CHARGING SYSTEM

Model 812FJ

OPERATIONS
MANUAL

WARNING
READ THIS MANUAL BEFORE
OPERATING THE TRAINER

ATech Training, Inc.

12290 Chandler Drive
Walton, KY 41094 USA
Phone: (859) 485-7229 • Fax: (859) 485-7299
Email: sales@atechtraining.com
Website: www.atechtraining.com

Copyright 2008, ATech Training, Inc.

 CHARGING SYSTEM
MODEL 812FJ

INTRODUCTION............................................................................................................................................. 2

INSPECTION AND ASSEMBLY PROCEDURE......................................................................................... 2

TRAINER ORIENTATION ............................................................................................................................ 3

SETUP AND OPERATION............................................................................................................................. 5

WARNINGS ...................................................................................................................................................... 6

DIAGNOSIS AND TESTING.......................................................................................................................... 7

EQUIPMENT MAINTENANCE .................................................................................................................... 8

FAULT OPERATION...................................................................................................................................... 9

FAULT CODES: ........................................................................................................................................... 9

Entering FAULT CODES: ........................................................................................................................... 9

COMPUTER FAULT INSERTION ............................................................................................................. 10

Computer with Trainer: ............................................................................................................................. 10

ANS with Trainer:....................................................................................................................................... 10

KEYPAD OPERATION ................................................................................................................................ 11

POWER BUSS ................................................................................................................................................ 13

CHARGING SYSTEM 812FJ – CIRCUIT SCHEMATIC ........................................................................ 13

SERVICE AND LIMITED WARRANTY ................................................................................................... 16

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 INTRODUCTION
ATech Charging System – Model 812FJ

The ATech Charging System Trainer is designed to teach the basic principles of the Charging System.
This ATech trainer allows for instructor demonstration or presentation as well as hands-on reinforcement
and troubleshooting experience. As a result, experience is gained prior to working on actual vehicles.

The ATech Charging System Trainer is composed of new 2003 Chevrolet 3.4L Impala components.
Power for the Charging System is to be supplied by a 12VDC automotive battery (not included).

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 INSPECTION AND ASSEMBLY PROCEDURE

The ATech Charging System Trainer was inspected and tested prior to delivery. However, we ask that
you unpack all items and inspect for any shipping damage. If any damage is noted, immediately contact
the carrier of the trainer for processing claims.

Identify the following:

 Board and Components

 Generator
 Motor
 Hardware – Ensure all hardware is tight (no loose bolts/nuts).

Assembly:

Place the shield over the Generator belt. Line it up with the 5 holes already drilled on the front of the
trainer. Use the screws (5) included to attach the shield to the front of the trainer.

Generator

Motor Shield

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 TRAINER ORIENTATION

The ATech trainer uses actual automotive components to keep the learning experience as realistic as
possible. Identify the following components on the ATech Charging System Trainer.

The Actual Components Include:

 Delphi AD-230 Generator (2003 Chevrolet Impala 3.4 VIN E RPO LA1 engine)

Your ATech Charging System Trainer Also Features:

Tip Jacks for measurement. The switch should be LCD Display, Keypad, and
used to connect or disconnect the connector. Scan Tool/User Mode Switch

GEN-L, Battery, and MIL

Indicator Lamps

Positive &
Negative
Battery
Terminals

Motor Ignition Fuse DLC System

Switch Switch Block Connector Power

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System Power:

The ATech Charging System Trainer is powered by an internal power supply. This power supply is used
to provide power to the Keypad, Display, and Circuit Boards inside the trainer. The trainer and Generator
drive motor will need to be plugged into 120VAC outlets (or 220VAC if so equipped). The internal
power supply is turned ON and OFF by the SYSTEM POWER switch located on the front panel.

The ATech Charging System Trainer is designed to be connected to a standard 12VDC automotive
battery (not included). The automotive battery is to be connected to the trainer’s positive and negative
battery terminals with suitable gauge automotive jumper cables or their equivalent.

Note: 12VDC automotive battery and the jumper cables are not supplied with the trainer and must be
acquired locally.

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 SETUP AND OPERATION

ATech Charging System Trainer - Model 812FJ

Follow these step-by-step procedures to operate the ATech Charging System Trainer:

1. Plug the trainer’s power cord into a 120VAC outlet.

2. Plug the power cord for the 1 ½ HP Generator drive motor into a standard 110VAC, 20Amp
outlet.

3. Turn the system power switch ON.

4. Make sure the Ignition Switch is in the OFF position.

5. Connect a 12VDC automotive battery to the positive and negative terminals on the trainer using
the appropriate jumper cables. (See “Warnings” on the next page.)

6. Turn the Ignition Switch to the ON position.

7. Turn the Motor Switch (located on the trainer side of the motor) to the ON position.

Connecting and Disconnecting Connectors

The ATech Charging System trainer features tip jacks for taking measurements and troubleshooting. To
disconnect or connect a connector, flip the toggle switch next to the tip jacks to the desired position. The
tip jacks are labeled with the component side and harness side of the connector.

GENERATOR CONNECTOR
Toggle Switch
B D

HARNESS CONNECTOR

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 WARNINGS

Pay close attention to polarity when connecting jumper cables from the automotive battery to the trainer.
Follow all safety precautions associated with the handling of automotive batteries. Observe all
procedures and safety precautions involved with the use of jumper cables and the jump starting of
vehicles. These procedures and precautions can be found in the service manual in the Battery Section.
Failure to do so could result in any or all of the following:

 PERSONAL INJURY

 EXPLOSION

 DAMAGE TO THE TRAINER

 DAMAGE TO THE BATTERY

Be sure to use jumper cables of a large enough size to carry the high current from the battery to the
trainer. No smaller than 4 gauge (21mm) stranded wire is recommended. Using a smaller wire could
result in any or all of the following:

 PERSONAL INJURY

 FIRE

 DAMAGE TO THE BATTERY AND/OR JUMPER CABLES

 DAMAGE TO THE TRAINER

To avoid personal injury, DO NOT operate the Charging System Trainer without the belt shield.

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 DIAGNOSIS AND TESTING

ATech Charging System Trainer - Model 812FJ

The following pieces of diagnostic equipment are required to troubleshoot the Charging System Trainer:

 2003 Chevrolet Impala Service Manual. The service manual pages containing information
about the Charging System are included in the Charging Instructional Materials (Model
812FJ).
 Digital Multi-Meter
 Starting and Charging Tester with inductive ammeter and carbon-pile load (VAT 40 or
equivalent)

The trainer has a built-in scan tool mode. Optionally, a Tech 2 scan tool can be used for troubleshooting.
Program the Tech 2 for a 2003 Chevrolet Impala 3.4 VIN E RPO LA1 engine.

Note: The ATech Model 812FJ Charging System Trainer does not have network communication
functions built in. When using a Tech 2 to diagnose the trainer, functions and options not related to
the charging system will not be available.

Using the Scan Tool Mode:

 Connect the ATech 812FJ Charging System Trainer to a fully charged 12 volt battery.
Be sure to observe the correct polarity!
 Turn the System Power Switch on.
 Turn the Ignition Switch on.

1. Flip the LCD Display Switch from User Mode to Scan Tool Mode. The Scan Tool Mode main
menu displays two options:

 GEN-L Status, which displays the current status of the PCM-commanded turn on signal to the
generator. Battery Voltage is also displayed.
 DTC Information, which displays and clears system diagnostic trouble codes.

2. Press 1 to display the GEN-L Status and Battery Voltage:

 The defaults are GEN-L off when the trainer’s motor is off, and GEN-L on when the trainer’s motor
is running.
 Press 1 to override the default and command the generator on.
 Press 2 to override the default and command the generator off.
 Press asterisk (*) to return to the Scan Tool Mode main menu.

3. Press 2 to display DTC Information:

 Press 1 to display any current DTCs. Press asterisk (*) to return.

 Press 2 to clear any stored DTCs. Press 1 for Yes or 2 for No to clear the DTCs. Press asterisk
(*) to return.
 Press asterisk (*) to return to the Scan Tool Mode main menu.

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 EQUIPMENT MAINTENANCE

ATech Charging System Trainer - Model 812FJ

The trainer requires little maintenance. Items to check are as follows:

1. Inspect, tighten, and clean all exposed connections.

2. Turn the Ignition Switch OFF after use.

3. Turn the System Power Switch OFF after use.

4. Turn the Motor Switch OFF after use.

5. Disconnect the battery from the trainer when not in use.

To tighten the generator belt:

1. Loosen the generator mounting bolts.

2. Pull the belt tight, being careful to keep the belt centered on the pulley.

3. Rotate the turnbuckle at the top of the Generator to the left to tighten the belt.

4. Tighten the generator mounting bolts.

Rotate to the left to

tighten the belt.

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 FAULT OPERATION

Located inside the ATech Charging System Trainer (model 812FJ) is a Fault Board. The Fault Board
contains relays that insert realistic faults into the Charging System Trainer in order to practice
troubleshooting. The Instructor can insert faults into the Charging circuit by entering the desired fault
code into the Keypad. The table below shows the faults available in the Charging System Trainer.

FAULTS:
The following 4 FAULTS are included:

Fault # Description Fault CKT# or Circuit# Wire Color

1 Generator Ground High Resistance 001 -
2 Generator Turn On Signal Open 225 RED
3 Generator Turn On Signal Short to GND 225 RED
4 Generator Output Open 002 RED

Entering FAULTS:
Faults can only be entered into the Keypad when either the trainer is not connected to the ANS-16 or the
Instructor's Management Program is not running on the Instructor’s computer. The following
instructions will allow the Instructor to insert faults using the Keypad.

1. Make sure the trainer’s power cord is plugged into a 120VAC outlet.

2. Turn the System Power Switch ON.

3. The LCD Display will show the trainer name and model number and then “No
Communication with ATech software”. The trainer detects that there is no
communication with the Instructor's Management Program. The Display will then
show “Enter Fault Code:”

4. Enter the desired fault code into the Keypad according to the table above and press the #
key. The trainer will insert the fault into the circuit.

5. After the fault has been inserted, students will be able to troubleshoot the circuit to find
the fault. The Display shows “Press 1 to clear fault”.

6. Press 1 to clear the fault from the circuit.

7. Repeat the previous steps to insert more faults.

Note:
When troubleshooting faults, use the schematics provided in the courseware and in the back of this
Operations Manual.

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 COMPUTER FAULT INSERTION
Computer with Trainer:
Using the Computer Cable (7’ black CAT5), included with the trainer, connect the trainer to the
computer. The RJ-45 connector (looks like a large phone connector) is inserted into the white jack on the
side of the trainer. The DB9 pin connector attaches to the com (serial communications) port on the back
of the computer.

With this option, faults can be inserted by clicking on the ATech Network System button in the main
menu of the Instructor’s Management Program. Central Record Keeping must be setup prior to
inserting faults from the Instructor's Management Program. Refer to the Instructor’s Management
Program Operations Manual for instructions.

ANS with Trainer:

Connect the trainer to the ANS-16 Serial Hub using the Interconnect Cable (25’ white CAT5 cable
included with ANS). The Serial Hub should be setup and installed on the network or directly to the
instructor’s computer (see ANS Operations Manual for installation instructions).

With this option, faults can be inserted into multiple trainers simultaneously by clicking on the ATech
Network System button in the main menu of the Instructor’s Management Program. Central Record
Keeping must be setup prior to inserting faults from the Instructor's Management Program. Refer to
the Instructor’s Management Program Operations Manual for instructions.

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 KEYPAD OPERATION

Refresh Display Logoff

Numeric digits – Used as to enter answers to questions.

Press this button to refresh the display and clear any incorrectly entered data.

Press this button to logoff the trainer. A student must logoff of the trainer before logging onto
another trainer. Once a fault has been entered, students cannot logoff until the fault is
completely answered.

1. Run the Instructor’s Management Program. Click on the ATech Network System
button in the main menu. Central Record Keeping must be setup prior to inserting faults
from the Instructor's Management Program. Refer to the Instructor’s Management
Program operation manual for instructions.

2. The Display should now show “Enter Student Id Number:”.

3. Once the correct ID Number is entered, Display will show “Press 1 to insert fault”.

4. Use the Instructor's Management Program to send a fault to the trainer. Press 1 on the
Keypad to insert the fault. The student will enter the three-digit circuit number for the
fault location. The three-digit number can be found by using the Circuit Schematic in the
back of this Operations Manual.

Note: The fault location will always be a three digit number. For example, circuit
number 2 should be entered 002.

5. Once a circuit number has been entered the Display will show “1-Open 2-Short to gnd 3-
High res. 4-Short to V”. The student will choose whether the fault is an open, short to
ground, high resistance, or short to voltage by pressing the corresponding number.

6. The Display will then show “Intermittent or hard? 1-Intermittent 2-Hard”. The student
will choose whether the fault is an intermittent or hard fault by pressing the
corresponding number.
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7. Now “Press 1 to accept answers Press 2 to redo” displays. The student will choose to
accept the answers they have entered or they may go back and change an answer they
entered.

8. After the student presses 1 to accept answers, a response of either “CORRECT” or

“INCORRECT” is displayed. If the Student’s answer is CORRECT the trainer continues
on to the next fault if more than one were sent to the trainer. If the answer is
INCORRECT, the student is provided with the correct answer and is asked to confirm the
fault location. If the instructor sends faults in exam mode, a correct or incorrect response
will not be returned to the student and the trainer will continue on to the next fault.

9. Once the student has completed all faults, the trainer displays the number of correct
answers out of possible answers. (Note: in exam mode this will not be displayed).

10. The student will then be asked if they want to logoff. Selecting Yes returns the Display
to the “Enter Student Id Number” screen. Selecting No will return the Display to the
“Press 1 to insert fault” screen.

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 POWER BUSS
BATTERY
WOOD BLOCK WOOD BLOCK WOOD BLOCK

812FJ FJ
830FJ FJ
860FJ

Note: The Isolation Blocks are simply pre-cut pieces of 2 x 4, customized to hold the welding
cable bus connectors in place. Trainers should not be more than 2 feet apart.

Applies To The Following Trainers:

310/310F Cooling Fan 811/811F/811FJ Starting System *
320/320F Blower Motor 812/812F/812FJ Charging System
700/700F Distributor Ignition 821/821F/821FJ Lighting System
822/822F/822FJ Instrument Panel
830/830F/830FJ Interval Wiper/Washer
832/832F Horn/Alarm
840/840F/840FJ Power Windows
850/850F/850FJ Power Door Locks
860/860F/860FJ Power Seat
870/870F Audio
Parts List:
 #4 Welding Cable (RED and/or Black Cable, 1 – 100 ft. role supplies 8 trainers)
 1 Wood Block for each trainer with 2 Ground Lugs on each block
 1 Vehicle Battery with top post connections
 Appropriate battery cable connectors for battery and each trainer
 When the Power Windows System is placed on the Buss and cranked, the higher current
causes a high voltage drop across the Buss. This reduces the power to the other trainers
causing them to shut down for a short period of time. Because of this, ATech recommends
placing the Power Windows System near the battery. Then run a separate line from the
trainer to the battery, or use a separate battery for the Power Windows System.

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WIRING DIAGRAMS

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CHARGING SYSTEM 812FJ – CIRCUIT SCHEMATIC

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 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
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.

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