CHAPTER 1 POWER DISTRIBUTION CHAPTER 2 …€¦ · · 2004-04-09CYLINDER SHORTING ... PROGRAM...

TABLE OF CONTENTS FOR SERIAL A

Effective06/2000

INTRODUCTION

GENERAL .................................................................................................................................................................IMODEL DIFFERENCES..........................................................................................................................................IIFUNCTIONAL DESCRIPTION................................................................................................................................III

MAJOR SUBASSEMBLIES .......................................................................................................................IIIELECTRONIC SAFETY PRECAUTIONS............................................................................................................... VSERVICE GUIDELINES.......................................................................................................................................... VHANDLING MOS ICS AND OTHER STATIC SENSITIVE DEVICES ................................................................... VI

CHAPTER 1 POWER DISTRIBUTION

POWER REQUIREMENTS.................................................................................................................................. 1-1POWER DISTRIBUTION ..................................................................................................................................... 1-2

DC DISTRIBUTION................................................................................................................................. 1-2AC DISTRIBUTION................................................................................................................................. 1-2

CHECKOUT PROCEDURE................................................................................................................................. 1-3POWER TEST: ....................................................................................................................................... 1-3

TROUBLESHOOTING......................................................................................................................................... 1-5

CHAPTER 2 COMPUTER

GENERAL ............................................................................................................................................................ 2-1THEORY OF OPERATION.................................................................................................................................. 2-1

SIGNAL SOURCE SELECTION ............................................................................................................. 2-1SYNC SOURCE SELECTION ................................................................................................................ 2-1KEYBOARD INPUTS.............................................................................................................................. 2-1VOLTAGE MEASUREMENT .................................................................................................................. 2-1VIDEO INPUTS....................................................................................................................................... 2-1

CHECK OUT PROCEDURE................................................................................................................................ 2-2SELF DIAGNOSTICS: ............................................................................................................................ 2-2INTERNAL TEST: ................................................................................................................................... 2-2


CHAPTER 3 IGNITION PROCESSING


AUXILIARY INPUT.................................................................................................................................. 3-1VOLTMETER INPUT (WHITE CLIP LEAD)............................................................................................ 3-1INDUCTIVE PICKUP (#1 CYLINDER PICKUP) ..................................................................................... 3-1PRIMARY/FUEL INJECTION (YELLOW CLIP LEAD) ........................................................................... 3-2SECONDARY AND EXTERNAL SYNC.................................................................................................. 3-2SYNC CIRCUITRY.................................................................................................................................. 3-3SIGNAL CIRCUIT ................................................................................................................................... 3-3MISCELLANEOUS.................................................................................................................................. 3-3CYLINDER SHORTING.......................................................................................................................... 3-3

CHECKOUT & CALIBRATION............................................................................................................................. 3-4TOOLS REQUIRED: ............................................................................................................................... 3-4EESX100A CALIBRATION: .................................................................................................................... 3-4VOLTAGE WAVEFORM SCREEN CALIBRATION:............................................................................... 3-5INPUT TEST ........................................................................................................................................... 3-5LAB SCOPE SCREEN CALIBRATION................................................................................................... 3-6SECONDARY SCREEN CALIBRATION ................................................................................................ 3-8

TROUBLESHOOTING....................................................................................................................................... 3-10

CHAPTER 4 KEYBOARD/REMOTE CONTROL

GENERAL ............................................................................................................................................................ 4-1KEYBOARD THEORY OF OPERATION............................................................................................................. 4-1

MAIN KEYBOARD .................................................................................................................................. 4-1SOFT KEYS KEYBOARD....................................................................................................................... 4-1

REMOTE CONTROL THEORY OF OPERATION (OPTIONAL) ......................................................................... 4-2INFRARED TRANSMITTER ................................................................................................................... 4-2


Effective06/2000

INFRARED RECEIVER .......................................................................................................................... 4-2PERFORMANCE .................................................................................................................................... 4-2

CHECKOUT PROCEDURE................................................................................................................................. 4-3KEYBOARD TEST .................................................................................................................................. 4-3REMOTE TEST:...................................................................................................................................... 4-3


CHAPTER 5 VIDEO


INTERCONNECTIONS........................................................................................................................... 5-2CHECKOUT PROCEDURE................................................................................................................................. 5-2

MONITOR ADJUSTMENTS.................................................................................................................... 5-2TROUBLESHOOTING......................................................................................................................................... 5-3

CHAPTER 6 POWER BALANCE PROBE (OPTIONAL)

GENERAL ............................................................................................................................................................ 6-1THEORY OF OPERATION.................................................................................................................................. 6-1TROUBLESHOOTING......................................................................................................................................... 6-2

CHAPTER 7 VACUUM PROBE (OPTIONAL)

GENERAL ............................................................................................................................................................ 7-1THEORY OF OPERATION.................................................................................................................................. 7-1TROUBLESHOOTING......................................................................................................................................... 7-2

CHAPTER 8 AMPS (OPTIONAL)


HIGH AMP PROBE................................................................................................................................. 8-1LOW AMP PROBE.................................................................................................................................. 8-1

CALIBRATION PROCEDURE ............................................................................................................................. 8-2HIGH AMP PROBE CALIBRATION........................................................................................................ 8-2LOW AMP PROBE CALIBRATION ........................................................................................................ 8-2


CHAPTER 9 COMMUNICATIONS


PROCESSOR ......................................................................................................................................... 9-1PROGRAM MEMORY ............................................................................................................................ 9-1BUFFER RAM......................................................................................................................................... 9-1COMMUNICATIONS PORTS: ................................................................................................................ 9-1

TEST PORT............................................................................................................................... 9-1RS232 PORTS........................................................................................................................... 9-1

SCREEN PRINT PROCESS................................................................................................................... 9-1CHECKOUT PROCEDURE................................................................................................................................. 9-2TROUBLESHOOTING......................................................................................................................................... 9-2

CHAPTER 10 PRINTERS

GENERAL .......................................................................................................................................................... 10-1AMT PARALLEL PRINTER................................................................................................................................ 10-1

USING THE SETUP MENU: ................................................................................................................. 10-1ACCESSING THE SETUP MENU ........................................................................................................ 10-2SELECTING OPERATIONS ................................................................................................................. 10-2

RUNNING PRINTER SELF TEST: .......................................................................................... 10-2BASIC PRINTER OPERATION: .............................................................................................. 10-2SELECTING PRINT MODES:.................................................................................................. 10-3SELECTING PAGE SETUP PARAMETERS:.......................................................................... 10-5SPECIFYING COMMUNICATIONS PARAMETERS:.............................................................. 10-7SELECTING SPECIAL MODES: ............................................................................................. 10-8


Effective06/2000

SERVICE MENU FUNCTIONS............................................................................................................. 10-9ERROR MESSAGES.......................................................................................................................... 10-11

PRINTER MESSAGES: ......................................................................................................... 10-111) CORRECTING OPERATING ERRORS: .......................................................................... 10-112) CORRECTING PROGRAMMING ERRORS: ................................................................... 10-113) UNDERSTANDING WARNINGS:..................................................................................... 10-114) CORRECTING COMMUNICATION ERRORS:................................................................ 10-125) CORRECTING PRINTER ERRORS: ............................................................................... 10-13

MT3010 SCRIBE II PARALLEL PRINTER ...................................................................................................... 10-14INDICATOR LIGHTS .......................................................................................................................... 10-14SELECTING THE POWER ON CONFIGURATION MODE: .............................................................. 10-14

POWER-ON CONFIGURATION............................................................................................ 10-14CHANGING THE POWER ON CONFIGURATION MODE ................................................................ 10-15THE MENU MODE.............................................................................................................................. 10-15

MENU MODE......................................................................................................................... 10-15CHANGING THE MENU MODE ......................................................................................................... 10-15RUNNING THE SELF TEST............................................................................................................... 10-15

MT1670A SERIAL PRINTER........................................................................................................................... 10-16FRONT PANEL CONTROLS AND DISPLAY..................................................................................... 10-16BACK PANEL...................................................................................................................................... 10-16

OKIDATA LED PRINTERS OL600E OKIPAGE 6E OKIPAGE 10E ...................................................... 10-17GENERAL ........................................................................................................................................... 10-17THEORY OF OPERATION................................................................................................................. 10-17

GENERAL .............................................................................................................................. 10-17COMMUNICATIONS.............................................................................................................. 10-17IMAGE DRUM........................................................................................................................ 10-17

INSTALLATION................................................................................................................................... 10-18MAINTENANCE ............................................................................................................................................... 10-19

IMAGE DRUM..................................................................................................................................... 10-19TONER CARTRIDGE ......................................................................................................................... 10-22LED ARRAY........................................................................................................................................ 10-24PAPER ................................................................................................................................................ 10-24

TROUBLESHOOTING..................................................................................................................................... 10-27DOT MATRIX PRINTERS................................................................................................................... 10-27LED PRINTERS .................................................................................................................................. 10-30

CHAPTER 11 EXHAUST EMISSIONS - HC/CO/CO2/O2GENERAL ................................................................................................................................................................1MODEL DIFFERENCES..........................................................................................................................................1INFRARED THEORY...............................................................................................................................................2

CALIBRATION GAS....................................................................................................................................3O2 THEORY .............................................................................................................................................................3AC/DC DISTRIBUTION............................................................................................................................................4

AC DISTRIBUTION.....................................................................................................................................4DC DISTRIBUTION.....................................................................................................................................5

PNEUMATIC THEORY............................................................................................................................................6ZERO MODE ..............................................................................................................................................6GAS CALIBRATION MODE........................................................................................................................7LEAK TEST.................................................................................................................................................8SAMPLE MODE..........................................................................................................................................9

GAS ANALYZER SETUP.......................................................................................................................................10CHECKOUT AND CALIBRATION .........................................................................................................................10

LEAK CHECK: ..........................................................................................................................................10PUMP/PUMP CONTROL CHECK: ...........................................................................................................11SOLENOID CHECK: .................................................................................................................................11

TROUBLESHOOTING...........................................................................................................................................13

CHAPTER 12 PARTS

GENERAL .......................................................................................................................................................... 12-1PARTS BY PICTORIAL ..................................................................................................................................... 12-2

TOP VIEW............................................................................................................................................. 12-2


Effective06/2000

FRONT PANEL ..................................................................................................................................... 12-3STANDARD LEADS AND ACCESSORIES.......................................................................................... 12-4OPTIONAL LEADS AND ACCESSORIES ........................................................................................... 12-5GAS ANALYZER, BLOWUP VIEW....................................................................................................... 12-6FILTER ASSEMBLY ............................................................................................................................. 12-7

PARTS IN ALPHABETICAL ORDER................................................................................................................. 12-8PARTS IN NUMERICAL ORDER .................................................................................................................... 12-11

APPENDIX A ERROR MESSAGES

GENERAL ............................................................................................................................................................A-1ERROR MESSAGES ...........................................................................................................................................A-1

APPENDIX B GLOSSARY

GENERAL ............................................................................................................................................................B-1

Effective10/96 Page i

INTRODUCTION

GENERAL

This service manual covers the MT-3000 and MT-3000A engine testers. The manual covers the following topics:

POWER DISTRIBUTION, COMPUTER, IGNITION PROCESSING, KEYBOARD/REMOTE, VIDEO, POWERBALANCE PROBE, VACUUM, AMPS, COMMUNICATIONS, PRINTERS, EXHAUST ANALYSIS , PARTSAND ERROR MESSAGES.

The MT-3000A is capable of displaying the following engine information:

• Primary Waveform

• Dwell Bar Graph

• Duty Cycle Bar Graph

• Secondary Waveform

• KV Data

• Burn Time Bar Graph

• Voltage Waveform

• Lab Scope Waveform

• Fuel Injection Waveform

• Alternator Waveform

• Power Balance Waveform

• Cylinder Shorting Bar Graph

• Cylinder Time Balance Bar Graph

• Amps readings (optional)

• Vacuum Waveform (optional)

• Exhaust gas readings (optional)

• Timing readings (optional)

• ALDL readings (optional)

This engine information is organized and can be displayed as follows:

• A Lab Scope mode where the operator can vary the sample sweep rate; with 12 selections ranging from50 microseconds/division to 200 milliseconds/division. The amplitude selection will include 6 ranges from200 millivolts/division to 10 volts/division.

• Amplitudes on all waveforms are measurable using grid lines (with the exception of Vacuum) or horizontalcursors. Time periods on all waveforms are measurable using grid lines or vertical cursors. Thesefeatures can be used on live, frozen, or memory waveforms.

• Memory capabilities include the storage of two waveforms from most "modes of waveform operation" aswell as storage of two bar graphs from each "mode of bar graph operation."

• Dual edge-triggered RPM Setpoints are available to provide capturing either one or two sets of data.

• Distributorless Ignition circuitry is built into this unit.

• An optional Vacuum transducer is available for waveform displays of intake manifold vacuum.

INTRODUCTION

EffectivePage ii 10/96

GENERAL continued...

• KV Histograph - a line graph composed of the last 256 KV values of a selected cylinder.

• KV Bar Graph - displays a bar graph showing firing voltages of each cylinder.

• Cylinder Time Balance - cylinder contribution bar graph derived from cylinder balance informationobtained during normal engine operation.

• Burn Time Bar Graph - a bar graph of the time durations of the spark plug burn time derived fromSecondary input information.

• Cranking Amps Bar Graph - a bar graph composed of Amp probe information, capable of being used atcranking engine speeds.

• Duty Cycle Bar Graph - a single bar graph used to monitor the duty cycle of solenoids; with readingsdisplayed in percentage, degrees, or volts.

• ALDL data is displayed in the Options page and requires a SNAP-ON SCANNER (Model MT2500) tooperate.

• Exhaust gas data is displayed in the Options page and requires an MT3100 to operate.

• Timing readings are read on the display of the timing device in use. The timing device may be poweredand triggered by connections at the rear of the MT3000 and MT-3000A.

MODEL DIFFERENCES

The MT-3000 and the MT-3000A are very similar in form and function. Most of the differences are in thesoftware, however; the Commmunications Board and the Video Board have some component differences as wellas different ROM chips. Therefore, some of the boards have different part numbers.

The boards that are different between the MT-3000 and the MT-3000A are: Digital Board, Video Board and theCommunications Board.

The operational differences are:

• The MT-3000 has a communications port labled “TEST PORT”. In the MT-3000A this port has beenchanged to a standard Parallel port.

• The MT-3000A has a page added to support the Power Balance Probe.

• The MT-3000A has an IR Gas page that allows on screen power balance testing and a vacuum readingssection as well as gas readings.

INTRODUCTION

Effective10/96 Page iii

FUNCTIONAL DESCRIPTION

MAJOR SUBASSEMBLIES1. The Input Protection Board (IPB) provides circuitry to attenuate input signals to safe levels and filter out

some ignition noise. It is placed right at the entry point of the signals to help keep noise and high voltageaway from the circuitry within the unit.

Most inputs have a neon bulb to ground to absorb occasional arc over from secondary ignition. The six IDlines also have resistor/zener diode protection.

Since typical primary signals exceed the turn-on voltage of neon bulbs, an arc gap, (in the form of a splitcapacitor), is used on that input. The Aux A (Lab Scope) input and the Alt/Bat inputs have Metal OxideVaristors (MOV), on their inputs instead of neon bulbs. The MOVs are able to absorb more energy to protectthe high impedance circuitry used for the lab scope and volt screen inputs.

2. The Backplane Board interconnects all circuit boards and contains the cylinder shorting circuitry.

3. The Video Monitor consists of the CRT assembly and the Driver Board. The Driver Board has the usualadjustments for video.

4. The Digital Video Board generates composite video, as instructed by the computer, for the Video Monitor.

5. The Digital Board interfaces between the Analog circuitry and the Display circuitry. It performs the followingfunctions:

a) Provides for the selection of input signal and sync sources on the Analog board.

b) Measures voltage levels as provided by the analog signals selected (KV's, Vacuum, Current, Voltages).

c) Measures the time period between sync signals and determines sample clock frequencies in accordancewith those periods.

d) Provides hardware addressing for the storage (Memory) of waveform samples taken.

e) Will take samples of the selected analog signal using a Flash Analog to Digital converter.

6. The Communications Board provides three data ports: 2 serial ports and a Test port (Parallel port).The test port is a Parallel Printer port on the MT-3000A model. These ports allow for the connection ofoptional devices like the four gas analyzer, printer and others.

The ports are wired from the Backplane Board to the rear of the tester, via ribbon cables.

The Communications Board also provides an RGB Color output, through the Backplane Board via aribbon cable to the rear panel.

7. The Analog Board processes signals from the vehicle into pulses for timing, and signal conditioning forthe Computer Board. With 2 inputs, an AC and a DC signal could be sent from the Amp Probe, VacuumProbe, or other Modules. This board also has the calibration pots for the analog signals. The signalsprocessed are:

a) AUXILIARY INPUT A - The incoming signal enters at the AUXINA terminal and passes through the inputvoltage divider and optionally, a coupling capacitor, (if AC coupling is selected). A potentiometer on the outputof the amplifier allows for calibration to a level of ±1.024 volts. The signal goes from here to the signalmultiplexer and to the sync multiplexer.

b) AUXILIARY INPUT B - This is a single range input that allows a 2nd signal to be sent from a module to thescope. Aux B could also be used as an external sync if needed.

INTRODUCTION

EffectivePage iv 10/96

MAJOR SUBASSEMBLIES, Continued...

NOTE: A pickup identification system is present for the auxiliary inputs. This systemhas three lines, all of which are protected by filters and buffers.

c) VOLTMETER INPUT - This input is used for DC voltage readings, simple voltage waveforms, andalternator waveform tests. The alternator circuitry is a bandpass filter that passes ripple but blocks DCand high frequencies. The Voltmeter signal is shared with the Aux B input. One of the two inputs isselected by an analog switch.

d) INDUCTIVE PICKUP - The signal from the Inductive Pickup is first conditioned by the Inductive Pickup.The output from that passes through a monostable gate to prevent multiple trigger pulses from thissource. This is particularly useful for multi-spark ignitions or noisy ignition systems. The signal passesfrom there to the Input Digital board.

e) PRIMARY/FUEL INJECTION - The signal passes through a filter and then branches to the waveform,dwell, and the sync conditioning circuits.

1. WAVEFORM - The signal is attenuated and clamped at +12/-10 volts ± 0.7 volts. The signal passesthrough a selectable gain amplifier with one gain for primary and another gain for fuel injection. Thewaveform then goes to the signal mux, primary sync circuit, and the sync mux.

f) DWELL - The Dwell Signal triggers a transistor circuit, driving it into saturation when the input value isabove 3.0 volts at the input terminal. The output signal from the transistor is applied to an invertor. Thedwell signal goes to a board connector on the Input Digital board.

1. SYNC CONDITIONING - The signal is attenuated, clamped positive and limited to +5 volts ± 0.7volts, filtered slightly, then goes to the sync multiplexer.

g) SECONDARY AND EXTERNAL SYNC

1. TOYOTA & HEI - The input signal is connected to the MAINSEC terminal and to the filter andattenuator circuit on the Input Protection Board. Standard cap pickup and External Sync come in onthe High Sec input. A unity gain non-inverting amplifier isolates the input. The output of the amplifiergoes to the secondary signal attenuators and to the sync conditioning circuit. The center tap of thepotentiometers connect to the signal mux.

NOTE: A pickup identification system is present for the secondary inputs. Thissystem has three lines, each of which is protected by a filter and a buffer.

2. DISTRIBUTORLESS IGNITION - The two DI input signals are separately applied to filter andattenuator circuits and to unity gain non-inverting amplifiers. From these, the two signals (True andWasted) are applied to the Input Selection multiplexer (ISM) and the Polarity/Sync circuit (PSC). Inthe PSC, the True and Wasted signals are applied to a differential amplifier whose output can bepositive or negative, but will have the polarity of the True signal. This signal is applied to an absolutevalue circuit to provide a sync signal and to a rectifier circuit to provide a 0 or 5 volt polarity signal.The polarity signal (DIPOL) signal goes to an 8 bit TTL latch and then to the Input Digital board. Thesync (DISYNC) signal goes to the sync multiplexer.

8. The Switching Power Supply is a DC to DC converter. It operates from DC only over the range of 8 to 16volts. There are actually two separate power supplies on one board. One supplies the +5 volt output and theother one supplies the +12 volt and -12 volt outputs. The two supplies are very similar and basically differonly in the number of turns on the toroidal transformers and the output filter components.

INTRODUCTION

Effective10/96 Page v

MAJOR SUBASSEMBLIES, Continued...8. The input circuitry of the power supply consists of several large capacitors, two inductors, and a reverse

connected diode across the input to protect the power supply against a reverse polarity at the input. In theevent that a reverse polarity voltage is applied to the input of the power supply, the circuit breaker will trip. Ifthe circuit breaker should fail to trip, a backup fuse will blow to provide double protection.

NOTE: System ground is formed on the Switching Power Supply and is notelectrically the same as chassis ground. Reference all DC voltagemeasurements to board ground, not chassis ground.

10. The Front Panel Controls consist of two PCBs and a pot. The PCBs are simple switch matrixes composedof copper traces and conductive rubber mats. When a button is pressed the conductive mat makes aconnection between the contacts of the copper traces. The bottom PCB also houses the receiver for the IRRemote Control.

ELECTRONIC SAFETY PRECAUTIONS

!DANGEROUS HIGH VOLTAGES

ARE PRESENT IN THIS EQUIPMENT

When working on this tester, keep three points in mind:

• This unit is powered by both low voltage battery and standard 120 vac, however, both voltages aremanipulated to generate high voltages within the tester.

• The input signals from the vehicle present potentially dangerous situations for electric shock.

• All DC voltage measurements are referenced to board ground, not chassis ground.

SERVICE GUIDELINES

• BEFORE REPLACING circuit boards, verify that the main power supply operates within specifications.

• VERIFY that board connectors are fully seated.

• NEVER remove boards or disconnect a connector with the power on!

• MAKE SURE that you completely understand what the tester does. (If it works, you can't fix it!) Refer to theMT-3000 or MT-3000A Operator's Manual.

• CONSULT the Service Bulletin Binder. It may identify and explain how to correct the problem.

• BE CAREFUL when handling circuit boards! Wear an anti-static wrist strap.

• WHEN TRANSPORTING circuit boards, use anti-static bags.

INTRODUCTION

EffectivePage vi 10/96

HANDLING MOS ICS AND OTHER STATIC SENSITIVE DEVICES

!USE STANDARD ANTI-STATIC PROCEDURESWHILE PERFORMING THESE INSTRUCTIONS

Most integrated circuits are high impedance devices. This characteristic makes them susceptible to damage byelectrostatic charges. Large electrostatic charges tend to build up in low humidity environments. If you provide adischarge path through the IC, you may damage the IC.

To prevent needless failures, employ these techniques when handling static-sensitive devices...

• Until circuit boards are ready for use, keep them in their static-protective packaging.

• Never remove or insert boards when the machine is under power.

• The correct board removal procedure is as follows:

When you're repairing equipment, it must be grounded.Wear your anti-static wrist strap. Connect it to the equipment chassis or nearest available ground. FieldService Kits include a wrist strap and grounding cord (0552-0032-01).

HANDLING MOS ICs AND OTHER STATIC SENSITIVE DEVICES, continued...

Neutralize static voltage differences! Touch the chassis, or any metal part of the equipment.Always grasp the board from two opposite edges with your forefingers.Place removed boards on a grounded static-dissipative mat (part of the field service kit).

• When inserting boards into the equipment:

Remove the board from the original packaging on static dissipative material. If you must ship a defectiveboard, save packaging material for reuse.

Be sure to remove power from the tester. When installing the replacement board, follow the steps in theremoval procedure.

Attach a reject tag to all parts returned. Pack defective boards in a shielded bag. Return the bag in the reusable container.

• Packing IC chips, or other static-sensitive devices: Use conductive foam or an equivalent, anti-static materialwith adequate physical protection.

• Avoid unnecessary contact with internal components.

• Avoid setting boards on static-prone insulating surfaces such as paper, glass, rubber or plastic.

• Beware of static generated by friction when...

Wearing silk or nylon garments.Walking on carpets.Scuffing shoes with rubber soles.

NOTICE

Relative humidity has a direct effect on static charge buildup. As humidity decreases, static buildup usuallyincreases.

+

J12

J7J5

J1

POT

J13

2

3

J3

J1

P4 J4 P7 J7

P5 J5

SECONDARY

MAIN KEYBOARD

J3J2J1

J5 J4

MONITOR

P6 J6

AUXILIARY

INPUT PROTECTIONBOARD

MAINKEYBOARD

FUNCTIONKEYBOARD

(SOFT KEYS)POWERSUPPLY

POWERSUPPLY

PRIMARYSIGNAL

VEHICLESIGNALS

ANALOGBOARD

DIGITALBOARD

VIDEOBOARD

BACKPLANE BOARD

All information contained or disclosed in thisdocument is considered confidential andproprietary by Sun Electric. Allmanufacturing, use, reproduction and sales rightsare reserved by Sun Electric andthe information contained herein shall notbe used in whole or in part without the expresswritten consent of Sun Electric.

PAGE:

SUN ELECTRICOne Sun ParkwayCrystal Lake, Illinois 60014 U.S.A.

DWG:

TITLE:

CHK BY:DWG BY:

MODEL: DWG. REV.:MT-3000AJ. D. Sparks

INTERCONNECTIONDIAGRAM

i-1

J2

J1

-

F120 AMP

CB115 AMP

+12 VDCJ2

CB 23 AMPS12VDC

MONITORASSEMBLY

BRIGHT-NESSPOT

J102

J8J4 J2J11

DC POWERLEADSET

ALT & BATTGND PROBE

PRIMARY PROBE

INDUCTIVE PICKUP

RemoteReceiver Circuit

vii

0896M. B. Clark

COMMBOARD

REAR PANEL

J7 J10

J6 J9

J5 J8SERIAL PORT A

SERIAL PORT B

TEST PORT(PARALLEL PORT)

J1P1

2 AMPFUSE

LINE FILTER/VOLTAGE SELECT

ASSEMBLY

REAR PANEL

J13 J15

TRIGGER LOOP

J4 J6

BATTERYGROUND

DISTRIBUTOR

STUDS ATREAR PANEL

YEL (AC)

RED (DC)

POWER SWITCH(RIGHT PANEL)

BRN

BLKBLUWHTBRN

BRIDGERECTIFIER

AC

AC

DC +

DC -

RED

RED

RED

BLK

RED

AC / DC SELECT SWITCH(REAR PANEL)

T-1TRANSFORMER

BLK

RED

BLK

J9COMPOSITE

VIDEO(NOT USED)

RGB COLOR J10 J3

J1

SOFT KEYS

AC PLUG

J3

INTRODUCTION

EffectivePage viii 10/96

Effective10/96 Page 1-1




Always use the “One Hand Rule” (keep one hand in a pocket or behind your back) when working with ACvoltages. Always verify that the Analyzer is “OFF” using the Power Switch on the side of the tester. It is alsoimportant to ensure the AC power cord is unplugged from the outlet before removing wires from the MT-3000/APower Supply board.

POWER REQUIREMENTS

The power requirement on the MT-3000/A when operated from a DC source, such as an automobile battery, is42 watts. This would be 3.5 amps at 12 volts. However, if the battery is low and measures 9 volts, the currentdraw could be as much as 5 amps. The heavy duty DC power cable supplied with the MT-3000/A must beattached to the scope through the DC power connector located in the lower right portion of the back panel, (asviewed from the rear), for operation in the DC Mode.

The power requirements of the MT-3000/A when operated on AC power are: 70 watts at 120 VAC and 0.55amps (240 volts and 0.27 amps).

NOTE: If the power leads are connected in reverse, (positive to negative and negativeto positive), the main circuit breaker will trip.

A separate connection to ground is supplied though the Input Protection Board and is protected by a 3 amp circuitbreaker. This circuit breaker protects against accidental ground faults to battery positive through a “non-battery”test lead.

The Power Supply Board has a DC to DC converter. It operates on 8 to 16 volts dc. There are two separatepower supplies on the Power Supply Board. One supplies the +5 volt output and the other one supplies the +12volt and -12 volt outputs. The two supplies are very similar and basically differ only in the number of turns on thetransformers and the output filter components.

The AC Power Supply consist, basically, of a Transformer and a Bridge Rectifier that feeds 12 volts to the PowerSupply Board discussed above.

The AC power input (100, 120, 220 and 240 VAC), is manually selectable through the Voltage Select / Line Filterassembly.


EffectivePage 1-2 10/96

POWER DISTRIBUTION

DC DISTRIBUTIONDC power is provided by the vehicle battery via the DC Power Leadset. The DC Power Leadset is connected tothe 3 pin Power Connector at the rear of the tester.

Battery positive and Battery ground are applied to pins 2 and 3 respectively of the Power Connector on the rearpanel. The ground side of the power is a black wire on the inside of the cabinet. The positive side of the power isa white wire on the inside of the cabinet.

The Battery Ground is routed to the AC/DC Select Switch and to J2 of the Power Supply Board. The BatteryPositive Voltage is routed through a 20 amp fuse and 15 amp circuit breaker to the Main Power Switch. It then isrouted through the AC/DC Select switch to J1 on the Power Supply Board.

The output of the Power Supply is through J4 and J5 to J4 on the Backplane board. Refer to Table 1 for thevoltages at each pin of the Power Supply Connectors.

PIN NUMBER J4 J51 Ground +12 volts2 Ground -12 volts3 Ground Ground4 +5 volts Ground5 +5 volts N/A6 +5 volts N/A7 Ground N/A

Table 1. Power Supply Output Pins

The Video Monitor Assembly is powered by +12 volts from J8 on the Backplane Board. The +12 volts exits J8 atpins 13 and 14 and is connected through a ribbon cable to P101 of the Driver Board of the Video MonitorAssembly.

DC Power is also routed to the Battery and Ground Studs at the rear of the tester. These Studs provide powerfor external devices like a Timing Light and are powered only when the DC Power Leadset is connected to thevehicle’s battery.

AC DISTRIBUTION

AC power enters the tester through a standard AC Lead Assembly and is fed into a Line Filter/Voltage SelectAssembly. This assembly selects various Primary Winding configurations from T1 to provide the appropriateinput voltage to the Bridge Rectifier, via the Power Switch. The rectified voltage is routed through the AC/DCSelect Switch, if AC operation is selected, to J1 and J2 of the Power Supply Board.

NOTE: All voltages are referenced to “Board Ground”, J6 of Power Supply Board.

NOTE: Connector pin numbers on boards start with pin 1, marked with a white“Dot” for pin 1.



CHECKOUT PROCEDURE

POWER TEST:This series of measurements is used to determine if the MT-3000A has the proper voltages and groundreferences

1. GROUND ISOLATION - Measure the resistance between chassis ground and J6, (top-center), on the PowerSupply Board. It should read greater than 20 Meg. Ohms.

NOTE: For Steps 2 through 6, refer to Figure 1 on Page 3.2. +5 VOLTS DC - Connect black lead of DVM to TP4 of Analog Board. Connect red lead of DVM to (+) side

of C17 on Analog Board. Check for a reading of 5 volts, ± 0.2 volts.

NOTE: Be careful not to short DVM probe between pins on J2 and (+) side of C17.3. +12 VOLTS DC - Connect black lead of DVM to TP4 of Analog Board. Connect red lead of DVM to (+) side

of C65 on Analog Board. Check for a reading of +12 volts, ± 1 volt.

Figure 1. Analog PCB Voltage Test Points

4. -12 VOLTS DC - Connect black lead of DVM to TP4 of Analog Board. Connect red lead of DVM to (-) sideof C70 on Analog Board. Check for a reading of -12 volts, ± 1 volt.

5. PRECISION +5 VOLTS DC - Connect black lead of DVM to TP4 of Analog Board. Connect red lead ofDVM to TP1 on the Analog Board. Check for a reading of 5 volts, ± 0.05 volts.



CHECKOUT PROCEDURE, continued...

6. A/D REFERENCE VOLTAGE - Connect black lead of DVM to TP4 of Analog Board. Connect red lead ofDVM to TP2 on the Analog Board. Check for a reading of 1.875 volts, ± 0.03 volts.

TEST COMPLETE



TROUBLESHOOTING

COMPLAINT CORRECTIVE ACTION

I. Blank screen • Check Power Switch and proper selection of AC/DC SelectSwitch

• Check Front Panel Brightness control

• Check power input supply connections (A/C or D/C)

• Check 15 amp Circuit Breaker (rear panel), and 20 amp Fuse(inside tester)

• Perform Checkout procedure on page 1-2.

• Refer to Power Distribution Drawing for detailed pinpointtroubleshooting

II. Tester operates from a DCsource but not an AC source

• Check 2 amp Fuse in Line Filter/Voltage Select Assembly (rearpanel)

• Refer to Power Distribution Drawing and check for approximately15 volts DC across the DC output of the Bridge Rectifier:

If voltage is present, replace AC/DC Select Switch

If voltage is not present, proceed to next step

• Refer to Power Distribution Drawing and check for approximately14 volts AC across the AC input of the Bridge Rectifier:

If voltage is present, replace Bridge Rectifier

If voltage is not present, proceed to the next step

NOTE: The following voltage tests are for U.S. standards(120 VAC), and do not apply to other standards.

Remove the Hot-Melt glue from the connections at the Line Filter /Voltage Select Assembly (inside, back panel). Measure 120 VACacross the Black and Blue wires and across the White and Brownwires:

If any of the two voltages are missing, replace the Line Filter / VoltageSelect Assembly

If voltages are present, replace Transformer - T1




III. Tester operates from an ACsource but not a DC source

• Check 15 amp Circuit Breaker (rear panel), and 20 amp Fuse(inside tester)

Check Power Switch and proper selection of AC/DC Select Switch

NOTE: Perform the following voltage checks with the DCPower Leadset connected to a charged 12 voltautomobile battery and the Power Switch set to ON.Also, insure that the AC/DC Select Switch is set forDC operation

• Refer to Power Distribution Drawing and check for approximately12 volts DC across pins 4 and 1 of the AC/DC Select Switch:

If voltage is present, replace the AC/DC Select Switch

If voltage is not present, replace the Power Switch

IV. No Voltages at J5 and J4 ofPower Supply Board

• Check for approximately 12 volts DC across J1 and J2 of thePower Supply Board:

If voltage is present, replace Power Supply Board

If voltage is not present, check Complaints II and III above

6431

5

2

2

4

1

5

12

GNDGND

34567

4321

GNDGND

J5

J4

GNDGND

POWERSUPPLY

J4

Removable Connectors

Soldered Connectors

GNDGND

+ 2

312VDC-

F120 AMP

CB115 AMP+12 VDCJ2

DC PowerLeadset

J1P1

2 AMPFUSE

LINE FILTER/VOLTAGE SELECT

ASSEMBLY

BATTERY

GROUNDStuds at

Rear Panel

RED (DC)

POWER SWITCH(RIGHT PANEL)

BRN

BLK

BLUWHTBRN

BRIDGERECTIFIER

AC

AC

DC +

DC -

RED

RED

RED

BLK

RED

AC / DC SELECT SWITCH(REAR PANEL)

T-1TRANSFORMER

BLK

J1 J2

REAR PANEL

YEL

+C175 VDC

(+/- 0.2 VOLTS)

+C65+12 VDC

(+/- 1 VOLT)

-C70-12 VDC

(+\- 1 VOLT)

A/D GND

+12 VDC-12 VDC

+5 VDCA/D +5 VDC

+5 VDCGND

+12 VDC

MONITORASSEMBLY

VIDEO BOARD

DIGITAL BOARD

ANALOG BOARD

P5

P4

BACKPLANE BOARD

P101

12

1314

1920

+12 VDCTP2

VREF1.875 VDC

(+/- 0.03 VOLTS)

TP15REF5 VDC

(+/- 0.05 VOLTS)TP4

BOARDGROUND


J8

COMMUNICATIONS BOARD

1-71-1

POWERDISTRIBUTION

J. D. SparksMT-3000A 04/96

M.D. Clark


CHAPTER 2 COMPUTER

GENERAL

The “Computer” for the MT-3000 is a combination of the Video Board and the Digital Board. The Digital Boardperforms the main “non-video, central data processing”. For this reason the Digital Board is regarded as the maindigital processor.

A different Digital Board is used in the MT-3000A that allows for new displays when used with the the new VideoBoard.

THEORY OF OPERATION

The Digital Board interfaces between the Analog Board and the Video Board. It performs the following functions:

• Provides for the selection of input signal and sync sources from the Analog Board.

• Measures voltage levels as provided by the analog signals selected (KV's, Vacuum, Current, Voltages).

• Provides hardware addressing for the storage (memory), of waveform samples taken.

• Takes samples of the selected analog signal using an Analog to Digital converter.

• Provides various controls (Front Panel I/O, Screen selection, etc.)

SIGNAL SOURCE SELECTIONThe Digital Board controls signal selection devices (SIGNAL MUX) on the Analog Board in response to selectionsmade on the keyboard. These selections will direct certain analog voltages to the Digital Board. The Computeralso reads a latch on the Analog Board to determine which Secondary pickup and which Auxiliary probe isconnected to the leadset. See Chapter 3, “Ignition Processing and Cylinder Shorting”, for more information.

SYNC SOURCE SELECTIONThe Digital Board controls sync signal selection devices (SYNC MUX) on the Analog Board in response toselections made on the keyboard. The sync signals from the Analog Board go to inputs on the Digital Board.The Digital Board measures the period associated with the sync signals. These time periods are used toassociate all incoming signals with each other for proper display as directed by the operator via the Keyboard-Digital-Board interface.

KEYBOARD INPUTSThe Digital Board operates the keyboard matrix that provides the interface between the unit and the operator. For moredetails see chapter 4, Keyboard and Remote.

VOLTAGE MEASUREMENTTwo analog signals (PEAK SIGNAL and AVERAGE SIGNAL) are directed to two inputs of the Digital Board’sA/D converter (through the Analog Board.). These are stored for either bar graph or numeric display. The inputvoltages measured could be: Secondary KV, Voltmeter values, Vacuum input values, etc.

VIDEO INPUTSThe Digital Board stores the incoming waveform and numerical data in non-volatile RAM and generates theRead/Write signal for the address bus. The waveform, numerical data address, and write lines are sent to theVideo Board.

CHAPTER 2 COMPUTER


CHECK OUT PROCEDURE

SELF DIAGNOSTICS:

To access the “SELF DIAGNOSTICS” screen, press <OPTIONS>, then press <F3> (SELF DIAGNOSTICS).

The following tests can be run from the “SELF DIAGNOSTICS” screen:

INTERNAL TEST - Tests the Analog Board, Computer Board, Video Board andCommunications Board.

INPUT TEST - Tests vehicle input signals through leads, Input Board, Backplane Board, AnalogBoard and Computer Board.

KEYBOARD TEST - Tests Key Pad operation.

REMOTE TEST - Tests optional Remote Control operation.

INTERNAL TEST:

The Internal Test checks the four main circuit boards: the Analog Board (1100), Digital Board (1300), VideoBoard (1400), and Communications Board (1600).

Follow this procedure:

1. Disconnect the Main Leadset from the back of the tester.

2. Access SELF DIAGNOSTIC SCREEN, see above.

3. Press , (INTERNAL TEST).

4. The function key ICON will become highlighted and “TESTING” will flash in the “RESULTS” column inthe upper left portion of the display.

5. When the test is complete the “RESULTS” column will display “PASS” or “FAIL” for each board.

6. The “PASS” indication is not a 100% indication of board integrity. However, the “FAIL” indication is veryreliable.

TEST COMPLETE

CHAPTER 2 COMPUTER


TROUBLESHOOTING


I. Blank screen • Check Power Troubleshooting in Chapter 1.

Check Front Panel Brightness Control.

Check Fuses and Circuit Breakers (rear panel and inside tester).

• Turn Power Switch to OFF. Reduce tester to MinimumConfiguration For Display (as described below):

Remove Communications Board and Analog Board. Disconnectthe following ribbon cables from the Backplane Board:

Soft Keys cable (J3) Main Keyboard cable (J2) Main Leadset cable Front Panel Brightens Pot cable (J11)

Turn Power Switch to ON. If a readable message appears, turnpower OFF and replace each connector and circuit board one at atime until the Blank Screen symptom reoccurs; this will pinpoint thecomponent that is causing the failure.

If a readable message does not appear, replace the ComputerBoard or refer to Chapter 5, Video, for more troubleshooting.

II. Engine readings are erratic butscreen operations worknormally

• Perform Check-out Procedure in Chapter 1 (Power Distribution).

• Perform Lead-Check test in Chapter 3 (Ignition Processing).

• Replace Analog Board.

• Replace Computer Board.

III. Tester operates erratically(Screen Operations are erratic)

• Perform Check-out Procedure in Chapter 1 (Power Distribution).

• Remove Remote Control from ”line-of-sight” of the Infra-Redsensor on the front panel.

If this corrects the problem, troubleshoot Remote Control unit.

If this does not correct the problem proceed to the next step.

• Substitute the following components:

Digital BoardMain KeyboardFunction Keyboard

CHAPTER 2 COMPUTER


AUX ProbeLatch

SYNCMUX

SIGNALMUX

Average

Peak

J2

J3

J7

J5

J6


PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


MT-3000AR. Z. WILSON

2-1 2-5

COMPUTER

LEADID

DETECT

SIGNALSELECT

CONTROL

SYNCSELECT

CONTROL

A/DCONVERTER

KEY BOARD SCANNER

WAVEFORMRAM

DIGITALPROCESSOR

ANALOGBOARD

See Chapter 3Ignition

Processing

VIDEOBOARD

See Chapter 5Video

MAINKEYBOARD

See Chapter 4Keyboard and

Remote Control

SOFT KEYSKEYBOARD

See Chapter 4Keyboard and Remote Control

BI-DIRECTIONALBUS

BUS

BACKPLANEBOARD

DIGITALBOARD

COMMUNICATIONBOARD

See Chapter 9Communications

Serial PortCOMM PORT 1 (A)


Serial PortCOMM PORT 2 (B)


TEST PORT(PARALLEL PORT)


BACKPLANEBOARD

M.B. Clark08/96

CHAPTER 2 COMPUTER




GENERAL

Signal processing is performed by a combination of the Input Protection Board and the Analog Board. The InputProtection Board acts primarily in a passive method to isolate potentially harmful transients from the rest of theunit. A description of the Input Protection Board can be found in the Introduction of this manual. All of the signalconditioning, i.e., amplification, attenuation, etc., is performed on the Analog Board. However, the Primary Signalis routed from the Input Protection Board through the Backplane Board to the Analog Board. A Zener Diode ismounted on the Backplane Board and is switched into the primary circuit during cylinder shorting.

All of the inputs will be from the test leads to the Analog Board, ignoring the generally passive effects of the InputProtection Board. Outputs, from the Analog Board, are directed to the Digital Board.

THEORY OF OPERATION

AUXILIARY INPUTThe Auxiliary Input lead is a part of the Main Leadset and is marked AUXILIARY. This input allows for the use ofthe standard Scope Lead or optional attachments: Vacuum Probe, Power Balance Probe and Amps Probe. Apickup identification system is present for the auxiliary inputs. This system has three lines, all of which are protected byfilters and buffers. The pins are grounded or pulled high to form a code identifying the device that is connected andconfiguring the signal processors accordingly.

AUXILIARY INPUT A - The incoming signal enters at the AUXINA terminal and passes the input voltage dividerand optionally, a coupling capacitor, (if AC coupling is selected). The voltage divider is a series of resistorswhose nodes are connected to reed relays. The output of one of the reed relays is selected by the DigitalBoard. The incoming signal is clamped. The signal then passes a selectable gain amplifier. The gain iscontrolled by the Digital Board. A potentiometer on the output of the amplifier allows for calibration adjustment.The signal goes from here to the signal multiplexer and the sync multiplexer.

AUXILIARY INPUT B - This is a single range input that allows a 2nd signal to be sent from a module tothe scope. With 2 inputs, an AC and a DC signal could be sent from the Amp Probe, Vacuum Probe, orother Modules. Aux B could also be used as an external sync if needed.

VOLTMETER INPUT (WHITE CLIP LEAD)This input is used for DC volts readings, simple voltage waveforms, and alternator waveform tests. The alternatorcircuitry is a bandpass filter that passes ripple but blocks DC and high frequencies. The Voltmeter signal isshared with the Aux B input.

INDUCTIVE PICKUP (#1 CYLINDER PICKUP)The signal from the Inductive Pickup is first conditioned by the Inductive Pickup Hybrid. The output from thatpasses through a monostable multivibrator to prevent multiple trigger pulses from this source. This is particularlyuseful for multi-spark ignitions or noisy ignition systems. The signal passes from there to the Input Digital board.



PRIMARY/FUEL INJECTION (YELLOW CLIP LEAD)The signal passes a filter and then branches to the waveform, dwell, and the sync conditioning circuits.

WAVEFORM - The signal is attenuated and clamped. The signal passes through a selectable gainamplifier with one gain for primary and another gain for fuel injection. The waveform then goes to thesignal mux and the sync mux.

DWELL - The waveform triggers a transistor circuit, driving it into saturation when the input value isabove 3.0 volts at the input terminal. The output signal from the transistor is applied to an invertor. Thedwell signal goes through the backplane board and then to the Digital Board for analog to digitalconversion.

SYNC CONDITIONING - The waveform is attenuated, clamped positive, filtered slightly and then sent tothe sync multiplexer.

SECONDARY AND EXTERNAL SYNCThe Secondary/External Sync lead is part of the Main Leadset and is labeled SECONDARY. This input allows for theuse of the standard Secondary Capacitive Lead or optional attachments (DI Pickup Lead, Toyota®/HEI® andHonda®). A pickup identification system is present for the auxiliary inputs. This system has three lines, all of which areprotected by filters and buffers. The pins are grounded or pulled high to form a code identifying the device that isconnected and configuring the signal processors accordingly.

TOYOTA, HEI and STANDARD - The input waveform for Toyota and HEI is connected to the MAINSECterminal. Standard capacitive pickup and External Sync come in on the High Sec input. A unity gain non-inverting amplifier isolates the input. The output of the amplifier goes to the secondary waveformcalibration potentiometers attenuaters and to the sync conditioning circuit. The center tap of thepotentiometers connects to the signal mux. The sync conditioning circuit isolates the previous stage,rectifies, and filters the waveform. The signal is then applied to the Sync mux.

DISTRIBUTORLESS IGNITION - The two DI inputs (power and wasted), are applied to the InputSelection multiplexer (ISM) and the Polarity/Sync circuit (PSC). In the PSC, the True and Wasted signalsare applied to a differential amplifier whose output can be positive or negative, but will have the polarity ofthe True signal. This signal is applied to an Absolute Value circuit (AVC), to provide a sync signal and toa rectifier circuit to provide a 0 or 5 volt polarity signal. The polarity signal (DIPOL) signal goes to an 8 bitTTL latch and then to the Digital Board. This will allow characterization (cylinder identification), based onany cylinder compared to its previous firings, and also how it compares to its companion cylinder on anyfiring.

The selected signal (now the True signal), is AC coupled to a calibration pot that is connected to thesignal mux.The calibration pot is used to set DI gain The signal is then sent to the A/D converter on theDigital Board.



SYNC CIRCUITRYThe Digital Board selects one of the Sync Mux inputs as needed or forced by the operator. The Sync Mux issupplied by the secondary or primary leads or the Lab Scope’s lead for internal triggering. This sync signal isused with other signals to derive various data, such as: RPM, Dwell, scope sync, etc.

SIGNAL CIRCUITThe Digital Board (under directions from the operator) selects one of the Signal Mux inputs. This is the selectionof the particular signal to be analyzed, displayed or otherwise used. All signals, except those from the #1 Pickupand Primary, are adjustable, as described in Checkout and Calibration starting on page 3-4.

MISCELLANEOUSI/O LATCHES (Digital Board): Three of the latches provides a total of 24 control signals from theDigital Board to control the MUX and relays on the analog board. The fourth latch is used to latch theprobe and pickup ID codes.

VOLTAGE REFERENCES: Provides a precision voltage of (1.875 VDC), used by the A/D converterson the Digital Board.

CYLINDER SHORTING

Cylinder Shorting is controlled by the Digital Board (as directed by inputs from the operator). Cylinder shortingsync is established through the inputs of the Inductive Pickup (#1) and either the Secondary or Primary signals.

The coil primary negative is “shorted” to the ground of the automobile through a Zener Diode (mounted on theBackplane Board). This “shorting” through a Zener Diode protects the Vehicle’s Spark Module and allows thevoltage to remain high enough for triggering with the primary circuit during shorting processes.



CHECKOUT & CALIBRATION

TOOLS REQUIRED:• Complete Tool Kit• IS 100A• EESX100A (Secondary cal standard)• MT3000 - 210A (DC Power Leadset)• EETA701A (power supply [optional])• 12 VDC automotive type battery

NOTE: The Voltage Waveform Screen calibration should be performed beforeperforming the Input Test.

NOTE: The Calibration on the EESX100A should be “checked” before performing anycalibration with this tool.

EESX100A CALIBRATION: 1. Make sure that the EESX100A KV calibrator power switch is in the off position.

2. There are two ways you can provide power to the EESX100A calibrator box:

a) Plug in the MT3000-210A DC leadset into the power receptacle on the back of the KV calibrator box.Connect the red lead of the DC leadset to the (+) positive terminal of the 12 VDC battery. Connect theblack lead of the DC leadset to the (-) negative terminal of the 12 VDC battery.

b) Plug the optional EETA701A power supply into the power receptacle on the back of the KV calibratorbox. Connect it’s ac line cord into a 120 vac 60 Hz supply outlet.

3. Connect the red lead of the DVM to the 9 volt jack and the black lead of the DVM to the GND jack on theback of the EESX100A KV calibrator marked Reference Voltage.

4. Turn the power switch on the EESX100A KV calibrator to the ON position. The DVM should read 9.00± 0.05 VDC. If it does not then adjust the pot labeled SEC on the left side of the EESX100A KV calibrator,so that the DVM reads 9.00 VDC, ± 0.05 VDC.

5. Remove the red lead of the DVM from the 9 volt jack and connect it to the 2.75 volt jack on the back of theEESX100A KV calibrator. The DVM should read 2.75 ± 0.05 VDC. If it does not then adjust the pot labeledDI on the left side of the EESX100A KV calibrator, so that the DVM does read 2.75 ± 0.05 VDC. Disconnectthe DVM leads from the EESX100A KV calibrator.

CALIBRATION COMPLETE



VOLTAGE WAVEFORM SCREEN CALIBRATION:1. Turn the MT-3000/A ON.

2. Short the black Ground Lead and the white Voltmeter Lead together.

3. Press <WAVEFORM> followed by (VOLTAGE WAVEFORM).

4. Check the display’s Volts reading (upper right), for a reading of 0.0, ± 0.1 volts. If the display does not showzero, press the key and then press .

5. Connect the black Ground Lead to the Reference Voltage Ground Terminal on the EESX100A

6. Connect the white Voltmeter Lead to the Sec. Reference Voltage (9 Volt), terminal on the EESX100A.

7. Adjust R144 (VOLT), located left side and middle of the Analog Board, so that the scope's voltage reads 9Volts ± 2%.

8. Short the black Ground Lead and the white Voltmeter Lead together.

9. Check the Scope voltage display for a reading of 0.0± 0.1 volts. If it does not, repeat the steps 2 through 9above.

10. The Ground marker should line up with baseline.

11. Connect the white Volt Lead to the 100 Hz Terminal on the EESX100A. This will output an 8 volt peak topeak 100 HZ square wave.

12. Connect the black Ground Lead of the to the Ground Terminal on the EESX100A.

13. Press <WAVEFORM>, then press (VOLTAGE WAVEFORM).

14. Press (AUTO TRIG/ENGINE SYNC) to highlight AUTO TRIG.

15. Waveform should be square with minimum rounding or over-shoot. Refer to Lab Scope PrecisionCalibration, Page 3-6, for adjustment.


INPUT TESTThe “Input Test” tests vehicle input signals through the Lead Set, Input Board, Backplane Board, Analog Boardand Computer Board.

1. Set-up the MT-3000/A as follows:

a) Press <RESET> to get to the setup screen.

b) Press (Modify Engine Data).

c) Press then , press numbers through in sequence and then .

2. Access SELF DIAGNOSTIC SCREEN, press <OPTIONS>, then press .

3. Connect lead set to MT-3000/A.

4. Connect the red Number One Trigger Pickup to the trigger loop on the IS-100A.

5. Connect the red standard Secondary Pickup to the Secondary Coil Wire, and the black Ground Lead to theGround Lug on the IS-100A.

6. Connect the yellow Primary Lead to the negative side of the Coil on the IS-100A.

7. Connect the red Lab Scope Lead to the positive side of Volts Output on the IS-100A.

8. Connect the red DVM lead to the positive side and the black DVM Lead to the negative side of the VoltsOutput on the IS-100A.

INPUT TEST, continued...



9. Connect the White Battery Lead to the positive side of Volts Output on the IS-100A.

10. Connect the Black Ground Lead to the ground side of Volts Output on the IS-100A.

11. Set-up the IS-100A as follows:

a) Volt/Ohm Switch = 13 volts

b) Ripple Switch = OFF

c) RPM Switch = 900

d) Number of Cylinders Switch = 8

e) KV Switch = OFF

f) Spark Line Slope Switch = OFF

g) Ignition Switch = ON

h) Power Switch = ON

12. Press (INPUT TEST).

13. The lower half of the screen (INPUT TEST) displays the input values for each lead, in the “RESULTS”column, as they are measured and stored in order:

a) Trigger Pickup, (Inductive Pickup) - Should read 900 RPM± 20 RPM.

b) Primary Pickup, (Yellow Lead) - Should read 900 RPM± 20 RPM.

c) Secondary Pickup - Should read 900 RPM± 20 RPM and ± 10% of the KV output of coil.

d) Volts Pickup, (White Lead) - Should read 13 volts ± 2% of reading.

e) AUX Lead, (red Lab Scope Lead) - Should read 13 volts ± 2% of reading.

f) Ground, (black Ground Lead) - Should have no reading in the results column.

NOTE: These are not continuous readings. The readings are a “Snap-shot”, takenone at a time, in order.

TEST COMPLETE

LAB SCOPE SCREEN CALIBRATION1. Basic Calibration:

a) Connect red Lab Scope Lead and black Ground Lead together.

b) Press <WAVEFORM> then (LAB SCOPE), to enter Lab Scope mode.

c) Press (MENU), to access Scope Setup. Use arrow keys to highlight “DEFAULT SETUP” mode, and thenpress <SELECT>.

d) Press (VOLTS RANGE/TIME BASE), and use or to adjust Volts/Divisions for 500 mv/div.



LAB SCOPE SCREEN CALIBRATION Continued...e) Connect black lead of DVM to TP4 (upper left), of Analog Board. Connect red lead of DVM to TP3

(upper left).

f) Adjust R73 (OFFSET), located upper left corner of the Analog Board for reading of 0.0 Millivolts, ± 5Millivolts DC, on multimeter.

g) Press (WAVEFORM POSITION), and position the baseline of the trace on the center grid line usingthe or .

h) Press followed by .

i) Press (VOLTS RANGE/TIME BASE), and use or , to adjust Volts/Divisions for 5 volts/div. range.

j) Check for a reading of 0.0 volts, ± 0.1 volts, on the scopes volts display, and that the ground marker islined up with the traceline.

k) Connect the red DVM Lead to the positive side and the black DVM Lead to the negative side of the VoltsOutput on the IS-100A.

l) Connect the Black Ground Lead to the Negative Volts Terminal on the IS-100A, and the red Lab Scope Leadto the Positive Volts Terminal on the IS-100A.

m) Turn on the IS-100A. Set the Volt/Ohm Switch to 13 volts. Adjust R71 (LAB), to match the reading onthe DVM ± 2% of the DVM Reading. Check that the trace on the scope has moved the appropriatenumber of divisions.

n) Reverse red Lab Scope Lead and black Ground Lead at Volts Output of IS-100A.

o) Check for a -13 volt reading. If -13 volts is not displayed, repeat steps j through i.

p) Turn off the IS-100A. 2. Precision Calibration:

a) Connect red Lab Scope Lead to the 100 HZ terminal on the EESX100A KV calibrator. This will output an8 volt peak to peak 100 HZ square wave.

b) Connect the black lead of the tester to the Ground Terminal of the EESX100A KV calibrator.

c) Press <WAVEFORM>, then press (LAB SCOPE WAVEFORM), to enter Lab Scope mode.

d) Press (MENU SELECT), and use the or , or to highlight “DEFAULT SETUP”, then press<SELECT>. Use the or , or to highlight “TRIGGER SOURCE”, then press <SELECT> until“AUX” is displayed.

e) Press (VOLTS RANGE/TIME BASE), and use the or to adjust Volts/divisions for 5 volts/div.range (displayed on the upper right side of the screen). Use the or to adjust time scale for 2 Milli-seconds per division (displayed on the upper left corner of the screen).

f) Turn on EESX100A KV calibrator.

g) Press (TRIGGER LEVEL) and use or , to set trigger level until square wave is at the center ofthe screen.

h) Adjust C94 (COMP) located on the middle left side of the Analog Board, for the “squarest” square wavepossible. The source wave is slightly rounded on its leading edge.

i) Check the square wave on the 5 volt/div and 10 volt/div scale. If necessary, C94 (COMP) can be slightlyreadjusted to give the best balance between the 2, 5, and 10 volt ranges.




SECONDARY SCREEN CALIBRATION

DI Calibration:

1. Connect the secondary connector of the main leadset from the MT-3000 to the CPC connector on the front ofthe EESX100A calibrator box.

2. Turn the selection knob on the EESX100A KV calibrator to the DI position.

3. Press <OPTIONS> then for scope setup. Press until OFF is highlighted to turn the error messages off.Press twice to return to the main menu.

4. Press Modify Engine Data, Press for single cylinder then for four cycle and again for firing order.Press to accept the modifications.

5. The tester should now be setup for 1 cylinder and 4 cycle operation.

6. Turn the EESX100A Calibrator box ON.

7. Press <SECONDARY> then to go to the secondary waveform screen. Press to highlighted “SINGLE”for single waveform mode and then so that TRUE is highlighted.

8. Adjust the DI pot, R116 on the Analog Board, until the display reads 10 KV.

HEI Calibration:

9. Turn the selection knob on the EESX100A calibrator box to the HEI position.

10. Adjust the HEI pot, R29 on the analog board, so that KV display reads XX KV where XX = the value shownon the 8-4962 label of the HEI secondary pickup. (see Fig. A below)

9.00 XX

(8-4962 label)

Fig. A

NOTE: If this label is not present on the HEI secondary pickup then adjust the HEI potso that the display reads 23 KV.

STANDARD Calibration:

11. Turn the selection knob on the EESX100A KV calibrator to the STD position.

12. Adjust the STD pot, R31 on the analog board, so that the KV display reads XX KV where XX = the valueshown on the 8-4962 label under the heat protective jacket of the wire on the STANDARD secondary pickup.(see Fig. A above).

NOTE: If this label is not present on the STANDARD secondary pickup then adjust theSTD pot so that KV display reads 18 KV.



TOYOTA CALIBRATION:

13. Turn the selection knob on the EESX100A KV calibrator to the TOY position.

14. Adjust the TOY pot, R30 on the analog board so that the KV display reads 20 KV.




TROUBLESHOOTING


I. No reading on Duty Cycle BarGraph

NOTE: The Duty Cycle BareGraph is simply the Dwellexpressed in percentage

• Check Engine Setup (number of cylinders and cycles).

• Check Ground Breaker (3 amp breaker at rear of tester).

• Perform Input Test on Page 3-5.

• Check Function:

Voltage is a static reading.

Duty Cycle requires a pulsed signal (running engine).

• Check Battery Positive (White booted lead), for connection.

• Check Battery Negative (Black booted lead), for connection.

• Refer to Ignition Processing Drawing for pin-point troubleshooting.

• Replace Input Protection Board.


II. No readings on Dwell BarGraph or readings are “off-scale”



• Perform Input Test on Page 3-5.

• Check Coil Negative (Yellow booted lead), for connection.

• Check Battery Negative (Black booted lead), for connection.

• Check Inductive Pick-up (#1), for closure and input (input can betested by the “Input Test” above, first reading - Inductive Pickup).

If Inductive Pickup does not show an RPM reading in the InputTest, replace Inductive Pickup.







III. No Primary Waveform • Check Engine Setup (number of cylinders and cycles).


• Perform Input Test on Page 3-5, look for Inductive Pickup (red #1pickup assembly), RPM reading.

If no reading is displayed for the Inductive Pickup in the “InputTest”, replace the Inductive (#1) pickup.

• Check “Input-Test” (above), look for Primary (yellow booted lead),RPM reading.

If no reading is displayed for the Primary lead of the “Input Test”,replace or repair the Main Leadset’s Primary connection.




IV. No Secondary waveform orwaveform is erratic



• Perform Input Test on Page 3-5, look for Secondary Pickup (redpickup assembly), RPM reading.

If no reading is displayed for the Secondary Pickup in the “InputTest”, replace the Secondary Pickup.









V. Secondary readings areinaccurate

• Perform “Calibration Procedure” (see page 3-7).



• Replace Digital Board.

VI. Tester will not perform a PowerBalance Test (no cylindershorting)





• Perform Input Test on Page 3-5, look for Primary (yellow bootedlead), RPM reading.

If no reading is displayed for the Primary lead of the “Input Test”,replace or repair the Main Leadset’s Primary connection.



• Replace Backplane Board.

BLK 3

RED 4

SHD 5

SHD

ENG GND

RED 2BLK 3

WHT 4

LAB SCOPE RED 15

SHD 5

STANDARD

PICKUPSHD

RED 4

WHT 9

BLK 3WHT 7

H.E.I.

PICKUP

BLK

RED 1

SIGNALGND

SIGNAL

SECONDARY

SECONDARY

SIGNALTOYOTA/NOVA

SECONDARYPICKUP

LEADSIGNAL

DITERMINAL

BLOCK(OPTIONAL)

58

4

3

5

BLK

YEL

ALT&BAT

GND

PICKUP ID1

PICKUP ID2

PICKUP ID3

ALTSEC

MAINSEC12

8

7

6

5

4 BLK

10

5 RED

9 SHD4

1

2

3

RED

CLR

BLK

3 BLK

SECONDARY

SHD

5 RED

AUXA

PROBE ID3

21

19

-12V

+12V

AUXB

GND

PROBE ID1

PROBE ID217

16

15

14

13

1 ORG

7 BLK

PRIMARY PROBEGND PROBE

PRI24

ENG GND 23

BLK

ALT & BAT

22

2 SHD SHD20

15 AUXA

10 WHT

9 GRN

8 BLU

13 BRN

AUXILIARY

18

5 SHD

1 RED

4 BRN

2 ORG

9 WHT

7 GRN

8 BLU

SHD

HIGHSEC

9

11

INDUCTIVE (#1)PICKUP

SIGNAL

P4 J4

SECONDARYSTANDARDDIHEITOYOTAHONDAAUXILIARYLAB SCOPE

PKID3 PKID2 PKID1

PRID3 PRID2 PRID1

1 1 11 1 01 0 10 1 10 1 0

1 1 1

PROBE ID CODESNOTE 1

P1 - J1

INPUTPROTECTION

BOARD

BACKPLANE BOARD

ANALOG BOARD DIGITALBOARD

SEENOTE 1

SEENOTE 1

J12

PRIMARYSIGNAL

J2 J1

AUXINA SELECTABLEVOLTAGEDIVIDER

SELECTABLEGAIN

AMPLIFIER

COUPLINGSELECTOR

(AC/DC)AUXINB

R73 R82OFFSETLAB

SIGNALMUX

SYNCMUX

PRIMARY

TOYOTA

HEI

R30

R29

SYNCCONDITIONING

HEI

TOY

DI+DI-

R116

J7

VOLTR144

STD R31STD

#1 PICKUP MONOSTABLE

DI

A/DCONVERTER

3

08/96M.B. Clark

3-13

PRIMARY/DWELLFUEL INJECTOR

PROCESSOR

ISM PSC AVC LATCH

DIPOLE

TRUE SIGNAL


PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


DWG REV:

CYLINDERSHORTING

CIRCUIT

MT-3000/AR. Z. Wilson

IGNITION PROCESSINGAND

CYLINDER SHORTING

3-1



GENERAL

The Front Panel Controls are the operator’s interface with the tester. All Operator inputs, other than test signalinputs, are made through the Front Panel Keyboard. The Brightness Control and the On/Off Switch are notconsidered part of the Front Panel Keyboard.

The keyboard “system”, or switch sense matrix, is composed of two sub-assemblies: Main Keyboard and SoftKeys Keyboard, (an infra-red Remote Control is optional). The Main Keyboard is a sealed, self contained unitand the Soft Keys Keyboard is constructed as an integral part of the Front Panel Bezel.

The Digital Board Scans the matrix for key presses. The Main Keyboard houses the Receiver/Encoder for theinfra red Remote Control.

The two keyboards cover three areas of operator inputs: Menu, Functions and Main. The Menu Keys, greenkeys, instruct the tester to display a general area test screen, e.g., Primary, Secondary, etc. The Main Keys, grayand red, supply supplemental inputs, e.g., numeric, cursor control, etc. The Soft Keys, just under the CRT on theBezel, are labeled F1 through F6; the function of these keys changes with each screen displayed. The currentfunction of each key is displayed on the CRT directly above the keys.

KEYBOARD THEORY OF OPERATION

MAIN KEYBOARDThe Main Keyboard is an assembly of copper traces that form the contacts for single-pole-single-throw,momentary switches. One side of each switch is connected to an Active line, Ax. The other side of a series ofswitches are connected to Sense lines, Sx, at the Backplane Board. The CPU Board applies a logic low to theActive line and reads each Sense line. When a logic low is sensed on a Sense line the corresponding key hasbeen pressed. The ribbon cable soldered to the Main Keyboard is connected to J2 of the Backplane Board.

SOFT KEYS KEYBOARDThe Soft Keys Keyboard is made as part of the Front Panel Bezel. One side of each switch is connected to theActive line, A6. The other side of each switch is connected to Sense lines, S1 through S6. The CPU Boardapplies a logic low to the Active line and reads each Sense line. When a logic low is sensed on a Sense line thecorresponding key has been pressed.



REMOTE CONTROL THEORY OF OPERATION (OPTIONAL)

The Infrared Remote Control can duplicate all the key functions of the scope at a distance of up to 25 feet. Theone exception is the remote does not have a reset key. The remote control has two separate parts of circuitry, atransmitter and a receiver. The transmitter is packaged separately and powered by 2 AA batteries. The receiveris located on the PC board of the Main Keyboard in the tester.

INFRARED TRANSMITTERThe Infrared Transmitter sends key information to the MT-3000/A via infrared light having a peak wavelength of940nm. The key information is sent on a 38kHz carrier. This carrier is removed from the signal when received.The key information is a 32 bit serial data stream. The bits are sent in a PWM (pulse width modulated) format. Aleader code introduces the data stream.

The custom code is a unique code that separates the MT-3000/A remote control from those of othermanufacturers. The data code contains the code for a particular key.

When a key remains pressed, only the leader code information is repeated and sent. When two or more keysare pressed, transmission will stop entirely. These are both functions of the transmitter chip that attempts toprevent excessive drain on the battery.

INFRARED RECEIVERThe receiver is mounted on a small PC board which in turn is mounted to the Main Keyboard. Its purpose is:

• To receive the infrared signal.• To amplify it.• To remove the carrier from the incoming signal• To send out the 32 bits of information at 0-5 volt level.

Only three electrical connections are needed: 5 volts, ground and a data line (RDATA), that ultimately goes to theCPU Board. The data on RDATA (the leader code and 32 bits of information), is inverted when compared tohow it is sent.

PERFORMANCEThe remote control has been designed to work at a distance of 25 feet with receiving and transmitting angles of±45° to the front of the unit.



CHECKOUT PROCEDURE

KEYBOARD TESTThe Keyboard Test will display the name of the keys as they are pressed. The name will appear next to theKEYBOARD TEST line in the lower left of the display.

1. Access SELF DIAGNOSTIC SCREEN by pressing <Options> on the menu options keyboard.

2. Press: , SELF DIAGNOSTICS, then , (KEYBOARD TEST).

3. Press each key and observe the “KEYBOARD TEST” line for the proper response.

NOTE: will turn the test off and <RESET> will reset the tester.

TEST COMPLETE

REMOTE TEST:

The Remote Control is optional. The REMOTE TEST operates similar to the KEYBOARD TEST above.

TEST COMPLETE

TROUBLESHOOTING


I. NONE of the “MAIN” keysrespond.

• Check connection at J2 on Backplane Board.

• Check for a “stuck key”, (a key that is held in the “pressed”position).

• Replace Main Keyboard Assembly.

II. NONE of the “SOFT KEYS”respond.

• Check connection at J3 on the Backplane Board.

• Check for a “stuck key”, (a key that is held in the “pressed”position).

• Replace Front Panel Bezel.




III. None of the Front Panel Keysrespond.

• Disconnect keyboards from Backplane Board, J2 and J3, thenreconnect each one, one at a time, to find the keyboard that isstopping the function.

Replace the keyboard that stops keyboard response.


• Replace Backplane Board.

IV. Remote Control is erratic, ordoes not function.

• Replace batteries in Remote Control.

• Check for "stuck keys", (keys that are held in the "pressed"position.

• Replace Remote Control

• Replace Main Keyboard.


MT-3000/AR. Z. Wilson

KEYBOARD

4-1

NOTE 1

A = ACTIVE LINE S = SENSE LINE

"Active" pulls the line low, "Sense"

reads the state : LOW or HIGH

SOFT KEYSKEYBOARD

6

5

4

3

2

1

7

S1

S2

S3

S4

S5

S6

A6

PRIMARY

SECONDARY

WAVEFORM

CYLINDER

OPTIONS

MEMORY

F1

F2

F3

F4

F5

F6

J3 P3

SETPOINT

FREEZE

SELECT

ENTER<1>

<2>

<9><0>

<8>

<7>

<6>

<5>

<4>

<3>

RESET

BACKPLANEBOARD

I-RRECIEVER

12S1

2A2

11S2

S310

S49

S58

S67

A3

3

A44

A55

13

6

A11

14

15

16

MAINKEYBOARD

RDATA

+5 VDC

4 - 5

J2

PRINT

HELP

BACKPLANEBOARD

M.B. Clark08/96


CHAPTER 5 VIDEO

GENERAL

The video display is generated using two major components: The Video Monitor Assembly and the Video DisplayBoard.

The Video Monitor Assembly consist of two sub-assemblies: The CRT Assembly and the Video Driver Board.

The Video Monitor Assembly is considered a single part and is generally not serviceable in the field. Normalmonitor adjustments are available on the Video Driver Board, VERT SIZE, CONTRAST, etc., however, theassembly is intended to be factory calibrated. Any field adjustments should be limited to minor adjustments ofBRIGHTNESS, FOCUS and CONTRAST, as labeled on the Video Driver Board.

The MT-3000A uses a different Video Display Board than the MT-3000. This new board allows for the followingdisplay enhancements:

• Addition of a Power Balance Waveform Screen.

• Added the words “RICH” and “LEAN” to the Duty Cycle Bar Graph Screen.

• Deleted the phrase “SNAP-ON TOOLS CORPORATION” from the menu screens.

• Added MT-3100 Gas Analyzer Screen.

• Changed references of the “SNAP-ON SCANNER” to “MT2500”.

THEORY OF OPERATION

The Video Display Board is responsible for creation and control of all video outputs to the Video MonitorAssembly. The video outputs are in the form of horizontal and vertical sync signals and TTL composite video.The primary processor on the Video Display Board has a 16 bit 8096 controller. This controller is capable ofselecting different “Screen ROMs”, as addressed and updated through the address and data busses. The “rawdata” (vehicle data), to be displayed is derived from the bi-directional communication with the Input Digital Boardor the Communications Board.

The complete display is composed of the “raw data” from the Input Digital Board (or Communications Board),and memory in 6 ROM chips on the Video Display Board:

U3 Program Memory

U6 thru U9 Screen ROMs

U12 Character ROM

The Cursor is generated on the Video Display Board using vertical and horizontal sync signals. The output of thevertical section is the column on/off signals and the output of the horizontal section is the row on/off signals.

CHAPTER 5 VIDEO


INTERCONNECTIONSComposite Video:

The TTL Composite Video Signal from the Video Display Board is fed to the Backplane Boardvia pin 1 of J1401 on the Backplane Board.

The TTL Composite Video Signal is transmitted to the Video Driver Board of the Video MonitorAssembly via pins 15 and 16 of J8 on the Backplane Board through the ribbon cable.

Vertical Sync:The Vertical Sync Signal from the Video Display Board is fed to the Backplane Board via pin 18of J1402 on the Backplane Board.

The Vertical Sync Signal is transmitted to the Video Driver Board of the Video Monitor Assemblyvia pin 17 of J8 on the Backplane Board through the ribbon cable.

Horizontal Sync:The Horizontal Sync Signal from the Video Display Board is fed to the Backplane Board via pin 3of J1402 on the Backplane Board.

The Horizontal Sync Signal is transmitted to the Video Driver Board of the Video MonitorAssembly via pin 11 and 12 of J8 on the Backplane Board through the ribbon cable.

Brightness Pot:The Front Panel Brightness Pot is connected to the Backplane Board through J11 on theBackplane Board. This connection is routed to J8, pins 7 & 8.

CHECKOUT PROCEDURE

MONITOR ADJUSTMENTSThe Monitor Assembly is factory calibrated and should require no field adjustments. If minor adjustments areneeded, (brightness, contrast), the Pots are labeled on the Monitor Driver Board

CHAPTER 5 VIDEO


TROUBLESHOOTING


I. Blank screen • Check front panel Brightness Control.

• Check Power Switch and proper selection of AC/DC SelectSwitch.

Check Power Troubleshooting, Chapter 1, Complaint I.


Remove Communications Board, Analog Board and DigitalBoard. Disconnect the following ribbon cables from theBackplane Board:

Soft Keys cable (J3) Main Keyboard cable (J2) Main Leadset cable (J1) Front Panel Brightens Pot cable (J11)

Turn Power Switch to ON. If a readable message appears, turnpower OFF and replace each connector and circuit board one at atime until the Blank Screen symptom reoccurs; this will pinpointthe component that is causing the failure.

If a readable message does not appear, continue to the next step.

• Refer to Video drawing, check for a TTL Composite Video signalat pins 15 and 16, J101.

If video signal is present, replace Video Monitor Assembly.

If video signal is not present, replace Video Board.

CHAPTER 5 VIDEO



II. A single horizontal line isdisplayed at mid-screen


Remove Communications Board, Analog Board and DigitalBoard. Disconnect the following ribbon cables from theBackplane Board:

Soft Keys cable (J3) Main Keyboard cable (J2) Main Leadset cable (J1) Front Panel Brightens Pot cable (J11)

Turn Power Switch to ON. If a readable message appears, turnpower OFF and replace each connector and circuit board one at atime until the Blank Screen symptom reoccurs; this will pinpointthe component that is causing the failure.

If a readable message does not appear, continue to the next step.

Refer to Video drawing, check for a TTL Composite Video signalat pins 15 and 16, J101.

If video signal is present, replace Video Monitor Assembly.

If video signal is not present, replace Video Board.

• Replace Video Monitor Assembly.

• Replace Video Board.

MONT3

MONT2

GND

EXTBRT2

NC

GND

VIDEO

+12 VDC

BACKPLANEBOARD

WAVEFORMGENERATOR

16 BITCONTROLLER

INTEL 8096

PROGRAMMEMORY

SCREENROMs

CHARACTERROM

U12U6 U7 U8 U9U3

DATA

BUS

BUS

WAVEFORMMEMORY

(RAM)

VIDEO BOARD

12

34

56

78

910

11

1213

1415

1617

1819

20

P679


TYPICAL TTL COMPOSITE VIDEO(TITLE SCREEN)

MT-3000AR. Z. WILSON

VIDEO5-1

BrightnessPot

1 2 3

5-5

VIDEODRIVERBOARD

-HORIZSYNC

VERTSYNC

J11

P11

M.B. Clark

J1401

J1402

FRONT PANEL

OSCILLOSCOPE SET TO:20 SEC/DIV2 VOLTS/DIV

J8

BI-DIRECTIONAL BUS

08/96

CHAPTER 5 VIDEO




GENERAL

The optional Power Balance Probe is designed to attach to the MT-3000/A through the AUXILIARY connector ofthe Main Leadset. A lead identification system informs the tester that the Power Balance Probe is connected andhow the signal processing circuitry should be configured.

The probe consists of a wheel with slots molded into the middle portion. On one side of the wheel there ismounted an infrared LED, a photo-transistor is mounted on the other side.

THEORY OF OPERATION

The Power Balance Waveform gets its shape by monitoring the increase and decrease in engine speed as the pistonsact on the crankshaft during the power stroke. This change in speed is plotted over a period of time. The rise and fall inRPM results in a sine wave. The rising portions of the waveform indicate an increase in engine speed. The falling slopeof the waveform indicates a decrease in engine speed since the rotating engine mass is coasting between powerstrokes. The waveform displays the lowest dip at the instant the speed is the lowest.

The waveform that shows the power of one cylinder consists of one cycle, beginning with its rising slope from zero, andending with its falling slope at zero. The total waveform in a balanced engine would have a sine wave shape. Thefrequency of the waveform is determined by the number of cylinders of the engine being tested. The more cylinders theengine has the greater the frequency of the waveform. The amplitude of the waveform for each cylinder should beroughly equal to each other.

A friction wheel is held against one of the rotating members of an engine, such as a pulley or belt. The friction wheelrotates at a speed proportional to the speed of the engine. The combustion of a cylinder power stroke applies torque tothe rotating member that speeds up until the combustion process has stopped. The rotating member then coasts untilthe next piston is fired, which again applies torque to the member.

An infrared LED is mounted on one side of the wheel. A photo-transistor is mounted on the other side of the wheel.These are mounted in line with small equally spaced holes that are drilled into the wheel. As the encoder wheel turns,each hole allows passage of light from the LED to reach the photo-transistor, creating a logic signal pulse. The output ofthe encoder is a train of pulses with a frequency relative to the engine speed. This proportion is dependent on the ratioof the pulley diameter to that of the friction wheel. The distance between each pulse becomes smaller as the speedincreases, and larger as the speed decreases. This repetitive frequency pattern is converted to a voltage by a frequencyto voltage converter.

The rise and fall of the engine RPM will create a continuous sine wave, assuming each cylinder is operating normally. Adrop in the power output of any one or more cylinders due to a problem creates a flaw in this waveform that is easilydistinguished from that of the other cylinders. By relating this waveform with the firing signal of the number one cylinder,and knowing the firing order of the engine, we can determine which cylinder is not providing power.



TROUBLESHOOTING

NOTE: The Auxiliary devices (Vacuum Probe, Power Balance Probe and AmpsProbes), are not considered as “field serviceable”. If the problem is in theprobe, that device should be replaced.

NOTE: The Power Balance Probe is a device that is particularly prone to operatorerror; always refer to the Operator’s Manual for proper usage instructions.


I. No Power Balance waveform • Refer to the Power Balance Probe drawing, check for -12 VDC atpin 13 and +12 VDC at pin 5 of the Auxiliary Connector on theMain Leadset. With ground referenced to board ground.

If voltage is present, refer to Power Balance Probe drawing andperform a continuity check on Main Leadset, from AuxiliaryConnector to Main Leadset Connector or:

Replace Power Balance Probe.

Replace Main Leadset.

If voltage is not present, continue to next step

• Check for -12 VDC at pin 13 and +12 VDC at pin 14 of the MainLeadset Connector at the rear of the tester. With groundreferenced to board ground.

If voltage is not present, troubleshoot per Chapter 1, PowerDistribution.

If voltage is present at Rear Panel Connector, replace MainLeadset.

• Refer to Operator’s Manual, Power Balance Waveform (page 18-1), for proper operating instructions.

• Check Power Balance Probe Connector for pins that may bereceded (pushed back in), to the body of the connector

• Replace Power Balance Probe.

• Replace Main Leadset.




TROUBLESHOOTING, continued...


II. Erratic Power Balancewaveform

NOTE: Most of the problems associated withunstable waveforms are operator related.Always refer to the Operator’s Manual forclear instructions on Probe operation.

NOTE: the Power Balance Probe requires a steadyhand.

NOTE: The higher the number of cylinders, the lowerthe engine RPM should be.

• a four cylinder engine may run a test at normal idle.

• an eight cylinder engine may require two people, one to operatethe Power Balance Probe and the other to place the vehicle ingear and hold the breaks (automatic transmissions only), see notebelow.

NOTE: While this procedure may be recommended inthe Operator’s Manual, it is highlyrecommended that all safety precautions betaken, as outlined in the operator’s manual.

• Refer to Power Balance Probe drawing for pinpointtroubleshooting.

• Replace Power Balance Probe.



AUXILIARY PRID3 PRID2 PRID10 1 0

PROBE ID CODENOTE 1

POWER BALANCEPROBE

PWRB PROBEFREEZE 0 0 0

P7 J7

5 RED

AUXAPROBE ID3

2119

-12V+12VAUXBGNDPROBE ID1PROBE ID2

1716151413

1 ORG7 BLK

2 SHD SHD2015 AUXA10 WHT9 GRN8 BLU

13 BRN

P6 J6

AUXILIARY CONNECTOR

BACK PANEL

18

POWER BALANCEPROBE

CONNECTOR

INPUTPROTECTION

BOARD

FREEZE BUTTON

POWERBALANCE

PROBE

SeeNote 1

ANALOGBOARD

DIGITALBOARD

A/DCONVERTERFREQUENCY

TO VOLTAGECONVERTER

BACKPLANEBOARD

-12 VDC+12 VDCNCGNDGNDGND/NCGNDAC OUTPUTSHD

J2


Soldered connectors

6 - 5

J1


PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


DWG REV:

J. D. Sparks

6-1

MT-3000/AM.B. Clark

08/96



GENERAL

The optional Vacuum Probe is designed to attach to the MT-3000/A through the AUXILIARY connector of theMain Leadset. A three pin lead identification system informs the tester that the Vacuum Probe is connected andhow the signal processing circuitry should be configured.

The Vacuum Probe is designed to read manifold vacuum and display the vacuum ripple. On a properly running engine,the ripple waveform will appear basically as a sine wave from cylinder to cylinder. In the presence of a mechanicaldefect, this rough sine wave will be distorted.

Refer to Operators Manual, Section 19 Vacuum Waveform, for more information.

THEORY OF OPERATION

The vacuum probe is sealed and non-serviceable. The circuitry consists of a pressure transducer supplying a signal to aseries of op-amps that provide AC and DC outputs to the tester. AC coupling will normally be selected since the ripplerepresents less than one percent of the normal engine vacuum.

During the intake stroke each piston creates a negative pressure (vacuum), in the intake manifold. This is representedby the lower part of the waveform, or valley. Each valley represents the amount of vacuum created by that cylinder.The farther the valley descends, the higher the vacuum created by that cylinder. This allows for a cylinder to cylindercomparison of vacuum. After the intake stroke is completed, the vacuum level will return towards atmospheric pressure.This is represented by the upper portion of the waveform, or peak. It is normal for numerous small fluctuations (hash), toappear throughout the complete waveform. These are the result of pressure pulses echoing inside the intake manifoldas a result of normal valve action. This hash serves no diagnostic purpose. Most of it has been filtered out by thesensing pickup, but cannot be totally removed.



TROUBLESHOOTING


NOTE: The Vacuum Probe is dependent upon precise readings; the length of theconnecting tube from the Probe to the engine should be less than 6 inches.Refer to the Operator’s Manual for proper usage instructions.


I. No Vacuum Waveform • Refer to the Vacuum Probe drawing, check for -12 VDC at pin 13and +12 VDC at pin 5 of the Auxiliary Connector on the MainLeadset:

If voltage is present, refer to Vacuum Probe drawing and performa continuity check on Main Leadset, from Auxiliary Connector toMain Leadset Connector or:

Replace Vacuum Probe.


If voltage is not present, continue to next step.

• Check for -12 VDC at pin 13 and +12 VDC at pin 14, J6 of theMain Leadset Connector at the rear of the tester.

If voltage is not present, troubleshoot as per Chapter 1, PowerDistribution.


• Refer to Operator’s Manual, Vacuum Waveform (page 19-1), forproper operating instructions.

• Replace Vacuum Probe.






II. Erratic Vacuum waveform NOTE: Most of the problems associated with unstablewaveforms are operator related. Always refer to the Operator’sManual for clear instructions on Probe operation.

• Remember: the Vacuum Probe requires a steady engine RPM

• Remember: lower engine RPM should be used to avoid dynamiceffects that may mask problems

• Refer to Vacuum Probe drawing for pinpoint troubleshooting

• Replace Vacuum Probe

• Replace Main Leadset

• Replace Analog Board


PROBE ID CODENOTE 1

VACUUM PROBE

P7 J7

5 RED

AUXAPROBE ID3

2119

-12V+12VAUXBGNDPROBE ID1PROBE ID2

1716151413

1 ORG7 BLK

2 SHD SHD2015 AUXA10 WHT9 GRN8 BLU

13 BRN

P6 J6

AUXILIARY CONNECTOR

BACK PANEL

18

INPUTPROTECTION

BOARD

SeeNote 1

ANALOGBOARD

DIGITALBOARD

A/DCONVERTER

BACKPLANEBOARD-12 VDC

+12 VDCDC OUTPUTGNDNCGNDNCAC OUTPUTSHD

VACUUMPROBE

CONNECTOR J1J2


Soldered connectors

7 - 5


PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


DWG REV:

VACUUMPROBE

VACUUM PROBE

MT-3000/AJ. D. Sparks

7-1

M.B. Clark08/96


CHAPTER 8 AMPS (OPTIONAL)

GENERAL

The High Amp Probe is used for the Cranking Amp Bar Graph Screen and the Lab Scope Screen. The LowAmp Probe is used to gather amp readings in the 20 amp (or less) range. These “low amps” readings aredisplayed in the Lab Scope Screen. Both probes consist of an inductive probe and a printed circuit board in asmall metal case. The AUXILIARY connector from the Main Leadset is connected to the 16 pin connector on theAmp Probe interface box.

A three pin lead identification system informs the tester that the Amps Probe is connected and how the signalprocessing circuitry should be configured. The pins are grounded or pulled high to form a code identifying thedevice that is connected.

THEORY OF OPERATION

HIGH AMP PROBEThe High Amp Probe provides an output of 1 volt for every 100 amps sensed by the probe. The circuitry on theprinted circuit board (in the Amplifier Box), provides the needed amplification, offset adjustment, and filtering forthe signal. The output from the High Amp Probe can be used on the Lab Scope Screen and the Cranking AmpBar Graph screen.

There are 4 connections to the Hall Effect chip. The red and black wires are for the positive and negative controlcurrent (25 ma). The white and green wires are the signal outputs from the Hall Effect IC. This signal isconnected to an instrumentation amplifier composed of 3 operational amplifiers. The first 2 operational amplifiersprovide gain and allow an offset adjustment to null out the Hall Effect probe and operational amplifiers. The thirdop amp changes the signal to a single ended signal, and is followed by a low pass filter to remove noise. Theoutput is connected to the Aux A line of the AUXILIARY lead of the main leadset. The AC coupled amplifierconnected to Aux B is not used for anything at this time.

For the High Amp Probe, the ID1 and ID2 lines are pulled high, and the ID3 line is connected to ground. Thissignals the scope that the High Amp Probe is connected to the leadset.

LOW AMP PROBEThe circuitry on the printed circuit board of the Low Amp Probe provide the needed amplification, offsetadjustment, and filtering for the signal. The output from the Low Amp Probe can be used on the Lab ScopeScreen. The Low Amp Probe outputs to the AUXINA input only.

The Amp Probe has 3 voltage regulators, + 8 and - 8 volts for the circuit power. Another is used as a constantcurrent source for the Hall Effect chip in the probe.

There are 4 connections to the Hall Effect chip. The red and black wires are for the positive and negative controlcurrent (25 ma). The white and green wires are the signal outputs from the Hall Effect IC. This signal isconnected to an instrumentation amplifier composed of two operational amplifiers. These operational amplifiersprovide gain and allow an offset adjustment to null out the Hall Effect probe and operational amplifiers. Theoutput is connected to the Aux A line of the AUXILIARY lead of the main leadset.

For the Low Amp Probe the ID2 and ID3 lines are connected to ground, and the ID1 line is pulled high. Thissignals the scope that the Low Amp Probe is connected to the leadset.

CHAPTER 8 AMP PROBE (OPTIONAL)


CALIBRATION PROCEDURE

HIGH AMP PROBE CALIBRATIONREQUIRED EQUIPMENT:

Calibration Screwdriver - 0001-0003DVMIS100A (Ignition Simulator)

1. Set DVM to DC Volts. Connect black lead of DVM to TP4, (upper left), on Analog Board, and red lead ofDVM to either side of C14, (middle of left edge), on the analog board.

2. Connect MT-3000-410 Amp Probe to the Auxiliary Connector of the Main Leadset.

3. Press <CYLINDER TEST MENU> followed by , (CRANKING AMPS BAR GRAPH).

4. With the Amp Probe disconnected from the IS100A, adjust R13 in the amp probe box for a reading ofzero on the DVM.

5. Clamp the Amp Probe around the current loop of the IS-100A so that the arrows on the head of the AmpProbe face up when the handle end is pointed at you.

6. Hold the IS-100A amp switch in the 200 amp position.

7. Adjust R14 in the Amp Probe box for a reading of +2.00 volts on the DVM.

8. Disconnect the amp probe from the current loop of the IS-100A and check the DVM for a reading of 0.00± 0.01 volts.

9. If the DVM does not read 0.00 ± 0.01 volts, repeat steps 4 through 8.

LOW AMP PROBE CALIBRATIONREQUIRED EQUIPMENT:

Calibration Screwdriver - 0001-0003DVMIS100A (Ignition Simulator)EESX100A (Secondary Cal Standard)

1. Connect Low Amps Probe (MT3000A440), to Auxiliary connector of the Main Leadset.

2. Turn MT-3000A Power Switch to ON and press <DIAGNOSTIC WAVEFORM MENU>.

3. Disconnect the Zero Pot from J2 of the Amplifier Box PCB.

4. Press (LAB SCOPE WAVEFORM). While holding the jaws of the Low Amp Probe open, adjust R8(on the Amplifier Box PCB), for a reading of 0.00.(±0.10), on the digital portion of the display, in the upperright corner of the display.

5. Set the DVM to read DC current (10 amp scale). Connect one end of the red banana connector lead(supplied with the EESX100A), to the 10 Amp receptacle of your DVM. Connect one end of the blackbanana connector lead (supplied with the EESX100A) to the COMMON receptacle of your DVM.

6. Connect the free end of the red banana connector lead to the red REF CURRENT jack on the back ofthe EESX100A. Connect the free end of the black banana connector lead to the black REF CURRENTjack on the back of the EESX100A. Turn power ON.

NOTE: Do not let the EESX100A remain attached to the DVM for more than 5 minutes;the source supplying the EESX100A should be able to support 2.5 amps.



LOW AMP PROBE CALIBRATION, continued...

7. The current reading on the DVM should be 2.5 amps, ± 0.5 amps.

8. Clamp the Low Amps Probe around one of the banana connector leads running between the DVM andthe EESX100A and open the Amplifier Box.

9. Adjust R13, on the PCB inside the Low Amp Probe box, until the screen reading, displayed as volts in theupper right corner, matches the reading of the DVM.

10. Connect the Zero adjust Pot to J2 of the Low Amp Probe Amplifier Box.

11. Turn the Zero Adjust Pot Fully clockwise and note the reading. Turn the Zero Adjust Pot fully counterclockwise and note the reading. The lower reading should be within 10% of the larger, if not, adjust R8so that the readings fall within 10%.




TROUBLESHOOTING


NOTE: Always refer to the Operator’s Manual for proper usage instructions.


I. No Cranking Amps Bar Graphreadings or Amp readings areinaccurate

• If readings are inaccurate, follow calibration procedure on page 8-2.

• Check that tester is receiving all signals needed: Input Test, page3-5.

• Refer to the Amp Probe drawing, check for +12 VDC (referencedto ground, pin 7), at pin 5 of the Auxiliary Connector on the MainLeadset:

If voltage is present, refer to Amp Probe drawing and perform acontinuity check on Main Leadset, from Auxiliary Connector toMain Leadset Connector or:

Replace affected Amp Probe.


If voltage is not present, continue to next step.

• Check for +12 VDC at pin 14 of the Main Leadset Connector atthe rear of the tester.

If voltage is not present, troubleshoot as per Chapter 1, PowerDistribution.


• Refer to Operator’s Manual, Cranking Amps Bar Graph (page 22-1), or optional section for Low Amp readings (included with LowAmps Option), for proper operating instructions.

• Replace affected Amp Probe.




________________________________________________________________________________________


PROBE ID CODENOTE 1

High Amp Probe

AUXILIARY CONNECTOR

BACK PANEL

INPUTPROTECTION

BOARD

SeeNote 1

ANALOGBOARD

DIGITALBOARD

A/DCONVERTER

BACKPLANEBOARD

8-5

ZEROPOT

Low Amp Probe 00 1

AUXINA

SELECTABLEVOLTAGEDIVIDER

SELECTABLEGAIN

AMPLIFIER

COUPLINGSELECTOR

(AC/DC)AUXINB

R13 R8

GAIN ZEROSYMMETRY

HIGH AMP PROBE

LOW AMP PROBE

RED

AUXA

PROBE ID3

21

19

-12V

+12V

AUXB

GND

PROBE ID1

PROBE ID217

16

15

14

13

ORG

BLK

SHD SHD20

AUXA

WHT

GRN

BLU

BRN

18

1

13

5

7

8

9

10

15

2


PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


DWG REV:

AMPS

R13ZERO

GAINR14

AMPPROBE

CONNECTIONAT AMPLIFIER BOX

MT-3000/AJ. D. Sparks

8-1

08/96M.B. Clark



GENERAL

It is the responsibility of the Communication Board to control the three external ports, two Serial RS232 ports andone Test Port (parallel). These ports provide a screen print to the various printers upon request, and provide acommunication channel for a Scanner or VT100 for control of the MT-3000 / MT-3000A screen.

A different Communications Board is used in the MT-3000A. This new board allows for the followingenhancements:• Added printer drivers for the complete line of printers.

• Added capacitors to the serial ports to compensate for Balco non-true RS232 levels and noise reduction.

THEORY OF OPERATION

PROCESSORThe 8096 microprocessor controls almost every operation on the Communication Board. The processor is at restwhen the MT-3000A is powered up or when the Reset Button on the keyboard is pressed. On-boardcommunications travel on a bi-directional 8 bit data bus.

PROGRAM MEMORYThe Program Memory for the Communication Board is stored in a 8K x 8 bit ROM. This ROM is labeled “U6” onthe Communications Board.

BUFFER RAMThe Buffer RAM is a 8K x 8 bit RAM and is labeled “U7” on the Communications Board. This ram will hold:information from the external VT100 device or scanner, screen print information in byte form to be sent to theprinter, information sent to and from the Video microprocessor.

COMMUNICATIONS PORTS:TEST PORTThe test port is hardware compatible with the Centronix parallel port standard. This port is an output onlyport on the MT-3000 version of the Communications Board. The parallel data is held on the test portdata lines by a latch. The control lines for the test port both input and output are controlled by the micro.All of the control lines are buffered before being sent out of the MT-3000 / MT-3000A.

RS232 PORTSThere are two separate RS232 serial ports. Both ports have exactly the same hardware. Both portshave a transmit, a receive, a clear-to-send and a ready-to-send line. All eight of these lines are drivenand converted to RS232 voltage levels by the RS232 driver. This IC converts the outputs to RS232levels and the inputs to TTL levels from RS232 levels. These ports may be used at the same time toobtain a screen print from a scanner using the VT100 screen interface cable.

SCREEN PRINT PROCESSThe screen print process is accomplished in two phases. The first phase must capture the information on thescreen. The second must read the screen information stored and output the information to the printer at thedesignated baud rate. The screen information is sent to the Communication Board through the Backplane Boardfrom the Video Board.



CHECKOUT PROCEDURE

The Communications Board works with external devices (printers, Scanner, etc.); the checkout ofcommunications should be referred to the chapter describing the device that is not working correctly.

TROUBLESHOOTING

The Communications Board works with external devices (printers, Scanner, etc.); the troubleshooting ofcommunications should be referred to the chapter describing the device that is not working correctly, however, ifmultiple external devices are found to be non-functional, the Communications Board is a common componentthat may be at fault.


PAGE:


DWG:

TITLE:

CHK BY:DWG BY:

MODEL: DWG. REV.:MT-3000AR. Z. WILSON

COMMUNICATIONS

9-1 9-3

PROGRAMMEMORY

BUFFERRAM

8096PROCESSOR

Soldered connectors

PARALLELPORT LATCH

U7

U4

U6

SCREEN OUTPUT TO VIDEO BOARD

PORT AISOLATI0NCIRCUITRY

PORT BISOLATI0NCIRCUITRY

RS232PORT

DRIVER

SERIAL A

SERIAL B

SCREENRAM

J1

J2

J5

J1601

J1602

J6

J7

JUMPERS

11 1

W1 W2 W3

SERIAL PORT A25 PIN DIN - MALE

SERIAL PORT B25 PIN DIN - MALE

TEST PORT(PARALLEL)25 PIN DIN

FEMALE

REAR PANEL

BACKPLANEBOARD

COMMUNICATIONSBOARD

08/96M.B. Clark


CHAPTER 10PRINTERS

GENERAL

There are two types of printers (Parallel, and Serial), that can be used with an MT-3000A. In addition, there aretwo different Dot Matrix printers that can be used with the MT-3000A. There are three LED printers that can beused with the MT3000A. All printers are optional and are described in detail below.

Information for the printer is generated on the communication board. It is then routed through the Backplaneboard and the Serial or Parallel Port, where the printer is connected. Refer to Functional Block Diagrams. Page10-33 and 10-35

AMT PARALLEL PRINTER

The “Screen Prints” of the MT-3000A are printed using the AMT-240 series, an 85 column, bi-directional, 24 pin,dot matrix, impact printer. When the printer is activated the print head will travel to the far right and then back tothe far left of the platen to indicate initialization. The LCD window on the front panel will display "DRAFT 10READY".

From any screen menu an operator can print the desired information by pressing <PRINT>. The AMT prints at arate of up to 240 cps (characters per second), and can print letter quality in any of eight available character faces(Fonts) and six character sizes (Pitch). The printer resolution is 360 x 360 dpi (dots per inch). The printer alsoincorporates self-diagnostics that will help in isolating a specific printer component for corrective action.

USING THE SETUP MENU:The Setup menu is a list of printer parameters organized into five categories. These are listed below.

OPERATIONS PAGE SETUP SPECIAL MODES1) RSTOR: User 19) LENGTH: 066 36) HEXMODE: Off2) SAVE: None 20) WIDTH: 8 37) AUTO CR: On3) DFALT: SUN 21) DEMAND: Auto 38) AUTO LF: Off4) TEST: User 22) BIN: None 39) AUTO FF: Off

PRINT MODES 23) TOP MAR: 000 40) PAPROUT: On5) EMUL: MT3010 24) BOT MAR: 066 41) SLASH 0: On6) FNT: Draft 25) LFT MAR: 000 42) QUIET: Off7) PITCH: 10 26) RGT MAR: 080 43) LF SPD: 5.08) LPI: 6 COMMUNICATIONS 44) DELAY: 3 SEC9) ITALICS: Off 27) DWNLOAD: Off10) Off HIGH: Off 28) INTRFCE: Par11) WIDE: Off 29) BAUD: 960012) SCRIPT: Off 30) PARITY: None13) UNDLINE: Off 31) DTA BITS: 814) BLD/SHA: Off 32) STOP BITS: 115) CTR/JST: Off 33) HNDSHAK: DTR16) LANG: PC437 34) DTR: Low17) DIRCTN: Bi-d 35) IPRIME: Off18) GRFICS: Uni

CHAPTER 10 PRINTERS


AMT PARALLEL PRINTER, continued...

ACCESSING THE SETUP MENUPress <Setup>, to enter the Setup menu. When the Setup menu appears, the control panel acts like a one-linewindow over the menu. Each line contains a different parameter. Turning the Select-dial scrolls the menu up ordown past the window. Each parameter is numbered so you can always tell where you are in the menu.

Beside each parameter is the current setting. Holding down <Alt> and turning the Select-dial cycles through thepossible settings. The current setting is displayed when <Alt> is released.

To leave the Setup menu and redisplay the status message, press <Setup> again. If you display the Setupmenu and do not use it for more than one minute, the status message will reappear automatically. Also,pressing any control panel button except <Alt> will redisplay the status message.

Change the current settings as required then save them for use at a later time. Specify the power-on defaults forthe printer to use. Print the Setup menu by holding down <Alt> and pressing <Status>.

SELECTING OPERATIONS

RUNNING PRINTER SELF TEST:

To run the printer self test press and hold <Alt>, and press <Test>.

BASIC PRINTER OPERATION:

The first section of the Setup menu is basic printer operations. Selecting an operation performs a specificaction. Unless otherwise specified for MT-3000 operation, the settings are identified directly behind the name ofthe function.

"1) RSTOR: None" Restore Printer Settings:

The first operation on the Setup menu is RSTOR. RSTOR is used to restore printer settings to the factorysettings or user settings that you saved previously with the SAVE operation. When RSTOR is selected, theprinter clears the data input buffer.

Selecting NONE can be used to cancel the operation; Fctry to restore the factory settings; or Usr 1 through Usr 3to restore the settings saved under one of these names.

"2) SAVE: None" Save Printer Settings:

SAVE is used to save the current printer setting in non-volatile memory for use at a later time.

To save the current printer settings, hold down <Alt> and turn the Select-dial to select one of the three usersnames. As soon as <Alt> is released, the printer saves the current printer settings and assigns the user namethat is selected. RSTOR is used to restore the settings that are saved; DFALT is used to make your savedsettings the power-on default settings.

None is selected to cancel the operation; or Usr 1 through Usr 3 to save the current settings under one of thesenames.

CHAPTER 10 PRINTERS



"3) DEFALT: Fctry" Select Power-On Default Settings:

DFALT is used to select the printer settings to use as the power-on default settings. Select the factory settingsor the settings were saved previously with a SAVE operation.

The printer keeps that DFALT selection in non-volatile memory so it is retained when the printer is off.

Select “Fctry” to use the factory settings as the power-on defaults or “Usr 1” through “Usr 3” to use settingssaved under one of these names.

"4) TEST: None" Run Printer Test

TEST allows a variety of printer tests, including a sensor check and a memory check. If a test fails, an errormessage will appear.

Select None is always the default and does not perform any test; Sensor runs the sensor check; or Memorychecks the printer memory.

SELECTING PRINT MODES:

Emulation is the most important print mode parameter and must be set to be compatible with the applicationprogram.

"5) EMUL: MT3010" Set Printer Emulation:

EMUL allows a selection for a printer emulation for the printer to use. Selecting an Emulation enables the printerto imitate other popular printers. When an emulation is selected, all current printer settings stay in effect.Selections include Epson, that causes the printer to imitate Epson LQ-570 and LQ-1070 printers; IBM, thatcauses the printer to imitate IBM XL24 and LEXMARK 2390/2391 printers; and MT3010, which causes theprinter to imitate the Snap-on MT3010 printer. The only setting which will print properly when working with anMT-3000/A is the MT3010 emulation.

"6) FNT: Draft" Set Font:

FNT is used to select a font (typestyle), such as, Roman, SanSrf, Courier, Prestige, Script, OCR-B, Orator, Draft,and HSDraft.

"7) PITCH: 10" Set Pitch:

PITCH is used to specify how many characters to print per inch. You can select 10, 12, 13, 15, 17, or 20. SelectPS for proportional spacing. If the current setting is Other, then the software has set the pitch to somenonstandard value.

"8) LPI: 6" Set Number of Lines Per Inch:

LPI specifies how many lines to print per inch. You can select 3, 4, 6, 8 or 12. If the current setting is "Other",then the software has set the number of lines per inch to some other numerical value.

"9) ITALICS: Off" Turn Italics Mode On and Off:

ITALIC is used to turn the italic mode on and off.

CHAPTER 10 PRINTERS



"10) HIGH: Off" Turn Double-High Mode On and Off:

HIGH is used to turn the Double-High mode on and off. In double-high mode, characters stretch downward totwice their normal height, and the LPI setting changes to three lines per inch. When the mode is turned off, theLPI settings change to six lines per inch.

"11) WIDE: Off" Turn Double-Wide Mode On and Off:

WIDE is used to turn double-wide mode on and off. In double-wide mode, characters stretch to the right twicetheir normal width. When the user turns on the double-wide mode, the pitch is set to half its current value.When the user turns off double-wide, the pitch is doubled to its previous value.

"12) SCRIPT: Off" Turn Super/Subscript Mode On and Off:

SCRIPT is used to turn on and off the superscript and subscript modes. In superscript mode, characters shrinkto about half their normal size and print above the print line. In subscript mode, the same small characters printbelow the normal print line. Select Supr to turn the superscript mode on, sub to turn the subscript mode on, orOff to turn both modes off.

"13) UNDLINE: Off" Turn Underline Mode On and Off:

UNDLINE is used to turn the underline mode on and off. In underline mode, all characters and spaces areunderlined.

"14) BLD/SHA: Off" Turn Bold/Shadow Modes On and Off:

BLD/SHA is used to turn on and off the bold shadow modes. In bold mode, characters are printed twice, one ontop of the other, to produce bold print. In shadow mode, characters are also printed twice, once and then slightlyoffset to the right, to produce shadow print. Select Bld to turn the bold mode on, Sha to turn the shadow modeon, or Off to turn both modes off.

"15) CTR/JST: Off" Turn Center/Justify Modes On and Off:

CTR/JST is used to turn on and off the center and justify modes. In the center mode, the printer centers eachline of text between the margins. In the justify mode, the printer expands or compresses each line of text asnecessary so that it ends at the right margin. If the printer must expand a line to over twice its original length orcompress a line so that characters overlap, the line prints unjustified. With both the center and justify modes, acarriage return or line feed code in the print marks the end of the line. Select Ctr to turn on the center mode, Jstto turn on the justify mode, or Off to turn both modes off.

"16) LANG: PC437" Set Language:

LANG is used to specify a language for the printer to use when printing text. When selecting any other languagethan USA, the printer replaces some of the standard ASCII printable characters with alternate characters that areused in a specific language. Use PC437 for the setup.

"17) DIRCTN: Bi-d" Set Text Printing Direction:

DIRCTN is used to specify whether the printer should print text in both directions or from left to right only.Printing only from left to right provides the highest possible vertical alignment, but slows down printing. SelectBi-d for bidirectional printing or Uni for left to right printing.

CHAPTER 10 PRINTERS



"18) GRFICS: Bi-d" Set Graphics Printing Direction:

GRFICS is used to specify whether the printer should print graphics in both directions or from left to right only.Printing from left to right only provides the highest possible vertical alignment, but slows down printing. You canselect Bi-d for bidirectional printing or Uni for left to right printing.

SELECTING PAGE SETUP PARAMETERS:

Page Setup parameters lets you specify page size and margins.

"19) LENGTH: 066" Set Page Length:

LENGTH is used to specify the length of the paper that the user is using in 1/6-inch increments. This setting isespecially important since it controls continuous-forms feeding. The user may select a number from 0 to 182.To determine the correct number to use for your paper, multiply the length of the paper in inches by 6. Forexample, if the paper is 11 inches long, select 66 (11 x 6 = 66).

When setting page length, the printer sets the top-of-form at the current line and clears top and bottom margins.If the length is set to 0, the printer does not keep track of lines per page.

When using single sheets, a form-feed control code ejects the page; when using pin-feed paper, a form-feedcontrol code performs a carriage return only.

"20) WIDTH: 8.5" Set Maximum Print Width:

WIDTH is used to specify the maximum print width. If the printer receives a line that exceeds the maximum printwidth, the excess prints on the next line. The user may specify 8, 8.5, or 13.6 inches (13.6 only applies to widecarriage printer models, therefore it should not be selected.

"21) DEMAND: Auto" Turn Demand Document Mode On and Off:

DEMAND is used to turn demand document mode on and off. The demand document mode lets the userremove a pin-fed page without wasting the next page. When demand document mode is on, pressing <Ready>turns printing off and feeds the paper until the bottom edge of the last printed page is at the tear bar. You canthen tear the page off. The display will show DEMND instead of PAUSE. Pressing <Ready> again causes oneof the following actions to occur:

A) If you removed the last printed page, the paper reverse feeds to the last top-of-form, the READYmessage reappears, and printing continues at the point where it left off.

B) If you did not remove the last printed page, the paper reverse feeds back to its original position, theREADY message reappears, and printing continues at the point where it left off.

The user can select On to turn the demand document mode on; Off, to turn the mode off; or Auto, which causesthe printer to present the paper for tear-off whenever the printer idle (you don’t have to press <Ready>). Ifdemand document mode is on and the user does not want the paper presented for tear off, just press <Ready>twice.

CHAPTER 10 PRINTERS



"22) BIN: None" Select Sheetfeeder Bin:

If the user is using a sheetfeeder option. BIN lets the user select a sheetfeeder bin to feed paper from. SelectNone when not using a sheet feeder; Front to feed paper from the front (or only) sheet feeder bin; Back to feedpaper from the back sheetfeeder bin; or Envel to feed from the envelope tray (if your printer has it installed).

"23) TOP MAR: 000" Set Top Margin:

TOP MAR is used to specify a top margin. On subsequent form feeds, paper advances to the top margin youspecify. The top margin can be from 0 to 181 lines down from the top of form; however, the user can only selecta line that is above the bottom margin setting.

The physical location of the top margin on the page is unaffected by subsequent changes to line spacing. If theuser changes the LENGTH (page length) setting, the top margin resets to 0.

"24) BOT MAR: 066" Set Bottom Margin:

BOT MAR is used to specify a bottom margin. After printing on this line, the printer performs a form feedoperation automatically; no printing occurs below the bottom margin. The bottom margin can be from 1 to 182lines down from the top-of-form; however, the user can only select a line that is below the top margin setting.

The physical location of the bottom margin on the page is unaffected by subsequent changes to line spacing. Ifthe user changes the LENGTH (page length) setting, the bottom margin resets to the new page length.

"25) LFT MAR: 000" Set Left Margin:

LFT MAR is used to specify a left margin. All subsequent carriage returns cause the printhead to move to theleft margin.

The left margin can be from 0 to 271 character spaces to the right of the far left print position; however, the usercan only select a character space that is to the left of the right margin setting.

To help the user visualize left margin locations as they scroll through the possible settings, the printhead movesto the displayed setting. The physical location of the left margin setting is unaffected by subsequent pitchchanges.

"26) RGT MAR: 085" Set Right Margin:

RGT MAR is used to specify a right margin. When printing reaches the right margin on a line, the printerperforms a carriage return/line feed and continues printing on the next line.

The right margin is also used in the center and justify modes. The right margin can be from 1 to 272 characterspaces to the right of the far left print position; however, the user can only select a character space that is to theright of the left margin setting.

To help the user visualize the right margin locations as they scroll through the possible settings. the printheadmoves to the displayed setting. The physical location of the right margin on the page is unaffected bysubsequent pitch changes.

CHAPTER 10 PRINTERS



SPECIFYING COMMUNICATIONS PARAMETERS:

The next section on the Setup menu is Communications. The communications parameters control datacommunications between the printer and the host computer. Before successful communications can occur,these parameters must be set to match those of the host computer. When you change a communicationssetting, the printer clears the data input buffer.

"27) DWNLOAD: Off" Allocating Memory for User-Defined Characters:

DWNLOAD is used to allocate a portion of the printers memory to hold user-defined characters that aredownloaded from the computer. Select ON to allocate eight kilobytes (8,191 bytes) of memory for user-definedcharacters or Off to allocate all of the printers memory for a data input buffer.

"28) INTRFCE: Par" Select Interface:

INTRFACE is used to select either the parallel or serial interface port for communication with the host computer.The user can select Par for parallel or Ser for serial. If the user selects serial, you must also set the BAUD,PARITY, DTA BITS, STOP BITS and HNDSHAK parameters to match the serial configuration of the hostcomputer. If the user selects parallel, these parameters are irrelevant. For our applications Par should beselected.

"29) BAUD: 9600" Specify Baud Rate:

BAUD is used to tell the printer what serial baud rate your computer is using. Baud rate is the speed that serialdata is transmitted between the computer and the printer. The user can select 150, 300, 600, 1200, 2400, 9600,19200 or 38400. Both the computer and the printer must be set to the same baud rate which is 9600 for the MT-3000.

"30) PARITY: None" Specify Parity:

PARITY is used to tell the printer what parity method your computer is using. Parity is a technique that lets theprinter check for data transmission errors.

The user must select None if the host computer does not support parity; Odd if the host computer uses oddparity; or Even if the host computer uses even parity. Both the computer and the printer must be set for thesame parity method.

"31) DTA BITS: 8" Specify Number of Data Bits:

DTA BITS are used to tell the printer how many data bits your computer is sending in each byte. The user mustselect 7 if your computer sends 7-bit bytes, 8 if the computer sends 8-bit bytes, or 8 if the computer sends 8-bitbytes and you want the printer to ignore the most significant bit (MSB). For MT-3000 operation the printer shouldbe set to 8.

"32) STOP BITS: 1" Specify Number of Stop Bits:

STOP BITS are used to tell the printer how many stop bits the host computer is sending in each byte. Stop bitsare necessary to separate consecutive bytes in the data stream. The user must select 1 if the host computersends one stop bit; or 2 if the host computer sends two stop bits. For the MT-3000 operation the printer shouldbe set to 1.

CHAPTER 10 PRINTERS



"33) HNDSHAK: DTR" Specify Handshaking Method:

HNDSHAK is used to tell the printer what handshaking method the host computer is using.

Handshaking is a technique that starts and stops data transmission between the host computer and the printer.This starting and stopping is important so that neither device receives more data than it can handle at any giventime.

The user can specify DTR for DTR hardware method; XON for the X-ON/X-OFF software method; ETX for theETX/ACK software method; D/X for both the DTR and X-ON/X-OFF methods; D/E for both the DTR andETX/ACK methods; or None for no handshaking method. Both the host computer and the printer must use thesame handshaking method. For the MT-3000 set this to DTR.

"34) DTR: Low" Set DTR Signal Polarity:

DTR is used to specify the polarity of the Data Terminal Ready signal in the printer’s serial interface. You canselect Low for a signal that goes low to disable data transmission; or High for a signal that goes high to disabledata transmission. For the MT-3000 set this to Low.

"35) IPRIME: Off" Enable and Disable IPRIME Signal:

IPRIME is used to enable and disable the IPRIME signal. When enabled, the computer can reset the printer bysetting the IPRIME signal low for at least 50 microseconds. The printer remains in the reset condition until thesignal returns high. You can select On to enable the IPRIME signal or Off to disable it. With most computersand software, this signal should be disabled.

SELECTING SPECIAL MODES:

The last section on the setup menu is Special Modes. These modes let the user invoke a variety of specialprinting features. They are as follows:

"36) HEXMODE: Off" Turn Hexadecimal Mode On and Off:

HEXMODE is used to turn the hexadecimal mode on and off. In the hexadecimal mode, the printer prints thehexadecimal and ASCII representations of every byte it receives. The printer does not interpret or execute anycontrol sequences, nor does it print any text.

Hexadecimal mode is useful when you need to view the codes being sent from the host computer to the printer.The user can select On to turn the hexadecimal mode on or Off to turn the mode off.

"37) AUTO CR: On" Turn Auto Carriage Return Modes On and Off:

AUTO CR is used to turn the automatic carriage return mode on and off. In automatic carriage return mode, theprinter performs a carriage return/line feed for each line feed code it receives. The user can select On to turnthe mode on or Off to turn the mode off.

"38) AUTO LF: Off" Turn Automatic Line Feed Mode On and Off:

AUTO LF is used to turn the automatic line feed mode on and off. In the automatic line feed mode, the printerperforms a carriage return/line feed for each carriage return code it receives. The user can select On to turn themode on or Off to turn the mode off.

CHAPTER 10 PRINTERS



"39) AUTO FF: Off" Turn Automatic Form Feed Mode On and Off:

AUTO FF is used to turn the automatic form feed mode on and off. In the automatic form feed mode, the printerskips over the perforations of the pin-fed paper by setting top and bottom margins to one half inch. The user canselect On to turn the mode On or Off to turn the mode off. For the automatic form feed mode to work correctly,the LENGTH parameter must be set to the correct page length.

"40) PAPROUT: On" Enable and Disable Paper Out Sensing:

PAPROUT is used to disable paper out detection by the printer’s paper out sensors. Disabling paper outdetection does not affect the printer’s ability to load paper. The user can select On to enable the mode or Off todisable the mode.

"41) SLASH 0: On" Turn Zero Flashing On and Off:

SLASH 0 is used to turn zero flashing on and off. The user can select Off to specify that the numeral 0 beprinted without a slash (0); or On to specify the numeral 0 be printed with a slash. The user’s selection affectsthe printing of the numeral 0 in all fonts.

"42) QUIET: Off" Turn Quiet Mode On and Off:

QUIET is used to turn quiet mode on and off. In quiet mode, the print speed slows down by about 10% in allmodes to decrease the amount of noise that is generated. The user can select On to turn the mode on or Off toturn the mode off.

SERVICE MENU FUNCTIONS

The Service mode settings are numbered 54 through 63. To access the Service modes enter the printer setupby pressing <Setup>. Once in the setup menu turn the dial clockwise until the numbers do not change. Withthe previous message displayed press and hold <Pitch>, and <Form Feed>, while turning the dial clockwise.This will bring up the Service Menu item number “54) ADJ.LQ10: 52”. To change to any other Service selectioncontinue holding <Pitch>, and <Form Feed> while turning the dial clockwise. To change any of the settingsrelease <Pitch>, and <Form Feed>. Then press and hold <Alt>, while turning the dial. Below are all the servicemodes, and their associated function.

SERVICE MODE

54) ADJ.LQ10: 5255) ADJ.HQ10: 1956) ADJ.DQ10: 2457) ADJ.DQ12: 4258) ADJ.DQ17: 5159) ADJ.DQ20: 5060) TEARBAR: -2461) P_SNSR: 4662) H_SNSR: 063) SET_USR:


CHAPTER 10 PRINTERS


"54) ADJ.LQ10: 52" Letter Quality 10 Pitch Vertical Adjustment:

When printing in letter quality mode, this adjustment will align the forward pass of the print head with thebackwards pass of the print head. If this is not set to the proper setting, the alignment of the lines in a printoutwill not line up with the left or right margin.

"55) ADJ.HQ10: 19" High Draft Quality 10 Pitch Vertical Adjustment:

When printing in HDraft mode, this adjustment will align the forward pass of the print head with the backwardspass of the print head. If this is not set to the proper setting, the alignment of the lines in a printout will not lineup with the left or right margin.

"56) ADJ.DQ10: 24" Draft Quality 10 Pitch Vertical Adjustment:

When printing in Draft mode, this adjustment will align the forward pass of the print head with the backwardspass of the print head. If this is not set to the proper setting, the alignment of the lines in a printout will not lineup with the left or right margin.







"60) TEARBAR: -8" Tearbar:

Sets the distance from the first printed line to the paper tear bar. Aligns the perforation on the paper to the papertear off bar.

"61) P_SNSR: 12" Page Sensor:

Sets the distance from the top of the form to the first printed line on the paper.

"62) H_SNSR: 0" Head Sensor:

Sets the spacing on the first column of the page with respect to the left perforation.

"63) SET_USR: " Set User:

Sets the printer to factory Default settings when changed to “DONE”.

CHAPTER 10 PRINTERS


ERROR MESSAGES

PRINTER MESSAGES:

When a printer message appears in the Select-dial control panel, find it in this section and perform the correctiveaction(s). There are five kinds of messages: operating errors, programming errors, warnings, communicationerrors and printer errors.

1) CORRECTING OPERATING ERRORS:

The printer can notify the user of three operator errors. When one of these errors occurs, the printerdoes not lose any buffered data. After the user performs the corrective action(s), printing continues where it leftoff.

"LOAD PAPER"

This error occurs when the printer has data to print but no paper is loaded in the printer.

"CLEAR PAPER JAM"

This error occurs when the printer detects a paper jam while ejecting the current page.

CORRECTIVE ACTION: Carefully remove the jammed paper and press the Ready button.

"PAPER ERROR"

This error occurs when the printer tries to eject a single sheet or perform a paper park operation, but continuesto detect paper in the printer.

CORRECTIVE ACTION: If the paper is jammed, carefully remove the jammed paper and press theReady button. If the user is just using a very long cut-sheet, press <FormFeed>. If the user is using tractor-fed paper, tear off the last printed sheetand then hold down <Alt> and press <Park>. If this error occurs with nopaper in the printer, one of the paper sensors is falsely detecting paper.Check for small scraps of paper caught in the front, behind or below theplaten.

2) CORRECTING PROGRAMMING ERRORS:

The printer can notify the user of only one programming error.

"DOWNLOAD ERROR"

This error occurs when the computer attempts to download a font to the printer, but the user has not allocatedprinter memory to store the font. When a download error occurs, the printer ignores the downloaded fontinformation and continues printing normally.

CORRECTIVE ACTION: Press <Ready> to stop the printing in progress. Change the downloadparameter setting to On. Then, restart the print job from the beginning.

3) UNDERSTANDING WARNINGS:

The printer offers three warnings to notify you of special conditions.


CHAPTER 10 PRINTERS


"CHECK TRACTR LVR"

After a paper park operation, this message appears to remind the user to move the paper select lever if the useris going to load a cut sheet into the printer. Moving this lever disengages the forms tractor and enables the cutsheet mode. If the user forgets to move this lever, a paper jam can result since both the cut sheet and pin-fedpaper will feed into the printer at the same time. If the user is not going to load a cut sheet, just ignore themessage. Pressing <Ready> or moving the paper select lever clears the message.

CORRECTIVE ACTION: If the user is going to load a cut sheet into the printer, push the paper selectlever towards the back of the printer and press <Ready> button.

"TEST IN PROGRESS"

When the user selects a printer test on the Setup menu, this message appears to notify the user that the printeris executing the test.

"TEST UNAVAILABLE"

When the user selects the printer test on the Setup menu, this message appears to notify the user that the test isnot contained on the printer and cannot be executed.

4) CORRECTING COMMUNICATION ERRORS:

The printer can notify the user of three communication errors. When a communication error occurs, printingstops and some or all of the print data is lost. After the user performs the corrective action(s), you must restartthe print job from the beginning.

"FRAMING ERROR"

This error occurs when the baud rate of the printer and the host computer are not the same.

CORRECTIVE ACTION: Change the BAUD and DTA BITS settings on the Setup menu to thecomputer’s baud rate and number of data bits. Then, press <Ready>button and restart the print job from the beginning.

"PARITY ERROR"

This error occurs when the printer, using the select parity method, detects a data transmission error affectingone or more data bytes.

CORRECTIVE ACTION: Change the PARITY setting on the Setup menu to the host computer’sparity method. Then, press <Ready> to re-enable printing; then, restart theprint job from the beginning.

If the printer’s parity setting is correct, hold down <Alt> and press <Clear> to clear the data input buffer and then<Ready> to re-enable printing; then start the print job from the beginning. If the error occurs, reset the hostcomputer and the printer for no parity checking and try again.

CHAPTER 10 PRINTERS



"BUFFER OVERFLOW"

This error occurs when the printer’s data input buffer overflows. A buffer overflow occurs when the followingcondition(s) exist(s):

The printer and the host computer are not using the same handshaking method and/or the baud rate exceedsthe print speed.

CORRECTIVE ACTION: Change the HNDSHAK setting on the Setup menu to the computershandshaking method. The, press <Ready> to re-enable printing and restartthe print job from the beginning. If the computer or software program doesnot use handshaking, you must reduce the baud rate of the computer andprinter to a rate that does not exceed the print speed.

5) CORRECTING PRINTER ERRORS:

The printer can notify the user of four printer errors. Printer errors occur when the printer is unable to continueprinting due to a malfunctioning printer component.

"MEMORY ERROR"

This error occurs when the printer logic detects defective memory during a printer memory test. Memory testsoccur during power up and when the user selects Memory Test on the Setup menu.

CORRECTIVE ACTION: The printer’s memory must be replaced. If this message appears during theSetup menu memory test, the user may be able to clear the message andreturn to the Setup menu by turning the Select-dial.

"CARRIAGE ERROR"

This error occurs when the printer is unable to index the carriage at the home position due to a jammed ribbon,dirty carriage shaft, or a malfunctioning carriage home switch.

CORRECTIVE ACTION: First, try replacing the ribbon cartridge with another. If the error recurs, trycleaning the carriage shaft with a soft, dry, lint free cloth. If the error stillrecurs, replace printer.

"EEROM ERROR"

This error occurs when the printer detects that its non-volatile memory is defective or does not contain thecorrect information.

"REPLACE BATTERY"

This error occurs when the printer’s battery, which refreshes the non-volatile memory when power is off,becomes weak and is not providing reliable voltage operation.

CHAPTER 10 PRINTERS


MT3010 SCRIBE II PARALLEL PRINTER

The results and/or diagnostic messages of the MT-3000/A can also be printed using the MT3010 Scribe IIparallel printer. When the printer is activated the print head will travel through its range of motion and will thenstop in the center position. The power indicator will then light to show that the power is on. At that point eitherthe Red P.E. (Printer Error) light illuminates, indicating an error, or the On Line indicator will illuminate.

From any screen, pressing <PRINT> will print the information on the screen. The MT3010 prints at a rate of 250cps (characters per second), and can print in near letter quality mode.

INDICATOR LIGHTS

There are four indicator lights used on the MT3010. They are : Power, On Line, Menu, and P.E. (for Printer Erroror Paper Empty).

When lit, the: POWER light shows that the printer is ON.P.E. light shows that an error condition exists.MENU light shows that the printer is in the MENU MODE, which allows selection of varioussettings using the <LF>, <FF>, <FONT>, and <PITCH> (down arrow, up arrow, left arrow, andright arrow respectively).ON LINE light shows that the printer is ON LINE.

NOTE: The MENU MODE settings will not change the way information from the MT-3000/A is printed

SELECTING THE POWER ON CONFIGURATION MODE:

1. With the power switch OFF, hold down <MENU> and turn the power switch ON. “POWER ON CONFIG” isshown on the LCD to confirm this.

2. Release <MENU>. “PRINT OUT?” is shown, asking if you want to print out the current configuration.

3. Press (Right Arrow) <PITCH> or (Left Arrow) <FONT> to begin the printout.

4. Compare the printout to the one below. These settings should match

POWER-ON CONFIGURATION

*ITEMS* *DATA*1. EMULATION TYPE12. CHARACTER SET ITALIC3. NATIONAL SET USA4. AUTOMATIC CR OFF5. AUTO LF OFF (CR)6. INPUT BUFFER 20kb7. A.S.F. OFF8. IBM-20-COMPR. ON9. INTERFACE PARALLEL10. BAUD RATE 9600 BPS11. PARITY NONE12. DATA BITS 8BITS13. TEAR OFF MANUAL14. ALIGNMENT 10

CHAPTER 10 PRINTERS


MT3010 SCRIBE II PARALLEL PRINTER, continued...

CHANGING THE POWER ON CONFIGURATION MODEIf an item setting does not match the Power-On configuration on the previous page when the LCD shows“PRINTOUT” use the down arrow key to scroll through the items (in the order listed on the printout). Then usethe left and right arrow keys to change the item’s setting. Continue this process for any other items that need tobe changed. To exit from the Power On Configuration Mode press <MENU>. This saves the changes justmade.

THE MENU MODE

1. Turn the printer power ON.

2. With the printer OFF LINE, press <MENU>. “MENU MODE” is displayed on the LCD to confirm this.

3. Release <MENU>. “PRINT OUT?” is shown, asking if you want to print out the current Menu Mode settings.Press the (right arrow) <Pitch>) or (left arrow) <Font> to begin printout.

4. Compare the printout to the one below. The settings should match. If not, refer to “Changing The MenuMode” below.

MENU MODE

*ITEMS* MENU 1 MENU 21. FONT DRAFT DRAFT2. PITCH 10CPI 10CPI3. LINE SPACE 6LPI 6LPI4. LEFT MARGIN 0 05. RIGHT MARGIN 80 806. PAGE LENGTH 66 667. TOP MARGIN 1 18. BOTTOM MARGIN 2 29. SLASHED ZERO OFF OFF10. DOUBLE HIGH OFF OFF11. PRINT DIRECTION BI (NORMAL) BI (NORMAL)12. DEFAULT MENU 1 1

CHANGING THE MENU MODE

If an Item setting does not match the example above, when the LCD shows “PRINTOUT” use the down arrowkey to scroll through the items (in the order listed on the printout). Then use the left and right arrow keys tochange the item’s setting. Continue this process for any other items that need to be changed. To exit from theMenu Mode press <MENU>. This saves the changes just made.

RUNNING THE SELF TEST

To run the printer self test, press and hold <LF>, while turning the printer on.

CHAPTER 10 PRINTERS


MT1670A SERIAL PRINTER

The MT1670A is a 40 column dot matrix printer that prints at a rate of eight lines per second. It is a Serialprinter that hooks directly to the MT-3000/A’s back panel “RS232” connector. A display indicates the function ofthe printer and four touch keys control the functions.

FRONT PANEL CONTROLS AND DISPLAY

LED DISPLAY: A dot in the center of the LED display signals the user that the printer is turned on, andthat it is ready to print. If the printer becomes jammed while printing it will display theletters J, A, and M in a continual sequence.

CONTROL PANEL: The control panel has four dual-function touch keys. When the printer is turned on, allof the functions listed on the top of the keys are automatically activated, except TEST(refer to test key below). The functions on the bottom of the keys are activated byturning the printer’s power switch to the “ON” position while the ID FORM key isdepressed.

PAPERFEED: Advances the paper.

TEST: TEST is used to check the character set and operation of the printer. To activate theTEST function, turn the printer’s power switch to “ON” while the TEST key is depressed.The printer should then print out all of the letters, numbers, and other charactersavailable, the version of the printer’s software (identified by date), the selected mode ofoperation (MT1665 or RS232 serial) and the RS232 baud rate (bits per secondtransmission speed) selected.

NOTE: For MT-3000/A applications the mode of operation is RS232.

ID FORM: ID FORM is used to print a customer/vehicle data form. This information includes thefollowing fields: Customer, Vehicle/Make, Year, Odometer Reading, and Date.

PRINT: Is inactive when hooked to an MT-3000/A.

BACK PANEL

POWER SWITCH: Turns the printer ON and OFF.

FUSE HOLDER: Contains a 1 amp fuse and a voltage selector that is set for 120 Volt operation. For 240Volt operation use a 3/4 amp fuse and change the voltage selector to the “240” position.

RS232CONNECTOR: The RS232 connector is a 25 pin communication port that can be used for

interconnecting the printer to the MT-3000/A.

BNCCONNECTOR: The BNC coaxial connector is used for connecting the printer to the Snap-on scope.

CHAPTER 10 PRINTERS


OKIDATA LED PRINTERS OL600E OKIPAGE 6E OKIPAGE 10E

GENERALThese LED printers provide a very high quality copy with relatively low maintenance. These printers usecomponents that are unique to this machine. This section should be reviewed completely to distinguish thesedifferences.

NOTE: This is not an impact matrix printer and will not print through multiple copyforms.

The OL600e, Okipage6E and Okipage10E have the normal printer functions and other functions that are uniqueto the LED type of printer. Some of these features are:

• Six pages per minute printing speed (maximum)

• One hundred sheet paper tray (maximum, using 20 lb. paper)

• 1MB memory, standard

• They connect through a Printer cable connected to the Parallel Printer Port on the rear of the MT3000A.

• All three of the Okidata LED printers are installed the same. They all work from the 75 DPI Mode.

THEORY OF OPERATIONGENERALA drum is charged with a negative static potential. This drum rotates through an area that is scanned by a lightsource. The scan pattern of the light source is a negative image of the document to be printed. The energy inthe light removes the static charge from the portion of the drum that will not have any image elements.

The drum now has a static image of the information to be printed. The drum is then rotated past positivelycharged toner. The toner is attracted to the portion of the drum that is still negatively charged. The toner nowtakes on a negative charge.

Positively charged paper is fed past the rotating drum. The negatively charged toner is attracted to the paper.The paper now has a toner image of the information to be printed. The paper is then rolled through a pair ofdrums; one of these drums is heated. The heat and pressure bond, or “fix”, the toner to the paper.

COMMUNICATIONSThe Computer/Digital Board communicates with the printer via a standard parallel porting scheme. This consistsof 8 data lines: strobe line, acknowledge line, busy line, select out line, auto feed line, +5 volt line, prime line,error line and a select in line. These lines are connected through a standard printer cable to a standardCentronics connector at the printer and the Parallel port on the Rear of the MT3000A.

IMAGE DRUMIn the LED printers, the drum mentioned above is called the Image Drum. The average life of the Image Drumwill vary with the number of pages printed during each print request. For example: if the average print job is onepage, the life of the Image Drum would be about 12,000 pages. If the average print job is fifteen pages, the lifeof the Image Drum would be about 20,000 pages. The Image Drum is coated with a photo-sensitive material.

NOTE: Do not expose the Image Drum to direct sunlight. Do not expose to light formore than 5 minutes. Do not touch the green surface of the Image Drum.

CHAPTER 10 PRINTERS


INSTALLATION1. Install the printer on top of the MT3000A. You will have to bend the front of the printer tray down so it

won’t interfere with the paper tray in the printer.2. Install the printer paper (maximum of 50 sheets of 20# 8 ½ X 11”).3. Connect printer cable and power cord to the printer.4. Connect the other end of the printer cable to the “parallel port” on the rear of the MT3000A.5. Plug the printer power cord into the power strip on the rear of the MT3000A.6. Power up the MT3000A and printer.7. On MT3000A, Press green “OPTION MENU” Button.8. Press “SCOPE SETUP”.

NOTE: Read “COMMUNICATION SETUP” in the middle of screen for cursor movementand data entry instructions.

9. Press ”COM PORT SETUP”.10. Change “PARALLEL PORT “ SETTINGS TO “75 DPI GRAPHICS MODE”.

DAY MM-DD-YY SCOPE SETUP HH:MM:SS AM

SET TIME AND DATE: PRESS F1. USE , TO MOVE CURSER, USE, TO CHANGE DATA. PRESS ENTER WHEN FINISHED.

ERROR MESSAGE: PRESS F3

INDICICATORS: (,,,,S): PRESS F5.

COMMUNICATION SETUP: PRESS F4. USE , TO MOVE CURSOR,USE SELECT TO CHANGE DATA. PRESS ENTER WHEN FINISHED.

SERIAL PORT A: GAS ANALYSER 9600 BAUD RATE

SERIAL PORT B: OFF 300 BAUD RATE

PARALLEL PORT: 75 DPI GRAPHICS MODEBEEPER: PRESS F2

SET TIMEAND DATE

F1

BEEPERON/OFF

F2

ERRMESSAGE

ON/OFFF3

COM PORTSETUP

F4

INDICATORSON/OFF

F5

Figure 10-1 Okidata Setup

11. Press “” to save changes.12. Press “OPTION MENU”.13. Press “RETURN TO START”.14. Press “PRINT” Button to test printer.15. If printer fails to print refer to troubleshooting section.

CHAPTER 10 PRINTERS


MAINTENANCE

IMAGE DRUMThe Image Drum is made of a photo-sensitive material. The drum surface is also sensitive to chemicals, suchas the oils in human skin.

NOTE: Do not expose the Image Drum to direct sunlight. Do not expose to light formore than 5 minutes. Do not touch the green surface of the Image Drum.

NOTE: After the Image Drum is changed, you should reset the Drum Counter. Refer tothe SOFTWARE and SETTINGS section in this chapter.

1. Press the tabs on both sides of the top cover to release the locking mechanism and open the top cover byraising it up and back.

Figure 10-2 Open top cover

CHAPTER 10 PRINTERS


IMAGE DRUM, continued...

2. Grasp the Image Drum and lift it up to remove. Remember, the Toner Cartridge fits into the Image Drum.Usually the Toner Cartridge is replaced when a new Image Drum is installed, however if the Toner Cartridgeis relatively new, it may be reused.

Figure 10-3 Remove old Image Drum

3. Remove the protective sheet from the new Image Drum.

Figure 10-4 Remove protective sheet from new drum

NOTE: Do not touch green surface of Image Drum, or expose Image Drum to directsunlight, or any light for more than 5 minutes.

CHAPTER 10 PRINTERS


IMAGE DRUM, continued...

4. Install the new Image Drum, orienting it as the old drum had been.

Figure 10-5 Insert new Image Drum

5. Remove the protective sponge from the toner cavity and install the Toner Cartridge.

Figure 10-6 Remove Sponge in toner cavity

NOTE: It may be necessary to periodically clean the drum using an automated featurecalled a Cleaning Page. Refer to the SOFTWARE and SETTINGS in thischapter.

CHAPTER 10 PRINTERS


TONER CARTRIDGE

NOTE: When handling the Toner Cartridge, be careful to not let the toner touchanything; toner stains are very difficult to remove.

1. When unwrapping the Toner Cartridge, be sure to save the LED Head Cleaner Pad to be used when cleaningthe LED Array.

Figure 10-7 Unwrap the Toner Cartridge

2. Shake the Toner Cartridge, laterally (left to right ), to evenly distribute the toner.

Figure 10-8 Shake cartridge

3. Remove the protective tape on the Toner Cartridge. Remember, the toner is now exposed, and toner stains.

Figure 10-9 Remove tape

CHAPTER 10 PRINTERS


TONER CARTRIDGE, continued...

4. Insert the new Toner Cartridge; be sure to engage cammed ends, see the blow up in figure 10-10, below.

Figure 10-10 Insert new cartridge

5. Push the blue lever, at the right of the cartridge, forward to lock the cartridge in place.

Figure 10-11 Push blue lever forward

6. Close the cover until it “clicks” shut.

Figure 10-12 Close cover

CHAPTER 10 PRINTERS


LED ARRAYThe LED Array should be cleaned when the Toner Cartridge or the Image Drum is changed or when there is aproblem with image quality. An LED Head Cleaning Pad is included with each new Toner Cartridge.

NOTE: Never use solvents or abrasive materials to clean the LED Array!

Refer to the drawing below; open the top cover and slide the LED Head Cleaner Pad back and forth horizontallyacross the LED Array several times.

Figure 10-13 LED Array

PAPERAs mentioned earlier, paper should be of a high quality, like copier paper. Paper weight must fall within 16 and24 pound. The Paper Tray capacity is 100 sheets, a stack about 1/2 inch thick using 20 pound paper. If toomuch paper is inserted, the printer will not operate correctly.

1. Push the handle of the paper tray to release the locking mechanism.

Figure 10-14 Push Paper Tray Handle

CHAPTER 10 PRINTERS


PAPER, continued...

2. Pull the Paper Tray out.

Figure 10-15 Pull Paper Tray out

3. Adjust both sets of Paper Guides for the size of the paper used.

Figure 10-16 Adjust Paper Guides

4. Insert the paper. Keep the paper in an even stack. Use no more than 100 sheets at a time; this will be astack about 1/2 inch thick if you are using 20 pound paper.

Figure 10-17 Insert paper

CHAPTER 10 PRINTERS


PAPER, continued...

5. Push the Paper Tray back into the printer until it “clicks” shut.

Figure 10-18 Re-insert the Paper Tray

Referring to the drawing below, note that the printer has two paper paths, Rear Exit and Front Exit. In somecircumstances it may be necessary to use the Rear Exit path. The Rear Exit is almost straight through, while theFront Exit bends the paper 135°.

NOTE: It is possible to feed paper in one sheet at a time through the Single SheetFeed Tray. This feature is used during the Cleaning Page process, discussedin the SOFTWARE AND SETTINGS section.

FusingUnit

Drum

Paper Tray (Disengaged for Single Sheet feed)

Paper ChargeRoller

Single Sheet Feed

Toner

Rear Paper Exit Front Paper Exit

Figure 10-19 Paper Paths

CHAPTER 10 PRINTERS


TROUBLESHOOTING

DOT MATRIX PRINTERS


I. Printer does not turn on. Power cable is not plugged into power outlet.

• Check power cable.

Power outlet is not supplying voltage.

• Check receptacle outlet for 110VAC and correctpolarity.

Fuse in Printer is blown (AMT).

• Replace 1 amp slo-blo fuse.

II. Error message appears on AMTSelect-dial control panel.

Find the Error message or flashing pattern in the AMToperators manual.

• Perform the corrective action.

III. Control Panel on AMT printer doesnot operate.

Printing is in progress.

• Wait for printing to stop, or press <READY> to haltprinting.

IV. Select dial does not move printerpaper on the AMT printer.

Printer is not paused.

• Press <Ready> and try again.

V. Self-test prints, but printer does notprint data sent from the analyzer.

Wrong interface settings are set.

• Check host analyzer and printer configurations.

Interface cable is loose, defective, or wired incorrectly.

• Check interface cable. Replace if defective.

VI. Printing is too light. Printer head gap is too wide.

• Push the paper head gap lever toward the back of theanalyzer.

Ribbon cartridge is not fully seated in place.

• Reload ribbon.

Ribbon is worn.

• Replace ribbon.

CHAPTER 10 PRINTERS


VII. Printing is smearing. Printer head gap is too narrow.

• Pull paper head gap lever towards the front of theprinter.

Ribbon is tangled or folded.

• Correct problem or replace ribbon.

Small piece of paper or debris is lodged in front of printhead.

• Remove obstruction.

VIII. Large portion of characters are notprinting

Ribbon is tangled or folded.

• Correct problem or replace ribbon.

IX. Characters are missing one ormore dots.

Printer head gap is too wide.

• Adjust printer paper head lever to correct problem.

X. Printer prints garbled text andpaper moves erratically.

Wrong printer setup or configuration.

• Ensure Printer and analyzer are set for the sameemulation, and the same configuration.

XI. Paper does not feed properly. Paper is not loaded correctly.

• Check for proper installation.• Check for paper wadding or a paper jam.

On 80 column printers, the tractor select lever is in the wrongposition.

• For single sheets push the lever towards the rear ofthe printer. For tractor feed paper push the levertowards the front of the printer.

XII. Printing goes off the right side ofthe page or does not print all theway across the page on the 80column printers (AMT & MT-3010)

Print width setting is wrong.

• Change the WIDTH setting in the SETUP menu.

XIII. Lines of text print on top of oneanother on an 80 column printer.

Automatic line feed mode is off.

• Try changing AUTO LF setting on the setup menu.

Paper is not taught between tractor feeder or around platen.

• Reload paper.

XIV. Printer leaves blank line after everyprint line on the AMT printer.

Automatic line feed mode is on.

• Try changing AUTO LF setting in setup menu.

CHAPTER 10 PRINTERS


XVI. Carriage does not return to theleft margin before printing next lineon the AMT printer.

Automatic carriage return is off; it needs to be turned on.

• Change the AUTO CR setting in the setup menu.

XVII. Printer prints on pin feedperforations, on the AMT printer.

Top-of-form is set incorrectly.

• Advance paper until the first print line is in front of theprinthead; then hold <Alt>, and press <Park>. Thenpress <Form Feed>.

XVIII. 40 column printer prints garbage. Setup of the MT-3000 or the printer is incorrect.

Confirm the configuration of the dipswitches in the papercompartment of the printer. Refer to this chapter for thecorrect settings.

Ensure the setup of the printer in the analyzer.

• Under Option Menu, Comm Setup.• Printer type should be SERIAL.• Printer Baud Rate should correspond to baud rate set

by switches on the printer. Default is 2400 Baud.

CHAPTER 10 PRINTERS


LED PRINTERS


I. Blank sheets are printed. • Reinstall Toner cartridge, see page 10-22.

• Reinstall Image Drum, see page 10-19.

NOTE: Do not expose the Image Drum to directsunlight. Do not expose to light for morethan 5 minutes. Do not touch the greensurface of the Image Drum.

• Replace Toner Cartridge, see page 10-22.

• Replace Image Drum, see page 10-19.

II. Entire page prints faintly. • Clean LED Array, see page 10-24


III. Page has gray background. • Dry environments may cause static electricity to buildup.

Try a smoother “laser bond” paper.

If possible, try using a humidifier.

• Replace Image Drum.

IV. Printer prints all black. • Remove Image Drum and carefully clean printer with a smallvacuum cleaner.

NOTE: Do not expose the Image Drum to directsunlight. Do not expose to light for morethan 5 minutes. Do not allow green surfaceof Image Drum to touch anything or beexposed to dust while cleaning printer.


• Replace Printer.

V. Page has equally spaced marksrunning down the page.

• Image Drum may have nicks, scratches or dirt causing marksevery 1.6 inches.


CHAPTER 10 PRINTERS


VI. An irregular “patch” of area onthe page prints faintly.

• Contaminated paper, replace paper and check storageconditions for possible causes of contamination.

VII. Prints vertical white streaks. • Clean LED Array, see page 10-24.


VIII. Prints vertical black lines. • Replace Toner Cartridge, see page 10-22.


IX. Fuzzy print. • Clean LED Array, see page 10-24.

X. Distorted print (wavy or tilted). • Check paper alignment; refer to pages 10-24 through 10-26 forproper paper loading procedure.

• Remove and reinstall Image Drum and Toner Cartridge.


• Replace Printer.

XI. Faded print after installation ofnew Toner Cartridge.

• Improperly installed toner cartridge, reinstall, see page 10-22

XII. Smeared or blotched print. • Remove Image Drum and carefully clean printer with a smallvacuum cleaner.


XIII. Print is light or blurred. • Clean LED Array, see page 10-24.

• Check that proper paper is being used, (copier or laser typepaper).


CHAPTER 10 PRINTERS


XIV. Bold characters and dark linesare smeared.


XV. Pages curl excessively. • Higher quality paper has a “print side”. The print side is indicatedon the package with an arrow. Place the print side down in thepaper tray.

• Try fresh paper. Paper may have excessive moisture (over 80%humidity). Always store paper in its package.

XVI. Okidata printer light flashingfast

Check printer paper.

• Refill paper, close paper tray to reset.Check paper jam.

• Open paper tray, remove jammed paper OR open top andremove jammed paper. Close top and push in paper tray toreset print command.

XVII. Okidata Printer prints too light Check Toner Cartridge.

Pull out Toner Cartridge, turn toner opening upward. Twist open andcheck for toner.

• If toner is packed solid, close opening and shake end to end.Reinstall in printer

• If Toner Cartridge is empty then replace it.

Soldered connectors

Snap-on Diagnostic420 Barclay Blvd.Lincolnshire, Illinois 60069 U.S.A.

PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE: SERIAL PRINTER

DWG:

All information contained or disclosed in thisdocument is considered confidential andproprietary by Snap-on Tools. All manufacturing,use, reproduction and sales rights arereserved by Snap-on Tools and the informationcontained herein shall not be used in wholeor in part without the express written consentof Snap-on Tools.

REV:MT-3000/A

D. Loechner

06/2000 REV B.

M. B. Clark

10-20 10-33

MOD BY: CHK BY: F. Zofinski

J. Sparks

E Q U I P M E N T S E R V I C E

Providing Factory Service ForAutomotive Service Equipment

O N S I T E

SERIAL PORT(A or B)

CONNECTORSERIAL

PRINTER

123456789

NOT USEDNOT USED

GNDDATA SET READY (DSR)CLEAR TO SEND (CTS)

REQUEST TO SEND (RTS)RECEIVE DATA (RXD)

TRANSMIT DATA (TXD)

10NOT USED

11NOT USED

12NOT USED

13NOT USED

14NOT USED

15NOT USED

16NOT USED

17NOT USED

18NOT USED

19202122232425

BACKPLANEBOARD

NOT USED

NOT USEDNOT USEDNOT USEDNOT USEDNOT USED

12345678910111213141516171819202122232425

COMMUNICATIONBOARD

BACK PANELRS232 CONNECTOR

NOT USED

DATA TRANSMIT READY (DTR)

CHAPTER 10 PRINTERS


Soldered connectors

Snap-on Diagnostic420 Barclay Blvd.Lincolnshire, Illinois 60069 U.S.A.

PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE: PARALLEL PRINTER

DWG:

All information contained or disclosed in thisdocument is considered confidential andproprietary by Snap-on Tools. All manufacturing,use, reproduction and sales rights arereserved by Snap-on Tools and the informationcontained herein shall not be used in wholeor in part without the express written consentof Snap-on Tools.

REV:MT3000/A

D. Loechner

06/2000 REV B.

M. B. Clark

10-21 10-35

MOD BY: CHK BY: F. Zofinski

J. Sparks

E Q U I P M E N T S E R V I C E

Providing Factory Service ForAutomotive Service Equipment

O N S I T E

PARALLELPRINTER

123456789

DATA 7DATA 6DATA 5DATA 4DATA 3DATA 2DATA 1DATA 0

10-ACK

11BUSY

12POUT

13SELOUT

14AUTOFEED

18+5V

31-IPRIME

32ERROR

36-SELIN

1819202122232425

161719202122232425262728293033

BACKPLANEBOARD

COMMUNICATIONBOARD

TEST PORT(PARALLEL)

CONNECTOR

BACK PANELPRINTER CONNECTOR

STB

CHAPTER 10 PRINTERS



CHAPTER 11 EXHAUST EMISSIONS - HC/CO/CO22/O22

GENERAL

The MT-3100 emission analyzer is an optional accessory for the MT-3000 engine analyzer. When used withother tools and equipment, the analyzer can also be used to detect and locate ignition, fuel, exhaust, emissioncontrol, and engine service problems.

When exhaust gas concentrations are within limits specified by the vehicle manufacture or the local, state orfederal government, it is generally assumed that the fuel, ignition, and emission control systems are functioningproperly. If exhaust gas concentrations exceed those specified limits, repairs or adjustments are probablyneeded.

MODEL DIFFERENCES

The MT-3100 gas analyzer has been produced in 3 different models: a straight MT-3100, an MT-3100A modeland an MT-3100C model.

REFER TO DRAWINGS 11-1 (PAGE 11-15) AND 11-2 (PAGE 11-17)The main difference between the MT-3100 and the MT-3100A model is the addition of Lambda and Air/FuelRatio readings. This addition was accomplished with a ROM chip upgrade to the Pneumatics Board.

A major upgrade program was implemented between the A and the C models. This upgrade included theaddition of Teflon Flapper Valves on the pump and the replacement of the single Tri-filter assembly with thestandard dual filter assembly.

The C model differences are more extensive and the A models cannot be updated to incorporate these changes.Three major components are different: Power Supply Board, Pneumatics Board and the Pump. The transformer,T1, has been eliminated in the C model.

In the C model the Power Supply Board now supplies the Pneumatics Board with its operating DC voltages. ThePneumatics Board no longer requires the AC voltages from T1 in order to generate its DC voltages. ThePneumatics Board also supplies 15 VDC to the new DC Pump instead of the Pump 1 control signal that wasused to activate the AC pump used in the MT-3100 /A models. As mentioned above, the Pump has beenchanged from an AC powered Pump to a DC powered Pump.

NOTE: The analyzers operate in the same way from model to model, this chapterdescribes the MT-3100 /A models and points out the differences in the C modelwhen needed.



INFRARED THEORY

There are three key components that make up the Infrared Exhaust Analyzer function. They include the InterfaceCircuitry, Andros Infrared Bench, and the Pneumatics. The Analyzers' purpose is to measure the concentrationsof Hydrocarbons (HC), Carbon Dioxide (CO2), Carbon Monoxide (CO),and Oxygen (O2) emitted from the exhaustof an automobile. The infrared bench is being used to measure HC, CO and CO2 concentrations. The O2readings are obtained from an O2 cell mounted on the rear of the analyzer.

The “IR Bench” creates infrared light. This light passes through a sample cell and is detected at the other end ofthe cell. Each of the gases passing through the cell absorb a different "Infrared Frequency". This is how aninfrared bench measures the concentration of each gas. The following figure and text is a breakdown of thecomponents used in an Infrared (IR) bench.

COHC

CO2

+7.5 VFILTERS

GAS FILLED

DETECTORSAMPLE TUBECHOPPER BLADEIR SOURCE

FIGURE 1. BASIC COMPONENTS OF THE IR BENCHThe Source is used to emit a broad band of "Infrared Light or Energy". The source is nothing more than a coil ofwire with current flowing through it, just like a light bulb.

The Chopper Blade is used as a reference or sync pulse, to allow the hardware interface of the gas bench todetermine the start of a stream of data. When the chopper blade is in front of the source it acts much as the darkpulse. This provides a reference to the computer to tell it that when the chopper blade drops, a reading of thegas will be taken and sent to the computer by the Interface Circuitry.

The Sample Cell is a cylinder that gases flow in and out of. The source is located at one end of the tube,radiating infrared energy through the tube. The gases inside the sample cell absorb the infrared energy as itpasses through. As the energy exits the cell, it passes through an opening that is covered by a concave material.This concave material acts as a lens and focuses the energy to a constant location.

The Optical Filters are located at the end of the sample cell, opposite to the source. The energy focused by thelens passes through the filters. The filters are referred to as Band Pass Filters. These filters will only allow thefrequency of IR light for each of the gases to pass. There are 4 filters used in this 3 gas IR benches, one each forthe three gases HC, CO and CO2 and a Reference filter. The 3 filters for the gases allow the particular frequencyof light for each gas to pass through. The fourth filter, "Reference," allows all the frequencies, except thoseabsorbed by the 3 gases, to pass through. This gives a known value for the source so absorption amount in thesample tube can be determined.

The Detector is positioned behind the filters. It receives the unabsorbed infrared energy. This unabsorbedamount is then turned into an analog voltage that is used in calculating the amount of gas inside the sample tube.The analog voltage is then processed by the Andros Bench, turned into a digital signal and sent to thePneumatics Board. From there the Pneumatics Board processes the digital signals and passes them on to theCommunications Board in the host tester (MT-3000).



CALIBRATION GASPEF (Propane Equivalency Factor) is a value used in calculating the amount of Hydrocarbons contained in thecalibration gas. PEF values will fall between .490-.540. The purpose of PEF is to make Propane Gas appear asHexane Gas during calibrations. Hexane is used by the BAR (Bureau of Automotive Repair) to set standards forthe Hydrocarbon's measurement. The reason Hexane was chosen is due to its molecular structure. It is in themiddle of all the Hydrocarbons that are emitted from vehicles. Hexane is not practical for field use due to itsinstability at different temperatures. This is why we use Propane for calibration, therefore we need a PEF valueto correlate the two readings.

An Example of How PEF is used in Gas Calculations:

Gas Tag Value for Hydrocarbons (HC) 300ppm x PEF from the Bench .510 = 153 ppm. During a GasCalibration, using a bottle with this value, the bench should read 153 ppm (parts per million).

NOTE: PEF is only used in the calculation of Hydrocarbons. CO and CO2 shouldequal the amount on the Gas Tag during calibration.

Gas Tag Values are the values that are written on tags located on gas bottles. These values indicate the mixtureof the HC (Hydrocarbons), CO (Carbon Monoxide) and CO2 (Carbon Dioxide) in the bottle. The Gas Tag Valuesare stored in the MT-3100 software by the operator, in the Gas Calibration Screen.

O2 THEORY

REFER TO DRAWING 11-1 PAGE 11-15The O2 content of the exhaust sample, from the engine under test, is measured by an O2 Cell. The cell outputs aDC voltage in the millivolts range when exposed to atmospheric oxygen. Typically the voltage is 11 millivolts +/-3millivolts when exposed to atmospheric oxygen (20.8%) at sea level. As the oxygen content of the exhaustsample decreases, the cell's DC output voltage decreases. The output of the O2 Cell is very stable throughout itslife. At the end of a O2 Cell life, the output will begin to ramp up as much as 40 millivolts. Therefore, if the outputis consistently out of specification, replacement is recommended.

The O2 Cell output is routed to the IR Analyzer at P8 pin 3 (signal voltage) and P8 pins 4 and 5 (ground). Theinput and ground signals then are digitized and are output through the serial communications on connector JD tothe Pneumatics Board on J1.



AC/DC DISTRIBUTION



Always use the “One Hand Rule” (keep one hand in a pocket or behind your back) when working with ACvoltages. Always verify that the Analyzer is “OFF” using the Power Switch on the side of the tester. It is alsoimportant to ensure the AC power cord is unplugged from the outlet before removing wires from the MT-3100power supply board.

AC DISTRIBUTION

NOTE: The description below is for the MT-3100 /A model testers. The C model feedsAC voltage to the Power Supply Board only, see drawing 11-2, page 11-17.

REFER TO DRAWING 11-1 PAGE 11-15While the host tester of the MT-3100 (the MT-3000), can operate from 120 VAC or 12 VDC, the MT-3100requires 120 VAC for operation. The MT-3100 has a standard AC Line Cord for its AC power feed.

AC power is supplied to the MT-3100 through a standard AC Cord that is plugged into an optional bus strip at therear of the host tester. AC power from the AC Cord ( hot, neutral and ground) is connected to a spade connectorbus strip inside the MT-3100. AC hot (or HI), is connected to pins 1 and 2 of the bus strip. From there AC hot isrouted to: connector J1, pin 1 on the Power Supply Board, one side of both primary windings of the transformerand to the AC HI spade connector on the Pneumatics Board. AC neutral is connected to connectors 3 and 4 ofthe bus strip. From there AC Neutral is routed to: connector J1, pin 2 on the Power Supply Board, one side ofboth primary windings of the transformer and to the AC NEU spade connector on the Pneumatics Board. ACGround is Connected to connector 5 of the bus strip. From there ac ground is routed to: connector J1, pin 3 onthe Power Supply Board and the AC GND spade connector on the Pneumatics Board.

The secondary windings of the transformer supply a center tapped 20 VAC to J4 on the Pneumatics Board. ThePneumatics Board uses this 20 VAC to create its operating DC voltages.



DC DISTRIBUTION

REFER TO DRAWINGS 11-1 (PAGE 11-15) AND 11-2 (PAGE 11-17)The Power Supply Board supplies dc voltages to the IR Bench and the Pneumatics Board.

The chart below describes routing of the dc voltages.

DC VOLTAGE REFERENCE CHART

DC VOLTAGE SIGNAL J2 OF POWERSUPPLY PIN

NUMBER

J4 OFPNEUMATICSBOARD PIN

NUMBER(C MODEL ONLY)

JA OF IRBENCH PINNUMBER

DIGITAL RET (GND) 1 1 1+5V 2 2 2

HP GROUND SENSE 3 3 3+15VHP SENSE 4 4 4

+15VHP 5 5 5+15V ANALOG 6 6 6

ANALOG RET (GND) 7 7 7-15V ANALOG 8 8 8

+15VHP RET (GND) 9 9 9



PNEUMATIC THEORY

REFER TO DRAWINGS 11-1 (PAGE 11-15) AND 11-2 (PAGE 11-17)The pneumatic system associated with the MT-3100 is controlled by two solenoid valves, which are in turncontrolled by solenoid drivers on the Pneumatics Board. The solenoids connect to the Pneumatics Board throughconnector J7. The +15vhp voltage is applied to pins 1 and 3 to supply both solenoids with a constant voltage.The ground return lines ( pin 2 for solenoid 1 and pin 4 for solenoid 2) are pulled low when a solenoid is to beenergized. On the A model the pump controller is supplied +5 volts at J6, pin 1. J6, pin 2 is pulled low when thepump is to be activated. On the C model the pump is supplied 15 VDC at pin 2 of J8 from the PneumaticsBoard to activate. The solenoid valves operate in four different modes. They are: Zero Mode, Gas CalibrationMode, Leak Test Mode, and Sample Mode. A detailed description of each follows.

ZERO MODETo maintain the high accuracy of the MT-3100 the analyzer must continually be zeroed. This can be donemanually by performing the Leak Test, page 11-5. The Zero function is also performed during the Warm-upphase of the unit’s operation. During the Zero Mode clean air is drawn in from the “Zero” port on the back of theanalyzer and into the manifold. The clean air is then drawn through the normally closed port of S1, through thecommon port and to the pump. From the pump the clean air is pushed through the Bench and O2 manifold, andout the port to the atmosphere. It is important to note that the vacuum pump is also aspirating moisture from theprimary filter bowl at this time as is consistent with any time the pump is running. Therefore, if for any reasonsolenoid S1 does not fully energize, gases from the filter assembly would be pulled in.

O2

In

In

VACPUMP

BPX-ducer

Back Panel

Bench Assembly

NO

COM

NC

S1MANIFOLD

NC

COMS2

Back Panel

BENCH

Restrictor

Check

Valve

Check

ValveExhaust

Exhaust

Pressure Transducer(On Pneumatics Board)

Restrictor

ZeroPort

Cal GasPort

ZERO MODECOMPONENT TYPE STATE ACTIVE PORT

PUMP NA ON NAS1 3-WAY ENERGIZED NCS2 NC DE-ENERGIZED NONE

DENOTES PRIMARY FLOW PATH

DENOTES OTHER AFFECTED PNEUMATICSMoisture Out

FIGURE 2. ZERO MODE



GAS CALIBRATION MODEWhile the MT-3100 is designed to maintain accuracy, it may be necessary to periodically perform a GasCalibration on the unit. To determine if a Gas Calibration needs to be performed the operator should consult theUser’s Manual. During a Gas Calibration the pump is off, or not running, and solenoid S2 is energized. Gas fromthe pressurized calibration gas bottle flows in through the back panel “Cal” port. From the “Cal” port thecalibration gas is forced through a restrictor which is internally molded into the manifold. The gas then travelsthrough S2 (which is energized), the Bench, and finally through the O2 manifold where it is pushed out to theatmosphere. As with all pneumatic modes it is important to note any residual flow in case there is a pneumaticrelated problem with the analyzer. The only residual flow in the Gas Calibration Mode would be from the Manifoldblock to the check valve on the exhaust side of the Vacuum pump.

O2

In

In

VACPUMP

BPX-ducer

Back Panel

Bench Assembly

NO

COM

NC

S1MANIFOLD

NC

COMS2

Back Panel

BENCH

Restrictor

Check

Valve

Check

ValveExhaust

Exhaust


Restrictor

ZeroPort

Cal GasPort

CALIBRATION MODE COMPONENT TYPE STATE ACTIVE PORT

PUMP NA OFF NAS1 3-WAY DE-ENERGIZED NOS2 NC ENERGIZED NC



FIGURE 3. CALIBRATION MODE



LEAK TESTDuring the Leak Test the operator must place a Leak Test Cap on the end of the exhaust probe. The pump thendraws a vacuum on the exhaust probe, filtering system, the Pressure Transducer (on the Pneumatics Board), andall tubing on the input side of the sampling system. During this portion of the Leak Test the Pressure Transducerthreshold is changed to allow the unit to accurately measure the vacuum draw, once the proper amount ofvacuum is sensed.

O2

In

In

VACPUMP

BPX-ducer

Back Panel

Bench Assembly

NO

COM

NC

S1 MANIFOLDNC

COMS2

Back Panel

BENCH

Restrictor

Check

Valve

Check

ValveExhaust

Exhaust


Restrictor

ZeroPort

Cal GasPort

LEAK TEST "A" MODE (PULL DOWN)COMPONENT TYPE STATE ACTIVE PORT

PUMP NA ON NAS1 3-WAY DE-ENERGIZED NOS2 NC DE-ENERGIZED NA

CAPEXHAUST

PROBE

EXHAUSTPORT



FIGURE 4. LEAK TEST MODE A



SAMPLE MODEThe Sample Mode is used to read gases from the vehicles exhaust pipe. The exhaust gases are drawn throughthe exhaust probe, primary and secondary filter assemblies, solenoid S1, and into the vacuum pump. From thevacuum pump the exhaust gases are pushed through the check valve, bench, O2 manifold, and out the port to theatmosphere. During this mode the low flow sensor is constantly monitoring the amount of vacuum from thevacuum pump to determine if sufficient flow exists. If it doesn’t have sufficient flow a “Low Flow” condition exists.

O2

In

In

VACPUMP

BPX-ducer

Back Panel

Bench Assembly

NO

COM

NC

S1MANIFOLD

NC

COMS2

Back Panel

BENCH

Restrictor

Check

Valve

Check

ValveExhaust

Exhaust


Restrictor

ZeroPort

Cal GasPort

SAMPLE MODECOMPONENT TYPE STATE ACTIVE PORT

PUMP NA ON NAS1 3-WAY DE-ENERGIZED NOS2 NC DE-ENERGIZED NA


DENOTES OTHER AFFECTED PNEUMATICS

ExhuastPort

Moisture Out

FIGURE 5. SAMPLE MODE



GAS ANALYZER SETUP

1. Turn MT-3000 on and press <OPTION MENU>. Press , SCOPE SETUP.

2. Press , COMM PORT SETUP, and use to highlight the row just next to the comm port you will havethe MT-3100A gas analyzer connected to.

3. Use the to scroll through the options until “MT-3100 GAS ANALYZER” appears in the highlighted row.

4. Press to select the BAUD RATE row, then use to scroll through the options until “9600” appears inthe highlighted row, (do not use 9600S). Press .

5. Press , untitled, to return to the Option Menu.

6. Turn the MT-3000A off and connect the Comm cable from the MT-3100 to the MT-3000A, then turn bothunits on.

7. Press <OPTIONS MENU> to enter the Options Menu..

8. Press , MT-3100 PORT A or ,MT-3100 PORT B, to select the Gas Analyzer’s “Basic Screen” andproceed with the checkout and calibration procedures below.

CHECKOUT AND CALIBRATION

The following procedures are a set of general operations that should insure proper operation and calibration.However, when troubleshooting problems, this text should be referenced in its entirety.

NOTE: In the following procedures, the “BASIC SCREEN” is the screen used for theExhaust Gas Analyzer, MT-3100. As described in each procedure below, thisscreen can be accessed by pressing <OPTION MENU>, and OR , MT-3100PORT A OR PORT B, depending on which port the MT-3100 has been installedon.

LEAK CHECK:1. Allow the analyzer to warm up to operating temperature.

2. Press <OPTIONS MENU>, then press or MT-3100, to enter Basic Screen.

3. From the Basic Screen, press , SERVICE. The screen displays page one of the Service Screen.

4. Press , NEXT PAGE, two times; Page 3 of the Service Screen will be displayed.

5. Press , LEAK TEST.

6. Follow the prompts in the message box, as described bellow.

7. Seal the tip of the Sample Probe with the Leak Check Cap.

8. Press , CONTINUE. While the leak test is being performed, “LEAK TEST IN PROGRESS” will bedisplayed in the message box. After the test is complete “REMOVE CAP FROM PROBE TIP PRESSCONTINUE WHEN READY” is displayed. Press CONTINUE.

9. Observe the message box. If “LEAK TEST FAILURE--SERVICE REQUIRED” is displayed, troubleshoot theleak.

10. If the leak test is passed, Press , Return, to return to the Basic Screen.

TEST COMPLETE



PUMP/PUMP CONTROL CHECK:1. Press <OPTIONS MENU>, then press , GAS ANALYZER, to enter Basic Screen.

2. Press , SERVICE, twice to access the second Service Screen.

3. Press , PUMP ON/OFF, to toggle pump on and off.

4. The pump should turn on and off with the controlling toggle. If the pump does not operate, troubleshoot thepump, then troubleshoot the MT-3000 Keyboard, chapter 4.

5. Press , Return, to return to the Basic Screen.

TEST COMPLETE

SOLENOID CHECK:1. Press <OPTIONS MENU>, then press , GAS ANALYZER, to enter Basic Screen.

2. Press , SERVICE, twice to access the second Service Screen.

3. Set the regulator of the cal gas bottle to an output of 10 PSI.

4. Connect the calibration gas bottle to the input of a flowmeter. Connect the output of the flowmeter to theCalibration Port at the rear of the MT-3100A module.

5. Press , SOLENOID 2, note that the flow meter reads between 0.7 and 2.0 CFPM.

6. Press , SOLENOID 2, again, to turn the solenoid off, and note that the reading is zero.

7. Turn the gas cal bottle off and relive all pressure (leave the regulator set to 10 PSI output). Connect thecalibration gas bottle to the input of a flowmeter. Connect the output of the flowmeter to the Zero Air Port atthe rear of the MT-3100A module.

8. Press , SOLENOID 1.

9. Turn the cal gas bottle valve so that the flow meter reads 4 CFPM.

10. Press , SOLENOID 1, again to turn the solenoid off, then note that the flow meter reads zero.

11. If the flow meter readings do not change as described above, troubleshoot the affected solenoid. Press ,Return, to return to the Basic Screen.

TEST COMPLETE



GAS CALIBRATION

NOTE: The unit will designate different tolerance ranges for different concentrationsof calibration gas. The chart below outlines these ranges.

Gas Tag Values Allowable Range (+/- Tolerance)HC PPM PPM140-240 11240-400 12400-2000 60

2000-10000 500CO % %0-1.0 0.05

1.0-2.0 0.062.0-5.0 0.155.0-7.0 0.207.0-10.0 0.30CO2 % %

All Concentrations 0.4

1. Allow analyzer to warm up for 30 minutes.

2. Press <OPTIONS MENU>, then press , GAS ANALYZER, to enter Basic Screen.

3. From the Basic Screen, press , SERVICE, The screen displays page one of the Service Screen.

4. Press , Gas Calibration

5. Follow the prompts in the message box, as described below.

6. Connect the calibration gas bottle to the Calibration Port and pressurize the system to between 7 PSI and 10PSI. Press , Continue.

7. The display will show the stored Gas Tag values for HC, CO and CO2.

8. If the displayed readings are different than the Gas Tag Values on the Calibration Gas Bottle, enter thecorrect reading into the display using the numeric keypad and arrow keys.

9. Press , CONTINUE. “GAS CALIBRATION IN PROGRESS” is displayed. The calibration begins with theZero Cycle, followed by the Calibration Cycle; a bar graph indicates the relative time remaining. Aftercalibration, the tester performs another Zero Cycle.

10. If the calibration is successful, the bar graph will end and the display will return to page 1 of the ServiceScreen. Press , RETURN, to return to the Basic Screen.

11. If the calibration was not successful, “CAL FAILED-DEFAULT CAL NOW IN USE” will be displayed. Theanalyzer is now using the factory calibration figures, resulting in possibly inaccurate readings. If the analyzerwill not pass a calibration, see the troubleshooting section on page 11-13.



TROUBLESHOOTING


I. Unit displays “RS-232 PORT XNOT RESPONDING”

• Check that MT-3100A is turned on.

• Check connections at rear of tester.

• Check setup, refer to setup procedure on page 11-7.

• Refer to drawing 11-1, check for +5 and + & -15 volts at J2 of thePower Supply Board.

If DC voltages are not present, check the AC voltage to the PowerSupply Board, J1. If AC voltage is not present at J1, troubleshootAC circuit. If AC voltage is present, replace Power Supply Board.

If DC voltages are present:

Replace Communications cable

Replace Pneumatics Board

Replace IR Bench

Replace Communications Board in host tester, MT-3000A

II. Unit displays “LEAK TESTFAILURE-SERVICEREQUIRED”

• Check that Probe Cap was on the probe tip before entering thetest.

• Check all connections; tighten as needed.

• Check all hoses and fittings for cuts, cracks and abrasions;replace as needed.

• Check Pump for: worn or contaminated Flapper Valves andDiaphragm for cracks; repair as needed or replace pump.

• Replace Pneumatics Board.

III. Unit displays “LOW FLOW -CHECK FILTERS HOSEPROBE”

• Check for kinked, plugged or pinched hose or probe. Removehose from Filter Assembly and blow out.

• Replace filter elements.

• Perform Leak Check, page 11-9, to reset Low flow/ Leak CheckTransducer sensitivity.

• Replace Pneumatics Board.




IV. Unit displays “LOW FLOW”during zeroing

• Check Zero port at rear of tester for blockage.

V. Unit displays “TAG VALUE OUTOF RANGE”

• Enter correct values, check cal gas tank tag and see page 11-11for Table of tolerances.

11-15

4321

123

/RXDHOST

123

12345

(MT-3000)

123

123

1234567

12345

12345

12345

123456

12345678910

Solenoid 1

Solenoid 2

VACUUMPUMP

DIGITAL RET (GND)+5V

HP GND SENSE+15VHP SENSE

+15VHP+15V ANALOG

ANALOG RET (GND)-15V ANALOG

+15VHP RET (GND)

123456

9

78

DIGITAL RET (GND)+5VHP GND SENSE+15VHP SENSE+15VHP+15V ANALOGANALOG RET (GND)-15V ANALOG+15VHP RET (GND)

123456789 RX

TXCOMMUNICATIONS GND

X1RESET

O2 SENSORO2 SENSOR RETURNO2 SENSOR RETURN

RXTXGNDNCRESET

(+) SOL1(-) SOL1

(+) SOL 2(-) SOL 2

(+) PUMP 1(-) PUMP 1

POWERSTRIP


PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


DWG REV:

A MODEL IRINTERCONNECTION

JD

JA

P8

POWER INPUT

TRANSDUCER INPUTS

J1AC INAC IN (NEUTRAL)AC GND

J2

POWER SUPPLYBOARD

IR ANALYZER

ANALYZERCOMMUNICATIONS

SENSORO2

AC (HI)

AC GNDAC (NEU)

120 VACINPUTAC GND

AC (HI)

AC (NEU)

/TXDHOSTGNDRTSHOSTCTSHOSTDTRHOSTDSRHOST

HOSTINTERFACECONNECTOR

J3

J1

J4

110VACCOMMON

220VAC

INPUTVOLTAGESELECTION

J4

PNEUMATICS BOARD

HICTLO

20 VACINPUT

110VACINPUT

CHASSISGND

HOST COMMUNICATIONS

M

J6PUMPCONTROLSIGNALS

SOLENOIDDRIVES

J7

MT-3100 A/BR. Z. Wilson

11-1

08/96M.B. Clark



Notes:

11-17

/RXDHOST

123

(MT-3000)

123

123

1234567

12345

12345

12345

123

12345678910

Solenoid 1

Solenoid 2

PUMP

DIGITAL RET (GND)+5V

HP GND SENSE+15VHP SENSE

+15VHP+15V ANALOG

ANALOG RET (GND)-15V ANALOG

+15VHP RET (GND)

123456

9

78


123456789 RX

TXCOMMUNICATIONS GND

X1RESET

O2 SENSORO2 SENSOR RETURNO2 SENSOR RETURN

RXTXGNDNCRESET

(+) SOL1(-) SOL1

(+) SOL 2(-) SOL 2

123456789

PUMP 1 (GND)+15 VDC HP

PUMP 2 (Not used)



PAGE:

CHK BY:

MODEL:

DWG BY:

TITLE:

DWG:


DWG REV:

MODEL C IRINTERCONNECTION

JD

JA

P8

POWER INPUT

TRANSDUCER INPUTS

J1AC INAC IN (NEUTRAL)AC GND

J2

POWER SUPPLYBOARD

IR ANALYZER

ANALYZERCOMMUNICATIONS

SENSORO2

/TXDHOSTGNDRTSHOSTCTSHOSTDTRHOSTDSRHOST

HOSTINTERFACECONNECTOR

J3

J1

J4

110VACCOMMON

220VAC

INPUTVOLTAGESELECTION

J4

PNEUMATICS BOARD

110VACINPUT

HOST COMMUNICATIONS

J8

SOLENOIDDRIVES

J7

MT-3100 CR. Z. Wilson

11-2

08/96



Notes:


CHAPTER 12 PARTS

GENERAL

This chapter describes assemblies, subassemblies and parts considered replaceable in field situations.

NOTE: The following is a breakdown description for the serial number.

Serial # Location - Back side of unit next to the main leadset connector.

Example:

95 23 0009

Year of MFG. Week of Year of MFG. Number of Unit

NS: NOT SHOWN IN PICTORIAL

CHAPTER 12 PARTS


PARTS BY PICTORIAL

TOP VIEW

T1

FRONT PANEL DETAILSEE PAGE 12-3

LEAD INPUT POCKET

1 2 3 4

5

6

7

8

9

1011121314151617

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Monitor Assy MT3000500A 13 Board, Analog MT3000A11002 Board, Power Supply MT3000A1700A 14a Board, Digital (MT3000A) MT3000A13003 Fuse, 20A 32V 210551 14b Board, Digital (MT3000) MT3000-13004 Fuse Holder 210951 15a Board, Video (MT3000A) MT3000A1400A5 Connector, 12V 212748 15b Board, Video (MT3000) MT3000-14006 Board, Input Protection MT3000A1800 16a Board, Communications

(MT3000A)MT3000A1600A

7 Circuit Breaker, 15 Amp 28851 16b Board, Communications(MT3000)

MT3000-1600

8 Switch, Power Select 28758 17 Board, Backplane MT3000A1000A9 Circuit Breaker, 3 Amp 28751 NS Rectifier, Bridge 2724010 Assembly, Line Filter 210751 NS Mounts, Rubber 8501811 Switch, ON / OFF 28658 NS Handle, Cord Wrap 8563312 Transformer, T1 711401 NS Cord, Line 62421

CHAPTER 12 PARTS


FRONT PANEL

SETPOINT

PRINTSELECT

FREEZE

ENTER

DIAGNOSTICWAVEFORM

MENU

RESET

HELP

MEMORYMENU

OPTIONMENU

CYLINDERTEST MENU

PRIMARYMENU

SECONDARYMENU

10

1 2 3

4 5 6

97 8

0

R

F1 F2 F3 F4 F5 F6

NOTE: FRONT PANEL BEZELINCLUDES "SOFTKEYS" ASSEMBLY

1 2

3

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Front Panel Bezel, with

Softkeys AssemblyMT3000A700 3 POT, Brightness MT300016A

2 Main Keyboard Assembly MT3000A60 3a Knob, Brightness MT30005A

CHAPTER 12 PARTS


STANDARD LEADS AND ACCESSORIES

Shell Size 13 Shell Size 17 Shell Size 23

1 23

4 5

67

8

9

1011 12

13

15

1617

18

1914

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Lead Assembly, Secondary MT3000320 11 Ring, Connector

Coupling, Small213248

2 Lead Assembly, 12 voltPower

MT3000210A 12 Ring, ConnectorCoupling, Medium

213348

3 Adapter, GM HEI MT3000300A 13 Ring, ConnectorCoupling, Large

213448

4 Adapter, Backprobe MT3000430A 14 Adapter, Ford TFI 0552-00435 Lead Assembly, Lab MT3000230 15 Adapter, GM TBI MT1665606 Pliers, Spark Plug Boot YA824-B 16 Adapter, Bosch FI MT1665707 Adapter. GM External Coil 0552-0044 17 Adapter, Honda MT3000310B8 Adapter Set, GM and Ford YA859 18 Adapter, Toyota MT30003309 Lead Assembly, Main MT3000A200 19 Lead Assembly,

Inductive, #1 TriggerMT60A08R

10 Adapter, GM Micropak 0552-0045

CHAPTER 12 PARTS


OPTIONAL LEADS AND ACCESSORIES

R

ZERO

AMT PARALLELPRINTER

MT3010SCRIBE IIPARALLELPRINTER

MT1670ASERIAL PRINTER

PRINTERS

12

3

4 5

6

87

9

121110

13 14 15

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Probe, Amps MT3000410AM 11 Probe, Low Amps MT3000A440M2 Probe, Power Balance MT3000420AM 12 Cable, RS232 Serial MT30002403 Pickup, DI Pickup

AssemblyMT3000345A 13 Printer, AMT Parallel, 110 v 0528-0029-01

4 Harness, Ignition SystemDiagnostic Harness

YA3601 14 Printer, AMT Parallel, 220 v 0528-0029-02

5 Pickup, DI MT1658200B 15 Printer, Scribe II Parallel.110 v

MT3010

6 Probe, Vacuum MT3000400B 16 Printer, Serial MT1670A7 Adapter, Null Modem

Gender ChangerMT300034 NS Paper, Printer 0528-0994

8 Leads, DI Expander Set MT3000341A NS Ribbon, AMT Printer 0528-1065-019 Remote Control MT3000-600 NS Ribbon, Scribe II Printer MT3010-310 Cable, Parallel Printer 6004-0707-01 NS Ribbon, Serial Printer 2-7366-2

CHAPTER 12 PARTS


GAS ANALYZER, BLOWUP VIEW

1

2

3

45

6

7

8

9

10

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Board, Power Supply MT3100-09A N/S Hose, Sample MT3100202a Board, Pneumatics

(MT3100A)MT3100-06A N/S Handle, Sample Probe MT31007

2b Board, Pneumatics(MT3100A[C])

MT3100-63 N/S Probe, Sample MT310018

3 Sensor Block, O2 MT31008 N/S Cap, Sample Probe MT3100324 Sensor, O2 7049-0004-01 N/S Fitting, Cal Gas 156805a Pump, Sample (MT3100A) MT3100 04B N/S Cord, Power MT3100-225b Pump, Sample

(MT3100A[C])MT3500A-21 N/S Harness, O2 Wiring MT3100-25

6 Block, Solenoid MT3100-27 N/S 2 Amp Circuit Breaker MT3100-377 Solenoid, Two Way MT3100-29 N/S Switch, On/Off MT3100-368 Solenoid, Three Way MT3100-28 N/S Transformer MT310010A9 IR Bench MT3100-46 N/S Cable, Interface MT3100-2310 Sample Cell MT3100-02A N/S Probe, Needle Adapter MT310019N/S Fitting, 90° Brass Male 113780 N/S Cap, Needle Probe Adapter MT310033N/S Fitting, Brass Pipe 113480

CHAPTER 12 PARTS


FILTER ASSEMBLY

6

5

1

3

2

7

2 2

11

1

6

1

12

10

9

8

1314

4

ITEM DESCRIPTION PART NUMBER ITEM DESCRIPTION PART NUMBER1 Fitting, Brass Nipple 0647030101 8 Nut, Bowl 03010948012 Nut, Brass Seal 0647030201 9 Nut, Element Retainer 03010946013 Fitting, Brass Elbow 0647030301 10 Bowl, Filter 03010947014 Fitting, Brass Flare 113380 11 Plug, Nylon 064701385 Filter Element, Primary 0301094401 12 Filter Element, Sec. 03010945016 Fitting, Brass 90° Barb 113680 13 Bracket, Filter MT3500A97 Fitting, Brass Pipe 113480 14 Filter Housing 0301094201

CHAPTER 12 PARTS


PARTS IN ALPHABETICAL ORDER

DESCRIPTION PART NUMBER COMMENTSAdapter, Backprobe MT3000430 Connectors used for “back-probing”.Adapter, Bosch Fuel Injector MT166570 Bosch Fuel Injector AdapterAdapter, Coil, Ford, TFI 0552-0043 Adapter for Ford TFI coil adapterAdapter, Coil, GM Micropak 0552-0045 Provides connections to primary of Micropak ignition

systemsAdapter, Coil, GM, External 0552-0044 Coil Adapter, GM, External connectionsAdapter, Coil, GM, Ford YA859 Coil Adapter Set, GM and FordAdapter, Coil, Honda MT3000310B Secondary pickup for Honda ignition systemsAdapter, Coil, Toyota, Chevrolet,Nova IIA

MT3000330 Coil Adapter for Toyota, Chevrolet, Nova IIA, requirescalibration, see chapter 3.

Adapter, GM TBI MT166560 Adapter for GM TBI systemsAdapter, HEI MT3000300A GM HEI pattern pickup with lead connectorAdapter, Null Modem Changer MT300034 25 pin DIN Gender ChangerAssembly, Line Filter 210751 Houses 20 amp fuse, Line Filter and AC connectorBench, IR MT3100-46 Infrared Bench assemblyBezel, Front Panel MT3000A700 Includes Softkeys (F1 - F6)Board, Analog MT3000A1100 Analog processing and calibrationBoard, Backplane MT3000A1000A Four main boards connect into this boardBoard, Communications MT3000A1600A Used on MT3000ABoard, Communications MT3000-1600 Used on MT3000Board, Digital MT3000A1300 Used on MT3000ABoard, Digital MT3000-1300 Used on MT3000Board, Input Protection MT3000A1800Board, Main Key MT3000A60 Main functionsBoard, Pneumatics MT3100-06A Pneumatics control for MT3100ABoard, Pneumatics MT3100-63 Pneumatics control for MT3100A(C)Board, Power Supply MT3100-09A Power supply for MT-3100Board, Power Supply MT3000A1700A Power supply for MT-3000Board, Video (MT3000A) MT3000A1400A Used on MT3000ABoard, Video MT3000-1400 Used on MT3000Cable, Interface MT3100-23 Inteface cable from MT3100 to MT-3000Cable, Parallel Printer 6004-0707-01Cable, RS232 Serial MT3000240Cap, Sample Probe MT310032 Used during leak testCap, Sample, Needle Adapter MT310033 Used to leak test Needle AdapterCircuit Breaker, 2 Amp MT3100-37 Circuit breaker for MT-3100Circuit Breaker, 3 Amp 28751 Ground Fault BreakerCircuit Breaker, 15 Amp 28851 Main BreakerConnector, 12 VDC 212748 3 Pin connector at back of testerCord, Line 62421 110 Volt line cordCord, Power (MT-3100) MT3100-22 Power cord for MT-3100Filter, Assembly, Primary 0301013601 Complete Primary filter assemblyFilter, Assembly, Secondary 0301094201 Complete secondary filter assemblyFilter Bowl 0301094701 Filter Bowl for both Primary and Secondary filtersFilter Housing, 0301094201 Housing for both Primary and Secondary filtersFilter, Primary 0301094401 Primary FilterFilter, Secondary 0301094501 Secondary FilterFitting, Brass Elbow 0647030201Fitting, Brass Flare 113380 Connection for Sample HoseFitting, Brass Nipple 06470030101 Connects to sample hoseFitting, Brass Pipe 113480 Connects Primary Filter Housing to Secondary FilterFitting, 90° Barb 113680 Bottom of Primary Filter Bowl and outlet of Secondary

Filter HousingFitting, Cal Gas Inlet 15680

CHAPTER 12 PARTS


DESCRIPTION PART NUMBER COMMENTSFuse, 32 VDC, 20 Amp 210551 Backup for 8 Amp BreakerFuseholder 210951Handle, Cord Wrap 85633Handle, Sample Probe MT31007Harness, Ignition SystemDiagnostic Harness

YA3601 For GM Integrated Direct Ignition (IDI) System

Harness, O2 Wiring MT3100-25 Wiring harness for O2 sensor in MT-3100Hose, Sample MT310020 Exhaust sample hose for MT-3100Kit, Tri-filter Retro Fit EAK0004A00AKnob, Brightness MT30005ALead Assembly, +12 VDC Power MT3000210A Power Lead-in from batteryLead Assembly, Lab Scope MT3000230 Single, red clip leadLead Assembly, Main MT3000A200 Main lead assembly, connected at rear of testerLead Assembly, Secondary MT3000320 Secondary pattern pickupLead Assembly, Trigger MT60A08A #1 Cylinder pickup for TriggeringLead, DI Pickup Lead MT1658200BLead, DI Lead Expander MT3000341A Allows testing of ten cylinder enginesLeads, Jumper MT30124 24" jumper leadsMonitor Assembly MT3000500A Pre-adjusted monitor assembly, Driver Board and CRT

Assembly are included as a setMounts, Rubber 84918 Rubber feet of testerNut, Bowls 0301094801 Retaining nut for filter bowlsNut, Filters 0301094601 Retaining nut for filtersPaper, Printer 0528-0994Pickup, DI Pickup Assembly MT3000345A Secondary pickup for distributorless ignitionsPliers, Spark Plug Boot Pliers YA824B Nonconductive Pliers for removing Spark Plug BootsPlug, Nylon 06470138 Plugs bottom of Secondary Filter BowlPot, Brightness MT300016A Includes CablePrinter, AMT Parallel, 110 v 0528-0029-01Printer, AMT Parallel, 220 v 0528-0029-02Printer, Scribe II Parallel, 110v MT3010Printer, Serial MT1670AProbe, Amps, Basic MT3000410 Inductive Amps Probe for testerProbe, Amps, Low MT3000A440 Reads a lower level of current flow.Probe, Power Balance MT3000420A Used for cylinder analysisProbe, Sample MT310018 Exhaust probe for MT-3100Probe, Sample, Needle Adapter MT310019 Samples vehicles with diffuser in tailpipeProbe, Vacuum MT3000400 Vacuum sensor, no calibrationPump, Sample MT3100-04B Sample pump for MT-3100APump, Sample MT3500A-21 Sample pump for MT3100A(C)Rectifier, Bridge 27240Remote Control MT3000600 Infra Red remote controlRibbon, AMT Printer 0528-1065-01Ring, Connector, Large 213448 Coupling ring for Main Lead Assembly at rear of testerRing, Connector, Medium 213348 Coupling ring for Auxiliary ConnectorRing, Connector, Small 213148 Coupling ring for #1 Plug Connector and Secondary

Pickup ConnectorRing, O 0301094301 O-ring for filter bowlsSample Cell MT3100-02A Sample cell for MT-3100Sensor Block, O2 MT3100-27 Manifold for O2 sensorSensor, O2 7049-0004-01Solenoid, 2 Way MT3100-29Solenoid, 3 Way MT3100-28Solenoid Block MT3100-27 Manifold for solenoidsSwitch, On/Off MT3100-36 Power switch for MT3100Switch, On/Off 28658 Main Power Switch

CHAPTER 12 PARTS


DESCRIPTION PART NUMBER COMMENTSSwitch, Power Select 28758 Selects between AC and DC powerTransformer MT310010A Transformer for MT-3100Transformer, T1 711401 Transformer for MT-3000

CHAPTER 12 PARTS


PARTS IN NUMERICAL ORDER

PART NUMBER DESCRIPTION COMMENTS06470302201 Nut, Brass Seal0647030301 Fitting, Brass Elbow0647030101 Fitting, Brass Nipple Connects to sample hose0301094801 Nut, Bowls Retaining nut for filter bowls0301094701 Filter Bowl Filter Bowl for both Primary and Secondary filters0301094601 Nut, Filters Retaining nut for filters0301094501 Filter, Secondary Secondary Filter0301094401 Filter, Primary Primary Filter0301094301 Ring, O O-ring for filter bowls0301094201 Filter, Assembly,

SecondaryComplete secondary filter assembly

0301094201 Filter Housing, Housing for both Primary and Secondary filters0301013601 Filter, Assembly, Primary Complete Primary filter assembly06470138 Plug, Nylon Plugs bottom of Secondary Filter Bowl711401 Transformer, T1 Transformer for MT-3000(A)213448 Ring, Connector Coupling,

LargeCoupling ring for Main Lead Assembly at rear of tester

213348 Ring, Connector Coupling,Medium

Coupling ring for Auxiliary Connector

213248 Ring, Connector Coupling,Small

Coupling ring for #1 Plug Connector and Secondary PickupConnector

212748 Connector, 12 VDC 3 Pin connector at back of tester210951 Fuseholder210751 Assembly, Line Filter Houses 20 amp fuse, Line Filter and AC connector210551 Fuse, 32 VDC, 20 Amp Backup for 8 Amp Breaker113780 Fitting, 90° Brass, Male113680 Fitting, 90° Barb Bottom of Primary Filter Bowl and outlet of Secondary Filter

Housing113480 Fitting, Brass Pipe Connects Primary Filter Housing to Secondary Filter Housing113380 Fitting, Brass Flare Connection for Sample Hose85633 Handle, Cord Wrap84918 Mounts, Rubber Rubber feet of tester62421 Cord, Line 110 Volt line cord28851 Circuit Breaker, 15 Amp Main Breaker28758 Switch, Power Select Selects between AC and DC power28751 Circuit Breaker, 3 Amp Ground Fault Breaker28658 Switch, On/Off Main Power Switch27240 Rectifier, Bridge15680 Fitting, Cal Gas Inlet7049-0004-01 Sensor, O26004-0707-01 Cable, Parallel Printer0552-0043 Adapter, Coil, Ford®, TFI Adapter for Ford® TFI coil adapter0552-0044 Adapter, Coil, GM, External Coil Adapter, GM, External connections0552-0045 Adapter, Coil, GM Micropak Provides connections to primary of Micropak® ignition

systems0528-0029-01 Printer, AMT Parallel 110 vMT3100-02A Sample Cell Sample cellMT3100-04B Pump, Sample Sample pump for MT3100AMT3100-06A Board, Pneumatics Pneumatics control for MT3100AMT3100-09A Board, Power Supply Power supplyMT35000A-21 Pump, Sample DC Pump used in MT3100A(C)MT3100-22 Cord, Power (MT-3100) Power cord forMT3100-23 Cable, Interface Inteface cable from MT3100 to MT3000

CHAPTER 12 PARTS


PART NUMBER DESCRIPTION COMMENTSMT3100-25 Harness, O2 Wiring Wiring harness for O2 sensorMT3100-27 Solenoid Block Manifold for solenoidsMY3100-27 Sensor Block, O2 Manifold for O2 sensorMT3100-28 Solenoid, 3 WayMT3100-29 Solenoid, 2 WayMT3100-36 Switch, On/Off Power switchMT3100-37 Circuit Breaker, 2 Amp Circuit breakerMT3100-46 Bench, IR Infrared Bench assemblyMT3100-63 Board, Pneumatics Used in MT3100A(C)0528-0994 Paper, Printer0528-1065-01 Ribbon, AMT PrinterMT3000-1300 Board, Digital Used in MT3000MT3000-1400 Board, Video Used in MT3000MT300-1600 Board, Communications Used in MT3000EAK0004A00A Kit, Tri-filter Retro FitMT1658200B Lead, DI Pickup LeadMT166560 Adapter, GM® TBI Adapter for GM TBI systemsMT166570 Adapter, Bosch® Bosch® Fuel Injector AdapterMT1670A Printer, SerialMT300016A POT, Brightness Includes CableMT3000210A Lead Assembly, +12 VDC

PowerPower Lead-in from battery

MT3000230 Lead Assembly, Lab Scope Single, red clip leadMT3000240 Cable, RS232 SerialMT3000300A Adapter, HEI GM HEI pattern pickup with lead connectorMT3000310B Adapter, Coil, Honda® Secondary pickup for Honda® ignition systemsMT3000320 Lead Assembly, Secondary Secondary pattern pickupMT3000330 Adapter, Coil, Toyota®,

Chevrolet®, Nova® IIACoil Adapter for Toyota®, Chevrolet®, Nova® IIA, requirescalibration, see chapter 3.

MT300034 Adapter, Null ModemGender Changer

25 pin DIN Gender Changer

MT3000341A Lead, DI Lead Expander Allows testing of ten cylinder enginesMT3000345A Pickup, DI Pickup

AssemblySecondary pickup for distributorless ignitions

MT3000400 Probe, Vacuum Vacuum sensor, no calibrationMT3000410A Probe, Amps, Basic Inductive Amps Probe for testerMT3000420A Probe, Power Balance Used for cylinder analysisMT3000430 Adapter, Backprobe Connectors used for “back-probing”.MT3000500A Monitor Assembly Pre-adjusted monitor assembly, Driver Board and CRT

Assembly are included as a setMT30005A Knob, BrightnessMT3000600 Remote Control Infra Red remote controlMT3000A1000A Board, BackplaneMT3000A1100 Board, Analog Analog processing and calibrationMT3000A1300 Board, Digital Used in MT3000AMT3000A1400A Board, Video Used in MT3000AMT3000A1600A Board, Communications Used in MT3000AMT3000A1700A Board, Power Supply Power supply for MT-3000AMT3000A1800 Board, Input ProtectionMT3000A200 Lead Assembly, Main Main lead assembly, connected at rear of testerMT3000A440 Probe, Amps, Low Reads a lower level of current flow.MT3000A60 Board, Main Key Main functionsMT3000A700 Bezel, Front Panel Includes Softkeys (F1 - F6)MT3010 Printer, Scribe II Parallel,

110vMT30124 Leads, Jumper 24" jumper leadsMT310010A Transformer Transformer for MT3100A

CHAPTER 12 PARTS


PART NUMBER DESCRIPTION COMMENTSMT310018 Probe, Sample Exhaust probeMT310020 Hose, Sample Exhaust sample hoseMT310019 Probe, Sample, Needle

AdapterSamples vehicles with diffuser in tailpipe

MT310032 Cap, Sample Probe Used during leak test

MT310033 Cap, Sample, NeedleAdapter

Used to leak test Needle Adapter

MT31007 Handle, Sample ProbeMT60A08R Lead Assembly, Trigger #1 Cylinder pickup for TriggeringYA3601 Harness, Ignition System

Diagnostic HarnessFor GM® Integrated Direct Ignition (IDI) System

YA824A Pliers, Spark Plug BootPliers

Nonconductive Pliers for removing Spark Plug Boots

YA859 Adapter, Coil, GM®, Ford® Coil Adapter Set, GM® and Ford®

CHAPTER 12 PARTS


Effective03/97 Page A-1

APPENDIX A ERROR MESSAGES

GENERAL

Error and Informational messages (hereon referred to as error messages) play a key roll in making the MT-3000AScope user friendly. Error messages will inform the operator of possible missing input signals (i.e., somenecessary lead is not attached), incorrect scope setup (i.e., wrong engine information), or an invalid operation(i.e., invalid key). Other messages will inform the operator as to what is happening when it appears nothing ishappening (i.e., characterizing in DI). Still others guide the operator through different steps that can be taken (i.e.,clear memory).

The error messages and possible causes are listed below:

ERROR MESSAGES

ERROR MESSAGE DESCRIPTION POSSIBLE CAUSEInvalid Key Invalid Key • The last key pressed was not valid

for the situation.

Invalid Firing Order Invalid Firing Order • Re-enter the firing order.

• Use the arrow, numeric andfunction keys as required to selectthe firing order.

• Press <ENTER>.

Yellow Lead No sync input from yellow booted lead. • Check connection at test point.

• Check ground connection(s).

• Check leadset integrity (with selfdiagnostics).

White Lead No input from white booted lead. • Check connection at test point.



Engine Data Engine data set for _ cylinder engine. Ignitionfirings indicate _ cylinders.

• Check engine data.

• Check ignition systemtriggering/crossfiring.

• Check ground connection (s).

Secondary Pickup No sync input from secondary pickup. • Check secondary pickup.



APPENDIX A ERROR CODES

EffectivePage A-2 03/97

ERROR MESSAGE DESCRIPTION POSSIBLE CAUSEInductive Pickup No sync input from #1 spark plug inductive

pickup.• Check inductive pickup for full

closure of thumb slide.

• Check cylinder #1 spark plug wirefor secondary voltage.



Cyl Shorting NoInput

Cylinder shorting attempted without inputfrom yellow booted lead.

• Check connections at test point.



Cyl Shorting DI Cylinder shorting not available with:• Distributorless Ignition• Screen indicating frozen or memory• Honda pickup

• Press any key to continue.

Fuel Injector No sync input from yellow booted lead. • Check fuel injector polarity.

• Check connection to fuel injectoradapter.



Amp Probe No sync input from auxiliary connector/ampprobe.

• Check amp probe attachment toauxiliary connector


• Check Leadset integrity (with selfdiagnostics).

Capacitive Clips No sync input from auxiliary connector/redlead.

• Check red lead attachment toauxiliary connector.

• Check connection to device undertest.



Vacuum Probe No sync input from auxiliaryconnector/vacuum probe.

• Check vacuum probe attachmentto auxiliary connector.

• Check vacuum supply line tovacuum probe.



Primary DI Primary waveform screen is not availablewith distributorless ignition.

• Select the duty cycle bar graphscreen or press another menu key.


Effective03/97 Page A-3

ERROR MESSAGE DESCRIPTION POSSIBLE CAUSEDwell Bar Graph DI Dwell bar graph not available with

distributorless ignition.• Select the duty cycle bar graph

screen or press another menu key.

No Screen to View No screen to view for this selection. • A screen has not been frozen inthis RPM set point selection.

Voltage WaveformNo Sync

No sync input for voltage waveform. • Engine sync requires connection ofone of the following: Primary(yellow) lead or Secondary pickupor #1 sparkplug inductive pickup.

Test Port Test port not responding • Check Connections.

Printer Paper Printer out of paper • Check paper supply in printer.

Printer notSelected

Printer not selected. • Select printer using scope setup inthe option menu.

Printer Malfunction Printer Error • Check printer for malfunction.

Screen Recall No Screen to be recalled. • Only "Saved" screens (screenswith time and date stamp) may berecalled.

Save Live Screen Attempting to save live screen. • Only "Frozen", screens may besaved.

Clear Confirmation • Press <CLEAR MEMORY> againif sure.

DI CharacterizingMessage

• Please wait. Characterizing ...

CTB SamplingMessage

• Please wait. Sampling ...

Clear ColumnMessage

• To clear entire memory column,press <CLEAR MEMORY> again.

Clear ScreenMessage

• To clear other memory column,press <CLEAR MEMORY> again.

Overwrite Memory • Press <SAVE MEMORY> again tooverwrite existing data.


EffectivePage A-4 03/97

Effective03/97 Page B-1

APPENDIX B GLOSSARY

GENERAL

The following is a Glossary of common terms that may have been used throughout this manual, but are notnecessarily limited to their use in this text. Many terms pertinent to the MT-3000A Engine Analyzer are incommon usage in the automotive repair industry. When reading this manual please refer to this appendix forterms you are uncertain about. If you come across a term which you are unfamiliar with and do not find it in thisappendix, please alert Technical Support in Crystal Lake, so they may make the proper adjustments.

AIR / FUEL RATIO A Specific quantity of air per one part of fuel, by weight, i.e., 14.7 pounds of air toone pound of fuel. This may be written as a ratio 14.7 to 1 or 14.7:1. The smallerthe quantity of air, the richer the fuel mixture. The larger the quantity of air, theleaner the mixture.

ALPHANUMERIC A set of alphabetic and numeric characters.

ALTERNATINGCURRENT (AC)

An electric current that reverses its direction at regularly occurring intervals.

AMBIENT Usually referred to in gas analyzers as ambient air. This is the air surrounding theanalyzer.

AMC American Motors Corporation.

AMPERAGE(AMPERES) (AMPS)

The amount of current flowing in an electrical circuit. One Amp equals the currentflow resulting from the application of one Volt across a one Ohm load. I=E/R

ANALOG SIGNAL A continuous electrical signal representing a condition (such as temperature, or theposition of a mouse). Unlike a digital signal, which is discrete, an analog signal canbe any frequency or amplitude.

ASCII American Standard Code for information interchange. Set of digital codes for allalpha-numeric and control codes.

ASYNCHRONOUS Not synchronous. Events, signals or portions of signals not occurring at preciselythe same time, or in which a regular time relationship is lacking, are asynchronous.

BAUD A measure of the rate at which digital data is transmitted in bits per second;typically ranges up to 57,600 baud (57.6k baud).

BASELINE The reference setting or 0% level of a waveform, as determined by superimposinga horizontal cursor on the waveform.

BUFFER 1) A circuit that isolates a sensitive input circuit from its corresponding driver toavoid unwanted reaction. A buffer circuit may produce either an inverted or non-inverted signal.

2) An electronic reservoir that temporarily stores data.

CAPACITANCE The storage of an electrostatic charge in a component when a voltage existsbetween two conductors separated by an insulating material.

COMPANIONCYLINDERS

A pair of engine cylinders whose firing relationship differs by 360 degrees ofcrankshaft rotation.

CRT Cathode ray tube. This is the most common form of a computer display screen. Itmay be a television set or a video monitor, or a slightly modified version of thesedisplay devices.

APPENDIX B GLOSSARY

EffectivePage B-2 03/97

CTS Acronym for Clear To Send. This is a signal sent by the peripheral to let thecomputer know that it is ready to receive commands.

CURRENT The flow of electrons from the electrically negative voltage potential to the moreelectrically positive voltage potential, relatively speaking, in an electrical circuit.I=E/R.

DC Direct current. DC Current flows in one direction.

DELTA (∆∆) The fourth letter of the Greek alphabet. Delta represents the change between twoquantities having the same reference.

DIS Distributorless ignition system.

DOT MATRIX A means by which printed characters are formed using a matrix or pattern of smalldots. The pattern is fixed and defined as so many dots wide by so many dots high.Typically patterns are 5x7, 7x9, 7x12, and so on.

DRIVER A program that provides communication between a computer and an peripheraldevices such as display adapters or a mouse.

DUTY CYCLE The amount of “on time” (in percent), of a circuit, compared to the whole on/off-cycle time. The ratio of the time “on” of a signal divided by the total cycle time.

DWELL The amount of time a circuit is closed. This time is usually expressed in degrees ofcamshaft rotation, however, dwell may also be expressed as a percentage of ontime compared to its total on/off-cycle time (duty cycle).

EFI (FI) Electronic fuel injection, (fuel injection).

EPROM Acronym for Erasable Programmable Read-Only Memory; a type of computermemory device that can be used to store data within a computer for instant access.Can be erased by ultraviolet light and reprogrammed. A nonvolatile memory thatretains programmed data even when no power is applied. See also PROM anROM.

FIELD The number of character spaces reserved in a data file for a specific piece of data.

FIRMWARE A computer program or software stored permanently in PROM or ROM or Semi-permanently in an EPROM.

FREQUENCY The rate of recurrence of a periodic signal or cycle, in a unit of time. Expressed inHertz (Hz). One Hertz is equal to one cycle per minute.

GAIN The ratio of signal output to signal input. The ratio may express an increase ordecrease of current, power or voltage.

GM A trade mark of General Motors.

GROUND A point in an electrical circuit that measures zero voltage and to which all otherpoints in a system are referenced. There may be more than one ground referencein a system; while the “chassis ground” is usually the same as “earth ground”, theelectronic ground of a system may have a separate zero reference point,sometimes called “board ground”.

HALL EFFECT A potential electrical difference created in a metal strip that is conducting current,when a magnetic field is placed perpendicular to the current flow.

HARD-WIRED Used to describe system components that function as a result of being solderedinto the system, rather than being connected through a connector.

HARDWARE Describes all items in a computer system that are not software: circuit boards,integrated circuits, transistors, discrete components, etc.

HEI High energy ignition, General Motors.

APPENDIX B GLOSSARY


HERTZ A measure of frequency or bandwidth. The same as cycles per second.

Hg The chemical element Mercury. A measure of vacuum.

I/O Input/Output. Refers to the paths by which information enters a computer system(input), and leaves the system (output). Some traditional input device might be akeyboard although some computer systems utilize joysticks, a mouse, touchscreens, or other similar devices. The usual output devices on modern computersis a video screen, or a printer.

INDUCTANCE An electromagnetic property measured in Henrys. Electrical current passingthrough a circuit creates a magnetic field. A varying current induces a voltage inthe same circuit or nearby circuits. One Henry equals a one volt potentialgenerated from the change in current flow of one ampere in one second.

INTERFACE An electronic or software device used to mate a computer and its peripherals withthe outside world.

Kv Abbreviation for Kilovolt. One Kilovolt (Kv), equals 1 thousand volts.

KEYPAD A calculator-style arrangement of numeric and arithmetic keys. This is the inputdevice that allows the operator to control the analyzer.

LAMBDA (λλ) The eleventh letter of the Greek alphabet. An alternate way of expressing air/fuelratio, where 1.0 lambda is the ideal air/fuel mixture (14.7:1). Rich mixtures arewritten as a value less than one (0.8), lean mixtures are written as a value greaterthan one (1.3).

LEAN MISFIRE A misfire that occurs when the air/fuel mixture is too lean to support combustion.

LEAN MIXTURE An air fuel ratio that contains more than the ideal amount of air or less than theideal amount of fuel.

LOCK-UP An undesirable occurrence in an electronic circuit in which the output of the circuitstops yielding effective data or signals.

MEGABYTE A term used to indicate millions of bytes, 1 megabyte (1Mb) = 1,024,000 bytes or1024 kilobytes (1000k).

MEMORY One of the main features of a computer is its ability to store and retrieveinformation very quickly. There are several kinds of memory. See RAM, ROM,EPROM.

MENU KEYS The keys, located on the right of the keyboard, used to select one of sevenanalyzer operation categories.

MONITOR A computer output device designed to show alphanumeric and/or graphics data. Inpersonal computing, the monitor is usually a TV like video screen.

NC Normally closed.

NO(Switch usage)

Normally open.

NO(Chemical usage)

An abbreviation for Nitric Oxide, which is an Oxide of Nitrogen.

NOx An abbreviation for Oxides of Nitrogen. One of which is Nitric Oxide

O2 Oxygen. The normal form of atmospheric oxygen is a molecule of two oxygenatoms: O + O = O2.

OHM (ΩΩ) Unit of measure of electrical resistance, symbolized by the Greek letter omega (Ω).One ohm is the resistance of a circuit in which a potential difference of one voltproduces a current of one ampere, R=E/I.

APPENDIX B GLOSSARY


PARALLEL A method of transmitting data in which the bits comprising a character are sent atthe same time.

PARALLEL PORT Used by peripherals to communicate with the host computer in a parallel format.

PEAK TO PEAKVOLTAGE

The difference between the most positive voltage and the most negative voltage insinewave.

PERIPHERAL Any device that connects to and is controlled by a computer, such as a terminal,printer, modem, etc.

PIXEL Picture element. Refers to the smallest single screen element directly addressableby a computer. The smaller the pixel size, the more pixels to a screen, and thusthe finer the graphics resolution.

PORT An Interface on a computer configured as data terminal equipment and capable ofattaching a modem or other peripheral for communication with a remote dataterminal.

PRIMARY(Automotive engineusage)

Refers to the low voltage portion of the ignition circuit. This circuit energizes theprimary windings of a step-up transformer (coil). This creates a magnetic fieldaround the entire coil. See Secondary.

PROM Acronym for Programmable Read-Only Memory; a permanent storage device thatcan be programmed by the device manufacturer, supplier, or user.

PSI Abbreviation for “pounds per square inch”, a measure of pressure.

RAM Acronym for Random-Access Memory. A volatile type of temporary storage devicethat can be written to by the user. Any data stored in RAM can be directly retrievedsimply by entering its address. Data stored in RAM is irretrievably lost when poweris shut down.

RFI Abbreviation for “Radio Frequency Interference”. High frequency electromagneticenergy capable of propagating in, and interfering with proper operation ofelectronic circuits.

RESISTANCE The opposition offered by a conductor to the flow of electrical current, as measuredin ohms (Ω), R = E / I.

RESOLUTION Refers to either the number of scanning lines on a video display terminal or thenumber of pixels addressable on the display screen.

RESPONSE TIME The elapsed time between the generation of the last character of a message at aterminal and the receipt of the first character of the reply. It includes terminal delayand network delay.

REVERSE VIDEO A term used to indicate, in some video terminals, the ability to display blackcharacter on a white (or green) background.

RICH MIXTURE An air/fuel mixture that contains less than an ideal amount of air or more than anideal amount of fuel.

RMS Abbreviation for “Root-Mean-Square”. A mathematical average of alternatingvoltages or currents. The RMS value of alternating currents and voltages is theeffective current or voltage applied to a circuit rather than the peak value. Thepower output, or consumption, of an AC circuit, using RMS values, is equivalent tothe DC power output, or consumption.

ROM Acronym for Read-Only Memory. A permanent data storage device that, onceprogrammed, cannot be re-programmed. The user can only read what is in theROM; he cannot write to it. This type of memory is non-volatile. See also EPROMand PROM.

RPM Abbreviation for “Revolutions-Per-Minute”. Used to indicate engine speed.

APPENDIX B GLOSSARY


RS-232C Interface between data terminal equipment and data communications equipmentemploying serial binary data interchange.

RTS Acronym for Request To Send. This is a signal sent by the host computer todetermine if the peripheral is ready to receive data.

RXD Acronym for the Receive Data Line in serial communications.

SCAN RATE The rate at which the video beam scans the line from the top to the bottom of thescreen. Higher scan rates work faster to produce sharper images.

SECONDARY(Automotive engineusage)

Refers to the high voltage portion of the ignition circuit. A magnetic field is createdaround the “coil” by the primary circuit, see Primary. When the voltage to theprimary circuit is turned off, the magnetic field collapses around the coil; thisinduces a high voltage potential in the secondary windings of the coil.

SERIAL A type of input or output utilizing an established protocol, writing, and informationformat so that data is submitted one bit at a time.

SERIAL PORT An Input/Output port in a computer through which data is transmitted and receivedone bit at a time. In most cases in personal computers, serial data is passedthrough an RS232C serial interface.

SIGNAL A voltage, current or magnetic field that can be detected, or used to conveyspecific information in an electronic circuit.

SINE WAVE The regular, undulating waveform of an alternating voltage or current.

SOFTKEYS These are the Keys located at the bottom of the Monitor, that are used to chooseselections that display on the screen.

SQUARE WAVE A square, or rectangular waveform that alternately switches between one of twovalues (high or low) for specific lengths of time.

STOICHIOMETRIC A term describing the ideal air/fuel ratio of 14.7:1.

SYNCHRONIZATION The timing of two functions such that one is in step with the other.

TACH Tachometer. Term describing the measure of engine RPM. Also used to describethe negative side of the ignition coil.

TIME PER DIVISION The value of time measurement that is assigned to the horizontal width of one gridsquare on the screen of a oscilloscope.

TRIGGER A signal that activates another circuit.

TXD Acronym for the Transmit Data Line in serial communications.

VOLTAGE The electrical force, or pressure, that causes electrons to flow (current), in a circuit.This “force” is the potential electrical difference between positive charges andnegative charges; measured in “volts”, E = I x R.

VOLTS PER DIVISION Refers to the voltage value that is assigned to one grid square of an oscilloscopescreen.

WASTED Kv In DI systems, when the coil “fires” it sends high voltage through a spark plug duringits a power stroke, and a spark plug during its exaust stroke; these are companioncylinders. The high voltage sent through the spark plug in its exhaust stroke is the“wasted Kv”.

WAVEFORM Display of voltage or current on an oscilloscope.

ZEROING Refers to the process of recording the “no input” reading of a sensor. This readingis added to, or subtracted from an actual “input” reading to offset errors in thesensor or circuitry.

APPENDIX B GLOSSARY


CHAPTER 1 POWER DISTRIBUTION CHAPTER 2 …€¦ · · 2004-04-09CYLINDER SHORTING ... PROGRAM...

Documents

Transcript of CHAPTER 1 POWER DISTRIBUTION CHAPTER 2 …€¦ · · 2004-04-09CYLINDER SHORTING ... PROGRAM...