MODEL 3631

TECHNICIAN TROUBLESHOOTING SKILL DEVELOPMENT PROGRAM

OPERATIONS MANUAL

ATech Training, Inc.

12290 Chandler Drive P.O. Box 297 Phone: (859) 485-7229 Fax: (859) 485-7299

Email: sales@atechtraining.com Website: www.atechtraining.com

Copyright 2003, ATech Training, Inc.

1

SOFTWARE LICENSE AGREEMENT This is a legal agreement between you, the end user, and ATech Training, Inc. (ATECH). The enclosed ATech software programs (SOFTWARE) are licensed by ATech Training, Inc. to the original customer of the product for use only on the terms set forth here. Please read this license agreement. Opening the diskette package and/or installing and utilizing this software indicates that you accept these terms. If you do not agree to these terms, return the full product with proof of purchase to your place of purchase within 30 days for a full refund. * Grant of License ATech Training, Inc. grants to you the right to use one copy of the enclosed SOFTWARE on a single computer (i.e. single CPU) not serving as a network server, or if the enclosed SOFTWARE is designated a Network Version, one copy of the SOFTWARE may be installed on a single computer serving as a network server and the SOFTWARE may be used concurrently on a single network by the number of users indicated on the system disk. * Copyright The SOFTWARE is owned by ATECH or its suppliers and is protected by United States copyright laws and international treaty provisions. You may either (a) make two copies of the SOFTWARE solely for backup or archival purposes provided that you reproduce all copyright and other proprietary notices that are on the original copy of the SOFTWARE provided to you, or (b) transfer the SOFTWARE to a single hard disk provided you keep the original solely for backup or archival purposes. You may not copy written materials accompanying the SOFTWARE. * Other Restrictions You may not rent or lease the SOFTWARE. You may not reverse engineer, decompile, disassemble, or create derivative works from the SOFTWARE.

2

SOFTWARE RE

This product must be registered. This softwregistering the software be sure the computer computer used by the students. To Register the Software: 1. Place the program CD-ROM into the Compu 2. Enter the Product serial number when asked

Product Serial Number: 3631-__ 3. The program then displays a product registr

Product Registration Number: _ 4. Call, Fax, or Email ATechs Software Regis

Phone: (859) 485-7229 Fax: (8Email: sales@atechtraining.com

Give them the Product Serial and Registratio They will give you the Product Authorization

Product Authorization Number:5. Enter the product authorization number whe6. The software is now registered and ready to

GISTRATION FORM

are is for use on ONLY ONE Computer. Before you register and setup/install the program on is the

ters CD-ROM drive. Setup program should start.

.

_________

ation number.

______________________

tration Department. 59) 485-7299

n Numbers. Number.

______________________ n asked. install.

3

SOFTWARE COMMENT FORM

ATech Training, Inc. welcomes your feedback as we strive to improve our automotive programs.

Use this form to advise us of any errors or problems you may find in our software.

Please record any problems with specific areas of the software as indicated below. Identify activity and part number if applicable.

1. List ATech software you are using: _______________________________________________

2. Student program installation procedure: ___________________________________________

______________________________________________________________________________

______________________________________________________________________________

3. Teacher program installation procedure: ___________________________________________

______________________________________________________________________________

______________________________________________________________________________

4. First time student program operation: _____________________________________________

______________________________________________________________________________

5. Any points of confusion for the student? ___________________________________________

6. Any poorly worded question(s)? _________________________________________________

______________________________________________________________________________

7. Additional comments: _________________________________________________________

______________________________________________________________________________

8. First impressions of overall program: _____________________________________________

Return your responses to: ATech Training, Inc.

12290 Chandler Drive P.O. Box 297 Walton, KY 41094 USA

Phone: (859) 485-7229 Fax: (859) 485-7299 Email: sales@atechtraining.com Website: www.atechtraining.com

4

TECHNICIAN TROUBLESHOOTING SKILL DEVELOPMENT PROGRAM

Model 3631

Software License Agreement Preface

Software Registration Form ... Preface

Software Comment Form .... Preface

Introduction .. 1

System Requirements .. 2

Installation .. 3

Running the Program . 4

Program Operation . 5

Selecting Circuits ... 5

Circuit Operation ..... 6

Advanced Diagnostics ....... 12

Troubleshooting a Circuit 13

Returning to the Main Screen . 15

Quitting the Program ... 16

Technical Support .... Appendix

Service and Warranty .... Appendix

5

INTRODUCTION

This is the first training system of its kind. Learn how to do Sensor End Diagnostics and practice those hard to find engine control system problems. The ATech 3631 Technician Troubleshooting Skill Development program will allow you to insert electrical faults of all types in either a random mode or in a controlled mode. The ATech 3631 trainer has 5 circuits to troubleshoot. The Fuel Pump Relay, Fuel Injector, Inlet Air Temperature Sensor, Coolant Temperature Sensor and the Throttle Position Sensor are the circuits that are the hardest to diagnose. The ATech 3631 can insert more that 60 different faults across the 5 circuits. The faults cover the entire range of open circuits, shorts to power, shorts to ground, shorted components, and high resistance. There is almost no way to bug components, or vehicles to achieve this level of troubleshooting practice. The ATech 3631 has two modes of operation - Training and Advanced. In the Training mode, measurements are allowed inside components. The Advanced mode creates the situation of only being able to backprobe connectors.

1

SYSTEM REQUIREMENTS The program requires, at a minimum, the following system configurations:

1. Pentium, 100 MHz or better, Personal Computer

2. 16 MB of memory (RAM)

3. Windows 98, 2000, NT or XP Operating System (Windows 3.1, 95, and ME are not supported.)

4. 12 MB of free disk space on the hard disk 5. Super VGA video card with 512K video memory, recommend 1 MB video memory

(must be capable of displaying 640 x 480 pixel screen resolution with 256 colors)

6. CD-ROM drive

7. Mouse

2

INSTALLATION Install the program to the computer's hard disk. The installation requires 12 MB of free hard disk space. For Windows 98, 2000, or XP:

1. Place the program CD-ROM into the CD-ROM drive. Program should autorun, if not proceed to step 2. 2. Left 'click' on the "Start" button 3. Left 'click' on "Run..." from the Start Menu 4. Type D:\SETUP (assuming "D:" is the CD_ROM drive letter)

3

RUNNING THE PROGRAM

For Windows 98, 2000, or XP: If the program is installed, you can start the program by doing the following:

1. Left click on start 2. Go to programs 3. Go to ATech 4. Click on AT3631 -----or----- 5. Double click on the AT3631 icon located on the desktop. The following screen will

appear.

After the garage door opens the main screen will appear.

Now circuits can be selected for troubleshooting skill development.

4

PROGRAM OPERATION

I. Selecting Circuits

A. Troubleshooting circuits can be selected in two different ways, Random Mode and Controlled Mode. Advanced Diagnostics, which adds a higher level of difficulty, can be used when selecting circuits in either mode. Advanced Diagnostics will be explained more in the next section.

B. Random Mode

1. When using Random Mode select a circuit and then select the O.K. button. Faults will be randomly inserted in a circuit one at a time. A fault will not occur again until all the faults for the circuit have been inserted. Some circuits will have more faults than others.

C. Controlled Mode

5

1. To access the Controlled Mode of fault insertion, press the keys Ctrl, Alt, and T at the same time. When the keys are pressed correctly two more options will appear under the circuit selection box.

2. To insert a specific fault choose Select Fault then select a circuit. Once a circuit is selected a fault selection box will appear. After a fault is selected another box will appear to select the location for the fault. Some faults will only have certain locations where they can be inserted.

3. Once the circuit, fault, and fault location have been selected, select the O.K. button to begin troubleshooting the circuit.

II. Circuit Operation

A. The following section will describe the operation of a circuit for troubleshooting. Some circuits will have functions to operate depending on their level of difficulty. The basic functions of circuit operation will be the same in all the circuits.

B. Circuit Information

1. When a circuit, for example the TP Sensor, is selected for troubleshooting the circuit

schematic will appear.

6

2. When a circuit is loaded it is in a normal operating mode. This allows for normal circuit measurements to be made.

3. All circuits contain the (1) Shop Manual Specs and the (2) Fault Code (DTC)

information the circuit as shown in the following screen. (1) (2)

C. Connecting and Disconnecting Circuit Connectors

1. When making measurements in a circuit some connectors may need to be disconnected and connected to isolate a component or possible fault location. To disconnect a connector, move the cursor to the connector and click on the connector as shown in the following screen. The cursor will change to a pointing hand when it is in the correct position. Click on the connector again to connect it back.

2. Connectors can only be disconnected on one side of the wire or the other.

7

D. Connecting and Disconnecting the Battery

1. Some troubleshooting procedure may require a circuit to be connected to or disconnected from the battery. To disconnect or connect the battery move the cursor to the battery post and click on the battery post as shown in the following screen. The cursor will change to a pointing hand when it is in the correct position.

E. Using the Digital Multi Meter (DMM) and Probes

1. Circuit voltage and circuit resistance are measured using the DMM. To change the DMM measurement function, move the cursor to the dial and click on the dial as shown in the following screen. The cursor will change to a hand when it is in the correct position. The DMM changes from OFF to Volts to Ohms and back to OFF with each click.

2. After a function on the DMM has been selected the next step is to move the meter

probes to make measurements.

8

3. To move the meter probes, move the cursor to the red or black probe and click and

hold the cursor on the probe. The cursor will change to a pointing hand when it is in the correct position. Drag the probe to the measurement point and release the cursor as shown in the following screen.

4. To get a correct resistance measurement, be sure to disconnect the battery when using

an Ohmmeter.

F. Connecting and Disconnecting the Chassis System Ground and the Fuse

1. A circuit may need to be connected to or disconnected from the Chassis System Ground. To disconnect or connect the chassis ground, move the cursor to the system ground and click on the connector as shown in the following screen. The cursor will change to a pointing hand when it is in the correct position.

9

2. Some troubleshooting procedures may require the Fuse to be connected to or

disconnected from a circuit. To disconnect or connect the fuse, move the cursor to the fuse and click on the fuse as shown in the following screen. The cursor will change to a pointing hand when it is in the correct position.

3. Some circuits will not have a fuse. When the fuse is disconnected, the system ground

will also disconnect and vice versa.

G. Ignition Key Operation

1. Some circuits may require the engine to be running for the circuit to operate correctly.

An ignition key is added to the circuits that need to have the engine running. To turn the ignition on, move the cursor to the ignition key and click on the key as shown in the following screen. The cursor will change to a pointing hand when it is in the correct position.

10

2. When the ignition key is turned on, a Start button will appear. Click on the start button to start the engine as shown in the following screen.

3. To turn the engine off, move the cursor to the ignition key and click on the key. The

cursor will change to a pointing hand when it is in the correct position.

H. Increasing and Decreasing the Throttle

1. When troubleshooting the TP Sensor circuit, the throttle plate can be adjusted from Idle to WOT (Wide Open Throttle). To increase and decrease the throttle, move the cursor to the TP Sensor scroll bar and click on the up arrow to increase the throttle or the down arrow to decrease the throttle. The throttle can also be adjusted by clicking and holding on the slide bar and dragging the cursor up and down. The cursor will change to a pointing hand when it is in the correct position as shown in the following screen.

11

III. Advanced Diagnostics

A. To add an increased level of difficulty to a circuit select the Advanced Diagnostic box after selecting the circuit.

B. After the selecting the circuit and Advanced Diagnostic select O.K. to begin

troubleshooting the circuit.

C. The circuit shows that Advance Mode was selected. D. When using Advanced Diagnostics, a components terminals are not accessible when the

connector is connected as shown in the previous and following screens.

12

E. The meter probes are moved to the position that back probes the connector.

IV. Troubleshooting a Circuit

A. After a circuit is selected and loaded, the circuit will operate in a normal mode until the fault is ready to be inserted.

B. Click the Continue button to insert a fault.

13

C. After the fault is inserted, use the Digital Multi Meter and the methods of operating the

circuit to troubleshoot the circuit and locate the fault.

D. When the fault is located, select the fault type and fault location from the right side of the

screen. The numbers inside the small circles correspond to the fault locations on the right side of the screen. The white numbers inside the PCM indicate the PCM terminals. After the fault type and location have been selected click O.K. to submit the answer.

14

E. The program will then give feedback by displaying whether the answer was correct or

incorrect and showing the fault and its location. F. To continue troubleshooting faults click Continue.

V. Returning to the Main Screen

A. To return to the main screen to select another circuit, click the Return button in the top right corner of the screen.

VI. Quitting the Program

15

A. To quit the program, click the Quit button in the top right corner of the screen.

16

TECHNICAL SUPPORT All inquiries are to be directed to Software Support to the address/numbers below. You may fill out this page and fax to (859) 485-7299. This same form is located on our Website www.atechtraining.com. If contacting us by phone, please have the following information ready: Product Name: ______________________________________ Model Number: ______________________________________ Software Serial Number: ________________________________ Software Version Number: ________________________________ Problem Description: ________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Contact Person: _________________________________________________________ Company or School Name: _________________________________________________ Company or School Address: Street: _________________________________________ City: __________________ State: ____ Zip: __________ Country: ____________________ Phone Number: (_____) _____-______ Fax Number: (_____) _____-______ Email Address: ______________________________________________________ Purchased From: _____________________________________________________

ATech Training, Inc. 12290 Chandler Drive P.O. Box 297

Walton, KY 41094 Phone: (859) 485-7229 Fax: (859) 485-7299

Email: service@atechtraining.com Website: www.atechtraining.com

17

SERVICE AND LIMITED WARRANTY

ATech believes you will be pleased with the performance of its products. ATech trainers have been designed with the greatest concern for student use and training. In the unlikely event you run into difficulties with the trainer, ATech offers the following limited warranty and repair services: 1. Limited Warranty ATech warrants that its product will be free from defects in material and workmanship for a period of one year from the date of shipment from the factory (the "Warranty Period"). If the trainer appears to be faulty during the Warranty Period, ATech will repair the problem pursuant to Sections 2 and 5 below. All ATech shipments are made FOB Walton, Kentucky. If you receive a product that has been damaged in shipment, contact your carrier and process a claim. 2. Service Under Warranty In the event you require technical assistance during the Warranty Period, you may call ATech at (859) 485-7229. Initial efforts will be made by a service technician to solve any difficulties via telephone. If, during the Warranty Period, the trainer needs to be shipped back to ATech for repair, you may contact ATech for a Return Authorization (RA). The shipping charges to ATech shall be paid by you. ATech will repair the trainer at no cost to you, and pay for shipping it back to you via the best transportation. ATech makes no warranties against shipping damage due to inadequate packaging on your part. 3. Service Out of Warranty If your trainer needs service after the Warranty Period has expired, you may contact ATech for a Return Authorization (RA). You will be responsible for all shipping costs for the trainer repair, both to and from ATech. A written quotation for repair costs will be sent to you once the trainer has been received and inspected by ATech. If you desire ATech to complete the repair, a purchase order number will be required. 4. Technical Assistance ATech will provide you with a reasonable amount of technical assistance on any problem you may encounter, at no charge to you. Please write, call or fax:

ATech Training, Inc. 12290 Chandler Drive P.O. Box 297

Walton, KY 41094 USA Phone: (859) 485-7229 Fax: (859) 485-7299

Email: service@atechtraining.com 5. Limitation of Liability ATech's liabilities for damages of any sort including but not limited to direct, indirect or consequential damages shall be limited to the correction of the defect, or replacement of the purchase price, whichever is less. Any damage to electrical components and/or other trainer parts due to moisture, abuse, or negligence, are not covered by the warranty. ATech limits the warranty of liability to that which the original manufacturer provides.

18

Model 3631 Operations ManualSoftware License AgreementSoftware Registration FormSoftware Comment FormTable of ContentsIntroductionSystem RequirementsInstallationRunning the ProgramProgram OperationTechnical SupportService and Limited Warranty