Model MF300VCLS Hydraulic Steering System/ Hydrostatic Transmission & Diagnostics Trainer OWNERS MANUAL For your safety and the safety of the students, read this manual carefully. MF300VCLS-OM IMPORTANT NOTICE Before unpacking your trainer, inspect the outside of the shipping con- tainer for damage or abuse. If there is any penetration of the shipping container, e.g. forklift forks, photograph and document the damage before opening the container. Remove the cover and inspect for damage to the trainer. Photograph and document any damage which the penetration may have caused to the trainer. Show the relationship of the penetration (if any) to the damage on the trainer. Report the damage to the shipping company immediately. Also, report the damage to the Fluid Power Training Institute™ - 1-888-222-3421 - as soon as possible. COPYRIGHT © 2010 FLUID POWER TRAINING INSTITUTE™ All rights reserved. No part of this manual may be used or repro- duced in any manner whatsoever without the written permission of the Publisher. Printed in the United States of America. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. Revised 11/10 CONGRATULATIONS! You have purchased one of the most advanced fluid power trainers in the world - the MF300VCLS. The MF300VCLS trainer was designed to make the task of teaching hydraulic steering and hydrostatic (closed-loop) transmission systems simple and re- warding, and to make the job of learning hydraulics downright fascinating. This owners manual contains all the information you need to become familiar with the MF300VCLS’s unique features, which include many safety features. You will get many years of safe and reliable opera- tion if you carefully follow the safety, operation, and maintenance guidelines and recommendations in this handbook. CONTENTS 1.0 SAFETY FIRST! - Safety Instructions ...................................1-1 2.0 Unpacking Your Trainer ........................................................ 2-1 3.0 Parts and Accessories Checklist ............................................3-1 4.0 Familiarizing yourself with the MF300VCLS Trainer ............. 4-1 5.0 Familiarizing yourself with the MF300VCLS Trainer - Hydrostatic (closed-loop) System ....................................... 5-1 6.0 Familiarizing yourself with the MF300VCLS Trainer - Steering System .................................................................. 6-1 7.0 Familiarizing yourself with the MF300VCLS Trainer - Components common to both systems .............................. 7-1 8.0 Familiarizing yourself with Components used with the MF300VCLS-TS (troubleshooting) Trainer ...................... 8-1 9.0 Troubleshooting Switch Reference Guide ............................. 9-1 10.0 Preparing your Trainer for Use .............................................10-1 11.0 Safety Features .................................................................. 11-1 12.0 Trainer Specifications ......................................................... 12-1 12.1 ......... Hydrostatic (closed-loop) System ..................... 12-1 12.2 ......... Steering System ................................................ 12-1 13.0 Service and Maintenance ................................................... 13-1 14.0 Troubleshooting your Trainer ............................................. 14-1 15.0 Where to Get Help ............................................................. 15-1 16.0 Recommended Spare Parts List ........................................ 16-1 17.0 Manufacturer’s Service/Operation Literature ..................... 17-1 18.0 Index .................................................................................. 18-1 1.0 SAFETY FIRST! - Safety Instructions 1-1 Electrical Connections - The MF300VCLS is equipped with two 115VAC male receptacles which are located on the electrical box, on the rear of the trainer. If extension cords are used, they must meet or exceed the following specifications: a. Heavy duty (15 amps). b. Must be grounded. c. Must be taped to the floor to avoid a trip hazard. If your trainer is placed in a permanent position, for safety purposes run the wiring in from overhead if possible. This will prevent unnecessary trip hazards associated with laying extension cords on the floor. CAUTION The trainer is shipped without hydraulic oil. DO NOT start the steering pump or hydrostatic pump until it has been filled with the recommended oil. Running a hydraulic pump without oil will result in severe and irreparable damage. WARNING DO NOT PUT YOUR HANDS NEAR A LEAK OR ATTEMPT TO SEARCH FOR A LEAK WITH YOUR HANDS. • Hydraulic oil can inflict three types of injuries: - skin penetration, burn, and eye. • Hydraulic oil can penetrate skin at pressures as low as 100 PSI (6.9 bar). Skin penetration can result in severe injury, permanent loss of hand or finger motion, hand or finger amputation, or death. • If you get injected, see a physician immediately. Do not eat or drink. • Take the MSDS sheet of the injected material with you. If the physician wants to simply clean and bandage the wound, refer him/her to http://www.fluidpowersafety.com. • Hydraulic oil can inflict second and third degree burns at normal operating temperature - as low as 130ºF (54.4ºC). 1-2 1.0 SAFETY FIRST! - Safety Instructions Operating or observing the operation of this trainer without safety glasses may lead to an accident which could result in severe eye injury or blindness. This trainer is to be operated only under the supervision of a trained, authorized instructor. Follow all safety instructions in the operator handbook before using this trainer. WARNING Prevention is better than cure! An eye-wash station must be located in an accessible location that requires no more than ten (10) seconds to reach and should be located within a travel distance no greater than 100 feet (30.5 m) from the hazard (ANSI Z358.1-1998). WARNING WARNING Post a warning sign on the entry door into the hydraulic training center. Warn people who enter the room that hydraulic system(s) are in operation and that they must wear safety glasses with side- shields which conform to ANSI Z87.1. WARNING Wipe all excess oil from trainer during operation and trainer activi- ties. Failure to maintain a clean, oil-free working environment could lead to a slip hazard injury. 1-3 1.0 SAFETY FIRST! - Safety Instructions WARNING The trainers have been designed to operate safely. Any type of change or modification could have a detrimental effect on that safety. Accordingly, ALL modifications or changes, regardless of how minor, must be approved in writing, by the FPTI™ - these include: • Changes in the design of the trainer. • Adding component(s) to the trainer. • Removing component(s) from the trainer. • Failing to properly maintain the trainer. • Making component substitutions. • Using the trainer for any purpose other than training and education. 2.0 Unpacking Your Trainer - SAFETY INSTRUCTIONS: a. The trainer weighs approximately 250 lbs. (113.4 kg). b. Before unpacking the trainer, make sure the shipping container is standing on a smooth, level surface. c. At least two people must be in attendance when the trainer is being unpacked. While there is no need to lift the trainer, the people who unpack it must be strong enough to hold it as it is rolled off the pallet. d. Wear safety glasses and steel-toe boots when unpacking the trainer. TOOLS REQUIRED: a. Phillips-head screwdriver. b. Scissors. c. 7/16” wrench (2). Step 1: Using a Phillips-head screwdriver, remove the screws from around the base of the cardboard container (approximately 12 screws (Figure 2-1)). Step 2: With a person positioned on either side of the cardboard container, carefully lift it up and over the top of the trainer. If there is no evidence of damage to the trainer, fold the cardboard container and please recycle it. NOTE: IF THE SHIPPING CONTAINER IS DAMAGED KEEP IT INTACT UNTIL THE FREIGHT COMPANY HAS COMPLETED ITS INVESTIGATION. Step 3: Carefully remove the protective plastic wrap from the trainer. DO NOT use a sharp instrument as the cutting tool may damage the trainer. Please recycle the plastic wrap! Step 4: Carefully remove the boxes which are stowed below the trainer. These boxes contain the hydraulic hoses and accessories. Step 5: Loosen and remove the ratchet straps which secure the trainer to the pallet. 2-1 Figure 2-1 2-2 2.0 Unpacking Your Trainer - cont’d. Figure 2-2 Step 6: Apply all caster brakes. To apply the brakes, push down firmly on the tab labelled “ON” on each individual brake lever. (Figure 2-2). To release the brakes, push down firmly on the tab labelled “OFF” on each individual brake lever (Figure 2-3). Caster brake applied Caster brake released Figure 2-3 Step 9: Once the trainer is off the pallet, apply the brakes and proceed with the start- up procedure. The trainer weighs approximately 250 lbs. (113.4 kg). DO NOT place feet or hands in the path of the casters. If the casters roll over your feet or hands, it could cause severe injury. CAUTION 2.0 Unpacking Your Trainer - cont’d. Step 7: Using a 7/16” wrench, loosen the bolts which secure the 1” x 1” timbers from either side of the pallet between the casters (Figure 2-4). 2-3 Figure 2-4 CAUTION When the bolts are removed, the trainer is free to roll. Before removing the bolts, make sure the pallet is standing on a smooth, level surface. Apply the caster brakes and have a person hold onto the trainer. CAUTION At least two (2) people must be in attendance when rolling the trainer off the pallet (one on either side of the trainer). Step 8: With a person on either side of the trainer, release the brakes on each caster, gently roll it forward, and carefully lower it to the floor. 3.0 Parts and Accessories Checklist - 3-1 3.1 MF300VCLS Trainer - Standard and Troubleshooting (TS) models Parts and accessories are contained in the boxes which are stored on the shipping crate below the trainer. We recommend that you inspect the contents for damage. Although we exercise care in packing the parts, we recommend that you check each item, and quantity, against the following parts list. MF300VCLS MF300VCLS-TS DESCRIPTION of ITEM 8 8 1/4”x 24” long hydraulic hoses with quick-connect couplings. 4 4 1/4”x 40” long hydraulic hoses with quick-connect couplings. 4 6 “T’s” with quick-connect couplings. 1 1 Oil funnel with 3/8” NPT male connector. - 1 0-100 PSI pressure gauge. - 1 0-30”Hg vacuum gauge. - 1 Flow meter test kit - 4 Instructor switch setting cards. NOTE: Report damages or missing components to the Fluid Power Training Institute™ immediately. Damaged components must be returned to the manufacturer. 4-1 4.0 Familiarizing yourself with the MF300VCLS Trainer Figure 4-1 4.1 Right-hand side view (Figure 4-1) Take a moment to familiarize yourself with the components on your MF300VCLS Hy- draulic Steering/Hydrostatic (closed-loop) Transmission & Diagnostics Trainer. 1 1. Right-rear drive wheel. 2. Right-hand, bi-directional flow meter - hydrostatic transmission. 3. Overcenter pump - cutaway model. 4. Panel-mounted tachometer - hydrostatic transmission. 5. Charge pressure gauge - hydrostatic transmission. 6. Control panel - hydrostatic transmission. 7. F-N-R control lever - hydrostatic transmission. 8. Power supply - hydrostatic transmission. 9. Right-front wheel. 10. Hydraulic pump - steering system. 11. Oil filter. 12. Caster brakes (x4) 13. Hydraulic oil reservoir. 14. Reservoir filler/breather. 15. Pressure/leak test pump (TS model only - not shown). 2 3 5 7 8 9 10 11 13 14 12 4 6 4-2 Figure 4-2 4.2 Left-hand side view (Figure 4-2) 4.0 Familiarizing yourself with the MF300VCLS Trainer 1. Left-front wheel. 2. Left-hand cylinder. 3. Steering wheel. 4. Oil temperature gauge. 5. Control panel - steering system. 6. Oil pressure gauge - steering system 7. Left-rear drive wheel. 8. Hydraulic oil reservoir. 9. Power supply - steering. 10. Caster brakes (x4). 11. Electric motor - steering pump. 12. Hose and “T” storage caddy. 13. Pressure/leak test pump (TS model only - not shown). 1 2 3 4 76 8 911 12 10 5 4-3 Figure 4-3 4.3 Front view - Steering system (Figure 4-3) 4.0 Familiarizing yourself with the MF300VCLS Trainer 1. Steering cylinder - right-hand. 2. Cross-port relief valve. 3. Steering cylinder - left-hand. 4. Orbitrol steering valve. 5. Steering pressure relief valve. 6. Priority flow divider. 7. Steering wheel. 8. Steering pump connector. 9. Tank return line - connector. 10. Tank return line - auxiliary. 11. Tank return line - auxiliary. 12. Pressure/leak test pump (TS model only - not shown). 1 2 5 6 43 7 8 9 1011 4-4 Figure 4-4 4.4 Rear view - Hydrostatic system (Figure 4-4) 4.0 Familiarizing yourself with the MF300VCLS Trainer 1. Power ON warning light - Steering System 2. Flow meter - left-hand. 3. Electric motor - hydrostatic pump. 4. Flow meter - right-hand. 5. Power ON warning light - Hydrostatic System 6. Hydrostatic pump control lever. 7. Drive motor - left-hand. 8. Hydrostatic pump - active cutaway. 9. Hydrostatic pump drive unit. 10. Drive motor - right-hand. 11. Magnetic sensor - Tachometer. 12. Pressure/leak test pump (TS model only - not shown). 2 4 6 7 9 10 11 3 8 1 5 5.1 Digital Tachometer - Hydrostatic transmission control panel The panel-mounted digital tachometer (Figure 5-1) receives feedback from the motor shaft via a proximity sensor which is attached to the main plate, under- neath the drive motor shaft of the right-rear wheel (Figure 5-2). The distance from the allen-screw on the motor-shaft and the proximity switch sensor is critical for proper operation. The factory set distance is approximately 0.080” (2mm). Figure 5-1 5.0 Familiarizing yourself with the MF300VCLS Trainer - Hydrostatic (closed-loop) System Figure 5-2 5-1 When the distance setting is correct, the red “sensor” light on the tachometer display will flash when the motor shaft is rotating. If the tachometer fails to display motor shaft speed, and the red light is not flashing, the problem is usually attributed to the “gap” setting. If the light does not flash when you move the sensor away from, or toward, the motor shaft, refer to troubleshooting information (Section 11.0), for further information. 5.2 Charge Pressure Gauge (0-100 PSI/0-6.9 bar) - Hydrostatic transmission control panel (Figure 5-3) The normal charge pressure is 20-25 PSI (1.38-1.72 bar). Figure 5-3 5-2 5.0 Familiarizing yourself with the MF300VCLS Trainer - Hydrostatic (closed-loop) System 5.3 Flow meters - Hydrostatic transmission (Figure 5-4) Each “leg” of the closed-loop circuit has a 0-5.0 GPM bi-directional flow meter. The flow meters read flow in two directions. Figure 5-4 5.0 Familiarizing yourself with the MF300VCLS Trainer - Hydrostatic (closed-loop) System 5-3 5.5 Hydrostatic Pump - (Figure 5-6) Figure 5-6 5.4 Wheel-Drive Motors - (Figure 5-5) Each rear wheel is equipped with a 0.5 cu.in./rev. hydraulic motor. The motors can be connected in parallel or series depending on the activity a student is undertaking. The physical size of a hydraulic motor can be very misleading with respect to a motors torque output. Small motors can produce relatively high torque. For safety purposes, the wheels on the MF300VCLS trainer rotate indepen- dently of the motor drive shaft. The wheel will spin when the motor rotates. However, the wheels will stop rotating if any attempt is made to prevent the motor from rotating or stop the wheels while in motion. Figure 5-5 Displacement: 0.37 cu.in./rev. (6.1 cc/rev.) Maximum Inlet Restriction: 4.0” Hg (mercury) Charge Pump Displacement: 0.13 cu.in./rev. (2.2 cc/rev.) 5.6 F-N-R Direction Control Lever - (Figure 5-7) Figure 5-7 5.0 Familiarizing yourself with the MF300VCLS Trainer - Hydrostatic (closed-loop) System 5-4 5.7 Power Supply - Hydrostatic Transmission System (Figure 5-8) The power switch for the hydrostatic (closed-loop) side of the trainer is located under the top plate, to the right-hand side of the hydrostatic control panel. The switch has integral overload protection. To reset the switch, push the switch lever down firmly. The switch is also equipped with a lockout tab. Figure 5-8 6.3 Orbitrol Steering Valve - Steering control panel (Figure 6-3) Figure 6-3 6.1 Digital Oil Temperature Gauge - Steering control panel (Figure 6-1) Figure 6-1 6.0 Familiarizing yourself with the MF300VCLS Trainer - Steering System 6-1 6.2 Steering System Pressure Gauge - Steering control panel (Figure 6-2) Figure 6-2 6-2 6.0 Familiarizing yourself with the MF300VCLS Trainer - Steering System 6.4 Steering System Pressure Relief Valve (adjustable) - (Figure 6-4) Figure 6-4 6.5 Priority Flow Divider (non-adjustable) - (Figure 6-5) Figure 6-5 6.6 Cross-port Relief Valve (adjustable) - (Figure 6-6) Figure 6-6 6.8 Steering System Pump - (Figure 6-8) Figure 6-8 6.7 Dual Steering Cylinders (steering mechanism) - (Figure 6-7) The steering axles are equipped with safety override springs which serve two primary functions: 1. Will override if a persons hand becomes trapped between the wheel and the trainer frame. 2. Will override and prevent damage if the transmission lines are incorrectly connected or if connection is made to one cylinder only. Figure 6-7 6-3 6.0 Familiarizing yourself with the MF300VCLS Trainer - Steering System 6.9 Power Supply - Steering System (Figure 6-9) The power switch for the steering system side of the trainer is located under the top plate, to the left-hand side of the steering control panel. The switch has integral overload protection. To reset the switch, push the switch lever down firmly. The switch is also equipped with a lockout tab. Figure 6-9 6-4 6.0 Familiarizing yourself with the MF300VCLS Trainer - Steering System 7.3 Hydraulic Oil Filter with Filter Bypass Indicator - (Figure 7-3) Figure 7-3 7-1 7.0 Familiarizing yourself with the MF300VCLS Trainer - Components common to both systems 7.1 Power Receptacles - (Figure 7-1) Left-Hand power receptacle - Steering system. Right-Hand power receptacle - Hydrostatic (closed-loop) system. Figure 7-1 7.2 Hydraulic Oil Reservoir - (Figure 7-2) Figure 7-2 Capacity: 4.0 U.S. gallons (15.14 liters) 7.7 Hoses and “T’s” Storage Caddy - (Figure 7-7) The trainer is equipped with a convenient, stowable, hose and “T” storage caddy. Place hoses and “T’s” neatly in the storage slots and rotate the tray under the trainer when not in use. Figure 7-7 7-2 7.0 Familiarizing yourself with the MF300VCLS Trainer - Components common to both systems 7.5 Hydraulic Oil Reservoir Filler/Breather Cap - (Figure 7-5) Figure 7-5 7.4 Hydraulic Reservoir Drain Valve - (Figure 7-4) The hydraulic reservoir drain valve is located below the trainer. Figure 7-4 8-1 8.0 Familiarizing yourself with Components used with the MF300VCLS-TS (troubleshooting) Trainer - 8.1 Pressure/Leak Test Pump - The pressure/leak test pump is designed for testing a variety of hydraulic components. While it bears the resemblance of a commercial porta-power, it is not a porta-power. The pressure/leak test pump does not need to be filled with oil. It automatically fills whenever the steering power unit is operating. If, while using the pressure/leak test pump it runs out of oil, simply run the pump run for approximately 30 seconds, and it will re-fill. To operate the pressure/leak test pump, rotate the knob (Figure 8-1) clockwise until it stops, and operate the hand-lever. To release the pressure, rotate the knob counterclockwise until it stops. Figure 8-1 Figure 8-2 Steering 8.2 “Fault-Set” Toggle-switches - The row of 2-position toggle switches located across the top of the control panels cause various components to “wear out.” This unique feature creates “real world” faults for students to find. Steering System - There are ten (10) two-position toggle switches for setting faults in the steering system. They are located across the back of the steering control panel (Figure 8-2). The switches ON/OFF positions are purposely staggered. Reference numbers (1 to 10) are located directly above each switch. 8-2 8.3 “Fault-Set” Toggle-switch Master Switch - The trainer is designed for teaching hydraulic system and hydraulic system/ component diagnostics. To avoid inadvertent operation of the “fault-set” toggle switches, the toggle switch circuit is equipped with a master switch (Figure 8-4). The master switch can be locked in the ON or OFF position. Figure 8-4 8.0 Familiarizing yourself with Components used with the MF300VCLS-TS (troubleshooting) Trainer - cont’d. Figure 8-3 Hydrostatic Hydrostatic System - There are five (5) two-position toggle switches for setting faults in the hydrostatic transmission system. They are located across the back of the hydrostatic transmission system control panel (Figure 8-3). The switches ON/OFF positions are purposely staggered. Reference numbers (1 to 5) are located directly above each switch. Step 2: Next, carefully aim the laser between the openings in the fan safety guard at the reflective tape (Figure 8-7). Hold the tachometer steady, and depress the white button. Wait a few seconds for the tachometer to respond. Pushing the black button on the tachometer will automatically submit the indicated speed to the tach- ometer’s memory. To learn more about the tachometer, read the instruction manual (See section 17.0). 8-3 Figure 8-7 8.0 Familiarizing yourself with Components used with the MF300VCLS-TS (troubleshooting) Trainer - cont’d. 8.4 Digital, Hand-Held, Laser-Type Tachometer (optional - Part # HC-DT207L) - The hand-held tachometer is used primarily when students are learning diagnostic skills. Its main purpose is for students to observe and record prime-mover (electric motor) speed. The state-of-the-art tachometer needs a reflective feedback medium to operate properly. A piece of self-adhesive reflective tape has been attached to the electric motor’s cooling fan (Figure 8-5) for this purpose. Step 1: To operate the tachometer, first rotate the dial to the correct position - “non-contact RPM” (Figure 8-6). Figure 8-5 Figure 8-6 8-4 8.6 Inlet Restriction (vacuum) Check Connection for Charge Pump - Figure 8-9 8.0 Familiarizing yourself with Components used with the MF300VCLS-TS (troubleshooting) Trainer - cont’d. 8.7 Case Pressure Check Connection for Overcenter Pump - Figure 8-10 8.5 Flow Meter Test Kit - The flow meter-test kit consists of an in-line, 0-2.0 GPM (0.76 liters) flow meter, load-cell, 0-1000 PSI (0-69 bar) glycerine-filled pressure gauge, and, quick- connectors (Figure 8-8). Figure 8-8 9.0 Troubleshooting Toggle Switch Position Reference Guide - (Troubleshooting model only) The following diagrams indicate the switch number, component type, and switch position for the normal operation mode of the steering system side (Figure 9-1) and hydrostatic (closed-loop) system side (Figure 9-2) of the MF300VCLS trainer. 9-1 Figure 9-1 - Steering system troubleshooting toggle switch reference guide Figure 9-2 - Hydrostatic (closed-loop) system troubleshooting toggle switch reference guide 1 2 3 4 5 UP DWN DWN Pump (FWD) Pump (REV) Blank Blank Blank UPUP 10.0 Preparing Your Trainer for Use - 10-1 Once you are satisfied that the parts and accessories are in good condition and ac- counted for, and, you have familiarized yourself with the MF300VCLS Trainer, go ahead and install the parts and accessorises into their respective positions on the trainer. 10.1 Hydraulic Hoses - Reach under the front of the trainer and swing out the hose caddy. Place the fourteen (14) hoses in the back four rows. The “T’s” can be placed in the front row of the caddy for convenience and accessability (Figure 10-1). Figure 10-1 10.2 Fill the Oil Reservoir - Oil type/grade: AW-32 hydraulic fluid. Reservoir Capacity: Approximately 4.0 U.S. gallons (15.14 liters). Step 1: Remove the filler/breather cap (Figure 10-2). Place a funnel in the filler neck. Hand-tighten only. Figure 10-2 10.0 Preparing Your Trainer for Use - cont’d. 10-2 Figure 10-3 Figure 10-4 Step 2: Add oil until it reaches the “OIL LEVEL” mark on the reservoir (Figure 10-3). Step 3: Connect the trainer to a 115 volt, single-phas electrical outlet (minimum 20 amps) using an approved electrical cord with ground. If the cord lays on the ground, it must be properly taped to prevent a trip hazard. All wiring must be done by a certified electrician. Step 4: Remove a hose from the hose caddy and use it to bridge the closed-loop. (Figure 10-5). Step 5: Start the power unit. Figure 10-5 Step 6: Observe the charge pressure gauge. The pressure must reach 45-75 PSI (3.1-5.2 bar) within approximately 15 seconds after starting the motor. Step 7: Re-check the oil level. Add oil if necessay. Step 8: Remove the funnel. Step 9: Replace the oil filler/breather cap and tighten by hand. Step 10: Remove the hose and store it in the hose caddy. 10.0 Preparing Your Trainer for Use - cont’d. 10-3 11.0 Safety Features - 11.1 Quick-connect/disconnect Safety Covers (if applicable) - The male quick-connect/disconnects (non flat-face connector style) are fitted with spring-loaded, self-closing, safety covers. The safety covers will diffuse the oil in the unlikely event that a quick-connect/disconnect remains open. To attach a hose to a quick-connect/disconnect, pull the cover away from the connector until the connector is exposed (Figure 11-1). Figure 11-1 Figure 11-2 Figure 11-3 Figure 11-4 Figure 11-5 11-1 Make sure that the hose-end connector is properly engaged in the male connector. If the connection is incomplete it will not allow oil to pass (Figures 11-4 & 11-5). NOTE: Check to see if the connector is secure by pulling on the connector. NOTE: Do not move the safety covers more than what is necessary to make a connection. Excessive force could cause the spring-loaded cover to distort. WARNING: Damaged safety covers must be replaced immediately! Push the female connector onto the male connector and push it until it stops (Figures 11-2 & 11-3). Correct Incorrect 12.0 Trainer Specifications - 12.1 Hydrostatic (closed-loop) System - Electrical: 120VAC single-phase. 10 amp service. Hydraulic Pump: 1 GPM (3.79 Lpm) variable-displacement, piston pump. Operating Pressure (max.): 1000 PSI (69 bar) Charge Pressure: 40-75 PSI (2.76-5.17 bar) Oil: AW32 hydraulic oil. Reservoir Capacity: Approx. 4 U.S. gallons (15.14 liters) Hyd. Motor Displacement: 0.5 cu. in./rev. 12.2 Steering System - Electrical: 120VAC single-phase. 10 amp service. Hydraulic Pump: 2 GPM (7.58 Lpm) fixed displacement gear pump. Operating Pressure (max.): 1000 PSI (69 bar) Oil: AW32 hydraulic oil. Reservoir Capacity: Approx. 4 U.S. gallons (15.14 liters) Cylinder Diameter: 1.5” (38.1 mm) Cylinder Stroke: 4” (101.6 mm) Shipping Weight: 350 lbs. (158.8 kg) Trainer Weight: 250 lbs (113.4 kg) *Trainer Dimensions: Height: 50” (127 cm) (Figure 12-1) Width: 45” (114 cm) Depth: 36” (91 cm) 12-1 Figure 12-1 *All dimensions taken with steering wheel removed. 13.0 Service and Maintenance - 13-1 13.1 Scheduled Service and Maintenance Intervals - Your MF300VCLS trainer is designed to require very little maintenance. However, to give you years of trouble-free operation there are a few things you must do: DAILY: 1. Check oil level. 2. Check for oil leaks dripping to floor. - repair immediately to prevent slip hazard. 3. Inspect, and replace if necessary, quick-disconnect safety covers. 4. Inspect electrical wires and connections. 5. Inspect for loose bolts. ANNUALLY: 1. Drain oil and replace - approximately 4.0 U.S. gallons [15.14 liters] (See 13.2). 2. Remove oil filter and replace (See 13.3). 13.0 Service and Maintenance - cont’d. 13-2 Figure 13-1 Step 1: Disconnect the power supply and lock the trainer out. Step 2: To drain the oil, place a receptacle that will hold at least 4.0 U.S. gallons (15.14 liters) under the drain valve. Turn the handle to the vertical (open) position (Photo shows “closed” position). Step 3: When the reservoir is empty, close the oil drain valve by turning the handle to the horizontal (closed) position. 13.2 Draining the Oil - An oil drain is located on the underside of the trainer (Figure 13-1). 13.0 Service and Maintenance - cont’d. 13.3 Oil Filter Service - The MF300VCLS Trainer is equipped with a spin-on/off type filter element (Figure 13-2). 13-3 Figure 13-2 To replace the filter element: Step 1: Disconnect the power supply and lock the trainer out. NOTE: A small amount of oil may escape from the filter housing when the seal is broken. Place a receptacle on the floor beneath the filter assembly to contain the leakage. Step 2: Turn the filter element (clockwise from above) by hand, and slowly remove it. Step 3: Discard the filter element in accordance with local and State laws. Step 4: Before installing the new filter element, lubricate the seal with hydraulic oil. Step 5: Install the new filter element and tighten by hand only - DO NOT OVER TIGHTEN. Step 6: Wipe residual oil off the filter element. Step 7: Fill the reservoir with new oil until it reaches the oil level mark (See 10.2). Step 8: Inspect the floor for signs of oil which may have spilled while removing the filter element. Clean oil spills thoroughly to prevent a slip-type accident. 14.0 Troubleshooting your Trainer - Steering System - 14-1 PROBLEM 1. Power-unit does not start. 2. Pump makes noise. 3. Breaker keeps tripping. SOLUTION a. Check red Power ON warning light. If not illuminated check power supply. b. If red Power ON warning light is illuminated, reset breaker on motor starter. To reset breaker, set switch to OFF position and push down firmly on the switch. Attempt to start motor. If motor fails to start, the electrical circuit must be checked by a certified electrician. a. Pump noise is usually caused by cavi- tation. Check oil level - add if necessary. a. Check pump flow - Flow adjustment screw must be set for 1.0 GPM (3.79 Lpm) flow rate. Check steering system safety relief valve pressure - Set at 1000 PSI (69 bar). Hydrostatic System - PROBLEM 1. Power-unit does not start. 2. Pump makes noise. 3. Breaker keeps tripping. SOLUTION a. Check red Power ON warning light. If not illuminated check power supply. b. If red Power ON warning light is illuminated, reset breaker on motor starter. To reset breaker, set switch to OFF position and push down firmly on the switch. Attempt to start motor. If motor fails to start, the electrical circuit must be checked by a certified electrician. a. Pump noise is usually caused by cavi- tation. Check oil level - add if necessary. a. Check pump flow - Flow adjustment screw must be set for 1.0 GPM (3.79 Lpm) flow rate. Check steering system safety relief valve pressure - Set at 1000 PSI (69 bar). 14.0 Troubleshooting your Trainer - cont’d. 14.1 Digital Tachometer - (panel-mounted) - The distance from the motor-shaft key-way and the proximity switch is critical for proper operation. The factory set distance is 0.08” (2 mm). If the tachometer fails to display motor shaft speed, and the red light is not flashing, the problem is usually attributed to the distance setting or the “gap”. Here is a simple technique for setting the “gap”: 1. Slightly loosen the upper and lower securing nuts on the sensor shaft. 2. While observing the red light on the tachometer, slowly move the sensor assembly away from the shaft, increasing the “gap.” If the light starts flashing, the tachometer will begin to operate - the gap was too small. 3. Tighten the two securing nuts and re-check the tachometer display. 4. If the light fails to start flashing, slowly move the sensor toward the motor shaft until the light starts flashing. Adjust it until you feel the sensor barely contact with the key in the motor shaft - DO NOT force it against the key! 5. Tighten the two securing nuts and re-check the tachometer display. If the light does not flash when you move the sensor away from, or toward, the motor shaft, refer to the troubleshooting section of this components documentation which can be found in section 17.0 - Manufacturer’s Service/Operation Literature, for further information. NOTE: When adjusting the sensor, turn the motor shaft to ensure the sensor does not interfere with the shaft. 14-2 15-1 15.0 Where to Get Help - If, after following the troubleshooting guide the problem(s) you are experiencing still persist, call the Fluid Power Training Institute™ for assistance at 1-888-222-3421. Please have the model number and serial number of your trainer available when you call. 16-1 16.0 Recommended Spare Parts List - The MF300VCLS trainers are equipped with parts which are designed for high-cycle operation. Given the proper care they should last for many years. However, certain items need regular service to keep your trainer operating reliably. ITEM DESCRIPTION PART # 1. Oil filter element VCLS-SF6520 2. - - 3. - - 4. - - 5. **Optional tachometer (hand-held) battery AA battery (qty. 2) ** MF300VCLS-TS troubleshooting trainer only. 17.0 Manufacturer’s Service/Operation Literature - 17.1 See accompanying documentation. 17-1 A. Accessories ..................................................................................................... 3-1 B Battery - tachometer (hand-held) - optional ............................................. 16-1 Brakes - caster .................................................................................................2-2 C Case-pressure check connection ...................................................................... 8-4 Casters .....................................................................................................2-2 Check list ..................................................................................................... 3-1 D Digital - oil temperature gauge ................................................................. 6-1 hand-held tachometer - optional ................................................. 8-3 panel-mount tachometer ............................................................. 5-1 Drain - oil ...................................................................................................13-2 E Electrical 115VAC ..................................................................................... 10-2 power .............................................................................. 5-4/6-4/7-1 Extension cord .................................................................................................. 1-1 Eye-wash station .............................................................................................. 1-2 F Familiarization .................................................................................................. 4-1 Filler/breather cap.............................................................................................. 7-2 Filling with oil ...................................................................................................10-1 Filter element – oil .......................................................................................... 16-1 Flow control valve (priority flow divider) ........................................................... 6-2 Flow meter - inline ............................................................................................ 5-2 test kit ........................................................................................... 8-4 18-1 18.0 INDEX - 18-2 G Gauges - charge pressure .......................................................................... 5-2 steering pressure ........................................................................ 6-1 oil temperature ............................................................................ 6-1 Glasses - safety ................................................................................................ 1-2 H Hose - caddy .......................................................................................... 7-2 hydraulic .................................................................................... 10-1 Hydraulic - hose ........................................................................................... 10-1 oil .............................................................................................. 10-1 reservoir ...................................................................................... 7-1 I J K L M Master keylock switch ........................................................................................8-2 Meter - flow .............................................................................................. 5-2 Motor - electric ................................................................................... 4-2/4-4 hydraulic ...................................................................................... 5-3 N O Oil - drain ............................................................................................ 7-2 filler/breather ............................................................................... 7-2 filter ............................................................................................. 7-1 18.0 INDEX - cont’d. hydraulic .................................................................................... 10-1 type/grade ................................................................................. 10-1 P Pallet ..................................................................................................... 2-1 Parts - list .................................................................................................3-1 spare ..........................................................................................16-1 Power - unit ........................................................................................ 4-2/4-4 supply (hydrostatic) ..................................................................... 5-4 supply (steering) ......................................................................... 6-4 Pressure - case ............................................................................................ 8-4 gauge (steering) ......................................................................... 6-1 gauge (charge)............................................................................. 5-2 relief valve ................................................................................... 6-2 system ....................................................................................... 12-1 Priority flow divider ........................................................................................... 6-2 Pressure/leak test pump ................................................................................... 8-1 Pump - fixed-displacement .............................................................. 6-3/12-1 pressure/leak test ........................................................................ 8-1 hydrostatic system .............................................................. 5-3/12-1 steering system ................................................................... 6-3/12-1 overcenter ........................................................................... 5-3/12-1 Q Quick-connect/disconnect .............................................................................. 11-1 R Receptacle – electric ...................................................................................... 10-2 Reservoir - hydraulic ......................................................................................... 7-1 18-3 18.0 INDEX - cont’d. S Safety - glasses ........................................................................................ 1-2 cover - quick-connect/disconnect .............................................. 11-1 warnings ......................................................................... 1-1/1-2/1-3 Specifications ................................................................................................ 12-1 Station – eye-wash ........................................................................................... 1-2 Switch - key-lock ........................................................................................ 8-2 master ......................................................................................... 8-2 panel ............................................................................................ 8-1 reference guide ........................................................................... 9-1 reset ............................................................................................ 9-1 toggle .......................................................................................... 8-1 troubleshooting ........................................................................... 8-1 T T’s ............................................................................................... 3-1/7-2 Tachometer - adjustment ................................................................................ 14-2 hand-held - optional .................................................................... 8-3 panel-mounted ............................................................................ 5-1 Temperature gauge - oil ................................................................................................ 6-1 Toggle switches ................................................................................................ 8-1 Troubleshooting ................................................................................................ 8-1 U Unpacking .................................................................................................... 2-1 V Valve - orbitrol steering ........................................................................... 6-1 18-4 18.0 INDEX - cont’d. pressure relief ............................................................................. 6-2 priority flow divider ...................................................................... 6-2 cross-port relief ........................................................................... 6-2 Vacuum (inlet restriction) check ........................................................................ 8-4 W Weight ................................................................................................... 12-1 X Y Z 18-5 18.0 INDEX - cont’d. If you have any questions that this document does not address, please contact us immediately for as- sistance. P.O. Box 711201 Salt Lake City, UT 84171 PH: 801-908-5456 FAX: 801-908-5734 e-mail: info@fpti.org web: www.fpti.org

Purpose- The MF400-HCTS is designed to help instructors teach and students learn how to safely and correctly perform the following skills: • Overhaul a hydraulic cylinder. • Identify and use the tools needed to overhaul a hydraulic cylinder. • Inspect the components in a hydraulic cylinder to determine root cause of failure. • Replace piston and gland seals. • Test a hydraulic cylinder. • Air bleed a hydraulic cylinder. How the MF400-HCTS will benefit instructors, students and the college: 1. Instructors will benefit because they will: • Teach a cylinder overhaul course with materials that were developed by cylinder overhaul specialists. • Teach overhaul techniques that are based on best industry practices that foster safety and efficiency in the lab and ultimately in the work-place. • Teach need-to-know information – cylinder defects are consistent with the most common causes of cylinder failure. • Efficient simulator design makes good use of valuable lab space while creating a safe and meaningful learning environment. 2. Students will benefit because they will: • Have skills that enable them to overhaul hydraulic cylinders safely and efficiently. • Have the skills needed to correctly analyze root causes of cylinder failure and remedy them. • Have skills that will set them apart from others when applying for jobs. Their unique abilities will afford them higher wages and long-term employment. • Be empowered not only to work safely themselves but also to promote a safe working environment. • Be an asset to their respective companies because their skills will increase productivity and profitability. • They will avoid safety hazards caused by trial and error cylinder overhaul practices. Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF400-HCTS Hydraulic Cylinder Training Simulator - 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org 3. Colleges will benefit because they will: • Attract students because students will see and appreciate the investment the college has made in lab equipment that is specifically designed for teaching skills safely. • Graduate students who will have the skill-sets needed to get, and keep, good paying jobs. • Serve industry well – properly trained technicians means increased productivity and profitability for employers. • Invest in training simulators that are designed for teaching specific skills safely leaving less chance for accidents and thus reducing liability. Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hands-on Activities - Hands-on activities include: • Steps on preparing a cylinder for service – removing, draining the oil, and securing it so it cannot move. • Tools - selection and safe and proper use. • Correct disassembly procedures. • Component inspection and failure analysis. • When to hone a cylinder tube. • Correct procedures for installing piston seals and rod seals. • Correct assembly procedures. • Correct test procedures. • Correct installation and air-bleeding procedures. Course material and Visual Aids - • Student manual – How to Service Hydraulic Cylinders – a guide for beginners. The MF400-HCTS consists of the following components: • Four-station mobile training module equipped with (4) swivel-lock casters. Steel and aluminum construc- tion with powder coat finish. • Welded steel anchors and cradles with mechanical locks to secure the cylinders for safety and handling. • Four (4) clear acrylic, cylinder safety covers at each cylinder station to protect the student from oil spray in the event they did not reassemble the cylinder, or install the seals, correctly. • Can store up to eighteen (18) hydraulic cylinders (available for purchase separately). CYLINDER TYPE PART # Round-weld type hydraulic cylinder MF400-RWC Tie-rod type hydraulic cylinder MF400-TRC The MF400-HCTS teaches students, in addition to proper and safe cylinder overhaul procedures, how to correctly analyze the most common types of cylinder failures – in real time. • Safe and ergonomic cylinder fixture design. Cylinders are anchored and secured in fixtures to prevent: - Barrel rotation while tightening/loosening rod glands. - Rod rotation while tightening/loosening piston retaining nuts. - Inadvertent cylinder movement/falling prevents the potential for leg/foot injuries. Warranty - As with all FPTI™ training systems, the MF400-HCTS Hydraulic Training Simulator is covered for two (2) years from date of delivery. Warranty covers defects in materials and quality of work. Warranty does not cover damage caused by abuse or modifications. MF400-HCTS Hydraulic Cylinder Training Simulator - 29.0” (74cm) 45.0” (114cm) 69.0” (175cm) Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF400-HCTS Hydraulic Cylinder Training Simulator - Shipping Specifications - Shipping weight: (does not include pallet and packaging) 825 lbs (374 kgs) Shipping dimensions: (includes pallet and packaging) 84” (213cm) Tall X 54” (137cm”) Wide X 42” (107cm) Deep Warranty - FPTI™ warrantees it’s products against defect in materials and/or workmanship for a period of two (2) years from date of delivery. MF400-HCTS (08/26/21) • COPYRIGHT © 2021

Simulator Activities Student Workbook MF400-HCTS Hydraulic Cylinder Training System REVISION 4.1 MF400-HCTS Hydraulic Cylinder Training System Simulator Activities Student Workbook Published by: FLUID POWER TRAINING INSTITUTE™ 2170 South 3140 West West Valley City, UT 84119 www.fpti.org HC-R025-TA (REV. 4.1) Unless permission is granted, this format or material con- tained herein shall not be copied, reproduced, or quoted for reproduction, by electrical, mechanical, or chemical process, or accomodation thereof, now or later developed. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. The information contained in this book is designed for educational purposes only. The FLUID POWER TRAINING INSTITUTE™ has carefully compiled and thoroughly checked this information for accuracy. However, since any segment of information can apply to one application and not to a similar application due to: differences in environmental conditions; operating personnel; operating conditions; materials; components; and since errors can occur in system circuits, tables, and text, we assume no liability for the safe and/or satisfactory operation of any machine or installation designed from the information contained in this book. Any design which could cause injury to personnel or dam- age to a machine or installation should be independently checked by a certified engineer. COPYRIGHT © 2021 FLUID POWER TRAINING INSTITUTE™ Rev 4.1 - October 14, 2021 Printed in the UNITED STATES of AMERICA INTRODUCTION ................................................................................. i GENERAL INSTRUCTIONS ................................................................... ii OBJECTIVES ........................................................................................ ii PROCEDURES ...................................................................................... ii SIMULATOR FAMILIARIZATION .......................................................... 1 SAFETY INSTRUCTIONS ...................................................................... 6 LAB ACTIVITY 1.0 - WELDED-TYPE CYLINDER with MICROLEAK 1.1 Leakage Test with MicroLeak System ......................................... 1-3 1.2 Disassemble, Inspect, Reseal, Assemble & Test .......................... 1-9 1.3 Leakage Re-Test with MicroLeak System .................................... 1-21 LAB ACTIVITY 2.0 - TIE-ROD CYLINDER with MICROLEAK 2.1 Leakage Test with MicroLeak System ......................................... 2-3 2.2 Disassemble, Inspect, Reseal, Assemble & Test ......................... 2-9 2.3 Leakage Re-Test with MicroLeak System .................................... 2-24 Contents The hands-on MF400-HCTS Hydraulic Cylinder Training System is an integral and essential part of the fluid power training process. There is no substitute for students to be able to disassemble, inspect, assemble, and test, welded type and tie-rod type hydraulic cylinders in the safety of the classroom. By observing the following safety procedures, you will insure a safe, effective and pleasant experience with our fluid power simulators. - Whenever the power is on and the simulator is energized: ALWAYS WEAR YOUR SAFETY GLASSES! If you are in doubt about what you are doing, stop and ask your instructor for assistance. The instructor, the equipment, and the training materials are for you to utilize to the fullest possible extent to enhance your understanding of this exciting subject. Please ask questions, make suggestions, or comment on any aspect of your training. Feel free to share your experience in fluid power with the class. Remember, there are no dumb questions! In addition to yourself, your fellow students and the instructor will benefit from your full participation in the learning process. If you see any way in which the program, the materials, or the simulators might be made more effective; please make a note of it, and include it in your course evaluation. Introduction Do not work on or around hydraulic systems with- out wearing safety glasses which conform to ANSI Z87.1-1989 standard. i General Instructions Before undertaking any of the activities, please consider the following in- structions which will apply throughout. Only by following instructions exactly, will you derive the maximum benefit from your hands-on experience. Objectives Be certain at the outset that you understand clearly the OBJECTIVE of the activity. By considering what you are supposed to be learning before you begin, you will be more likely to make the correct observations and analysis of the experiment. Look for and identify all the components that are referred to in the objective statement at the beginning of each activity. Be sure that you understand all the terminology that is used. If there is any- thing that you don’t fully understand, do not hesitate to ask. THERE ARE NO DUMB QUESTIONS! Procedures Study the entire activity thoroughly, and understand all the terminology used, before proceeding to implement any procedure. Locate, on the simulator, all the components that are to be used in the activity. Follow the instructions to the letter. Do not deviate in any way from the prescribed sequence. Complete each step, and answer any questions before going on to the next one. After you have completed the activity, and are comfortable with the results, shut off the power to de-energize the simulator. ii 1 MF400-HCTS Hydraulic Cylinder Training System Simulator Familiarization 2 MF400-HCTS Hydraulic Cylinder Training System Description - The model MF400-HCTS is a training system that is designed to teach students how to safely disassemble, inspect, assemble, and test welded type and tie-rod type hydraulic cylinders. NOTE: Welded-type cylinders and tie-rod type cylinders are available for purchase for use with the MF400-HCTS trainers. If additional cylinders are needed, the part number for the cylinders are as follows: Welded cylinders - MF400-RWC Tie-rod cylinders - MF400-TRC The model MF400-HCTS Hydraulic Cylinder Training System has a number of key features: • Four (4) individual cylinder test stations, which operate inde- pendently from one another. One to four students are able to test cylinders at the same time. • Integrated storage racks that store up to eighteen (18) cylinders. • Each test station has a transparent safety cover which is harnessed to the trainer with a cable. The covers store conveniently on pins above each station. • Each test station has a mechanical ratcheting system, which allows the student to push the cylinder rod back to evacuate the oil before placing it in the storage rack. • Residual oil is never wasted. The filler cap on the top tray of the trainer is designed to permit the student to pour excess oil back into the reservoir. The filler is equipped with a atrainer that is de- signed to clean the recycled oil before it is returned to the reservoir. • Special tools are needed to disassemble the cylinders. The tools include a 2” (50mm) wrench to remove and install the gland, and a tool for installing the gland seals. • Four (4) heavy-duty casters with brakes. Seal kits can be purchased from FPTI™. Both the welded type cylinder and the tie-rod type cylinder utilize the same seals. The part number for the seal kit is – MF400-SK For cylinder and seal kit prices, please send an email to: matt@fpti.org 3 SPECIFICATIONS - MF400-HCTS Power: 120VAC Pump: Variable volume pressure-compensated vane pump Flow: 1.0 GPM (3.78 Lpm) Pressure compensator setting: 750 PSI (52 bar) Oil reservoir: 12 gallons (46 Liters) Type of oil: AW32 Hydraulic oil or equivalent Cylinders: Welded-type Tie rod-type 29.0” (74cm) 45.0” (114cm) 69.0” (175cm) MF400-HCTS Dimensions Figure 1 4 SIMULATOR FAMILIARIZATION - MF400-HCTS Figure 2 Take a moment to familiarize yourself with the components on your model MF400-HCTS Hydraulic Cylinder Training Simulator. NOTE: Some components may vary from those shown in the photographs. 1 2 3 4 5 6 7 8 1. Cylinder Test stations (4) 2. Joystick – controls cylinder travel direction 3. Pressure gauge – 0-1000 PSI (0-69 bar) 4. Cylinder safety shield in stored position 5. Oil filler/recycle pod 6. Cylinder test fixture with locking pin 7. Power switch 8. Filter with by-pass indicator 9. Hydraulic reservoir 10. Hydraulic pump 11. Electrical plug 12. Electric motor 13. Casters with brakes (4) 14. Cylinder storage rack (double-sided) (cylinders not included) 9 10 1213 14 11 5 SAFETY INSTRUCTIONS - MF400-HCTS 1. The MF400 must be used under the supervision of a trained and authorized instructor(s). Students must not be allowed to be left alone during lab activities. 2. The MF400 is designed to be used in conjunction with the specially- designed training cylinders. It is unsafe to use the MF400 in conjunc- tion with any other type of hydraulic or pneumatic cylinders. WARNING: Using any other type of cylinder in conjunction with the MF400 can lead to an incident that can result in severe injury. 3. The training cylinders are heavy. It is recommended that students wear steel-toe boots when using the MF400. Especially when carrying the cylinders to and from the workbenches. 4. Students MUST wear safety glasses while performing ALL learning activities related to the MF400. 5. DO NOT attempt to increase the pressure setting of the MF400. 6. When testing a cylinder on the MF400 the security pin must be installed and the transparent safety cover MUST be in place. CAUTION: There is a possibility the oil will spray from the cylinder if a seal has been incorrectly installed or damaged during the installation. The safety covers are designed to protect students from oil spray. If the covers are not installed and there is an oil leak, there is a chance the student will get sprayed with oil. Failure to wear safety glasses, and/or install the safety covers over the cylinders while the power unit is operating, can lead to eye injury. 7. Do not modify the MF400 in any way shape or form. All modifications must be approved in writing by the Fluid Power Training Institute™. 8. NEVER attempt to disassemble a hydraulic cylinder with air pressure. 6 WARNING: Using compressed air to disassemble a hydraulic cylinder is extremely dangerous. Compressed air can cause parts of a cylinder to explode. It can also cause an inferno if there is residual oil in the cylinder and the atomized oil comes into contact with an ignition source. Workers that have used compressed air to aid in disassembling cylinders have, in some instances, been severely injured or killed. 9. There is a possibility that a small amount of oil will be spilled when a hydraulic cylinder is disassembled. The Fluid Power Training Institute™ recommends that the disassembly table should be designed to prevent the oil from spilling onto the floor. Any oil that is spilled onto the floor must be cleaned up imme- diately. CAUTION: Oil spills must be cleaned up immediately. Oil spills create dangerous slip hazards. If slip hazards are ignored they can lead to falls. Falls have, in some instances, caused workers to suffer severe injury or death. 7 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ Hydraulic cylinders are used to convert hydraulic power into mechanical pow- er. They are energy conversion devices that convert fluid power expressed as flow and pressure into linear mechanical power expressed as speed and force. Hydraulic cylinders are sized according to their bore diameter (inside diam- eter), stroke (rod travel), rod diameter, and maximum rated pressure. TYPES OF CYLINDERS: WHAT A SINGLE-ACTING, SINGLE ROD CYLINDER CONSISTS OF: 8 HOW A SINGLE-ACTING, SINGLE ROD CYLINDER WORKS: TYPICAL APPLICATION OF A SINGLE-ACTING, SINGLE ROD CYLINDER: 9 WHAT A DOUBLE-ACTING, SINGLE ROD CYLINDER CONSISTS OF: HOW A DOUBLE-ACTING, SINGLE ROD CYLINDER WORKS: HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ 10 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ TYPICAL APPLICATION OF A DOUBLE-ACTING, SINGLE ROD CYLINDER: 11 WHAT A DOUBLE-ACTING, DOUBLE ROD CYLINDER CONSISTS OF: HOW A DOUBLE-ACTING, DOUBLE ROD CYLINDER WORKS: HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ 12 TYPICAL APPLICATION OF A DOUBLE-ACTING, DOUBLE ROD CYLINDER: MF400-HCTS Hydraulic Cylinder Training System________________________________________________ 13 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ WHAT A TELESCOPING CYLINDER CONSISTS OF: HOW A TELESCOPING CYLINDER WORKS: 14 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ TYPICAL APPLICATION OF A TELESCOPING CYLINDER: 15 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ HYDRAULIC CYLINDERS IN HIGH-RISK APPLICATIONS: A hydraulic system functions on the basis of transmitting power by pushing on a confined liquid. A hydraulic system can only work if the liq- uid is confined. Also, the movement of an actuator can only be controlled if the liquid is confined. What will happen if the oil transmission line that transports oil to and from the control valve to the cylinder breaks and leaves the liquid free to leave the system? If the cylinder is supporting a load, the force of gravity will convert the cylinder into a pump. As the load drops it will pump the oil out of the cylinder leaving the operator with no way to control the speed of the cylinder or distance of travel. This is a concern when using hydraulic cyl- inders to lift workers, position booms on cranes, lift and whirl children on amuse- ment park rides and set ladders for fire- fighters. 16 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ Cylinders used in these types of applications must be equipped with some type of valve that will contain the oil in the cylinder if the oil transmission line fails. These valves are typically called counterbalance valves, pilot-operated check valves, and velocity fuses. Also, as an added safety measure, these types of valves are oftentimes “hidden” inside the cylinder housing. These valves add another dimension of hazard when rebuilding hydraulic cylinders. Those people that rebuild hydraulic cylinders MUST be aware of these valves and their knowledge must extend to how these valves function, their settings, and how to test them. Here are some photos that will help to identify where the valves are typically located in cylinders. CAUTION: These photos do not show all configurations. 17 HYDRAULIC CYLINDERS - INTRODUCTION________________________________________________ Here are the steps that must be taken when receiving hydraulic cylinders for repair: 1. You MUST know if the cylinder was removed from a system/ machine that works with hazardous waste and/or materials. 2. You must ask the company to provide the MSDS report for the liquid within the cylinder or system. 3. You MUST know from what type of machine the cylinder was removed. Record the information on the work order that will be given to the rebuild technician. 4. You MUST also record the reason why the cylinder was removed from the machine. 5. If the cylinder was removed from an aerial platform, scissor lift, utility (bucket) truck, crane, amusement park ride, firetruck, or any high-risk application, DO NOT receive it unless you are authorized to repair the cylinder by the original equipment manufacturer. The following are a company’s conditions of acceptance for repairing hydraulic cylinders: 1. The company must have the means to safely transport the cylinder within the facility. 2. The company must have the tools and fixtures needed to safely disassemble and assemble the cylinder. 3. If it is necessary to weld the cylinder, all welding must meet the original cylinder manufacturer’s specifications. 4. If it is necessary to replace parts, all parts, including seals, must be purchased from the original cylinder manufac- turer. 18 MF400-HCTS Hydraulic Cylinder Training System________________________________________________ 5. If it is necessary to remanufacture parts the parts must be manufactured with the same material and to the same specifications as set forth by the original cylinder manu- facturer. 6. The company must have the torque wrenches needed to torque all bolts and nuts to the respective cylinder manu- facturer’s recommended torque specifications. 7. The company must have a test bench that can test the cylinder to the maximum pressure recommended by the original cylinder manufacturer. 8. If the cylinder is equipped with a load-holding valve the repair facility must be able to test the pressure setting and performance of the valve. 9. If you cannot test the cylinder to the maximum pressure recommended by the original cylinder manufacturer it is your duty of care to advise your client. 10. If you cannot test a cylinder that is equipped with an integrated load-holding valve it is your duty of care to advise your client. 11. The company must have the fixtures and equipment needed to remove residual oil from the cylinder and dis- pose of it according to local laws. 12. The company must have the fixtures and equipment needed to thoroughly clean the exterior surfaces of the cylinder. DO NOT use solvents that can damage or deface warning labels. 19 1-1 Lab Activity 1 WELDED-TYPE CYLINDER LEAKAGE TEST with MICROLEAK TEST SYSTEM 1-3 1. Remove a welded-type cylinder (blue) from the storage rack and slide the cylin- der welded plate into the test fixture and install the locking pin (Figure 1.3-1). 2. Install the transparent safety shield (Figure 1.3-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed-end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 1.3-3). Figure 1.1-2 Figure 1.1-3 Figure 1.1-1 LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 1.1-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 1.1-5). NOTE: It is safe to connect the oil trans- mission lines to the cylinder ports while the power unit is running. 6. Activate the joy-stick to position “A” (Figure 1.1-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 1.1-7) and hold position of the joy- stick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ Figure 1.1-7 Figure 1.1-6 Figure 1.1-5 1-4 Figure 1.1-4 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 1.1-8). 9. While the button is depressed, fully extend then fully retract the cylinder rod by operating the joystick to position “A” and then to position “B” (Figure 1.1-9). 10. Perform a cylinder seal, bypass test. 11. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 1.1-10). 12. Operate the MicroLeak test pump (Figure 1.1-11). If the cylinder piston seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ Figure 1.1-10 Figure 1.1-8 Figure 1.1-9 1-5 Figure 1.1-11 If the pressure fails to increase, there is leakage across the cylinder piston seals. NOTE: Before removing the cylinder from the test station, to conduct Lab Activity 1.2, drain the oil from the cylinder using the following procedure: 13. Disconnect the MicroLeak test pump hose from the the live-end cylinder port. Connect the quick-disconnect hose from port “B,” on the control cabinet, to the live-end cylinder port (Figure 1.1-12). 14. Activate the joy-stick to position “A” to extend the cylinder rod (Figure 1.1-13). Release the joystick when the cylinder rod is fully extended. 15. Lockout the power supply at the test station at which you are working. 16. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. (Figure 1.1-14). LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ Figure 1.1-13 1-6 Figure 1.1-12 Figure 1.1-14 17. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 1.1-15). 18. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 1.1-16). 19. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the proce- dure until the cylinder rod stops at the fully retracted position (Figure 1.1-17). 20. Disconnect the hoses from the cylinder. 21. Remove the safety cover and store it on the pegs (Figure 1.1-18). 22. Proceed to LAB ACTIVITY 1.2 where you will learn how to disassemble, inspect, reseal, assemble and then re-test your cylinder. LAB ACTIVITY 1.1 - WELDED-TYPE CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 1-7 Figure 1.1-16 Figure 1.1-17 Figure 1.1-18 Figure 1.1-15 1-9 1.2-1 CAUTIONS 1. These instructions and procedures apply only to cylinders with the following part numbers - MF400-RWC and MF400-TRC. Performing these activities with any other cylinder(s) can cause an incident that can lead to severe injury. 2. The cylinders are specifically designed for training. They are equipped with safety handles and mounting plates. Always carry them using the integrated handles. Lock them firmly in a vice with the locking plates (Figure 1.2-1). Figure 1.2-1 PPE required for this activity: • Safety glasses with side shields • Steel-toe boots or approved protective shoe covers • Gloves Seal kit part number: MF400-SK LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-10 1.2-2 TOOLS AND FIXTURES REQUIRED FOR THIS ACTIVITY • Workbench with vice. Jaws of vice must be a least 6” (152mm). Vice must be firmly attached to the workbench with four mounting bolts. • Small oil-drip tray to catch the residual oil in the cylinder. Tool kit required for use with Lab Activity 1.2: Welded-type Cylinder (Figure 1.2-2): • Safety glasses (not supplied) • Medium size mallet (not supplied) • Snap-ring pliers - external (not supplied) • Wrench to remove piston (not supplied) • Picks to remove seals (not supplied) • Small flashlight (not supplied) • Oil catch pan (not supplied) • Oil can (not supplied) • 2” (50mm) open-end wrench (supplied) • Internal seal installation tool (supplied) • Seal kit (supplied) Figure 1.2-2 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-11 1.2-3 DISASSEMBLY INSTRUCTIONS 1. Remove the cylinder retaining pin in the test fixture of the welded- type cylinder (blue) that you tested and found to be leaking in Activity 1.1. Carry the cylinder to the vice on your workbench. CAUTION: ALWAYS carry the cylinders using the integrated carry handle. The vice used in this activity must be securely attached to a workbench. If it is not secure, and it falls off the table, it could cause severe injury to you and or a colleague. 2. Lower the integrated steel mounting plate into the vice and tighten it securely. Leave approximately 1” (25.4mm) of space between the vice and the cylinder (Figure 1.2-3). 3. Remove the male quick-connect valves from both ends of the hydraulic cylinder. 4. Use the 2” (50mm) open-end wrench and loosen the cylinder gland (Figure 1.2-4). Put the oil catch pan under the cylinder gland and slowly screw it out. 5. Hold the cylinder rod firmly and pull it out of the cylinder tube (Figure 1.2-5). It may be necessary to tap the edge of the cylin- der rod retaining plate to extract the cyl- inder rod from the cylinder. Hold the oil- drip tray below the cylinder gland to catch residual oil from the cylinder. Place the cylinder rod and gland assembly on the workbench. 6. Use a lint-free cloth and wipe the residual oil out of the cylinder tube. Figure 1.2-5 Figure 1.2-3 Figure 1.2-4 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-12 7. Remove the cylinder tube from the vice and place it on the workbench. 8. The cylinder rod is equipped with an integrated plate to hold it securely in the vice (Figure 1.2-6). Place the plate in the vice and tighten it securely. 9. Remove all of the seals from the cylinder piston (Figure 1.2-7). 10. Use the snap-ring pliers and remove the snap-ring from the end of the cylinder rod (Figure 1.2-8). 11. The piston is attached to the cylinder rod with threads. Use the spanner wrench and loosen the cylinder piston. Remove the cylinder piston from the cylinder rod and place it on the workbench (Figure 1.2-9). Figure 1.2-9 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-7 Figure 1.2-8 Figure 1.2-6 12. Use a pick and remove the small O-ring from the cylinder rod (Figure 1.2-10). 13. Slide the cylinder gland off the cylinder rod and place it on the workbench. 14. Hold onto the cylinder rod and loosen the vice. Place the cylinder rod on the work- bench. 15. Place the cylinder gland in the vice and secure it. Do not overtighten the vice (Figure 1.2-11). 16. Use a pick and remove the wiper seal and fiber wear band. 17. Loosen the vice and turn the cylinder gland around 180º and secure it. Do not overtighten the vice (Figure 1.2-12). 18. Use the pick and remove the fiber wear band, cylinder rod seal, and external O-ring. 19. Hold onto the cylinder gland and loosen the vice. Place the cylinder gland on the workbench. 1-13 Figure 1.2-10 Figure 1.2-11 Figure 1.2-12 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1.2-4 CLEANING AND INSPECTING THE COMPONENTS • Cylinder Tube: 1. Clean inside the cylinder tube with a biodegradable agent. 2. Inspect the outside surfaces of the cylinder tube for damage. You are looking for cracks, dents, and corrosion. 3. Inspect the inside surfaces of the cylinder tube for wear and or damage. You are looking for damage caused by contamination, misalignment, corrosion, and “ballooning” due to excessive pressure. Write your assessment of the cylinder tube’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Rod: 1. Clean the cylinder rod. 2. Inspect the cylinder rod. You are looking for surface damage caused by surface strikes due to the application, surface damage due to misalign- ment, gouging, and rod alignment. If the cylinder rod is equipped with a mounting clevis or eye, inspect it for wear. If it is equipped with bushings inspect the bushings for wear. Write your assessment of the cylinder rod’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 1-14 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-15 • Cylinder Rod Piston: 1. Clean the cylinder rod piston. 2. Inspect the piston. On the outside surfaces of the cylinder rod piston you are looking for wear caused by contamination, corrosion, and misalignment. Inspect the seal grooves, and threads. Write your assessment of the cylinder rod piston’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Gland: 1. Clean the cylinder gland. 2. Inspect the cylinder gland. Inspect the inside surfaces for wear due to contamination, misalignment and corrosion. Inspect the threads. Write your assessment of the cylinder gland’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 1-16 1.2-5 ASSEMBLE SUB-ASSEMBLIES • Assemble the Cylinder Gland 1. Secure the cylinder gland in the vice. 2. Use the oil can and squirt oil into the cylinder gland grooves. 3. Remove the cylinder rod seal from the kit. Lubricate the seal. Make sure the cylinder rod seal is facing the correct direction. Use the seal installation tool and install the cylinder rod seal in its groove (Figure 1.2-13). 4. Install the wear band. The wear band is fabricated out of a fiber. Consequently, it breaks very easily. Squeeze it just enough to slide it into its groove (Figure 1.2-14). 5. Install the O-ring (Figure 1.2-15). LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-13 Figure 1.2-14 Figure 1.2-15 1-17 7. Remove the cylinder gland from the vice, rotate it 180º and again, secure it in the vice and install the second wear band (Figure 1.2-16). 8. Use the seal installation tool and install the wiper seal (Figure 1.2-17). 9. Remove the cylinder gland and place it on the workbench. • Assemble the Cylinder Rod: 1. Fasten the cylinder rod in the vice and install the small O-ring into the O-ring groove on the cylinder rod. 2. Lubricate the cylinder rod and the inside of the cylinder gland with oil (Figure 1.2-18). Slide the cylinder gland onto the cylinder rod, make sure it is correctly aligned. If necessary, tap the cylinder gland gently with the mallet. LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-18 Figure 1.2-17 Figure 1.2-16 1-18 3. Screw the cylinder piston onto the cylin- der rod and use the spanner wrench to tighten it (Figure 1.2-19). 4. Use the snap-ring pliers and install the snap-ring on the end of the cylinder rod. 5. Slide the thin nylon seals (white) into the seal groove. Be careful not to stretch them (Figure 1.2-20). 6. Install the rubber seal (black) in the groove. 7. Carefully slide the white nylon seals onto the grooves on either side of the rubber seal. Be careful not to stretch them (Figure 1.2-21). LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-21 Figure 1.2-20 Figure 1.2-19 1-19 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ 8. Install the first of the two nylon (blue) wear bands. The wear bands are very flexible (Figure 1.2-22). 9. Pull the wear band apart and slide it over the cylinder rod. Now slide it into position on the piston. 10. Install the second wear band (Figure 1.2-23). 11. Lubricate the seals. 12. Remove the cylinder rod from the vice. Figure 1.2-23 Figure 1.2-22 1-20 1.2-6 Assemble the Cylinder 1. Fasten the cylinder barrel in the vice. Tighten it securely (Figure 1.2-24). 2. Lubricate the inside surfaces of the cylin- der barrel. 3. Slide the cylinder piston into the cylin- der tube (Figure 1.2-25). Make sure it’s correctly aligned. Push it, while at the same time moving it side to side, and up and down. If necessary, tap the end of the cylinder rod with a mallet. 4. Slide the cylinder rod into the cylinder barrel and thread the cylinder gland into the cylinder barrel (Figure 1.2-26). Tighten it with the 2” (50mm) wrench. 5. Install the two male quick-connect valves and tighten them securely. 6. Proceed to LAB ACTIVITY 1.3 to re-test your rebuilt cylinder. Figure 1.2-25 Figure 1.2-26 LAB ACTIVITY 1.2 - WELDED-TYPE CYLINDER Disassemble, inspect, reseal, assemble & test_____________________________________________________ Figure 1.2-24 1-21 1. Remove from the vice, the welded-type cylinder (blue) which you have just finished rebuilding. Slide the cylinder welded plate into the test fixture on your test station. Install the locking pin (Figure 1.3-1). 2. Install the transparent safety shield (Figure 1.3-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed-end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 1.3-3). Figure 1.3-2 Figure 1.3-3 Figure 1.3-1 LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 1.3-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 1.3-5). 6. Activate the joy-stick to position “A” (Figure 1.3-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 1.3-7) and hold position of the joy- stick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-7 Figure 1.3-6 Figure 1.3-5 1-22 Figure 1.3-4 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 1.3-8). 9. Operate the joystick valve to position “A” and fully extend the cylinder rod (Figure 1.3-9). 10. Now, operate the joystick to position “B” and fully retract the cylinder rod. Hold position of the joystick and inspect for leakage at the cylinder rod seal and cylin- der gland (Figure 1.3-10). If there are no signs of oil leakage, pro- ceed to Step 11. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. 11. Turn off the power unit (Figure 1.3-11). LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-10 1-23 Figure 1.3-8 Figure 1.3-9 Figure 1.3-11 Figure 1.3-12 12. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 1.3-12). 13. Operate the MicroLeak test pump (Figure 1.3-13). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 14. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. 14. Disconnect the MicroLeak test pump hose from the the live-end of the cylinder. Connect the quick-disconnect hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 1.3-14). LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 1-24 Figure 1.3-13 Figure 1.3-14 15. Start the power unit and activate the joy-stick to position “A” to extend the cylinder rod (Figure 1.3-15). Release the joystick when the cylinder rod is fully extended. 16. Lockout the power supply at the test station at which you are working. 17. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the closed- end of the cylinder (Figure 1.3-16). 18. Operate the MicroLeak test pump (Figure 1.3-17). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 18. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 1-25 Figure 1.3-16 Figure 1.3-15 Figure 1.3-17 Figure 1.3-19 1-26 18. Disconnect the MicroLeak test pump hose from the port at the closed-end of the cylinder. Disconnect the hose from the live-end of the cylinder (Figure 1.3-18). 19. The following steps should be followed to remove the majority of the oil from a cylinder prior to storing it in the rack. 20. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 1.3-19). 21. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 1.3-20). 22. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the proce- dure until the cylinder rod stops at the fully retracted position (Figure 1.3-21). LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-18 Figure 1.3-21 Figure 1.3-22 1-27 LAB ACTIVITY 1.3 - WELDED-TYPE CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 1.3-23 Figure 1.3-22 23. Disconnect the hoses from the cylinder. 24. Remove the safety cover and store it on the pegs (Figure 1.3-22). 25. Remove the cylinder retaining pin. 26. Remove the cylinder from the test fixture and place it in the storage rack (Figure 1.3-23). 2-1 Lab Activity 2 TIE-ROD CYLINDER LEAKAGE TEST with MICROLEAK TEST SYSTEM 1. Remove a tie-rod cylinder (red) from the storage rack and slide the cylinder welded plate into the test fixture and install the locking pin (Figure 2.1-1). 2. Install the transparent safety shield (Figure 2.1-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed- end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 2.1-3). Figure 2.1-1 Figure 2.1-2 Figure 2.1-3 2-3 LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 2.1-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 2.1-5). NOTE: It is safe to connect the oil transmis- sion lines to the cylinder ports while the power unit is running. 6. Activate the joy-stick to position “A” (Figure 2.1-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 2.1-7) and hold position of the joystick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-4 Figure 2.1-5 Figure 2.1-7 Figure 2.1-6 Figure 2.1-4 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 2.1-8). 9. While the button is depressed, fully extend then fully retract the cylinder rod by operating the joystick to position “A” and then to position “B” (Figure 2.1-9). 10. Perform a cylinder seal, bypass test. 11. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 2.1-10). 12. Operate the MicroLeak test pump (Figure 2.1-11). If the cylinder piston seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, there is leakage across the cylinder piston seals. Figure 2.1-8 LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-5 Figure 2.1-9 Figure 2.1-10 Figure 2.1-11 NOTE: Before removing the cylinder from the test station, to conduct Lab Activity 2.2, drain the oil from the cylinder using the following procedure: 13. Disconnect the MicroLeak test pump hose from the live-end cylinder port. Connect the quick-disconnect hose from port “B,” on the control cabinet, to the live-end cylinder port (Figure 2.1-13). 14. Activate the joy-stick to position “A” to extend the cylinder rod (Figure 2.1-13). Release the joystick when the cylinder rod is fully extended. 15. Lockout the power supply at the test station at which you are working. 16. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. (Figure 2.1-14). 17. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-6 Figure 2.1-13 Figure 2.1-12 Figure 2.1-14 Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 2.1-16). 18. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 2.1-17). 19. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the proce- dure until the cylinder rod stops at the fully retracted position (Figure 2.1-18). 20. Disconnect the hoses from the cylinder. 21. Remove the safety cover and store it on the pegs (Figure 2.1-19). 22. Proceed to LAB ACTIVITY 2.2 where you will learn how to disassemble, inspect, reseal, assemble and then re-test your cylinder. LAB ACTIVITY 2.1 - TIE-ROD CYLINDER Leakage Test with MicroLeak Test System_____________________________________________________ 2-7 Figure 2.1-16 Figure 2.1-18 Figure 2.1-17 Figure 2.1-19 2-9 2.2-1 CAUTIONS 1. These instructions and procedures apply only to cylinders with the following part numbers - MF400-RWC and MF400-TRC. Performing these activities with any other cylinder(s) can cause an incident that can lead to severe injury. 2. The cylinders are specifically designed for training. They are equipped with safety handles and mounting plates. Always carry them using the integrated handles. Lock them firmly in a vice with the mounting plates (Figure 2.2-1). Figure 2.2-1 PPE required for this activity: • Safety glasses with side shields • Steel-toe boots or approved protective shoe covers • Gloves Seal kit part number: MF400-SK LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2-10 2.2-2 TOOLS AND FIXTURES REQUIRED FOR THIS ACTIVITY • Workbench with vice. Jaws of vice must be a least 6” (152mm). Vice must be firmly attached to the workbench with four mounting bolts. • Small oil-drip tray to catch the residual oil in the cylinder. Tool kit required for use with Activity 2.2: Tie-Rod Cylinder (Figure 2.2-2): • Safety glasses (not supplied) • Large adjustable wrench (not supplied) • Two (2) 9/16” wrenches (not supplied) • Wrench to remove piston (not supplied) • Snap-ring pliers - external (not supplied) • Small flashlight (not supplied) • Picks to remove seals (not supplied) • Medium size mallet (not supplied) • Torque wrench (not supplied) • Oil catch pan (not supplied) • Oil can (not supplied) • Internal seal installation tool (supplied) • Female quick-connect air-release valve (supplied) • Seal kit (supplied) Figure 2.2-2 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2.2-3 INSTRUCTIONS 1. Remove the cylinder retaining pin in the test fixture of the tie-rod cylinder (red) that you tested and found to be leaking in Activity 2.1. Carry the cylinder to the vice on your workbench. CAUTION: ALWAYS carry the cylinders using the integrated carry handle. The vice used in this activity must be securely attached to a workbench. If it is not secure, and it falls off the table, it could cause severe injury to you and or a colleague. 2. Lower the integrated steel mounting plate into the vice and tighten it securely. Leave approximately 1” (25.4mm) of space be- tween the vice and the cylinder (Figure 2.2-3). 3. To release trapped air, place the female quick-connect air-release valve on the male quick-connect valve on the closed- end of the hydraulic cylinder (Figure 2.2-4). 4. Use two (2) 9/16” wrenches and remove the four (4) tie-rod retaining bolts (Figure 2.2-5). NOTE: Use a diagonal pattern to loosen the tie-rod bolts (See Figure 2.2-6). 2-11 Figure 2.2-5 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-3 Figure 2.2-4 Figure 2.2-7 Figure 2.2-8 Figure 2.2-6 5. Place an oil-drip tray below the closed- end of the cylinder. Hold the end-cap with one hand. Use a mallet and gently strike the end-cap. Place it on the workbench (Figure 2.2-7). 6. Place the oil-drip tray underneath the cap at the rod-end of the cylinder. Use a mal- let and gently strike the end-cap. Hold firmly on to the cylinder rod and pull it out of the cylinder tube. Place the cylin- der rod and gland assembly on the work- bench (Figure 2.2-8). 7. Use a lint-free cloth and wipe the residual oil out of the cylinder tube. 8. Remove the cylinder tube from the vice and place it on the workbench. 2-12 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-9 9. The cylinder rod is equipped with an integrated plate to hold it securely in the vice. Place the plate in the vice and tight- en it securely (Figure 2.2-9). 10. Use the snap-ring pliers and remove the snap-ring from the end of the cylinder rod (Figure 2.2-10). 11. The cylinder piston is attached to the cylin- der rod with threads. Use the spanner wrench and loosen the cylinder piston (Figure 2.2-11). 12. Remove the seals from the cylinder piston and remove it from the cylinder rod and place the cylinder piston on the work- bench. 13. Use a pick and remove the small O-ring from the threaded end of the cylinder rod (Figure 2.2-12). 2-13 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-10 Figure 2.2-11 Figure 2.2-12 Figure 2.2-14 Figure 2.2-13 14. Slide the cylinder gland off the cylinder rod and place it on the workbench (Figure 2.2-13). 15. Hold onto the cylinder rod and loosen the vice. Place the cylinder rod on the work- bench. 16. Place the cylinder gland in the vice and secure it. Do not overtighten it. 17. Use a pick and remove the external O-ring, fiber wear band, rod seal, and wiper seal (Figure 2.2-14). 18. Hold onto the cylinder gland and loosen the vice. Place the cylinder gland on the workbench. 2-14 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2.2-4 CLEANING AND INSPECTING THE COMPONENTS • Cylinder Tube: 1. Clean the cylinder tube with a biodegradable agent. 2. Inspect the outside surfaces of the cylinder tube for damage. You are looking for cracks, dents, and corrosion. 3. Inspect the inside surfaces of the cylinder tube for wear and or dam- age. You are looking for damage caused by contamination, misalign- ment, corrosion, and “ballooning” due to excessive pressure. Write your assessment of the cylinder tube’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Rod: 1. Clean the cylinder rod. 2. Inspect the cylinder rod. You are looking for surface damage caused by surface strikes due to the application, surface damage due to misalign- ment, gouging, and cylinder rod alignment. If the cylinder rod is equipped with a mounting clevis or eye inspect it for wear. If it is equipped with bushings inspect the bushings for wear. Write your assessment of the cylinder rod’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 2-15 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ • Cylinder Piston 1. Clean the cylinder piston. 2. Inspect the cylinder piston. On the outside surfaces of the cylinder piston you are looking for wear caused by contamination, corrosion, and misalignment. Inspect the seal grooves, and threads. Write your assessment of the cylinder piston’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ • Cylinder Gland 1. Clean the cylinder gland. 2. Inspect the cylinder gland. Inspect the inside surfaces for wear due to contamination, misalignment and corrosion. Inspect the threads. Write your assessment of the cylinder gland’s condition here: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 2-16 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 2-17 2.2-5 ASSEMBLE SUB-ASSEMBLIES • Assemble the Cylinder Gland 1. Secure the cylinder gland in the vice. 2. Use the oil can and squirt oil into the cyl- inder gland grooves. 3. Remove the wear band from the seal kit. The wear band is fabricated out of a fiber. Consequently, it breaks very easily. Lubricate it first then squeeze it just enough to slide it into its groove (Figure 2.2-15). 4. Remove the cylinder rod seal from the kit. Lubricate the seal. Make sure the cyl- inder rod seal is facing the correct direc- tion. Use the seal installation tool and install the cylinder rod seal in its groove (Figure 2.2-16). 5. Remove the second wear band from the seal kit. Remember, the wear band is fab- ricated out of a fiber and can break very easily. Lubricate it first then squeeze it just enough to slide it into its groove (Figure 2.2-17). LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-15 Figure 2.2-16 Figure 2.2-17 2-18 6. Install the O-ring (Figure 2.2-18). 7. Remove the cylinder gland, rotate it 180º and secure it in the vice. 8. Use the seal installation tool and install the wiper seal (Figure 2.2-19). 9. Remove the cylinder gland and place it on the workbench. • Assemble the Cylinder Rod 1. Fasten the cylinder rod in the vice 2. Lubricate the cylinder rod. 3. Install the small O-ring into the O-ring groove on the threaded end of the cylin- der rod (Figure 2.2-20). 4. Slide the cylinder gland cap-end onto the cylinder rod (Figure 2.2-21). Make sure it is correctly aligned. 5. Now, slide the cylinder gland onto the cylinder rod (Figure 2.2-21). If necessary, tap it gently with the mallet. LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-19 Figure 2.2-20 Figure 2.2-21 Figure 2.2-18 2-19 6. Screw the cylinder piston onto the cylin- der rod and use the spanner wrench to tighten it (Figure 2.2-22). 7. Use the snap-ring pliers and install the snap-ring to the end of the cylinder rod (Figure 2.2-23). 8. Slide the thin nylon seals (white) into the seal groove on the cylinder piston. Be careful not to stretch them (Figure 2.2-24). 9. Install the rubber seal (black) into the center groove on the cylinder piston (Figure 2.2-25). LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-22 Figure 2.2-23 Figure 2.2-24 Figure 2.2-25 2-20 10. Carefully slide the white nylon seals onto the grooves on either side of the black rubber seal. Be careful not to stretch them. (Figure 2.2-26). 11. Install the first of the two nylon (blue) wear bands. The wear bands are very flex- ible. 12. Pull the wear band apart and slide it over the cylinder rod. Now slide it into position on the cylinder piston (Figure 2.2-27). 13. Install the second blue nylon wear band (Figure 2.2-28). 14. Lubricate the seals. 15. Remove the cylinder rod from the vice. LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-26 Figure 2.2-28 Figure 2.2-27 2-21 2.2-6 Assemble the Cylinder 1. Fasten the cylinder tube in the vice. Tight- en it securely (Figure 2.2-29). 2. Lubricate the inside surfaces of the cylin- der tube. 3. Before installing the cylinder rod and piston assembly into the cylinder tube, (Figure 2.2-30) read the instructions below. Slide the cylinder rod and piston assembly into the cylinder tube. Make sure it’s cor- rectly aligned (see NOTE: below). Push it in while at the same time moving it side to side and up and down. If necessary, tap the end of the cylinder rod with a mallet. NOTE: Although the end-caps can be installed in either end of the cylinder tube the cylinder mounting plate has a hole in it that must be correctly aligned in closer proximity to the live-end than the closed- end of the cylinder (Figure 2.2-31). Figure 2.2-31 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-30 Figure 2.2-29 2-22 4. Install the O-ring on the cap-end cover (Figure 2.2-32). 5. Install the closed-end end-cap (Figure 2.2-33). 6. Install the four (4) tie-rod bolts. Install the flat washers and screw the nuts onto the threads. Use two (2) 9/16” wrenches and tighten the bolts until they are snug (Figure 2.2-34). NOTE: The end-caps must be aligned before the bolts are tightened to the specified torque. To align the end-caps, remove the cylinder from the vice and place it on a flat surface (Figure 2.2-35). Apply a downward force to both end- caps. The end-caps are aligned when they do NOT rock when a force is applied to the opposing corners. LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ Figure 2.2-32 Figure 2.2-33 Figure 2.2-34 Figure 2.2-35 2-23 LAB ACTIVITY 2.2 - TIE-ROD CYLINDER Disassemble, Inspect, Reseal, Assemble & Test _____________________________________________________ 7. Put the cylinder back into the vice and tighten securely. 8. The specified torque for the four (4) nuts is 35-feet pounds/40 Newton meters). The nuts must be torqued in stages until the correct torque is achieved. See STEP 9. for directions. 9. Using a torque wrench (Figure 2.2-36), tighten the bolts using the diagonal pat- tern and torque specifications shown below. NOTE: Use a diagonal pattern to tighten the tie-rod bolts (See Figure 2.2-37). Figure 2.2-37 Here are the torques for each tightening stage: Stage 1 - 10-feet pounds/13.5 Newton meters. Stage 2 - 20-feet pounds/27 Newton meters. Stage 3 - 35-feet pounds/47 Newton meters. 10. Proceed to LAB ACTIVITY 2.3 to re-test your rebuilt cylinder. Figure 2.2-36 1. Remove from the vice, the tie-rod cylinder (red) which you have just finished rebuild- ing. Slide the cylinder welded plate into the test fixture on your test station. Install the locking pin (Figure 2.3-1). 2. Install the transparent safety shield (Figure 2.3-2). CAUTION: If you do not install the transpar- ent safety shield and the cylinder leaks, you could be sprayed with hydraulic oil. NOTE: After repairing a hydraulic cylinder, or when placing a cylinder in a test station from the storage rack, it will be neces- sary to first refill it with oil and purge the air from that cylinder. 3. Connect the hose from port “A,” on the control cabinet, to the closed- end of the cylinder. Connect the hose from port “B,” on the control cabinet, to the live-end of the cylinder (Figure 2.3-3). Figure 2.3-1 Figure 2.3-2 Figure 2.3-3 2-24 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 4. Connect the MicroLeak air-bleed hose assembly to the red-capped, Safe-T-Bleed valves on the cylinder (Figure 2.3-4). Rotate the knobs until they are fully engaged on the valves. Tighten them by hand only. 5. Start the power unit (Figure 2.3-5). 6. Activate the joy-stick to position “A” (Figure 2.3-6) and hold position until the cylinder rod is fully extended. Continue to hold the joystick in position “A” for approximately 1-minute. This will purge air from the cylinder. 7. Activate the joystick to position “B” (Figure 2.3-7) and hold position of the joystick until the cylinder rod is fully retracted. Continue to hold the joystick in position “B” for approximately 1-minute. This will purge air from the cylinder. Figure 2.3-4 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-25 Figure 2.3-5 Figure 2.3-7 Figure 2.3-6 8. Remove the MicroLeak air-bleed hose assembly and replace the red caps on the Safe-T-Bleed valves (Figure 2.3-8). 9. Operate the joystick valve to position “A” and fully extend the cylinder rod. Hold position of the joystick and inspect for leakage at the closed-end cylinder gland (Figure 2.3-9). 10. Now, operate the joystick to position “B” and fully retract the cylinder rod. Hold position of the joystick and inspect for leakage at the cylinder rod seal and live- end cylinder gland (Figure 2.3-10). 11. Turn off the power unit (Figure 2.3-11). LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-26 Figure 2.3-10 Figure 2.3-9 Figure 2.3-11 Figure 2.3-8 Figure 2.3-12 12. Remove the quick-disconnect hose from the port at the live-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the live-end of the cylinder (Figure 2.3-12). 13. Operate the MicroLeak test pump (Figure 2.3-13). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 14. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. 14. Disconnect the MicroLeak test pump hose from the live-end port of the cylinder. Connect the quick-disconnect hose from port “B, “ on the control cabinet, to the live-end port of the cylinder (Figure 2.3-14). LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-27 Figure 2.3-13 Figure 2.3-14 15. Start the power unit and activate the joy- stick to position “A” to extend the cylinder rod (Figure 2.3-15). Release the joystick when the cylinder rod is fully extended. 16. Remove the quick-disconnect hose from the port at the closed-end of the cylinder. Connect the MicroLeak test pump hose to the quick-connect fitting on the port at the closed-end of the cylinder (Figure 2.3-16). 17. Operate the MicroLeak test pump (Figure 2.3-17). If the cylinder seals are in good condition, the pressure will begin to increase. Stop when the pressure reaches 1000 PSI (69 bar). If the pressure fails to increase, the seal is leaking. If there are no signs of oil leakage, pro- ceed to Step 18. If there are signs of oil leakage, stop and report the problem to your instructor for further instructions. NOTE: Before removing the cylinder from the test station, drain the oil from the cylinder using the following procedure: LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 2-28 Figure 2.3-17 Figure 2.3-16 Figure 2.3-15 18. Lockout the power supply at the test station at which you are working. 20. Connect a drain-line hose from one of the drain ports to the live-end of the cylinder. Connect a drain-line hose from the other drain port to the closed-end of the cylin- der (Figure 2.3-20). 21. Remove the pry-bar from the tool rack and slide it into the plate welded to the cylinder rod and into the plate mounted below the cylinder rod (Figure 2.3-21). 22. Apply force to the pry-bar and push the cylinder rod back into the cylinder. Realign the pry-bar and repeat the pro- cedure until the cylinder rod is fully retracted (Figure 2.3-22). 23. Disconnect the hoses from the cylinder. 25. Remove the safety cover and store it on the pegs (Figure 2.3-23). 26. Remove the cylinder retaining pin. 2-29 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ Figure 2.3-20 Figure 2.3-21 Figure 2.3-22 Figure 2.3-23 2-30 LAB ACTIVITY 2.3 - TIE-ROD CYLINDER Leakage Re-Test with MicroLeak Test System_____________________________________________________ 27. Remove the cylinder and place it in the storage rack (Figure 2.3-24). Figure 2.3-24

Answer Keys for CL-1930_053283 Connector Trainer Circuit and Signal Acquisition Teacher Only 91-CL-1930_REVA © ConsuLab Educatech Inc, 2023. Tous droits réservés. 91-CL-1930 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 Instructor Notes 4 Theory Hall Effect Sensor 8 Throttle Position Sensor 9 Magnetic Induction Sensor 10 Student Theory Quiz 11 Student Theory Quiz — Answers 12 Student Assignments — Part A: DSO Labs SA-1 — Analyzing a Constant Voltage DC Signal Using a DSO — Answers 14 SA-2 — Analyzing a DC Signal Using a DSO — Answers 15 SA-3 — Analyzing the Pulse Width (PWM) of the Signal Using a DSO — Answers 16 SA-4 — Capturing a Single Event with a DSO — Answers 17 SA-5 — Analyzing an AC Signal from Sensor #3 Using a DSO — Answers 18 SA-6 — Using Dual Trace to Capture and Display 2 Signals — Answers 19 Part B: Connector Labs SA-7 — Identifying the CL-1930 Components — Answers 21 SA-8 — Analyzing the Signal from Sensor #1 Using a DMM — Answers 22 SA-9 — Analyzing the Signal from Sensor #2 Using a DMM — Answers 23 SA-10 — Analyzing the Signal from Sensor #3 Using a DMM — Answers 24 SA-11 — Analyzing the Signal from Sensor #1 Using a DSO — Answers 25 SA-12 — Analyzing the Signal from Sensor #1 Using a DSO — Answers 26 SA-13 — Analyzing the Signal from Sensor #1 Using a DSO — Answers 27 SA-14 — Analyzing the Signal from Sensor #1 Using a DSO — Answers 28 SA-15 — Analyzing the Signal from Sensor #2 Using a DSO — Answers 29 SA-16 — Analyzing the Signal from Sensor #2 Using a DSO — Answers 30 SA-17 — Analyzing the Signal from Sensor #2 Using a DSO — Answers 31 SA-18 — Analyzing the Signal from Sensor #3 Using a DSO — Answers 32 91-CL-1930 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 053283 and above. SA-19 — Analyzing the Signal from Sensor #3 Using a DSO — Answers 33 SA-20 — Analyzing Sensor #1 Frequency and Pulse Width — Answers 34 SA-21 — Analyzing Sensor #3 for Frequency and Voltage — Answers 35 Quiz (after completion of the assignments) 37 Quiz — Answers 39 Class Activities — Answers Sensor #1 Activities — Answers 41 Sensor #2 Activities — Answers 46 Sensor #3 Activities — Answers 50 Wiring Diagrams Connectors and Sensors 57 Limited Access Connector C5 58 Harness-Harness Connector C4 59 ECU 60 Connector End Views 61 91-CL-1930 Students Notes consulab.com info@consulab.com 4 Instructor Notes The purpose of the CL-1930 is to teach: 1. The use of a DSO including setting Voltage, Time, input AC, DC, or Hz. Students will practice capturing signals from the three sensors and learn how to use cursors, trigger and dual trace capabilities. 2. The correct procedure for following a wiring diagram and learning to back probe a connector. Before using it, make sure you have the correct Back-pinning Probes like the ones shown in the picture: Using anything other than pin type probes will make getting a signal difficult or impossible and will likely destroy the connection. The CL-1930 has 8 different connectors. The labs will have you follow a signal through the different connectors. Suc- cessful completion of the labs will require you to follow the signal wire through complicated connectors. Make sure you follow the wire to a connection before testing it. In this way the correct signal will indicate that you have followed the wiring diagram correctly. The wiring diagram will have additional wires shown that will not have the signal you are looking for. This will test your ability to follow the correct wire on the diagram. Connector #5 is accessed directly with the cover open or with the cover down and locked. It will allow students to test their ability to back probe in tight spaces. All harnesses are replaceable as frequent back probing, especially incorrectly will destroy the connection. Your sales- person can assist you in purchasing replacement harnesses. There are 6 DSO labs labeled SA-1 – SA-6 in part A of the student manual and 15 connector student labs labeled as SA- 7- SA-21 in part B. CL-1930 Student Notes: The purpose of the CL-1930 is to teach: 1. The use of a DSO including se?ng Voltage, Time, input AC, DC, or Hz. Students will pracGce capturing signals from the three sensors and learn how to use cursors, trigger and dual trace capabiliGes. 2. The correct procedure for following a wiring diagram and learning to back probe a connector. Before using it, make sure you have the correct Back- pinning Probes like these: Using anything other than pin type probes will make ge?ng a signal difficult or impossible and will likely destroy the connecGon. The CL-1930 has 8 different connectors. The labs will have you follow a signal through the different connectors. Successful compleGon of the labs will require you to follow the signal wire through complicated connectors. Make sure you follow the wire to a connecGon before they test it. In this way the correct signal will indicate that you have followed the wiring diagram correctly. The wiring diagram will have addiGonal wires shown that will not have the signal you are looking for. This will test your ability to follow the correct wire on the diagram. Connector #5 is accessed directly with the cover open or with the cover down and locked, will test your ability to back probe in Gght spaces. All harnesses are replaceable as frequent back probing, especially incorrectly will destroy the connecGon. Your salesperson can assist you in purchasing replacement harnesses. There are 6 DSO labs labeled A 1 – A 6 and 15 connector student labs labeled as B 1- B 15 The CL-1930 can be useful as a DSO trainer since there are three sensors generaGng a signal. Sensor #1 is a Hall-Effect sensor generaGng a square wave signal. It has an adjustable signal by using the switches. The input voltage, ground resistance, frequency and pulse width are all adjustable. Having you learn how to “read” the DSO especially for frequency and PWM will increase your knowledge and ability on scopes. The CL-1930 can be useful as a DSO trainer since there are three sensors generating a signal. Sensor #1 is a Hall-Effect sensor providing a square wave signal. It has an adjustable signal by using the switches. The input voltage, ground resis- tance, frequency and pulse width are all adjustable. Having you learn how to “read” the DSO especially for frequency and PWM will increase your knowledge and ability on scopes. Sensor #2 is a Thro`le PosiGon Sensor (TPS). Again, the fault switch can be used to change the input voltage thereby changing the pa`ern available. Learn how to capture a TPS sweep. It will be used to teach the use of trigger and single trace capability. Sensor #2 is a Throttle Position Sensor (TPS). Again, the fault switch can be used to change the input voltage thereby changing the pattern available. Learn how to capture a TPS sweep. It will be used to teach the use of trigger and single trace capability. Sensor #2 is a Thro`le PosiGon Sensor (TPS). Again, the fault switch can be used to change the input voltage thereby changing the pa`ern available. Learn how to capture a TPS sweep. It will be used to teach the use of trigger and single trace capability. The #3 sensor is an analog AC generator.The #3 sensor is an analog AC generator. By using the fault switch #8 & 9, you can vary the frequency and the voltage level. It is important to note that every sensor can be affected by changing the input voltage, reference voltage or ground resistance. You will Experiment with different combinaGons to “test” your comprehension. One of the last labs in the DSO secGon will have you put an AC signal on one channel and a DC signal on the other channel of a 2 channel DSO. AddiGonally, there are three quiz type exams to test your ability to understand the sensors, DSO operaGon, and Back-Probing connectors aeer following a wiring diagram. Your instructor will show you how to use the Back-pinning Probes. 91-CL-1930 Students Notes consulab.com info@consulab.com 5 91-CL-1930 Titre de la section consulab.com info@consulab.com 6 By using the fault switch #8 & 9, you can vary the frequency and the voltage level. It is important to note that every sensor can be affected by changing the input voltage, reference voltage or ground resistance. You will experiment with different combinations to “test” your comprehension. One of the last labs in the DSO section will have you put an AC signal on one channel and a DC signal on the other chan- nel of a 2 channel DSO. Additionally, there are three quiz type exams to test your ability to understand the sensors, DSO operation,and Back-Probing connectors after following a wiring diagram. Another suggestion is to keep the fault box locked, opening it only when you want to check the student’s ability to do or measure something. In this manner the fault or scenarios can be used to test comprehension. This simplified wiring diagram is only for your use. Do not give it to the students! Their diagrams have extra wires shown which are not on the CL-1930 designed to engage their minds as they trace during the labs. CL-1930 Connectors and Sensors © ConsuLab Educatech Inc, 2025. All rights reserved.REV1.11 RED BLK WHT WHT Sensor 1 19 20 Connector limited access (C5) A B C Sensor 3 1 2 Sensor 2 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 RED WHT WHT WHT WHT BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 EC U SEN3+ SEN3- SEN2 VREF SEN2 LOW REF SEN2 SIG SEN1 VREF SEN1 LOW REF SEN1 SIG GND GND BAT BAT C3 C2 C1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 Harness Connector (C4) BLK BRN BRN RED RED RED WHT WHT WHT BLK BLK WHT WHT WHT BLK BLK BLK BLK BLK BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 S3 Vbat RED BLK BRN BLK RED BRN WHT BLK WHT WHT RED WHT BRN WHT WHT WHT WHT WHTWHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT BRN RED BLK BRN BLK RED BLK BLK WHT WHT WHT WHT WHT WHT BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN RED RED BLK BRN RED BRN RED BLK WHT WHT WHT WHT BLK BRN BRN BRN BLK WHT WHT WHT WHT BLK BLK RED BLK BLK RED WHT RED WHT RED BLK BLK RED RED BLK BLK BRN RED RED BRN RED RED RED BLK BLK RED BLK WHT WHT Sensor 1 19 20 Connector limited access (C5) A B C Sensor 3 1 2 Sensor 2 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 RED WHT WHT WHT WHT BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 EC U SEN3+ SEN3- SEN2 VREF SEN2 LOW REF SEN2 SIG SEN1 VREF SEN1 LOW REF SEN1 SIG GND GND BAT BAT C3 C2 C1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 Harness Connector (C4) BLK BRN BRN RED RED RED WHT WHT WHT BLK BLK WHT WHT WHT BLK BLK BLK BLK BLK BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 S3 Vbat RED BLK BRN BLK RED BRN WHT BLK WHT WHT RED WHT BRN WHT WHT WHT WHT WHTWHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT BRN RED BLK BRN BLK RED BLK BLK WHT WHT WHT WHT WHT WHT BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN RED RED BLK BRN RED BRN RED BLK WHT WHT WHT WHT BLK BRN BRN BRN BLK WHT WHT WHT WHT BLK BLK RED BLK BLK RED WHT RED WHT RED BLK BLK RED RED BLK BLK BRN RED RED BRN RED RED RED BLK BLK 91-CL-1930 Theory consulab.com info@consulab.com 7 Theory 91-CL-1930 Theory consulab.com info@consulab.com 8 There are three sensors on the CL-1930. In this section we will look at how they typically function in an automobile Hall Effect Sensor CL-1930 STUDENT Theory There are three sensors on the CL-1930. In this sec6on we will look at how they typically func6on in an automobile HALL EFFECT SENSOR Sensor One is a Hall Effect Sensor. It is referred to as an ac6ve sensor. It will have three wires: usually a 5V feed, a ground, and a signal. Note: all ac6ve sensors require power from an external source. The Hall Effect is described as when a current is passed through a semiconductor, a voltage is generated propor6onal to the strength of the permanent magnet. An integrated circuit, inside the body of the sensor will create a DC (Direct Current) square wave output. The hall sensor and magnet are posi6oned so that as the notches and teeth of the wheel pass by, they will influence the magne6c field. The output amplitude will remain the same as will the distance between pulses. The sensor is considered ac6ve since it generates a signal at virtually any speed or even stopped, as opposed to a magne6c sensor that requires reluctor speed to generate a signal. Sensor One is a Hall Effect Sensor. It is referred to as an active sensor. It will have three wires: usually a 5V feed, a ground, and a signal. Note: All active sensors require power from an external source. The Hall Effect is described as when a current is passed through a semiconductor, a voltage is generated proportional to the strength of the perma- nent magnet. An integrated circuit, inside the body of the sensor will create a DC (Direct Current) square wave output. The hall sensor and magnet are positioned so that as the notches and teeth of the wheel pass by, they will influence the magnetic field. The output amplitude will remain the same as will the distance between pulses. The sensor is considered active since it generates a signal at virtually any speed or even stopped, as opposed to a magnetic sensor that requires reluctor speed to generate a signal. The PICO scope display above shows the sensor at about 25% PWM (Pulse Width Modula6on) in red with voltages read on the right-side scale. The signal is on at 5 Volts and off at 0 Volts. The blue trace is read on the leZ side and indicates a 4.5kHz frequency. THROTTLE POSITION SENSOR Sensor #2 is a TPS (Thro^le Posi6on Sensor). Its func6on is evident in its name. It will indicate to the ECM the posi6on of the thro^le. The sensor on the CL-1930 is spring loaded in the closed posi6on, but can be manually moved throughout its range of travel. Turning it clockwise (looking at the blades) to full travel would normally indicate a wide-open thro^le condi6on. TPS’s usually have 3 wires: a 5 V power, a ground, and a signal. It can be considered an ac6ve The PICO scope displayed above shows the sensor at about 25% PWM (Pulse Width Modulation) in red with voltages read on the right-side scale. The signal is on at 5 volts and off at 0 volt. The blue trace is read on the left side and indi- cates a 4.5kHz frequency. 91-CL-1930 Theory consulab.com info@consulab.com 9 Throttle Position Sensor The PICO scope display above shows the sensor at about 25% PWM (Pulse Width Modula6on) in red with voltages read on the right-side scale. The signal is on at 5 Volts and off at 0 Volts. The blue trace is read on the leZ side and indicates a 4.5kHz frequency. THROTTLE POSITION SENSOR Sensor #2 is a TPS (Thro^le Posi6on Sensor). Its func6on is evident in its name. It will indicate to the ECM the posi6on of the thro^le. The sensor on the CL-1930 is spring loaded in the closed posi6on, but can be manually moved throughout its range of travel. Turning it clockwise (looking at the blades) to full travel would normally indicate a wide-open thro^le condi6on. TPS’s usually have 3 wires: a 5 V power, a ground, and a signal. It can be considered an ac6ve Sensor #2 is a TPS (Throttle Position Sensor). Its function is evident in its name. It will indicate to the ECM the position of the throttle. The sensor on the CL-1930 is spring loaded in the closed position, but can be manually moved throughout its range of travel. Turning it clockwise (looking at the blades) to full travel would normally indicate a wide-open throttle condition. TPS’s usually have 3 wires: a 5V power, a ground, and a signal. It can be considered an active sensor since it will indicate position anytime power and ground are present. If a scope is set up for enough time, the TPS can be moved slowly, and a pattern can be captured.sensor since it will indicate posi6on any6me power and ground are present. If a scope is set up for enough 6me, the TPS can be moved slowly, and a pa^ern can be captured. MAGNETIC INDUCTION SENSOR . Sensor 3 is a Passive Induc6on Sensor, some6mes called a Magne6c Induc6on Sensor. It will generate an AC (Alterna6ng Current) signal. The sensor has a coil of wire wrapped around a permanent magnet. A spinning ferromagne6c tooth reluctor called the target gear in the diagram will absorb or concentrate the lines of force from the magnet. The slots in the reluctor cause the lines of force to move back and forth near the coil of wire in the sensor. When the 91-CL-1930 Theory consulab.com info@consulab.com 10 Magnetic Induction Sensor sensor since it will indicate posi6on any6me power and ground are present. If a scope is set up for enough 6me, the TPS can be moved slowly, and a pa^ern can be captured. MAGNETIC INDUCTION SENSOR . Sensor 3 is a Passive Induc6on Sensor, some6mes called a Magne6c Induc6on Sensor. It will generate an AC (Alterna6ng Current) signal. The sensor has a coil of wire wrapped around a permanent magnet. A spinning ferromagne6c tooth reluctor called the target gear in the diagram will absorb or concentrate the lines of force from the magnet. The slots in the reluctor cause the lines of force to move back and forth near the coil of wire in the sensor. When the Sensor 3 is a Passive Induction Sensor, sometimes called a Magnetic Induction Sensor. It will generate an AC (Alternat- ing Current) signal. The sensor has a coil of wire wrapped around a permanent magnet. A spinning ferromagnetic tooth reluctor called the target gear in the diagram will absorb or concentrate the lines of force from the magnet. The slots in the reluctor cause the lines of force to move back and forth near the coil of wire in the sensor. When the lines of force move in one direction, we get a positive voltage or signal. When the lines of force move in the opposite direction, we generate a negative voltage or signal. The coil of wire in the sensor “sees” this + then – pulse. This pulse will be an ana- log (sine wave) signal. The output of the sensor will vary with the strength of the magnetic field, the distance between the reluctor and the sensor and the speed of the reluctor. In the CL-1930, the signal is simulated so that it can be controlled. With all faults off it will look like the pattern displayed below. lines of force move in one direc6on, we get a posi6ve voltage or signal. When the lines of force move in the opposite direc6on, we generate a nega6ve voltage or signal. The coil of wire in the sensor “sees” this + then – pulse. This pulse will be an analog (sine wave) signal. The output of the sensor will vary with the strength of the magne6c field, the distance between the reluctor and the sensor and the speed of the reluctor. In the CL-1930, the signal is simulated so that it can be controlled. With all faults off it will look like the pa^ern displayed below. 91-CL-1930 Theory consulab.com info@consulab.com 11 Student Theory Quiz Use the answer sheet for your answers. Do not write on this paper. 1. What type of signal does a Hall-Effect sensor generate? A. Flat line DC B. Square wave DC C. AC sine wave D. Variable voltage based on position 2. Most sensors are “fed” with what voltage? A. B+ B. B− C. 9 VDC D. 5 VDC 3. Two technicians are discussing sensors. Technician A states that the sensor voltage from a TPS will indicate position of the throttle. Technician B states that the TPS sensor needs power and ground to function. Who is correct? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A or Technician B 4. Two technicians are discussing a Hall-Effect sensor. Technician A states that the input voltage has no effect on the output voltage. Technician B states that the level of pulse with modulation is used to note position or speed to the ECU. Who is correct? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A or Technician B 5. A passive sensor will... A. generate a voltage without having a voltage applied to it B. generally change frequency during normal operation C. be unaffected by changes in B+ or ground D. All of the above 91-CL-1930 Theory consulab.com info@consulab.com 12 Student Theory Quiz — Answers Darken out the letter of the correct answer. Do not circle or “X” the letter. If you wish to change your first attempt, write in your final choice after the “D” answer. 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 91-CL-1930 Student Assignments — Part A: DSO Labs consulab.com info@consulab.com 13 Student Assignments Part A: DSO Labs 91-CL-1930 SA-1 — Analyzing a Constant Voltage DC Signal Using a DSO consulab.com info@consulab.com 14 SA-1 — Analyzing a Constant Voltage DC Signal Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze a DC signal using both a DMM and a DSO. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, a DMM and DSO from your instructor. Note: Both connectors should use the normal pins. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe of the DMM into the ground receptacle located in the bottom right corner of the unit. Plug the positive lead into the 12V receptacle. 3. Turn on the DMM to the VDC position. Record the reading: 12.39 VDC. 4. Remove the DMM leads. 5. Plug in the DSO leads into the same receptacles and turn on the DSO. Adjust the DSO to a setting that will display a flat line between 12 and 13 VDC. Press the hold button, disconnect the leads. 6. Show your instructor the pattern. CL-1930 SA-A1 STUDENT ASSIGNMENT Analyzing a constant voltage DC signal using a DSO You should put your answers directly on this page. Objec&ve: To analyze a DC signal using both a DMM and a DSO Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, a DMM and DSO from your instructor. Note: Both connectors should use the normal pins. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper leK of the trainer. Note: you should have a green light on. If the red light is on, noNfy your instructor. 2. Plug the negaNve probe of the DMM into the ground receptacle located in the bo1om right corner of the unit. Plug the posi7ve lead into the 12V receptacle. 3. Turn on the DMM to the VDC posi7on. Record the reading __12.39___VDC 4. Remove the DMM leads 5. Plug in the DSO leads into the same receptacals and turn on the DSO. Adjust the DSO to a seIng that will display a flat line between 12 and 13 VDC. Press the hold bu1on, disconnect the leads. 91-CL-1930 SA-2 — Analyzing a DC Signal Using a DSO consulab.com info@consulab.com 15 SA-2 — Analyzing a DC Signal Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a signal at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connector should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #1 closest connector with the DSO. Find the signal wire. What color is it? White 4. Use the time per division to show at least 5 patterns on the screen. 5. Use the volts per division to show the entire pattern on the screen. 6. What type of signal does Sensor #1 generate? Square wave 7. Use the voltage cursors to read the lowest voltage: 0 V. 8. Use the voltage cursors to read the highest voltage: 5 V. 9. Use the time cursors to read the time of one full signal: 0.239 mS (milliseconds). 10. Either show your instructor the pattern or print it and staple it to this sheet. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-3 — Analyzing the Pulse Width (PWM) of the Signal Using a DSO consulab.com info@consulab.com 16 SA-3 — Analyzing the Pulse Width (PWM) of the Signal Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a signal at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connector should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #1 closest connector with the DSO. Find the signal wire. What color is it? White 4. Set your Time/Div and V/Div so that at least 2 full patterns are visible on the screen. 5. Set the DSO to measure the pulse width of the signal. Note: Most DSO’s are capable of measuring the pulse width of a signal. Ask your instructor how your DSO does this. 6. Capture the screen and press the hold button. 7. What is the pulse width of the signal (what percent of the entire signal is it on)? 23.74 %. 8. Either show your instructor the pattern or print it and staple it to this sheet. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-4 — Capturing a Single Event with a DSO consulab.com info@consulab.com 17 SA-4 — Capturing a Single Event with a DSO — Answers You should put your answers directly on this page. Objective: To capture a single event with a DSO. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connector should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #2 closest connector with the DSO. Find the signal wire. What color is it? White 4. Set your Time/Div and V/Div so that you will able to see a full sweep of the TPS on the screen (500mS/Div and 1V/ Div suggested). 5. Turn on the trigger and set it to a positive slope, single trace. Adjust the trigger voltage to slightly above the closed throttle voltage of the TPS. 6. Move the TPS blades through a full sweep from closed throttle to WOT and back to closed throttle during the total time on the screen. 7. If the DSO has been set correctly, once the trigger voltage is achieved the scope will display the time for one screen capture and automatically go to hold. 8. It may take multiple tries to correctly capture the sweep. When correctly done it will fill the screen. 9. Either show your instructor the pattern or print it and staple it to this sheet. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleIon _____________________________ Grade _________ 91-CL-1930 SA-5 — Analyzing an AC Signal from Sensor #3 Using a DSO consulab.com info@consulab.com 18 SA-5 — Analyzing an AC Signal from Sensor #3 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #3 and obtain an AC signal. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the nor- mal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: you should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Set your DSO for AC Voltage. This should put 0V in the middle of the screen. If not adjust 0V to the center. 4. Insert the Bock-Probe pin into the connector. Either wire should give you a pattern. 5. Adjust the Time/Div and Volts/Div until the trace shows at least 6 full patterns. 6. Use the V cursors to measure peak to peak voltage. Record: 4 V peak to peak. 7. With the scope live, switch the input over to view frequency. Record: 102 Hz. 8. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleIon _____________________________ Grade _________ 91-CL-1930 SA-6 — Using Dual Trace to Capture and Display 2 Signals consulab.com info@consulab.com 19 SA-6 — Using Dual Trace to Capture and Display 2 Signals — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #3 and obtain a signal at connector #4. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the nor- mal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: you should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Set your DSO for AC Voltage (channel A). This should put 0V in the middle of the screen. If not adjust 0V to the cen- ter. 4. Insert the Bock-Probe pin into the connector for sensor 3. Either wire should give you a pattern. 5. Adjust the Time/Div and Volts/Div for the A channel until the trace shows at least 6 full patterns. 6. Turn on the B channel. Set channel B for DC Voltage and adjust the V/Div to match channel A. 7. Connect the ground to the CL-1930 ground (with the channel A ground). 8. Use another Back-Probe pin and connect to the signal wire of sensor 1. 9. Adjust the pattern positions until both the AC signal and the DC signal are on the screen. 10. Show your instructor or print the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleIon _____________________________ Grade _________ 91-CL-1930 Student Assignments — Part B: Connector Labs consulab.com info@consulab.com 20 Student Assignments Part B: Connector Labs 91-CL-1930 SA-7 — Identifying the CL-1930 Components consulab.com info@consulab.com 21 SA-7 — Identifying the CL-1930 Components — Answers You should put your answers directly on this page. Objective: To identify all the components on the CL-1930 Connector Trainer and indicate their positions on the wiring diagram and physically on the trainer. Procedure: Obtain the CL-1930 Connector Trainer, and the wiring diagrams from your instructor. 1. Use the wiring diagrams to fill in the following: A. How many sensors are used on this trainer? 3 sensors. B. How many connectors does each sensor pass through? 3 or 4 connectors. C. How can you identify the various wires? Color and connector pin 2. Sensor #1 signal goes through which connectors? 1, 4, 5, C1 (ECU) 3. Sensor #2 signal goes through which connectors? 2, 4, C-2 4. Sensor #3 signal goes through which connectors? 3, 4, C-2 91-CL-1930 SA-8 — Analyzing the Signal from Sensor #1 Using a DMM consulab.com info@consulab.com 22 SA-8 — Analyzing the Signal from Sensor #1 Using a DMM — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a voltage at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, DMM, and DSO from your instructor. Note: The positive connectors on the DMM and the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe of the DMM into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #1 closest connector with the DMM on Volts DC. Record your results: A. Red wire: 5.06 VDC. B. Black wire: 0.0 VDC. C. White: 1.27 VDC. 4. What is the purpose of the Red wire? Power to the sensor. 5. What is the purpose of the Black wire? Ground to the Sensor. 6. What is the purpose of the White wire? Signal from the sensor. 91-CL-1930 SA-9 — Analyzing the Signal from Sensor #2 Using a DMM consulab.com info@consulab.com 23 SA-9 — Analyzing the Signal from Sensor #2 Using a DMM — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #2 and obtain a voltage at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, DMM, and DSO from your instructor. Note: The positive connectors on the DMM and the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe of the DMM into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #2 closest connector with the DMM on DC volts. Record your results. Note: Rotate the metal tabs (Throttle Position Sensor) as you record the volts and possible change. A. Top White wire: 0 VDC. Did moving the TPS cause a change in VDC? No B. Middle White wire: 5.06 VDC. Did moving the TPS cause a change in VDC? No C. Bottom White wire: 0.2 VDC. Did moving the TPS cause a change in VDC? Yes 4. What is the purpose of the top wire? Ground to the sensor 5. What is the purpose of the middle wire? Power to the sensor 6. What is the purpose of the bottom wire? Signal from the sensor for throttle position. 91-CL-1930 SA-10 — Analyzing the Signal from Sensor #3 Using a DMM consulab.com info@consulab.com 24 SA-10 — Analyzing the Signal from Sensor #3 Using a DMM — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #3 and obtain a voltage at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, DMM, and DSO from your instructor. Note: The positive connectors on the DMM and the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe of the DMM into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #3 closest connector with the DMM on DC volts. Record your results. Note: Record both the DC volts and AC volts. A. Top White wire: 0.0 VDC 1.49 VAC. B. Bottom White wire: 0.0 VDC 1.49 VAC. 4. What is the purpose of the top wire? AC signal 5. What is the purpose of the bottom wire? AC signal. 91-CL-1930 SA-11 — Analyzing the Signal from Sensor #1 Using a DSO consulab.com info@consulab.com 25 SA-11 — Analyzing the Signal from Sensor #1 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a signal at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #1 closest connector with the DSO. Find the signal wire. What color is it? White A. What type of signal does Sensor #1 generate? Square wave. B. Use the cursors to determine the lowest voltage on the screen: 0 V. C. Use the cursors to determine the highest voltage on the screen: 5 V. 4. Either show your instructor the pattern or print it and staple it to this sheet. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-12 — Analyzing the Signal from Sensor #1 Using a DSO consulab.com info@consulab.com 26 SA-12 — Analyzing the Signal from Sensor #1 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a signal at connector #4. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: you should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Use the connector pin-out diagram for connecter 4. Find the signal wire from sensor #1: A. What pin of connector #4 carries the signal from sensor #1? Pin # 7 B. What is the lowest voltage on the screen? 0 V C. What is the highest voltage on the screen? 5 V 4. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-13 — Analyzing the Signal from Sensor #1 Using a DSO consulab.com info@consulab.com 27 SA-13 — Analyzing the Signal from Sensor #1 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a signal at the connector #5 (limited access connector). Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: you should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Use the connector pin-out diagram for connecter 5. Find the signal wire from sensor #1. A. What pin of connector #5 carries the signal from sensor #1? Pin # 17 B. What is the lowest voltage on the screen? 0 V C. What is the highest voltage on the screen? 5 V 4. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-14 — Analyzing the Signal from Sensor #1 Using a DSO consulab.com info@consulab.com 28 SA-14 — Analyzing the Signal from Sensor #1 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and obtain a signal at the ECU. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: you should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Use the connector pin-out diagram for the ECU connectors. Find the signal wire from sensor #1: A. What connector and pin of the ECU carries the signal from sensor #1? Connector # 2 Pin # 12. B. What is the lowest voltage on the screen? 0 V. C. What is the highest voltage on the screen? 5 V. 4. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-15 — Analyzing the Signal from Sensor #2 Using a DSO consulab.com info@consulab.com 29 SA-15 — Analyzing the Signal from Sensor #2 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #2 and obtain a signal at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: you should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #2 closest connector with the DSO. Find the signal wire. What color is it? White. A. What type of signal does Sensor #2 generate as you move the blades of the TPS? Variable DC Voltage. B. What is the lowest voltage on the screen? 0.200 V. C. What is the highest voltage on the screen? 4.3 V. 4. Set you DSO for 1 Sec/Div. Move the TPS through its full travel and capture the pattern. 5. Either show your instructor the pattern or print it and staple it to this sheet. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleIon _____________________________ Grade _________ 91-CL-1930 SA-16 — Analyzing the Signal from Sensor #2 Using a DSO consulab.com info@consulab.com 30 SA-16 — Analyzing the Signal from Sensor #2 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #2 and obtain a signal at connector #4. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Use the connector pin-out diagram for connecter 4. Find the signal wire from sensor #2. A. What pin of connector #4 carries the signal from sensor #1? Pin # 12 B. What is the lowest voltage on the screen? 0.2 V. C. What is the highest voltage on the screen? 4.6 V (while moving the blade). 4. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleIon _____________________________ Grade _________ 91-CL-1930 SA-17 — Analyzing the Signal from Sensor #2 Using a DSO consulab.com info@consulab.com 31 SA-17 — Analyzing the Signal from Sensor #2 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #2 and obtain a signal at the ECU. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the nor- mal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Use the connector pin-out diagram for the ECU connectors. Find the signal wire from sensor #2. A. What connector and pin of the ECU carries the signal from sensor #2? Connector # C1 Pin # 17 B. What is the lowest voltage on the screen? 0.200 V C. What is the highest voltage on the screen? 4.8 V (while moving the blade) 4. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleIon _____________________________ Grade _________ 91-CL-1930 SA-18 — Analyzing the Signal from Sensor #3 Using a DSO consulab.com info@consulab.com 32 SA-18 — Analyzing the Signal from Sensor #3 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #3 and obtain a signal at the sensor. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #3 closest connector with the DSO. Find the signal wire. What color is it? White A. What type of signal does Sensor #3 generate? AC or sine wave B. What is the lowest voltage on the screen? -2 V. C. What is the highest voltage on the screen? +2 V. 4. Either show your instructor the pattern or print it and staple it to this sheet. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-19 — Analyzing the Signal from Sensor #3 Using a DSO consulab.com info@consulab.com 33 SA-19 — Analyzing the Signal from Sensor #3 Using a DSO — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #3 and obtain a signal at connector #4. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the nor- mal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Use the connector pin-out diagram for connector #4. Find the signal wire from sensor #3: A. What pin of connector #4 carries the signal from sensor #3? Pin # 14 or 15 B. What is the lowest voltage on the screen? -2 V C. What is the highest voltage on the screen? +2 V 4. Show your instructor the pattern. Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleHon _____________________________ Grade _________ 91-CL-1930 SA-20 — Analyzing Sensor #1 Frequency and Pulse Width consulab.com info@consulab.com 34 SA-20 — Analyzing Sensor #1 Frequency and Pulse Width — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #1 and measure the frequency and pulse width (PWM) of the signal. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #1 closest connector with the DSO. Find the signal wire. What color is it? White. A. What type of signal does Sensor #1 generate? AC or sine wave. B. Using the features of your DSO calculate the PWM of the signal: %. C. What is the frequency of the signal? 103.7 Hz. 4. Either show your instructor the pattern or print it and staple it to this sheet. 5. Your instructor will adjust the CL-1930. Measure and record Note: Use fault switchs 8 and 9 to vary the frequency and voltage. Students should measure and record and it should match the seDngs of the fault switch. A. ____50% PWM B. ______ Hz Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleNon _____________________________ Grade _________ 5. Your instructor will adjust the CL-1930. Measure and record: Note: Use fault switchs 8 and 9 to vary the frequency and voltage. Students should measure and record and it should match the settings of the fault switch. A. 50 % PWM. B. Hz. 91-CL-1930 SA-21 — Analyzing Sensor #3 for Frequency and Voltage consulab.com info@consulab.com 35 SA-21 — Analyzing Sensor #3 for Frequency and Voltage — Answers You should put your answers directly on this page. Objective: To analyze the wiring of sensor #3 and measure the frequency and the voltage (peak to peak) of the signal. Procedure: Obtain the CL-1930 Connector Trainer, the wiring diagrams, and DSO from your instructor. Note: The positive connectors of the DSO should have Back-pinning Probes. The negative connectors should use the normal pin. 1. Plug in the CL-1930 to a 110V source. Switch on the unit using the switch in the upper left of the trainer. Note: You should have a green light on. If the red light is on, notify your instructor. 2. Plug the negative probe into the ground receptacle located in the bottom right corner of the unit. 3. Backprobe each wire at the sensor #3 closest connector with the DSO. Find the signal wire. What color is it? White. A. What type of signal does Sensor #3 generate? AC or sine wave B. Using the features of your DSO measure the peak to peak Voltage: 4 V. C. What is the frequency of the signal? 107 Hz. 4. Either show your instructor the pattern or print it and staple it to this sheet. 5. Your instructor will adjust the CL-1930. Measure and record Note: Using switch #8 or #9, the peak to peak voltage can be varied to either 3V or 10V. The frequency will change from 10Hz to 100Hz This is the paMern with switch 8 up. Note freq in lower leN. This is the freq with switch 9 down. 91-CL-1930 Titre de la section consulab.com info@consulab.com 36 5. Your instructor will adjust the CL-1930. Measure and record: Note: Using switch #8 or #9, the peak to peak voltage can be varied to either 3 V or 10 V. The frequency will change from 10 Hz to 100 Hz. This is the pattern with switch 8 up. Note freq in lower left. 5. Your instructor will adjust the CL-1930. Measure and record Note: Using switch #8 or #9, the peak to peak voltage can be varied to either 3V or 10V. The frequency will change from 10Hz to 100Hz This is the paMern with switch 8 up. Note freq in lower leN. This is the freq with switch 9 down. This is the freq with switch 9 down. A. ______V (peak to peak) B. ______ Hz Be prepared to discuss your results with your instructor. Student _____________________________________________ Date __________________ Instructor Signature upon compleLon _____________________________ Grade _________ A. V (peak to peak) B. Hz. 91-CL-1930 Quiz consulab.com info@consulab.com 37 Quiz (after completion of the assignments) Use the answer sheet for your answers. Do not write on this paper. 1. On a three wire sensor, the three wires are usually... A. 12.6V, 5V and the signal output B. Ground, 12.6V and the signal output C. 5V, ground and the signal output D. 9V, 5V and the signal output 2. Two technicians are discussing a TPS. Technician A states that the sensor output will vary with the position of the throttle. Technician B states that the sensor will be powered from full B+ and system ground. Who is correct? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A or Technician B 3. Sensor #3 is considered a passive sensor. Why? A. It needs to have power applied B. It does not need to have ground applied C. It will generate a square wave signal D. None of the above 4. Sensor #1 has power and ground. This indicates that it is a sensor. A. wheel speed B. passive C. O2S D. active 5. Two technicians are discussing back probing connectors. Technician A states that a dull DMM probe works best. Technician B states that a thin flexible pin style probe works best. Who is correct? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A or Technician B 91-CL-1930 Quiz consulab.com info@consulab.com 38 6. A method of capturing a TPS sweeps with a DSO is to use what feature? A. Single trigger B. Negative slope C. Automatic voltage D. Automatic time 7. Two technicians are discussing the DSO pattern shown below. Technician A states that it shows what may be a PWM signal. Technician B states that the output is around 5 VDC. Who is correct? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A or Technician B A. single trigger B. nega9ve slope C. automa9c voltage D. automa9c 9me 6. Two technicians are discussing the DSO paSern shown here. Technician A states that it shows what may be a PWM signal. Technician B states that the output is around 5 VDC. Who is correct? A. Technician A only B. Technician B only C. Both Technician A and Technician B D. Neither Technician A or Technician B 91-CL-1930 Quiz consulab.com info@consulab.com 39 Quiz — Answers Darken out the letter of the correct answer. Do not circle or “X” the letter. If you wish to change your first attempt, write in your final choice after the “D” answer. 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 consulab.com info@consulab.com 40 91-CL-1930 Class Activities Class Activities Answers consulab.com info@consulab.com 41 91-CL-1930 Sensor #1 Activities — Answers Sensor #1 Activities — Answers consulab.com info@consulab.com 42 91-CL-1930 Sensor #1 Activities — Answers consulab.com info@consulab.com 43 91-CL-1930 Sensor #1 Activities — Answers consulab.com info@consulab.com 44 91-CL-1930 Sensor #1 Activities — Answers consulab.com info@consulab.com 45 91-CL-1930 Sensor #1 Activities — Answers consulab.com info@consulab.com 46 91-CL-1930 Sensor #2 Activities — Answers Sensor #2 Activities — Answers consulab.com info@consulab.com 47 91-CL-1930 Sensor #2 Activities — Answers consulab.com info@consulab.com 48 91-CL-1930 Sensor #2 Activities — Answers consulab.com info@consulab.com 49 91-CL-1930 Sensor #2 Activities — Answers 13 consulab.com info@consulab.com 50 91-CL-1930 Sensor #3 Activities — Answers Sensor #3 Activities — Answers consulab.com info@consulab.com 51 91-CL-1930 Sensor #3 Activities — Answers consulab.com info@consulab.com 52 91-CL-1930 Sensor #3 Activities — Answers consulab.com info@consulab.com 53 91-CL-1930 Sensor #3 Activities — Answers consulab.com info@consulab.com 54 91-CL-1930 Sensor #3 Activities — Answers consulab.com info@consulab.com 55 91-CL-1930 Sensor #3 Activities — Answers 91-CL-1930 Wiring Diagrams consulab.com info@consulab.com 56 Wiring Diagrams consulab.com info@consulab.com 57 91-CL-1930 Wiring Diagrams Connectors and Sensors C L-19 3 0 C onnectors and S ensors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.11 RED BLK W H T W H T Sensor 1 1920 C onnector lim ited access (C 5) ABC Sensor 3 12 Sensor 2 123 123456789101112131415161718 21 RED W H T W H T W H T W H T BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 204 ECU SEN 3+ SEN 3- SEN 2 V REF SEN 2 LO W REF SEN 2 SIG SEN 1 V REF SEN 1 LO W REF SEN 1 SIG G N D G N D BA T BA T C 3 C 2 C 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 201 2 3 H arness C onnector (C 4) BLK BRN BRN RED RED RED W H T W H T W H T BLK BLK W H T W H T W H T BLK BLK BLK BLK BLK BLK 1234567891011 121314151617 18 S3 V bat RED BLK BRN BLK RED BRN W H T BLK W H T W H T RED W H T BRN W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T BRN RED BLK BRN BLK RED BLK BLK W H T W H T W H T W H T W H T W H T BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN RED RED BLK BRN RED BRN RED BLK W H T W H T W H T W H T BLK BRN BRN BRN BLK W H T W H T W H T W H T BLK BLK RED BLK BLK RED W H T RED W H T RED BLK BLK RED RED BLK BLK BRN REDRED BRN REDRED RED BLK BLK RED BLK W H T W H T Sensor 1 1920 C onnector lim ited access (C 5) ABC Sensor 3 12 Sensor 2 123 123456789101112131415161718 21 RED W H T W H T W H T W H T BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 204 ECU SEN 3+ SEN 3- SEN 2 V REF SEN 2 LO W REF SEN 2 SIG SEN 1 V REF SEN 1 LO W REF SEN 1 SIG G N D G N D BA T BA T C 3 C 2 C 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 201 2 3 H arness C onnector (C 4) BLK BRN BRN RED RED RED W H T W H T W H T BLK BLK W H T W H T W H T BLK BLK BLK BLK BLK BLK 1234567891011 121314151617 18 S3 V bat RED BLK BRN BLK RED BRN W H T BLK W H T W H T RED W H T BRN W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T BRN RED BLK BRN BLK RED BLK BLK W H T W H T W H T W H T W H T W H T BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN RED RED BLK BRN RED BRN RED BLK W H T W H T W H T W H T BLK BRN BRN BRN BLK W H T W H T W H T W H T BLK BLK RED BLK BLK RED W H T RED W H T RED BLK BLK RED RED BLK BLK BRN REDRED BRN REDRED RED BLK BLK 91-CL-1930 Wiring Diagrams consulab.com info@consulab.com 58 C L-19 3 0 P lan C lient © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 2.10 H EA D LIG H TS SYSTEM H O RN S SYSTEM TH RO TTLE AC TU ATO R C TRL O PEN H EA D LIG H TS SYSTEM SH IFT IN TERLO C K SYSTEM D O O R LO K C S SYSTEM H O RN S SYSTEM D O O R LO C KS SYSYTEM SH IFT IN TERLO C K SYSTEM C RU ISE C O N TRO L SYSYTEM C RU ISE C O N TRO L SYSTEM 5 2 1378 6 4 RED BLK W H T W H T Sensor 1 1920 C onnector lim ited access (C 5) ABC Sensor 3 AB Sensor 2 S1038 (sm p) 123 1234567891011 1213 14151617 1821 RED W H T BRN BLK W H T W H T W H T W H T TH RO TTLE AC TU ATO R C TRL O PEN RED RED RED RED RED BRN BRN BRN BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T BLK BLK BLK BLK Limited Access Connector C5 91-CL-1930 Wiring Diagrams consulab.com info@consulab.com 59 Harness-Harness Connector C4 C L-19 3 0 P lan C lient © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 2.10 1234567891011 121314 151617 18 H arness-H arness connector (C 4) PO W ER W IN D O W S SYSTEM W IPER/ W ASH ER SYSTEM W IPER/ W A SH ER SYSTEM PO W ER W IN D O W S SYSTEM 12 RED BLK BLK BRN BLK RED BRN W H T W H T BRN RED M EM O RY SYSTEM N A V IG A TIO N SYSTEM N A V IG A TIO N SYSTEMBO O ST PRESSU RE SEN SO R BO O ST PRESSU RE SEN SO R 2 15 3478 6 5 786 34 W H T W H T W H T W H T W H T W H T W H T BLK BLK BRN BLK RED BRN W H T W H T RED W H T W H T W H T W H T W H T W H T W H T W H T W H T 91-CL-1930 Wiring Diagrams consulab.com info@consulab.com 60 ECU C L-19 3 0 P lan C lient © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 2.10 C H A RG E IN D C TRL LO W SPEED C O O LIN G K N O C K SEN SO R SIG N AL IG N ITIO N C O N TRO L O U TPU T SPD W AK EU P SERIA L D A TA PRIM A RY RELAY C V T U N IT IN STRU M EN T C LU STER SYSTEM AC C PED A L PO S TEM PERA TU RE SEN SO R FA N RLY C TRL D O O R LO C KS SYSTEM SH IFT IN TERLO C K SYSTEM STEERIN G SEN SO R LO W REF FU EL PU M P R LY AIRBAG SEN SO R 378 46 5 BLK BLK RED RED WHT BLK RED RED BRN BLK WHT BRN WHT WHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 BRN BLK WHT WHT WHT RED RED BRN BLK BRN BLK RED RED BLK BLK RED RED WHT BLK BLK RED RED BLK BLK 19 20 1 2 3 4 EC U 12 WHT WHT BLK RED BRN SEN3+ SEN3- SEN2 VREF SEN2 LOW REF SEN2 SIG SEN1 VREF SEN1 LOW REF SEN1 SIG GND GND BAT BAT C 3 C 2 C 1 EX TERIO R LIG H T IN TERIO R LIG H T EN G IN E C O N TRO L SYSTEM SO U N D SYSTEM SEATS SYSTEM C O M PU TER D A TA LIN E SYSTEM W ARN IN G SYSTEM BRN 91-CL-1930 Wiring Diagrams consulab.com info@consulab.com 61 C L-19 3 0 End view connectors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.10 RED BLK WHT A B C RED BLK WHT A B C Sensor 1 ABC SEN SO R PLU G H A RN ESS REC EPTAC LE Sensor 2 123 1 2 3 WHT 1 2 3 WHT WHT H A RN ESS REC EPTAC LE SEN SO R PLU G Sensor 3 AB 7A B A A B2A B A H A RN ESS REC EPTAC LE SEN SO R PLU G N O TE: EN D V IEW S A RE SEEN FRO M TERM IN A L SID E. Connector End Views consulab.com info@consulab.com 62 91-CL-1930 Wiring Diagrams C L-19 3 0 End view connectors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.10 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 C 4 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 C 4 SEN SO R SID E PLU G H A RN ESS SID E REC EPTAC LE C 5 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 192021 C 5 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 192021 H A RN ESS SID E REC EPTAC LE SEN SO R SID E PLU G N O TE: EN D V IEW S A RE SEEN FRO M TERM IN A L SID E. consulab.com info@consulab.com 63 91-CL-1930 Wiring Diagrams C L-19 3 0 End view connectors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.10 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 C 1 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 J 4 H A RN ESS PLU G EC U 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 C 2 H A RN ESS PLU G 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 J 5 EC U C 3 1 2 3 4 BLK BLK RED RED EC U J 6 1 2 3 4 H A RN ESS PLU G N O TE: EN D V IEW S A RE SEEN FRO M TERM IN A L SID E. consulab.com info@consulab.com 64 91-CL-1930 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved. Instructor Notes Theory Hall Effect Sensor Throttle Position Sensor Magnetic Induction Sensor Student Theory Quiz Student Theory Quiz — Answers Student Assignments SA-1 — Analyzing a Constant Voltage DC Signal Using a DSO — Answers SA-2 — Analyzing a DC Signal Using a DSO — Answers SA-3 — Analyzing the Pulse Width (PWM) of the Signal Using a DSO — Answers SA-4 — Capturing a Single Event with a DSO — Answers SA-5 — Analyzing an AC Signal from Sensor #3 Using a DSO — Answers SA-6 — Using Dual Trace to Capture and Display 2 Signals — Answers SA-7 — Identifying the CL-1930 Components — Answers SA-8 — Analyzing the Signal from Sensor #1 Using a DMM — Answers SA-9 — Analyzing the Signal from Sensor #2 Using a DMM — Answers SA-10 — Analyzing the Signal from Sensor #3 Using a DMM — Answers SA-11 — Analyzing the Signal from Sensor #1 Using a DSO — Answers SA-12 — Analyzing the Signal from Sensor #1 Using a DSO — Answers SA-13 — Analyzing the Signal from Sensor #1 Using a DSO — Answers SA-14 — Analyzing the Signal from Sensor #1 Using a DSO — Answers SA-15 — Analyzing the Signal from Sensor #2 Using a DSO — Answers SA-16 — Analyzing the Signal from Sensor #2 Using a DSO — Answers SA-17 — Analyzing the Signal from Sensor #2 Using a DSO — Answers SA-18 — Analyzing the Signal from Sensor #3 Using a DSO — Answers SA-19 — Analyzing the Signal from Sensor #3 Using a DSO — Answers SA-20 — Analyzing Sensor #1 Frequency and Pulse Width — Answers SA-21 — Analyzing Sensor #3 for Frequency and Voltage — Answers Quiz (after completion of the assignments) Quiz — Answers Class Activities Answers Sensor #1 Activities — Answers Sensor #2 Activities — Answers Sensor #3 Activities — Answers Wiring Diagrams Connectors and Sensors Limited Access Connector C5 Harness-Harness Connector C4 ECU Connector End Views

Instructors Manual for CL-1930_053283 Connector Trainer Circuit and Signal Acquisition Teacher Only 96-CL-1930_REVA © ConsuLab Educatech Inc, 2023. Tous droits réservés. 96-CL-1930 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 053283 and above. Table of Contents Harness replacement 4 Harness Location Identification 4 CL-1930 Fault Insertion 5 Component & Scenario Explanations 6 Scenario Switch Box 6 System Voltage Test Points 7 Sensor #1 Scenarios 7 Sensor #2 Scenarios 9 Sensor #3 Scenarios 10 General Notes 12 Wiring Diagrams Connectors and Sensors 14 Limited Access Connector C5 15 Harness-Harness Connector C4 16 ECU 17 Connector End Views 18 consulab.com info@consulab.com 4 96-CL-1930 Harness replacement Harness replacement The CL-1930 Connector & Signal Acquisition trainer is designed for easy replacement of individual connecter harnesses if required. Please refer to the below drawing and parts list to properly identify the specific harness you need. Contact your sales representative or ConsuLab Support with the part number to obtain a quotation. 6 2 1 3 4 10 11 12 9 8 7 5 Harness Location Identification CONNECTER # HARNESS *** 1 (C-5)F 70163-07 2 (C-5)M 70163-10 3 (C-4)M 70163-13 4 (C-4)F 70163-14 5 (SEN-1)F 70163-04 6 (SEN-1)M 70163-05 7 (SEN-2)F 70163-08 8 (SEN-3)M 70163-09 9 (SEN-3)F 70163-11 10 ECU C-1 70163-17 11 ECU C-2 70163-16 12 ECU C-3 70163-18 *** NOTE – THE BLACK LOOM MATERIAL MAY HAVE TO BE SLID BACK TO REVEAL THE HARNESS NUMBER TAGS 96-CL-1930 Instructor Notes consulab.com info@consulab.com 5 CL-1930 Fault Insertion After the fault box lid is open you will see the 5 multiple position switches. The most frequent use of the faults is to check your students progress by inserting a fault and seeing if they can figure out the change. Note: The five switches actually give 9 scenar- ios. Switch One/Two With the switch in the up position the system will drop the system voltage to 10 VDC. With the switch in the middle po- sition the system voltage will be normal, around 12.6 VDC. With the switch in the down position the system voltage will adjust down to 7 Volts. This voltage change changes the operating voltage of the entire CL-1930. Switch Three With this switch in the down position, the system ground will be at 0 VDC. With the switch up the ground voltage is raised up for the whole trainer. This impacts all three sensors. Switch Four/Five In the middle position the reference voltage for Sensor’s One and Two will be 5 VDC, which is normal. Moving the switch up changes the reference voltage to 2 VDC. Moving the switch down changes the reference voltage to 1.2 VDC. Switch Six/Seven Will change the sensor #1 frequency and pulse width modulation (PWM). Moving the switch up wil result in 450 Hz and 25% PWM. The middle position will result in 4.5 Hz and 25% PWM. With the switch down the frequency will be 4.5 Hz, but the PWM will change to 95 %. Switch Eight/Nine Will change sensor #3. The middle position (normal) results in 100 Hz and an output of 3 VAC. Moving the switch up will change the output to 10 Hz and keep the voltage at 3 VAC. Moving the switch down from center changes to 100 Hz and 9 VAC. Notes: Changing more than one switch at a time might give a confusing result. The CL-1930 was designed to function “best” with one switch not in the normal position. The faults are normally used to test the students ability to interpret a DMM reading or a DSO pattern. Students should not have access to the fault switches. Lock the door and keep the key out of student reach. 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 6 Component & Scenario Explanations Scenario Switch Box The SCENARIO SWITCH BOX consists of five toggle switches identified as: S1-2, S3, S4-5, S6-7 & S8-9. Each one can be used singularly or in combination with others to create many different operational and diagnostic situations requiring proper diagnosis to identify. Their operation is explained below: S1-2 Has three switch positions: Middle, Up and Down. In the middle position, system voltage for the trainer will be 12.6VDC±. In the up position, it will change to 10VDC±. In the down posi- tion, system voltage will be 7VDC±. This switch can be used to simulate low battery charge or charging system problems. S3 Has two positions: Up and Down. In the down position the ground circuits for the trainer are “normal” with no unwanted resistance inserted. In the up position, a 2VDC± voltage drop is Inserted in the ECU ground circuit. Specific location is between the GND test point and ECU ground wires connected to the ECU. S4-5 Has three positions: Middle, Up and Down. In the middle position, the ECU Vref voltage is 5VDC±. In the up position, it changes to 2VDC± and in the down position, it becomes 1.2VDC±. S6-7 Has three positions: Middle, Up and Down. In the middle position, Sensor #1 signal will be measured at 4.5kHz± frequen- cy and a 25%± duty cycle. In the up position, the signal will become a 450Hz± frequency and a 25%± duty cycle. In the down position, the signal will become 4.5kHz± frequency and a 95%± duty cycle. S8-9 Has three positions: Middle, Up and Down. In the middle position, Sensor #3 will be measured at 10kHz± frequency and 3VAC±rms measured at the sensor or 1.5VACrms± measured to system ground. Peak-to-Peak measured at the sensor will be 9VAC± and 4VAC± measured to system ground at a frequency of 100Hz±. In the up position, the sensor’s fre- quency changes to 10kHz at the same voltage. In the down position, the voltage changes to 9VAC±rms measured at the sensor and 25VAC± Peak-to-Peak at the same frequency of 100Hz±. The scenario switches can be used singularly or in combination to create numerous abnormal operational conditions requiring accurate measurement to diagnose and identify. 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 7 System Voltage Test Points S1-2: SYSTEM VOLTAGE CHANGES CAN BE MEASURED HERE TO GND. S4-5: VREF VOLTAGE CHANGES CAN BE MEASURED HERE TO GND. (AND AT SENSORS ALSO) S3: GND VOLTAGE DROP OR RESISTANCE CAN BE MEASURED HERE TO ECU GND. Sensor #1 Scenarios S1 - Sensor #1 is a typical Hall Effect Sensor operating on a 5V reference voltage. A Hall Effect sensor generates a digital square wave signal that varies in frequency as the speed of the trigger wheel varies. The signal outputs duty cycle can also be commanded to change based on the application of the sensor. The CL-1930 Hall Effect sensor uses a “generated” signal in which two frequencies and two different duty cycles can be selected. The sensor actual speed and duty cycle cannot be adjusted in a “live” setting. Creating Different Operational Conditions with the Scenario Switches Switch S1-2 and switch S6-7 are both in the middle position, (NORMAL) sensor #1 will output a 5V± square wave with a 25%± duty cycle at a frequency of 4.5kHz±. Switch S1-2 in UP position will change the system voltage (measurable at ECU) to 10VDC± with no effect on the sensors operation. The system voltage is measurable at the ECU test points. Switch S1-2 in the DOWN position will cause the system voltage at the ECU to be 7VDC± and sensor #1 will not operate because the ECU will not generate a 5VDC± reference voltage with a system voltage of 7VDC±. The system voltage is measurable at the ECU test points. Voltage readings of zero will be at all three terminals of sensor #1 during this condi- tion. 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 8 Switch S6-7 in UP position will change Sensor #1 frequency to 450Hz± at a duty cycle of 25%±. Switch S6-7 in DOWN position will change Sensor #1 frequency to 4.5kHz± and a duty cycle of 95%±. Switch S4-5 in MIDDLE position will create a 5VDC± sensor Vref voltage and sensor #1 will operate normally. Switch S4-5 in UP position creates a 2VDC± Vref voltage and sensor #1 will not operate. Switch S4-5 in DOWN position creates a 1.2VDC± Vref voltage and sensor #1 will not operate. Switch S3 in DOWN position creates a NORMAL ECU ground path and sensor will work normally. Switch S3 in UP position drops the ECU system voltage to 10.5VDC± volts by inserting resistance in the ECU ground circuit (between negative battery post and ECU ground terminal) measurable at ECU test points. With this condition, Sensor #1 Vref voltage and signal voltage both go to 5.00VDC±. A voltage measurement on sensor #1 ground will read 2.000VDC± and the sensor stops working. Measuring ground voltage drop between main GROUND terminal and ECU C3 GROUND will show about a 2.00VDC± drop. Sensor #1 will work “part-time” with Scenario #3 inserted and sensor #2 disconnected because the total voltage drop with Scenario #3 is less and variable than if Sensor #2 were connected. The variation is caused by Sensor 1 itself within its internal electronics. Scope pattern of sensor #1 signal will be intermittent and switches from “working” to “not work- ing”. RED – VREF BLK – GND WHT - SIGNAL CONNECTER VIEW 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 9 Sensor #2 Scenarios S2 - Sensor #2 is a variable resistance TPS or APP sensor from a 2008 Hyundai Accent. The internal construction of the sensor has a 2.2kΩ± resistor with a movable wiper arm that varies the measured resistance which creates a signal voltage based on throttle or pedal position. Normal signal voltage range varies from 0.19 VDC± to 4.89VDC± and the measured variable resistance varies from 1kΩ± to 3kΩ± from “idle” to “WOT”. The sensor is supplied by a 5V Vref volt- age from the ECU. WHT – GND WHT – VREF WHT CONNECTER VIEW Switch S1-2 and switch S4-5 are both in the middle position. Sensor #2 operates normally with a signal voltage range varying from 0.19 VDC± to 4.89VDC±. Switch S1-2 in UP position will change the system voltage (measurable at ECU) to 10VDC± with no effect on the sensors operation. The system voltage is measurable at the ECU test points. Sensor #2 can operate with an ECU system voltage of 10.00VDC±. Switch S1-2 in the DOWN position will cause the system voltage at the ECU to be 7VDC± and sensor #2 will not operate because the ECU will not generate a 5VDC± reference voltage with a system voltage of 7VDC±. The system voltage is measurable at the ECU test points. Voltage readings of zero will be at all three terminals of sensor #2 during this condi- tion. Switch S4-5 in UP position creates a Vref voltage to sensor #2 of 2VDC±. This affects the signal voltage of sensor #2 with readings of 0.07VDC± to 1.94VDC±. This scenario could be caused from corrosion or loose connections in the Vref circuit. Switch S4-5 in DOWN position creates a Vref voltage to sensor #2 of 1.2VDC±. The affects the signal voltage of sensor #2 with readings of 0.04VDC± to 1.21VDC±. This scenario might cause a student to misread their voltmeter thinking the Vref voltage was 12.00VDC± instead of the real reading of 1.20VDC±. This fault dramatically effects the output signal voltage of the sensor which would cause vehicle operation problems. Switch S3 in UP position creates a 2.00VDC± voltage drop in the ECU ground circuit. This fault will raise the ground voltage of sensor #2 up to about 2.00VDC± from zero and the signal voltage range will be from 2.00VDC± to 5.00VDC±. This condition would also cause vehicle operation problems. 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 10 Getting a meaningful waveform from sensor #2 (full sweep) requires setting up the scope to a long time/div and a very low voltage/div. The uScope works best on 1V/div and 2sec/div. without any faults inserted. Sensor #3 Scenarios S3 – Sensor #3 represents a Variable Reluctance sensor that normally generates an AC sine wave. An actual VR sensor from a vehicle would vary the AC voltage amplitude and frequency based on trigger wheel speed. For purposes of this trainer, the AC voltage output is a generated signal that is displayed as a pure AC sine wave. Scenario switches can vary the voltage amplitude and frequencies. There are two wires connected to the sensor which also connect to the ECU. With all scenario switches in the “neutral” position, the output voltage of sensor #3 should be 3.00VAC± rms measured from both terminals of the sensor or 1.500VAC± rms measured from either sensor wire to system ground. The 3.00VAC± is defined as the “root mean square” AC voltage of the sensor. There will be variations on voltage measurements and reading with sensor and system tolerances. Variations should be in the 0.100± VAC range. Using an oscilloscope to mea- sure sensor #3 output voltage results in viewing the “peak-to-peak” voltage which will be considerably more than the measured rms voltage. The waveform of Sensor #3 can be obtained from either wire of the sensor to scope channel positive and the scope channel ground to system ground at the GND test point OR both positive and ground scope channels connected to both wires of the sensor. Polarity doesn’t matter. TAKEN FROM SENSOR TO SYSTEM GROUND 4.16VAC± PtoP 1.34 VAC± rms (SCOPE) 1.41 VAC± rms (METER)(1/2 of rms) TAKEN AT THE SENSOR (BOTH WIRES) 8.96 VDC± PtoP 3.07 VAC± rms (SCOPE) 2.99 VAC± rms (METER) 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 11 Switch S8-9 in DOWN position should result in a 9VAC± rms signal at 100Hz± measured at the sensor. TAKEN FROM SENSOR TO SYSTEM GROUND 12.0 VAC± PtoP 4.04 VAC± rms (SCOPE) 4.26 VAC± (METER)(1/2 OF RMS) TAKEN AT THE SENSOR (BOTH WIRES) 25.4VAC± PtoP 9.31 VAC± rms (SCOPE) 9.00 VAC± rms (METER) Switch S8-9 in UP position should result in a 3VAC± signal at 10kHz± frequency. TAKEN FROM SENSOR TO SYSTEM GROUND 3.85VAC PtoP 1.158 VAC± rms (METER) 1.21 VAC± rms (SCOPE)(1/2 OF RMS) TAKEN FROM SENSOR BOTH WIRES 10.1VAC PtoP 3.20 VAC± rms (METER) 3.48 VAC± rms (SCOPE) Switch #3 in UP position will insert a 2.00VDC± voltage drop in the ECU ground circuit. This scenario will cause the sig- nal of sensor #3 to move up on the scope screen about 2.00VDC± if the scope is connected with scope channel positive and ground both at the sensor. SWITCH S3 IN DOWN POSITION – NORMAL OPERATION SWITCH S3 IN UP POSITION – 2VDC± VOLTAGE DROP IN ECU GROUND CIRCUIT (PATTERN MOVES UP 2.00VDC±) 96-CL-1930 Component & Scenario Explanations consulab.com info@consulab.com 12 General Notes Switch S1-2 in the MIDDLE and UP position will have no effect on the operation of sensor #3. However, if switch S1-2 is moved to the DOWN position, this creates a system voltage of 7VDC± which is not sufficient for the ECU to operate properly. Moving S3 to the UP position inserts the ground voltage drop into the ECU ground, but has no effect on the signal of sensor S3 when measured at the sensor. If measured between sensor and ECU ground, the pattern will rise about 2VDC± with switch #3 in the UP position. Switch S4-5 changes the system Vref voltage. In the middle position, Vref in MIDDLE position is 5VDC, UP is 2VDC± and DOWN is 1.2VDC±. Changing switch S3 from DOWN (normal) to UP will insert resistance in ECU ground circuit which cre- ates a 2.00VDC± voltage drop in the ECU ground circuit. However, if the system Vref voltage is changed, the amount of voltage drop created in the ECU ground circuit will also change. S45 in UP (Vref of 2VDC± will change the ground voltage drop from 2.00VDC± to 0.80VDC±). If switch S4-5 is moved to the DOWN position, the ground voltage drop changes to 0.500VDC±. When observing scope patterns, it will be noticed that the pattern will move “up” from existing “zero” line when additional ground resistance is inserted into the ECU ground circuit and will also move based on the selected Vref voltages from switch S4-5. (if measured with both scope connections made at the sensor) Sensor #3 – When reading rms voltage, Do the following math to calculate peak-to-peak voltage: 3.48VACrms. 3.48 X 1.4142 = 4.92 which is the “peak” voltage either from 0 to + or 0 to -. To calculate Peak-to-Peak, multiply the peak voltage times 2 or 4.44VAC X 2 = 9.84 = VAC peak-to-peak. The uScope reads 10.1VAC± peak-to-peak (based on scope averaging) WHT WHT CONNECTER VIEW Pico scope showing sensor #3 with switch #3 in down position (both scope wires connected at sensor #3) Pico scope showing sensor #3 with switch #3 in up position (both scope wires connected at sensor #3) 96-CL-1930 Wiring Diagrams consulab.com info@consulab.com 13 Wiring Diagrams consulab.com info@consulab.com 14 96-CL-1930 Wiring Diagrams Connectors and Sensors C L-19 3 0 C onnectors and S ensors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.11 RED BLK W H T W H T Sensor 1 1920 C onnector lim ited access (C 5) ABC Sensor 3 12 Sensor 2 123 123456789101112131415161718 21 RED W H T W H T W H T W H T BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 204 ECU SEN 3+ SEN 3- SEN 2 V REF SEN 2 LO W REF SEN 2 SIG SEN 1 V REF SEN 1 LO W REF SEN 1 SIG G N D G N D BA T BA T C 3 C 2 C 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 201 2 3 H arness C onnector (C 4) BLK BRN BRN RED RED RED W H T W H T W H T BLK BLK W H T W H T W H T BLK BLK BLK BLK BLK BLK 1234567891011 121314151617 18 S3 V bat RED BLK BRN BLK RED BRN W H T BLK W H T W H T RED W H T BRN W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T BRN RED BLK BRN BLK RED BLK BLK W H T W H T W H T W H T W H T W H T BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN RED RED BLK BRN RED BRN RED BLK W H T W H T W H T W H T BLK BRN BRN BRN BLK W H T W H T W H T W H T BLK BLK RED BLK BLK RED W H T RED W H T RED BLK BLK RED RED BLK BLK BRN REDRED BRN REDRED RED BLK BLK RED BLK W H T W H T Sensor 1 1920 C onnector lim ited access (C 5) ABC Sensor 3 12 Sensor 2 123 123456789101112131415161718 21 RED W H T W H T W H T W H T BLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 204 ECU SEN 3+ SEN 3- SEN 2 V REF SEN 2 LO W REF SEN 2 SIG SEN 1 V REF SEN 1 LO W REF SEN 1 SIG G N D G N D BA T BA T C 3 C 2 C 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 201 2 3 H arness C onnector (C 4) BLK BRN BRN RED RED RED W H T W H T W H T BLK BLK W H T W H T W H T BLK BLK BLK BLK BLK BLK 1234567891011 121314151617 18 S3 V bat RED BLK BRN BLK RED BRN W H T BLK W H T W H T RED W H T BRN W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T BRN RED BLK BRN BLK RED BLK BLK W H T W H T W H T W H T W H T W H T BLK BLK BLK BLK BLK BLK BLK BLK BRN BRN RED RED BLK BRN RED BRN RED BLK W H T W H T W H T W H T BLK BRN BRN BRN BLK W H T W H T W H T W H T BLK BLK RED BLK BLK RED W H T RED W H T RED BLK BLK RED RED BLK BLK BRN REDRED BRN REDRED RED BLK BLK consulab.com info@consulab.com 15 96-CL-1930 Wiring Diagrams consulab.com info@consulab.com 15 C L-19 3 0 P lan C lient © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 2.10 H EA D LIG H TS SYSTEM H O RN S SYSTEM TH RO TTLE AC TU ATO R C TRL O PEN H EA D LIG H TS SYSTEM SH IFT IN TERLO C K SYSTEM D O O R LO K C S SYSTEM H O RN S SYSTEM D O O R LO C KS SYSYTEM SH IFT IN TERLO C K SYSTEM C RU ISE C O N TRO L SYSYTEM C RU ISE C O N TRO L SYSTEM 5 2 1378 6 4 RED BLK W H T W H T Sensor 1 1920 C onnector lim ited access (C 5) ABC Sensor 3 AB Sensor 2 S1038 (sm p) 123 1234567891011 1213 14151617 1821 RED W H T BRN BLK W H T W H T W H T W H T TH RO TTLE AC TU ATO R C TRL O PEN RED RED RED RED RED BRN BRN BRN BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T W H T BLK BLK BLK BLK Limited Access Connector C5 consulab.com info@consulab.com 16 96-CL-1930 Wiring Diagrams consulab.com info@consulab.com 16 Harness-Harness Connector C4 C L-19 3 0 P lan C lient © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 2.10 1234567891011 121314 151617 18 H arness-H arness connector (C 4) PO W ER W IN D O W S SYSTEM W IPER/ W ASH ER SYSTEM W IPER/ W A SH ER SYSTEM PO W ER W IN D O W S SYSTEM 12 RED BLK BLK BRN BLK RED BRN W H T W H T BRN RED M EM O RY SYSTEM N A V IG A TIO N SYSTEM N A V IG A TIO N SYSTEMBO O ST PRESSU RE SEN SO R BO O ST PRESSU RE SEN SO R 2 15 3478 6 5 786 34 W H T W H T W H T W H T W H T W H T W H T BLK BLK BRN BLK RED BRN W H T W H T RED W H T W H T W H T W H T W H T W H T W H T W H T W H T consulab.com info@consulab.com 17 96-CL-1930 Wiring Diagrams consulab.com info@consulab.com 17 ECU C L-19 3 0 P lan C lient © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 2.10 C H A RG E IN D C TRL LO W SPEED C O O LIN G K N O C K SEN SO R SIG N AL IG N ITIO N C O N TRO L O U TPU T SPD W AK EU P SERIA L D A TA PRIM A RY RELAY C V T U N IT IN STRU M EN T C LU STER SYSTEM AC C PED A L PO S TEM PERA TU RE SEN SO R FA N RLY C TRL D O O R LO C KS SYSTEM SH IFT IN TERLO C K SYSTEM STEERIN G SEN SO R LO W REF FU EL PU M P R LY AIRBAG SEN SO R 378 46 5 BLK BLK RED RED WHT BLK RED RED BRN BLK WHT BRN WHT WHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 BRN BLK WHT WHT WHT RED RED BRN BLK BRN BLK RED RED BLK BLK RED RED WHT BLK BLK RED RED BLK BLK 19 20 1 2 3 4 EC U 12 WHT WHT BLK RED BRN SEN3+ SEN3- SEN2 VREF SEN2 LOW REF SEN2 SIG SEN1 VREF SEN1 LOW REF SEN1 SIG GND GND BAT BAT C 3 C 2 C 1 EX TERIO R LIG H T IN TERIO R LIG H T EN G IN E C O N TRO L SYSTEM SO U N D SYSTEM SEATS SYSTEM C O M PU TER D A TA LIN E SYSTEM W ARN IN G SYSTEM BRN consulab.com info@consulab.com 18 96-CL-1930 Wiring Diagrams consulab.com info@consulab.com 18 C L-19 3 0 End view connectors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.10 RED BLK WHT A B C RED BLK WHT A B C Sensor 1 ABC SEN SO R PLU G H A RN ESS REC EPTAC LE Sensor 2 123 1 2 3 WHT 1 2 3 WHT WHT H A RN ESS REC EPTAC LE SEN SO R PLU G Sensor 3 AB 7A B A A B2A B A H A RN ESS REC EPTAC LE SEN SO R PLU G N O TE: EN D V IEW S A RE SEEN FRO M TERM IN A L SID E. Connector End Views consulab.com info@consulab.com 19 96-CL-1930 Wiring Diagrams C L-19 3 0 End view connectors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.10 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 C 4 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 C 4 SEN SO R SID E PLU G H A RN ESS SID E REC EPTAC LE C 5 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 192021 C 5 18 15 12 9 6 3 17 14 11 8 5 2 16 13 10 7 4 1 192021 H A RN ESS SID E REC EPTAC LE SEN SO R SID E PLU G N O TE: EN D V IEW S A RE SEEN FRO M TERM IN A L SID E. consulab.com info@consulab.com 20 96-CL-1930 Wiring Diagrams C L-19 3 0 End view connectors © C onsuLab Educatech Inc, 2025. A ll rights reserved. REV 1.10 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 C 1 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 J 4 H A RN ESS PLU G EC U 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 C 2 H A RN ESS PLU G 1 2 3 4 5 6 11 12 13 14 18 7 8 9 10 15 16 17 19 20 J 5 EC U C 3 1 2 3 4 BLK BLK RED RED EC U J 6 1 2 3 4 H A RN ESS PLU G N O TE: EN D V IEW S A RE SEEN FRO M TERM IN A L SID E. 96-CL-1930 Notes consulab.com info@consulab.com 21 Notes 96-CL-1930 Notes consulab.com info@consulab.com 22 Notes 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. Tous droits réservés. 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved. Harness replacement Harness Location Identification CL-1930 Fault Insertion Component & Scenario Explanations Scenario Switch Box System Voltage Test Points Sensor #1 Scenarios Sensor #2 Scenarios Sensor #3 Scenarios General Notes Wiring Diagrams Connectors and Sensors Limited Access Connector C5 Harness-Harness Connector C4 ECU Connector End Views

Student Assignments for HV-950-B6.7_035101 ConsuLink™ engine bench Cummins B6.7 EPA 2021 new HV-950-B6.7_035101-95_V2023-2 © ConsuLab Educatech Inc, 2023. Tous droits réservés. HV-950-B6.7_035101-95 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 © ConsuLab Educatech Inc, 2023. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. Table of Contents Student Assignments SA-1 — Components — Basic ID 5 SA-2 — Components — Engine Specific ID 7 SA-3 — Components — Sensor ID 9 SA-4 — Components — Actuator ID 11 SA-5 — Charging System 12 SA-6 — Wiring Diagram Practice 13 SA-7 — Expected Voltages 17 SA-8 — Measured Voltages 18 SA-9 — Case Study Diagnosis — CS01 19 SA-9 — Case Study Diagnosis — CS02 20 SA-9 — Case Study Diagnosis — CS03 21 SA-9 — Case Study Diagnosis — CS04 22 SA-9 — Case Study Diagnosis — CS05 23 SA-9 — Case Study Diagnosis — CS06 24 SA-9 — Instructor Case Study Diagnosis — ICS01 25 SA-9 — Instructor Case Study Diagnosis — ICS02 26 HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 4 Student Assignments HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 5 SA-1 Components — Basic ID HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. COMPONENT FUNCTION/DETAILS LOCATION Engine Mounts Transmission Transmission Fluid Level Inspection Coolant Hoses Coolant Reservoir & Cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain Plug Oil Dipstick Air Filter Fuel Filter(s) Throttle (body) HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 6 Name : Group : Date : Instructor : Grade : COMPONENT FUNCTION/DETAILS LOCATION Positive Crankcase Ventilation System Batteries Starter Alternator Belt(s) Exhaust Aftertreatment DEF Fluid reservoir Fuse box – power DLC HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 7 SA-2 Components — Engine Specific ID HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. ENGINE SYSTEM ENGINE SPECIFIC INFORMATION VIN & Decode Engine Type Engine Model Engine Displacement Number of Cylinders Cylinder Numbering Firing Order Direction of Engine Rotation Compression Ratio Aspiration Turbo N/A Supercharged Camshaft Configuration OHV SOHC DOHC Turbo Type Charge Air Cooler Location & Function Fuel System Type DEF Reservoir HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 8 ENGINE SYSTEM ENGINE SPECIFIC INFORMATION J1939 Parameter Display Unit Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF OTHER TECHNOLOGIES Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 9 SA-3 Components — Sensor ID HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step three in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. SENSOR FUNCTION LOCATION ECU PIN #’s Accelerator Pedal Position 1 Accelerator Pedal Position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 10 SENSOR FUNCTION LOCATION ECU PIN #’s DPF Outlet Pressure Exhaust Gas Recirculation (EGR) temp EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 11 SA-4 Components — Actuator ID HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step four in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. ACTUATOR FUNCTION LOCATION ECU PIN #’s Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbocharger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 12 SA-5 Charging System HV-950 Engine Application: | In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step five in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. TASK RECORD RESULTS & INTERPRET Visual Inspection of Batteries Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV? YES NO Is this system functioning properly? VOLTAGE DROPS TO VERIFY SYSTEM INTEGRITY NOTE: Current has to be flowing to perform an accurate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceeding with diagnosing engine performance issues? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 13 SA-6 Wiring Diagram Practice - Connector J1 HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. PIN WIRE COLOR CIRCUIT # FUNCTION (Signal / Control / Reference / ?) 1 2 3 4 10 11 13 16 17 18 19 25 26 27 28 31 32 34 35 36 41 42 43 44 45 49 50 HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 14 PIN WIRE COLOR CIRCUIT # FUNCTION (Signal / Control / Reference / ?) 51 54 55 57 58 59 61 62 63 65 66 67 68 69 70 71 72 73 74 75 76 78 79 81 82 83 90 93 94 95 96 Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 15 SA-6 Wiring Diagram Practice - Connector J2 HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. PIN WIRE COLOR CIRCUIT # FUNCTION (Signal / Control / Reference / ?) 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 32 33 35 38 39 40 HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 16 PIN WIRE COLOR CIRCUIT # FUNCTION (Signal / Control / Reference / ?) 41 42 44 45 46 48 49 53 54 57 61 62 64 65 68 71 72 75 76 77 78 79 82 83 86 87 90 91 92 94 95 96 Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 17 SA-7 Expected Voltages - Connector HV-950 Engine Application: In preparation Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s understanding of certain common engine management systems. Prior knowledge of the principles of operation for the following systems is required. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. PIN WIRE KEY OFF KOEO KOER COMPONENT / SENSOR* EXAMPLE 1 5 V 4.2 V Engine Coolant Sensor Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 18 SA-8 Measured Voltages - Connector HV-950 Engine Application: In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provided below. Compare results to Student Assignment #7 (SA7). PIN WIRE SYSTEM / VOLTAGE KEY OFF ACC KOEO KOER EXAMPLE 1 APP sensor 1 signal 0 V .9 V .9 V .9 V Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 19 SA-9 Case Study Diagnosis - CS01 HV-950 Engine Application: Clear all codes before beginning each case study. For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please re- move any case study after engine has been turned OFF. Using all the information gathered in Student Assignments SA-1 to SA-8 and the repair order style case study diagnosis handout provided by the instructor, verify the customer con- cern and document your diagnostic process. Follow OEM troubleshooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECU breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECU breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. CS01 Customer Concern The customer states that the engine will crank but does not start. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 20 SA-9 Case Study Diagnosis - CS02 HV-950 Engine Application: Clear all codes before beginning each case study. For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please re- move any case study after engine has been turned OFF. Using all the information gathered in Student Assignments SA-1 to SA-8 and the repair order style case study diagnosis handout provided by the instructor, verify the customer con- cern and document your diagnostic process. Follow OEM troubleshooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECU breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECU breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. CS02 Customer Concern The customer states that the engine will turn over but does not start up. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 21 SA-9 Case Study Diagnosis - CS03 HV-950 Engine Application: Clear all codes before beginning each case study. For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please re- move any case study after engine has been turned OFF. Using all the information gathered in Student Assignments SA-1 to SA-8 and the repair order style case study diagnosis handout provided by the instructor, verify the customer con- cern and document your diagnostic process. Follow OEM troubleshooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECU breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECU breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. CS03 Customer Concern The customer states that engine acceleration feels different, feels slow on response. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 22 SA-9 Case Study Diagnosis - CS04 HV-950 Engine Application: Clear all codes before beginning each case study. For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please re- move any case study after engine has been turned OFF. Using all the information gathered in Student Assignments SA-1 to SA-8 and the repair order style case study diagnosis handout provided by the instructor, verify the customer con- cern and document your diagnostic process. Follow OEM troubleshooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECU breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECU breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. CS04 Customer Concern The customer states that the engine has poor performance, sluggish acceleration and fuel economy is down. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 23 SA-9 Case Study Diagnosis - CS05 HV-950 Engine Application: Clear all codes before beginning each case study. For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please re- move any case study after engine has been turned OFF. Using all the information gathered in Student Assignments SA-1 to SA-8 and the repair order style case study diagnosis handout provided by the instructor, verify the customer con- cern and document your diagnostic process. Follow OEM troubleshooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECU breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECU breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. CS05 Customer Concern The customer states that the engine is hard to start after warmed up and fuel economy is down. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 24 SA-9 Case Study Diagnosis - CS06 HV-950 Engine Application: Clear all codes before beginning each case study. For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please re- move any case study after engine has been turned OFF. Using all the information gathered in Student Assignments SA-1 to SA-8 and the repair order style case study diagnosis handout provided by the instructor, verify the customer con- cern and document your diagnostic process. Follow OEM troubleshooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECU breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECU breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. CS06 Customer Concern The customer states that the engine is hard to start when cold. Check and advise. Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 25 SA-9 Instructor Case Study Diagnosis - ICS01 HV-950 Engine Application: Clear all DTC’s before beginning each case study. This is an instructor led lesson where an IMP sensor code and drivability issue can be demonstrated. Follow the OEM troubleshooting sequence using linked documents for wiring diagrams and ECM breakout box information. You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instruc- tor. ICS01 Reverse engineer the customer concern based on the demonstrated case study and vehicle perfor- mance. Student Observation Explain Strategy Tests Performed Fault Component This is an instructor led lesson where an Intake Manifold Pressure sensor DTC is created by simulating a fixed circuit voltage. Input/Output? Name : Group : Date : Instructor : Grade : HV-950-B6.7_035101-95 Student Assignments consulab.com info@consulab.com 26 SA-9 Instructor Case Study Diagnosis - ICS02 HV-950 Engine Application: Clear all DTC’s before beginning each case study. This is an instructor led lesson where an CKP-P sensor code and drivability issue can be demonstrated. Follow the OEM troubleshooting sequence using linked documents for wiring diagrams and ECM breakout box information. You can explore with the scan tool to see if there are any codes or data that lead you to the root cause. Measurements can also be taken at the ECM breakout box. Clear all DTC’s at the end of each case study as directed by your instruc- tor. ICS02 Reverse engineer the customer concern based on the demonstrated case study and vehicle perfor- mance. Student Observation Explain Strategy Tests Performed Fault Component This is an instructor led lesson for the Crankcase Pressure Sensor to be adjusted and compared to Cummins Document (019-445) for the nominal value with engine OFF. Input/Output? Name : Group : Date : Instructor : Grade : 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved. Furses and Circuit Protection Power Connections Ground Connections

Instructor Manual for HV-950-B6.7_035101 ConsuLink™ engine bench Cummins B6.7 EPA 2021 new 96-HV-950-B6.7_REVA © ConsuLab Educatech Inc, 2023. Tous droits réservés. 96-HV-950-B6.7 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, 2023. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. Table of Contents General Description 4 Main Features 4 Component Identification 5 Dashboard 5 ECM Breakout Box (BOB) 6 J1939 DLC Breakout Box (BOB) 6 Engine 7 Diesel Aftertreatment Unit 9 Fuses and Relays 10 Safety Rules 11 Instructions to the HV-950 Family of Diesel Engine Benches 13 Consulink™ Student Learning Platform — Student Facing 15 Consulink™ Student Learning Platform — Instructor Facing 17 Student Assignments — Basic Orientation and Troubleshooting 19 Types of Case Studies 21 Explanation of Grading Rubric for Case Studies 22 SA-8 Measured Voltage Answers 23 Instructor Answers For Case Studies and Fault Insertion 27 HV-950-B6.7_035101 Wiring Diagram W/Fault Location for Case Studies 32 consulab.com info@consulab.com 4 96-HV-950-B6.7 General Description General Description The ConsuLink™ Cummins B6.7 engine bench is an innovative training solution for your classroom. The intuitive Con- suLink™ student learning platform empowers students to perform diagnosis without needing direct input from an in- structor. Various diagnostic scenarios can be created and inserted in multiple ways; by the student with instructions, by the student blindly, by the instructor, or by manually inserted faults. The brand-new Cummins B6.7 represents the pinna- cle of modern diesel technology with cutting-edge emissions systems, advanced injection technologies and high-power density. Integrated breakout boxes for the engine ECU and Deutsch 9-pin DLC facilitate durable and repeatable multime- ter and oscilloscope measurements. Main Features: • Single camshaft • High Pressure Common Rail (HPCR) fuel system • ECM 2450 (this control module incorporates DEF dosing control) • Variable Geometry Turbocharger (VGT) • Exhaust Gas Recirculation system (EGR) • Steel tubing engine stand with four removable casters, two locking • Fuel tank • Radiator • Charge-air cooler • Air filter • Instrument panel with : - Ignition key and testing points - Indicator lamps and switches - Breakout box - Murphy PV101 control panel for J1939 parameters - J1939 Data Link Connector • Accelerator pedal • Emergency stop switches (2) • Batteries (2) with master disconnect switch and smart battery charger • Safety guards on all rotating or high temperature components • Electronic programmable fault box • Aftertreatment system: - Single Module DPF and SCR consulab.com info@consulab.com 5 HV-950-B6.7_035101-96 Component Identification Component Identification Dashboard 1 2 3 4 5 6 7 8 9 10 11 12 13141516 17 18 19 20 21 2223242526 1 ECM Breakout Box 14 Diesel Exhaust Fluid Warning Light 2 J1939 DLC Breakout Box 15 Diesel Particulate Filter Regeneration Warning Light 3 Key Ignition Switch 16 Main Switch Indicator Light 4 ConsuLink Instructor Mode Lockout 17 High Exhaust System Temperature (HEST) Warning Light 5 ConsuLink Power Button 18 Diesel Particulate Filter Regeneration Switch (UP = Force − MID = Automatic − DOWN = Stop) 6 ConsuLink Student Learning Platform 19 Parking Brake Switch (I = Engage − O = Disengage) 7 PV101 Murphy Display 20 Service Brake Switch (I = Apply − O = Release) 8 Ignition Switch Indicator Light 21 Clutch Switch (I = Disengage − O = Engage) 9 Emergency Stop Switch Indicator Light 22 PTO Engine Speed Switch (UP = Increase − DOWN = Decrease) 10 Glow Plug Indicator Light 23 PTO System Control Switch (I = Activate − O = Deacti- vate) 11 Engine Warning Light 24 Fan Override Switch (I = Force − O = Normal) 12 Engine Shotdown Indicator Light 25 Engine Retarder Switch (I = Activate − O = Deactivate) 13 Malfunction Indicator Light 26 Engine Retarder Indicator Light consulab.com info@consulab.com 6 HV-950-B6.7_035101-96 Component Identification ECM Breakout Box The ConsuLink™ HV-950-B6.7 ECM Breakout Box is designed for easy testing of input and output signals coming from various sensors and actuators in the complete engine operational system. The identification of all test points match OEM ECM pinout diagrams. Testing at the Breakout Box (BOB) is the same as back probing the ECM harness without any danger of damaging pins! • J1 & J2 connectors (Cummins’ terminology for ECM labeling). • 2 mm test receptacles to accept most multimeter and oscilloscope test leads. • Faults with variable values; students must use either a scan tool or the ECM BOB for obtaining their diagnostic mea- surements. - Students are not allowed to back-probe or measure at the faulted sensor as there will be false readings. - This is because when a fault with a variable value is selected, the “real” sensor signal is still present at the sensor. • When using open circuit faults students may back-probe or measure at the sensor as required, at instructors discretion (Case Studies 1-9). • The ECM BOB pin numbers match OEM service information. • Some pins are not used for specific vehicle and trainer applications. J1939 Data Link Connector Breakout Box • Specifically designed for use in educational environments with robust 2MM test pins and LED activity indicators for all 9 pins of a standard J1939 DLC. • Y-harness configuration allows for replaceable DLC installation on the trainer. • The ability to replace the Y-harness subassembly allows for a cost-effective repair in case the connector gets damaged. • LED lights indicate data communication is occurring. # COLOR DESCRIPTION A GRN Ground B RED Unswitched Battery C YEL J1939 CAN High (+) D GRN J1939 CAN Low (−) E RED J1939 CAN Shield (if available) F RED J1708 CAN High (+) G RED J1708 CAN Low (−) H RED OPEN J RED OPEN J1939 DLC BREAKOUT BOX ECM BREAKOUT BOX consulab.com info@consulab.com 7 HV-950-B6.7_035101-96 Component Identification Engine 1 Alternator 2 Thermostat Housing 3 Clutch Fan Hub 4 EGR Tube 5 Intake Throttle Actuator 6 Oil Pressure Switch 7 CMP (Camshaft Position Sensor) 8 CKP (Crankshaft Position Sensor) 9 Viscous Vibration Damper 10 Timing Gear Cover 11 Belt Tensioner 12 Water Pump 13 Turbocharger Compressor Inlet 14 Turbocharger Compressor Outlet FRONT LH ISO FRONT REVISIONS REV. DESCRIPTION DATE APPROUVE POIDS APPROX.: 340.08 Lbs. FINITION: AUCUNE B FORMAT NO.INV. 66407-4 PRODUIT HV-950-B6.7_035101 DESSINÉ SELON LES NORMES ASME Y14.5M-1994 ET ASME Y14.36M DESCRIPTION MOTEUR DIESEL CUMMINS B6.7 EPA 2021 NEUF REVNO. DE DESSIN 66407-4ÉPAISSEUR: N/A MATÉRIAU: N/A ÉCHELLE 1:10 .X .XX .XXX X/X ANGLE .015" .010" .001" 1/16" .5 DIMENSIONS EN POUCES TOL. SAUF SI SPÉCIFIÉES DESSINÉ PAR: DANIEL CLAVET DATE: 13-04-2022 FEUILLE 1/2 C:\PDM\PRODUITS\05-MOTEURS CUMMINS\B6_7_2021\ TOUTES LES ARÊTES VIVENT DOIVENT ÊTRE ENLEVÉES. CE DESSIN EST LA PROPRIÉTÉ DE CONSULAB. TOUTE REPRODUCTION TOTALE OU PARTIELLE NE PEU ÊTRE FAITE SANS LE CONSENTEMENT ÉCRIT DE CONSULAB EDUCATECH 6330 ZÉPHIRIN-PAQUET, SUITE 400 QUÉBEC,QC, G2C 0M3 A A B B C C D D E E F F 3 3 2 2 1 1 0 0 π π μ μ Ω Ω Δ Δ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 EGR Valve 25 High Pressure - Fuel Supply to Rail 16 EGR DPF (Differential Pressure Sensor) 26 Alternate Dipstick Location 17 Fuel Rail Drain - rail pressure relief 27 Drain Oil - Low Pressure Supply (lubricating type) 18 Engine Lifting Fixture (rear) 28 Lubricating Oil Pan 19 Low Pressure - Fuel Filter Return Line 29 Crankshaft Tone Ring 20 Crankcase Vent Tube 30 ECM - Engine Control Module 21 Fuel Pump Actuator 31 Fuel Filter Supply Line 22 High-Pressure Fuel Pump 32 Fuel Filters 23 Fuel Pump - Low Pressure Supply (gear type) 33 ECM - Engine Control Module 24 Flywheel Housing 34 Engine Air Intake FRONT LH ISO FRONT REVISIONS REV. DESCRIPTION DATE APPROUVE POIDS APPROX.: 340.08 Lbs. FINITION: AUCUNE B FORMAT NO.INV. 66407-4 PRODUIT HV-950-B6.7_035101 DESSINÉ SELON LES NORMES ASME Y14.5M-1994 ET ASME Y14.36M DESCRIPTION MOTEUR DIESEL CUMMINS B6.7 EPA 2021 NEUF REVNO. DE DESSIN 66407-4ÉPAISSEUR: N/A MATÉRIAU: N/A ÉCHELLE 1:10 .X .XX .XXX X/X ANGLE .015" .010" .001" 1/16" .5 DIMENSIONS EN POUCES TOL. SAUF SI SPÉCIFIÉES DESSINÉ PAR: DANIEL CLAVET DATE: 13-04-2022 FEUILLE 1/2 C:\PDM\PRODUITS\05-MOTEURS CUMMINS\B6_7_2021\ TOUTES LES ARÊTES VIVENT DOIVENT ÊTRE ENLEVÉES. CE DESSIN EST LA PROPRIÉTÉ DE CONSULAB. TOUTE REPRODUCTION TOTALE OU PARTIELLE NE PEU ÊTRE FAITE SANS LE CONSENTEMENT ÉCRIT DE CONSULAB EDUCATECH 6330 ZÉPHIRIN-PAQUET, SUITE 400 QUÉBEC,QC, G2C 0M3 A A B B C C D D E E F F 3 3 2 2 1 1 0 0 π π μ μ Ω Ω Δ Δ 15 16 17 33 18 20 21 22 24 28 27 23 25 19 32 31 26 29 30 34 consulab.com info@consulab.com 8 HV-950-B6.7_035101-96 Component Identification 35 EGR Cooler 47 Coolant Inlet Connection 36 Coolant Return Line - Variable Geometry Turbo (VGT) 48 Turbocharger Coolant Supply Line 37 Turbocharger Oil Supply Line 49 Turbocharger Oil Drain Line 38 EGR Cooler - Coolant Return Line 50 Starter Motor 39 Front Exhaust - Pressure Sensor Line 51 Flywheel Housing 40 Exhaust Manifold 52 Service Access/Barring Location 41 Front Engine Lifting Fixture 53 Crankcase Breather - Oil Drain Line 42 Coolant Heater Port 54 VGT Actuator 43 Oil Filter - Oil Cooler 55 Variable Geometry Turbocharger 44 Oil Pressure Regulator 56 Rear Exhaust - Pressure Sensor Line 45 Engine Oil Filter 57 EGR Cooler - Coolant Supply Line 46 NOx Sensor Mounted on Block (sensor installed in exhaust plumbing at turbocharger outlet) 58 Cylinder Head Fuel Drain 59 Crankcase Pressure Sensor 60 Crankcase Ventilation Housing 61 Crankcase Breather Oil Drain Tube 62 Exhaust Outlet Connection 63 Flywheel 64 Flywheel Housing 65 Crankcase Breather Outlet Tube RH REAR ISO REAR TOUTES LES ARÊTES VIVENT DOIVENT ÊTRE ENLEVÉES. CE DESSIN EST LA PROPRIÉTÉ DE CONSULAB. TOUTE REPRODUCTION TOTALE OU PARTIELLE NE PEU ÊTRE FAITE SANS LE CONSENTEMENT ÉCRIT DE CONSULAB EDUCATECH B FORMAT NO.INV. 66407-4 PRODUIT HV-950-B6.7_035101 DESSINÉ SELON LES NORMES ASME Y14.5M-1994 ET ASME Y14.36M REVNO. DE DESSIN 66407-4 MATÉRIAU: N/A ÉCHELLE 1:10 .XX .XXX X/X ANGLE FINI DE SURFACE .015" .005" 1/16" .5 N/A DIMENSIONS EN POUCES TOL. SAUF SI SPÉCIFIÉES DESSINÉ PAR: DANIEL CLAVET DATE: 13-04-2022 FEUILLE 2/26330 ZÉPHIRIN-PAQUET, SUITE 400 QUÉBEC,QC, G2C 0M3 C:\PDM\PRODUITS\05-MOTEURS CUMMINS\B6_7_2021\ A A B B C C D D E E F F 3 3 2 2 1 1 0 0 π π μ μ Ω Ω Δ Δ 35 36 37 38 40 41 39 43 44 45 46 47 42 49 4850 51 52 53 54 55 56 57 RH REAR ISO REAR TOUTES LES ARÊTES VIVENT DOIVENT ÊTRE ENLEVÉES. CE DESSIN EST LA PROPRIÉTÉ DE CONSULAB. TOUTE REPRODUCTION TOTALE OU PARTIELLE NE PEU ÊTRE FAITE SANS LE CONSENTEMENT ÉCRIT DE CONSULAB EDUCATECH B FORMAT NO.INV. 66407-4 PRODUIT HV-950-B6.7_035101 DESSINÉ SELON LES NORMES ASME Y14.5M-1994 ET ASME Y14.36M REVNO. DE DESSIN 66407-4 MATÉRIAU: N/A ÉCHELLE 1:10 .XX .XXX X/X ANGLE FINI DE SURFACE .015" .005" 1/16" .5 N/A DIMENSIONS EN POUCES TOL. SAUF SI SPÉCIFIÉES DESSINÉ PAR: DANIEL CLAVET DATE: 13-04-2022 FEUILLE 2/26330 ZÉPHIRIN-PAQUET, SUITE 400 QUÉBEC,QC, G2C 0M3 C:\PDM\PRODUITS\05-MOTEURS CUMMINS\B6_7_2021\ A A B B C C D D E E F F 3 3 2 2 1 1 0 0 π π μ μ Ω Ω Δ Δ 58 59 60 61 62 63 64 65 consulab.com info@consulab.com 9 HV-950-B6.7_035101-96 Component Identification Exhaust Aftertreatment Unit 1 Particulate sensor 2 Outlet NOx sensor 3 Exhaust Gas Temperature sensor 4 Diesel particulate filter differential pressure sensor 5 Diesel exhaust fluid dosing valve 6 Decomposition reactor tube 7 Diesel particulate filter (DPF) 8 Diesel oxidation catalyst (DOC) 9 Diesel exhaust fluid tank 10 Diesel exhaust fluid tank control valve 11 Selective catalytic reduction (SCR) 6 9 10 7 8 11 1 3 2 4 5 consulab.com info@consulab.com 10 HV-950-B6.7_035101-96 Component Identification F1 ECM Supply Fuse - 30 A F11 Fault Box Supply - 5 A F2 ECM Ignition Fuse - 5 A F12 Ignition Test Point Fuse - 3 A F3 DEF Dosing Fuse - 10 A R1 Aftertreatment Power Relay F4 Aftertreatment Power - 15 A R2 Brake Light Relay F5 DEF Line Heater - 30 A R3 Fan Clutch Relay F6 Fan Clutch Fuse - 5 A R4 Starter Lockout Relay F7 Key Supply - 10 A R5 Line Heater 1 Relay F8 Accessories Fuse - 5 A R6 Line Heater 2 Relay F9 DLC Fuse - 5 A R7 Line Heater 3 Relay F10 PV101 Display Fuse - 5 A R8 DEF Dosing Unit Relay Fuses and Relays consulab.com info@consulab.com 11 HV-950-B6.7_035101-96 Safety Rules Safety Rules Definition of WARNING, NOTE, and IMPORTANT The diagnosis and repair procedures in our manuals contain both general and specific safety cautions titled: WARNING, NOTE, and IMPORTANT. Certain procedures may present a hazard to the technician if they are not followed in the rec- ommended manner. WARNING, NOTE, and IMPORTANT are elements designed to prevent these hazards, however not all hazards can be foreseen. This information is placed at strategic locations within the operation manual and is designed to prevent the following from occurring: • Serious bodily injury or death to the technician • Damage to the equipment • Unnecessary repairs WARNING defined: When encountering a CAUTION, you will be asked to take a necessary action or not to take a prohibited action. If a CAU- TION is not heeded, the following consequences may occur: • Serious bodily injury or death to the technician • Serious bodily injury or death to other technicians in the workplace area NOTE defined: NOTE calls for special attention to a necessary action or to a prohibited action. If a NOTE is not heeded, the following consequences may occur: • Damage to the equipment • Unnecessary repairs • Unnecessary component replacement • Improper operation or performance of the system or component under repair • Damage to any systems or components which are dependent upon the proper operation of the system or component under repair • Damage to fasteners, basic tools, or special tools • The leakage of coolant, lubricant, or other vital fluids consulab.com info@consulab.com 12 HV-950-B6.7_035101-96 Safety Rules IMPORTANT defined: IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. IMPORTANT state- ments are designed to do the following: • Clarify a procedure • Present additional information for accomplishing a procedure • Give insight into the reason or reasons for performing a procedure in the manner recommended • Present information that will help to accomplish a procedure in a more effective manner 1. Moving Parts and Hot Surfaces WARNING Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury. 2. Fuel/Diesel Vapors WARNING Fuel or diesel vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher near- by. 3. Battery Warning/Battery Disconnect WARNING The batteries give off explosive hydrogen gas during normal operation. A spark or flame can cause the batteries to explode with enough force to kill or seriously hurt you. When conducting any battery maintenance, wear protective clothing and a face shield. Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precau- tions may result in personal injury and/or damage to the vehicle or its components. 4. Radiator Cap WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap. 5. Engine Exhaust WARNING Exhaust fumes can irritate the eyes and respiratory tract, and are a risk to health when breathed in. Engine exhaust fumes contain carbon monoxide, a poisonous gas. Keep the workspace well ventilated. Connect an approved exhaust gas extractor system to the tailpipe when running the engine. consulab.com info@consulab.com 13 HV-950-B6.7_035101-96 Safety Rules 6. Emergency Stop NOTE In case of an emergency requiring the engine to be shut off immediately, press the red emergency STOP button located on the dashboard to stop the engine. Before restarting, the emergency stop button will need to be first reset, then the engine will again start with the key. If the red indicator light is lit, the button will need to be reset before the engine will start. 7. Test Probe NOTE Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use an approved terminal test tool in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. consulab.com info@consulab.com 14 96-HV-950-B6.7 Introduction to the HV-950 family of diesel engine benches Introduction to the HV-950 family of diesel engine benches ConsuLab understands that today’s classroom has changed and we want to encourage the transition from an instructor just dispensing information to one who is a facilitator of actual learning. Today’s automotive instructor is ultimately re- sponsible to provide a learning environment that encourages student led learning. We want to help! The following is our recommendation for integrating our HV-950 Engine bench trainer with fault box into your program. Recommended ways to introduce the ConsuLab HV-950 engine bench to students: • Explain the key and security system (all VIN specific): - Encourage students to not drop or lose key. • Show location of the engine bench batteries and master disconnect switch: - The batteries must always be connected while operating the trainer. - Recommended to wait 10 minutes after engine shut down before opening this switch: • ECM and DEF supply module power must be maintained for a minimum 10 minutes after key off for all applica- tions, even for those applications where the ECM is powered through a battery disconnect device. - Locate the MASTER battery disconnect switch and explain LOCK OUT / TAG OUT. Switch should remain open when stored or not in use. - Explain the 12-volt test points by ignition switch • NEVER power up anything off of this test point! - Student Assignment 5 (SA5) covers charging system operation and inspection • Show location of the battery charger: - Demonstrate correct operation. - Explain that the best engine bench test results are achieved with this plugged in during use as well as just for battery maintenance: • If the battery voltage drops below 12V it could affect the fault box’s ability to retain a fault and the fault could clear itself. • Discuss proper exhaust safety: - Connection and coupling of the exhaust after-treatment unit - Do not run this inside closed area, ALWAYS use exhaust hoses: • Carbon monoxide is a colorless, odorless deadly gas. • NEVER perform a re-gen process inside of the shop, move trainer outside. • Have students demonstrate the correct connection of exhaust hose and battery charger • Show the location of the diesel fuel cell: - Explain that the fuel pickup is not on the bottom of the tank and the fuel gauge has to read something in the tank for the engine to start. - Explain complete evaporative emission system testing can be performed. consulab.com info@consulab.com 15 96-HV-950-B6.7 Introduction to the HV-950 family of diesel engine benches • Show location of the DEF tank. • Show and discuss dash board controls, warnings and indicators: - Some benches have a Student Assignment for this. (SA2-B) • Show location of the Murphy PV101 with explanation. • Show location of the breakout box and explain what is a breakout box: - Explain terminology for ECU labeling. - When using faults with variable signals, the students must use either the scan tool or break out box for their diag- nostic measurements. Do not allow students to back-probe or measure at the faulted sensor as there will be false readings. When a fault with a variable value is selected, the “real” sensor signal is still present at the sensor. - When using open circuit faults students may back-probe or measure at the sensor as required. - Explain that the breakout box pin #’s match factory service info. - Explain that some pins are not used for trainer purposes. • Show location of Data Link Connector (DLC) and DLC Breakout Box (BOB) - Explain J1939 DLC BOB LED activity indicators: • LED’s indicate data communication is present. • Specifically designed for use in an educational environment using robust 2mm test ports and LED indicators or all 9 pins of a standard Deutsch DLC. • Y-harness configuration allows for replaceable DLC installation on the trainer. - The ability to replace the Y-harness subassembly allows for a cost effective repair in case the connector gets damaged - Have students correctly connect scan tool & introduce it to engine, do a VIN learn - Some scan tools might ask for option codes (RPO). Random choices here will not affect any engine performance diagnostics or scan tool communication. • Demonstrate safety! - Explain this is an expensive piece of equipment and to respect it! - Safety glasses required to operate this equipment every time. - No ear buds – complete attention is required when working with this trainer! - Demonstrate emergency STOP button. • NOTE: sometimes the emergency STOP button can be “disturbed” and result in a crank/no start condition. • There will be a red light illuminated inside the button to indicate it has been tripped and is OPEN, needing reset. § If STOP/START scan tool data shows “INVALID DATA”, check the BATTERY SENSOR MODULE / BATTERY STATE INFORMATION status. § If the status is “Not Available”, perform the following process: • Remove the 3A inline fuse at the back of the ConsuLink tablet • Unplug the DLC connector harness (see photo) • Disconnect the battery negative cable and allow to remain disconnected and undisturbed for 3 hours • Discuss proper exhaust safety o Do not run this inside closed area, ALWAYS use exhaust hoses § Carbon monoxide is a colorless, odorless deadly gas o Stop here and have students demonstrate correctly connecting exhaust hose and battery maintainer • Show the location of the fuel cell o Explain that the OEM style fuel pump pickup does not extend to the bottom of this custom fuel cell o It is recommended that the fuel gauge read ¼ of a tank or more for the engine to start and operate properly o Complete evaporative emission system operation and testing can be demonstrated • Demonstrate automatic transmission operation o Allows for wheel speed operation o Locate brake pedal assembly o Locate accelerator pedal o Locate automatic shift selector o DO NOT put into park while axle is rotating § Stop/Start option will allow braking ability through the one axle provided o Maximum engine and road speed are internally limited by design o Transmission may only achieve 3rd gear and is normal for trainer operation and safety • Demonstrate safety! (move from page 12 to here) o Explain that this is an expensive piece of equipment and to respect it! o Safety glasses required to operate this equipment every time o No ear buds – complete attention is required when working with this trainer! o Demonstrate emergency STOP Button § NOTE: sometimes the emergency STOP button can be “disturbed” and will result in a crank / no start condition § There will be a red light illuminated inside the button to indicate it has been tripped and is OPEN, needing reset . (crop as needed) § If there is ever a no start condition not related to any case studies, ALWAYS push the emergency STOP button first, then rotate it allowing it to “POP” back up into the closed position, and try to start the engine again (insert photos from current manual of button open and closed) • Show location of the steering wheel control pad required for STOP/START (photo) • Show location of the entertainment center - required for STOP/START (photo) • If there is ever a no start condition not related to any case studies, ALWAYS push the emergency STOP button first, then rotate it allowing it to “POP” back up into the closed position, and try to start the engine again. Open Circuit Closed Circuit consulab.com info@consulab.com 16 96-HV-950-B6.7 ConsuLink™ Student Learning Platform ConsuLink™ Student Learning Platform To turn ON, locate the tablet start button and press long (5 seconds) to allow tablet to boot up. STUDENT FACING Accessible Features: • Operation Manual Button: - Optional equipment - Fuel System - Exhaust System - ECM BOB - DLC w/BOB - ConsuLink™ student learning platform operation • How to navigate: - Hit “HOME” button. • Case Studies Button: - Note: Student Assignments (SA) 1 – 8 are different than case studies and need to be completed before Case Studies are assigned. - Student Assignment 9 (SA9) consists of nine (9) student led discovery Case Studies already pro- grammed into the Consulink™ student learning platform. - Opening up the case studies: • Select the Case Study assigned by your instructor • Student will have an assignment sheet to complete for each case study • Case studies are written similar to a repair order - Student will need to check for any DTC’s first that may have been left from previous exercises. - Any stored DTC must be cleared before starting on a new case study diagnosis. - Each case study page has a quick link to: • Wiring diagrams • ECM BOB diagrams - Press GREEN button to start Case Study with ENGINE OFF to begin lesson. - REMOVE Case Study only after engine shut down. - Verify DTC’s and clear after each lesson is completed. consulab.com info@consulab.com 17 96-HV-950-B6.7 ConsuLink™ Student Learning Platform • Wiring Diagrams Button: - How to navigate: • Pinch & Zoom • OEM diagrams with PIN numbers matching the trainer • Breakout Box (BOB) Button: - How to navigate: • Pinch & Zoom - OEM diagrams with PIN numbers matching the trainer • Component Locator Button: - “Call outs” and information it reveals. - Use this with Student Assignment SA-1,2,3 & 4. • Scenario Number Button: - Scenario numbers are just a different way for your instructor to assign case studies. • Start up engine and demonstrate “known good” performance • Review sensors on this engine - Have students discover and discuss operation – see SA-1 – SA-4 sheets • Turn off engine, and review procedure for end of day storage - Remove key and store correctly. - To turn OFF the ConsuLinkTM, long press ON/OFF button and select Power Off since it is powered independent of the bench. - Battery quick-disconnect. • Allow 10 minutes of computer shut down before disconnecting battery. - Install optional vinyl cover after engine cool down. consulab.com info@consulab.com 18 96-HV-950-B6.7 ConsuLink™ Student Learning Platform INSTRUCTOR FACING Accessible Features: • Instructors Guide Button: - Optional equipment - General operation - Battery, 12V Regulated Charger - Safety and Master - Engine starter button (if equipped) - Fuel System - Exhaust System - Emergency STOP button - ECM BOB - DLC BOB • Case Studies – Instructor Button - NOTE: Student Assignments (SA) 1 – 8 are different than case studies and need to be completed before Case Studies are assigned. - Instructor mode includes 13 more Instructor led case studies (ICS). - Instructor MODE provides enhanced instructor information for all case studies, both student led and ICS. - Instructor Case Study descriptions also include: • ALL student led case studies are OPEN circuits. • Instructor MODE provides: - Solutions - Test points - DTC’s - Symptoms - When to expect a Check Engine Light (CEL) - Wiring diagram with fault location. • We don’t recommend students be allowed to diagnose ICS as they are not just OPEN circuits. • We have manipulated the data sent to the computer to simulate realistic performance issues. • The diagnostic process should be led by the instructor and discussed openly. • Your engine bench will actually perform with very realistic symptoms, exactly like an automobile would consulab.com info@consulab.com 19 96-HV-950-B6.7 ConsuLink™ Student Learning Platform • Scenario Number Button - Each Case Study will also have a “scenario” number assigned to it. - A “scenario” is just a different way to assign a case study. Students tend to remember a case study number and its diagnosis, so an instructor can also assign them by the scenario number instead. - This helps verify if the student can correctly diagnose a problem based on a customer concern and learned skills, not just memorizing case study numbers. • Wiring Diagrams with Faults Button: - These diagrams show specific locations where the faults are placed in the circuit. - Instructor MODE includes access to a different version of wiring diagrams. - Easy to read line diagrams. • Fault Insertion Button – Custom Case Study Creation: - ConsuLink™ is based on a selection of 16 programmed faults: • All faults are either ON/OFF or adjustable. • All case studies were created using versions of these 16 faults. • There are 9 student led case studies available in the student facing mode. • There are 13 more instructor led case studies available in the instructor mode. • Student worksheets are available for all case studies. • In addition to case studies, the 16 core faults are also available in the “Fault Insertion” tab and can be manipu- lated individually to be used as instructor led lessons: - 9 basic and 7 advanced - Multiple faults can be inserted - Intermittent faults can be created - New case studies can be created here and saved by the instructor. ADDITIONAL FEATURES: • ConsuLink™ Student Learning Platform lockout: - There are two ways to access “Instructor Mode”: - Press the Instructor Mode buton at top right corner of the home screen and enter the PIN. Your ConsuLink has been programmed to open in Instructor Mode with the default PIN - 8246. You can change that PIN by selecting the “reset PIN” option upon opening up Instructor Mode. - If concerned about students seeing this PIN number, try this: • Use key provided to unlock “Instructor Mode” and then lock it back into “Student Mode” after Instructor Case Study (ICS) has been selected – no PIN required when using the key function. • ConsuLink™ Student Learning Platform Wi-Fi Update Process: - Boot up tablet. - Open up Instructor Mode (use PIN or key). • Updates will NOT be available outside of Instructor MODE. - Select “Settings” on the tablet. - Make sure tablet is connected to the Internet through Wi-Fi. • Press on “Check for Updates. • Follow instructions provided. - Recommend rebooting tablet after any update is performed. consulab.com info@consulab.com 20 96-HV-950-B6.7 Student Assignments — Basic Orientation and Troubleshooting Student Assignments — Basic Orientation and Troubleshooting Our HV-950 Engine Trainers all vary a little in application so it is recommended to have an advanced student gather these answers to Student Assignments 1-8 for the instructor to have as a guide for future reference. This will ensure the answers are accurate to this particular trainer. Wiring Diagram Navigation and Interpretation ConsuLab realizes the following steps are important in the development of an accurate diagnostic strategy and recom- mends that each student perform Student Activities 1-8 (SA-1 to SA-8) exercises in order to build the foundation needed to proceed to Student Activity 9 – Engine Performance Discovery. Student Assignment 1 (SA-1) — Component Identification – BASIC In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step one in getting familiar with this trainer in general. Student Assignment 2 (SA-2) — Component Identification – SPECIFIC In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step two in getting familiar with the specific engine in this trainer. Student Assignment 3 (SA-3) — Component Identification – SENSORS In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step three in getting familiar with this trainer and related sensors. Student Assignment 4 (SA-4) — Component Identification – ACTUATORS In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step four in getting familiar with this trainer and related actuators. Student Assignment 5 (SA-5) — Charging System Verification In preparation to diagnosing any engine management issue, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first! consulab.com info@consulab.com 21 96-HV-950-B6.7 Student Assignments — Basic Orientation and Troubleshooting Student Assignment 6 (SA-6) — Wiring Diagram Practice In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step six in getting familiar with this trainer and wiring to the ECM. Using service information fill in each blank with as much information as possible: ECM Breakout box This will require an understanding of reading a wiring diagram. Students are asked to identify the following, for each of the ECM PIN #’s: • Wire color (reference wiring diagram) • Function (sensor/component) • Is sensor/component a signal, control, or reference voltage? Student Assignment 7 (SA-7) — Expected voltages at ECM BOB Pin Panel Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s understanding of certain common engine management systems. Prior knowledge of the principle of operation for any system in this activity is required. Having completed SA-6 but before proceeding to SA-8 (where the student will actually take voltage measurements at the ECM BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the ECM PIN’s identified. INSTRUCTOR NOTE: Select a few systems to be used that are commonly nee ded to be understood in industry or will best reflect student understanding Student Assignments 8 (SA-8) — Measured voltages at ECM BOB Pin Panel In preparation to diagnosing any engine management issue, one has to know what they are working on first. This exercise is step eight in getting familiar with this trainer and ECM breakout box. Follow instructions for ignition “KEY” position and then take and record voltage measurements in the corresponding box of the chart provided. Start by verifying B+ and GROUND at the DLC BOB (Pin ? = B+, Pins ? & ? = GROUND) then test all ECM BOB PIN points under the following “key” positions: • Key OFF • ACC • Key ON/Engine Running Test and record voltage measurements in the correct box of the chart provided in Student Assignment #8. consulab.com info@consulab.com 22 96-HV-950-B6.7 Student Assignments — Basic Orientation and Troubleshooting Student Assignments 9 (SA-9) — Troubleshooting Clear all codes before beginning each case study. NOTE: For consistent case study results, it is recommended to insert any case study before starting the engine. It does not require the key to be ON. For the same stability reason, please remove any case study after engine has been turned OFF. Using all the information gathered in Student Assignments 1-8 and this repair order style case study diagnosis handout provided by the instructor, verify the customer concern and document your diagnostic process. Follow OEM trouble- shooting procedures along with ConsuLink™ provided service information for wiring diagrams and ECM breakout box identification. Connect a scan tool to look for any DTC’s or data that leads to the root cause. Using a multi-meter, you may also take and compare measurements at the ECM breakout box. Diagnose up to the point of unplugging harness connectors for further testing. It is NOT recommended to disturb any electrical connectors. Report your findings to the instructor and be prepared to explain each step. Clear all codes at the end of each case study when directed by your instructor. SA-9 Engine Performance Discovery Each of these engine performance case studies are based on a “customer concern” and students will be asked: • Student observation of condition/concern • Explain strategy & tests performed - record test results - and more importantly - explain why? • Explain DTC’s (if any) • Identify component suspected • Is fault an Input/Output? consulab.com info@consulab.com 23 96-HV-950-B6.7 Student Assignments — Basic Orientation and Troubleshooting TYPES OF CASE STUDIES: • ON / OFF - Student Led diagnostic Case Studies - Can be inserted and diagnosed by students - At instructor’s discretion, wiring could be back probed to isolate failure between a component and the ECM BOB - ADJUSTABLE - Instructor led simulated Case Studies - These faults cannot be diagnosed by back probing a harnesses and connectors due to fault box design and placement - It is best that this is instructor led discussions to best illustrate how a certain component failure presents itself on a scan tool or at the ECM (breakout box) and as an actual performance issue • Each Case Study will have a “scenario” number assigned to it as well - A “scenario” is just a different way to assign a case study. Students tend to remember a case study number and its diagnosis so you can just assign them the scenario number to verify they can correctly diagnose a problem based on a customer concern and learned skills. • FAULT INSERTION - NOTE: New case studies can be created by the instructor in addition to intermittent faults resulting in almost infinite possibilities - Most testing / measuring should not be made at any component on the engine bench. • Engine harness connections are protected this way. SA-9 Case Study diagnosis – CS01 – START – Scenario 1125 SA-9 Case Study diagnosis – CS02 – CKP CMP – Scenario 1126 SA-9 Case Study diagnosis – CS03 – APP – Scenario 1127 SA-9 Case Study diagnosis – CS04 – INJ – Scenario 1128 SA-9 Case Study diagnosis – CS05 – IMT – Scenario 1129 SA-9 Case Study diagnosis – CS06 – ECT – Scenario 1130 SA-9 Instructor Case Study diagnosis – ICS01 – IMP – Scenario 1131 SA-9 Instructor Case Study diagnosis – ICS02 – CKP-P – Scenario 1132 RECOMMENDED GRADING RUBRIC FOR CASE STUDIES TASK % Student observation 5 Explain strategy & tests performed – record test results and explain why? Assessment of knowledge 50 DTC (if any) 5 Component suspected 15 Input/Output? 5 Recommended repair 20 TOTAL 100 consulab.com info@consulab.com 24 96-HV-950-B6.7 Explanation of grading rubric for case studies Recommended grade weight % Fault EXAMPLE Customer complaint Repair order style activities are recommended in order to start preparing the student for a shop environment. After student becomes familiar with a well written repair order, introduce a poorly written one and ask for examples of why it wastes time, and what additional information does the technician need before proceeding with diagnosis. Role play with one student being the customer and another being the service advisor. Then reverse roles! Discuss how does this process affect technicians payroll as well as the efficiency / productivity of a shop? Student observation 5 % This is an important part of training a technician! At this stage of learning, the student should be required to document their observation process after first receiving a vehicle to diagnose. (take out the ear buds and pay attention!) Everything from the cosmetic condition of the vehicle upon receiving it for service to the stance of the vehicle, tire wear and pressures, looking for leaks and any existing conditions that may or may not affect accurate diagnosis. Teach them to be observant! Explain strategy & tests performed – record test results and explain why? 50 % This is the most important part of training a technician! At this stage of learning, the student should be required to document their diagnostic thought and observation process after receiving a vehicle to diagnose. Each step should have a reason – Why this step, why this test? Then the order of diagnostic steps should be discussed, corrected if needed, and repeated. A diagnostic style should be developed by each student to use and gain confidence with, eventually moving to a real vehicle using this same strategy. DTC (if any) 5 % While a DTC is an important part of diagnosing, teach your student to understand that a check engine light does not always mean the retrieved DTC will lead straight to the repair. Prove that it is just a direction in which to proceed, just a piece of the diagnostic evidence. When a performance issue exists and there is no MIL, we have to work for the customer. However when a MIL is on, we work for the ECU, PCM, TCM, or whatever controls the light. Component suspected 15 % The identification of a failure or replacement of a component should be thoroughly explained by the student. Encourage at least three testing procedures be tried and documented before any parts are going to be suspected defective. And again, if the suspected part is defective, why after replacement will the complaint be corrected? And will the new part be damaged after installation? Did something else cause it to fail? Input/Output? 5 % The correct answer here is critical and indicates a deeper level of system understanding. Recommended repair 20 % As instructors, we are challenged to discourage parts changing without an accurate diagnosis. Whether it is a failed part or a system repair needed, there are multiple learning moments in this discussion. We recommend having small teams diagnose trainer faults and then to come back together as a class to report out to each other with their diagnosis. Let the students convince each other of the accuracy to their diagnosis. Teach that only accurate diagnosis counts! Explanation of grading rubric for case studies consulab.com info@consulab.com 25 96-HV-950-B6.7 SA-8 Measured Voltage - Connector J1 - Answers SA-8 Measured Voltage - Connector J1 - Answers HV-950 Engine Application: Our HV-950 Diesel Engine Trainers all vary a little in application so it is recommended to have an advanced student gather these answers to Student Assignments #8 for the instructor to have as a guide for future reference. This will ensure the answers are accurate to this particular trainer. PIN WIRE SYSTEM / VOLTAGE KEY OFF ACC KOEO KOER EXAMPLE APP sensor 1 signal 0 V .9 V .9 V .9 V 1 2 3 4 10 11 13 16 17 18 19 25 26 27 28 31 32 34 35 36 41 42 43 44 45 49 50 51 consulab.com info@consulab.com 26 96-HV-950-B6.7 SA-8 Measured Voltage - Connector J1 - Answers PIN WIRE SYSTEM / VOLTAGE KEY OFF ACC KOEO KOER 54 55 57 58 59 61 62 63 65 66 67 68 69 70 71 72 73 74 75 76 78 79 81 82 83 90 93 94 95 96 consulab.com info@consulab.com 27 96-HV-950-B6.7 SA-8 Measured Voltage - Connector J2 - Answers SA-8 Measured Voltage - Connector J2 - Answers HV-950 Engine Application: Our HV-950 Diesel Engine Trainers all vary a little in application so it is recommended to have an advanced student gather these answers to Student Assignments #8 for the instructor to have as a guide for future reference. This will ensure the answers are accurate to this particular trainer. PIN WIRE SYSTEM / VOLTAGE KEY OFF ACC KOEO KOER EXAMPLE APP sensor 1 signal 0 V .9 V .9 V .9 V 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 32 33 35 38 39 40 41 consulab.com info@consulab.com 28 96-HV-950-B6.7 SA-8 Measured Voltage - Connector J2 - Answers PIN WIRE SYSTEM / VOLTAGE KEY OFF ACC KOEO KOER 42 44 45 46 48 49 53 54 57 61 62 64 65 68 71 72 75 76 77 78 79 82 83 86 87 90 91 92 94 95 96 consulab.com info@consulab.com 29 96-HV-950-B6.7 Instructor Answers for Case Studies Instructor Answers for Case Studies SA-9 Case Studies and Fault Insertion ANSWERS INSTRUCTOR MODE Quick Reference CASE STUDIES Student LED CASE TITLE FAULT DTC SCENARIO # WARNING: You must clear all DTC’s before starting this lesson CS01 START Engine crank does not start OPEN in the circuit between the F2 ‘‘Key Supply Fuse’’ and BOB PIN J2-05. The (10A) Fuse F2 remains HOT. (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) No Code 1125 CS02 CKP CMP Crank, no start OPEN in the circuit for the Crankshaft Position Sensor (CKP) between PIN 3 of CKP sensor and BOB PIN J1-31 AND an open in the circuit for the Camshaft Position Sensor (CMP) between PIN 3 of CMP sensor and BOB PIN J1-18 (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) Cummins DTC 234, 689, 2321, 6595, 3253, 778, 2322, 731 1126 CS03 APP Poor performance OPEN in the circuit between PIN 6(A) of the APP and BOB PIN J2-10. (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) Cummins DTC 132 1127 CS04 INJ Engine is running rough OPEN in the circuit between ECM PIN F of #1 Injector and BOB PIN J1-25. (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) Cummins DTC 322, 1139 1128 CS05 IMT Poor performance ADJUSTING the intake manifold air temperature sensor (IMT) signal between PIN 3 of the sensor and BOB PIN J1-62. (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) Cummins DTC 436, 153, 154, 2564, or 488 1129 consulab.com info@consulab.com 30 96-HV-950-B6.7 Instructor Answers for Case Studies INSTRUCTOR MODE Quick Reference CS06 ECT Poor performance ADJUSTING the engine coolant temperature sensor (ECT) signal between PIN B of the sensor and BOB PIN J1-83 and INTRODUC- ING a new signal into the circuit. (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) P0073, P0558 P018D, P0453 P0533, P0463 1130 WARNING: ALL ICS lessons will not affect the internal operation of any sensor, so if you were to take measure- ments at the sensor you would measure a normal value and NOT the same value as on the scan tool or at the BOB. CASE STUDIES Instructor LED CASE TITLE FAULT DTC SCENARIO # WARNING: You must clear all DTC’s before starting this lesson ICS01 IMP Sensor value held to 2.4 V With fault inserted, the IMP (Intake Manifold Pressure) sensor is toggled on and set to 2.40 V with NO intermittence.. (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) Cummins DTC 436, 153, 154, 2564, or 488 1131 ICS02 CKP-P Crankshaft pressure sensor with engine OFF ADJUSTING the Crankcase Pressure Sensor and then compared to Cummins Document (019-445) for the nominal value with engine OFF . (See Case Studies - Instructor for more case study detail. Also, open Wiring Diagrams with Faults for exact fault location.) Cummins DTC 556, 1942, 1843, 1844, 1974, or 555 1132 consulab.com info@consulab.com 31 96-HV-950-B6.7 Instructor Answers for Case Studies INSTRUCTOR MODE Quick Reference FAULT INSERTION FAULT COMPONENT DETAILS DTC F1 Advanced Engine Coolant Temperature Sensor (ECT) This fault adjusts the OEM Engine Coolant Temperature (ECT) sensor signal between PIN B of the sensor and BOB PIN J1-83 by introducing a new signal into the circuit. The signal can vary from a minimum to a maximum, which is represented by a percentage. This fault is suggested for instructor demonstrations or custom case studies, and not intended for student diagnostics. Refer to the electri- cal diagrams in instructor mode to find the exact location of the fault and its pins. Cummins DTC 151, 334, 144, 145, 2963, 146, 2646 F2 Advanced Intake Manifold Air Temperature Sensor (IMAT) This fault adjusts the OEM intake manifold air temperature sensor (IMAT) signal between PIN 3 of the sensor and BOB PIN J1-62 by intro- ducing a new signal into the circuit. The signal can vary from a mini- mum to a maximum, which is represented by a percentage. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 436, 153, 154, 2564, or 488 F3 Advanced Intake Manifold Pressure Sensor (IMP) This fault adjusts the OEM Intake Manifold Pressure (IMP) sensor signal between PIN 1 of the sensor and BOB PIN J1-45 by introducing a new signal into the circuit. The signal can vary from a minimum to a maxi- mum, which is represented by a voltage. By varying the voltage of the fault, the circuit resistance changes as well as the signal voltage to the ECM. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 4729, 2973, 122, 123, 3361, 124, 125, 5989, or 5991 F4 Advanced Exhaust Gas Recirculation Differential Pressure (EGR-DP) This fault adjusts the Exhaust Gas Recirculation Differential Pressure (EGR-DP) sensor signal between PIN 3 of the sensor and BOB PIN J1-66 by introducing a new signal into the circuit. The signal can vary from a minimum to a maximum, which is represented by a voltage. By varying the voltage of the fault, the circuit resistance changes as well as the signal voltage to the ECM. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 1866, 2273, or 2274 consulab.com info@consulab.com 32 96-HV-950-B6.7 Instructor Answers for Case Studies INSTRUCTOR MODE Quick Reference FAULT INSERTION FAULT COMPONENT DETAILS DTC F5 Advanced Crankcase Pressure Sensor (CKP-P) This fault adjusts the Exhaust Gas Recirculation Differential Pressure (EGR-DP) sensor signal between PIN 3 of the sensor and BOB PIN J1-66 by introducing a new signal into the circuit. The signal can vary from a minimum to a maximum, which is represented by a voltage. By varying the voltage of the fault, the circuit resistance changes as well as the signal voltage to the ECM. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 1866, 2273, or 2274 F6 Advanced #1 Fuel Injector This fault opens the control circuit for #1 Fuel Injector between ECM PIN F of #1 Injector and BOB PIN J1-25. With this fault inserted, the engine will have a constant cylinder misfire. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 322 or 1139 F7 Advanced Crankshaft Position Sensor (CKP) This fault opens the circuit for the Crankshaft Position Sensor (CKP) between PIN 3 of CKP sensor and BOB PIN J1-31. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 234, 689, 2321, 6595, or 3253 F8 Advanced Camshaft Position Sensor (CMP) This fault opens the circuit for the Camshaft Position Sensor (CMP) between PIN 2 of CMP sensor and BOB PIN J1-18. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 778, 2322,731 F9 Advanced Exhaust Gas Pressure Sensor (EGP) This fault opens the circuit for the Exhaust Gas Pressure Sensor (EGP) signal between PIN 3 of the sensor and BOB PIN J1-36 by introducing a new signal into the circuit. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 2554, 2373, 2374, 7273, or 4728 consulab.com info@consulab.com 33 96-HV-950-B6.7 Instructor Answers for Case Studies INSTRUCTOR MODE Quick Reference FAULT INSERTION FAULT COMPONENT DETAILS DTC F10 Advanced Accelerator Pedal Position Sensor (APS) This fault creates an intermittent open in the Accelerator Pedal Po- sition (APS) sensor signal which can be captured and demonstrated using a scan tool or oscilloscope. It simulates a glitch in the sensor signal by momentarily opening the circuit between PIN 6(A) of the APP and BOB PIN J2-10. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 132 F11 Advanced Ignition Key This fault opens the ignition circuit between PIN 5 of the ignition circuit and the ignition switch. (This is an excellent problem to give your students for diagnosis. (See instructors wiring diagram for exact fault and BOB location) No Code F12 Advanced Exhaust Gas Recirculation Temperature (EGR-T) This fault simulates an open in the Exhaust Gas Recirculation Tempera- ture Sensor (EGR-T) by opening the circuit sensor signal between PIN B of the sensor and BOB PIN J1-65. (This fault is recommended for instructor demonstration or custom case study creation, not student diagnosis. See instructors wiring dia- gram for exact fault and BOB location.) Cummins DTC 1867, 2375, 2376 or 7935 consulab.com info@consulab.com 34 96-HV-950-B6.7 HV-950-B6.7_035101 Wiring Diagram w/Fault location for Case Studies HV-950-B6.7_035101 Wiring Diagram w/Fault location for Case Studies J1-83 BOB F1 ECT SENSOR SIM 0-5V F2 F3 F4 F5 F7 F8 F9 F10 F11 F12 FAULT BOX SIM 0-5V SIM 0-5V SIM 0-5V IMT SENSOR IMP SENSOR EGR-DP SENSOR CKP-P SENSOR INJECTOR #1 CKP SENSOR CMP SENSOR EGP SENSOR PIN B PIN 3 PIN 1 PIN 3 PIN F PIN 3 PIN 3 PIN 3 RLY ECU 86 85 30 87a 12V F6 APS SENSOR PIN 6(A) IGN SENSOR ERT SENSOR PIN B J1-62 J1-45 J1-66 J1-63 J1-25 J1-31 J1-18 J1-36 J2-10 J2-05 J1-65 J1-83 J1-62 J1-45 J1-66 J1-63 J1-25 J1-31 J1-18 J1-36 J2-10 J2-05 J1-65 SIM 0-5V PIN 3 WHT WHT WHT WHT WHT WHT RED WHT WHT PPL RED WHT RED BLK 151,334,144,145, 2963,146,2646 STOP ENGINE NO CRANK DIAGNOSTIC FAULT CODE 436,153,154,2564 or 488 4729,2973,122,123, 3361,124,125, 5989 or 5991 322 or 1139 132 1867,2375, 2376 or 7935 2554,2373,2374, 7273 or 4728 778,2322,731 566,1942,1843, 1844,1974 or 555 234,689,2321, 6595 or 3253 1866,2273 or 2274 consulab.com info@consulab.com 35 96-HV-950-B6.7 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. All rights reserved.

Model MF100ACC Accumulator Module OWNERS MANUAL For your safety and the safety of the students, read this manual carefully. IMPORTANT NOTICE Before unpacking your module, inspect the outside of the shipping container for damage or abuse. If there is any penetration of the ship- ping container, e.g. forklift forks, photograph and document the damage before opening the container. Remove the cover and inspect for damage to the module. Photograph and document any damage which the penetration may have caused to the module. Show the relationship of the penetration (if any) to the damage on the module. Report the damage to the shipping company immediately. Also, report the damage to the Fluid Power Training Institute™ - 1-888-222-3421 - as soon as possible. MF100-ACC-OM COPYRIGHT © 2012 FLUID POWER TRAINING INSTITUTE™ All rights reserved. No part of this manual may be used or repro- duced in any manner whatsoever without the written permission of the Publisher. Printed in the United States of America. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. Operating or observing the operation of this module without safety glasses may lead to an accident which could result in severe eye injury or blindness. This module is to be operated only under the supervision of a trained, authorized instructor. Follow all safety instructions in the operator handbook before using this module. WARNING 1.2 MF100-ACC - Accumulator module - NOTE: Photos and location of components may vary from the actual components. SAFETY INSTRUCTIONS: a. Wear safety glasses when installing the accumulator module. b. At least two people are required to perform this job safely. 1.0 Installing the Accumulator Module Figure 1-1 Figure 1-3 1 Step 2: Gently slide the option assembly into the slot (Figure 1-2) in the side cover of the trainer and make sure that the option assembly drops into position (Figure 1-3). Figure 1-2 Step 1: Using a 3/16” allen-wrench, loosen the two (2) bolts (Figure 1-1) located on the upper right-hand or left-hand side of the front panel depending upon the model of your Accumulator module (back them off approximately three turns). Step 3: Tighten the two bolts securely (Figure 1-6). Step 4: Make the necessary connections to the mainframe trainer. Step 5: Connect the included accumulator safety bleed hose to the bleed-off test point. The bleed-off test point may be located underneath the trainer either on the reservoir or between the panels (Figure 1-7). On newer models, the bleed-off is located on one of the tees that are included with the trainer. Connect this tee to a tank return port on the front of the trainer and then attach the safety bleed hose to the test point. 1.0 Installing the Accumulator Module Figure 1-6 2 Figure 1-4 Frame with mounting boss Optional package plate Figure 1-5 Frame Front panel Loosened bolt (qty. 2) The diagrams below (Figures 1-4 & 1-5) illustrate how to correctly position the bracket on the mounting bosses which are located on the frame. Figure 1-7 1.0 Installing the Accumulator Module 3 Step 6: Connect the other end of the included accumulator safety bleed hose to the test point located on the bottom of the rear accumulator panel (Figure 1-8). Tighten it securely (by hand only). Step 7: Close the bleed valve located on the front of the accumulator assembly panel (rotate clockwise to close). Step 8: Before attempting to operate the accumulator module, the accumulator must be charged with nitrogen to 350 PSI (24 bar) using the included charging valve and hose assembly similar to the one shown below (Figure 1-9). Figure 1-8 WARNING DO NOT operate or attempt to operate this module without the safety bleed hose properly installed. Failure to heed this warning could lead to damage to the module and/or trainer, severe injury or death. WARNING Accumulator repair and service MUST be done by trained, autho- rized personnel only. Failure to heed this warning could lead to severe injury or death. Figure 1-9 If you have any questions that this document does not address, please contact us immediately for assistance. PO Box 711201 Salt Lake City, UT 84171 PH: 801-908-5456 FAX: 801-908-5734 e-mail: info@fpti.org web: www.fpti.org

Model MF100-PDCV Proportional Directional/Flow Control Valve module OWNERS MANUAL For your safety and the safety of the students, read this manual carefully. IMPORTANT NOTICE Before unpacking your trainer, inspect the outside of the shipping con- tainer for damage or abuse. If there is any penetration of the shipping container, photograph and document the damage before opening the container. Open the box and inspect for damage. Photograph and document any damage which the penetration may have caused to the trainer. Show the relationship of the penetration (if any) to the damage on the trainer. Report the damage to the shipping company immediately. Also, report the damage to the Fluid Power Training Institute™ - 1-888-222-3421 - as soon as possible. MF100-PDCV-OM COPYRIGHT © 2009 FLUID POWER TRAINING INSTITUTE™ All rights reserved. No part of this manual may be used or repro- duced in any manner whatsoever without the written permission of the Publisher. Printed in the United States of America. Violations will be pursued vigorously by all legal means available against the companies and individuals involved. Revision 01 - December 2009 CONGRATULATIONS! You have purchased a state-of-the-art Proportional Directional/Flow Control Valve training module. This training module is designed to make the task of teaching hydraulics simple and rewarding, and, to make the job of learning hydraulics exhilarating and downright fascinating. This owners manual contains all the information you need to help you and your students become familiar with the Proportional Directional/Flow Control Valve training module’s unique features, which include a number of safety features. You will get many years of safe and reliable operation if you follow the safety, operation, and maintenance guidelines and recommendations in this manual carefully. CONTENTS 1.0 SAFETY FIRST! - Safety instructions ...................................... 1 2.0 Installing the trainer module ..................................................... 3 3.0 Component familiarization .........................................................5 4.0 Terminology and Description of Settings ................................... 6 5.0 Trainer module specifications .................................................. 8 6.0 Service and maintenance ........................................................ 8 7.0 Where to get help .................................................................... 8 8.0 Recommended spare parts list ............................................... 8 9.0 Manufacturer service/operation literature ................................ 9 1.0 SAFETY FIRST! - Safety instructions 1 Electrical Connections - The Proportional Directional/Flow Control Valve trainer module requires a 24VDC power supply, which is conveniently located on the side of the MF100 series trainer. The module has an electrical cord with a special 24VDC plug. Once the module has been installed on the trainer, plug it into the receptacle on the side of the trainer and engage the locking device. Prevention is better than cure! An eye-wash station must be located in an accessible location that requires no more than ten (10) seconds to reach and should be located within a travel distance no greater than 100 feet (30.5 m) from the hazard (ANSI Z358.1-1998). Operating or observing the operation of this trainer without safety glasses may lead to an accident which could result in severe eye injury or blind- ness. This trainer is to be operated only under the supervision of a trained, authorized instructor. Follow all safety instructions in the operator handbook before using this trainer. WARNING WARNING CAUTION Disconnect the main power supply (120VAC) to the MF100 series trainer when connecting the Proportional Directional/Flow Control Valve module to the 24VDC power supply. 2 1.0 SAFETY FIRST! - Safety instructions - cont’d. WARNING Post a warning sign on the entry door into the hydraulic training center. Warn people who enter the room that hydraulic system(s) are in opera- tion and that they must wear safety glasses with side-shields which conform to ANSI Z87.1. WARNING DO NOT PUT YOUR HANDS NEAR A LEAK OR ATTEMPT TO SEARCH FOR A LEAK WITH YOUR HANDS. • Hydraulic oil can inflict three types of injuries: - skin penetration, burn, and eye. • Hydraulic oil can penetrate skin at pressures as low as 100 PSI (6.9 bar). Skin penetration can result in severe injury, permanent loss of hand or finger motion, hand or finger amputation, or death. • If you get injected, see a physician immediately. Do not eat or drink. • Take the MSDS sheet of the injected material with you. If the physician wants to simply clean and bandage the wound, refer him/her to http://www.fluidpowersafety.com. • Hydraulic oil can inflict second and third degree burns at normal operating temperature - as low as 130ºF (54.4ºC). WARNING The training module has been designed to operate safely. Any type of change or modification could have a detrimental effect on that safety. Accordingly, ALL modifications or changes, regardless of how minor, must be approved in writing, by the FPTI™ - these include: • Changes in the design of the module. • Adding component(s) to the module. • Removing component(s) from the module. • Failing to properly maintain the module. • Making component substitutions. • Using the trainer for any purpose other than training and education. MF100-PDCV - Proportional Directional/Flow Control Valve module - SAFETY INSTRUCTIONS: a. Wear safety glasses when installing the Proportional Directional/Flow Control Valve trainer module. b. At least two people are required to perform this job safely. TOOLS REQUIRED: a. 3/16” Allen-wrench. b. 1/2” wrench. c. 9/16” wrench. Step 1: Loosen the two black knobs on the right-hand side of the simulator front panel approximately three or four turns. On older models, using a 3/16” Allen-wrench, loosen the two (2) bolts located on the upper right-hand side of the front panel - back them off approximately three turns (Figure 2-1). 2.0 Installing the trainer module - Figure 2-1 Figure 2-2 CAUTION DO NOT connect the trainer to an electrical power source until this installation is complete. 3 Step 2: Gently slide the training module mounting bracket into the slot in the louvered side cover of the trainer and lower it onto the bosses to lock it in place (Figure 2-2). 3/16” Allen-head screws Figure 2-3 Figure 2-4 4 2.0 Installing the trainer module - cont’d. Step 3: Tighten the two mounting bracket knobs (bolts) securely. Step 4: Make the necessary connections (if any) to the mainframe trainer. Step 5: There is a 24VDC receptacle located on the side plate of the mainframe trainer (Figure 2-5). Plug the cord from the Proportional Directional/Flow Control Valve package into the receptacle and lock it into position with the locking arm. Figure 2-5 The diagrams below (Figures 2-3 & 2-4) illustrate how the PDCV trainer module slides over the mounting boss welded to the frame. Frame with mounting boss Optional package plate Frame Front panel Loosened bolt (qty. 2) The proportional directional/flow control valve trainer consists of the following components (Figure 3-1): 1. Power On Indicator Light 2. In-line fuse 3. Optional cylinder feedback cable jacks 4. Optional positioning controller knob 5. ON/OFF switch 6. Proportional valve drive display 7. Ramping joystick 8. Proportional valve drive controller knobs 9. Proportional directional/flow control valve 3.0 Component familiarization - 5 7 6 5 4 3 2 Figure 3-1 1 8 9 • AHI: ‘A’ high, output current corresponding to the highest input, in amps. This setting effectively controls the maximum amount of current used to drive the “A” side of the valve based on the input control voltage. By setting the value lower than the default the valve may not fully open in the “A” direction. • AJg: ‘A’ jog, used to simulate signal, in amps. Allows manual movement (jogging) of the hydraulic cylinder. • ALO: ‘A’ low, output current corresponding to the lowest input, in amps. This setting effectively controls the minimum amount of current used to drive the “A” side of the valve based on the input control voltage. By setting the value higher than the default the valve may not fully close in the “A” direction. The LO setting is meant to take out (compensate for) the valve spool overlap / deadband. • AUP: ‘A’ ramp up, time required for the output to increase from ALO to AHI, in seconds. When set to 0.00, the ramp is disabled, that is the output voltage changes virtually instantly. Due to the inductance of the coil, the output current may take about 0.1s more to change. The ramp is adjustable from 0.00s to 99.9s in 0.1s increments. When the ramp is set to 5.00s, it takes 5s for the output to complete transition when input steps from zero to full input but only 2.5s if the input changes from zero to half way. When the input steps back before the completion of the transition, the ramp instantly starts back towards the new value without completing the previous transition. • Adn: ‘A’ ramp down, time required for the output to decrease from AHI to ALO, in seconds. When set to 0.00, the ramp is disabled, that is the output voltage changes virtually instantly. Due to the inductance of the coil, the output current may take about 0.1s more to change. The ramp is adjustable from 0.00s to 99.9s in 0.1s increments. When the ramp is set to 5.00s, it takes 5s for the output to complete transition when input steps from zero to full input but only 2.5s if the input changes from zero to half way. When the input steps back before the completion of the transition, the ramp instantly starts back towards the new value without completing the previous transition. • Adb: ‘A’ deadband, output is disabled when output signal is less than this setting, in %. It is used to disable the driver in case of cable break / lost signal / stand-by mode. Increasing the value of this setting will increase the input signal value required to allow the controller to output current to the coil. • bHI: ‘B’ high, output current corresponding to the highest input, in amps. This setting effectively controls the maximum amount of current used to drive the “B” side of the valve based on the input control voltage. By setting the value lower than the default the valve may not fully open in the “B” direction. • bJg: ‘B’ jog, used to simulate signal, in amps. Allows manual movement (jogging) of the hydraulic cylinder. 4.0 Terminology and Description of Settings - 6 7 • bLO: ‘B’ low, output current corresponding to the lowest input, in amps. This setting effectively controls the minimum amount of current used to drive the “B” side of the valve based on the input control voltage. By setting the value higher than the default the valve may not fully close in the “B” direction. The LO setting is meant to take out (compensate for) the valve spool overlap / deadband. • bUP: ‘B’ ramp up, time required for the output to increase from bLO to bHI, in seconds. When set to 0.00, the ramp is disabled, that is the output voltage changes virtually instantly. Due to the inductance of the coil, the output current may take about 0.1s more to change. The ramp is adjustable from 0.00s to 99.9s in 0.1s increments. When the ramp is set to 5.00s, it takes 5s for the output to complete transition when input steps from zero to full input but only 2.5s if the input changes from zero to half way. When the input steps back before the completion of the transition, the ramp instantly starts back towards the new value without completing the previous transition. • bdn: ‘B’ ramp down, time required for the output to decrease from bHI to bLO, in seconds. When set to 0.00, the ramp is disabled, that is the output voltage changes virtually instantly. Due to the inductance of the coil, the output current may take about 0.1s more to change. The ramp is adjustable from 0.00s to 99.9s in 0.1s increments. When the ramp is set to 5.00s, it takes 5s for the output to complete transition when input steps from zero to full input but only 2.5s if the input changes from zero to half way. When the input steps back before the completion of the transition, the ramp instantly starts back towards the new value without completing the previous transition. • bdb: ‘B’ deadband, output is disabled when output signal is less than this setting, in %. It is used to disable the driver in case of cable break / lost signal / stand-by mode. Increasing the value of this setting will increase the input signal value required to allow the controller to output current to the coil. • dF: Dither frequency, in Hz. Dither is a small vibration of the solenoid current superimposed over the average value. It has the purpose of reducing the hysteresis (“sticking”) of a valve by keeping its moving parts in constant motion. In order to reduce the valve hysteresis we have to lower the dither frequency but if the frequency is too low then the valve may actually be able to follow the signal and it may generate vibrations of the system pressure or flow; if the frequency is too high then the hysteresis may be too high, leading to poor accuracy; the best compromise is in between. The dither amplitude depends on the power supply voltage, the solenoid resistance & inductance as well as the dither frequency. The only way to adjust the dither amplitude is to adjust the dither frequency: the lower the frequency the higher the amplitude / the higher the frequency the lower the amplitude. • di: Display orientation, normal or up-side-down 6.0 Service and maintenance - Your MF100-PDCV Proportional Directional/Flow Control Valve module is designed to require very little maintenance. However, to give you years of trouble-free operation there are a few things you must do: DAILY: 1. Inspect electrical wires and connections. 2. Inspect for loose connectors and/or fittings. 8 5.0 Trainer module specifications - Electrical: 24VDC Trainer Module Weight: MF100-PDCV - 20 lbs. (9.1 kg) Trainer Module Dimensions: Height: 20.5” (52cm) Width: 12” (30.5cm) Depth: 19.5” (49.5cm) 7.0 Where to get help if you are experiencing problems- If your MF100-PDCV Proportional Directional/Flow Control Valve module is not operating correctly contact the Fluid Power Training Institute™ for assistance at: 1-888-222-3421. Please have your model number and serial number available when you call. Model #: _________________________ Serial #: ___________________________ MF100-PDCV 8.0 Recommended spare parts list - The MF100-PDCV-L module is equipped with parts which are designed for high-cycle operation. Given the proper care they should last for many years. However, certain items need regular service to keep your training module operating reliably. ITEM PART # DESCRIPTION 1. - 2-amp fast-acting fuse. 9.0 Manufacturer service/operation literature - 9.1 Proportional Directional/Flow Control Valve MODEL NO.: HYVAIR EPD03-2B-2G-12VDC FUNCTIONS: This is an electro-hydraulic proportional control valve which is composed of DC proportional solenoids in addition to the conventional 4-way solenoid valve to provide both directional control and flow control functions. Directional control is performed by applying an input current on one of the two proportional solenoids. The flow volume is controlled by changing the magnitude of the input current. Remote control and shockless acceleration and deceleration control are possible and the hydraulic circuit can be simplified. SPECIFICATIONS: Maximum operating pressure (T port): 2000 PSI (210 bar) Maximum operating pressure (P,A,B ports): 5000 PSI (350 bar) Rated flow range: 2.0 GPM (7.57 lpm) Rated current: 1.76A Hysteresis: 5% or less Response time (transient function with stepped electrical input signals): 36ms @ 70 PSI drop (26ms returning to center) Weight - 6.4 lbs. (2.9 kg) 9 If you have any questions that this document does not address, please contact us immediately for assistance. PH: 801-908-5456 FAX: 801-908-5734 e-mail: info@fpti.org web: www.fpti.org

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