simplified test equipment for internal … 09109a-244.pdf · tm 09109a-24/4 operating procedures...

TM 09109A-24/4

OPERATING PROCEDURES MANUAL

SIMPLIFIED TEST EQUIPMENTF O R

INTERNAL COMBUSTION ENGINESREPROGRAMMABLE

(STE/ICE-R)

AS APPLICABLE TO

CRANE, HIGH SPEED, HIGH MOBILITYHSHMC-25

A U G U S T 1 9 9 2

PCN 184 091093 00

WARNINGS

WARNING

Vehicle engine must be off before installing cables to prevent injury to personnel or damage toequipment.

WARNING

Do not have a battery charger connected when performing electrical system tests.

WARNING

On vehicles with a master switch in the negative (-) battery cable, sparking may occur if the VTMcase touches the vehicle while master switch is off and VTM is on. Sparking in the presence offuel or fuel vapors presents a potential hazard. Avoid hazard by doing all testing with the vehiclein a well ventilated area.

TABLE OF CONTENTS

PAGE

SECTION I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. General Measurements . . . . . . . . . . . . . . . . . . . . . . .

SECTION II. STE/ICE POWER CONNECTION . . . . . . . . . . . . . . . . . . . .

2-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Vehicle Test Cards . . . . . . . . . . . . . . . . . . . . . . . . .2-4. Test 66 - Confidence Test . . . . . . . . . . . . . . . . . . . .

SECTION III. DIAGNOSTIC CONNECTOR ASSEMBLY TESTS . . . . . . . . .

3-1.3-2.3-3.3-4.3-5.3-6.3-7.3-8.3-9.3-10.3-11.3-12.3-13.3-14.3-15.3-16.3-17.3-18.3-19.3-20.3-21.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test 10 - Engine Idle Speed . . . . . . . . . . . . . . . . . . . .Test 12 -Engine Power Test.. . . . . . . . . . . . . . . . . .Test 67- Battery Voltage Test . . . . . . . . . . . . . . . . . .Test 68- Starter Voltage Test.. . . . . . . . . . . . . . . . . .Test 70- Starter Solenoid Voltage . . . . . . . . . . . . . . . .Test 71- Average Starter Current . . . . . . . . . . . . . . . .Test 72- Starter Current, First Peak . . . . . . . . . . . . . .Test 74 -Starter Circuit Resistance . . . . . . . . . . . . . . .Test 73- Battery Internal Resistance . . . . . . . . . . . . . .Test 82- Alternator Output Voltage . . . . . . . . . . . . . . .Test 84- Alternator Negative Cable Voltage Drop . . . . . .Test 67 - Cranking Voltage . . . . . . . . . . . . . . . . . . . .Test 24- Fuel Supply Pressure . . . . . . . . . . . . . . . . . .Test 26 - Fuel Filter Restriction . . . . . . . . . . . . . . . . .Test 27 - Fuel Solenoid Voltage . . . . . . . . . . . . . . . . .Test 10 - Vehicle Cranking Speed . . . . . . . . . . . . . . . .Test 75 - Battery Internal Resistance Change . . . . . . . . .Test 69 - Engine Ground . . . . . . . . . . . . . . . . . . . . . .Test 80 - Battery Current . . . . . . . . . . . . . . . . . . . . .Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION IV. TEST KIT (TK MODE) TESTS . . . . . . . . . . . . . . . . . . . . . .

4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Test 50 - Engine Oil Pressure . . . . . . . . . . . . . . . . . . .4-3. Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1-11-2

2-1

2-12-12-32-3

3-1

3-13-13-23-23-33-33-33-43-43-53-53-63-63-63-73-73-73-83-83-93-9

4-1

4-14-14-2

Section I. INTRODUCTION

1-1. DESCRIPTION

a. The Simplified Test Equipment for InternalCombustion Engines (hereafter referred to as STE/ICE)performs many tests on internal combustion engines.Engine power, electrical tests, and pressure tests can beperformed without the need of other special test equipment.

b. The major components of the STE/ICE and theiruses are listed below. Refer to Figure 1-1.

(1) Vehicle Test Meter (VTM) - used to testvehicle/equipment components.

(2) Transit Case - a fitted carrying case used totransport all items of the STE/ICE.

(3) Cable Assemblies - used to supply operatingpower and test data to the VTM. Cable assemblies arereferenced by cable number and by name which tells howthe cable is used. The following cables are used to test theHSHMC-25 crane.

(a) W1 Cable - connects to receptaclemounted in vehicle cab and to J1 (DCA/PWR) on VTM.Connects VTM to STE/ICE Diagnostic ConnectorAssembly of crane. Supplies battery power to VTM.

(b) W4 Cable - connects to J2 TK receptacleon VTM and to transducer at test site.

Figure 1-1. STE/lCE Components

1-1

(4) Transducer Kit - contains transducers, adapters,and current probe. Used to connect VTM to vehicle fortesting in the TK mode. The following transducers andadapters are used to test the HSHMC-25.

(a) Transducer - blue striped, transducer kititem 17, part number 12258876 (a, Figure 1-2). The bluetransducer is used to check pressures in excess of 25 psi.

(b) Adapter - transducer kit item 20, partnumber 444012 (b, Figure 1-2). Used to connecttransducer to 1/8 inch plug hole in oil pressure connections.

(c) Snubber - transducer kit item 21, partnumber 12258881 (c, Figure 1-2). Used with blue stripedtransducer to prevent and reduce pulsations caused by high

pressure fluid.

1-2. GENERAL MEASUREMENTS

a. General

(1) General measurements are those for which theVTM does not require a vehicle identification number inorder to conduct the measurements. These include voltage,pressure, current, and resistance.

(2) The tests included in this supplement includeprocedures for each of the measurements.

b. Measurement Table

(1) Table 1-1 l is ts the STE/ICE generalmeasurements applicable to the HSHMC crane.

(2) General measurements are separated betweenthe Diagnostic Connector Assembly (DCA) mode and theTest Kit (TK) mode.

(3) The DCA mode tests read measurementssupplied by the Diagnostic Connector Assembly mountedon the vehicle instrument panel. Refer to Figure 1-3.

(4) TK mode tests require the installation oftransducers and connection of a cable to the Vehicle TestMeter.

Figure 1-2. Transducer Kit

1-2

TABLE 1-1. GENERAL MEASUREMENTS

TESTMODE

DCA

TESTNO.

10

12

67

68

70

71

MACHINE FUNCTION I MEASURED ACCEPTABLEVALUE RANGE I

Engine Idle Speed 690 to 875 rpm

Engine Power 2900 to 3200 rpm/sec

Battery Voltage 24.5 to 28.5 volts

Starter Voltage minimum 19.0 volts

Starter Solenoid Voltage minimum 19.0 volts

Average Starter Current maximum 360 amps

72 Starter Current, First Peak

74 Starter Circuit Resistance

73 Battery Internal Resistance

82 Alternator Output Voltage

84 Alternator Negative Cable Voltage Drop

67 Cranking Voltage

I 24 Fuel Supply Pressure

26 Fuel Filter Restriction

27 Fuel Solenoid Voltage

10 Vehicle Cranking Speed

I 75 Battery Internal Resistance Change

69

80

TK 50

maximum 1500 amps

maximum 27 milliohms

maximum 25 milliohms

26.5 to 28.5 volts

maximum 0.4 volts

minimum 19.0 volts

18 to 35 psi

PASS

25 to 29 volts

minimum 120 rpm

maximum 50 milliohm/sec

Engine Ground maximum 0.4 volts

Battery Current 250 to 500 amps

Engine Oil Pressure I 55 to 80 psi

1-3

Figure 1-3. Carrier and Instrument Panel

1-4

Section II. STE/ICE POWER CONNECTION

2-1. GENERAL

a. Park HSHMC-2S crane on level ground or floor.

b. Perform the following steps before installingSTE/ICE:

(1) Operate crane and lower boom onto boom rest.Engage house lock.

(2) Set the swing brake. Set all drum pawls.Engage parking brake.

CAUTION

If operating crane indoors, connect metaltubing to exhaust stack to deliver exhaustgases to outside area.

(3) Shut off engine.

2-2. CABLE INSTALLATION

a. Remove cable assembly W1 from transit case.

b. Remove Vehicle Test Meter from transit case andplace on suitable stand.

CAUTION

Do not connect cable to VTM when VTMpower switch is on.

c. Connect cable W1 to J1 DCA/PWR connector onVTM. Refer to Figure 2-1.

d. Refer to Figure 2-2 and connect cable W1 to DCAmounted on vehicle instrument panel. Twist locking ringto secure cable.

WARNING

On vehicles with a master switch in thenegative (-) battery cable, sparking mayoccur if the VTM case touches the vehiclewhile the master switch is off and the VTMis on. Sparking in the presence of fuel orfuel vapors presents a potential hazard.Avoid hazard by doing all testing in a wellventilated area.

e. Turn master switch on.

f. Check that power is present at VTM.

(1) PUSH ON VTM power switch. Refer toFigure 2-3.

Figure 2-1. Cable Connection to VTM

2-1

Figure 2-2. Cable WI Connected to DCA

Figure 2-3. VTM Components

2-2

(2) Observe VTM display.

(3) Verify that the figures .8.8.8.8 appear on thedisplay for approximately 2 seconds and then change to----- This sequence assures that power is present at VTM.

2-3. VEHICLE TEST CARDS

a. The Vehicle Test Card is intended as a quickreference for personnel already familiar with STE/ICEoperation. The Test Card provides connection informationfor the most common VTM tests on the vehicle.

b. The card contains all information, in abbreviatedformat, needed to perform common measurements.

c. Included on the card are the following:

(1)

(2)the crane.

(3)

(4)

VTM power up sequence.

List of measurements used in troubleshooting

Operating conditions.

Connections required.

(5) Minimum and maximum measurement limits.

d. The Text Card listing allows measurements with thecrane engine turned off to be performed first. Theremaining measurements are organized as follows:

(1) Measurements requiring engine to be crankingbut not running.

(2) Measurements with the engine running but notwarm.

(3) Measurements requiring engine to be warm andrunning.

2-4. TEST 66- CONFIDENCE TEST

NOTE

This test is designated as Test 66. Theprocedure provides an overall check of theVTM. The test should be performed beforeand after each measurement to ensureaccuracy of results.

Figure 2-4. Confidence Test in Program

2-3

a. Refer to paragraph 2-2 and check that power ispresent at the VTM.

b. Set TEST SELECT switches to 66.

c. Refer to Figure 2-4 and press TEST button. Waitfor display to show 0066.

d. Set TEST SELECT switches to 99.

e. Press and release TEST button. Display shouldshow 0099. Display will then turn blank.

NOTE

When performing step e, observe and verifythat all segments of the display are on.

f. The display will show .8.8.8.8. This indicates allsegments are operating.

g. The display will turn blank.

NOTE

If a test is in progress, the test results willappear in the display window. The endresult of the confidence test will alternatelyshow the software revision number and thePASS message.

h. Refer to Figure 2-5 for confidence test display.Wait for the alternate display of the revision number andPASS message.

i. PULL OFF button to shut off VTM.

Figure 2-5. Confidence Test Display

2 - 4

Section III. DIAGNOSTIC CONNECTOR ASSEMBLY TESTS

3-1 ● GENERAL

NOTE

To perform the following tests, a minimumof two personnel is suggested.

a. The following tests are performed in the DCAmode.

b. Refer to paragraph 2-2 and check to be sure theVTM is connected to the DCA connector.

c. Refer to paragraph 2-4 andtest prior to each DCA mode test.

d. VTM must be connectedperform all of the following tests.

perform the confidence

to DCA connector to

3-2. TEST 10 - ENGINE IDLE SPEED

a. General. This test measures engine speed while thecrane idles.

b. Test procedures

(1) Make sure VTM is off. PULL OFF VTMpower switch.

(2) Check to see that cable W1 is attached to J1connector on VTM and to DCA connector on the vehicleinstrument panel.

(3) Refer to paragraphconfidence test.

(4) Turn on vehicle masterApply service brakes.

2-4 and perform the

switch and start engine.

Figure 3-1. VTM Settings for Engine Idle Speed Test

3-1

(5) Set TEST SELECT switches to 10. NOTE

(6) PUSH ON button to power VTM. Wait forVTM to display ----.

Two numbers will be displayed. The firstnumber will go away after a few seconds.The second number is the test result. Thisnumber will remain on VTM display.(7) Press and release TEST button.

(8) Observe display while engine idles. Readingshould be 690 to 875 RPM.

(9) Observe display. Reading should be 2900 to3200 rpm/sec.

(9) Shut Off engine. (10) Allow engine to idle at least 2 minutes.

(10) PULL OFF button to shut off VTM. (11) Shut off engine.

3-3. TEST 12- ENGINE POWER TEST (12) PULL OFF button to shut off VTM.

a. General. This test measures engine power at fullthrottle.

3-4. TEST 67- BATTERY VOLTAGE TEST

a. General. This test measures battery voltage.Voltage is measured directly at the power source of theVTM.

b. Test procedures

(1) Refer to Figure 2-3 for location of VTMcomponents. b. Test Procedures

(2) Check to see that cable W1 is connected to J1connector at VTM and to DCA on vehicle instrument panel.

(1) Refer to Figure 2-3 for location of VTMcomponents.

(3) Refer to paragraph 2-4 and perform theconfidence test.

(2) Check to see that cable W1 is connected to J1connector at VTM and to DCA connector on vehicleinstrument panel.

(4) Turn on vehicle master switch and start engine.Apply service brakes. Allow engine to reach operatingtemperature before proceeding to step 5.

(3) Refer to paragraph 2-4 and perform confidencetest.

(5) Set TEST SELECT switches to 12. (4) Make sure vehicle master switch and all vehicleaccessories are off.

(6) PUSH ON button to power VTM. Wait forVTM to display ----. (5) Set TEST SELECT switches to 67.

(7) Press and release TEST button. (6) PUSH ON button to power VTM. Wait forVTM to display ----.

(8) When VTM displays CIP, press down sharplyon engine accelerator and hold pedal to the floor. WhenVTM displays a number, release accelerator.

(7) Press and release TEST button.

(8) Observe display. Reading should be 24.5 to28.5 Volts.CAUTION

Allow engine to idle for at least 2 minutesafter running engine power test to preventdamage to vehicle.

(9) PULL OFF button to shut off VTM.

3-2

3-5. TEST 68- STARTER VOLTAGE TEST

a. General. This test checks the voltage of the startermotor while cranking the engine.

b. Test Procedures


(2) Check to see that cable W1 is connected to J1connector on VTM and to DCA connector on vehicleinstrument panel.


(4) Make sure master switch and all vehicleaccessories are off.

(5) Set TEST SELECT switches to 68.


(7)

(8)seconds.

(9)19.0 volts.

(l0)

Press and release TEST button.

Depress starter button and engage starter for 3

Observe display. Reading should be

PULL OFF button to shut off VTM.

3-6. TEST 70 - STARTER SOLENOIDVOLTAGE

at least

a. General. This test provides a check of the voltageat the starter solenoid while cranking the engine.

b. Test Procedures




(4) Make sure master switch and all vehicleaccessories are off.


(6) PUSH ON button to power VTM. Wait forVTM to display -----

(7)

(8)seconds.

(9)19.0 volts.

( l 0 )


Depress starter button and engage starter for 3

Observe display. Reading should be


at least

3-7 . TEST 71 - AVERAGE STARTERCURRENT

a. General. This test measures average starter currentwhile cranking the engine.

b. Test procedures


(2) Check to see that cable W1 is attached to J1connector on VTM and to DCA connector on vehicleinstrument panel.

(3)confidence

(4)

Refer to paragraph 2-4 and perform thetest.

Perform offset test as follows:

(a) Ensure vehicle master switch is off.

(b) Set TEST SELECT switches to 71.

(c) PUSH ON button to power VTM. Waitfor VTM to display ----.

(d) Press and hold TEST button until theletters CAL appear on display.

(e) Release TEST button, Observe display.Reading should be between -150 and + 150.

(5)

(6)


Depress starter for 3 seconds then disengage.

3-3

(7) Observe display. Reading should be less than360 amps.


3-9. T E S T 7 4 - S T A R T E R C I R C U I TRESISTANCE(8) PULL OFF button to shut off VTM.

3-8. TEST 72- STARTER CURRENT, FIRSTPEAK

a. General. This test measures starter circuitresistance.

a. General. This test measures the overall condition ofthe complete starting system.

b. Test Procedures

(1) Refer to Figure 2-3 for VTM cableconnections.b. Test Procedures






(4) Perform offset test as follows:

(a) Make sure vehicle master switch and allvehicle accessories are off.(4) Perform offset test as follows:

(a) Ensure vehicle master switch is off. (b) Set TEST SELECT switches to 74.

(b) Set TEST SELECT switches to 72. (c) PUSH ON button to power VTM. Waitfor VTM to display ----.

(c) PUSH ON button to power VTM. Waitfor VTM to display ----. (d) Press and hold TEST button until the

letters CAL appear on display.(d) Press and hold TEST button until the

letters CAL appear on display. (e) Release TEST button. Observe display.Reading should be between -150 and + 150.

(e) Release TEST button. Observe display.Reading should be between -150 and + 150. (5) Press and release TEST button.

(5) Press and release TEST button. NOTE

NOTE Never engage starter for longer than 3seconds. If the letters GO appear andremain on display, a battery may be bad.Check and replace battery if necessary.

Never engage starter for longer than 3seconds. If the letters GO appear andremain on display, a battery may be bad.Check and replace battery if necessary. (6) When GO appears on the display, depress

stinter for 3 seconds, or until the letters OFF appear ondisplay. Disengage starter.(6) When GO appears on the display, depress

starter button and engage starter for 3 seconds, or until theletters OFF appear on display. Disengage starter. (7) Observe display. Reading should be less than

27 milliohms.(7) Observe display. Reading should be less than

1500 amps. (8) PULL OFF button to shut off VTM.

3-4

3-10. TEST 73 - BATTERY INTERNALRESISTANCE

a. General. This test measures the state of charge ofthe batteries.

3-11. TEST 82- ALTERNATOR OUTPUTVOLTAGE

a. General. This test checks alternator output voltagewhile the engine is running and accessories are on. Thistest alternately displays engine speed and output voltage.

b. Test Proceduresb. Test Procedures


(2) Check to see that cable W 1 is attached to J1connector on VTM and to DCA connector on vehicleinstrument panel.



(a) Make sure vehicle master switch and allvehicle accessories are off.




(4) Turn on master switch, vehicle lights, andheater fan.

(5) Set TEST SELECT switches to 01.(b) Set TEST SELECT switches to 73.



(e) Release TEST button. Observe display.Reading should be between -150 and + 150.



(8) Wait for VTM to display Con.

(9) Perform output voltage test as follows:

(a) Set TEST SELECT switches to 82.(5) Press and release TEST button.

(b) Press and release TEST button.NOTE

Never engage starter for longer than 3seconds. If the letters GO appear andremain on display, a battery may be bad.Check and replace battery if necessary.

(6) When GO appears on the display, depressstarter button and engage starter for 3 seconds, or until theletters OFF appear on display. Disengage starter.

(7) Observe display. Reading should be less than25 milliohms.

(c) Start engine. Apply service brakes.

NOTE

VTM will alternately display engine speedand alternator output voltage.

(d) Observe VTM display. Increase enginespeed to 1500 RPM.

(e) With engine running at 1500 RPM,observe VTM display. Alternator output voltage readingshould be between 26.5 and 28.5 volts.


3-5

(10) Shut off engine. Turn off lights and heater fan.


3-12. TEST 84 - ALTERNATOR NEGATIVECABLE VOLTAGE DROP

a. General. This teat checks the negative cable voltagedrop of the alternator while the engine is running andaccessories are on. This test alternately displays enginespeed and alternator negative cable voltage drop.

b. Test Procedures


(2) Check to see that cable W1 is attached to J1connector on VTM and to DCA on vehicle instrumentpanel.


(4) Turn on master switch, vehicle lights andheater fan.




(8) Wait for VTM to display Con.

(9) Perform alternator negative cable voltage droptest as follows:

(a)

(b)

(c)

Set TEST SELECT switches to 84.


Start engine. Apply service brakes.

NOTE

VTM will alternately display engine speedand alternator negative cable voltage drop.

(d) Observe VTM display. Increase enginespeed to 1500 RPM.

(e) With engine running at 1500 RPM,observe VTM display. Alternator negative cable voltagedrop should be no greater than 0.4 volts.

(10) Shut off engine. Turn off lights and heater fan.


3-13 TEST 67- CRANKING VOLTAGE

a. General. This test provides a check of the batteryvoltage while cranking the engine.

b. Test Procedures




(4) Make sure vehicle master switch is off.



(7)

(8)starter.

(9)19.0 volts.

(lo)


Depress starter for 3 seconds. Disengage

Observe display. Reading should be at least


3-14. TEST 24- FUEL SUPPLY PRESSURE

a. General. This test measures fuel supply pressurewhile the engine idles.

b. Test Procedures


3-6




(7) Turn on master switch and start engine. Applyservice brakes.

(8) While engine idles, observe display. VTMshould display PASS.

(4) Perform offset test as follows:(9) Shut off engine.

(a) Make sure vehicle master switch is off.(10) PULL OFF button to shut off VTM.

(b) Set TEST SELECT switches to 2-4.3-16. TEST 27- FUEL SOLENOID VOLTAGE



(e) Release TEST button. Observe display.Reading should be between -4.5 and +4.5.



(7) Allow engine to idle 60 seconds and observeVTM display. Reading should be 18 to 35 PSI.

(8) Shut off engine. PULL OFF button to shut offVTM .

a. General. This test measures voltage at the fuelsolenoid.

b. Test Procedures

(1) Check voltmeter reading to ensure batteries arecharged (refer to Figure 1-2).




(5) Set TEST SELECT switches to 27.3-15. TEST 26- FUEL FILTER RESTRICTION

a. General. This test provides a check of the conditionof the fuel filter.


(7) Press and release TEST button.b. Test Procedures





(9) Allow engine to idle for 60 seconds andobserve VTM display. Reading should be 25 to 29 volts.


(11 ) PULL OFF button to shut off VTM.

3-17. TEST 10- VEHICLE CRANKING SPEED(4) Set TEST SELECT switches to 26.


a. General. This test measures engine speed whilecranking the engine.

3-7

b. Test Procedures for VTM to display ----.

(1) Make sure vehicle master switch is off. (d) Press and hold TEST button until theletters CAL appear on display.

(2) Refer to Figure 2-3 for location of VTMcomponents. (e) Release TEST button. Observe display.

Reading should be between -150 and + 150.(3) Check to see that cable W1 is attached to J1

connector on VTM and to DCA connector on vehicleinstrument panel.


NOTE(4) Refer to paragraph 2-4 and perform the

confidence test. Never engage starter for longer than 3seconds. If the letters GO appear andremain on display, a battery may be bad.Check and replace battery if necessary.


(6) PUSH ON button to power VTM. Wait forVTM to display ----. (6) When GO appears on the display, depress

starter for 3 seconds, or until the letters OFF appear ondisplay. Disengage starter.(7) Press and release TEST button.

(8) Depress starter button and engage starter for 2seconds. Disengage starter.

(7) Observe display. Reading should no greaterthan 50 milliohms/sec.

(9) Observe display. Reading should be at least120 RPM.


3-19. TEST 69- ENGINE GROUND(10) PULL OFF button to shut off VTM.

a. General. This test checks the condition of theelectrical system while cranking the engine.3-18. TEST 75 - BATTERY INTERNAL

RESISTANCE CHANGEb. Test Procedures

a. General. This test measures the rate of change ofbattery resistance. (1) Make sure vehicle master switch is off.


b. Test Procedures

(1) Refer to Figure 2-3 for location of VTMcomponents. (3) Check to see that cable W1 is attached to J1

connector on VTM and to DCA connector on vehicleinstrument panel.(2) Check to see that cable W 1 is attached to J1

connector on VTM and to DCA connector on vehicleinstrument panel. (4) Refer to paragraph 24 and perform the

confidence test.(3) Refer to paragraph 2-4 and perform the

confidence test. (5) Set TEST SELECT switches to 69.

(4) Perform offset test as follows: (6) PUSH ON button to power VTM. Wait forVTM to display ----.

(a) Make sure vehicle master switch is off.(7) Press and release TEST button.

(b) Set TEST SELECT switch to 75.(8) Depress starter for 3 seconds then disengage.

(c) PUSH ON button to power VTM. Wait

3-8

(9) Observe display. Reading should be no greaterthan 0.4 volts.


3-20. TEST 80- BATTERY CURRENT

a. General. This test measures the strength of theelectric current delivered by the batteries.

b. Test Procedures




(4) Make sure vehicle master switch and all vehicleaccessories are off.


(a) Set TEST SELECT switches to 80.

(b) PUSH ON button to power VTM. Waitfor VTM to display -----

(c) Press and hold TEST button until theletters CAL appear on display.

(d) Release TEST button. Observe display.Reading should be between -150 and + 150.


(7) Depress starter button and engage starter for 3seconds. Disengage starter.

(8) Observe display. Reading should be 250 to500 amps.

3-21. TEST RESULTS

a. General. Perform my of the above tests as requiredto check any suspected troubles with the vehicle.

b. Disposition. If the results of any of the above testsshow discrepancies or do not meet the specifications noted,the object or function should be repaired. Notify thecorrect echelon of maintenance to perform the repair orreplacement required to correct the discrepancy.

C. STE/ICE Shutdown

(1) Turn off vehicle master switch. PULL OFFbutton to shut off VTM.

(2) Refer to Figure 2-2 and disconnect W1 cablefrom Diagnostic Connector Assembly.

(3) Refer to Figure 2-1 and disconnect cable W1from VTM.

(4) Install cable and VTM in transit case.


3-9

Section IV. TEST KIT (TK MODE) TESTS

4-1. GENERAL

NOTE

To perform the following tests, a minimumof two personnel is required.

a. TK Mode Tests

NOTE

Before starting the TK mode tests, turn themaster switch on and leave switch on untilall tests are completed.

(1) The TK mode tests require the installation oftransducers at the area to be tested for pressure settings.

(2) The TK mode tests require the installation of acable between the test site and VTM.

b. Cable Application

(1) The TK mode tests require that cable W1 beconnected between the Diagnostic Connector Assembly(DCA) and the Vehicle Test Meter (VTM).

(2) Cable W4 from the STE/ICE connects to J2connector on the VTM and to the transducer at the test site.

c. Transducer Application

(1) A blue-striped transducer (part number12258876) is used in the TK mode test for the crane.

(2) An adapter (part number 444012) and snubber(part number 12258881 ) help connect the transducer at thetest site.

4-2. TEST 50- ENGINE OIL PRESSURE

a. General. This test measures engine oil pressure atthe air compressor while the engine is running.

b. Installation and Checks of Test Equipment

(1) Refer to Figure 1-3 and remove cap fromDiagnostic Connector Assembly.

(2) Refer to Figure 2-2 and connect cable W1 toDiagnostic Connector Assembly.

(3) Refer to Figure 2-1 and connect cable W1 toconnector J1 on the VTM.


Figure 4-1. Cable Connection at VTM

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c. Test Connections (3) Start engine. Engage parking brake.


(2) Check to see that cable W1 is connected to J1connector on VTM and to DCA connector on vehicleinstrumen t panel.

(3) Refer to Figure 4-1 and connect W4 cable to J2connector on VTM.

(4) Connect the transducer and W4 cable to the oilpipe plug located near the lower left side of the aircompressor. The air compressor is located on the right sideof the crane within the engine compartment. Proceed asfollows:

(a) Connect adapter, part number 444012,to snubber, part number 12258881.

(b) Connect blue striped transducer, partnumber 12258876, to adapter/snubber.

(c) Remove the oil passage pipe plug from theair compressor. Refer to Figure 4-2.

(d) Install adapter/snubber/transducer in oilport of air compressor. Do not overtighten.

(e) Connect W4 cable to transducer in aircompressor.

d. Test Procedures


(a) Turn engine off. With engine off, systemwill not be pressurized.

(b) Set TEST SELECT switches to 50.

(c) PUSH ON button to power VTM. Waitfor VTM to display -----

(d) Press and hold TEST button until theletters CAL appear on VTM display.

(e) Release TEST button. Wait for offsetvalue to appear on VTM display. Display should readbetween -150 to + 150.

(4) Allow engine to idle 2-3 minutes beforeperforming step 5.

(5) While engine idles, observe VTM display.Reading should be 55 to 80 psi.



(8) Refer to Figure 4-2 and disconnect W4 cablefrom transducer. Disconnect adapter, snubber, andtransducer from air compressor.

(9) Install pipe plug in air compressor.

4-3. TEST RESULTS

a. General. Perform the above test as required tocheck any suspected troubles with the vehicle.

b. Disposition. If the results of the above test showdiscrepancies or do not meet the specifications noted, theobject or function should be repaired. Notify the correctechelon of maintenance to perform the repair orreplacement required to correct the discrepancy.

C. STE/ICE Shutdown

(1) Turn off master switch.

(2) Refer to Figure 2-2 and disconnect W1 cablefrom Diagnostic Connector Assembly. Install cap (Figure1-3) on Diagnostic Connector Assembly.

(3) Refer to Figure 2-1 and disconnect cable W1from VTM.

(4) Install cable, transducers, snubber, adapter, andcurrent probe in transit case.


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Figure 4-2. Engine Oil Pressure Test

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