63B33E01TMDE

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Test, Measurement, and Diagnostic Equipment63B33E01 / Version MOSC

01 Oct 2004

SECTION I. ADMINISTRATIVE DATA

All CoursesIncluding ThisLesson

Course Number Version Course Title091-63B30-MOSC MOSC Wheel Vehicle Mechanic BNCOC

Task(s)Taught(*) orSupported

Task Number Task Title

091-63B-3401 (*) Perform Diagnostic Procedures On Wheeled Vehicle'sElectrical System

091-63B-3402 (*) Perform Diagnostic Procedures on Wheeled Vehicle's DieselEngine

091-63B-3407 (*) Perform Diagnostic Procedures on Vehicle's Hydraulic System

ReinforcedTask(s)

Task Number Task Title

091-63B-3400 Perform Diagnostic Procedures on Wheeled Vehicle's FuelSystem

091-63B-3410 Perform Diagnostic Procedures on Wheeled Vehicle's Air System

091-63B-3414 Perform Diagnostic Procedures on Wheeled Vehicle's CentralTire Inflation System

091-63B-3417 Perform Diagnostic Procedures on Wheeled Vehicle's FuelInjection System

091-63B-3418 Perform Diagnostic Procedures on Automatic Transmissions091-63B-3421 Perform Diagnostic Procedures on Wheeled Vehicle's Engine

Air Induction System091-63B-3422 Perform Diagnostics Electrical Interface System

AcademicHours

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

ResidentHours/Methods

4 hrs / Conference / Discussion2 hrs / Demonstration6 hrs / Practical Exercise (Performance)

Test 0 hrsTest Review 0 hrs

Total Hours: 12 hrs

Test LessonNumber

Hours Lesson No.

Testing(to include test review) 2 hrs 63B33E10 version MOSC

8 hrs 25 mins 63B33E11 version MOSC

PrerequisiteLesson(s)

Lesson Number Lesson TitleNone

ClearanceAccess

Security Level: UnclassifiedRequirements: There are no clearance or access requirements for the lesson.

ForeignDisclosureRestrictions

FD5. This product/publication has been reviewed by the product developers incoordination with the CASCOM-TD foreign disclosure authority. This product isreleasable to students from all requesting foreign countries without restrictions.

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ReferencesNumber Title Date

AdditionalInformation

EM 0103 TM 9-6625-SPORT/CTS, InteractiveElectronic Technical Manuals for TestSet, Electronic Systems, AN/PSM-80,Test Set Electronic System, AN/PSM-95 (This Product Includes the

Following Items) TM 9-6625-2298-12&P (010430) TM 9-6625-2298-30&P

Apr 2001

TM 11-6625-3199-14 Operators, Unit, Intermediate DirectSupport, and General SupportMaintenance Manual for DigitalMultimeter AN/PSM-45A (NSN 6625-01-265-6000)

Dec 1988

TM 9-2320-364-20-1 Unit Maintenance Manual, Volume Ifor Palletized Load System ModelM1074/M1075

Aug 1999

TM 9-2320-364-20-2 Unit Maintenance Manual, Volume I Ifor Palletized Load System ModelM1074/M1075

Aug 1999

TM 9-2320-365-20-1 Maintenance Instructions for UnitMaintenance M1078 Series, 2 1/2-Ton, 4X4 Light Medium TacticalVehicles (LMTV) Truck, Car., LMTV,M1078W/WN, W/O WN; Truck, Van,LMTV, M1079 W/WN, W/O WN;Truck, Chas, LMTV, M1080; Truck,Car., LMTV, Air Dr

Jun 1998 Change 1

TM 9-2320-365-20-2 Maintenance Instructions UnitMaintenance M1078 Series, 2 1/2-Ton, 4X4, Light Medium TacticalVehicles (LMTV) Vol. No. 2 of 5 forTruck, Car., LMTV, M1078 W/WN,W/O WN; Truck, Van, LMTV, M1079W/WN, W/O WN; Truck, Chas,

LMTV, M1080; Truck,

Jun 1998 Change 1

TM 9-2320-366-20-1 Maintenance Instructions UnitMaintenance M1083 Series, 5-Ton,6X6, Medium Tactical Vehicles (MTV)for Truck, Car., MTV, M1083 W/WN,W/O WN; Truck, Car., MTV,W/Material Handling Equipment(MHE), M1084; Truck, Car., MTV,LWB, M1085 W/WN, W/

Sep 1998 Change 1

TM 9-2320-366-20-2 Maintenance Instructions UnitMaintenance for M1083 Series, 5-Ton, 6X6, Medium Tactical Vehicles(MTV) Vol. No. 2 of 5 Truck, Car.,MTV, M1083 W/WN, W/O WN; Truck,Car., MTV, w/Material HandlingEquipment (MHE), M1084; TruckCar., MTV, LWB,

Sep 1998 Change 1

Student StudyAssignments

None

InstructorRequirements

One instructor per group, during CO.

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AdditionalSupport Name

StuRatio Qty Man Hours

PersonnelRequirements

None

EquipmentRequired

IdName

StuRatio

InstrRatio Spt Qty Exp

for Instruction 2320-01-304-2278TRUCK, PALLETIZED LOADING

1:6 No 0 No

2320-01-354-4528TRUCK, WRECKER

1:6 No 0 No

2320-01-360-1898TRUCK, CARGO

1:6 No 0 No

4910-00-357-5342TABLE, WORK, AUTOMOTIVE MAINTENANC

1:6 No 0 No

4910-01-343-3508TESTER, INTERNAL COMBUSTION ENGIN

1:6 No 0 Yes

6625-01-265-6000MULTIMETER

1:6 No 0 No

6625-01-445-0085

TEST SET, ELECTRONIC SYSTEMS

1:6 No 0 No

6625-01-493-8984TEST SET, ELECTRONIC SYSTEMS

1:6 No 0 No

*70032NMonitor, Television, Color

1:12 No 0 No

*P16312Light PRO Projector

1:12 No 0 No

*ZX7022Industry Standard Laptop (Toughbook)

1:12 No 0 No

MaterialsRequired

Instructor Materials:Overhead Projector w/Computer/Video Projector Video Tape63B33E01, Supplement 1b and 2b Instructor's Guide

63B33E01, Supplement 1c and 2c Practical Exercise Checklist

Student Materials:63B33E01, Supplement 1a and 2b, Student's GuideReferences listed above

Classroom,Training Area,and RangeRequirements

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

AmmunitionRequirements Id Name Exp

StuRatio

InstrRatio

SptQty

None

InstructionalGuidance

NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying thislesson and identified reference material.

Print out the power point slides as hand outs (3 per sheet) and hand them out tostudents. Encourage them to take notes.

ProponentLesson PlanApprovals

Name

Deilus, John

Rank

GS-12

Position

Military Analyst

Date

01 Jul 2004

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SECTION II. INTRODUCTION

Method of Instruction: Conference / DiscussionInstructor to Student Ratio is: 1:18Time of Instruction: 5 minsMedia: Large Group Instruction

Motivator In order for supervisors to properly diagnose problems, they must know how toproperly perform diagnostic procedures on particular pieces of equipment. Youhave computerized test equipment at your disposal that is capable of diagnosingfaults on computer controlled vehicles.

TerminalLearningObjective

NOTE: Inform the students of the following Terminal Learning Objective requirements.

At the completion of this lesson, you [the student] will:

Action: Use TMDE

Conditions: In a classroom/shop environment, given an AN/PSM-45AMultimeter, Diagnostic Data Reader Prolink 9000, SPORT, MSD,M1074,M1098 and M1078 vehicles, and the necessary references.

Standards: IAW applicable TMs

SafetyRequirements

Inform students of the following safety precaution:

1. Remove jewelry and observe shop safety procedures.2. Wear hearing protection while operating vehicles.3. Ensure vehicle is properly chocked.4. Remember that electrical shorts can cause severe burns or fire.

5. Improper connection of electrical leads or test equipment can cause injury topersonnel and damage to the equipment.6. Never use a multimeter to measure resistance on live circuits.

RiskAssessmentLevel

Low - It is the instructor's responsibility to conduct a risk assessment prior toinstruction using FM 100-14 as guidance. A copy of the risk management worksheet must be present at time of instruction.

EnvironmentalConsiderations

NOTE: It is the responsibility of all soldiers and DA civilians to protect the environment fromdamage.

Adhere to the safety evacuation plans.

Evaluation In lesson 63B33E10 you (the students) will have 1 hour and 30 minutes to take aJob Knowledge Test and Review on the material presented in this lesson.

InstructionalLead-In We are now ready to begin our instruction on the latest TMDE.

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SECTION III. PRESENTATION

NOTE: Inform the students of the Enabling Learning Objective requirements.

A. ENABLING LEARNING OBJECTIVE

ACTION: Identify TMDE componentsCONDITIONS: In a classroom or shop environment, given a Digital Multimeter, Pro

Link 9000, SPORT, MSD and assistance

STANDARDS: IAW applicable references without causing damage to equipmentor injury to personnel.

1. Learning Step / Activity 1. Discuss the characteristics of the AN/PSM-45A Digital Multimeter

Method of Instruction: Conference / Discussion

Instructor to Student Ratio: 1:12Time of Instruction: 40 minsMedia: Large Group Instruction

NOTE: Show slide 1 through 4

a. Multimeter, Digital (Fluke 27/FM)

NOTE: Show students the actual components as they are discussed.

(1) Purpose - measures resistance, ac and dc voltage, and ac and dc current.

(2) Major components and descriptions:

(a) Carrying case - rigid case that protects components inside.

(b) Can measure up to 5,000 v AC or DC with high voltage probe.

(c) Has a current shunt that extends range of multimeter to 10 amps AC or DC.

(d) Pushbutton power, function, and range switches simplify operation.

NOTE: Show slides 5 and 6

NOTE: This voltage refers to the Fluke Multimeter

(e) High voltage probe - extends voltage range to 6000 volts ac or dc.

(f) Test leads - one black and one red lead, to test circuit under test.

(3) Operators controls:

(a)Function selector rotary switch with 11 positions, including off.

NOTE: Show slide 7

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NOTE: Explain symbols around rotary switch.

(b) Range - select voltage desired voltage range.

1. Meter is auto-ranging at all times.

2. Can be changed to manual ranging with this switch.

(c) Relative mode - shows difference between two readings.

(d) Minimum/maximum - shows minimum and maximum readings during test.

NOTE: Show slide 8

(e) Hold- holds current measurement.

(f) Volt, Ohms, Diode test terminal:

1. Connects red test lead for volt and ohms testing.

2. This terminal is also used for diode testing.

NOTE: Show slide 9

(g) mA and A input - connects red test lead for ac and dc currentmeasurements.

1. mA scale - up to 320 mA.

2. A scale - up to 10 A (20A for 30 seconds).

NOTE: Show slide 10

(h) Com. input - connects black lead for all measurements.

(i) Buzzer - sounds tone for pulse detection and continuity functions when thisfunction is selected on the rotary switch.

NOTE: Conduct a check on learning and summarize the learning activity.

2. Learning Step / Activity 2. Identify Prolink 9000 Components

Method of Instruction: Conference / DiscussionInstructor to Student Ratio: 1:12

Time of Instruction: 1 hr

Media: Large Group Instruction


a. Pro-Link 9000 - DDR (Diagnostic Data Reader). The (DDR) diagnostic data readerreceives information from the vehicle on board computer, or ECM, through aconnector called the (DDL) display data line.

NOTE: Show slide 13

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(1) Power source - from vehicle being tested.

(a) Powered by the vehicle J1708 port or cigarette lighter adapter.

(b) Gathers vehicle data.

(c) Used with vehicle that have (DDEC) or (ATEC) systems.

(2) Protector circuit - internal fuse.


(3) Removable cartridges.

(a) DDEC.

(b) ABS.

(c) ATEC.

NOTE: Show slide 16

(4) Supporting systems TMDE.

(a) Pushbutton - Cylinder cutout test manual.

(b) Data Readout - Identifies from ECM what system DDEC II or III.

(c) The Pro-Link has to function selection menu: [ENGINE] or [PRO-LINK].

NOTE: Show slide 17

(d) Engine Functions.

1. Diagnostic Codes.

2. View Calibration.

3. Fuel Injector Information.

4. Engine/Trip Data.

5. Calibration Change.

6. Switch/Light Statistics.

7. Activate Outputs.

8. MID's Received.

9. Reset Components.

NOTE: Show slide 18

(e) Diagnostic Codes.

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1. Active Codes.

2. Inactive Codes.

3. Clear Codes.

4. Diagnostic Code Description Option.

NOTE: Show slide 19

(f) View Calibration.

1. Engine Configuration.

2. VSG Configuration.

3. Engine Protection.

4. Idle Shutdown.

5. Cruise Control.

6. ECM's Ins/Outs

7. Progress Shift.

NOTE: Show slide 20

(g) Fuel Injector Information.

1. Cylinder cutout.

2. Response Times.

3. Calibration Update.

4. Change Date.

NOTE: Show slide 21

(h) Sub-menus that follow

1. Engine Trip Data.

2. Calibration Change

3. Switch/Light Statistics

4. Activate Outputs

5. MIDs Received

6. Reset Components


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3. Learning Step / Activity 3. Identify AN/PSM95 SPORT Components


Time of Instruction: 1 hrMedia: Large Group Instruction

NOTE: Switch PowerPoint for the SPORT. Use actual AN/PSM-95 and associated componentsduring the discussion. Show Power Point slides 1 through 6.a. Purpose.

(1) The SPORT equipment was designed to aid the mechanic in troubleshooting andfault isolation in automotive equipment.

(2) The SPORT equipment is designed to be used as a diagnostic tool onelectronically controlled and non-electronically automotive equipment.

b. Components and characteristics.

NOTE: Use actual SPORT equipment; and the SPORT CDA connected to a monitor/TV toproject the CDA screen images so that all students can see illustrations of components.Click on SPORT Training Icon on the CDA screen desktop; and then click on theinventory section. Discuss components as they are shown.

(1) Controller Diagnostic Aid (CDA)

NOTE: Inform students that the SPORT CDA is a rugged, compact, lightweight portablecomputer with Windows 95 operation system and Pentium processor.

NOTE: Show slides 7 through 12

(a) Weight-Approximately 10 lb.

(b) Physical dimensions- 12W X 3 X 9.38D

(c) Processor-Pentium 120 MHz

(d) 64 MB RAM

(e) 4 GB hard drive

(f) Keyboard-standard phone-pad style located on face of CDA

(g) Keyboard-external

(2) Connectors-standard: Serial RS232, Parallel, Small Computer System Interface

(SCSI), Video Graphic Adapter (VGA), Auxiliary Universal Interface (AUI).

(3) CD-ROM Used to run Electronic Technical Manuals (ETMs) and (IETMs).

(4) Personal Computer Memory Card International Association- PCMCIA Drive-Useto run special function PCMCIA Cards.

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

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(5) Power connector-Use to connect the external power supply/charger.

(6) Ground Connector-Used to attach a ground cable to the CDA.

(7) Power requirement-Internal battery 12V or 18-32V DC to the supply/charger or115-230V AC to Supply/Charger.

c. Power Supply/Charger.

NOTE: Show slides 13 through 16. Double click on SPORT training icon on desktop screen;then click on SPORT in the displayed menu. Next click on the power supply/charger iconand discuss the Supply/Charger.

(1) DC input connector-Used to attach the NATO cable for DC power from a vehicle.

(2) AC input connector-Used to connect an AC power cable to the Supply/Charger.

(3) DC Output cable-This cable is attached to the Power supply/charger andconnects to the CDA power connector.

(4) Battery Compartment-Use to charge the extra battery. The battery is chargedwhenever the power supply/charger is connected to an external power source(AC or DC).

(5) Battery Status Indicator-Illuminate to indicate that the extra battery is beingcharged.

NOTE: The internal battery is designed to operate the CDA for 1.5 hours. The battery LED onthe power supply/charger and the CDA illuminates green when the internal battery hassufficient charge to operate the CDA.

(a) DC power indicator-Illuminates to indicate DC power is applied to the powersupply/charger.

(a) AC power indicator-Illuminates to indicate AC power is applied to the powersupply/charger.

(6) Adapter Kit, Internal Combustion Engine (ICE) Test.

NOTE: Double click on the SPORT Training icon on CDA desktop screen; then optionalequipment; ICE Test kit and inventory. Discuss components as they are shown.


(a) ICE Box- a junction box for connections between the SPORT CDA and avehicle under test.

NOTE: The ICE box must receive external DC power for it to function. A power selector switchon the ICE box must be set to the NATO or DCA position.

(b) W1 0R Diagnostic Connector Assembly (DCA) cable- this cable connects theICE Box (J1Connector) to the 52 pin DCA connector on the vehicle undertest.

(c) W4 or TK1 and TK2 Cables-These cables are use to connect the ICE box to

the transducers.

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(d) Adapter Set ICE Kit- The kit contains transducers and fitting needed toperform TK testing.

(e) Volt/Ohm Cable- This cable connect to the CDA and attaches the to the

circuit test point.

(f) Probe Set-The Probe set contains cables, two sizes of probes, spade lugs,and alligator clips that are necessary to make voltage and resistancediagnostic measurements.

(g) DMM 224 PCMCIA card with data/power cable- the card converts signalsfrom the vehicle under test, which are routed through the ICE box, intosignals useable by the SPORT CDA.

NOTE: Show slides 22 through 35d. Kit Data Bus.

NOTE: The kit contains components necessary for monitoring J1708 data on Detroit Diesel

Electronically Controlled (DDEC) equipped vehicles. The kit is stored in the ICE kitcontainer.

(1) J1708 Adapter- An adapter that is connected to the Diagnostic Data Link (DDL)on a Detroit Diesel Electronically Controlled (DDEC) equipped vehicle.

(2) Dearborn Protocol Adapter (DPA)- An adapter that is connected between theSPORT CDA and to the J1708 Adapter.

(3) Serial Cable- This cable connects to the SPORT CDA RS232 port and to theDPA.

(4) Special Purpose Cable-This cable is use to connect the DPA to the ICE Box. This

cable would be used only if there was a problem with the DDL connector on thevehicle.

e. Power sources for the CDA

NOTE: Discuss the different modes of supplying power to the CDA.

(1) Battery internal, in the CDA

(2) External DC power through the W1 DCA cable to the ICE box that connects tothe CDA.

(3) External DC power using power supply/charger- Connects the NATO cable to the

vehicle and to the power supply/charger; and connect the power supply/chargerto the CDA.

(4) External DC power directly from vehicle- Connect the NATO cable Adapter to theNATO cable; and the cable adapter to the CDA.

(5) External AC power (115V to 230V) with power supply/charger- Connect the ACpower cord to power supply/charger; and connect power supply/charger DCoutput cable connector to the CDA power input connector.

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g. Setting up SPORT equipment for DCA mode testing.

(1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in theCDA PC card drive slot.

NOTE: Install the card in the slot closest to the compartment door opening. Insert the card withlabeled side facing toward front of CDA.

(2) Connect the P3 end of the data/power cable to the power connector on the CDA.Align red dots on cable connector and CDA connector.

(3) Connect the ground connector (P4) on the data/power cable to the ground lug onthe CDA.

(4) Connect the P1 end of the data/power cable to the ICE box J6 connector.

NOTE: Place the power selector switch on the ICE box to the off position before making anyconnections

(5) Connect the W1 cable to the ICE box and the vehicle DCA connector. P1 end of

the cable connects to the J1 connector on the ICE box; and the P2 end connectsto the DCA connector on the vehicle.

(6) Position the power selector switch on the ICE box to the DCA Position.

NOTE: Power can be supplied to the CDA through the ICE box when using the (W1) DCA cable.For TK testing, the NATO cable must be used to transfer power from the vehicle throughthe ICE box to the CDA.

h. Setting up SPORT equipment for TK mode testing

(1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in theCDA PC card drive slot.

NOTE: Install the card in the slot closest to the compartment door opening. Insert the card withlabeled side facing toward front of CDA.

(2) Connect the P3 end of the data/power cable to the power connector on the CDA.Align red dots on cable connector and CDA connector.

(3) Connect the ground connector (P4) on the data/power cable to the ground lug onthe CDA.


(5) Connect the W4 (transducer) cable(s) P1 end, to J2 or J3 on the ICE box.

(6) Connect a selected transducer to the P2 end of the W4 cable.

NOTE: A transducer is connected directly to a test point on a vehicle for test measurements.

(7) Connect the NATO power cable to the ICE box J5 connector.

(8) Position the power selector switch on the ICE box to the NATO position.

i. Setting up SPORT equipment for J1708 Data bus testing

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(1) Connect the NATO cable to the power supply charger DC input connector.

(2) Connect the power supply/charger DC output cable connector to the CDA powerinput connector.

NOTE: Power can be supplied to the CDA using the NATO cable and NATO cable adapter,connected directly to the CDA input power connector.(For J1708 data bus test andmeasurement)However, the extra battery in the power supply charger would not becharged if the power supply/charger were not used.

(3) Connect the SPORT serial cable to the Controller Diagnostic Aid RS232 serialport and to a port on the Dearborn Protocol Adapter. (One end to the CDA andthe other to the DPA).

NOTE: There are two ports or connectors on the DPA. One port on each end. The serial Cablecan be connected to only one of the ports, and the J1708 Adapter connects to the other.

(4) Connect the J1708 Adapter to a port on the DPA.

(5) Connect the J1708 Adapter to the Diagnostic Data Link (DDL) on the DDEC

equipped vehicle.

j. Operation.

(1) Power up Controller Diagnostic Aid (CDA)

(2) Connect an external power source to the CDA or use internal battery

(a) Press the ON/OFF button

(3) Performing a test using the SPORT using CDA

(a) Connect the CDA to the vehicle

(b) Power up the CDA

(c) Use the track ball to move the pointer over the Self Test icon for the desiredtest to be performed, i.e. ICE or J1708.

(d) Follow the instruction on the screen. Step-by-step instructions are shownalong with illustrations.

k. Care of the AN/PSM-95/SPORT.

(1) Inspect CDA carrying case and ICE equipment container for damage.

(2) Open containers and inspect components. Ensure port connectors and cables areclean and that the pins are not bent, burned, broken or missing. Checkreceptacles for similar damage.

(3) Perform before and after operation PMCS IAW with electronic technical manual.Conduct an inventory IAW the ETM.

(4) Store all components in their original containers and store cases in a controlledenvironment.

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4. Learning Step / Activity 4. Identify AN/PSM95B MSD Components


Time of Instruction: 1 hrMedia: Large Group Instruction

NOTE: Show Slide 1

NOTE: TO THE INSTRUCTOR; THE COMPONENTS FOR THE MSD ARE THE SAME AS THESPORT EXCEPT FOR A FEW CHANGES LISTED, SO YOU ONLY HAVE FIVE SLIDESTO THE STUDENTS HOW THE MSD LOOKS LIKE.

NOTE: Switch to the MSD for the PowerPoint. Use actual AN/PSM-95A and associated

components during the discussion.


a. Purpose, Components, Characteristics, Operation, and CarePurpose

(1) The MSD equipment is a Field Ready configuration, which provides acomprehensive maintenance and diagnostic system, utilized as a on system testset in support of all U.S. Army weapon platforms.

(2) The MSD allows maintenance and operations manuals to be transported andutilized electronically versus the need to maintain reams of paper and volumes ofmanuals at the forward site.

b. Components and characteristics

NOTE: Use actual MSD equipment and connected to a monitor/TV to project the screenimages so that all students can see illustrations of components. Click on MSDTraining Icon on the screen desktop; and then click on the inventory section.Discuss components as they are shown.

NOTE: Inform students that the MSD is a rugged, laptop portable computer with Windows2000 Pro operation system and Pentium processor.

NOTE: show slides 5 through 7

(1) CPU

(a) Weight-Approximately 13 lb. including batteries.

(b) Physical dimensions- 13W X 12 D X 4H

(c) Processor-Pentium 1.3 GHz

(d) 512 MB SDRAM

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(e) 40 GB removable hard drive

(f) Keyboard-standard and environmentally sealed

(g) Hula point mouse

(2) Connectors-standard: Two Serial RS-232, Parallel, Small Computer SystemInterface Controller (SCSI), Video Graphic Adapter (SVGA), Auxiliary UniversalInterface (AUI).

(3) DVD / CD-RW Used to run Interactive Electronic Technical Manuals (IETMs).

(4) Personal Computer Memory Card International Association- Two type II PCMCIACard Slots Drive-Use to run special function PCMCIA Cards.

NOTE: The MSD was issued with a flash ram and modern card.

(5) Power connector-Use to connect the external power supply/charger

(6) Ground Connector-Used to attach a ground cable.

(7) Power requirement-Internal battery 12V or 18-32 VDC to the supply/charger orexternal power adapter 110-220 VAC to Supply/Charger.

c. Power Supply/Charger

(1) DC input connector-Used to attach the NATO cable for DC power from a vehicle.

(2) AC input connector-Used to connect an AC power cable to the Supply/Charger.

(3) DC Output cable-This cable is attached to the Power supply/charger andconnects to the power connector.

(4) Battery Compartment-Use to charge the extra battery. The battery is chargedwhenever the power supply/charger is connected to an external power source(AC or DC).

(5) Battery Status Indicator-Illuminate to indicate that the extra battery is beingcharged.

NOTE: The internal battery is designed to operate for 2.75 hours at 25 degrees Celsius. Thebattery LED on the power supply/charger and illuminate green when the internalbattery has sufficient charge to operate.

(a) DC power indicator-Illuminates to indicate DC power is applied to the powersupply/charger.

(b) AC power indicator-Illuminates to indicate AC power is applied to the powersupply/charger.

(6) Adapter Kit, Internal Combustion Engine (ICE) Test

(a) ICE Box- a junction box for connections between the MSD-ICE and a vehicleunder test.

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NOTE: The ICE box must receive external DC power for it to function. A power selectorswitch on the ICE box must be set to the NATO or MSD position.

(b) W1 0R MSD cable- this cable connects the ICE Box (J1Connector) to the 52pin MSD connector on the vehicle under test.

(c) W4 or TK1 and TK2 Cables-These cables are use to connect the ICE box tothe transducers.

(d) Adapter Set ICE Kit- The kit contains transducers and fitting needed toperform TK testing.

(e) Volt/Ohm Cable- This cable connect to the MSD and attaches the to thecircuit test point.

(f) Probe Set-The Probe set contains cables, two sizes of probes, spade lugs,and alligator clips that are necessary to make voltage and resistancediagnostic measurements.

(g) DMM 224 PCMCIA card with data/power cable- the card converts signals

from the vehicle under test, which are routed through the ICE box, into signalsuseable by the MSD-ICE.

d. Kit Data Bus

NOTE: The kit contains components necessary for monitoring J1708 data on Detroit DieselElectronically Controlled (DDEC) equipped vehicles. The kit is stored in the ICE kitcontainer.

(1) J1708 Adapter- An adapter that is connected to the Diagnostic Data Link (DDL) ona Detroit Diesel Electronically Controlled (DDEC) equipped vehicle.

(2) Dearborn Protocol Adapter (DPA)- An adapter that is connected between the ICE

and to the J1708 Adapter.

(3) Serial Cable- This cable connects to the MSD RS-232 port and to the DPA.

(4) Special Purpose Cable-This cable is use to connect the DPA to the ICE Box. Thiscable would be used only if there was a problem with the DDL connector on thevehicle.

(3) External DC power using power supply/charger- Connects the NATO cable to thevehicle and to the power supply/charger.

(4) External DC power directly from vehicle- Connect the NATO cable Adapter to theNATO cable.

(5) External AC power (110V to 220V) with power supply/charger- Connect the ACpower cord to power supply/charger; and connect power supply/charger DCoutput cable connector to the power input connector.

e. Setting up MSD equipment for DCA mode testing

(1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in theMSD PC card drive slot.

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NOTE: Install the card in the slot closest to the compartment door opening. Insert the cardwith labeled side facing toward front of MSD.

(2) Connect the P3 end of the data/power cable to the power connector on the MSD.Align red dots on cable connector and MSD connector.

(3) Connect the ground connector (P4) on the data/power cable to the ground lug onthe MSD.


NOTE: Place the power selector switch on the ICE box to the off position before makingany connections.

(5) Connect the W1 cable to the ICE box and the vehicle MSD connector. P1 end ofthe cable connects to the J1 connector on the ICE box; and the P2 end connectsto the DCA connector on the vehicle.

(6) Position the power selector switch on the ICE box to the DCA position.

NOTE: Power can be supplied through the ICE box when using the (W1) DCA cable. For TKtesting, the NATO cable must be used to transfer power from the vehicle throughthe ICE box.

f. Setting up SPORT equipment for TK mode testing

(1) Install the DMM224 card, with data/power cable (P2 end) attached to card, in thePC card slot.

NOTE: Install the card in the slot closest to the compartment door opening. Insert the cardwith labeled side facing toward front of MSD.

(2) Connect the P3 end of the data/power cable to the power connector on the MSD.

Align red dots on cable connector and MSD connector.

(3) Connect the ground connector (P4) on the data/power cable to the ground lug onthe MSD.


(5) Connect the W4 (transducer) cable(s) P1 end, to J2 or J3 on the ICE box.

(6) Connect a selected transducer to the P2 end of the W4 cable.

NOTE: A transducer is connected directly to a test point on a vehicle for testmeasurements.

(7) Connect the NATO power cable to the ICE box J5 connector.

(8) Position the power selector switch on the ICE box to the NATO position.

g. Setting up MSD equipment for J1708 Data bus testing

(1) Connect the NATO cable to the power supply charger DC input connector.

(2) Connect the power supply/charger DC output cable connector.

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18

(3) Connect the MSD serial cable to the RS232 serial port and to a port on theDearborn Protocol Adapter.

NOTE: There are two ports or connectors on the DPA. One port on each end. The serialCable can be connected to only one of the ports, and the J1708 Adapter connects tothe other.

(4) Connect the J1708 Adapter to a port on the DPA.

(5) Connect the J1708 Adapter to the Diagnostic Data Link (DDL) on the DDECequipped vehicle.

h. Operation.

(1) Power up MSD-ICE

(2) Connect an external power source to the MSD or use internal battery

(3) Press the ON/OFF button

(4) Performing a test using the MSD-ICE

(a) Connect the MSD-ICE to the vehicle

(b) Power up the MSD-ICE

(c) Use the track ball to move the pointer over the Self-Test icon for the desiredtest to be performed, i.e. ICE or J1708.

(d) Follow the instruction on the screen. Step-by-step instructions are shownalong with illustrations.

i. Care of the AN/PSM-95B MSD

(1) Inspect MSD carrying case and ICE equipment container for damage.

(2) Open containers and inspect components. Ensure port connectors and cables areclean and that the pins are not bent, burned, broken or missing. Checkreceptacles for similar damage.

(3) Perform before and after operation PMCS IAW with electronic technical manual.Conduct an inventory IAW the ETM / IETM.

(4) Store all components in their original containers and store cases in a controlledenvironment.



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19

CHECK ON LEARNING: Conduct a check on learning and summarize the ELO.

B. ENABLING LEARNING OBJECTIVE

ACTION: Set-up Test Measurement, and Diagnostic Equipment

CONDITIONS: In a shop environment, given an A?PSM-45A multimeter, Prolink9000, Sport, MSD, selected wheeled vehicles and references

STANDARDS: IAW applicable references

1. Learning Step / Activity 1. Demonstrate Set-up Procedures

Method of Instruction: DemonstrationInstructor to Student Ratio: 1:6

Time of Instruction: 2 hrsMedia: Large Group Instruction

NOTE: The instructor will demonstrate TMDE Hook up and setup procedures onselected equipment.

NOTE: Instructor will demonstrate various testing procedures on each TMDE.


2. Learning Step / Activity 2. Set-up TMDE

Method of Instruction: Practical Exercise (Performance)Instructor to Student Ratio: 1:6

Time of Instruction: 6 hrsMedia: Large Group Instruction

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NOTE: Restate safety precautions that are listed in the introduction.Ensure that all necessary training materials listed in lesson plan are available.

Divide class into groups and assign an assistant instructor as necessary.

Assign groups to vehicles in the shop area and rotate when tasks are completed.

Throughout the exercise, use Supplement 1, Practical Exercise Checklist, to check theprogress of the students to ensure they are accomplishing the tasks.

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SECTION IV. SUMMARY

Method of Instruction: Conference / DiscussionInstructor to Student Ratio is: 1:18Time of Instruction: 5 minsMedia: Large Group Instruction

Check onLearning

Determine if students have learned the material presented by --

a. Soliciting student questions and explanations.

b. Asking questions and getting answers from the students.

c. Correcting student misunderstanding.

QUES: On the SPORT, what cables are use to supply power to the powersupply/charger?

ANS: NATO and AC power cables.

QUES: What are the tests that can be performed with the multimeter?

ANS: Voltage, continuity, current.

QUES: How much voltage can be measured with the high voltage probeon the Fluke 27/FM multimeter?

ANS: 6000 volts.

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

ANS: 1.5 hours

QUES: How many types of analog test is the MSD-ICE capable ofperforming?

ANS: 50 types

Review /SummarizeLesson

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SECTION V. STUDENT EVALUATION

TestingRequirements

NOTE: Describe how the student must demonstrate accomplishment of the TLO.Refer student to the Student Evaluation Plan.

In lesson 63B33E10 you (the students) will have 1 hour and 30 minutes to take a

Job Knowledge Test on the material presented during Annex E.

FeedbackRequirements

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

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63B33E01 Suppl 1a

63B33E01JUN 04

Suppl 1a

PRACTICAL EXERCISE SHEET 63B33E01PE1

Title J1708 Test with the MSD or SPORT

Lesson Number/ Title

63B33E01 version MOSC / Test, Measurement, and Diagnostic Equipment


NOTE: The instructor should inform the students of the following Terminal Learning

Objective covered by this practical exercise.


Action: J1708 TestConditions: In a classroom/shop environment, given an SPORT or, MSD, and

the necessary references.Standards: IAW applicable TMs

SafetyRequirements

None

RiskAssessment

Low - It is the instructor's responsibility to conduct a risk assessment prior toinstruction using FM 100-14 as guidance. A copy of the risk management worksheet must be present at time of instruction.


None


InstructionalLead-In

None

ResourceRequirements

Student Materials:63B33E01, Supplement 1a Student's Guide

References listed above

SpecialInstructions

None

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63B33E01 Suppl 1a

Procedures:

1. Click on the J1708 icon on the desktop. Self-test will run

2. Turn ignition switch to accessories then click OK.

NOTE: If a fault is in the vehicle a warning note will appear. Click OK and exit fromwarning to continue test.

3. Go to function, then DDEC II options, then cylinder cut out.

NOTE: Read all screens carefully before performing test.

CAUTION: Read all cautions carefully

4. Select auto, 1000 rpms, and number of cylinders for vehicle and click start. (Test willrun)

5. Annotate cylinder cutout test results.

6. Click cancel; go to function, DDEC II options, injector response time.

7. Annotate IRTs results

8. Exit back to desk top

END OF TASK


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63B33E01 Suppl 1b

63B33E01JUN 04

Suppl 1b

PRACTICAL EXERCISE INSTRUCTORS GUIDE

Title TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT

References Number Title Date Page No. Add'l Info

Enabling ACTION: J1708 Test with the MSD or SPORTLearningObjective CONDITION(S): In a classroom with assistance, given a MSD or SPORT

applicable references.

STANDARD: IAW appropriate references without causing damage toequipment or injury to personnel.

Safety Requirements 1. Keep clear of the engines moving parts when the engine is running.2. Remove all jewelry (watches, rings, ID tags).3. No horseplay in the shop or classroom.4. Use caution when handling any training aid. Sharp edges, moving parts, and

electrical components can cause injury.5. Disconnect power source from circuits when measuring ohms.6. Pay special attention to all safety procedures listed in technical manuals when

using electronic TMDE.7. Use caution with electrical sources; 50 volts or more can cause loss of life.8. Use extreme care while walking around the vehicle while TMDE wires are

connected. Tripping over wires can cause injury to personnel and severedamage to testing equipment.

Risk AssessmentLevel

Low. (See Appendix A)


Exhaust system must be used when engines are running. Hearing protection mustbe worn when operating equipment. Ensure appropriate containers are available tocollect any engine fluids. Clean all spills immediately. Wash your hands if you comein contact with POL products.

Procedures 1. Verify students have performed inventory and PMCS on the MSD or SPORT.Direct students to perform setup procedures.

2. Verify students have performed setup procedures IAW Reference guide. Directstudents to power-up the equipment and prepare it for testing.

3. Verify students have Selected the J1708 test.

4. Verify students have Correctly conduct the J1708 test.

5. Verify students have received historical and active codes from equipment beingtested.

6. Verify students have interpreted codes

END OF TASK

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63B33E01 Suppl 1c

63B33E01Jun 04

Suppl 1c

PRACTICAL EXERCISE CHECKLIST

COURSE: WHEEL VEHICLE MECHANIC (BNCOC) 63B30

SUBJECT: TEST J1708

REFERENCES: Students handout

DIRECTIONS TO THE INSTRUCTOR:

1. Complete page 2 of this form as the group performs the task. Once the group has correctlyperformed a step, place a check in that column.

2. Ensure that each student participates. Rotate students so that all members of the group usereferences, tools, and perform the hands-on steps of the task. Have students rotate betweenstations once the task is completed.

3. If a safety violation occurs, stop the group, correct on the spot and restart the group.

4. If a student misses the practical exercise or a group needs remedial training for longer then the PEallows, then conduct this remedial training at earliest opportunity.

STUDENT NAMES: CLASS NUMBER:____________ _________________________

DATE: ____________________________________________

START TIME:_______________________________________

STOP TIME:________________________________________

TOTAL TIME:_______________________________________

_________________________ ______________________________INSTRUCTOR'S SIGNATURE

_________________________

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63B33E01 Suppl 1c

5. Conduct a detailed review to ensure that each student can accomplish the following performancemeasures:

a. Observe maintenance discipline and safety procedures.

b. Select and properly interpret references.

c. Prepare MSD or SPORT for operation correctly.

d. Properly conduct the J1708 test.

(1) _____ Cylinder cutout.

(2) Injector response time.

e. Annotate corrective action on DA Form 2404 correctly.

f. Complete task without injury to personnel or damage to equipment.

g. Return all tools, equipment and references to proper location.

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63B33E01 Suppl 2a

63B33E01Jun 04

Suppl 2a

PRACTICAL EXERCISE SHEET 63B33E01PE2

Title SPORT ICE TEST

Lesson Number/ Title

63B33E01 version MOSC / Test, Measurement, and Diagnostic Equipment


NOTE: The instructor should inform the students of the following Terminal LearningObjective covered by this practical exercise.


Action: SPORT ICE TESTConditions: In a classroom/, given an SPORT ICE and the necessary references.Standards: IAW applicable TMs

SafetyRequirements

None

Risk

Assessment

Low - It is the instructor's responsibility to conduct a risk assessment prior to

instruction using FM 100-14 as guidance. A copy of the risk management worksheet must be present at time of instruction.


None


InstructionalLead-In

ResourceRequirements

Student Materials:

63B33E01, Supplement 2b, Student Guide

References listed above

SpecialInstructions

None

Procedures

1. Click on the ICE testing on the desktop.

2. Click number 1, select vehicle then click OK.

3. Go to function, then DDEC II options, then cylinder cut out .

NOTE: Self-test will run and pass test.

4. Click OK

5. Read directions carefully (make sure ICE TEST OFF SET switch is on.

6. Click OK, test will run.

NOTE: If a fault code show up click cancel then OK and turn off STE ICE OFF SETswitch.

7. Engine will be on for this test.

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63B33E01 Suppl 2a

8. Enter test number 12, then click OK, click run, test number 10 will show up, clickenter

9. Clicks run, ACCEL will appear, have partner press accelerator to the floor untilDECEL shows up

10. Click OK and annotate results from test number 12.

11. Click enter, then enter test number 10, click OK, click RUN, click enter andannotate test results.

12. Click enter and enter test number 24, click OK then turn off engine.

13. Click run, and annotate results.

14. Enter test number 67, click on Run 2nd test, and then click OK.

15. Enter 2nd test number 68, then click OK.

16. Click Ready, select run, then crank engine without starting for about 2 seconds,annotate results.

17. Click enter and enter test number 72, then click OK. Read caution and click OK,click Ready read info, click RUN, then crank engine without starting for 2 seconds,press enter, annotate results from test number 72,73,74 and 75.

18. Exit back to desktop and shut down computer.

END OF TASK


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63B33E01 Suppl 2b

63B33E01Jun 04Suppl 2b

PRACTICAL EXERCISE INSTRUCTORS GUIDE

Title TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT

References Number Title Date Page No. Add'l Info

Enabling ACTION: SPORT ICE TESTLearningObjective CONDITION(S): In a classroom/, given an SPORT ICE and the necessary

references.

STANDARD: IAW applicable TMs

Safety Requirements 1. Keep clear of the engines moving parts when the engine is running.2. Remove all jewelry (watches, rings, ID tags).3. No horseplay in the shop or classroom.4. Use caution when handling any training aid. Sharp edges, moving parts,

and electrical components can cause injury.

5. Disconnect power source from circuits when measuring ohms.6. Pay special attention to all safety procedures listed in technical manualswhen using electronic TMDE.

7. Use caution with electrical sources; 50 volts or more can cause loss of life.8. Use extreme care while walking around the vehicle while TMDE wires are

connected. Tripping over wires can cause injury to personnel and severedamage to testing equipment.

Risk AssessmentLevel

Low. (See Appendix A)


Exhaust system must be used when engines are running. Hearing protectionmust be worn when operating equipment. Ensure appropriate containers areavailable to collect any engine fluids. Clean all spills immediately. Wash yourhands if you come in contact with POL products.

Procedures 1. Verify students have performed inventory and PMCS on SPORT ICE. Directstudents to perform setup procedures.

2. Verify students have performed setup procedures IAW Reference guide. Directstudents to power-up the equipment and prepare it for testing.

3. Verify students have Selected the SPORT ICE test.

4. Verify students have Correctly conduct the SPORT ICE test.

5. Verify students have received historical and active codes from equipment being

tested.

6. Verify students have interpreted codes

END OF TASK

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63B33E01 Suppl 2b

63B33E01Jun 04

Suppl 2c

PRACTICAL EXERCISE CHECKLIST

COURSE: WHEEL VEHICLE MECHANIC (BNCOC) 63B30

SUBJECT: SPORT ICE TEST

REFERENCES: Students handout

DIRECTIONS TO THE INSTRUCTOR:

1. Complete page 2 of this form as the group performs the task. Once the group has correctlyperformed a step, place a check in that column.

2. Ensure that each student participates. Rotate students so that all members of the group usereferences, tools, and perform the hands-on steps of the task. Have students rotate betweenstations once the task is completed.

3. If a safety violation occurs, stop the group, correct on the spot and restart the group.

4. If a student misses the practical exercise or a group needs remedial training for longer then the PEallows, then conduct this remedial training at earliest opportunity.

STUDENT NAMES: CLASS NUMBER:____________ _________________________

DATE: ____________________________________________

START TIME:______________

_________________________STOP TIME:_______________

_________________________TOTAL TIME:______________

_________________________

_________________________ ______________________________INSTRUCTOR'S SIGNATURE

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5. Conduct a detailed review to ensure that each student can accomplish the following performancemeasures:

a. Observe maintenance discipline and safety procedures.

b. Select and properly interpret references.

c. Prepare SPORT ICE for operation correctly.

d. Properly conduct the SPORT ICE test.

(1) _____ Cylinder cutout.

e. Annotate corrective action on DA Form 2404 correctly.

f. Complete task without injury to personnel or damage to equipment.

g. Return all tools, equipment and references to proper location.

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