Group Tester One and OPPS
Model: All
Production Date: All
Objectives of The Module
After completing this article you will be able to
- Identify the components of the GT1.
- Demonstrate diagnostic operations using the GT1.
- Perform changes to VKM settings.
- Understand how to change batteries in the GT1.
- Understand what the OPPS Tester is used for.
- Correctly Identify the OPPS Harnesses and Connectors.
Scheme 611
The GT1 (Group Tester One) replaces the MoDiC series of portable diagnostic tools. It has the same processor as the DISplus; a Pentium III, with 256 MB RAM and a 20 GB hard-drive. Other features include
Scheme 612
- DVD ROM Drive - 14 GB storage capacity
- 12.1 TFT color display, 1024 x 768 resolution
- Integrated PCMCIA card reader
- Integrated chip card reader
- Touch screen - same as DISplus
- Workshop grade case
- ASM-technology motherboard
- Temperature operating range from 35°F to 105°F
- 2.5 hours of operation with a fully charged battery.
- Can be powered by vehicle battery.
- Weighs 7.7 lbs.
Control Panel
The control panel is the central component of the GT1. The operating system and the application programs are stored here.
Located on the front of the Control Panel
Scheme 613
- PCMCIA interface (radio card slot in left handle)
- Monitor with touch capabilities
- Control Block
- Battery Compartment (in right handle)
Monitor
The surface of the monitor is covered by a touch-sensitive plastic sheet that senses the pressure of a finger or the touch pen and transfers it to the system.
Note. Use only your finger or the touch pen supplied to operate the touch screen. If other objects are used, it may damage the GT1 Screen.
Control Block
The main control block of the GT1 control panel is located under the center of the touch-screen. It consists of 1 on/off switch, 3 LEDs and the infrared receiver port. The infrared port is the connection to the wireless keyboard used during programming.
The On/Off switch is used to switch the control panel on and off or to initiate a forced switch-off. If a fault occurs that causes the unit to "lock-up", you can shut down the unit by holding down the on/off button for 5 seconds. This may cause the loss of operating software, necessitating a reinstall (use only in an emergency).
The status of the switch does not affect the charging operation.
Scheme 614
The "temperature" LED will glow red when the control panel is overheated. The control panel will shut down approximately 10 seconds later.
The "battery" LED will glow yellow during charging. It will switch off to signify the battery is fully charged. It will flash yellow if excessive temperatures continue.
The "operation" LED will glow green when using an external power source, glow orange when using the internal battery. A flashing orange LED signifies a discharged battery.
Alternately flashing orange/green LED denotes that the internal battery is defective or has been removed.
Scheme 615
Scheme 616
Power Supply
The control panel is supplied power from one of three voltage sources
- Internally from the battery (approximately 2.5 hours of operating time).
- Externally from the bench power unit or the docking station.
- Externally from the vehicle electrical system.
DVD Drive
The DVD Drive is accessible from the top of the control panel. It accommodates DVD's and CD-ROM's for installing programs, applications or updates of the control panel.
Note. When you open and close the DVD drive the control panel must be in the 14° inclination position as shown, otherwise the drive tray or the disc may be damaged.
Do not use the DVD unless the control panel is attached to the docking station.
Scheme 617
Docking Station
The Docking Station is intended for stationary operation, it replaces the bench power unit and provides the power supply. The Docking Station also provides the interfaces for connection to a USB device and the LAN Network.
Scheme 618
Scheme 619
Bench Power Unit
As an alternative to the docking station, the bench power unit may be used to power the control panel. The bench power unit consists of the built in connecting cable on the control panel, the power unit itself and a separate power cable. When the control panel receives power from the bench power unit, the internal battery is simultaneously charged.
Scheme 620
Scheme 621
The keyboard uses an Infrared link to communicate with the GT1 control panel. It is used only for service programs and can not be used in place of the virtual keyboard of the control panel. The keyboard must always face the control panel when in use and must be less than 1 meter away from the control panel (IR). The keyboard uses 4 AA batteries as an internal power supply.
| CAUTION | Old batteries can leak and damage the keyboard. Always keep fresh batteries in the keyboard (or remove when not in use). |
If more than one GT1 is in use in the workshop, the optical keyboard should be configured to a specific GT1 control panel as follows
Scheme 622
- Press and hold the identification key while pointing the keyboard at the control panel.
- Press a numeric key, 0-7 on the keyboard. The control panel will now respond only to commands from that keyboard.
If necessary the identification can be changed at any time following the above instructions.
LAN Control Panel Cable (Crossed)
The LAN control panel adapter (crossed) is approximately 30 cm long with a RJ45 connector and a RJ45 socket. It is identified by a black (yellow on early units) stripe near the socket and a label reading "LAN Adapter BT X."
LAN Cable Crossed
Scheme 623
LAN Cable Uncrossed
Scheme 624
LAN Control Panel Adapter (Uncrossed)
The LAN control panel adapter (uncrossed) is approximately 30 cm long with a RJ45 socket and a RJ45 connector. It can be identified by a gray stripe near the socket and a label reading "LAN Adapter 1:1."
LAN Control Panel Cable
The LAN diagnostic head cable is 10 meters long and has a RJ45 connector and an orange plug connector.
The LAN docking station cable is of the same design.
Scheme 625
MFK1 and MFK2
The MFK1 and MFK2 cables function similar in operation to the DISplus. Only one cable, either MFK1 or MFK2 (visual markings) may be connected to the control panel at one time.
MFK1
Scheme 626
MFK2
Scheme 627
Touch Pen
The Touch Pen is an ergonomic operating aid for the touch screen that makes it easier to operate the displays.
Optional Cables
Vehicle battery adapter cable - to use while in vehicle, does not charge the internal battery .
Scheme 628
50A Ammeter clip and adapter to bring the GT1 current measuring to DISplus standard. Requires the use of the size 2 adapter.
Scheme 629
The size 2 adapter. It connects the 50 A ammeter clip to the control panel.
Scheme 630
USB/Centronics Adapter
A USB/Centronics adapter may be used to connect one of the recommended PostScript printers to the control panel or docking station to serve as a local printer.
Battery
Power is supplied by the integrated battery when the control panel is not connected to an external power source. The battery must be charged to insure uninterrupted use of the control panel as a mobile test unit. The battery is charged automatically as soon as the control panel is placed in the docking station or connected to the bench power supply. Charging time is approximately 2 hours and while the battery is being charged the "Battery" LED illuminates in yellow.
To achieve the longest possible service life for the integrated battery, it must be fully charged, then discharged for normal use. Once a month the battery should be "formed" which entails fully discharging the battery, then fully recharging it. To "form" the battery
- Disconnect the bench power unit from the control panel or undock from the docking station or disconnect the docking station from a power source.
- Fully discharge the battery, by leaving the control panel "ON" until all the LEDs are out.
- Dock the control panel or supply power to the docking station or connect the bench power unit.
Charging is complete when the "Battery" LED goes out.
Note. Always replace a defective battery with a new battery. Never operate the control panel with out a battery (it acts as a buffer). Sudden interruption of power my cause the control panel to loose the installed operating system.
Scheme 631
- Switch off power and undock control panel.
- Remove screw on right hand handle.
- Pull off handle.
- Remove battery.
- Press down on the retainer for the connector and carefully remove connector.
- Connect new battery.
- Insert new battery in handle.
- Reinstall handle on control panel.
- Completely charge new battery.
Control Panel Faults
| Symptom | Possible Causes | Remedy |
|---|---|---|
| The system "crashes"; the hourglass no longer changes back to the cursor arrow; no operation possible | Internal Fault | If 'normal' switch-off not possible, use a forced switch-off (press the on/off switch for approx. 5 seconds) to switch the control panel off and on again. |
| With the control panel docked, the "Operation" LED lights up orange. | Docking station power supply is interrupted. Control Panel is not supplied with power via the docking contact. | Check whether power is present. Insert the power plug correctly. Check the spring contacts for dirt or foreign objects. To set up a correct connection, undock and then redock the control panel tow or three times (also see ). If no faults can be determined, send a Fault Report Fax. |
| "Temperature" LED lights up red; control panel switches off. | Excess internal temperature circuit breaker activated. | Move the control panel to a cooler room and allow it to cool down adequately. Switch the control panel on again. If the "Temperature" LED flashes yellow without the presence of high ambient temperature, send a Fault Report Fax. |
| "Battery" LED flashes yellow for 10 seconds on startup; control panel does not start. | After the control panel shuts itself off, there is still excess temperature. | Move the control panel to a cooler room and allow it to cool down adequately. Switch the control panel on again. If the "battery" LED flashes yellow without the presence of high ambient temperature, send a Fault Report Fax. |
| System does not power up completely; gets 'stuck' with an error message. | Internal run error | Switch the control panel off (press the on/off switch for 5 seconds = forced switch off) and then on again. If the system still freezes, you must reinstall the Base CD in accordance with Section 3.5.3. If this fault occurs repeatedly, send a Fault Report Fax. |
| After complete discharge and docking at the docking station, the system does not power up. | Profound discharge of the battery. | After a profound discharge and docking at the docking station, you must wait approx. 3 minutes before the system can be powered up |
CONTROL PANEL FAULTS
Note. The power supply to the control panel cannot be measured at the open docking contact because the power is through-connected via a proximity switch only when the control panel is docked.
| CAUTION | Forced Switch-Off may be used only in the case of special faults. Continued use of this feature may cause operating system failure and device shut down. Normal shut off is performed by pressing the ON/OFF switch for 2 seconds |
Touch Screen
| Symptom | Possible Causes | Remedy |
|---|---|---|
| The cursor does not respond (does not follow finger contact). | Touch controller defective or system 'crashed'. | Switch the control panel off (press the on/off switch for 5 seconds = forced switch-off) and then on again. If the fault persists or occurs more frequently, send a Fault Report Fax. |
| The touch screen remains dark; no error message by means on LED. | Touch screen is in the energy-saving mode. Backlighting failure. | Not a fault. The screen image reappears when the touch screen is touched. If you glance sideways at the touch screen, you can detect vague characters. Send a Fault Report Fax. |
| The cursor arrow is not located beneath the point of touch (touch offset) | Touch the controller set incorrectly. | The touch controller must be calibrated in the "Administration" window. Press the "Calibrating touch screen" button, enter the password and follow the instructions that are displayed. If this does not eliminate the problem, send a Fault Report Fax. |
| Incorrect pixel colors | Individual transistors defective. | Individual pixels of incorrect colors are tolerable. If the entire screen rows or columns are incorrect, send a Fault Report Fax. |
TOUCH SCREEN PROBLEM SYSMPTOM
| IMPORTANT | Use only your finger or the touch pen to operate the screen. |
Plug-in Connections
| Symptom | Possible Causes | Remedy |
|---|---|---|
| 50 A ammeter clip cannot be connected | Connectors on the ammeter clip do not fit in the socket. | Use the size 2 adapter |
| Cable connection via LAN interface to diagnostic head interrupted | Plug-in connections on LAN adapter defective | Check that the plug-in connections are correctly seated and undamaged. Check whether the plug-in connection via the LAN control panel adapter (uncrossed) has been established. |
PLUG-IN CONNECTIONS PROBLEM SYMPTOM
| IMPORTANT | Never use force to insert the connectors. The connectors on the measuring and diagnostic cables are marked with a red dot that must be aligned with a corresponding dot on the socket. |
Printer
| Symptom | Possible Causes | Remedy |
|---|---|---|
| Local Printer does not print | Printer connected to docking station, control panel undocked. Printer is defective. | Dock the control panel or insert the USB cable on the printer in the control panel. Check that the connection is correctly seated. In the "Administration" window, press the "Self-test" button and select the "Printer connection" function from the menu displayed. The printer should print a page with the heading "PS". If this does not occur, check the cable connection to the printer. |
| Network Printer does not print. | Network printer connected via LAN cable to docking station; control panel undocked. Radio link to diagnostic head established Cable link to diagnostic head established. Printer Defective. | Dock the control panel. Disconnect the cable connection to the diagnostic head and established a connection to the network printer in accordance with Section 4.4.8. Disconnect the cable connection to the diagnostic head and established a connection to the network printer in accordance with Section 4.4.8. In the "Administration" window, press the "self-test" button and select the "printer connection" function from the menu displayed. The printer should print a page with the heading "PS". If this does not occur, chack whether the correct IP address for the printer is entered in the "Administration -Network configuration" window. |
PRINTER PROBLEM SYMPTOM
Accessories
| Symptom | Possible Causes | Remedy |
|---|---|---|
| No measurements possible with MFK1. | Measuring head defective. | In "Administration", run a self-test of the MFK1. If an error message is issued regarding the measurement system or measuring cable, send a Fault Report Fax. |
| No measurements possible with MFK2. | Measuring head defective. | In "Administration", run a self-test of the MFK2. If an error message is issued regarding the measurement system or measuring cable, send a Fault Report Fax. |
| No input possible via the optical keyboard. | No IR connection possible or batteries discharged. | Check whether the transmit and receive windows of the infrared connection are covered. Change the distance between the devices. Replace the batteries in the optical keyboard. If no connection can be set up, send a Fault Report Fax. |
ACCESSORIES PROBLEM SYMPTOM
| Symptom | Possible Causes | Remedy |
|---|---|---|
| No power supply to the control panel ( "Operation" LED does not light up in green on docking when switched on). | No power supply or power supply plug disconnected. Docking contacts dirty Foreign object prevents the perfect seating of the plug-in contacts Proximity switch is defective, does not through-connect power. Power supply unit defective LED defective | Insert the power supply plug. Press the on/off switch. Carefully clean the contacts on the docking station with a lint-free cloth. Remove the foreign object. Send a Fault Report Fax Send a Fault Report Fax Send a Fault Report Fax |
| "Battery" LED does not light up orange when switch off. | Battery is fully charged. Docking contacts dirty. Power supply unit defective. LED defective. | Not a Fault. Carefully clean the contacts on the docking station with a lint-free cloth. Send a Fault Fax Send a Fault Report Fax |
DOCKING STATION PROBLEM SYMPTOM
Fault Codes
| Codes | Fault Group |
|---|---|
| 000 | System error from UNIX operating system |
| 100 | Fault in the measurement system, internal |
| 200 | Fault in the EDIC application |
| 300 | Fault in the system technology |
| 400 | Fault in the TOROS application |
| 500 | Fault in the measurement system application |
| 800 | Run error |
| 900 | Internal error |
FAULT CODES
OBD & Network Connection
- OBD connection (2)
- DK LAN connection (1)
- 2 color LED (4)
- Green- flashing OPPS is free
- Green solid OPPS is connected.
- Green rapid flash Software update active
- Orange self test active or fault
Scheme 632
- External voltage testing (3)
Scheme 633
- These connections are not in use at this time and should not be used.
MOST Connection
MOST bus test cables and programming cable attach to this connector (1). The white protective cap should be replaced after use to keep the fiber Optic connections clean.
LED (2)
Red LED = voltage is supplied
Yellow LED = accessing MOST bus
Green LED = Bus lock
Scheme 634
Byteflight Connection
- Test connection (2)
- Reference connection (1)
OBD Connections
As stated earlier, OPPS comes with 2 OBD cables
"Short version" P/N 663 111 which is used for CIP programming through the OBD (2) and MOST bus as well as diagnosis of al E65/E66 modules.
Scheme 635
"Long version" P/N 663 112 (2) which is used for Optical module and bus testing of modules located a distance from the vehicle OBD connector such as in the vehicle trunk.
The long OBD cable 663 112 only transmits at a baud rate of 10400 compared to the high speed 115K baud for 663 111.
Scheme 636
E65/E66 CIP Programming Setup
Attach the OPPS and GT1 in accordance to Cabling setup 1 or 2.
Scheme 637
Scheme 638
Scheme 639
Scheme 640
- Attach the MOST bus programming cable (663 121) to the OPPS MOST connection (1).
- Run the MOST bus cable to the glove compartment (4).
- Pull down the trap door inside the glove compartment Disconnect the MOST bus interface (1) Plug the MOST bus harness (2) into the MOST programming cable (3).
Review Questions
- What is the OPPS Tool used for?
- How is the GT1 battery recharged?
- In what sequence must the three hardwire connection cables be attached between the diagnostic head and the GT1 control panel?
- Where is the floppy disc drive located on the GT1?
- What additional lead can be plugged into the Base Measurement connector shared with MFK 1 and MFK 2? What is the procedure for configuring the Optical Keyboard when more than one GT1 is used in the workshop? What does an orange glowing "operation" LED on the GT1 indicate? List the uses of the following OPPS OBD cables: The short cable #663 111 The long cable #663 112