#180 LOADpro OPERATING MANUAL

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Dorcas Palmer
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April 2011 Version 1.2 Protected by U.S.

OPERATING MANUAL Watch our product videos at youtube.

1 April 2011 Version 1.2 Protected by U.S. Patent 6,356,853 EU Patent 1,203,202 Japan Patent Pending Caterpillar P/N UPS P/N Volvo P/N #180 LOADpro OPERATING MANUAL Watch our product videos at youtube.com Just type: ElectronSpecialties into the search box Using LOADpro Dynamic Meter Leads with your digital voltmeter This is NOT a special tool. This is a set of normal VOLTmeter leads that has a special function of locating high resistance in wiring by applying a 40mA/V dynamic load with EVERY VOLTAGE TEST. Remove your normal voltmeter leads and install these. Works with any digital voltmeter with standard banana plugs. Electronic Specialties Incorporated P/N Elizabeth Lane Genoa City, WI fax

2 General Information LOADpro Voltmeter Leads are designed to replace the load in an electrical circuit so a load test (voltage drop test) can be made with the component removed. This is the best way to make the initial test. The normal drop in a clean circuit varies, and you ll need to develop a sense of how much drop constitutes a fault. A drop of 0.5V in a 12V system is an effective resistance of 5Ω. See page 5 for more information. Things To Consider The digital VOLTmeter function in the multimeter is the best diagnostic tool you can use. The system voltage is more powerful than the 3V the ohmmeter supplies. Testing with voltage drop is more accurate and easier. Don t use the LOADpro Probe (positive) in the negative side of the circuit. You may inadvertantly operate a component switched in ground. Testing your LoadPRO Leads Install your LOADpro Leads into your digital meter, and set the meter to measure Ohms (Ω). DO NOT TOUCH LEADS Together. Depress the LOADpro button. Your meter should read approx 25Ω. If the reading is outside of this range, or reads 0Ω or OLΩ, your LOADpro Leads are not working. Contact us for warranty service Warnings and Cautions 1. Primarily designed as a replacement for the component. 2. Don t use the LOADpro Probe (positive) in the negative side of the circuit. You may inadvertantly operate a component switched in ground. Know where you are! 3. Use up to 28.5V (DC or AC) only. Max 5-8 seconds per test - prolonged use may overheat/damage LOADpro. 4. Not for computer (ECM) INPUT circuits. This tool has been tested successfully and will test computer (ECM) sensor driver circuits (B+ and Gnd/Return). 5. Not designed for high voltage circuits. 6. Do not use positive LOADpro probe (positive) in the negative side of the circuit. Use the BLACK lead on ground with LoadPRO probe energized (powered test light mode - see page 3) 7. Use only with the DIGITAL VOLTMETER 8. LOADpro will not function with AMMETER or OHMMETER How To Calculate LOADpro Amp Draw 1. Measure your LoadPRO voltage 2. Divide by this is the ma draw 3. Example - 5VDC 100 = 50mA How To Calculate Your Actual Circuit Resistance See chart on Page 5 (Advanced Testing) 1. Measure your actual system voltage 2. Measure LOADpro voltage 3. Divide LOADpro Voltage by this is the LOADpro Amperage 4. Subtract voltage 2 from voltage 1 this is the resistance voltage drop 5. Divide resistance voltage drop by LOADpro Amperage this is the circuit resistance (Ω). V A=Ω 6. Multiply the circuit resistance (Ω) by your normal circuit amperage this is the actual voltage drop. USE LOADpro! It finds problems you might normally miss! 1. Read VOLTAGE like you normally do. 2. Push button. 3. Read VOLTAGE again. 4. Did VOLTAGE drop? If yes - you have a problem in the wire. 5. Did VOLTAGE NOT drop? - Wire is clean. 6. See next page for specific instructions and see page 5 for resistances if you need to.

3 Here s How Simple The Process Can Be... There are ONLY 3 FAULTS THAT CAN OCCUR IN A SINGLE WIRE: 1. OPEN 2. SHORT-TO-GROUND 3. HIGH RESISTANCE Basic System Test Procedure: 1. Disconnect the load component (light bulb, etc.) from the wiring harness. 2. Insert both the LOADpro probe and the negative probe into the wiring Harness connector. See diagram below for polarity. 3. Read system voltage and compare to manufacturer s specifications. Zero (0.000) volts, is a SHORT-TO-GROUND in the positive circuit. GHOST voltage, is an OPEN circuit in either the positive or negative circuit. To determine if the OPEN is on the positive or negative circuit: Move the black lead to a known good ground. If voltage rises to mfr. specs, the OPEN is in the ground side of the circuit. If the ghost voltage remains, then the OPEN is in the positive side. System voltage, the circuit is complete, but may have HIGH RESISTANCE (see next step) To test for HIGH RESISTANCE in the positive or negative circuit: 4. Depress LOADpro probe button (maximum of 5 to 8 seconds). If system voltage does not change or drops very little, the wiring is good If the voltage drops, there is HIGH RESISTANCE in the wiring circuit. To determine if the HIGH RESISTANCE is on the positive or negative circuit; 5. Move the black probe to a known good ground and repeat step #4. If the voltage drops, then the resistance is in the positive side of the circuit. If system voltage is present, then the resistance is in the ground side of the Circuit. Ghost Voltage- When the DMM is set to the lowest DC Millivolts scale, the reading appears to float around and shows random readings. This happens because the test circuit is open. Touch your test probes together and the DMM reading will ZERO itself. When you touch the DMM test probes together, you have closed the test circuit. Using this characteristic of your DMM can help you find open circuits.

4 TESTING FOR RESISTANCE IN THE POSITIVE 1. Use the positive LOADpro Probe in the RED side of the circuit 2. Use the LOADpro Leads just like a test light - black to ground, and test with the LOADpro Probe. 3. Break the circuit at connectors as needed to test each segment 4. Depress the LOADpro button with each voltage test 5. Any drop in voltage indicates a problem (high resistance) in the circuit. Think of LOADpro Voltmeter Leads as a powered test light. If you are looking for a big resistance problem (corrosion) in positive, clip the black lead to ground and check the positive wires with the LOADpro probe. If you re looking for a ground problem, clip the LOADpro probe to a clean voltage source, and check the ground connections and wires with the black probe. TESTING FOR RESISTANCE IN THE NEGATIVE 1. Use the LOADpro Leads just like a POWERED test light - connect the LOADpro probe to a clean voltage supply. 2. Use the black probe in the ground circuit to check for a bad ground. Break the circuit as needed to test each segment 3. Depress the LOADpro button with each voltage test 4. A constant voltage means the ground is clean. 5. A drop in voltage means the ground has high resistance (corrosion). Use the RED lead in the RED side (positive) and the BLACK lead in the BLACK (negative) side. Using the LOADpro Probe (positive) in ground wires doesn t work. Attach the LOADpro Probe to a clean voltage supply.

Your Ω (Corrosion) for Your System Voltages LOADpro Voltage is read with LOADpro button depressed 5 V Sensor 8 V Sensor 12V System 14.5V System 24V System 28.

5 Your Ω (Corrosion) for Your System Voltages LOADpro Voltage is read with LOADpro button depressed 5 V Sensor 8 V Sensor 12V System 14.5V System 24V System 28.5V System Fault Fault Fault Fault Fault Fault LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance 4.95V.2Ω 7.9V.3Ω 11.8V.4Ω 14.3V.3Ω 23.75V.2Ω 28.2V.2Ω 4.9V.5Ω 7.8V.6Ω 11.6V.8Ω 14.1V.7Ω 23.5V.5Ω 27.9V.5Ω 4.85V.7Ω 7.7V.9Ω 11.4V 1.3Ω 13.9V 1Ω 23.25V.8Ω 27.6V.8Ω 4.8V 1Ω 7.6V 1.3Ω 11.2V 1.7Ω 13.7V 1.4Ω 23V 1Ω 27.3V 1Ω 4.75V 1.3Ω 7.5V 1.6Ω 11V 2.2Ω 13.5V 1.8Ω 22.75V 1.3Ω 27V 1.3Ω 4.7V 1.5Ω 7.4V 2Ω 10.8V 2.7Ω 13.3V 2.2Ω 22.5V 1.6Ω 26.7V 1.6Ω 4.65V 1.8Ω 7.3V 2.3Ω 10.6V 3.3Ω 13.1V 2.6Ω 22.25V 1.9Ω 26.4V 1.9Ω 4.6V 2.1Ω 7.2V 2.7Ω 10.4V 3.8Ω 12.9V 3.1Ω 22V 2.2Ω 26.1V 2.2Ω 4.55V 2.4Ω 7.1V 3.1Ω 10.2V 4.4Ω 12.7V 3.5Ω 21.75V 2.5Ω 25.8V 2.6Ω 4.5V 2.7Ω 7V 3.5Ω 10V 5Ω 12.5V 4Ω 21.5V 2.9Ω 25.5V 2.9Ω 4.45V 3Ω 6.9V 3.9Ω 9.8V 5.6Ω 12.3V 4.4Ω 21.25V 3.2Ω 25.2V 3.2Ω 4.4V 3.4Ω 6.8V 4.4Ω 9.6V 6.2Ω 12.1V 4.9Ω 21V 3.5Ω 24.9V 3.6Ω 4.35V 3.7Ω 6.7V 4.8Ω 9.4V 6.9Ω 11.9V 5.4Ω 20.75V 3.9Ω 24.6V 3.9Ω 4.3V 4Ω 6.6V 5.3Ω 9.2V 7.6Ω 11.7V 5.9Ω 20.5V 4.2Ω 24.3V 4.3Ω 4.25V 4.4Ω 6.5V 5.7Ω 9V 8.3Ω 11.5V 6.5Ω 20.25V 4.6Ω 24V 4.6Ω 4.2V 4.7Ω 6.4V 6.2Ω 8.8V 9Ω 11.3V 7Ω 20V 5Ω 23.7V 5Ω 4.15V 5.1Ω 6.3V 6.7Ω 8.6V 9.8Ω 11.1V 7.6Ω 19.75V 5.3Ω 23.4V 5.4Ω 4.1V 5.4Ω 6.2V 7.2Ω 8.4V 10.7Ω 10.9V 8.2Ω 19.5V 5.7Ω 23.1V 5.8Ω 4.05V 5.8Ω 6.1V 7.7Ω 8.2V 11.5Ω 10.7V 8.8Ω 19.25V 6.1Ω 22.8V 6.2Ω 4V 6.2Ω 6V 8.3Ω 8V 12.5Ω 10.5V 9.5Ω 19V 6.5Ω 22.5V 6.6Ω 3.95V 6.6Ω 5.9V 8.8Ω 7.8V 13.4Ω 10.3V 10.1Ω 18.75V 7Ω 22.2V 7Ω 3.9V 7Ω 5.8V 9.4Ω 7.6V 14.4Ω 10.1V 10.8Ω 18.5V 7.4Ω 21.9V 7.5Ω 3.85V 7.4Ω 5.7V 10Ω 7.4V 15.5Ω 9.9V 11.6Ω 18.25V 7.8Ω 21.6V 7.9Ω 3.8V 7.8Ω 5.6V 10.7Ω 7.2V 16.6Ω 9.7V 12.3Ω 18V 8.3Ω 21.3V 8.4Ω 3.75V 8.3Ω 5.5V 11.3Ω 7V 17.8Ω 9.5V 13.1Ω 17.75V 8.8Ω 21V 8.9Ω 3.7V 8.7Ω 5.4V 12Ω 6.8V 19.1Ω 9.3V 13.9Ω 17.5V 9.2Ω 20.7V 9.4Ω 3.65V 9.2Ω 5.3V 12.7Ω 6.6V 20.4Ω 9.1V 14.8Ω 17.25V 9.7Ω 20.4V 9.9Ω 3.6V 9.7Ω 5.2V 13.4Ω 6.4V 21.8Ω 8.9V 15.7Ω 17V 10.2Ω 20.1V 10.4Ω 3.55V 10.2Ω 5.1V 14.2Ω 6.2V 23.3Ω 8.7V 16.6Ω 16.75V 10.8Ω 19.8V 10.9Ω 3.5V 10.7Ω 5V 15Ω 6V 25Ω 8.5V 17.6Ω 16.5V 11.3Ω 19.5V 11.5Ω 3.45V 11.2Ω 4.9V 15.8Ω 5.8V 26.7Ω 8.3V 18.6Ω 16.25V 11.9Ω 19.2V 12.1Ω 3.4V 11.7Ω 4.8V 16.6Ω 5.6V 28.5Ω 8.1V 19.7Ω 16V 12.5Ω 18.9V 12.6Ω 3.35V 12.3Ω 4.7V 17.5Ω 5.4V 30.5Ω 7.9V 20.8Ω 15.75V 13Ω 18.6V 13.3Ω 3.3V 12.8Ω 4.6V 18.4Ω 5.2V 32.6Ω 7.7V 22Ω 15.5V 13.7Ω 18.3V 13.9Ω 3.25V 13.4Ω 4.5V 19.4Ω 5V 35Ω 7.5V 23.3Ω 15.25V 14.3Ω 18V 14.5Ω 3.2V 14Ω 4.4V 20.4Ω 4.8V 37.5Ω 7.3V 24.6Ω 15V 15Ω 17.7V 15.2Ω 3.15V 14.6Ω 4.3V 21.5Ω 4.6V 40.2Ω 7.1V 26Ω 14.75V 15.6Ω 17.4V 15.9Ω 3.1V 15.3Ω 4.2V 22.6Ω 4.4V 43.1Ω 6.9V 27.5Ω 14.5V 16.3Ω 17.1V 16.6Ω 3.05V 15.9Ω 4.1V 23.7Ω 4.2V 46.4Ω 6.7V 29.1Ω 14.25V 17.1Ω 16.8V 17.4Ω 3V 16.6Ω 4V 25Ω 4V 59Ω 6.5V 30.7Ω 14V 17.8Ω 16.5V 18.1Ω 2.95V 17.3Ω 3.9V 26.2Ω 3.8V 53.9Ω 6.3V 32.5Ω 13.75V 18.6Ω 16.2V 18.9Ω 2.9V 18.1Ω 3.8V 27.6Ω 3.6V 58.3Ω 6.1V 34.4Ω 13.5V 19.4Ω 15.9V 19.8Ω 2.85V 18.8Ω 3.7V 29Ω 3.4V 63.2Ω 5.9V 36.4Ω 13.25V 20.2Ω 15.6V 20/6ω 2.8V 19.6Ω 3.6V 30.5Ω 3.2V 68.7Ω 5.7V 38.5Ω 13V 21.1Ω 15.3V 21.5Ω 2.75V 20.4Ω 3.5V 32.1Ω 3V 75Ω 5.5V 40.9Ω 12.75V 22Ω 15V 22.5Ω 2.7V 21.2Ω 3.4V 33.8Ω 2.8V 82.1Ω 5.3V 43.3Ω 12.5V 23Ω 14.7V 23.4Ω 2.65V 22.1Ω 3.3V 35.6Ω 2.6V 90.3Ω 5.1V 46Ω 12.25V 23.9Ω 14.4V 24.4Ω 2.6V 23Ω 3.2V 37.5Ω 2.4V 100Ω 4.9V 48.9Ω 12V 25Ω 14.1V 25.5Ω

6 5 V Sensor 8 V Sensor 12V System 14.5V System 24V System 28.5V System Fault Fault Fault Fault Fault Fault LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance LOADpro V Resistance 2.55V 24Ω 3.1V 39.5Ω 2.2V 111.3Ω 4.7V 52.1Ω 11.75V 26Ω 13.8V 26.6Ω 2.5V 25Ω 3V 41.6Ω 2V 125Ω 4.5V 55.5Ω 11.5V 27.1Ω 13.5V 27.7Ω 2.45V 26Ω 2.9V 43.9Ω 1.8V 141.6Ω 4.3V 59.3Ω 11.25V 28.3Ω 13.2V 28.9Ω 2.4V 27Ω 2.8V 46.4Ω 1.6V 162.5Ω 4.1V 63.4Ω 11V 29.5Ω 12.9V 30.2Ω 2.35V 28.1Ω 2.7V 49Ω 1.4V 189.2Ω 3.9V 67.9Ω 10.75V 30.8Ω 12.6V 31.5Ω 2.3V 29.3Ω 2.6V 51.9Ω 1.2V 225Ω 3.7V 72.9Ω 10.5V 32.1Ω 12.3V 32.9Ω 2.25V 30.5Ω 2.5V 55Ω 1V 275Ω 3.5V 78.5Ω 10.25V 33.5Ω 12V 34.3Ω 2.2V 31.8Ω 2.4V 58.3Ω.8V 350Ω 3.3V 84.8Ω 10V 35Ω 11.7V 35.8Ω 2.15V 33.1Ω 2.3V 61.9Ω.6V 475Ω 3.1V 91.9Ω 9.75V 36.5Ω 11.4V 37.5Ω 2.1V 34.5Ω 2.2V 65.9Ω.4V 725Ω 2.9V 100Ω 9.5V 38.1Ω 11.1V 39.1Ω 2.05V 35.9Ω 2.1V 70.2Ω.2V 1475Ω 2.7V 109.2Ω 9.25V 39.8Ω 10.8V 40.9Ω 2V 37.5Ω 2V 75Ω 2.5V 120Ω 9V 41.6Ω 10.5V 42.8Ω 1.95V 39.1Ω 1.9V 80.2Ω 2.3V 132.6Ω 8.75V 43.5Ω 10.2V 44.8Ω 1.9V 40.7Ω 1.8V 86.1Ω 2.1V 147.6Ω 8.5V 45.5Ω 9.9V 46.9Ω 1.85V 42.5Ω 1.7V 92.6Ω 1.9V 165.7Ω 8.25V 47.7Ω 9.6V 49.2Ω 1.8V 44.4Ω 1.6V 100Ω 1.7V 188.2Ω 8V 50Ω 9.3V 51.6Ω 1.75V 46.4Ω 1.5V 108.3Ω 1.5V 216.6Ω 7.75V 52.4Ω 9V 54.1Ω 1.7V 48.5Ω 1.4V 117.8Ω 1.3V 253.8Ω 7.5V 55Ω 8.7V 56.8Ω 1.65V 50.7Ω 1.3V 128.8Ω 1.1V 304.5Ω 7.25V 57.7Ω 8.4V 59.8Ω 1.6V 53.1Ω 1.2V 141.6Ω.9V 377.7Ω 7V 60.7Ω 8.1V 62.9Ω 1.55V 55.6Ω 1.1V 156.8Ω 6.75V 63.8Ω 7.8V 66.3Ω 1.5V 58.3Ω 1V 175Ω 6.5V 67.3Ω 7.5V 70Ω 1.45V 61.2Ω.9V 197.2Ω 6.25V 71Ω 7.2V 73.9Ω 1.4V 64.2Ω.8V 225Ω 6V 75Ω 6.9V 78.2Ω 1.35V 67.5Ω.7V 260.7Ω 5.75V 79.3Ω 6.6V 82.9Ω 1.3V 71.1Ω.6V 308.3Ω 5.5V 84Ω 6.3V 88Ω 1.25V 75Ω.5V 375Ω 5.25V 89.2Ω 6V 93.7Ω 1.2V 79.1Ω 5V 95Ω 5.7V 100Ω 1.15V 83.6Ω 4.75V 101.3Ω 5.4V 106.9Ω 1.1V 88.6Ω 5.1V 114.7Ω 1.05V 94Ω 4.8V 123.4Ω 1V 100Ω Warranty Information 4.5V 133.3Ω.95V 106.5Ω 4.2V 144.6Ω.9V 113.8Ω This product is warranted to be free from defects for 3.9V 157.6Ω.85V 122Ω 3.6V 172.9Ω one year. If this product fails during the first 12 months.8v 131.2Ω 3.3V 190.9Ω due to faulty materials or workmanship, it will be.75v 141.6Ω 3V 212.5Ω.7V 153.5Ω repaired or replaced free of charge, at the discretion.65v 167.3Ω of the manufacturer..6v 183.3Ω.55V 202.2Ω For warranty and service coverage, please return this.5v 225Ω product to your dealer for processing and evaluation..45v 252.7Ω.4V 287.5Ω OR, return it directly to:.35v 332.1Ω.3V 391.6Ω.25V 475Ω Electronic Specialties, Inc. 139 Elizabeth Ln. Genoa City, WI Fax Defective units being returned to your dealer or to the factory should include proof of purchase date. Any testers that do not function due to misuse or abuse will be subject to out of warranty service charges.

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