Instructors Manual for HV-950 Diesel Engine Training Bench HV-950-96_V2025-1 © ConsuLab Educatech Inc, 2025. All rights reserved. HV-950-96 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 2 © 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. Printed in Canada. Table of Contents General description 3 Educational Advantages 3 Introduction to the HV-950 Family of Diesel Engine Benches 4 Student Assignments Basic Orientation Thru Advanced And Troubleshooting 7 Explanation of recommended student assignment outcomes 11 SA1 — Component identification — Basic — Answers 13 SA2-A — Component Identification — Specific — Answers 15 SA2-B — Component Identification — Dashboard Specific ID — Answers 17 SA3 — Component Identification — Sensors ID / HD Diesel — Answers 20 SA4 — Component Identification — Actuator ID/HD Diesel — Answers 22 SA5 — Charging System Verification— Answers 23 SA6 — Wiring diagram practice — Answers 24 SA7 — Expected voltages — Answers 28 SA8 — Measured voltages — Answers 32 SA9 — Engine performance fault diagnosis — Answers Template 36 consulab.com info@consulab.com 3 HV-950-95 General description General description The HV-950 family of diesel engine trainers are fully operational engines mounted on a mobile stand. The trainers are easy to work on and all major components, wiring and connectors match OEM configuration. Each trainer is either a one or two piece construction design depending on the model. Part one is the actual engine mounted on a mobile stand constructed of 2” (5 cm) tubular steel equipped with four 5” (12.5 cm) phenol casters (2-fixed and 2-swivel w/locks), and may or may not include the after-treatment unit on top. For some models part two is the exhaust after-treatment unit that must be properly connected to the engine prior to trainer use. Students can perform many ASE Educational Foundation related Engine Performance and Electrical/Electronic tasks using this trainer. Trainers are equipped with safety guards covering all rotating components. Educational Advantages • Demonstration of major engine systems to groups of students without the access limitations of a complete vehicle. • Engine systems respond to inserted fauts with real world symptoms, OEM DTC’s and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demostration of exhaust after treatment emission system operation if applicable. TWO-PIECE DIESEL ENGINE TRAINER ONE-PIECE DIESEL ENGINE TRAINER consulab.com info@consulab.com 4 HV-950-95 Introduction to the HV-950 Family of Diesel Engine Benches Introduction to the HV-950 Family of Diesel Engine Benches ConsuLab understands that today’s classroom has changed and we want to encourage the transition from an instructor just dispensing information to one who is a facilitator of actual learning. Today’s automotive instructor is ultimately re- sponsible to provide a learning environment that encourages student led learning. We want to help! The following is our recommendation for integrating our HV-950 Engine bench trainer with fault box into your program. Recommended ways to introduce the ConsuLab HV-950 engine bench to students: • Explain the key and security system (all VIN specific): - Encourage students to not drop or lose key. • Show location of the engine bench batteries and master disconnect switch: - The batteries must always be connected while operating the trainer. - Recommended to wait 10 minutes after engine shut down before opening this switch: - ECM and DEF supply module power must be maintained for a minimum 10 minutes after key off for all applica- tions, even for those applications where the ECM is powered through a battery disconnect device. - Switch should remain open when stored or not in use. - Explain the 12-volt test points by ignition switch - NEVER power up anything off of this test point! - Student Assignment 5 (SA5) covers charging system operation and inspection • Show location of the battery charger: - Demonstrate correct operation. - Explain that the best engine bench test results are achieved with this plugged in during use as well as just for bat- tery maintenance: - If the battery voltage drops below 12V it could affect the fault box’s ability to retain a fault and the fault could clear itself. • Discuss proper exhaust safety: - Connection and coupling of the exhaust after-treatment unit - Do not run this inside closed area, ALWAYS use exhaust hoses: - Carbon monoxide is a colorless, odorless deadly gas. - NEVER perform a re-gen process inside of the shop, move trainer outside. • Have students demonstrate the correct connection of exhaust hose and battery charger consulab.com info@consulab.com 5 HV-950-95 Introduction to the HV-950 Family of Diesel Engine Benches • Show the location of the diesel fuel cell: - Explain that the fuel pickup is not on the bottom of the tank and the fuel gauge has to read something in the tank for the engine to start. - Explain complete evaporative emission system testing can be performed. • Show location of the DEF tank. • Show and discuss dash board controls, warnings and indicators: - Some benches have a Student Assignment for this. (SA2-B) • Show location of the CAN plus 600 with explanation. • Show location of the breakout box and explain what is a breakout box: - Explain terminology for ECU labeling. - When using faults with variable signals, the students must use either the scan tool or breakout box for their diag- nostic measurements. Do not allow students to back-probe or measure at the faulted sensor as there will be false readings. When a fault with a variable value is selected, the “real” sensor signal is still present at the sensor. - When using open circuit faults students may back-probe or measure at the sensor as required. - Explain that the breakout box pin #’s match factory service info. - Explain that some pins are not used for trainer purposes • Demonstrate safety! - Explain that this is an expensive piece of equipment and to respect it! - Safety glasses required to operate this equipment every time. - Demonstrate emergency kill switch: - NOTE: sometimes the emergency switch can be “disturbed” and result in a crank / no start condition. If there is ever a no start situation ALWAYS push and release the emergency STOP button and try again to start it up. - No ear buds – complete attention is required when working with this trainer! • Start up engine and demonstrate “know good” performance. • Review sensors and actuators on this engine: - Have students discover and discuss operation – see SA 1,2,3,4. • Turn off engine, and review procedure for end of day storage: - Remove key and store correctly. - Battery quick-disconnect after 10 minutes. - Install optional vinyl cover after engine cool down. consulab.com info@consulab.com 6 HV-950-95 Student Assignments Student Assignments consulab.com info@consulab.com 7 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Basic Orientation Thru Advanced And Troubleshooting ConsuLab realizes the following steps are important in the development of an accurate diagnostic strategy and recom- mends that each student perform Student Assignments 1-8 (SA1-8) exercises in order to build the foundation needed to proceed to Student Assignment 9 – Engine Performance Fault Diagnosis. Student Assignment 1 SA1 Component identification – BASIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer in general. Student Assignment 2A SA2 Component identification – SPECIFIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 2B SA2 Component identification – DASHBOARD In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 3 SA3 Component identification – SENSORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step three in getting familiar with this trainer and related sensors. Student Assignment 4 SA4 Component identification – ACTUATORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step four in getting familiar with this trainer and related actuators. consulab.com info@consulab.com 8 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 5 SA5 Charging system verification In preparation to diagnosing any engine management issues, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first! Student Assignment 6 In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. SA6 WIRING DIAGRAM PRACTICE Breakout box 1 - Service information and wiring diagram This will require an understanding of reading a wiring diagram Students are asked to identify the following, for each of the PIN #’s: • Wire color (reference wiring diagram) • Function (sensor/component) • Is sensor/component a signal, control, or reference voltage? Student Assignment 7 SA7 EXPECTED VOLTAGES at Break Out Box PIN Panel Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principle of operation for any system in this activity is required. Having completed SA-6 but before proceeding to SA-8 (where the student will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. (Select a few systems to be used that are commonly needed to be understood in industry or will reflect student knowl- edge best) consulab.com info@consulab.com 9 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 8 SA8 MEASURED VOLTAGES at Break Out Box PIN Panel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take and record voltage measurements in the corresponding box of the chart provided. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s: • Key OFF • ACCessory • Key ON / Engine OFF • Key ON / Engine RUN Student Assignment 9 Using all the information gathered in Student Assignments 1-8 and the repair order style chart provided, verify customer concern and document your diagnostic process. Be prepared to defend each step! SA9 Engine Performance Fault Diagnosis For each of these engine performance faults, based on “customer concern”, students will be asked: • Student observation of condition/concern • Explain strategy & tests performed - record test results - and more importantly - explain why? • Explain DTC (if any) • Identify component suspected • Is fault an Input/Output? • 2 TYPES OF FAULTS : - ON / OFF - ADJUSTABLE • NOTE : Multiple faults can be inserted as well as intermittent faults, resulting in almost infinite possibilities See fault box instructional video for more using the following links and QR codes. Links for video part #1 https://www.youtube.com/watch?v=LH7cTzXuja0 Links for video part #2 https://www.youtube.com/watch?v=bgS357skp6c consulab.com info@consulab.com 10 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting • All programmed values are saved in memory after fault box is powered off • No testing / measuring should be made at any component on the engine bench. - Engine harness connections are protected this way. - All measuring should be performed at the breakout box or the DLC with a scan tool • Fault Box software for the electronically programable fault boxes is recommended due to the following advantages: - Ease of fault insertion - Repeat fault consistency - Dependable student experience - Saving of fault scenarios for future use • Repetitive • Consistent • Sharable Our HV-950 Diesel Engine Trainers all vary a little in application so it is recommended to have an advanced student gather these answers to Student Assignments 1-8 for the instructor to have as a guide for future reference. This will ensure the answers are accurate to this particular trainer. consulab.com info@consulab.com 11 HV-950-95 Explanation of recommended student assignment outcomes Explanation of recommended student assignment outcomes Recommended grade weight % Fault example Customer complaint Repair order style activities are recommended in order to start preparing the student for a shop environment. After student becomes familiar with a well written repair order, introduce a poorly written one and ask for examples of why it wastes time, and what additional information does the technician need before proceeding with diagnosis. Role play with one student being the customer and another being the service advisor. Then reverse roles ! Discuss how does this process affect technicians payroll as well as the efficiency / pro- ductivity of a shop ? Student observation 5 % This is an important part of training a technician ! At this stage of learning, the student should be required to document their observation process after first receiving a vehicle to diagnose. (take out the ear buds and pay attention !) Everything from the cosmetic condition of the vehicle upon receiving it for service to the stance of the vehicle, tire wear and pressures, looking for leaks and any existing condi- tions that may or may not affect accurate diagnosis. Teach them to be observant ! Explain strategy & tests performed – record test results and explain why ? 50 % This is the most important part of training a technician! At this stage of learning, the stu- dent should be required to document their diagnostic thought and observation process after receiving a vehicle to diagnose. Each step should have a reason – Why this step, why this test ? Then the order of diagnostic steps should be discussed, corrected if needed, and repeated. A diagnostic style should be developed by each student to use and gain confidence with, eventually moving to a real vehicle using this same strategy. consulab.com info@consulab.com 12 HV-950-95 Explanation of recommended student assignment outcomes Recommended grade weight % Fault example DTC (if any) 5 % While a DTC is an important part of diagnosing, teach your student to understand that a check engine light does not always mean the retrieved DTC will lead straight to the repair. Prove that it is just a direction in which to proceed, just a piece of the diagnostic evidence. When a performance issue exists and there is no MIL, we have to work for the customer. However when a MIL is on, we work for the ECU, PCM, TCM, or whatever controls the light. Component suspected 15 % The identification of a failure or replacement of a component should be thoroughly ex- plained by the student. Encourage at least three testing procedures be tried and docu- mented before any parts are going to be suspected defective. And again, if the suspected part is defective, why after replacement will the complaint be corrected ? And will the new part be damaged after installation ? Did something else cause it to fail ? Input/Output ? 5 % The correct answer here is critical and indicates a deeper level of system understanding. Recommended repair 20 % As instructors, we are challenged to discourage parts changing without an accurate di- agnosis. Whether it is a failed part or a system repair needed, there are multiple learning moments in this discussion. We recommend having small teams diagnose trainer faults and then to come back togeth- er as a class to report out simultaneously to each other with their diagnosis. Let the students then convince each other of the accuracy to their diagnosis. Teach that only an accurate diagnosis counts since this is where their paycheck will come from ! consulab.com info@consulab.com 13 HV-950-95 SA1 Student assignment #1 — Answers SA1 Student assignment #1 — Answers Component identification — Basic (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Component Function Location HV-950 Diesel Engine Application: Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug Oil dipstick Air Filter Fuel Filter(s) Throttle (body) Positive Crankcase Ventilation system consulab.com info@consulab.com 14 HV-950-95 SA1 Student assignment #1 — Answers Component Function Location Batteries Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box - power DLC Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 15 HV-950-95 SA2-A Student assignment #2A — Answers SA2-A Student assignment #2A — Answers Component Identification — Specific (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Engine system Engine specific information HV-950 Diesel Engine Application: VIN & decode Engine type Gasoline Diesel Engine model Engine displacement Numbers of cylinders Cylinder numbering Firing order Direction of engine rotation Compression ratio Aspiration Turbo N/A Supercharged Camshaft configuration OHV SOHC DOHC Turbo type Charge air cooler location & function Fuel system type DEF Fluid reservoir J1939 parameter display unit consulab.com info@consulab.com 16 HV-950-95 SA2-A Student assignment #2A — Answers Engine system Engine specific information Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other technologies : Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 17 HV-950-95 SA2-B Student assignment #2B — Answers SA2-B Student assignment #2B — Answers Component Identification — Dashboard Specific ID (3 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Dash icon & name Description 1. MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. 2. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. 3. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. 4. ENGINE SHUTDOWN Notifies the operator that a serious system error occurred, and protection actions are approaching. When the abnormal operating condition remains and a shutdown condition is met, the engine will shut down in 30 seconds un- less the operator activates the Engine Protection Shutdown Override Switch. 5. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. 6. IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. 7. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. 8. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated sufficiently to start the engine. consulab.com info@consulab.com 18 HV-950-95 SA2-B Student assignment #2B — Answers Dash icon & name Description 9. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. 10. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regen- erate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. 11. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replen- ished. 12. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreatment regeneration. 13. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. Switch Position Function 14. ENGINE RETARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level. 15. CRUISE CONTROL I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. consulab.com info@consulab.com 19 HV-950-95 SA2-B Student assignment #2B — Answers Switch Position Function 16. PTO SYSTEM CONTROL 17. PTO ENGINE SPEED I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. 18. REGENERATION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all re- quired entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. 19. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. 20. SERVICE BRAKE I Applies the service brake. O Releases the service brake 21. CLUTCH I Disengages the clutch. O Engages the clutch 22. FAN OVERRIDE I Forces the radiator fan to operate O Normal operating mode 23. DIAGNOSTIC REQUEST I Activates diagnostic request O Normal operating mode consulab.com info@consulab.com 20 HV-950-95 SA3 Student assignment #3 — Answers SA3 Student assignment #3 — Answers Component Identification — Sensors ID / HD Diesel(2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step three in getting familiar with this trainer and sensors. Using service information fill in each blank with as much information as possible. Sensor Function Location ECM/PCM Connector & Pin #’s EXAMPLE J2 9, 10, 33 Accelerator pedal position 1 Accelerator pedal position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure consulab.com info@consulab.com 21 HV-950-95 SA3 Student assignment #3 — Answers Sensor Function Location ECM/PCM Connector & Pin #’s Exhaust Gas Recirculation (EGR) temp EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel INSERT ANY SENSORS SPECIFIC TO THIS ENGINE consulab.com info@consulab.com 22 HV-950-95 SA4 Student assignment #4 — Answers SA4 Student assignment #4 — Answers Component Identification — Actuator ID/HD Diesel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step four in getting familiar with this trainer and actuators. Using service information fill in each blank with as much information as possible. Actuator Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbo- charger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE consulab.com info@consulab.com 23 HV-950-95 SA5 Student assignment #5 — Answers SA5 Student assignment #5 — Answers Charging System Verification HV-950 Diesel Engine Application: Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accu- rate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceed- ing with diagnosing engine performance issues? consulab.com info@consulab.com 24 HV-950-95 SA6 Student assignment #6 — Answers SA6 Student assignment #6 — Answers HV-950 — Wiring diagram practice — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Example 1 DK BLU 1161 APP sensor 1 signal # RED 1178 Injector 1 (Pin E) return signal consulab.com info@consulab.com 25 HV-950-95 SA6 Student assignment #6 — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 26 HV-950-95 SA6 Student assignment #6 — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 27 HV-950-95 SA6 Student assignment #6 — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 28 HV-950-95 SA7 Student assignment #7 — Answers SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principles of operation for the follow- ing systems is required. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity Example 1 5 V 4.2 V Engine Coolant Sensor consulab.com info@consulab.com 29 HV-950-95 SA7 Student assignment #7 — Answers Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity consulab.com info@consulab.com 30 HV-950-95 SA7 Student assignment #7 — Answers Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity consulab.com info@consulab.com 31 HV-950-95 SA7 Student assignment #7 — Answers Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity consulab.com info@consulab.com 32 HV-950-95 SA8 Student assignment #8 — Answers SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provied below. Compare results to Student Assignment #7 (SA7). Pin wire System / Voltage Key off ACC KOEO KOER Example 1 APP sensor 1 signal 0 V .9V .9V .9V consulab.com info@consulab.com 33 HV-950-95 SA8 Student assignment #8 — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 34 HV-950-95 SA8 Student assignment #8 — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 35 HV-950-95 SA8 Student assignment #8 — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 36 HV-950-95 SA9 Student assignment template SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages) Using all the information gathered in Student Activities 1-8 and the repair order style chart below, verify customer con- cern and document your diagnostic process. Be prepared to defend each step. Create a repair order style concern to fit the fault selected. Details Customer Concern Student Observation Explain Strategy Tests Performed Fault Component Input/Output? consulab.com info@consulab.com 37 HV-950-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. General description Educational Advantages Introduction to the HV-950 Family of Diesel Engine Benches Student Assignments Basic Orientation Thru Advanced And Troubleshooting Explanation of recommended student assignment outcomes SA1 Student assignment #1 — Answers Component identification — Basic (2 pages) SA2-A Student assignment #2A — Answers Component Identification — Specific (2 pages) SA2-B Student assignment #2B — Answers Component Identification — Dashboard Specific ID (3 pages) SA3 Student assignment #3 — Answers Component Identification — Sensors ID / HD Diesel(2 pages) SA4 Student assignment #4 — Answers Component Identification — Actuator ID/HD Diesel SA5 Student assignment #5 — Answers Charging System Verification SA6 Student assignment #6 — Answers HV-950 — Wiring diagram practice — ECU connector (4 pages) SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages)

Student Assignments for HV-950 Diesel Engine Training Bench HV-950-95_V2025-1 © ConsuLab Educatech Inc, 2025. All rights reserved. HV-950-95 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 © ConsuLab Educatech Inc, 2024. 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. Table of Contents General description 3 Educational Advantages 3 Student Assignments Basic Orientation Thru Advanced And Troubleshooting 5 SA1 — Component identification — Basic (2 pages) 8 SA2-A — Component Identification — Specific (2 pages) 10 SA2-B — Component Identification — Dashboard Specific ID (3 pages) 12 SA3 — Component Identification — Sensors ID / HD Diesel(2 pages) 15 SA4 — Component Identification — Actuator ID/HD Diesel 17 SA5 — Charging System Verification 18 SA6 — Wiring diagram practice 19 SA7 — Expected voltages 23 SA8 — Measured voltages 27 SA9 Student assignment template — Engine performance fault diagnosis 31 consulab.com info@consulab.com 3 HV-950-95 General description General description The HV-950 family of diesel engine trainers are fully operational engines mounted on a mobile stand. The trainers are easy to work on and all major components, wiring and connectors match OEM configuration. Each trainer is either a one or two piece construction design depending on the model. Part one is the actual engine mounted on a mobile stand constructed of 2” (5 cm) tubular steel equipped with four 5” (12.5 cm) phenol casters (2-fixed and 2-swivel w/locks), and may or may not include the after-treatment unit on top. For some models part two is the exhaust after-treatment unit that must be properly connected to the engine prior to trainer use. Students can perform many ASE Educational Foundation related Engine Performance and Electrical/Electronic tasks using this trainer. Trainers are equipped with safety guards covering all rotating components. Educational Advantages • Demonstration of major engine systems to groups of students without the access limitations of a complete vehicle. • Engine systems respond to inserted fauts with real world symptoms, OEM DTC’s and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demostration of exhaust after treatment emission system operation if applicable. TWO-PIECE DIESEL ENGINE TRAINER ONE-PIECE DIESEL ENGINE TRAINER consulab.com info@consulab.com 4 HV-950-95 Student Assignments Student Assignments consulab.com info@consulab.com 5 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Basic Orientation Thru Advanced And Troubleshooting ConsuLab realizes the following steps are important in the development of an accurate diagnostic strategy and recom- mends that each student perform Student Assignments 1-8 (SA1-8) exercises in order to build the foundation needed to proceed to Student Assignment 9 – Engine Performance Fault Diagnosis. Student Assignment 1 SA1 Component identification – BASIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer in general. Student Assignment 2A SA2 Component identification – SPECIFIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 2B SA2 Component identification – DASHBOARD In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 3 SA3 Component identification – SENSORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step three in getting familiar with this trainer and related sensors. Student Assignment 4 SA4 Component identification – ACTUATORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step four in getting familiar with this trainer and related actuators. consulab.com info@consulab.com 6 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 5 SA5 Charging system verification In preparation to diagnosing any engine management issues, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first! Student Assignment 6 In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. SA6 WIRING DIAGRAM PRACTICE Breakout box 1 - Service information and wiring diagram This will require an understanding of reading a wiring diagram Students are asked to identify the following, for each of the PIN #’s: • Wire color (reference wiring diagram) • Function (sensor/component) • Is sensor/component a signal, control, or reference voltage? Student Assignment 7 SA7 EXPECTED VOLTAGES at Break Out Box PIN Panel Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principle of operation for any system in this activity is required. Having completed SA-6 but before proceeding to SA-8 (where the student will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. consulab.com info@consulab.com 7 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 8 SA8 MEASURED VOLTAGES at Break Out Box PIN Panel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take and record voltage measurements in the corresponding box of the chart provided. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s: • Key OFF • ACCessory • Key ON / Engine OFF • Key ON / Engine RUN Student Assignment 9 Using all the information gathered in Student Assignments 1-8 and the repair order style chart provided, verify customer concern and document your diagnostic process. Be prepared to defend each step! SA9 Engine Performance Fault Diagnosis For each of these engine performance faults, based on “customer concern”, students will be asked: • Student observation of condition/concern • Explain strategy & tests performed - record test results - and more importantly - explain why? • Explain DTC (if any) • Identify component suspected • Is fault an Input/Output? consulab.com info@consulab.com 8 HV-950-95 SA1 Student assignment #1 SA1 Student assignment #1 Component identification — Basic (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Component Function Location HV-950 Diesel Engine Application: Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug Oil dipstick Air Filter Fuel Filter(s) Throttle (body) Positive Crankcase Ventilation system consulab.com info@consulab.com 9 HV-950-95 SA1 Student assignment #1 Component Function Location Batteries Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box - power DLC Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 10 HV-950-95 SA2-A Student assignment #2A SA2-A Student assignment #2A Component Identification — Specific (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Engine system Engine specific information HV-950 Diesel Engine Application: VIN & decode Engine type Gasoline Diesel Engine model Engine displacement Numbers of cylinders Cylinder numbering Firing order Direction of engine rotation Compression ratio Aspiration Turbo N/A Supercharged Camshaft configuration OHV SOHC DOHC Turbo type Charge air cooler location & function Fuel system type DEF Fluid reservoir J1939 parameter display unit consulab.com info@consulab.com 11 HV-950-95 SA2-A Student assignment #2A Engine system Engine specific information Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other technologies : Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 12 HV-950-95 SA2-B Student assignment #2B SA2-B Student assignment #2B Component Identification — Dashboard Specific ID (3 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Dash icon & name Description 1. 2. 3. 4. 5. 6. 7. 8. consulab.com info@consulab.com 13 HV-950-95 SA2-B Student assignment #2B Dash icon & name Description 9. 10. 11. 12. 13. Switch Position Function 14. I O 1-2-3 15. I O 16. I O consulab.com info@consulab.com 14 HV-950-95 SA2-B Student assignment #2B Switch Position Function 17. AUTO 18. I O 19. I O 20. I O 21. I O 22. I O Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 15 HV-950-95 SA3 Student assignment #3 SA3 Student assignment #3 Component Identification — Sensors ID / HD Diesel(2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step three in getting familiar with this trainer and sensors. Using service information fill in each blank with as much information as possible. Sensor Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Accelerator pedal position 1 Accelerator pedal position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure Exhaust Gas Recirculation (EGR) temp consulab.com info@consulab.com 16 HV-950-95 SA3 Student assignment #3 Sensor Function Location ECM/PCM Connector & Pin #’s EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel INSERT ANY SENSORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 17 HV-950-95 SA4 Student assignment #4 SA4 Student assignment #4 Component Identification — Actuator ID/HD Diesel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step four in getting familiar with this trainer and actuators. Using service information fill in each blank with as much information as possible. Actuator Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbo- charger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 18 HV-950-95 SA5 Student assignment #5 SA5 Student assignment #5 Charging System Verification HV-950 Diesel Engine Application: Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accu- rate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceed- ing with diagnosing engine performance issues? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 19 HV-950-95 SA6 Student assignment #6 SA6 Student assignment #6 HV-950 — Wiring diagram practice — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Example 1 DK BLU 1161 APP sensor 1 signal consulab.com info@consulab.com 20 HV-950-95 SA6 Student assignment #6 Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 21 HV-950-95 SA6 Student assignment #6 Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 22 HV-950-95 SA6 Student assignment #6 Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 23 HV-950-95 SA7 Student assignment #7 SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principles of operation for the follow- ing systems is required. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. Pin wire Key off KOEO KOER Component / Sensor* Example 1 5 V 4.2 V Engine Coolant Sensor consulab.com info@consulab.com 24 HV-950-95 SA7 Student assignment #7 Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 25 HV-950-95 SA7 Student assignment #7 Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 26 HV-950-95 SA7 Student assignment #7 Pin wire Key off KOEO KOER Component / Sensor* Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 27 HV-950-95 SA8 Student assignment #8 SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provied below. Compare results to Student Assignment #7 (SA7). Pin wire System / Voltage Key off ACC KOEO KOER Example 1 APP sensor 1 signal 0 V .9V .9V .9V consulab.com info@consulab.com 28 HV-950-95 SA8 Student assignment #8 Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 29 HV-950-95 SA8 Student assignment #8 Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 30 HV-950-95 SA8 Student assignment #8 Pin wire System / Voltage Key off ACC KOEO KOER Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 31 HV-950-95 SA9 Student assignment template SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages) Using all the information gathered in Student Activities 1-8 and the repair order style chart below, verify customer con- cern and document your diagnostic process. Be prepared to defend each step. Details Customer Concern Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 32 HV-950-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. General description Educational Advantages Student Assignments Basic Orientation Thru Advanced And Troubleshooting SA1 Student assignment #1 Component identification — Basic (2 pages) SA2-A Student assignment #2A Component Identification — Specific (2 pages) SA2-B Student assignment #2B Component Identification — Dashboard Specific ID (3 pages) SA3 Student assignment #3 Component Identification — Sensors ID / HD Diesel(2 pages) SA4 Student assignment #4 Component Identification — Actuator ID/HD Diesel SA5 Student assignment #5 Charging System Verification SA6 Student assignment #6 HV-950 — Wiring diagram practice — ECU connector (4 pages) SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages)

Operation Manual for HV-950-C4.4-TIER4_035153 Diesel engine bench CAT C4.4 TIER4F new 93-HV-950-C4.4-TIER4_REVA © ConsuLab Educatech Inc, 2025. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space https://www.consulab.com/customer-space 93-HV-950-C4.4-TIER4 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 © ConsuLab Educatech Inc, 2026. 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. The content of this manual is applicable to models 035153 and above. Table of Contents Main Features 4 Functional aftertreatment systems 4 Optional equipment 4 Instructions 5 Batteries and Master Disconnect Switch 5 Diesel Tank 5 DEF Storage Tank 5 Exhaust System Warning 6 Diesel Exhaust Particulate Filter Cleaning Warning 6 List of Fuses and Relays 7 Starting 7 Lamp Identification and Function (if available) 8 Switch Identification and Function (if available) 9 EM-250-2 Electronic Programmable Fault Box 10 Fault Box Electrical Schematic 15 Emergency Stop Electric Schematic 16 Intelligent Battery Charger Instructions 17 consulab.com info@consulab.com 4 93-HV-950-C4.4-TIER4 Main Features Main Features • New OEM In-line 4-cylinder, 4-stroke cycle diesel engine • Mounting frame • Radiator • OEM Air intake system with turbocharger and air filter • Complete OEM engine cooling system with fan, air-to-air, radiator, and fuel system • Exhaust system with SCR and DOC maintenance indicators and muffler • Engine lubrication system with filters • OEM Engine harness • Murphy PV-101 featuring a customized setup and display feature for data available on the diesel engine bench • Accelerator pedal • OEM electronic control module • DLC Data Link Connector • Custom tubular steel stands with casters • 5 gallon (19L) fuel tank • DEF storage tank • Emergency stop switch (2) • Master battery disconnect switch • 12V batteries (2) w/intelligent battery charger • Breakout box • Electronic programmable fault box Functional aftertreatment systems • EGR – Exhaust Gas Recirculation system • DOC – Diesel Oxidation Catalyst • PTO – Power Take-off • SCR – Selective Catalytic Reduction) Optional equipment • Dust cover • Load Bank consulab.com info@consulab.com 5 93-HV-950-C4.4-TIER4 Instructions Instructions This section of the manual provides instructions to follow when preparing and starting your diesel engine for demonstra- tion or maintenance purposes. We recommend that students wear protective eyewear at all times. Batteries and Master Disconnect Switch The batteries must always be connected while operating the trainer. ECM and DEF supply module power must be main- tained for 70 seconds after key off for all applications, even for those applications where the ECM is powered through a battery disconnect. BATTERIES MASTER DISCONNECT SWITCH Diesel Tank Fill the tank with clean ultra-low sulfur diesel fuel before starting the engine. All diesel engine benches equipped with an aftertreatment system require the use of 15 PPM maximum, ultra-low sulfur diesel fuel. DO NOT use 500 PPM low sulfur diesel in this engine. This tank is equipped with a fuel level sensor. DIESEL TANK DEF Storage Tank Fill the tank with clean, fresh, Caterpillar recommended, DEF. DEF TANK consulab.com info@consulab.com 6 93-HV-950-C4.4-TIER4 Exhaust System Warning Exhaust System Warning When running an engine bench in an indoor environment, use an exhaust removal system to prevent inhalation of dan- gerous gases. Diesel Exhaust Particulate Filter Cleaning Warning Exhaust outlet temperature can exceed 300°C (572°F) during this procedure. To help prevent personal injury or proper- ty damage from fire or burns, ensure the following: • Do not connect any shop exhaust removal hoses to the tailpipe during the regenerative process. We suggest that the regeneration mode be conducted with the trainer placed outside. • Move the trainer outdoors and set up a safe area. Confirm that nothing is on or near the exhaust system surfaces, keep all combustible material away during this procedure. • Do not leave the trainer unattended. • Due to the elevated engine temperatures created while performing this procedure it is imperative to ensure proper airflow across the radiator by keeping all obstructions clear. Aftertreatment Features Regeneration: The DOC/SCR modular design offers a simple, compact package while providing high levels of perfor- mance. A DOC/DPF/SCR option is available for higher power machines. While in use, both DOC/SCR an DOC/DPF/SCR systems offer transparent operation to the user. Mounting: Extensive range of inlets and outlets, as well as remote and on-engine installations, provide flexibility for many installations. Service: Both DOC/SCR an DOC/DPF/SCR systems are service-free for the emissions life of the engine. Available in 12V or 24V systems. Exhaust aftertreatment unit integrated to the diesel training bench consulab.com info@consulab.com 7 93-HV-950-C4.4-TIER4 List of Fuses and Relays & Starting List of Fuses and Relays Starting 1. Turn the master disconnect switch to the ON position. 2. Start up the engine using the ignition key switch on the instrument panel. 3. On startup closely monitor the screen display oil pressure screen for proper pressure. Shut down the engine imme- diately if low pressure is observed. Example of HV-950-C4.4 dash Fuse # AMP Protected component F1 25 A Unswitched Battery Fuse F2 15 A ELP Supply Fuse F3 10 A Key Switch Fuse F4 5 A Ignition Power Fuse F5 5 A Screen Display Fuse F6 5 A DLC Fuse F7 5 A Fault Box Fuse F8 30 A XNOx Suppy Fuse R1 ELP Relay R2 Fault Box Relay R3 XNOx Power Relay consulab.com info@consulab.com 8 93-HV-950-C4.4-TIER4 Lamp Identification and Function (if available) Lamp Identification and Function (if available) Symbol Lamp Name Function MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. ENGINE SHUTDOWN Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated suffi- ciently to start the engine. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regenerate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replenished. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreat- ment regeneration. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. consulab.com info@consulab.com 9 93-HV-950-C4.4-TIER4 Switch Identification and Function (if available) Switch Identification and Function (if available) Switch Position Function ENGINE RETARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level CRUISE CONTROL (left switch) CRUISE CONTROL (Right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. PTO SYSTEM CONTROL (left switch) PTO ENGINE SPEED (Right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. REGENERATION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all required entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. SERVICE BRAKE I Applies the service brake. O Releases the service brake CLUTCH I Disengages the clutch. O Engages the clutch consulab.com info@consulab.com 10 93-HV-950-C4.4-TIER4 EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 2 EM-250-2-96_V2023-1 Electronic Programmable Fault Box EM-250-2 Electronic Programmable Fault Box Explanatory video : Link to video part 1 https://youtu.be/LH7cTzXuja0 Link to video part 2 https://youtu.be/bgS357skp6c EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 11 93-HV-950-C4.4-TIER4 EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 3 EM-250-2-96_V2023-1 General description General description The EM-250-2 is an electronic programmable fault box designed for any ConsuLab standard or custom engine training benches. Operation guide for the EM-250-2 In addition to manual fault insertion capabilities, the EM-250-2 fault box also permits the user to insert all faults remote- ly through software provided, to be installed on your Windows based computer and connected to the EM-250-2 fault box with a USB cable provided. The EM-250-2 fault box provides for two types of fault circuits : Simulated Signal Fault Circuit • Any simulated signal that is inserted in a circuit will be reflected in scan tool data, engine operational symptoms as well as any measurements made at the break-out box on the trainer. • Depending on which engine bench you have, the EM-250-2 is capable of simulating various input signals such as : - Variable voltage or current - Pulse width modulation - Variable frequency - Voltage drops - Open circuit Open/Closed Fault Circuit • Any simple open that is inserted in a circuit that will be reflected in scan tool data, engine operational symptoms as well as any measurements made at the break-out box on the trainer ALL faults are inserted between the engine and PCM, so all testing HAS TO BE PERFORMED at break out box and with a scan tool. No testing or disconnecting should be done at the component location. Note: Simulation is only possible when a given sensor is installed on your engine and ConsuLab has preprogrammed the related fault in. All the fault names and fault box models mentioned in this guide may not refer to your specific EM-250-2 fault box. consulab.com info@consulab.com 12 93-HV-950-C4.4-TIER4 EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 4 EM-250-2-96_V2023-1 Operating instructions Operating instructions Power Pressing this button starts and stops the fault box and can be used from any displayed menu. When you set up one or multiple faults, a data log is saved in the internal flash memory only after the fault box has been powered off. The saving procedure is automatically started upon shutdown. The faults will remain when the fault box is powered back on 1. ESC The back-up key. It backs you up one menu display screen per push of the button. ENT Pressing the ENT button confirms and sets any desired function that is flashing. NOTE : Flashing text is ALWAYS the one selected when the ENT button is pushed. Left arrow The left arrow key can be used for selecting which menu flashes or to decrease various signal values once the > > cursor appears next to that value. Right arrow The right arrow key can be used for selecting which menu flashes or to increase various signal values once the > > cursor appears next to that value. 1. We strongly recommend only operating the fault box with the supplied battery charger plugged in for consistent results. consulab.com info@consulab.com 13 93-HV-950-C4.4-TIER4 EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 5 EM-250-2-96_V2023-1 Quick guide to fast and simple operation Quick guide to fast and simple operation A. Turn on/off Press Qté: - REV:A DESCRIPTION: # DE PIÈCE: OUIBiseaux: Aimants NON 40008-01 ID. Façade, Bte Fautes EM-250-2C MATÉRIEL: Gravoply 1/16" gravé BlancNNOOIIRR XXNNOONN OUI X 8 ,2 7 " 9,40" and wait until the red light is flashing. B. Select manual or intermittent mode Arrow left or right and press ENT when MANUAL is flashing. Arrow left or right and press ENT when INTERMITTENT is flashing (see H below for details on intermittent fault insertion) C. Choose a system/sensor to fault Arrow left or right and press ENT when your choice is flashing. D. Adjusting simulated fault values Arrow left or right and press ENT when % is flashing. Flashing cursor (> > ) indicates value can now be adjusted. Arrow left or right to adjust %, then press ESC when finished. ** Don’t let the % confuse ! It is just a percentage of the original reference voltage. Keep it simple and adjust values while comparing it to a scan tool that reads the actual values the PCM will see. E. Activating the fault Pushing ESC after simulated value is set will return you to screen with NORMAL flashing, press ENT. Arrow left or right to allow change from NORMAL to FAULT. NOTE : The GREEN light next to the fault description will turn RED when FAULT is active. Press ESC and fault is set. F. Inserting OPEN faults There are only two choices with an OPEN fault. Arrow left or right to allow NORMAL or FAULT to flash, then press ENT to select. FAULT will be active when light turns RED. G. Inserting multiple faults The EM-250-2 has the capability of inserting multiple faults at once. Once one fault is inserted, push ESC and select another, follow the same procedure to activate and then push ESC. The more faults, the more red lights are illuminated. consulab.com info@consulab.com 14 93-HV-950-C4.4-TIER4 EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 6 EM-250-2-96_V2023-1 Quick guide to fast and simple operation H. Inserting intermittent faults At the opening menu, arrow right to allow INTERMITTENT to flash, press ENT. Arrow right or left to select sensor or system you want to insert an intermittent fault in, then press ENT. Four lines of information are now visible : 1. First line reminds us of the type of fault and system. 2. Second line is STATE : - This tells us the state of the fault, if the fault is ON or OFF. 3. Third line is DUTY : - Expressed as a % of the TIME chosen that the fault actually occurs. ‣ Example: an open injector that remains open for 50% (1.5 min) of the chosen 3.0 minute, 0 second time frame. 4. Fourth line is TIME: - This is the total window of time you choose for an intermittent fault to occur. - You choose what % of that window of time is actually a faulted condition (above on the Third line). I. Saving faults When you set up one or multiple faults, a data log is saved in the internal flash memory only after the fault box has been powered off. - The saving procedure is automatically started upon shutdown. The faults will remain when the fault box is powered back on. consulab.com info@consulab.com 15 93-HV-950-C4.4-TIER4 Fault Box Electrical Schematic Fault Box Electrical Schematic B OB UC E J2-50 J2-50 F1 R OS NE S T CE BLU SIM 0-5V PIN 1 J2-62 J2-62 F2 R OS NE S TA MI BLU SIM 0-5V PIN 1 J2-54 J2-54 F3 R OS NE S PA MI PN K SIM 0-5V PIN 3 J2-53 J2-53 F4 R OS NE S P OE G R Y SIM 0-5V PIN 3 J2-45 J2-45 F5 R OS NE S PB G R Y SIM 0-5V PIN 3 V2 1 J2-76 F6 J2-76 PN K 8630 R LY 8587a PIN 2 J1-69 J1-69 F7 A5 4F BLK J2-27 J2-27 F8 R OS NE S PK C BLU PIN 2 J1-80 J1-80 F10 R OS NE S PT BLK PIN C D C U -35 D C U -35 F11 W H T D C U -18 D C U -18 F12 R OS NE S T R CS W H T PIN 2 2# R OT CE J NI J2-28 J2-28 F9 R OS NE S P M C BR N PIN 2 R OS NE S T C O D PIN 2 D C U Fault box R EV. D ESC R IPTIO N D ATE BY D R AW N BY: C H EC KED BY: D ATE: - - - - - - - - - --- AR ISTID E N . ALEXAN D R E L. 2019-09-24 #H V -950-C4.4-TIER4_035153 #H V -950-C4.4-TIER4 FA U LT BO X ELECTRICA L SCH EM A TIC V 0 © C onsuLab Educatech 2020 all rights reserved consulab.com info@consulab.com 16 93-HV-950-C4.4-TIER4 Emergency Stop Electric Schematic Emergency Stop Electric Schematic 1 2 3 42 1 EM ER G EN C Y STO P LIG H T EM ER G EN C Y R ELAY EM ER G EN C Y STO P FLYW H EEL BATTER IES 21138 STAR TER R ELAY FU SE BO X D ASH BLK W H T G R N R ED O R G LO C K A C C O N STA R T DT06-12S DT04-12P 112 112 D EU TSC H 6 PIN S DT06-12S DT04-12P 5 D EU TSC H 12 PIN S 70 W AY C U STO M ER IN TER FAC E C O N N EC TO R 4157 W B R O1 2 3 41 2 EM ER G EN C Y STO P EN G IN E R AD IATEU R BLK W H T G R N R ED W B R O O R G W H T G R N R ED W H T G R N O R G O R G BLK 48 3 291011 548 3 291011 BLK G R N R ED O R G BLK R ED G R N R ED R ED G R N R ED R ED O R G R ED R ED R ED R ED R ED F1 25A F3 10A R EV. D ESC R IPTIO N D ATE BY D R AW N BY: C H EC KED BY: D ATE: N O ÉM IE AN C TIL ALEXAN D R E L. 2021-03-15 H V -950-C4.4-TIER4_035153 H V -950-C4.4-TIER4_035153 EM ERG EN CY STO P ELECTRICA L SCH EM A TIC V 2 © C onsuLab Educatech 2020 all rights reserved consulab.com info@consulab.com 17 93-HV-950-C4.4-TIER4 Intelligent Battery Charger Instructions Intelligent Battery Charger Instructions OPERATION MANUAL HV-950-X15-93 CONSULAB.COM 21 INTELLIGENT BATTERY CHARGER INSTRUCTIONS Visiter le site de OPTIMATE pour télécharger le manuel de l'utilisateur : https://static1.squarespace.com/static/58ee35f3e6f2e1f4c4896f44/t/5a7b12734192028e230a2c74/ 1518015093415/TM194_OptiMate6_12-24V.pdf 6 USING THE OPTIMATE 6 VERY FLAT NEGLECTED BATTERIES: If the battery is deeply discharged (and possibly sulfated), remove from the vehicle or equipment and inspect the battery before connecting the charger for a recovery attempt. The charger’s TURBO recovery mode cannot engage if it senses that the battery is still connected to a circuit which effectively offers a lower electrical resistance than the battery on its own. However, if the deep-discharged battery is not removed for recovery, neither battery nor vehicle or equipment electronics will be damaged. Pay particularly close attention to the following A battery left deep-discharged for an extended period may develop permanent damage in one or more cells. Such batteries may heat up excessively during high current charging. Monitor the battery temperature during the first hour, then hourly there-after. Check for unusual signs, such as bubbling or leaking electrolyte, heightened activity in one cell compared to others, or hissing sounds. If at any time the battery is uncomfortably hot to touch or you notice any unusual signs, DISCONNECT THE CHARGER IMMEDIATELY. CHARGING TIME Charge time on a flat but otherwise undamaged battery is slightly less than 25% of the battery’s Ah rating, so a 100Ah battery should take no more than about 25 hours to progress to the self-discharge check (§ 5). Deep-discharged batteries may take significantly longer. If using the OptiMate 6 on a severely discharged battery of larger than 240Ah capacity, a full charge may not be achieved within the 72 hour charge safety limit. In this case follow the reset procedure below. RESETTING THE CHARGE & TEST CYCLE Disconnect from the AC mains. Wait for the POWER ON LED #1 to go out. Upon reconnection to AC power LEDs #6, 7 and 8 will flash twice to confirm micro processor health, irrespective if the charger remains connected to a battery or not. ECO POWER SAVING MODE WHEN THE CHARGER IS CONNECTED TO AC SUPPLY: The power converter switches to ECO mode when the charger is not connected to a battery resulting in a very low power draw of less than 1.7W, equivalent to power consumption of 0.042 kWh per day. When a battery is connected to the charger power consumption depends on the current demand of the battery and its connected vehicle / electronic circuitry. After the battery has been charged and the charger is in long term maintenance charge mode (to keep the battery at 100% charge) the total power consumption is estimated to be 0.060 kWh or less per day. PROCEEDING TO CHARGE The LED indicators below are sequenced as they may come on through the course of the program. 2 1 AC:100-240V REVERSE POLARITY 7 6 6 5 5 TEST MAINTAIN AMPS 5A max. 1A - 4A ampmatic 0.2 - 1A 10 9 OPTIMIZE CHARGESAVE LED MODE - - - - 4 4 3 3 TURBO SAVE 8 POWER ON: LED #1 - Confirms AC power supply to the charger. HIGH and LOW intensity indication: The"POWER ON" LED #1 will indicate brightly when current is delivered to the battery. The "POWER ON" LED #1 will reduce intensity to a low level to indicate low power "ECO" mode. This will occur if there is no battery connected, or when a battery is connected and the program finds itself in the voltage retention test mode or the 'rest' periods of Maintenance Charge mode. REVERSE POLARITY PROTECTION: LED #2 - Lights when the battery connections are incorrect. The charger is electronically protected so no damage will result, and the output will remain disabled until the connections are corrected. CHARGE CURRENT BAR: LED #8, 9, 10 - Lights when pulsed or continuous current is delivered to the battery. Current level indications: LED #8: 0.4A minimum current. LED#8 and 9: 0.4A - 4.5A The ampmatic™ charge current program automatically determines the most efficient rate of charge current for the connected battery. LED #8, 9 and 10: 5A maximum current. consulab.com info@consulab.com 18 93-HV-950-C4.4-TIER4 Notes Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. Tous droits réservés. Main Features Functional aftertreatment systems Optional equipment Instructions Batteries and Master Disconnect Switch Diesel Tank DEF Storage Tank Exhaust System Warning Diesel Exhaust Particulate Filter Cleaning Warning List of Fuses and Relays Starting Lamp Identification and Function (if available) Lamp Identification and Function (if available) EM-250-2 Electronic Programmable Fault Box Fault Box Electrical Schematic Emergency Stop Electric Schematic Intelligent Battery Charger Instructions

Instructors Manual for HV-950 Diesel Engine Training Bench HV-950-96_V2025-1 © ConsuLab Educatech Inc, 2025. All rights reserved. HV-950-96 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 2 © 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. Printed in Canada. Table of Contents General description 3 Educational Advantages 3 Introduction to the HV-950 Family of Diesel Engine Benches 4 Student Assignments Basic Orientation Thru Advanced And Troubleshooting 7 Explanation of recommended student assignment outcomes 11 SA1 — Component identification — Basic — Answers 13 SA2-A — Component Identification — Specific — Answers 15 SA2-B — Component Identification — Dashboard Specific ID — Answers 17 SA3 — Component Identification — Sensors ID / HD Diesel — Answers 20 SA4 — Component Identification — Actuator ID/HD Diesel — Answers 22 SA5 — Charging System Verification— Answers 23 SA6 — Wiring diagram practice — Answers 24 SA7 — Expected voltages — Answers 28 SA8 — Measured voltages — Answers 32 SA9 — Engine performance fault diagnosis — Answers Template 36 consulab.com info@consulab.com 3 HV-950-95 General description General description The HV-950 family of diesel engine trainers are fully operational engines mounted on a mobile stand. The trainers are easy to work on and all major components, wiring and connectors match OEM configuration. Each trainer is either a one or two piece construction design depending on the model. Part one is the actual engine mounted on a mobile stand constructed of 2” (5 cm) tubular steel equipped with four 5” (12.5 cm) phenol casters (2-fixed and 2-swivel w/locks), and may or may not include the after-treatment unit on top. For some models part two is the exhaust after-treatment unit that must be properly connected to the engine prior to trainer use. Students can perform many ASE Educational Foundation related Engine Performance and Electrical/Electronic tasks using this trainer. Trainers are equipped with safety guards covering all rotating components. Educational Advantages • Demonstration of major engine systems to groups of students without the access limitations of a complete vehicle. • Engine systems respond to inserted fauts with real world symptoms, OEM DTC’s and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demostration of exhaust after treatment emission system operation if applicable. TWO-PIECE DIESEL ENGINE TRAINER ONE-PIECE DIESEL ENGINE TRAINER consulab.com info@consulab.com 4 HV-950-95 Introduction to the HV-950 Family of Diesel Engine Benches Introduction to the HV-950 Family of Diesel Engine Benches ConsuLab understands that today’s classroom has changed and we want to encourage the transition from an instructor just dispensing information to one who is a facilitator of actual learning. Today’s automotive instructor is ultimately re- sponsible to provide a learning environment that encourages student led learning. We want to help! The following is our recommendation for integrating our HV-950 Engine bench trainer with fault box into your program. Recommended ways to introduce the ConsuLab HV-950 engine bench to students: • Explain the key and security system (all VIN specific): - Encourage students to not drop or lose key. • Show location of the engine bench batteries and master disconnect switch: - The batteries must always be connected while operating the trainer. - Recommended to wait 10 minutes after engine shut down before opening this switch: - ECM and DEF supply module power must be maintained for a minimum 10 minutes after key off for all applica- tions, even for those applications where the ECM is powered through a battery disconnect device. - Switch should remain open when stored or not in use. - Explain the 12-volt test points by ignition switch - NEVER power up anything off of this test point! - Student Assignment 5 (SA5) covers charging system operation and inspection • Show location of the battery charger: - Demonstrate correct operation. - Explain that the best engine bench test results are achieved with this plugged in during use as well as just for bat- tery maintenance: - If the battery voltage drops below 12V it could affect the fault box’s ability to retain a fault and the fault could clear itself. • Discuss proper exhaust safety: - Connection and coupling of the exhaust after-treatment unit - Do not run this inside closed area, ALWAYS use exhaust hoses: - Carbon monoxide is a colorless, odorless deadly gas. - NEVER perform a re-gen process inside of the shop, move trainer outside. • Have students demonstrate the correct connection of exhaust hose and battery charger consulab.com info@consulab.com 5 HV-950-95 Introduction to the HV-950 Family of Diesel Engine Benches • Show the location of the diesel fuel cell: - Explain that the fuel pickup is not on the bottom of the tank and the fuel gauge has to read something in the tank for the engine to start. - Explain complete evaporative emission system testing can be performed. • Show location of the DEF tank. • Show and discuss dash board controls, warnings and indicators: - Some benches have a Student Assignment for this. (SA2-B) • Show location of the CAN plus 600 with explanation. • Show location of the breakout box and explain what is a breakout box: - Explain terminology for ECU labeling. - When using faults with variable signals, the students must use either the scan tool or breakout box for their diag- nostic measurements. Do not allow students to back-probe or measure at the faulted sensor as there will be false readings. When a fault with a variable value is selected, the “real” sensor signal is still present at the sensor. - When using open circuit faults students may back-probe or measure at the sensor as required. - Explain that the breakout box pin #’s match factory service info. - Explain that some pins are not used for trainer purposes • Demonstrate safety! - Explain that this is an expensive piece of equipment and to respect it! - Safety glasses required to operate this equipment every time. - Demonstrate emergency kill switch: - NOTE: sometimes the emergency switch can be “disturbed” and result in a crank / no start condition. If there is ever a no start situation ALWAYS push and release the emergency STOP button and try again to start it up. - No ear buds – complete attention is required when working with this trainer! • Start up engine and demonstrate “know good” performance. • Review sensors and actuators on this engine: - Have students discover and discuss operation – see SA 1,2,3,4. • Turn off engine, and review procedure for end of day storage: - Remove key and store correctly. - Battery quick-disconnect after 10 minutes. - Install optional vinyl cover after engine cool down. consulab.com info@consulab.com 6 HV-950-95 Student Assignments Student Assignments consulab.com info@consulab.com 7 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Basic Orientation Thru Advanced And Troubleshooting ConsuLab realizes the following steps are important in the development of an accurate diagnostic strategy and recom- mends that each student perform Student Assignments 1-8 (SA1-8) exercises in order to build the foundation needed to proceed to Student Assignment 9 – Engine Performance Fault Diagnosis. Student Assignment 1 SA1 Component identification – BASIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer in general. Student Assignment 2A SA2 Component identification – SPECIFIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 2B SA2 Component identification – DASHBOARD In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 3 SA3 Component identification – SENSORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step three in getting familiar with this trainer and related sensors. Student Assignment 4 SA4 Component identification – ACTUATORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step four in getting familiar with this trainer and related actuators. consulab.com info@consulab.com 8 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 5 SA5 Charging system verification In preparation to diagnosing any engine management issues, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first! Student Assignment 6 In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. SA6 WIRING DIAGRAM PRACTICE Breakout box 1 - Service information and wiring diagram This will require an understanding of reading a wiring diagram Students are asked to identify the following, for each of the PIN #’s: • Wire color (reference wiring diagram) • Function (sensor/component) • Is sensor/component a signal, control, or reference voltage? Student Assignment 7 SA7 EXPECTED VOLTAGES at Break Out Box PIN Panel Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principle of operation for any system in this activity is required. Having completed SA-6 but before proceeding to SA-8 (where the student will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. (Select a few systems to be used that are commonly needed to be understood in industry or will reflect student knowl- edge best) consulab.com info@consulab.com 9 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 8 SA8 MEASURED VOLTAGES at Break Out Box PIN Panel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take and record voltage measurements in the corresponding box of the chart provided. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s: • Key OFF • ACCessory • Key ON / Engine OFF • Key ON / Engine RUN Student Assignment 9 Using all the information gathered in Student Assignments 1-8 and the repair order style chart provided, verify customer concern and document your diagnostic process. Be prepared to defend each step! SA9 Engine Performance Fault Diagnosis For each of these engine performance faults, based on “customer concern”, students will be asked: • Student observation of condition/concern • Explain strategy & tests performed - record test results - and more importantly - explain why? • Explain DTC (if any) • Identify component suspected • Is fault an Input/Output? • 2 TYPES OF FAULTS : - ON / OFF - ADJUSTABLE • NOTE : Multiple faults can be inserted as well as intermittent faults, resulting in almost infinite possibilities See fault box instructional video for more using the following links and QR codes. Links for video part #1 https://www.youtube.com/watch?v=LH7cTzXuja0 Links for video part #2 https://www.youtube.com/watch?v=bgS357skp6c consulab.com info@consulab.com 10 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting • All programmed values are saved in memory after fault box is powered off • No testing / measuring should be made at any component on the engine bench. - Engine harness connections are protected this way. - All measuring should be performed at the breakout box or the DLC with a scan tool • Fault Box software for the electronically programable fault boxes is recommended due to the following advantages: - Ease of fault insertion - Repeat fault consistency - Dependable student experience - Saving of fault scenarios for future use • Repetitive • Consistent • Sharable Our HV-950 Diesel Engine Trainers all vary a little in application so it is recommended to have an advanced student gather these answers to Student Assignments 1-8 for the instructor to have as a guide for future reference. This will ensure the answers are accurate to this particular trainer. consulab.com info@consulab.com 11 HV-950-95 Explanation of recommended student assignment outcomes Explanation of recommended student assignment outcomes Recommended grade weight % Fault example Customer complaint Repair order style activities are recommended in order to start preparing the student for a shop environment. After student becomes familiar with a well written repair order, introduce a poorly written one and ask for examples of why it wastes time, and what additional information does the technician need before proceeding with diagnosis. Role play with one student being the customer and another being the service advisor. Then reverse roles ! Discuss how does this process affect technicians payroll as well as the efficiency / pro- ductivity of a shop ? Student observation 5 % This is an important part of training a technician ! At this stage of learning, the student should be required to document their observation process after first receiving a vehicle to diagnose. (take out the ear buds and pay attention !) Everything from the cosmetic condition of the vehicle upon receiving it for service to the stance of the vehicle, tire wear and pressures, looking for leaks and any existing condi- tions that may or may not affect accurate diagnosis. Teach them to be observant ! Explain strategy & tests performed – record test results and explain why ? 50 % This is the most important part of training a technician! At this stage of learning, the stu- dent should be required to document their diagnostic thought and observation process after receiving a vehicle to diagnose. Each step should have a reason – Why this step, why this test ? Then the order of diagnostic steps should be discussed, corrected if needed, and repeated. A diagnostic style should be developed by each student to use and gain confidence with, eventually moving to a real vehicle using this same strategy. consulab.com info@consulab.com 12 HV-950-95 Explanation of recommended student assignment outcomes Recommended grade weight % Fault example DTC (if any) 5 % While a DTC is an important part of diagnosing, teach your student to understand that a check engine light does not always mean the retrieved DTC will lead straight to the repair. Prove that it is just a direction in which to proceed, just a piece of the diagnostic evidence. When a performance issue exists and there is no MIL, we have to work for the customer. However when a MIL is on, we work for the ECU, PCM, TCM, or whatever controls the light. Component suspected 15 % The identification of a failure or replacement of a component should be thoroughly ex- plained by the student. Encourage at least three testing procedures be tried and docu- mented before any parts are going to be suspected defective. And again, if the suspected part is defective, why after replacement will the complaint be corrected ? And will the new part be damaged after installation ? Did something else cause it to fail ? Input/Output ? 5 % The correct answer here is critical and indicates a deeper level of system understanding. Recommended repair 20 % As instructors, we are challenged to discourage parts changing without an accurate di- agnosis. Whether it is a failed part or a system repair needed, there are multiple learning moments in this discussion. We recommend having small teams diagnose trainer faults and then to come back togeth- er as a class to report out simultaneously to each other with their diagnosis. Let the students then convince each other of the accuracy to their diagnosis. Teach that only an accurate diagnosis counts since this is where their paycheck will come from ! consulab.com info@consulab.com 13 HV-950-95 SA1 Student assignment #1 — Answers SA1 Student assignment #1 — Answers Component identification — Basic (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Component Function Location HV-950 Diesel Engine Application: Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug Oil dipstick Air Filter Fuel Filter(s) Throttle (body) Positive Crankcase Ventilation system consulab.com info@consulab.com 14 HV-950-95 SA1 Student assignment #1 — Answers Component Function Location Batteries Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box - power DLC Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 15 HV-950-95 SA2-A Student assignment #2A — Answers SA2-A Student assignment #2A — Answers Component Identification — Specific (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Engine system Engine specific information HV-950 Diesel Engine Application: VIN & decode Engine type Gasoline Diesel Engine model Engine displacement Numbers of cylinders Cylinder numbering Firing order Direction of engine rotation Compression ratio Aspiration Turbo N/A Supercharged Camshaft configuration OHV SOHC DOHC Turbo type Charge air cooler location & function Fuel system type DEF Fluid reservoir J1939 parameter display unit consulab.com info@consulab.com 16 HV-950-95 SA2-A Student assignment #2A — Answers Engine system Engine specific information Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other technologies : Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 17 HV-950-95 SA2-B Student assignment #2B — Answers SA2-B Student assignment #2B — Answers Component Identification — Dashboard Specific ID (3 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Dash icon & name Description 1. MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. 2. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. 3. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. 4. ENGINE SHUTDOWN Notifies the operator that a serious system error occurred, and protection actions are approaching. When the abnormal operating condition remains and a shutdown condition is met, the engine will shut down in 30 seconds un- less the operator activates the Engine Protection Shutdown Override Switch. 5. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. 6. IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. 7. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. 8. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated sufficiently to start the engine. consulab.com info@consulab.com 18 HV-950-95 SA2-B Student assignment #2B — Answers Dash icon & name Description 9. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. 10. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regen- erate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. 11. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replen- ished. 12. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreatment regeneration. 13. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. Switch Position Function 14. ENGINE RETARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level. 15. CRUISE CONTROL I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. consulab.com info@consulab.com 19 HV-950-95 SA2-B Student assignment #2B — Answers Switch Position Function 16. PTO SYSTEM CONTROL 17. PTO ENGINE SPEED I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. 18. REGENERATION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all re- quired entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. 19. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. 20. SERVICE BRAKE I Applies the service brake. O Releases the service brake 21. CLUTCH I Disengages the clutch. O Engages the clutch 22. FAN OVERRIDE I Forces the radiator fan to operate O Normal operating mode 23. DIAGNOSTIC REQUEST I Activates diagnostic request O Normal operating mode consulab.com info@consulab.com 20 HV-950-95 SA3 Student assignment #3 — Answers SA3 Student assignment #3 — Answers Component Identification — Sensors ID / HD Diesel(2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step three in getting familiar with this trainer and sensors. Using service information fill in each blank with as much information as possible. Sensor Function Location ECM/PCM Connector & Pin #’s EXAMPLE J2 9, 10, 33 Accelerator pedal position 1 Accelerator pedal position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure consulab.com info@consulab.com 21 HV-950-95 SA3 Student assignment #3 — Answers Sensor Function Location ECM/PCM Connector & Pin #’s Exhaust Gas Recirculation (EGR) temp EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel INSERT ANY SENSORS SPECIFIC TO THIS ENGINE consulab.com info@consulab.com 22 HV-950-95 SA4 Student assignment #4 — Answers SA4 Student assignment #4 — Answers Component Identification — Actuator ID/HD Diesel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step four in getting familiar with this trainer and actuators. Using service information fill in each blank with as much information as possible. Actuator Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbo- charger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE consulab.com info@consulab.com 23 HV-950-95 SA5 Student assignment #5 — Answers SA5 Student assignment #5 — Answers Charging System Verification HV-950 Diesel Engine Application: Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accu- rate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceed- ing with diagnosing engine performance issues? consulab.com info@consulab.com 24 HV-950-95 SA6 Student assignment #6 — Answers SA6 Student assignment #6 — Answers HV-950 — Wiring diagram practice — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Example 1 DK BLU 1161 APP sensor 1 signal # RED 1178 Injector 1 (Pin E) return signal consulab.com info@consulab.com 25 HV-950-95 SA6 Student assignment #6 — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 26 HV-950-95 SA6 Student assignment #6 — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 27 HV-950-95 SA6 Student assignment #6 — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 28 HV-950-95 SA7 Student assignment #7 — Answers SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principles of operation for the follow- ing systems is required. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity Example 1 5 V 4.2 V Engine Coolant Sensor consulab.com info@consulab.com 29 HV-950-95 SA7 Student assignment #7 — Answers Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity consulab.com info@consulab.com 30 HV-950-95 SA7 Student assignment #7 — Answers Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity consulab.com info@consulab.com 31 HV-950-95 SA7 Student assignment #7 — Answers Pin wire Key off KOEO KOER Component / Sensor* *select certain circuits and systems with the maximum learning opportunity consulab.com info@consulab.com 32 HV-950-95 SA8 Student assignment #8 — Answers SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provied below. Compare results to Student Assignment #7 (SA7). Pin wire System / Voltage Key off ACC KOEO KOER Example 1 APP sensor 1 signal 0 V .9V .9V .9V consulab.com info@consulab.com 33 HV-950-95 SA8 Student assignment #8 — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 34 HV-950-95 SA8 Student assignment #8 — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 35 HV-950-95 SA8 Student assignment #8 — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 36 HV-950-95 SA9 Student assignment template SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages) Using all the information gathered in Student Activities 1-8 and the repair order style chart below, verify customer con- cern and document your diagnostic process. Be prepared to defend each step. Create a repair order style concern to fit the fault selected. Details Customer Concern Student Observation Explain Strategy Tests Performed Fault Component Input/Output? consulab.com info@consulab.com 37 HV-950-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. General description Educational Advantages Introduction to the HV-950 Family of Diesel Engine Benches Student Assignments Basic Orientation Thru Advanced And Troubleshooting Explanation of recommended student assignment outcomes SA1 Student assignment #1 — Answers Component identification — Basic (2 pages) SA2-A Student assignment #2A — Answers Component Identification — Specific (2 pages) SA2-B Student assignment #2B — Answers Component Identification — Dashboard Specific ID (3 pages) SA3 Student assignment #3 — Answers Component Identification — Sensors ID / HD Diesel(2 pages) SA4 Student assignment #4 — Answers Component Identification — Actuator ID/HD Diesel SA5 Student assignment #5 — Answers Charging System Verification SA6 Student assignment #6 — Answers HV-950 — Wiring diagram practice — ECU connector (4 pages) SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages)

Student Assignments for HV-950 Diesel Engine Training Bench HV-950-95_V2025-1 © ConsuLab Educatech Inc, 2025. All rights reserved. HV-950-95 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 © ConsuLab Educatech Inc, 2024. 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. Table of Contents General description 3 Educational Advantages 3 Student Assignments Basic Orientation Thru Advanced And Troubleshooting 5 SA1 — Component identification — Basic (2 pages) 8 SA2-A — Component Identification — Specific (2 pages) 10 SA2-B — Component Identification — Dashboard Specific ID (3 pages) 12 SA3 — Component Identification — Sensors ID / HD Diesel(2 pages) 15 SA4 — Component Identification — Actuator ID/HD Diesel 17 SA5 — Charging System Verification 18 SA6 — Wiring diagram practice 19 SA7 — Expected voltages 23 SA8 — Measured voltages 27 SA9 Student assignment template — Engine performance fault diagnosis 31 consulab.com info@consulab.com 3 HV-950-95 General description General description The HV-950 family of diesel engine trainers are fully operational engines mounted on a mobile stand. The trainers are easy to work on and all major components, wiring and connectors match OEM configuration. Each trainer is either a one or two piece construction design depending on the model. Part one is the actual engine mounted on a mobile stand constructed of 2” (5 cm) tubular steel equipped with four 5” (12.5 cm) phenol casters (2-fixed and 2-swivel w/locks), and may or may not include the after-treatment unit on top. For some models part two is the exhaust after-treatment unit that must be properly connected to the engine prior to trainer use. Students can perform many ASE Educational Foundation related Engine Performance and Electrical/Electronic tasks using this trainer. Trainers are equipped with safety guards covering all rotating components. Educational Advantages • Demonstration of major engine systems to groups of students without the access limitations of a complete vehicle. • Engine systems respond to inserted fauts with real world symptoms, OEM DTC’s and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demostration of exhaust after treatment emission system operation if applicable. TWO-PIECE DIESEL ENGINE TRAINER ONE-PIECE DIESEL ENGINE TRAINER consulab.com info@consulab.com 4 HV-950-95 Student Assignments Student Assignments consulab.com info@consulab.com 5 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Basic Orientation Thru Advanced And Troubleshooting ConsuLab realizes the following steps are important in the development of an accurate diagnostic strategy and recom- mends that each student perform Student Assignments 1-8 (SA1-8) exercises in order to build the foundation needed to proceed to Student Assignment 9 – Engine Performance Fault Diagnosis. Student Assignment 1 SA1 Component identification – BASIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer in general. Student Assignment 2A SA2 Component identification – SPECIFIC In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 2B SA2 Component identification – DASHBOARD In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with the specific engine in this trainer. Student Assignment 3 SA3 Component identification – SENSORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step three in getting familiar with this trainer and related sensors. Student Assignment 4 SA4 Component identification – ACTUATORS In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step four in getting familiar with this trainer and related actuators. consulab.com info@consulab.com 6 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 5 SA5 Charging system verification In preparation to diagnosing any engine management issues, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first! Student Assignment 6 In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. SA6 WIRING DIAGRAM PRACTICE Breakout box 1 - Service information and wiring diagram This will require an understanding of reading a wiring diagram Students are asked to identify the following, for each of the PIN #’s: • Wire color (reference wiring diagram) • Function (sensor/component) • Is sensor/component a signal, control, or reference voltage? Student Assignment 7 SA7 EXPECTED VOLTAGES at Break Out Box PIN Panel Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principle of operation for any system in this activity is required. Having completed SA-6 but before proceeding to SA-8 (where the student will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. consulab.com info@consulab.com 7 HV-950-95 Basic Orientation Thru Advanced And Troubleshooting Student Assignment 8 SA8 MEASURED VOLTAGES at Break Out Box PIN Panel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take and record voltage measurements in the corresponding box of the chart provided. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s: • Key OFF • ACCessory • Key ON / Engine OFF • Key ON / Engine RUN Student Assignment 9 Using all the information gathered in Student Assignments 1-8 and the repair order style chart provided, verify customer concern and document your diagnostic process. Be prepared to defend each step! SA9 Engine Performance Fault Diagnosis For each of these engine performance faults, based on “customer concern”, students will be asked: • Student observation of condition/concern • Explain strategy & tests performed - record test results - and more importantly - explain why? • Explain DTC (if any) • Identify component suspected • Is fault an Input/Output? consulab.com info@consulab.com 8 HV-950-95 SA1 Student assignment #1 SA1 Student assignment #1 Component identification — Basic (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Component Function Location HV-950 Diesel Engine Application: Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug Oil dipstick Air Filter Fuel Filter(s) Throttle (body) Positive Crankcase Ventilation system consulab.com info@consulab.com 9 HV-950-95 SA1 Student assignment #1 Component Function Location Batteries Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box - power DLC Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 10 HV-950-95 SA2-A Student assignment #2A SA2-A Student assignment #2A Component Identification — Specific (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Engine system Engine specific information HV-950 Diesel Engine Application: VIN & decode Engine type Gasoline Diesel Engine model Engine displacement Numbers of cylinders Cylinder numbering Firing order Direction of engine rotation Compression ratio Aspiration Turbo N/A Supercharged Camshaft configuration OHV SOHC DOHC Turbo type Charge air cooler location & function Fuel system type DEF Fluid reservoir J1939 parameter display unit consulab.com info@consulab.com 11 HV-950-95 SA2-A Student assignment #2A Engine system Engine specific information Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other technologies : Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 12 HV-950-95 SA2-B Student assignment #2B SA2-B Student assignment #2B Component Identification — Dashboard Specific ID (3 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Dash icon & name Description 1. 2. 3. 4. 5. 6. 7. 8. consulab.com info@consulab.com 13 HV-950-95 SA2-B Student assignment #2B Dash icon & name Description 9. 10. 11. 12. 13. Switch Position Function 14. I O 1-2-3 15. I O 16. I O consulab.com info@consulab.com 14 HV-950-95 SA2-B Student assignment #2B Switch Position Function 17. AUTO 18. I O 19. I O 20. I O 21. I O 22. I O Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 15 HV-950-95 SA3 Student assignment #3 SA3 Student assignment #3 Component Identification — Sensors ID / HD Diesel(2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step three in getting familiar with this trainer and sensors. Using service information fill in each blank with as much information as possible. Sensor Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Accelerator pedal position 1 Accelerator pedal position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure Exhaust Gas Recirculation (EGR) temp consulab.com info@consulab.com 16 HV-950-95 SA3 Student assignment #3 Sensor Function Location ECM/PCM Connector & Pin #’s EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel INSERT ANY SENSORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 17 HV-950-95 SA4 Student assignment #4 SA4 Student assignment #4 Component Identification — Actuator ID/HD Diesel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step four in getting familiar with this trainer and actuators. Using service information fill in each blank with as much information as possible. Actuator Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbo- charger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 18 HV-950-95 SA5 Student assignment #5 SA5 Student assignment #5 Charging System Verification HV-950 Diesel Engine Application: Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accu- rate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceed- ing with diagnosing engine performance issues? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 19 HV-950-95 SA6 Student assignment #6 SA6 Student assignment #6 HV-950 — Wiring diagram practice — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Example 1 DK BLU 1161 APP sensor 1 signal consulab.com info@consulab.com 20 HV-950-95 SA6 Student assignment #6 Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 21 HV-950-95 SA6 Student assignment #6 Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 22 HV-950-95 SA6 Student assignment #6 Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 23 HV-950-95 SA7 Student assignment #7 SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principles of operation for the follow- ing systems is required. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. Pin wire Key off KOEO KOER Component / Sensor* Example 1 5 V 4.2 V Engine Coolant Sensor consulab.com info@consulab.com 24 HV-950-95 SA7 Student assignment #7 Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 25 HV-950-95 SA7 Student assignment #7 Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 26 HV-950-95 SA7 Student assignment #7 Pin wire Key off KOEO KOER Component / Sensor* Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 27 HV-950-95 SA8 Student assignment #8 SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provied below. Compare results to Student Assignment #7 (SA7). Pin wire System / Voltage Key off ACC KOEO KOER Example 1 APP sensor 1 signal 0 V .9V .9V .9V consulab.com info@consulab.com 28 HV-950-95 SA8 Student assignment #8 Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 29 HV-950-95 SA8 Student assignment #8 Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 30 HV-950-95 SA8 Student assignment #8 Pin wire System / Voltage Key off ACC KOEO KOER Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 31 HV-950-95 SA9 Student assignment template SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages) Using all the information gathered in Student Activities 1-8 and the repair order style chart below, verify customer con- cern and document your diagnostic process. Be prepared to defend each step. Details Customer Concern Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 32 HV-950-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. General description Educational Advantages Student Assignments Basic Orientation Thru Advanced And Troubleshooting SA1 Student assignment #1 Component identification — Basic (2 pages) SA2-A Student assignment #2A Component Identification — Specific (2 pages) SA2-B Student assignment #2B Component Identification — Dashboard Specific ID (3 pages) SA3 Student assignment #3 Component Identification — Sensors ID / HD Diesel(2 pages) SA4 Student assignment #4 Component Identification — Actuator ID/HD Diesel SA5 Student assignment #5 Charging System Verification SA6 Student assignment #6 HV-950 — Wiring diagram practice — ECU connector (4 pages) SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages)

MF102 Series Hydraulic Simulators OWNERS MANUAL For your safety and the safety of the students, read this manual carefully This handbook covers the following simulator models: • MF102-H - Practical Simulator • MF102-H-TS - Troubleshooting Simulator • MF102-H-TSE - Troubleshooting Electronic Simulator Model MF102D-H-TSE shown with optional sideplate modules i IMPORTANT NOTICE Before unpacking your simulator, inspect the outside of the shipping container for damage or abuse. If there is any penetration of the ship- ping container, e.g. forklift forks, photograph and document the damage before opening the container. Remove the cover and inspect for damage to the simulator. Photograph and document any damage which the penetration may have caused to the simulator. Show the relationship of the penetration (if any) to the damage on the simulator. Report the damage to the shipping company immediately. Also, report the damage to the Fluid Power Training Institute™ - 1-888-222-3421 - as soon as possible. MF102-OM Revised January 07, 2025 COPYRIGHT © 2025 FLUID POWER TRAINING INSTITUTE™ All rights reserved. No part of this manual may be used or repro- duced in any manner whatsoever without the written permission of the Publisher. Printed in the United States of America. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. ii iii CONGRATULATIONS! You have purchased the most advanced fluid power simulator in the world - the MF102 series. The MF102 series simulator was designed to make the task of teaching hydraulics simple and rewarding, and to make the job of learning hydraulics downright fasci- nating. This owners manual contains all the information you need to become familiar with the MF102’s unique fea- tures, which include many safety features. You will get many years of safe and reliable opera- tion if you carefully follow the safety, operation, and maintenance guidelines and recommendations in this handbook. iv v CONTENTS 1.0 SAFETY FIRST! - Safety Instructions . . . . . . . . . . . . . . . 1 2.0 Unpacking Your Simulator . . . . . . . . . . . . . . . . . . . . . . . . 3 3.0 Parts and Accessories Checklist . . . . . . . . . . . . . . . . . . . 7 4.0 Familiarizing yourself with the MF102 Simulator . . . . . . . 9 5.0 Familiarizing yourself with the Additional Components (MF102-H-TS & MF102-H-TSE models only). . . . . . . . . . 21 6.0 Installing the Touchscreen Monitor(s) (MF102-H-TSE models only) . . . . . . . . . . . . . . . . . . . . . . 27 7.0 Touchscreen Monitor Startup Instructions (MF102-H-TSE models only) . . . . . . . . . . . . . . . . . . . . . . 28 8.0 Troubleshooting Button Reference Guide (MF102-H-TS models only) . . . . . . . . . . . . . . . . . . . . . . . 30 9.0 Installing the Option Package(s). . . . . . . . . . . . . . . . . . . . 31 10.0 Preparing Your Simulator for Use . . . . . . . . . . . . . . . . . . . 35 11.0 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12.0 Powering up your Simulator . . . . . . . . . . . . . . . . . . . . . . . 39 13.0 Simulator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 40 14.0 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 41 15.0 Troubleshooting your Simulator . . . . . . . . . . . . . . . . . . . . 43 16.0 Where to Get Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 17.0 Recommended Spare Parts List. . . . . . . . . . . . . . . . . . . . 43 18.0 Manufacturer’s Warranty Information . . . . . . . . . . . . . . . . 44 19.0 INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I vi 1 1.0 SAFETY FIRST! - Safety Instructions Electrical Connections - Model (MF102) simulators are equipped with AC male receptacles which are located on the lower, left-hand side of the simulator. Dual-station simulators have an additional AC receptacle on the opposite side of the simulator. If an extension cord is used, it must meet or exceed the following specifications: a. Heavy duty (15 amps). b. Must be grounded. c. Must be taped to the floor to avoid a trip hazard. If your simulator is placed in a permanent position, for safety purposes run the wiring in from overhead if possible. This will prevent unnecessary trip hazards associated with laying extension cords on the floor. Your simulator is equipped with safety fuses/breakers to protect the simulator’s electri- cal system in the event of a power spike or surge (see Section 13.0 for further details). CAUTION The simulator is shipped without hydraulic oil. DO NOT start the simu- lator until it has been filled with the recommended oil. Running the pump without oil will result in severe and irreparable pump damage. WARNING DO NOT PUT YOUR HANDS NEAR A LEAK OR ATTEMPT TO SEARCH FOR A LEAK WITH YOUR HANDS. • Hydraulic oil can inflict three types of injuries: - skin penetration, burn, and eye. • Hydraulic oil can penetrate skin at pressures as low as 100 PSI (6.9 bar). Skin penetration can result in severe injury, permanent loss of hand or finger motion, hand or finger amputation, or death. • If you get injected, see a physician immediately. Do not eat or drink. • Take the MSDS sheet of the injected material with you. If the physician wants to simply clean and bandage the wound, refer him/her to http://www.fluidpowersafety.com. • Hydraulic oil can inflict second and third degree burns at normal operating temperature - as low as 130ºF (54.4ºC). 2 1.0 SAFETY FIRST! - Safety Instructions WARNING The simulators have been designed to operate safely. Any type of change or modification could have a detrimental effect on that safety. Accordingly, ALL modifications or changes, regardless of how minor, must be approved in writing, by the FPTI™ - these include: • Changes in the design of the simulator. • Adding component(s) to the simulator. • Removing component(s) from the simulator. • Failing to properly maintain the simulator. • Making component substitutions. • Using the simulator for any purpose other than training and education. Failure to heed this warning may result in voiding of simulator warranty. Operating or observing the operation of this simulator without safety glasses may lead to an accident which could result in severe eye injury or blindness. This simulator is to be operated only under the supervi- sion of a trained, authorized instructor. Follow all safety instructions in the operator handbook before using this simulator. WARNING Prevention is better than cure! An eye-wash station must be located in an accessible location that requires no more than ten (10) seconds to reach and should be located within a travel distance no greater than 100 feet (30.5 m) from the hazard (ANSI Z358.1-1998). WARNING WARNING Post a warning sign on the entry door into the hydraulic training center. Warn people who enter the room that hydraulic system(s) are in operation and that they must wear safety glasses with side- shields which conform to ANSI Z87.1. 3 2.0 Unpacking Your Simulator SAFETY INSTRUCTIONS: a. Before unpacking the simulator, make sure the shipping container is standing on a smooth, level surface. b. At least two people must be in attendance when the simulator is being unpacked. While there is no need to lift the simulator, the people who unpack it must be strong enough to hold it as it is rolled off the pallet. c. Wear safety glasses and steel-toe boots when unpacking the simulator. TOOLS REQUIRED: a. Flat-head screwdriver or prying tool. b. Scissors. c. Two 3/4” wrenches. Step 1: Using a flat-head screwdriver, remove the retainers from around the base of the cardboard container (Figure 2-1). Step 2: With a person positioned on either side of the cardboard container, carefully lift it up and over the top of the simulator. If there is no evidence of damage to the simulator, fold the cardboard container and please recycle. NOTE: IF THE SHIPPING CONTAINER IS DAMAGED KEEP IT INTACT UNTIL THE FREIGHT COMPANY HAS COMPLETED ITS INVESTIGATION. Step 3: Carefully remove the protective plastic wrap from the simulator. DO NOT use a sharp instrument as the cutting tool may damage the simulator. Please recycle the plastic wrap! Step 4: Carefully remove the boxes (if any), and the pre-fabricated ramp which are stowed below the simulator. Figure 2-1 Remove retainers 4 Step 5: Make sure all caster brakes are applied. To apply the brakes, push down firmly on the individual brake levers (Figure 2-2). Step 6: Loosen and remove all ratchet straps, which secure the simulator to the pallet (Figure 2-3) 2.0 Unpacking Your Simulator - cont’d. CAUTION Before removing the bolts and straps, make sure the pallet is standing on a smooth, level surface. Make sure the caster brakes are applied, and have another person hold onto the simulator to prevent it from rolling. Figure 2-3 The simulator is heavy. DO NOT place feet or hands in the path of the casters. If the casters roll over your feet or hands, it could cause severe injury. CAUTION CAUTION At least two (2) people must be in attendance when rolling the simulator off the pallet (one on either side of the simulator). Figure 2-2 Brake applied 5 Step 7: Place the ramp on the OPPOSITE side of the pallet from the casters that are being held in place with bolts on the caster track (Figure 2-4). Step 8: While one person holds the simulator securely, use a 3/4” wrench to loosen and remove the bolts that secure the caster to the caster track. Repeat this Step on both casters (Figure 2-5). Step 9: When all of the straps and bolts have been removed, and the ramp has been properly placed, make sure that there is still at least one person holding the simu- lator securely. You may now release the brakes on all four casters (Figure 2-6). 2.0 Unpacking Your Simulator - cont’d. Figure 2-5 Bolts Figure 2-4 Caster track Figure 2-6 Brake released 6 Step 10: With at least two people holding onto the simulator, one on each end, begin pushing the simulator towards the ramp along the cast- er track. Slowly guide the simulator down the ramp until it is completely off the pallet (Figure 2-7). Step 11: Once the simulator is off the pallet, remove the locking bolts from the four casters to allow them to swivel ( Figure 2-8). Step 12: Apply the brakes and proceed with familiarizing yourself with the simulator by reading through this owner’s manual. 2.0 Unpacking Your Simulator - cont’d. Figure 2-8 Locking bolt Figure 2-7 7 3.0 Parts and Accessories Checklist 3.1 MF102 Model Simulators - Single-station and Dual-station Parts and accessories are contained in the boxes which are stored on the shipping crate below the simulator and can also be found on the tray. We recommend that you inspect the contents for damage. Although we exercise care in packing the parts, we recommend that you check each item, and quantity, against the following parts list. MF102S MF102D DESCRIPTION of ITEM 4 8 1/4”x 60” hydraulic hoses w/quick-connect couplings (6.35mm x 152cm) 8 16 1/4”x 42” hydraulic hoses w/quick-connect couplings (6.35mm x 107cm) 6 12 1/4”x 28” hydraulic hoses w/quick-connect couplings (6.35mm x 71cm) 8 16 “T’s” with quick-connect couplings. 3 6 0-1500 PSI pressure gauges marked P1, P2, and P3. (0-103.4 bar) 1 2 Set of laminated hydraulic schematic activities. (Not included with MF102-H-TSE models). 1 1 Oil funnel with 3/8” NPT male connector. 4 4 Laminated instructor switch setting cards. (TS models only) Recommended diagnostic accessories (not included): 1 2 Flow meter kit with pressure gauge, adjustable load-cell, and quick-couplers. 1 2 0-30” Hg vacuum gauge. 1 2 0-100 PSI pressure gauge. (0-6.9 bar) 1 2 Hand-held, non-contact/contact laser tachometer. NOTE: Report damages or missing components to the Fluid Power Training Institute™ immediately. Damaged components must be returned to the manufacturer. 8 9 4.0 Familiarizing yourself with the MF102 Simulator Figure 4-1 Figure 4-2 Rear cover panel Four- wheel steering with locks 4.1 Left-hand side view (single-station) - (Figure 4-1) 4.2 Right-hand side view (single-station) - (Figure 4-2) Figure 4-3 Figure 4-4 Four- wheel steering with locks 4.3 Left-hand side view (dual-station) - (Figure 4-3) 4.4 Right-hand side view (dual-station) - (Figure 4-4) AC plug AC plug 24VDC plug, AC plug 24VDC plug 24VDC plugs 24VDC plugs 6 amp fuse, & AC breaker 6 amp fuse, & AC breaker 6 amp fuse, & AC breaker 10 Figure 4-5 2 30 10 21 20 19 18 16 15 14 13 22232526272829 31 1 12 11987 6 5 4 *3 32 33 17 24 (Location of components may vary) 34 35 11 Your MF102 series Hydraulic Simulator is loaded with components. Take a moment to familiarize yourself with the components found on your simulator 4.5 Front view (Dual-station) - (Figure 4-5) 4.0 Familiarizing yourself with the MF102 Series Simulator (MF102-H and *MF102-H-TS Models only) 1. Swing-out hose storage caddy 2. Power unit ON/OFF switch 3. *Microleak test pump 4. Check valve 5. Overhead laminated schematic holder 6. Loadable bi-directional hydraulic motor 7. Digital Display 8. Sequence valve (equipped with Safe-T- Bleed® bleed-off connectors) 9. Pilot-operated relief valve 10. Cylinder - double-acting, single-rod (equipped with Safe-T-Bleed® bleed-off connectors) 11. Pressure reducing valve (equipped with Safe-T-Bleed® bleed-off connectors) 12. Counterbalance valve 13. Mechanical load engage mechanism 14. Pressure-compensated flow control valve - restrictor type 15. Cylinder - double-acting, double-rod (equipped with Safe-T-Bleed® bleed-off connectors) 16. Pilot-operated check valve 17. Swing-out power unit assembly with convenient work tray 18. Variable displacement, pressure-compensated piston pump 19. One-way flow control valve 20. Needle valve 21. Flex Plate w/solenoid activation button (open-center, handlever-operated, mobile directional control valve included) 22. Cylinder load - mechanically-actuated 23. Direct-operated relief valve 24. Motor Torque Control port 25. Directional control valve - (float-center) - solenoid-operated with flow control module 26. Directional control valve - (closed-center) - solenoid-operated with flow control module 27. Module storage tray 28. Directional control valve - (closed-center) - solenoid-operated with flow control module 29. Directional control valve - (tandem-center) - solenoid-operated with dual one-way flow control module 30. Return line filter 31. Four (4) joysticks - For directional control valve operation 32. Coil voltage test leads 33. Dual 0-2.0 GPM (0-7.57 Lpm) inline flow meters 34. Ball valve (equipped with Safe-T-Bleed® bleed-off connectors) 35. Oil fill port (one-side only) (*MF102-H-TS models only.). 12 Figure 4-6 (Location of components may vary) 2 30 10 20 18 16 15 14 13 21 232527 262829 31 1 121197 6 5 4 3 33 34 17 24 19 22 8 35 32 13 Your MF102-H-TSE Hydraulic Simulator is loaded with components. Take a moment to familiarize yourself with the components found on your simulator (Location of components may vary). 4.6 Front view (Dual-station) - (Figure 4-6) 4.0 Familiarizing yourself with the MF102-H-TSE Simulator 1. Swing-out hose storage caddy 2. Power unit ON/OFF switch 3. Microleak test pump 4. Touchscreen monitor 5. Check valve 6. Loadable bi-directional hydraulic motor 7. Digital Display 8. Sequence valve (equipped with Safe-T- Bleed® bleed-off connectors) 9. Pilot-operated relief valve 10. Cylinder - double-acting, single-rod (equipped with Safe-T-Bleed® bleed-off connectors) 11. Pressure reducing valve (equipped with Safe-T-Bleed® bleed-off connectors) 12. Counterbalance valve 13. Mechanical load engage mechanism 14. Pressure-compensated flow control valve - restrictor type 15. Cylinder - double-acting, double-rod (equipped with Safe-T-Bleed® bleed-off connectors) 16. One-way flow control valve 17. Pilot-operated check valve 18. Variable displacement, load-sensing, pressure-compensated piston pump 19. Swing-out power unit assembly with convenient work tray 20. Needle valve 21. Flex Plate w/solenoid activation button (open-center, handlever-operated, mobile directional control valve included) 22. Cylinder load - mechanically-actuated 23. Direct-operated relief valve 24. Module storage tray 25. Motor Torque Control port 26. Directional control valve - (float-center) - solenoid-operated with flow control module 27. Directional control valve - (closed-center) - solenoid-operated with flow control module 28. Directional control valve - (closed-center) - solenoid-operated with flow control module 29. Directional control valve - (tandem-center) - solenoid-operated with dual one-way flow control module 30. Return line filter 31. Four (4) joysticks - For directional control valve operation 32. Coil voltage test leads 33. Dual 0 - 2.0 GPM (0 - 7.57 Lpm) inline flow meters 34. Ball valve (equipped with Safe-T-Bleed® bleed-off connectors) 35. Oil fill port (one-side only) 14 4.7 Ball Valve - When the ball valve handle is at right angles to the oil transmission line it is closed (Figure 4-6). Shift the handle until it is more or less parallel with the oil transmission line to open it (Figure 4-7). 4.8 Digital Display - (Figure 4-8) - The digital display contains a stop watch, ambient temp, oil temp, mo- tor rpm, and ammeter. The digital display on the MF102-H-TS and TSE models will also display the troubleshooting buttons which allow the instructor to set the faults. (Figure 4-9) Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator 15 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Figure 4-10 Figure 4-11 Figure 4-12 Figure 4-13 4.9 *Fixed Displacement and Pressure- Compensated Hydraulic Pumps - The simulator is designed so students can learn how both conventional fixed-displacement, “open-center” type hydraulic systems, and pressure- compensated, “closed-center” type systems operate. It is important, when learning hydraulics, for the transition from an “open-center” environment to a “closed-center” environment to be “realistic” and seamless. To accomplish this, instead of putting two different types of pumps on the simulator, the MF102 models employ a unique 4-station manifold design, which accomplishes the same thing. On the right-hand side of the tray there is a quick-coupler which is adjacent to the symbol for a fixed displace- ment pump (Figure 4-10). To the right of that quick-coupler there is a symbol for a variable volume, pressure- compensated pump (Figure 4-11). The left-hand directional control valve on the MF102 series simulator (Figure 4-12) is generally used in “open-center” hydraulic system designs which, are typically tandem- center or open-center. The three right-hand directional control valves on the MF102 series simulators (Figure 4-13) are generally used in “pressure manifold” or “closed-center” hydraulic design. They are typically float-center or closed-center. 16 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Although it is not visually detectable, the manifold is divided into two completely separate chambers (Figure 4-14). When a student is doing “hands-on” activities pertaining to a fixed-displacement type pump, either the open-center or tandem-center valve is used. When doing activities associated with a variable-displacement, pressure- compensated pump, either the closed-center or float-center valve is used. This unique design helps the students learn how “open-center” and “closed-center” systems work without any confusion - the transition is absolutely seamless! It is important to note that when a student is working with either the open-center or float center directional control valves, the “pump” and “tank” connections MUST be made on the corresponding side of the manifold (Figure 4-15). When working with the closed-center or float-center directional control valves, the “pump” and “tank” connections MUST be made on the opposite side of the manifold (Figure 4-16). Figure 4-14 Figure 4-15 Figure 4-16 “P” “T” “Open-center” side “T” “P” “Closed-center” side 17 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Figure 4-19a Figure 4-20 4.11 Variable Displacement, Pressure-compensated Pump - The variable displacement, pressure-compensated pump has two adjustments: 1. Pressure adjustment: The pressure adjusting screw is located on the pressure-compensator (Figure 4-19a). It consists of a threaded rod with a jam-nut. The pressure compensator is pre- set at 1000 PSI (69 bar). The pressure adjusting screw, for trainers equipped with the load-sense pump option, is located on the block on top of the pump (Figure 4-19b). 2. Flow adjustment: The flow adjusting screw is located on the back of the pump housing (Figure 4-20). It consists of a threaded rod with a jam-nut. The pump flow is pre-set at 1.0 GPM (3.8 liters). 4.10 Power Unit - The power unit (located under the right side of the front tray) is locked in place with a self-locking mech- anism (Figure 4-17). To swing the power unit out from under the tray, lift up on the latch and swing the power unit out into position (Figure 4-18). To store the power unit under the tray, simply swing it back under the front tray. The latch mechanism will drop into place locking the power unit into position. Figure 4-17 Figure 4-18 Figure 4-19b 18 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Figure 4-22 4.13 Component Adjustment Screws - You will notice that many of the valves on the trainer have an adjusting screw with knurled knobs. One of them - the pilot-operated check valve (Figure 4-22) does not have a knob. This is the only valve which is non-adjustable. With the exception of the counter- balance valve, turning the adjusting knob in (clockwise from the top of the valve) increases pressure and turning it out (counter-clockwise), decreases the pressure. The counterbalance valve adjust- ment is totally opposite to the other valves - turning the valve adjust- ment knob in (clockwise from the top of the valve), decreases pressure, and turning it out (counterclockwise), increases the pressure. 4.12 Load-sense pump (optional) - To operate the pump in load-sense mode, the handle of the ball valve must be perpendicular with the body. To operate in pressure-compensated mode, the handle of the ball valve must be parallel with the body (Figure 4-21). Figure 4-21 19 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator 4.14 Valve Body Markings - A critical component in the design of the MF102 series simulators was to keep all component markings consistent with what is typically found in the “real world.” Generally, these markings consist of letters and numbers. The only deviation from an actual valve is that the markings are bold. The markings on a directional control valve manifold consist of the letters “P” and “T” which represent “pump” and “tank.” “A” and “B” typically represent the “work ports.” Cartridge valve manufacturers generally mark the ports on their respective valves with numbers - “1,” “2,” and, if it’s a 3-port valve, the number “3” (Figure 4-23). Figure 4-23 WARNING There are no standards, that FPTI™ is aware of, with regard to what symbol a manufacturer uses to mark cartridge valve bodies, or the relationship of that symbol to the port. NEVER assume, for example, that if one manufacturer marks the inlet port with the number “1” that all cartridge valve manufacturers use the same marking. ALWAYS check the respective cartridge valve manufacturers speci- fications with respect to port markings before making connections. An error could result in severe injury or death. The cartridge valves on the MF102 model simulators are manufactured by Sun Hydraulics™. All markings on the valve bodies are made in accordance with the manufacturer’s specifications. 20 4.15 Flex Plate - The Flex Plate is a standard fixture on all MF102 series simulators. The Flex Plate allows the instructor to add a number of optional valves to the simulator to extend its teaching capabilities to the students (Figure 4-24). 4.16 24VDC Electrical Fuse - All MF102 series simulators are equipped with 24VDC slow-blow 6 amp fuses to protect the electrical system in the event of a power spike or surge (Figure 4-25). See Section 13.0 for further details. 4.17 AC Electrical Fuse Breaker - All MF102 series simulators are equipped with AC fuse breakers to protect the electrical system in the event of a power spike or surge (Figure 4-25). See Section 13.0 for further details. Figure 4-24 Figure 4-25 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator 21 5.0 Familiarizing yourself with the Additional Components Figure 5-1 5.1 Pressure/Leak Test Pump (Microleak Tester) - The pressure/leak test pump is designed for testing a variety of hydraulic components. While it bears resemblance to a commer- cial porta-power, it is not a porta- -power. The pressure/leak test pump does not need to be filled with oil. It automatically fills when ever the power unit is operating. If, while the pressure/leak test pump is being used, it runs out of o i l , s imply connect the pump directly to a tank port and let the pump run for approximately 30 seconds, and it will re-fill. To operate the pressure/leak test pump, s imply rotate the knob (Figure 5-1) clockwise until it stops, a n d m o v e t h e h a n d - l e v e r backwards and forwards. To release the pressure, rotate the knob counterclockwise unt i l i t stops. (MF102-H-TS & MF102-H-TSE models only) (These items are included on both the single-station and dual-station trouble- shooting simulators and are NOT included with the MF102-H simulators). 22 Step 2: Next, carefully aim the laser between the openings in the fan safety guard at the reflective tape (Figure 5-6). Hold the tachometer steady, and depress the side button. Wait a few seconds for the tach- ometer to respond. Pushing the MEM button on the tachometer will automatically submit the indicated speed to the tachometer’s memory. 5.2 *Digital, Hand-Held, Laser-Type Tachometer - The hand-held tachometer, located in the module tray underneath the t ra iner (F igure 5-12), is used primarily when students are learning troubleshooting ski l ls. Its main purpose is for students to observe and record prime-mover (electric motor) speed. The state-of-the-art tachometer needs a re f l ec t i ve f eedback medium to operate properly. A piece of self-adhesive reflective tape has been attached to the electric motor’s cooling fan (Figure 5-4) for this purpose. Step 1: To operate the tachometer, first adjust the switch the correct position- “RPM” (Figure 5-5). Figure 5-4 Figure 5-5 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators Figure 5-6 23 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators 5.3 *Flow Meter Test Kit - The flow meter test kit, located in the module tray underneath the trainer (Figure 5-12), consists of an in-line, 0-2.0 GPM (0.76 liters) flow meter, a load-cell, a 0-1000 PSI (0-69 bar) glycer ine-f i l led p r e s s u r e g a u g e , a n d q u i c k - connectors (Figure 5-7). It is identical to the two (2) which are mounted on the panel. The only difference is that this one is con- figured identically to those used in the field. To operate the flow meter simply connec t i t i n -ser ies w i th the appropriate oil transmission line. Open the load-valve (turn counter- clockwise) and proceed. Closing the load-valve will restrict the flow and create an “artificially generated load” which is necessary when executing certain component test procedures. Figure 5-7 *These items are included in the optional diagnostic accessories package (MF102-DA) which is available for purchase. 24 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators 5.4 *Case Pressure Gauge (0-100 PSI/0-6.9 bar) - There are two pressure check points on the pump - one for checking pump case pressure, and the other for checking case drain-line resistance. Two pressure check points are needed because excessive case pressure can be caused by excessive internal leakage or, excessive case drain-line resistance. The 0-100 PSI (6.9 bar) pressure gauge is equipped with a special connector, which permits safe installation and removal on both the case pressure connector and the case drain-line connector, under pressure. Step 1: To install the case pressure gauge, remove the metal dust c a p f r o m t h e a p p r o p r i a t e connector (Figure 5-8). Step 2: Screw the knurled female swivel connector on the gauge onto the male connector on the pump. Hand-tighten only (Figure 5-9 & Figure 5-10). Always replace the dust cap after use to keep contami- nation out of the connector. NOTE: Once the case drain pressure gauge is installed, DO NOT attempt to store the power unit under the oil drip tray as damage to the gauge and/or tray may occur (Figure 5-11). When the case pressure gauge is not in use, store in the module tray located underneath the trainer (Figure 5-12). Figure 5-8 Figure 5-11 Figure 5-9 Figure 5-10 25 Figure 5-12 Figure 5-14 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators 5.5 Module Storage Tray - A tray is located underneath the simulator for clutter-free storage of all the diagnostic equipment that is used with the MF102-TS model trainers. The storage tray also conveniently stores several of the modules that can be affixed to the Flex-Plate. 5.6 *Vacuum Gauge - A glycerine-filled vacuum gauge, located in the module tray underneath the trainer (Figure 5-12), is provided for students to learn how to check pump inlet restriction. A vacuum gauge is an extremely sensitive instrument. When a gauge is filled with glycerine it will have a sealed case to prevent the glycerine from leaking out. Changes in ambient temperature will cause minor fluctuations in the case pressure as expansion and contraction naturally occurs. These pressure fluctuations could have a negative effect on the gauge’s accuracy. To overcome this problem, the vacuum gauge is equipped with a plastic case plug. When the case plug is moved to the OPEN position it momentarily opens the case to atmosphere and allows the pressures to equalize. Before using the vacuum gauge - especially if the needle is not pointing to the “0 Hg” position - hold the gauge in the upright position, move the small plastic plug to the OPEN position (Figure 5-13) for a few seconds, and then move it back to the CLOSED position (Figure 5-14). The vacuum gauge should now be ready for use. Figure 5-13 *These items are included in the optional diagnostic accessories package (MF102-DA) which is available for purchase. 26 Figure 5-15 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators The vacuum gauge and pump, are equipped with a special pressure coupling system. This coupling system makes it possible to safely install and remove the vacuum gauge while the pump is operating. The female swivel on the vacuum gauge mates with a threaded male coupling which is fastened to the connector at the inlet port of the pump (Figure 5-15). The connector is equipped with a metal dust cap which is chained to the connector to prevent it from falling to the ground or from being misplaced. To install the vacuum gauge, screw the metal dust cap off, and place the connector on the thread and rotate the knurled swivel - hand-tighten only! Always replace the dust cap after use to keep contamination out of the connector. 5.7 Motor Torque Control valve - This motor torque control valve is used to adjust the flow to the motor. Turn- ing the knob counterclockwise will decrease the flow and turning the knob clockwise will increase the flow. (Figure 5-16).. Figure 5-16 27 6.0 Installing the Touchscreen Monitor(s) (MF102-H-TSE models only) After unpacking your MF102-H-TSE mod- el trainer, you will need to mount your touchscreen(s). NOTE: Two (2) people are required to safely install the touchscreen. Step 1: To install the touchscreen, one per- son aligns the mounting holes on the back of the touchscreen with the mounting holes on the bracket while the second person installs the four (4) screws (Figures 6-1 & 6-2). Step 2: On the bottom of the touchscreen connect the computer to the trainer. First select the black round cable. This will be plugged into the far-left round connector port (Figure 6-3). Figure 6-1 Figure 6-2 Figure 6-3 28 6.0 Installing the Touchscreen Monitor(s) (MF102-H-TSE models only) Step 3: Now select the white USB cable. This will be connected to the right of the power connection into the port labeled, “USB.” Once these cables have been connected. The touchscreen can now be safely powered on. WARNING Plugging the MF102 simulator into a power source BEFORE plug- ging the USB cable into the monitor may cause erratic monitor operation. WARNING NEVER unplug the simulator power source until the touchscreen monitor(s) have been shut off using the BLACK button on the side of the monitor. 7.0 Touchscreen Monitor Startup Instructions (MF102-H-TSE models only) START-UP Once the simulator has been plugged back in and turned on, the USB cable and power cable have been plugged into the monitor, and the power button on the front of the monitor has been pressed, the touchscreen monitor will automatically begin startup. HOW TO EXIT THE TRAINING PROGRAM There are two (2) instances in which the instructor will need to exit the training program completely and access the operating system: 1. System/software upgrades. 2. Manual activation of troubleshooting solenoids. Figure 6-4 29 To exit the training program for upgrades, follow these steps: 1. Go to the HOME screen and, select the INSTRUCTOR LOGIN button. 2. When the Key-Pad screen appears enter the following code: 9989 select ENTER. 3. The Instructor log-in page will appear, press the SYSTEM SETTINGS button. 4. Then select the EXIT TO WINDOWS button. 5. A little window will popup, select YES. This will exit the program allowing you access to Windows™. To re-enter the training program without upgrading or making any changes, double click the FPTI™ icon on the desktop. To update the training software: 1. Go to the HOME screen and, select the INSTRUCTOR LOGIN button. 2. When the Key-Pad screen appears enter the following code: 9989 select ENTER. 3. From the left menu, select SYSTEM SETTINGS. 4. From this screen you can then select CHECK FOR UPDATES. You will then be asked to make sure you have an internet connection. After making sure you are connected to the internet, select YES to proceed. To manually fault the components for troubleshooting follow these steps: 1. Go to the HOME screen and, select the INSTRUCTOR LOGIN button. 2. When the Key-Pad screen appears enter the following code: 9989 select ENTER 3. From the left menu, select MANAGE FAULTS. 4. This will display a list of all the components that can be faulted. 4. Select the button of the component that you wish to fault. The button will turn RED indicating that the component has been “faulted.” 5. To return the component to its original state, select the component button again and the box will turn GREEN. IMPORTANT NOTE: When a component has been manually faulted it must also be manually reset after the activity has been completed otherwise it will remain in the “faulted” position. ADDITIONAL INFORMATION To change the time/date displayed on the monitor, exit the training program, go to the Windows™ operating system, click the bottom left-hand corner of the screen to make the Windows™ bar accessible, and click on the time/date icon in the bottom right-hand corner of the screen. To re-enter the training program without upgrading or making any changes, double click the FPTI™ icon on the desktop. 30 8.0 Troubleshooting Button Reference Guide (MF102-H-TS models only) Figure 8-1 Direct-operated Relief Valve (GREEN = Normal Operation) (RED = Fault) Check Valve (GREEN = Normal Operation) (RED = Fault) Double-Rod Cylinder (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Closed-Center "B" port) (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Closed-Center "A" port) (GREEN = Normal Operation) (RED = Fault) Pressure Reducing Valve (GREEN = Normal Operation) (RED = Fault) Sequence Valve (GREEN = Normal Operation) (RED = Fault) Pilot-operated Relief Valve (GREEN = Normal Operation) (RED = Fault) Counterbalance Valve (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Tandem-Center "A" & Float-Center "A" ports) (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Tandem-Center "B" & Float-Center "B" ports) (GREEN = Normal Operation) (RED = Fault) Hydraulic Pump (GREEN = Normal Operation) (RED = Fault) 1 2 3 4 5 6 7 8 9 10 12 Tandem-Center Directional Control Valve "A" Solenoid (GREEN = Normal Operation) (RED = Fault)14 Single-Rod Cylinder (GREEN = Normal Operation) (RED = Fault) 13 11 Hydraulic Motor (GREEN = Normal Operation) (RED = Fault) Pilot-to-Open Check Valve (GREEN = Normal Operation) (RED = Fault) 16 BLANK17 15 The following diagram (Figure 8-1) indicates the button number, component type, and button color for the normal operation and fault mode. 31 9.1 MF100-ACC - Accumulator Unloading Valve module (if applicable) - SAFETY INSTRUCTIONS: a. Wear safety glasses when installing the accumulator package. b. Due to the unbalanced weight of the optional sideplate modules, at least two people are required to perform this job safely. Step 1: Loosen the two (2) hand-latches (Figure 9-1) located on the upper left-hand side of the front panel. Step 2: Gently slide the option assembly into the slot (Figure 9-2) in the side cover of the simulator and make sure that the option assembly drops into position (Figure 9-3). 9.0 Installing the Option Package(s) Figure 9-1 Figure 9-3 Figure 9-2 32 Step 3: Tighten the two hand latches securely (Figure 9-6). Step 4: Make the necessary connections to the mainframe simulator. 9.0 Installing the Option Package(s) Figure 9-6 Figure 9-4 Figure 9-5 Frame Front panel Loosened latch (qty. 2) The diagrams below (Figures 9-4 & 9-5) illustrate how to correctly position the bracket on the mounting bosses which are welded to the frame. 33 9.2 MF100-PDCV - Proportional Directional/Flow Control Valve package (if applicable) - 9.0 Installing the Option Package(s) Figure 9-10 CAUTION DO NOT connect the simulator to an electrical power source until this installation is complete. SAFETY INSTRUCTIONS: a. Wear safety glasses when in- stalling the Proportional Directional/ Flow Control Valve package. b. Due to the unbalanced weight of the optional sideplate modules, at least two people are required to perform this job safely. Step 1: Loosen the two (2) hand-latches (Figure 9-10) located on the upper right-hand side of the front panel. Step 2: Gently slide the option assembly into the slot in the side cover of the simulator (Figure 9-11) and make sure that the option assembly drops into position. Figure 9-11 34 9.0 Installing the Option Package(s) Step 3: Tighten the two hand-latches securely (Figure 9-14). Step 4: Make the necessary connections to the mainframe trainer. Step 5: There are either one (1) or two (2) 24VDC receptacles located on the side plates of the mainframe simulators (Figure 9-15). Plug the Proportional Directional/ Flow Control Valve cord into one of the receptacles and slide the locking arm into position. Figure 9-14 Figure 9-15 Figure 9-12 Figure 9-13 The diagrams below (Figures 9-12 & 9-13) illustrate how to correctly position the bracket on the mounting bosses which are welded to the frame. Frame Front panel Loosened latch (qty. 2) 35 10.0 Preparing Your Simulator for Use Once you are satisfied that the parts and accessories are in good condition and ac- counted for, and, you have familiarized yourself with the MF102 simulator, go ahead and install the parts and accessories into their respective positions on the simulator. Figure 10-1 Figure 10-2 Figure 10-4 Figure 10-3 10.1 0-1500 PSI (0-103.4 bar) Pressure Gauges - There are three (3) 0-1500 PSI (0-103.4 bar) pressure gauges, located in the module tray under- neath the trainer (Figure 5-12), which are marked P1, P2, and P3. They may be placed on the power unit tray or on the main tray while the simulator is in use (Figure 10-1). 10.2 Filling the MF102 Simulator with Oil - Fill the simulator with a good quality AW-32 hydraulic fluid. Reservoir Capacity (approx.): 4.5 U.S. gallons (17 liters). Step 1: Remove the filler/breather cap (Figure 10-2) and screw the oil funnel into the filler boss (Figure 10-3). Hand-tighten only. Location of oil filler may vary. The oil funnel is capable of turning the oil flow ON and OFF. To allow flow, rotate the oil funnel in a counter-clockwise direction. To stop flow, rotate the oil funnel in a clockwise direction. Step 2: Fill the simulator until oil is visible in the oil level sight glass on the reservoir (Figure 10-4). 36 10.0 Preparing Your Simulator for Use Figure 10-5 Figure 10-6 Step 3: Connect a hose from the pump outlet port to the bottom of the Flow meter. Connect the top of the flow meter to the tank return port (Figure 10-5). Step 4: Connect a suitable grounded elec- trical cord from the simulators electrical plug (Figure 10-6) to a 115 volt, 15 amp, single-phase elec- trical circuit (for each motor). Step 5: Start the power unit using the main electrical ON/OFF switch (Figure 10-7). After waiting a minute, recheck the oil level. Top-up if necessary. Step 6: Remove the oil funnel. Step 7: Replace the oil filler/breather cap. 10.3 Laminated Schematic Pages Holder (All MF102 models except TSE) - Step 1: Install the laminated schematic holder on the post located on the left-hand side of the simulator (Figure 10-8). Step 2: Remove the laminated sche- matics from their packaging. Slip the three (3) retaining rings over the arm and into position (Figure 10-9). Figure 10-7 Figure 10-8 Figure 10-9 37 10.0 Preparing Your Simulator for Use 10.5 Hose Caddy - The hoses used on the simulator are stored neatly under the left- hand side of the front tray on a swing-out caddy (Figure 10-12). To swing out the hose caddy, locate the hose caddy retention pin and re- move it (Figure 10-13). Once the pin has been removed rotate out from underneath the front tray. The T connectors are stored on the underside of the hose caddy. To access them remove the T connector pin (Figure 10-14). To store the hose caddy under the tray, simply swing it back under the front tray and re-insert the hose caddy pin to lock in place. Figure 10-13 Figure 10-14 Figure 10-12 38 11.0 Safety Features Figure 11-2Figure 11-1 Figure 11-3 WARNING DO NOT operate the simulator without the safety covers. If a safety cover is removed, it MUST be replaced BEFORE operating the simulator. Failure to replace the safety cover(s) could result in an accident which could cause severe injury or death. 11.1 Transparent Safety Covers - Transparent safety guards allow a person to see how components operate while protecting them from moving mechanisms. There are four (4) safety guards on the MF102 series simulators which cover: • Hydraulic motor output shaft (Figure 11-1) • Hydraulic cylinder double-rod C2 - Upper (Figure 11-2) • Weight-load system (Figure 11-3) 39 12.0 Powering up your Simulator NOTE: The symbol for each component is clearly printed on the panel, adjacent to the re- spective component. Figure 12-1 To familiarize yourself with the operation of the MF102 series simulator, go ahead and construct this simple hydraulic circuit shown below. Step 1: Build the circuit as shown on Figure 12-1. Step 2: Start the motor and set the pressure relief valve at 500 PSI (34.5 bar) - dead-head the cylinder to set the pressure relief valve. Step 3: Operate the A-B toggle switch and extend the cylinder rod. Step 4: Now retract the cylinder rod - it’s that simple! 40 13.0 Simulator Specifications Figure 13-1 Simulator dimensions Electrical: US & Canada - 115VAC single-phase. 10 amp service. International - 220VAC single-phase. 50 Hz. Hydraulic Pump: 1.0 GPM (3.79 Lpm) variable-displacement, pressure- compensated piston pump. Operating Pressure (max.): 1000 PSI (69 bar) Oil: AW32 hydraulic oil. Reservoir Capacity: approx. 4.5 U.S. gallons (17 liters) Motor Displacement: 0.25 cu. in./rev. (4.1 cu. cm/rev.) Cylinder Rod Diameter: 1.0” (25.4 mm) Single-rod and Double-rod Cylinder Stroke: 14” (355.6 mm) Single-rod and Double-rod Trainer Weight: MODEL SINGLE UNIT DOUBLE UNIT (Does not include MF102-H 910 lbs (413 kg) 1125 lbs (510 kg) packaging weight) MF102-H-TS 920 lbs. (417 kg) 1145 lbs (519 kg) MF102-H-TSE 940 lbs (426 kg) 1205 lbs (547 kg) Fuses and Breakers: 24VDC fuse (6 amp SLOW BLOW) 115-220VAC breaker (push button to reset) 41 14.0 Service and Maintenance Figure 14-1 Figure 14-2 Figure 14-3 DAILY: 1. Check oil level. 2. Check for oil leaks dripping to floor - repair immediately to prevent slip hazard. 3. Inspect, and replace if necessary, safety covers on hydraulic motor shaft, cylinder rods, and, weight. 4. Inspect, and replace if necessary, any faulty quick-disconnects. 5. Inspect electrical wires and connections. 6. Inspect for loose bolts. ANNUALLY: 1. Drain oil and replace - approximately 4.5 U.S. gallons [17 liters] (See 14.1). 2. Remove oil filter and replace (See 14.2). 14.1 Draining the Oil - The oil reservoir is located on the frame. An oil drain is located on the underside of the reservoir. Step 1: To drain the oil, first make sure the handle of the drain cock is in the horizontal (closed) position (Figure 14-1). Step 2: Use a 5/16” allen wrench, and remove the plug from the bottom of the drain valve (Figure 14-2). Step 3: Place a receptacle, which holds at least 4.5 U.S. gallons (17 liters), under the drain valve and turn the handle to the vertical (open) position (Figure 14-3). NOTE: The reservoir holds about 4.5 U.S. gallons (17 liters) of oil. Step 4: When the reservoir is empty, close the drain valve and replace the plug. Your MF102 series simulators are designed to require very little maintenance. However, to give you years of trouble-free operation there are a few things you must do: 42 14.0 Service and Maintenance 14.2 Oil Filter Service - The MF102 series simulators are equipped with a spin-on/off type filter element (Figure 14-4). To replace the filter element: Step 1: Disconnect the power supply and lock the simulator out. Step 2: Place a receptacle on the floor beneath the filter to contain the small amount of leakage which may occur. Step 3: Turn the filter element, by hand and slowly remove it. Step 4: Discard the filter element in accordance with local and state laws. Step 5: Lubricate the seal on the new filter with hydraulic oil. Step 6: Install the new filter element and tighten securely - DO NOT overtighten. Step 7: Fill the reservoir with new oil until it is present in the sight glass (See 10.2). Step 8: Start the power unit and allow it to run for approximately 30 seconds. Step 9: Recheck the oil level. If necessary, add oil until it is present in the sight glass. Step 10: Wipe residual oil off the new filter element. Step 11: Inspect the floor for signs of oil which may have spilled while removing the filter element. Clean oil spills thoroughly to prevent a slip-type accident. Figure 14-4 43 15.0 Troubleshooting your Simulator 16.0 Where to Get Help * MF102-H-TS and TSE model simulators only. PROBLEM SOLUTION 1. Simulator does not power up. a. Check electrical connections. b. Push down firmly on power unit ON/OFF switch and reset breaker. c. Reset AC fuse breaker by pressing in. 2. Pump makes a noise (cavitation). a. Check oil level. If, after following the troubleshooting guide the problem still persists, call the Fluid Power Training Institute™ for assistance at 1-888-222-3421. Please have your model number and serial number available when you call. 17.0 Recommended Spare Parts List The MF102 series simulators are designed with as few parts requiring replacement as possible and to provide you with many years of trouble-free performance. They are equipped with parts which are designed for high-cycle operation. Given the proper care they should last for many years. However, certain items need regular service to keep your trainer operating reliably. ITEM PART # DESCRIPTION 1. SF6520 Oil filter. 2. AA battery (qty. 2) *Tachometer (hand-held) battery. 3. 6 amp SLOW-BLOW fuse Fuse for 24VDC system 44 18.0 Manufacturer’s Warranty Information The MF102 series simulators are covered by their manufacturer’s respective warranty. FPTI™ also offers an additional 2-year warranty, guaranteeing the simulator will be free from defects for that period of time. If any problems arise, that are not covered by this manual, contact FPTI™ immediately. If any attempt is made to disassemble or alter any component on the simulator, without the consent of FPTI™, this warranty will be void. I 19.0 INDEX A Accessories . . . . . . . . . . . . . . . . . .35 Accumulator. . . . . . . . . . . . . . . . . .31 Adjusting screw component . . . . . . . . . . . . . . . . . .18 flow adjustment . . . . . . . . . . . . . .17 pressure adjustment . . . . . . . . . .17 B Ball valve . . . . . . . . . . . . . . .11,13,14 Battery . . . . . . . . . . . . . . . . . . . . . .43 Brakes caster . . . . . . . . . . . . . . . . . . . .4,5,6 Breaker . . . . . . . . . . . . . . 9,20,40,43 C Case pressure gauge . . . . . . . . . .24 Casters . . . . . . . . . . . . . . . . . . .4,5,6 Cautions . . . . . . . . . . . . . . . 1,5,6,33 Checklist . . . . . . . . . . . . . . . . . . . . .7 Check valve basic . . . . . . . . . . . . . . . . . . . 11,13 Pilot-operated . . . . . . . . . . . . 11,13 Closed-center . . . . . . . . . . . . . 11,13 Counterbalance . . . . . . . . . .11,13,18 Cylinder double-rod . . . . . . . . . . 11,13,38,40 single-rod . . . . . . . . . . . . . .11,13,40 D DC 24 volt . . . . . . . . . . . .9,20,34,40,43 Digital display . . . . . . . . . . .11,13,14 Directional control valve closed-center . . . . . . . . 11,13,15,16 float-center . . . . . . . . . 11,13,15,16 open-center . . . . . . . . . 11,13,15,16 proportional . . . . . . . . . . . . . . . . .33 tandem-center . . . . . . . . . .11,13,16 Direct-operated relief valve . . . 11,13 Drain oil. . . . . . . . . . . . . . . . . . . . . . . . .41 E Electrical 24VDC . . . . . . . . . . . .9,20,34,40,43 AC. . . . . . . . . . . . . . . . . . . . . . . . .9 connections . . . . . . . . . . . . .1,41,43 power . . . . . . . . . . . . . . 11,13,33,36 Extension cord . . . . . . . . . . . . . . . . .1 F Familiarization . . . . . . . . . . .11,13,39 Filler/breather . . . . . . . . . . . . . 35,36 Filling with oil . . . . . . . . . . . . . . . . .35 Filter element oil. . . . . . . . . . . . . . . . . . . . . . 42,43 Fixed displacement pump . . . . . . .15 Flex Plate. . . . . . . . . . . . . . .11,13,20 Float-center . . . . . . . . . . 11,13,15,16 Flow adjustment pump . . . . . . . . . . . . . . . . . . . . . .17 Flow control valve . . . . . 11,13,33,34 Flow meter inline . . . . . . . . . . . . . . . . . . . 11,13 test kit . . . . . . . . . . . . . . . . . . . . .23 Funnel oil. . . . . . . . . . . . . . . . . . . . .7,35,36 Fuse 6 amp slow-blow . . . . . . 9,20,40,43 AC breaker . . . . . . . . . . . . . . 20,43 G Gauges case pressure . . . . . . . . . . . . . . .24 pressure . . . . . . . . . . . . 7,23,24,35 vacuum . . . . . . . . . . . . . . . .7,25,26 Glasses Safety . . . . . . . . . . . . . . . 2,3,31,33 H Handle ball valve . . . . . . . . . . . . . . . . . . .14 Holder schematic . . . . . . . . . . . . . . . . . .36 Hose caddy . . . . . . . . . . . . . . . . .11,13,37 hydraulic . . . . . . . . . . . . . . . . . . . .7 Hydraulic hose . . . . . . . . . . . . . . . . . . . . . . . .7 oil. . . . . . . . . . . . . . . .1,26,35,40,42 reservoir . . . . . . . . . . . . . . . . 35,40 L Laminated schematics . . . . . . . 11,36 II 19.0 INDEX Load. . . . . . . . . . . . . . . . . . . . . 11,13 M Maintenance . . . . . . . . . . . . . . 41,42 Manifold . . . . . . . . . . . . . . . .15,16,19 Meter amps . . . . . . . . . . . . . . . . . . . . . . .1 flow . . . . . . . . . . . . . .7,11,13,23,36 Microleak tester . . . . . . . . . . . . . . .21 Monitor. . . . . . . . . . . . . . . . .13,28,29 Motor electric . . . . . . . . . . . . . . . . . . 22,36 hydraulic . . . . . . 11,13,26,38,40,41 O Oil drain . . . . . . . . . . . . . . . . . . . . . .41 filler/breather . . . . . . . . . . . . . 35,36 filling . . . . . . . . . . . . . . . . . . . . . .35 filter . . . . . . . . . . . . . . . . . .41,42,43 funnel . . . . . . . . . . . . . . . . . .7,35,36 hydraulic . . . . . . . . . . . . 1,26,40,42 P Pallet . . . . . . . . . . . . . . . . . . . . .3,5,6 Parts list. . . . . . . . . . . . . . . . . . . . . . . . . .7 spare . . . . . . . . . . . . . . . . . . . . . .43 Pilot-operated check valve . . . . . . . . . . . . . . 11,13 relief valve . . . . . . . . . . . . . . . 11,13 Power unit . 11,13,17,21,24,36,42,43 Pressure adjustment . . . . . . . . . . . . . . . . . .17 gauge . . . . . . . . . . . . . . . . . . . 7,23 case pressure . . . . . . . . . . . . . .24 reducing valve . . . . . . . . . . . . 11,13 Pressure-compensated piston pump . 11,13,17 Pressure compensator . . . . . . . . .17 Pressure/leak test pump . . . . . 13,21 Proportional directional/flow control valve . . . . . . . . . . . . . . . . . . .33 Pump adjustment . . . . . . . . . . . . . . . . . .17 fixed-displacement . . . . . . . . 15,16 pressure-compensated . . . . . . . . . . 11,13,15,16,17,40 pressure/leak test . . . . . . . . . . . .13 R Receptacle electric . . . . . . . . . . . . . . 1,34,41,42 Reservoir . . . . . . . . . . . . 26,35,41,42 Restrictor type Pressure-compensated flow control valve . . . . . . . . . . . . . . . . . . . 11,13 S Safety glasses . . . . . . . . . . . . . . 2,3,31,33 transparent covers . . . . . . . . . . . .38 warnings . . . . . . . . . . .1,2,19,28,38 Schematic holder . . . . . . . . . .7,11,36 Sequence valve . . . . . . . . . . . . 11,13 Service. . . . . . . . . . . . . . . . . . . . . .42 Sight glass . . . . . . . . . . . . . . . . 35,42 Specifications . . . . . . . . . . . .1,19,40 Station eye-wash . . . . . . . . . . . . . . . . . . . .2 Switch electrical . . . . . . . 7,11,13,22,36,43 T Tachometer . . . . . . . . . . . . . .7,22,43 Tandem-center. . . . . . . . . . .11,13,16 Temperature ambient . . . . . . . . . . . . . . . . . 14,25 oil 14 Touchscreen . . . . . . . . . . . .13,27,28 Troubleshooting . . . . .14,22,28,29,43 U Unpacking . . . . . . . . . . . . . . . . i,3,27 V Vacuum gauge . . . . . . . . . . . .7,25,26 Valve ball. . . . . . . . . . . . . . . . 11,13,14,18 check . . . . . . . . . . . . . . . . . . . 11,13 counterbalance . . . . . . . . .11,13,18 directional control . . . . 11,13,15,19 direct-operated . . . . . . . . . . . 11,13 flow control . . . . . . . . . . . . . . 11,13 needle . . . . . . . . . . . . . . . . . . 11,13 III 19.0 INDEX pilot-operated . . . . . . . . . .11,13,18 pressure-compensated flow control 11,13 pressure reducing . . . . . . . . . 11,13 pressure relief . . . . . . . . . . . . . . .39 sequence . . . . . . . . . . . . . . . . 11,13 Variable displacement, pressure com- pensated pump . . . . . .11,13,17 W Warnings . . . . . . . . . . . .1,2,19,28,38 Warranty . . . . . . . . . . . . . . . . . . 2,44 Weight . . . . . . . . . . . . . . 31,33,40,41 If you have any questions that this document does not address, please contact us immediately for assistance. PO Box 711201 Salt Lake City, UT 84171 PH: 801-908-5456 FAX: 801-908-5734 e-mail: info@fpti.org web: www.fpti.org

MF102 Series Hydraulic Simulators OWNERS MANUAL For your safety and the safety of the students, read this manual carefully This handbook covers the following simulator models: • MF102-H - Practical Simulator • MF102-H-TS - Troubleshooting Simulator • MF102-H-TSE - Troubleshooting Electronic Simulator Model MF102D-H-TSE shown with optional sideplate modules i IMPORTANT NOTICE Before unpacking your simulator, inspect the outside of the shipping container for damage or abuse. If there is any penetration of the ship- ping container, e.g. forklift forks, photograph and document the damage before opening the container. Remove the cover and inspect for damage to the simulator. Photograph and document any damage which the penetration may have caused to the simulator. Show the relationship of the penetration (if any) to the damage on the simulator. Report the damage to the shipping company immediately. Also, report the damage to the Fluid Power Training Institute™ - 1-888-222-3421 - as soon as possible. MF102-OM Revised January 07, 2025 COPYRIGHT © 2025 FLUID POWER TRAINING INSTITUTE™ All rights reserved. No part of this manual may be used or repro- duced in any manner whatsoever without the written permission of the Publisher. Printed in the United States of America. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. ii iii CONGRATULATIONS! You have purchased the most advanced fluid power simulator in the world - the MF102 series. The MF102 series simulator was designed to make the task of teaching hydraulics simple and rewarding, and to make the job of learning hydraulics downright fasci- nating. This owners manual contains all the information you need to become familiar with the MF102’s unique fea- tures, which include many safety features. You will get many years of safe and reliable opera- tion if you carefully follow the safety, operation, and maintenance guidelines and recommendations in this handbook. iv v CONTENTS 1.0 SAFETY FIRST! - Safety Instructions . . . . . . . . . . . . . . . 1 2.0 Unpacking Your Simulator . . . . . . . . . . . . . . . . . . . . . . . . 3 3.0 Parts and Accessories Checklist . . . . . . . . . . . . . . . . . . . 7 4.0 Familiarizing yourself with the MF102 Simulator . . . . . . . 9 5.0 Familiarizing yourself with the Additional Components (MF102-H-TS & MF102-H-TSE models only). . . . . . . . . . 21 6.0 Installing the Touchscreen Monitor(s) (MF102-H-TSE models only) . . . . . . . . . . . . . . . . . . . . . . 27 7.0 Touchscreen Monitor Startup Instructions (MF102-H-TSE models only) . . . . . . . . . . . . . . . . . . . . . . 28 8.0 Troubleshooting Button Reference Guide (MF102-H-TS models only) . . . . . . . . . . . . . . . . . . . . . . . 30 9.0 Installing the Option Package(s). . . . . . . . . . . . . . . . . . . . 31 10.0 Preparing Your Simulator for Use . . . . . . . . . . . . . . . . . . . 35 11.0 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12.0 Powering up your Simulator . . . . . . . . . . . . . . . . . . . . . . . 39 13.0 Simulator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 40 14.0 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 41 15.0 Troubleshooting your Simulator . . . . . . . . . . . . . . . . . . . . 43 16.0 Where to Get Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 17.0 Recommended Spare Parts List. . . . . . . . . . . . . . . . . . . . 43 18.0 Manufacturer’s Warranty Information . . . . . . . . . . . . . . . . 44 19.0 INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I vi 1 1.0 SAFETY FIRST! - Safety Instructions Electrical Connections - Model (MF102) simulators are equipped with AC male receptacles which are located on the lower, left-hand side of the simulator. Dual-station simulators have an additional AC receptacle on the opposite side of the simulator. If an extension cord is used, it must meet or exceed the following specifications: a. Heavy duty (15 amps). b. Must be grounded. c. Must be taped to the floor to avoid a trip hazard. If your simulator is placed in a permanent position, for safety purposes run the wiring in from overhead if possible. This will prevent unnecessary trip hazards associated with laying extension cords on the floor. Your simulator is equipped with safety fuses/breakers to protect the simulator’s electri- cal system in the event of a power spike or surge (see Section 13.0 for further details). CAUTION The simulator is shipped without hydraulic oil. DO NOT start the simu- lator until it has been filled with the recommended oil. Running the pump without oil will result in severe and irreparable pump damage. WARNING DO NOT PUT YOUR HANDS NEAR A LEAK OR ATTEMPT TO SEARCH FOR A LEAK WITH YOUR HANDS. • Hydraulic oil can inflict three types of injuries: - skin penetration, burn, and eye. • Hydraulic oil can penetrate skin at pressures as low as 100 PSI (6.9 bar). Skin penetration can result in severe injury, permanent loss of hand or finger motion, hand or finger amputation, or death. • If you get injected, see a physician immediately. Do not eat or drink. • Take the MSDS sheet of the injected material with you. If the physician wants to simply clean and bandage the wound, refer him/her to http://www.fluidpowersafety.com. • Hydraulic oil can inflict second and third degree burns at normal operating temperature - as low as 130ºF (54.4ºC). 2 1.0 SAFETY FIRST! - Safety Instructions WARNING The simulators have been designed to operate safely. Any type of change or modification could have a detrimental effect on that safety. Accordingly, ALL modifications or changes, regardless of how minor, must be approved in writing, by the FPTI™ - these include: • Changes in the design of the simulator. • Adding component(s) to the simulator. • Removing component(s) from the simulator. • Failing to properly maintain the simulator. • Making component substitutions. • Using the simulator for any purpose other than training and education. Failure to heed this warning may result in voiding of simulator warranty. Operating or observing the operation of this simulator without safety glasses may lead to an accident which could result in severe eye injury or blindness. This simulator is to be operated only under the supervi- sion of a trained, authorized instructor. Follow all safety instructions in the operator handbook before using this simulator. WARNING Prevention is better than cure! An eye-wash station must be located in an accessible location that requires no more than ten (10) seconds to reach and should be located within a travel distance no greater than 100 feet (30.5 m) from the hazard (ANSI Z358.1-1998). WARNING WARNING Post a warning sign on the entry door into the hydraulic training center. Warn people who enter the room that hydraulic system(s) are in operation and that they must wear safety glasses with side- shields which conform to ANSI Z87.1. 3 2.0 Unpacking Your Simulator SAFETY INSTRUCTIONS: a. Before unpacking the simulator, make sure the shipping container is standing on a smooth, level surface. b. At least two people must be in attendance when the simulator is being unpacked. While there is no need to lift the simulator, the people who unpack it must be strong enough to hold it as it is rolled off the pallet. c. Wear safety glasses and steel-toe boots when unpacking the simulator. TOOLS REQUIRED: a. Flat-head screwdriver or prying tool. b. Scissors. c. Two 3/4” wrenches. Step 1: Using a flat-head screwdriver, remove the retainers from around the base of the cardboard container (Figure 2-1). Step 2: With a person positioned on either side of the cardboard container, carefully lift it up and over the top of the simulator. If there is no evidence of damage to the simulator, fold the cardboard container and please recycle. NOTE: IF THE SHIPPING CONTAINER IS DAMAGED KEEP IT INTACT UNTIL THE FREIGHT COMPANY HAS COMPLETED ITS INVESTIGATION. Step 3: Carefully remove the protective plastic wrap from the simulator. DO NOT use a sharp instrument as the cutting tool may damage the simulator. Please recycle the plastic wrap! Step 4: Carefully remove the boxes (if any), and the pre-fabricated ramp which are stowed below the simulator. Figure 2-1 Remove retainers 4 Step 5: Make sure all caster brakes are applied. To apply the brakes, push down firmly on the individual brake levers (Figure 2-2). Step 6: Loosen and remove all ratchet straps, which secure the simulator to the pallet (Figure 2-3) 2.0 Unpacking Your Simulator - cont’d. CAUTION Before removing the bolts and straps, make sure the pallet is standing on a smooth, level surface. Make sure the caster brakes are applied, and have another person hold onto the simulator to prevent it from rolling. Figure 2-3 The simulator is heavy. DO NOT place feet or hands in the path of the casters. If the casters roll over your feet or hands, it could cause severe injury. CAUTION CAUTION At least two (2) people must be in attendance when rolling the simulator off the pallet (one on either side of the simulator). Figure 2-2 Brake applied 5 Step 7: Place the ramp on the OPPOSITE side of the pallet from the casters that are being held in place with bolts on the caster track (Figure 2-4). Step 8: While one person holds the simulator securely, use a 3/4” wrench to loosen and remove the bolts that secure the caster to the caster track. Repeat this Step on both casters (Figure 2-5). Step 9: When all of the straps and bolts have been removed, and the ramp has been properly placed, make sure that there is still at least one person holding the simu- lator securely. You may now release the brakes on all four casters (Figure 2-6). 2.0 Unpacking Your Simulator - cont’d. Figure 2-5 Bolts Figure 2-4 Caster track Figure 2-6 Brake released 6 Step 10: With at least two people holding onto the simulator, one on each end, begin pushing the simulator towards the ramp along the cast- er track. Slowly guide the simulator down the ramp until it is completely off the pallet (Figure 2-7). Step 11: Once the simulator is off the pallet, remove the locking bolts from the four casters to allow them to swivel ( Figure 2-8). Step 12: Apply the brakes and proceed with familiarizing yourself with the simulator by reading through this owner’s manual. 2.0 Unpacking Your Simulator - cont’d. Figure 2-8 Locking bolt Figure 2-7 7 3.0 Parts and Accessories Checklist 3.1 MF102 Model Simulators - Single-station and Dual-station Parts and accessories are contained in the boxes which are stored on the shipping crate below the simulator and can also be found on the tray. We recommend that you inspect the contents for damage. Although we exercise care in packing the parts, we recommend that you check each item, and quantity, against the following parts list. MF102S MF102D DESCRIPTION of ITEM 4 8 1/4”x 60” hydraulic hoses w/quick-connect couplings (6.35mm x 152cm) 8 16 1/4”x 42” hydraulic hoses w/quick-connect couplings (6.35mm x 107cm) 6 12 1/4”x 28” hydraulic hoses w/quick-connect couplings (6.35mm x 71cm) 8 16 “T’s” with quick-connect couplings. 3 6 0-1500 PSI pressure gauges marked P1, P2, and P3. (0-103.4 bar) 1 2 Set of laminated hydraulic schematic activities. (Not included with MF102-H-TSE models). 1 1 Oil funnel with 3/8” NPT male connector. 4 4 Laminated instructor switch setting cards. (TS models only) Recommended diagnostic accessories (not included): 1 2 Flow meter kit with pressure gauge, adjustable load-cell, and quick-couplers. 1 2 0-30” Hg vacuum gauge. 1 2 0-100 PSI pressure gauge. (0-6.9 bar) 1 2 Hand-held, non-contact/contact laser tachometer. NOTE: Report damages or missing components to the Fluid Power Training Institute™ immediately. Damaged components must be returned to the manufacturer. 8 9 4.0 Familiarizing yourself with the MF102 Simulator Figure 4-1 Figure 4-2 Rear cover panel Four- wheel steering with locks 4.1 Left-hand side view (single-station) - (Figure 4-1) 4.2 Right-hand side view (single-station) - (Figure 4-2) Figure 4-3 Figure 4-4 Four- wheel steering with locks 4.3 Left-hand side view (dual-station) - (Figure 4-3) 4.4 Right-hand side view (dual-station) - (Figure 4-4) AC plug AC plug 24VDC plug, AC plug 24VDC plug 24VDC plugs 24VDC plugs 6 amp fuse, & AC breaker 6 amp fuse, & AC breaker 6 amp fuse, & AC breaker 10 Figure 4-5 2 30 10 21 20 19 18 16 15 14 13 22232526272829 31 1 12 11987 6 5 4 *3 32 33 17 24 (Location of components may vary) 34 35 11 Your MF102 series Hydraulic Simulator is loaded with components. Take a moment to familiarize yourself with the components found on your simulator 4.5 Front view (Dual-station) - (Figure 4-5) 4.0 Familiarizing yourself with the MF102 Series Simulator (MF102-H and *MF102-H-TS Models only) 1. Swing-out hose storage caddy 2. Power unit ON/OFF switch 3. *Microleak test pump 4. Check valve 5. Overhead laminated schematic holder 6. Loadable bi-directional hydraulic motor 7. Digital Display 8. Sequence valve (equipped with Safe-T- Bleed® bleed-off connectors) 9. Pilot-operated relief valve 10. Cylinder - double-acting, single-rod (equipped with Safe-T-Bleed® bleed-off connectors) 11. Pressure reducing valve (equipped with Safe-T-Bleed® bleed-off connectors) 12. Counterbalance valve 13. Mechanical load engage mechanism 14. Pressure-compensated flow control valve - restrictor type 15. Cylinder - double-acting, double-rod (equipped with Safe-T-Bleed® bleed-off connectors) 16. Pilot-operated check valve 17. Swing-out power unit assembly with convenient work tray 18. Variable displacement, pressure-compensated piston pump 19. One-way flow control valve 20. Needle valve 21. Flex Plate w/solenoid activation button (open-center, handlever-operated, mobile directional control valve included) 22. Cylinder load - mechanically-actuated 23. Direct-operated relief valve 24. Motor Torque Control port 25. Directional control valve - (float-center) - solenoid-operated with flow control module 26. Directional control valve - (closed-center) - solenoid-operated with flow control module 27. Module storage tray 28. Directional control valve - (closed-center) - solenoid-operated with flow control module 29. Directional control valve - (tandem-center) - solenoid-operated with dual one-way flow control module 30. Return line filter 31. Four (4) joysticks - For directional control valve operation 32. Coil voltage test leads 33. Dual 0-2.0 GPM (0-7.57 Lpm) inline flow meters 34. Ball valve (equipped with Safe-T-Bleed® bleed-off connectors) 35. Oil fill port (one-side only) (*MF102-H-TS models only.). 12 Figure 4-6 (Location of components may vary) 2 30 10 20 18 16 15 14 13 21 232527 262829 31 1 121197 6 5 4 3 33 34 17 24 19 22 8 35 32 13 Your MF102-H-TSE Hydraulic Simulator is loaded with components. Take a moment to familiarize yourself with the components found on your simulator (Location of components may vary). 4.6 Front view (Dual-station) - (Figure 4-6) 4.0 Familiarizing yourself with the MF102-H-TSE Simulator 1. Swing-out hose storage caddy 2. Power unit ON/OFF switch 3. Microleak test pump 4. Touchscreen monitor 5. Check valve 6. Loadable bi-directional hydraulic motor 7. Digital Display 8. Sequence valve (equipped with Safe-T- Bleed® bleed-off connectors) 9. Pilot-operated relief valve 10. Cylinder - double-acting, single-rod (equipped with Safe-T-Bleed® bleed-off connectors) 11. Pressure reducing valve (equipped with Safe-T-Bleed® bleed-off connectors) 12. Counterbalance valve 13. Mechanical load engage mechanism 14. Pressure-compensated flow control valve - restrictor type 15. Cylinder - double-acting, double-rod (equipped with Safe-T-Bleed® bleed-off connectors) 16. One-way flow control valve 17. Pilot-operated check valve 18. Variable displacement, load-sensing, pressure-compensated piston pump 19. Swing-out power unit assembly with convenient work tray 20. Needle valve 21. Flex Plate w/solenoid activation button (open-center, handlever-operated, mobile directional control valve included) 22. Cylinder load - mechanically-actuated 23. Direct-operated relief valve 24. Module storage tray 25. Motor Torque Control port 26. Directional control valve - (float-center) - solenoid-operated with flow control module 27. Directional control valve - (closed-center) - solenoid-operated with flow control module 28. Directional control valve - (closed-center) - solenoid-operated with flow control module 29. Directional control valve - (tandem-center) - solenoid-operated with dual one-way flow control module 30. Return line filter 31. Four (4) joysticks - For directional control valve operation 32. Coil voltage test leads 33. Dual 0 - 2.0 GPM (0 - 7.57 Lpm) inline flow meters 34. Ball valve (equipped with Safe-T-Bleed® bleed-off connectors) 35. Oil fill port (one-side only) 14 4.7 Ball Valve - When the ball valve handle is at right angles to the oil transmission line it is closed (Figure 4-6). Shift the handle until it is more or less parallel with the oil transmission line to open it (Figure 4-7). 4.8 Digital Display - (Figure 4-8) - The digital display contains a stop watch, ambient temp, oil temp, mo- tor rpm, and ammeter. The digital display on the MF102-H-TS and TSE models will also display the troubleshooting buttons which allow the instructor to set the faults. (Figure 4-9) Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator 15 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Figure 4-10 Figure 4-11 Figure 4-12 Figure 4-13 4.9 *Fixed Displacement and Pressure- Compensated Hydraulic Pumps - The simulator is designed so students can learn how both conventional fixed-displacement, “open-center” type hydraulic systems, and pressure- compensated, “closed-center” type systems operate. It is important, when learning hydraulics, for the transition from an “open-center” environment to a “closed-center” environment to be “realistic” and seamless. To accomplish this, instead of putting two different types of pumps on the simulator, the MF102 models employ a unique 4-station manifold design, which accomplishes the same thing. On the right-hand side of the tray there is a quick-coupler which is adjacent to the symbol for a fixed displace- ment pump (Figure 4-10). To the right of that quick-coupler there is a symbol for a variable volume, pressure- compensated pump (Figure 4-11). The left-hand directional control valve on the MF102 series simulator (Figure 4-12) is generally used in “open-center” hydraulic system designs which, are typically tandem- center or open-center. The three right-hand directional control valves on the MF102 series simulators (Figure 4-13) are generally used in “pressure manifold” or “closed-center” hydraulic design. They are typically float-center or closed-center. 16 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Although it is not visually detectable, the manifold is divided into two completely separate chambers (Figure 4-14). When a student is doing “hands-on” activities pertaining to a fixed-displacement type pump, either the open-center or tandem-center valve is used. When doing activities associated with a variable-displacement, pressure- compensated pump, either the closed-center or float-center valve is used. This unique design helps the students learn how “open-center” and “closed-center” systems work without any confusion - the transition is absolutely seamless! It is important to note that when a student is working with either the open-center or float center directional control valves, the “pump” and “tank” connections MUST be made on the corresponding side of the manifold (Figure 4-15). When working with the closed-center or float-center directional control valves, the “pump” and “tank” connections MUST be made on the opposite side of the manifold (Figure 4-16). Figure 4-14 Figure 4-15 Figure 4-16 “P” “T” “Open-center” side “T” “P” “Closed-center” side 17 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Figure 4-19a Figure 4-20 4.11 Variable Displacement, Pressure-compensated Pump - The variable displacement, pressure-compensated pump has two adjustments: 1. Pressure adjustment: The pressure adjusting screw is located on the pressure-compensator (Figure 4-19a). It consists of a threaded rod with a jam-nut. The pressure compensator is pre- set at 1000 PSI (69 bar). The pressure adjusting screw, for trainers equipped with the load-sense pump option, is located on the block on top of the pump (Figure 4-19b). 2. Flow adjustment: The flow adjusting screw is located on the back of the pump housing (Figure 4-20). It consists of a threaded rod with a jam-nut. The pump flow is pre-set at 1.0 GPM (3.8 liters). 4.10 Power Unit - The power unit (located under the right side of the front tray) is locked in place with a self-locking mech- anism (Figure 4-17). To swing the power unit out from under the tray, lift up on the latch and swing the power unit out into position (Figure 4-18). To store the power unit under the tray, simply swing it back under the front tray. The latch mechanism will drop into place locking the power unit into position. Figure 4-17 Figure 4-18 Figure 4-19b 18 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator Figure 4-22 4.13 Component Adjustment Screws - You will notice that many of the valves on the trainer have an adjusting screw with knurled knobs. One of them - the pilot-operated check valve (Figure 4-22) does not have a knob. This is the only valve which is non-adjustable. With the exception of the counter- balance valve, turning the adjusting knob in (clockwise from the top of the valve) increases pressure and turning it out (counter-clockwise), decreases the pressure. The counterbalance valve adjust- ment is totally opposite to the other valves - turning the valve adjust- ment knob in (clockwise from the top of the valve), decreases pressure, and turning it out (counterclockwise), increases the pressure. 4.12 Load-sense pump (optional) - To operate the pump in load-sense mode, the handle of the ball valve must be perpendicular with the body. To operate in pressure-compensated mode, the handle of the ball valve must be parallel with the body (Figure 4-21). Figure 4-21 19 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator 4.14 Valve Body Markings - A critical component in the design of the MF102 series simulators was to keep all component markings consistent with what is typically found in the “real world.” Generally, these markings consist of letters and numbers. The only deviation from an actual valve is that the markings are bold. The markings on a directional control valve manifold consist of the letters “P” and “T” which represent “pump” and “tank.” “A” and “B” typically represent the “work ports.” Cartridge valve manufacturers generally mark the ports on their respective valves with numbers - “1,” “2,” and, if it’s a 3-port valve, the number “3” (Figure 4-23). Figure 4-23 WARNING There are no standards, that FPTI™ is aware of, with regard to what symbol a manufacturer uses to mark cartridge valve bodies, or the relationship of that symbol to the port. NEVER assume, for example, that if one manufacturer marks the inlet port with the number “1” that all cartridge valve manufacturers use the same marking. ALWAYS check the respective cartridge valve manufacturers speci- fications with respect to port markings before making connections. An error could result in severe injury or death. The cartridge valves on the MF102 model simulators are manufactured by Sun Hydraulics™. All markings on the valve bodies are made in accordance with the manufacturer’s specifications. 20 4.15 Flex Plate - The Flex Plate is a standard fixture on all MF102 series simulators. The Flex Plate allows the instructor to add a number of optional valves to the simulator to extend its teaching capabilities to the students (Figure 4-24). 4.16 24VDC Electrical Fuse - All MF102 series simulators are equipped with 24VDC slow-blow 6 amp fuses to protect the electrical system in the event of a power spike or surge (Figure 4-25). See Section 13.0 for further details. 4.17 AC Electrical Fuse Breaker - All MF102 series simulators are equipped with AC fuse breakers to protect the electrical system in the event of a power spike or surge (Figure 4-25). See Section 13.0 for further details. Figure 4-24 Figure 4-25 4.0 Familiarizing yourself with the MF102 Simulator Let’s take a walk around the Simulator 21 5.0 Familiarizing yourself with the Additional Components Figure 5-1 5.1 Pressure/Leak Test Pump (Microleak Tester) - The pressure/leak test pump is designed for testing a variety of hydraulic components. While it bears resemblance to a commer- cial porta-power, it is not a porta- -power. The pressure/leak test pump does not need to be filled with oil. It automatically fills when ever the power unit is operating. If, while the pressure/leak test pump is being used, it runs out of o i l , s imply connect the pump directly to a tank port and let the pump run for approximately 30 seconds, and it will re-fill. To operate the pressure/leak test pump, s imply rotate the knob (Figure 5-1) clockwise until it stops, a n d m o v e t h e h a n d - l e v e r backwards and forwards. To release the pressure, rotate the knob counterclockwise unt i l i t stops. (MF102-H-TS & MF102-H-TSE models only) (These items are included on both the single-station and dual-station trouble- shooting simulators and are NOT included with the MF102-H simulators). 22 Step 2: Next, carefully aim the laser between the openings in the fan safety guard at the reflective tape (Figure 5-6). Hold the tachometer steady, and depress the side button. Wait a few seconds for the tach- ometer to respond. Pushing the MEM button on the tachometer will automatically submit the indicated speed to the tachometer’s memory. 5.2 *Digital, Hand-Held, Laser-Type Tachometer - The hand-held tachometer, located in the module tray underneath the t ra iner (F igure 5-12), is used primarily when students are learning troubleshooting ski l ls. Its main purpose is for students to observe and record prime-mover (electric motor) speed. The state-of-the-art tachometer needs a re f l ec t i ve f eedback medium to operate properly. A piece of self-adhesive reflective tape has been attached to the electric motor’s cooling fan (Figure 5-4) for this purpose. Step 1: To operate the tachometer, first adjust the switch the correct position- “RPM” (Figure 5-5). Figure 5-4 Figure 5-5 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators Figure 5-6 23 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators 5.3 *Flow Meter Test Kit - The flow meter test kit, located in the module tray underneath the trainer (Figure 5-12), consists of an in-line, 0-2.0 GPM (0.76 liters) flow meter, a load-cell, a 0-1000 PSI (0-69 bar) glycer ine-f i l led p r e s s u r e g a u g e , a n d q u i c k - connectors (Figure 5-7). It is identical to the two (2) which are mounted on the panel. The only difference is that this one is con- figured identically to those used in the field. To operate the flow meter simply connec t i t i n -ser ies w i th the appropriate oil transmission line. Open the load-valve (turn counter- clockwise) and proceed. Closing the load-valve will restrict the flow and create an “artificially generated load” which is necessary when executing certain component test procedures. Figure 5-7 *These items are included in the optional diagnostic accessories package (MF102-DA) which is available for purchase. 24 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators 5.4 *Case Pressure Gauge (0-100 PSI/0-6.9 bar) - There are two pressure check points on the pump - one for checking pump case pressure, and the other for checking case drain-line resistance. Two pressure check points are needed because excessive case pressure can be caused by excessive internal leakage or, excessive case drain-line resistance. The 0-100 PSI (6.9 bar) pressure gauge is equipped with a special connector, which permits safe installation and removal on both the case pressure connector and the case drain-line connector, under pressure. Step 1: To install the case pressure gauge, remove the metal dust c a p f r o m t h e a p p r o p r i a t e connector (Figure 5-8). Step 2: Screw the knurled female swivel connector on the gauge onto the male connector on the pump. Hand-tighten only (Figure 5-9 & Figure 5-10). Always replace the dust cap after use to keep contami- nation out of the connector. NOTE: Once the case drain pressure gauge is installed, DO NOT attempt to store the power unit under the oil drip tray as damage to the gauge and/or tray may occur (Figure 5-11). When the case pressure gauge is not in use, store in the module tray located underneath the trainer (Figure 5-12). Figure 5-8 Figure 5-11 Figure 5-9 Figure 5-10 25 Figure 5-12 Figure 5-14 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators 5.5 Module Storage Tray - A tray is located underneath the simulator for clutter-free storage of all the diagnostic equipment that is used with the MF102-TS model trainers. The storage tray also conveniently stores several of the modules that can be affixed to the Flex-Plate. 5.6 *Vacuum Gauge - A glycerine-filled vacuum gauge, located in the module tray underneath the trainer (Figure 5-12), is provided for students to learn how to check pump inlet restriction. A vacuum gauge is an extremely sensitive instrument. When a gauge is filled with glycerine it will have a sealed case to prevent the glycerine from leaking out. Changes in ambient temperature will cause minor fluctuations in the case pressure as expansion and contraction naturally occurs. These pressure fluctuations could have a negative effect on the gauge’s accuracy. To overcome this problem, the vacuum gauge is equipped with a plastic case plug. When the case plug is moved to the OPEN position it momentarily opens the case to atmosphere and allows the pressures to equalize. Before using the vacuum gauge - especially if the needle is not pointing to the “0 Hg” position - hold the gauge in the upright position, move the small plastic plug to the OPEN position (Figure 5-13) for a few seconds, and then move it back to the CLOSED position (Figure 5-14). The vacuum gauge should now be ready for use. Figure 5-13 *These items are included in the optional diagnostic accessories package (MF102-DA) which is available for purchase. 26 Figure 5-15 5.0 Familiarizing yourself with the Additional Components used with the MF102-H-TS & MF102-H-TSE Simulators The vacuum gauge and pump, are equipped with a special pressure coupling system. This coupling system makes it possible to safely install and remove the vacuum gauge while the pump is operating. The female swivel on the vacuum gauge mates with a threaded male coupling which is fastened to the connector at the inlet port of the pump (Figure 5-15). The connector is equipped with a metal dust cap which is chained to the connector to prevent it from falling to the ground or from being misplaced. To install the vacuum gauge, screw the metal dust cap off, and place the connector on the thread and rotate the knurled swivel - hand-tighten only! Always replace the dust cap after use to keep contamination out of the connector. 5.7 Motor Torque Control valve - This motor torque control valve is used to adjust the flow to the motor. Turn- ing the knob counterclockwise will decrease the flow and turning the knob clockwise will increase the flow. (Figure 5-16).. Figure 5-16 27 6.0 Installing the Touchscreen Monitor(s) (MF102-H-TSE models only) After unpacking your MF102-H-TSE mod- el trainer, you will need to mount your touchscreen(s). NOTE: Two (2) people are required to safely install the touchscreen. Step 1: To install the touchscreen, one per- son aligns the mounting holes on the back of the touchscreen with the mounting holes on the bracket while the second person installs the four (4) screws (Figures 6-1 & 6-2). Step 2: On the bottom of the touchscreen connect the computer to the trainer. First select the black round cable. This will be plugged into the far-left round connector port (Figure 6-3). Figure 6-1 Figure 6-2 Figure 6-3 28 6.0 Installing the Touchscreen Monitor(s) (MF102-H-TSE models only) Step 3: Now select the white USB cable. This will be connected to the right of the power connection into the port labeled, “USB.” Once these cables have been connected. The touchscreen can now be safely powered on. WARNING Plugging the MF102 simulator into a power source BEFORE plug- ging the USB cable into the monitor may cause erratic monitor operation. WARNING NEVER unplug the simulator power source until the touchscreen monitor(s) have been shut off using the BLACK button on the side of the monitor. 7.0 Touchscreen Monitor Startup Instructions (MF102-H-TSE models only) START-UP Once the simulator has been plugged back in and turned on, the USB cable and power cable have been plugged into the monitor, and the power button on the front of the monitor has been pressed, the touchscreen monitor will automatically begin startup. HOW TO EXIT THE TRAINING PROGRAM There are two (2) instances in which the instructor will need to exit the training program completely and access the operating system: 1. System/software upgrades. 2. Manual activation of troubleshooting solenoids. Figure 6-4 29 To exit the training program for upgrades, follow these steps: 1. Go to the HOME screen and, select the INSTRUCTOR LOGIN button. 2. When the Key-Pad screen appears enter the following code: 9989 select ENTER. 3. The Instructor log-in page will appear, press the SYSTEM SETTINGS button. 4. Then select the EXIT TO WINDOWS button. 5. A little window will popup, select YES. This will exit the program allowing you access to Windows™. To re-enter the training program without upgrading or making any changes, double click the FPTI™ icon on the desktop. To update the training software: 1. Go to the HOME screen and, select the INSTRUCTOR LOGIN button. 2. When the Key-Pad screen appears enter the following code: 9989 select ENTER. 3. From the left menu, select SYSTEM SETTINGS. 4. From this screen you can then select CHECK FOR UPDATES. You will then be asked to make sure you have an internet connection. After making sure you are connected to the internet, select YES to proceed. To manually fault the components for troubleshooting follow these steps: 1. Go to the HOME screen and, select the INSTRUCTOR LOGIN button. 2. When the Key-Pad screen appears enter the following code: 9989 select ENTER 3. From the left menu, select MANAGE FAULTS. 4. This will display a list of all the components that can be faulted. 4. Select the button of the component that you wish to fault. The button will turn RED indicating that the component has been “faulted.” 5. To return the component to its original state, select the component button again and the box will turn GREEN. IMPORTANT NOTE: When a component has been manually faulted it must also be manually reset after the activity has been completed otherwise it will remain in the “faulted” position. ADDITIONAL INFORMATION To change the time/date displayed on the monitor, exit the training program, go to the Windows™ operating system, click the bottom left-hand corner of the screen to make the Windows™ bar accessible, and click on the time/date icon in the bottom right-hand corner of the screen. To re-enter the training program without upgrading or making any changes, double click the FPTI™ icon on the desktop. 30 8.0 Troubleshooting Button Reference Guide (MF102-H-TS models only) Figure 8-1 Direct-operated Relief Valve (GREEN = Normal Operation) (RED = Fault) Check Valve (GREEN = Normal Operation) (RED = Fault) Double-Rod Cylinder (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Closed-Center "B" port) (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Closed-Center "A" port) (GREEN = Normal Operation) (RED = Fault) Pressure Reducing Valve (GREEN = Normal Operation) (RED = Fault) Sequence Valve (GREEN = Normal Operation) (RED = Fault) Pilot-operated Relief Valve (GREEN = Normal Operation) (RED = Fault) Counterbalance Valve (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Tandem-Center "A" & Float-Center "A" ports) (GREEN = Normal Operation) (RED = Fault) Directional Control Valve (Tandem-Center "B" & Float-Center "B" ports) (GREEN = Normal Operation) (RED = Fault) Hydraulic Pump (GREEN = Normal Operation) (RED = Fault) 1 2 3 4 5 6 7 8 9 10 12 Tandem-Center Directional Control Valve "A" Solenoid (GREEN = Normal Operation) (RED = Fault)14 Single-Rod Cylinder (GREEN = Normal Operation) (RED = Fault) 13 11 Hydraulic Motor (GREEN = Normal Operation) (RED = Fault) Pilot-to-Open Check Valve (GREEN = Normal Operation) (RED = Fault) 16 BLANK17 15 The following diagram (Figure 8-1) indicates the button number, component type, and button color for the normal operation and fault mode. 31 9.1 MF100-ACC - Accumulator Unloading Valve module (if applicable) - SAFETY INSTRUCTIONS: a. Wear safety glasses when installing the accumulator package. b. Due to the unbalanced weight of the optional sideplate modules, at least two people are required to perform this job safely. Step 1: Loosen the two (2) hand-latches (Figure 9-1) located on the upper left-hand side of the front panel. Step 2: Gently slide the option assembly into the slot (Figure 9-2) in the side cover of the simulator and make sure that the option assembly drops into position (Figure 9-3). 9.0 Installing the Option Package(s) Figure 9-1 Figure 9-3 Figure 9-2 32 Step 3: Tighten the two hand latches securely (Figure 9-6). Step 4: Make the necessary connections to the mainframe simulator. 9.0 Installing the Option Package(s) Figure 9-6 Figure 9-4 Figure 9-5 Frame Front panel Loosened latch (qty. 2) The diagrams below (Figures 9-4 & 9-5) illustrate how to correctly position the bracket on the mounting bosses which are welded to the frame. 33 9.2 MF100-PDCV - Proportional Directional/Flow Control Valve package (if applicable) - 9.0 Installing the Option Package(s) Figure 9-10 CAUTION DO NOT connect the simulator to an electrical power source until this installation is complete. SAFETY INSTRUCTIONS: a. Wear safety glasses when in- stalling the Proportional Directional/ Flow Control Valve package. b. Due to the unbalanced weight of the optional sideplate modules, at least two people are required to perform this job safely. Step 1: Loosen the two (2) hand-latches (Figure 9-10) located on the upper right-hand side of the front panel. Step 2: Gently slide the option assembly into the slot in the side cover of the simulator (Figure 9-11) and make sure that the option assembly drops into position. Figure 9-11 34 9.0 Installing the Option Package(s) Step 3: Tighten the two hand-latches securely (Figure 9-14). Step 4: Make the necessary connections to the mainframe trainer. Step 5: There are either one (1) or two (2) 24VDC receptacles located on the side plates of the mainframe simulators (Figure 9-15). Plug the Proportional Directional/ Flow Control Valve cord into one of the receptacles and slide the locking arm into position. Figure 9-14 Figure 9-15 Figure 9-12 Figure 9-13 The diagrams below (Figures 9-12 & 9-13) illustrate how to correctly position the bracket on the mounting bosses which are welded to the frame. Frame Front panel Loosened latch (qty. 2) 35 10.0 Preparing Your Simulator for Use Once you are satisfied that the parts and accessories are in good condition and ac- counted for, and, you have familiarized yourself with the MF102 simulator, go ahead and install the parts and accessories into their respective positions on the simulator. Figure 10-1 Figure 10-2 Figure 10-4 Figure 10-3 10.1 0-1500 PSI (0-103.4 bar) Pressure Gauges - There are three (3) 0-1500 PSI (0-103.4 bar) pressure gauges, located in the module tray under- neath the trainer (Figure 5-12), which are marked P1, P2, and P3. They may be placed on the power unit tray or on the main tray while the simulator is in use (Figure 10-1). 10.2 Filling the MF102 Simulator with Oil - Fill the simulator with a good quality AW-32 hydraulic fluid. Reservoir Capacity (approx.): 4.5 U.S. gallons (17 liters). Step 1: Remove the filler/breather cap (Figure 10-2) and screw the oil funnel into the filler boss (Figure 10-3). Hand-tighten only. Location of oil filler may vary. The oil funnel is capable of turning the oil flow ON and OFF. To allow flow, rotate the oil funnel in a counter-clockwise direction. To stop flow, rotate the oil funnel in a clockwise direction. Step 2: Fill the simulator until oil is visible in the oil level sight glass on the reservoir (Figure 10-4). 36 10.0 Preparing Your Simulator for Use Figure 10-5 Figure 10-6 Step 3: Connect a hose from the pump outlet port to the bottom of the Flow meter. Connect the top of the flow meter to the tank return port (Figure 10-5). Step 4: Connect a suitable grounded elec- trical cord from the simulators electrical plug (Figure 10-6) to a 115 volt, 15 amp, single-phase elec- trical circuit (for each motor). Step 5: Start the power unit using the main electrical ON/OFF switch (Figure 10-7). After waiting a minute, recheck the oil level. Top-up if necessary. Step 6: Remove the oil funnel. Step 7: Replace the oil filler/breather cap. 10.3 Laminated Schematic Pages Holder (All MF102 models except TSE) - Step 1: Install the laminated schematic holder on the post located on the left-hand side of the simulator (Figure 10-8). Step 2: Remove the laminated sche- matics from their packaging. Slip the three (3) retaining rings over the arm and into position (Figure 10-9). Figure 10-7 Figure 10-8 Figure 10-9 37 10.0 Preparing Your Simulator for Use 10.5 Hose Caddy - The hoses used on the simulator are stored neatly under the left- hand side of the front tray on a swing-out caddy (Figure 10-12). To swing out the hose caddy, locate the hose caddy retention pin and re- move it (Figure 10-13). Once the pin has been removed rotate out from underneath the front tray. The T connectors are stored on the underside of the hose caddy. To access them remove the T connector pin (Figure 10-14). To store the hose caddy under the tray, simply swing it back under the front tray and re-insert the hose caddy pin to lock in place. Figure 10-13 Figure 10-14 Figure 10-12 38 11.0 Safety Features Figure 11-2Figure 11-1 Figure 11-3 WARNING DO NOT operate the simulator without the safety covers. If a safety cover is removed, it MUST be replaced BEFORE operating the simulator. Failure to replace the safety cover(s) could result in an accident which could cause severe injury or death. 11.1 Transparent Safety Covers - Transparent safety guards allow a person to see how components operate while protecting them from moving mechanisms. There are four (4) safety guards on the MF102 series simulators which cover: • Hydraulic motor output shaft (Figure 11-1) • Hydraulic cylinder double-rod C2 - Upper (Figure 11-2) • Weight-load system (Figure 11-3) 39 12.0 Powering up your Simulator NOTE: The symbol for each component is clearly printed on the panel, adjacent to the re- spective component. Figure 12-1 To familiarize yourself with the operation of the MF102 series simulator, go ahead and construct this simple hydraulic circuit shown below. Step 1: Build the circuit as shown on Figure 12-1. Step 2: Start the motor and set the pressure relief valve at 500 PSI (34.5 bar) - dead-head the cylinder to set the pressure relief valve. Step 3: Operate the A-B toggle switch and extend the cylinder rod. Step 4: Now retract the cylinder rod - it’s that simple! 40 13.0 Simulator Specifications Figure 13-1 Simulator dimensions Electrical: US & Canada - 115VAC single-phase. 10 amp service. International - 220VAC single-phase. 50 Hz. Hydraulic Pump: 1.0 GPM (3.79 Lpm) variable-displacement, pressure- compensated piston pump. Operating Pressure (max.): 1000 PSI (69 bar) Oil: AW32 hydraulic oil. Reservoir Capacity: approx. 4.5 U.S. gallons (17 liters) Motor Displacement: 0.25 cu. in./rev. (4.1 cu. cm/rev.) Cylinder Rod Diameter: 1.0” (25.4 mm) Single-rod and Double-rod Cylinder Stroke: 14” (355.6 mm) Single-rod and Double-rod Trainer Weight: MODEL SINGLE UNIT DOUBLE UNIT (Does not include MF102-H 910 lbs (413 kg) 1125 lbs (510 kg) packaging weight) MF102-H-TS 920 lbs. (417 kg) 1145 lbs (519 kg) MF102-H-TSE 940 lbs (426 kg) 1205 lbs (547 kg) Fuses and Breakers: 24VDC fuse (6 amp SLOW BLOW) 115-220VAC breaker (push button to reset) 41 14.0 Service and Maintenance Figure 14-1 Figure 14-2 Figure 14-3 DAILY: 1. Check oil level. 2. Check for oil leaks dripping to floor - repair immediately to prevent slip hazard. 3. Inspect, and replace if necessary, safety covers on hydraulic motor shaft, cylinder rods, and, weight. 4. Inspect, and replace if necessary, any faulty quick-disconnects. 5. Inspect electrical wires and connections. 6. Inspect for loose bolts. ANNUALLY: 1. Drain oil and replace - approximately 4.5 U.S. gallons [17 liters] (See 14.1). 2. Remove oil filter and replace (See 14.2). 14.1 Draining the Oil - The oil reservoir is located on the frame. An oil drain is located on the underside of the reservoir. Step 1: To drain the oil, first make sure the handle of the drain cock is in the horizontal (closed) position (Figure 14-1). Step 2: Use a 5/16” allen wrench, and remove the plug from the bottom of the drain valve (Figure 14-2). Step 3: Place a receptacle, which holds at least 4.5 U.S. gallons (17 liters), under the drain valve and turn the handle to the vertical (open) position (Figure 14-3). NOTE: The reservoir holds about 4.5 U.S. gallons (17 liters) of oil. Step 4: When the reservoir is empty, close the drain valve and replace the plug. Your MF102 series simulators are designed to require very little maintenance. However, to give you years of trouble-free operation there are a few things you must do: 42 14.0 Service and Maintenance 14.2 Oil Filter Service - The MF102 series simulators are equipped with a spin-on/off type filter element (Figure 14-4). To replace the filter element: Step 1: Disconnect the power supply and lock the simulator out. Step 2: Place a receptacle on the floor beneath the filter to contain the small amount of leakage which may occur. Step 3: Turn the filter element, by hand and slowly remove it. Step 4: Discard the filter element in accordance with local and state laws. Step 5: Lubricate the seal on the new filter with hydraulic oil. Step 6: Install the new filter element and tighten securely - DO NOT overtighten. Step 7: Fill the reservoir with new oil until it is present in the sight glass (See 10.2). Step 8: Start the power unit and allow it to run for approximately 30 seconds. Step 9: Recheck the oil level. If necessary, add oil until it is present in the sight glass. Step 10: Wipe residual oil off the new filter element. Step 11: Inspect the floor for signs of oil which may have spilled while removing the filter element. Clean oil spills thoroughly to prevent a slip-type accident. Figure 14-4 43 15.0 Troubleshooting your Simulator 16.0 Where to Get Help * MF102-H-TS and TSE model simulators only. PROBLEM SOLUTION 1. Simulator does not power up. a. Check electrical connections. b. Push down firmly on power unit ON/OFF switch and reset breaker. c. Reset AC fuse breaker by pressing in. 2. Pump makes a noise (cavitation). a. Check oil level. If, after following the troubleshooting guide the problem still persists, call the Fluid Power Training Institute™ for assistance at 1-888-222-3421. Please have your model number and serial number available when you call. 17.0 Recommended Spare Parts List The MF102 series simulators are designed with as few parts requiring replacement as possible and to provide you with many years of trouble-free performance. They are equipped with parts which are designed for high-cycle operation. Given the proper care they should last for many years. However, certain items need regular service to keep your trainer operating reliably. ITEM PART # DESCRIPTION 1. SF6520 Oil filter. 2. AA battery (qty. 2) *Tachometer (hand-held) battery. 3. 6 amp SLOW-BLOW fuse Fuse for 24VDC system 44 18.0 Manufacturer’s Warranty Information The MF102 series simulators are covered by their manufacturer’s respective warranty. FPTI™ also offers an additional 2-year warranty, guaranteeing the simulator will be free from defects for that period of time. If any problems arise, that are not covered by this manual, contact FPTI™ immediately. If any attempt is made to disassemble or alter any component on the simulator, without the consent of FPTI™, this warranty will be void. I 19.0 INDEX A Accessories . . . . . . . . . . . . . . . . . .35 Accumulator. . . . . . . . . . . . . . . . . .31 Adjusting screw component . . . . . . . . . . . . . . . . . .18 flow adjustment . . . . . . . . . . . . . .17 pressure adjustment . . . . . . . . . .17 B Ball valve . . . . . . . . . . . . . . .11,13,14 Battery . . . . . . . . . . . . . . . . . . . . . .43 Brakes caster . . . . . . . . . . . . . . . . . . . .4,5,6 Breaker . . . . . . . . . . . . . . 9,20,40,43 C Case pressure gauge . . . . . . . . . .24 Casters . . . . . . . . . . . . . . . . . . .4,5,6 Cautions . . . . . . . . . . . . . . . 1,5,6,33 Checklist . . . . . . . . . . . . . . . . . . . . .7 Check valve basic . . . . . . . . . . . . . . . . . . . 11,13 Pilot-operated . . . . . . . . . . . . 11,13 Closed-center . . . . . . . . . . . . . 11,13 Counterbalance . . . . . . . . . .11,13,18 Cylinder double-rod . . . . . . . . . . 11,13,38,40 single-rod . . . . . . . . . . . . . .11,13,40 D DC 24 volt . . . . . . . . . . . .9,20,34,40,43 Digital display . . . . . . . . . . .11,13,14 Directional control valve closed-center . . . . . . . . 11,13,15,16 float-center . . . . . . . . . 11,13,15,16 open-center . . . . . . . . . 11,13,15,16 proportional . . . . . . . . . . . . . . . . .33 tandem-center . . . . . . . . . .11,13,16 Direct-operated relief valve . . . 11,13 Drain oil. . . . . . . . . . . . . . . . . . . . . . . . .41 E Electrical 24VDC . . . . . . . . . . . .9,20,34,40,43 AC. . . . . . . . . . . . . . . . . . . . . . . . .9 connections . . . . . . . . . . . . .1,41,43 power . . . . . . . . . . . . . . 11,13,33,36 Extension cord . . . . . . . . . . . . . . . . .1 F Familiarization . . . . . . . . . . .11,13,39 Filler/breather . . . . . . . . . . . . . 35,36 Filling with oil . . . . . . . . . . . . . . . . .35 Filter element oil. . . . . . . . . . . . . . . . . . . . . . 42,43 Fixed displacement pump . . . . . . .15 Flex Plate. . . . . . . . . . . . . . .11,13,20 Float-center . . . . . . . . . . 11,13,15,16 Flow adjustment pump . . . . . . . . . . . . . . . . . . . . . .17 Flow control valve . . . . . 11,13,33,34 Flow meter inline . . . . . . . . . . . . . . . . . . . 11,13 test kit . . . . . . . . . . . . . . . . . . . . .23 Funnel oil. . . . . . . . . . . . . . . . . . . . .7,35,36 Fuse 6 amp slow-blow . . . . . . 9,20,40,43 AC breaker . . . . . . . . . . . . . . 20,43 G Gauges case pressure . . . . . . . . . . . . . . .24 pressure . . . . . . . . . . . . 7,23,24,35 vacuum . . . . . . . . . . . . . . . .7,25,26 Glasses Safety . . . . . . . . . . . . . . . 2,3,31,33 H Handle ball valve . . . . . . . . . . . . . . . . . . .14 Holder schematic . . . . . . . . . . . . . . . . . .36 Hose caddy . . . . . . . . . . . . . . . . .11,13,37 hydraulic . . . . . . . . . . . . . . . . . . . .7 Hydraulic hose . . . . . . . . . . . . . . . . . . . . . . . .7 oil. . . . . . . . . . . . . . . .1,26,35,40,42 reservoir . . . . . . . . . . . . . . . . 35,40 L Laminated schematics . . . . . . . 11,36 II 19.0 INDEX Load. . . . . . . . . . . . . . . . . . . . . 11,13 M Maintenance . . . . . . . . . . . . . . 41,42 Manifold . . . . . . . . . . . . . . . .15,16,19 Meter amps . . . . . . . . . . . . . . . . . . . . . . .1 flow . . . . . . . . . . . . . .7,11,13,23,36 Microleak tester . . . . . . . . . . . . . . .21 Monitor. . . . . . . . . . . . . . . . .13,28,29 Motor electric . . . . . . . . . . . . . . . . . . 22,36 hydraulic . . . . . . 11,13,26,38,40,41 O Oil drain . . . . . . . . . . . . . . . . . . . . . .41 filler/breather . . . . . . . . . . . . . 35,36 filling . . . . . . . . . . . . . . . . . . . . . .35 filter . . . . . . . . . . . . . . . . . .41,42,43 funnel . . . . . . . . . . . . . . . . . .7,35,36 hydraulic . . . . . . . . . . . . 1,26,40,42 P Pallet . . . . . . . . . . . . . . . . . . . . .3,5,6 Parts list. . . . . . . . . . . . . . . . . . . . . . . . . .7 spare . . . . . . . . . . . . . . . . . . . . . .43 Pilot-operated check valve . . . . . . . . . . . . . . 11,13 relief valve . . . . . . . . . . . . . . . 11,13 Power unit . 11,13,17,21,24,36,42,43 Pressure adjustment . . . . . . . . . . . . . . . . . .17 gauge . . . . . . . . . . . . . . . . . . . 7,23 case pressure . . . . . . . . . . . . . .24 reducing valve . . . . . . . . . . . . 11,13 Pressure-compensated piston pump . 11,13,17 Pressure compensator . . . . . . . . .17 Pressure/leak test pump . . . . . 13,21 Proportional directional/flow control valve . . . . . . . . . . . . . . . . . . .33 Pump adjustment . . . . . . . . . . . . . . . . . .17 fixed-displacement . . . . . . . . 15,16 pressure-compensated . . . . . . . . . . 11,13,15,16,17,40 pressure/leak test . . . . . . . . . . . .13 R Receptacle electric . . . . . . . . . . . . . . 1,34,41,42 Reservoir . . . . . . . . . . . . 26,35,41,42 Restrictor type Pressure-compensated flow control valve . . . . . . . . . . . . . . . . . . . 11,13 S Safety glasses . . . . . . . . . . . . . . 2,3,31,33 transparent covers . . . . . . . . . . . .38 warnings . . . . . . . . . . .1,2,19,28,38 Schematic holder . . . . . . . . . .7,11,36 Sequence valve . . . . . . . . . . . . 11,13 Service. . . . . . . . . . . . . . . . . . . . . .42 Sight glass . . . . . . . . . . . . . . . . 35,42 Specifications . . . . . . . . . . . .1,19,40 Station eye-wash . . . . . . . . . . . . . . . . . . . .2 Switch electrical . . . . . . . 7,11,13,22,36,43 T Tachometer . . . . . . . . . . . . . .7,22,43 Tandem-center. . . . . . . . . . .11,13,16 Temperature ambient . . . . . . . . . . . . . . . . . 14,25 oil 14 Touchscreen . . . . . . . . . . . .13,27,28 Troubleshooting . . . . .14,22,28,29,43 U Unpacking . . . . . . . . . . . . . . . . i,3,27 V Vacuum gauge . . . . . . . . . . . .7,25,26 Valve ball. . . . . . . . . . . . . . . . 11,13,14,18 check . . . . . . . . . . . . . . . . . . . 11,13 counterbalance . . . . . . . . .11,13,18 directional control . . . . 11,13,15,19 direct-operated . . . . . . . . . . . 11,13 flow control . . . . . . . . . . . . . . 11,13 needle . . . . . . . . . . . . . . . . . . 11,13 III 19.0 INDEX pilot-operated . . . . . . . . . .11,13,18 pressure-compensated flow control 11,13 pressure reducing . . . . . . . . . 11,13 pressure relief . . . . . . . . . . . . . . .39 sequence . . . . . . . . . . . . . . . . 11,13 Variable displacement, pressure com- pensated pump . . . . . .11,13,17 W Warnings . . . . . . . . . . . .1,2,19,28,38 Warranty . . . . . . . . . . . . . . . . . . 2,44 Weight . . . . . . . . . . . . . . 31,33,40,41 If you have any questions that this document does not address, please contact us immediately for assistance. PO Box 711201 Salt Lake City, UT 84171 PH: 801-908-5456 FAX: 801-908-5734 e-mail: info@fpti.org web: www.fpti.org

EPA 2017 CUMMINS X15 DIESEL ENGINE BENCH BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 400-6330 Zéphirin-Paquet St Quebec City, PQ G2C 0M3 Canada Phone: 418.688.9067 / 800.567.0791 Fax: 418.843.3444 info@consulab.com WWW.CONSULAB.COM BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 2 of 11 ECM J1 CONNECTOR PIN SIGNAL TYPE FUNCTION 1 RETURN Injector Solenoid 1 (Pin 2) 2 RETURN Injector Solenoid 2 (Pin 4) 3 RETURN Injector Solenoid 3 (Pin 6) 4 DC SUPPLY Variable Geometry Turbocharger Actuator (Pin 1) 5 OUTPUT SIGNAL Aftertreatment Fuel Injector (Pin 2) 6 OUTPUT SIGNAL Aftertreatment Purge Air Actuator (Pin 1) 7 - Not Used 8 RETURN Aftertreatment Fuel Shutoff Valve (Pin 2) 9 - Not Used 10 RETURN Fuel Pump Actuator (Pin 1) 11 OUTPUT SIGNAL Fuel Pump Actuator (Pin 2) 12 - Not Used 13 OUTPUT SIGNAL Battery Power Required Lamp / Braking Lamp Relay (14-p Connector Pin 4) 14 DC SUPPLY Fuel Lift Pump (Pin 1) 15 - Not Used 16 RETURN Turbocharger Speed Sensor (Pin 2) 17 INPUT SIGNAL Turbocharger Speed Sensor Supply (Pin 1) 18 INPUT SIGNAL Camshaft Position Sensor (Pin 3) 19 INPUT SIGNAL Fan Speed Sensor (14-p Connector Pin 11) (Pin B) 20 - Not Used 21 - Not Used 22 INPUT SIGNAL Exhaust Gas Recirculation Valve - Position C (Pin 4) 23 OUTPUT SIGNAL Exhaust Gas Recirculation Valve - Motor A (Pin 8) 24 OUTPUT SIGNAL Exhaust Gas Recirculation Valve - Motor B (Pin 6) 25 OUTPUT SIGNAL Injector Solenoid 1 (Pin 1) 26 OUTPUT SIGNAL Injector Solenoid 2 (Pin 3) 27 OUTPUT SIGNAL Injector Solenoid 3 (Pin 5) 28 RETURN Variable Geometry Turbocharger Actuator (Pin 2) 29 RETURN Aftertreatment Fuel Injector (Pin 1) 30 RETURN Aftertreatment Purge Air Actuator (Pin 2) / Aftertreatment Fuel Shutoff Valve (Pin 1) 31 INPUT SIGNAL Crankshaft Position Sensor (Pin 3) 32 - Not Used 33 - Not Used 34 RETURN Coolant Temperature Sensor (Pin A) / Turbocharger Compressor Intake Temperature Sensor (Pin A) / Oil Temperature Sensor (Pin A) / Exhaust Gas Recirculation Temperature Sensor (Pin 2) 35 - Not Used 36 INPUT SIGNAL Exhaust Gas Pressure Sensor (Pin 3) 37 INPUT SIGNAL Aftertreatment Fuel Pressure Sensor (Pin 3) 38 - Not Used 39 RETURN Fuel Lift Pump (Pin 2) 40 - Not Used BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 3 of 11 ECM J1 CONNECTOR PIN SIGNAL TYPE FUNCTION 41 INPUT SIGNAL Fuel Level Sensor (14-p Connector Pin 12) (Pin B) 42 INPUT SIGNAL Fuel Rail Pressure Sensor - Pressure 2 - Temperature (Pin 4) 43 - Not Used 44 INPUT SIGNAL Barometric Pressure Sensor (Pin 3) 45 INPUT SIGNAL Intake Manifold Air Pressure/Temperature Sensor - Pressure (Pin 1) 46 INPUT SIGNAL Exhaust Gas Recirculation Valve - Position B (Pin 3) 47 INPUT SIGNAL Exhaust Gas Recirculation Valve - Position A (Pin 2) 48 OUTPUT SIGNAL Exhaust Gas Recirculation Valve - Motor C (Pin 7) 49 OUTPUT SIGNAL Injector Solenoid 4 (Pin 7) 50 OUTPUT SIGNAL Injector Solenoid 5 (Pin 11) 51 OUTPUT SIGNAL Injector Solenoid 6 (Pin 15) 52 - Not Used 53 - Not Used 54 RETURN Camshaft Position Sensor (Pin 2) / Intake Manifold Air Pressure/Temperature Sensor (Pin 4) / Barometric Pressure Sensor (Pin 2) / Crankcase Pressure Sensor (Pin 2) / Oil Pressure Sensor (Pin 2) 55 RETURN Crankshaft Position Sensor (Pin 2) 56 - Not Used 57 RETURN Aftertreatment Fuel Pressure Sensor (Pin 2) / Exhaust Gas Recirculation Differential Pressure Sensor (Pin 2) / Exhaust Gas Pressure Sensor (Pin 2) / Exhaust Gas Recirculation Valve (Pin 5) / Engine Intake Actuator Motor (Pin 4) / Exhaust Gas Recirculation Pressure Sensor (Pin 2) 58 RETURN Fuel Rail Pressure Sensor (Pin 2) 59 INPUT SIGNAL Fuel Rail Pressure Sensor - Pressure 1 (Pin 3) 60 - Not Used 61 INPUT SIGNAL Turbocharger Compressor Intake Temperature Sensor (Pin B) 62 INPUT SIGNAL Intake Manifold Air Pressure/Temperature Sensor - Temperature (Pin 3) 63 INPUT SIGNAL Crankcase Pressure Sensor (Pin 3) 64 - Not Used 65 INPUT SIGNAL Exhaust Gas Recirculation Temperature Sensor (Pin 1) 66 INPUT SIGNAL Exhaust Gas Recirculation Differential Pressure Sensor (Pin 3) 67 INPUT SIGNAL Exhaust Gas Recirculation Pressure Sensor (Pin 3) 68 - Not Used 69 DATA LINKS Variable geometry Turbocharger Actuator (Pin 3) / SAE J1939 Data Link Connector (Pin A) / After- treatment Intake Nox Sensor (Pin 3) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 7) (14-p Connector Pin 2) (Pin 3) / Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 1) (14-p Connector Pin 2) (Pin 3) J1939 POSITIVE 70 - Not Used 71 RETURN Crankcase Breather Heater (Pin 2) 72 DC SUPPLY Crankcase Breather Heater - Battery (Pin 1) 73 RETURN Injector Solenoid 4 (Pin 10) 74 RETURN Injector Solenoid 5 (Pin 14) 75 RETURN Injector Solenoid 6 (Pin 16) 76 - Not Used 77 - Not Used BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 4 of 11 ECM J1 CONNECTOR PIN SIGNAL TYPE FUNCTION 78 INPUT SIGNAL Fuel Level Sensor (14-p Connector Pin 12) (Pin B) 79 DC SUPPLY Crankshaft Position Sensor - 5V (Pin 1) 80 - Not Used 81 DC SUPPLY Aftertreatment Fuel Pressure Sensor (Pin 1) / Exhaust Gas Recirculation Differential Pressure Sensor (Pin 1) / Exhaust Gas Pressure Sensor (Pin 1) / Exhaust Gas Recirculation Valve (Pin 1) / Engine Intake Actuator Motor (Pin 3) / Exhaust Gas Recirculation Pressure Sensor (Pin 1) 5V SUPPLY 82 DC SUPPLY Fuel Rail Pressure Sensor 5V (Pin 1) 83 INPUT SIGNAL Coolant Temperature Sensor (Pin B) 84 - Not Used 85 INPUT SIGNAL Oil Pressure Sensor (Pin 3) 86 - Not Used 87 - Not Used 88 - Not Used 89 - Not Used 90 INPUT SIGNAL Oil Temperature Sensor (Pin B) 91 - Not Used 92 - Not Used 93 DATA LINKS Variable geometry Turbocharger Actuator (Pin 4) / SAE J1939 Data Link Connector (Pin B) / After- treatment Intake Nox Sensor (Pin 2) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 8) (14-p Connector Pin 9) (Pin 2) / Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 2) (14-p Connector Pin 9) (Pin 2) J1939 NEGATIVE 94 - Not Used 95 - Not Used 96 - Not Used BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 5 of 11 ECM J2 OEM CONNECTOR PIN SIGNAL TYPE FUNCTION 1 DC SUPPLY 30A Fuse / Battery + / All switches / Service Tool Connector (Pin B) 2 RETURN Key Ignition - Accessory 3 RETURN Diesel Exhaust Fluid Line Relays 4 - Not Used 5 DC SUPPLY Key Ignition - Ignition 6 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Unit - Temperature (Pin 10) 7 RETURN Aftertreatment Diesel Exhaust Fluid Dosing Unit Heater Relay 8 DC SUPPLY Accelerator Pedal or lever Analog Accelerator - APS2 (Pin 3 - D) / PWM - APS2 (Pin C) 9 DC SUPPLY Accelerator Pedal or lever Analog Accelerator - APS1 (Pin 4 - C) / PWM - APS1 (Pin C) 10 INPUT SIGNAL Accelerator Pedal or lever Analog Accelerator - APS1 (Pin 6 - A) 11 - Not Used 12 INPUT SIGNAL Cruise Control - PTO Set & Resume Switch 13 INPUT SIGNAL Water In Fuel Sensor (Pin B) 14 INPUT SIGNAL 2-wire/3-wire Aftertreatment Diesel Exhaust Fluid Tank Level Sensor (Pin 1) 15 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Tank Temperature Sensor (Pin 1) 16 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Unit - Fluid Pressure (Pin 3) 17 - Not Used 18 - Not Used 19 INPUT SIGNAL Cruise Control - PTO Set & Resume Switch 20 INPUT SIGNAL Parking Brake Switch 21 - Not Used 22 DATA LINKS Service Tool Connector (Pin C) / 120 ohm Termination Resistors (Pin A) J1939 POSITIVE 23 RETURN Key Ignition - Accessory 24 - Not Used 25 - Not Used 26 - Not Used 27 - Not Used 28 - Not Used 29 - Not Used 30 - Not Used 31 - Not Used 32 RETURN Remote Accelerator Pedal or Lever Assembly (Pin A) / 3-wire or 2-wire Engine Coolant Sensor 1 (Pin C) / Fuel Level Sensor (Pin C) / Fan Speed Sensor (Pin C) / Aftertreatment Diesel Particulate Filter Differential-Outlet Pressure Sensor (J15 Pin 5) (J18 Pin 1) / Aftertreatment Diesel Exhaust Fluid Dosing Unit - Temperature (Pin 4) 33 RETURN Accelerator Pedal or Lever Analog Accelerator - APS1 (Pin 5 - B) / PWM - APS1 (Pin A) (Pin B) 34 - Not Used 35 INPUT SIGNAL 3-wire or 2-wire Engine Coolant Sensor 1 (Pin B) 36 - Not Used 37 - Not Used 38 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Line Heater 1 (Pin 1) / Diesel Exhaust Fluid Line Heater Relay Supply / Key Ignition BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 6 of 11 ECM J2 OEM CONNECTOR PIN SIGNAL TYPE FUNCTION 39 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Line Heater 2 (Pin 1) / Diesel Exhaust Fluid Line Heater Relay Supply / Key Ignition 40 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Line Heater 3 (Pin 1) / Diesel Exhaust Fluid Line Heater Relay Supply / Key Ignition 41 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Differential/Outlet Pressure Sensor - Differential Pressure (J15 Pin 6) (J16 Pin 6) (J18 Pin 2) 42 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Differential/Outlet Pressure Sensor - Outlet Pressure (J15 Pin 7) (J16 Pin 7) (J18 Pin 3) 43 - Not Used 44 INPUT SIGNAL Brake Pedal Position Switch Signal 1 45 - Not Used 46 DATA LINKS Service Tool Connector (Pin D) / 120 ohm Termination Resistors (Pin B) J1939 NEGATIVE 47 - Not Used 48 RETURN Key Ignition - Accessory 49 RETURN Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 3) (J16 Pin 3) (Pin 1) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 9) (J13 Pin 9) (Pin 1) / Aftertreatment Diesel Exhaust Fluid Tank Heater Control Valve (Pin 2) / Aftertreatment Intermediate NH3 Sensor (4-pin Connector Pin 4) / Aftertreatment Outlet NOX Sensor (Pin 4) / Aftertreatment Diesel Exhaust Fluid Tank Level-Temperature-Quality Sensor (Pin 3) / Service Tool Connector (Pin A) / Battery Negative 50 - Not Used 51 - Not Used 52 - Not Used 53 RETURN Aftertreatment Diesel Exhaust Dosing Valve (Pin 2) 54 RETURN Aftertreatment Diesel Exhaust Fluid Dosing Unit (Pin 8) / Return Valve (Pin 12) 55 - Not Used 56 - Not Used 57 RETURN Aftertreatment Diesel Exhaust Fluid Tank Heater Control Valve (Pin 2) / Fan Clutch (Pin A) 58 - Not Used 59 - Not Used 60 - Not Used 61 RETURN Accelerator Pedal or Lever Analog Accelerator - APS2 (Pin 1 - F) / PWM - APS2 (Pin B) (Pin E) 62 RETURN All switches / 2-wire/3-wire Aftertreatment Diesel Exhaust Fluid Tank Level Sensor (Pin 2) / Aftertreatment Diesel Exhaust Fluid Tank Temperature Sensor (Pin 2) / Ambient Air Temperature Sesnor (Pin A) / Water In Fuel Sensor (Pin A) 63 - Not Used 64 INPUT SIGNAL Accelerator Pedal or lever Analog Accelerator - APS2 (Pin 2 - E) 65 INPUT SIGNAL Ambient Air Temperature Sensor (Pin B) 66 - Not Used 67 - Not Used 68 INPUT SIGNAL Engine Brake Selector Switch Signal 1 69 - Not Used 70 - Not Used BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 7 of 11 ECM J2 OEM CONNECTOR PIN SIGNAL TYPE FUNCTION 71 RETURN Key Ignition - Accessory 72 RETURN Key Ignition - Accessory 73 RETURN Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 3) (J16 Pin 3) (Pin 1) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 9) (J13 Pin 9) (Pin 1) / Aftertreatment Diesel Exhaust Fluid Tank Heater Control Valve (Pin 2) / Aftertreatment Intermediate NH3 Sensor (4-pin Connector Pin 4) / Aftertreatment Outlet NOX Sensor (Pin 4) / Aftertreatment Diesel Exhaust Fluid Tank Level-Temperature-Quality Sensor (Pin 3) / Service Tool Connector (Pin A) / Battery Negative 74 - Not Used 75 - Not Used 76 RETURN Starter Lockout (Pin B) / Ether Injection Solenoid - Battery Power Required Lamp - Battery Lamp Relay - Braking Lamp Relay - Idle Shutdown Relay - Air Shutoff Valve Lamp 77 OUTPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Valve (Pin 1) 78 INPUT SIGNAL Fan Clutch (Pin B) 79 DC SUPPLY Aftertreatment Diesel Exhaust Fluid Dosing Unit (Pin 9) 80 - Not Used 81 OUTPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Unit - Return Valve (Pin 11) 82 OUTPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Tank Heater Control Valve (Pin 1) 83 OUTPUT SIGNAL Starter Lockout (Pin A) 84 - Not Used 85 RETURN Aftertreatment Diesel Exhaust Fluid Line Heater 3 (Pin 2) 86 INPUT SIGNAL Engine Brake Selector Switch Signal 2 87 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Regeneration Permit-Inhibit Switch 88 - Not Used 89 - Not Used 90 INPUT SIGNAL Cruise Control/PTO ON-OFF Switch 91 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Regeneration - Diagnostic Test Mode Switch 92 INPUT SIGNAL Clutch Pedal Position Switch 93 - Not Used 94 - Not Used 95 INPUT SWITCH Remote PTO Switch 96 - Not Used 31 45 62 59 1 2 2 1 B A 3 2 1 55 79 183 2 1 1 2 3 4 2 3 1 3 2 85 44 1 2 10 11 4 1 BA C 54 78 58 82 34 21 7 1 12 6 1 3 2 3 2 63 1 C A B 1 2 3 4 04 28 69 93 2 3 1 17 16 2 3 1 66 363 2 1 6 5 3 4 81 1 2 7 8 47 46 22 57 24 48 23 4 3 2 B A 83 2 1 31 4 7 14 1 8 1 3 6 1 10 5 1 1 61 1 3 2 67 B A B A 90 2 1 1 2 29 05 1 2 08 09 0713 12 08 02 01 04 03 06 05 15 16 14 11 10 07 75 51 74 50 73 49 03 27 02 26 01 25 33 15 11 7 3 1 16 14 10 6 2 9 10 2 3 1 37 09 424 14 15 39 38 2 1 06 30 19 13 41 2 4 1 3 5 68 95 96 1 5 2 3 4 1 1 2 72 71 1 2 65 00 00 44 88 33 B C A A C BE F C D B A 55 09 63 61 31 08 12 19 90 93 91 66 94 67 30 83 B A D C 22 46 01 25 - + 50 51 96 B A C 71 72 02 26 52 B C A B A 32 B A C 76 20 43 B A 60 59 95 27 49 48 B A 65 1 2 4 3 5 6 09 02 04 09 02 04 0606 1313 1111 1212 23 A B C A B C 73 28 47 70 87 68 24 89 11 86 92 B A 13 74 74 69 35B A C 33 10 09 61 64 08 35B A C 05 75 15 141 2 2 1 62 141 2 3 B A 78 04 01 02 08 06 07 05 03 04 01 02 08 06 07 05 03 04 02 03 01 04 03 02 01 12 11 10 07 08 09 03 12 11 10 07 08 09 03 04 03 02 01 03 02 04 01 01 02 03 04 A B C 01 02 03 04 82 2 1 57 40 2 1 39 2 1 38 2 1 84 85 77 2 1 53 03 07 09 06 03 08 10 11 12 04 02 05 01 07 79 16 54 06 81 42 41 1 05 07 08 01 02 03 04 3823993 4919351 4919351 3164596 3823994 4919351 3164596 3164596 3164596 4919351 4919351 1 3164596 3164596 7 148 3164596 CRANKSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR FUEL RAIL PRESSURE SENSOR 5 VOLT SUPPLY OIL PRESSURE SENSOR FUEL PUMP ACTUATOR BAROMETRIC PRESSURE SENSOR CONNECTOR MATING FACE CONNECTOR MATING FACE CRANKCASE PRESSURE SENSOR SUPPLY VARIABLE GEOMETRY TURBOCHARGER ACTUATOR TURBOCHARGER SPEED SENSOR EXHAUST GAS RECIRCULATION DIFFERENTIAL PRESSURE SENSOR EXHAUST GAS PRESSURE SENSOR POSITION C POSITION B POSITION A COOLANT TEMPERATURE SENSOR CONNECTOR MATING FACE 14 PIN OEM CROSSOVER CONNECTOR OEM HARNESS MATING FACE CONNECTOR MATING FACE SUPPLY RETURN 5 VOLT SUPPLY SIGNAL RETURN EXHAUST GAS RECIRCULATION PRESSURE SENSOR TURBOCHARGER COMPRESSOR INTAKE TEMPERATURE SENSOR OIL TEMPERATURE SENSOR RETURN AFTERTREATMENT FUEL INJECTOR SIGNAL AFTERTREATMENT FUEL SHUTOFF VALVE CONNECTOR MATING FACE AFTERTREATMENT FUEL PRESSURE SENSOR WATER IN FUEL SENSOR CONNECTOR MATING FACE CONNECTOR MATING FACE SIGNAL 5 VOLT SUPPLY SIGNAL RETURN 5 VOLT SUPPLY PRESSURE SIGNAL SIGNAL TEMPERATURE SIGNAL INTAKE MANIFOLD AIR PRESSURE/TEMPERATURE SENSOR RETURN SIGNAL CONNECTOR MATING FACE 5 VOLT SUPPLY SIGNAL RETURN SIGNAL RETURN 5 VOLT SUPPLY RETURN NEGATIVE POSITIVE SUPPLY RETURN SIGNAL SIGNAL NEGATIVE POSITIVE RETURN SIGNAL CONNECTOR MATING FACE EXHAUST GAS RECIRCULATION VALVE MOTOR RETURN 5 VOLT SUPPLY RETURN SIGNAL RETURN SIGNAL FUEL LIFT PUMP SIGNAL ENGINE BRAKE SOLENOID 1 SIGNAL ENGINE BRAKE SOLENOID 2 INJECTOR 1 SIGNAL RETURN INJECTOR 2 INJECTOR 3 INJECTOR 4 INJECTOR 5 INJECTOR 6 SIGNAL RETURN SIGNAL RETURN SIGNAL RETURN SIGNAL RETURN SIGNAL RETURN RETURN ENGINE BRAKE SOLENOID SIGNAL RETURN RETURN SIGNAL INJECTOR SOLENOID 1 INJECTOR SOLENOID 1 INJECTOR SOLENOID 2 INJECTOR SOLENOID 2 INJECTOR SOLENOID 3 INJECTOR SOLENOID 3 INJECTOR SOLENOID 4 INJECTOR SOLENOID 4 INJECTOR SOLENOID 5 INJECTOR SOLENOID 5 INJECTOR SOLENOID 6 INJECTOR SOLENOID 6 5 VOLT SUPPLY RETURN RETURN RETURN RETURN RETURN 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY SIGNAL SAE J1939 DATA LINK CONNECTOR NEGATIVE POSITIVE PRESSURE 1 SIGNAL PRESSURE 2/TEMPERATURE SUPPLY RETURN AFTERTREATMENT PURGE AIR ACTUATOR RETURN SIGNAL FAN SPEED FUEL LEVEL RETURN RETURN SIGNAL 5 VOLT SUPPLY ENGINE INTAKE THROTTLE ACTUATOR MOTOR IF EQUIPPED SIGNAL SENSOR SUPPLY 3 SENSOR SUPPLY 1 BATTERY SENSOR SUPPLY 6 BATTERY BATTERY POSITION SENSOR SUPPLY 2 AIR INTAKE THROTTLE CONNECTOR MATING FACE RETURNCRANKCASE BREATHER HEATER OEM RESPONSIBILITY CUMMINS RESPONSIBILITY EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR RETURN SIGNAL ISX15 CM2350 X101 Wiring Diagram Cummins Inc. Printed in U.S.A. 09-SEPTEMBER-2013 Bulletin 4310638 GROUNDS, SHIELDS AND RETURNS REPRESENTS MALE PINS REPRESENTS FEMALE PINS REPRESENTS SHIELD REPRESENTS TWISTED PAIR INPUT SIGNAL OUTPUT SIGNAL DATA LINKS DC VOLTAGE PURPLE BLACK BLUE GREEN RED SOME OF THE CIRCUITS SHOWN HERE WILL NOT BE ACTIVE IN ALL APPLICATIONS. CONSULT THE EQUIPMENT MANUFACTURER´S LITERATURE TO DETERMINE WHICH CIRCUITS ARE USED. NOTE: APS1 APS2 FUEL LEVEL SENSOR REMOTE ACCELERATOR PEDAL OR LEVER ASSEMBLY SERVICE TOOL CONNECTOR 1(F) 2(E) 4(C) 3(D) 5(B) 6(A)APS1 APS2 PULSE WIDTH MODULATION ACCELERATOR PEDAL OR LEVER PARKING BRAKE SWITCH AIR CONDITIONER PRESSURE SWITCH BRAKING LAMP RELAY VEHICLE SPEED SENSOR BRAKE PEDAL POSITION SWITCH 30 AMP FUSE 5 VOLT SUPPLY SIGNAL SIGNAL RETURN SIGNAL SIGNAL RETURN SIGNAL SIGNAL SIGNAL ENGINE PROTECTION OVERRIDE SWITCH CRUISE CONTROL/PTO SET/RESUME SWITCH CRUISE CONTROL/PTO ON/OFF SWITCH SIGNAL ACCELERATOR INTERLOCK / ENGINE TORQUE LIMIT SWITCH SIGNAL SIGNAL MAXIMUM OPERATING SPEED/GOVERNOR TYPE SWITCH SIGNAL REMOTE ACCELERATOR ON/OFF SWITCH REMOTE PTO SWITCH TACHOMETER SIGNAL STARTER LOCKOUT SIGNAL RETURN SUPPLY POSITIVE RETURN NEGATIVE BATTERY SUPPLY SUPPLY RETURN RETURN RETURN RETURN AFTERTREATMENT DIESEL PARTICULATE FILTER REGENERATION/DIAGNOSTIC TEST MODE SWITCH RETURN SUPPLY RETURN ACCESSORY SIGNAL FAN SPEED SENSOR SIGNAL SIGNAL CLUTCH PEDAL POSITION SWITCH SUPPLY RETURN RETURN RETURN RETURN SIGNALAMBIENT AIR TEMPERATURE SENSOR SIGNAL 1 ENGINE BRAKE SELECTOR SWITCH 1 POSITION 1 POSITION 1RETURN RETURN POSITION 2 POSITION 2 RETURN RETURN SIGNAL SIGNAL RETURN SAE J1939 DATA LINK SAE J1939 DATA LINK RETURN 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY SIGNAL NEGATIVE POSITIVE SUPPLY RETURN SIGNAL SIGNAL RETURN 120 OHM TERMINATION RESISTOR POSITIVE NEGATIVE 120 OHM TERMINATION RESISTOR POSITIVE NEGATIVE RETURN SUPPLY SIGNAL OEM ENGINE PROTECTION SHUTDOWN SWITCH SIGNAL BRAKE PEDAL POSITION SWITCH 2 / REAR AXLE RATIO SWITCH SIGNAL AFTERTREATMENT DIESEL PARTICULATE FILTER REGENERATION PERMIT/INHIBIT SWITCH SIGNAL SIGNAL ACCELERATOR ERROR LIMP HOME SWITCH SIGNAL AIR SHUTOFF VALVE TEST SWITCH SIGNAL FAN CONTROL SWITCH SIGNAL ENGINE BRAKE SELECTOR SWITCH 2 SIGNAL SIGNAL WATER IN FUEL SENSOR RETURN SIGNAL IDLE SHUTDOWN RELAY SIGNAL RETURN AIR SHUTOFF VALVE LAMP SIGNAL RETURN SIGNAL AIR SHUTOFF VALVE OVERRIDE SWITCH FUSE ENGINE COOLANT LEVEL SIGNAL RETURN 5 VOLT SUPPLY SIGNAL SIGNAL RETURN POSITION 1 POSITION 1RETURN POSITION 2 POSITION 2 5 VOLT SUPPLY ENGINE COOLANT LEVEL SIGNAL RETURN 5 VOLT SUPPLY3 WIRE SENSOR SENSOR 4 SENSOR 5 SENSOR 4 SENSOR 5 OEM RESPONSIBILITY CUMMINS RESPONSIBILITY 5 AMP FUSE IGNITION SUPPLY START FUSE 10 AMP FUSE ETHER INJECTION SOLENOID SIGNAL RETURN RETURN SIGNAL SIGNAL RETURN AFTERTREATMENT DIESEL EXHAUST FLUID TANK TEMPERATURE SENSOR AFTERTREATMENT DIESEL EXHAUST FLUID TANK LEVEL SENSOR 2 WIRE SENSORS SIGNAL RETURN AFTERTREATMENT DIESEL EXHAUST FLUID TANK LEVEL SENSOR 3 WIRE SENSORS SUPPLY FAN CLUTCH RETURN SIGNAL SUPPLY AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE RETURN SAE J1939 DATA LINK POSITIVE J15 AFTERTREATMENT DIESEL PARTICULATE FILTER OUTLET PRESSURE J16 J18J17 AFTERTREATMENT DIESEL PARTICULATE FILTER TEMPERATURE SENSOR MODULE J13 J14 RETURN SUPPLY AFTERTREATMENT OUTLET NOX SENSOR POSITIVE NEGATIVE RETURN SUPPLY POSITIVE NEGATIVE POSITIVE NEGATIVE 120 OHM TERMINATION RESISTOR POSITIVE NEGATIVE RETURN SUPPLYSUPPLY RETURN POSITIVE NEGATIVE CUMMINS RESPONSIBILITY AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL/OUTLET PRESSURE SENSOR SUPPLY RETURN SAE J1939 DATA LINK NEGATIVE AFTERTREATMENT SELECTIVE CATALYTIC REDUCTION TEMPERATURE SENSOR MODULE CUMMINS RESPONSIBILITY CUMMINS RESPONSIBILITY BATTERY AFTERTREATMENT DIESEL EXHAUST FLUID TANK LEVEL/TEMPERATURE/ QUALITY SENSOR IF EQUIPPED CUMMINS RESPONSIBILITY RETURN POSITIVE NEGATIVE SUPPLY CUMMINS RESPONSIBILITY AFTERTREATMENT DIESEL EXHAUST FLUID TANK HEATER CONTROL VALVE SIGNAL RETURN LINE HEATER RELAY AFTERTREATMENT DIESEL EXHAUST FLUID LINE HEATER 3 AFTERTREATMENT DIESEL EXHAUST FLUID LINE HEATER 2 AFTERTREATMENT DIESEL EXHAUST FLUID LINE HEATER 1 SIGNAL SIGNAL SIGNAL AFTERTREATMENT DIESEL EXHAUST FLUID DOSING VALVE CUMMINS RESPONSIBILITY SIGNAL RETURN 15 AMP FUSE HEATER 10 AMP FUSE RETURN SIGNAL SUPPLY SIGNAL RETURN RETURN RETURN CUMMINS RESPONSIBILITY RETURN AFTERTREATMENT FUEL INJECTOR AFTERTREATMENT PURGE AIR ACTUATOR AFTERTREATMENT FUEL SHUTOFF VALVE EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR INTAKE MANIFOLD TEMPERATURE/PRESSURE SENSOR CONNECTOR MATING FACE FUEL PUMP ACTUATOR CRANKCASE BREATHER HEATER FUEL LIFT PUMP CONNECTOR MATING FACE EXHAUST GAS RECIRCULATION VALVE POSITION SENSOR TURBOCHARGER SPEED SENSOR MOTOR C RETURNEXHAUST GAS RECIRCULATION VALVE MOTOR A MOTOR B SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL CONNECTOR MATING FACE TURBOCHARGER COMPRESSOR INTAKE TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR OIL TEMPERATURE SENSOR INJECTOR SOLENOID DRIVER PASS-THROUGH ENGINE BRAKE SOLENOID CAMSHAFT POSITION SENSOR CRANKCASE PRESSURE SENSOR OIL PRESSURE SENSOR EXHAUST GAS RECIRCULATION DIFFERENTIAL PRESSURE SENSOR CRANKSHAFT POSITION SENSOR EXHAUST GAS RECIRCULATION OUTLET PRESSURE SENSOR BAROMETRIC AIR PRESSURE SENSOR EXHAUST GAS PRESSURE SENSOR AFTERTREATMENT FUEL PRESSURE SENSOR SAE J1939 DATA LINK AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT CONNECTOR MATING FACE AFTERTREATMENT DIESEL EXHAUST FLUID DOSING VALVE VARIABLE GEOMETRY TURBOCHARGER ACTUATOR AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE SENSOR AFTERTREATMENT DIESEL PARTICULATE FILTER OUTLET PRESSURE SENSOR FUEL RAIL PRESSURE SENSOR AFTERTREATMENT INTAKE NOX SENSOR 14 PIN CROSSOVER CONNECTOR ANALOG ACCELERATOR ACCELERATOR PEDAL OR LEVER SENSOR 1 SENSOR 1 DIESEL EXHAUST FLUID LINE HEATER RELAY DIESEL EXHAUST FLUID LINE HEATER RELAY DIESEL EXHAUST FLUID AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT RELAY AFTERTREATMENT INTAKE NOX SENSOR 06 SUPPLY SIGNAL RETURN SIGNAL SIGNAL RETURN RETURN SIGNAL 2 WIRE SENSOR BATTERY POWER REQUIRED LAMP SIGNAL RETURN TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD AFTERTREATMENT OUTLET NOX SENSOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR AFTERTREATMENT DIESEL PARTICULATE FILTER TEMPERATURE SENSOR MODULE AFTERTREATMENT SELECTIVE CATALYTIC REDUCTION TEMPERATURE SENSOR MODULE TEST LEAD TEST LEAD 14 PIN OEM CROSSOVER CONNECTOR ENGINE HARNESS MATING FACE TEST LEAD ENGINE CONTROL MODULE OEM CONNECTOR ENGINE CONTROL MODULE ENGINE HARNESS CONNECTOR 3164596 TEST LEAD 3164596 TEST LEAD 24 48 1 25 4972 7396 24 48 1 25 4972 7396 24 48 1 25 49 72 73 96 24 48 1 25 49 72 73 96 ENGINE CONTROL MODULE ENGINE CONTROL MODULE ENGINE CONNECTOR ENGINE CONTROL MODULE OEM CONNECTOR CONNECTOR MATING FACE MATING FACE ENGINE CONTROL MODULE ENGINE ENGINE CONTROL MODULE OEM CONNECTOR OEM CONNECTORENGINE CONNECTOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR HEATER AFTERTREATMENT INTERMEDIATE NH3 SENSOR HEATER AFTERTREATMENT INTERMEDIATE NH3 SENSOR TRIM RESISTOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR AMMONIA AFTERTREATMENT INTERMEDIATE NH3 SENSOR NOX AFTERTREATMENT INTERMEDIATE NH3 SENSOR PROBE AFTERTREATMENT INTERMEDIATE NH3 SENSOR TRIM RESISTOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR TEMPERATURE AFTERTREATMENT INTERMEDIATE NH3 SENSOR AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT AFTERTREATMENT DIESEL EXHAUST FLUID RETURN VALVE AFTERTREATMENT DIESEL EXHAUST FLUID RETURN VALVE RETURN 5 VOLT SUPPLY AFTERTREATMENT DIESEL EXHAUST FLUID PRESSURE AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT DOSING UNIT SIGNAL / DOSING UNIT TEMPERATURE AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT HEATER AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT HEATER BRAKING LAMP RELAY / BATTERY POWER REQUIRED LAMP SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SUPPLY BATTERY BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 8 of 11 FUSES AND RELAYS IDENTIFICATION R1 Starter Lockout Relay R2 Brake Lamp Relay R3 Fan Clutch Relay F1 ECM Ignition Fuse (5 A) F2 Key Battery Fuse (10 A) F3 Accessories Fuse (5 A) F4 DLC Fuse (5 A) F5 Display Unit Fuse (5A) F6 Test Point Fuse (5 A) F7 Fan Clutch Fuse (5 A) F8 Fault Box Fuse (5 A BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 9 of 11 EMERGENCY STOP SWITCH SCHEMATIC PLAN LOCK ACC ON START (10A) F8 BLOC FUSIBLE+ 28 29 27 1 2 3 4 1 2 3 4 ARRÊT URGENCE POST-TRAITEMENT C O N N EC T. D EU TS C H (3 1 PI N S) ARRÊT URGENCE MOTEUR TÉMOIN ARRÊT URGENCE REV. DESCRIPTION DATE BY DRAWN BY: CHECKED BY: DATE: - - - - - - - - - - - - ANTOINE R. ALEXANDRE LAPOINTE 2019-08-28 #HV-950-ISX_CPN-069 HV-950-ISX (SUR MESURE J4300-1) SHÉMA ÉLECTRIQUE, ARRÊTS URGENCE V0 FUSE HOLDERFUSE HOLDER AFTERTREATMENTAFTERTREATMENT EMERGENCY STOPEMERGENCY STOP DIESEL ENGINEDIESEL ENGINE EMERGENCY STOPEMERGENCY STOP EMERGENCY STOPEMERGENCY STOP LAMPLAMP BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 10 of 11 Lamp Identification and Function (if available) SYMBO L LAMP NAME FUNCTION MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. ENGINE SHUTDOWN Notifies the operator that a serious system error occurred, and protection actions are approaching. When the abnormal operating condition remains and a shutdown condition is met, the engine will shut down in 30 seconds unless the operator activates the Engine Protection Shutdown Override Switch. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. IGNITION IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated sufficiently to start the engine. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regenerate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replenished. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreatment regeneration. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. BREAKOUT BOX PIN IDENTIFICATION HV-950-X15_035103 CONSULAB.COM Page 11 of 11 Switch Identification and Function (if available) SWITCH POSITION FUNCTION ENGINE RETARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level CRUISE CONTROL (left switch) CRUISE CONTROL (right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. PTO SYSTEM CONTROL (left switch) PTO ENGINE SPEED (right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. REGENERATION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all required entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. SERVICE BRAKE I Applies the service brake. O Releases the service brake CLUTCH I Disengages the clutch. O Engages the clutch FAN OVERRIDE I Forces the radiator fan to operate O Normal operating mode DIAGNOSTIC REQUEST I Activates diagnostic request O Normal operating mode

Breakout Box Pin Identification for HV-950-X15_035103 Cummins X15 EPA 2017 HV-950-X15-SA_2017 © ConsuLab Educatech Inc, 2023. All rights reserved. Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 2 ECM J1 Connector Pin Signal type Function 1 RETURN Injector Solenoid 1 (Pin 2) 2 RETURN Injector Solenoid 2 (Pin 4) 3 RETURN Injector Solenoid 3 (Pin 6) 4 DC SUPPLY Variable Geometry Turbocharger Actuator (Pin 1) 5 OUTPUT SIGNAL Aftertreatment Fuel Injector (Pin 2) 6 OUTPUT SIGNAL Aftertreatment Purge Air Actuator (Pin 1) 7 - Not Used 8 RETURN Aftertreatment Fuel Shutoff Valve (Pin 2) 9 - Not Used 10 RETURN Fuel Pump Actuator (Pin 1) 11 OUTPUT SIGNAL Fuel Pump Actuator (Pin 2) 12 - Not Used 13 OUTPUT SIGNAL Battery Power Required Lamp / Braking Lamp Relay (14-p Connector Pin 4) 14 DC SUPPLY Fuel Lift Pump (Pin 1) 15 - Not Used 16 RETURN Turbocharger Speed Sensor (Pin 2) 17 INPUT SIGNAL Turbocharger Speed Sensor Supply (Pin 1) 18 INPUT SIGNAL Camshaft Position Sensor (Pin 3) 19 INPUT SIGNAL Fan Speed Sensor (14-p Connector Pin 11) (Pin B) 20 - Not Used 21 - Not Used 22 INPUT SIGNAL Exhaust Gas Recirculation Valve - Position C (Pin 4) 23 OUTPUT SIGNAL Exhaust Gas Recirculation Valve - Motor A (Pin 8) 24 OUTPUT SIGNAL Exhaust Gas Recirculation Valve - Motor B (Pin 6) 25 OUTPUT SIGNAL Injector Solenoid 1 (Pin 1) 26 OUTPUT SIGNAL Injector Solenoid 2 (Pin 3) 27 OUTPUT SIGNAL Injector Solenoid 3 (Pin 5) 28 RETURN Variable Geometry Turbocharger Actuator (Pin 2) 29 RETURN Aftertreatment Fuel Injector (Pin 1) Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 3 Pin Signal type Function 30 RETURN Aftertreatment Purge Air Actuator (Pin 2) / Aftertreatment Fuel Shutoff Valve (Pin 1) 31 INPUT SIGNAL Crankshaft Position Sensor (Pin 3) 32 - Not Used 33 - Not Used 34 RETURN Coolant Temperature Sensor (Pin A) / Turbocharger Compressor Intake Temperature Sensor (Pin A) / Oil Temperature Sensor (Pin A) / Exhaust Gas Recirculation Temperature Sensor (Pin 2) 35 - Not Used 36 INPUT SIGNAL Exhaust Gas Pressure Sensor (Pin 3) 37 INPUT SIGNAL Aftertreatment Fuel Pressure Sensor (Pin 3) 38 - Not Used 39 RETURN Fuel Lift Pump (Pin 2) 40 - Not Used 41 INPUT SIGNAL Fuel Level Sensor (14-p Connector Pin 12) (Pin B) 42 INPUT SIGNAL Fuel Rail Pressure Sensor - Pressure 2 - Temperature (Pin 4) 43 - Not Used 44 INPUT SIGNAL Barometric Pressure Sensor (Pin 3) 45 INPUT SIGNAL Intake Manifold Air Pressure/Temperature Sensor - Pressure (Pin 1) 46 INPUT SIGNAL Exhaust Gas Recirculation Valve - Position B (Pin 3) 47 INPUT SIGNAL Exhaust Gas Recirculation Valve - Position A (Pin 2) 48 OUTPUT SIGNAL Exhaust Gas Recirculation Valve - Motor C (Pin 7) 49 OUTPUT SIGNAL Injector Solenoid 4 (Pin 7) 50 OUTPUT SIGNAL Injector Solenoid 5 (Pin 11) 51 OUTPUT SIGNAL Injector Solenoid 6 (Pin 15) 52 - Not Used 53 - Not Used 54 RETURN Camshaft Position Sensor (Pin 2) / Intake Manifold Air Pressure/Temperature Sensor (Pin 4) / Barometric Pressure Sensor (Pin 2) / Crankcase Pressure Sensor (Pin 2) / Oil Pressure Sensor (Pin 2) 55 RETURN Crankshaft Position Sensor (Pin 2) 56 - Not Used Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 4 Pin Signal type Function 57 RETURN Aftertreatment Fuel Pressure Sensor (Pin 2) / Exhaust Gas Recirculation Differential Pressure Sensor (Pin 2) / Exhaust Gas Pressure Sensor (Pin 2) / Exhaust Gas Recircu- lation Valve (Pin 5) / Engine Intake Actuator Motor (Pin 4) / Exhaust Gas Recirculation Pressure Sensor (Pin 2) 58 RETURN Fuel Rail Pressure Sensor (Pin 2) 59 INPUT SIGNAL Fuel Rail Pressure Sensor - Pressure 1 (Pin 3) 60 - Not Used 61 INPUT SIGNAL Turbocharger Compressor Intake Temperature Sensor (Pin B) 62 INPUT SIGNAL Intake Manifold Air Pressure/Temperature Sensor - Temperature (Pin 3) 63 INPUT SIGNAL Crankcase Pressure Sensor (Pin 3) 64 - Not Used 65 INPUT SIGNAL Exhaust Gas Recirculation Temperature Sensor (Pin 1) 66 INPUT SIGNAL Exhaust Gas Recirculation Differential Pressure Sensor (Pin 3) 67 INPUT SIGNAL Exhaust Gas Recirculation Pressure Sensor (Pin 3) 68 - Not Used 69 DATA LINKS Variable geometry Turbocharger Actuator (Pin 3) / SAE J1939 Data Link Connector (Pin A) / Aftertreatment Intake Nox Sensor (Pin 3) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 7) (14-p Connector Pin 2) (Pin 3) / Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 1) (14-p Connector Pin 2) (Pin 3) J1939 POSITIVE 70 - Not Used 71 RETURN Crankcase Breather Heater (Pin 2) 72 DC SUPPLY Crankcase Breather Heater - Battery (Pin 1) 73 RETURN Injector Solenoid 4 (Pin 10) 74 RETURN Injector Solenoid 5 (Pin 14) 75 RETURN Injector Solenoid 6 (Pin 16) 76 - Not Used 77 - Not Used 78 INPUT SIGNAL Fuel Level Sensor (14-p Connector Pin 12) (Pin B) 79 DC SUPPLY Crankshaft Position Sensor - 5V (Pin 1) 80 - Not Used 81 DC SUPPLY Aftertreatment Fuel Pressure Sensor (Pin 1) / Exhaust Gas Recirculation Differential Pressure Sensor (Pin 1) / Exhaust Gas Pressure Sensor (Pin 1) / Exhaust Gas Recircu- lation Valve (Pin 1) / Engine Intake Actuator Motor (Pin 3) / Exhaust Gas Recirculation Pressure Sensor (Pin 1) 5V SUPPLY 82 DC SUPPLY Fuel Rail Pressure Sensor 5V (Pin 1) Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 5 Pin Signal type Function 83 INPUT SIGNAL Coolant Temperature Sensor (Pin B) 84 - Not Used 85 INPUT SIGNAL Oil Pressure Sensor (Pin 3) 86 - Not Used 87 - Not Used 88 - Not Used 89 - Not Used 90 INPUT SIGNAL Oil Temperature Sensor (Pin B) 91 - Not Used 92 - Not Used 93 DATA LINKS Variable geometry Turbocharger Actuator (Pin 4) / SAE J1939 Data Link Connector (Pin B) / Aftertreatment Intake Nox Sensor (Pin 2) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 8) (14-p Connector Pin 9) (Pin 2) / Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 2) (14-p Connector Pin 9) (Pin 2) J1939 NEGATIVE 94 - Not Used 95 - Not Used 96 - Not Used Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 6 ECM J2 OEM Connector Pin Signal type Function 1 DC SUPPLY 30A Fuse / Battery + / All switches / Service Tool Connector (Pin B) 2 RETURN Key Ignition - Accessory 3 RETURN Diesel Exhaust Fluid Line Relays 4 - Not Used 5 DC SUPPLY Key Ignition - Ignition 6 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Unit - Temperature (Pin 10) 7 RETURN Aftertreatment Diesel Exhaust Fluid Dosing Unit Heater Relay 8 DC SUPPLY Accelerator Pedal or lever Analog Accelerator - APS2 (Pin 3 - D) / PWM - APS2 (Pin C) 9 DC SUPPLY Accelerator Pedal or lever Analog Accelerator - APS1 (Pin 4 - C) / PWM - APS1 (Pin C) 10 INPUT SIGNAL Accelerator Pedal or lever Analog Accelerator - APS1 (Pin 6 - A) 11 - Not Used 12 INPUT SIGNAL Cruise Control - PTO Set & Resume Switch 13 INPUT SIGNAL Water In Fuel Sensor (Pin B) 14 INPUT SIGNAL 2-wire/3-wire Aftertreatment Diesel Exhaust Fluid Tank Level Sensor (Pin 1) 15 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Tank Temperature Sensor (Pin 1) 16 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Unit - Fluid Pressure (Pin 3) 17 - Not Used 18 - Not Used 19 INPUT SIGNAL Cruise Control - PTO Set & Resume Switch 20 INPUT SIGNAL Parking Brake Switch 21 - Not Used 22 DATA LINKS Service Tool Connector (Pin C) / 120 ohm Termination Resistors (Pin A) J1939 POSITIVE 23 RETURN Key Ignition - Accessory 24 - Not Used 25 - Not Used 26 - Not Used 27 - Not Used 28 - Not Used 29 - Not Used Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 7 Pin Signal type Function 30 - Not Used 31 - Not Used 32 RETURN Remote Accelerator Pedal or Lever Assembly (Pin A) / 3-wire or 2-wire Engine Cool- ant Sensor 1 (Pin C) / Fuel Level Sensor (Pin C) / Fan Speed Sensor (Pin C) / After- treatment Diesel Particulate Filter Differential-Outlet Pressure Sensor (J15 Pin 5) (J18 Pin 1) / Aftertreatment Diesel Exhaust Fluid Dosing Unit - Temperature (Pin 4) 33 RETURN Accelerator Pedal or Lever Analog Accelerator - APS1 (Pin 5 - B) / PWM - APS1 (Pin A) (Pin B) 34 - Not Used 35 INPUT SIGNAL 3-wire or 2-wire Engine Coolant Sensor 1 (Pin B) 36 - Not Used 37 - Not Used 38 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Line Heater 1 (Pin 1) / Diesel Exhaust Fluid Line Heater Relay Supply / Key Ignition 39 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Line Heater 2 (Pin 1) / Diesel Exhaust Fluid Line Heater Relay Supply / Key Ignition 40 INPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Line Heater 3 (Pin 1) / Diesel Exhaust Fluid Line Heater Relay Supply / Key Ignition 41 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Differential/Outlet Pressure Sensor - Differential Pressure (J15 Pin 6) (J16 Pin 6) (J18 Pin 2) 42 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Differential/Outlet Pressure Sensor - Outlet Pressure (J15 Pin 7) (J16 Pin 7) (J18 Pin 3) 43 - Not Used 44 INPUT SIGNAL Brake Pedal Position Switch Signal 1 45 - Not Used 46 DATA LINKS Service Tool Connector (Pin D) / 120 ohm Termination Resistors (Pin B) J1939 NEGATIVE 47 - Not Used 48 RETURN Key Ignition - Accessory 49 RETURN Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 3) (J16 Pin 3) (Pin 1) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 9) (J13 Pin 9) (Pin 1) / Aftertreatment Diesel Exhaust Fluid Tank Heat- er Control Valve (Pin 2) / Aftertreatment Intermediate NH3 Sensor (4-pin Connector Pin 4) / Aftertreatment Outlet NOX Sensor (Pin 4) / Aftertreatment Diesel Exhaust Fluid Tank Level-Temperature-Quality Sensor (Pin 3) / Service Tool Connector (Pin A) / Battery Negative 50 - Not Used Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 8 Pin Signal type Function 51 - Not Used 52 - Not Used 53 RETURN Aftertreatment Diesel Exhaust Dosing Valve (Pin 2) 54 RETURN Aftertreatment Diesel Exhaust Fluid Dosing Unit (Pin 8) / Return Valve (Pin 12) 55 - Not Used 56 - Not Used 57 RETURN Aftertreatment Diesel Exhaust Fluid Tank Heater Control Valve (Pin 2) / Fan Clutch (Pin A) 58 - Not Used 59 - Not Used 60 - Not Used 61 RETURN Accelerator Pedal or Lever Analog Accelerator - APS2 (Pin 1 - F) / PWM - APS2 (Pin B) (Pin E) 62 RETURN All switches / 2-wire/3-wire Aftertreatment Diesel Exhaust Fluid Tank Level Sensor (Pin 2) / Aftertreatment Diesel Exhaust Fluid Tank Temperature Sensor (Pin 2) / Ambi- ent Air Temperature Sesnor (Pin A) / Water In Fuel Sensor (Pin A) 63 - Not Used 64 INPUT SIGNAL Accelerator Pedal or lever Analog Accelerator - APS2 (Pin 2 - E) 65 INPUT SIGNAL Ambient Air Temperature Sensor (Pin B) 66 - Not Used 67 - Not Used 68 INPUT SIGNAL Engine Brake Selector Switch Signal 1 69 - Not Used 70 - Not Used 71 RETURN Key Ignition - Accessory 72 RETURN Key Ignition - Accessory 73 RETURN Aftertreatment Diesel Particulate Filter Temperature Sensor Module (J15 Pin 3) (J16 Pin 3) (Pin 1) / Aftertreatment Selective Catalytic Reduction Temperature Sensor Module (J14 Pin 9) (J13 Pin 9) (Pin 1) / Aftertreatment Diesel Exhaust Fluid Tank Heat- er Control Valve (Pin 2) / Aftertreatment Intermediate NH3 Sensor (4-pin Connector Pin 4) / Aftertreatment Outlet NOX Sensor (Pin 4) / Aftertreatment Diesel Exhaust Fluid Tank Level-Temperature-Quality Sensor (Pin 3) / Service Tool Connector (Pin A) / Battery Negative 74 - Not Used 75 - Not Used Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 9 Pin Signal type Function 76 RETURN Starter Lockout (Pin B) / Ether Injection Solenoid - Battery Power Required Lamp - Battery Lamp Relay - Braking Lamp Relay - Idle Shutdown Relay - Air Shutoff Valve Lamp 77 OUTPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Valve (Pin 1) 78 INPUT SIGNAL Fan Clutch (Pin B) 79 DC SUPPLY Aftertreatment Diesel Exhaust Fluid Dosing Unit (Pin 9) 80 - Not Used 81 OUTPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Dosing Unit - Return Valve (Pin 11) 82 OUTPUT SIGNAL Aftertreatment Diesel Exhaust Fluid Tank Heater Control Valve (Pin 1) 83 OUTPUT SIGNAL Starter Lockout (Pin A) 84 - Not Used 85 RETURN Aftertreatment Diesel Exhaust Fluid Line Heater 3 (Pin 2) 86 INPUT SIGNAL Engine Brake Selector Switch Signal 2 87 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Regeneration Permit-Inhibit Switch 88 - Not Used 89 - Not Used 90 INPUT SIGNAL Cruise Control/PTO ON-OFF Switch 91 INPUT SIGNAL Aftertreatment Diesel Particulate Filter Regeneration - Diagnostic Test Mode Switch 92 INPUT SIGNAL Clutch Pedal Position Switch 93 - Not Used 94 - Not Used 95 INPUT SWITCH Remote PTO Switch 96 - Not Used 31 45 62 59 1 2 2 1 B A 3 2 1 55 79 183 2 1 1 2 3 4 2 3 1 3 2 85 44 1 2 10 11 4 1 BA C 54 78 58 82 34 21 7 1 12 6 1 3 2 3 2 63 1 C A B 1 2 3 4 04 28 69 93 2 3 1 17 16 2 3 1 66 363 2 1 6 5 3 4 81 1 2 7 8 47 46 22 57 24 48 23 4 3 2 B A 83 2 1 31 4 7 14 1 8 1 3 6 1 10 5 1 1 61 1 3 2 67 B A B A 90 2 1 1 2 29 05 1 2 08 09 0713 12 08 02 01 04 03 06 05 15 16 14 11 10 07 75 51 74 50 73 49 03 27 02 26 01 25 33 15 11 7 3 1 16 14 10 6 2 9 10 2 3 1 37 09 424 14 15 39 38 2 1 06 30 19 13 41 2 4 1 3 5 68 95 96 1 5 2 3 4 1 1 2 72 71 1 2 65 00 00 44 88 33 B C A A C BE F C D B A 55 09 63 61 31 08 12 19 90 93 91 66 94 67 30 83 B A D C 22 46 01 25 - + 50 51 96 B A C 71 72 02 26 52 B C A B A 32 B A C 76 20 43 B A 60 59 95 27 49 48 B A 65 1 2 4 3 5 6 09 02 04 09 02 04 0606 1313 1111 1212 23 A B C A B C 73 28 47 70 87 68 24 89 11 86 92 B A 13 74 74 69 35B A C 33 10 09 61 64 08 35B A C 05 75 15 141 2 2 1 62 141 2 3 B A 78 04 01 02 08 06 07 05 03 04 01 02 08 06 07 05 03 04 02 03 01 04 03 02 01 12 11 10 07 08 09 03 12 11 10 07 08 09 03 04 03 02 01 03 02 04 01 01 02 03 04 A B C 01 02 03 04 82 2 1 57 40 2 1 39 2 1 38 2 1 84 85 77 2 1 53 03 07 09 06 03 08 10 11 12 04 02 05 01 07 79 16 54 06 81 42 41 1 05 07 08 01 02 03 04 3823993 4919351 4919351 3164596 3823994 4919351 3164596 3164596 3164596 4919351 4919351 1 3164596 3164596 7 148 3164596 CRANKSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR FUEL RAIL PRESSURE SENSOR 5 VOLT SUPPLY OIL PRESSURE SENSOR FUEL PUMP ACTUATOR BAROMETRIC PRESSURE SENSOR CONNECTOR MATING FACE CONNECTOR MATING FACE CRANKCASE PRESSURE SENSOR SUPPLY VARIABLE GEOMETRY TURBOCHARGER ACTUATOR TURBOCHARGER SPEED SENSOR EXHAUST GAS RECIRCULATION DIFFERENTIAL PRESSURE SENSOR EXHAUST GAS PRESSURE SENSOR POSITION C POSITION B POSITION A COOLANT TEMPERATURE SENSOR CONNECTOR MATING FACE 14 PIN OEM CROSSOVER CONNECTOR OEM HARNESS MATING FACE CONNECTOR MATING FACE SUPPLY RETURN 5 VOLT SUPPLY SIGNAL RETURN EXHAUST GAS RECIRCULATION PRESSURE SENSOR TURBOCHARGER COMPRESSOR INTAKE TEMPERATURE SENSOR OIL TEMPERATURE SENSOR RETURN AFTERTREATMENT FUEL INJECTOR SIGNAL AFTERTREATMENT FUEL SHUTOFF VALVE CONNECTOR MATING FACE AFTERTREATMENT FUEL PRESSURE SENSOR WATER IN FUEL SENSOR CONNECTOR MATING FACE CONNECTOR MATING FACE SIGNAL 5 VOLT SUPPLY SIGNAL RETURN 5 VOLT SUPPLY PRESSURE SIGNAL SIGNAL TEMPERATURE SIGNAL INTAKE MANIFOLD AIR PRESSURE/TEMPERATURE SENSOR RETURN SIGNAL CONNECTOR MATING FACE 5 VOLT SUPPLY SIGNAL RETURN SIGNAL RETURN 5 VOLT SUPPLY RETURN NEGATIVE POSITIVE SUPPLY RETURN SIGNAL SIGNAL NEGATIVE POSITIVE RETURN SIGNAL CONNECTOR MATING FACE EXHAUST GAS RECIRCULATION VALVE MOTOR RETURN 5 VOLT SUPPLY RETURN SIGNAL RETURN SIGNAL FUEL LIFT PUMP SIGNAL ENGINE BRAKE SOLENOID 1 SIGNAL ENGINE BRAKE SOLENOID 2 INJECTOR 1 SIGNAL RETURN INJECTOR 2 INJECTOR 3 INJECTOR 4 INJECTOR 5 INJECTOR 6 SIGNAL RETURN SIGNAL RETURN SIGNAL RETURN SIGNAL RETURN SIGNAL RETURN RETURN ENGINE BRAKE SOLENOID SIGNAL RETURN RETURN SIGNAL INJECTOR SOLENOID 1 INJECTOR SOLENOID 1 INJECTOR SOLENOID 2 INJECTOR SOLENOID 2 INJECTOR SOLENOID 3 INJECTOR SOLENOID 3 INJECTOR SOLENOID 4 INJECTOR SOLENOID 4 INJECTOR SOLENOID 5 INJECTOR SOLENOID 5 INJECTOR SOLENOID 6 INJECTOR SOLENOID 6 5 VOLT SUPPLY RETURN RETURN RETURN RETURN RETURN 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY SIGNAL SAE J1939 DATA LINK CONNECTOR NEGATIVE POSITIVE PRESSURE 1 SIGNAL PRESSURE 2/TEMPERATURE SUPPLY RETURN AFTERTREATMENT PURGE AIR ACTUATOR RETURN SIGNAL FAN SPEED FUEL LEVEL RETURN RETURN SIGNAL 5 VOLT SUPPLY ENGINE INTAKE THROTTLE ACTUATOR MOTOR IF EQUIPPED SIGNAL SENSOR SUPPLY 3 SENSOR SUPPLY 1 BATTERY SENSOR SUPPLY 6 BATTERY BATTERY POSITION SENSOR SUPPLY 2 AIR INTAKE THROTTLE CONNECTOR MATING FACE RETURNCRANKCASE BREATHER HEATER OEM RESPONSIBILITY CUMMINS RESPONSIBILITY EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR RETURN SIGNAL ISX15 CM2350 X101 Wiring Diagram Cummins Inc. Printed in U.S.A. 09-SEPTEMBER-2013 Bulletin 4310638 GROUNDS, SHIELDS AND RETURNS REPRESENTS MALE PINS REPRESENTS FEMALE PINS REPRESENTS SHIELD REPRESENTS TWISTED PAIR INPUT SIGNAL OUTPUT SIGNAL DATA LINKS DC VOLTAGE PURPLE BLACK BLUE GREEN RED SOME OF THE CIRCUITS SHOWN HERE WILL NOT BE ACTIVE IN ALL APPLICATIONS. CONSULT THE EQUIPMENT MANUFACTURER´S LITERATURE TO DETERMINE WHICH CIRCUITS ARE USED. NOTE: APS1 APS2 FUEL LEVEL SENSOR REMOTE ACCELERATOR PEDAL OR LEVER ASSEMBLY SERVICE TOOL CONNECTOR 1(F) 2(E) 4(C) 3(D) 5(B) 6(A)APS1 APS2 PULSE WIDTH MODULATION ACCELERATOR PEDAL OR LEVER PARKING BRAKE SWITCH AIR CONDITIONER PRESSURE SWITCH BRAKING LAMP RELAY VEHICLE SPEED SENSOR BRAKE PEDAL POSITION SWITCH 30 AMP FUSE 5 VOLT SUPPLY SIGNAL SIGNAL RETURN SIGNAL SIGNAL RETURN SIGNAL SIGNAL SIGNAL ENGINE PROTECTION OVERRIDE SWITCH CRUISE CONTROL/PTO SET/RESUME SWITCH CRUISE CONTROL/PTO ON/OFF SWITCH SIGNAL ACCELERATOR INTERLOCK / ENGINE TORQUE LIMIT SWITCH SIGNAL SIGNAL MAXIMUM OPERATING SPEED/GOVERNOR TYPE SWITCH SIGNAL REMOTE ACCELERATOR ON/OFF SWITCH REMOTE PTO SWITCH TACHOMETER SIGNAL STARTER LOCKOUT SIGNAL RETURN SUPPLY POSITIVE RETURN NEGATIVE BATTERY SUPPLY SUPPLY RETURN RETURN RETURN RETURN AFTERTREATMENT DIESEL PARTICULATE FILTER REGENERATION/DIAGNOSTIC TEST MODE SWITCH RETURN SUPPLY RETURN ACCESSORY SIGNAL FAN SPEED SENSOR SIGNAL SIGNAL CLUTCH PEDAL POSITION SWITCH SUPPLY RETURN RETURN RETURN RETURN SIGNALAMBIENT AIR TEMPERATURE SENSOR SIGNAL 1 ENGINE BRAKE SELECTOR SWITCH 1 POSITION 1 POSITION 1RETURN RETURN POSITION 2 POSITION 2 RETURN RETURN SIGNAL SIGNAL RETURN SAE J1939 DATA LINK SAE J1939 DATA LINK RETURN 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY 5 VOLT SUPPLY SIGNAL NEGATIVE POSITIVE SUPPLY RETURN SIGNAL SIGNAL RETURN 120 OHM TERMINATION RESISTOR POSITIVE NEGATIVE 120 OHM TERMINATION RESISTOR POSITIVE NEGATIVE RETURN SUPPLY SIGNAL OEM ENGINE PROTECTION SHUTDOWN SWITCH SIGNAL BRAKE PEDAL POSITION SWITCH 2 / REAR AXLE RATIO SWITCH SIGNAL AFTERTREATMENT DIESEL PARTICULATE FILTER REGENERATION PERMIT/INHIBIT SWITCH SIGNAL SIGNAL ACCELERATOR ERROR LIMP HOME SWITCH SIGNAL AIR SHUTOFF VALVE TEST SWITCH SIGNAL FAN CONTROL SWITCH SIGNAL ENGINE BRAKE SELECTOR SWITCH 2 SIGNAL SIGNAL WATER IN FUEL SENSOR RETURN SIGNAL IDLE SHUTDOWN RELAY SIGNAL RETURN AIR SHUTOFF VALVE LAMP SIGNAL RETURN SIGNAL AIR SHUTOFF VALVE OVERRIDE SWITCH FUSE ENGINE COOLANT LEVEL SIGNAL RETURN 5 VOLT SUPPLY SIGNAL SIGNAL RETURN POSITION 1 POSITION 1RETURN POSITION 2 POSITION 2 5 VOLT SUPPLY ENGINE COOLANT LEVEL SIGNAL RETURN 5 VOLT SUPPLY3 WIRE SENSOR SENSOR 4 SENSOR 5 SENSOR 4 SENSOR 5 OEM RESPONSIBILITY CUMMINS RESPONSIBILITY 5 AMP FUSE IGNITION SUPPLY START FUSE 10 AMP FUSE ETHER INJECTION SOLENOID SIGNAL RETURN RETURN SIGNAL SIGNAL RETURN AFTERTREATMENT DIESEL EXHAUST FLUID TANK TEMPERATURE SENSOR AFTERTREATMENT DIESEL EXHAUST FLUID TANK LEVEL SENSOR 2 WIRE SENSORS SIGNAL RETURN AFTERTREATMENT DIESEL EXHAUST FLUID TANK LEVEL SENSOR 3 WIRE SENSORS SUPPLY FAN CLUTCH RETURN SIGNAL SUPPLY AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE RETURN SAE J1939 DATA LINK POSITIVE J15 AFTERTREATMENT DIESEL PARTICULATE FILTER OUTLET PRESSURE J16 J18J17 AFTERTREATMENT DIESEL PARTICULATE FILTER TEMPERATURE SENSOR MODULE J13 J14 RETURN SUPPLY AFTERTREATMENT OUTLET NOX SENSOR POSITIVE NEGATIVE RETURN SUPPLY POSITIVE NEGATIVE POSITIVE NEGATIVE 120 OHM TERMINATION RESISTOR POSITIVE NEGATIVE RETURN SUPPLYSUPPLY RETURN POSITIVE NEGATIVE CUMMINS RESPONSIBILITY AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL/OUTLET PRESSURE SENSOR SUPPLY RETURN SAE J1939 DATA LINK NEGATIVE AFTERTREATMENT SELECTIVE CATALYTIC REDUCTION TEMPERATURE SENSOR MODULE CUMMINS RESPONSIBILITY CUMMINS RESPONSIBILITY BATTERY AFTERTREATMENT DIESEL EXHAUST FLUID TANK LEVEL/TEMPERATURE/ QUALITY SENSOR IF EQUIPPED CUMMINS RESPONSIBILITY RETURN POSITIVE NEGATIVE SUPPLY CUMMINS RESPONSIBILITY AFTERTREATMENT DIESEL EXHAUST FLUID TANK HEATER CONTROL VALVE SIGNAL RETURN LINE HEATER RELAY AFTERTREATMENT DIESEL EXHAUST FLUID LINE HEATER 3 AFTERTREATMENT DIESEL EXHAUST FLUID LINE HEATER 2 AFTERTREATMENT DIESEL EXHAUST FLUID LINE HEATER 1 SIGNAL SIGNAL SIGNAL AFTERTREATMENT DIESEL EXHAUST FLUID DOSING VALVE CUMMINS RESPONSIBILITY SIGNAL RETURN 15 AMP FUSE HEATER 10 AMP FUSE RETURN SIGNAL SUPPLY SIGNAL RETURN RETURN RETURN CUMMINS RESPONSIBILITY RETURN AFTERTREATMENT FUEL INJECTOR AFTERTREATMENT PURGE AIR ACTUATOR AFTERTREATMENT FUEL SHUTOFF VALVE EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR INTAKE MANIFOLD TEMPERATURE/PRESSURE SENSOR CONNECTOR MATING FACE FUEL PUMP ACTUATOR CRANKCASE BREATHER HEATER FUEL LIFT PUMP CONNECTOR MATING FACE EXHAUST GAS RECIRCULATION VALVE POSITION SENSOR TURBOCHARGER SPEED SENSOR MOTOR C RETURNEXHAUST GAS RECIRCULATION VALVE MOTOR A MOTOR B SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL SIGNAL CONNECTOR MATING FACE TURBOCHARGER COMPRESSOR INTAKE TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR OIL TEMPERATURE SENSOR INJECTOR SOLENOID DRIVER PASS-THROUGH ENGINE BRAKE SOLENOID CAMSHAFT POSITION SENSOR CRANKCASE PRESSURE SENSOR OIL PRESSURE SENSOR EXHAUST GAS RECIRCULATION DIFFERENTIAL PRESSURE SENSOR CRANKSHAFT POSITION SENSOR EXHAUST GAS RECIRCULATION OUTLET PRESSURE SENSOR BAROMETRIC AIR PRESSURE SENSOR EXHAUST GAS PRESSURE SENSOR AFTERTREATMENT FUEL PRESSURE SENSOR SAE J1939 DATA LINK AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT CONNECTOR MATING FACE AFTERTREATMENT DIESEL EXHAUST FLUID DOSING VALVE VARIABLE GEOMETRY TURBOCHARGER ACTUATOR AFTERTREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE SENSOR AFTERTREATMENT DIESEL PARTICULATE FILTER OUTLET PRESSURE SENSOR FUEL RAIL PRESSURE SENSOR AFTERTREATMENT INTAKE NOX SENSOR 14 PIN CROSSOVER CONNECTOR ANALOG ACCELERATOR ACCELERATOR PEDAL OR LEVER SENSOR 1 SENSOR 1 DIESEL EXHAUST FLUID LINE HEATER RELAY DIESEL EXHAUST FLUID LINE HEATER RELAY DIESEL EXHAUST FLUID AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT RELAY AFTERTREATMENT INTAKE NOX SENSOR 06 SUPPLY SIGNAL RETURN SIGNAL SIGNAL RETURN RETURN SIGNAL 2 WIRE SENSOR BATTERY POWER REQUIRED LAMP SIGNAL RETURN TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD TEST LEAD AFTERTREATMENT OUTLET NOX SENSOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR AFTERTREATMENT DIESEL PARTICULATE FILTER TEMPERATURE SENSOR MODULE AFTERTREATMENT SELECTIVE CATALYTIC REDUCTION TEMPERATURE SENSOR MODULE TEST LEAD TEST LEAD 14 PIN OEM CROSSOVER CONNECTOR ENGINE HARNESS MATING FACE TEST LEAD ENGINE CONTROL MODULE OEM CONNECTOR ENGINE CONTROL MODULE ENGINE HARNESS CONNECTOR 3164596 TEST LEAD 3164596 TEST LEAD 24 48 1 25 4972 7396 24 48 1 25 4972 7396 24 48 1 25 49 72 73 96 24 48 1 25 49 72 73 96 ENGINE CONTROL MODULE ENGINE CONTROL MODULE ENGINE CONNECTOR ENGINE CONTROL MODULE OEM CONNECTOR CONNECTOR MATING FACE MATING FACE ENGINE CONTROL MODULE ENGINE ENGINE CONTROL MODULE OEM CONNECTOR OEM CONNECTORENGINE CONNECTOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR HEATER AFTERTREATMENT INTERMEDIATE NH3 SENSOR HEATER AFTERTREATMENT INTERMEDIATE NH3 SENSOR TRIM RESISTOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR AMMONIA AFTERTREATMENT INTERMEDIATE NH3 SENSOR NOX AFTERTREATMENT INTERMEDIATE NH3 SENSOR PROBE AFTERTREATMENT INTERMEDIATE NH3 SENSOR TRIM RESISTOR AFTERTREATMENT INTERMEDIATE NH3 SENSOR TEMPERATURE AFTERTREATMENT INTERMEDIATE NH3 SENSOR AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT AFTERTREATMENT DIESEL EXHAUST FLUID RETURN VALVE AFTERTREATMENT DIESEL EXHAUST FLUID RETURN VALVE RETURN 5 VOLT SUPPLY AFTERTREATMENT DIESEL EXHAUST FLUID PRESSURE AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT DOSING UNIT SIGNAL / DOSING UNIT TEMPERATURE AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT HEATER AFTERTREATMENT DIESEL EXHAUST FLUID DOSING UNIT HEATER BRAKING LAMP RELAY / BATTERY POWER REQUIRED LAMP SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SAE J1939 DATA LINK POSITIVE SAE J1939 DATA LINK NEGATIVE SUPPLY BATTERY Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 10 Fuses and Relays Identification Fuse # AMP Protected component F1 5A ECM Ignition Fuse F2 10A Key Battery Fuse F3 5A Accessories Fuse F4 5A DLC Fuse F5 5A Display Unit Fuse F6 5A Test Point Fuse F7 5A Fan Clutch Fuse F8 5A Fault Box Fuse R1 Starter Lockout Relay R2 Brake Lamp Relay R3 Fan Clutch Relay Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 11 Emergency Stop Switch Schematic Plan EM ER G EN C Y ST O P EN G IN E D EU TS C H 3 PI N S EM ER G EN C Y ST O P LA M P EM ER G EN C Y ST O P AF TE R T R EA TM EN T FU SE B O X 12 V BA TT D AS H R ED W H T G R N GRN RED BL K R ED D T 0 4 - 6 P B C AD T 0 6 - 6 S BL K W H T 1 2 3 4 B C A K EY B A TT ER Y FU SE 1 0 A M P BL K W H T G R N 1 2 3 4 LO C KA C C O N ST A R T BL K W H T G R N C ÂB LE S A W G # 16 /3 R EV . D ES C R IP TI O N D AT E BY D R AW N B Y: C H EC KE D B Y: D AT E: --- --- --- - - - N O ÉM IE A N C TI L M IC H AE L BL O U IN 20 22 -0 4- 20 H V -9 50 -X 15 _0 35 10 3 H V -9 50 -X 15 _0 35 10 3 EM ER G EN CY S TO P EL EC TR IC A L SC H EM A TI C R 0 Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 12 Lamp Identification and Function (if available) Symbol Lamp Name Function MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. ENGINE SHUTDOWN Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated suffi- ciently to start the engine. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regenerate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replenished. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreat- ment regeneration. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. Cummins X15 EPA 2017 Breakout Box Pin Identification consulab.com info@consulab.com 13 Switch Identification and Function (if available) Switch Position Function ENGINE RETARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level CRUISE CONTROL (left switch) CRUISE CONTROL (Right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. PTO SYSTEM CONTROL (left switch) PTO ENGINE SPEED (Right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. REGENERATION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all required entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. SERVICE BRAKE I Applies the service brake. O Releases the service brake CLUTCH I Disengages the clutch. O Engages the clutch 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved.

Multiplex network diagnostic trainer MP-750_052808 Rev. 2025/10 MP-750_052808 Multiplex network diagnostic trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EDUCATIONAL ADVANTAGES INCLUDED COMPONENTS Do your students have difficulty understanding the operation of Multiplex and CAN Bus systems? Do you have access to vehicles that allow you to easi- ly teach the operation, diagnosis and repair of CAN Bus circuits? The MP-750 Multiplex Network Diagnostic Trainer was designed from the ground up to assist you with these difficult tasks. • Full curriculum package with student assignments and instructors answer keys • Provides a “real-world” functional vehicle systems trainer with full accessibility to com- ponents • Full available communication between all modules • Allows “hands-on” student activities for learning CAN Bus system operation, diagnosis and repair • Fault box provides 12 “real-world” vehicle problems requiring diagnosis and repair proce- dures • All components, fuse box, wiring and connectors exactly match OEM colors and service information • DLC provides full access for scan tool and oscilloscope testing access • Is a powerful teaching tool for demonstrating full functionality of vehicle CAN Bus system operation • Trainer systems respond to inserted faults with real world symptoms, OEM DTC’s, scan tool datastream changes and check engine light operation The MP-750 is a totally functional vehicle CAN Bus trainer based on a Honda vehicle platform. The trainer includes all of the following operational OEM vehicle systems : • Functional Multiplex & CAN Bus systems with 11 system modules • All OEM vehicle lighting systems • Functional Honda F (CAN Hi/Lo), B and K-line circuits • Entertainment (Radio, CD/DVD, Bluetooth), Immobilizer, Alarm • OEM Instrument panels with gauges • Multi-Information, HVAC and Entertainment dashboard displays • Wipers, Horn, Power Door Locks, Mirrors and Windows • Operational vehicle doors with electrical controls • Recycled vehicle harness, lighting components, electrical power distribution components and door assemblies • Mobile stand constructed of 2” (5cm2) tubular steel equipped with four 5” (12.7cm) phe- nol casters (2-fixed and 2-swivel w/locks) • Original instrument panel • OBDII data link connector with matching OEM terminal identification and wire colors • Original fuse box and power distribution center with circuit protection • Integrated 55A power supply 120VAC/12VDC 60Hz MP-750_052808 Multiplex network diagnostic trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product FEATURES SUPPORT MATERIALS TECHNICAL INFORMATION • OEM fuse box and power distribution center (matches OEM service information) • All OEM components are used – no simulation • Provides easy access to all components without limitations of a complete vehicle • Integrated 55A power supply 120VAC/12VDC 60Hz (operates on a standard 15A recepta- cle circuit) • Sturdy powder coated metal frame • Compact and fits through standard door openings • Manual fault box with 12 selectable system faults The following support materials for the MP-750 package are available for download from our website: • Electrical schematics • Operation manual • Curriculum with student exercises & instructors guide Product familiarization training is available, both at our headquarters, remotely or through videoconference. Dimensions : 81’’ L x 43’’ W x 54’’ H (202.5 x 107.5 x 135 cm) / 84’’ L x 48’ W x 54’ H (210 x 120 x 135 cm) with packaging Weight : 376 lb (170.9 kg) / 456 lb (207.3 kg) with packaging