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User's Manual

NGS+ User's Manual

Trademark Acknowledgements
Ford is a registered trademark of Ford Motor Company.

Copyright Information
NGS+ Users Manual. 2003 Ford Motor Company All rights reserved. The information, specifications and illustrations in this manual are based on the latest information available at the time of printing. Ford Motor Company reserves the right to make changes at any time without notice

T able of Contents
DEFINITIONS, ACRONYMS, AND ABBREVIATIONS 1

INTRODUCTION

SAFETY PROPER INSTALLATION AND USE OF THIS EQUIPMENT EQUIPMENT PRECAUTIONS

4 4 6
6 6

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

GETTING STARTED SYSTEM COMPONENTS CONVERSION FROM NGS CLASSIC TO NGS+

THINCARD UPDATE VCM/CADDY A SSEMBLY HARDWARE CONVERSION

7 7 9
9 10 11

NGS+ SOFTWARE USAGE FUNCTIONAL DIFFERENCES BETWEEN NGS+ AND NGS C LASSIC
DIAGNOSTIC DIFFERENCES BETWEEN NGS+ AND NGS CLASSIC

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NGS+ OPERATING TIPS TROUBLESHOOTING

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SUPPORT INSTRUCTIONS

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Note: An electronic version of this manual is available on CD or at the Internet location in which DBS SW is obtained.

T able of Figures
Figure 1: NGS+ System Figure 2: Standard Equipment for NGS+ Configuration Figure 3: Removing Caddy Rear Holder Figure 4: Installing VCM in the VCM Caddy Figure 5: Reinstalling the VCM Caddy Rear Holder Figure 6: Completed NGS+ Assembly 3 7 10 11 11 12

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Definitions, Acronyms, and Abbreviations

BCE CAN CARB CMDTC DBS Body, Chassis, Electrical Controller Area Network California Air Resources Board (State Agency) Continuous Memory Diagnostic Trouble Code Diagnostic Base Station, a PC loaded with Diagnostic Base Station software Software that is necessary to load and transfer files to the VCM Data Communications Link; 7-pin VIP connector (EEC IV vehicles) Diagnostic Data Link (Villager) Data Link Connector - vehicle diagnostic connector, SAE J1962 (16-pin OBD II vehicles) Diagnostic Trouble Code Diagnostic Trouble Code Count. Provides the number of Continuous DTCs. Digital Volt/Ohm Meter Electronic Control Unit. An onboard electronic module that controls a vehicle subsystem function. International Standards Organization Serial communication protocol implemented in Ford and CARB versions. Light Emitting Diode New Generation Star Tester (NGS Classic) Product name for the VCM when combined with the Caddy and used with the NGS T-handle Off the shelf Generic term to describe sensor, actuator, switch, etc. information that is retrieved from the module. Personal Computer Powertrain Control Module Parameter Identifier. An index number used to refer to a parameter within a module without knowing its storage location. Portable Test Unit Standard Corporate Protocol

DBS SW DCL DDL DLC DTC DTC CNT DVOM ECU ISO ISO-9141 LED NGS NGS+ OTS Parameter PC PCM PID PTU SCP

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SST SW Tester TIS UART UBP USB VCM VIM

VIN WDS

Small Service Tool Software Any off-board device that may cause an ECU to enter a test mode or communicate stored codes, PIDs, or status. Technical Information Support Hotline. Universal Asynchronous Receiver Transmitter UART Based Protocol Universal Serial Bus Vehicle Communication Module Vehicle Interface Module (removable module of NGS Classic) Vehicle Identification Number Worldwide Diagnostic System

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Introduction

ew Generation Star is a hand-held diagnostic tool for on-board monitoring, measuring, and recording of vehicle signals. This modular tool can be used in the service bay as well as for on-the-road testing. Ford Motor Company adapted the NGS tool to handle future vehicle diagnostic needs. The NGS+ is a system that incorporates the original NGS T-handle, a vehicle communication module (VCM), and a caddy (see Figure 1). The NGS+ is capable of supporting most vehicles, model year 1994 and forward using the 16-pin DLC (OBD II) connector (there is no current plan for Mercury Villager support on NGS+). For easy distinction we will refer to the previous NGS tool utilizing the VIM as the NGS Classic, and the newly introduced tool utilizing the VCM as the NGS+. The Diagnostic Base Station (DBS) is a PC loaded with Diagnostic Base Station Software (DBS SW). The DBS SW is used with the VCM to load and update the unit with NGS+ Software. Detailed instructions are available in the DBS User's Manual. This manual has been produced to assist in the installation and operation of the new VCM when used with the NGS T -handle. It does not include detailed operation of diagnostic software. Please, read and understand the important safety information contained in this manual before installation and use of the NGS+. It is advised to keep this manual with the NGS+ for reference and troubleshooting. Please, read and understand the instructions before using this equipment. Figure 1: NGS+ System

NGS T-handle NGS T-handle Thincard slot VCM Unit

VCM Caddy

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Chapter

Safety

ead and understand this safety information before installing, assembling, and using this equipment. This equipment has been designed, manufactured and tested, however, like any apparatus, care must be taken in its installation and use. DO observe the safety warnings and cautions in this document.

This indicates the presence of a hazard that can cause serious personal injury if the hazard is not avoided

This indicates the presence of a hazard that can cause damage to the NGS+, a vehicle, other equipment connected to the NGS+, or might corrupt software if the hazard is not avoided.

Proper Installation and Use of this Equipment

This equipment must only be used by properly trained personnel.

Do not allow any cables of this equipment to be positioned where they can be trapped, snagged, stretched across sharp edges, or create any potential hazard.

If the NGS+ is being used in a moving vehicle, ensure that the NGS+ and cables do not distract or interfere with the driver, or form a hazard in any way.

Do not allow any cables to become entangled with operator or driving controls. This can cause interference with driving and can cause injury.

DO use this equipment in accordance with the operating procedures.

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Before carrying out maintenance and cleaning of the NGS+, make sure the unit is not connected to a power source, vehicle, or PC. Use only a well-diluted, mild, non-abrasive cleaning agent applied using a soft, lint free cloth. DO NOT use or apply undiluted cleaning agent directly to the equipment surface and do not soak the cloth. Take care that cleaning fluid does not enter connector receptacles. DO NOT expose this equipment to spilled liquids. DO NOT continue to use this equipment if you have ANY doubts that it may not be working properly or it is damaged in anyway. Contact the Ford TIS Hotline. DO NOT remove any fixed covers unless you are authorized/qualified to do so. A defective electrical earth (ground) connection to any equipment may cause an electric shock hazard. This hazard may pass through the signal cabling and to any other equipment interconnected. It is recommended that you check electrical wiring at frequent intervals and whenever alterations are made. As a part of safety requirements, the manufacturer is required to define the intended operating environment. DO keep the NGS+ away from devices that generate radio interference.

Do ensure the NGS+ is not subjected to extreme temperature or prolonged exposure to direct sunlight that may cause heating of the NGS+.

If any liquid is spilled on this equipment remove the power immediately and ensure that it is dried out completely before restoring power.

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Equipment Precautions
The following warnings must be observed when using the NGS+:

IMPORTANT SAFETY INSTRUCTIONS

Failure to follow these instructions will increase the risk of personal injury

Step 1: Read all instructions. Step 2: Care must be taken as burns can occur from touching hot parts or surfaces. Step 3: DO NOT operate equipment if damage to unit or cord is suspected. Step 4: DO NOT let cord hang over edge of table, bench or counter or come in contact with hot manifolds or moving fan blades. Step 5: DO NOT place tools or test equipment on vehicle fenders or other places inside the engine compartment. Step 6: Let equipment cool completely before putting away. Loop cord loosely around equipment when storing. Step 7: Adequate ventilation should be provided when working on operating internal combustion engines. Step 8: Keep hair, loose clothing, jewelry, fingers and all parts of body away from moving parts of the vehicle. Step 9: Use this equipment only as described in the manual. Use only manufacturers recommended attachments. Step 10: ALWAYS WEAR SAFETY GLASSES WHEN USING GARAGE EQUIPMENT. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.
SAVE THESE INSTRUCTIONS

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Chapter

Getting Started

everal key steps must be followed in order to convert your NGS classic to the NGS+. This manual provides clear instructions on assembling, connecting, and preparing the NGS+ for use. Check all components against the manifest provided with the NGS+ before proceeding with conversion. Read and understand all safety information before installing, assembling, and using this equipment.

System Components
These NGS+ components are listed for information only. Some of these items may be standard or optional based on the configuration appropriate to the market. Some items have a Cable Identifier (Cable ID) that is used to indicate the appropriate cable, adapter or other hardware required to operate the VCM. The following information will help identify the system components. Figure 2: Standard Equipment for NGS+ Configuration

VCM Unit * Part No. 078-00496

VCM Caddy * Part No. 078-00480

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Power Supply Unit * Part No. 078-00477

16-Pin DLC Long Cable (8 ft) * Part No. 078-00479

Off-The-Shelf Ethernet Cable * Part No. 078-00490 (also known as Ethernet Patch Cable)

Off-The-Shelf USB Cable * Part No. 078-00491 (also known as USB device cable)

V CD

Diagnostic Service and Tools Manual *Part No. 078-00478

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Conversion from NGS Classic to NGS+

Once all components are accounted for, the following instructions must be completed in order to successfully convert the NGS Classic to the NGS+: Thincard Update A NGS+ thincard must be used in order for communication between the NGS T-handle and the VCM to be established. NGS+ thincard software does not contain vehicle diagnostic functionality. The NGS+ thincard software allows the VCM to execute vehicle diagnostics and provide the results on the T-handle display. Pre-programmed NGS+ thincards are available for purchase through Rotunda. You may also choose to program your existing NGS thincard utilizing an available WDS unit. WDS updates to thincards can be done as follows: Step 1: On the WDS System Utilities Tab select Update Special functions, Press tick. Step 2: Enter 83061, Press tick. Step 3: Slide the thincard into either the rear or forward PCMCIA slot located on the righthand side of the PTU. Step 4: Allow WDS to build drivers (this may take a minute). Remove thincard from PCMCIA slot. Step 5: Acknowledge pop-up window Step 6: Select NGS Software Update from the System Utilities Tab (Lower right-hand menu), Press tick Step 7: Select the latest version of NGS+ thincard software, "NGS+ Thincard Version X.X" Step 8: Slide the thincard into either the rear or forward PCMCIA slot located on the righthand side of the PTU. Step 9: Select the appropriate slot from the menu selection. Step 10: At completion, your NGS+ thincard will be programmed with the selected software
Note: We highly recommend keeping the NGS Diagnostic Software Version 17.2 intact in case reversion to NGS Classic is deemed necessary.

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VCM/Caddy Assembly Step 1: Remove the two Philips head screws from the bottom of the rear holder on the VCM Caddy assembly (see Figure 3). Step 2: Press in the two latches together on the rear holder and lift and remove the rear holder (see Figure 3). Step 3: Place the VCM unit into the VCM Caddy assembly with the plastic cover facing up and forward. Step 4: Slide the VCM unit forward until the connector fully seats into the mating VCM Caddy connector (see Figure 4). Step 5: Replace the rear holder onto the VCM Caddy by placing the front guides into the top, then lowering the rear holder until the two latches snap into place on the bottom (See Figure 5). Step 6: Replace the two Philips screws and lightly tighten until snug. Figure 3: Removing Caddy Rear Holder
Screws

Latches

VCM Caddy

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Figure 4: Installing VCM in the VCM Caddy

Plastic cover for the PCMCIA expansion slot

VCM Unit

Figure 5: Reinstalling the VCM Caddy Rear Holder

Hardware Conversion Step 1: Replace the NGS thincard with the reprogrammed NGS+ thincard by sliding it into the NGS T-handle thincard slot.
Note: The NGS+ thincard MUST BE placed into the NGS T-handle. The NGS+ tool will NOT function properly if NGS+ thincard is inserted into the VCM.

Step 2: Secure the VCM into the Caddy (see above, VCM/Caddy Assembly). Step 3: Follow the instructions in the DBS User's Manual, NGS+ and DBS Section, to load necessary software onto the VCM/Caddy for use.
Note: The NGS+ SW is updateable via a PC that meets the specifications listed in the DBS User's Manual, Getting Started Section
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Step 4: Disconnect the VCM/Caddy from the PC once all software has been loaded. Step 5: Disconnect the Vehicle Interface Module from the NGS T-handle Step 6: Slide the VCM-Caddy combination into the T-Handle, 120 pin connector first, until the Caddy connector fully seats into the mating T-Handle connector. (see Figure 6). Step 7: Attach the VCM 16-Pin DLC (OBD II) cable to the VCM. The NGS+ is now ready for use.

Figure 6: Completed NGS+ Assembly

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Chapter

NGS+ Software Usage

ost of the display on the NGS+ is identical to NGS classic. However, there is a significant amount of diagnostic functionality added "behind the scenes" and may not be apparent to the user. There are some functional differences between the two tools and limitations of use that are outlined below.

Functional Differences between NGS+ and NGS Classic

NGS+ will cover Ford/Lincoln/Mercury North American vehicles, model year 1994 and forward, with a 16-pin DLC (OBD II) connector.
Note: We highly recommend keeping the NGS Diagnostic Software Version 17.2 intact in case reversion to NGS Classic is deemed necessary.

Vehicle coverage for the NGS+ will NOT include: Mercury Villager Vehicles without a 16-pin DLC (OBD II) connector Includes Super Duty Trucks through 1997 Model Year

Vehicles that use both the 16-pin DLC (OBD II) connector and the 7-pin VIP connector will only have support for the modules on the 16-pin DLC (OBD II).

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Diagnostic differences between NGS+ and NGS Classic Service functions, such as PATS functions and ABS Service Bleeds, will be listed under a generic FUNCTION TESTS selection within a vehicle and module pick on NGS+, rather than on a separate card under a module and vehicle pick on NGS Classic. Programmable Module Installation and Customer Preference Items are located under MODULE CONFIGURATION, and will be accessed within a vehicle and module pick on NGS+ No DVOM measurement capabilities on NGS+

NGS+ Operating Tips

The following tips were developed to save the user valuable diagnostic time: For quick menu lists (i.e. Vehicle & Engine Selection, PID Selection) navigation, use the NGS T-Handle "softkeys" to page through the list: Softkey 1 moves to the previous screen Softkey 2 moves to the first screen Softkey 9 moves to the last screen Softkey 0 moves to the next screen

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Chapter

Troubleshooting

he user should perform the following simple checks to determine if they can resolve any problems with the NGS+ system. Ensure that all steps have been performed before contacting the Ford Technical Information Support with any concerns: Check 1 : Verify that the NGS+ operates in the same manner on another vehicle, if available Check 2 : Ensure the VCM/Caddy is properly seated in the NGS T- handle. Check 3 : Confirm the thincard is properly seated and has the proper software update. Check 4 : Verify the VCM's LEDs are lit (see the VCM Hardware Manual, LED Status Indicators section). Check 5 : Reseat the Diagnostic Cable at the vehicles DLC connector and the VCM. Check 6 : Look for any pin push out at the vehicles DLC connector. Check7: Reinstall the NGS+ software per the Diagnostic Base Station User's Manual, NGS+ and DBS section, and perform the same NGS+ operation. Check 8 : Cycle (remove/connect) the power to the VCM. Make sure that the VCM performs the power On boot-up successfully

The following table details errors that may be seen on the NGS+ display and potential remedies.
Problem Symptoms Checks & Possible Causes

UNABLE TO PERFORM TEST/FUNCTION SUB FUNCTION NOT SUPPORTED or INVALID FORMAT

Check that the option being commanded is supported on the vehicle. If so, record the vehicle pick and the command or service function name. Report this information to the TIS hotline. Ensure that the proper vehicle set-up is in place. Improper vehicle set-up (.e., door needs to be shut) or software error may be root cause.

UNABLE TO PERFORM TEST/FUNCTION CONDITIONS INCORRECT CHECK SHOP MANUAL FOR PROPER TEST/FUNCTION
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REQUIREMENTS UNABLE TO PERFORM TEST/FUNCTION NOT RESPONDING/NOT EQUIPPED CHECK IGNITION STATUS CHECK CABLE CONNECTIONS THIS MODULE MAY BE BLANK UNABLE TO PERFORM TEST/FUNCTION NOT RESPONDING/NOT EQUIPPED CHECK IGNITION STATUS VERIFY CABLE REQUIREMENTS CHECK CABLE CONNECTIONS UNABLE TO PERFORM TEST/FUNCTION NOT RESPONDING/NOT EQUIPPED PATS FUNCTION MAY BE INTEGRATED IN PCM

or software error may be root cause. Turn the key on. Run other diagnostics (Self Test, Code Retrieval, PID Monitor) to determine that the ECU does, or does not, communicate. Fix any communication link issues. The PCM may need to be reprogrammed. Turn the key on. Run other diagnostics (Self Test, Code Retrieval, PID Monitor) to determine that the ECU does, or does not, communicate. Fix any communication link issues.

Select the proper module.

Note: Additional troubleshooting tips for the VCM are available in the VCM Hardware Manual, Troubleshooting section.

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Chapter

Support Instructions

f the checks in the Troubleshooting section did not resolve your NGS+ concern, contact the Ford Technical Information Support for assistance. For U.S. Ford Dealership support information see www.fmcdealer.com

For Canadian Ford Dealership support information see www.inford.com For non-Ford Dealerships support information is available at www.motorcraftservice.com

Please have the following information available: Vehicle Make, Model, Year, and Engine Size PCM part number or Tear Tag number NGS+ Software Level found under New Generation Setup/Software Version Thincard software level, displayed on the screen after the card is inserted

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