Instructor Manual for CL-1902_053242 96-CL-1902_053242_REVA © ConsuLab Educatech Inc, 2025. All rights reserved. Electromagnetism Trainer Teacher only 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 96-CL-1902 Table of Contents Table of Contents Table of contents 3 Trainer Use and Familiarization 4 Introduction 5 Teaching Modules 6 Instrumentation 8 Curriculum Blueprint 11 © 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. The content of this manual is applicable to models 053242 and above. consulab.com info@consulab.com 4 96-CL-1902 Trainer Use and Familiarization Trainer Use and Familiarization This manual is designed to provide instructors with all the fault descriptions and schematics. This manual is for the teacher’s eyes only as it reveals some answers and fault locations. Be sure to read, understand, and follow all content of the Operation Manual and this Instructor Manual before using this product. Both manuals are also available in PDF format on our website. This product includes two additional resources: Student Assignments and Answer Keys. Both are available in PDF format on our website. The Student Assignments provide theory, student activities, and assessments for the classroom. The Answer Keys include the same theory section, plus instructor notes and solutions for all activities and assessments. • Operation Manual • Instructor Manual • Student Assignments • Answers Keys • Operation Manual • Instructor Manual Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space consulab.com info@consulab.com 5 96-CL-1902 Introduction Introduction The CL-1902_053242 Electromagnetism Trainer is designed to teach the principles of magnetism and electromagnetism to demonstrate magnetic fields (Flux, Flux Lines, Lines of Force), how they are generated, and what automotive com- ponents use these principles. This curriculum is designed for self-directed learning, allowing students to independently follow the material and master these principles. They will learn to build magnetic lines of force circuits for CL-1902 Modules A-1, A-2, B-1 and B-2, and to describe what takes place when current and voltage are applied to a coil of wire. Modules B-1, B-2, and C will allow students to learn about self and mutual inductance. Module D demonstrates a working model of the Right Hand Rule. This section explains what occurs when a magnet passes through a coil of wire, illustrating Michael Faraday’s Laws of Electromagnetic Induction. It establishes the connection between magnetism and the operation of solenoids, motors, and generators. Module E explores how electromagnetism produces current in an AC generator, while Module F allows students to investigate the principles behind electric motor operation. This contextual curriculum material will use a Criterion Referenced Instruction (CRI), which is instruction driven by specif- ic learning objectives. CRI Intructional Strategies • Performance Objectives – A precise description of the expected outcomes and the criteria for evaluating them, clearly defining what learners need to master. • Contextual Teaching/Learning Media – Demonstrate completion of the learning objectives by constructing the 21 student assignments at 3 levels in Modules A to F along with group discussions, and other available material. • Criterion Referenced Testing – Evaluation of learning in terms of the knowledge/skills specified in the learning ob- jectives. • Laboratory Experiences – Found through the completion of the 21 student assignments. Power Supply Adapter Rods Jumper wires E F-2F-1 C B-2 B-1 D A-2 A-1 Magnetic Fiel Indicator Compass Power Supply unit consulab.com info@consulab.com 6 96-CL-1902 Teaching Modules Teaching Modules Module A-1 : A coil of wire to demonstrate how a current carrying conductor creates a magnetic field. The two ends of the coil are connected to the blue and yellow receptacles. Module A-2 : A coil of wire to demonstrate how a current carrying conductor creates a magnetic field, wound in the opposite direction than that of A-1, to demonstrate how the direction of windings affects the magnetic field generated. The two ends of the coil are connected to the blue and yellow recepta- cles. Module B-1 : A single coil of wire with an open core. It is identical to Module A-2. The two ends of the coil are connected to the blue and yellow receptacles. There is a red and green diode connected between the two receptacles. The diodes are connected with opposite polarities. The diodes are used to show induced voltage polarities. Module B-2 : A single coil of wire with an open core. This module demonstrates mutual induction by showing how electricity is transferred from one coil to another using an iron core. B-2 has ½ the number of turns as B-1. There is a physical gap between B-1 & B-2. The two ends of the coil are connected to the blue and yellow receptacles. There is a red and green diode connected between the two receptacles. The diodes are connected with opposite polarities. Module C : Demonstrates the increase in induction efficiency when one coil is put within another and uses an iron core. Two coil’s of different number of turns with the left coil able to be moved back and forth inside the right coil. The two ends of each coil are connected to the blue and yellow receptacles. There is a red and green diode connected between each coil’s two receptacles. The diodes are connected with opposite polarities. The left hand coil has several iron core rods located inside the core. consulab.com info@consulab.com 7 96-CL-1902 Teaching Modules Module D : Demonstrates how a current carrying conductor has a magnetic field generated around it, shows the right-hand rule. Two permanent magnets are positioned between conductive non-magnetic rods. Another conductive non-magnetic movable shaft (axle) that lays across the two rods on which two plastic wheels are mounted. One fixed rod is connected to the yellow receptacle and the other is connected to the blue receptacle. Module E : A permanent magnet mounted on a shaft (rotor) that is able to be rotated by a hand wheel crank. A single coil of wire wound stationary but positioned near the rotor with its two ends connected to the blue and yellow receptacles. In addition, a single diode is mounted to the panel with its two ends connected to blue and yellow receptacles. The are four other diodes connected to form a rectifier bridge (Wheat- stone) with two diode junctions connected to blue and yellow receptacles and two other diode junctions connected to red and black receptacles. This module is used to show AC output, full and half-wave rectification. Module F-1 : F-1 is a DC motor with a single pair of commutated sections and one winding. A single coil of wire is wound around an armature (one segment) that can be rotated with a hand wheel crank. The two ends of the coil are each connected to a copper commutator segment mounted on the armature shaft. The segments are electrically insulated from each other. Two brushes ride on the copper commutator segments. Red and black wires are connected to the brushes which are connected to the blue and yellow receptacles. The brushes are mounted in a brush holder that allows manual adjustment of the brush position around the commutator. NOTE : There is a sliding coupler on the right side end of the armature shaft can that be posi- tioned to connect Modules F-1 and F-2 together. Align the flat surface of both shafts before sliding coupler over. F-1 and F-2 can be either driven electrically, manually with a hand crank or can be coupled together. Module F-2 : F-2 is a DC motor with multiple pairs of commutated sections and many windings. Two coils of wire are wound at 90º around an armature (two segments) that can be rotated with a hand wheel crank. Each end of the two coils are connected to a copper commutator segment mounted on the armature shaft. There are a total of four commutator segments. The segments are electrically insulated from each other. The two brushes ride on the commutator against the four segments 90º to each other. Red and black wires are connected to the brushes which are connected to the blue and yellow receptacles. The brushes are mounted in a brush holder that is not adjustable. consulab.com info@consulab.com 8 96-CL-1902 Instrumentation Instrumentation 1. Master ON / OFF 2. Voltmeter 0-15V 3. Bipolar diode 4. 12V / 10V switch 5. Ammeter 0-3A 6. Galvanometer 7. Polarity switch 8. Circuit connection receptacle 9. LED Readout 10. Circuit connection receptacle 11. Power supply adapter and cord 11 1 2 3 4 10 9 8 7 6 5 consulab.com info@consulab.com 9 96-CL-1902 Instrumentation Voltmeter 0-15V – Ammeter 0-3A The power supply voltmeter and ammeter are internally connected to the output receptacles and no further connections are necessary. Galvanometer The galvanometer (micro-ammeter) must be electrically connected in a circuit using its blue and yel- low μA receptacles. It includes a magnetic field viewer with smaller magnets encased to show pres- ence of magnetic field. Bipolar Diode The bipolar diode must be electrically connected in a circuit using its blue and yellow receptacles. 12V / 10V Switch Choice of system voltage either 10 VDC or 12 VDC. Polarity Switch and LED Readouts Power supply + and – output polarities can be manually reversed by the operator. The power supply has a polarity switch which determines the positive and negative of the blue and yellow output receptacles. Yellow LED readouts will indicate the selected polarity. After a period of inactivity (approx. 30 minutes) with the trainer power supply turned on, the LED display window will begin to randomly display the below combination of displays. In this event, simply make an adjustment of polarity switch or cycle the power supply master power button to reset the system. After a period of inactivity (approx. 30 minutes) with the trainer power supply turned on, the LED display window will begin to randomly display the above combination of displays. In this event, simply make an adjustment of polarity switch or cycle the power supply master power button to reset the system. LED Readouts SWITCH IN CENTER POSITION (INDICATES THE POWER SUPPLY IS ON) SWITCH IN LEFT POSITION SWITCH IN RIGHT POSITION The power supply has a POLARITY SWITCH which determines the positive and negative polarities of the blue and yellow output receptacles. Yellow LED readouts will indicator selected polarity. Polarity Switch Positions consulab.com info@consulab.com 10 96-CL-1902 Instrumentation Compass A common compass is used to detect and indicate poles of magnetic fields. NOTE : The red arrow points to the earth’s NORTH pole (magnetic SOUTH pole). The compass is used on the trainer to indicate the magnetic NORTH and SOUTH poles of the module compo- nents and not the earth’s directional NORTH or SOUTH poles. Magnetic Field Indicator A series of small ferrous rods each held within a small captive compartment. The rods will be affected by nearby magnetic fields when brought in close proximity to components on the trainer. Rods One 3 in (8 cm) x 1/2 in (1.25) permanent magnet rod One 5 in (12 cm) x 1/2 in (1.25) aluminum rod (non-ferrous) One 5 in (12 cm) x 1/2 in (1.25) steel rod (ferrous) Jumper Wires Two 32 in (81.3 cm) red wires Two 32 in (81.3 cm) black wires Earth’s North pole MAGNETIC FIELD INDICATOR – A series of small ferrous rods each held within a small captive compartment. The rods will be affected by nearby magnetic fields when brought in close proximity to components on the trainer. MAGNETIC FIELD INDICATOR – A series of small ferrous rods each held within a small captive compartment. The rods will be affected by nearby magnetic fields when brought in close proximity to components on the trainer. Ferrous rods consulab.com info@consulab.com 11 96-CL-1902 Curriculum Blueprint Curriculum Blueprint for CL-1902 Electromagnetic Trainer Guiding Question: How do electromagnetic principles create, control, and convert electrical energy into mechanical motion in automotive systems? Student Activities Learning Module Skill Level Magnetism Learning Outcomes A-1 1 SA-1 — Exploring Magnetic Fields Students will identify magnetic flux lines and polarity using magnets and visualize field patterns, demonstrating understanding of basic magnetic principles. 2 SA-2 — Current and Magnetic Fields Students will show how electric current through a conductor creates a magnetic field and apply the Right-Hand Rule to predict field direction. 3 SA-3 — Faraday’s Law in Coil Circuits Students will build a coil circuit and apply Faraday’s Law to observe how changing current affects magnetic field strength and induced voltage. Learning Module Skill Level Electromagnetism Learning Outcomes A-2 1 SA-4 — Reverse Polarity Students will demonstrate that the polarity of a coil can be switched by reversing current flow, using Coil A-1 and Coil A-2. 2 SA-5 — Electromagnet Solenoid Students will operate an electromagnetic solenoid to illustrate how electrical ener- gy creates mechanical motion for device actuation. 3 SA-6 — Solenoid / Actuator Students will explain and test how electromagnetic induction powers solenoids and actuators by applying voltage and observing movement. Assessment Checkpoint Modules Number of Questions Format A-1 & A-2 10 Multiple Choice, Matching consulab.com info@consulab.com 12 96-CL-1902 Curriculum Blueprint Learning Module Skill Level Inductance Learning Outcomes B-1 & B-2 1 SA-7 — Self-Inductance Students will observe how varying current in a circuit induces an EMF within the same coil to understand the concept of self-inductance. 2 SA-8 — Exploring Coil Interaction Students will examine how changes in one coil affect voltage and current in a sec- ondary coil to explain the principle of mutual inductance. 3 SA-9 — Measuring Mutual Inductance Students will use Coil B-1 and Coil B-2 to measure induced voltage and determine how energy transfers between coils through mutual inductance. Learning Module Skill Level Automotive Ignition Learning Outcomes C 1 SA-10 — Center Core Behavior Students will explore how the center core of a coil reacts to magnetic field changes to determine how energy is stored and released. 2 SA-11 — Polarity and Induction Students will investigate how reversing polarity in the primary coil induces voltage in the secondary coil to understand mutual induction principles 3 SA-12 — Magnetic Field Collapse Effect Students will analyze how the collapse of a magnetic field in the secondary coil causes a surge in current flow to explain its role in ignition system performance. Assessment Checkpoint Modules Number of Questions Format B-1, B-2, & C 20 Multiple Choice Learning Module Skill Level Right Hand Rule Learning Outcomes D 1 SA-13 — Applying Lenz’s Law Students will apply the Right-Hand Rule to determine the direction of induced cur- rent according to Lenz’s Law 2 SA-14 — Magnetic Field Orientation Students will use the Right-Hand Rule to identify how magnetic field direction changes between positive and negative leads. 3 SA-15 — Determining Flux Direction Students will apply the Right-Hand Rule to establish the direction of magnetic flux lines in a conductor. consulab.com info@consulab.com 13 96-CL-1902 Curriculum Blueprint Assessment Checkpoint Modules Number of Questions Format D 10 Multiple Choice Learning Module Skill Level AC Generation Learning Outcomes E 1 SA-16 — Rotor Current Action Students will observe how rotor movement generates alternating current in the AC generator to understand the principle of electromagnetic induction. 2 SA-17 — Half-Wave Rectification Students will perform half-wave rectification to see how a single diode converts AC into pulsating DC. 3 SA-18 — Full-Wave Rectification Students will carry out full-wave rectification to determine how multiple diodes produce a smoother DC output from AC. Assessment Checkpoint Modules Number of Questions Format E 20 Multiple Choice Learning Module Skill Level AC Generation Learning Outcomes F 1 SA-19 — Controlling Motor Speed Students will operate a DC motor and adjust brush position to determine how brush alignment affects motor speed. 2 SA-20 — Motor Design and Direction Students will compare motors with different numbers of field coils and commuta- tor segments to see how design impacts speed and learn how reversing polarity changes rotation direction. 3 SA-21 — Motor as a Generator Students will convert a DC motor into a generator to demonstrate how mechanical energy can be transformed into electrical energy. Assessment Checkpoint Modules Number of Questions Format F 20 Multiple Choice consulab.com info@consulab.com 14 96-CL-1902 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. Table of contents Trainer Use and Familiarization Introduction Teaching Modules Instrumentation Curriculum Blueprint

Operation manual for CL-1902_053242 Electromagnetism Trainer Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 93-CL-1902_053242 © ConsuLab Educatech Inc, 2025. All rights reserved. 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, 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. The content of this manual is applicable to models 053242 and above. 93-CL-1902 Table of Contents Table of Contents CL-1902-95 Student Assignments — Table of Contents 4 CL-1902-91 Answer Key — Table of Contents 4 CL-1902-96 Instructors Guide — Table of Contents 5 Purpose and Function 6 Infrastructure Requirements 6 Unpacking Instructions 7 Pre-operation Checks 7 Support Contact Information 7 Component Identification 8 Power Supply Identification 9 Power Supply and Trainer Component Operation 10 Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 93-CL-1902 Teacher Resources consulab.com info@consulab.com 4 CL-1902-95 Student Assignments — Table of Contents CL-1902-91 Answer Key — Table of Contents consulab.com info@consulab.com 5 93-CL-1902 Teacher Resources CL-1902-96 Instructors Guide — Table of Contents CL-1902-91 Answer Key — Table of Contents consulab.com info@consulab.com 6 93-CL-1902 Introduction Purpose and Function The CL-1902_053242 Electromag Trainer is a self-contained educational system that assists students in learning the principles of magnetism and how they are used to perform useful work in electric vehicule and electronic system applications. These principles have long been theoretically proven but are often found to be complicated and difficult to understand by the learner. The individual learning activities included are designed for students to perform various individual hands-on experiments which provide relevant application of magnetism. Concepts that are covered with the CL-1902 curriculum include : • Permanent magnets and identification of NORTH and SOUTH magnetic poles • Magnetic fields (visualization and application) • Electromagnetism and how it is created • Coil construction, winding direction and the demonstration of the “RIGHT HAND RULE” of magnetism and current flow • Induction (creating electricity using magnetic fields and conductors) • Mutual induction (step up and step down transformer principles using two coils of different construction specifica- tions) • Motor principles – Motor operation and construction • Generator principles – Generator operation and construction Trainer Component Layout : • A total of eight (8) modules are arranged on the base. (see additional details below) • An adjustable power supply (10V & 12V) that is internally protected from short-circuit conditions • Power supply + and – output polarities can be manually reversed by operator • Power supply contains a voltmeter, ammeter, micro-ammeter and LED readouts showing circuit conditions • All components have dedicated storage locations that allow for quick inventory of items Infrastructure Requirements Power supply 120VAC 60HZ 1.3A consulab.com info@consulab.com 7 93-CL-1902 Introduction Unpacking Instructions The CL-1902 is shipped in a cardboard box designed to ensure safe transport and prevent damage. Two foam bags are placed above the product for its protection. Remove the CL-1902 from its box and place it on a stable work surface. We also offer the kit with 12 sets of CL-1902 (CL-1902-12_053286). It comes in a multi-unit storage (up to 16) and transport case on wheels. Pre-operation Checks Perform a visual inspection of the entire unit using the component identification page. Check that all detachable acces- sories are present in the assembly. Support Contact Information ConsuLab Support contact information For any technical support requests related to your ConsuLab product ( damage, defects, configuration, troubleshooting and suggestions ), you can contact our dedicated team immediately : Toll-free : Canada +1 ( 800 ) 567-0791 / USA +1 ( 810 ) 222-4525 Phone : Canada +1 ( 418 ) 688-9067 Email : support@consulab.com Website : www.consulab.com consulab.com info@consulab.com 8 93-CL-1902 Component Identification 1. Module A-1 2. Module A-2 3. Module D 4. Module B-1 5. Module B-2 6. Module C 7. Module F-1 8. Module F-2 9. Module E 10. Jumper wires (2 red & 2 black) 11. Rods 12. Power supply adapter 13. Power supply unit 14. Compass 15. Magnetic field indicator Component Identification 5” Non-ferrous rod 5” Ferrous rod 3” Magnet rod 1 2 3 4 5 6 7 8 9 10 11 12 13 1415 consulab.com info@consulab.com 9 93-CL-1902 Power supply identification Power Supply Identification 1. Master ON / OFF 2. Voltmeter 0-15V 3. Bipolar diode 4. 12V / 10V switch 5. Ammeter 0-3A 6. Galvanometer 7. Polarity switch 8. Circuit connection receptacle 9. LED Readout 10. Circuit connection receptacle 11. Power supply adapter and cord 1 2 3 4 10 9 8 7 6 5 11 consulab.com info@consulab.com 10 93-CL-1902 Power Supply and Trainer Component Operation Power Supply and Trainer Component Operation 1. To operate the trainer, remove the power adapter from its Velcro strap. 2. Plug the power adapter into a 110V receptacle and plug the power cord into the power supply receptacle on the right side of power supply. Move the master ON/OFF rocker switch to turn on the trainer. 3. Power supply + and – output polarities can be manually reversed by the operator. The power supply has a polarity switch which determines the positive and negative of the blue and yellow output receptacles. Yellow LED readouts will indicate the selected polarity. After a period of inactivity (approx. 30 minutes) with the trainer power supply turned on, the LED display window will begin to randomly display the below combination of displays. In this event, simply make an adjustment of polarity switch or cycle the power supply master power button to reset the system. LED Readouts SWITCH IN CENTER POSITION (INDICATES THE POWER SUPPLY IS ON) SWITCH IN LEFT POSITION SWITCH IN RIGHT POSITION The power supply has a POLARITY SWITCH which determines the positive and negative polarities of the blue and yellow output receptacles. Yellow LED readouts will indicator selected polarity. Polarity Switch Positions After a period of inactivity (approx. 30 minutes) with the trainer power supply turned on, the LED display window will begin to randomly display the above combination of displays. In this event, simply make an adjustment of polarity switch or cycle the power supply master power button to reset the system. Velcro strap Power supply receptacle consulab.com info@consulab.com 11 93-CL-1902 Power Supply and Trainer Component Operation 4. The power supply voltmeter and ammeter are internally connected to the output receptacles and no further con- nections are necessary. 5. Galvanometer : The galvanometer (micro-ammeter) must be electrically connected in a circuit using its blue and yellow μA recepta- cles. 6. Bipolar diode : The bipolar diode must be electrically connected in a circuit using its blue and yellow receptacles. 7. Short circuit protection : If a short circuit condition is created by a user anywhere on the trainer, the power supply has internal protection that prevents damage. During a short circuit event, an internal light bulb will illuminate and the voltmeter will display about 2.5V and the ammeter will display about 2A ±. These conditions will remain until the short circuit condition has been corrected. 8. Compass : A common compass is used to detect and indicate poles of magnetic fields. NOTE : The red arrow points to the earth’s NORTH pole (magnetic SOUTH pole). The com- pass is used on the trainer to indicate the magnetic NORTH and SOUTH poles of the module components and not the earth’s directional NORTH or SOUTH poles. 9. Magnetic field indicator : A series of small ferrous rods each held within a small captive compart- ment. The rods will be affected by nearby magnetic fields when brought in close proximity to components on the trainer. 10. Rods : One 3 in (8 cm) x 1/2 in (1.25 cm) permanent magnet rod One 5 in (12 cm) x 1/2 in (1.25 cm) aluminum rod (non-ferrous) One 5 in (12 cm) x 1/2 in (1.25 cm) steel rod (ferrous) Voltmeter Ammeter ~ 2.5V ~2A± μA receptacles Diode receptacles Earth’s North pole MAGNETIC FIELD INDICATOR – A series of small ferrous rods each held within a small captive compartment. The rods will be affected by nearby magnetic fields when brought in close proximity to components on the trainer. MAGNETIC FIELD INDICATOR – A series of small ferrous rods each held within a small captive compartment. The rods will be affected by nearby magnetic fields when brought in close proximity to components on the trainer. Ferrous rods consulab.com info@consulab.com 12 93-CL-1902 Power Supply and Trainer Component Operation 11. Module A-1 : A single coil of wire with an open core. It is wound in a clockwise direction when viewed from the left side of the trainer. The two ends of the coil are connected to the blue and yellow receptacles. 12. Module A-2 : A single coil of wire with an open core. It is identical to Module A-1 except that it is wound in a counter clockwise di- rection when viewed from the left side of the trainer. The two ends of the coil are connected to the blue and yellow receptacles. 13. Module B-1 : A single coil of wire with an open core. It is identical to Module A-2. The two ends of the coil are connected to the blue and yellow receptacles. There is a red and green diode connected between the two receptacles. The diodes are connected with opposite polarities. 14. Module B-2 : A single coil of wire with an open core. It has less windings than B-1. The two ends of the coil are connected to the blue and yellow receptacles. There is a red and green diode connected between the two receptacles. The diodes are connected with opposite polarities. Coil receptacles Coil receptacles Coil receptacles and diodes Coil receptacles and diodes consulab.com info@consulab.com 13 93-CL-1902 Power Supply and Trainer Component Operation 15. Module C : Two coils of different number of turns with the left coil able to be moved back and forth inside the right coil. The two ends of each coil are connected to the blue and yellow receptacles. There is a red and green diode connected between each coil’s two receptacles. The diodes are connected with opposite polarities. The left hand coil has sev- eral iron core rods located inside the core. 16. Module D : Two permanent magnets are positioned between conductive non-magnetic rods. Another conductive non-magnetic movable shaft (axle) lays across the two rods on which two plastic wheels are mounted. One fixed rod is connected to the yellow receptacle and the other is connected to the blue receptacle. 17. Module E : A permanent magnet mounted on a shaft (rotor) that is able to be rotated by a hand wheel crank. A single coil of wire wound stationary but positioned near the rotor with its two ends connected to the blue and yellow recepta- cles. In addition, a single diode is mounted to the panel with its two ends connected to blue and yellow receptacles. The four other diodes connected to form a rectifier bridge with two diode junctions connected to blue and yellow receptacles and two other diode junctions connected to red and black receptacles. NOTE: The rubber drive belt is removable. Left coil receptacles and diodes Right coil receptacles and diodes Moving rod Plastic wheel Fixed rod receptacles Movable axle Rectifier bridge Permanent magnet Drive belt Single diode consulab.com info@consulab.com 14 93-CL-1902 Power Supply and Trainer Component Operation 18. Module F-1 : Two permanent field magnets are positioned across from each other on the frame. A single coil of wire is wound around an armature (one segment) that can be rotated with a hand wheel crank. The two ends of the coil are each connected to a copper commutator segment mounted on the armature shaft. The segments are electrically insulat- ed from each other. Two brushes ride on the copper commutator segments. Red and black wires are connected to the brushes which are connected to the blue and yellow receptacles. The brushes are mounted in a brush holder that allows manual adjustment of the brush position around the commutator. NOTE : There is a sliding coupler on the right side end of the armature shaft can that be positioned to connect Modules F-1 and F-2 together. Align the flat surface of both shafts before sliding coupler over. NOTE: The rubber drive belt is removable. 19. Module F-2 : Two permanent field magnets are positioned across from each other in the frame. Two coils of wire are wound at 90º around an armature (two segments) that can be rotated with a hand wheel crank. Each end of the two coils are connected to a copper commutator segment mounted on the armature shaft. There are a total of four commutator segments. The segments are electrically insulated from each other. The two brushes ride on the commutator against the four segments 90º to each other. Red and black wires are connected to the brushes which are connected to the blue and yellow receptacles. The brushes are mounted in a brush holder that does not allow the adjustment of brush position. NOTE : The rubber drive belt is removable. 20. Jumper wires : Two red and two black circuit jumper wires (approx 32” long) are provided with the trainer. Brush receptacles Brush holderPermanent magnets Sliding coupler F-1 F-2 Permanent magnets Brush receptacles 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. CL-1902-95 Student Assignments — Table of Contents CL-1902-91 Answer Key — Table of Contents CL-1902-96 Instructors Guide — Table of Contents Purpose and function Infrastructure Requirements Unpacking Instructions (MIGHT CHANGE) Pre-operation Checks Support Contact Information Component identification Power supply identification Power supply and trainer component operation

Answer Keys and Theory for HV-1918-2S_053300/HV-1918-2D_053301 Heavy Vehicle Lighting System Trainer Teacher Only HV-1918-2-91_V2025-1 © ConsuLab Educatech Inc, 2024. All rights reserved. HV-1918-2-91 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of contents General Description 5 Educational Advantages 5 Features 5 Options 5 Guidelines 6 Warnings & Cautions 6 Levels of Difficulty 6 General Information 7 Circuit Construction Wires: 7 Connecting the power supply to the Moduponent™ panels 7 HV-1918 Moduponent™ Panels 8 Component Identification 9 Method 1- (Entry Level Students) 9 Method 2- (Advanced Level Students) 9 General Comments 11 Multi-function Switch — Pin Identification Chart 12 Trailer Connecter — Pin Identification Chart 13 5-Pin ISO Relay — Pin Identification Chart 14 Student Assignments Answers Student Learning Assignment Example & Instructions 16 Example of a Simple Circuit Assignment 17 Back Up Lights 17 Backup Light Circuit — Student Assignment Schematic — Answers 19 Ohm’s Law Experiments 20 HV-1918-2-91 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 SA-1 — Series Circuit with One Resistance 21 SA-1 — Series Circuit with One Resistance — Answers 22 SA-1 — Student Assignment Schematic — Answers 23 SA-2 — Series Circuit with Two Resistances 24 SA-2 — Series Circuit with Two Resistances — Answers 25 SA-2 — Student Assignment Schematic — Answers 26 SA-3 — Parallel Circuit with Two Resistances 27 SA-3 — Parallel Circuit with Two Resistances — Answers 29 SA-3 — Student Assignment Schematic — Answers 30 Incandescent Light Bulb — Static and Dynamic Resistances Experiments 31 Incandescent Light Bulb — Static and Dynamic Resistances Experiments — Answers 33 Relay Controlled ON/OFF Circuit (Latched Relays) 34 Relay Controlled ON/OFF Circuit (Latched Relays) — Answers 36 Headlights Circuit (Ground Switched) — Entry Level 37 Headlights Circuit (Ground Switched) — Advanced Level 40 Headlights Circuit (Ground Switched) — Entry and Advanced Levels — Answers 42 Headlights Circuit (Ground Switched) — Entry and Advanced Level — Student Assignment Schematic — Answers 43 Headlights Circuit (Positive Switched) — Entry Level 44 Headlights Circuit (Positive Switched) — Entry Level — Answers 47 Headlights Circuit (Positive Switched) — Advanced Level 48 Headlights Circuit (Positive Switched) — Advanced Level — Answers 50 Headlights Circuit (Positive Switched) — Entry and Advanced Levels — Student Assignment Schematic — Answers 51 Parking, Tail and Marker Lights Circuit — Entry Level 52 Parking, Tail and Marker Lights Circuit — Entry Level — Answers 56 Parking, Tail and Marker Lights Circuit — Advanced Level 57 Parking, Tail and Marker Lights Circuit — Advanced Level — Answers 60 Parking, Tail and Marker Lights Circuit — Entry and Advanced Levels — Student Assignment Schematic — Answers 62 HV-1918-2-91 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 4 © 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. The content of this manual is applicable to models 053300 and above. Turn Signals and Hazard Circuit — Entry Level 63 Turn Signals and Hazard Circuit — Entry Level — Answers 66 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level 67 Turn Signals, Hazard & Brake Lights to Trailer Connector —Advanced Level — Answers 70 Turn Signals, Hazard & Brake Lights — Entry and Advanced Level — Student Assignment Schematic — Answers 71 Auxiliary Circuits 72 Auxiliary Circuits — Answers 75 Auxiliary Circuits — Student Assignment Schematic — Answers 76 Additional Assignments Answers HV-1918 Whole Trainer Wiring 78 HV-1918 Whole Trainer Wiring — Answers 83 Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic — Answers 83 Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic — Answers 84 Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic — Answers 85 Student Fault Identification Assignment Sheet 86 Student Study Questions Answers Test 1 — General Electrical Diagnosis 89 Test 1 — General Electrical Diagnosis — Answers 91 Test 2 — Relays 92 Test 2 — Relays — Answers 94 Test 3 — General Diagnosis 95 Test 3 — General Diagnosis — Answers 97 consulab.com info@consulab.com 5 HV-1918-2-91 General Description General Description The ConsuLab HV-1918-1 Heavy Vehicle Lighting System Trainers utilize the “Moduponent™” design feature which allows unlimited expansion capabilities. A Moduponent™ consists of a clear Plexiglas™ sheet with components, wiring and socket test points attached. The Moduponent® is attached to the trainer using disconnect fasteners which allows easy adaptation and configuration for different applications. Educational Advantages • The trainer is a complete heavy vehicle lighting system with front, rear, brake, clearance, turn/hazard and backup lights with a 7 wire connector; • Meets CSA/UL safety requirements; • Most complete heavy vehicle lighting and accessory circuit trainer available; • Modular LED lights (except headlights) that match on-highway truck components; • Built to train up to four students at a time Features • Available single sided (HV-1918-2S) or double sided (HV-1918-2D) • Manual fault box with 12 faults for the Lighting Switch Controls • HV-1918-01 Front Lights Moduponent™ (1) • HV-1918-02 Lighting Switch Controls Moduponent™ (1) • HV-1918-03 Rear Lights Moduponent™ (1) • HV-1918-08 5-Clearance Lights Kit (1) • HV-1918-12A Set of 89 jumper leads (1) • Stand with lockable storage box • 12VDC Power Supply (1) Options • HV-1918-1U Upgrade Kit — This upgrade kit converts a single sided trainer to a double side. Each kit contains: - HV-1918-01 Front Lights Moduponent®(1) - HV-1918-02 Control Panel Moduponent® (1) - HV-1918-03 Rear Lights with red turn/brake lights Modupnent® (1) - HV-1918-12A Set of 89 jumper wires (1) - 12VDC Power Supply (1) consulab.com info@consulab.com 6 HV-1918-2-91 Guidelines Guidelines This manual is designed to provide instructors and students with necessary information for the proper and safe opera- tion of the HV-1918 Heavy Vehicle Lighting System Trainer. Be sure to read and understand each section. NOTE: Before proceeding with this manual, the HV-1918 trainer should have already been assembled. STUDENTS CONDUCTING ASSIGNMENTS RELATED TO THIS PRODUCT SHOULD HAVE THE FOLLOWING PREREQUI- SITE SKILLS AND KNOWLEDGES: 1. Understand the proper setup and use of a digital multi-meter for purposes of accurately measuring volts, ohms and amperes. 2. Ability to read and understand basic electrical wiring schematics. 3. Basic understanding of Ohm’s Law pertaining to relationships between volts, ohms and amps. Warnings & Cautions 1. It is expected that all circuits be wired with fuse overcurrent protection. Never connect a positive wire to any com- ponent without going through a fuse first. 2. Be sure to read, understand and follow each set of instructions. Be sure to ask your instructor if you have any ques- tions about any instruction or component. 3. Never “guess” about the results of a circuit. Always follow written instructions to avoid “guesswork”. Levels of Difficulty 1. ENTRY LEVEL - There are two sets of student assignments covering the same circuits on the HV-1918 trainer. One set is titled “ENTRY LEVEL” and contains more detailed and comprehensive instructions to the student for comple- tion of each project. Detailed information gives “point to point” circuit hookup and wiring instructions to students. Entry level students may use this package to learn how lighting circuits are constructed and operate. Students are also asked to answer CIRCUIT UNDERSTANDING questions that check their comprehension of the circuit they con- structed. 2. ADVANCED LEVEL - The other set of assignments is titled “ADVANCED LEVEL” and contains only general informa- tion and instructions necessary for the construction of the circuit. The student is required to apply cognitive thinking and problem solving skills in order to construct and understand circuits. The detailed step-by-step instructions that are included in the ENTRY LEVEL package are not included in the ADVANCED LEVEL package. Students are asked to draw the circuit first using trainer templates, obtain instructor verification and then construct the circuit on the trainer. Students are asked to answer CIRCUIT UNDERSTANDING questions that check their comprehension of the circuit they constructed. There may be additional more complex questions that ask for knowledge of diagnosis and troubleshooting. 3. Instructors may choose from either option, which allows the customizing the HV-1918 trainer assignments to their specific educational needs and objectives. consulab.com info@consulab.com 7 HV-1918-2-91 General Information General Information All circuit and component wiring for both power and grounds, must be made to the front surfaces of the Moduponent® panels. The middle panel, (HV-1918-02), has eight red power receptacles (+) on the right-hand side and three black ground receptacles on the left-hand side (G). The trainer has six 15A fuses connected to main power supply. The bottom two fuses are 10A and can be fed from switched power sources such as the Ignition Switch. All circuits must have the positive power fed through a fuse during installation. All circuit connections are made by using the red and black jumper wires that plug into the receptacles located at each component. Circuit Construction Wires: There are black and red jumper wires of different lengths used for students constructing various circuits on the trainer. The ends of the jumper wires are equipped with terminal plugs that allow them to be “stacked” on top of each oth- er which allows more than one wire to be connected to the same receptacle. When stacking jumper wires, try to avoid using more than 3-4 at one connection point. To avoid unnecessary handling, it is preferable to start building circuits using the short wires and use the long wires as necessary to avoid having to undo connections when the long wires run out. Connecting the power supply to the Moduponent™ panels Before the CL-1918-02A (middle panel) is mounted to the frame, notice that there is a black two wire terminal block mounted inside on one side of the frame. A black and a red wire is attached to the terminal block using friction tabs which are also connected to the power supply. A flat tip screwdriver of the proper size is used to push in on each fric- tion tab to either insert or remove a wire. Locate the red and black wires coming from the back side of the middle panel and properly connect them to the terminal block. Release tabs PUSH IN Push to release and attach When the middle panel’s red and black wires are properly connected to the power supply terminal block and when the power supply is turned on, the RED power indicator light on the middle panel should illuminate. NOTE : Confirm that the trainer’s power cord is plugged into a receptacle. NOTE : It is normal for the power indicator light to stay on for a few seconds after power supply is switched OFF. HV-1918-2-91 HV-1918 Moduponent™ Panels HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918 Moduponent™ Panels consulab.com info@consulab.com 9 HV-1918-2-91 Component Identification Component Identification Before starting the student experiments, it is important that you understand the component location and pin identifica- tion used on the trainer. (See template on previous page for trainer component layout and identification) Depending on the desires of the instructor, students can identify component and pin identification using two different methods. Method 1- (Entry Level Students) Refer to the templates that are provided. These templates contain all component and terminal pin identifications. They can be used for construction of individual circuits and for wiring the entire vehicle lighting system. Method 2- (Advanced Level Students) The Moduponent™ panels components and terminal identification can be performed using a digital multi-meter mea- suring resistance or a set of jumper wires connected to power and ground. This method requires cognitive thinking and problem solving skills. The exceptions to this are all the LED lights. LED lights are polarity sensitive, but the HV-1918 trainer and lights have internal circuit protection at each LED to prevent damage from improper hookup by students. The templates mentioned in Method 1 can be used for verification of student results. All Light Bulbs (Except Headlights) All light bulbs (except headlights) used on the HV-1918 trainer are LED type bulbs. Each LED light is internally protected with circuits to prevent damage due to reverse or incorrect polarity hookup of jumper wires. If any of the following LED light bulbs are hooked up with reverse polarity, the bulbs will operate normally: • Front Clearance Lights • Front Side Marker Lights • Rear Clearance Lights • License Plate Light If any of the following LED light bulbs are hookup up with reverse polarity, the bulbs will not operate, but no harm will be done to the trainer. • Front Park/Turn Lights • Rear Tail/Turn Lights • Backup Light • Left & Right Hand Turn Indicators consulab.com info@consulab.com 10 HV-1918-2-91 Component Identification • High Beam Indicator • Parking Brake Indicator Dual-Filament light bulbs (3 terminals) The HV-1918 headlights use dual-filament incandescent light bulbs. The HV-1918 trainer has icons printed on the Modu- ponents that identify the headlights high and low beams as well as COM terminals. However, if a three terminal light bulb terminals were not identified, there are several different methods that could be used to identify 1- COM, 2- High Brightness and 3- Low Brightness. With all POWER shut OFF, a digital multi-meter can be used to measure the resistance of the two filaments with the brightest filament having the lowest resistance. With trainer POWER turned ON, a positive and negative jumper wire (fused through one of the trainers’ fuses) can also be used to determine terminal identification. HV-1918 Switches The HV-1918 trainer is equipped with the following switches: • Backup Light Switch (push button N.O. type) • Stop Lamp Switch (push button N.O. type) • Head Lamp Switch (six terminals) [DPDT (double pole, double throw)] (two SPST switches operated by a single lever) • Ignition Key Switch (BAT, ACC, IGN and START) • Parking Brake Switch [SPST (single pole, single throw)] • Auxiliary Switch [SPST (single pole, single throw)] • Multi-Function Switch (Turn Signals, Dimmer Switch and Hazard Warning Switch) Multi-function Switch The Multi-Function Switch controls the Turn Signals, Hazard Warning Lights and the Headlight Dimmer/Flash-to-pass Switch. There are two rows of four terminals. There are assignments in this manual for proper pin identification of this switch as well as a legend that identifies them. See Pin Identification Chart on section “Multi-function Switch — Pin Identi- fication Chart”. Terminals 31 & 33A of the multi-function switch are a set of latching contacts inside the switch operated by a push button on the end of the switch stalk. Pushing the button in either connects or disconnects terminals 31 & 33A. They will remain either connected or disconnected until the button is pushed again. Terminals 31 & 33A are used to operate the headlight HIGH beam circuits using relays #1 & #2. In the event of a circuit wiring error, the 31 & 33A contacts are protected by a 1A Slo-Blo fuse. This fuse is located to the right of terminals 31 & 33A on the middle Moduponent™ panel. If continuity is not present between terminals 31 & 33A, check and replace the fuse with the correct 1A Slo-Blo specifications. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date FAULT BOX 1A SLO-BLO FUSE consulab.com info@consulab.com 11 HV-1918-2-91 Component Identification Trailer Plug The trailer plug is an industry standard seven round pins. There are seven terminals for student wiring of the trailer plug to the trainer’s circuits. Confirmation of proper hookup of the trailer plug can be accomplished by using a 12 volt test light, DVOM or a commercially available trailer plug tester (LED type). See Pin Identification Chart on section “Trailer Connecter — Pin Identification Chart”. ISO Relays The trainer is equipped with four standard ISO five terminal relays. They can be used for numerous circuit hookups and operation. Each relay has five terminals for student wiring assignments. The relays use industry standard terminal identification terminal numbers of 85, 86, 87, 87A and 30. See Pin Identification Chart on section “5-Pin ISO Relay — Pin Identification Chart”. Turn Signal Flasher The Turn Signal Flasher has three terminals identified on the Moduponent panel. Terminal identification is GRD, BAT and SIG. General Comments The HV-1918 trainer is designed as a “generic” lighting system for a typical medium to heavy-duty truck. Being generic, there are countless ways that lighting circuits can be designed and wired for proper operation. For example, headlights can be designed to operate either with a power or ground switched circuit design. Relays can be used for both left and right sides. This manual will include typical lighting circuit student learning exercises, but the trainer allows many other custom circuit wiring options for instructors to design to their own needs and desires. When the entire trainer is wired for operation of all lighting circuits, the instructions will cover only one of the many different possibilities available. The trainer allows a variety of different circuit designs for different student skill levels. consulab.com info@consulab.com 12 HV-1918-2-91 Component Identification Multi-function Switch — Pin Identification Chart HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date PIN DESCRIPTION 113 Power Out To Right Front Turn Lamp 111 Power In To Multi-Function Switch 112 Power Out To Left Front Turn Lamp 116 Power Out To Right Rear Stop And Turn Lamp 71 Power In From Stop Lamp Switch 115 Power Out To Left Rear Stop And Turn Lamp 31 Dimmer Switch Contacts - Latching (See Note Above) 33A Dimmer Switch Contacts - Latching (See Note Above) NOTE- Terminals 31 & 33A contacts are protected by a 1A Slo-Blo fuse located on the trainer’s fault box. consulab.com info@consulab.com 13 HV-1918-2-91 Component Identification Trailer Connecter — Pin Identification Chart HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date PIN DESCRIPTION 1 Ground 2 Right Marker Lights - (some upper trailer marker lights) 3 Right Turn 4 Stop Lights 5 Left Turn 6 Left Marker Lights - (some lower trailer marker lights) 7 12 V or Lift Axle or ABS consulab.com info@consulab.com 14 HV-1918-2-91 Component Identification 5-Pin ISO Relay — Pin Identification Chart HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date PIN DESCRIPTION 85 Normally Coil Ground 86 Normally Coil 12V Feed 30 12V Feed In for Controlled Circuit or 12V Out to Controlled Component 87A Normally Closed Contact — Can Be 12V Feed In or 12V Out to Controlled Component 87 Normally Open Contact — Can Be 12V Feed In or 12V Out to Controlled Component 30 & 87A Normally Closed When Relay is Off 30 & 87 Normally Open When Relay is Off consulab.com info@consulab.com 15 HV-1918-2-91 Student Assignments Answers Student Assignments Answers As has been stated previously, the HV-1918 is a “generic” heavy duty vehicle lighting trainer. It is not indicative of any specific vehicle application. There are countless methods of constructing general lighting and control circuits using the included components. Other separate components can be added to expand the trainers capability even more. For example, a vehicle horn could be connected with this trainer using one of the ISO relays and the push button Back Up Light switch. It is recommended that the maximum circuit load controlled by the ISO relays not exceed 30 amps. consulab.com info@consulab.com 16 HV-1918-2-91 Student Learning Assignment Example & Instructions Student Learning Assignment Example & Instructions On the next page the example of a simple circuit (Back Up Lights) shows the layout and organization used for all student assignments using the HV-1918 trainer. Typically, an assignment begins with a CIRCUIT UNDERSTANDING paragraph, then asks the student to fill out a worksheet on which the student draws out the circuit. Upon instructor verification, stu- dents are asked to construct the circuit on the trainer. Upon instructor verification, the circuit is operated and verified. Answer sheets are designed for submission to instructors for assignment credit. ENTRY LEVEL students are given step-by-step instructions for correct wiring of the circuit. Students are asked to draw the circuit on the provided circuit schematic template and all answers to circuit understanding questions are to be en- tered on the Student Answer Sheet to be submitted for evaluation. ADVANCED LEVEL students are asked to complete the circuit diagram, but are not given step-by-step wiring instruc- tions. They are expected to use their knowledge to construct the circuit on the trainer. Students are also asked to answer circuit understanding questions and all answers are to be submitted on the Student Answer Sheet. consulab.com info@consulab.com 17 HV-1918-2-91 Example of a Simple Circuit Assignment Example of a Simple Circuit Assignment Back Up Lights Circuit Understanding A typical backup light circuit operates when the ignition and the transmission backup light switches are switched ON. Therefore, to construct this circuit, wiring would be connected to the following components: Fuse, Ignition Switch, Backup Light Switch, Backup Light and Grounds. Refer to the attached diagram for proper circuit hookup for the backup lights: With the circuit constructed as the diagram indicates, the backup light should operate when the Ignition Switch is turned to the ON position and the Backup Light switch is pushed in (ON). Entry Level Make sure the power supply is correctly connected to the trainer and is turned OFF. Using the black and red jumper wires, make the following connections to the trainer. 1. Connect a red jumper wire from the red terminal of the F1 fuse to the BAT terminal of the Ignition Switch. 2. Connect a red jumper wire from IGN terminal of the Ignition Switch to the right-hand terminal of the Back-Up Switch on the middle panel. 3. Connect a red jumper wire from the left-hand terminal of the Back-Up Switch the right-hand terminal of the Back-Up Light on the bottom panel. 4. Connect a black jumper wire from the left-hand terminal of the Back-Up Light to any of the four black terminals on the left-hand side of the bottom panel. 5. Connect a black jumper wire from any of the four black terminals on the bottom panel to any of the three black terminals on the middle panel. Circuit Operation Confirmation 1. Double check all connections. 2. Turn ON power supply. 3. Turn Ignition Switch to the “ON” position. 4. Push the Back-Up Switch. 5. Back-Up Light should come ON when button is pushed. 6. Turn in your wiring schematic for grading. consulab.com info@consulab.com 18 HV-1918-2-91 Example of a Simple Circuit Assignment See Back-Up Light circuit template on the next page and draw the circuit that you have just wired on the template. Use red color for positive wires and black color for ground wires. Use a blank template for your answers. Advanced Level 1. Make sure the power supply is correctly connected to the trainer and is turned OFF. 2. Read the Back-Up Light circuit description. 3. Discuss and learn how the Back-Up Light circuit operates. 4. Using the blank template, draw all necessary red and black wires to connect the Back-Up Light circuit. 5. Turn in your drawing to your instructor for grading and verification. 6. After instructor verification and while using the filled out wiring diagram, connect all necessary red and black wires to properly construct the Back-Up Light circuit. 7. Have instructor verify your wiring on the trainer. 8. After instructor verification, turn ON trainer power supply. 9. Turn Ignition to the “ON” position. 10. Push the Back-Up Light switch. 11. The Back-Up Light should come ON each time the Back-Up Light is pushed in. 12. Confirm proper operation of the circuit. 13. If circuit does not operate properly, diagnose and troubleshoot the cause of the malfunction. 14. Turn in your wiring schematic for instructor grading. consulab.com info@consulab.com 19 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Example of a Simple Circuit Assignment Backup Light Circuit — Student Assignment Schematic — Answers consulab.com info@consulab.com 20 HV-1918-2-91 Ohm’s Law Experiments Ohm’s Law Experiments The HV-1918 Trainer is equipped with LED lights for all circuits except the front headlights. Therefore, because of the extremely small amperage draw of LED lights, the Ohm’s Law experiments will be conducted using primarily the incan- descent headlight bulbs. The HV-1918 can be used to demonstrate the effect on voltage, current and resistance in series and parallel circuits. Carefully read and follow the below instructions to learn how series and parallel circuits “behave”. NOTE: It is assumed that students are familiar with the proper and safe use of a digital multi-meter (DMM) and that they can properly measure resistance, voltage and amperage. Be sure to check with your instructor if you do not understand these concepts. Meter damage can occur if it is improperly connected to circuits. NEVER GUESS!!! consulab.com info@consulab.com 21 HV-1918-2-91 SA-1 — Series Circuit with One Resistance SA-1 — Series Circuit with One Resistance 1. Connect a red jumper wire from the red terminal of the F1 fuse to the BAT terminal of the Ignition Switch. 2. Connect a red jumper wire from the IGN terminal of the Ignition Switch to the LOW beam yellow terminal of the right-hand headlight. 3. Connect a black jumper wire from the right-hand headlight COM terminal to any of the four black ground terminals on the left-hand side of top Moduponent™ panel (HV-1918-01) 4. Connect a black jumper wire from any of the four right-hand ground terminals to any of the three black ground ter- minals of the middle Moduponent panel (HV-1918-02) 5. Make sure power supply is turned ON and the BATTERY indicator light is “ON”. 6. Turn the Ignition Switch to the ON position. The right-hand headlight should now be ON. 7. Using a digital multi-meter (DMM) set to read voltage and choose a scale that will accurately read 12 volts DC. 8. Place the red lead of the voltmeter on the LOW TEST POINT terminal of the headlight. 9. Place the black lead of the voltmeter on the COM TEST POINT terminal of the headlight. Read the available voltage to the headlight. Use the student answer sheet for your answer. 10. The voltmeter should read approximately the available voltage of the battery. (NOTE-voltage will vary based on the variations of power supply and available outlet voltages. Range should be around 12.6 – 12.8 volts DC) 11. With the headlight ON, disconnect the red jumper wire at the headlight. The light will go OFF. 12. With the headlight ON, disconnect the black jumper wire at the headlight. The light will go OFF. 13. Turn Ignition Switch OFF and reconnect all jumper wires previously removed. 14. Set up the DMM to measure amperage. Confirm your meter setup. 15. Remove the red jumper wire connecting the IGN terminal of the Ignition Switch to the LOW beam terminal of the right-hand headlight. 16. Connect the ammeter to the circuit by placing the meter’s red lead to the IGN terminal of the Ignition Switch. 17. Place the black lead of the ammeter to the LOW beam terminal of the right-hand headlight. 18. Turn ON the Ignition Switch and measure the amperage. 19. Record the amperage of the right-hand headlight on the Student Answer Sheet. 20. Turn Ignition Switch OFF and remove ammeter. Reconnect all previously disconnected wires. Conclusions This is a “SERIES” circuit with one resistance. In a normally operating series circuit with one resistance, all the supply voltage is available to the resistance. That’s why the voltage at the headlight measured battery voltage. In a SERIES circuit, there is only one path for circuit to flow and thus, any break in either the power or ground side of the circuit will result in the entire circuit being “opened” and quit functioning. That is why the headlight went OFF when either the ground or power wires were disconnected. consulab.com info@consulab.com 22 HV-1918-2-91 SA-1 — Series Circuit with One Resistance — Answers SA-1 — Series Circuit with One Resistance — Answers 9. 12.5 - 12.8 V 19. 2.7 - 3.2 A consulab.com info@consulab.com 23 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 SA-1 — Series Circuit with One Resistance — Answers SA-1 — Student Assignment Schematic — Answers consulab.com info@consulab.com 24 HV-1918-2-91 SA-2 — Series Circuit with Two Resistances SA-2 — Series Circuit with Two Resistances 1. Begin with the trainer wired according the Ohm’s Law SA-1. 2. Make sure the Ignition Switch is turned OFF. 3. Disconnect the black jumper wire from the top Moduponent left-hand ground terminal. 4. Connect this black jumper wire to the COM terminal of the left-hand head-light. 5. Connect a black jumper wire from the left-hand headlight LOW beam terminal to any of the four black ground termi- nals on the top Moduponent panel (HV-1918-01) 6. Turn Ignition Switch ON. 7. Notice the operation of the headlights and describe their operation on the Student Answer Sheet. 8. Set up the DMM to measure voltage. 9. Measure the voltage available to the left-hand headlight by placing the red DMM lead on the LOW TEST POINT head- light terminal and the black DMM lead on the COM headlight terminal. Record your reading on the answer sheet. 10. Now, measure the voltage available at the right-hand headlight using the DMM voltmeter in the same way. Record your reading on the answer sheet. 11. Turn the Ignition Switch OFF. 12. Set up the DMM for measuring amperage. Confirm your setup procedure. 13. Disconnect the red wire between the IGN terminal of the Ignition Switch and the LOW beam terminal of the right- hand headlight. 14. Place the red lead of the ammeter on the IGN terminal of the Ignition switch. 15. Place the black lead of the ammeter on the LOW beam terminal of the right-hand headlight. 16. Turn the Ignition Switch ON. 17. Measure the circuit amperage and record on the answer sheet. 18. Turn the Ignition Switch OFF. 19. Disconnect the ammeter and reconnect the red jumper wire you removed for this step. Conclusions When two resistances are connected in series, there is still only one path for current to flow, therefore the voltage must “split” between them. This usually results in an improper circuit operation usually noticed by reduced current. Most vehi- cle circuits (other than some newer vehicle headlight circuits) do not use series circuits with more than one resistance. If you see a circuit that has reduced current and the subsequent negative operation affects the performance of the circuit, you must begin to locate the cause of the unwanted resistance and repair it. In a SERIES circuit if there is more than one resistance, the total resistance of the circuit always increases. All resistanc- es in a series circuit add together to form the total circuit resistance. Therefore, unwanted resistance in a series circuit will cause the circuit current to decrease and the voltage will vary at each resistance. We call this “voltage drop” at each resistance. The total voltage drops of all resistances should equal the total circuit source voltage. consulab.com info@consulab.com 25 HV-1918-2-91 SA-2 — Series Circuit with Two Resistances — Answers SA-2 — Series Circuit with Two Resistances — Answers 7. Describe headlight operation Both bulbs are ON, but dimmer than normal 9. 6.52 – 6.68 Volts available at the right-hand headlight. 10. 6.52 – 6.68 Volts available at the left-hand headlight. 17. 2.00 -3.00 Circuit amperage of both headlights in series consulab.com info@consulab.com 26 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 SA-2 — Series Circuit with Two Resistances — Answers SA-2 — Student Assignment Schematic — Answers consulab.com info@consulab.com 27 HV-1918-2-91 SA-3 — Parallel Circuit with Two Resistances SA-3 — Parallel Circuit with Two Resistances 1. Before proceeding with SA-3, make sure that all previously connected jumper wires are disconnected from the trainer. 2. Connect a red jumper wire from the F1 fuse terminal to the BAT terminal of the Ignition Switch. 3. Connect a red jumper wire from the IGN terminal of the Ignition switch to the LOW beam terminal of the right-hand headlight. 4. Using the piggy back feature, connect another red jumper wire from the red LOW beam terminal of the right-hand headlight to the LOW beam terminal of the left-hand headlight. 5. Connect a black jumper wire from the COM terminal of the right-hand headlight to the COM terminal of the left- hand headlight. 6. Using the piggy back feature, connect a black jumper wire from the black GRD terminal of the left-hand headlight to any of the four black ground terminals on the left-hand side of the top Moduponent (HV-1918-01) 7. Connect a black jumper wire from any of the four ground terminals on the top Moduponent to any of the three black ground terminals on the middle Moduponent (HV-1918-02) 8. Turn the Ignition Switch ON. 9. Both headlights should be operating at full brilliance. 10. Set up a DMM to read voltage. Confirm your meter setup. 11. Measure the available voltage at the left-hand headlight by placing the red meter lead on the LOW beam terminal and the black meter lead on the COM terminal. 12. Fill in your voltage reading on the answer sheet. 13. Now, measure the available voltage at the right-hand headlight using the same procedure as for Step #11. 14. Fill in your voltage reading on the answer sheet. 15. Turn Ignition Switch OFF. 16. Set up the DMM to measure amperage. Confirm your meter setup. 17. Remove the red jumper wire connecting the Ignition Switch IGN terminal to the LOW beam headlight terminal on the right-hand headlight. 18. Connect the DMM ammeter by placing the red lead of the ammeter on the Ignition Switch IGN terminal and the black lead of the ammeter into the LOW TEST POINT terminal of the right-hand headlight. 19. Turn the Ignition Switch ON. 20. Both headlights should be operating normally. 21. Read the amperage flowing in this circuit. 22. Record your reading on the answer sheet. 23. Turn Ignition Switch OFF. 24. Disconnect the red jumper wire connected to the left-hand LOW beam terminal of the LEFT-HAND headlight. 25. Turn Ignition Switch ON. consulab.com info@consulab.com 28 HV-1918-2-91 SA-3 — Parallel Circuit with Two Resistances 26. Using the DMM ammeter, measure the amperage of the right-hand headlight. 27. Record amperage reading on the answer sheet. 28. Turn Ignition Switch OFF. 29. Reconnect all jumper wires previously removed. Conclusions With two resistances connected in parallel to the battery, each resistance has full battery voltage available. A parallel circuit consists of two or more circuit branches containing resistances of which each branch is supplied with a separate path for battery power. This means that if there is a break in one of the branches, the others will continue to operate normally. Some parallel circuits share common power and ground circuits, but not always. Additional branches can be added which increases the amperage draw from the battery. This is opposite of a series circuit where additional resis- tances will decrease the total amperage because there is only one path for current to flow. consulab.com info@consulab.com 29 HV-1918-2-91 SA-3 — Parallel Circuit with Two Resistances — Answers SA-3 — Parallel Circuit with Two Resistances — Answers 12. 12.6 – 12.8 Available voltage at left-hand headlight 14. 12.6 – 12.8 Available voltage at the right-hand headlight 22. 6 ± 0.5 A Total circuit amperage 27. 3 ± 0.5 A Amperage of right-hand headlight consulab.com info@consulab.com 30 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 SA-3 — Parallel Circuit with Two Resistances — Answers SA-3 — Student Assignment Schematic — Answers consulab.com info@consulab.com 31 HV-1918-2-91 Incandescent Light Bulb — Static and Dynamic Resistances Experiments Incandescent Light Bulb — Static and Dynamic Resistances Experiments Light Bulb Static Resistance Incandescent light bulbs can have the internal resistance measured when the bulb is OFF for purposes of testing the continuity of the bulb only. This test is called “STATIC” resistance and is NOT an indication of how much resistance the bulb actually has. This test is used for initial bulb continuity testing only. 1. Make sure the Ignition Switch is turned OFF. 2. Set up the DMM to read resistance. Confirm the meter setup you have made. 3. With no jumper leads connected to the headlights, measure the resistance of the LOW beam filament by connect- ing the two DMM ohmmeter leads to the LOW TEST terminal and the COM TEST POINT terminal of the right-hand headlight. NOTE- This reading will be very low and holding the meter leads steady is critical to this measurement. NOTE- If the DMM has a “zero” feature for Ohm’s testing, set up this feature to get a true “zero” when both meter leads are connected together. Failure to do this may result in inaccurate readings. 4. Fill in the Student Answer Sheet will your resistance reading obtained from Step 3. 5. In the same manner measure the static resistance of the left-hand headlight bulb. 6. Fill in the Student Answer Sheet with your resistance reading obtained from Step 5. Light Bulb Dynamic Resistance Dynamic light bulb resistance is the actual resistance when the bulb is turned ON. The only way to determine the actual DYNAMIC or “live” resistance of an incandescent bulb is the use Ohm’s Law to calculate it. You must know the value of the bulb’s voltage and amperage before this calculation can be made. Ohm’s Law states that if two of the three values of OHMS, VOLTAGE or AMPERAGE are known, then the remaining third can be determined. If we wish to determine the actual DYNAMIC resistance of the headlight bulb, we would use the Ohm’s Law formula of VOLTAGE/AMPERAGE = RE- SISTANCE. 7. Obtain the voltage and amperage measured from Steps 11 and 20 of SA-1. 8. Use the formula of VOLTAGE / AMPERAGE = RESISTANCE to calculate the headlight bulbs dynamic resistance. 9. Fill in the Student Answer Sheet with your answer. 10. Compare the STATIC and DYNAMIC resistances for the headlight. consulab.com info@consulab.com 32 HV-1918-2-91 Incandescent Light Bulb — Static and Dynamic Resistances Experiments Conclusions The reason that there is a difference between STATIC and DYNAMIC bulb resistances is that when the bulb is ON, the filament of the bulb heats up which raises its resistance and thus decreases the amperage. Note When working with incandescent light bulbs and calculating resistances and amperages, it must be remembered that dynamic resistances change with each circuit. For example, if a single headlight bulb was connected to the battery and its amperage was measured, it would sound reasonable that if another identical headlight bulb was connected in series, the total amperage would be about one-half of the single headlight. This isn’t true because the dynamic resistance of each bulb changes based on the voltage available to it. The total amperage of both bulbs will be less than one single bulb, but will not be exactly one-half. consulab.com info@consulab.com 33 HV-1918-2-91 Incandescent Light Bulb — Static and Dynamic Resistances Experiments — Answers Incandescent Light Bulb — Static and Dynamic Resistances Experiments — Answers Light Bulb Static Resistance Experiments 4. 0.5 – 0.8 Ω of static resistance of right-hand headlight (low beam filament) 6. 0.5 – 0.8 Ω of static resistance of left-hand headlight (low beam filament) Light Bulb Dynamic Resistance Experiments 2. 12.6 V divided by 2.50 A = 5.04 Ω of Dynamic Resistance. consulab.com info@consulab.com 34 HV-1918-2-91 Relay Controlled ON/OFF Circuit (Latched Relays) Relay Controlled ON/OFF Circuit (Latched Relays) The HV-1918-1S (single sided) or HV-1918-2S (double sided) trainer can be used for several different learning objectives besides vehicle lighting. Instructors can develop custom circuits for specific learning objectives and goals. There are countess possibilities using the components and wiring jumpers on the Moduponents to construct circuits. The below example of how the trainer can be utilized for supplemental learning uses a latched relay control circuit that turns a light bulb ON/OFF using momentary push buttons. See below for a circuit explanation. NOTE : In order for the circuit to operate properly, it is absolutely necessary that the below instructions be carefully fol- lowed. With detailed connection instructions, it is very easy to make a mistake and mis-wire a connection. Always slowly read each step and confirm that you have made the correct connections for the circuit. Experiment 1. Connect a red jumper wire from the F1 15 A fuse to terminal #30of relay #1. 2. Connect a red jumper wire from terminal #87A of relay #1 to terminal #30 of relay #2. 3. Connect a red jumper wire from terminal #87 of relay #2 to terminal 86 of relay #2. 4. Using the piggy back feature, connect a red jumper wire from terminal #86 of relay #2 to positive (+) terminal (right- hand side) of the backup light on the lower Moduponent panel. 5. Using the piggy back feature, connect a red jumper wire from the F1 15 A fuse to the left-hand terminal of the Stop Light push button switch. 6. Using the piggy back feature, connect a red jumper wire from the left-hand terminal of the Stop Light push button switch to the left-hand terminal of the Back Up Light push button switch. 7. Connect a red jumper wire from the right-hand terminal of the Back Up Light push button switch to terminal #86 of relay #1. 8. Using the piggy back feature, connect a red jumper wire from terminal #87 of relay #2 to the right-hand terminal of the Brake Light push button switch. 9. Connect a black jumper wire from terminal #85 of relay #1 to terminal #85 of relay #2. 10. Using the piggy back feature, connect a black jumper wire from terminal #85 of either relay #1 or relay #2 to any of the three black ground terminals on the left-hand side of the middle Moduponent panel. 11. Connect a black jumper wire from the (-) terminal (left-hand) of the Back Up Light on the lower Moduponent panel to any of the four black ground terminals on the left-hand side of the middle Moduponent panel. 12. Make sure the BATTERY panel light is ON. 13. Push the Brake Light push button switch. The Back Up Light should come ON and stay ON. 14. Confirm proper operation. 15. Push the Back Up Light push button. The Back Up Light should go OFF. consulab.com info@consulab.com 35 HV-1918-2-91 Relay Controlled ON/OFF Circuit (Latched Relays) 16. Confirm proper operation. 17. If the circuit does not function as it should, go back over the connection instructions to find your errors and correct. Operational Description of ON/OFF Latched Relay Circuit To turn the backup light “ON” 1. Battery power is available at all times to the following circuit points: A. F1 15A fuse B. Terminal 30 of Relay #1 C. Left-hand side of Backup Light Push Button switch D. Left-hand side of Stop Lamp Push Button switch E. Terminal 87A of Relay #1 F. Terminal 30 of Relay #2 2. If the backup light is in the OFF position, pushing the Stop Lamp switch will provide battery voltage to terminal 87 of Relay #2. 3. Because terminal 87 of Relay #2 is connected to terminal 86 of the same relay, the relay coil now is energized and the relay “turns ON”. (The relay’s coil ground circuit (#85) is connected to ground at all times). 4. Turning Relay #2 ON, connects battery power from terminal 30 to terminal 87 of Relay #2. This provides a positive power source to the backup light. Power comes from the 15A fuse, to terminal 30 of Relay #1, through the normal- ly closed connection to terminal 87A of Relay #1, through to terminal 30 of Relay #2, through the closed contacts (relay ON), and out of Relay #2 on terminal 87, to terminal 86 of Relay #2 (jumper wire) to the backup light positive wire. The light turns ON because it is grounded by the black wire. 5. Releasing the Stop Lamp switch keeps the backup light ON because the Relay #1 coil control circuit is connected to battery positive through the connection from terminal 87 to terminal 86 of Relay #1, back through the normally closed contacts (87A to 30) of Relay #1 and back to the 15A fuse. 6. At this point, Relay #2 is “latched” in the “ON” position and the backup light is ON. To turn the backup light “OFF” 1. Pushing the Backup Light push button switch provides positive battery voltage to terminal 86 of Relay #1 resulting in the relay #1 coil being energized and the relay “turns ON”. (The relay’s coil ground circuit (#85) is connected to ground at all times). 2. Turning Relay #1 ON breaks the positive circuit to the backup light by interrupting the power connection between terminals 30 and 87A of Relay #1. 3. As Relay #1 is turning ON, this action also turns OFF Relay #2 by breaking the connection between terminals 30 and 87A of Relay #1 which was providing a circuit to Relay #2’s coil control circuit. Relay #2 now turns OFF and the backup light goes OFF. 4. Releasing the Backup Light push button switch reconnects terminals 30 and 87A of Relay #1, but the backup light stays OFF because the connection between terminals 30 and 87 of Relay #2 was broken when the Backup Light push button switch was pushed. consulab.com info@consulab.com 36 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Relay Controlled ON/OFF Circuit (Latched Relays) — Answers Relay Controlled ON/OFF Circuit (Latched Relays) — Answers consulab.com info@consulab.com 37 HV-1918-2-91 Headlights Circuit (Ground Switched) — Entry Level Headlights Circuit (Ground Switched) — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlights circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch Carefully follow the below instructions that will define how to properly construct this ground switched headlight circuit. Because of the internal design of the HV-1918 headlight switch, the headlights circuit should be split between the left and right hand sides. Each relay controls the high/low beam circuit for that particular vehicle side. 1. As you complete each of the below circuit construction steps, draw the jumper wire connection you make during each step on the template labeled: HEADLIGHTS CIRCUIT (GROUND SWITCHED) and submit the schematic when you turn in your student answer sheet. 2. Connect a red jumper wire from the red terminal of the F1 15A fuse to the left-hand BAT terminal of the headlight switch. 3. Connect a red jumper wire from the red terminal of the F2 15A fuse to the right-hand BAT terminal of the headlight switch. 4. Connect a red jumper wire from the left-hand H terminal of the headlight switch to terminal 31 of the multi-function switch. consulab.com info@consulab.com 38 HV-1918-2-91 Headlights Circuit (Ground Switched) — Entry Level 5. Using the piggy back feature, connect a red jumper wire from the right-hand H terminal of the headlight switch to terminal 31 of the multi-function switch. 6. Using the piggy back feature, connect a red wire from the left-hand H terminal of the headlight switch to the black ground terminal of the left-hand headlight. 7. Using the piggy back feature, connect a red wire from the right-hand H terminal of the headlight switch to the black ground terminal of the right-hand headlight. 8. Connect a red wire from the LOW beam terminal of the left-hand headlight to terminal 87A of relay #1. 9. Connect a red wire from the LOW beam terminal of the right-hand headlight to terminal 87A of relay #2. 10. Connect a red wire from the HIGH beam terminal of the left-hand headlight to terminal 87 of relay #1. 11. Connect a red wire from the HIGH beam terminal of the right-hand headlight to terminal 87 of relay #2. 12. Connect a red wire from terminal 33A of the multi-function switch to terminal 85 of relay #1. 13. Using the piggy back feature, connect a red wire from terminal 85 of relay #1 to terminal 85 of relay #2. 14. Connect a black wire from any of the three black ground terminals on the left-hand side of the middle Moduponent panel to terminal 30 of relay #1. 15. Using the piggy back feature, connect a black wire from any of the three black ground terminals on the left-hand side of the middle Moduponent panel to terminal 30 of relay #2. 16. Using the piggy back feature, connect a black wire from terminal 86 to terminal 30 of relay #1. 17. Using the piggy back feature, connect a black wire from terminal 86 to terminal 30 of relay #2. 18. Connect a red wire from terminal 33A of the multi-function switch to the red terminal of the HIGH BEAM INDICATOR lamp. 19. Connect a black wire from the black terminal of the HIGH BEAM INDICATOR lamp to any of the three black ground terminals on the left-hand side of the middle Moduponent panel. 20. Confirm all connections are correct. 21. Confirm that the trainer BATTERY light is ON. (If not turn ON the power supply) 22. Move the headlight switch toggle DOWN to turn ON the headlights. 23. With the headlights ON, push in the dimmer switch button on the end of the multi-function switch lever. The head- lights should switch from LOW to HIGH beam with the HIGH BEAM INDICATOR lamp coming ON with the high beam headlights. 24. Confirm correct circuit operation. 25. If the circuit does not operate normally, go back over each step to identify where errors were made. 26. Obtain verification from your instructor and have him/her sign your student answer sheet. 27. Now, answer the circuit understanding questions below and put your answers on the student answer sheet. consulab.com info@consulab.com 39 HV-1918-2-91 Headlights Circuit (Ground Switched) — Entry Level Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Trace the flow of power from the fuse to ground for the LOW beam for the right-hand headlight. 2. Trace the flow of power from the fuse to ground for the HIGH beam for the left-hand headlight. 3. Explain what would happen to the circuit if the coil of relay #2 were to fail by being “OPEN”. consulab.com info@consulab.com 40 HV-1918-2-91 Headlights Circuit (Ground Switched) — Advanced Level Headlights Circuit (Ground Switched) — Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlight circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch General Circuit Construction Instructions To construct the ground switched headlight circuit, carefully read the following general description of the circuit, then, obtain a blank template for the HV-1918 trainer and carefully draw all positive and negative wires required to make the circuit operate correctly. FUSES : Use two fuses for this circuit. One for the left headlight and one for the right headlight. HEADLIGHT SWITCH : Use the left side of the switch for the left headlight and the right side for the right headlights. RELAYS : Use relays #1 for the left headlight and #2 for the right headlight. The relays are responsible for switching from LOW to HIGH beam when commanded by the dimmer switch. MULTI-FUNCTION SWITCH : Pins 31 and 33A are for the dimmer switch. It is a latched push button switch located at the consulab.com info@consulab.com 41 HV-1918-2-91 Headlights Circuit (Ground Switched) — Advanced Level end of the lever. Pushing it once will either open or close the switch depending on the position it was previously in. The dimmer switch will control the relays in this circuits HEADLIGHTS : Use the common COM terminal for power feed and the power flow will exit the lights either from the LOW or HIGH beam terminals. Instructions 1. Draw the ground switched headlight circuit on the blank template. Include ALL necessary wires for correct operation of the circuit. 2. Hand in your drawing to your instructor for verification. 3. When you have verification, construct the circuit you have drawn on the trainer. Verify all wiring is correct. 4. With instructors permission, turn ON power supply and confirm correct circuit operation. If circuit do not operate properly, recheck your work to find and correct your errors. 5. Answer the following circuit understanding questions. Put your answers on the student answer sheet. 6. Turn in your answer sheet to your instructor for credit. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Trace the flow of power from the fuse to ground for the LOW beam for the right-hand headlight. 2. Trace the flow of power from the fuse to ground for the HIGH beam for the left-hand headlight. 3. Explain what would happen to the circuit if the coil of relay #2 were to fail by being “OPEN”. consulab.com info@consulab.com 42 HV-1918-2-91 Headlights Circuit (Ground Switched) — Entry and Advanced Levels — Answers Headlights Circuit (Ground Switched) — Entry and Advanced Levels — Answers 1. Trace the flow of power from the fuse to ground for the LOW beam for the right-hand headlight. Power flows from the F2 15A fuse to the right-hand BAT terminal of the headlight switch. When the switch is turned ON, power flows out of the H terminal of the headlight switch and into GRD terminal of the right-hand headlight and also to terminal 31 of the multi-function switch. From the GRD terminal of the right-hand headlight, power flows through the LOW beam filament and into terminal 87A of relay #1. The relay will be OFF for LOW BEAM operation. Power flows through the normally closed contacts and out of the relay on terminal 30, where it is connected by a jumper to terminal 86. From terminal 86, power flows to ground at the ground connection. 2. Trace the flow of power from the fuse to ground for the HIGH beam for the left-hand headlight. Power flows from the F1 15A fuse to the left-hand BAT terminal of the headlight switch. When the switch is turned ON, power flows out of the H terminal of the headlight switch and into the GRD terminal of the left-hand headlight and also to terminal 31 of the multi-function switch. From the GRD terminal of the left-hand headlight, power flows through the HIGH beam filament and into terminal 87 of relay #1. Power also is supplied to terminal 31 of the multi-function switch from the BAT terminal of the headlight switch. When the dimmer switch is pushed in, power flows from terminal 31 into 33A of the multi-function switch and into terminal 85 of relay #1. Terminal 86 of relay #1 is grounded. This causes the relay to turn ON which connects the normally open contacts of 87 and 30 together. Power then flows out of terminal 30 of relay #1 which is grounded and thus the left-hand headlight HIGH BEAM fila- ment comes ON. Power also leaves terminal 33A of the multi-function switch and enters the red terminal of the HIGH BEAM INDICATOR lamp which is grounded through the black terminal and thus comes on with the HIGH BEAM lamp. 3. Explain what would happen to the circuit if the coil of relay #2 were to fail by being “OPEN”. If the coil for relay #1 were to fail by being OPEN, there would be no left-hand HIGH beam circuit power because the relay coil is responsible to closing terminals 87 and 30 which directs power from the high beam filament to ground. The LOW beam portion of the left-hand headlight would operate normally because power for the LOW beam circuit flows through the normally closed relay contacts of #87A and #30. consulab.com info@consulab.com 43 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Headlights Circuit (Ground Switched) — Entry and Advanced Levels — Answers Headlights Circuit (Ground Switched) — Entry and Advanced Level — Student Assignment Sche- matic — Answers consulab.com info@consulab.com 44 HV-1918-2-91 Headlights Circuit (Positive Switched) — Entry Level Headlights Circuit (Positive Switched) — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlight circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch Carefully follow the below instructions that will define how to properly construct this positive switched headlight circuit. Because of the internal design of the HV-1918 headlight switch, the headlight circuit should be split between the left and right hand sides. Each relay controls the high/low beam circuit for that particular vehicle side. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “HEADLIGHTS (POSITIVE SWITCHED)” and submit the schematic when you turn in your Student Answer Sheet. 2. The circuit will be constructed by component. 3. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. consulab.com info@consulab.com 45 HV-1918-2-91 Headlights Circuit (Positive Switched) — Entry Level Fuses And Headlamp Switch 1. Connect a red jumper wire from the red receptacle of fuse F1 to the right-hand “BAT” terminal of the headlamp switch. 2. Connect a red jumper wire from the red receptacle of fuse F2 to the left-hand “BAT terminal of the headlamp switch. 3. Connect a red jumper wire from the right-hand “H” terminal of the headlamp switch to terminal #30 of relay #2. 4. Connect a red jumper wire from the left-hand “H” terminal of the headlamp switch to terminal #30 of relay #1. 5. Connect a red jumper wire from the left-hand “H” terminal of the headlamp switch to terminal #31 of the multi-func- tion switch. Relays, Multi-Function Switch, High Beam Indicator and Headlights 6. Connect a black jumper wire from terminal #85 of relay #2 to terminal #85 of relay #1. 7. Connect a black jumper wire from terminal #85 of relay #1 to any of the three black ground receptacles on the left- hand side of the middle Moduponent panel. 8. Connect a red jumper wire from the left-hand headlight LOW beam receptacle to terminal #87A of relay #1. 9. Connect a red jumper wire from the left-hand headlight HIGH beam receptacle to terminal #87 of relay #1. 10. Connect a red jumper wire from the right-hand headlight LOW beam receptacle to terminal #87A of relay #2. 11. Connect a red jumper wire from the right-hand headlight HIGH beam receptacle to terminal #87 of relay #2. 12. Connect a black jumper wire from the black ground receptacle of the right-hand headlight to the black ground re- ceptacle of the left-hand headlight. 13. Connect a black jumper wire from the black ground receptacle of the left-hand headlight to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. 14. Connect a red jumper wire from terminal #86 of relay #2 to terminal #86 of relay #1. 15. Connect a red jumper wire from terminal #86 of relay #1 to terminal #33A of the multi-function switch. 16. Connect a red jumper wire from terminal #33A of the multi-function switch to the red receptacle of the HIGH BEAM INDICATOR lamp. 17. Connect a black jumper wire from the black terminal of the HIGH BEAM INDICATOR lamp to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Circuit Operation Confirmation 18. Recheck all of your circuit connections to confirm correct circuit construction. 19. Make sure the trainer power supply is turned ON and the BATTERY light is ON. 20. Turn the headlamp switch DOWN to the headlamps ON position. 21. Headlights should now be ON. 22. Move the pushbutton on the end of the multifunction lever to change from HIGH to LOW beams. 23. Confirm that the HIGH BEAM INDICATOR comes ON when high beam headlights are selected. (NOTE- High beam headlights will illuminate in a higher position than low beam on a wall.) 24. If the circuit does not operate normally, go back over your connections to identify and repair the errors. consulab.com info@consulab.com 46 HV-1918-2-91 Headlights Circuit (Positive Switched) — Entry Level 25. Confirm that you have drawn the circuit schematic on the Student Schematic sheet. 26. Obtain operation verification from your instructor. 27. Answer the circuit understanding questions below and put your answers on the Student Answer Sheet. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Explain what the impact on the circuit would be if fuse F1 was open. 2. Explain what how the circuit would behave if relay #2 contacts #87 and #30 were stuck together inside the relay. 3. Explain what an open in the ground circuit to relay #1 would have on the operation of the circuit. 4. Explain what a short together between the left-hand “H” and right-hand “H” terminals of the headlamp switch would have on the circuit. consulab.com info@consulab.com 47 HV-1918-2-91 Headlights Circuit (Positive Switched) — Entry Level — Answers Headlights Circuit (Positive Switched) — Entry Level Answers 1. Explain what the impact on the circuit would be if fuse F1 was open. Because fuse F1 supplies power to the right-hand side of the headlamp switch, an open fuse would result in no op- eration of the right-hand headlamps in either HIGH or LOW beam. 2. Explain what how the circuit would behave if relay #2 contacts #87 and #30 were stuck together inside the relay. In this particular headlight circuit, the LOW beam filaments are designed to switch OFF during HIGH beam opera- tion. With terminals #30 and #87 stuck together on relay #2, the LOW beam filament would remain ON during HIGH beam operation. This would create a brighter than normal illumination on the right side because both HIGH and LOW beam filaments would be ON at the same time. 3. Explain what an open in the ground circuit to relay #1 would have on the operation of the circuit. An open circuit in the coil winding of relay #1 would result in the left-hand LOW beam staying ON all the time even when the HIGH beam circuit is selected. 4. Explain what a short together between the left-hand “H” and right-hand “H” terminals of the headlamp switch would have on the circuit. A short between the left-hand and right-hand terminals “H” of the headlamp would have no initial negative impact on the circuit. However, with this situation, if either fuse F1 or F2 would fail, the other fuse would be required to supply the power for that side of the circuit which would double the amperage flow through the remaining fuse. consulab.com info@consulab.com 48 HV-1918-2-91 Headlights Circuit (Positive Switched) — Advanced Level Headlights Circuit (Positive Switched) — Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlight circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch Carefully follow the below instructions that will define how to properly construct this positive switched headlight circuit. Because of the internal design of the HV-1918 headlight switch, the headlight circuit should be split between the left and right hand sides. Each relay controls the high/low beam circuit for that particular vehicle side. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “HEADLIGHTS (POSITIVE SWITCHED)” and submit the schematic when you turn in your Student Answer Sheet. 2. The circuit will be constructed by component. 3. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. consulab.com info@consulab.com 49 HV-1918-2-91 Headlights Circuit (Positive Switched) — Advanced Level Circuit Construction Construct the positive side switched headlight circuit following the below instructions. Fuses, Headlamp Switch and Dimmer Switch 1. Use fuse F1 for the right-hand headlight and fuse F2 for the left-hand headlight. 2. Either side of the headlamp switch can feed the dimmer switch. 3. Include the dimmer switch in the headlight circuit. Relays and Multi-Function Switch 4. Use relay #1 for the left-hand headlight and relay #2 for the right-hand headlight. 5. Use terminals #31 and #33A of the multi-function switch for the dimmer switch. 6. Use relay terminals #85 for the coil ground circuits Headlights 7. Use the left-hand headlight for the headlight ground circuit. Circuit Confirmation 8. Recheck all of your circuit connections to confirm they are correct. 9. Make sure the trainers power supply is turned ON and the BATTERY light is ON. 10. Turn the headlamp switch to the upper position to turn ON the headlight circuit. 11. Operate the dimmer switch to confirm proper operation of the high beam headlights and the high beam indicator lamp. 12. If there is any circuit malfunction, go back over your connections to identify and repair the error. 13. Make sure you have correctly drawn this circuit on the schematic template. 14. Obtain instructor verification of correct circuit operation. 15. Answer the CIRCUIT UNDERSTANDING QUESTIONS below and put your answers on the Student Answer Sheet. Circuit Understanding And Diagnosis Questions (Use the student answer sheet for your answers) 1. Explain what the impact on the circuit would be if fuse F1 was open. 2. Explain what how the circuit would behave if relay #2 contacts #87 and #30 were stuck together inside the relay. 3. Explain what an open in the ground circuit to relay #1 would have on the operation of the circuit. 4. Explain what a short together between the left-hand “H” and right-hand “H” terminals of the headlamp switch would have on the circuit. 5. What effect would very high resistance in the black wire from terminal #85 of relay #1 to the ground terminal of the middle Moduponent panel have on circuit performance? 6. What effect would a short between the HIGH and LOW beam headlight wires at the connector have on circuit perfor- mance? (there is no short to ground, but just between high and low beam circuits) 7. There is an open wire from the right-hand headlamp switch terminal “H” to terminal #30 of relay #2. What effect on circuit performance would this condition have? consulab.com info@consulab.com 50 HV-1918-2-91 Headlights Circuit (Positive Switched) — Advanced Level — Answers Headlights Circuit (Positive Switched) — Advanced Level Answers 1. Explain what the impact on the circuit would be if fuse F1 was open. Because fuse F1 supplies power to the right-hand side of the headlamp switch, an open fuse would result in no op- eration of the right-hand headlamps in either HIGH or LOW beam. 2. Explain what how the circuit would behave if relay #2 contacts #87 and #30 were stuck together inside the relay. In this particular headlight circuit, the LOW beam filaments are designed to switch OFF during HIGH beam opera- tion. With terminals #30 and #87 stuck together on relay #2, the LOW beam filament would remain ON during HIGH beam operation. This would create a brighter than normal illumination on the right side because both HIGH and LOW beam filaments would be ON at the same time. 3. Explain what an open in the ground circuit to relay #1 would have on the operation of the circuit. An open circuit in the coil winding of relay #1 would result in the left-hand LOW beam staying ON all the time even when the HIGH beam circuit is selected. 4. Explain what a short together between the left-hand “H” and right-hand “H” terminals of the headlamp switch would have on the circuit. A short between the left-hand and right-hand terminals “H” of the headlamp would have no initial negative impact on the circuit. However, with this situation, if either fuse F1 or F2 would fail, the other fuse would be required to supply the power for that side of the circuit which would double the amperage through the remaining fuse. 5. What effect would very high resistance in the black wire from terminal #85 of relay #1 to the ground terminal of the middle Moduponent panel have on circuit performance? High resistance in the black wire from terminal #85 of relay #1 would result in there being no action of the relay when high beam headlights are switched ON. The relay coils of relays #1 and #2 would not be able to complete their circuits to ground and the relays wouldn’t turn ON. This would result in the headlights staying ON LOW beam regardless of the position of the dimmer switch. The HIGH BEAM INDICATOR would operate normally, but the high beam headlights would not function. 6. What effect would a short between the HIGH and LOW beam headlight wires at the connector have on circuit perfor- mance? (there is no short to ground, but just between high and low beam circuits) With the HIGH and LOW beam wires of the right-hand headlight being shorted together, both the high and low beam headlight filaments of the right-hand headlight would be on at the same time. This would be true regardless of the position of the dimmer switch. The amperage flowing in the circuit would be the combination of the high and low beam filaments. This would result in the right-hand headlight being somewhat “brighter” than the left-hand side. 7. There is an open wire from the right-hand headlamp switch terminal “H” to terminal #30 of relay #2. What effect on circuit performance would this condition have? With an open in the wire from the right-hand side “H” terminal of the headlamp switch to terminal #30 of relay #2, there would be no headlight operation for the right-hand headlight. This is because there would be no power to terminal #30 which provides power to both the high and low beam headlight. consulab.com info@consulab.com 51 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Headlights Circuit (Positive Switched) — Entry and Advanced Levels — Answers Headlights Circuit (Positive Switched) — Entry and Advanced Levels — Student Assignment Sche- matic — Answers consulab.com info@consulab.com 52 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Entry Level Parking, Tail and Marker Lights Circuit — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Most medium and heavy duty trucks come equipped with many park, tail and clearance marker lights. Because of this fact, relays are normally used to reduce the circuit load on the headlight switch. The HV-1918 trainer uses all LED style lamps for the park, tail and marker lights which results in a significant reduction in total circuit amperage. Most modern trucks today also commonly use LED lights. The HV-1918 trainer has the following lighting components for the park, tail and marker light circuit: • Two (2) front amber parking lights • Five (5) amber marker lights in a mounting bar • Two (2) amber side marker lights • Two (2) red taillights • Five (5) red marker lights • One (1) license plate light • One (1) trailer plug • One (1) headlamp switch • Two (2) relays • Three (3) fuses Circuit Construction Because of the number of wires involved in this circuit, the instructions for constructing this circuit will be grouped by component, then the components will be connected together. It is very important to read each step very carefully and confirm that you are attaching the wires exactly as described. NOTE: It is possible to install more than one jumper wires on the same terminal by using the “piggy back” feature that allows the wires to be “stacked”. IMPORTANT: AS YOU MAKE EACH JUMPER WIRE CONNECTION, DRAW THE CONNECTION THAT YOU MADE ON THE SCHEMATIC TEMPLATE. consulab.com info@consulab.com 53 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Entry Level Front Marker and Side Clearance Lights 1. Connect all five amber marker lights using four (4) red jumper wires in the red receptacles. 2. Connect a red jumper wire from either the left or right end marker light to either the left or right side marker light on the top Moduponent. Use the red receptacle. 3. Connect all five amber marker lights using four (4) black jumper wires in the black receptacles. 4. Connect a black jumper wire from either the left or right end marker light to either the left or right side marker light on the top Moduponent. Use the black receptacle. 5. Connect a red jumper wire from the red receptacle of the right-hand side marker light to the red receptacle of the left-hand side marker light. 6. Connect a black jumper wire from the black receptacle of the right-hand side marker light to the black receptacle of the left-hand side marker light. 7. Connect a black jumper wire from the black receptacle of the left-hand side marker to any of the three ground receptacle on the left-hand side of the middle Moduponent. Front Parking Lights 8. Connect a red jumper wire from the “P” terminal of the left-hand parking light to the red terminal of the left-hand side marker light. 9. Connect a black jumper wire from the “GND” terminal of the left-hand parking light to the black terminal of the left- hand side marker light. 10. Connect a red jumper wire from the “P” terminal of the right-hand parking light to the red terminal of the right-hand side marker light. 11. Connect a black jumper wire from the “GND” terminal of the right-hand parking light to the black terminal of the right-hand side marker light. Rear Marker, Tail and License Plate Lights 12. Connect all five red marker lights on the bottom Moduponent using four (4) red jumper wires in the red receptacles. 13. Connect a red jumper wire from the left rear marker light to the left side tail light. Use the middle red receptacle identified by “P”. 14. Connect a red jumper wire from the right-rear marker light red receptacle to the “P” terminal of the right-rear tail- light. 15. Connect all five red marker lights using four (4) black jumper wires in the black receptacles. 16. Connect a black jumper wire from the black terminal of hte left-hand rear marker light to the GND terminal of the left side tail light. 17. Connect a red jumper wire from the red receptacle of the license plate light to any of the red receptacles of the red marker lights. 18. Connect a black jumper wire from the black receptacle of the license plate light to any of the black receptacles of the red marker lights. consulab.com info@consulab.com 54 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Entry Level 19. Connect a black jumper wire from the black receptacle of the left-hand taillight identified by “GND” to the black receptacle of the left-hand rear marker light. 20. Connect a black jumper wire from the “GND” receptacle of the left-rear taillight to any of the four black ground receptacles on the left-hand side of the lower Moduponent panel. 21. Connect a black jumper wire from any of the four ground receptacles on the lower Moduponent panel to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. 22. Connect a black jumper wire from the “GND” terminal of the right-hand taillight to the “GND” terminal of the right- hand taillight. Trailer Plug 23. Connect a red jumper wire from the “P” terminal of the right-hand taillight to terminal #86 of relay 4. 24. Connect a red jumper wire from the 87 terminal of relay 4 to the terminal # 2 of the trailer plug connecter. 25. Connect a red jumper wire from terminal #2 to terminal #6 of the trailer plug connecter. 26. Connect a red jumper wire from the F6 terminal to terminal # 30 of the relay 4 27. Connect a black jumper wire from the “GND” terminals of the right hand taillight to terminal #85 of relay 4. 28. Connect a black jumper wire from the “GND” terminals of the right hand taillight to terminal # 1 of the trailer plug connecter. Headlamp Switch 29. Connect a red jumper wire from the red terminal of F4 fuse on the middle Moduponent panel to the right-hand side “BAT” terminal of the headlamp switch. 30. Connect a red jumper wire from the “BAT” terminal of the left-hand side of the headlamp switch to the “BAT” termi- nal of the right-hand side of the headlamp switch. Relays 31. Connect a red jumper wire from the “P” terminal of the left-hand side of the headlamp switch to terminal #86 of relay #3. 32. Connect a red jumper wire from the “P” terminal of the right-hand side of the headlamp switch to terminal #86 of relay #4. 33. Connect a red jumper wire from terminal #30 of relay #3 to the “P” terminal of the right-hand front parking light. 34. Connect a red jumper wire from terminal #30 of relay #4 to the “P” terminal of the right-hand rear taillight. 35. Connect a black jumper wire from terminal #85 of relay #3 to terminal #85 of relay #4. 36. Connect a black jumper wire from terminal #85 of relay #4 to any of the three black ground receptacles on the left- hand side of the middle Moduponent panel. Fuses 37. Connect a red jumper wire from the red receptacle of fuse F5 to terminal #87 of relay #3. consulab.com info@consulab.com 55 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Entry Level 38. Connect a red jumper wire from the red receptacle of fuse F6 to terminal #87 of relay #4. 39. Confirm that the trainers power supply is turned ON and the BATTERY light is ON. 40. Move the headlamp switch up to turn ON the parking, marker and taillights. 41. Confirm correct circuit operation. If circuit operation is incorrect, recheck all of the connections to determine errors and correct. 42. Obtain verification from your instructor. 43. Answer the circuit understanding questions below and put your answers on the Student Answer Sheet. When com- pleted, turn in the Student Answer Sheet and the schematic to your instructor for credit. Circuit Explanation Fuse F4 provides power to the headlamp switch and the coil circuits of both relays #4 and #5. This circuit is called the “control circuit”. Fuse F5 supplies power to terminal #87 of relay #3 which controls the front lighting circuit. This circuit is called the “controlled circuit”. Fuse F6 supplies power to terminal #87 of relay #4 which controls the rear lighting circuit. This circuit is called the “controlled circuit”. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Explain what circuit problems would occur is there was an “open” in the wire from terminal #86 of relay #4 to the “P” terminal of the headlamp switch. 2. Explain what circuit problems would occur is fuse F4 was defective and electrically OPEN. 3. Explain what circuit problems would occur if the black wire was OPEN connected between terminal #85 of relay #4 and terminal #85 of relay #3. 4. What effect on the circuit would an open coil in relay #4 have? 5. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with no rear tail or marker lights. What specific components would you check to deter- mine the cause? 6. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with only the right rear taillight on, but no marker lights, license plate light or left-rear taillight on the rear of the cab and on the box. What specific components would you check to determine the cause? consulab.com info@consulab.com 56 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Entry Level — Answers Parking, Tail and Marker Lights Circuit — Entry Level Answers 1. Explain what circuit problems would occur is there was an “open” in the wire from terminal #86 of relay #4 to the “P” terminal of the headlamp switch. There would be no front parking or marker lights because the wire connecting the “P” terminal of the headlight switch sends power to the + relay coil terminal for relay #3. Relay #3 controls the front parking and taillights and thus, if the relay doesn’t energize, no power would be sent to this circuit. 2. Explain what circuit problems would occur is fuse F4 was defective and electrically OPEN. There would be no parking, tail or marker lights operating. This is because fuse F4 provides power to the headlight switch which in turn, turns ON both relays when the PARK, TAIL and MARKER lights are switched. 3. Explain what circuit problems would occur if the black wire was OPEN connected between terminal #85 of relay #4 and terminal #85 of relay #3. The open ground wire connected between terminal 85 of relay 3 and terminal 85 of relay 4 would result in relay 3 being non-functional. Relay 3 controls all front park and front marker lights and thus, there would be no function of these lights. 4. What effect on the circuit would an open coil in relay #4 have? An open coil in relay #4 would result in no relay operation. Relay 4 controls the rear tail, license plate, trailer plug and rear marker lights and thus, there would be no function of these lights. 5. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with no rear tail or marker lights. What specific components would you check to deter- mine the cause? Because all rear tail, license plate, trailer plug and rear marker lights are non-operational, the first component to check would be fuse F6 (power to relay #4 terminal 87) and fuse F4 (power for relay control circuits). If fuse F6 was OK, the next place to check would be relay #4. Check for a power at terminal 87 and for a signal from the headlight switch at terminal 86. If there is no signal to terminal 86 of the relay, check for the signal at the right-hand “P” ter- minal of the headlight switch. A signal there indicates an open wire between the headlamp switch and relay #4. No signal at the “P” terminal would require testing for power at the “BAT” terminal of the headlamp switch. If power was present, the headlamp switch is defective. No power indicates an open from the “BAT” terminal to the fuse. 6. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with only the right rear taillight ON, but no marker lights, license plate light or left-rear taillight on the rear of the cab and on the box. What specific components would you check to determine the cause? Because power is fed to the rear marker lights, license plate light, trailer plug and left-rear taillight from the right- rear taillight, the location of the problem must be in the red wire connected from terminal “P” of the right-rear taillight to the right-side rear marker light. consulab.com info@consulab.com 57 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Advanced Level Parking, Tail and Marker Lights Circuit — Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Most medium and heavy duty trucks come equipped with many park, tail and clearance marker lights. Because of this fact, relays are normally used to reduce the circuit load on the headlight switch. The HV-1918 trainer uses all LED style lamps for the park, tail and marker lights which results in a significant reduction in total circuit amperage. Most modern trucks today also commonly use LED lights. The HV-1918 trainer has the following lighting components for the park, tail and marker light circuit: • Two (2) front amber parking lights • Five (5) amber marker lights in a mounting bar • Two (2) amber side marker lights • Two (2) red taillights • Five (5) red marker lights • One (1) license plate light • One (1) trailer plug • One (1) headlamp switch • Two (2) relays • Three (3) fuses Circuit Construction Because of the number of wires involved in this circuit, the instructions for constructing this circuit will be grouped by component, then the components will be connected together. It is very important to read each step very carefully and confirm that you are attaching the wires exactly as described. NOTE: It is possible to install more than one jumper wires on the same terminal by using the “piggy back” feature that allows the wires to be “stacked”. consulab.com info@consulab.com 58 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Advanced Level Instructions 1. Read the circuit construction instructions below and draw the circuit on the template as you would construct it on the trainer. 2. Submit your drawing to your instructor for verification. 3. Upon verification, construct the circuit you have designed on the trainer. Follow the below instructions for circuit construction. NOTE : As has been stated previously, there are several different methods of wiring these circuits which would all result in normal operation of the lighting circuits. To make sure your circuits match the schematic included with this manual, be sure to follow the general rules listed below. Front Marker and Side Clearance Lights 1. Construct the front marker and side clearance lights be connecting all components with red and black wires. In or- der for your circuit to match the manual schematic, feed the right-side parking light with power from relay #3 which will control all front lighting. Feed the right-side of the amber clearance lights from the right-side parking light. Front Parking Lights 2. Construct the circuits for the front parking lights with red and black wires. In order for your circuit to match the manual schematic, feed the right-side parking light with power from relay #3. Rear Marker, Tail and License Plate Lights 3. Construct the circuits for the rear marker, taillights and license plate lights with red and black wires. In order for your circuit to match the manual schematic, feed the right-rear taillight with power from relay #4 which controls all rear lighting. Feed the right-side red marker lights from the right-side taillight. 4. Feed the trailer connecter from the right-side taillight. 5. Feed the license plate light from the 2nd from the left red marker light. Headlamp Switch 6. Use fuse F4 for the relay control circuits for both front and rear lighting. 7. Use the left-side of the headlamp switch for the front lights and the right-hand side of the headlamp switch for the rear lighting. Relays 8. Use relay #3 for the front lighting circuit. 9. Use relay #4 for the rear lighting circuit. 10. Use fuse F5 for the front lights. 11. Use fuse F6 for the rear lights. consulab.com info@consulab.com 59 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Advanced Level Verification 1. Confirm that all circuit wiring is correct and matches your schematic. 2. Turn ON trainer power supply and make sure BATTERY light is ON. 3. Turn ON the headlight switch to confirm proper operation of the Park, Tail and Marker lights circuit. 4. If circuit does not function correctly, go back over your work to find and correct any errors. 5. Get instructors verification that the circuit is operating normally. 6. Answer the circuit understanding questions below and put your answer on the Student Answer Sheet. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Explain what circuit problems would occur is there was an “open” in the wire from terminal #86 of relay #4 to the “P” terminal of the headlamp switch. 2. Explain what circuit problems would occur is fuse F4 was defective and electrically OPEN. 3. Explain what circuit problems would occur if the black wire was OPEN connected between terminal #85 of relay #4 and terminal #85 of relay #3. 4. What effect on the circuit would an open coil in relay #4 have? 5. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with no rear tail or marker lights. What specific components would you check to deter- mine the cause? 6. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with only the right rear taillight ON, but no marker lights, license plate light or left-rear taillight on the rear of the cab and on the box. What specific components would you check to determine the cause? 7. You wish to have the trailer marker lights on a separate circuit from the truck cab lights, yet turned ON with the truck cab lights. Draw the required circuit using relay #4 (or any other open relay) and fuse F6 with the wires neces- sary to accomplish this goal. It is not necessary to draw all of the wires that were connected during the construction of the Tail, Park and Marker light circuit above. consulab.com info@consulab.com 60 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Advanced Level — Answers Parking, Tail and Marker Lights Circuit — Advanced Level Answers 1. Explain what circuit problems would occur is there was an “open” in the wire from terminal #86 of relay #4 to the “P” terminal of the headlamp switch. There would be no front parking or marker lights because the wire connecting the “P” terminal of the headlight switch sends power to the + relay coil terminal for relay #3. Relay #3 controls the front parking and taillights and thus, if the relay doesn’t energize, no power would be sent to this circuit. 2. Explain what circuit problems would occur is fuse F4 was defective and electrically OPEN. There would be no parking, tail or marker lights operating. This is because fuse F4 provides power to the headlight switch which in turn, turns ON both relays when the PARK, TAIL and MARKER lights are switched. 3. Explain what circuit problems would occur if the black wire was OPEN connected between terminal #85 of relay #4 and terminal #85 of relay #3. The open ground wire connected between terminal 85 of relay 3 and terminal 85 of relay 4 would result in relay 3 being non-functional. Relay 3 controls all front park and front marker lights and thus, there would be no function of these lights. 4. What effect on the circuit would an open coil in relay #4 have? An open coil in relay #4 would result in no relay operation. Relay 4 controls the rear tail, license plate, trailer plug and rear marker lights and thus, there would be no function of these lights. 5. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with no rear tail or marker lights. What specific components would you check to deter- mine the cause? Because all rear tail, license plate, trailer plug and rear marker lights are non-operational, the first component to check would be fuse F6 (power to relay #4 terminal 87) and fuse F4 (power for relay control circuits). If fuse #6 was OK, the next place to check would be relay F4. Check for a power at terminal 87 and for a signal from the headlight switch at terminal 86. If there is no signal to terminal 86 of the relay, check for the signal at the right-hand “P” ter- minal of the headlight switch. A signal there indicates an open wire between the headlamp switch and relay #4. No signal at the “P” terminal would require testing for power at the “BAT” terminal of the headlamp switch. If power was present, the headlamp switch is defective. No power indicates an open from the “BAT” terminal to the fuse. 6. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with only the right rear taillight on, but no marker lights, license plate light or left-rear taillight on the rear of the cab and on the box. What specific components would you check to determine the cause? Because power is fed to the rear marker lights, license plate light, trailer plug and left-rear taillight from the right- rear taillight, the location of the problem must be in the red wire connected from terminal “P” of the right-rear taillight to the right-side rear marker light. consulab.com info@consulab.com 61 HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Advanced Level — Answers 7. You wish to have the trailer marker lights on a separate circuit from the truck cab lights, yet turned ON with the truck cab lights. Draw the required circuit using relay #4 (or any other open relay) and fuse F6 with the wires neces- sary to accomplish this goal. It is not necessary to draw all of the wires that were connected during the construction of the Tail, Park and Marker light circuit above. (See the schematic) In order to have the trailer clearance and marker lights on a separate circuit, a relay is needed. Power is supplied to terminal #30 of the relay by fuse F6. Power leaves the relay on terminal #87 (when the relay is turned ON) and enters the trailer connecter at terminal #2 (left-side marker lights) and is jumped across to terminal #6 (right-side marker lights). The relay coil is grounded by terminal #85. The relay is turned ON by power coming from the “P” terminal of the headlamp switch and is connected to terminal #86 of the relay. When the headlamp switch is turned ON to the “P” position, the relay will also turn ON, thus turning ON the trailers marker lights. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 62 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Parking, Tail and Marker Lights Circuit — Entry and Advanced Levels — Answers Parking, Tail and Marker Lights Circuit — Entry and Advanced Levels — Student Assignment Sche- matic — Answers consulab.com info@consulab.com 63 HV-1918-2-91 Turn Signals and Hazard Circuit — Entry Level Turn Signals and Hazard Circuit — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding The turn signal and hazard circuits on most medium and heavy duty trucks can be operated regardless of ignition switch position. The HV-1918 does not utilize the ignition switch for this circuit. If the ignition switch was installed in the circuit, then the turn signal and hazard flasher circuits would only be able to be operated with the ignition switch ON. A typical truck turn signal and hazard circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Multi-function switch • Flasher • Front and rear turn signal lights • Rear stop lights • Stop light switch • Trailer plug Carefully follow the below instructions that will define how to properly construct the turn signal and hazard circuit. Be- cause of the internal design of the multi-function switch, power to the switch will be supplied without going through the ignition switch. This will allow both circuits to be operated regardless of the position of the ignition switch. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “TURN SIGNALS & HAZARD CIRCUIT” and submit the schematic when you turn in your Student Answer Sheet. 2. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. Circuit Construction Construct the turn signal and hazard circuit following the below instructions. Be sure to refer to the templates for the multi-function switch and the trailer plug connecter pin identification. consulab.com info@consulab.com 64 HV-1918-2-91 Turn Signals and Hazard Circuit — Entry Level Front Lights, Flasher and Indicator Lamps 1. Connect a red jumper wire from the red receptacle of fuse F6 to the BAT terminal of the flasher unit. 2. Connect a red jumper wire from the “SIG” terminal of the flasher unit to terminal #111 of the multi-function switch. 3. Connect a black jumper wire from the “GND” terminal of the flasher unit to any of the three black ground recepta- cles on the left-hand side of the middle Moduponent panel. 4. Connect a red jumper wire from the “BAT” terminal of the flasher unit to the right-hand yellow receptacle of the STOP LAMP SWITCH. 5. Connect a red jumper wire from the left-hand terminal of the STOP LAMP SWITCH to terminal #71 of the multi-func- tion switch. 6. Connect a red wire from terminal #113 of the multi-function switch to the “TS” terminal of the right-front park and turn light. 7. Connect a red jumper wire from terminal #112 of the multi-function switch to the “TS” terminal of the left-front park and turn light. 8. Connect a red jumper wire from terminal #112 of the multi-function switch to the red receptacle of the LEFT TURN indicator light. 9. Connect a red jumper wire from terminal #113 of the multi-function switch to the red receptacle of the RIGHT TURN indicator lamp. 10. Connect a black jumper wire from the black ground terminal of the right-front park and turn light to the black ground terminal of the left-hand park and turn light. 11. Connect a black jumper wire from the left-hand black ground terminal of the left-front park and turn light to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. 12. Connect a black jumper wire from the black receptacle of the RIGHT TURN indicator lamp to the black receptacle of the LEFT TURN indicator lamp. 13. Connect a black jumper wire from the black receptacle of the LEFT TURN indicator lamp to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Rear Lights and Trailer Plug 14. Connect a red jumper wire from terminal #116 of the multi-function switch to the “TS / S” terminal of the right-rear tail/turn and stop light. 15. Connect a red jumper wire from the “TS / S” terminal of the right-rear tail/turn and stop light to terminal #3 of the trailer connecter. 16. Connect a red jumper wire from terminal #115 of the multi-function switch to the “TS / S” terminal of the left-rear tail/turn and stop light. 17. Connect a red jumper wire from the “TS / S” terminal of the left-rear tail/turn and stop light to terminal #5 of the trailer connector. 18. Connect a red jumper wire from terminal #71 of the multi-function switch to terminal #4 of the trailer connecter. 19. Connect a black jumper wire from terminal #1 of the trailer plug to the “GND” terminal of the right-rear tail/turn and stop light. consulab.com info@consulab.com 65 HV-1918-2-91 Turn Signals and Hazard Circuit — Entry Level 20. Connect a black jumper wire from the “GND” terminal of the right-rear tail/turn and stop light to the “GND” terminal of the left-rear tail/turn and stop lamp. 21. Connect a black jumper wire from the “GND” terminal of the left-rear tail/turn and stop light to any of the four black ground receptacles on the left-hand side of the bottom Moduponent panel. 22. Connect a black jumper wire from any of the four ground receptacles on the left-hand side of the bottom Modupo- nent panel to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Circuit Confirmation 23. Recheck all circuit connections to make sure they are correct. 24. Make sure you have drawn the circuit you have constructed on the Student Answer Sheet. 25. Confirm that the trainers power supply is turned ON and the BATTERY lamp is ON. 26. Move the multi-function lever UP to turn ON the right turn signals. The right-front turn, right-rear turn/stop and the right turn indicator lamp should all be flashing. 27. Move the multi-function lever DOWN to turn ON the left turn signals. The left-front turn, left-rear turn/stop and the left turn indicator lamp should all be flashing. 28. Pull out on the HAZARD lever on the multi-function switch. All front turn, rear turn/stop and both turn indicators should be flashing. 29. Push the STOP LAMP SWITCH in and the rear turn/stop lights should come ON. 30. Confirm that the trailer plug has been correctly wired by using either a trailer plug tester or a voltmeter or 12 volt test light. 31. If the circuit does not function correctly, go back over your connections until you find and correct the errors. 32. Obtain verification from your instructor. 33. Answer the CIRCUIT UNDERSTANDING QUESTIONS below and put your answers on the Student Answer Sheet. 34. Turn in your wiring schematic and Student Answer Sheet for this circuit. Circuit Understanding Questions 1. What terminal of the multi-function switch supplies power to the left-front turn light? 2. What terminal of the trailer plug is for the right turn circuit? 3. What terminal of the multi-function switch is for power to enter the switch? 4. What is pin #1 of the trailer plug used for? 5. What is terminal #115 of the multi-function switch used for? 6. What would an open circuit in the black wire connecting the left-rear tail/turn and stop light to the black ground receptacles on the bottom Moduponent panel cause? consulab.com info@consulab.com 66 HV-1918-2-91 Turn Signals and Hazard Circuit — Entry Level — Answers Turn Signals and Hazard Circuit — Entry Level — Answers 1. What terminal of the multi-function switch supplies power to the left-front turn light? Terminal #112. 2. What terminal of the trailer plug is for the right turn circuit? Terminal #3. 3. What terminal of the multi-function switch is for power to enter the switch? Terminal #111. 4. What is pin #1 of the trailer plug used for? Trailer ground circuit. 5. What is terminal #115 of the multi-function switch used for? Power out to left-rear stop and turn lamp. 6. What would an open circuit in the black wire connecting the left-rear tail/turn and stop light to the black ground receptacles on the bottom Moduponent panel cause? An open in this ground circuit would stop operation of all rear lighting including the trailer plug. consulab.com info@consulab.com 67 HV-1918-2-91 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding The turn signal and hazard circuits on most medium and heavy duty trucks can be operated regardless of ignition switch position. The HV-1918 does not utilize the ignition switch for this circuit. If the ignition switch was installed in the circuit, then the turn signal and hazard flasher circuits would only be able to be operated with the ignition switch ON. A typical truck turn signal and hazard circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Multi-function switch • Flasher • Front and rear turn signal lights • Rear stop lights • Stop light switch • Trailer plug Carefully follow the below instructions that will define how to properly construct the turn signal and hazard circuit. Be- cause of the internal design of the multi-function switch, power to the switch will be supplied without going through the ignition switch. This will allow both circuits to be operated regardless of the position of the ignition switch. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “TURN SIGNALS & HAZARD CIRCUIT” and submit the schematic when you turn in your Student Answer Sheet. 2. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. consulab.com info@consulab.com 68 HV-1918-2-91 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Circuit Construction Construct the turn signal and hazard circuit following the below instructions. Be sure to refer to the templates for the multi-function switch and the trailer plug connecter pin identification. Front Lights, Flasher and Indicator Lamps 1. Use fuse F6 for the power supply for the turn signal and hazard circuit. 2. The terminal identification of the flasher unit is “GND” for ground, “BAT” for power and “SIG” for the lighting circuits. 3. To assure that your circuit is similar to the instructor’s answer key schematic, use the left-hand side of the front and rear park, turn and stop lights for the ground connections to the system ground. 4. No relays or ignition switch is used in this circuit. Rear Lights and Trailer Plug 5. Be sure to follow the pin identification of the trailer plug for correct circuit construction. 6. Be sure to include the left and right turn indicators in the wiring of this circuit. Circuit Confirmation 7. Recheck all of your circuit connections to make sure they are correct. 8. Make sure you have drawn the circuit on the TURN SIGNALS AND HAZARD LIGHTS circuit template as you construct- ed the circuit on the trainer. 9. Confirm that the trainers power supply is turned ON and the BATTERY lamp is ON. 10. Operate the STOP LAMP SWITCH and the MULTI-FUNCTION SWITCH through all circuits including: left-turn, right turn, hazard flashers, stop lights, left & right turn indicators, and the trailer plug for correct connections and opera- tion. 11. If any portion of the circuit does not operate correctly, go back over your connections to correct the errors. 12. Obtain instructor verification that the circuit operates correctly. 13. Answer the CIRCUIT UNDERSTANDING QUESTIONS below. 14. After answering the circuit understanding questions, make sure the answer sheet is completed filled out and the circuit schematic is completed. 15. Turn in your schematic and answer sheet to your instructor for credit. consulab.com info@consulab.com 69 HV-1918-2-91 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Circuit Understanding Questions 1. What terminal of the multi-function switch supplies power to the left-front turn light? 2. What terminal of the trailer plug is for the right turn circuit? 3. What terminal of the multi-function switch is for power to enter the switch? 4. What is pin #1 of the trailer plug used for? 5. What is terminal #115 of the multi-function switch used for? 6. What would an open circuit in the black wire connecting the left-rear tail/turn and stop light to the black ground receptacles on the bottom Moduponent panel cause? 7. If you wished to install relays for the trailer turn signal and stop lights to have power feed circuits separate than what the truck cab uses, describe the connections you would have to make to relay #1 and #2 for the turn signals and relay #3 for the stop lights to correctly construct this circuit. Draw the connections on a blank template. It is not necessary to re-draw the wires that were previously connected to make the turn signals and hazard circuit work. Just draw the“new” needed wires to make this circuit function. Use the separate schematic template titled “TURN SIGNALS & HAZARD FLASHER STUDENT QUESTION #7 ANSWER SHEET for your answer to question #7. consulab.com info@consulab.com 70 HV-1918-2-91 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level — Answers Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level — Answers 1. What terminal of the multi-function switch supplies power to the left-front turn light? Terminal #112. 2. What terminal of the trailer plug is for the right turn circuit? Terminal #3. 3. What terminal of the multi-function switch is for power to enter the switch? Terminal #111. 4. What is pin #1 of the trailer plug used for? Trailer ground circuit. 5. What is terminal #115 of the multi-function switch used for? Power out to left-rear stop and turn lamp. 6. What would an open circuit in the black wire connecting the left-rear tail/turn and stop light to the black ground receptacles on the bottom Moduponent panel cause? An open in this ground circuit would stop operation of all rear lighting including the trailer plug. 7. If you wished to install relays for the trailer turn signal and stop lights to have power feed circuits separate than what the truck cab uses, describe the connections you would have to make to relay #1 and #2 for the turn signals and relay #3 for the stop lights to correctly construct this circuit. Draw the connections on a blank template. It is not necessary to re-draw the wires that were previously connected to make the turn signals and hazard circuit work. Just draw the“new” needed wires to make this circuit function. Use the separate schematic template titled “TURN SIGNALS & HAZARD FLASHER STUDENT QUESTION #7 ANSWER SHEET for your answer to question #7. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date consulab.com info@consulab.com 71 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Turn Signals, Hazard & Brake Lights — Entry and Advanced Level — Answers Turn Signals, Hazard & Brake Lights — Entry and Advanced Level — Student Assignment Sche- matic — Answers consulab.com info@consulab.com 72 HV-1918-2-91 Auxiliary Circuits Auxiliary Circuits The HV-1918 trainer is equipped with auxiliary circuits that can be constructed as needed. Among them are: 1- Parking Brake Indicator lamp and switch, Backup light and switch and Auxiliary Switch. These components can be utilized in a number of different scenarios to design custom circuits for students to learn with. This assignment will allow students to construct three common circuits for the learning experience, but instructors can design additional circuits and compo- nent options based on their needs. Because of the simplicity of these circuits and components, student assignments will be designed at one competence level instead of the normal ENTRY and ADVANCED levels. Parking Brake Indicator Circuit Circuit Understanding Most heavy vehicles are equipped with a parking brake indicator circuit that is designed to warn the driver that the parking brake is applied. Components needed are: • Power supply (battery) • Overcurrent protection (fuses) • Switch • Indicator lamp • Power and ground wiring Circuit Construction 1. Connect a red jumper wire from the red receptacle of any of the top six (6) fuses to the right-hand yellow receptacle of the PARKING BRAKE SWITCH. 2. Connect a red jumper wire from the yellow left-hand receptacle of the PARKING BRAKE SWITCH to the red recepta- cle of the PARKING BRAKE LIGHT. 3. Connect a black jumper wire from the black receptacle of the PARKING BRAKE LIGHT to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. consulab.com info@consulab.com 73 HV-1918-2-91 Auxiliary Circuits Circuit Confirmation 4. Confirm that the trainers’ power supply is turned ON the BATTERY light is ON. 5. Turn the PARKING BRAKE SWITCH ON and the PARKING BRAKE LIGHT should illuminate. 6. Recheck your connections if the circuit does not perform properly. 7. Answer the circuit understanding questions below. Put your answers on the Student Answer Sheet. Circuit Understanding Questions 1. What would be the effect on the circuit of a shorted parking brake switch? 2. What would be the effect on the circuit of an open ground wire in the Parking Brake indicator light? Auxiliary Circuit Circuit Understanding The auxiliary circuit can be used for many different applications on a vehicle. In this case, the circuit in this assignment will operate a relay that will provide power to the truck’s trailer on the AUXILIARY terminal of the trailer connector. This could be used for applying an auxiliary tag axle or a 12 volt power source. This circuit will be controlled by the IGNITION switch when it is turned ON. Components needed are: • Power supply (battery) • Overcurrent protection (fuses) • Auxiliary switch • Ignition switch • Relay • Trailer connecter • Power and ground wiring Circuit Construction 1. Connect a red jumper wire from the red receptacle of any of the top six (6) fuses to the BAT receptacle of the IGNI- TION switch. 2. Connect a red jumper wire from the IGN terminal of the IGNITION switch to the right-hand receptacle of the AUXILIA- RY switch. 3. Connect a red jumper wire from the left-hand yellow receptacle of the AUXILIARY switch to terminal #86 of any of the four relays (#1 to #4) 4. Connect a black jumper wire from terminal #85 of the relay to any of the three black ground receptacles on the left- hand side of the middle Moduponent panel. consulab.com info@consulab.com 74 HV-1918-2-91 Auxiliary Circuits 5. Connect a red jumper wire from the left-hand yellow receptacle of another fuse (other than the one used for step #1) to terminal #30 of the relay. 6. Connect a red jumper wire from terminal #87 of the relay to terminal #7 of the trailer connecter. 7. Connect a black jumper wire from terminal #1 of the trailer connecter to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Circuit Confirmation 8. Confirm that the trainers’ power supply is turned ON and the BATTERY light is ON. 9. Turn the AUXILIARY switch ON, the relay should turn ON and power should be available to terminal #7 of the trailer connecter. 10. There should also be a ground circuit at terminal #1 of the trailer connecter. 11. If the circuit does not function correctly, go back over your connections and identify and correct any errors. 12. NOTE: An alternative method of checking this circuit is to connect terminals #7 (pos) and #1 (neg) of the trailer con- necter to the BACK UP light on the lower panel. The light would come ON when the relay was turned ON. An trailer plug tester, 12 volt test light or DMM (digital multi-meter) can also be used. 13. Answer the circuit understanding questions below and put your answers on the Student Answer Sheet. Circuit Understanding Questions 1. What would the effect be on the circuit if the two terminals of the AUXILIARY switch were shorted together without touching ground? 2. What would be the effect be on the circuit if the ground circuit at the trailer terminal #1 were open? 3. The contacts of the relay terminals #30 and #87A are fused together. What circuit impact would this condition have? 4. The fuse that feeds terminal #86 of the relay is open. What circuit impact would that have? 5. The relay does not turn ON when the AUXILIARY switch is turned ON. What points would you test to identify the cause of this problem? consulab.com info@consulab.com 75 HV-1918-2-91 Auxiliary Circuits — Answers Auxiliary Circuits — Answers Parking Brake Indicator Circuit 1. What would be the effect on the circuit of a shorted parking brake switch? A shorted Parking Brake Switch would result in the Parking Brake indicator lamp being ON all the time regardless of the position of the Parking Brake Switch. 2. What would be the effect on the circuit of an open ground wire in the Parking Brake indicator light? An open ground wire of the Parking Brake indicator light would result in no operation of the light regardless of the position of the Parking Brake Switch. Auxiliary Circuit 1. What would the effect be on the circuit if the two terminals of the AUXILIARY switch were shorted together without touching ground? If the AUXILIARY switch terminals were shorted together, the relay would be ON all the time and thus, power would be sent to the trailer connecter regardless of the position of the switch. 2. What would be the effect be on the circuit if the ground circuit at the trailer terminal #1 were open? An open in the ground circuit feeding terminal #1 of the trailer connecter would result in no power being available to the auxiliary trailer circuit on terminal #7. 3. The contacts of the relay terminals #30 and #87A are fused together. What circuit impact would this condition have? If the relay contacts #30 and #87A were fused together, there would be no negative effect on the circuit as long as the other function of the relay worked normally. This is because there are no wires connected to the normally closed contacts of #30 and #87A. The circuit would function normally. 4. The fuse that feeds terminal #86 of the relay is open. What circuit impact would that have? If the fuse feeding relay terminal #86 were open, the relay would not function, thus causing no power being sent to the trailer connecter. Relay terminal #30 would still have power available because it is fed from another fuse. 5. The relay does not turn ON when the AUXILIARY switch is turned ON. What points would you test to identify the cause of this problem? If the relay does not function, testing should be done with a 12 volt test light or DMM at terminal #86 of the relay. If power is available, a jumper wire should be connected between terminal #85 of the relay and a good known ground. If the relay still does not function, a fused jumper wire should be connected to terminal #86 of the relay. No relay function indicates a defective relay. If power is not available at terminal #86 of the relay, testing should be done at the fuse that feeds the relay’s coil circuit, and the AUXILIARY switch. consulab.com info@consulab.com 76 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 Auxiliary Circuits — Answers Auxiliary Circuits — Student Assignment Schematic — Answers consulab.com info@consulab.com 77 HV-1918-2-91 Additional Assignments — Answers Additional Assignments Answers consulab.com info@consulab.com 78 HV-1918-2-91 HV-1918 Whole Trainer Wiring HV-1918 Whole Trainer Wiring This student assignment will give instructions on the circuit connections necessary for operation of the entire trainer. As has been previously mentioned, there are many different correct variations of how the trainer could be wired and have it function normally. It is not the intention of this manual to cover all of the circuit variations. Instructors can custom design various other circuit construction and designs to suit their specific needs. This assignment will be organized into the wiring of the trainer from the top down with the top front cab marker light bar first, then the Moduponent panel, then the middle panel and finally the lower panel. Because of the number of wires involved, it is extremely important that students carefully read, follow and understand EACH circuit connection. Confirm that you are working on the correct side (either left or right) that the instructions are describing. This assignment is also designed to teach students the importance of following written instructions which is an acknowledged requirement in the repair trades. This assignment will use the “positive switched” design of headlight circuit. Carefully follow the below instructions to construct all of the circuits on the trainer. When completed, submit your Student Answer Sheet to your instructor for circuit verification. Front Cab Marker Lights Panel (HV-1918-08) Ground Circuits (use black jumper wires for all below connections): 1. Connect all black receptacles of five marker lights together with four jumper wires. 2. Right-side marker light black receptacle to black receptacle of right-side side marker light on top Moduponent panel (HV-1918-01) Positive Circuits (use red jumper wires for all below connections): 3. Connect all red receptacles of five marker lights together with four jumper wires. 4. Right-side marker light red receptacle to red receptacle of right-side side marker light on top Moduponent panel (HV-1918-01) consulab.com info@consulab.com 79 HV-1918-2-91 HV-1918 Whole Trainer Wiring Top Moduponent Panel (HV-1918-01) Ground Circuits (use black jumper wires for all below connections): Right Side 5. Headlight ” COM” receptacle to black receptacle of side marker light. 6. Black receptacle of side marker light to black “GND” receptacle on park light. 7. Headlight “COM” receptacle to any of the four black ground receptacles on left side of Moduponent panel. Left Side 8. Headlight “COM” receptacle to black receptacle of side marker light. 9. Black receptacle of side marker light to black “GND” receptacle on park light 10. Headlight “COM” receptacle to any of the four black ground receptacles on the left-side of Moduponent panel. 11. Any of the four black ground receptacles to any of the three black ground receptacles on the middle Moduponent panel. Positive Circuits (use red jumper wires for all below connections): Right Side 12. Side marker light red receptacle to red park light “P” receptacle. 13. Side marker light red receptacle to terminal #87 of relay #3. 14. Right side red “P” receptacle of park light to left side red “P” receptacle of park light. 15. Red “HIGH” beam headlight receptacle to terminal #87 of relay #2. 16. Red “LOW” beam headlight receptacle to terminal #87A of relay #2. 17. Park light red “T/S” receptacle to terminal #113 of multi-function switch. Left Side 18. Red receptacle of side marker light to park light red “P” receptacle. 19. Red “P” receptacle of park light to terminal #87 of relay #3. 20. “HIGH” beam headlight receptacle to terminal #87 of relay #1. 21. “LOW” beam headlight receptacle to terminal #87A of relay #1. 22. Park light red “T/S” receptacle to terminal #112 of multi-function switch. Middle Moduponent Panel (HV-1918-02) Ground Circuits (use black jumper wires for all below connections): 23. Terminal #85 of relay #3 to terminal #85 of relay #2. 24. Terminal #85 of relay #2 to terminal #85 of relay 1. consulab.com info@consulab.com 80 HV-1918-2-91 HV-1918 Whole Trainer Wiring 25. Terminal #85 of relay #1 to any of the three black ground receptacles on the left-side of the middle Moduponent panel. 26. “GND” receptacle of the turn signal flasher to any of the three black ground receptacles of the middle Moduponent panel. 27. Black receptacle of the right-turn indicator to the black receptacle of the high-beam indicator. 28. Black receptacle of the high-beam indicator to the black receptacle of the parking brake light. 29. Black receptacle of the parking brake light to the black receptacle of the left-turn indicator. 30. Black receptacle of the left-turn indicator to any of the three black ground receptacles of the middle Moduponent panel. 31. Black receptacle of any three ground receptacles of the middle Moduponent panel to any of the four black ground receptacles of the bottom Moduponent panel. Positive Circuits (use red jumper wires for all below connections): 32. Red receptacle of fuse F1 to the right-hand “BAT” receptacle of headlamp switch. 33. Left-hand “BAT” receptacle of headlamp switch to right-hand “BAT” receptacle of headlamp switch. 34. Left-hand “BAT” receptacle of headlamp switch to the right-hand yellow receptacle of the stop lamp switch. 35. Right-hand “BAT” receptacle of the headlamp switch to the right-hand yellow receptacle of the parking brake switch. 36. Left-hand “H” receptacle of headlamp switch to terminal #30 of relay #1. 37. Right-hand “H” receptacle of headlamp switch to terminal #30 of relay #2. 38. Right-hand “H” receptacle of headlamp switch to terminal #31 of multi-function switch. 39. Left-hand “P” receptacle of headlamp switch to terminal #87 of relay #3. 40. Terminal #33A of the multi-function switch to the red receptacle of the high-beam indicator lamp. 41. Terminal #33A of the multi-function switch to terminal #86 of relay #2. 42. Terminal #86 of relay #1 to terminal #86 of relay #2. 43. Terminal #86 of relay #3 to terminal #30 of relay #2. 44. Terminal #30 of relay #3 to the red receptacle of fuse F2. 45. Terminal #87 of relay #3 to the red receptacle of the right-hand rear marker light on the lower Moduponent panel. 46. Red receptacle of fuse F3 to the “BAT” receptacle of the ignition switch. 47. Red receptacle of fuse F4 to the red “BAT” receptacle of the turn signal flasher. 48. Yellow “SIG” receptacle of the turn signal flasher to terminal #111 of the multi-function switch. 49. Yellow “IGN” receptacle of the ignition switch to the right-hand yellow receptacle of the backup light switch. 50. Left-hand yellow receptacle of the stop lamp switch to terminal #71 of the multi-function switch. 51. Left-hand yellow receptacle of the backup light switch to the red receptacle of the backup light on lower Modupo- nent panel. 52. Left-hand yellow receptacle of the parking brake lamp switch to the right-hand yellow receptacle of the parking brake light. 53. Right-hand yellow receptacle of the parking brake lamp switch to the right-hand yellow receptacle of the stop lamp switch. consulab.com info@consulab.com 81 HV-1918-2-91 HV-1918 Whole Trainer Wiring 54. Right-hand yellow receptacle of the right turn indicator lamp to terminal #113 of the multi-function switch. 55. Right-hand yellow receptacle of the left turn indicator lamp to terminal #112 of the multi-function switch. 56. Terminal #115 of the multi-function switch to the red “T/S” receptacle of the left-rear tail/stop and turn light on the lower Moduponent panel. 57. Terminal #71 of the multi-function switch to terminal #4 of the trailer connecter on the lower Moduponent panel. 58. Terminal #116 of the multi-function switch to the red “T/S” receptacle of the right-rear tail/stop and turn light on the lower Moduponent panel. Lower Moduponent Panel (HV-1918-03) Ground Circuits (use black jumper wires for all below connections): 59. Black receptacle of left-hand rear marker light to black receptacle of license plate light. 60. Black receptacle of left-hand rear marker light to black receptacle of the 2nd from the left rear marker light.. 61. Black receptacle of the 2nd from the left rear marker light to the black receptacle of the 3rd from the left rear marker light. 62. Black receptacle of the 3rd from the left rear marker light to the black receptacle of the backup light. 63. Black receptacle of the 3rd from the left rear marker light to the black receptacle of the 4th from the left rear mark- er light. 64. Black receptacle of the 4th from the left rear marker light to the black receptacle of the right rear marker light. 65. Black receptacle of the right-rear marker light to black receptacle of the right-rear tail/stop and turn light. 66. Black receptacle of the right-rear tail/stop and turn light to any of the four black ground receptacles on the left- hand side of the lower Moduponent panel. 67. Black receptacle of the left-rear tail/stop and turn light to any of the four black ground receptacles on the left-hand side of the lower Moduponent panel. 68. Terminal #1 of the trailer connecter plug to any of the four black ground receptacles on the left-hand side of the lower Moduponent panel. Positive Circuits (use red jumper wires for all below connections): 69. Red receptacle of the left-rear marker light to the red receptacle of the 2nd from left rear marker light. 70. Red receptacle of the 2nd from left rear marker light to the red receptacle of the 3rd from the left rear marker light. 71. Red receptacle of the 3rd from the left rear marker light to the red receptacle of the 4th from the left rear marker light. 72. Red receptacle of the 4th from the left rear marker light to the red receptacle of the right-hand rear marker light. 73. Red receptacle of the 2nd from the left rear marker light to the red receptacle of the license plate light. 74. Red receptacle of the left-hand rear marker light to the “P” terminal of the left-rear tail/stop and turn light. 75. Red receptacle of the right-hand rear marker light to terminal “P” of the right-rear tail/stop and turn light. 76. Red “T/S” receptacle of the right rear tail/stop and turn light to terminal #3 of the trailer plug connecter. 77. Red “T/S” receptacle of the left-rear tail/stop and turn light to terminal #5 of the trailer plug connecter. consulab.com info@consulab.com 82 HV-1918-2-91 HV-1918 Whole Trainer Wiring 78. Terminal #2 of the trailer connecter to terminal #6 of the trailer connecter. 79. Terminal #2 of the trailer connecter to the red “P” receptacle of the right-rear tail/stop and turn light. 80. With instructor’s permission and for extra credit, construct a circuit that supplies a separate protected 12V power through a relay controlled by the auxiliary switch to terminal #7 of the trailer connector. (no further instruc- tions will be given to construct this circuit.) Use the knowledge you have acquired so far during the whole trainer circuit construction. Fill out separate Student Answer Sheet for the extra credit assignment. Confirmation of Circuit Operation 81. Confirm that the trainers’ power supply is plugged in and the BATTERY light is ON. 82. Operate each circuit and confirm correct operation of all components. Park, Tail and Marker Lights Headlights (High & Low Beam & High Beam Indicator) Back Up Light Turn Signals & Hazard Warning Lights (w/ Left & Right Indicators) Parking Brake Warning Light All Seven Terminals of the Trailer Connecter Plug Extra Credit Power Supply Circuit To Trailer Connecter 83. If any circuit does not operate correctly, identify and correct any wiring errors. 84. Turn in your Student Answer Sheet for instructor grading/credit. 85. If you completed the extra credit auxiliary circuit, also submit that answer sheet (schematic). consulab.com info@consulab.com 83 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 HV-1918 Whole Trainer Wiring — Answers HV-1918 Whole Trainer Wiring — Answers Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic — Answers consulab.com info@consulab.com 84 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 HV-1918 Whole Trainer Wiring — Answers Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic — Answers consulab.com info@consulab.com 85 HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918-2-91 HV-1918 Whole Trainer Wiring — Answers Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic — Answers consulab.com info@consulab.com 86 HV-1918-2-91 Student Fault Identification Assignment Sheet Student Fault Identification Assignment Sheet ASSIGNMENT FAULT NUMBER : Name : Date : Circuit Description : Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. 1. Begin with either the entire trainer wired or with the specific circuit you are assigned wired correctly. 2. Confirm that the circuit operates correctly. 3. Ask instructor to insert a fault(s). 4. Turn ON the master power switch and operate the assigned circuit. 5. Depending on your assignment, there may or may not be more than one fault in the trainer. If more than one, list each one separately. 6. Identify the malfunction(s) and describe in the space provided: Malfunction : 7. Determine and obtain what electrical test equipment you will need to properly diagnose the circuit problem. (DVOM’s, 12 volt test light, etc) 8. Obtain the correct wiring schematic for the circuit affected. 9. Using the schematic and your test equipment, begin to diagnose the problem. Often, an efficient method of circuit troubleshooting is using the schematic to test for the presence of voltage at various accessible points in the circuit. This is called “point-to-point” diagnosis. 10. When you have properly identified the point of the malfunction, describe what you think is the cause of the problem. consulab.com info@consulab.com 87 HV-1918-2-91 Student Fault Identification Assignment Sheet Diagnosis : 11. Submit your diagnosis to your instructor for credit. consulab.com info@consulab.com 88 HV-1918-2-91 Student Study Questions — Answers Student Study Questions Answers consulab.com info@consulab.com 89 HV-1918-2-91 Test 1 — General Electrical Diagnosis Test 1 — General Electrical Diagnosis Answer the below study questions and use a separate answer sheet for your answers. 1. A non-locking push button switch normally is a ? type of switch. A. SPDT B. N.C. C. N.O. D. DPDT 2. A toggle switch with two electrical terminals is normally a ? type of switch. A. SPDT B. N.C. C. N.O. D. DPDT 3. A turn signal switch normally has to have separate turn signal circuits for the front and rear because of the? A. Stop light circuit B. Left turn circuit C. Right turn circuit D. Hazard light circuit 4. Generally, which pin of a truck trailer connecter is for the ground circuit? A. 1 B. 4 C. 6 D. 7 5. How many total terminals are there on a typical ISO relay used on vehicles today? A. 2 B. 3 C. 7 D. 5 consulab.com info@consulab.com 90 HV-1918-2-91 Test 1 — General Electrical Diagnosis 6. A headlight has three terminals identified as: HIGH, LOW and COM. If the low beam headlight circuit is to be “ground switched”, what terminal of the headlight will be connected to 12V positive? A. HIGH beam B. COM C. LOW beam D. A jumper between LOW beam and COM 7. Normally all lighting circuits on most vehicles are connected in: A. Parallel B. Series C. Combination series/parallel D. None of the above 8. On a standard truck trailer connecter, the middle terminal of the plug is used for ? . A. Ground B. Left turn C. 12V for various applications D. Right turn 9. The parking brake indicator light is ON all the time. All of the below conditions could cause this symptom EXCEPT one. Which one would not be a cause of this condition ? A. Shorted parking brake switch B. Grounded positive feed wire to switch C. Ground side of switch is shorted to ground D. Parking brake switch always has continuity 10. What type of switch can we normally find on the brake pedal ? A. SPDT B. N.C C. N.O D. DPDT consulab.com info@consulab.com 91 HV-1918-2-91 Test 1 — General Electrical Diagnosis — Answers Test 1 — General Electrical Diagnosis — Answers 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D consulab.com info@consulab.com 92 HV-1918-2-91 Test 2 — Relays Test 2 — Relays Answer the below study questions and use a separate answer sheet for your answers. 1. What two terminals of an ISO relay are the two ends of the relay’s coil winding? A. 87A and 87 B. 30 and 87A C. 86 and 87A D. 85 and 86 2. What two terminals of an ISO relay are “normally closed” when the relay is OFF? A. 30 and 87A B. 87A and 87 C. 87 and 30 D. 30 and 86 3. When an ISO relay is turned ON, what two terminals are connected? A. 30 and 87A B. 87A and 87 C. 87 and 30 D. 30 and 86 4. Which terminal of an ISO relay is normally the ground for the coil winding? A. 30 B. 87 C. 86 D. 85 5. True or False If a relay “clicks”, it is known to be good. A. True B. False 6. To cause a relay to operate for testing purposes you connect jumper wires to: A. + 12V to terminal 86 and ground to terminal 85 B. + 12V to terminal 85 and ground to terminal 86 C. + 12V between terminals 85 and 86 D. + 12V between terminals 30 & 87A consulab.com info@consulab.com 93 HV-1918-2-91 Test 2 — Relays 7. What would an ohmmeter indicate if connected between terminals 30 and 87 with relay turned OFF? A. Continuity B. 20-70 ohms C. Infinity D. 1K – 4K ohms 8. +12V power is connected to terminals 30 and also to terminal 86 of an ISO relay. Terminal 85 is grounded. What other relay terminal will have +12 available to it? A. 86 B. 85 C. 87A D. 87 9. An easy method of testing a particular ISO relay is to ? . A. Test for coil resistance B. Test for voltage at all terminals C. Substitute with another identical ISO relay D. Test for voltage on terminals 86 & 85 10. +12V is applied to ISO relay terminal 86 and terminal 85 is grounded. A voltmeter connected to terminal 85 reads 12 volts. What does this reading indicate? A. Nothing, this is a normal reading B. It means the relay coil is open C. It means the connection between terminals 30 and 87 is open D. It means the ground circuit connected to terminal 85 is open consulab.com info@consulab.com 94 HV-1918-2-91 Test 2 — Relays — Answers Test 2 — Relays — Answers 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D consulab.com info@consulab.com 95 HV-1918-2-91 Test 3 — General Diagnosis Test 3 — General Diagnosis Answer the below study questions and use a separate answer sheet for your answers. 1. The headlight is dim. All of the below statements could be a cause of this symptom EXCEPT one. Which one would not cause this symptom? A. Voltage drop across the power and ground terminals. B. High resistance on the positive side of the headlight. C. High resistance on the ground side of the headlight. D. Voltage drop between the headlight ground terminal and vehicle ground. 2. A relay “clicks” but does not control the circuit. All of the below statements could be a cause of this symptom EX- CEPT one. Which one could not cause this symptom? A. No power on terminal #30 when relay is ON. B. No power on terminal #87 when relay is ON. C. Open in the relay coil. D. Defective relay contacts. 3. A 3-terminal headlight is connected in a “ground switched” circuit. The headlight switch is turned OFF. The alligator clip of a 12V test light is connected to a clean engine ground. How many terminals of the headlight will cause the test light to turn ON? A. 1 B. 2 C. 3 D. None 4. A voltmeter is connected between the ground terminal of a headlight and a clean engine ground. The headlight is turned ON. The voltmeter reads 185mv. Which of the below statements is true about this reading? A. There is high resistance in the ground circuit. B. There is high resistance in the positive circuit. C. There is an open in the ground circuit. D. This is a normal reading. Nothing is wrong. 5. An ignition switch is turned to the “ON” position, but there is no power on the IGN terminal. All of the below condi- tions EXCEPT one could be the cause this symptom. Which one could not cause this condition? A. A dead battery. B. An open inside the ignition switch between BAT and IGN terminals. C. No power on IGN terminal. D. No power on BAT terminal. consulab.com info@consulab.com 96 HV-1918-2-91 Test 3 — General Diagnosis 6. The left and right side headlights are on individual circuits each controlled by relays. The left side has a dim bulb on LOW beam. Which statement below is the MOST likely cause of this problem? A. A defective relay. B. High resistance in headlight switch. C. High resistance in the connecter to the right LOW beam terminal. D. A voltage drop between the left-hand headlight ground terminal and ground. 7. A 5 terminal ISO relay is being bench tested with an ohmmeter. All of the below ohmmeter readings are correct EXCEPT one. Which one is not correct? A. 50 ohms between terminals 85 and 86. B. 50 ohms between terminals 30 and 87A. C. O resistance between terminals 30 and 87A. D. Infinity between terminals 30 and 87. 8. A headlight circuit is ground switched and is controlled by a relay. Which statement below could be the cause of a “dim” headlight? A. High resistance between relay terminals 85 and 86. B. An open between relay terminals 30 and 87. C. High resistance between relay terminals 30 and 87. D. Bad ground on relay terminal 85. 9. The brake lights are inoperative. Which of the below causes is the LEAST likely to cause this symptom? A. Both brake light bulbs are open. B. Brake light switch is open. C. No power to brake light switch. D. Blown fuse to brake light switch. 10. A 5 terminal ISO relay installed in a vehicle is being tested with a voltmeter. The relay is switched ON. All of the be- low voltmeter readings are correct EXCEPT one. Which reading is not correct? A. 12 volts on both terminals 85 and 86. B. 12 volts between terminals 85 and 86. C. 12 volts on terminal 30. D. 0 volts between 87A and ground. consulab.com info@consulab.com 97 HV-1918-2-91 Test 3 — General Diagnosis — Answers Test 3 — General Diagnosis — Answers 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. General Description Educational Advantages Features Options Guidelines Warnings & Cautions Levels of Difficulty General Information Circuit Construction Wires: Connecting the power supply to the Moduponent™ panels HV-1918 Moduponent™ Panels Component Identification Method 1- (Entry Level Students) Method 2- (Advanced Level Students) General Comments Multi-function Switch — Pin Identification Chart Trailer Connecter — Pin Identification Chart 5-Pin ISO Relay — Pin Identification Chart Student Assignments Answers Student Learning Assignment Example & Instructions Example of a Simple Circuit Assignment Back Up Lights Backup Light Circuit — Student Assignment Schematic — Answers Ohm’s Law Experiments SA-1 — Series Circuit with One Resistance SA-1 — Series Circuit with One Resistance — Answers SA-1 — Student Assignment Schematic — Answers SA-2 — Series Circuit with Two Resistances SA-2 — Series Circuit with Two Resistances — Answers SA-2 — Student Assignment Schematic — Answers SA-3 — Parallel Circuit with Two Resistances SA-3 — Parallel Circuit with Two Resistances — Answers SA-3 — Student Assignment Schematic — Answers Incandescent Light Bulb — Static and Dynamic Resistances Experiments Incandescent Light Bulb — Static and Dynamic Resistances Experiments — Answers Relay Controlled ON/OFF Circuit (Latched Relays) Relay Controlled ON/OFF Circuit (Latched Relays) — Answers Headlights Circuit (Ground Switched) — Entry Level Headlights Circuit (Ground Switched) — Advanced Level Headlights Circuit (Ground Switched) — Entry and Advanced Levels — Answers Headlights Circuit (Ground Switched) — Entry and Advanced Level — Student Assignment Schematic — Answers Headlights Circuit (Positive Switched) — Entry Level Headlights Circuit (Positive Switched) — Entry Level Answers Headlights Circuit (Positive Switched) — Advanced Level Headlights Circuit (Positive Switched) — Advanced Level Answers Headlights Circuit (Positive Switched) — Entry and Advanced Levels — Student Assignment Schematic — Answers Parking, Tail and Marker Lights Circuit — Entry Level Parking, Tail and Marker Lights Circuit — Entry Level Answers Parking, Tail and Marker Lights Circuit — Advanced Level Parking, Tail and Marker Lights Circuit — Advanced Level Answers Parking, Tail and Marker Lights Circuit — Entry and Advanced Levels — Student Assignment Schematic — Answers Turn Signals and Hazard Circuit — Entry Level Turn Signals and Hazard Circuit — Entry Level — Answers Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level — Answers Turn Signals, Hazard & Brake Lights — Entry and Advanced Level — Student Assignment Schematic — Answers Auxiliary Circuits Auxiliary Circuits — Answers Auxiliary Circuits — Student Assignment Schematic — Answers Additional Assignments Answers HV-1918 Whole Trainer Wiring HV-1918 Whole Trainer Wiring — Answers Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic — Answers Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic — Answers Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic — Answers Student Fault Identification Assignment Sheet Student Study Questions Answers Test 1 — General Electrical Diagnosis Test 1 — General Electrical Diagnosis — Answers Test 2 — Relays Test 2 — Relays — Answers Test 3 — General Diagnosis Test 3 — General Diagnosis — Answers

Operation manual for HV-1918-2S_053300/HV-1918-2D_053301 Heavy Vehicle Lighting System Trainer HV-1918-2-93_V2024-1 © ConsuLab Educatech Inc, 2024. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space https://www.consulab.com/customer-space HV-1918-2-93 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, 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. The content of this manual is applicable to models 053300 and above. Table of contents HV-1918-2-95 Student Assignments — Table of Contents 4 HV-1918-2-91 Answer keys and theory — Table of Contents 5 HV-1918-2-96 Instructor’s Guide — Table of Contents 6 General Description 7 Trainer Use & Familiarization 8 Warnings and Cautions 8 Power Supply 8 Connecting the power supply to the Moduponent™ panels 9 Circuit Construction Wires 9 Removable Fuses 10 Moduponent™ Panel Identification and Layout 10 LED Lights 10 HV-1918-01 Top Moduponent™ Familiarization 11 HV-1918-02 Middle Moduponent™ Familiarization 12 HV-1918-03 Bottom Moduponent™ Familiarization 13 HV-1918-08S Cabin Clearance Marker Lights Panel Familiarization 14 Electronic Fault Box 15 consulab.com info@consulab.com 4 HV-1918-2-93 Teacher Resources We have included the table of contents from three other manuals in this operation manual. This serves as a reference to make you aware of all the documentation that comes with the product. HV-1918-2-95 Student Assignments — Table of Contents HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of contents General Description 5 Educational Advantages 5 Features 5 Options 5 Guidelines 6 Warnings & Cautions 6 Levels of Difficulty 6 General Information 7 Circuit Construction Wires: 7 Connecting the power supply to the Moduponent™ panels 7 HV-1918 Moduponent™ Panels 8 Component Identification 9 Multi-function Switch — Pin Identification Chart 12 Trailer Connecter — Pin Identification Chart 13 5-Pin ISO Relay — Pin Identification Chart 14 Student Assignments Student Learning Assignment Example & Instructions 16 Example of a Simple Circuit Assignment 17 Back Up Lights 17 Backup Light Circuit — Student Assignment Schematic 19 Ohm’s Law Experiments 20 SA-1 — Series Circuit with One Resistance 21 SA-1 — Student Answer Sheet 22 SA-1 — Student Assignment Schematic 23 SA-2 — Series Circuit with Two Resistances 24 HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 SA-2 — Student Answer Sheet 25 SA-2 — Student Assignment Schematic 26 SA-3 — Parallel Circuit with Two Resistances 27 SA-3 — Student Answer Sheet 29 SA-3 — Student Assignment Schematic 30 Incandescent Light Bulb — Static and Dynamic Resistances Experiments 31 Static and Dynamic Resistances Experiments — Student Answer Sheet 33 Relay Controlled ON/OFF Circuit (Latched Relays) 34 Relay Controlled ON/OFF Circuit (Latched Relays) — Student Assignment Schematic 36 Headlights Circuit (Ground Switched) — Entry Level 37 Headlights Circuit (Ground Switched) — Entry Level — Student Answer Sheet 39 Headlights Circuit (Ground Switched) — Entry Level — Student Assignment Schematic 40 Headlights Circuit (Ground Switched) — Advanced Level 41 Headlights Circuit (Ground Switched) — Advanced Level — Student Answer Sheet 43 Headlights Circuit (Ground Switched) — Advanced Level — Student Assignment Schematic 44 Headlights Circuit (Positive Switched) — Entry Level 45 Headlights Circuit (Positive Switched) — Entry Level — Student Answer Sheet 48 Headlights Circuit (Positive Switched) — Entry Level — Student Assignment Schematic 49 Headlights Circuit (Positive Switched) — Advanced Level 50 Headlights Circuit (Positive Switched) — Advanced Level — Student Answer Sheet 52 Headlights Circuit (Positive Switched) — Advanced Level — Student Assignment Schematic 54 Parking, Tail and Marker Lights Circuit — Entry Level 55 Parking, Tail and Marker Lights Circuit — Entry Level — Student Answer Sheet 59 Parking, Tail and Marker Lights Circuit — Entry Level — Student Assignment Schematic 61 Parking, Tail and Marker Lights Circuit — Advanced Level 62 Parking, Tail and Marker Lights Circuit — Advanced Level — Student Answer Sheet 65 Parking, Tail and Marker Lights Circuit — Advanced Level — Student Assignment Schematic 67 Turn Signals and Hazard Circuit — Entry Level 68 HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 SA-2 — Student Answer Sheet 25 SA-2 — Student Assignment Schematic 26 SA-3 — Parallel Circuit with Two Resistances 27 SA-3 — Student Answer Sheet 29 SA-3 — Student Assignment Schematic 30 Incandescent Light Bulb — Static and Dynamic Resistances Experiments 31 Static and Dynamic Resistances Experiments — Student Answer Sheet 33 Relay Controlled ON/OFF Circuit (Latched Relays) 34 Relay Controlled ON/OFF Circuit (Latched Relays) — Student Assignment Schematic 36 Headlights Circuit (Ground Switched) — Entry Level 37 Headlights Circuit (Ground Switched) — Entry Level — Student Answer Sheet 39 Headlights Circuit (Ground Switched) — Entry Level — Student Assignment Schematic 40 Headlights Circuit (Ground Switched) — Advanced Level 41 Headlights Circuit (Ground Switched) — Advanced Level — Student Answer Sheet 43 Headlights Circuit (Ground Switched) — Advanced Level — Student Assignment Schematic 44 Headlights Circuit (Positive Switched) — Entry Level 45 Headlights Circuit (Positive Switched) — Entry Level — Student Answer Sheet 48 Headlights Circuit (Positive Switched) — Entry Level — Student Assignment Schematic 49 Headlights Circuit (Positive Switched) — Advanced Level 50 Headlights Circuit (Positive Switched) — Advanced Level — Student Answer Sheet 52 Headlights Circuit (Positive Switched) — Advanced Level — Student Assignment Schematic 54 Parking, Tail and Marker Lights Circuit — Entry Level 55 Parking, Tail and Marker Lights Circuit — Entry Level — Student Answer Sheet 59 Parking, Tail and Marker Lights Circuit — Entry Level — Student Assignment Schematic 61 Parking, Tail and Marker Lights Circuit — Advanced Level 62 Parking, Tail and Marker Lights Circuit — Advanced Level — Student Answer Sheet 65 Parking, Tail and Marker Lights Circuit — Advanced Level — Student Assignment Schematic 67 Turn Signals and Hazard Circuit — Entry Level 68 HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 4 © 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. The content of this manual is applicable to models 053300 and above. Turn Signals and Hazard Circuit — Entry Level — Student Answer Sheet 71 Turn Signals and Hazard Circuit — Entry Level — Student Assignment Schematic 72 Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level 73 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level — Student Answer Sheet 76 Turn Signals, Hazard & Brake Lights — Advanced Level — Student Assignment Schematic 78 Auxiliary Circuits 79 Auxiliary Circuits — Student Answer Sheet 82 Auxiliary Circuits — Student Assignment Schematic 83 Additional Assignments HV-1918 Whole Trainer Wiring 85 Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic 90 Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic 91 Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic 92 Student Fault Identification Assignment Sheet 93 Student Study Questions Test 1 — General Electrical Diagnosis 96 Student Answer Sheet 98 Test 2 — Relays 99 Student Answer Sheet 101 Test 3 — General Diagnosis 102 Student Answer Sheet 104 consulab.com info@consulab.com 5 HV-1918-2-93 Teacher Resources HV-1918-2-91 Answer keys and theory — Table of Contents HV-1918-2-91 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of contents General Description 5 Educational Advantages 5 Features 5 Options 5 Guidelines 6 Warnings & Cautions 6 Levels of Difficulty 6 General Information 7 Circuit Construction Wires: 7 Connecting the power supply to the Moduponent™ panels 7 HV-1918 Moduponent™ Panels 8 Component Identification 9 Method 1- (Entry Level Students) 9 Method 2- (Advanced Level Students) 9 General Comments 11 Multi-function Switch — Pin Identification Chart 12 Trailer Connecter — Pin Identification Chart 13 5-Pin ISO Relay — Pin Identification Chart 14 Student Assignments Answers Student Learning Assignment Example & Instructions 16 Example of a Simple Circuit Assignment 17 Back Up Lights 17 Backup Light Circuit — Student Assignment Schematic — Answers 19 Ohm’s Law Experiments 20 HV-1918-2-91 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 SA-1 — Series Circuit with One Resistance 21 SA-1 — Series Circuit with One Resistance — Answers 22 SA-1 — Student Assignment Schematic — Answers 23 SA-2 — Series Circuit with Two Resistances 24 SA-2 — Series Circuit with Two Resistances — Answers 25 SA-2 — Student Assignment Schematic — Answers 26 SA-3 — Parallel Circuit with Two Resistances 27 SA-3 — Parallel Circuit with Two Resistances — Answers 29 SA-3 — Student Assignment Schematic — Answers 30 Incandescent Light Bulb — Static and Dynamic Resistances Experiments 31 Incandescent Light Bulb — Static and Dynamic Resistances Experiments — Answers 33 Relay Controlled ON/OFF Circuit (Latched Relays) 34 Relay Controlled ON/OFF Circuit (Latched Relays) — Answers 36 Headlights Circuit (Ground Switched) — Entry Level 37 Headlights Circuit (Ground Switched) — Advanced Level 40 Headlights Circuit (Ground Switched) — Entry and Advanced Levels — Answers 42 Headlights Circuit (Ground Switched) — Entry and Advanced Level — Student Assignment Schematic — Answers 43 Headlights Circuit (Positive Switched) — Entry Level 44 Headlights Circuit (Positive Switched) — Entry Level — Answers 47 Headlights Circuit (Positive Switched) — Advanced Level 48 Headlights Circuit (Positive Switched) — Advanced Level — Answers 50 Headlights Circuit (Positive Switched) — Entry and Advanced Levels — Student Assignment Schematic — Answers 51 Parking, Tail and Marker Lights Circuit — Entry Level 52 Parking, Tail and Marker Lights Circuit — Entry Level — Answers 56 Parking, Tail and Marker Lights Circuit — Advanced Level 57 Parking, Tail and Marker Lights Circuit — Advanced Level — Answers 60 Parking, Tail and Marker Lights Circuit — Entry and Advanced Levels — Student Assignment Schematic — Answers 62 HV-1918-2-91 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 4 © 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. The content of this manual is applicable to models 053300 and above. Turn Signals and Hazard Circuit — Entry Level 63 Turn Signals and Hazard Circuit — Entry Level — Answers 66 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level 67 Turn Signals, Hazard & Brake Lights to Trailer Connector —Advanced Level — Answers 70 Turn Signals, Hazard & Brake Lights — Entry and Advanced Level — Student Assignment Schematic — Answers 71 Auxiliary Circuits 72 Auxiliary Circuits — Answers 75 Auxiliary Circuits — Student Assignment Schematic — Answers 76 Additional Assignments Answers HV-1918 Whole Trainer Wiring 78 HV-1918 Whole Trainer Wiring — Answers 83 Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic — Answers 83 Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic — Answers 84 Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic — Answers 85 Student Fault Identification Assignment Sheet 86 Student Study Questions Answers Test 1 — General Electrical Diagnosis 89 Test 1 — General Electrical Diagnosis — Answers 91 Test 2 — Relays 92 Test 2 — Relays — Answers 94 Test 3 — General Diagnosis 95 Test 3 — General Diagnosis — Answers 97 consulab.com info@consulab.com 6 HV-1918-2-93 Teacher Resources HV-1918-2-96 Instructor’s Guide — Table of Contents HV-1918-2-96 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 3 Table of contents Trainer Use and Familiarization 4 General Description 5 Educational Advantages 5 Features 5 Options 5 Guidelines 6 Warnings & Cautions 6 Levels of Difficulty 6 General Information 7 Circuit Construction Wires: 7 Connecting the power supply to the Moduponent™ panels 7 HV-1918 Moduponent™ Panels 8 Component Identification 9 Method 1- (Entry Level Students) 9 Method 2- (Advanced Level Students) 9 General Comments 11 Multi-function Switch — Pin Identification Chart 12 Trailer Connecter — Pin Identification Chart 13 5-Pin ISO Relay — Pin Identification Chart 14 Power Supply 15 Protections 15 Electronic Fault Box 16 12 Faults Explanation 17 Electric Schematic with faults 23 consulab.com info@consulab.com 7 HV-1918-2-93 General Description General Description The HV-1918-2 Heavy Vehicle Lighting System Trainer contains lighting system components mounted on modular plastic panels – called Moduponents™ – where the student completes all of the circuit wiring. The trainer is built to help the student evolve from building basic circuits to more complex electrical troubleshooting on heavy vehicles. Due to the fact that the trainer is fully modular, additional Moduponents™ can be added to follow technical evolutions in the medium and heavy truck industry. The trainer is able to be configured single- or optional double-sided to allow more than one group of students to work simultaneously on the trainer. A built-in regulated 12V power supply included with the trainer and meets CSA/UL safety requirements. NOTE- A double sided trainer will have two separate power supplies. The single-sided HV-1918-2S_053300 trainer includes: • One (1) HV-1918-01 Front Lights Moduponent™ • One (1) HV-1918-02 Lighting System Controls Moduponent™ • One (1) HV-1918-03 Rear Lights Moduponent™ • One (1) HV-1918-08 Cabin Clearance Lights Moduponent™ • One (1) CL-1918-10B Mobile Upright Stand with wire holding brackets • One (1) Power Supply • One (1) HV-1918-12A Set of 89 jumper wires The double-sided HV-1918-2D_053301 trainer includes: • Two (2) HV-1918-01 Front Lights Moduponents™ • Two (2) HV-1918-02 Lighting System Controls Moduponents™ • Two (2) HV-1918-03 Rear Lights Moduponents™ • Two (2) HV-1918-08 Cabin Clearance Lights Moduponents™ • One (1) CL-1918-10B Mobile Upright Stand with wire holding brackets • Two (2) Power Supplies • Two (2) HV-1918-12A Sets of 89 jumper wires The ConsuLab HV-1918-2U_053302 Heavy Vehicle Lighting System Trainer Upgrade Kit allows to convert the single-sided HV-1918-2S to a double-sided HV-1918-2D using the same stand. consulab.com info@consulab.com 8 HV-1918-2-93 Trainer Use & Familiarization Trainer Use & Familiarization This manual is designed to provide instructors with the necessary information for the proper and safe operation of the HV-1918-2S / HV-1918-2D Heavy Vehicle Lighting System Trainer. Be sure to read, understand and follow all content which will provide a safe working environment for students and instructors. NOTE – Before proceeding with this manual, the HV-1918-2 single or double sided trainer(s) should already be checked for shipping damage if any. PREREQUISITES: STUDENTS CONDUCTING ASSIGNMENTS RELATED TO THIS PRODUCT SHOULD HAVE THE FOLLOWING PREREQUISITE SKILLS AND KNOWLEDGES: 1. Understand the proper setup, use and interpretation of a digital multimeter for purposes of accurately and safely measuring voltage, amperage and resistance. 2. Ability to read and understand electrical wiring schematics. 3. How to work safely using electrical circuits, power supplies and components. Warnings and Cautions 1. Be sure to insert the trainers AC power cord into a 3-wire properly grounded 120V 15A or 20A circuit receptacle. 2. It is required that ALL circuits be constructed using fuse protection. Never connect a positive wire to any component on the trainer without going through a fuse first. (See fuse box details) 3. Be sure to read and understand each set of instructions. Have students ask any questions they may have about circuit construction or electrical components. NEVER GUESS!! Power Supply Once the power supply’s power cord is plugged into a 120V receptacle, the power supply is turned on/off with a red rocker switch located on the power supply and the rocker switch will illuminate with a red color when turned ON. The power supply on this trainer is internally protected from direct short circuits. With the current design of the trainer, a “short circuit” condition would be very rare. The power supply is equipped with an ammeter and voltmeter. Meters will display system voltage and amperage as trainer is used. In the event of an accidental direct short circuit, the ammeter display will increase to about 25-35 amps and the voltmeter will display approximately 3 volts. Although the power supply will sustain a short circuit condition, the circuit wires may feel warm to the touch. If power supply meters display above readings, immediately switch the rocker switch to the OFF position and correct the short circuit. There will be a separate power supply for each side of a double-sided trainer (if equipped). WARNING- The power supply should NEVER be used as a battery charger due to potential serious component damage and the voiding of the warranty. The power supply is specifically designed ONLY to supply a DC power source for our trainers. consulab.com info@consulab.com 9 HV-1918-2-93 Trainer Use & Familiarization Connecting the power supply to the Moduponent™ panels Before the HV-1918-02 (middle panel) is mounted to the frame, notice that there is a black two wire terminal block mounted inside on one side of the frame. A black and a red wire is attached to the terminal block using friction tabs which are also connected to the power supply. A flat tip screwdriver of the proper size is used to push in on each fric- tion tab to either insert or remove a wire. Locate the red and black wires coming from the back side of the middle panel and properly connect them to the terminal block. Release tabs PUSH IN Push to release and attach When the middle panel’s red and black wires are properly connected to the power supply terminal block and when the power supply is turned on, the RED power indicator light on the middle panel should illuminate. NOTE : Confirm that the trainer’s power cord is plugged into a receptacle. NOTE : It is normal for the power indicator light to stay on for a few seconds after power supply is switched off. Circuit Construction Wires There are black and red jumper wires of two different lengths used for students constructing various circuits on the trainer. The ends of the jumper wires are equipped with jumper wires that allow them to be “stacked” on top of each other which allows more than one wire to be connected to the same receptacle. When stacking jumper wires, try to avoid using more than 3-4 at one connection point. consulab.com info@consulab.com 10 HV-1918-2-93 Trainer Use & Familiarization Removable Fuses The trainer is equipped with a protection section consisting of eight removable fuses with different amperages. The top six fuses are powered from a common bus connected to the main power supply.. The other two fuses must be powered with jumper wires. ALWAYS connect all circuits through a fuse. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date CIRCUIT FUSE PANEL INFORMATION “HOT” ALL TIMES MUST BE FED FROM IGN SWITCH OR OTHER POWER SOURCE B+ CIRCUIT CONNECTION POINTS “SWITCHED” CIRCUIT CONNECTION POINTS Moduponent™ Panel Identification and Layout The trainer has three removable panels called “Moduponents™” that are attached with retaining clips to the main frame. The three panels are: HV-1918-01 (front lights), HV-1918-02 (Control switches and components), and HV-1918-03 (rear lights). It also includes the HV-1918-08 clearance lights located on top of the stand. Normal configuration for the trainer is for the HV-1918-01 panel to be mounted on the top, HV-1918-02 in the middle and HV-1918-03 on the bottom. NOTE- Each Moduponent™ panel has its own product serial number that is often requested for any service or repair needs. It is advised that you record the Moduponent™ serial numbers for your records. LED Lights LED lights are polarity sensitive for correct operation. Each LED light on the trainer has positive (red) and negative (black) connection receptacles to identify correct polarity. However, the HV-1918-2 trainer incorporates LED protection from incorrect hookup polarity and no LED damage will occur. If LED lights are connected with incorrect polarity, they simply will not operate. consulab.com info@consulab.com 11 HV-1918-2-93 HV-1918-01 Top Moduponent™ Familiarization HV-1918-01 Top Moduponent™ Familiarization The top panel (HV-1918-01_053294) Moduponent™ contains the heavy vehicles front lighting components. The are four black ground receptacles that are internally connected together. The top panel must be connected to the middle panel ground bus by using a black jumper wire. The GND bus can be used for the ground connections of each light on the panel. Each light on all Moduponents™ has an electrical symbol schematic located close by for student reference. See below for the location and identification of all components on this panel. A B C D G H I J K L E F M M A. 4-Receptacle Ground Bus (internally connected together behind panel) B. Left LED Side Marker C. Left-Front Headlight Schematic Symbols and Connection Receptacles D. Left-Front Headlight H4656 Sealed Beam E. Right-Front Headlight H4656 Sealed Beam F. Right-Front Headlight Schematic Symbol and Connection Receptacles G. Right LED Side Marker H. 4-Receptacle Positive Bus (internally connected together behind panel) I. Left LED Front Park/Turn Signal Light Schematic Symbols and Connection Receptacles J. Left LED Front Park/Turn Signal Light K. Right LED Front Park/Turn Signal Light L. Right LED Front Park/Turn Signal Light Schematic Symbols and Connection Receptacles M. 2mm Test Points consulab.com info@consulab.com 12 HV-1918-2-93 HV-1918-02 Middle Moduponent™ Familiarization HV-1918-02 Middle Moduponent™ Familiarization The middle panel (HV-1918-02_053316) Moduponent™ contains all switches, fuses, relays, indicator lights and the electronic fault box. The are three black ground receptacles that are internally connected together. The GND bus can be used for the ground connections of each light or component on the panel. See below for the location and identification of all components on this panel. A B C D E F G H H H I QQ HO R P S NMLK J A. 3-Receptacle ground bus (Internally connected together behind panel) B. Left turn LED indicator light C. High beam LED indicator light D. Right turn LED indicator light E. Headlight switch F. Back-up switch G. Parking brake LED indicator light H. Relay I. 6-Receptacle positive bus (F1 to F6 - Hot at all times) J. Main power LED indicator light (should be ON anytime the power supply is turned on.) K. Multi-function switch L. Protection fuse (1A S.B.) for dimmer switch (pins 31 & 33A)V M. Auxiliary switch N. Key ignition switch O. Signal Flasher P. Electronic fault box Q. 4-Switched circuit connection receptacles (F7 and F8 - Must be fed from ign switch or other power source) R. Stop lamp switch S. Parking brake switch consulab.com info@consulab.com 13 HV-1918-2-93 HV-1918-03 Bottom Moduponent™ Familiarization HV-1918-03 Bottom Moduponent™ Familiarization The bottom panel (HV-1918-03_052926) Moduponent™ contains the vehicles rear lighting components. There are four black ground receptacles that are internally connected together and must be connected to the middle panel using a black jumper wire. The GND bus can be used for the ground connections of each light on the panel. See below for the location and identification of all components on this panel. A B B B B B C D E F G H A. 4-Receptacle ground bus (Internally connected together behind panel) B. Rear clearance marker lamps C. 4-Receptacle positive bus (Internally connected together behind panel) D. Left rear position / Turn / Stop LED light E. License plate LED light F. Backup LED light G. Trailer 7-way connector H. Right rear position / Turn / Stop LED light consulab.com info@consulab.com 14 HV-1918-2-93 HV-1918-08S Cabin Clearance Marker Lights Panel Familiarization HV-1918-08S Cabin Clearance Marker Lights Panel Familiarization A A A A A B C C C C CB B B B A. Cabin clearance marker LED Lights B. Ground terminal C. Positive terminal consulab.com info@consulab.com 15 HV-1918-2-93 Electronic Fault Box Electronic Fault Box The HV-1918-2 trainer has 12 pre-wired electrical faults designed into the circuits. They can be selected individually or in any multiple combinations. Faults are controlled by push-buttons located on the front panel of the fault box inte- grated in the HV-1918-02 Lighting System Control Moduponent™. They are identified and explained in the HV-1918-2-96 Instructors Manual. FAULT INSERTION INSTRUCTIONS GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A BLUE LIGHT ON BLUE LIGHT OFF “ON” POSITION “OFF” POSITION KEY LOCK FAULT SELECTION BUTTONS Push down & release to: Set a fault = Blue light ON Clear a fault = Blue light OFF Key lock must be in the ON position to insert or clear a fault KEY LOCK IN THE “ON” POSITION Faults can now be inserted, push down & release but- ton of fault(s) desired When fault is inserted a blue light will come on indicating it is inserted in the circuit KEY LOCK IN THE “OFF” POSITION Turns off any fault indicator light(s) Any blue fault indicator light will be OFF, but fault will be inserted A small arrow in the center of the key shaft points to the direction you have selectedt WARNING - the fault box programming key only turns 90º. DO NOT attempt to force the key beyond the 90º limits or the key tab will be broken off. 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. Tous droits réservés. HV-1918-2-95 Student Assignments — Table of Contents HV-1918-2-91 Answer keys and theory — Table of Contents HV-1918-2-96 Instructor’s Guide — Table of Contents General Description Trainer Use & Familiarization Warnings and Cautions Power Supply Connecting the power supply to the Moduponent™ panels Circuit Construction Wires Removable Fuses Moduponent™ Panel Identification and Layout LED Lights HV-1918-01 Top Moduponent™ Familiarization HV-1918-02 Middle Moduponent™ Familiarization HV-1918-03 Bottom Moduponent™ Familiarization HV-1918-08S Cabin Clearance Marker Lights Panel Familiarization Electronic Fault Box

Student Assignments for HV-1918-2S_053300/HV-1918-2D_053301 Heavy Vehicle Lighting System Trainer HV-1918-2-95_V2025-1 © ConsuLab Educatech Inc, 2024. All rights reserved. HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of contents General Description 5 Educational Advantages 5 Features 5 Options 5 Guidelines 6 Warnings & Cautions 6 Levels of Difficulty 6 General Information 7 Circuit Construction Wires: 7 Connecting the power supply to the Moduponent™ panels 7 HV-1918 Moduponent™ Panels 8 Component Identification 9 Multi-function Switch — Pin Identification Chart 12 Trailer Connecter — Pin Identification Chart 13 5-Pin ISO Relay — Pin Identification Chart 14 Student Assignments Student Learning Assignment Example & Instructions 16 Example of a Simple Circuit Assignment 17 Back Up Lights 17 Backup Light Circuit — Student Assignment Schematic 19 Ohm’s Law Experiments 20 SA-1 — Series Circuit with One Resistance 21 SA-1 — Student Answer Sheet 22 SA-1 — Student Assignment Schematic 23 SA-2 — Series Circuit with Two Resistances 24 HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 SA-2 — Student Answer Sheet 25 SA-2 — Student Assignment Schematic 26 SA-3 — Parallel Circuit with Two Resistances 27 SA-3 — Student Answer Sheet 29 SA-3 — Student Assignment Schematic 30 Incandescent Light Bulb — Static and Dynamic Resistances Experiments 31 Static and Dynamic Resistances Experiments — Student Answer Sheet 33 Relay Controlled ON/OFF Circuit (Latched Relays) 34 Relay Controlled ON/OFF Circuit (Latched Relays) — Student Assignment Schematic 36 Headlights Circuit (Ground Switched) — Entry Level 37 Headlights Circuit (Ground Switched) — Entry Level — Student Answer Sheet 39 Headlights Circuit (Ground Switched) — Entry Level — Student Assignment Schematic 40 Headlights Circuit (Ground Switched) — Advanced Level 41 Headlights Circuit (Ground Switched) — Advanced Level — Student Answer Sheet 43 Headlights Circuit (Ground Switched) — Advanced Level — Student Assignment Schematic 44 Headlights Circuit (Positive Switched) — Entry Level 45 Headlights Circuit (Positive Switched) — Entry Level — Student Answer Sheet 48 Headlights Circuit (Positive Switched) — Entry Level — Student Assignment Schematic 49 Headlights Circuit (Positive Switched) — Advanced Level 50 Headlights Circuit (Positive Switched) — Advanced Level — Student Answer Sheet 52 Headlights Circuit (Positive Switched) — Advanced Level — Student Assignment Schematic 54 Parking, Tail and Marker Lights Circuit — Entry Level 55 Parking, Tail and Marker Lights Circuit — Entry Level — Student Answer Sheet 59 Parking, Tail and Marker Lights Circuit — Entry Level — Student Assignment Schematic 61 Parking, Tail and Marker Lights Circuit — Advanced Level 62 Parking, Tail and Marker Lights Circuit — Advanced Level — Student Answer Sheet 65 Parking, Tail and Marker Lights Circuit — Advanced Level — Student Assignment Schematic 67 Turn Signals and Hazard Circuit — Entry Level 68 HV-1918-2-95 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 4 © 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. The content of this manual is applicable to models 053300 and above. Turn Signals and Hazard Circuit — Entry Level — Student Answer Sheet 71 Turn Signals and Hazard Circuit — Entry Level — Student Assignment Schematic 72 Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level 73 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level — Student Answer Sheet 76 Turn Signals, Hazard & Brake Lights — Advanced Level — Student Assignment Schematic 78 Auxiliary Circuits 79 Auxiliary Circuits — Student Answer Sheet 82 Auxiliary Circuits — Student Assignment Schematic 83 Additional Assignments HV-1918 Whole Trainer Wiring 85 Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic 90 Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic 91 Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic 92 Student Fault Identification Assignment Sheet 93 Student Study Questions Test 1 — General Electrical Diagnosis 96 Student Answer Sheet 98 Test 2 — Relays 99 Student Answer Sheet 101 Test 3 — General Diagnosis 102 Student Answer Sheet 104 consulab.com info@consulab.com 5 HV-1918-2-95 General Description General Description The ConsuLab HV-1918-1 Heavy Vehicle Lighting System Trainers utilize the “Moduponent™” design feature which allows unlimited expansion capabilities. A Moduponent™ consists of a clear Plexiglas™ sheet with components, wiring and socket test points attached. The Moduponent® is attached to the trainer using disconnect fasteners which allows easy adaptation and configuration for different applications. Educational Advantages • The trainer is a complete heavy vehicle lighting system with front, rear, brake, clearance, turn/hazard and backup lights with a 7 wire connector; • Meets CSA/UL safety requirements; • Most complete heavy vehicle lighting and accessory circuit trainer available; • Modular LED lights (except headlights) that match on-highway truck components; • Built to train up to four students at a time Features • Available single sided (HV-1918-2S) or double sided (HV-1918-2D) • Manual fault box with 12 faults for the Lighting Switch Controls • HV-1918-01 Front Lights Moduponent™ (1) • HV-1918-02 Lighting Switch Controls Moduponent™ (1) • HV-1918-03 Rear Lights Moduponent™ (1) • HV-1918-08 5-Clearance Lights Kit (1) • HV-1918-12A Set of 89 jumper leads (1) • Stand with lockable storage box • 12VDC Power Supply (1) Options • HV-1918-1U Upgrade Kit — This upgrade kit converts a single sided trainer to a double side. Each kit contains: - HV-1918-01 Front Lights Moduponent®(1) - HV-1918-02 Control Panel Moduponent® (1) - HV-1918-03 Rear Lights with red turn/brake lights Modupnent® (1) - HV-1918-12A Set of 89 jumper wires (1) - 12VDC Power Supply (1) consulab.com info@consulab.com 6 HV-1918-2-95 Guidelines Guidelines This manual is designed to provide instructors and students with necessary information for the proper and safe opera- tion of the HV-1918 Heavy Vehicle Lighting System Trainer. Be sure to read and understand each section. NOTE: Before proceeding with this manual, the HV-1918 trainer should have already been assembled. STUDENTS CONDUCTING ASSIGNMENTS RELATED TO THIS PRODUCT SHOULD HAVE THE FOLLOWING PREREQUI- SITE SKILLS AND KNOWLEDGES: 1. Understand the proper setup and use of a digital multi-meter for purposes of accurately measuring volts, ohms and amperes. 2. Ability to read and understand basic electrical wiring schematics. 3. Basic understanding of Ohm’s Law pertaining to relationships between volts, ohms and amps. Warnings & Cautions 1. It is expected that all circuits be wired with fuse overcurrent protection. Never connect a positive wire to any com- ponent without going through a fuse first. 2. Be sure to read, understand and follow each set of instructions. Be sure to ask your instructor if you have any ques- tions about any instruction or component. 3. Never “guess” about the results of a circuit. Always follow written instructions to avoid “guesswork”. Levels of Difficulty 1. ENTRY LEVEL - There are two sets of student assignments covering the same circuits on the HV-1918 trainer. One set is titled “ENTRY LEVEL” and contains more detailed and comprehensive instructions to the student for comple- tion of each project. Detailed information gives “point to point” circuit hookup and wiring instructions to students. Entry level students may use this package to learn how lighting circuits are constructed and operate. Students are also asked to answer CIRCUIT UNDERSTANDING questions that check their comprehension of the circuit they con- structed. 2. ADVANCED LEVEL - The other set of assignments is titled “ADVANCED LEVEL” and contains only general informa- tion and instructions necessary for the construction of the circuit. The student is required to apply cognitive thinking and problem solving skills in order to construct and understand circuits. The detailed step-by-step instructions that are included in the ENTRY LEVEL package are not included in the ADVANCED LEVEL package. Students are asked to draw the circuit first using trainer templates, obtain instructor verification and then construct the circuit on the trainer. Students are asked to answer CIRCUIT UNDERSTANDING questions that check their comprehension of the circuit they constructed. There may be additional more complex questions that ask for knowledge of diagnosis and troubleshooting. 3. Instructors may choose from either option, which allows the customizing the HV-1918 trainer assignments to their specific educational needs and objectives. consulab.com info@consulab.com 7 HV-1918-2-95 General Information General Information All circuit and component wiring for both power and grounds, must be made to the front surfaces of the Moduponent® panels. The middle panel, (HV-1918-02), has eight red power receptacles (+) on the right-hand side and three black ground receptacles on the left-hand side (G). The trainer has six 15A fuses connected to main power supply. The bottom two fuses are 10A and can be fed from switched power sources such as the Ignition Switch. All circuits must have the positive power fed through a fuse during installation. All circuit connections are made by using the red and black jumper wires that plug into the receptacles located at each component. Circuit Construction Wires: There are black and red jumper wires of different lengths used for students constructing various circuits on the trainer. The ends of the jumper wires are equipped with terminal plugs that allow them to be “stacked” on top of each oth- er which allows more than one wire to be connected to the same receptacle. When stacking jumper wires, try to avoid using more than 3-4 at one connection point. To avoid unnecessary handling, it is preferable to start building circuits using the short wires and use the long wires as necessary to avoid having to undo connections when the long wires run out. Connecting the power supply to the Moduponent™ panels Before the CL-1918-02A (middle panel) is mounted to the frame, notice that there is a black two wire terminal block mounted inside on one side of the frame. A black and a red wire is attached to the terminal block using friction tabs which are also connected to the power supply. A flat tip screwdriver of the proper size is used to push in on each fric- tion tab to either insert or remove a wire. Locate the red and black wires coming from the back side of the middle panel and properly connect them to the terminal block. Release tabs PUSH IN Push to release and attach When the middle panel’s red and black wires are properly connected to the power supply terminal block and when the power supply is turned on, the RED power indicator light on the middle panel should illuminate. NOTE : Confirm that the trainer’s power cord is plugged into a receptacle. NOTE : It is normal for the power indicator light to stay on for a few seconds after power supply is switched OFF. consulab.com info@consulab.com 8 HV-1918-2-95 HV-1918 Moduponent™ Panels HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date HV-1918 Moduponent™ Panels consulab.com info@consulab.com 9 HV-1918-2-95 Component Identification Component Identification Before starting the student experiments, it is important that you understand the component location and pin identifica- tion used on the trainer. (See template on previous page for trainer component layout and identification) Depending on the desires of the instructor, students can identify component and pin identification using two different methods. Method 1- (Entry Level Students) Refer to the templates that are provided. These templates contain all component and terminal pin identifications. They can be used for construction of individual circuits and for wiring the entire vehicle lighting system. Method 2- (Advanced Level Students) The Moduponent™ panels components and terminal identification can be performed using a digital multi-meter mea- suring resistance or a set of jumper wires connected to power and ground. This method requires cognitive thinking and problem solving skills. The exceptions to this are all the LED lights. LED lights are polarity sensitive, but the HV-1918 trainer and lights have internal circuit protection at each LED to prevent damage from improper hookup by students. The templates mentioned in Method 1 can be used for verification of student results. All Light Bulbs (Except Headlights) All light bulbs (except headlights) used on the HV-1918 trainer are LED type bulbs. Each LED light is internally protected with circuits to prevent damage due to reverse or incorrect polarity hookup of jumper wires. If any of the following LED light bulbs are hooked up with reverse polarity, the bulbs will operate normally: • Front Clearance Lights • Front Side Marker Lights • Rear Clearance Lights • License Plate Light If any of the following LED light bulbs are hookup up with reverse polarity, the bulbs will not operate, but no harm will be done to the trainer. • Front Park/Turn Lights • Rear Tail/Turn Lights • Backup Light • Left & Right Hand Turn Indicators consulab.com info@consulab.com 10 HV-1918-2-95 Component Identification • High Beam Indicator • Parking Brake Indicator Dual-Filament light bulbs (3 terminals) The HV-1918 headlights use dual-filament incandescent light bulbs. The HV-1918 trainer has icons printed on the Modu- ponents that identify the headlights high and low beams as well as COM terminals. However, if a three terminal light bulb terminals were not identified, there are several different methods that could be used to identify 1- COM, 2- High Brightness and 3- Low Brightness. With all POWER shut OFF, a digital multi-meter can be used to measure the resistance of the two filaments with the brightest filament having the lowest resistance. With trainer POWER turned ON, a positive and negative jumper wire (fused through one of the trainers’ fuses) can also be used to determine terminal identification. HV-1918 Switches The HV-1918 trainer is equipped with the following switches: • Backup Light Switch (push button N.O. type) • Stop Lamp Switch (push button N.O. type) • Head Lamp Switch (six terminals) [DPDT (double pole, double throw)] (two SPST switches operated by a single lever) • Ignition Key Switch (BAT, ACC, IGN and START) • Parking Brake Switch [SPST (single pole, single throw)] • Auxiliary Switch [SPST (single pole, single throw)] • Multi-Function Switch (Turn Signals, Dimmer Switch and Hazard Warning Switch) Multi-function Switch The Multi-Function Switch controls the Turn Signals, Hazard Warning Lights and the Headlight Dimmer/Flash-to-pass Switch. There are two rows of four terminals. There are assignments in this manual for proper pin identification of this switch as well as a legend that identifies them. See Pin Identification Chart on section “Multi-function Switch — Pin Identi- fication Chart”. Terminals 31 & 33A of the multi-function switch are a set of latching contacts inside the switch operated by a push button on the end of the switch stalk. Pushing the button in either connects or disconnects terminals 31 & 33A. They will remain either connected or disconnected until the button is pushed again. Terminals 31 & 33A are used to operate the headlight HIGH beam circuits using relays #1 & #2. In the event of a circuit wiring error, the 31 & 33A contacts are protected by a 1A Slo-Blo fuse. This fuse is located to the right of terminals 31 & 33A on the middle Moduponent™ panel. If continuity is not present between terminals 31 & 33A, check and replace the fuse with the correct 1A Slo-Blo specifications. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date FAULT BOX 1A SLO-BLO FUSE consulab.com info@consulab.com 11 HV-1918-2-95 Component Identification Trailer Plug The trailer plug is an industry standard seven round pins. There are seven terminals for student wiring of the trailer plug to the trainer’s circuits. Confirmation of proper hookup of the trailer plug can be accomplished by using a 12 volt test light, DVOM or a commercially available trailer plug tester (LED type). See Pin Identification Chart on section “Trailer Connecter — Pin Identification Chart”. ISO Relays The trainer is equipped with four standard ISO five terminal relays. They can be used for numerous circuit hookups and operation. Each relay has five terminals for student wiring assignments. The relays use industry standard terminal identification terminal numbers of 85, 86, 87, 87A and 30. See Pin Identification Chart on section “5-Pin ISO Relay — Pin Identification Chart”. Turn Signal Flasher The Turn Signal Flasher has three terminals identified on the Moduponent panel. Terminal identification is GRD, BAT and SIG. General Comments The HV-1918 trainer is designed as a “generic” lighting system for a typical medium to heavy-duty truck. Being generic, there are countless ways that lighting circuits can be designed and wired for proper operation. For example, headlights can be designed to operate either with a power or ground switched circuit design. Relays can be used for both left and right sides. This manual will include typical lighting circuit student learning exercises, but the trainer allows many other custom circuit wiring options for instructors to design to their own needs and desires. When the entire trainer is wired for operation of all lighting circuits, the instructions will cover only one of the many different possibilities available. The trainer allows a variety of different circuit designs for different student skill levels. consulab.com info@consulab.com 12 HV-1918-2-95 Component Identification Multi-function Switch — Pin Identification Chart HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date PIN DESCRIPTION 113 Power Out To Right Front Turn Lamp 111 Power In To Multi-Function Switch 112 Power Out To Left Front Turn Lamp 116 Power Out To Right Rear Stop And Turn Lamp 71 Power In From Stop Lamp Switch 115 Power Out To Left Rear Stop And Turn Lamp 31 Dimmer Switch Contacts - Latching (See Note Above) 33A Dimmer Switch Contacts - Latching (See Note Above) NOTE- Terminals 31 & 33A contacts are protected by a 1A Slo-Blo fuse located on the trainer’s fault box. consulab.com info@consulab.com 13 HV-1918-2-95 Component Identification Trailer Connecter — Pin Identification Chart HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date PIN DESCRIPTION 1 Ground 2 Right Marker Lights - (some upper trailer marker lights) 3 Right Turn 4 Stop Lights 5 Left Turn 6 Left Marker Lights - (some lower trailer marker lights) 7 12 V or Lift Axle or ABS consulab.com info@consulab.com 14 HV-1918-2-95 Component Identification 5-Pin ISO Relay — Pin Identification Chart HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date PIN DESCRIPTION 85 Normally Coil Ground 86 Normally Coil 12V Feed 30 12V Feed In for Controlled Circuit or 12V Out to Controlled Component 87A Normally Closed Contact — Can Be 12V Feed In or 12V Out to Controlled Component 87 Normally Open Contact — Can Be 12V Feed In or 12V Out to Controlled Component 30 & 87A Normally Closed When Relay is Off 30 & 87 Normally Open When Relay is Off consulab.com info@consulab.com 15 HV-1918-2-95 Student Assignments Student Assignments As has been stated previously, the HV-1918 is a “generic” heavy duty vehicle lighting trainer. It is not indicative of any specific vehicle application. There are countless methods of constructing general lighting and control circuits using the included components. Other separate components can be added to expand the trainers capability even more. For example, a vehicle horn could be connected with this trainer using one of the ISO relays and the push button Back Up Light switch. It is recommended that the maximum circuit load controlled by the ISO relays not exceed 30 amps. consulab.com info@consulab.com 16 HV-1918-2-95 Student Learning Assignment Example & Instructions Student Learning Assignment Example & Instructions On the next page the example of a simple circuit (Back Up Lights) shows the layout and organization used for all student assignments using the HV-1918 trainer. Typically, an assignment begins with a CIRCUIT UNDERSTANDING paragraph, then asks the student to fill out a worksheet on which the student draws out the circuit. Upon instructor verification, stu- dents are asked to construct the circuit on the trainer. Upon instructor verification, the circuit is operated and verified. Answer sheets are designed for submission to instructors for assignment credit. ENTRY LEVEL students are given step-by-step instructions for correct wiring of the circuit. Students are asked to draw the circuit on the provided circuit schematic template and all answers to circuit understanding questions are to be en- tered on the Student Answer Sheet to be submitted for evaluation. ADVANCED LEVEL students are asked to complete the circuit diagram, but are not given step-by-step wiring instruc- tions. They are expected to use their knowledge to construct the circuit on the trainer. Students are also asked to answer circuit understanding questions and all answers are to be submitted on the Student Answer Sheet. consulab.com info@consulab.com 17 HV-1918-2-95 Example of a Simple Circuit Assignment Example of a Simple Circuit Assignment Back Up Lights Circuit Understanding A typical backup light circuit operates when the ignition and the transmission backup light switches are switched ON. Therefore, to construct this circuit, wiring would be connected to the following components: Fuse, Ignition Switch, Backup Light Switch, Backup Light and Grounds. Refer to the attached diagram for proper circuit hookup for the backup lights: With the circuit constructed as the diagram indicates, the backup light should operate when the Ignition Switch is turned to the ON position and the Backup Light switch is pushed in (ON). Entry Level Make sure the power supply is correctly connected to the trainer and is turned OFF. Using the black and red jumper wires, make the following connections to the trainer. 1. Connect a red jumper wire from the red terminal of the F1 fuse to the BAT terminal of the Ignition Switch. 2. Connect a red jumper wire from IGN terminal of the Ignition Switch to the right-hand terminal of the Back-Up Switch on the middle panel. 3. Connect a red jumper wire from the left-hand terminal of the Back-Up Switch the right-hand terminal of the Back-Up Light on the bottom panel. 4. Connect a black jumper wire from the left-hand terminal of the Back-Up Light to any of the four black terminals on the left-hand side of the bottom panel. 5. Connect a black jumper wire from any of the four black terminals on the bottom panel to any of the three black terminals on the middle panel. Circuit Operation Confirmation 1. Double check all connections. 2. Turn ON power supply. 3. Turn Ignition Switch to the “ON” position. 4. Push the Back-Up Switch. 5. Back-Up Light should come ON when button is pushed. 6. Turn in your wiring schematic for grading. consulab.com info@consulab.com 18 HV-1918-2-95 Example of a Simple Circuit Assignment See Back-Up Light circuit template on the next page and draw the circuit that you have just wired on the template. Use red color for positive wires and black color for ground wires. Use a blank template for your answers. Advanced Level 1. Make sure the power supply is correctly connected to the trainer and is turned OFF. 2. Read the Back-Up Light circuit description. 3. Discuss and learn how the Back-Up Light circuit operates. 4. Using the blank template, draw all necessary red and black wires to connect the Back-Up Light circuit. 5. Turn in your drawing to your instructor for grading and verification. 6. After instructor verification and while using the filled out wiring diagram, connect all necessary red and black wires to properly construct the Back-Up Light circuit. 7. Have instructor verify your wiring on the trainer. 8. After instructor verification, turn ON trainer power supply. 9. Turn Ignition to the “ON” position. 10. Push the Back-Up Light switch. 11. The Back-Up Light should come ON each time the Back-Up Light is pushed in. 12. Confirm proper operation of the circuit. 13. If circuit does not operate properly, diagnose and troubleshoot the cause of the malfunction. 14. Turn in your wiring schematic for instructor grading. consulab.com info@consulab.com 19 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Example of a Simple Circuit Assignment Backup Light Circuit — Student Assignment Schematic consulab.com info@consulab.com 20 HV-1918-2-95 Ohm’s Law Experiments Ohm’s Law Experiments The HV-1918 Trainer is equipped with LED lights for all circuits except the front headlights. Therefore, because of the extremely small amperage draw of LED lights, the Ohm’s Law experiments will be conducted using primarily the incan- descent headlight bulbs. The HV-1918 can be used to demonstrate the effect on voltage, current and resistance in series and parallel circuits. Carefully read and follow the below instructions to learn how series and parallel circuits “behave”. NOTE: It is assumed that students are familiar with the proper and safe use of a digital multi-meter (DMM) and that they can properly measure resistance, voltage and amperage. Be sure to check with your instructor if you do not understand these concepts. Meter damage can occur if it is improperly connected to circuits. NEVER GUESS!!! consulab.com info@consulab.com 21 HV-1918-2-95 SA-1 — Series Circuit with One Resistance SA-1 — Series Circuit with One Resistance 1. Connect a red jumper wire from the red terminal of the F1 fuse to the BAT terminal of the Ignition Switch. 2. Connect a red jumper wire from the IGN terminal of the Ignition Switch to the LOW beam yellow terminal of the right-hand headlight. 3. Connect a black jumper wire from the right-hand headlight COM terminal to any of the four black ground terminals on the left-hand side of top Moduponent™ panel (HV-1918-01) 4. Connect a black jumper wire from any of the four right-hand ground terminals to any of the three black ground ter- minals of the middle Moduponent panel (HV-1918-02) 5. Make sure power supply is turned ON and the BATTERY indicator light is “ON”. 6. Turn the Ignition Switch to the ON position. The right-hand headlight should now be ON. 7. Using a digital multi-meter (DMM) set to read voltage and choose a scale that will accurately read 12 volts DC. 8. Place the red lead of the voltmeter on the LOW TEST POINT terminal of the headlight. 9. Place the black lead of the voltmeter on the COM TEST POINT terminal of the headlight. Read the available voltage to the headlight. Use the student answer sheet for your answer. 10. The voltmeter should read approximately the available voltage of the battery. (NOTE-voltage will vary based on the variations of power supply and available outlet voltages. Range should be around 12.6 – 12.8 volts DC) 11. With the headlight ON, disconnect the red jumper wire at the headlight. The light will go OFF. 12. With the headlight ON, disconnect the black jumper wire at the headlight. The light will go OFF. 13. Turn Ignition Switch OFF and reconnect all jumper wires previously removed. 14. Set up the DMM to measure amperage. Confirm your meter setup. 15. Remove the red jumper wire connecting the IGN terminal of the Ignition Switch to the LOW beam terminal of the right-hand headlight. 16. Connect the ammeter to the circuit by placing the meter’s red lead to the IGN terminal of the Ignition Switch. 17. Place the black lead of the ammeter to the LOW beam terminal of the right-hand headlight. 18. Turn ON the Ignition Switch and measure the amperage. 19. Record the amperage of the right-hand headlight on the Student Answer Sheet. 20. Turn Ignition Switch OFF and remove ammeter. Reconnect all previously disconnected wires. Conclusions This is a “SERIES” circuit with one resistance. In a normally operating series circuit with one resistance, all the supply voltage is available to the resistance. That’s why the voltage at the headlight measured battery voltage. In a SERIES circuit, there is only one path for circuit to flow and thus, any break in either the power or ground side of the circuit will result in the entire circuit being “opened” and quit functioning. That is why the headlight went OFF when either the ground or power wires were disconnected. consulab.com info@consulab.com 22 HV-1918-2-95 SA-1 — Series Circuit with One Resistance SA-1 — Student Answer Sheet Name : Group : Date : 9. V 19. A Instructor grade : Comments : consulab.com info@consulab.com 23 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 SA-1 — Series Circuit with One Resistance SA-1 — Student Assignment Schematic consulab.com info@consulab.com 24 HV-1918-2-95 SA-2 — Series Circuit with Two Resistances SA-2 — Series Circuit with Two Resistances 1. Begin with the trainer wired according the Ohm’s Law SA-1. 2. Make sure the Ignition Switch is turned OFF. 3. Disconnect the black jumper wire from the top Moduponent left-hand ground terminal. 4. Connect this black jumper wire to the COM terminal of the left-hand head-light. 5. Connect a black jumper wire from the left-hand headlight LOW beam terminal to any of the four black ground termi- nals on the top Moduponent panel (HV-1918-01) 6. Turn Ignition Switch ON. 7. Notice the operation of the headlights and describe their operation on the Student Answer Sheet. 8. Set up the DMM to measure voltage. 9. Measure the voltage available to the left-hand headlight by placing the red DMM lead on the LOW TEST POINT head- light terminal and the black DMM lead on the COM headlight terminal. Record your reading on the answer sheet. 10. Now, measure the voltage available at the right-hand headlight using the DMM voltmeter in the same way. Record your reading on the answer sheet. 11. Turn the Ignition Switch OFF. 12. Set up the DMM for measuring amperage. Confirm your setup procedure. 13. Disconnect the red wire between the IGN terminal of the Ignition Switch and the LOW beam terminal of the right- hand headlight. 14. Place the red lead of the ammeter on the IGN terminal of the Ignition switch. 15. Place the black lead of the ammeter on the LOW beam terminal of the right-hand headlight. 16. Turn the Ignition Switch ON. 17. Measure the circuit amperage and record on the answer sheet. 18. Turn the Ignition Switch OFF. 19. Disconnect the ammeter and reconnect the red jumper wire you removed for this step. Conclusions When two resistances are connected in series, there is still only one path for current to flow, therefore the voltage must “split” between them. This usually results in an improper circuit operation usually noticed by reduced current. Most vehi- cle circuits (other than some newer vehicle headlight circuits) do not use series circuits with more than one resistance. If you see a circuit that has reduced current and the subsequent negative operation affects the performance of the circuit, you must begin to locate the cause of the unwanted resistance and repair it. In a SERIES circuit if there is more than one resistance, the total resistance of the circuit always increases. All resistanc- es in a series circuit add together to form the total circuit resistance. Therefore, unwanted resistance in a series circuit will cause the circuit current to decrease and the voltage will vary at each resistance. We call this “voltage drop” at each resistance. The total voltage drops of all resistances should equal the total circuit source voltage. consulab.com info@consulab.com 25 HV-1918-2-95 SA-2 — Series Circuit with Two Resistances SA-2 — Student Answer Sheet Name : Group : Date : 7. Describe headlight operation 9. Volts available at the right-hand headlight. 10. Volts available at the left-hand headlight. 17. Circuit amperage of both headlights in series Instructor grade : Comments : consulab.com info@consulab.com 26 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 SA-2 — Series Circuit with Two Resistances SA-2 — Student Assignment Schematic consulab.com info@consulab.com 27 HV-1918-2-95 SA-3 — Parallel Circuit with Two Resistances SA-3 — Parallel Circuit with Two Resistances 1. Before proceeding with SA-3, make sure that all previously connected jumper wires are disconnected from the trainer. 2. Connect a red jumper wire from the F1 fuse terminal to the BAT terminal of the Ignition Switch. 3. Connect a red jumper wire from the IGN terminal of the Ignition switch to the LOW beam terminal of the right-hand headlight. 4. Using the piggy back feature, connect another red jumper wire from the red LOW beam terminal of the right-hand headlight to the LOW beam terminal of the left-hand headlight. 5. Connect a black jumper wire from the COM terminal of the right-hand headlight to the COM terminal of the left- hand headlight. 6. Using the piggy back feature, connect a black jumper wire from the black GRD terminal of the left-hand headlight to any of the four black ground terminals on the left-hand side of the top Moduponent (HV-1918-01) 7. Connect a black jumper wire from any of the four ground terminals on the top Moduponent to any of the three black ground terminals on the middle Moduponent (HV-1918-02) 8. Turn the Ignition Switch ON. 9. Both headlights should be operating at full brilliance. 10. Set up a DMM to read voltage. Confirm your meter setup. 11. Measure the available voltage at the left-hand headlight by placing the red meter lead on the LOW beam terminal and the black meter lead on the COM terminal. 12. Fill in your voltage reading on the answer sheet. 13. Now, measure the available voltage at the right-hand headlight using the same procedure as for Step #11. 14. Fill in your voltage reading on the answer sheet. 15. Turn Ignition Switch OFF. 16. Set up the DMM to measure amperage. Confirm your meter setup. 17. Remove the red jumper wire connecting the Ignition Switch IGN terminal to the LOW beam headlight terminal on the right-hand headlight. 18. Connect the DMM ammeter by placing the red lead of the ammeter on the Ignition Switch IGN terminal and the black lead of the ammeter into the LOW TEST POINT terminal of the right-hand headlight. 19. Turn the Ignition Switch ON. 20. Both headlights should be operating normally. 21. Read the amperage flowing in this circuit. 22. Record your reading on the answer sheet. 23. Turn Ignition Switch OFF. 24. Disconnect the red jumper wire connected to the left-hand LOW beam terminal of the LEFT-HAND headlight. 25. Turn Ignition Switch ON. consulab.com info@consulab.com 28 HV-1918-2-95 SA-3 — Parallel Circuit with Two Resistances 26. Using the DMM ammeter, measure the amperage of the right-hand headlight. 27. Record amperage reading on the answer sheet. 28. Turn Ignition Switch OFF. 29. Reconnect all jumper wires previously removed. Conclusions With two resistances connected in parallel to the battery, each resistance has full battery voltage available. A parallel circuit consists of two or more circuit branches containing resistances of which each branch is supplied with a separate path for battery power. This means that if there is a break in one of the branches, the others will continue to operate normally. Some parallel circuits share common power and ground circuits, but not always. Additional branches can be added which increases the amperage draw from the battery. This is opposite of a series circuit where additional resis- tances will decrease the total amperage because there is only one path for current to flow. consulab.com info@consulab.com 29 HV-1918-2-95 SA-3 — Parallel Circuit with Two Resistances SA-3 — Student Answer Sheet Name : Group : Date : 12. Available voltage at left-hand headlight 14. Available voltage at the right-hand headlight 22. Total circuit amperage 27. Amperage of right-hand headlight Instructor grade : Comments : consulab.com info@consulab.com 30 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 SA-3 — Parallel Circuit with Two Resistances SA-3 — Student Assignment Schematic consulab.com info@consulab.com 31 HV-1918-2-95 Incandescent Light Bulb — Static and Dynamic Resistances Experiments Incandescent Light Bulb — Static and Dynamic Resistances Experiments Light Bulb Static Resistance Incandescent light bulbs can have the internal resistance measured when the bulb is OFF for purposes of testing the continuity of the bulb only. This test is called “STATIC” resistance and is NOT an indication of how much resistance the bulb actually has. This test is used for initial bulb continuity testing only. 1. Make sure the Ignition Switch is turned OFF. 2. Set up the DMM to read resistance. Confirm the meter setup you have made. 3. With no jumper leads connected to the headlights, measure the resistance of the LOW beam filament by connect- ing the two DMM ohmmeter leads to the LOW TEST terminal and the COM TEST POINT terminal of the right-hand headlight. NOTE- This reading will be very low and holding the meter leads steady is critical to this measurement. NOTE- If the DMM has a “zero” feature for Ohm’s testing, set up this feature to get a true “zero” when both meter leads are connected together. Failure to do this may result in inaccurate readings. 4. Fill in the Student Answer Sheet will your resistance reading obtained from Step 3. 5. In the same manner measure the static resistance of the left-hand headlight bulb. 6. Fill in the Student Answer Sheet with your resistance reading obtained from Step 5. Light Bulb Dynamic Resistance Dynamic light bulb resistance is the actual resistance when the bulb is turned ON. The only way to determine the actual DYNAMIC or “live” resistance of an incandescent bulb is the use Ohm’s Law to calculate it. You must know the value of the bulb’s voltage and amperage before this calculation can be made. Ohm’s Law states that if two of the three values of OHMS, VOLTAGE or AMPERAGE are known, then the remaining third can be determined. If we wish to determine the actual DYNAMIC resistance of the headlight bulb, we would use the Ohm’s Law formula of VOLTAGE/AMPERAGE = RE- SISTANCE. 7. Obtain the voltage and amperage measured from Steps 11 and 20 of SA-1. 8. Use the formula of VOLTAGE / AMPERAGE = RESISTANCE to calculate the headlight bulbs dynamic resistance. 9. Fill in the Student Answer Sheet with your answer. 10. Compare the STATIC and DYNAMIC resistances for the headlight. consulab.com info@consulab.com 32 HV-1918-2-95 Incandescent Light Bulb — Static and Dynamic Resistances Experiments Conclusions The reason that there is a difference between STATIC and DYNAMIC bulb resistances is that when the bulb is ON, the filament of the bulb heats up which raises its resistance and thus decreases the amperage. Note When working with incandescent light bulbs and calculating resistances and amperages, it must be remembered that dynamic resistances change with each circuit. For example, if a single headlight bulb was connected to the battery and its amperage was measured, it would sound reasonable that if another identical headlight bulb was connected in series, the total amperage would be about one-half of the single headlight. This isn’t true because the dynamic resistance of each bulb changes based on the voltage available to it. The total amperage of both bulbs will be less than one single bulb, but will not be exactly one-half. consulab.com info@consulab.com 33 HV-1918-2-95 Incandescent Light Bulb — Static and Dynamic Resistances Experiments Static and Dynamic Resistances Experiments — Student Answer Sheet Name : Group : Date : Light Bulb Static Resistance Experiments 4. Ω of static resistance of right-hand headlight (low beam filament) 6. Ω of static resistance of left-hand headlight (low beam filament) Light Bulb Dynamic Resistance Experiments 2. V divided by A = Ω of Dynamic Resistance. Instructor grade : Comments : consulab.com info@consulab.com 34 HV-1918-2-95 Relay Controlled ON/OFF Circuit (Latched Relays) Relay Controlled ON/OFF Circuit (Latched Relays) The HV-1918-1S (single sided) or HV-1918-2S (double sided) trainer can be used for several different learning objectives besides vehicle lighting. Instructors can develop custom circuits for specific learning objectives and goals. There are countess possibilities using the components and wiring jumpers on the Moduponents to construct circuits. The below example of how the trainer can be utilized for supplemental learning uses a latched relay control circuit that turns a light bulb ON/OFF using momentary push buttons. See below for a circuit explanation. NOTE : In order for the circuit to operate properly, it is absolutely necessary that the below instructions be carefully fol- lowed. With detailed connection instructions, it is very easy to make a mistake and mis-wire a connection. Always slowly read each step and confirm that you have made the correct connections for the circuit. Experiment 1. Connect a red jumper wire from the F1 15 A fuse to terminal #30of relay #1. 2. Connect a red jumper wire from terminal #87A of relay #1 to terminal #30 of relay #2. 3. Connect a red jumper wire from terminal #87 of relay #2 to terminal 86 of relay #2. 4. Using the piggy back feature, connect a red jumper wire from terminal #86 of relay #2 to positive (+) terminal (right- hand side) of the backup light on the lower Moduponent panel. 5. Using the piggy back feature, connect a red jumper wire from the F1 15 A fuse to the left-hand terminal of the Stop Light push button switch. 6. Using the piggy back feature, connect a red jumper wire from the left-hand terminal of the Stop Light push button switch to the left-hand terminal of the Back Up Light push button switch. 7. Connect a red jumper wire from the right-hand terminal of the Back Up Light push button switch to terminal #86 of relay #1. 8. Using the piggy back feature, connect a red jumper wire from terminal #87 of relay #2 to the right-hand terminal of the Brake Light push button switch. 9. Connect a black jumper wire from terminal #85 of relay #1 to terminal #85 of relay #2. 10. Using the piggy back feature, connect a black jumper wire from terminal #85 of either relay #1 or relay #2 to any of the three black ground terminals on the left-hand side of the middle Moduponent panel. 11. Connect a black jumper wire from the (-) terminal (left-hand) of the Back Up Light on the lower Moduponent panel to any of the four black ground terminals on the left-hand side of the middle Moduponent panel. 12. Make sure the BATTERY panel light is ON. 13. Push the Brake Light push button switch. The Back Up Light should come ON and stay ON. 14. Confirm proper operation. 15. Push the Back Up Light push button. The Back Up Light should go OFF. consulab.com info@consulab.com 35 HV-1918-2-95 Relay Controlled ON/OFF Circuit (Latched Relays) 16. Confirm proper operation. 17. If the circuit does not function as it should, go back over the connection instructions to find your errors and correct. Operational Description of ON/OFF Latched Relay Circuit To turn the backup light “ON” 1. Battery power is available at all times to the following circuit points: A. F1 15A fuse B. Terminal 30 of Relay #1 C. Left-hand side of Backup Light Push Button switch D. Left-hand side of Stop Lamp Push Button switch E. Terminal 87A of Relay #1 F. Terminal 30 of Relay #2 2. If the backup light is in the OFF position, pushing the Stop Lamp switch will provide battery voltage to terminal 87 of Relay #2. 3. Because terminal 87 of Relay #2 is connected to terminal 86 of the same relay, the relay coil now is energized and the relay “turns ON”. (The relay’s coil ground circuit (#85) is connected to ground at all times). 4. Turning Relay #2 ON, connects battery power from terminal 30 to terminal 87 of Relay #2. This provides a positive power source to the backup light. Power comes from the 15A fuse, to terminal 30 of Relay #1, through the normal- ly closed connection to terminal 87A of Relay #1, through to terminal 30 of Relay #2, through the closed contacts (relay ON), and out of Relay #2 on terminal 87, to terminal 86 of Relay #2 (jumper wire) to the backup light positive wire. The light turns ON because it is grounded by the black wire. 5. Releasing the Stop Lamp switch keeps the backup light ON because the Relay #1 coil control circuit is connected to battery positive through the connection from terminal 87 to terminal 86 of Relay #1, back through the normally closed contacts (87A to 30) of Relay #1 and back to the 15A fuse. 6. At this point, Relay #2 is “latched” in the “ON” position and the backup light is ON. To turn the backup light “OFF” 1. Pushing the Backup Light push button switch provides positive battery voltage to terminal 86 of Relay #1 resulting in the relay #1 coil being energized and the relay “turns ON”. (The relay’s coil ground circuit (#85) is connected to ground at all times). 2. Turning Relay #1 ON breaks the positive circuit to the backup light by interrupting the power connection between terminals 30 and 87A of Relay #1. 3. As Relay #1 is turning ON, this action also turns OFF Relay #2 by breaking the connection between terminals 30 and 87A of Relay #1 which was providing a circuit to Relay #2’s coil control circuit. Relay #2 now turns OFF and the backup light goes OFF. 4. Releasing the Backup Light push button switch reconnects terminals 30 and 87A of Relay #1, but the backup light stays OFF because the connection between terminals 30 and 87 of Relay #2 was broken when the Backup Light push button switch was pushed. consulab.com info@consulab.com 36 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Relay Controlled ON/OFF Circuit (Latched Relays) Relay Controlled ON/OFF Circuit (Latched Relays) — Student Assignment Schematic consulab.com info@consulab.com 37 HV-1918-2-95 Headlights Circuit (Ground Switched) — Entry Level Headlights Circuit (Ground Switched) — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlights circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch Carefully follow the below instructions that will define how to properly construct this ground switched headlight circuit. Because of the internal design of the HV-1918 headlight switch, the headlights circuit should be split between the left and right hand sides. Each relay controls the high/low beam circuit for that particular vehicle side. 1. As you complete each of the below circuit construction steps, draw the jumper wire connection you make during each step on the template labeled: HEADLIGHTS CIRCUIT (GROUND SWITCHED) and submit the schematic when you turn in your student answer sheet. 2. Connect a red jumper wire from the red terminal of the F1 15A fuse to the left-hand BAT terminal of the headlight switch. 3. Connect a red jumper wire from the red terminal of the F2 15A fuse to the right-hand BAT terminal of the headlight switch. 4. Connect a red jumper wire from the left-hand H terminal of the headlight switch to terminal 31 of the multi-function switch. consulab.com info@consulab.com 38 HV-1918-2-95 Headlights Circuit (Ground Switched) — Entry Level 5. Using the piggy back feature, connect a red jumper wire from the right-hand H terminal of the headlight switch to terminal 31 of the multi-function switch. 6. Using the piggy back feature, connect a red wire from the left-hand H terminal of the headlight switch to the black ground terminal of the left-hand headlight. 7. Using the piggy back feature, connect a red wire from the right-hand H terminal of the headlight switch to the black ground terminal of the right-hand headlight. 8. Connect a red wire from the LOW beam terminal of the left-hand headlight to terminal 87A of relay #1. 9. Connect a red wire from the LOW beam terminal of the right-hand headlight to terminal 87A of relay #2. 10. Connect a red wire from the HIGH beam terminal of the left-hand headlight to terminal 87 of relay #1. 11. Connect a red wire from the HIGH beam terminal of the right-hand headlight to terminal 87 of relay #2. 12. Connect a red wire from terminal 33A of the multi-function switch to terminal 85 of relay #1. 13. Using the piggy back feature, connect a red wire from terminal 85 of relay #1 to terminal 85 of relay #2. 14. Connect a black wire from any of the three black ground terminals on the left-hand side of the middle Moduponent panel to terminal 30 of relay #1. 15. Using the piggy back feature, connect a black wire from any of the three black ground terminals on the left-hand side of the middle Moduponent panel to terminal 30 of relay #2. 16. Using the piggy back feature, connect a black wire from terminal 86 to terminal 30 of relay #1. 17. Using the piggy back feature, connect a black wire from terminal 86 to terminal 30 of relay #2. 18. Connect a red wire from terminal 33A of the multi-function switch to the red terminal of the HIGH BEAM INDICATOR lamp. 19. Connect a black wire from the black terminal of the HIGH BEAM INDICATOR lamp to any of the three black ground terminals on the left-hand side of the middle Moduponent panel. 20. Confirm all connections are correct. 21. Confirm that the trainer BATTERY light is ON. (If not turn ON the power supply) 22. Move the headlight switch toggle DOWN to turn ON the headlights. 23. With the headlights ON, push in the dimmer switch button on the end of the multi-function switch lever. The head- lights should switch from LOW to HIGH beam with the HIGH BEAM INDICATOR lamp coming ON with the high beam headlights. 24. Confirm correct circuit operation. 25. If the circuit does not operate normally, go back over each step to identify where errors were made. 26. Obtain verification from your instructor and have him/her sign your student answer sheet. 27. Now, answer the circuit understanding questions below and put your answers on the student answer sheet. consulab.com info@consulab.com 39 HV-1918-2-95 Headlights Circuit (Ground Switched) — Entry Level Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Trace the flow of power from the fuse to ground for the LOW beam for the right-hand headlight. 2. Trace the flow of power from the fuse to ground for the HIGH beam for the left-hand headlight. 3. Explain what would happen to the circuit if the coil of relay #2 were to fail by being “OPEN”. Headlights Circuit (Ground Switched) — Entry Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. Instructor grade : Comments : consulab.com info@consulab.com 40 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Headlights Circuit (Ground Switched) — Entry Level Headlights Circuit (Ground Switched) — Entry Level — Student Assignment Schematic consulab.com info@consulab.com 41 HV-1918-2-95 Headlights Circuit (Ground Switched) — Advanced Level Headlights Circuit (Ground Switched) — Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlight circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch General Circuit Construction Instructions To construct the ground switched headlight circuit, carefully read the following general description of the circuit, then, obtain a blank template for the HV-1918 trainer and carefully draw all positive and negative wires required to make the circuit operate correctly. FUSES : Use two fuses for this circuit. One for the left headlight and one for the right headlight. HEADLIGHT SWITCH : Use the left side of the switch for the left headlight and the right side for the right headlights. RELAYS : Use relays #1 for the left headlight and #2 for the right headlight. The relays are responsible for switching from LOW to HIGH beam when commanded by the dimmer switch. MULTI-FUNCTION SWITCH : Pins 31 and 33A are for the dimmer switch. It is a latched push button switch located at the consulab.com info@consulab.com 42 HV-1918-2-95 Headlights Circuit (Ground Switched) — Advanced Level end of the lever. Pushing it once will either open or close the switch depending on the position it was previously in. The dimmer switch will control the relays in this circuits HEADLIGHTS : Use the common COM terminal for power feed and the power flow will exit the lights either from the LOW or HIGH beam terminals. Instructions 1. Draw the ground switched headlight circuit on the blank template. Include ALL necessary wires for correct operation of the circuit. 2. Hand in your drawing to your instructor for verification. 3. When you have verification, construct the circuit you have drawn on the trainer. Verify all wiring is correct. 4. With instructors permission, turn ON power supply and confirm correct circuit operation. If circuit do not operate properly, recheck your work to find and correct your errors. 5. Answer the following circuit understanding questions. Put your answers on the student answer sheet. 6. Turn in your answer sheet to your instructor for credit. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Trace the flow of power from the fuse to ground for the LOW beam for the right-hand headlight. 2. Trace the flow of power from the fuse to ground for the HIGH beam for the left-hand headlight. 3. Explain what would happen to the circuit if the coil of relay #2 were to fail by being “OPEN”. consulab.com info@consulab.com 43 HV-1918-2-95 Headlights Circuit (Ground Switched) — Advanced Level Headlights Circuit (Ground Switched) — Advanced Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. Instructor grade : Comments : consulab.com info@consulab.com 44 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Headlights Circuit (Ground Switched) — Advanced Level Headlights Circuit (Ground Switched) — Advanced Level — Student Assignment Schematic consulab.com info@consulab.com 45 HV-1918-2-95 Headlights Circuit (Positive Switched) — Entry Level Headlights Circuit (Positive Switched) — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlight circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch Carefully follow the below instructions that will define how to properly construct this positive switched headlight circuit. Because of the internal design of the HV-1918 headlight switch, the headlight circuit should be split between the left and right hand sides. Each relay controls the high/low beam circuit for that particular vehicle side. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “HEADLIGHTS (POSITIVE SWITCHED)” and submit the schematic when you turn in your Student Answer Sheet. 2. The circuit will be constructed by component. 3. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. consulab.com info@consulab.com 46 HV-1918-2-95 Headlights Circuit (Positive Switched) — Entry Level Fuses And Headlamp Switch 1. Connect a red jumper wire from the red receptacle of fuse F1 to the right-hand “BAT” terminal of the headlamp switch. 2. Connect a red jumper wire from the red receptacle of fuse F2 to the left-hand “BAT terminal of the headlamp switch. 3. Connect a red jumper wire from the right-hand “H” terminal of the headlamp switch to terminal #30 of relay #2. 4. Connect a red jumper wire from the left-hand “H” terminal of the headlamp switch to terminal #30 of relay #1. 5. Connect a red jumper wire from the left-hand “H” terminal of the headlamp switch to terminal #31 of the multi-func- tion switch. Relays, Multi-Function Switch, High Beam Indicator and Headlights 6. Connect a black jumper wire from terminal #85 of relay #2 to terminal #85 of relay #1. 7. Connect a black jumper wire from terminal #85 of relay #1 to any of the three black ground receptacles on the left- hand side of the middle Moduponent panel. 8. Connect a red jumper wire from the left-hand headlight LOW beam receptacle to terminal #87A of relay #1. 9. Connect a red jumper wire from the left-hand headlight HIGH beam receptacle to terminal #87 of relay #1. 10. Connect a red jumper wire from the right-hand headlight LOW beam receptacle to terminal #87A of relay #2. 11. Connect a red jumper wire from the right-hand headlight HIGH beam receptacle to terminal #87 of relay #2. 12. Connect a black jumper wire from the black ground receptacle of the right-hand headlight to the black ground re- ceptacle of the left-hand headlight. 13. Connect a black jumper wire from the black ground receptacle of the left-hand headlight to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. 14. Connect a red jumper wire from terminal #86 of relay #2 to terminal #86 of relay #1. 15. Connect a red jumper wire from terminal #86 of relay #1 to terminal #33A of the multi-function switch. 16. Connect a red jumper wire from terminal #33A of the multi-function switch to the red receptacle of the HIGH BEAM INDICATOR lamp. 17. Connect a black jumper wire from the black terminal of the HIGH BEAM INDICATOR lamp to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Circuit Operation Confirmation 18. Recheck all of your circuit connections to confirm correct circuit construction. 19. Make sure the trainer power supply is turned ON and the BATTERY light is ON. 20. Turn the headlamp switch DOWN to the headlamps ON position. 21. Headlights should now be ON. 22. Move the pushbutton on the end of the multifunction lever to change from HIGH to LOW beams. 23. Confirm that the HIGH BEAM INDICATOR comes ON when high beam headlights are selected. (NOTE- High beam headlights will illuminate in a higher position than low beam on a wall.) 24. If the circuit does not operate normally, go back over your connections to identify and repair the errors. consulab.com info@consulab.com 47 HV-1918-2-95 Headlights Circuit (Positive Switched) — Entry Level 25. Confirm that you have drawn the circuit schematic on the Student Schematic sheet. 26. Obtain operation verification from your instructor. 27. Answer the circuit understanding questions below and put your answers on the Student Answer Sheet. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Explain what the impact on the circuit would be if fuse F1 was open. 2. Explain what how the circuit would behave if relay #2 contacts #87 and #30 were stuck together inside the relay. 3. Explain what an open in the ground circuit to relay #1 would have on the operation of the circuit. 4. Explain what a short together between the left-hand “H” and right-hand “H” terminals of the headlamp switch would have on the circuit. consulab.com info@consulab.com 48 HV-1918-2-95 Headlights Circuit (Positive Switched) — Entry Level Headlights Circuit (Positive Switched) — Entry Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. 4. Instructor grade : Comments : consulab.com info@consulab.com 49 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Headlights Circuit (Positive Switched) — Entry Level Headlights Circuit (Positive Switched) — Entry Level — Student Assignment Schematic consulab.com info@consulab.com 50 HV-1918-2-95 Headlights Circuit (Positive Switched) — Advanced Level Headlights Circuit (Positive Switched) — Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Headlight circuits on modern medium and heavy duty trucks today can use either the power switched or ground switched design. Most vehicles today use separate overcurrent protection (fuses) for the left and right headlight circuits. Separate relays are also commonly used for the headlight circuits. The circuit constructed in this activity is a generic circuit that may or may not be identical to a specific year, make and model of vehicle. A typical truck headlight circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Headlight switch • Relays • Headlights • Dimmer switch Carefully follow the below instructions that will define how to properly construct this positive switched headlight circuit. Because of the internal design of the HV-1918 headlight switch, the headlight circuit should be split between the left and right hand sides. Each relay controls the high/low beam circuit for that particular vehicle side. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “HEADLIGHTS (POSITIVE SWITCHED)” and submit the schematic when you turn in your Student Answer Sheet. 2. The circuit will be constructed by component. 3. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. consulab.com info@consulab.com 51 HV-1918-2-95 Headlights Circuit (Positive Switched) — Advanced Level Circuit Construction Construct the positive side switched headlight circuit following the below instructions. Fuses, Headlamp Switch and Dimmer Switch 1. Use fuse F1 for the right-hand headlight and fuse F2 for the left-hand headlight. 2. Either side of the headlamp switch can feed the dimmer switch. 3. Include the dimmer switch in the headlight circuit. Relays and Multi-Function Switch 4. Use relay #1 for the left-hand headlight and relay #2 for the right-hand headlight. 5. Use terminals #31 and #33A of the multi-function switch for the dimmer switch. 6. Use relay terminals #85 for the coil ground circuits Headlights 7. Use the left-hand headlight for the headlight ground circuit. Circuit Confirmation 8. Recheck all of your circuit connections to confirm they are correct. 9. Make sure the trainers power supply is turned ON and the BATTERY light is ON. 10. Turn the headlamp switch to the upper position to turn ON the headlight circuit. 11. Operate the dimmer switch to confirm proper operation of the high beam headlights and the high beam indicator lamp. 12. If there is any circuit malfunction, go back over your connections to identify and repair the error. 13. Make sure you have correctly drawn this circuit on the schematic template. 14. Obtain instructor verification of correct circuit operation. 15. Answer the CIRCUIT UNDERSTANDING QUESTIONS below and put your answers on the Student Answer Sheet. Circuit Understanding And Diagnosis Questions (Use the student answer sheet for your answers) 1. Explain what the impact on the circuit would be if fuse F1 was open. 2. Explain what how the circuit would behave if relay #2 contacts #87 and #30 were stuck together inside the relay. 3. Explain what an open in the ground circuit to relay #1 would have on the operation of the circuit. 4. Explain what a short together between the left-hand “H” and right-hand “H” terminals of the headlamp switch would have on the circuit. 5. What effect would very high resistance in the black wire from terminal #85 of relay #1 to the ground terminal of the middle Moduponent panel have on circuit performance? 6. What effect would a short between the HIGH and LOW beam headlight wires at the connector have on circuit perfor- mance? (there is no short to ground, but just between high and low beam circuits) 7. There is an open wire from the right-hand headlamp switch terminal “H” to terminal #30 of relay #2. What effect on circuit performance would this condition have? consulab.com info@consulab.com 52 HV-1918-2-95 Headlights Circuit (Positive Switched) — Advanced Level Headlights Circuit (Positive Switched) — Advanced Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. 4. 5. consulab.com info@consulab.com 53 HV-1918-2-95 Headlights Circuit (Positive Switched) — Advanced Level 6. 7. Instructor grade : Comments : consulab.com info@consulab.com 54 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Headlights Circuit (Positive Switched) — Advanced Level Headlights Circuit (Positive Switched) — Advanced Level — Student Assignment Schematic consulab.com info@consulab.com 55 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level Parking, Tail and Marker Lights Circuit — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Most medium and heavy duty trucks come equipped with many park, tail and clearance marker lights. Because of this fact, relays are normally used to reduce the circuit load on the headlight switch. The HV-1918 trainer uses all LED style lamps for the park, tail and marker lights which results in a significant reduction in total circuit amperage. Most modern trucks today also commonly use LED lights. The HV-1918 trainer has the following lighting components for the park, tail and marker light circuit: • Two (2) front amber parking lights • Five (5) amber marker lights in a mounting bar • Two (2) amber side marker lights • Two (2) red taillights • Five (5) red marker lights • One (1) license plate light • One (1) trailer plug • One (1) headlamp switch • Two (2) relays • Three (3) fuses Circuit Construction Because of the number of wires involved in this circuit, the instructions for constructing this circuit will be grouped by component, then the components will be connected together. It is very important to read each step very carefully and confirm that you are attaching the wires exactly as described. NOTE: It is possible to install more than one jumper wires on the same terminal by using the “piggy back” feature that allows the wires to be “stacked”. IMPORTANT: AS YOU MAKE EACH JUMPER WIRE CONNECTION, DRAW THE CONNECTION THAT YOU MADE ON THE SCHEMATIC TEMPLATE. consulab.com info@consulab.com 56 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level Front Marker and Side Clearance Lights 1. Connect all five amber marker lights using four (4) red jumper wires in the red receptacles. 2. Connect a red jumper wire from either the left or right end marker light to either the left or right side marker light on the top Moduponent. Use the red receptacle. 3. Connect all five amber marker lights using four (4) black jumper wires in the black receptacles. 4. Connect a black jumper wire from either the left or right end marker light to either the left or right side marker light on the top Moduponent. Use the black receptacle. 5. Connect a red jumper wire from the red receptacle of the right-hand side marker light to the red receptacle of the left-hand side marker light. 6. Connect a black jumper wire from the black receptacle of the right-hand side marker light to the black receptacle of the left-hand side marker light. 7. Connect a black jumper wire from the black receptacle of the left-hand side marker to any of the three ground receptacle on the left-hand side of the middle Moduponent. Front Parking Lights 8. Connect a red jumper wire from the “P” terminal of the left-hand parking light to the red terminal of the left-hand side marker light. 9. Connect a black jumper wire from the “GND” terminal of the left-hand parking light to the black terminal of the left- hand side marker light. 10. Connect a red jumper wire from the “P” terminal of the right-hand parking light to the red terminal of the right-hand side marker light. 11. Connect a black jumper wire from the “GND” terminal of the right-hand parking light to the black terminal of the right-hand side marker light. Rear Marker, Tail and License Plate Lights 12. Connect all five red marker lights on the bottom Moduponent using four (4) red jumper wires in the red receptacles. 13. Connect a red jumper wire from the left rear marker light to the left side tail light. Use the middle red receptacle identified by “P”. 14. Connect a red jumper wire from the right-rear marker light red receptacle to the “P” terminal of the right-rear tail- light. 15. Connect all five red marker lights using four (4) black jumper wires in the black receptacles. 16. Connect a black jumper wire from the black terminal of hte left-hand rear marker light to the GND terminal of the left side tail light. 17. Connect a red jumper wire from the red receptacle of the license plate light to any of the red receptacles of the red marker lights. 18. Connect a black jumper wire from the black receptacle of the license plate light to any of the black receptacles of the red marker lights. consulab.com info@consulab.com 57 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level 19. Connect a black jumper wire from the black receptacle of the left-hand taillight identified by “GND” to the black receptacle of the left-hand rear marker light. 20. Connect a black jumper wire from the “GND” receptacle of the left-rear taillight to any of the four black ground receptacles on the left-hand side of the lower Moduponent panel. 21. Connect a black jumper wire from any of the four ground receptacles on the lower Moduponent panel to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. 22. Connect a black jumper wire from the “GND” terminal of the right-hand taillight to the “GND” terminal of the right- hand taillight. Trailer Plug 23. Connect a red jumper wire from the “P” terminal of the right-hand taillight to terminal #86 of relay 4. 24. Connect a red jumper wire from the 87 terminal of relay 4 to the terminal # 2 of the trailer plug connecter. 25. Connect a red jumper wire from terminal #2 to terminal #6 of the trailer plug connecter. 26. Connect a red jumper wire from the F6 terminal to terminal # 30 of the relay 4 27. Connect a black jumper wire from the “GND” terminals of the right hand taillight to terminal #85 of relay 4. 28. Connect a black jumper wire from the “GND” terminals of the right hand taillight to terminal # 1 of the trailer plug connecter. Headlamp Switch 29. Connect a red jumper wire from the red terminal of F4 fuse on the middle Moduponent panel to the right-hand side “BAT” terminal of the headlamp switch. 30. Connect a red jumper wire from the “BAT” terminal of the left-hand side of the headlamp switch to the “BAT” termi- nal of the right-hand side of the headlamp switch. Relays 31. Connect a red jumper wire from the “P” terminal of the left-hand side of the headlamp switch to terminal #86 of relay #3. 32. Connect a red jumper wire from the “P” terminal of the right-hand side of the headlamp switch to terminal #86 of relay #4. 33. Connect a red jumper wire from terminal #30 of relay #3 to the “P” terminal of the right-hand front parking light. 34. Connect a red jumper wire from terminal #30 of relay #4 to the “P” terminal of the right-hand rear taillight. 35. Connect a black jumper wire from terminal #85 of relay #3 to terminal #85 of relay #4. 36. Connect a black jumper wire from terminal #85 of relay #4 to any of the three black ground receptacles on the left- hand side of the middle Moduponent panel. Fuses 37. Connect a red jumper wire from the red receptacle of fuse F5 to terminal #87 of relay #3. consulab.com info@consulab.com 58 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level 38. Connect a red jumper wire from the red receptacle of fuse F6 to terminal #87 of relay #4. 39. Confirm that the trainers power supply is turned ON and the BATTERY light is ON. 40. Move the headlamp switch up to turn ON the parking, marker and taillights. 41. Confirm correct circuit operation. If circuit operation is incorrect, recheck all of the connections to determine errors and correct. 42. Obtain verification from your instructor. 43. Answer the circuit understanding questions below and put your answers on the Student Answer Sheet. When com- pleted, turn in the Student Answer Sheet and the schematic to your instructor for credit. Circuit Explanation Fuse F4 provides power to the headlamp switch and the coil circuits of both relays #4 and #5. This circuit is called the “control circuit”. Fuse F5 supplies power to terminal #87 of relay #3 which controls the front lighting circuit. This circuit is called the “controlled circuit”. Fuse F6 supplies power to terminal #87 of relay #4 which controls the rear lighting circuit. This circuit is called the “controlled circuit”. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Explain what circuit problems would occur is there was an “open” in the wire from terminal #86 of relay #4 to the “P” terminal of the headlamp switch. 2. Explain what circuit problems would occur is fuse F4 was defective and electrically OPEN. 3. Explain what circuit problems would occur if the black wire was OPEN connected between terminal #85 of relay #4 and terminal #85 of relay #3. 4. What effect on the circuit would an open coil in relay #4 have? 5. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with no rear tail or marker lights. What specific components would you check to deter- mine the cause? 6. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with only the right rear taillight on, but no marker lights, license plate light or left-rear taillight on the rear of the cab and on the box. What specific components would you check to determine the cause? consulab.com info@consulab.com 59 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level Parking, Tail and Marker Lights Circuit — Entry Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. 4. consulab.com info@consulab.com 60 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level 5. 6. Instructor grade : Comments : consulab.com info@consulab.com 61 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Entry Level Parking, Tail and Marker Lights Circuit — Entry Level — Student Assignment Schematic consulab.com info@consulab.com 62 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Advanced Level Parking, Tail and Marker Lights Circuit — Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding Most medium and heavy duty trucks come equipped with many park, tail and clearance marker lights. Because of this fact, relays are normally used to reduce the circuit load on the headlight switch. The HV-1918 trainer uses all LED style lamps for the park, tail and marker lights which results in a significant reduction in total circuit amperage. Most modern trucks today also commonly use LED lights. The HV-1918 trainer has the following lighting components for the park, tail and marker light circuit: • Two (2) front amber parking lights • Five (5) amber marker lights in a mounting bar • Two (2) amber side marker lights • Two (2) red taillights • Five (5) red marker lights • One (1) license plate light • One (1) trailer plug • One (1) headlamp switch • Two (2) relays • Three (3) fuses Circuit Construction Because of the number of wires involved in this circuit, the instructions for constructing this circuit will be grouped by component, then the components will be connected together. It is very important to read each step very carefully and confirm that you are attaching the wires exactly as described. NOTE: It is possible to install more than one jumper wires on the same terminal by using the “piggy back” feature that allows the wires to be “stacked”. consulab.com info@consulab.com 63 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Advanced Level Instructions 1. Read the circuit construction instructions below and draw the circuit on the template as you would construct it on the trainer. 2. Submit your drawing to your instructor for verification. 3. Upon verification, construct the circuit you have designed on the trainer. Follow the below instructions for circuit construction. NOTE : As has been stated previously, there are several different methods of wiring these circuits which would all result in normal operation of the lighting circuits. To make sure your circuits match the schematic included with this manual, be sure to follow the general rules listed below. Front Marker and Side Clearance Lights 1. Construct the front marker and side clearance lights be connecting all components with red and black wires. In or- der for your circuit to match the manual schematic, feed the right-side parking light with power from relay #3 which will control all front lighting. Feed the right-side of the amber clearance lights from the right-side parking light. Front Parking Lights 2. Construct the circuits for the front parking lights with red and black wires. In order for your circuit to match the manual schematic, feed the right-side parking light with power from relay #3. Rear Marker, Tail and License Plate Lights 3. Construct the circuits for the rear marker, taillights and license plate lights with red and black wires. In order for your circuit to match the manual schematic, feed the right-rear taillight with power from relay #4 which controls all rear lighting. Feed the right-side red marker lights from the right-side taillight. 4. Feed the trailer connecter from the right-side taillight. 5. Feed the license plate light from the 2nd from the left red marker light. Headlamp Switch 6. Use fuse F4 for the relay control circuits for both front and rear lighting. 7. Use the left-side of the headlamp switch for the front lights and the right-hand side of the headlamp switch for the rear lighting. Relays 8. Use relay #3 for the front lighting circuit. 9. Use relay #4 for the rear lighting circuit. 10. Use fuse F5 for the front lights. 11. Use fuse F6 for the rear lights. consulab.com info@consulab.com 64 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Advanced Level Verification 1. Confirm that all circuit wiring is correct and matches your schematic. 2. Turn ON trainer power supply and make sure BATTERY light is ON. 3. Turn ON the headlight switch to confirm proper operation of the Park, Tail and Marker lights circuit. 4. If circuit does not function correctly, go back over your work to find and correct any errors. 5. Get instructors verification that the circuit is operating normally. 6. Answer the circuit understanding questions below and put your answer on the Student Answer Sheet. Circuit Understanding Questions (Use the student answer sheet for your answers) 1. Explain what circuit problems would occur is there was an “open” in the wire from terminal #86 of relay #4 to the “P” terminal of the headlamp switch. 2. Explain what circuit problems would occur is fuse F4 was defective and electrically OPEN. 3. Explain what circuit problems would occur if the black wire was OPEN connected between terminal #85 of relay #4 and terminal #85 of relay #3. 4. What effect on the circuit would an open coil in relay #4 have? 5. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with no rear tail or marker lights. What specific components would you check to deter- mine the cause? 6. Answer the following: Based on a vehicle being wired exactly as the circuit you have just constructed on the trainer, a truck comes into the shop with only the right rear taillight ON, but no marker lights, license plate light or left-rear taillight on the rear of the cab and on the box. What specific components would you check to determine the cause? 7. You wish to have the trailer marker lights on a separate circuit from the truck cab lights, yet turned ON with the truck cab lights. Draw the required circuit using relay #4 (or any other open relay) and fuse F6 with the wires neces- sary to accomplish this goal. It is not necessary to draw all of the wires that were connected during the construction of the Tail, Park and Marker light circuit above. consulab.com info@consulab.com 65 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Advanced Level Parking, Tail and Marker Lights Circuit — Advanced Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. 4. consulab.com info@consulab.com 66 HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Advanced Level 5. 6. 7. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : consulab.com info@consulab.com 67 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Parking, Tail and Marker Lights Circuit — Advanced Level Parking, Tail and Marker Lights Circuit — Advanced Level — Student Assignment Schematic consulab.com info@consulab.com 68 HV-1918-2-95 Turn Signals and Hazard Circuit — Entry Level Turn Signals and Hazard Circuit — Entry Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding The turn signal and hazard circuits on most medium and heavy duty trucks can be operated regardless of ignition switch position. The HV-1918 does not utilize the ignition switch for this circuit. If the ignition switch was installed in the circuit, then the turn signal and hazard flasher circuits would only be able to be operated with the ignition switch ON. A typical truck turn signal and hazard circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Multi-function switch • Flasher • Front and rear turn signal lights • Rear stop lights • Stop light switch • Trailer plug Carefully follow the below instructions that will define how to properly construct the turn signal and hazard circuit. Be- cause of the internal design of the multi-function switch, power to the switch will be supplied without going through the ignition switch. This will allow both circuits to be operated regardless of the position of the ignition switch. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “TURN SIGNALS & HAZARD CIRCUIT” and submit the schematic when you turn in your Student Answer Sheet. 2. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. Circuit Construction Construct the turn signal and hazard circuit following the below instructions. Be sure to refer to the templates for the multi-function switch and the trailer plug connecter pin identification. consulab.com info@consulab.com 69 HV-1918-2-95 Turn Signals and Hazard Circuit — Entry Level Front Lights, Flasher and Indicator Lamps 1. Connect a red jumper wire from the red receptacle of fuse F6 to the BAT terminal of the flasher unit. 2. Connect a red jumper wire from the “SIG” terminal of the flasher unit to terminal #111 of the multi-function switch. 3. Connect a black jumper wire from the “GND” terminal of the flasher unit to any of the three black ground recepta- cles on the left-hand side of the middle Moduponent panel. 4. Connect a red jumper wire from the “BAT” terminal of the flasher unit to the right-hand yellow receptacle of the STOP LAMP SWITCH. 5. Connect a red jumper wire from the left-hand terminal of the STOP LAMP SWITCH to terminal #71 of the multi-func- tion switch. 6. Connect a red wire from terminal #113 of the multi-function switch to the “TS” terminal of the right-front park and turn light. 7. Connect a red jumper wire from terminal #112 of the multi-function switch to the “TS” terminal of the left-front park and turn light. 8. Connect a red jumper wire from terminal #112 of the multi-function switch to the red receptacle of the LEFT TURN indicator light. 9. Connect a red jumper wire from terminal #113 of the multi-function switch to the red receptacle of the RIGHT TURN indicator lamp. 10. Connect a black jumper wire from the black ground terminal of the right-front park and turn light to the black ground terminal of the left-hand park and turn light. 11. Connect a black jumper wire from the left-hand black ground terminal of the left-front park and turn light to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. 12. Connect a black jumper wire from the black receptacle of the RIGHT TURN indicator lamp to the black receptacle of the LEFT TURN indicator lamp. 13. Connect a black jumper wire from the black receptacle of the LEFT TURN indicator lamp to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Rear Lights and Trailer Plug 14. Connect a red jumper wire from terminal #116 of the multi-function switch to the “TS / S” terminal of the right-rear tail/turn and stop light. 15. Connect a red jumper wire from the “TS / S” terminal of the right-rear tail/turn and stop light to terminal #3 of the trailer connecter. 16. Connect a red jumper wire from terminal #115 of the multi-function switch to the “TS / S” terminal of the left-rear tail/turn and stop light. 17. Connect a red jumper wire from the “TS / S” terminal of the left-rear tail/turn and stop light to terminal #5 of the trailer connector. 18. Connect a red jumper wire from terminal #71 of the multi-function switch to terminal #4 of the trailer connecter. 19. Connect a black jumper wire from terminal #1 of the trailer plug to the “GND” terminal of the right-rear tail/turn and stop light. consulab.com info@consulab.com 70 HV-1918-2-95 Turn Signals and Hazard Circuit — Entry Level 20. Connect a black jumper wire from the “GND” terminal of the right-rear tail/turn and stop light to the “GND” terminal of the left-rear tail/turn and stop lamp. 21. Connect a black jumper wire from the “GND” terminal of the left-rear tail/turn and stop light to any of the four black ground receptacles on the left-hand side of the bottom Moduponent panel. 22. Connect a black jumper wire from any of the four ground receptacles on the left-hand side of the bottom Modupo- nent panel to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Circuit Confirmation 23. Recheck all circuit connections to make sure they are correct. 24. Make sure you have drawn the circuit you have constructed on the Student Answer Sheet. 25. Confirm that the trainers power supply is turned ON and the BATTERY lamp is ON. 26. Move the multi-function lever UP to turn ON the right turn signals. The right-front turn, right-rear turn/stop and the right turn indicator lamp should all be flashing. 27. Move the multi-function lever DOWN to turn ON the left turn signals. The left-front turn, left-rear turn/stop and the left turn indicator lamp should all be flashing. 28. Pull out on the HAZARD lever on the multi-function switch. All front turn, rear turn/stop and both turn indicators should be flashing. 29. Push the STOP LAMP SWITCH in and the rear turn/stop lights should come ON. 30. Confirm that the trailer plug has been correctly wired by using either a trailer plug tester or a voltmeter or 12 volt test light. 31. If the circuit does not function correctly, go back over your connections until you find and correct the errors. 32. Obtain verification from your instructor. 33. Answer the CIRCUIT UNDERSTANDING QUESTIONS below and put your answers on the Student Answer Sheet. 34. Turn in your wiring schematic and Student Answer Sheet for this circuit. Circuit Understanding Questions 1. What terminal of the multi-function switch supplies power to the left-front turn light? 2. What terminal of the trailer plug is for the right turn circuit? 3. What terminal of the multi-function switch is for power to enter the switch? 4. What is pin #1 of the trailer plug used for? 5. What is terminal #115 of the multi-function switch used for? 6. What would an open circuit in the black wire connecting the left-rear tail/turn and stop light to the black ground receptacles on the bottom Moduponent panel cause? consulab.com info@consulab.com 71 HV-1918-2-95 Turn Signals and Hazard Circuit — Entry Level Turn Signals and Hazard Circuit — Entry Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. 4. 5. 6. Instructor grade : Comments : consulab.com info@consulab.com 72 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Turn Signals and Hazard Circuit — Entry Level Turn Signals and Hazard Circuit — Entry Level — Student Assignment Schematic consulab.com info@consulab.com 73 HV-1918-2-95 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. Circuit Understanding The turn signal and hazard circuits on most medium and heavy duty trucks can be operated regardless of ignition switch position. The HV-1918 does not utilize the ignition switch for this circuit. If the ignition switch was installed in the circuit, then the turn signal and hazard flasher circuits would only be able to be operated with the ignition switch ON. A typical truck turn signal and hazard circuit normally consists of: • Power supply (battery) • Overcurrent protection (fuses) • Wiring for power and ground circuits • Multi-function switch • Flasher • Front and rear turn signal lights • Rear stop lights • Stop light switch • Trailer plug Carefully follow the below instructions that will define how to properly construct the turn signal and hazard circuit. Be- cause of the internal design of the multi-function switch, power to the switch will be supplied without going through the ignition switch. This will allow both circuits to be operated regardless of the position of the ignition switch. 1. As you complete each step of the below circuit construction steps, draw the jumper wire connection that you make during each step on the template labeled: “TURN SIGNALS & HAZARD CIRCUIT” and submit the schematic when you turn in your Student Answer Sheet. 2. More than one jumper wire can be attached to the same receptacle by “stacking” them on top of each other. consulab.com info@consulab.com 74 HV-1918-2-95 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Circuit Construction Construct the turn signal and hazard circuit following the below instructions. Be sure to refer to the templates for the multi-function switch and the trailer plug connecter pin identification. Front Lights, Flasher and Indicator Lamps 1. Use fuse F6 for the power supply for the turn signal and hazard circuit. 2. The terminal identification of the flasher unit is “GND” for ground, “BAT” for power and “SIG” for the lighting circuits. 3. To assure that your circuit is similar to the instructor’s answer key schematic, use the left-hand side of the front and rear park, turn and stop lights for the ground connections to the system ground. 4. No relays or ignition switch is used in this circuit. Rear Lights and Trailer Plug 5. Be sure to follow the pin identification of the trailer plug for correct circuit construction. 6. Be sure to include the left and right turn indicators in the wiring of this circuit. Circuit Confirmation 7. Recheck all of your circuit connections to make sure they are correct. 8. Make sure you have drawn the circuit on the TURN SIGNALS AND HAZARD LIGHTS circuit template as you construct- ed the circuit on the trainer. 9. Confirm that the trainers power supply is turned ON and the BATTERY lamp is ON. 10. Operate the STOP LAMP SWITCH and the MULTI-FUNCTION SWITCH through all circuits including: left-turn, right turn, hazard flashers, stop lights, left & right turn indicators, and the trailer plug for correct connections and opera- tion. 11. If any portion of the circuit does not operate correctly, go back over your connections to correct the errors. 12. Obtain instructor verification that the circuit operates correctly. 13. Answer the CIRCUIT UNDERSTANDING QUESTIONS below. 14. After answering the circuit understanding questions, make sure the answer sheet is completed filled out and the circuit schematic is completed. 15. Turn in your schematic and answer sheet to your instructor for credit. consulab.com info@consulab.com 75 HV-1918-2-95 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Circuit Understanding Questions 1. What terminal of the multi-function switch supplies power to the left-front turn light? 2. What terminal of the trailer plug is for the right turn circuit? 3. What terminal of the multi-function switch is for power to enter the switch? 4. What is pin #1 of the trailer plug used for? 5. What is terminal #115 of the multi-function switch used for? 6. What would an open circuit in the black wire connecting the left-rear tail/turn and stop light to the black ground receptacles on the bottom Moduponent panel cause? 7. If you wished to install relays for the trailer turn signal and stop lights to have power feed circuits separate than what the truck cab uses, describe the connections you would have to make to relay #1 and #2 for the turn signals and relay #3 for the stop lights to correctly construct this circuit. Draw the connections on a blank template. It is not necessary to re-draw the wires that were previously connected to make the turn signals and hazard circuit work. Just draw the“new” needed wires to make this circuit function. Use the separate schematic template titled “TURN SIGNALS & HAZARD FLASHER STUDENT QUESTION #7 ANSWER SHEET for your answer to question #7. consulab.com info@consulab.com 76 HV-1918-2-95 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level — Student Answer Sheet Name : Group : Date : Verification of Circuit Operating Properly — Instructor’s Initials 1. 2. 3. 4. 5. 6. consulab.com info@consulab.com 77 HV-1918-2-95 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level 7. HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : consulab.com info@consulab.com 78 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level Turn Signals, Hazard & Brake Lights — Advanced Level — Student Assignment Schematic consulab.com info@consulab.com 79 HV-1918-2-95 Auxiliary Circuits Auxiliary Circuits The HV-1918 trainer is equipped with auxiliary circuits that can be constructed as needed. Among them are: 1- Parking Brake Indicator lamp and switch, Backup light and switch and Auxiliary Switch. These components can be utilized in a number of different scenarios to design custom circuits for students to learn with. This assignment will allow students to construct three common circuits for the learning experience, but instructors can design additional circuits and compo- nent options based on their needs. Because of the simplicity of these circuits and components, student assignments will be designed at one competence level instead of the normal ENTRY and ADVANCED levels. Parking Brake Indicator Circuit Circuit Understanding Most heavy vehicles are equipped with a parking brake indicator circuit that is designed to warn the driver that the parking brake is applied. Components needed are: • Power supply (battery) • Overcurrent protection (fuses) • Switch • Indicator lamp • Power and ground wiring Circuit Construction 1. Connect a red jumper wire from the red receptacle of any of the top six (6) fuses to the right-hand yellow receptacle of the PARKING BRAKE SWITCH. 2. Connect a red jumper wire from the yellow left-hand receptacle of the PARKING BRAKE SWITCH to the red recepta- cle of the PARKING BRAKE LIGHT. 3. Connect a black jumper wire from the black receptacle of the PARKING BRAKE LIGHT to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. consulab.com info@consulab.com 80 HV-1918-2-95 Auxiliary Circuits Circuit Confirmation 4. Confirm that the trainers’ power supply is turned ON the BATTERY light is ON. 5. Turn the PARKING BRAKE SWITCH ON and the PARKING BRAKE LIGHT should illuminate. 6. Recheck your connections if the circuit does not perform properly. 7. Answer the circuit understanding questions below. Put your answers on the Student Answer Sheet. Circuit Understanding Questions 1. What would be the effect on the circuit of a shorted parking brake switch? 2. What would be the effect on the circuit of an open ground wire in the Parking Brake indicator light? Auxiliary Circuit Circuit Understanding The auxiliary circuit can be used for many different applications on a vehicle. In this case, the circuit in this assignment will operate a relay that will provide power to the truck’s trailer on the AUXILIARY terminal of the trailer connector. This could be used for applying an auxiliary tag axle or a 12 volt power source. This circuit will be controlled by the IGNITION switch when it is turned ON. Components needed are: • Power supply (battery) • Overcurrent protection (fuses) • Auxiliary switch • Ignition switch • Relay • Trailer connecter • Power and ground wiring Circuit Construction 1. Connect a red jumper wire from the red receptacle of any of the top six (6) fuses to the BAT receptacle of the IGNI- TION switch. 2. Connect a red jumper wire from the IGN terminal of the IGNITION switch to the right-hand receptacle of the AUXILIA- RY switch. 3. Connect a red jumper wire from the left-hand yellow receptacle of the AUXILIARY switch to terminal #86 of any of the four relays (#1 to #4) 4. Connect a black jumper wire from terminal #85 of the relay to any of the three black ground receptacles on the left- hand side of the middle Moduponent panel. consulab.com info@consulab.com 81 HV-1918-2-95 Auxiliary Circuits 5. Connect a red jumper wire from the left-hand yellow receptacle of another fuse (other than the one used for step #1) to terminal #30 of the relay. 6. Connect a red jumper wire from terminal #87 of the relay to terminal #7 of the trailer connecter. 7. Connect a black jumper wire from terminal #1 of the trailer connecter to any of the three black ground receptacles on the left-hand side of the middle Moduponent panel. Circuit Confirmation 8. Confirm that the trainers’ power supply is turned ON and the BATTERY light is ON. 9. Turn the AUXILIARY switch ON, the relay should turn ON and power should be available to terminal #7 of the trailer connecter. 10. There should also be a ground circuit at terminal #1 of the trailer connecter. 11. If the circuit does not function correctly, go back over your connections and identify and correct any errors. 12. NOTE: An alternative method of checking this circuit is to connect terminals #7 (pos) and #1 (neg) of the trailer con- necter to the BACK UP light on the lower panel. The light would come ON when the relay was turned ON. An trailer plug tester, 12 volt test light or DMM (digital multi-meter) can also be used. 13. Answer the circuit understanding questions below and put your answers on the Student Answer Sheet. Circuit Understanding Questions 1. What would the effect be on the circuit if the two terminals of the AUXILIARY switch were shorted together without touching ground? 2. What would be the effect be on the circuit if the ground circuit at the trailer terminal #1 were open? 3. The contacts of the relay terminals #30 and #87A are fused together. What circuit impact would this condition have? 4. The fuse that feeds terminal #86 of the relay is open. What circuit impact would that have? 5. The relay does not turn ON when the AUXILIARY switch is turned ON. What points would you test to identify the cause of this problem? consulab.com info@consulab.com 82 HV-1918-2-95 Auxiliary Circuits Auxiliary Circuits — Student Answer Sheet Name : Group : Date : Confirmation of correct parking brake indicator circuit operation Confirmation of correct auxiliary circuit w/ relay circuit operation Parking Brake Light Circuit 1. 2. Auxiliary Circuit 1. 2. 3. 4. 5. Instructor grade : Comments : consulab.com info@consulab.com 83 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 Auxiliary Circuits Auxiliary Circuits — Student Assignment Schematic consulab.com info@consulab.com 84 HV-1918-2-95 Additional Assignments Additional Assignments consulab.com info@consulab.com 85 HV-1918-2-95 HV-1918 Whole Trainer Wiring HV-1918 Whole Trainer Wiring This student assignment will give instructions on the circuit connections necessary for operation of the entire trainer. As has been previously mentioned, there are many different correct variations of how the trainer could be wired and have it function normally. It is not the intention of this manual to cover all of the circuit variations. Instructors can custom design various other circuit construction and designs to suit their specific needs. This assignment will be organized into the wiring of the trainer from the top down with the top front cab marker light bar first, then the Moduponent panel, then the middle panel and finally the lower panel. Because of the number of wires involved, it is extremely important that students carefully read, follow and understand EACH circuit connection. Confirm that you are working on the correct side (either left or right) that the instructions are describing. This assignment is also designed to teach students the importance of following written instructions which is an acknowledged requirement in the repair trades. This assignment will use the “positive switched” design of headlight circuit. Carefully follow the below instructions to construct all of the circuits on the trainer. When completed, submit your Student Answer Sheet to your instructor for circuit verification. Front Cab Marker Lights Panel (HV-1918-08) Ground Circuits (use black jumper wires for all below connections): 1. Connect all black receptacles of five marker lights together with four jumper wires. 2. Right-side marker light black receptacle to black receptacle of right-side side marker light on top Moduponent panel (HV-1918-01) Positive Circuits (use red jumper wires for all below connections): 3. Connect all red receptacles of five marker lights together with four jumper wires. 4. Right-side marker light red receptacle to red receptacle of right-side side marker light on top Moduponent panel (HV-1918-01) consulab.com info@consulab.com 86 HV-1918-2-95 HV-1918 Whole Trainer Wiring Top Moduponent Panel (HV-1918-01) Ground Circuits (use black jumper wires for all below connections): Right Side 5. Headlight ” COM” receptacle to black receptacle of side marker light. 6. Black receptacle of side marker light to black “GND” receptacle on park light. 7. Headlight “COM” receptacle to any of the four black ground receptacles on left side of Moduponent panel. Left Side 8. Headlight “COM” receptacle to black receptacle of side marker light. 9. Black receptacle of side marker light to black “GND” receptacle on park light 10. Headlight “COM” receptacle to any of the four black ground receptacles on the left-side of Moduponent panel. 11. Any of the four black ground receptacles to any of the three black ground receptacles on the middle Moduponent panel. Positive Circuits (use red jumper wires for all below connections): Right Side 12. Side marker light red receptacle to red park light “P” receptacle. 13. Side marker light red receptacle to terminal #87 of relay #3. 14. Right side red “P” receptacle of park light to left side red “P” receptacle of park light. 15. Red “HIGH” beam headlight receptacle to terminal #87 of relay #2. 16. Red “LOW” beam headlight receptacle to terminal #87A of relay #2. 17. Park light red “T/S” receptacle to terminal #113 of multi-function switch. Left Side 18. Red receptacle of side marker light to park light red “P” receptacle. 19. Red “P” receptacle of park light to terminal #87 of relay #3. 20. “HIGH” beam headlight receptacle to terminal #87 of relay #1. 21. “LOW” beam headlight receptacle to terminal #87A of relay #1. 22. Park light red “T/S” receptacle to terminal #112 of multi-function switch. Middle Moduponent Panel (HV-1918-02) Ground Circuits (use black jumper wires for all below connections): 23. Terminal #85 of relay #3 to terminal #85 of relay #2. 24. Terminal #85 of relay #2 to terminal #85 of relay 1. consulab.com info@consulab.com 87 HV-1918-2-95 HV-1918 Whole Trainer Wiring 25. Terminal #85 of relay #1 to any of the three black ground receptacles on the left-side of the middle Moduponent panel. 26. “GND” receptacle of the turn signal flasher to any of the three black ground receptacles of the middle Moduponent panel. 27. Black receptacle of the right-turn indicator to the black receptacle of the high-beam indicator. 28. Black receptacle of the high-beam indicator to the black receptacle of the parking brake light. 29. Black receptacle of the parking brake light to the black receptacle of the left-turn indicator. 30. Black receptacle of the left-turn indicator to any of the three black ground receptacles of the middle Moduponent panel. 31. Black receptacle of any three ground receptacles of the middle Moduponent panel to any of the four black ground receptacles of the bottom Moduponent panel. Positive Circuits (use red jumper wires for all below connections): 32. Red receptacle of fuse F1 to the right-hand “BAT” receptacle of headlamp switch. 33. Left-hand “BAT” receptacle of headlamp switch to right-hand “BAT” receptacle of headlamp switch. 34. Left-hand “BAT” receptacle of headlamp switch to the right-hand yellow receptacle of the stop lamp switch. 35. Right-hand “BAT” receptacle of the headlamp switch to the right-hand yellow receptacle of the parking brake switch. 36. Left-hand “H” receptacle of headlamp switch to terminal #30 of relay #1. 37. Right-hand “H” receptacle of headlamp switch to terminal #30 of relay #2. 38. Right-hand “H” receptacle of headlamp switch to terminal #31 of multi-function switch. 39. Left-hand “P” receptacle of headlamp switch to terminal #87 of relay #3. 40. Terminal #33A of the multi-function switch to the red receptacle of the high-beam indicator lamp. 41. Terminal #33A of the multi-function switch to terminal #86 of relay #2. 42. Terminal #86 of relay #1 to terminal #86 of relay #2. 43. Terminal #86 of relay #3 to terminal #30 of relay #2. 44. Terminal #30 of relay #3 to the red receptacle of fuse F2. 45. Terminal #87 of relay #3 to the red receptacle of the right-hand rear marker light on the lower Moduponent panel. 46. Red receptacle of fuse F3 to the “BAT” receptacle of the ignition switch. 47. Red receptacle of fuse F4 to the red “BAT” receptacle of the turn signal flasher. 48. Yellow “SIG” receptacle of the turn signal flasher to terminal #111 of the multi-function switch. 49. Yellow “IGN” receptacle of the ignition switch to the right-hand yellow receptacle of the backup light switch. 50. Left-hand yellow receptacle of the stop lamp switch to terminal #71 of the multi-function switch. 51. Left-hand yellow receptacle of the backup light switch to the red receptacle of the backup light on lower Modupo- nent panel. 52. Left-hand yellow receptacle of the parking brake lamp switch to the right-hand yellow receptacle of the parking brake light. 53. Right-hand yellow receptacle of the parking brake lamp switch to the right-hand yellow receptacle of the stop lamp switch. consulab.com info@consulab.com 88 HV-1918-2-95 HV-1918 Whole Trainer Wiring 54. Right-hand yellow receptacle of the right turn indicator lamp to terminal #113 of the multi-function switch. 55. Right-hand yellow receptacle of the left turn indicator lamp to terminal #112 of the multi-function switch. 56. Terminal #115 of the multi-function switch to the red “T/S” receptacle of the left-rear tail/stop and turn light on the lower Moduponent panel. 57. Terminal #71 of the multi-function switch to terminal #4 of the trailer connecter on the lower Moduponent panel. 58. Terminal #116 of the multi-function switch to the red “T/S” receptacle of the right-rear tail/stop and turn light on the lower Moduponent panel. Lower Moduponent Panel (HV-1918-03) Ground Circuits (use black jumper wires for all below connections): 59. Black receptacle of left-hand rear marker light to black receptacle of license plate light. 60. Black receptacle of left-hand rear marker light to black receptacle of the 2nd from the left rear marker light.. 61. Black receptacle of the 2nd from the left rear marker light to the black receptacle of the 3rd from the left rear marker light. 62. Black receptacle of the 3rd from the left rear marker light to the black receptacle of the backup light. 63. Black receptacle of the 3rd from the left rear marker light to the black receptacle of the 4th from the left rear mark- er light. 64. Black receptacle of the 4th from the left rear marker light to the black receptacle of the right rear marker light. 65. Black receptacle of the right-rear marker light to black receptacle of the right-rear tail/stop and turn light. 66. Black receptacle of the right-rear tail/stop and turn light to any of the four black ground receptacles on the left- hand side of the lower Moduponent panel. 67. Black receptacle of the left-rear tail/stop and turn light to any of the four black ground receptacles on the left-hand side of the lower Moduponent panel. 68. Terminal #1 of the trailer connecter plug to any of the four black ground receptacles on the left-hand side of the lower Moduponent panel. Positive Circuits (use red jumper wires for all below connections): 69. Red receptacle of the left-rear marker light to the red receptacle of the 2nd from left rear marker light. 70. Red receptacle of the 2nd from left rear marker light to the red receptacle of the 3rd from the left rear marker light. 71. Red receptacle of the 3rd from the left rear marker light to the red receptacle of the 4th from the left rear marker light. 72. Red receptacle of the 4th from the left rear marker light to the red receptacle of the right-hand rear marker light. 73. Red receptacle of the 2nd from the left rear marker light to the red receptacle of the license plate light. 74. Red receptacle of the left-hand rear marker light to the “P” terminal of the left-rear tail/stop and turn light. 75. Red receptacle of the right-hand rear marker light to terminal “P” of the right-rear tail/stop and turn light. 76. Red “T/S” receptacle of the right rear tail/stop and turn light to terminal #3 of the trailer plug connecter. 77. Red “T/S” receptacle of the left-rear tail/stop and turn light to terminal #5 of the trailer plug connecter. consulab.com info@consulab.com 89 HV-1918-2-95 HV-1918 Whole Trainer Wiring 78. Terminal #2 of the trailer connecter to terminal #6 of the trailer connecter. 79. Terminal #2 of the trailer connecter to the red “P” receptacle of the right-rear tail/stop and turn light. 80. With instructor’s permission and for extra credit, construct a circuit that supplies a separate protected 12V power through a relay controlled by the auxiliary switch to terminal #7 of the trailer connector. (no further instruc- tions will be given to construct this circuit.) Use the knowledge you have acquired so far during the whole trainer circuit construction. Fill out separate Student Answer Sheet for the extra credit assignment. Confirmation of Circuit Operation 81. Confirm that the trainers’ power supply is plugged in and the BATTERY light is ON. 82. Operate each circuit and confirm correct operation of all components. Park, Tail and Marker Lights Headlights (HIGH & LOW Beam & HIGH Beam Indicator) Back Up Light Turn Signals & Hazard Warning Lights (w/ Left & Right Indicators) Parking Brake Warning Light All Seven Terminals of the Trailer Connecter Plug Extra Credit Power Supply Circuit To Trailer Connecter 83. If any circuit does not operate correctly, identify and correct any wiring errors. 84. Turn in your Student Answer Sheet for instructor grading/credit. 85. If you completed the extra credit auxiliary circuit, also submit that answer sheet (schematic). consulab.com info@consulab.com 90 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 HV-1918 Whole Trainer Wiring Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic consulab.com info@consulab.com 91 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 HV-1918 Whole Trainer Wiring Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic consulab.com info@consulab.com 92 Circuit Name Date HV-1918-2 Level 1 Trainer Wiring Blank Template consulab.com info@consulab.com 1 Circuit Name Date Instructor grade : Comments : HV-1918-2-95 HV-1918 Whole Trainer Wiring Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic consulab.com info@consulab.com 93 HV-1918-2-95 Student Fault Identification Assignment Sheet Student Fault Identification Assignment Sheet ASSIGNMENT FAULT NUMBER : Name : Date : Circuit Description : Before proceeding, it is assumed that the following items have been completed and understood by students. A. All trainer components and terminal pins have been identified using either Method 1 or 2 covered previously. B. The HV-1918 properly assembled and setup. The power supply has been plugged into a 120VAC receptacle. 1. Begin with either the entire trainer wired or with the specific circuit you are assigned wired correctly. 2. Confirm that the circuit operates correctly. 3. Ask instructor to insert a fault(s). 4. Turn ON the master power switch and operate the assigned circuit. 5. Depending on your assignment, there may or may not be more than one fault in the trainer. If more than one, list each one separately. 6. Identify the malfunction(s) and describe in the space provided: Malfunction : 7. Determine and obtain what electrical test equipment you will need to properly diagnose the circuit problem. (DVOM’s, 12 volt test light, etc) 8. Obtain the correct wiring schematic for the circuit affected. 9. Using the schematic and your test equipment, begin to diagnose the problem. Often, an efficient method of circuit troubleshooting is using the schematic to test for the presence of voltage at various accessible points in the circuit. This is called “point-to-point” diagnosis. 10. When you have properly identified the point of the malfunction, describe what you think is the cause of the problem. consulab.com info@consulab.com 94 HV-1918-2-95 Student Fault Identification Assignment Sheet Diagnosis : 11. Submit your diagnosis to your instructor for credit. Instructor grade : Comments : consulab.com info@consulab.com 95 HV-1918-2-95 Student Study Questions Student Study Questions consulab.com info@consulab.com 96 HV-1918-2-95 Test 1 — General Electrical Diagnosis Test 1 — General Electrical Diagnosis Answer the below study questions and use a separate answer sheet for your answers. 1. A non-locking push button switch normally is a ? type of switch. A. SPDT B. N.C. C. N.O. D. DPDT 2. A toggle switch with two electrical terminals is normally a ? type of switch. A. SPDT B. N.C. C. N.O. D. DPDT 3. A turn signal switch normally has to have separate turn signal circuits for the front and rear because of the? A. Stop light circuit B. Left turn circuit C. Right turn circuit D. Hazard light circuit 4. Generally, which pin of a truck trailer connecter is for the ground circuit? A. 1 B. 4 C. 6 D. 7 5. How many total terminals are there on a typical ISO relay used on vehicles today? A. 2 B. 3 C. 7 D. 5 consulab.com info@consulab.com 97 HV-1918-2-95 Test 1 — General Electrical Diagnosis 6. A headlight has three terminals identified as: HIGH, LOW and COM. If the low beam headlight circuit is to be “ground switched”, what terminal of the headlight will be connected to 12V positive? A. HIGH beam B. COM C. LOW beam D. A jumper between LOW beam and COM 7. Normally all lighting circuits on most vehicles are connected in: A. Parallel B. Series C. Combination series/parallel D. None of the above 8. On a standard truck trailer connecter, the middle terminal of the plug is used for ? . A. Ground B. Left turn C. 12V for various applications D. Right turn 9. The parking brake indicator light is ON all the time. All of the below conditions could cause this symptom EXCEPT one. Which one would not be a cause of this condition ? A. Shorted parking brake switch B. Grounded positive feed wire to switch C. Ground side of switch is shorted to ground D. Parking brake switch always has continuity 10. What type of switch can we normally find on the brake pedal ? A. SPDT B. N.C C. N.O D. DPDT consulab.com info@consulab.com 98 HV-1918-2-95 Test 1 — General Electrical Diagnosis Student Answer Sheet Name : Group : Date : 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D Instructor grade : Comments : consulab.com info@consulab.com 99 HV-1918-2-95 Test 2 — Relays Test 2 — Relays Answer the below study questions and use a separate answer sheet for your answers. 1. What two terminals of an ISO relay are the two ends of the relay’s coil winding? A. 87A and 87 B. 30 and 87A C. 86 and 87A D. 85 and 86 2. What two terminals of an ISO relay are “normally closed” when the relay is OFF? A. 30 and 87A B. 87A and 87 C. 87 and 30 D. 30 and 86 3. When an ISO relay is turned ON, what two terminals are connected? A. 30 and 87A B. 87A and 87 C. 87 and 30 D. 30 and 86 4. Which terminal of an ISO relay is normally the ground for the coil winding? A. 30 B. 87 C. 86 D. 85 5. True or False If a relay “clicks”, it is known to be good. A. True B. False 6. To cause a relay to operate for testing purposes you connect jumper wires to: A. + 12V to terminal 86 and ground to terminal 85 B. + 12V to terminal 85 and ground to terminal 86 C. + 12V between terminals 85 and 86 D. + 12V between terminals 30 & 87A consulab.com info@consulab.com 100 HV-1918-2-95 Test 2 — Relays 7. What would an ohmmeter indicate if connected between terminals 30 and 87 with relay turned OFF? A. Continuity B. 20-70 ohms C. Infinity D. 1K – 4K ohms 8. +12V power is connected to terminals 30 and also to terminal 86 of an ISO relay. Terminal 85 is grounded. What other relay terminal will have +12 available to it? A. 86 B. 85 C. 87A D. 87 9. An easy method of testing a particular ISO relay is to ? . A. Test for coil resistance B. Test for voltage at all terminals C. Substitute with another identical ISO relay D. Test for voltage on terminals 86 & 85 10. +12V is applied to ISO relay terminal 86 and terminal 85 is grounded. A voltmeter connected to terminal 85 reads 12 volts. What does this reading indicate? A. Nothing, this is a normal reading B. It means the relay coil is open C. It means the connection between terminals 30 and 87 is open D. It means the ground circuit connected to terminal 85 is open consulab.com info@consulab.com 101 HV-1918-2-95 Test 2 — Relays Student Answer Sheet Name : Group : Date : 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D Instructor grade : Comments : consulab.com info@consulab.com 102 HV-1918-2-95 Test 3 — General Diagnosis Test 3 — General Diagnosis Answer the below study questions and use a separate answer sheet for your answers. 1. The headlight is dim. All of the below statements could be a cause of this symptom EXCEPT one. Which one would not cause this symptom? A. Voltage drop across the power and ground terminals. B. High resistance on the positive side of the headlight. C. High resistance on the ground side of the headlight. D. Voltage drop between the headlight ground terminal and vehicle ground. 2. A relay “clicks” but does not control the circuit. All of the below statements could be a cause of this symptom EX- CEPT one. Which one could not cause this symptom? A. No power on terminal #30 when relay is ON. B. No power on terminal #87 when relay is ON. C. Open in the relay coil. D. Defective relay contacts. 3. A 3-terminal headlight is connected in a “ground switched” circuit. The headlight switch is turned OFF. The alligator clip of a 12V test light is connected to a clean engine ground. How many terminals of the headlight will cause the test light to turn ON? A. 1 B. 2 C. 3 D. None 4. A voltmeter is connected between the ground terminal of a headlight and a clean engine ground. The headlight is turned ON. The voltmeter reads 185mv. Which of the below statements is true about this reading? A. There is high resistance in the ground circuit. B. There is high resistance in the positive circuit. C. There is an open in the ground circuit. D. This is a normal reading. Nothing is wrong. 5. An ignition switch is turned to the “ON” position, but there is no power on the IGN terminal. All of the below condi- tions EXCEPT one could be the cause this symptom. Which one could not cause this condition? A. A dead battery. B. An open inside the ignition switch between BAT and IGN terminals. C. No power on IGN terminal. D. No power on BAT terminal. consulab.com info@consulab.com 103 HV-1918-2-95 Test 3 — General Diagnosis 6. The left and right side headlights are on individual circuits each controlled by relays. The left side has a dim bulb on LOW beam. Which statement below is the MOST likely cause of this problem? A. A defective relay. B. High resistance in headlight switch. C. High resistance in the connecter to the right LOW beam terminal. D. A voltage drop between the left-hand headlight ground terminal and ground. 7. A 5 terminal ISO relay is being bench tested with an ohmmeter. All of the below ohmmeter readings are correct EXCEPT one. Which one is not correct? A. 50 ohms between terminals 85 and 86. B. 50 ohms between terminals 30 and 87A. C. O resistance between terminals 30 and 87A. D. Infinity between terminals 30 and 87. 8. A headlight circuit is ground switched and is controlled by a relay. Which statement below could be the cause of a “dim” headlight? A. High resistance between relay terminals 85 and 86. B. An open between relay terminals 30 and 87. C. High resistance between relay terminals 30 and 87. D. Bad ground on relay terminal 85. 9. The brake lights are inoperative. Which of the below causes is the LEAST likely to cause this symptom? A. Both brake light bulbs are open. B. Brake light switch is open. C. No power to brake light switch. D. Blown fuse to brake light switch. 10. A 5 terminal ISO relay installed in a vehicle is being tested with a voltmeter. The relay is switched ON. All of the be- low voltmeter readings are correct EXCEPT one. Which reading is not correct? A. 12 volts on both terminals 85 and 86. B. 12 volts between terminals 85 and 86. C. 12 volts on terminal 30. D. 0 volts between 87A and ground. consulab.com info@consulab.com 104 HV-1918-2-95 Test 3 — General Diagnosis Student Answer Sheet Name : Group : Date : 1. A B C D 2. A B C D 3. A B C D 4. A B C D 5. A B C D 6. A B C D 7. A B C D 8. A B C D 9. A B C D 10. A B C D Instructor grade : Comments : 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. General Description Educational Advantages Features Options Guidelines Warnings & Cautions Levels of Difficulty General Information Circuit Construction Wires: Connecting the power supply to the Moduponent™ panels HV-1918 Moduponent™ Panels Component Identification Multi-function Switch — Pin Identification Chart Trailer Connecter — Pin Identification Chart 5-Pin ISO Relay — Pin Identification Chart Student Assignments Student Learning Assignment Example & Instructions Example of a Simple Circuit Assignment Back Up Lights Backup Light Circuit — Student Assignment Schematic Ohm’s Law Experiments SA-1 — Series Circuit with One Resistance SA-1 — Student Answer Sheet SA-1 — Student Assignment Schematic SA-2 — Series Circuit with Two Resistances SA-2 — Student Answer Sheet SA-2 — Student Assignment Schematic SA-3 — Parallel Circuit with Two Resistances SA-3 — Student Answer Sheet SA-3 — Student Assignment Schematic Incandescent Light Bulb — Static and Dynamic Resistances Experiments Static and Dynamic Resistances Experiments — Student Answer Sheet Relay Controlled ON/OFF Circuit (Latched Relays) Relay Controlled ON/OFF Circuit (Latched Relays) — Student Assignment Schematic Headlights Circuit (Ground Switched) — Entry Level Headlights Circuit (Ground Switched) — Entry Level — Student Answer Sheet Headlights Circuit (Ground Switched) — Entry Level — Student Assignment Schematic Headlights Circuit (Ground Switched) — Advanced Level Headlights Circuit (Ground Switched) — Advanced Level — Student Answer Sheet Headlights Circuit (Ground Switched) — Advanced Level — Student Assignment Schematic Headlights Circuit (Positive Switched) — Entry Level Headlights Circuit (Positive Switched) — Entry Level — Student Answer Sheet Headlights Circuit (Positive Switched) — Entry Level — Student Assignment Schematic Headlights Circuit (Positive Switched) — Advanced Level Headlights Circuit (Positive Switched) — Advanced Level — Student Answer Sheet Headlights Circuit (Positive Switched) — Advanced Level — Student Assignment Schematic Parking, Tail and Marker Lights Circuit — Entry Level Parking, Tail and Marker Lights Circuit — Entry Level — Student Answer Sheet Parking, Tail and Marker Lights Circuit — Entry Level — Student Assignment Schematic Parking, Tail and Marker Lights Circuit — Advanced Level Parking, Tail and Marker Lights Circuit — Advanced Level — Student Answer Sheet Parking, Tail and Marker Lights Circuit — Advanced Level — Student Assignment Schematic Turn Signals and Hazard Circuit — Entry Level Turn Signals and Hazard Circuit — Entry Level — Student Answer Sheet Turn Signals and Hazard Circuit — Entry Level — Student Assignment Schematic Turn Signals, Hazard & Brake Lights to Trailer Connector Advanced Level Turn Signals, Hazard & Brake Lights to Trailer Connector — Advanced Level — Student Answer Sheet Turn Signals, Hazard & Brake Lights — Advanced Level — Student Assignment Schematic Auxiliary Circuits Auxiliary Circuits — Student Answer Sheet Auxiliary Circuits — Student Assignment Schematic Additional Assignments HV-1918 Whole Trainer Wiring Whole Trainer Wiring - Ground Circuits — Student Assignment Schematic Whole Trainer Wiring - Positive Circuits — Student Assignment Schematic Auxiliary 12V Feed Circuit to Trailer Connecter — Student Assignment Schematic Student Fault Identification Assignment Sheet Student Study Questions Test 1 — General Electrical Diagnosis Student Answer Sheet Test 2 — Relays Student Answer Sheet Test 3 — General Diagnosis Student Answer Sheet

Unpacking and Setup Instructions for 1918 Series (CL-HV-MP) Automotive Lighting System Trainers 1918 Series_Unpacking and Setup_V2024-2 © ConsuLab Educatech Inc, 2024. All rights reserved. 1918 Series (CL-HV-MP) Unpacking and Setup Instructions consulab.com info@consulab.com 2 Unpacking and Setup Instructions Thank you for purchasing one of the 1918 Series lighting trainers. We hope that you enjoy this product and find it very useful for the training of students in the design, operation, diagnosis, and repair of automotive lighting circuits. Please carefully follow the below instructions for unpacking and setup of this trainer. After initial unpacking and set-up, refer to the following instructions for trainer use. 1. UNPACKING • Please carefully examine the shipping pallet and all boxes for signs of shipment damage. If any damage is noticed, please take pictures, and send to support@consulab.com to report any abnormal conditions noticed. • Carefully remove any shrink wrap, tie-downs or other shipping materials attaching the trainers frame and boxes to the pallet. • Set the trainers frame on the floor. Notice that all four casters are the swivel design and can be locked at desired location. mailto:support@consulab.com 1918 Series (CL-HV-MP) Unpacking and Setup Instructions consulab.com info@consulab.com 3 2. SETUP • ConsuLab identifies these panels as Moduponents™. The three Moduponents™ are identified with embossed yellow letters located on the upper left corner of each panel. • The correct Moduponent™ identifications are: - CL-1918-01A, HV-1918-01A or MP-1918-01A for the front vehicle lighting panel - CL-1918-02A, HV-1918-02A or MP-1918-02A for the instrument panel - CL-1918-03A, HV-1918-03A or MP-1918-03A for the rear vehicle lighting panel. • Insert the three panels into the frame in the following order: CL/HV/MP-1918-03A (bottom) CL/HV/MP-1918-02A (middle) CL/HV/MP-1918-01A (top) IMPORTANT – Notice that the middle and top Moduponents™ of 1918 trainers have a multi-connector electrical plug that must be connected after the Moduponents™ are installed in the frame. Access the two connecters from behind the Moduponents™ Notice the polarity positioning method and connect the two plugs together making sure that they are fully engaged. MODUPONENT™ ID NUMBER SERIAL NUMBER DIGITS HV-1918 CL-1918 MP-1918 top middle bottom top middle bottom 1918 Series (CL-HV-MP) Unpacking and Setup Instructions consulab.com info@consulab.com 4 • Notice that there is a storage drawer on each side of the trainer’s frame. The drawer is lockable and the keys for the drawer, the ignition switch and the trainers fault box are be attached to one of the black plastic Moduponent™ clips. Locate the keys and open the storage drawer. There are three sets of two keys each for the following: - Two (2) ignition switch keys (A) - Two (2) fault box keys (B) - Two (2) storage drawer keys (A). • If you purchased a “double-sided” trainer, each drawer will have supplies for that side of the trainer. If you purchased a single side trainer, one drawer will be empty. The contents of the drawer are as follows: CL-1918 HV-1918 MP-1918 • 6 Long red test leads - 19 A (1 m - 39.4 in) • 8 Long black test leads - 19 A (1 m - 39.4 in) • 50 Short red test leads - 19 A (50 cm - 19.7 in) • 25 Short black test leads - 19 A (50 cm - 19.7 in) • 1 Trainer power cord • 1 Test lead holder & small hardware package • 6 Long red test leads - 19 A (1 m - 39.4 in) • 8 Long black test leads - 19 A (1 m - 39.4 in) • 50 Short red test leads - 19 A (50 cm - 19.7 in) • 25 Short black test leads - 19 A (50 cm - 19.7 in) • 1 Trainer power cord • 1 Test lead holder & small hardware package • 1 Long red test leads - 19 A (1 m - 39.4 in) • 21 Long black test leads - 19 A (1 m - 39.4 in) • 25 Short red test leads - 19 A (75 cm - 29.5 in) • 8 Short green test leads - 19 A (50 cm - 19.7 in) • 8 Short yellow test leads - 19 A (50 cm - 19.7 in) • 1 Trainer power cord • 1 Test lead holder & small hardware package • Attach the two blue metal test lead holder to one side of the trainer frame at the top as shown. Use screws and washers. • Distribute the test leads into the lead holders. B A 1918 Series (CL-HV-MP) Unpacking and Setup Instructions consulab.com info@consulab.com 5 • Once the power supply’s power cord is plugged into a 120V receptacle, the power supply is turned on/off with a red rocket switch located on the right-side of the power supply. The power supply is internally protected from short-circuits. The power supply is equipped with an ammeter and voltmeter. Meters will display system current and voltage as trainer is used. There will be a separate power supply for each side of a double-sided trainer (if equipped) WARNING: The power supply should NEVER be used as a battery charger due to potential serious component damage and the voiding of the warranty. The power supply is specifically designed ONLY to supply a DC power source for our trainers. Connecting the Power Supply to the Moduponent™ Panels Before the CL/HV/MP-1918-02A (middle panel) is mounted to the frame, notice that there is a black two wire terminal block mounted inside on one side of the frame. A black and a red wire is attached to the terminal block using friction tabs which are also connected to the power supply. A flat tip screwdriver of the proper size is used to push in on each friction tab to either insert or remove a wire. Locate the red and black wires coming from the back side of the middle panel and properly connect them to the terminal block. When the middle panel’s red and black wires are properly connected to the power supply terminal block and when the power supply is turned on, the RED power indicator light on the middle panel should illuminate. NOTE : Confirm that the trainer’s power cord is plugged into a receptacle. NOTE : It is normal for the power indicator light to stay on for a few seconds after power supply is switched off. • The student assignments and instructors manuals are available on our website as download- able PDF files. • You have now unpacked and set up the CL-1918-3 trainer. Please make note of any damage, missing parts or other conditions and contact call Support @ 1-800-567-0791 for customer service or support@consulab.com. CL-1918-4S_053304-93 Trainer Use and Familiarization consulab.com info@consulab.com 4 Release tabs PUSH IN Push to release and attach When the middle panel’s red and black wires are properly connected to the power supply terminal block and when the power supply is turned on, the RED power indicator light on the middle panel should illuminate. NOTE : Confirm that the trainer’s power cord is plugged into a receptacle. NOTE : It is normal for the power indicator light to stay on for a few seconds after power supply is switched off. Circuit Construction Wires: There are black and red jumper wires of different lengths used for students constructing various circuits on the trainer. The ends of the jumper wires are equipped with terminal plugs that allow them to be “stacked” on top of each other which allows more than one wire to be connected to the same receptacle. When stacking jumper wires, try to avoid using more than 3-4 at one connection point. Fuse Section : The trainer is equipped with a fuse section consisting of eight fuses of different amperages. The top three fuses are pow- ered from a common bus connected to the power supply. The other five fuses must be powered with jumper wires. (see fuse box details) ALWAYS connect all circuits through a fuse. FUSE PANEL INFORMATION MUST BE FED FROM B+ FEED EX.: IGN SWITCH F1 - F3 HOT AT ALL TIMES F4 - F8 CKT’S TO BE SWITCHED WITH B+ GND BAT 1ACOM COM 1A GND SIG BAT MAIN PWR 25A PWR RLY 5A CL-1918-02A_053317 REVB BRAKE SWITCH BACK-UP SWITCH HORN BREAKER 0.5A HORN BUTTON HAZARD FLASHER TURN SIGNAL FLASHER GND SIG BAT 10A OFF LEFT INDICATOR HIGH BEAM INDICATOR RIGHT INDICATOR MULTIFUNCTION SWITCH SIG RIGHTLEFTHEADPARKFLASHHIGHLOW DIMMER LIGHTS TURN IGNITION SWITCH CANCEL LEVER LEFT RIGHTGND SIG HAZARD SWITCH RELAY 3 RELAY 4 87A 30 8685 87A87 30 87 8685 BAT ACC IGN START F1 F2 F3 F4 F5 F6 F7 F8 10A 10A 10A 10A 20A 15A 5A F9 MAIN POWER PROTECTION FUSE 25A F10 POWER RELAY PROTECTION mailto:support@consulab.com

Operation manual for EM-122-HN02_052621 Disc & drum ABS brake trainer + faults Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 93-EM-122-HN02_REVB © ConsuLab Educatech Inc, 2025. All rights reserved. https://www.consulab.com/customer-space 93-EM-122-HN02 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 Table of Contents Teacher Resources 4 EM-122-HN02-95 Student Assignments — Table of contents 4 EM-122-HN02-91 Answer Key — Table of contents 4 EM-122-HN02-96 Instructors Manual — Table of contents 4 Product Description 5 Educational Advantages 6 Infrastructure Requirements 6 Unpacking instructions 7 Support Contact Information 7 Instructions 8 Casters 8 DC Power supply 8 DLC Connector 8 VIN 8 Front panel component indentification 9 ABS module breakout box pin identification 10 Pre-operation checks 11 Operating instructions 11 Maintenance instructions 14 Consumable Parts and Replacement Parts 14 EM-122-HN02 Wiring Schematic 15 © 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. The content of this manual is applicable to models 052621 and above. consulab.com info@consulab.com 4 93-EM-122-HN02 Teacher Resources Teacher Resources We have included the table of contents from three other manuals in this operation manual. This serves as a reference to make you aware of all the documentation that comes with the product. 95-EM-122-HN02 Student Assignments — 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. The content of this manual is applicable to models 052621 and above. EM-122-HN02-95_V2025-1 Table of contents Table des matières Introduction 3 EM-122-HN02 Wiring Schematic 5 Student assignments 6 SA1 - Student activity #1 7 SA2 - Student activity #2 11 SA2-A - Student activity #2-A 16 SA2-B - Student activity #2-B 18 SA2-C - Student activity #2-C 19 SA3 - Student activity #3 20 SA3-A - Student activity #3-A 25 SA3-B - Student activity #3-B 27 SA4 - Student activity #4 28 SA5 - Student activity ABS 1 30 SA5 - Student activity ABS 2 31 SA5 - Student activity ABS 3 32 SA5 - Student activity ABS 4 33 SA5 - Student activity ABS 5 34 SA5 - Student activity ABS 6 35 91-EM-122-HN02 Answer Key — 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. The content of this manual is applicable to models 052621 and above. EM-122-HN02-91_V2025-1 Table of contents Table des matières Introduction 3 EM-122-HN02 Wiring Schematic 5 Student assignments Answers 6 SA1 - Student activity #1 Answers 7 SA2 - Student activity #2 Answers 11 SA2-A - Student activity #2-A Answers 16 SA2-B - Student activity #2-B 18 SA2-C - Student activity #2-C Answers 19 SA3 - Student activity #3 20 SA3-A - Student activity #3-A Answers 25 SA3-B - Student activity #3-B 27 SA4 - Student activity #4 28 SA5 - Student activity ABS 1 31 SA5 - Student activity ABS 2 32 SA5 - Student activity ABS 3 33 SA5 - Student activity ABS 4 34 SA5 - Student activity ABS 5 35 SA5 - Student activity ABS 6 36 SA-5 Student activity ABS - Answers 37 96-EM-122-HN02 Instructors Manual — Table of contents EM-122-HN02-96_V2025-1 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, 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. The content of this manual is applicable to models 052621 and above. Table des matières Trainer Use and Familiarization 4 Task correlation 5 Instructor introduction 10 Manual fault insertion 11 Wiring schematic with electrical faults 12 Wiring schematic without electrical faults 13 Mechanical faults 14 Left front disc (#1) 15 Right front disc (#3) 16 Left rear drum (#4) 17 Right rear drum 17 consulab.com info@consulab.com 5 93-EM-122-HN02 Product Description Product Description The EM-122-HN02_052621 Disc and Drum ABS Brake trainer is used to demonstrate the functionality of the ABS braking systems as it operates on a real vehicle. The trainer is built with OEM components and is based on the 2010-2006 Hon- da Civic platform. The trainer can be used in the classroom environment for demonstrations to students. The instructor can manually select which wheel combinations are desired to lockup prior to application of brake pedal. In addition to simulating multiple ABS wheel speed conditions, this trainer also has multiple built in mechanical faults which provides additional student diagnostic and learning opportunities dealing with common abnormal conditions found on today’s vehicies. The trainer provides a safe and effective method of demonstrating the principles of braking systems used on today’s vehicles. The EM-122-HN02 ABS brake trainer includes the following : • “Real” automotive components with fully functional ABS 3-channel hydraulic system. • Equipped with DLC for scan tool hookup providing data stream and PID’s in addition to DTC retrieval and code clearing ability. • OEM vehicle instrument panel with indicator lamps. • ABS Control Unit breakout box to allow measurements to be taken with a DVOM and Oscilloscope. • Individual pressure gauges at each wheel. • Lockable fault insertion box with 6 electrical faults. • Components with mechanical faults. • Simulator/Sensor toggle switch allows for manipulation of the ABS wheel speed sensors signals to the ABS control module. • Disc/drum four-wheel brake assemblies (NOTE- discs, drums, wheel cylinders, calipers and all friction materials are new. All other OEM components are recycled from actual vehicles). • Fully functional parking brake system. • 120VAC to 12VDC (55A) power supply included. • Heavy Duty metal stand with casters for easy transport of trainer. • All routine brake service procedures can be performed on this trainer including component replacement, adjust- ments and hydraulic bleeding. consulab.com info@consulab.com 6 93-EM-122-HN02 Educational Advantages Educational Advantages • Demonstrates full functionality of a 4-wheel ABS system • Allows choice of wheel combinations to “lock-up” during ABS operation • Allows choice of ABS “application” timing for clearer demonstrations • Six system electrical faults that are manually selected by the instructor • Trainer follows OEM wiring schematics • Trainer can be used for full mechanical service and repair operations of: • Front disc brakes - Rear drum brakes • Master Cylinder & Hydraulic system (w/ pedal) • ABS Electrical System (w/ wheel speed sensors) • ABS Hydraulic Control unit • Parking Brake system, • Provides “real world” brake pedal feedback pulsations during ABS operation. • Simulator/Sensor toggle switch allows for manipulation of the ABS wheel speed sensors signals to the ABS control module. • Components with mechanical faults test students ability to precision measure and compare results to service information for a safe diagnosis. More information on the mechanical faults can be found in the instructor’s manual (96-EM-122-HN02). • Many ASE Education Foundation (NATEF) and Red Seal tasks can be accomplished using this trainer. • Trainer can fit through a standard 30” door opening. Infrastructure Requirements Power Supply 120 VAC to 12 VDC (55 A) consulab.com info@consulab.com 7 EM-122-HN02-93 Unpacking instructions and Support contact information Unpacking instructions Your test bench is shipped in a sturdy wooden crate designed to ensure transport quality and prevent damage. To remove the packaging, you will need a drill with a #2 Phillips bit. The test bench is secured to a pallet. The casters and their hardware are included in the packaging. Support Contact Information ConsuLab support contact information For any technical support requests related to your ConsuLab product ( damage, defects, configuration, troubleshooting and suggestions ), you can contact our dedicated team immediately : Toll-free : Canada +1 ( 800 ) 567-0791 / USA +1 ( 810 ) 222-4525 Phone : Canada +1 ( 418 ) 688-9067 Email : support@consulab.com Website : www.consulab.com consulab.com info@consulab.com 8 93-EM-122-HN02 Instructions Instructions Read the following pages carefully for assembly and maintenance of the EM-122-HN02 trainer. It is recommended that you are very careful when performing experiments and/or demonstrations with this trainer and its components. Casters Install both swivel casters under the bench front legs (panel side) and the fixed ones under the rear legs (power supply side). Make sure to properly tighten all nuts, bolts and lock washers supplied with the trainer. DC Power supply The DC power supply power cord must be plugged in a 120V, 20A receptacle before operating the trainer. NOTE- Do not leave power supply cord plugged into an outlet when not using the trainer. DLC Connector Connect the scan tool or diagnostic tool in the DLC located on the frame to analyze the ABS operation on each wheel. VIN The VIN location can be found on the dashboard, in the lower right corner, as well as on the key tag provided with the product. Fixed casters Swivel casters consulab.com info@consulab.com 9 93-EM-122-HN02 Instructions Front panel component indentification 3 2 1 4 5 7 6 89 10 1. B+ test receptacle 2. GND test receptacle 3. Key ignition switch & key 4. Rear wheel LED indicators 5. Rear/front toggle switch 6. Front wheel LED indicators 7. Left/rear roggle switch 8. Simulator/sensor toggle switch 9. ABS module BOB test receptacles 10. Wheel lockup button 11. Frozen VIN 11 consulab.com info@consulab.com 10 93-EM-122-HN02 Instructions ABS module breakout box pin identification The ABS module breakout box is designed for accessing fifteen (15) test points of the output signals coming from various sensors in the ABS assembly. The breakout box is connected in parallel to the ABS control unit. All breakout box test points are well identified and connected to the pinout according to the OEM wiring schematics. OEM Honda 25-PIN connector PIN Wire color PIN name Function 1 WHT CAN-H F-CAN communication circuit 2 GRN RF+B Detects right-front wheel speed sensor signal 3 GRY LF-GND Detects left-front wheel speed sensor signal 5 PUR LR-GND Detects left-rear wheel speed sensor signal 6 LT GRN RR+B Detects right-rear wheel speed sensor signal 8 WHT FSR+B Power source for the fail-safe relay 9 RED MR+B Power source for the motor relay 10 LT BLU K-LINE Communication with HDS 12 ORN LF+B Detects left-front wheel speed sensor signal 14 BLU LR+B Detects left-rear wheel speed sensor signal 15 WHT RR-GND Detects right-rear wheel speed sensor signal 16 GRY IG1 Power source for activating the system 17 RED CAN-L F-CAN communication circuit 18 PNK RF-GND Detects right-front wheel speed sensor signal 25 BLK MR-GND Ground for the pump motor consulab.com info@consulab.com 11 93-EM-122-HN02 Pre-operation checks and Operating instructions Pre-operation checks Perform a visual check of the brake fluid level in the tank; it should be between the MIN and MAX marks. Operating instructions 1. Select the SIMULATOR mode using the simulator/sensor toggle switch to allow manipulation of the ABS wheel speed sensors signals to the ABS control module. 2. Turn the ignition switch key to ON position. The ABS control unit should operate in selftest mode for checking prop- er operation of all electronic devices. During the test the following warning lamps/indicators are turned ON for 3 seconds and turned OFF after successful system prove out is completed : - ABS warning lamp (dashboard). - Braking system warning lamp (dashboard). - If any of the indicator lights stay on during this or other system tests, confirm that all faults in the fault box are turned OFF. NOTE - Inserted faults MUST be cleared with a scan tool even if the fault box switch has been turned off. 3. Turn the key ignition switch to START position and release it. 4. At this stage you can observe the following : - After “start up”the vehicle is now moving forward up to speed. - In running mode (after 5 to 10 seconds) the 4-wheel LED indicator lights flash during acceleration then remain on when the speed reaches around 19 mph (30 km/h). - The ABS control unit briefly starts making another self-test. At this stage, the electronic control module operates the internal relays, the valves and the pump for about 1 second to check overall system operation. The pump operation should be heard during this system check. - At about 19 mph (30 km/h) the 4-wheel LED indicator lights stop flashing and remain on to indicate that road speed has been achieved. Please note that the road speed has been programmed to around 19 mph (30 km/h) since above 31 mph (50 km/h) communication is disconnected with the ABS module due to OEM programming. (Honda protocol). - Rear/Front & Left/Right switch selectors provide the ability to program 9 different wheel speed conditions. 5. Select the SENSOR mode using the simulator/sensor toggle switch to allow live wheel speed sensor signals to the ABS control module. NOTE : this Honda ABS brake system use magneto-restive sensors for wheel speed detection. The magneto-resistive speed and position sensor has been used in vehicles today since the mid-2000’s. It is a very accurate sensor and is used on today’s vehicles with ABS, Traction Control, Hill Assist and Smart-Cruise systems. It is important that technicians, instructor’s and students have a good understanding of how they work and the diag- nostic procedures needed to properly test them. consulab.com info@consulab.com 12 93-EM-122-HN02 Operating instructions The Magneto-Resistive sensor is an active sensor. Therefore, it requires an external power source to operate. Dif- ferent manufacturers can use voltages from 5V to 12V depending on the style. This voltage usually comes from the PCM or other computer modules. MR sensors today usually have two wires connected to them, but a few may have three with a GND wire sometimes used. Technicians today often look at an MR sensor with two wires and mistakenly think it is a passive inductive AC generator. If testing procedures for a passive sensor are used by technicians, they will get what they may think are improp- er results and may condemn a perfectly good active MR sensor. The important difference is that the MR sensor will have a supply voltage and a ground circuit, where a passive sensor usually does not have any voltage on the two wires. TESTING & DIAGNOSIS — MR sensors are testing differently than passive and other active sensors. Most experts agree that there is no value in resistance testing of any part of the MR sensor. In fact, some manufacturers indicate that the small voltage applied to the circuit when using an ohmmeter can destroy the internal sensitive MR circuitry. SCAN TOOL TESTING : Today, experts agree that the scan tool and oscilloscope are the most accurate method of determining proper MR sensor operation. Scan tools often have PID’s showing individual wheel RPM’s or MPH for each MR WSS’s and some may be able to graph the signal output. Also, there are a host of DTC’s for identifying WSS sensor and circuit prob- lems. Be sure to check with service information for specific scan tool PID’s for the vehicle you are working on. OSCILLOSCOPE TESTING : The oscilloscope is the only diagnostic tool that can display abnormalities in the trigger wheel and sensor signals caused from physical damage, dirt & mud and damaged or missing pole magnets. Electrical problems can include opens, shorts and high resistance in wiring and connecters. Also, remember that the frequency of the signal changes with wheel speed. To live test the MR wheel speed sensors, the SIMULATOR / SENSOR switch must be in the SENSOR position. 6. Select the wheel or wheel combination to be locked up using the appropriate wheel toggle switches. The wheel lockup function is available in the simulating mode only. Several examples of possible wheel combinations are listed below : Examples Two rear wheel lockup combination : A. The top toggle switch (right or left) must be in the center position. B. The bottom toggle switch (rear or front) must be in the down position. consulab.com info@consulab.com 13 93-EM-122-HN02 Operating instructions Two right wheel lockup combination : A. The top toggle switch (right or left) must be in the right position. B. The bottom toggle switch (rear or front) must be in the center position. Right rear wheel lockup : A. The top toggle switch (right or left) must be in the left position. B. The bottom toggle switch (rear or front) must be in the center position. 7. Then firmly press down the brake pedal, keeping it depressed while also pressing on the wheel lockup button. The wheel LED indicator(s) will not be illuminated when the wheel(s) is/are locked “at the same time”. At this stage you can observe the following results : - The selected wheels are locked up and then the ABS control module releases pressure on the wheels. - Driver will feel pulsing of the brake pedal in normal operation. - When selecting rear wheel lockup combinations, you will see that the EM-122-HN02 trainer is a 3-channel hydrau- lic braking system. 8. The EM-122-HN02 Disc and Drum ABS Trainer Manual Fault Box is designed for generating fault or malfunction in- sertion of the sensors and actuators used in the trainer, so as to avoid the replacement or repair of the faulty parts. The fault box is configured to the ABS system installed on the trainer, and includes the following: - Six (6) switches allowing instructors to enable or disable ABS system faults. - One (1) locking metal case with keys. - After turning OFF the fault, a scan tool will need to be used at the DLC to clear codes and turn off any dash warn- ing indicators. - Worksheets are provided for these faults in the instructors manual (EM-122-HN02-96). consulab.com info@consulab.com 14 93-EM-122-HN02 Maintenance instructions Maintenance instructions The brake fluid used is DOT3. The amount required to fill the system is 0.35 liters. When filling, press the brake pedal and allow the fluid to enter the system. Recheck the level and fill it up if necessary. NOTE - It is recommended to wear work gloves, eye protection, and safety shoes for brake maintenance procedures, including component replacement, adjustments, and hydraulic system bleeding. SDS Sheet The brake fluid (DOT 3) safety data sheet is available in PDF format on our website in your customer area. Consumable Parts and Replacement Parts The product does not include a list of consumable parts, as normally there is no wear on the components due to handling during the product’s lifetime. However, if exceptionally some components break during handling, with the test bench’s serial number (VIN), we can provide you with information on all the parts you need. consulab.com info@consulab.com 15 93-EM-122-HN02 EM-122-HN02 Wiring Schematic EM-122-HN02 Wiring Schematic 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 D ESSIN E : VER IFIE : D ATE D E C R EATIO N : IN D IC E D ATE M O D IFIC ATIO N D ES. HO N DA CIVIC ABS TRAIN ER EM -122-1 07/05/2014 1 W H T 17 R ED 10 LT BLU 8 W H T 9 R ED 16 G R Y BREAKO U T BO X 24 BLK 25 BLK ABS MODULE 1171089162425 H O T IG N ITIO N K EY + G N D B A T IG N STA R T B R A K E SW ITC H BR AKE LIG H T A 8ORG A 42RED A 31BRN A 37RED A 36WHT A 6 A 40GRN B 36BLK B 1BLK C 1WHT GRN C 36BLK YEL C 44BRN YEL C 40BRN YEL C 2BLK IG N IG N 4BLK 7LT BLU 14RED 6WHT 9ORG 12RED 16WHT D LC 5BLK H O T 27 GRN 28 GRN 15 BLK 16 BLK 1 WHT 19 RED 18 WHT 17 BRN C LU STER H O T IG N BRAKE FLUID LEVEL SWITCHPA R K B R A K E SW ITC H P.S. 12VD C +- PO W ER IG N ITIO N IG N H O T 12 W H T O R O R G 3 R ED O R G R Y 123 2 G R N 18 PN K 218 14 YEL O R BLU 5 R ED O R PPL 145 6 LT BLU O R G R N 15 G R Y O R W H T 615 TO C O N TR O LLER EC M A B C *** ALL SW ITC H ES TH AT G O TO TH E SIM U LATIO N C AR D AN D SEN SO R S AR E SIM U LTAN EO U SLY AC TU ATED R EAR R IG H T SEN SO R R EAR LEFT SEN SO R FR O N T R IG H T SEN SO R FR O N T LEFT SEN SO R IG N SIM U LATIO N C AR D I-106 SW -SEN SO R / SIM U LATIO N FU SE BO X H O T 5A BR AKE 5A ABS1 30A ABS2 30A IG N #18 IG N ITIO N 5A YEL O R G G R N BL PPL G R Y BR N R D 1818 1010 88 1818 1010 C 31WHT GRN J12 J15 J9 J20 J25 J28 J12-2 J28-1 BLK IG N J28-2 SW Sim ulator IN O U T H I LO W B R A K E SW ITC H R D G U ILLA U M E LEM IEU X 04/12/2019 3 N O ÉM IE A N C TIL 01/12/2020 4 7 21/10/2025 D C 25224 FS 8 16/02/2026 N C 26-038 FS R EV -8 consulab.com info@consulab.com 16 93-EM-122-HN02 Notes Notes consulab.com info@consulab.com 17 93-EM-122-HN02 Notes Notes consulab.com info@consulab.com 18 93-EM-122-HN02 Notes Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. Tous droits réservés. Teacher Resources EM-122-HN02-95 Student Assignments — Table of contents EM-122-HN02-91 Answer Key — Table of contents EM-122-HN02-96 Instructors Manual — Table of contents Product Description Educational Advantages Infrastructure Requirements Unpacking instructions Support Contact Information Instructions Casters DC Power supply DLC Connector VIN Front panel component indentification ABS module breakout box pin identification Pre-operation checks Operating instructions Maintenance instructions Consumable Parts and Replacement Parts EM-122-HN02 Wiring Schematic

Student assignments for EM-122-HN02_052621 Disc & drum ABS brake trainer + faults 95-EM-122-HN02_REVB © ConsuLab Educatech Inc, 2025. All rights reserved. 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. The content of this manual is applicable to models 052621 and above. 95-EM-122-HN02 Table of contents Table of contents Introduction 3 EM-122-HN02 Wiring Schematic 5 Student assignments 6 SA1 - Student activity #1 7 SA2 - Student activity #2 11 SA2-A - Student activity #2-A 16 SA2-B - Student activity #2-B 18 SA2-C - Student activity #2-C 19 SA3 - Student activity #3 20 SA3-A - Student activity #3-A 25 SA3-B - Student activity #3-B 27 SA4 - Student activity #4 28 SA5 - Student activity ABS 1 30 SA5 - Student activity ABS 2 31 SA5 - Student activity ABS 3 32 SA5 - Student activity ABS 4 33 SA5 - Student activity ABS 5 34 SA5 - Student activity ABS 6 35 consulab.com info@consulab.com 3 95-EM-122-HN02 Introduction Introduction The EM-122-HN02_052621 Disc and Drum ABS Brake System trainer is used to demonstrate the functionality of the ABS braking system as it operates on a real vehicle. The trainer is built with OEM components and is based on the 2010- 2006 Honda Civic platform. The trainer can be used in the classroom environment for demonstrations to students. The instructor can manually select which wheel combinations are desired to lockup prior to application of brake pedal. The trainer provides a safe and effective method of demonstrating the principles of braking systems used on today’s vehi- cles. The ABS system (anti-lock braking system) is a safety device that automatically adjusts brake pressure to prevent wheel lock-up. The EM-122 provides an interactive road test. It allows simulating different road conditions and experiencing ABS acti- vation, while observing in real time the behavior of each wheel individually, based on wheel speed variations and the response of the hydraulic system. Additionally, it is possible to perform all routine brake maintenance procedures, including component replacement, adjustments, and hydraulic system bleeding. Application 2010-2006 ABS Honda Civic Features • “Real” automotive components with fully functional ABS 3-channel hydraulic system • Equipped with DLC for scan tool data stream hookup • OEM vehicle instrument panel with indicator lamps • ABS Control Unit breakout box for hookup of DVOM and Oscilloscope • Hydraulic pressure gauges at each wheel (4) • Fault insertion box (lockable) 6 faults • Components with mechanical faults • Disc/drum four wheel brake assemblies (NOTE- discs, drums, wheel cylinders, calipers and all friction materials are new. All other OEM components are recycled from actual vehicles) • Fully functional parking brake system • 120VAC to 12VDC 55A power supply included • Heavy Duty metal stand with casters for easy transport of trainer • All routine brake service procedures can be performed on this trainer including component replacement, adjust- ments and hydraulic bleeding consulab.com info@consulab.com 4 95-EM-122-HN02 Introduction Educational advantages • Demonstrates full functionality of a 4-wheel ABS system • Allows choice of wheel combinations to “lock-up” during ABS operation • Allows choice of ABS “application” timing for clearer demonstrations • Six electrical system faults that are selected by the instructor • Trainer follows OEM wiring schematics • Trainer can be used for full mechanical service and repair operations of : - Front disc brakes - Rear drum brakes - Master Cylinder & Hydraulic system (w/ pedal) - ABS Electrical System (w/ wheel speed sensors) - ABS Hydraulic Control unit - Parking Brake system • Provides “real world” brake pedal feedback pulsations during ABS operation • Many ASE Education Foundation (NATEF) and Red Seal tasks can be accomplished using this trainer • Trainer can fit through a standard 30” door opening Breakout box instructions The breakout box allows measuring electrical signals without having to disassemble or damage the wiring harness or circuit connector. With the accessible terminals on the Breakout box, it is possible to connect a multimeter or an oscil- loscope to measure output signals from different circuits of the ABS system. All test terminals are clearly identified and connected to the original connector according to the manufacturer’s wiring diagrams. consulab.com info@consulab.com 5 95-EM-122-HN02 EM-122-HN02 Wiring Schematic EM-122-HN02 Wiring Schematic 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 D ESSIN E : VER IFIE : D ATE D E C R EATIO N : IN D IC E D ATE M O D IFIC ATIO N D ES. HO N DA CIVIC ABS TRAIN ER EM -122-1 07/05/2014 1 W H T 17 R ED 10 LT BLU 8 W H T 9 R ED 16 G R Y BREAKO U T BO X 24 BLK 25 BLK ABS MODULE 1171089162425 H O T IG N ITIO N K EY + G N D B A T IG N STA R T B R A K E SW ITC H BR AKE LIG H T A 8ORG A 42RED A 31BRN A 37RED A 36WHT A 6 A 40GRN B 36BLK B 1BLK C 1WHT GRN C 36BLK YEL C 44BRN YEL C 40BRN YEL C 2BLK IG N IG N 4BLK 7LT BLU 14RED 6WHT 9ORG 12RED 16WHT D LC 5BLK H O T 27 GRN 28 GRN 15 BLK 16 BLK 1 WHT 19 RED 18 WHT 17 BRN C LU STER H O T IG N BRAKE FLUID LEVEL SWITCHPA R K B R A K E SW ITC H P.S. 12VD C +- PO W ER IG N ITIO N IG N H O T 12 W H T O R O R G 3 R ED O R G R Y 123 2 G R N 18 PN K 218 14 YEL O R BLU 5 R ED O R PPL 145 6 LT BLU O R G R N 15 G R Y O R W H T 615 TO C O N TR O LLER EC M A B C *** ALL SW ITC H ES TH AT G O TO TH E SIM U LATIO N C AR D AN D SEN SO R S AR E SIM U LTAN EO U SLY AC TU ATED R EAR R IG H T SEN SO R R EAR LEFT SEN SO R FR O N T R IG H T SEN SO R FR O N T LEFT SEN SO R IG N SIM U LATIO N C AR D I-106 SW -SEN SO R / SIM U LATIO N FU SE BO X H O T 5A BR AKE 5A ABS1 30A ABS2 30A IG N #18 IG N ITIO N 5A YEL O R G G R N BL PPL G R Y BR N R D 1818 1010 88 1818 1010 C 31WHT GRN J12 J15 J9 J20 J25 J28 J12-2 J28-1 BLK IG N J28-2 SW Sim ulator IN O U T H I LO W B R A K E SW ITC H R D G U ILLA U M E LEM IEU X 04/12/2019 3 N O ÉM IE A N C TIL 01/12/2020 4 7 21/10/2025 D C 25224 FS 8 16/02/2026 N C 26-038 FS R EV -8 consulab.com info@consulab.com 6 95-EM-122-HN02 Student assignments Student assignments consulab.com info@consulab.com 7 95-EM-122-HN02 SA1 - Student activity #1 SA1 - Student activity #1 Master cylinder inspection service 1. Look up the correct Honda brake service and safety information before proceeding. 2. Inspect and note these items : 3. Check that all parts are free of dirt and other foreign particles. Why ? 4. Do not allow dirt or foreign matter to contaminate the brake fluid. Why ? 5. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 8 95-EM-122-HN02 SA1-A - Student activity #1-A SA1-A - Student activity #1-A Master cylinder remove/replace (3 pages) 1. Look up the correct Honda brake service and safety information before proceeding. 2. Special tools required? 3. Be careful not to damage or bend the brake lines during removal and installation. 4. After removal, plug the ends of the hoses and the joints to prevent spilling brake fluid. Why ? 5. Remove the reservoir cap and brake fluid from the master cylinder reservoir with a syringe. 6. Disconnect the brake fluid level switch connector (A). 7. Remove the reservoir tank mounting bolt (B). consulab.com info@consulab.com 9 95-EM-122-HN02 SA1-A - Student activity #1-A 8. Disconnect the brake lines (A) from the master cylinder (B). To prevent spills, cover the hose joints with clean rags or shop towels. 9. Remove the master cylinder mounting nuts (C) and washers (D). 10. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder. 11. Remove the rod seal (F) from the master cylinder. NOTE: During installation, set the new rod seal onto the master cylinder with its grooved side (G) toward the master cylinder. 12. Do not try to disassemble the master cylinder assembly. 13. Honda recommends replacing the master cylinder assembly with a new part if necessary. Why ? consulab.com info@consulab.com 10 95-EM-122-HN02 SA1-A - Student activity #1-A 14. Reinstall the master cylinder with a new rod seal in the reverse order of removal, and note these items : • Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798- 9013). • Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves. • Check the brake pedal height and free play after installing the master cylinder, and adjust if necessary. • If the reservoir tank hose was disconnected, install the reservoir tank (A) and the reservoir tank hose (B) to the sub-reservoir (C). - NOTE : Align the ‘‘Δ ‘’ marks (D) on the reservoir tank and sub-reservoir with the paint marks (E) on the hose. Posi- tion the direction of the clamp (F). 15. Bleed the brake system (See SA-4 worksheet). 16. Spin the wheels to check for brake drag. Why? 17. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 11 95-EM-122-HN02 SA2 - Student activity #2 SA2 - Student activity #2 Brake pad replacement (5 pages) 1. Look up the correct Honda brake service and safety information before proceeding. 2. Special tools required ? 3. Any safety cautions to be observed ? • • • • 4. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. Brake pad thickness : Standard specifications : Service Limit specifications : 5. After inspection, are these brake pads within service limits? If not, what is recommended to do? Inner pad Outer pad consulab.com info@consulab.com 12 95-EM-122-HN02 SA2 - Student activity #2 Replacement of pads 6. Remove some brake fluid from the master cylinder. Why ? 7. Remove the flange bolt (A), and pivot the caliper body (B) up out of the way. 8. Secure caliper up with a tie strap. Why ? 9. Check the hose and pin boots for damage and deterioration. 10. Remove the pad shims (A) and the brake pads (B). 11. Remove the pad retainers (A). consulab.com info@consulab.com 13 95-EM-122-HN02 SA2 - Student activity #2 12. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed. 13. Inspect the brake disc for runout, thickness, parallelism, and check for damage and cracks. *** See Student Activity SA2-A. 14. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows). 15. Install the pad retainers. Wipe off the excess assembly paste from the retainers. Keep the assembly paste away from the brake disc and the brake pads. 16. Install the brake caliper piston compressor tool (A) on the caliper body (B). 17. Press in the piston with the brake caliper piston compressor tool so the caliper body will fit over the brake pads. 18. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper body down. consulab.com info@consulab.com 14 95-EM-122-HN02 SA2 - Student activity #2 19. NOTE : Be careful when pressing in the piston; brake fluid might overflow from the master cylinder’s reservoir. Why? 20. If brake fluid gets on any painted surface, wash it off immediately with water. 21. Remove the brake caliper piston compressor tool. 22. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), the back of the brake pads (B) and the other areas indicated by the arrows. 23. Wipe off the excess assembly paste from the pad shims and the brake pads friction material. 24. Keep grease and assembly paste away from the brake disc and the brake pads. Contaminated brake disc or brake pads reduce stopping ability. 25. Install the brake pads and the pad shims correctly. 26. Why are shims needed? 27. Install the brake pad with the wear indicator (C) on the upper inside position. 28. NOTE : If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a tem- porary loss of braking efficiency. consulab.com info@consulab.com 15 95-EM-122-HN02 SA2 - Student activity #2 29. Pivot the caliper body down into position. Install the flange bolt (A), and tighten it to the specified torque. 30. Press the brake pedal several times to make sure the brakes work. 31. NOTE : Engagement may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. Why? 32. Add brake fluid as needed. 33. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then recheck for leaks. 34. Clean up work area and return tools to the proper place, hand in worksheet. 35. Have instructor check work Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 16 95-EM-122-HN02 SA2-A - Student activity #2-A SA2-A - Student activity #2-A Front brake disc inspection (2 pages) 1. Look up the correct Honda brake service and safety information before proceeding. Thickness and Parallelism 2. Remove the brake pads. 3. Using a micrometer (A), measure the brake disc thickness at eight points, about 45 ° apart and 10 mm (0.39 in) in from the outer edge of the brake disc. 4. Replace the brake disc if the smallest measurement is less than the maximum refinishing limit. 5. Brake disc thickness : Standard specifications : Maximum refinishing limit specifications : Brake disc parallelism* specifications : * This is the maximum allowable difference between the thickness measurements. 6. Is this disc within spec’s ? Runout 7. Inspect the brake disc to wheel surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust. 8. Look up the correct wheel lug nut torque value and record here: 9. Install suitable flat washers (A) and wheel nuts (B), and tighten the wheel nuts to the specified torque to hold the brake disc securely against the hub. 10. Set up the dial gauge (C) against the brake disc as shown, and measure the runout at 10 mm (0.39 in) from the outer edge of the brake disc. consulab.com info@consulab.com 17 95-EM-122-HN02 SA2-A - Student activity #2-A 11. Brake disc runout specifications : Service limit : If any brake disc is beyond the service limit, what does Honda recommend as the repair ? Maximum refinishing limit : Actual runout measured : NOTE : If the brake disc is beyond the service limit for refinishing, replace it. If the brake disc is replaced with a new one, check the new disc for runout. If the new disc is out of specification, refinish the disc. 12. Clean up work area and return tools to the proper place, hand in worksheet. Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 18 95-EM-122-HN02 SA2-B - Student activity #2-B Year and Model: VIN: Rotor Location: LF RF RR LR Rotor thickness before refinishing Rotor run-out before refinishing Rotor thickness variation (measure in 8 places): 1. 2. 3. 4. 5. 6. 7. 8. Attach to R.O. # Disc Brake Rotor Refinishing Worksheet © 2002 American Honda Motor Co., Inc. - All Rights Reserved GJA 24213 (0212) Date: Rotor Location: LF RF RR LR Rotor thickness before refinishing Rotor run-out before refinishing Rotor thickness variation (measure in 8 places): 1. 2. 3. 4. 5. 6. 7. 8. Thickest part Thinnest part Maximum variation Refinishing time overall min. Rough-cut time min. Fine-cut time min. – = Technician Signature Technician Number Rotor thickness after refinishing Rotor run-out after refinishing Thickest part Thinnest part Maximum variation Refinishing time overall min. Rough-cut time min. Fine-cut time min. – = Rotor thickness after refinishing Rotor run-out after refinishing Copyright 2009 - 2013 Service Repair Solutions, Inc. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. SA2-B - Student activity #2-B Front brake disc refinishing consulab.com info@consulab.com 19 95-EM-122-HN02 SA2-C - Student activity #2-C SA2-C - Student activity #2-C Front brake caliper inspection 1. Look up the correct Honda brake service and safety information before proceeding. 2. Remove, inspect, reassemble, and install the caliper, and note any defects observed with these items : • Make sure that the caliper pins are installed correctly. Upper caliper pin and lower caliper pin are different. - If these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid brake pad wear, and possibly uneven tire wear. • To prevent dripping brake fluid, cover disconnected hose joints with clean rags or shop towels. • Before reassembling, check that all parts are free of dirt and other foreign particles. - Make sure no dirt or other foreign matter gets in the brake fluid. • Make sure no grease or oil gets on the brake discs or pads. • When reusing brake pads, always reinstall them in their original.positions to prevent loss of braking efficiency. • Do not reuse drained brake fluid. Use only new Honda DOT 3 Brake Fluid from an unopened container. - - Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. • Use recommended greases in the front caliper set. • After performing a visual inspection, were there any other defects noticed ? 3. After installing the caliper, check the brake hose and line for leaks, interference, and twisting. 4. Clean up work area and return tools to the proper place, hand in worksheet Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 20 95-EM-122-HN02 SA3 - Student activity #3 SA3 - Student activity #3 Rear brake shoe inspection and replacement (5 pages) 1. Look up the correct Honda brake service and safety information before proceeding. CAUTION: Frequent inhalation of brake shoe dust, regardless of material composition, could be hazardous to your health. AVOID BREATHING DUST PARTICLES. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. 2. Release the parking brake, and remove the breake drum. 3. Check the wheel cylinder for leakage (See SA3-B). consulab.com info@consulab.com 21 95-EM-122-HN02 SA3 - Student activity #3 4. Remove the tension pins (A) by pushing the respective retainer springs (B), and turning the pin. 5. Remove the lower return spring (A), and remove the brake shoe assembly over the hub. 6. Remove the forward brake shoe (B) by removing the upper return spring (C), and disassemble the brake shoe assembly. 7. Remove the rearward brake shoe (D) by disconnecting the parking brake cable from the parking brake lever (E). consulab.com info@consulab.com 22 95-EM-122-HN02 SA3 - Student activity #3 8. Remove the U-clip (A), the wave washer (B), and the pivot pin (C), and separate the parking brake lever (D) from the brake shoe (E). Reassembly 9. Install the parking brake lever (C) and the wave washer (D) on the pivot pin, and secure the pin with a new U-clip (E). 10. Apply Molykote 44MA grease to the sliding surface of the pivot pin (A) for the rearward brake shoe (B). 11. Connect the parking brake cable to the parking brake lever. NOTE: Pinch the U-clip securely to prevent the parking brake lever from coming out of the brake shoe 12. Apply a thin coat of Molykote 44MA grease to the connecting rod ends (A), and the sliding surfaces (B) as shown consulab.com info@consulab.com 23 95-EM-122-HN02 SA3 - Student activity #3 13. Wipe off any excess. Keep grease away from the brake linings. 14. Install connecting rods A and B on the adjuster bolt (C). NOTE: Clean the threaded portions of connecting rod A and the sliding surface of connecting rod B, then coat them with Molykote 44MA grease. 15. Shorten connecting rod A by fully turning in the adjuster bolt. 16. Assemble the brake shoes with the upper return spring (D), with the connecting rods and the adjuster bolt onto the backing plate. 17. Reconnect the parking brake cable to the parking brake lever (E), then install the self-adjuster lever (F) and the self- adjuster spring (G) on the forward brake shoe (H). 18. Install the tension pins (A) and the retainer springs (B) by pushing in the respective spring and turning each pin. consulab.com info@consulab.com 24 95-EM-122-HN02 SA3 - Student activity #3 19. Install the lower return spring. NOTE: Make sure the brake shoes are positioned on the brake shoe bosses on the backing plate, and the fitting on the top of the brake shoes are fitted into the wheel cylinder pistons. 20. Install the brake drum. NOTE: Before installing the brake drum, clean the mating surfaces between the hub bearing unit and the inside of the brake drum. 21. Press the brake pedal several times to make sure the brakes work and to set the self-adjusting brake. NOTE: Engagement of the brakes may require a greater pedal stroke immediately after the brake shoes have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 22. Adjust the parking brake. 23. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 25 95-EM-122-HN02 SA3-A - Student activity #3-A SA3-A - Student activity #3-A Rear brake drum inspection and service (2 pages) 1. Look up the correct Honda brake service and safety information before proceeding. 2. Release the parking brake, and remove the brake drum. 3. Check the wheel cylinder (A) for leakage (See SA3-B). 4. Check the brake linings (B) for cracking, glazing, wear, and contamination. NOTE: Contaminated brake linings or drums reduce stopping ability. 5. Measure the brake lining thickness (C). Measurement does not include the metal brake shoe thickness. 6. Brake lining thickness specifications : Standard specifications : Service limit specifications : Actual measurement : 7. If any part of the brake lining thickness is less than the service limit, replace the brake shoes as an axle set. 8. Check the hub bearing unit (D) for smooth operation. If it requires servicing, replace the hub bearing unit. consulab.com info@consulab.com 26 95-EM-122-HN02 SA3-A - Student activity #3-A 9. Measure the inside diameter of the brake drum with inside vernier caliper. 10. Drum inside diameter specifications : Standard specifications : Service limit specifications : Actual measurement : 11. Do the drums measure within factory specifications ? If not, what is recommended as a repair ? 12. Check the brake drum for scoring, grooves, corrosion, and cracks. 13. Install the brake drum. 14. Clean up work area and return tools to the proper place, hand in worksheet. Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 27 95-EM-122-HN02 SA3-B - Student activity #3-B SA3-B - Student activity #3-B Wheel cylinder inspection and service 1. Look up the correct Honda brake service and safety information before proceeding. 2. Remove the brake shoes (see Student Activity SA3). 3. Disconnect the brake line (A) from the wheel cylinder (B). 4. Remove the bolts (C) and the wheel cylinder from the backing plate. NOTE: Use the special bolts on reassembly. 5. Apply Cemedine 366E sealant or equivalent between the wheel cylinder and backing plate (D), and install the wheel cylinder, then connect the brake line. 6. Install the brake shoes. Bleed the brake system. 7. Inspect and adjust the parking brake. 8. Spin the wheels to check for brake drag. 9. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. 10. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 28 95-EM-122-HN02 SA4 - Student activity #4 SA4 - Student activity #4 Bleeding brake service (2 pages) 1. Look up the correct Honda brake service and safety information before proceeding. 2. Do not reuse the drained fluid. Use only new Honda DOT 3 Brake Fluid from an unopened container. Using a non- Honda brake fluid can cause corrosion and shorten the life of the system. 3. Make sure no dirt or other foreign matter gets in the brake fluid. The reservoir connected to the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure, and checked after bleeding each wheel location. Add fluid as required. 4. Make sure the brake fluid level in the reservoir (A) is at the MAX (upper) level line (B). 5. Have someone slowly pump the brake pedal several times, then apply steady pressure. 6. Start the bleeding at the driver’s side of the front brake system. NOTE: Bleed the calipers or the wheel cylinders in the sequence shown. consulab.com info@consulab.com 29 95-EM-122-HN02 SA4 - Student activity #4 7. Attach a length of clear drain tube (A) to the bleed screw (B), then loosen the bleed screw to allow air to escape from the system. 8. Then tighten the bleed screw securely. 9. Refill the master cylinder reservoir to the MAX (upper) level line. 10. Repeat the procedure for each brake circuit until there are no air bubbles in the fluid. 11. Clean up work area and return tools to the proper place, hand in worksheet. consulab.com info@consulab.com 30 95-EM-122-HN02 SA5 - Student activity ABS 1 SA5 - Student activity ABS 1 Fault diagnosis Fault #1 Customer Complaint : ABS dash light is on. Student Observation : Explain Strategy : Tests Performed : Fault : Component : Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 31 95-EM-122-HN02 SA5 - Student activity ABS 2 SA5 - Student activity ABS 2 Fault diagnosis Fault #2 Customer Complaint : ABS dash light is on. Brake System Indicator is on. Student Observation : Explain Strategy : Tests Performed : Fault : Component : Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 32 95-EM-122-HN02 SA5 - Student activity ABS 3 SA5 - Student activity ABS 3 Fault diagnosis Fault #3 Customer Complaint : ABS dash light is on. Brake System Indicator is on. Student Observation : Explain Strategy : Tests Performed : Fault : Component : Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 33 95-EM-122-HN02 SA5 - Student activity ABS 4 Fault #4 Customer Complaint : ABS dash light is on. Student Observation : Explain Strategy : Tests Performed : Fault : Component : Input/Output ? Name : Group : Date : Instructor : Grade : SA5 - Student activity ABS 4 Fault diagnosis consulab.com info@consulab.com 34 95-EM-122-HN02 SA5 - Student activity ABS 5 SA5 - Student activity ABS 5 Fault diagnosis Fault #5 Customer Complaint : ABS dash light is on. Student Observation : Explain Strategy : Tests Performed : Fault : Component : Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 35 95-EM-122-HN02 SA5 - Student activity ABS 6 SA5 - Student activity ABS 6 Fault diagnosis Fault #6 Customer Complaint : Brake System Indicator is on. Student Observation : Explain Strategy : Tests Performed : Fault : Component : Input/Output ? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 36 95-EM-122-HN02 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. Introduction EM-122-HN02 Wiring Schematic Student assignments SA1 - Student activity #1 SA2 - Student activity #2 SA2-A - Student activity #2-A SA2-B - Student activity #2-B SA2-C - Student activity #2-C SA3 - Student activity #3 SA3-A - Student activity #3-A SA3-B - Student activity #3-B SA4 - Student activity #4 SA5 - Student activity ABS 1 SA5 - Student activity ABS 2 SA5 - Student activity ABS 3 SA5 - Student activity ABS 4 SA5 - Student activity ABS 5 SA5 - Student activity ABS 6

Operation manual for EV-100_053374 ConsuKit Student-Built Brushless DC Motor 93-EV-100_REVA © ConsuLab Educatech Inc, 2026. 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-EV-100 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 Table of Contents Teacher Resources 4 95-EV-100 Student Assignments — Table of Contents 4 91-EV-100 Answer Key — Table of Contents 4 96-EV-100 Instructor Manual — Table of Contents 4 The Basics of the EV-100 5 Support Contact Information 5 EV-100 Specifications 5 Dimensions 5 Weight 5 Rated Specifications 5 EV-100 Component Identification 6 Warnings and Precautions 7 Troubleshooting the EV-100 8 consulab.com info@consulab.com 4 93-EV-100 Teacher Resources Teacher Resources We have included the table of contents from three other manuals in this operation manual. This serves as a reference to make you aware of all the documentation that comes with the product. 95-EV-100 Student Assignments — Table of Contents 95-EV-100 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, 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 053374 and above. Table of Contents About This Manual 3 Glossary 3 Text Formatting 3 Student Assignments SA-01 — Building the Rotor 5 SA-02 — Building the Stator 8 SA-03 — Axial vs. Radial Flux 12 SA-04 — Reading Motor Pulse 14 Core Oscilloscope Vocabulary 19 SA-05 — DC Brushed or Brushless? How DC Motors Communicate 20 SA-06 — Rotor Types 23 SA-07 — Stator Winding Patterns 26 Optional Extension Activity 30 SA-08 — Wave Forms in Action 31 Glossary 37 91-EV-100 Answer Key — Table of Contents 91-EV-100 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of Contents About This Manual 4 Glossary 4 Text Formatting 4 Diagrams and Schematics 4 Student Assignments Instructor Notes and Answer Keys SA-01 — Building the Rotor 6 Instructor Notes 6 Answer key 7 SA-02 — Building the Stator 10 Instructor Notes 10 Practical Application: 10 Answer key 11 SA-03 — Axial vs. Radial Flux 15 Instructor Notes 15 Answer key 16 SA-04 — Reading Motor Pulse 18 Instructor Notes 18 Answer Key 19 Core Oscilloscope Vocabulary 23 SA-05 — DC Brushed or Brushless? How DC Motors Communicate 24 Instructor Notes 24 Answer Key 25 SA-06 — Rotor Types 28 Instructor Notes 28 Answer Key 29 91-EV-100 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 Table of Contents About This Manual 4 Glossary 4 Text Formatting 4 Diagrams and Schematics 4 Student Assignments Instructor Notes and Answer Keys SA-01 — Building the Rotor 6 Instructor Notes 6 Answer key 7 SA-02 — Building the Stator 10 Instructor Notes 10 Practical Application: 10 Answer key 11 SA-03 — Axial vs. Radial Flux 15 Instructor Notes 15 Answer key 16 SA-04 — Reading Motor Pulse 18 Instructor Notes 18 Answer Key 19 Core Oscilloscope Vocabulary 23 SA-05 — DC Brushed or Brushless? How DC Motors Communicate 24 Instructor Notes 24 Answer Key 25 SA-06 — Rotor Types 28 Instructor Notes 28 Answer Key 29 91-EV-100 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 053374 and above. SA-07 — Stator Winding Patterns 32 Instructor Notes 32 Answer key 33 Optional Extension Activity 37 SA-08 — Wave Forms in Action 38 Instructor Notes 38 Answer key 39 Glossary 44 96-EV-100 Instructor Manual — Table of Contents 96-EV-100 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 Table of Contents Trainer Use and Familiarization 4 EV-100 Curriculum Blueprint 5 Student Activities 5 Vehicle Applications 6 consulab.com info@consulab.com 5 93-EV-100 The Basics of the EV-100 The Basics of the EV-100 The EV-100 ConsuKit Student-Built Brushless DC Motor is a hands-on educational tool designed to bridge theory and practice in STEM, engineering, and trades programs. With its modular design and safe operating voltage (12 VDC, the EV-100 enables students to build and test a real three-phase motor or generator from scratch, exploring coil design, magnet placement, and wiring in a safe classroom environment. Supported by step-by-step guides and ready-to-use worksheets, this kit fosters critical thinking, creativity, and practical skills in wiring, assembly, and troubleshooting. Whether used in physics, electrical engineering, mechatronics, or green energy courses, the EV-100 connects classroom learning directly to emerging technologies in electric vehicles and renewable energy, making it an ideal platform for inquiry-based exploration and real-world skill development. Support Contact Information For any technical support requests related to your ConsuLab product ( damage, defects, configuration, troubleshooting and suggestions ), you can contact our dedicated team immediately : Toll-free : Canada +1 ( 800 ) 567-0791 / USA +1 ( 810 ) 222-4525 Phone : Canada +1 ( 418 ) 688-9067 Email : support@consulab.com Website : www.consulab.com EV-100 Specifications Dimensions • Storage Box: 9 x 9 4 inch (22.86 x 22.86 x 10.16 cm) • Product Once Built: 3.53 x 6.59 x 3.76 inch (8.96 x 16.74 x 9.55 cm) Weight • Storage Box: 3 lbs. (1.36 kg) • Product Once Built: 1 lb. (0.45 kg) Rated Specifications • Voltage: 12 VDC • Current: 1.3 A • Plug Type: NEMA Connector consulab.com info@consulab.com 6 93-EV-100 EV-100 Component Identification EV-100 Component Identification 96 7 8 5 2 1 12 13 15 14 16 17 18 19 20 21 22 11 3 4 10 1. Assembly Instructions 2. O-Ring 3. Magnets (5) 4. Rotor 5. EV-100 Base 6. Clock-wise bobbins (7) 7. Grommets (14) 8. Power supply 9. Counter-clock wise bobbins 10. Nail clipper 11. Wire 12. Rotor cover 13. Pulley 14. Shaft 15. Allen key 16. Handle 17. Bushing 18. Turn-nut tool 19. Nuts (14) 20. Hex head screws (14) 21. WAGO connector 2P (9) 22. WAGO connector 3P consulab.com info@consulab.com 7 93-EV-100 Warnings and Precautions Warnings and Precautions • Read All Instructions: Before assembling or operating the EV-100, carefully read all instructions and safety guide- lines provided in this manual. • Use Only Approved Power Sources: Operate the EV-100 exclusively within the recommended voltage range (12 VDC). Never connect to AC mains or higher voltages. • Adult Supervision Required: Minor students should assemble and operate the EV-100 under adult supervision, especially when handling electrical components. • Avoid Short Circuits: Double-check all wiring and connections before powering the motor. Incorrect wiring may cause short circuits, damage components, or pose a safety risk. • Handle Magnets Safely: Permanent magnets are strong and can pinch fingers or attract metal objects unexpectedly. Keep magnets away from electronic devices, credit cards, and medical implants. • Protect Eyes and Hands: Wear safety glasses and use caution when handling tools, wire cutters, and sharp compo- nents. • Check for Damaged Parts: Do not use the kit if any parts appear damaged or defective. Contact your sales repre- sentative or support for replacements. • Disconnect Power Before Adjustments: Always disconnect the power supply before making adjustments, rewiring, or inspecting the motor. • Keep Workspace Dry: Avoid operating the EV-100 in wet or damp conditions to prevent electrical hazards. • Store Safely: After use, store all components in the provided box to prevent loss or damage. consulab.com info@consulab.com 8 93-EV-100 Troubleshooting the EV-100 Troubleshooting the EV-100 Building and wiring the EV-100 motor is a hands-on process, and sometimes things don’t work as expected. Use these tips to diagnose and fix common problems: 1. Stator Coil is Miswound • Symptoms: Motor won’t spin smoothly, or one phase doesn’t work. • What to Do: - Check the winding direction for each coil (CW or CCW) and compare with the instructions. - If a coil is wound the wrong way, unwind and rewind it in the correct direction. - Use a multimeter to check resistance, each coil should have a similar value, give or take 10%. 2. U, V, W Phases Aren’t Wired Correctly • Symptoms: Motor won’t start, runs unevenly, or vibrates. • What to Do: - Double-check that each group of four coils is connected in series for U, V, and W. - Make sure the phase leads (U, V, W) are connected to the correct points on the controller housing. - Use a multimeter to measure resistance for each phase group; all should be similar, give or take 10%. 3. Not Enough Copper Enamel Removed (No Electrical Continuity) • Symptoms: Multimeter shows “OL” (open loop) or infinite resistance; motor does not work. • What to Do: - Make sure the enamel is fully scraped off the ends of the wire before connecting each bobbin. - Re-clean the wire ends and retest each bobbin with the multimeter for a low resistance reading. 4. Short Circuit or Zero Resistance • Symptoms: Multimeter shows 0.0Ω; possible overheating or no motor function. • What to Do: - Check for non-series wires touching each other where enamel is removed. - Inspect connections for accidental shorts and separate any touching wires. 5. Motor Still Doesn’t Work • What to Do: - Check all connections for loose wires or poor contact. - Inspect rotor magnets for correct polarity and placement. - Make sure the power supply is within the safe range (12 VDC). consulab.com info@consulab.com 9 93-EV-100 Notes Notes consulab.com info@consulab.com 10 93-EV-100 Notes Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. Tous droits réservés. Teacher Resources 95-EV-100 Student Assignments — Table of Contents 91-EV-100 Answer Key — Table of Contents 96-EV-100 Instructor Manual — Table of Contents The Basics of the EV-100 Support Contact Information EV-100 Specifications Dimensions Weight Rated Specifications EV-100 Component Identification Warnings and Precautions Troubleshooting the EV-100

Student Assignments for EV-100_053374 ConsuKit Student-Built Brushless DC Motor 95-EV-100_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. 95-EV-100 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, 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 053374 and above. Table of Contents About This Manual 3 Glossary 3 Text Formatting 3 Student Assignments SA-01 — Building the Rotor 5 SA-02 — Building the Stator 8 SA-03 — Axial vs. Radial Flux 12 SA-04 — Reading Motor Pulse 14 Core Oscilloscope Vocabulary 19 SA-05 — DC Brushed or Brushless? How DC Motors Communicate 20 SA-06 — Rotor Types 23 SA-07 — Stator Winding Patterns 26 Optional Extension Activity 30 SA-08 — Wave Forms in Action 31 Glossary 37 consulab.com info@consulab.com 3 95-EV-100 About This Manual About This Manual Welcome to the ConsuLab Student Manual! This manual is designed to support your learning as you use this training aid. The information below will help you under- stand how the manual is organized and how to use it effectively. Glossary A Glossary is provided at the back of this manual. It contains definitions for key technical terms and core vocabulary used throughout the manual. • Words shown in bold text are core vocabulary terms • All bold terms are defined in the Glossary Text Formatting Different text styles are used to highlight important information: • Bold text Indicates important terms or concepts. These words are defined in the Glossary. • Italic text Indicates helpful hints, notes, or additional explanations intended to support understanding. • Red text Indicates warnings or cautions. Pay close attention to this information to avoid potential errors, damage, or safety risks. consulab.com info@consulab.com 4 95-EV-100 Student Assignments Student Assignments consulab.com info@consulab.com 5 95-EV-100 SA-01 — Building the Rotor SA-01 — Building the Rotor Name : Group : Date : Objective: Build the rotor for an electric motor and check its magnetic poles with a magnet or compass to make sure it’s aligned correctly. Required Equipment: 5 permanent magnets (round ones supplied in the kit), 4-pole rotor core (slots for magnets in the kit), Dry erase marker or tape, Compass or small test magnet, Tape or adhesive to hold magnets, Polarity tester (if avail- able), and Assembly Instructions Part 1 – Understanding Pole Arrangement A 4-pole rotor has two North poles and two South poles placed alternately around the rotor. Think of it like this: 🧲 N – S – N – S (evenly spaced around the circle). This alternating pattern ensures smooth rotation when interacting with the stator’s magnetic field. Part 2 – Marking the Rotor 1. Use a marker to divide the rotor into four equal quadrants (like a clock at 12, 3, 6, and 9 o’clock). 2. Label them Position 1, Position 2, Position 3, Position 4. These will be where your magnets are installed into each slot consulab.com info@consulab.com 6 95-EV-100 SA-01 — Building the Rotor Part 3 – Identifying Magnet Polarity 3. Take your test magnet or a compass. 4. Hold one end of the magnet near the compass. Magnet Test Magnet Method 1 Method 2 Magnet Compass Tips on using a magnet: • If the two magnets attract each other they are South and North • If the two magnets repel each other they are North and North or South and South • CAUTION: The magnets in this kit are extremely strong. If they are allowed to snap or slam together, they may become damaged. Handle with controlled movement to prevent impact. Tips on using a compass: • If the compass needle points north toward the magnet, that magnet face is a South pole. • If the compass needle points south toward the magnet, that magnet face is a North pole. • Mark the North side of each magnet with “N” and the South side with “S.” Tip: Always test both sides to confirm before placing magnets. Part 4 – Installing the Magnets 5. Place the first magnet in Position 1 with the North pole facing outward. 6. Place the second magnet Position 2 with the South pole facing outward. 7. Place the third magnet Position 3 with the North pole facing outward. 8. Place the fourth magnet in Position 4 with the South pole facing outward. Your rotor should now follow this pattern: N – S – N – S around the circle. consulab.com info@consulab.com 7 95-EV-100 SA-01 — Building the Rotor Part 5 – Testing the Assembly 9. Slowly bring a test magnet or compass near the surface of the rotor. 10. Move around each magnet position. You should detect alternating poles (N, S, N, S). 11. Record your results in the chart below: Position Tested Pole (North facing or South facing) Correct? (✓/✗) 1 2 3 4 Reflection Questions 1. Why is it important that the poles alternate in a 4-pole rotor? 2. What would happen if two North poles were placed side by side? 3. Why do engineers spend time checking magnet polarity before assembling the rest of the motor? Instructor : Grade : consulab.com info@consulab.com 8 95-EV-100 SA-02 — Building the Stator SA-02 — Building the Stator Name : Group : Date : Objective: Build a 12-pole stator and measure the coils’ resistance to ensure the wiring is correct and functioning properly. Materials Required: 12 bobbins (these are the base stator core in the kit), Magnet wire (insulated copper wire, specified gauge), Wago connectors, Digital multimeter (DMM), Dry erase marker or tape for labeling, Coil winding jig (Allen key in kit), and Assembly Instructions Procedures: Part 1 – Understanding the 12-Pole Stator The stator has 12 poles, and each pole is made by winding wire around a bobbin. These 12 bobbins are grouped into 3 phases (U, V, and W), with 4 bobbins in each phase. • Each bobbin = one stator coil • Each coil is wound with about 50 turns of insulated copper wire. • The coils in the same phase are connected in series, meaning the current flows through one coil and then continues through the next coil in that group. This keeps the magnetic field strong and balanced across all four bobbins in the phase. Why is this important? When the coils are wound and connected correctly, they create strong and balanced magnetic fields when electricity flows through them. This is what makes the motor work efficiently later. consulab.com info@consulab.com 9 95-EV-100 SA-02 — Building the Stator Part 2 – Preparing for Winding Plan the winding pattern: All bobbins in each phase must be wound in a clockwise (CW) and counterclockwise (CCW) pattern in the same group. Draw out the direction for each pole in each group and place CW (or right arrow) and CCW (or left arrow) for each corre- sponding bobbin. The first two have been done for you. CW -> U CCW