire count 144 Fuse Box Identification for Whole Trainer Wiring Assignement 144 SA-19 — Level 1 / Level 2 Assignment 145 Answer Sheet 148 SA-19 — Level 1 — Ground Circuits 149 SA-20 — Level 1 — Positive Circuits 150 SA-19 — Level 2 — Ground Circuits 151 SA-20 — Level 2 — Positive Circuits 152 SA-19 — Level 3 — Ground Circuits 153 SA-20 — Level 3 — Positive Circuits 156 Ohm’s and Kirchhoff’s Laws Assignments CL-1918-4S_053304-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 5 Ohm’s and Kirchhoff’s Laws Assignments 160 Circuit Assignments Instructions 160 SA-21 Circuit #1 — Resistances in Parallel 161 SA-22 Circuit #2 — Resistances in Series 161 SA-23 Circuit #3 — Combination Resistances (Series & Para) 162 SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) 162 SA-25 Circuit #5 — Bulbs with Same Resistances in Series 163 SA-26 Circuit #6 — Resistances of Different Values in Combination Series & Parallel 164 SA-27 Circuit #7 — Relay Control Circuit with High Resistance 165 Answer Sheets 166 SA-21 Circuit #1 — Resistances in Parallel 166 SA-22 Circuit #2 — Resistances in Series 167 SA-23 Circuit #3 — Combination Resistances (Series & Para) 168 SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) 169 SA-25 Circuit #5 — Bulbs with Same Resistances in Series 170 SA-26 Circuit #6 — Resistances of Different Values in Combination Series & Parallel 171 SA-27 Circuit #7 — Relay Control Circuit with High Resistance 172 Optional Circuits SA-28 — Generic Vehicle Alarm System Circuit 174 Circuit Description : 174 List of Components and their Role Answer Sheet 175 Circuit Explanation Answer Sheet 177 SA-28 — Level 1 / Level 2 Assignment 181 Answer Sheet 182 SA-28 — Level 3 Assignment 183 Answer Sheet 184 SA-29 — Emergency Lighting System 185 Circuit Explanation 185 Circuit Description 185 Circuit Explanation Answer sheet 186 SA-30 — Removable Relay Circuit (Positive Switched Relay) 189 Removable Relay Information 191 Answer Sheet 192 SA-31 — Removable Relay Circuit (Ground Switched Relay) 193 Answer Sheet 195 Optional Circuit Assignments 196 CL-1918-4S_053304-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 6 © ConsuLab Educatech Inc, 2023. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. SA-32 — Custom Circuit #1 196 SA-33 — Custom Circuit #2 196 SA-34 — Custom Circuit #3 197 SA-35 — Custom Circuit #4 197 SA-36 — Custom Circuit #5 197 SA-37 — Custom Circuit #6 198 Answer Sheet 199 SA-32 — Circuit #1 199 SA-33 — Circuit #2 199 SA-34 — Circuit #3 199 SA-35 — Circuit #4 199 SA-36 — Circuit #5 199 SA-37 — Circuit #6 199 consulab.com info@consulab.com 7 CL-1918-4S_053304-95 Student Assignment Explanations Student Assignment Explanations The CL-1918-4 lighting trainer will have three separate levels of assigning student’s various assignments. It will be up to your instructor to choose which of the three levels are appropriate for each student. The three levels change in difficulty and each is explained below. Additional assignments involving circuit explanations are also included. All assignments have completed instructors answer keys. It is important to monitor student access to answer keys. LEVELS 1 & 2 – When completing a lighting circuit assignment, be sure to choose between the L1 or L2 procedure. The Level 1 assignment is identical to the Level 2 with the exception of the following : LEVEL 1 – Level 1 assignments are designed for the student with little or no previous experience with electrical lighting circuits. Your instructor may choose to assign you a completed schematic showing how the circuit is wired or may give you a complete schematic showing industry electrical symbols for the wired circuit. The Level 1 student assignment will use a picture of the trainer’s panels (Moduponents) with red and black wires shown with the completed circuit. Your instructor will choose which diagram each student uses to learn and construct the cir- cuit. There is a student answer sheet for the Level 1 assignment which is identical to the level 2. The LEVEL 1 assignments can be compared to the ASE Education Foundation (formerly NATEF) MLR Automotive Standards level. See below for example of L1 schematic : REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 8 CL-1918-4S_053304-95 Student Assignment Explanations LEVEL 2 – The Level 2 student assignment will show the three panels (Moduponents) with industry standard schematic symbols in place of pictures of the connection points. You may be assigned a completed schematic or one that shows the proper hookup of the red and black jumper wires. The student answer sheet is identical to the level 1 answer sheet. The L2 assignments can be compared to the ASE Education Foundation (formerly NATEF) AST Automotive Standards level. Your instructor will choose which diagram you use to learn and construct the circuit. There is also an instructors answer key included : See below for example of L2 schematic : CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD LEVEL 3 – The Level 3 is designed for students who have some existing training or experience. Be sure to use the level 3 student assignment procedure that is different than the levels 1&2. It contains more detailed instructions and extra circuit measurements and calculations. The level 3 student assignment is structured around the student looking at the Level 3 blank two-page schematic that shows all the components used on the trainer, but without any connecting wiring. One assignment might be for students to design a specific circuit by connecting needed black and red wiring on the blank schematic, obtaining a check, then actually wiring the circuit they designed. Another option would be after the student has mastered the circuit using Level 1 or 2 schematics, they would draw out the wires of the circuit on the blank Level 3 schematic. The Level 3 schematic closely matches most OEM type schematics. There is also a student answer sheet for the Level 3 assignment and instructor’s answer key. The L3 assignments can be compared to the ASE Educa- tion Foundation (formerly NATEF) MAST Automotive Standards level : See below for exmple of L3 schematic : consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 consulab.com info@consulab.com 9 CL-1918-4S_053304-95 Student Assignment Explanations LEVELS 1&2 STUDENT ASSIGNMENT : Assignments are organized with a step-by-step procedure asking students to answer questions about the circuit being worked with or making measurements of voltage, amperage or resistance. Each assignment is accompanied with a student answer sheet and an instructor’s answer key. The assignment is designed to be accompanied with either the Level 1 or Level 2 schematic that you assigned to the student. The written assignment instructions are the same for both Levels 1 & 2, but the schematics used are different. LEVEL 3 STUDENT ASSIGNMENT : The Level 3 assignment may contain some elements of Levels 1&2 assignments, but will also have higher level of circuit assignments, questions and measurements. The Level 3 assignment also includes a student answer sheet and instruc- tor’s answer key. Level 3 assignments use the OEM style wiring schematics which are unique to Level 3 only. CIRCUIT EXPLANATION ASSIGNMENTS : Each circuit will contain a narrative explaining how the circuit operates. Your instructor may choose to distribute this document or let the students figure it out on their own. Each circuit also includes a CIRCUIT EXPLANATION assignment. This assignment measures the students understand- ing of what each component in the circuit does and how it contributes to the entire circuit. It consists of a detailed list of components and asks students to explain the function of each terminal of every component used. The assignment includes a student answer sheet and instructor’s answer key. NOTE : Many components can share a common power feed and common ground connections. For this purpose, the red and black jumper wires can be “stacked” on top of each other to join more than one wire together. Although, most wiring diagrams may show individual connections for power and ground, you may choose to “stack” jumper leads togeth- er for circuit construction purposes. When stacking jumper wires at a single connection point, do not exceed three stacked wires. or damage can occur to the wires or the socket. If you are assigned to “draw” the circuit you have constructed, you should show the exact configuration of your circuit on a blank trainer template (provided). (Level 1, Level 2 or Level 3 schematics) consulab.com info@consulab.com 10 CL-1918-4S_053304-95 Student Assignment Explanations REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date LEFT RIGHT consulab.com info@consulab.com 11 CL-1918-4S_053304-95 Circuit Construction Notes Circuit Construction Notes The CL-1918-4 lighting trainer is a very powerful teaching and learning tool for instructors and students. All of the light- ing circuits used on the trainer are “generic” in nature and do not apply to one specific vehicle or manufacturer. Howev- er, there may be many similarities to specific manufacture circuit designs. POWER CONNECTIONS : When connecting red positive jumper wires to components on the trainer, be sure to follow any one of the three levels of wiring schematics that are included with the student assignments. Each red jumper wire is designed to be plugged into the appropriate circuit receptacle and most will be of a YELLOW or RED color. If the receptacle is YELLOW, po- larity is not critical. If the receptacle is RED, it must be connected to a positive source. For example, the two backup lights have two yellow receptacles each. Because these bulbs are incandescent, it makes no difference which terminal is positive and which is ground. On any light that is an LED, the receptacles are either RED or BLACK as correct polarity is essential to an LED lamp. The CL-1918-4 trainer is internally protected on all LED lights from reversed polarity con- nections and no damage with occur. If hooked up with backwards polarity, any LED lamp on the trainer will simply not operate. Many times it will be necessary to connect more than one wire at the same receptacle and to allow this, all of the jumper wires can be “stacked” on top of each other. Be sure that the stacked wires are properly seated to each other and try to avoid more than 3 wires together. There are short and long red jumper wires provided with the trainer to allow access between components. GROUND CONNECTIONS : When connecting black ground jumper wires to components on the trainer, be sure to follow any one of the three levels of wiring schematics that are included with the student assignments. Each black jumper wire is designed to be plugged into the appropriate circuit receptacle and most will be BLACK in color. NOTE- There are no internal ground connections between the three panels. Therefore, it will be necessary to connect the ground circuits of all three panels together with black jumper wires between the 01 (top), the 02 (middle) and the 03 (bottom) panels. There are three black ground recep- tacles at both the top and bottom panels and there are six ground receptacles on the middle panel. At each panel, the ground receptacles are internally connected together from behind the panel, BUT are not connected together BETWEEN each panel. Additionally, as with the positive jumper wires, ground wires can be safely “stacked” on top of each other at the same connection receptacle in order to connect more than one wire. FUSES AND CIRCUIT PROTECTION : Be sure to read and understand the section on the trainers fuse box in the OPERATION MANUAL. It is required that all circuits connected by students on this trainer MUST be connected through a fuse. This will prevent potential damage to components. Be aware that the top three HOT AT ALL TIMES positive connections to the right of the top three fuses are circuit protected by Fuse F9. Be sure to read the POWER SUPPLY NOTES below. consulab.com info@consulab.com 12 CL-1918-4S_053304-95 Circuit Construction Notes WARNING ! ! ! POWER SUPPLY NOTES WARNING ! ! ! As has been previously stated, the CL-1918-4 trainer power supply is capable of outputting approximately 30 amps of power within a typical voltage range of 13.00 – 13.85 volts. It is internally protected from short circuits. With the middle panel being connected to the power supply junction block located behind the middle panel, and fuses F1, F2 and F3 (hot at all times) fuses protected by fuse F9, there should be no possible way to create a “short power to ground” circuit. Fuse F9 will blow if the combined current of F1, F2 and F3 exceeds 25A. No other connections should be made to the power supply junction block mounted on the trainers frame. WARNING - THE CL-1918-4 POWER SUPPLY MUST NEVER BE USED AS A BATTERY CHARGER ! POTENTIAL DAMAGE AND THE VOIDING OF THE WARRANTY CAN OCCUR IF THIS OCCURS. consulab.com info@consulab.com 13 CL-1918-4S_053304-95 Student Assignments Current Measurement Methods Student Assignments Current Measurement Methods NOTE – CIRCUIT AMPERAGE MEASUREMENTS : There are three acceptable methods of measuring circuit current on vehicles and on the CL-1918-4 lighting trainer. They are : DIGITAL MULTI-METER - Using the milli-amp or amp measuring function of your digital multi-meter and connecting the ammeter in series with the circuit you are measuring. Most DMM’s are protected with one or more ammeter fuses. AL- WAYS follow instructions when using this method. DIGITAL MULTI-METER CAPABLE OF DIRECT MEASUREMENT OF AMPERAGE COM TERMINAL – BLACK LEAD SELECTABLE AMP SCALE – RED LEAD AMPS or MILLIAMPS A CURRENT CLAMP connected to your digital multi-meter. This tool is a common test equipment accessory and is often used in industry. Be sure to set your DMM to read milli-volts and not amps when using this tool. It is also nec- essary to convert the displayed readings of milli-volts to milli-amps based on the selected scale of the current clamp. Follow instructions. CURRENT CLAMP USED IN COMBINATION WITH A DIGITAL MULTI-METER. READING MILLI-VOLTS & CONVERTING TO MILLI-AMPS CLAMP AMMETER - A meter with a built-in inductive ammeter is perhaps the “quickest” and easiest method of measur- ing amperage, but requires a unit that accurately measures in the milli-amp range. Using larger range inductive clamps designed for starter and alternator testing will not provide accuracy. STAND ALONE INDUCTIVE CLAMP NO DIRECT CIRCUIT CONNECTIONS REQUIRED consulab.com info@consulab.com 14 CL-1918-4S_053304-95 CL-1918-4 Level 1 Trainer Wiring Blank Template REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 15 CL-1918-4S_053304-95 CL-1918-4 Level 2 Trainer Wiring Blank Template CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD CL-1918-4 Level 2 Trainer Wiring Blank Template consulab.com info@consulab.com 16 CL-1918-4S_053304-95 CL-1918-4 Level 3 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V CL-1918-4 Level 3 Trainer Wiring Blank Template P-1 consulab.com info@consulab.com 17 CL-1918-4S_053304-95 CL-1918-4 Level 3 Trainer Wiring Blank Template consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H CL-1918-4 Level 3 Trainer Wiring Blank Template P-2 consulab.com info@consulab.com 18 CL-1918-4S_053304-95 CL-1918-4 Level 3 Trainer Wiring Blank Template CL-1918-4 Level 3 Trainer Wiring Blank Template P-3 consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 consulab.com info@consulab.com 19 CL-1918-4S_053304-95 Circuit Assignments Circuit Assignments consulab.com info@consulab.com 20 CL-1918-4S_053304-95 SA-1 — Backup Lights Circuit SA-1 — Backup Lights Circuit Circuit Explanation The BACKUP lights circuit on vehicles is used to assist the driver when backing up the vehicle by providing lighting to illuminate the area. Some newer vehicles may use LED lamps instead of the traditional incandescent bulbs. In addition, many vehicles now use CAN Bus circuits to control lighting circuits. The backup lights circuit on a “traditional” vehicle consists of the appropriate fuse(s), ignition switch, backup lights switch, backup lights and the required positive and negative wiring necessary to operate the circuit. CAN Bus systems often do not use a “backup lights” switch, but use the transmission selector switch to know when the driver has selected REVERSE and a computer then turns on the backup lights. On most vehicles, the ignition switch must be in the ON position in order for the backup lights to operate. The CL-1918-4 uses the “traditional” backup lights circuit. Power for the backup lights is routed from the battery, through Fuse #1, then on to the IGNITION switch. It leaves the ignition switch when the switch is turned to the IGNITION position and is directed to Fuse #4, through the fuse, then on to the BACKUP LIGHTS switch. If the backup lights switch is closed, power then is directed to each backup light bulb and then is grounded back to the battery. consulab.com info@consulab.com 21 SA-1 — Backup Lights Circuit — Circuit Component Explanation — Answer Sheet Obtain a schematic of the backup lights circuit (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #1 – LOAD SIDE FUSE #4 – LOAD SIDE IGNITION SWITCH TERMINALS ACC IGNITION START BAT BACKUP LIGHT SWITCH 1ST TERMINAL 2nd TERMINAL BACKUP LIGHTS GROUND CIRCUITS CL-1918-4S_053304-95 SA-1 — Backup Lights Circuit Instructor : Grade : consulab.com info@consulab.com 22 CL-1918-4S_053304-95 SA-1 — Backup Lights Circuit SA-1 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the BACKUP LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the backup light components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the BACKUP LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right-hand backup light. B. Voltage drop across the left-hand backup light. C. What if the voltage drop across a backup light was 8.0V ? What does that reading tell you ? D. Total backup circuit current draw. 7. Are backup lights typically connected in series or in parallel on most vehicles ? 8. What would happen to the circuit if one backup light bulb was burned out ? 9. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 23 CL-1918-4S_053304-95 SA-1 — Backup Lights Circuit SA-1 — Level 1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. A Volts B Volts C D Amps 7. 8. 9. Instructor : Grade : consulab.com info@consulab.com 24 CL-1918-4S_053304-95 SA-1 — Backup Lights Circuit SA-1 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the backup light components. 4. Obtain instructor’s check. 5. With circuit turned OFF, measure the static resistance of each bulb with all wires disconnected. Then, reconnect circuit wires. 6. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the BACKUP LIGHT CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 7. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right-hand backup light. B. What would explain a voltage drop reading of 6.5V on the left-hand backup light ? C. Voltage drop across the left-hand backup light. D. Total backup circuit current draw. E. Measure current flow in right-hand backup light. F. Measure current flow in left-hand backup light. G. If the measured current of the left-hand backup light was significantly less than the right-hand side, what would that reading indicate might be wrong with the circuit ? 8. Now calculate the dynamic resistance of each backup light bulb. 9. Are backup lights typically connected in series or in parallel on most vehicles ? 10. What would happen to the circuit is one backup light bulb was burned out ? 11. On this specific trainer, what circuits must have the IGNITION switch turned on before operating ? 12. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 25 CL-1918-4S_053304-95 SA-1 — Backup Lights Circuit SA-1 — Level 3 Assignment — Answer Sheet Name : Group : Date : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : CIRCUIT MEASUREMENTS 5. A Ω B Ω 7. A VOLTS B C VOLTS D AMPS E AMPS F AMPS G 8. A Ω B Ω 9. 10. 11. 12. Instructor : Grade : consulab.com info@consulab.com 26 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit SA-2 — Hazard Lights Circuit Circuit Explanation The HAZARD LIGHTS circuit on vehicles is used to warn nearby vehicles that the vehicle is experiencing some type of ab- normal condition. Examples could be a vehicle that has been disabled and is located either in or near traffic flow or the driver is experiencing hazardous road conditions, is driving very slow and wishes to warn others of this condition. This circuit is extremely important for safe vehicle operation and should be checked often during routine safety inspections. Some newer vehicles can use LED lamps instead of the traditional incandescent bulbs. The CL-1918-4 uses LED lamps for the hazard lights circuit and correct circuit hookup polarity must be followed. If the LED stop lights are hooked up backwards, no component or circuit damage will occur. On most vehicles the hazard lights circuit turns on both the front amber turn signals and the rear red stop lights (if amber turn signal lights are used at the rear, options could use either amber turn or red stop lights for the hazard circuit.). The CL-1918-4 hazard lights circuit begins with battery power flowing through Fuse #2 (hot all times) and then connects to the BAT terminal of the HAZARD FLASHER. The HAZARD FLASHER GND terminal is connected to a system ground and the SIG (signal) terminal is connected to SIG terminal of the HAZARD SWITCH. The HAZARD SWITCH GND terminal is also connected to a system ground. The LEFT terminal connects to the following lights : LEFT TURN INDICATOR, LEFT FRONT TURN, and LEFT REAR STOP lights. The RIGHT terminal connects to the following lights : RIGHT TURN INDICATOR, RIGHT FRONT TURN, and RIGHT REAR STOP lights. In addition, all six of these lights have ground circuits connected to common system ground circuits. Pushing the HAZARD SWITCH button in connects battery power through the hazard switch and on to the left and right sides front turn and rear stop lights as well as both left and right turn indicators respectively. NOTE : For purposes of consistency and learning, it is desired when constructing ONLY the hazard lights circuit, to only use wires necessary for the operation of that circuit only. It is recognized that there can be inter-connection between the hazard and turn signal circuits, but please keep them separate when wiring these circuit assignments. We believe this will enhance the student learning experience when studying individual circuits. The circuits will be connected together when wiring the entire lighting system. consulab.com info@consulab.com 27 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit SA-2 — Hazard Lights Circuit — Circuit Component Explanation — Answer Sheet (2 pages) Obtain a schematic of the hazard lights circuit (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #2 – HAZARD SWITCH – GND – SIG – LEFT – RIGHT – HAZARD FLASHER – BAT – SIG – GND – LEFT & RIGHT INDICATORS – FRONT LEFT & RIGHT TURN LIGHTS – REAR LEFT & RIGHT TURN LIGHTS – consulab.com info@consulab.com 28 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit GROUND CIRCUITS – Instructor : Grade : consulab.com info@consulab.com 29 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit SA-2 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the HAZARD LIGHTS CIRCUIT, and following the schematic, correct- ly connect red and black circuit wires to the hazard light components. Please connect ONLY the necessary wires to operate JUST the hazard lights circuit and no other circuits. Be sure to use separate ground circuits for the left and right side of the vehicle. Do not combine the grounds together. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HAZARD LIGHT CIRCUIT. There should be a total of six lights operating. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are hazard lights typically connected in series or in parallel on most vehicles ? 7. As an experiment, remove the ground wire from the left front turn signal bulb. What effect did that have on the circuit ? 8. What would happen to the circuit if the right rear turn signal bulb was burned out ? 9. Measure the voltage available to the hazard lights flasher at the BAT terminal. 10. What would be the voltage reading from step 9 if fuse #2 were open ? 11. If fuse #2 was confirmed good and the voltage at the BAT terminal of the hazard flasher was zero, what could be the cause of this condition ? 12. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 30 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit SA-2 — Level 1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. 7. 8. 9. VOLTS 10. VOLTS 11. 12. Instructor : Grade : consulab.com info@consulab.com 31 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit SA-2 — Level 3 Assignment (2 pages) 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the hazard lights components. Please connect ONLY the necessary wires to operate JUST the hazard lights circuit and no other circuits. Be sure to use separate ground circuits for the left and right side of the vehicle. Do not combine the grounds together. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HAZARD LIGHT CIRCUIT. There should be a total of six lights operating. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are hazard lights typically connected in series or in parallel on most vehicles ? 7. Using proper jumper wires, set up the hazard circuit to be able to measure the total current for only the RIGHT side of the hazard circuit. You must use a jumper wire to have only the right side operate constantly to accurately mea- sure the current. Now measure the current of the right side of the hazard circuit. NOTE- You must make necessary changes to the circuit so that the right side lights stay on in order to measure total current flow. 8. Using the same procedure as step 7, repeat the current measurement for the LEFT side of the hazard circuit. 9. Add the answers from steps 7 & 8 together. What is the total hazard lights circuit current ? 10. What effect would an open wire between the GND terminal of the hazard switch and system ground cause in the hazard lights circuit ? 11. Remove the red wire connecting between the hazard flasher SIG terminal and the hazard switch SIG terminal. 12. Connect a long red wire from the SIG terminal of the hazard flasher to either terminals of the right rear marker light. 13. Connect a long red wire from the other terminal of the right rear marker light to the SIG terminal of the hazard flash- er switch. You have now inserted some unwanted resistance in the SIG circuit of the hazard lights circuits. Turn on the circuit and explain what circuit performance characteristics you notice. 14. With the circuit on, use a short red jumper wire to momentarily jump across the two terminals of the right rear mark- er light and record what you noticed happening to the circuit. 15. Explain what conditions on a vehicle could cause this condition. 16. Using more red jumper wires, add additional side marker lights, license plate light and backup lights all in SERIES to observe what effect added resistance has on this circuit. What happens as you add more resistance into the SIG circuit ? consulab.com info@consulab.com 32 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit 17. Remove the jumper wire and all other extra red wires and restore the circuit back to normal operating conditions. 18. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 33 CL-1918-4S_053304-95 SA-2 — Hazard Lights Circuit SA-2 — Level 3 Assignment — Answer Sheet Name : Group : Date : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : CIRCUIT MEASUREMENTS : 6. 7. 8. 9. 10. 13. 14. 15. 16. 18. Instructor : Grade : consulab.com info@consulab.com 34 CL-1918-4S_053304-95 SA-3 — Horn Circuit SA-3 — Horn Circuit (Positive Switched) Circuit Explanation The HORN circuit on vehicles is used to get the attention of someone near your vehicle and for other emergency type uses. The HORN circuit can consist of one or more horns of different tones to create a loud noise when operated. The specific tone of a vehicles horn will vary between manufacturers and vehicle models. The CL-1918-4 uses a low am- plitude audible tone device so that the tone is not objectionable. Vehicles use the steering wheel for locations of horn switches and the horn circuit is often connected to the keyless entry and security systems. The CL-1918-4 uses a com- mon push button switch as the horn switch. Most vehicles today use a relay to operate the horn because the horns can draw significant amounts of current which needs to be controlled by a low current control circuit. The CL-1918-4 horn circuit consists of two circuits. (LOW CURRENT CONTROL & HIGH CURRENT CONTROLLED circuits) CONTROL CIRCUIT – This circuit starts at Fuse #2 (15A) (hot all times). It leaves fuse #2 and connects to one terminal of the horn switch. The other terminal of the horn switch connects to terminal # 86 of relay #4. Terminal #85 of relay #4 is connected to system ground. This is the horn circuit “control” or low amperage circuit. In this case, the horn switch supplies “positive” power to the relay coil terminal #86. Some vehicles use the horn switch as a “ground switch”. CONTROLLED CIRCUIT – This circuit starts at Fuse #3(5A) (hot at all times) and after the fuse is connected to terminal #30 of relay #4. Terminal #87 of relay #4 is connected to the RED terminal of the horn and circuit breaker. The horn is grounded from the BLACK terminal of the horn to a system ground. There is a 2mm test point between the RED and BLACK terminals of the horn for testing purposes. The circuit breaker is present for purposes of the horn fault. This is the “controlled” or high current circuit. NOTE : The CL-1918-4 uses an electronic tone device in place of a normal vehicle horn. Most vehicle horn circuits use a relay to safety handle the high current of the horn(s) so that the current doesn’t have to flow through the horn switch. In this particular case, the current draw of the “horn” is much lower than even the coil (control) circuit of the relay. It must be understood by students that this would not be the case in an actual vehicle. Pushing the horn button causes relay #4 to energize (#86 & #85) which connects power from terminal #30 to #87, which in turn causes the horn to operate. (if the circuit breaker is not open). NOTE : After you have completed first HORN CIRCUIT assignments, there is an additional assignment to setup and learn how a “ground-switched” horn circuit operates. Be sure to complete this portion of the assignment also. consulab.com info@consulab.com 35 CL-1918-4S_053304-95 SA-3 — Horn Circuit SA-3 — Horn Circuit — Circuit Component Explanation — Answer Sheet Obtain a schematic of the horn circuit (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #2 – LOAD SIDE FUSE #3 – LOAD SIDE HORN BUTTON 1ST TERMINAL- 2ND TERMINAL- RELAY #4 TERMINAL #30- TERMINAL #87- TERMINAL #86- TERMINAL #85- TERMINAL #87a- consulab.com info@consulab.com 36 CL-1918-4S_053304-95 SA-3 — Horn Circuit HORN 1ST TERMINAL- 2ND TERMINAL- GROUND CIRCUITS- Instructor : Grade : consulab.com info@consulab.com 37 CL-1918-4S_053304-95 SA-3 — Horn Circuit SA-3 Level 1 / Level 2 Assignment 1. Fill out the level 1&2 student answer sheet with name, class and information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the HORN CIRCUIT, and following the schematic, correctly connect red and black circuit wires to all horn components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HORN CIRCUIT. If the horn circuit does not operate properly, go back over your work to locate the error and correct. 6. What is the purpose of the horn relay in this circuit ? 7. As an experiment, temporarily remove the black wire connected to terminal # 85 of relay # 4. What happens ? What are some basic conclusions drawn from this experiment ? 8. What would happen to the horn circuit if fuse # 3 was open or defective ? 9. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) 10. Ask instructor if you are to be assigned the OPTIONAL ground switched horn circuit. If so, obtain the assignments pertaining to it. consulab.com info@consulab.com 38 CL-1918-4S_053304-95 SA-3 — Horn Circuit SA-3 Level 1 / Level 2 Assignment — Anwser Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : CIRCUIT MEASUREMENTS : 6. 7. What happened to the circuit ? CONCLUSIONS : 8. 9. Instructor : Grade : consulab.com info@consulab.com 39 CL-1918-4S_053304-95 SA-3 — Horn Circuit SA-3 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the horn circuit components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the HORN CIRCUIT. 6. If circuit does not operate properly, go back over your work to locate the error and correct. 7. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Current draw for the CONTROL CIRCUIT of the horn relay. B. Current draw for the CONTROLLED CIRCUIT of the horn relay. C. Measure the voltage available at both terminals of the horn switch with the push button not pushed in. D. Measure the voltage available at terminal #30 of the horn relay. 8. NOTE : Because this trainer uses a piezo type “horn” in this circuit, the amperage will be very low. Using necessary jumper wires, remove the horn from the circuit and connect the two front marker lights in parallel so that the horn relay now controls them. After confirming proper circuit hookup, measure the current flow of the new CONTROLLED CIRCUIT. 9. Describe in detail what would happen to the horn circuit if there was an open in fuse #3 ? 10. What would happen if you connected a jumper wire from a positive voltage source to terminal # 86 of relay #3 ? 11. Disconnect the ground wire from terminal #85 of relay #4. 12. Predict what the voltage would be at terminal #85 of relay #4 when the horn push button is pushed in. 13. Now, push in the horn button with a voltmeter on terminal #85 of relay #4. What is the reading ? 14. Explain why you measured the reading you did in question #12. 15. What two terminals of relay #4 are for the “low current” circuit ? 16. What two terminals of relay #4 are for the “high current” circuit ? 17. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) 18. Ask your instructor if you are to be assigned the OPTIONAL ground switched horn circuit and if so, obtain the SA-4 assignments for it. consulab.com info@consulab.com 40 CL-1918-4S_053304-95 SA-3 — Horn Circuit SA-3 — Level 3 Assignment — Answer Sheet Name : Group : Date : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : CIRCUIT MEASUREMENTS : 7. A AMPS B AMPS C One terminal VOLTS & The other terminal VOLTS D VOLTS 8. AMPS 9. 10. 12. 13. VOLTS 14. 15. Terminals # & # are the low current circuit of the relay. 16. Terminals # & # are the high current circuit of the relay. 17. Instructor : Grade : consulab.com info@consulab.com 41 CL-1918-4S_053304-95 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Horn Circuit (Ground Switched) Circuit Component Explanation — Answer Sheet (2 Pages) Obtain a schematic of the horn circuit (ground switched) (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #2 – LOAD SIDE FUSE #3 – LOAD SIDE HORN BUTTON 1ST TERMINAL- 2ND TERMINAL- RELAY #4 TERMINAL #30- TERMINAL #87- TERMINAL #86- TERMINAL #85- TERMINAL #87a- consulab.com info@consulab.com 42 CL-1918-4S_053304-95 SA-4 — Optional Circuit Horn Circuit (Ground Switched) HORN 1ST TERMINAL- 2ND TERMINAL- GROUND CIRCUITS- Instructor : Grade : consulab.com info@consulab.com 43 CL-1918-4S_053304-95 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Level 3 Assignment In this assignment, you are going to hook up a horn circuit with the horn switch controlling the ground side of the relay. 1. Obtain a blank Level 3 schematic showing all components and circuit receptacles. Label the circuit as : “HORN CIRCUIT – GROUND SWITCHED” and fill in your name, class and date information. 2. Using your obtained knowledge, design a horn circuit where the horn switch will control the ground side of the horn relay. Draw all necessary wires on the schematic and double check your work. 3. After confirming your circuit design, hook up all necessary red and black jumper wires to the horn circuit. 4. Confirm proper horn circuit operation (ground switched) 5. Ask instructor for confirmation of your circuit design. 6. Did you construct the circuit according to the correct answer schematic ? 7. Remove all circuit wiring from the trainer. consulab.com info@consulab.com 44 CL-1918-4S_053304-95 SA-4 — Optional Circuit Horn Circuit (Ground Switched) SA-4 — Level 3 Assignment — Answer Sheet Name : Group : Date : 5. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. Instructor : Grade : consulab.com info@consulab.com 45 CL-1918-4S_053304-95 SA-5 — Stop Lights Circuit SA-5 — Stop Lights Circuit Circuit Explanation The STOP LIGHTS circuit on vehicles is used to warn following drivers that you are either slowing down or braking your vehicle using the brake pedal. The term BRAKE LIGHT is often also used for the stop lights and there is no difference be- tween the two. This circuit is extremely important for safe vehicle operation and should be checked often during routine safety inspections. Some newer vehicles can use LED lamps instead of the traditional incandescent bulbs. The CL-1918- 4 uses LED lamps for its stop light circuit and correct circuit hookup polarity must be followed. If the LED stop lights are hooked up backwards, no component or circuit damage will occur. The stop lights will not operate with reversed polarity. On vehicles that do not have amber rear turn signals, it is com- mon to use both rear right and left turn signal bulbs for the stop lights. On vehicles with amber turn signals, there will be separate RED bulbs used only for the stop lights. Also, on newer vehicles, the CHMSL (Center High Mounted Stop Light) is used. The stop light circuit normally consists of a one or more fuses, brake light switch that closes when the driver steps on the brake pedal, brake lights in the rear of the vehicle and the required positive and negative wiring necessary to operate the circuit. Newer vehicles can use CAN Bus circuits to operate the brake lights from signals produced by the stop light switch. The stop light circuit will normally operate regardless of the position of the ignition switch. The CL-1918-4 uses LED bulbs for the stop lights circuit. Power for the stop lights is obtained from battery, then to the “hot at all times” fuse # 2. Power is then routed from the fuse to the stop lights push button switch, to the three LED stop lights (left, right and CHMSL). From the three stop lights, power is then routed through the ground circuit back to the battery. consulab.com info@consulab.com 46 CL-1918-4S_053304-95 SA-5 — Stop Lights Circuit SA-5 — Stop Lights Circuit — Circuit Component Explanation — Answer Sheet Obtain a schematic of the stop lights circuit (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #2(15A) — LOAD SIDE BRAKE SWITCH 1ST TERMINAL- 2ND TERMINAL- CHMSL STOP TERMINAL- GND TERMINAL- LEFT & RIGHT REAR STOP LIGHTS STOP TERMINALS- GND TERMINALS- GROUND CIRCUITS- Instructor : Grade : consulab.com info@consulab.com 47 CL-1918-4S_053304-95 SA-5 — Stop Lights Circuit SA-5 — Level 1 / Level 2 Assignment 1. Fill out the level 1&2 student answer sheet with name, class and information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the STOP LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the stop light components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the STOP LIGHTS CIRCUIT. There should be a total of three stop lights operating. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are stop lights typically connected in series or in parallel on most vehicles ? 7. As an experiment, correctly connect the red right rear marker light to the circuit and operate the stop light switch. What happens ? What are some basic conclusions drawn from this experiment ? 8. What would happen to the circuit if one stop light bulb was burned out ? 9. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 48 CL-1918-4S_053304-95 SA-5 — Stop Lights Circuit SA-5 — Level 1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. 7. 8. 9. Instructor : Grade : consulab.com info@consulab.com 49 CL-1918-4S_053304-95 SA-5 — Stop Lights Circuit SA-5 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the stop lights circuit components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the STOP LIGHTS CIRCUIT. There should be three stop lights operating when the stop light switch is pushed. 6. If circuit does not operate properly, go back over your work to locate the error and correct. 7. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Total current draw for the entire stop light circuit. B. Current draw for the right hand stop light. C. Current draw for the left hand stop light. D. Current draw for the center high mounted stop light. 8. Add up the individual bulb current draws. What is the total compared with answer 7A ? What might explain any small difference between the two readings ? 9. As an experiment, add the right hand rear red marker light to the stop light circuit. What happens when you push the stop light switch button ? 10. Measure the current draw of the right rear marker light ? 11. Measure the total stop lights circuit current with the marker light included. 12. How much more current did the addition of the right hand red marker light add to the total circuit current ? 13. What conclusions can you make from this experiment regarding the current draw of incandescent bulbs compared with LED bulbs ? 14. Are stop lights typically connected in series or in parallel on most vehicles ? 15. What would happen to the circuit if one stop light bulb was burned out ? 16. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 50 CL-1918-4S_053304-95 SA-5 — Stop Lights Circuit SA-5 — Level 3 Assignment — Answer Sheet Name : Group : Date : 4. INSTRUCTOR’S CHECK : 7. A mA B mA C mA D mA 8. mA 9. 10. mA 11. mA 12. mA 13. 14. 15. 16. Instructor : Grade : consulab.com info@consulab.com 51 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Tail-Park Lights Circuit (Ground Switched) Circuit Explanation All vehicles today use a TAIL-PARK lights circuit. It is designed to give notice to nearby vehicles that the vehicle is pres- ent. Some manufacturers use different names for this circuit. Other totally proper names that are used can be : RUNNING LIGHTS, CLEARANCE LIGHTS and others. NHTSA (National Highway Traffic Safety Association) have laws and require- ments involving vehicle lighting circuits. Most all current vehicles today must have amber colored park lights at the left and right side at the front of the vehicle and also amber colored side lights at both the left and right side of the vehicles front end. The rear of the vehicle must have a red colored tail light at both the left and right side as well as a red col- ored side lights at each side of the rear of the vehicle. Tail-park light circuits can be controlled many different ways. Some vehicles use common manual light switches, while others use some variation of “automatic” lighting switching. Most of todays vehicles use CAN Bus circuits to control the lights which allows the turning ON and OFF of vehicle lighting circuits without actual operation of a switch. This feature is utilized for security systems, vehicle locking system, keyless fob lighting control, timer circuits and many others. There are many different types of lighting circuits used on vehicles. Some can be “positive” switched while other are “ground” switched. The only difference is what circuit (positive or ground) contains the switching controls. Tail-Park Lights Circuit On the CL-1918-4 trainer, it is possible to use either a positive or ground switched tail-park lights circuit. The 3-page OEM wiring diagram uses the “ground switched” method. There will be additional assignments to have students con- struct positive switched circuits also. Tail-Park Circuit Ground Switched : Power from the battery is connected to Fuse #1 (20A) where it flows through the fuse and connects to the Tail-Park relay #3 at terminal #86. A jumper connects from terminal #86 to relay #3 terminal #30. Tail-Park Lights Low Current Control Circuit : The low current control circuit for the tail-park lights consists of the relay coil of Relay #3 (PARK-TAIL LAMPS). After leaving terminal 85, it is connected to the PARK terminal of the multi-function switch. If the multi-function switch is turned ON to the PARK position, the PARK terminal is connected to a ground path out of the “COM” terminal and on to the sys- tem GROUND which in turn causes relay #3 to energize which connects terminal #30 to #87. This is a ground-switched circuit. Tail-Park Lights High Current Circuit : The high current circuit for the tail-park lights starts at terminal #30 of relay #3. When the relay is energized by the multi-function switch, power from terminal #30 is connected to terminal #87 and on to all of the tail and park lights. consulab.com info@consulab.com 52 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) Left-Side Tail & Park Lights Terminal #87 is connected to fuses #7 (10A) & #8 (10A). Fuse #7 connects to the left front marker light and with ad- ditional wires to the left-front park light. Another wire connects from the left front marker light to the left-rear marker light. Other wires then connect the left-rear tail and license plate light. Ground wires are connected from all of these lights to the common ground bus on all left sides of the top, middle and bottom panels. Right-Side Tail & Park Lights Fuse #8 (10A) is connected from terminal #87 of relay #3. Fuse #8 connects to the right-front marker light and will addi- tional wires to the right-front park light. Another wire connects from the right front marker light to the right rear marker light. Other wires then connect the right rear tail light. Ground wires are connected from all of these lights to the com- mon ground bus on the .left sides of top, middle and bottom panels. It is intentional to keep the left and right circuit sides electrically separate. VARIATIONS : It is acknowledged that there are many other methods of safely connecting the tail and park lights in a circuit. For purposes of reference and to as closely as possible match typical vehicle configurations, it is preferred to follow the included Level 3 OEM type wiring diagram when constructing this circuit. consulab.com info@consulab.com 53 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Tail-Park Lights Circuit — Circuit Component Explanation — Answer Sheet (3 pages) Obtain a schematic of the tail and park lights circuit (Levels 1,2 or 3) and in your own words, explain how the circuit func- tions and what each component contributes to the circuit. Name : Group : Date : FUSE #1 (20A) — LOAD SIDE FUSE #7 (10A) — POWER SIDE FUSE #7 (10A) — LOAD SIDE FUSE #8 (10A) — POWER SIDE FUSE #8 (10A) — LOAD SIDE RELAY #3 TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- MULTI-FUNCTION SWITCH PARK TERMINAL- COM TERMINAL- consulab.com info@consulab.com 54 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) FRONT LEFT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- FRONT LEFT PARK LIGHT GND TERMINAL- PARK TERMINAL- FRONT RIGHT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- FRONT RIGHT PARK LIGHT GND TERMINAL- PARK TERMINAL- REAR LEFT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- REAR LEFT TAIL LIGHT GND TERMINAL- TAIL TERMINAL- LICENSE PLATE LIGHT 1ST TERMINAL- 2ND TERMINAL- consulab.com info@consulab.com 55 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) RIGHT REAR TAIL LIGHT GND TERMINAL- TAIL TERMINAL- REAR RIGHT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- GROUND CIRCUITS Instructor : Grade : consulab.com info@consulab.com 56 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF) and that the power supply red and black wires are connected to the trainer. 3. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the TAIL-PARK LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the tail-park lights components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right front marker light. B. Voltage drop across the left rear tail light. C. Total tail-park lights circuit current draw. 7. With the tail-park lights turned OFF, make the following voltage measurements : A. Voltage available at terminal #86 of relay #3 to ground. B. Voltage available at terminal #85 of relay #3 to ground. 8. Explain why there is voltage available on both sides of the relay coil ? 9. Are tail-park lights typically connected in series or in parallel on most vehicles ? 10. What would happen to the circuit if the right front marker light bulb was burned out ? 11. What would happen to the tail-park circuit if there was an open in the wire from terminal #85 of relay #3 and the COM terminal of the turn-signal switch ? 12. What would happen to the circuit if the wire between the right hand rear tail light GND terminal and system ground were open ? 13. What would happen to the circuit if fuse #8 were open ? 14. What would happen to the circuit if there was a constant short in the multi-function switch between the PARK and GND terminals ? 15. What would happen to the circuit if there was a short between POS and GND of the license plate light ? 16. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 57 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. A VOLTS B VOLTS C AMPS 7. A VOLTS B VOLTS 8. 9. 10. 11. 12. 13. 14. 15. 16. Instructor : Grade : consulab.com info@consulab.com 58 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 3 Assignment (2 pages) 1. Fill out level 3 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the tail-park lights components. NOTE- There are many components in this circuit. Be sure you spend suffi- cient time studying the circuit to determine the correct hookup of each component. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right front marker light. B. Voltage drop across the left rear tail light. C. Total tail-park lights circuit current draw. D. Current draw of the left rear marker light. E. Current draw of the left rear tail light. 7. Compare the differences between the current draw measured in 6D and 6E. What is the design advantage for manu- facturers to use LED bulbs ? 8. With the tail-park lights turned OFF, make the following voltage measurements : A. Voltage available at terminal #86 of relay #3 to ground. B. Voltage available at terminal #85 of relay #3 to ground. 9. Explain why there is voltage available on both sides of the relay coil ? 10. If you were to use a fused jumper wire, explain how you could energize relay #3 without having to turn on the tail- park lights switch ? This test is often performed in diagnosis. 11. Are tail-park lights typically connected in series or in parallel on most vehicles ? 12. What would happen to the circuit if the right front marker light bulb was burned out ? 13. What would happen to the tail-park circuit if there was an open in the wire from terminal #85 of relay #3 and ground ? 14. What would happen to the circuit if the wire between the right hand rear tail light GND terminal and system ground were open ? consulab.com info@consulab.com 59 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) 15. What would happen to the circuit if fuse #8 were open ? 16. What would happen to the circuit if there was a constant short in the multi-function switch between the PARK and GND terminals ? 17. What would happen to the circuit if there was a short between POS and GND of the license plate light ? 18. Now, remove the end of red positive wire that comes from the front left marker light to the left rear marker light at the left rear marker light and connect it to either terminal of the left hand backup light. Leave all other wires con- nected to the left rear marker light. 19. Connect another red positive wire from the other terminal of the backup light to the left rear marker light (red termi- nal). Now, turn on the TAIL-PARK lights circuit. 20. What happened to the tail-park lights now ? 21. Measure the voltage drop across the following lights : A. Left rear marker light B. Left rear tail light C. License plate light D. Left backup light 22. Explain what has caused the “faulted” condition that you noticed in step #20. 23. Now, remove the ground from the license plate light. Describe what the circuit is doing now. 24. Measure the voltage drops across the following lights : A. Left rear marker light B. Left rear tail light C. Left backup light 25. Explain what has caused the difference in circuit performance with the license plate light removed from the circuit. 26. Restore the circuit back to normal by removing the backup light from the circuit and confirm proper operation. 27. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 60 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) SA-6 — Level 3 Assignment — Answer Sheet (2 pages) Name : Group : Date : 4. INSTRUCTOR’S CHECK OF CORRECT CIRCUIT WIRING : 6. A VOLTS B VOLTS C AMPS D AMPS E AMPS 7. 8. A VOLTS B VOLTS 9. 10. 11. 12. 13. 14. 15. 16. 17. 20. consulab.com info@consulab.com 61 CL-1918-4S_053304-95 SA-6 — Tail-Park Lights Circuit (Ground Switched) 21. A VOLTS B VOLTS C VOLTS D VOLTS 22. 23. 24. A VOLTS B VOLTS C VOLTS 25. 27. Instructor : Grade : consulab.com info@consulab.com 62 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Tail-Park Lights Circuit (Positive Switched) Circuit Explanation All vehicles today use a TAIL-PARK lights circuit. It is designed to give notice to nearby vehicles that the vehicle is pres- ent. Some manufacturers use different names for this circuit. Other totally proper names that are used can be : RUNNING LIGHTS, CLEARANCE LIGHTS and others. NHTSA (National Highway Traffic Safety Association) have laws and require- ments involving vehicle lighting circuits. Most all current vehicles today must have amber colored park lights at the left and right side at the front of the vehicle and also amber colored side lights at both the left and right side of the vehicles front end. The rear of the vehicle must have a red colored tail light at both the left and right side as well as a red col- ored side lights at each side of the rear of the vehicle. Tail-park light circuits can be controlled many different ways. Some vehicles use common manual light switches, while others use some variation of “automatic” lighting switching. Most of todays vehicles use CAN Bus circuits to control the lights which allows the turning ON and OFF of vehicle lighting circuits without actual operation of a switch. This feature is utilized for security systems, vehicle locking system, keyless fob lighting control, timer circuits and many others. There are many different types of lighting circuits used on vehicles. Some can be “positive” switched while other are “ground” switched. The only difference is what circuit (positive or ground) contains the switching controls. In this assignment, you will learn how the “positive switched” circuit differs from the “ground switched” option. Tail-Park Lichts Circuit On the CL-1918-4 trainer, it is possible to use either a positive or ground switched tail-park lights circuit. The 3-page OEM wiring diagram uses the “positive switched” method. Tail-Park Circuit (Included OEM Schematic) Power Switched : Power from fuse F1 connects terminal #30 of relay #3 and continues on to the COM terminal of the multi-function switch. When the PARK lights are selected, power flows out of the multi-function switch on the PARK terminal which con- nects to terminal #86 of relay #3. Terminal #87 of relay #3 connects to fuse F7 & F8 which power the right park lights (F8) and left park lights (F7). Tail-Park Lights Low Current Control Circuit The low current control circuit for the tail-park lights consists of the relay coil of Relay #3 (PARK-TAIL LAMPS). Terminal #85 is connected to system ground. Terminal #86 is connected to the PARK terminal of the multi-function light switch. If the light switch is turned ON to the PARK position, B+ voltage is sent to terminal #86 of relay #3 which in turn caus- es relay to energize which connects terminals #30 to #87. This is a power-switched circuit. The COM terminal of the multi-function switch is connected to B+ from terminal #30 of relay #3. consulab.com info@consulab.com 63 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) NOTE : CIRCUIT FUNCTION FROM THIS POINT BELOW IS THE SAME AS WITH THE GROUND SWITCHED CIRCUIT. Tail-Park Lights High Current Circuit : The high current circuit for the tail-park lights starts at terminal #30 of relay #3. When the relay is energized by the multi-function switch, power from terminal #30 is connected to terminal #87 which is then connected to the power side of both fuses #7(10A) and #8(10A). Left-Side Tail & Park Lights Fuse #7 connects to the left front marker light and with additional wires to the left-front park light. Another wire con- nects from the left front marker light to the left-rear marker light. Other wires then connect the left-rear tail and license plate light. Ground wires are connected from all of these lights to the common ground bus on the left side of the trainer. Right-Side Tail & Park Lights Fuse #8 connects to the right-front marker light and will additional wires to the right-front park light. Another wire connects from the right front marker light to the right rear marker light. Other wires then connect the right rear tail light. Ground wires are connected from all of these lights to the common ground bus on the left side of the trainer. It is intentional to keep the left and right circuit sides electrically separate. VARIATIONS : It is acknowledged that there are many other methods of safely connecting the tail and park lights in a circuit. For purposes of reference and to as closely as possible match typical vehicle configurations, it is preferred to follow the included 4-page OEM type wiring diagram when constructing this circuit. consulab.com info@consulab.com 64 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Tail-Park Lights Circuit (Positive Switched) — Circuit Component Explanation — Answer Sheet (3 pages) Obtain a schematic of the tail and park lights circuit (Levels 1,2 or 3) and in your own words, explain how the circuit func- tions and what each component contributes to the circuit. Name : Group : Date : FUSE #1 (20A) — LOAD SIDE FUSE #7 (10A) — POWER SIDE FUSE #7 (10A) — LOAD SIDE FUSE #8 (10A) — POWER SIDE FUSE #8 (10A) — LOAD SIDE RELAY #3 TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- MULTI-FUNCTION SWITCH PARK TERMINAL- COM TERMINAL- consulab.com info@consulab.com 65 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) FRONT LEFT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- FRONT LEFT PARK LIGHT GND TERMINAL- PARK TERMINAL- FRONT RIGHT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- FRONT RIGHT PARK LIGHT GND TERMINAL- PARK TERMINAL- REAR LEFT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- REAR LEFT TAIL LIGHT GND TERMINAL- TAIL TERMINAL- LICENSE PLATE LIGHT 1ST TERMINAL- 2ND TERMINAL- consulab.com info@consulab.com 66 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) RIGHT REAR TAIL LIGHT GND TERMINAL- TAIL TERMINAL- REAR RIGHT SIDE MARKER LIGHT 1ST TERMINAL- 2ND TERMINAL- GROUND CIRCUITS Instructor : Grade : consulab.com info@consulab.com 67 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 positive switched wiring schematic that your instructor has assigned for the TAIL-PARK LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the tail-park lights components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurements and put readings on your answer sheet. A. Voltage drop across the right front marker light. B. Voltage drop across the left rear tail light. C. Total tail-park lights circuit current draw. 7. With the tail-park lights turned OFF, make the following voltage measurements : A. Voltage available at terminal #86 of relay #3 to ground. B. Voltage available at terminal #85 of relay #3 to ground. 8. Explain why there is not voltage available on both sides of the relay coil ? 9. Are tail-park lights typically connected in series or in parallel on most vehicles ? 10. What would happen to the circuit if the right front marker light bulb was burned out ? 11. What would happen to the tail-park circuit if there was an open in the wire from terminal #85 of relay #3 and ground ? 12. What would happen to the circuit if the wire between the right hand rear tail light GND terminal and system ground were open ? 13. What would happen to the circuit if fuse #8 were open ? 14. What would happen to the circuit if there was a constant short in the multi-function switch between the PARK and COM terminals ? 15. What would happen to the circuit if there was a short between POS and GND of the license plate light ? 16. Describe the difference between the ground switched and power switched TAIL-PARK light circuits. 17. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 68 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. A VOLTS B VOLTS C AMPS 7. A VOLTS B VOLTS 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Instructor : Grade : consulab.com info@consulab.com 69 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 3 Assignment (2 pages) 1. Fill out level 3 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the tail-park lights components. NOTE- There are many components in this circuit. Be sure you spend suffi- cient time studying the circuit to determine the correct hookup of each component. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TAIL-PARK LIGHTS CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Explain the differences between a ground switched and positive switched tail-park circuit. Define what components are wired differently. 7. You are diagnosing a non-functional positive switched tail-park circuit PROBLEM DESCRIPTION : When you turn the light switch to the PARK position, no lights function. You have a voltmeter available for diagnosis. Answer the questions below : A. What is the very first component you should test ? B. How would you test the item in item A ? C. After testing the item in step A, where would go next ? D. Explain how to temporarily bypass the light switch for diagnostic purposes. E. Explain how to make the relay operate without the need of the PARK switch input. 8. The relay for the tail-park circuit does not operate. List the steps in the order you would use to diagnose this prob- lem. Use letters (A, B, C, D, etc) for your steps. Be as detailed as possible. 9. With the tail-park switch turned off, what should the voltage reading at terminal #86 of relay #3 be ? 10. With the tail-park switch turned on, what should the voltage reading at terminal #87 of relay #3 be ? 11. You are checking for voltage on terminal #30 of relay #3 and the reading is zero. What are two things that could be wrong ? 12. With the circuit turned OFF and using the below schematic, modify the circuit to insert the right backup light bulb in series with the circuit. consulab.com info@consulab.com 70 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date FROM RIGHT FRONT MARKER LIGHT 13. Turn the circuit on and describe the operation of the right rear tail and side marker light. 14. Make voltage measurements between the following points : A. E to A B. E to B C. A to B D. A to C E. E to D 15. What did the reading of E to A tell you ? 16. What did the reading of E to B tell you ? 17. What did the reading of A to B tell you ? 18. What did the reading of A to C tell you ? 19. What did the reading of E to D tell you ? 20. Using a jumper wire, connect terminal D of side marker light to terminal A of backup light. Describe what happened to the circuit and why. 21. Describe a “real-world” cause of the condition you have described for this circuit modification. 22. Restore the circuit to its original operating condition. 23. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) AB C D E consulab.com info@consulab.com 71 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) SA-7 — Level 3 Assignment — Answer Sheet (2 pages) Name : Group : Date : 4. INSTRUCTOR’S CHECK OF CORRECT CIRCUIT WIRING : 6. 7. A B C D E 8. (USE BACK OF ANSWER SHEET IF MORE SPACE IS NEEDED) A B C D E F G consulab.com info@consulab.com 72 CL-1918-4S_053304-95 SA-7 — Tail-Park Lights Circuit (Positive Switched) H 9. VOLTS 10. VOLTS 11. 14. A VOLTS B VOLTS C VOLTS D VOLTS E VOLTS 15. 16. 17. 18. 19. 20. 21. 23. Instructor : Grade : consulab.com info@consulab.com 73 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit SA-8 — Turn Signal Circuit Circuit Explanation The TURN SIGNAL circuit on vehicles is used to warn nearby vehicles that the vehicle is going to turn either left or right. Use of turn signals by the driver is required by law in most states and provinces. The turn signals are usually command- ed by the driver. Some newer vehicles can use LED lamps instead of the traditional incandescent bulbs. The CL-1918-4 uses LED lamps for the front and rear turn signal circuit and correct circuit hookup polarity must be followed. If the LED turn signal lights are hooked up backwards, no component or circuit damage will occur. On most vehicles the turn signal lights circuit turns on both the front and rear amber turn signals. Not all vehicles use amber rear turn signals and if not, the left and right red stop lights is used for signaling turns. Most newer vehicles today use amber rear turn signals. The CL-1918-4 turn signal circuit begins with battery power flowing through Fuse #1 (20A) (hot all times) and then con- nects to the BAT terminal of the IGNITION SWITCH. From the IGNITION SWITCH, if the switch in put in the IGNITION position, power flows out of the IGN terminal and into Fuse #4 (10A). If flows out of Fuse #4 where it connects to the BAT terminal of the TURN SIGNAL FLASHER. The other terminals of the TURN SIGNAL FLASHER are SIG (signal) and GND (ground). The SIG terminal is connected to the SIG terminal of the MULTI-FUNCTION SWITCH. The GND terminal is con- nected to system ground. The purpose of the flasher to cause the circuit to come on and off when connected through the SIG terminal through a turn signal light(s) to ground. NOTE : If a 12V test light connected to GROUND was connected to SIG of either the multi-function switch or the turn signal flasher, the flasher would operate. This proves that the SIG circuit is “waiting for a connection to a load, then to ground. If a 12V test light connected to GROUND was connected to SIG of either the multi-function switch or the turn signal flasher, the flasher would operate. This proves that the SIG circuit is waiting for a connection to a load, then to ground. The purpose of the MULTI-FUNCTION switch is to direct the SIG circuit to either the LEFT or RIGHT turn signal bulbs and after the bulb, to a ground circuit. The left and right turn signal circuits are also connected to the LEFT and RIGHT INDICATOR lamps and each has its own ground circuit. The INDICATOR lights inform the driver that the circuit is functioning. CAN Bus circuits can be used with turn signals on some vehicles and not all vehi- cles are identical. The newest of vehicles do not use a turn signal flasher because electronic modules are used instead. In those cases, the normal audible “clicking” of the turn signal flasher can be artificially created by using electronics. NOTE : For purposes of consistency and learning, it is desired when constructing ONLY the turn signal circuit, to only use wires necessary for the operation of that circuit only. It is recognized that there can be inter-connection between the turn and hazard signal circuits, but please keep them separate when wiring these circuit assignments. We believe this will enhance the student learning experience when studying individual circuits. The circuits will be connected together when wiring the entire lighting system. consulab.com info@consulab.com 74 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit SA-8 — Turn Signal Circuit — Circuit Component Explanation — Answer Sheet (3 pages) Obtain a schematic of the turn signals circuit (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #1 (20A) — LOAD SIDE FUSE #4 (10A) — POWER SIDE FUSE #4 (10A) — LOAD SIDE IGNITION SWITCH ACC TERMINAL- IGN TERMINAL- START TERMINAL- BAT TERMINAL- MULTI-FUNCTION SWITCH (TURN SIGNAL PORTION) SIG TERMINAL- consulab.com info@consulab.com 75 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit LEFT TERMINAL- RIGHT TERMINAL- TURN SIGNAL FLASHER GND TERMINAL - SIG TERMINAL - BAT TERMINAL - LEFT INDICATOR LIGHT - RIGHT INDICATOR LIGHT - LEFT FRONT TURN LIGHT TURN TERMINAL - GND TERMINAL - RIGHT FRONT TURN LIGHT TURN TERMINAL - GND TERMINAL - consulab.com info@consulab.com 76 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit LEFT REAR TURN LIGHT TURN TERMINAL- GND TERMINAL - RIGHT REAR TURN LIGHT TURN TERMINAL - GND TERMINAL - GROUND CIRCUITS Instructor : Grade : consulab.com info@consulab.com 77 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit SA-8 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the level 1 or level 2 wiring schematic for the TURN SIGNAL LIGHTS CIRCUIT, and following the schematic, correctly connect red and black circuit wires to the turn signal lights components. Please connect ONLY the neces- sary wires to operate JUST the turn signal lights circuit and no other circuits. Be sure to use separate ground circuits for the left and right side of the vehicle. Do not combine the grounds together. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TURN SIGNAL LIGHTS circuit. There should be a total of three lights for each LEFT and RIGHT sides. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Are the turn signal lights typically connected in series or in parallel on most vehicles ? 7. As an experiment, remove the ground wire from the right front turn signal bulb. What effect did that have on the circuit ? 8. What would happen to the circuit if the right rear turn signal light bulb was burned out ? 9. Measure the voltage available to the turn signal lights flasher at the BAT terminal. 10. What would be the voltage reading from step 9 if fuse #4 were open ? 11. If fuse #4 was confirmed good and the voltage at the BAT terminal of the turn signal flasher was zero, what could be the cause of this condition ? 12. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 78 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit SA-8 — Level 1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : CIRCUIT MEASUREMENTS : 6. 7. 8. 9. VOLTS 10. VOLTS 11. 12. Instructor : Grade : consulab.com info@consulab.com 79 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit SA-8 — Level 3 Assignment (2 pages) 1. Fill out level 3 student answer sheet with name, class and information. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF). 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the turn signal circuit components. NOTE- There are many components in this circuit. Be sure you spend sufficient time studying the circuit to determine the correct hookup of each component. For the purposes of just this assignment please hook up ONLY those wires that have to do with the turn signal circuit even though some others may be shown on schematic. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the TURN SIGNALS circuit. If circuit does not operate properly, go back over your work to locate the error and correct. 6. Once circuit is operating properly, make the following measurement and put reading on your answer sheet. Set up your test equipment to measure the current draw of the right front turn signal. NOTE- in order to do this, you will have to separate the right front turn lamp from all other circuits and temporarily connect your ammeter in series with either the ground or the positive side) [if you are using a direct reading amme- ter and supply either a fused power or ground to the right front turn light. Record your reading on the answer sheet. NOTE- You may want to install a jumper wire from any BAT source to the right front turn signal light to allow the light to stay on all the time for easy current measurement. 7. After the measurement in step 6A, restore the entire circuit to normal operation and confirm that it works. 8. Now, using additional red wires, using the below schematic as a reference, connect the coil circuits (terminals #85 & #86) of relays #1 & #2 in SERIES with the wire coming from the RIGHT terminal of the turn signal switch AND the TURN receptacle of the right front turn light. RIGHT #85 #85#86 RELAY #1 RELAY #2 RIGHT FRONT TURN GND #86 9. Double check your connections and turn on the right turn signals. Describe the performance of the circuit. 10. Following the same procedure as in step 6, set up the circuit to measure only the current of the modified right front turn lamp. Record your reading on the answer sheet. NOTE- You may want to install a jumper wire from any BAT source to the right front turn signal light to allow the light to stay on all the time for easy current measurement. 11. List your conclusions about why the right front turn signal lamp operated as it did with this modification. consulab.com info@consulab.com 80 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit 12. With the circuit still modified, turn on the circuit and measure the voltage drop across the coil circuits of relay #1, relay #2 and the right front turn signal lamp. Record your readings on the answer sheet. A. Voltage drop across relay #1 coil circuit ? B. Voltage drop across relay #2 coil circuit ? C. Voltage drop across right front turn signal lamp ? 13. Add up all of the three individual voltage drops and record your answer on answer sheet. 14. What conclusions can you make from the reading in step 13 ? 15. Using a red jumper wire, connect terminals #85 and #86 of relay #1 together and describes what happens to the circuit. 16. Measure the voltage drop across the following components and record your readings : A. Coil circuit of relay #1 B. Coil circuit of relay #2 C. Right front turn signal lamp 17. Describe what effect unwanted resistances will have in a lighting circuit. 18. Describe the best method of diagnosing and locating the exact location of any unwanted resistance. 19. Remove the red wire connected to the TURN receptacle of the right front turn signal lamp that comes from the relay coil circuit. 20. Measure the voltage available from the end of that disconnected wire to ground and record your reading on answer sheet. 21. Explain the reading obtained in step 20. What conclusions can you make from this step regarding checking voltage drop across any electrical device ? 22. Remove all of your circuit modifications and restore the circuit back to normal functionality. Confirm that it works properly. 23. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 81 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit SA-8 — Level 3 Assignment — Answer Sheet (2 pages) Name : Group : Date : 4. INSTRUCTOR’S CHECK OF CORRECT CIRCUIT WIRING : CIRCUIT MEASUREMENTS : 6. AMPS or MILLIAMPS 9. 10. AMPS or MILLIAMPS 11. 12. A VOLTS B VOLTS C VOLTS 13. VOLTS 14. 15. 16. A VOLTS B VOLTS C VOLTS 17. 18. consulab.com info@consulab.com 82 CL-1918-4S_053304-95 SA-8 — Turn Signal Circuit 20. VOLTS 21. 23. Instructor : Grade : consulab.com info@consulab.com 83 CL-1918-4S_053304-95 Headlights Circuits Headlights Circuits consulab.com info@consulab.com 84 CL-1918-4S_053304-95 Headlights Circuits Notice Pertaining to CL-1918-4 Headlight Circuits There are countless variations to properly design and build a properly operating headlight circuit on this trainer. The first circuit that will be assigned to students will be Assignment SA-9 “GROUND SWITCHED” option where the headlights are switched on and off using the multi-function switch to control the ground circuits of the relays. It is important to remember that whatever circuit options are used, at no time can any higher current than 1A be passed through the multifunction switch. If this condition is created, either one or both of the 1A replaceable fuses will blow and will need replacing. Headlight circuit designs can include any or all of the following design options : 1. Switch the ground circuits of the headlights 2. Switch the positive circuits of the headlights 3. Switch the ground circuits of the relay coils 4. Switch the positive circuits of the relay coils 5. Using 2, 3 or 4 relays in the headlight circuit Replacement 1A fuse is a T1AH 250V consulab.com info@consulab.com 85 CL-1918-4S_053304-95 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identi- fication The multifunction switch on the CL-1918-3I & CL-1918-4 trainer is from an OEM 2007-2010 Hyundai Elantra. It may or may not have the optional fog light switch, but, if equipped, it is not used for this trainer. See below for the schematic of the switch. For purposes of this trainer, the multifunction switch will be used as both a positive and ground switched device for additional student learning. Therefore, using an OEM electrical schematic will not necessarily reflect actual circuit construction. Below is the electrical schematic for the switch. We have added two 1A circuit breakers or two 1A fuses in series with the COM terminals to protect the switch from high current circuits. Therefore, when constructing headlight circuits, the multifunction switch must only control relay coil current and not full headlight bulb current. The circuit breaker will trip or the 1A fuses will blow if more than one amp of current flows through the switch. The circuit breaker is resettable if tripped and the two 1A fuses are replaceable. WARNING- Do not hold down the reset button if tripped. Replacement 1A fuse is a T1AH 250V type. MULTIFUNCTION SWITCH POSITION EXPLANATIONS 1. HEADLIGHT SWITCH OFF – LEFT COM CONNECTED TO LOW – RIGHT COM NOT CONNECTED 2. HEADLIGHT SWITCH TO PARK – LEFT COM TO LOW – RIGHT COM TO PARK consulab.com info@consulab.com 86 CL-1918-4S_053304-95 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification 3. HEADLIGHT SWITCH TO HEADLIGHT – LEFT COM TO LOW – RIGHT COM TO PARK & HEAD 4. HEADLIGHTS ON - SWITCH LEVER DOWN TO HIGH – LEFT COM TO HIGH - RIGHT COM TO PARK & HEAD consulab.com info@consulab.com 87 CL-1918-4S_053304-95 CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification HEADLIGHTS ON LOW – SWITCH UP TO FLASH-TO- PASS LEFT COM TO FLASH & HIGH HEADLIGHTS OFF – SWITCH LEVER UP TO FLASH- TO-PASS LEFT COM TO FLASH & HIGH - RIGHT COM NOT CONNECTED HEADLIGHTS OFF – SWITCH LEVER DOWN TO HIGH LEFT COM TO HIGH - RIGHT COM NOT CONNECTED LEFT COM TO HIGH HEADLIGHTS ON HIGH – SWITCH UP TO FLASH-TO- PASS LEFT COM TO FLASH & HIGH consulab.com info@consulab.com 88 CL-1918-4S_053304-95 Headlights and Plug Explanation Headlights and Plug Explanation BACK OF HEADLIGHT BULB H4656 RED - LOW YELLOW - HIGH BLACK - GND The CL-1918-4 lighting system trainer uses an H4656 sealed beam headlight. The H4656 halogen bulb complies with re- cent changes in DOT specifications regarding candlepower and filament current of headlight bulbs. It was once common that the high beam used higher current than the low beam, but that is no longer the case. The H4656 uses light prisms and refraction in the lense to direct the high beam light source to a higher level off the ground than the low beam fila- ment does. These changes result in a bulb that is very similar in current consumption on low and high beam circuits. The current of the low and high beams can vary between one bulb to another but will be within .5A total. The designed specifications of this bulb are as follows : With an available (unloaded) voltage of 13.83 V, the current draw of each element is : LOW BEAM - 2.80A-2.90A± HIGH BEAM - 2.60A - 2.70A± (Measurements taken with a FlukeTM model 88 multi-meter and each bulb was tested out of the circuit by itself) actual “in-circuit” readings might vary with changes in system voltage and how many bulbs are in the circuit.) The important factor here is to know that this bulb (and many others) uses a lower amperage “high beam” filament, but the prism de- sign inside the bulb results in a beam that is focused higher than the low beam. consulab.com info@consulab.com 89 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) SA-9 — Headlights Circuit (Ground Switched) Circuit Design and Operation : The headlights circuit on vehicles is used to illuminate the area in front of the vehicle so that the driver can safely see during periods of darkness, fog or low-light situations. Some vehicles also turn the headlights on (or at a reduced bright- ness) during the daytime to warn oncoming vehicles that the vehicle is in the area. Headlights on today’s vehicles come in many different types, designs, styles and control circuits. Some use (LED, Halide, incandescent, projection beam, halo, HID and xenon. Headlight systems and circuits have changed dramatically in recent years. Some components are very, very expensive and diagnosis and repair can be a high-technician level requiring special tools and equipment. Because of the above statements, the CL-1918-4 trainer uses a basic incandescent Wagner H4656 halogen sealed beam headlight system. The components used on the trainer allow the headlight circuit to be set up using many different wiring options. Students can construct the headlight circuit using ground-switched or positive switched options. With the CL- 1918-4, it is absolutely necessary to construct all headlight circuits to be controlled by relays. NEVER attempt to direct full headlight current through the multi-function switch. If this is attempted, the 1 amp protection fuse will blow. (NOTE- The protection devices are there to protect the multifunction switch contacts from excessive current). NOTE : Replace- ment 1A fuse is a T1AH 250V. NOTE : IT IS ADVISABLE TO HAVE YOUR STUDENTS READ THE EXPLANATION OF HOW THE MULTI-FUNCTION SWITCH IS WIRED AND CONNECTED INTERNALLY SO THEY WILL UNDERSTAND HOW IT CONTROLS THE PARK & HEAD LIGHTS. For purposes of educational continuity, the first headlight circuit that will be discussed will be a ground-switched circuit using two relays. Later on in this curriculum, students will be asked to build headlight circuits using other design varia- tions. Ground Switched Headlights : Circuit Description Power for the headlight circuit is obtained from Fuse #1 (20A) and connects to both COM terminals of the left and right headlights. Fuse #2 (15A) feeds terminals #86 of relays #1, #2 & #3 for the coil circuits and also to the RED terminal of the HIGH BEAM INDICATOR light. This fuse supplies B+ to all relay coils. Terminal #85 of relay #3 connects to FLASH terminal of the multifunction switch. Terminal #85 of relay #2 connects to the HEAD terminal of the multifunction switch. Terminal #85 of relay #1 connects HIGH terminal of the multifunction switch. The two COM terminals of the multifunc- tion switch both connect to system ground. Therefore, the multifunction switch controls relays #1, #2 and #3 coils ground circuits . Terminal #87 of relay #1 connects to the HIGH terminal of both the left and right hand headlights. Ter- minal #87a of relay #1 is connected to both LOW terminals of the left and right hand headlights. Terminal #30 of relay #1 is connected to terminal #87 of relay #2. The trainers top panel ground is connected to the middle panel ground with a jumper wire. Terminal #87 of relay #3 is connected to system ground. Terminal #30 of relay #3 is connected to terminal #87 of relay #1. The black wire of the HIGH BEAM INDICATOR connects to the HIGH terminal of the lefthand headlight. consulab.com info@consulab.com 90 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) LOW BEAM OPERATION -When the multifunction switch is moved to HEAD from the PARK position, the right-hand COM terminal of the multifunction switch is connected to the HEAD terminal which grounds the coil of relay #2 by providing a ground path and the relay turns on. With relay #2 on, terminals #30 and #87 of relay #2 are now connected. Termi- nal #87 of relay #2 is connected to the terminal #30 of relay #1. Because relay #1 if off, terminals #30 and #87a are connected with turns on the LOW beam headlights. Power flows from Fuse F1, to both headlight COM terminals, then through the LOW beam filaments to terminal #87a to terminal #30 of relay #1, then to terminal #87 and #30 of relay #2, then to system ground through terminal #30 of relay #2. The LOW terminal of the multifunction switch is not needed with this circuit design. HIGH BEAM OPERATION - When the multifunction switch is moved to HIGH, relay #1 is turned on by the connection of the left-hand multifunction switch COM to HIGH providing a ground circuit for relay #1 coil and relay #2 remains on because the right-hand COM to HEAD terminals are still connected. With both relays #1 and #2 on, the headlight HIGH beam ground circuit is from terminal #30 of relay #1 to terminal #87 of relay #1 which grounds both HIGH terminals of the right-hand headlight, over to the left-hand headlight HIGH terminal and also to the black terminal of the HIGH BEAM INDICATOR and it now turns on. This circuit controls the headlight ground circuits using relays #1 and #2. FLASH TO PASS OPERATION Whether the multi-function switch is on or off in any position, pulling the switch stalk towards you (UP) will connect the multifunction switch left-hand COM to HIGH and FLASH terminals which will turn on relay #3 and the HIGH BEAM head- lights will stay on as long as the stalk is kept “UP”. Relay #3 when on connects terminals #30 to #87 which completes the HIGH beam ground circuit through relay #1 terminals #30 to #87. Pushing the stalk downward (DOWN) connects multifunction switch terminals left-hand COM to HIGH which again turns on relay #3 and HIGH beam headlights are now on. This function will operate regardless of whether the light switch is on or off. NOTE : Some car manufacturers will turn off the LOW beam headlights when the HIGH beams are selected while others turn both LOW and HIGH beams on at the same time when HIGH is selected. Other circuit assignments in this curriculum will instruct students to build headlight circuit with many different design options. This headlight circuit design controls the ground circuits of the relay coils for relays #1, #2 and #3. The multifunction switch completes the relay coil ground circuits when LOW, HIGH and FLASH-TO-PASS circuits are selected. Relays #1 and #2 control the high current consumed by the LOW and HIGH beam headlights. Only relay coil current is directed through the multifunction switch. consulab.com info@consulab.com 91 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) SA-9 — Headlights Circuit (Ground Switched) — Circuit Component Explanation — Answer Sheet (3 pages) Obtain a schematic of the sa-9 headlights circuit (ground switched) (levels 1, 2 or 3) explain how each component is con- nected in the circuit and also explain how each component operates in the circuit. Name : Group : Date : FUSE #1 — LOAD SIDE FUSE #2 — LOAD SIDE LEFT SIDE HEAD LIGHT HIGH TERMINAL- COM TERMINAL- LOW TERMINAL- RIGHT SIDE HEAD LIGHT HIGH TERMINAL- COM TERMINAL- LOW TERMINAL- RELAY #1 TERMINAL #87a- TERMINAL #30- consulab.com info@consulab.com 92 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) TERMINAL #87- TERMINAL #85- TERMINAL #86 - RELAY #2 TERMINAL #87a- TERMINAL #30- TERMINAL #87- TERMINAL #85- TERMINAL #86 - RELAY #3 TERMINAL #87a- TERMINAL #30- TERMINAL #87- TERMINAL #85- TERMINAL #86 - consulab.com info@consulab.com 93 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- DIMMER SWITCH : LOW TERMINAL - COM TERMINAL - HIGH TERMINAL - FLASH TERMINAL- HEADLIGHT SWITCH : PARK TERMINAL - HEAD TERMINAL - COM TERMINAL - Instructor : Grade : consulab.com info@consulab.com 94 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) In your own words, explain how the headlights ground switched circuit operates. Explain the function of each component. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 95 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) SA-9 — Level1 / Level 2 Assignment 1. Fill out Level 1 or 2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment you were assigned by the instructor. Put the answers to all questions on this sheet. DO NOT WRITE ON THIS PAPER. 2. Make sure the trainer is properly connected to a 120V power supply and is turned OFF. 3. Obtain a Level 1 or Level 2 wiring schematic that your instructor has assigned for the correct operation of the SA-9 HEADLIGHTS CIRCUIT (GROUND SWITCHED). Using the schematic, properly connect red and black jumper wires to all components necessary for this circuit. NOTE- At this time do not connect any PARK or TAIL-LIGHTS to the circuit. ONLY the headlights. 4. Obtain instructors check at this point. 5. With instructor’s permission, turn on the power supply for the trainer and confirm the correct operation of the headlight circuit including : LOW and HIGH BEAMS, FLASH-TO-PASS and HIGH BEAM INDICATOR. If any portion of the circuit does not function correctly, go back over your work to find and correct the wiring errors. 6. Once the circuit is functioning properly, and with the headlights circuit OFF, make the following voltage measure- ments to ground where indicated and put your readings on the answer sheet. A. Voltage at terminal #86 of relay #1 B. Voltage at terminal #85 of relay #1 (Why is there voltage at both terminal #86 & #85 of relay #1 ?) C. Voltage at terminal #87 of relay #3 D. Voltage at terminal #85 of relay #3 7. What conclusions can you make from the above measurements regarding how this headlight circuit operates ? 8. With the headlights switched to LOW beam, measure the voltage between left headlight terminals COM and LOW. 9. Switch the circuit to HIGH beams. Make the following voltage measurements : A. Black voltmeter lead on to the HIGH terminal of the left headlight. B. Red voltmeter lead to the COM terminal of the left headlight. C. Measure the voltage of the HIGH beam headlights now D. What conclusions can you make when evaluating these two voltage (LOW and HIGH) measurements ? 10. By looking at a wall or flat surface in front of the headlights on the trainer, do the HIGH beam headlights appear to be located at a “higher” distance from the ground that the LOW beam headlights ? 11. With headlights turned OFF, use a black jumper wire and connect terminal #85 of relay #3 to system ground. What happens ? Why ? 12. Are the headlights on this trainer connected in series or parallel ? 13. Obtain final check from your instructor, confirm that all answers have been completed and turn in your answer sheet. NOTE- If instructed to do so, disconnect and return all wires to their storage place, turn off the trainer and unplug power cord from wall outlet. consulab.com info@consulab.com 96 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) SA-9 — Level1 / Level 2 Assignment — Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTORS CHECK OF PROPER CIRCUIT WIRING & PERFORMANCE 5. Did the FLASH TO PASS circuit operate properly ? 6. A Volts between terminal #86 of relay #1 and ground. B Volts between terminal #85 of relay #1 and ground. Why ? C Volts between terminal #87 of relay #3 and ground. Why ? D Volts between terminal #85 of relay #3 and ground. Why ? 7. 8. Volts between left headlight terminals COM and LOW with LOW beams on. 9. C Volts between left headlight COM and HIGH with HIGH beams on. D EXPLANATION : 10. 11. What happened ? Why ? 13. Instructor : Grade : consulab.com info@consulab.com 97 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) SA-9 — Level 3 Assignment (2 Pages) 1. Fill out the SA-9 Level 3 student answer sheet with name, class and date information. Put all answers to these ques- tions on the student answer sheet. DO NOT WRITE ON THIS PAPER. 2. Make sure trainer is properly connected to a 120 outlet and that the trainers power supply is turned OFF. 3. Obtain a Level 3 blank schematic (3 pages) and after studying the circuit components, draw in the red (positive) and black (negative) wires to correctly construct the ground switched headlight circuit. Following your schematic, cor- rectly connect red and black wires to the headlight components. 4. Obtain instructors check. 5. With instructors permission, turn on the trainer power supply and confirm correct operation of the HEADLIGHTS cir- cuit. Confirm that LOW, HIGH and FLASH-TO-PASS circuits all work properly. If any circuit does not operate correct- ly, go back over your work to find and correct your errors. 6. Once circuit is operating properly, and with the headlights OFF, make the following voltage measurements to system ground and put readings on your answer sheet. A. Voltage at terminal #86 of relay #1 B. Voltage at terminal #85 of relay #1 (Why is there voltage at both terminal #86 & #85 of relay #1 ?) C. Voltage at terminal #87 of relay #3 D. Voltage at terminal #85 of relay #3 7. What conclusions can you make from the above measurements regarding how this headlight circuit operates ? 8. With the headlights switched to LOW beam, measure the voltage between left headlight terminals COM and LOW. 9. Switch the circuit to HIGH beam A. Black voltmeter lead on to the HIGH terminal of the left headlight. B. Red voltmeter lead to the COM terminal of the left headlight. C. Measure the voltage of the HIGH beam headlights now. D. What conclusions can you make when evaluating these two voltage (LOW and HIGH) measurements ? 10. By looking at a wall or flat surface in front of the headlights on the trainer, do the HIGH beam headlights appear to be located at a “higher” distance from the ground that the LOW beam headlights. consulab.com info@consulab.com 98 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) 11. Properly make the indicated measurements below and record your readings on the answer sheet. A. Current draw of JUST the right headlight on LOW beam. B. Current draw of JUST the left headlight on LOW beam. C. Current draw of JUST the right leadlight on HIGH beam. D. Current draw of JUST the left headlight on HIGH beam. E. What conclusions can you make regarding the current draw of the HIGH and LOW beams ? F. Current draw of JUST the HIGH BEAM INDICATOR light ? G. Current draw of JUST the coil control current of relay #3. 12. With headlights turned OFF, use a black jumper wire and connect terminal #85 of relay #3 to system ground. What happens ? Why ? 13. Measure the voltage drop across relay #3 contacts with the HIGH beam headlights ON. 14. Obtain final check from your instructor, confirm that all answers have been completed and turn in your answer sheet. NOTE- If instructed to do so, disconnect and return all wires to their storage place, turn off the trainer and unplug power cord from wall outlet. consulab.com info@consulab.com 99 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) SA-9 — Level 3 Assignment — Answer Sheet (2 pages) Name : Group : Date : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING AND PERFORMANCE : 5. DID THE HIGH, LOW BEAMS & FLASH-TO-PASS CIRCUITS OPERATE NORMALLY ? 6. A Volts between terminal #86 of relay #1 and ground. B Volts between terminal #85 of relay #1 and ground. Why ? C Volts between terminal #87 of relay #3 and ground. Why ? D Volts between terminal #85 of relay #3 and ground. Why ? 7. 8. Volts between left headlight terminals COM and LOW. 9. C Volts between left headlight terminals COM and HIGH D Conclusions 10. YES or NO 11. A current draw of JUST right headlight LOW beam B current draw of JUST left headlight on LOW beam C current draw of JUST right headlight on HIGH beam D current draw of JUST left headlight on HIGH beam E Conclusions consulab.com info@consulab.com 100 CL-1918-4S_053304-95 SA-9 — Headlights Circuit (Ground Switched) F current draw of HIGH BEAM INDICATOR LIGHT G current draw of the relay coil current of relay #3 12. What happened and why ? 13. Voltage drop of relay #3 contacts with HIGH beam headlights ON. 14. Instructor : Grade : consulab.com info@consulab.com 101 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) SA-10 — Headlights Circuit (Positive Switched) Circuit Explanation CIRCUIT DESIGN AND OPERATION : The headlights circuit on vehicles is used to illuminate the area in front of the vehicle so that the driver can safely see the area in periods of darkness or inclement weather conditions. Some vehicles also turn the headlights on during the day (either at full or partial brightness) to warn oncoming vehicles that the vehicle is in the area. These are often called DAYTIME RUNNING LIGHTS. Headlights on today’s vehicles are available in many different styles and designs such as LED, Halide, Xenon, Halo, HID, Projector Beam and many others. Some are extremely expensive to service and replace and often require expensive special tools and training to properly complete repairs. Because of the above reasons, the CL-1918-4 uses a basic incandescent sealed beam headlight system. The compo- nents used on the trainer allow the headlights circuit to be constructed in many different designs. Specific design charac- teristics can be ground or positive switched, 2, 3, or 4 relay controls, etc. You should have already completed “SA-9 GROUND SWITCHED CIRCUIT” previous to this assignment SA-10. This assignment will be a “positive switched” circuit using two relays. In this assignment you will be asked to insert faults into this circuit to learn “real world” symptoms and diagnostic skills. Carefully following step-by-step instructions is CRITICAL for successful completion of this assignment. POSITIVE SWITCHED HEADLIGHTS : CIRCUIT DESCRIPTION B+ CIRCUITS : Power for the headlight control circuit is taken from Fuse F2 (15A) and is connected to the right COM terminal of the multi-function switch. Another connection is made from the right COM terminal to the FLASH terminal of the multi-function switch. Power for the headlights themselves is supplied by Fuse F4 (10A) for the low beam headlights switched by relay #1 and Fuse F5 (10A) for the high beam headlights switched by relay #2. The supply side of fuses F4 (10A) & F5 (10A) are fed from fuse F1 (20A). Both fuses power relays #1 & #2 at terminals #30 for the LOW and HIGH beams. The LOW terminal of the multi-function switch is connected to terminal #86 of relay #1. The HIGH terminal of the multi-function switch is connected to terminal #86 of relay #2 and also to the positive terminal of the HIGH BEAM INDI- CATOR light. Terminal #87 of relay #1 is connected to the right-hand headlight LOW terminal and another wire connects the right-hand side to the left-hand side headlight LOW terminal. Terminal #87 of relay #2 is connected to the right-hand headlight HIGH terminal and another wire connects the right-hand side to the left-hand side headlight HIGH terminal. GROUND CIRCUITS : Relays #1 and #2 control coils are both connected to system ground from terminals #85. Both headlights are connected to system ground by wires from the COM terminals to system ground. The HIGH BEAM INDICA- TOR light is also connected to system ground. consulab.com info@consulab.com 102 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) LOW BEAM OPERATION : The multi-function stalk switch is turned to the 2nd position which connects the B+ voltage at the right-hand COM termi- nal to the HEAD terminal. B+ leaves from the HEAD terminal and connects to left-hand COM terminal of the multi-func- tion switch. The dimmer switch section always has a connection from COM to LOW and thus, B+ leaves the multi-func- tion switch from the LOW terminal and connects to terminal #86 of relay #1. Relay #1 turns on connecting terminals #30 (Fused B+) to #87 (LOW beam headlights and both LOW beam headlights come on. HIGH BEAM OPERATION : If the stalk of multi-function is pushed down, the left COM terminal is connected to HIGH terminal and B+ leaves from the HIGH terminal of the switch and connects to the HIGH BEAM INDICATOR and terminal #86 of relay #2. This turns relay #2 on connecting terminals #30 (Fused B+) & #87 which connects both HIGH beam headlights and they both come on as well as the HIGH BEAM INDICATOR light. FLASH-TO-PASS OPERATION : If the headlights are on in either LOW or HIGH position, lifting up the stalk switch will connect left COM to both FLASH and HIGH turning on the HIGH beam #2 relay. If the headlights are off, pushing the stalk lever down will not operate the HIGH beams in this circuit. If the headlights are off, and the stalk switch is pulled UP the left COM to FLASH of the multi-function switch are connected which turns on the HIGH beams by turning on relay #2. consulab.com info@consulab.com 103 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) Answer Sheet (2 pages) Obtain a schematic of the headlight circuit (positive switched) (levels 1, 2 or 3) and in your own words, explain how each component of the circuit functions and what it contributes to the entire circuit. Name : Group : Date : FUSE #1 (20A) — LOAD SIDE FUSE #2 (15A) — LOAD SIDE FUSE #4 (10A) — POWER SIDE FUSE #4 (10A) — LOAD SIDE FUSE #5 (10A) — POWER SIDE FUSE #5 (10A) — LOAD SIDE HEADLIGHT SWITCH OF MULTI-FUNCTION SWITCH COM TERMINAL- HEAD TERMINAL- DIMMER SWITCH OF MULTI-FUNCTION SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH TERMINAL- RELAY #1 TERMINAL #87a- TERMINAL #30- TERMINAL #87- TERMINAL #85- consulab.com info@consulab.com 104 TERMINAL #86- RELAY #2 TERMINAL #87a- TERMINAL #30- TERMINAL #87- TERMINAL #85- TERMINAL #86- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- GROUND CIRCUITS CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) Instructor : Grade : consulab.com info@consulab.com 105 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) SA-10 — All Level Assignment (2 pages) Fill in all answers to this assignment where indicated on the student answer sheet – do not write on this paper. 1. Obtain the SA-10 HEAD LIGHTS (POSITIVE SWITCHED) either Level 1, 2 or 3 circuit schematic from your instructor and construct this circuit properly. 2. Confirm that the circuit operates properly. If it doesn’t correct any wiring errors and re-test. 3. Obtain the SA-10 — CIRCUIT EXPLANATION from your instructor and complete all of the questions in the assign- ment. Hand in your assignment when completed for instructors check. 4. Obtain the student answer sheet for SA-10 HEADLIGHTS CIRCUIT – POSITIVE SWITCHED assignment. 5. THE FOLLOWING ASSIGNMENTS REQUIRE THAT YOU HAVE A FULL UNDERSTANDING OF HOW THIS CIRCUIT OPERATES IN ORDER TO CORRECLTY ANSWER THE QUESTIONS. 6. With the circuit operating correctly, perform each of the following steps and fill in your answers for each step. 7. Remove the COM wire from the left-hand headlight and turn on the headlights to LOW beam. Describe how the cir- cuit performs on the answer sheet. 8. Using a voltmeter, measure the available voltage at the following points and answer each question. A. LOW terminal of right headlight. Is this a normal reading ? Yes or No B. LOW terminal of the left headlight. Is this a normal reading ? Yes or No C. HIGH terminal of the right headlight. Is this a normal reading ? Yes or No D. HIGH terminal of the left headlight. Is this a normal reading ? Yes or No 9. Explain why you got the reading in step 8B. 10. Explain why you got the reading in step 8D. 11. Measure the voltage to ground at the COM terminal of the left headlight. Is this a normal reading ? Yes or No 12. What does the reading in step 11 indicate ? 13. What is the voltage available to the left LOW beam headlight terminal ? 14. While measuring the voltage at the COM terminal of the left headlight, temporarily connect a jumper wire from sys- tem ground to the COM terminal of the left headlight. What is the voltage reading now ? 15. Restore the circuit to normal operation and turn the headlights off. 16. Remove the HIGH beam wire from the left headlight and connect it to either terminal of the left front marker light. 17. Connect a red jumper wire from the other terminal of the left front marker light to the left headlight HIGH terminal. 18. Before you turn the circuit on, explain what you have just done to the circuit. 19. Make a prediction of what the circuit will do when you turn it on. consulab.com info@consulab.com 106 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) 20. Turn on the headlight circuit and describe the circuit performance for each mode : A. LOW BEAM B. HIGH BEAM 21. Measure the voltage drop across the left front marker light with lights on HIGH BEAM. 22. Measure the voltage drop across the left HIGH beam headlight with the circuit on HIGH BEAM. 23. What is the operating voltage of the left HIGH beam headlight ? 24. Are the marker lights and the left HIGH beam lights connected in series or parallel ? 25. Measure the current flowing in the marker light and left HIGH beam headlight circuit. 26. Explain why the left marker light is on at full brilliance and the left HIGH beam headlight is off ? 27. Remove the wire connected to the left HIGH beam headlight and measure the voltage from that wire to system ground. 28. Explain why you got the reading you did in step 27. 29. Record the following readings while measuring the voltage drop across the left HIGH beam headlight. A. With the left marker light in the circuit. B. With a red jumper wire connected across the two terminals of the left front marker light. 30. This assignment is designed to help you understand the effect on circuit performance of unwanted resistance any- where in the circuit. The resistance could be in the positive side, the ground side OR more importantly, BOTH. With your instructors permission, you may experiment with inserting resistance in various lighting circuits. Just remem- ber to insert the resistance in SERIES and NOT in parallel. Why ? Remember that adding resistances in parallel will INCREASE the current flow in the circuit. If this is done, it is a certainly that fuses will blow. NEVER USE ANY LED LIGHTS IN THESE CIRCUIT EXPERIMENTS. The following lights all have different resistances and will cause varying degrees of negative circuit performance : A. Any side marker lights B. License plate light C. Backup lights D. Relay coil (#85 and #86) E. Headlights 31. Turn in your completed answer sheet, obtain instructors check and restore the trainer to its normal condition. consulab.com info@consulab.com 107 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) Answer Sheet (2 pages) Name : Group : Date : Level Assigned : 2. DID TRAINER OPERATE PROPERLY ? 3. COMPLETE STUDENT ASSIGNMENT – CIRCUIT EXPLANATION assignment. 7. CIRCUIT DESCRIPTION 8. A VOLTS. ANSWER B VOLTS. ANSWER C VOLTS. ANSWER D VOLTS. ANSWER 9. 10. 11. VOLTS. ANSWER 12. 13. VOLTS 14. VOLTS 18. 19. PREDICTION 20. A LOW BEAM B HIGH BEAM 21. VOLTS (left front marker light) 22. VOLTS (left high beam with circuit turned on HIGH beams) consulab.com info@consulab.com 108 CL-1918-4S_053304-95 SA-10 — Headlights Circuit (Positive Switched) 23. VOLTS (operating voltage of left HIGH beam) 24. 25. AMPS (flowing in left marker light & HIGH beam headlight circuit) 26. 27. VOLTS (removed red wire end to ground) 28. 29. A. VOLTS. (with left marker light in the circuit) B VOLTS. (with jumper wire across the two market light terminals) Instructor : Grade : consulab.com info@consulab.com 109 CL-1918-4S_053304-95 Headlights Circuit (Optional Circuit Designs) Headlights Circuit (Optional Circuit Designs) Assignment Explanations There are countless ways to correctly wire the headlights circuits on the CL-1918-4 lighting trainer. With the headlights and multi-function being both compatible with both positive and ground switching, many different wiring designs can be created. The only critical design requirement is that at no time should any current in excess of 1a flow through any part of the multi-function switch. The switch is protected by two replaceable 1A fuses which will open if excessive current is detected. The multi-function switch on the CL-1918-4 lighting trainer must only control relay coil current to operate the headlights. This is a design change from other CL-1918-3 trainers. In addition to assignment SA-8 & SA-9, here are eight additional circuit options that can be constructed and understood by students. A brief explanation of each follows : 1. Option A – Option A is a ground switched circuit, but the relay’s control b+ power to the headlights. This circuit uses three relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 turns on the headlights by sending b+ to relay 2. Relay 2 determines whether the low or high beam headlights operate. Relay 2 is turned on by the high beam switch circuit. Relay 4 serves only to operate the “flash-to- pass” circuit if the headlights are turned off. 2. Option B – Option B is a ground switched circuit. The relay’s control the high current ground circuits of the head- lights. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 controls the low beam headlights and relay 4 controls the high beam head- lights. 3. Option C – Option C is a ground switched circuit and is very similar to option b. The relay’s control the high current ground circuits of the headlights. The main difference is how the multi-function switch connects to system ground. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and nec- essary ground circuits. Relay 3 controls the low beam headlights and relay 4 controls the high beam headlights. 4. Option D – Option D is a ground switched circuit and uses two relays to control the high current b+ power to the headlights. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indi- cator and necessary ground circuits. Relay 3 operates the high beam headlights and relay 4 operates the low beam headlights. 5. Option E – Option E is a positive switched circuit and uses two relays to control the high current b+ power to the headlights. The multi-function switch controls the b+ power to the relay’s coil current. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 operates the low beam headlights and relay 4 operates the high beam headlights. 6. Option F- Option F is positive switched circuit and uses two relays to control the high current b+ power to the head- lights. The multi-function is wired differently than option e and allows students to better understand the multi-func- tion switch operation. The multi-function switch controls the b+ power to the relay’s coil current. This circuit uses two relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 3 operates the low beam headlights and relay 4 operates the high beam headlights. consulab.com info@consulab.com 110 CL-1918-4S_053304-95 Headlights Circuit (Optional Circuit Designs) 7. Option G – Option G is a positive switched circuit and uses four relays to control the high current b+ power to the headlights. The multi-function is wired differently than option f and allows students to better understand the multi-function switch operation. The multi-function switch controls the b+ power to the relay’s coil current. This cir- cuit uses four relays, headlight and dimmer switches, two fuses, two headlights, high beam indicator and necessary ground circuits. Relay 1 operates the left low beam headlight, relay 2 operates the right low beam headlight. Relay 3 operates the left high beam headlight and relay 4 operates the right high beam headlight. There is a relay for each headlight in this circuit. 8. Option H – Option H is positive switched circuit and uses two relays. The multi-function switch controls the b+ power to the relay’s coil current. This circuit uses two relays, headlight and dimmer switches, two fuses, two head- lights, high beam indicator and necessary ground circuits. Relay 1 supplies high current b+ power to relay #2 when the headlights are turned on. Relay 2 (if off) supplies high current b+ power from terminal 87a to the right low beam headlight which is then cross-connected to the left headlight. When relay 2 is turned on by the multi-function switch, it changes b+ connection from its 87a terminal (low beam) to terminal 87 (high beam). This assignment using eight different wiring options should consist or no more than 1 or 2 students for the completion of the circuit explanation assignment and the actual construction of each circuit. Depending on the level of your students, you may wish to assign additional learning assignments on these circuits to include : 1. Disconnect various ground circuits to either predict circuit behavior or report on what happens. 2. Adding unwanted resistances into portions of the circuit for voltage drop testing and diagnosis experience. You may use the back up, side marker lights, license plate light or any relay coil not being used. These activities will build student diagnostic abilities in learning how voltage drop testing is so critical to know. 3. Have students draw the circuit schematic on a level 1, 2 or 3 blank template. This provides great experience at hav- ing students read and understanding schematics. 4. Design other headlight circuit options or create special circuits like an emergency vehicle with a “wig-way” flashing headlight, taillight or turn/hazard lights. 5. Set up student competitions to see who can build a functioning headlight circuit the fastest, yet still operate proper- ly. consulab.com info@consulab.com 111 CL-1918-4S_053304-95 SA-11 — Headlights Circuit — Option A SA-11 — Headlights Circuit — Option A At this point in your assignments, you will be given additional headlight circuit options that are different from SA-9 and SA-10 circuits. Obtain a Level 1, 2 or 3 schematic from your instructor and follow the below instructions for assignments SA-11. You will be asked to explain the operation of each component in the circuit on the student answer sheet. Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-11 HEADLIGHTS CIRCUIT (OPTION A) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-11 HEADLIGHT CIRCUIT (OPTION A) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-11 CIRCUIT EXPLANATION (OPTION A) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 112 CL-1918-4S_053304-95 SA-11 — Headlights Circuit — Option A SA-11 — Headlights Circuit - Option A — Circuit component explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) — LOAD SIDE RELAY #2 (Used to ) TERMINAL #86 TERMINAL #85 TERMINAL #30 TERMINAL #87 TERMINAL #87a RELAY #3 (Used to ) TERMINAL #86 TERMINAL #85 TERMINAL #30 TERMINAL #87 TERMINAL #87a RELAY #4 (Used to ) TERMINAL #86 TERMINAL #85 TERMINAL #30 TERMINAL #87 TERMINAL #87a consulab.com info@consulab.com 113 CL-1918-4S_053304-95 SA-11 — Headlights Circuit — Option A LIGHT SWITCH COM TERMINAL PARK TERMINAL HEAD TERMINAL DIMMER SWITCH COM TERMINAL LOW TERMINAL HIGH TERMINAL FLASH TERMINAL HIGH BEAM INDICATOR RED TERMINAL BLACK TERMINAL LEFT HEADLIGHT LOW TERMINAL COM TERMINAL HIGH TERMINAL RIGHT HEADLIGHT LOW TERMINAL COM TERMINAL HIGH TERMINAL GROUND CIRCUITS 1. RELAY #2 2. RELAY #3 3. RELAY #4 4. LIGHT SWITCH consulab.com info@consulab.com 114 CL-1918-4S_053304-95 SA-11 — Headlights Circuit — Option A 5. DIMMER SWITCH 6. HIGH BEAM INDICATOR 7. LEFT HEADLIGHT 8. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 115 CL-1918-4S_053304-95 SA-12 — Headlights Circuit — Option B SA-12 — Headlights Circuit — Option B Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-12 HEADLIGHTS CIRCUIT (OPTION B) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-12 HEADLIGHT CIRCUIT (OPTION B) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-12 CIRCUIT EXPLANATION (OPTION B) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 116 CL-1918-4S_053304-95 SA-12 — Headlights Circuit — Option B SA-12 — Headlights Circuit - Option B — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) — LOAD SIDE RELAY #3 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #4 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL - PARK TERMINAL - HEAD TERMINAL - consulab.com info@consulab.com 117 CL-1918-4S_053304-95 SA-12 — Headlights Circuit — Option B DIMMER SWITCH COM TERMINAL - LOW TERMINAL - HIGH TERMINAL - HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGH HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- consulab.com info@consulab.com 118 CL-1918-4S_053304-95 SA-12 — Headlights Circuit — Option B GROUND CIRCUITS 1. RELAY #3 2. RELAY #4 3. HIGH BEAM INDICATOR 4. DIMMER SWITCH 5. LIGHT SWITCH 6. LEFT HEADLIGHT 7. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 119 CL-1918-4S_053304-95 SA-13 — Headlights Circuit — Option C SA-13 — Headlights Circuit — Option C Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-13 HEADLIGHTS CIRCUIT (OPTION C) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-13 HEADLIGHT CIRCUIT (OPTION C) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-13 CIRCUIT EXPLANATION (OPTION C) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 120 CL-1918-4S_053304-95 SA-13 — Headlights Circuit — Option C SA-13 — Headlights Circuit - Option C — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) FUSE #4 (10A) — POWER SIDE RELAY #3 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #4 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL- consulab.com info@consulab.com 121 CL-1918-4S_053304-95 SA-13 — Headlights Circuit — Option C PARK TERMINAL- HEAD TERMINAL- DIMMER SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT LOW TERMINAL- consulab.com info@consulab.com 122 CL-1918-4S_053304-95 SA-13 — Headlights Circuit — Option C COM TERMINAL- HIGH TERMINAL- GROUND CIRCUITS 1. RELAY #3 2. RELAY #4 3. HIGH BEAM INDICATOR 4. DIMMER SWITCH 5. LIGHT SWITCH 6. LEFT HEADLIGHT 7. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 123 CL-1918-4S_053304-95 SA-14 — Headlights Circuit — Option D SA-14 — Headlights Circuit — Option D Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-14 HEADLIGHTS CIRCUIT (OPTION D) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-14 HEADLIGHT CIRCUIT (OPTION D) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-14 CIRCUIT EXPLANATION (OPTION D) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 124 CL-1918-4S_053304-95 SA-14 — Headlights Circuit — Option D SA-14 — Headlights Circuit - Option D — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) — LOAD SIDE RELAY #3 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #4 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL- PARK TERMINAL- consulab.com info@consulab.com 125 CL-1918-4S_053304-95 SA-14 — Headlights Circuit — Option D HEAD TERMINAL- DIMMER SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT LOW TERMINAL- COM TERMINAL- consulab.com info@consulab.com 126 CL-1918-4S_053304-95 SA-14 — Headlights Circuit — Option D HIGH TERMINAL- GROUND CIRCUITS 1. RELAY #3 2. RELAY #4 3. HIGH BEAM INDICATOR 4. DIMMER SWITCH 5. LIGHT SWITCH 6. LEFT HEADLIGHT 7. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 127 CL-1918-4S_053304-95 SA-15 — Headlights Circuit — Option E SA-15 — Headlights Circuit — Option E Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-15 HEADLIGHTS CIRCUIT (OPTION E) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-15 HEADLIGHT CIRCUIT (OPTION E) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-15 CIRCUIT EXPLANATION (OPTION E) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 128 CL-1918-4S_053304-95 SA-15 — Headlights Circuit — Option E SA-15 — Headlights Circuit - Option E — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) RELAY #3 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #4 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL- PARK TERMINAL- consulab.com info@consulab.com 129 CL-1918-4S_053304-95 SA-15 — Headlights Circuit — Option E HEAD TERMINAL- DIMMER SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT LOW TERMINAL- COM TERMINAL- consulab.com info@consulab.com 130 CL-1918-4S_053304-95 SA-15 — Headlights Circuit — Option E HIGH TERMINAL- GROUND CIRCUITS 1. RELAY #3 2. RELAY #4 3. HIGH BEAM INDICATOR 4. LEFT HEADLIGHT 5. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 131 CL-1918-4S_053304-95 SA-16 — Headlights Circuit — Option F SA-16 — Headlights Circuit — Option F Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-16 HEADLIGHTS CIRCUIT (OPTION F) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-16 HEADLIGHT CIRCUIT (OPTION F) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-16 CIRCUIT EXPLANATION (OPTION F) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 132 CL-1918-4S_053304-95 SA-16 — Headlights Circuit — Option F SA-16 — Headlights Circuit - Option F — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) RELAY #3 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #4 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL- PARK TERMINAL- HEAD TERMINAL- consulab.com info@consulab.com 133 CL-1918-4S_053304-95 SA-16 — Headlights Circuit — Option F DIMMER SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- consulab.com info@consulab.com 134 CL-1918-4S_053304-95 SA-16 — Headlights Circuit — Option F GROUND CIRCUITS 1. RELAY #3 2. RELAY #4 3. HIGH BEAM INDICATOR 4. LEFT HEADLIGHT 5. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 135 CL-1918-4S_053304-95 SA-17 — Headlights Circuit — Option G SA-17 — Headlights Circuit — Option G Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-17 HEADLIGHTS CIRCUIT (OPTION G) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-17 HEADLIGHT CIRCUIT (OPTION G) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-17 CIRCUIT EXPLANATION (OPTION G) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 136 CL-1918-4S_053304-95 SA-17 — Headlights Circuit — Option G SA-17 — Headlights Circuit - Option G — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) RELAY #1 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #2 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #3 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- consulab.com info@consulab.com 137 CL-1918-4S_053304-95 SA-17 — Headlights Circuit — Option G RELAY #4 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL- PARK TERMINAL- HEAD TERMINAL- DIMMER SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- consulab.com info@consulab.com 138 CL-1918-4S_053304-95 SA-17 — Headlights Circuit — Option G LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- GROUND CIRCUITS 1. RELAY #1 2. RELAY #2 3. RELAY #3 4. RELAY #4 5. HIGH BEAM INDICATOR 6. LEFT HEADLIGHT 7. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 139 CL-1918-4S_053304-95 SA-18 — Headlights Circuit — Option H SA-18 — Headlights Circuit — Option H Student Assignment 1. Obtain a level 1, 2 or 3 schematic for SA-18 HEADLIGHTS CIRCUIT (OPTION H) from your instructor. 2. Looking at the schematic, learn how the circuit works and what each component does in the circuit. 3. With instructors permission, construct the SA-18 HEADLIGHT CIRCUIT (OPTION H) on the trainer. 4. Confirm correct circuit operation and correct any errors. 5. Obtain the SA-18 CIRCUIT EXPLANATION (OPTION H) ANSWER SHEET and explain what each part of the circuit does and how it operates. 6. Turn in your assignment sheet to the instructor. consulab.com info@consulab.com 140 CL-1918-4S_053304-95 SA-18 — Headlights Circuit — Option H SA-18 — Headlights Circuit - Option H — Circuit Component Explanation — Answer Sheet (3 pages) Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) RELAY #1 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- RELAY #2 (Used to ) TERMINAL #86- TERMINAL #85- TERMINAL #30- TERMINAL #87- TERMINAL #87a- LIGHT SWITCH COM TERMINAL- PARK TERMINAL- HEAD TERMINAL- consulab.com info@consulab.com 141 CL-1918-4S_053304-95 SA-18 — Headlights Circuit — Option H DIMMER SWITCH COM TERMINAL- LOW TERMINAL- HIGH TERMINAL- FLASH- HIGH BEAM INDICATOR RED TERMINAL- BLACK TERMINAL- LEFT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- RIGHT HEADLIGHT LOW TERMINAL- COM TERMINAL- HIGH TERMINAL- consulab.com info@consulab.com 142 CL-1918-4S_053304-95 SA-18 — Headlights Circuit — Option H GROUND CIRCUITS 1. RELAY #1 2. RELAY #2 3. HIGH BEAM INDICATOR 4. LEFT HEADLIGHT 5. RIGHT HEADLIGHT Instructor : Grade : consulab.com info@consulab.com 143 CL-1918-4S_053304-95 Whole Trainer Wiring Whole Trainer Wiring CL-1918-4S_053304-95 SA-19 — Level 3 — Ground Circuits consulab.com info@consulab.com 144 SA-19 & SA-20 — Whole Trainer Wiring General Information The CL-1918-4 Lighting Trainer is a “generic” lighting system. There are countless different methods of wiring the entire trainer so that all circuits properly function. Each option would result in the trainer operating normally. However, when working with a group of students, and for consistency, it is advisable to follow the suggested methods included in Stu- dent Assignments SA-19 and SA-20. Due to the number of jumper wires involved in wiring the entire trainer, we have split the assignments into two halves. SA-19 will show how to connect all black ground wires and SA-20 will show how to connect all red positive wires. Below is the jumper wire count for this trainer and all connections must be made so that the connections are possible with the wire count provided. CL-1918-4 Total Jumper Wire count • 8 LONG BLACK (1 METER – 43”) (used in assignment SA-19 = 3) • 25 SHORT BLACK (58cm – 23”) (used in assignment SA-19 = 25) • 6 LONG RED (1 METER – 43”) (used in assignment SA-20 = 3) • 50 SHORT RED (58cm – 23”) (used in assignment SA-20 = 49) It will be necessary to “stack” more than one jumper wire at the same connection point. We recommend that no more than three jumper wires be stacked at any one point. Fuse Box Identification for Whole Trainer Wiring Assignement GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A Feed From Fuse 1 Relays #1 & #2 Terminals #30 HD lights and feed to Fuses 4, 5, 6 & 7 IGN Switch BAT feed Horn & Brake Lights Realy #3 Terminal #30 (Parking Lights) Realy #4 Terminal #30 (Horn) Hazard Lights Multi-Function Switch Power Turn Signals & Backup Lights (switched) Feed From Fuse 1 Feed From Fuse 1 Feed From Fuse 1 Feed From IGN SWT (IGN) consulab.com info@consulab.com 145 CL-1918-4S_053304-95 SA-19 — Level 1 / Level 2 Assignment SA-19 — Level 1 / Level 2 Assignment (2 pages) The assignment of wiring the entire trainer with all lighting circuits requires a careful reading and understand of instruc- tions. Please carefully read, understand and follow the instructions you are given to complete this assignment. There are many jumper wires of both red and black that need to be installed in order to construct all of the circuits on this trainer. To avoid potential confusion, the instructions will separate the positive (power) and negative (ground) por- tions of the circuit into two different assignments. With so many wires necessary, the diagram will be somewhat compli- cated and there will be many wires routed throughout. Be sure to double check each connection with the schematic. 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the ENTIRE TRAINER WIRING, GROUND CIRCUITS (SA-19) and POWER CIRCUITS (SA-20). While carefully following each schematic, correctly con- nect red and black circuit wires according to the instructions. 3. The assignments will be in two parts : NEGATIVE (GROUND) SIDE (SA-19) and POSITIVE (POWER) SIDE (SA-20) 4. Start with the NEGATIVE (GROUND) side (SA-19). Connect black jumper wires for each of the following circuits : TOP MODUPONENT PANEL CL-1918-01A A. HEADLIGHTS B. PARK-TURN LIGHTS C. FRONT SIDE MARKER LIGHTS D. RELAYS #1 and #2 E. GROUND CONNECTION FROM TOP TO MIDDLE PANEL MIDDLE MODUPONENT PANEL CL-1918-O2A A. LEFT, HIGH BEAM and RIGHT INDICATOR LIGHTS B. HAZARD SWITCH C. RELAYS #3 and #4 D. HORN E. HAZARD FLASHER F. TURN SIGNAL SWITCH G. HEADLIGHT SWITCH H. DIMMER SWITCH consulab.com info@consulab.com 146 CL-1918-4S_053304-95 SA-19 — Level 1 / Level 2 Assignment BOTTOM MODUPONENT PANEL CL-1918-O3A A. REAR SIDE MARKER LIGHTS B. REAR TURN SIGNAL LIGHTS C. TAIL-STOP LIGHTS D. BACKUP LIGHTS E. LICENSE PLATE LIGHT F. CHMSL LIGHT G. GROUND CONNECTION FROM BOTTOM TO MIDDLE PANEL 5. Continue with the POSITIVE (POWER) side (SA-20). Connect red jumper wires for each of the following circuits : TOP MODUPONENT PANEL CL-1918-01A A. HEADLIGHTS B. FRONT SIDE MARKER LIGHTS C. PARK-TURN LIGHTS D. RELAYS #1 and #2 MIDDLE MODUPONENT PANEL CL-1918-O2A A. LEFT, HIGH BEAM AND RIGHT INDICATORS B. IGNITION SWITCH C. HAZARD SWITCH D. RELAYS #3 and #4 E. FUSE PANEL F. HORN BUTTON G. HORN H. BACKUP LIGHT SWITCH I. BRAKE SWITCH J. HAZARD FLASHER K. TURN SIGNAL FLASHER L. TURN SIGNAL SWITCH consulab.com info@consulab.com 147 CL-1918-4S_053304-95 SA-19 — Level 1 / Level 2 Assignment BOTTOM MODUPONENT PANEL CL-1918-O3A A. REAR SIDE MARKER LIGHTS B. REAR TURN SIGNAL LIGHTS C. TAIL-STOP LIGHTS D. BACKUP LIGHTS E. LICENSE PLATE LIGHT F. CHMSL LIGHT G. GROUND CONNECTION FROM BOTTOM TO MIDDLE PANEL 6. With instructor’s permission, turn on the power to the trainer and confirm that every circuit functions normally. If not, go back over your work to find and repair any errors. 7. List any circuits that did not properly function at first on your answer sheet. 8. If required, remove all circuit wiring and place jumper wires correctly in their storage place. 9. Submit your answer sheet to instructor for check and credit. consulab.com info@consulab.com 148 CL-1918-4S_053304-95 SA-19 — Level 1 / Level 2 Assignment Answer Sheet Name : Group : Date : Level Assigned : 7. Circuits not functioning normally after first attempt A Circuit B Circuit C Circuit D Circuit E Circuit F Circuit Instructor : Grade : consulab.com info@consulab.com 149 CL-1918-4S_053304-95 SA-19 — Level 1 — Positive Circuits SA-19 — Level 1 — Ground Circuits Student name Date REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 150 CL-1918-4S_053304-95 SA-19 — Level 1 — Ground Circuits SA-20 — Level 1 — Positive Circuits Student name Date REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 151 CL-1918-4S_053304-95 SA-19 — Level 2 — Positive Circuits SA-19 — Level 2 — Ground Circuits Student name Date CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD consulab.com info@consulab.com 152 CL-1918-4S_053304-95 SA-19 — Level 2 — Ground Circuits SA-20 — Level 2 — Positive Circuits Student name Date CL-1918-4S Level 2 Trainer wiring blank template consulab.com info@consulab.com 1 Circuit Name Date PARK GND GND TURN HIGH COM LOW TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 87A 30 87 8685 RELAY 2 87A 30 87 8685 RELAY 1 TEST POINT REVD CL-1918-01A_053143 MARKER ACC IGN START LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR IGNITION SWITCH LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 87 8685 87A 30 87 REV B BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON GND SIG BAT CL-1918-02A_053317 BRAKE SWITCH HAZARD FLASHER TURN SIGNAL FLASHER GND GND SIG BAT F7 10A F8 10A MAIN PWR 25A PWR RLY 5A F6 10A F5 10A F4 10A F3 5A F2 15A F1 20A BAT COM SIGCOM MULTIFUNCTION SWITCH DIMMER LIGHTS TURN LOW HIGH FLASH PARK HEAD LEFT RIGHT 8685BAT TAILSTOP LICENSE BACKUP TURN TEST POINT GND GND TEST POINT GND GND STOPTAIL STOP GND BACKUP TEST POINTTEST POINT TURN GND CL-1918-03A_053141 MARKER MARKER CHM STOP LIGHT REVD consulab.com info@consulab.com 153 CL-1918-4S_053304-95 SA-19 — Level 3 — Positive Circuits SA-19 — Level 3 — Ground Circuits Student name Date consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V consulab.com info@consulab.com 154 CL-1918-4S_053304-95 SA-19 — Level 3 — Positive Circuits Student name Date consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H CL-1918-4S_053304-95 SA-19 — Level 3 — Ground Circuits consulab.com info@consulab.com 155 Student name Date consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 consulab.com info@consulab.com 156 CL-1918-4S_053304-95 SA-19 — Level 3 — Ground Circuits SA-20 — Level 3 — Positive Circuits (2 pages) Student name Date consulab.com info@consulab.com 1 Circuit Name Date CL-1918-4S Level 3 Trainer wiring blank template PG-1 RELAY #2 LEFT HEAD LAMP RIGHT HEAD LAMP 86 85 87 87 30 87A COM HIGH LOW COM HIGH LOW ACC. BAT OFF IGN START IGNITION SWITCH TPTP TP TP TP TP TP Location of test points on the panels TP TP TP TP TP RELAY #1 85 86 30 87A FUSE #1 20 AMP FUSE #5 10 AMP FUSE #6 10 AMP FUSE #8 10 AMP FUSE #7 10 AMP FUSE #2 15 AMP FUSE #3 5 AMP FUSE #4 10 AMP FUSE BOX 1 HOT ALL TIMES GND OFF PARK HEADFLASH LOW HIGH LIGHT SWITCH MULTIFUNCTION SWITCH LOW TURN SWITCH LEFT RIGHT SIG HIGHFLASH HEAD COM COM DIMMER SWITCH Fuse 1A Fuse 1A PARK A B C D E F G H J K L M N O P Q R S T U V consulab.com info@consulab.com 157 CL-1918-4S_053304-95 SA-19 — Level 3 — Ground Circuits Student name Date consulab.com info@consulab.com 2 CL-1918-4S Level 3 Trainer wiring blank template PG-2 RIGHT FRONT PARK / TURN SIGNAL LAMP LEFT FRONT PARK / TURN SIGNAL LAMP TURN LICENSE LAMP HAZARD FLASHER GND BAT GND TURN GND PARKTURNPARK GND TAILSTOP GND STOPTAIL TURNBACK-UP BACK-UP RELAY #3 LEFT REAR COMBINATION LAMPS 85 86 87 30 87A RELAY #4 TURN FLASHER GND BAT LEFT REAR MARKER LAMP RIGHT REAR COMBINATION LAMPS RIGHT REAR MARKER LAMP LEFT FRONT MARKER LAMP RIGHT FRONT MARKER LAMP GNDGNDGNDGND SIG SIG CHM STOP LAMP GND TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP TP Location of test points on the panels 85 86 87 30 87A GND J K L M N O P Q R S T U V 9 01 11 21 31 41 15 61 17 81 1 2 3 4 5 6 7 8 A B C D E F G H CL-1918-4S_053304-95 SA-19 — Level 3 — Ground Circuits consulab.com info@consulab.com 158 Student name Date consulab.com info@consulab.com 3 CL-1918-4S Level 3 Trainer wiring blank template PG-3 BACK-UP SWITCH LEFT TURN INDICATOR RIGHT TURN INDICATOR HAZARD SWITCH CLUSTER LEFT RIGHT SIG GND HORN SWITCH BRAKE SWITCH GNDGND GND HORN Circuit breaker 0.5A HIGH BEAM INDICATOR GND TP Location of test points on the panels GND 1 2 3 4 5 6 7 8 9 01 11 21 31 41 15 61 17 81 consulab.com info@consulab.com 159 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments Ohm’s and Kirchhoff’s Laws Assignments consulab.com info@consulab.com 160 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments Ohm’s and Kirchhoff’s Laws Assignments The CL-1918-4 Lighting Circuits Trainer can be utilized for the learning of Ohm’s & Kirchhoff’s Law’s and how different resistances behave in different circuits. This section uses all of the incandescent bulbs and NOT the LED bulbs. This is primarily due to the extremely high resistance of LED bulbs and the subsequent low current values. Each of the incan- descent bulbs will be “re-named” with a resistor number which makes the schematics and assignments easier to read and perform. SA-21 — Resistances in Parallel SA-22 — Resistances in Series SA-23 — Combination Resistances (Series & Para) SA-24 — Bulbs of Different Resistances (Series & Para) SA-25 — Bulbs with Same Resistances in Series SA-26 — Resistances of Different Values in Combination Series & Parallel SA-27 — Relay Control Circuit with High Resistance Circuit Assignments Instructions This series of assignments are designed to demonstrate Ohm’s and Kirchhoff’s Laws covering the behavior of resistanc- es con¬nected in series and parallel circuits. Be sure to read, understand and follow each assignments instruction’s and ask your instruc¬tor if you have any questions. You will be asked to make voltage and amperage measurements for some assignments. Be sure you fully understand the proper use and hookup of volt and ammeters. All of these assignments will be constructed on the CL-1918-4 trainer. Be sure to ALWAYS use fuses to protect all cir- cuits. Fill out the Ohm’s & Kirchoff’s Law circuit assignment student answer sheet with name, class and information. Put all answers to these questions on the student answer sheet. Do not write on this paper. NOTE- The light bulbs on the CL-1918-4 will be assigned “R” numbers so that there will be clarity and consistency in constructing the circuits for these assignments. Be sure to use the correct bulb based on its “R” number. The legend is as follows : LIGHT BULB TO RESISTANCE IDENTIFICATION LF MARKER R1 R - HEADLIGHT - LOW R7 #2 RELAY COIL R13 RF PARK LIGHT R19 RF MARKER R2 R - HEADLIGHT - HIGH R8 #3 RELAY COIL R14 L TURN INDICATOR R20 LR MARKER R3 LEFT BACKUP R9 #4 RELAY COIL R15 R TURN INDICATOR R21 RR MARKER R4 RIGHT BACKUP R10 LF TURN LIGHT R16 HIGH INDICATOR R22 L - HEADLIGHT - LOW R5 LICENSE PLATE R11 LF PARK LIGHT R17 LEFT STOP R23 L - HEADLIGHT - HIGH R6 #1 RELAY COIL R12 RF TURN LIGHT R18 RIGHT STOP R24 consulab.com info@consulab.com 161 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-21 Circuit #1 — Resistances in Parallel 1. Connect R1 & R2 side marker lights in parallel and use the backup light toggle switch to control the circuit. (See Circuit #1 schematic if needed) 2. Confirm that the circuit operates correctly. 3. Measure the voltage drop across each light. 4. Measure the voltage drop across the toggle switch. 5. What is an acceptable voltage drop across a toggle switch ? 6. What would explain an excessive voltage drop across the toggle switch ? 7. Measure the current flowing though each R1 & R2 marker light individually. 8. Add the sum of the individual current draws together. 9. Now, measure the total circuit current draw of R1 & R2 and compare with the answer in question #8. Was it very close to being the same ? 10. What would explain a voltage drop lower than expected at one of the marker lights ? 11. One can conclude that in a parallel circuit, the ? Is the same at all resistances in the circuit and the ? changes at each resistance. 12. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. SA-22 Circuit #2 — Resistances in Series 1. Connect the R1 & R2 marker lights in series and use the backup light toggle switch to control the circuit. (See Circuit #2 schematic if needed) 2. Confirm that the circuit operates correctly. 3. What is the first thing you notice about the brightness of the marker lights compared to Circuit #1 ? 4. Measure the voltage drop across R1 & R2 lights. 5. Measure the current flowing between the switch and the R1 marker light. 6. Measure the current flowing between the R1 & R2 marker lights. 7. Measure the current flowing between the R2 marker light and ground. 8. Disconnect the wire between the R1 & R2 marker lights. What happened ? 9. How many different paths are there in this circuit for current to flow ? 10. What would be your prediction of circuit performance if you installed another marker light in series ? 11. Install R3 in series with R1 & R2 and describe what happened to the circuit performance. 12. One can conclude that in a series circuit, the ? is the same throughout the entire circuit and the ? changes at each resistance. 13. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 162 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-23 Circuit #3 — Combination Resistances (Series & Para) 1. Refer to Circuit #3 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Confirm that the circuit operates correctly. 3. There should be three branches to this circuit. R1 is connected in series with the parallel branch of R2 & R3, which is connected in series to R4. 4. Describe the performance of each bulb in the circuit. 5. Measure the voltage drop across R1, R2, R3 and R4. 6. Measure the current flow in the circuit from the backup light switch to R1. 7. Measure the current flow in the circuit from R4 to ground. 8. Measure the current flow in R2 and R3. 9. Explain why the current flow in R2 and R3 was less than R1 and R4 if all bulbs are identical ? 10. Install a jumper wire that will bypass R2 & R3 and just leave R1 & R4 in the circuit. 11. Measure the current flow in the revised circuit. 12. Measure the voltage drop across R1 & R4. 13. Explain why the readings are different than when R2 & R3 were in the circuit. 14. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) 1. Refer to Circuit #4 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Confirm that the circuit operates correctly. 3. Describe the performance of each bulb. 4. Measure the source voltage available at the load side of the backup toggle switch to ground. 5. Measure the voltage drop across R9 & R7. 6. Measure the current flow in this circuit. 7. Explain why R9 bulb is on and R7 bulb is not on. 8. Connect a jumper wire across the terminals of R9 and explain what happens. 9. Measure the voltage drop across R7. 10. Explain why the reading is now different than it was in step #4. 11. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 163 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-25 Circuit #5 — Bulbs with Same Resistances in Series 1. Refer to Circuit #5 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Confirm that the circuit operates correctly. 3. Describe the performance of each bulb. 4. Measure the voltage drop across each bulb. 5. Are most circuits in a vehicle connected in parallel or series ? 6. Now insert R14 in series with R4. Confirm that your wiring is correct. 7. Describe the operation of R4 now. 8. Measure the current flow in JUST the circuit with R4 and 14. 9. Measure the voltage drop across R4 and R14. 10. What conclusions can you make from this circuit ? 11. Using a jumper wire, jump across the two terminals of R14 and describe what happens to R4. 12. Remove R14 from the circuit. 13. Measure the total current flow of all four bulbs in this circuit. 14. Now, modify the circuit to add R14 in parallel with R1, R2, R3 & R4. 15. Measure the total circuit amperage including R14. 16. What conclusions can you make from this result ? 17. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 164 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-26 Circuit #6 — Resistances of Different Values in Combination Series & Parallel 1. Refer to Circuit #6 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. Turn on the switch and describe the performance of the circuit. 3. Measure the voltage drop at R2, R1, R7 and R5. 4. Measure the total current flow in this circuit. 5. Using a jumper wire, temporarily bypass R2 and describe what the per- formance of the circuit. 6. Measure the current flow in this “modified circuit”. Do you suspect that it will be higher or lower than before ? 7. Look at the circuit schematic and predict what will happen if you bypass R1 ? (Leave R2 “bypassed” for this step) 8. Using a jumper wire, temporarily bypass R1 and describe the performance of the circuit. 9. Explain why the circuit is operating as described in Step #8. 10. Measure the total circuit current flow at this point. 11. Remove the jumper wire from R1 and leave the jumper wire attached to R2. 12. Explain why the right headlight (R7) is not on and yet the left headlight (R5) is on. 13. Measure the voltage drop across R1 and R7. 14. Measure the current flow in the circuit of R1 and R7. 15. Remove the ground wire that attaches R1 bulb to ground and measure the voltage between the disconnected end and ground. 16. Explain why you got the voltage reading that you did on this wire. 17. Using jumper wires, jumper across the terminals of R1 and R2, then describe the performance of the circuit. 18. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 165 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-27 Circuit #7 — Relay Control Circuit with High Resistance 1. Refer to Circuit #7 schematic to construct the circuit and use the backup light toggle switch to control the circuit. 2. In this circuit, relay #3 controls the LOW beam (R7) on the right headlight. 3. Turn on the switch and describe what happens. Leave switch on unless instructed to turn it off. 4. Measure the voltage drop across the coil of relay #3 (R14). 5. In a normal operating circuit, what should the voltage drop be across the coil of relay #3 (R14) ? 6. In a normal operating circuit, what should the voltage at the supply side of the relay coil to ground ? 7. Measure the voltage available at the power supply side of relay #3 coil (R14). 8. In a normal operating circuit, what should be voltage to ground be at the ground side of relay coil #3 (R14) ? 9. Measure the voltage from the ground side of relay #3 (R14) ground terminal to ground. 10. What does the reading from Step #9 indicate ? 11. Measure the voltage drop across the relay coil of relay #3 (R14). 12. Would a defective relay coil explain the reading measured in Step #11 ? (Yes or No) 13. Using a jumper wire, connect terminal 85 of relay #1 (R12) to terminal 85 of relay #3 (R14). Explain what happens. 14. Remove the jumper wire and explain what happens. 15. Turn the switch OFF and back ON again. Explain what happens ? 16. Reconnect the jumper wire as you did in Step 13. What happens ? 17. Measure the voltage drop across the relay coil of relay #3 (R14) with jumper still installed. 18. Measure the voltage drop from terminal #85 of relay #3 (R14) to ground. 19. Is the reading from Step 18 considered to be “normal” ? Turn the backup light switch OFF. 20. Remove the jumper wire and turn switch ON. Measure the voltage drop across each of the three relay coils. 21. Remove the wire connected from terminal #85 of relay #1 (R12) to ground and measure from the end of that wire to ground. 22. The last measurement should prove to you that when attempting to locate unwanted resistances, checking an “open circuit” voltage (a connector unplugged) will NEVER tell you where the resistance is located. The reading of an open circuit voltage will always be source voltage because there is very, very little current flowing in it. (voltmeter imped- ance only). ALWAYS use the voltage drop method of testing to located unwanted resistances. 23. Could the unwanted resistance also be in the positive side of the circuit ? 24. The purpose of this assignment is to teach you how to located unwanted resistance in a circuit using the measure- ment of voltage drop to exactly located the source of the problem. Do you understand this concept ? 25. Obtain instructors check on your answer sheet and remove all circuit jumper wires from the trainer. B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 B+ R1 R2 Circuit #1 B+ R1 R2 Circuit #2 R3 B+ R2 R3 R1 R4 B+ R9 R7 Circuit #3 Circuit #4 Circuit #5 B+ R1 R2 R3 R4 R14 R14 Circuit #6 Circuit #7 B+ R2 LOW COM R7 R1 R5 8586 87 30 87A B+ R13 R12 R7 R14 8586 8586 © ConsuLab Educatech consulab.com info@consulab.com 166 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments Answer Sheets Name : Group : Date : SA-21 Circuit #1 — Resistances in Parallel 3. R1 VOLTS R2 VOLTS 4. TOGGLE SWITCH - VOLTS 5. VOLTS 6. 7. R1 AMPS R2 AMPS 8. R1 + R2 = AMPS 9. MEASURED TOTAL CURRENT OF R1 & R2 - AMPS 10. 11. 12. REMAINS THE SAME & CHANGES AT EACH RESISTANCE Instructor : Grade : consulab.com info@consulab.com 167 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-22 Circuit #2 — Resistances in Series 3. 4. R1 VOLTS R2 VOLTS 5. SWITCH & R1 - AMPS 6. BETWEEN R1 & R2 - AMPS 7. BETWEEN R2 AND GROUND - AMPS 8. 9. 10. 11. 12. REMAINS THE SAME & CHANGES AT EACH RESISTANCE Instructor : Grade : consulab.com info@consulab.com 168 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-23 Circuit #3 — Combination Resistances (Series & Para) 4. 5. R1 V R2 V R3 V R4 V 6. AMPS 7. AMPS 8. R2 AMPS R3 AMPS 9. 11. AMPS 12. R1 VOLTS R4 VOLTS 13. Instructor : Grade : consulab.com info@consulab.com 169 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) 3. 4. VOLTS 5. R9 VOLTS R7 VOLTS 6. AMPS 7. 9. VOLTS 10. Instructor : Grade : consulab.com info@consulab.com 170 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-25 Circuit #5 — Bulbs with Same Resistances in Series 3. 4. R1 VOLTS R2 VOLTS R3 VOLTS R4 VOLTS 5. 7. 8. R4 + R14 AMPS 9. R4 VOLTS R14 VOLTS 10. 11. 13. AMPS 15. AMPS 16. Instructor : Grade : consulab.com info@consulab.com 171 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-26 Circuit #6 — Resistances of Different Values in Combination Series & Parallel 2. 3. R2 VOLTS R7 VOLTS R1 VOLTS R5 VOLTS 4. AMPS 5. 6. AMPS 7. 8. 9. 10. AMPS 12. 13. R1 VOLTS R2 VOLTS 14. AMPS 15. VOLTS 16. 17. Instructor : Grade : consulab.com info@consulab.com 172 CL-1918-4S_053304-95 Ohm’s and Kirchhoff’s Laws Assignments SA-27 Circuit #7 — Relay Control Circuit with High Resistance 3. 4. VOLTS 5. VOLTS 6. VOLTS 7. VOLTS 8. VOLTS 9. VOLTS 10. 11. VOLTS 12. 13. 14. 15. 16. 17. VOLTS 18. VOLTS 19. 20. RELAY #3 VOLTS RELAY #2 VOLTS RELAY #1 VOLTS 21. VOLTS 23. 24. Instructor : Grade : consulab.com info@consulab.com 173 CL-1918-4S_053304-95 Optional Circuits Optional Circuits consulab.com info@consulab.com 174 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Generic Vehicle Alarm System Circuit Circuit Criteria Instructions This assignment asks you to design a “generic” vehicle alarm system similar to what might be seen in common vehicle applications. You will use the trainer’s components for different applications from when they were originally designed. Be sure to carefully follow the circuit criteria explained below. Please carefully follow all of the below instructions to complete this assignment. You are allowed to use any of the components on the CL-1918-4 trainer, BUT, no additional components are permitted. Circuit Description : Using your knowledge and understanding of the CL-1918-4 trainer, design the alarm system to meet the following criteria : 1. The alarm system must NOT be able to operate anytime the ignition switch is in the IGN position. (turning on the ignition switch to IGN must disable the alarm system even though it may have been armed previously). 2. The system must be able to be armed anytime the ignition switch is turned to the OFF position. 3. There must be one “door switch” used in the system. You must choose from the switches available on the trainer. The alarm system must be “tripped” anytime the door is opened. 4. When the alarm system is tripped, both the front LOW beam headlights, both rear STOP lamps and the horn must flash on and off as long as the system remains in “alarm mode”. 5. This circuit must have an “arming switch” (most likely would be a key fob in a real vehicle) where the system can be manually turned on and off, but if the ignition switch is in the ON position, the arming switch will not be able to arm the system. On the CL-1918-4 trainer, you have to use one of the switches on the trainer for the “arming switch”. 6. All circuits must be protected by fuses. 7. Any of the components on the trainer can be used to operate this circuit. NO OTHER COMPONENTS ALLOWED. 8. Obtain a Level 1, 2 or 3 blank schematic for the trainer and draw your circuit as you design it. 9. Confirm correct circuit operation or correct any errors that are discovered. 10. Fill out the student answer sheet and explain what each component in the circuit does. 11. Upon successful completion of the circuit, turn in your completed schematic and answer sheet to your instructor. consulab.com info@consulab.com 175 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit List of Components and their Role Answer Sheet (2 pages) List all of the components (other than wires) that you used to complete the alarm system and explain the role of each component in the circuit. Use additional paper if needed and refer to the assigned part number on the additional paper. Name : Group : Date : Component What does it do in the circuit ? 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. consulab.com info@consulab.com 176 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit 12. 13. 14. 15. Instructor’s Confirmation of Correct Circuit Operation : Attempt # Grade : Date : consulab.com info@consulab.com 177 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit Circuit Explanation Answer Sheet (4 pages) Obtain a schematic of the generic vehicle alarm circuit (Levels 1,2 or 3) and in your own words, explain how the circuit functions and what each component contributes to the circuit. Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) LOW BEAM HEADLIGHTS REAR STOP LIGHTS RELAY #1 TERMINAL #30- TERMINAL #86- TERMINAL #85- TERMINAL #87- TERMINAL #87a - consulab.com info@consulab.com 178 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit RELAY #2 TERMINAL #30- TERMINAL #86- TERMINAL #85- TERMINAL #87- TERMINAL #87a - RELAY #3 TERMINAL #30- TERMINAL #86- TERMINAL #85- TERMINAL #87- TERMINAL #87a - IGNITION SWITCH ACC TERMINAL- IGN TERMINAL- START TERMINAL- BAT TERMINAL- consulab.com info@consulab.com 179 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit TURN SIGNAL FLASHER GND TERMINAL- SIG TERMINAL- BAT TERMINAL- DOOR SWITCH (REPLACED BY : ) 1ST TERMINAL- 2ND TERMINAL- ARMING SWITCH (REPLACED BY : ) 1ST TERMINAL- 2ND TERMINAL- HORN RED TERMINAL- BLACK TERMINAL- HORN RED TERMINAL- BLACK TERMINAL- consulab.com info@consulab.com 180 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit GROUND CIRCUITS Instructor : Grade : consulab.com info@consulab.com 181 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 1 / Level 2 Assignment 1. Fill out levels 1&2 student answer sheet with name, class and date information. Indicate on the answer sheet what level assignment schematic you were assigned by the instructor. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF) and that the power supply red and black wires are connected to the trainer. 3. Obtain the level 1 or level 2 wiring schematic that your instructor has assigned for the ALARM CIRCUIT, and follow- ing the schematic, correctly connect red and black circuit wires to the optional alarm circuit components. 4. Obtain instructor’s check. 5. With instructor’s permission, turn on trainer power supply and confirm the correct operation of the ALARM CIRCUIT. If circuit does not operate properly, go back over your work to locate the error and correct. 6. What SPECIFIC action does the system arming switch perform ? How does the circuit work with the arming switch ? 7. If Fuse #2 was open, that affect would that condition have on the alarm system ? 8. According to the schematic, what would the circuit do if the connection from system ground to the left front COM terminal of the left-front headlight was open ? 9. According to the schematic, what would the circuit do if the connection from system ground to the horn was open ? 10. According to the schematic, what would the circuit do if the connection from terminal #86 of relay #2 and the door switch (brake) was open ? 11. According to the schematic, what would the circuit do if the connection from system ground to terminal #85 of relay #1 was open ? 12. According to the schematic, what would the circuit do if the terminal #86 of relay #2 was shorted to ground ? 13. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 182 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit Answer Sheet Name : Group : Date : Level Assigned : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 6. 7. 8. 9. 10. 11. 12. Instructor : Grade : consulab.com info@consulab.com 183 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit SA-28 — Level 3 Assignment 1. Fill out the level 3 student answer sheet with name, class and date information. Put all answers to these questions on the student answer sheet. Do not write on this paper. 2. Make sure trainer is properly connected to a 120V power supply (turned OFF) and that the power supply red and black wires are connected to the trainer. 3. Obtain the Level 3 blank schematic (2 pages) and after studying the components, draw in the red (positive) and black (negative) wires to correctly operate the circuit. Following the schematic, correctly connect red and black circuit wires to the alarm circuit components. 4. Obtain instructor’s check. 5. According to the circuit schematic, what affect would an open Fuse #1 have on the alarm system ? 6. According to the circuit schematic, what affect would an open wire at terminal #87a of relay #2 have on the alarm system ? 7. According to the circuit schematic, what affect would a short circuit between the SIG and BAT terminals of the turn signal flasher have on the alarm system have on the alarm system ? 8. According to the circuit schematic, what affect would an open in the wire connected between terminal #86 of relay #1 and IGN terminal of the ignition switch have on the alarm system ? 9. According to the circuit schematic, what affect would an open circuit in the coil of relay #3 have on the alarm sys- tem ? 10. According to the circuit schematic, what affect would a short-to-ground at terminal #87a of relay #3 have on the alarm system ? 11. If you wanted to add more doors switches to this system, would you install the switches in parallel or series ? 12. Using your knowledge of the circuits construction and operation, design a modification to the circuit that would allow the front LOW beam headlights and the rear stop lamps to flash alternately when the system is in alarm mode. Include your design changes on the schematic and submit to instructor. Once approved, insert your modifications in the circuit by connecting the necessary red and black wires to the added components. 13. Does your modified circuit work as desired ? 14. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) consulab.com info@consulab.com 184 CL-1918-4S_053304-95 SA-28 — Generic Vehicle Alarm System Circuit Answer Sheet Name : Group : Date : 4. INSTRUCTOR’S CHECK OF PROPER CIRCUIT WIRING : 5. 6. 7. 8. 9. 10. 11. 12. INSTRUCTOR’S APPROVAL OF CIRCUIT DESIGN CHANGES 13. Instructor : Grade : consulab.com info@consulab.com 185 CL-1918-4S_053304-95 SA-29 — Emergency Lighting System SA-29 — Emergency Lighting System Circuit Explanation Emergency vehicles often have an EMERGENCY LIGHTING CIRCUIT when enroute to call. Most vehicles alternately flash the high beam headlights as well as the rear stop lights. You will construct this circuit using the components on the CL- 1918-04 trainer. Circuit Description Using your knowledge and understanding of the CL-1918-4 trainer, design the emergency lighting system to meet the following criteria : 1. The emergency lighting circuit should only operate when the ignition switch is in the IGN position. 2. There needs to be a manual switch to turn the lighting system on and off. 3. The emergency lighting system needs to do the following : A. The system must flash the headlights and stop lights alternately on and off. B. The left front headlight and the right rear stop light must flash together. C. The right front headlight and the left rear stop light must flash together. D. The horn (siren) must be on constantly any the time the system is operating. E. The horn and all lights MUST be controlled by relays and must not be direct wired. 4. All current of all lights and horn must NOT flow through any relay coil circuit. 5. All circuits must be protected by fuses rated for the current of the components. Assignment 1. This assignment applies to all three levels (1,2 & 3). The difference will be what level of schematic you use to design, confirm and then draw the final circuit. 2. Obtain a Level 1, 2 or 3 blank schematic and using your knowledge of the components on the trainer, design a cir- cuit that meets the above criteria. 3. Obtain your instructor’s approval of your design, then construct your circuit design on the trainer using black and red jumper wires. Once completed, confirm proper operation of the circuit. Correct any errors that you discover. 4. Fill out the COMPONENT EXPLANATION SHEET where you explain the operation of the components you used in the circuit. Turn assignment sheet in to your instructor when completed. 5. Fill out a final Level 1, 2 or 3 schematic showing the circuit you have designed and turn in to your instructor. consulab.com info@consulab.com 186 CL-1918-4S_053304-95 SA-29 — Emergency Lighting System Circuit Explanation Answer sheet List all of the components (other than wires) that you used to complete the Emergency Lights System and explain the role of each component in the circuit. Use additional paper if needed and refer to the assigned part number on the addi- tional paper (if used). Obtain a schematic of the emergency lighting circuit (levels 1, 2 or 3) and in your own words, explain how the circuit func- tions and what each component contributes to the circuit. Name : Group : Date : FUSE #1 (20A) FUSE #2 (15A) LOW BEAM HEADLIGHTS REAR STOP LIGHTS RELAY #1 TERMINAL #30- TERMINAL #86- TERMINAL #85- TERMINAL #87- TERMINAL #87a - consulab.com info@consulab.com 187 CL-1918-4S_053304-95 SA-29 — Emergency Lighting System RELAY #2 TERMINAL #30- TERMINAL #86- TERMINAL #85- TERMINAL #87- TERMINAL #87a - IGNITION SWITCH ACC TERMINAL- IGN TERMINAL- START TERMINAL- BAT TERMINAL- TURN SIGNAL FLASHER GND TERMINAL- SIG TERMINAL- BAT TERMINAL- consulab.com info@consulab.com 188 CL-1918-4S_053304-95 SA-29 — Emergency Lighting System HORN RED TERMINAL- BLACK TERMINAL- GROUND CIRCUITS Instructor : Grade : consulab.com info@consulab.com 189 CL-1918-4S_053304-95 SA-30 — Removable Relay Circuit (Positive Switched Relay) SA-30 — Removable Relay Circuit (Positive Switched Relay) Relay #4 on the CL-1918-4 is made to be removed for additional educational learning experiences. In addition, the ISO micro-relay was chosen as it is readily available, commonly used in vehicles, inexpensive and is usually found around most school automotive shops. During routine diagnosis of relay controlled circuits, it is often required to remove the relay and test the terminals in the socket. For this purpose, relay #4 is designed to be removed WARNING : If at any time this assignment directs you to use a jumper wire to make a connection, but sure to use ONLY a jumper wire that is routed through a fuse to protect the trainer and yourself from potential injuries Prior to completing this assignment, you should already have received the study guide showing details of relay #4, the terminal and pin identification of both the socket and relay. Be sure you understand this information before completing this assignment. Look at the below diagram and learn how the terminals are organized. This relay socket and all other standard ISO relay sockets have been standardized throughout the industry. Be aware that there are still many special use relays used by OEM manufacturers that do not follow this standardization. Assignment 1. Obtain the STUDENT ANSWER SHEET for this assignment. 2. Construct the circuit shown in REMOVABLE RELAY #4 ASSIGNMENT (POWER SWITCHED) on the trainer. REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 190 CL-1918-4S_053304-95 SA-30 — Removable Relay Circuit (Positive Switched Relay) 3. Confirm that the circuit works by switching the toggle switch on and off. 4. Carefully remove relay #4 and lay aside. 5. Referring to the drawing below, answer the below questions with the trainer turned OFF. Be sure to put all your answers in the STUDENT ANSWER SHEET for this assignment. DO NOT WRITE ON THIS PAPER. 6. A. What terminal of the relay socket should have B+ voltage at all times ? B. What terminal of the relay socket represents the ground for the relay coil ? C. Which two terminals of the relay socket could be jumped with a fused jumper wire to turn on the controlled device ? D. Which two terminals of the relay socket would you hook up a voltmeter to show the presence of B+ voltage at all times ? E. What would happen if you jumped across terminals #30 and #85 on the relay socket ? 7. Turn power on to the trainer with the relay still removed from the socket. Answer the below questions : A. Using a voltmeter, confirm your answer in question #5A. What terminal is the correct answer ? B. Using a voltmeter, confirm your answer in question #5B. What terminal is the correct answer ? 8. With instructor’s permission AND using a fused jumper wire, confirm the answer for #5C. Were you correct ? 9. Using a voltmeter confirm the answer to question #5D. What terminals are the correct answer ? 10. What could be the cause of a zero voltage to ground reading on terminal #30 of relay #4 socket ? 11. What could be the cause of having B+ voltage to ground on terminal #85 of the socket ? 12. If the circuit from terminal #85 of the relay socket was open, what test procedures would you to confirm that condi- tion ? 13. Insert relay #4 back into the socket and again, confirm correct circuit operation. 14. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a consulab.com info@consulab.com 191 CL-1918-4S_053304-95 SA-30 — Removable Relay Circuit (Positive Switched Relay) Removable Relay Information FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a consulab.com info@consulab.com 192 CL-1918-4S_053304-95 SA-30 — Removable Relay Circuit (Positive Switched Relay) Answer Sheet Name : Group : Date : 6. A TERMINAL B TERMINAL C & TERMINALS D & TERMINALS E 7. A YES NO B YES NO 8. YES NO 9. YES NO 10. 11. 12. Instructor : Grade : consulab.com info@consulab.com 193 CL-1918-4S_053304-95 SA-31 — Removable Relay Circuit (Ground Switched Relay) SA-31 — Removable Relay Circuit (Ground Switched Relay) Relay #4 on the CL-1918-4 is made to be removed for additional educational learning experiences. In addition, the ISO micro-relay was chosen as it is readily available, commonly used in vehicles, inexpensive and is usually found around most school automotive shops. During routine diagnosis of relay controlled circuits, it is often required to remove the relay and test the terminals in the socket. For this purpose, relay #4 is designed to be removed. WARNING : If at any time this assignment directs you to use a jumper wire to make a connection, but sure to use ONLY a jumper wire that is routed through a fuse to protect the trainer and yourself from potential injuries. Prior to completing this assignment, you should already have received the study guide showing details of relay #4, the terminal and pin identification of both the socket and relay. Be sure you understand this information before completing this assignment. Look at the below diagram and learn how the terminals are organized. This relay socket and all other standard ISO relay sockets have been standardized throughout the industry. Be aware that there are still many special use relays used by OEM manufacturers that do not follow this standardization. Assignment 1. Obtain the STUDENT ANSWER SHEET for this assignment. 2. Construct the circuit shown in SA-24 REMOVABLE RELAY #4 ASSIGNMENT (GROUND SWITCHED) on the trainer. REV D CL-1918-01A_053143 TEST POINTMARKER PARK GND TURN HIGH COM LOW GND TEST POINT MARKER PARK GND TURN HIGH COM LOW TEST POINT TEST POINT 85 RELAY 2 87A 30 87 8685 RELAY 1 87A 30 87 86 GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A MARKER TAILSTOP LICENSE BACKUPTURN CHM STOP LIGHTGND TEST POINT GND MARKER TEST POINT GND STOPTAIL GND STOP GND BACKUP TEST POINTTEST POINT REVD TURN GND CL-1918-03A_053141 CL-1918-4 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 194 CL-1918-4S_053304-95 SA-31 — Removable Relay Circuit (Ground Switched Relay) 3. Confirm that the circuit works by switching the toggle switch on and off. 4. Carefully remove relay #4 and lay aside. 5. Referring to the drawing below, answer the below questions with the trainer turned OFF. Be sure to put all your answers in the STUDENT ANSWER SHEET for this assignment. DO NOT WRITE ON THIS PAPER. 6. A. What terminal of the relay socket should have B+ voltage at all times ? B. What terminal of the relay socket represents the ground for the relay coil ? C. Which two terminals of the relay socket could be jumped with a fused jumper wire to turn on the controlled device ? D. Which two terminals of the relay socket would you hook up a voltmeter to show the presence of B+ voltage at all times ? E. What would happen if you jumped across terminals #30 and #85 on the relay socket ? 7. Turn power on to the trainer with the relay still removed from the socket. Answer the below questions : A. Using a voltmeter, confirm your answer in question #5A. What terminal is the correct answer ? B. Using a voltmeter, confirm your answer in question #5B. What terminal is the correct answer ? 8. With instructor’s permission AND using a fused jumper wire, confirm the answer for #5C. Were you correct ? 9. Using a voltmeter confirm the answer to question #5D. What terminals are the correct answer ? 10. What could be the cause of a zero voltage to ground reading on terminal #30 of relay #4 socket ? 11. What could be the cause of having B+ voltage to ground on terminal #85 of the socket ? 12. If the circuit from terminal #85 of the relay socket was open, what test procedures would you to confirm that condi- tion ? 13. Insert relay #4 back into the socket and again, confirm correct circuit operation. 14. Obtain final check from instructor and turn in your answer sheet. (If required, disconnect and return all wires to their storage place and turn off trainer power supply) FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a FRONT VIEW OF RELAY SOCKET BOTTOM VIEW OF RELAY TERMINAL #85 - COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY GND) TERMINAL #86 – COIL CIRCUIT – CAN BE EITHER POSITIVE OR GROUND (NORMALLY POSITIVE) TERMINAL #87 – N.O. CONTACT – CAN GO TO EITHER CONTROLLED DEVICE OR POWER (NORMALLY CONTROLLED DEVICE) TERMINAL #87a – N.C. CONTACT – CONNECTED TO #30 WHEN RELAY IS OFF – CAN GO TO A CIRCUIT THAT IS OFF WHEN RELAY IS OFF TERMINAL #30 – CONTACT – CAN GO TO EITHER POWER OR CONTROLLED DEVICE – (NORMALLY POWER) 86 87a 8730 85 86 85 87 30 87a CIRCUIT CONNECTIONS CL-1918-4 REMOVABLE RELAY INFORMATION 30 87 85 86 87a consulab.com info@consulab.com 195 CL-1918-4S_053304-95 SA-31 — Removable Relay Circuit (Ground Switched Relay) Answer Sheet Name : Group : Date : 6. A TERMINAL B TERMINAL C & TERMINALS D & TERMINALS E 7. A YES NO B YES NO 8. YES NO 9. YES NO 10. 11. 12. Instructor : Grade : consulab.com info@consulab.com 196 CL-1918-4S_053304-95 Optional Circuit Assignments Optional Circuit Assignments SA-32 to SA-37 are custom designed circuits that must meet all of the defined circuit criteria for each assignment. Students will need to have a basic understanding of how all components on the trainer function in order to successfully build these circuits. Be sure to very carefully read the “circuit criteria” listed for each circuit, then using ONLY the components on the trainer, design and build a circuit that complies with all criteria. SA-32 — Custom Circuit #1 SA-33 — Custom Circuit #2 SA-34 — Custom Circuit #3 SA-35 — Custom Circuit #4 SA-36 — Custom Circuit #5 SA-37 — Custom Circuit #6 Each of these assignments will consist of a description of what the circuit must be designed to do. The instructor will give you either a blank Level 1, Level 1 or Level 3 schematic FOR EACH CIRCUIT for you to design the circuit on. After obtaining your instructors check, construct the circuit on the trainer and confirm normal operation. Correct any errors noticed. Upon confirma¬tion that your circuit design is correct, obtain instructors check and go to the next assignment. SA-32 — Custom Circuit #1 Design a circuit that meets the following criteria : A. When the brake switch is pushed in, all rear stop lights flash on and off. B. All circuit components and wiring must be protected by fuses. C. The circuit must function anytime the trainer is powered on. SA-33 — Custom Circuit #2 Design a circuit that meets the following criteria : A. When the light switch is turned to the headlight LOW beam position, both LOW beam headlights come on. B. When the light switch is turned to the headlight HIGH beam position, the HIGH beam headlights and the rear stop lights come on together, but the left and right sides of both headlights & stop lights will flash alternately off and on. C. All headlight current must be controlled by relays. D. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 197 CL-1918-4S_053304-95 Optional Circuit Assignments SA-34 — Custom Circuit #3 Design a circuit that meets the following criteria : A. The left front marker light is to be positive switched. B. The right front marker light is to be ground switched. C. The backup lights toggle switch is to control both lights. D. All circuit wiring must be protected by fuses. SA-35 — Custom Circuit #4 Design a circuit that meets the following criteria : A. The normal headlight circuit must be totally functional with HIGH, LOW and HIGH BEAM INDICATOR working normally. B. Regardless of whether the headlights are on or off, turning on the toggle switch will turn on the headlights and the HIGH and LOW beams will flash from HIGH to LOW alternately. C. The circuit is to be totally independent of the headlights and no headlights should be on when the toggle switch and the headlight switch are off. D. All circuit components and wiring must be protected by fuses. SA-36 — Custom Circuit #5 Design a circuit that uses the horn to warn you that you have left your headlights on when you open the door. NOTE- Due to the design of the CL-1918-4 components, it will be necessary to use the backup lights toggle switch in the “open or off” position when the “door” is in the closed position and when you open the door, the switch will turn “on” or closed position. A. The headlights must be controlled by relays and the headlight switch. B. The “door” switch must be the toggle (backup light switch) C. Regardless of whether either the HIGH or LOW beams are left on, the horn must sound when the door is opened. D. Door opens = switch closed – door closed = switch open E. The flash-to-pass circuit must also function normally. F. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 198 CL-1918-4S_053304-95 Optional Circuit Assignments SA-37 — Custom Circuit #6 Design a circuit to demonstrate the difference with light bulbs connected in both SERIES and parallel configurations. A. The LEFT FRONT MARKER and LEFT REAR MARKER are to be connected in SERIES on their ground side circuits. B. The RIGHT FRONT TURN, RIGHT MARKER, RIGHT BACKUP, RIGHT TURN and the RIGHT MARKER lights are to be connected in PARALLEL. C. When the toggle switch is turned on, the parallel connected circuit will turn on without the series circuit being on. D. Regardless of whether the parallel either on or off, when the HORN push button is pushed down, the series connected circuit will come on. E. In addition, when the series circuit is turned on, pushing the BRAKE switch button will temporarily connect the LEFT FRONT MARKER and LEFT REAR MARKER bulbs from series to a parallel connection. Both MARKER lights will come on a normal brilliance. F. Relays can be used if desired. G. All circuit components and wiring must be protected by fuses. consulab.com info@consulab.com 199 CL-1918-4S_053304-95 Optional Circuit Assignments Answer Sheet Name : Group : Date : SA-32 — Circuit #1 Instructor : Grade : SA-33 — Circuit #2 Instructor : Grade : SA-34 — Circuit #3 Instructor : Grade : SA-35 — Circuit #4 Instructor : Grade : SA-36 — Circuit #5 Instructor : Grade : SA-37 — Circuit #6 Instructor : Grade : consulab.com info@consulab.com 200 CL-1918-4S_053304-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved. Student Assignment Explanations Circuit Construction Notes Student Assignments Current Measurement Methods CL-1918-4 Level 1 Trainer Wiring Blank Template CL-1918-4 Level 2 Trainer Wiring Blank Template CL-1918-4 Level 3 Trainer Wiring Blank Template P-1 Circuit Assignments SA-1 — Backup Light Circuit Circuit Explanation SA-1 — Backup Light Circuit — Circuit Component Explanation — Answer Sheet SA-1 — Level 1 / Level 2 Assignment SA-1 — Level 1 / Level 2 Assignment — Answer Sheet SA-1 — Level 3 Assignment SA-1 — Level 3 Assignment — Answer Sheet SA-2 — Hazard Lights Circuit Circuit Explanation SA-2 — Hazard Lights Circuit — Circuit Component Explanation — Answer Sheet (2 pages) SA-2 — Level 1 / Level 2 Assignment SA-2 — Level 1 / Level 2 Assignment — Answer Sheet SA-2 — Level 3 Assignment SA-2 — Level 3 Assignment — Answer Sheet SA-3 — Horn Circuit (Positive Switched) Circuit Explanation SA-3 — Horn Circuit — Circuit Component Explanation — Answer Sheet SA-3 Level 1 / Level 2 Assignment SA-3 Level 1 / Level 2 Assignment — Anwser Sheet SA-3 — Level 3 Assignment SA-3 — Level 3 Assignment — Answer Sheet SA-4 — Horn Circuit (Ground Switched) Circuit Component Explanation — Answer Sheet (2 Pages) SA-4 — Level 3 Assignment SA-4 — Level 3 Assignment — Answer Sheet SA-5 — Stop Lights Circuit Circuit Explanation SA-5 — Stop Lights Circuit — Circuit Component Explanation — Answer Sheet SA-5 — Level 1 / Level 2 Assignment SA-5 — Level 1 / Level 2 Assignment — Answer Sheet SA-5 — Level 3 Assignment SA-5 — Level 3 Assignment — Answer Sheet SA-6 — Tail-Park Lights Circuit (Ground Switched) Circuit Explanation SA-6 — Tail-Park Lights Circuit — Circuit Component Explanation — Answer Sheet (3 pages) SA-6 — Level 1 / Level 2 Assignment SA-6 — Level 1 / Level 2 Assignment — Answer Sheet SA-6 — Level 3 Assignment SA-6 — Level 3 Assignment — Answer Sheet (2 pages) SA-7 — Tail-Park Lights Circuit (Positive Switched) Circuit Explanation SA-7 — Tail-Park Lights Circuit (Positive Switched) — Circuit Component Explanation — Answer Sheet (3 pages) SA-7 — Level 1 / Level 2 Assignment SA-7 — Level 1 / Level 2 Assignment — Answer Sheet SA-7 — Level 3 Assignment SA-7 — Level 3 Assignment — Answer Sheet (2 pages) SA-8 — Turn Signal Circuit Circuit Explanation SA-8 — Turn Signal Circuit — Circuit Component Explanation — Answer Sheet (3 pages) SA-8 — Level 1 / Level 2 Assignment SA-8 — Level 1 / Level 2 Assignment — Answer Sheet SA-8 — Level 3 Assignment SA-8 — Level 3 Assignment — Answer Sheet (2 pages) Headlights Circuits Notice Pertaining to CL-1918-4 Headlight Circuits CL-1918-3I & CL-1918-4 Multifunction Switch Terminal Identification Headlights and Plug Explanation SA-9 — Headlights Circuit (Ground Switched) Circuit Design and Operation : SA-9 — Level1 / Level 2 Assignment SA-9 — Level1 / Level 2 Assignment — Answer Sheet SA-9 — Level 3 Assignment SA-9 — Level 3 Assignment — Answer Sheet (2 pages) SA-10 — Headlights Circuit (Positive Switched) Circuit Explanation Answer Sheet (2 pages) SA-10 — All Level Assignment Answer Sheet (2 pages) Headlights Circuit (Optional Circuit Designs) Assignment Explanations SA-11 — Headlights Circuit — Option A SA-11 — Headlights Circuit - Option A — Circuit component explanation — Answer Sheet (3 pages) SA-12 — Headlights Circuit — Option B SA-12 — Headlights Circuit - Option B — Circuit Component Explanation — Answer Sheet (3 pages) SA-13 — Headlights Circuit — Option C SA-13 — Headlights Circuit - Option C — Circuit Component Explanation — Answer Sheet (3 pages) SA-14 — Headlights Circuit — Option D SA-14 — Headlights Circuit - Option D — Circuit Component Explanation — Answer Sheet (3 pages) SA-15 — Headlights Circuit — Option E SA-15 — Headlights Circuit - Option E — Circuit Component Explanation — Answer Sheet (3 pages) SA-16 — Headlights Circuit — Option F SA-16 — Headlights Circuit - Option F — Circuit Component Explanation — Answer Sheet (3 pages) SA-17 — Headlights Circuit — Option G SA-17 — Headlights Circuit - Option G — Circuit Component Explanation — Answer Sheet (3 pages) SA-18 — Headlights Circuit — Option H SA-18 — Headlights Circuit - Option H — Circuit Component Explanation — Answer Sheet (3 pages) Whole Trainer Wiring SA-19 & SA-20 — Whole Trainer Wiring General Information CL-1918-4 Total Jumper Wire count Fuse Box Identification for Whole Trainer Wiring Assignement SA-19 — Level 1 / Level 2 Assignment Answer Sheet SA-19 — Level 1 — Ground Circuits SA-20 — Level 1 — Positive Circuits SA-19 — Level 2 — Ground Circuits SA-20 — Level 2 — Positive Circuits SA-19 — Level 3 — Ground Circuits SA-20 — Level 3 — Positive Circuits Ohm’s and Kirchhoff’s Laws Assignments Ohm’s and Kirchhoff’s Laws Assignments Circuit Assignments Instructions SA-21 Circuit #1 — Resistances in Parallel SA-22 Circuit #2 — Resistances in Series SA-23 Circuit #3 — Combination Resistances (Series & Para) SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) SA-25 Circuit #5 — Bulbs with Same Resistances in Series SA-26 Circuit #6 — Resistances of Different Values in Combination Series & Parallel SA-27 Circuit #7 — Relay Control Circuit with High Resistance Answer Sheets SA-21 Circuit #1 — Resistances in Parallel SA-22 Circuit #2 — Resistances in Series SA-23 Circuit #3 — Combination Resistances (Series & Para) SA-24 Circuit #4 — Bulbs of Different Resistances (Series & Para) SA-25 Circuit #5 — Bulbs with Same Resistances in Series SA-26 Circuit #6 — Resistances of Different Values in Combination Series & Parallel SA-27 Circuit #7 — Relay Control Circuit with High Resistance Optional Circuits SA-28 — Generic Vehicle Alarm System Circuit Circuit Description : List of Components and their Role Answer Sheet (2 pages) Circuit Explanation Answer Sheet (4 pages) SA-28 — Level 1 / Level 2 Assignment Answer Sheet SA-28 — Level 3 Assignment Answer Sheet SA-29 — Emergency Lighting System Circuit Explanation Circuit Description Circuit Explanation Answer sheet SA-30 — Removable Relay Circuit (Positive Switched Relay) Removable Relay Information Answer Sheet SA-31 — Removable Relay Circuit (Ground Switched Relay) Answer Sheet Optional Circuit Assignments SA-32 — Custom Circuit #1 SA-33 — Custom Circuit #2 SA-34 — Custom Circuit #3 SA-35 — Custom Circuit #4 SA-36 — Custom Circuit #5 SA-37 — Custom Circuit #6 Answer Sheet SA-32 — Circuit #1 SA-33 — Circuit #2 SA-34 — Circuit #3 SA-35 — Circuit #4 SA-36 — Circuit #5 SA-37 — Circuit #6
