OPERATOR S MANUAL #M2000 MOBILE UNIVERSAL TRAILER TESTER

Transcription

1 ORIGINAL EQUIPMENT MANUFACTURER (OEM) USA #M2000 MOBILE UNIVERSAL TRAILER TESTER OPERATOR S MANUAL MADE IN USA Test Trailers Using 7 Round Pin and 12 Pin NATO Harnesses. Uses External 12/24 Volt Battery or Power Source. 1

2 LETTER FROM THE PRESIDENT OF IPA My name is Peter Vinci and I am the president of IPA. I would like to first thank you for your interest in IPA s product line and share my commitment to you, our products and our policies. In today s world, we have all experienced the lack of service and consideration demonstrated by many companies after you buy their products. They say whatever they can to make the sale, and then it s like pulling teeth to get any service response out of them. I know this myself firsthand and because of this, I want to be sure that your experience with IPA meets your expectations and that IPA never disappoints you with our service or customer response. To prove my commitment to you, if for any reason, you are not happy with one of our products or more importantly, with the response from our customer service or any member of the IPA team, I invite you to contact me directly via my , peter@ipatools.com or call me at Your satisfaction is more important to me than the sale itself. We will not be in business for long if we don t make you completely happy with our products and service. I want IPA to be different and be known for its quality and service. With that said, please take a look at our product line. You will see innovative first time products that were created to help you do your job faster and better than before. I would also like to invite you to critique our products. If you can think of a better way to make them or changes that will make them work better, please contact me directly and I will be sure to look into it. If you have an innovation and would like some feedback, give me a call. From all of us at IPA, we thank you for taking the time to review our product line and wish you and your family the very best of everything. Peter Vinci President IPA Toll Free: Phone: Fax:

3 8 FT. RED GLAND HAND #7900AP-11AS #M2000 PARTS Fig. 1 - Parts Diagram Antenna Handle Mute Switch 8 FT. BLUE GLAD HAND #7900AP-12AS FEMALE 2 PRONG PLUG POWER ADAPTER #7900K-93 Main Power Switch 12 Pin NATO Out to Trailer Emergency Side Gauge Emergency Side Air Out (Red Hose) Shop Air Inlet Emergency Air Exhaust Switch Emergency Side Air Control Switch Hang Hook for Face Shield to use as Battery Cover Insert Hook into Slot to Hang Face Shield to use as Battery Cover Electrical Testing Panel See Fig. 6 Trailer Type Switch Fuse 7 Round Pin Out to Trailer Service Side Gauge AMP Power Input Chassis Ground Outlet 12V Aux Trickle Charge Input Service Side Air Out (Bllue Hose) Service Side Air Control Switch Wheels REMOTE CONTROL FOB (Qty. 3 Included) #MUT-RAS Face Shield Battery Cover Foot CONTROL FOB BATTERY (12V Alkaline Energizer AE or A23) #7900K-34B 8 FT. 7-WAY ROUND PIN CABLE #7900K FT. CHASSIS GROUND CABLE #7900K-2BCHAS ANTENNA #7900K-79AS Insert Hooks onto Edge to Hang Face Shield for use as Battery Cover AL " SUPER MUTT ALE 7900K FT. 7-WAY ROUND PIN CABLE 7900K AMP AMMETER GAUGE MUT-RAS REMOTE CONTROL FOB 7900K-48 10" WHEEL 7900K-49 LUGGAGE HANDLE 7900K-79AS ANTENNA WIRE ASSEMBLY 7900K-8Z 7 ROUND ZINC SOCKET 7900AP-11AS 8 FT. RED GLAD HAND 7900AP-12AS 8 FT. BLUE GLAD HAND 7900AP-14 SOLENOID VALVE 4-WAY 12V DC 7900AP PSI 2" PANEL MOUNT GAUGE R FACE SHIELD / BATTERY COMPARTMENT COVER CHRG-3AMP 3 AMP CHARGER BATTERY BRACKET (NOT SHOWN) 3 AMP CHARGER #CHRG-3AMP VELCRO FOR CHARGER MOUNTING USE THE REFERENCE NUMBERS PROVIDED WHEN ORDERING PRODUCTS & PARTS ABOVE OR Toll Free:

4 IMPORTANT SAFETY INSTRUCTIONS IT IS IMPORTANT TO READ, UNDERSTAND AND FOLLOW ALL SAFETY MESSAGES AND INSTRUCTIONS PRINTED IN THIS MANUAL AND ON THE EQUIPMENT BEFORE OPERATING. IF SAFETY INFORMATION IS NOT HEEDED, SERIOUS INJURY OR DEATH TO THE OPERATOR OR BYSTANDERS MAY OCCUR. DANGER: Indicates a hazardous situation, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. WARNING: Indicates a hazardous situation, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. CAUTION: Indicates a hazardous situation, if not avoided, may result in minor or major injury. The possible hazards are shown in the adjoining symbols or explained in the text. THE FOLLOWING SAFETY ALERT SYMBOLS ARE USED IN THIS MANUAL SYMBOL 1: Potential burn hazard. Sparks from electrical shorts can ignite flammable liquids such as fuel or oil. Heat from electrical overloads can cause a fire hazard. SYMBOL 2: Potential electrical hazard. Batteries have enough electrical energy potential to ignite flammable liquids such as fuel or oil. Wire overloads can cause electrical failures. Shock hazard exists. SYMBOL 3: Potential explosive air hazard. Pneumatic pressure used with this equipment can cause explosive failure on damaged equipment. SYMBOL 4: Potential eye hazard. Wear OSHA approved safety glasses. Battery acid and high air pressures create hazardous situations for eyes. SYMBOL 5: Potential chemical burn hazard. Wear protective gloves. Battery acid is corrosive and can cause skin damage. SYMBOL 6: Potential electrical hazard. Electrical energy can cause heat and burn hazards. SYMBOL 7: Potential fire hazard. Use caution with flammable liquids such as fuel and oil. Electrical shorts can ignite flammable liquids and wiring. SYMBOL 8: Important information is stated. 4

5 BATTERY GASES, TESTER PREPARATION AND TESTER/CHARGER LOCATION RISK OF EPLOSION Gases produced by a battery are highly explosive. Wear safety goggles and protective clothing for both users and bystanders. Use in an area having at least four air changes per hour. Read, understand and follow all instructions for the charger, battery, vehicle and any equipment used near the battery and charger. Do not smoke, strike a match, place metal tools on battery or cause a spark in the vicinity of the battery. When removing battery cables, remove the ground cable first. Clean terminals before charging battery. During cleaning, keep corrosive particles from eyes, nose and mouth. Use baking soda and water to neutralize acid and help eliminate airborne corrosion. Never allow clamps on charger cables to touch each other. Do not expose tester or charger to rain, snow or wet conditions. Do not allow battery gases or acid to contact MUTT cabinet. Do not place charger directly above or below battery. Fill battery to level specified by battery manufacturer using distilled water. Do not remove cell caps while charging per manufacturer s instructions. Make sure tester cable clamps make tight connections. Battery explosion can cause injury. ACID BURNS Battery acid is highly corrosive sulfuric acid. Wear safety goggles for both users and bystanders. Wear safety gloves. Make sure someone can hear you or is close enough to provide aid when working near battery. Have plenty of fresh water and soap nearby. If battery acid contacts skin, clothing or eyes, flush the exposed area with soap and water for 10 minutes. Seek medical help. Do not touch eyes while working near battery. Battery acid can burn eyes and skin. DC POWER ONLY Do NOT plug directly into AC wall outlet 5

6 GENERAL CHARGER USE RISK OF ELECTRIC SHOCK AND FIRE Before connecting charger to unit, make sure controls are set to OFF. Do not remove or bypass the grounding pin. Do not operate charger with damaged cord or plug. Replace cord or plug immediately if damage occurs. Position power cord and charger cables away from the hood, doors or hot and/or moving engine parts where they could be damaged. Unplug power cord using plug rather than cord when disconnecting charger from outlet. Charger power cord uses equipment-grounding conductor and a grounding plug. Plug only into a 120V AC outlet that is correctly installed and grounded in accordance with all ordinances and local codes. Unplug power cord from outlet before cleaning or maintaining tester and charger. Turning off controls does not reduce this risk. Do not operate charger after a sharp impact, drop or any other damage. Do not disassemble charger. Use only recommended attachments. Do not charge a frozen battery. Do not overcharge a battery. Use charger only for lead-acid automotive batteries. Do not use charger for charging dry cell batteries. Electric shock or fire can cause injury. RISK OF ENTANGLEMENT Keep yourself, clothing and battery charger leads clear of moving parts such as fan blades, pulleys, hood and doors. Moving parts can cause injury. RISK OF BURNS Batteries can produce short circuit current high enough to weld jewelry such as rings, bracelets and watches. You must remove them before working near batteries. Short circuits can cause injury. 6

7 ALE AND WHEEL INSTALLATION Insert axle (fig. 2-A) into left and right axle bores (fig. 2-B) at rear underside of the MUTT. Slide 1 spacer (fig. 2-C) onto each side of the axle (fig. 2-A). Install 1 wheel (fig. 2-D) onto each side of the axle (fig. 2-A) with valve stem facing away from the MUTT. Insert 1 E-Clip (fig. 2/3-E) into the groove (fig. 3-F) in the axle end in front of the wheel to each side. Check tire pressure. It must not exceed 8 PSI. D FRONT D E C B A B C E F (UNDERSIDE OF MUTT ) F Fig. 2: Axle and Wheel Installation (PUSH ONTO ALE) E VALVE STEM WHEEL TIRE F GROOVE Fig. 3: E-Clip Installation NOTE: Install the Foot at the bottom of the unit with 45 angle side towards the back of the unit. 7

8 CHOOSING A BATTERY The MUTT is a 12/24V DC device. Attempting to power your MUTT with anything other than a 12 or 24 Volt DC power source will destroy the internal circuitry and void your warranty. (Manufacturer s Suggested Battery Type: Group 31. MUTT will auto detect 12 or 24 Volts. If 24 volts is required, two smaller 12 volt batteries can be used, but they must be wired in series.) Battery Voltage: 12/24V DC Battery Type: Lead Acid Battery Compartment Dimensions: 13.5" L x 11" H x 9.25" D Battery Protection: In-line 30 amp Fuse for Overcharge Battery must be clean and leak free. Identify battery polarity. Attach ring terminal (with red heat-shrink) to positive (+) side and ring terminal (with black heat-shrink) to negative (-) side. Also, see warning indicators on pages 14 and 15. Connections must only be made to clean terminal rings. Any loose or corroded connectors may cause misdiagnosis or result in erroneous readings. Use well-charged battery. LOW VOLTAGE POWER CUT OUT If the input battery voltage to the MUTT drops below 11 volts at any time during testing, you may experience erroneous readings. Be certain the battery stays charged while testing. If the voltage drops below 10.5 while testing, the MUTT s microprocessor will momentarily power down before reapplying power. This may occur repeatedly and will correspond with the battery voltage indicator illuminated red, signifying a low battery voltage. (Low voltage cutout should not be confused with overload/short circuit power pulsing, which will apply and remove power when a short circuit is detected.) BATTERY COMPARTMENT INSIDE DIMENSIONS Width: 13.5" Depth (front to rear): 9.25" Height at Front: 11" Height Inside (front): 12" Height Inside (back): 9.5" DC POWER ONLY Do NOT plug directly into AC wall outlet Fig. 4: Battery Compartment 8

9 ANTENNA INSTALLATION See fig. 5 below for installation of the Antenna (included in the accessories bag). Insert Antenna into hole on knob Tighten knob to secure Fig. 5: Antenna Installation OPERATION AND TESTING QUICK REFERENCE GUIDE ELECTRICAL TESTING 1. PLACE THE TESTER ON A FLAT, LEVEL SURFACE. Chock trailer wheels to avoid rolling. CHOCK ALL WHEELS BEFORE TESTING BRAKES. 2. INSTALL A FULLY CHARGED GROUP 31, 12 VOLT DC BATTERY in the battery compartment of your MUTT. 3. INSTALL THE ANTENNA (in the included accessories bag) into the MUTT antenna jack (see fig. 5). 4. MAINTAIN CONNECTORS: Dielectric grease should be used on all connections to avoid corrosion. If a bad connection exists at the terminal junction, you may get an erroneous reading and the MUTT will not work properly. Make sure you have a solid connection in the socket. 5. GROUND INTEGRITY: When the MUTT is first turned on, Ground Integrity and Open Circuit checks are being performed. The green lights around the control knob will blink and disappear one at a time until only the Ground Integrity light remains solid green. When all the lights blink, this indicates a poor cable connection or bad ground. Individual blinking lights indicate an open circuit (Refer to pg. 14). 6. CIRCUIT PROBLEM INDICATION: As you turn the MUTT control knob to test each circuit, a steady green light verifies a properly working circuit. Refer to the three red LEDs to the left of the control knob for circuit problem indication. These LEDs will blink and the MUTT will sound if there is a problem. 7. LOW DRAW LED TRAILERS: The MUTT will identify any circuit drawing less than 100 ma as an open circuit. The trailer must have a minimum of two standard LED pods on each circuit. ABS circuits using ABS computers are typically within the threshold and do not require any additional load. 8. CIRCUIT SELECTION: Circuits can be selected by pressing the Control Knob for Auto Cycle mode, manually turning the control knob or by using the remote control. 9. ALL CIRCUITS ON: All circuits can be turned on at one time by holding the large remote button for five seconds. To cancel, press and release the large button on the remote. 9

10 11. PROGRAM REMOTE: Turn the MUTT on while holding down the large button on the remote, then release after 3 seconds. The remote is now programed for the tester. (Up to 24 separate remotes can be purchased and programmed to one MUTT.) AIR BRAKE TESTING Optimum testing pressure is 100 PSI. DO NOT ECEED 120 PSI. (See detailed instructions on pg ) 1. AIR BRAKE TESTING: Turn main power on. 2. LEAK DOWN TEST: To conduct leak down testing on the Service and Emergency line air circuits, switch the Emergency Side Air Control Switch to OPEN to charge the circuit with air, then switch it to CLOSED and note any pressure drop. Any pressure drop on the gauge indicates a leak in the circuit. Repeat leak down test on the Service Side. 3. ACTUATE BRAKES: With the Emergency Side OPEN, push the Service Side Air Control switch to the EHAUST/REMOTE position. Then by using the remote control, actuate the brake servos in real time. This feature allows you to see the slacker adjustments and the push rod travel in real time. 4. TO FIND STICKY OR BAD BRAKE SERVOS: To check the mechanical servo operation, slowly turn the PSI up and note the point at which both servos engage. Then reduce PSI and note the point at which the servos release. They should engage and release together at the same time. To check for a leaking servo, you can charge the Service Side and switch the Emergency Side Air Control switch to the CLOSED position. There should be no increase in PSI on the Emergency Side. Then reverse the procedure and charge the Emergency Side and switch the Service Side Air Control switch to the CLOSED position. No air should leak into the Service Side. NOTE: Be certain to CHOCK ALL TRAILER WHEELS before conducting trailer testing. 10

11 OPERATING INSTRUCTIONS The Mobile Universal Trailer Tester (MUTT ) is a diagnostic aid for trailer electrical operations wired to the North American style 7-way round pin (SAE J560) or 7-way spade pin configurations. FUNCTIONAL DESCRIPTIONS The following describes the Control and Information Panel (fig. 6): B A MOBILE UNIVERSAL TRAILER TESTER PROGRAM REMOTE: Hold down large button on remote while powering up unit. Release after 5 seconds. AUTO CYCLE: Press and release control knob. ALL CIRCUITS ON: Press and hold control knob or remote for 5 seconds. * ACCESS ABS BLINK CODES: Refer to ABS Manufacturer Manual to determine mfg. sequence. Select ABS or BRAKE LIGHT. To flash power between circuits, press and release control knob. To maintain power between circuits, hold control knob for 3 seconds until beep. C D E F VISIBLE ALERTS Ground Integrity: During startup, all circuits blinking indicate poor ground pin or chassis ground problem. Individual circuit(s) blinking indicates bad return ground for that circuit. (Check cable/pin connection.) Open Circuit: Blinking circuit with audible alert indicates disconnected or open circuit. Crossed Circuit: Selected circuit is illuminated and crossed circuit(s) blinks with audible alert. OFF ON ABS REVERSE *ABS BRAKE B/O STOP ELEC. BRAKE NATO 7 SPADE 6/5/4 PIN TAIL/TAG B/O RUNNING AUILIARY TRAILER TYPE NATO/7 SPADE/6/5/4 PIN MODE 7-WAY ROUND PIN MODE GROUND INTEGRITY 7-WAY ROUND PIN RIGHT TURN RIGHT TURN CLEARANCE TAIL LIGHTS LEFT TURN LEFT TURN BRAKE LIGHTS G H I J K L Fig. 6: Control and Information Panel A. POWER SOURCE SWITCH Select between Internal Battery, External Power or Power Off. Center: Up: Down: OFF (battery charge in this position only) Installed Battery ON External Power ON (power supply is an optional accessory) B. ANTENNA Receives RF signal from wireless remote up to 100 feet. Binding post allows antenna length insertion for further distances in inclement weather. It is recommended that the antenna be installed for optimum performance. C. BACKLIT 30 AMP AMMETER Meter shows current draw of a selected circuit up to 30 amps. D. MUTE SWITCH ON disables sound. OFF enables sound. E. TROUBLE WARNING INDICATORS Flashing red LEDs indicate problems that may exist in a selected circuit. Overload Indicator Open Circuit Indicator Reversed (Battery) Polarity Indicator 11

12 F. AUTO CYCLE INDICATOR Illuminates when Auto Cycle is engaged. Auto Cycle tests all circuits in five second intervals in a clockwise rotation. (You cannot access Auto Cycle mode when in Auxiliary or Brake modes.) To enter Auto Cycle mode press the Control Knob once. Press it a second time to cancel Auto Cycle mode. G. VOLTAGE INDICATOR Shows supplied battery voltage integrity. Operating Voltage Range: 12/24 volt DC. H. GROUND INTEGRITY A large green LED above the Control Knob indicates ground status. Ground Integrity is automatically verified when power is turned on. If a ground fault is indicated, attach the supplied 10 ft. ground cable to the chassis of the trailer. If the fault clears, the problem is in the chassis ground. If the fault continues, the problem is with the ground return in the plug. I. CONTROL KNOB Knob activates all electrical test modes and circuits to be diagnosed. Manual Mode Auto Cycle Mode Warning Sound Bypass All Circuits On Mode ABS Blink Code Activation J. CIRCUIT INDICATORS The small green LEDs illuminate or blink in testing phase. K. 30 AMP FUSE SOCKET Overload protection. L. TRAILER TYPE SWITCH Selecting a mode changes wiring configuration. NATO/7 SPADE/6/5/4 PIN 7-WAY ROUND PIN 12

13 A B C D E F G ON OFF LEFT SIDE Fig. 7: MUTT Side Panels RIGHT SIDE A. 12 PIN NATO CABLE OUT TO TRAILER Receptacle used to connect your 12 Pin NATO Trailer to the MUTT to test electrical ccircuits. B. 12V DC BATTERY TRICKLE CHARGE INPUT Used to connect the trickle charger to the battery (battery not included). Allows for a float charge to be kept on the battery when the unit is not in use. C. SHOP AIR INPUT A bulk head air input with external stone filter that is used to connect an air compressor to the MUTT for testing air brakes on a trailer. D. EMERGENCY AIR EHUAST SWITCH Used to exhaust all air pressure in the Emergency Side air lines. E. 20 AMP INDEPENDENT POWER INPUT SOURCE Used for connection of external 12V 20 amp max. power supply. (Power supply is an optional accessory. Not for battery charging.) DC POWER ONLY Do NOT plug directly into AC wall outlet F. CHASSIS GROUND OUTLET Insert the supplied ground cable into this socket for trailers using the frame or body for ground connection instead of the ground pin in the harness. G. 7 ROUND PIN CABLE OUT TO TRAILER Receptacle for testing the integrity of 7 Round Pin trailer cable. Can also be used to verify that the MUTT is operating correctly. 13

14 WARNING INDICATORS Explanation of the diagnostic functions of the warning indicators. VOLTAGE INDICATOR When the battery supply voltage drops to 9V or less, the MUTT shuts down power to all circuits and the voltage indicator flashes red. Charging or replacing the battery is required to continue testing. Between 10V-11V (22-23V) the indicator is RED, showing the battery is too low to accurately test. Between 11V-12V (23-24V) the indicator is YELLOW, showing the battery is low. At or above 12V (24V), the indicator is GREEN showing the battery is fully charged. REVERSED POLARITY INDICATOR Light flashes when battery clamps have been crossed at the battery posts. Correcting polarity of the battery terminal clamps deactivates the warning. The MUTT is internally protected from polarity reversal. OVERLOAD INDICATOR When the MUTT confronts a constant amperage draw above 20 amps or a direct short, the indicator flashes and the beeper sounds. Voltage is cycled to the shorted or overloaded circuit in three second intervals to aid in diagnosing the extreme amperage draw. (This function is comparable to an auto reset circuit breaker.) The MUTT goes into Pulsar Mode. OPEN CIRCUIT INDICATOR In the instance a selected circuit is not completed through the trailer harness, (e.g., a faulty ground or no load detected), the Open Circuit warning flashes and sounds. CROSSED CIRCUIT WARNING CHARACTERISTICS Green Circuit Indicators flash to show troubled circuits. In the instance of crossed circuits where a circuit (or circuits) other than the selected circuit are inadvertently powered by the selected circuit, the unselected Circuit Indicators flash while the selected indicator remains steady. This is caused by worn wires or improperly wired plugs on the trailer. In some cases, it may be normal for more than one circuit to be operated by a single circuit, such as certain ABS systems and custom aftermarket lighting. Refer to trailer specific wiring schematics for the unit in question. 14 Fig. 8: Warning Indicators

15 GROUND INTEGRITY WARNING Ground Integrity is explained in the Testing Procedure (pg. 16, #12). When the MUTT is first turned on, Ground Integrity and Open Circuit checks will be performed. The green lights around the control knob will blink and disappear one at a time until only the Ground Integrity light remains solid green. When all lights blink at the same time, it indicates a poor cable connection or a bad ground. Individual blinking lights indicate an open circuit or poor pin connection. AUTO SHUTDOWN FEATURE To preserve battery life, the MUTT enters a Sleep Mode if inactive after 20 minutes with the power on. A sound is emitted every seconds to inform the operator of the condition. Activation of any test mode takes the MUTT out of Sleep Mode. TRAILER CONFIGURATION SETUP The MUTT is a microprocessor-controlled diagnostic trailer tester specifically designed to test lights and electric brakes on trailers with 7 Round Pin and 12 Pin NATO Type connections. SELECTING TRAILER TYPE Before you begin testing, select which trailer type you will be working on. The MUTT has two testing modes: NATO/7 SPADE/6/5/4 PIN mode (designated by the green text around the control knob) or 7-WAY ROUND PIN mode (designated by the white text around the control knob). To select the testing mode, push the trailer type switch to the desired setting (see fig. 6). When a mode is selected, the microproccessor instantly changes firmware settings to optimize the tester for the selected trailer type. TESTING 4, 5, AND 6 ROUND PIN TYPE TRAILER CONNECTIONS The MUTT is hard wired to a 7-spade pin connector, located on the side of the tester. Each unit is supplied with a plug-in adapter, which will adapt the MUTT to 4,5 and 6 round pin type connections. To test trailers with these types of connections, this adapter must be plugged In line between the Tester and the Trailer. The instructions above for Trailer configuration set up, should be used for more efficient and accurate testing. Call with any technical questions. 15

16 16 ELECTRICAL/LIGHT TESTING PROCEDURES To avoid false readings, visually inspect trailer socket for corroded and/or squeezed pins. Bad or broken socket pins can cause false readings. (Replace socket if pins are broken or socket appears to be out of tolerance. Clean all connections and load socket with dielectric grease). 1. CHOCK ALL WHEELS BEFORE TESTING BRAKES. 2. Select battery type and install. 3. Install antenna (in the included accessories bag) into the MUTT antenna jack (see fig. 5, pg. 9). 4. Prior to any trailer testing, connect the trailer cable or you will receive erroneous readings. The MUTT is intended to be used while connected to a trailer or while cable testing. 5. Secure the battery connections to tester. 6. Make sure the Remote Key Fob has been programmed (pg. 18). 7. Using the Power Source switch (fig. 6-A, pg. 11), select a power source. 8. Check the Voltage Indicator (fig. 6-G, pg. 11) for green illumination. In the case of low or weak supply voltage, yellow illuminates. Red illumination from the Voltage Indicator shows inadequate power supply. Also see the Warning Indicators section (pg. 14). 9. Initial power starts a test cycle through all the LEDs. This performs the Ground Integrity Test. 10. Ground Integrity Test: When the MUTT is first turned on, notice the green lights circling the dial. This indicates the MUTT testing for Ground Integrity. If there is a lack of ground, all the green lights begin to flash to alert you to the ground problem. If you only see one green LED flashing, this indicates an Open Circuit (check your trailer cable first, then the trailer). If you do not have Ground Integrity, the MUTT cannot continue normal testing functions until a solid ground is established. To troubleshoot, first you need to understand the type of ground being used on your particular trailer. There are two types. The first type is wired with each light receptacle and grounded by the ground return wire leading back through the plug at the front of the trailer. The second type is the chassis ground, where the light receptacles are grounded directly to the trailer chassis. 10a. If the trailer is grounded through the plug, the technician needs to locate the source of the poor ground. Some systems use both wire and chassis ground. Suggestion: Check the cable, plug sockets and pin contacts FIRST for loose or broken connections. 10b. If the trailer lights are chassis grounded, use the following instructions: Your MUTT comes supplied with a 10 ft. Chassis Ground Cable accessory. Plug in the 10 ft. Chassis Ground Cable to the MUTT Chassis Ground outlet (fig. 7-F, pg. 13). Then, using the alligator clip, attach the other end of the Chassis Ground Cable to the chassis of the trailer. This effectively grounds your trailer and allows testing to continue. 11. After the Ground Integrity Test, the Control Knob (fig. 6-H, pg. 11) may be

17 rotated in either direction to select a circuit to diagnose. The corresponding Circuit Indicator (fig. 6-J, pg. 11) illuminates to indicate the selected circuit. AUTO CYCLE MODE NOTE: Cannot be accessed when Auxiliary or Brake circuit is selected. 1. After Ground Integrity has been established, momentarily push and release the Control Knob (fig. 6-I, pg. 11). The Auto Cycle Indicator (fig. 6-F, pg. 11) will illuminate. 2. Power is applied by the MUTT to one circuit at a time for five seconds in a clockwise direction starting from the Ground Integrity Indicator (fig. 6-H, pg. 11). 3. A 5 second delay commences before power is automatically applied to the first circuit. 4. To pause or stop the Auto Cycle mode, momentarily press and release the Control Knob, turning off the Auto Cycle Indicator. MUTING WARNING SOUND How to override the warning sound: Push the Mute switch to the ON position to disable audible alerts. To restore sound, return the switch to the OFF position. ALL CIRCUITS ON (OVERRIDE) Turns All Circuits On (maximum load amount 20 amps total). All Circuits On mode can be accessed by the Control Knob or Remote Control: Hold down the Control Knob for ten seconds. Listen for the second beep and release Control Knob. Hold down the large button on the remote for five seconds. On trailers using incandescent bulbs, All Circuits On will typically result in an overload because the amperage draw will exceed the maximum 20 amp. NOTE: Short Circuit sensing is operational in this mode. If a Short Circuit is found, the MUTT will not be able to identify which circuit is the cause of the short. Open and Crossed Circuit sensing is not operational. To cancel All Circuits On mode, turn the Control Knob or press and release the large remote button. 17

18 REMOTE PROGRAMING AND FUNCTIONS When the MUTT s in the OFF position, hold down the large button (fig. 9-1) on the remote while simultaneously turning the MUTT power ON. Release after 2 seconds. The remote is now programmed. Up to 24 separate remotes may be programmed to a single MUTT. HOW TO USE THE WIRELESS REMOTE 1. LIGHTS & ELECTRIC BRAKES Press button (fig. 9-1) to select the next available electrical circuit (including electric brakes when available). 2. AIR BRAKE OPERATION NOTE: Be certain to CHOCK ALL TRAILER WHEELS before conducting trailer testing. Set Emergency Side Air Control Switch to OPEN and charge circuit with 100 PSI. Use the small button on the remote to actuate Service Side (fig. 9-2). Fig. 9: Remote Control 3. REMOTE CONFIRMATION INDICATOR Red light illuminates to confirm that a button has been pressed, indicating Remote Battery Power. NOTE: With each press of a button, the red light (fig. 9-3) of the remote illuminates, confirming button depression and battery integrity of the remote. Inclement weather, nearby power transformers and closely parked trailers may reduce in the remote signal. The antenna wire (included in the accessories bag) can be inserted into the MUTT antenna jack (fig. 6-B, pg. 11). It is recommended that the antenna is installed upon set-up (fig. 5, pg. 9). In extreme scenarios, the operator may choose to install a longer wire such as standard mechanic s wire, to achieve a better signal. This is only necessary when working on trailers that are parked within 18 feet of each other. In normal situations, the remote control will work from up to 100 feet away from the MUTT. The remote Key Fob battery supplied is a 12V, Alkaline Energizer type A23. A Gold Peak type 23AE or Duracell MN21 battery can be used. WARNING: Be careful when using remote controls in multi-bay shops where another MUTT may be in operation. One remote may be inadvertently programmed to multiple MUTT s. This can happen when the large button on a remote is being held down at the same time another MUTT is being powered up, effectively programming one remote to two units. To avoid this, be sure any other MUTT users alert you when they power up their unit. A remote control can only be synchronized to a MUTT during the power up phase. 18

19 OPERATING INSTRUCTIONS FOR AIR BRAKE CONTROLS DANGER WARNING! BEFORE CONNECTING AIR TO TESTER PANEL, BE SURE TO CHOCK ALL WHEELS ON TRAILER TO PREVENT TRAILER FROM ROLLING. TRAILER CAN ROLL AND CAUSE SERIOUS INJURY OR DEATH. DO NOT CONNECT SHOP AIR UNTIL COMPLETING THE TESTING SETUP PROCEDURES IN STEPS 1 THROUGH 6 (PAGE 20). FAILURE TO FULLY UNDER- STAND THESE WARNINGS CAN RESULT IN MINOR TO SERIOUS INJURY AND POSSIBLY DEATH. A B C D E F G SHOP AIR IN on side of MUTT Fig. 10: Air Brake Panel AIR PANEL (Fig. 10) A. Emergency Side Air Out To Red Hose B. Emergency Side Gauge C. Emergency Side Air Control Switch D. Air Regulator Knob E. Service Side Air Control Switch F. Service Side Gauge G. Service Side Air Out To Blue Hose 19

20 AIR BRAKE TESTING SETUP 1. Read and understand all Safety Warnings before operation. 2. CHOCK ALL WHEELS BEFORE TESTING OR ATTACHING SHOP AIR TO UNIT. 3. Push the main Power Source rocker switch (fig. 6-A) to the OFF position. 4. Push both Emergency and Service Side Control Rocker Switches (fig. 10) to the CLOSED setting. 5. Attach gladhand hoses from the MUTT directly to your trailer s air system, securing the red hose to the Emergency Side and the blue hose to the Service Side. 6. Connect your shop air to the Shop Air Inlet on the left hand side of the tester. SETTING DESIRED WORKING PRESSURE NOTE: The Emergency Side air gauge is used when setting Regulator pressure (Do not exceed 120 PSI). 1. Turn main system power on. 2. Push Emergency Side switch to the OPEN position. 3. Pull and turn Regulator knob clockwise or counterclockwise until needle points to the desired operating pressure (Most shops prefer PSI during testing). 20 LEAK DOWN TESTING EMERGENCY SIDE MANUAL LEAK DOWN TEST Prior to testing, listen for any air leaks where the shop air connects to the tester, to avoid erroneous results. 1. With gladhands connected to trailer, push Emergency Side rocker switch (fig. 10-C) to the OPEN position this fills the Emergency Side air lines. 2. Once air has filled, push the switch to the CLOSED position to begin leak down test. 3. View the needle on the air gauge and note any PSI drop after pressure stabilizes. 4. Look for air loss according to your local specifications by noting consistent air drop over time. If air pressure continues to drop at an unacceptable rate, you can turn your air supply back on the Emergency Side (fig. 10) and look for the leak by inspecting the air system. SERVICE SIDE MANUAL LEAK DOWN TEST 1. Push Emergency Side (red) rocker switch to the OPEN position (fig. 10-C). 2. Push Service Side (blue) rocker switch to the OPEN position. This fills the Service Side air lines. 3. Once the Service Side is fully charged, push the switch to the CLOSED position to begin leak down test. 4. View the needle on the air gauge and note any PSI drop after pressure stabilizes. 5. Look for air loss according to your local specifications by noting consistent airdrop over time. If air pressure continues to drop at an unacceptable rate, you can turn your air supply back on the Service Side (fig. 10-E) and look for the leak by inspecting the air system drop over time.

21 TESTING WITH THE REMOTE CONTROL The remote control can be used to cycle air on and off to the Service Side by depressing the small button on the remote control. The remote control allows a technician to operate the Service Side air and actuate the brakes, thereby allowing inspection and service of the air brake system. When operating the Service Side via remote, the Emergency Side must be precharged with the switch in the OPEN position. If the Emergency Side has insufficient pressure, the Service Side brakes will not actuate. WARNING: Remember to sufficiently chock the trailer wheels before operation to prevent rolling. Trailers should always be parked on a flat/level surface before testing. Before using the remote, please be aware that trailer brake parts and components can explode, dislodge or become damaged when air pressure is introduced to the system. For the safety of the user and others in the vicinity, extreme caution should be used to avoid injury or death. Do not put yourself in harm s way. SERVICE SIDE ACTIVATION VIA REMOTE 1. Turn the Emergency Side switch to the OPEN position. 2. Charge the Emergency Side with desired air pressure. 3. Push the Service Side switch (fig. 10-E, pg. 19) to Remote/Exhaust. 4. Point the remote in the general direction of the MUTT. (Install antenna for improved range). 5. Press the small button once to engage the service air brakes. 6. Press the small button again to disengage the brakes. 7. Repeat as necessary. EHAUSTING EMERGENCY AIR To apply the parking brake at any time during testing, simply push this switch to exhaust all air pressure in the Emergency Side air lines. NOTE: Main system power must be on during this step. 1. Make sure the Power Source on the Control Panel is on. 2. Push the Emergency Air Exhaust switch to the OPEN position to exhaust air. Emergency Air Exhaust switch OPEN ON OFF CLOSED 21

22 TYPICAL TRAILER WIRING Note: Not all trailers/vehicles are wired to this standard. The use of an electrical circuit tester is necessary to ensure proper match of vehicle s wiring to trailer s wiring. On the 6-way round plugs, the 12V wire and electric brake wire may be reversed on some trailers (particularly horse trailers). 6-WAY ROUND PIN PLUG TRAILER SIDE 7-WAY ROUND PIN SOCKET CONFIGURATION TAIL LIGHTS (TM) GROUND (GD) ELECTRIC BRAKES (EB) RIGHT TURN (RT) 12V GROUND (GD) LEFT TURN (LT) TAIL LIGHTS RIGHT TURN (RT) AU (ABS) STOP/BRAKE CLEARANCE LEFT TURN (LT) 7-WAY FLAT PIN PLUG 4/5 PIN PLUG LIGHTS (TM) 12 VOLT (12V) RIGHT TURN & BRAKES TAIL LIGHTS LEFT TURN (LT) RIGHT TURN (RT) BU GN Y BR WH BACK-UP LIGHTS (BU) GROUND ELECTRIC BRAKE (EB) BACK -UP LIGHTS LEFT TURN & GROUND 22

23 REMOVING THE HEAD In the event your MUTT should need service or repair, the unit has been designed so that the head, which contains all the electro-mechanical components, can easily be removed to simplify and reduce the cost of packing and shipping. You will need only a Phillips-head screwdriver to remove the 8 screws that attach the head to the cart body. See fig. 11 below. After removal of the eight screws, simply lift the head up from the cart body and pull the battery cable up through the channel in the cart body. To reassemble, feed the battery cables through the channel while lowering the head onto the cart body and reinsert the eight screws. BACK 2 pieces x 1/2 in. Phillips 2 pieces x 3/8 in. Phillips Air Exhaust Lines LEFT SIDE 2 pieces x 1/2 in. Phillips RIGHT SIDE ON OFF Fig. 11: Removing the Head 23

24 ABS CODES BLINK CODE DIAGNOSTICS The Trailer ABS ECU detects any electrical fault in the trailer ABS. Each of the faults has a code. When a fault occurs, the ECU stores the code for that fault in its memory. There are two kinds of faults: active and stored. Active faults are those currently existing in the system, such as a broken wire. Stored faults are errors that have occurred but do not presently exist. Active faults can be cleared only after repairs are completed. The ECU signals a fault exists by lighting both the internal and external indicator lamp. The external ABS indicator lamp is usually mounted on the left rear of the trailer, near the rear wheels. There are two ways to obtain blink codes:» Ignition Power Activation (recommended method)» Diagnostic Tool Although the ECU can store multiple faults in its memory, it only displays one blink code at a time. This is why it is important to re-check the blink codes after repairing a fault. lf there are additional codes in the memory, they only blink after you have repaired the first fault. IGNITION SWITCH POWER ACTIVATION USING THE TRACTOR Ignition Power Activation is the process of interrupting the power on the blue wire by some other means (Auxilary Circuit) to display blink codes on the trailer ABS indicator lamp located on the side of the trailer. To obtain blink codes using ignition power activation, perform the following procedures: 1. Activate Auxilary Circuit for no longer than five seconds. The ABS indicator lamp will be on. 2. Turn the Auxilary Circuit off. The ABS indicator lamp will go out. 3. Turn the Auxilary Circuit on. The ABS indicator lamp will then come on, then go out. 4. The blink code will be displayed three times by the ABS indicator lamp on the trailer. TO ACCESS ABS CODES USING THE MUTT : Select the AU or Brake light circuit, then press the Control Knob to select either the Brake or AU line to access the trailer blink codes. Other methods include applying and removing power to the AU or Brake circuit in sequence with the ABS manufacturer s specifications. Consult the ABS system of manufacturer s manual for detailed instructions. The diagnostic chart (pg ) references some of the ABS codes and the method for releasing them from the CPU utilizing the MUTT s auxiliary circuit. 24

25 WABCO BLINK CODES Select AU circuit and depress Control Knob to flash brake lights in sequence. Blink Code 3 4 Sensor BUI Sensor YEI Problem Area Action Determine sensor location. Check sensor installation. Make necessary repairs. Determine sensor location. Check senor installation. Make necessary repairs. 5 Sensor BU2 Determine sensor location. Check sensor installation. Make necessary repairs. 6 Sensor YE2 Determine sensor location. Check sensor installation. Make necessary repairs. 7 External ABS Modulator Valve Verify proper electrical modulator installation. Check power supply. Make necessary corrections. 9 Internal Modulator Failure Inlet Valve #2 Verify proper installation. If code continues, contact Meritor WABCO for assistance. 10 Internal Modulator Failure Inlet Valve #1 Verify proper installation. If code continues, contact Meritor WABCO for assistance. 11 Internal Modulator Failure Inlet Valve Verify proper installation. If code continues, contact Meritor WABCO for assistance. 14 Power Supply Verify proper electrical installation. Check power supply. Make necessary corrections. 15 ECU Failure Verify proper installation. If code continues, contact Meritor WABCO for assistance. 16 SAE JI 708 Failure Internal failure, contact Meritor WABCO. 17 SAE J2497 (PLC) Failure Internal failure, contact Meritor WABCO. 18 Generic I/O Failure Verify proper electrical installation. Check power supply. Make necessary corrections. For diagnostic and troubleshooting assistance, call Meritor WABCO at

26 HALDE BLINK CODES Select Brake circuit and depress Control Knob to flash AU in sequence. Item Flash Count Actual Fault System OK Light Stays On 07 Sensor 1A 1 Flash 01 Sensor 1B 2 Flashes 02 Sensor 2A 3 Flashes 03 Sensor 2B 4 Flashes 04 Sensor 3A 5 Flashes 05 Sensor 3B 6 Flashes 06 Red Valve 7 Flashes 61, 67, 71, 77, 81, & 87 Blue Valve 8 Flashes 62, 68, 72, 78, 82, & 88 Yellow Valve 9 Flashes 63, 69, 73, 79, 83, & 89 Low Voltage 10 Flashes 90 ECU Failure 11 Flashes 93, 99, & E-Codes Fault Code Explanation Possible Causes PLC Select 1M PLC Select 2M 00 System OK (with vehicle traveling > 6 mph). ABS is operational. Displays 00 when traveling > 6 MPH Red channel wheel speed sensor wiring S1A has an Open or Short circuit. Red channel wheel speed sensor wiring S1B has an Open or Short circuit. Blue channel wheel speed sensor wiring S2A has an Open or Short circuit. Yellow channel wheel speed sensor wiring S2B has an Open or Short circuit. Blue channel wheel speed sensor wiring S3A has an Open or Short circuit. Yellow channel wheel speed sensor wiring S3B has an Open or Short circuit. Indicates a wheel speed sensor or its wiring has short or open circuit. Disconnect the relevant sensor and measure the resistance between the two pins in the sensor connector housing. If sensor extensions are used verify extension continuity and connections. Replace sensor and/ or extension cable. The Ohm meter reading for the sensor or sensor and extension cable should be between 980 and 2350 Ohm (.98K and 2.35K Ohm) If not, replace sensor and/ or extension cable. 07 System OK (No Active Fault). ABS ECU is fully operational. Displays 07 vehicle is stationary. 26

27 Fault Code Explanation Possible Causes PLC Select 1M PLC Select 2M Red channel speed sensor S1A has low sensor output. Red channel speed sensor S1B has low sensor output. Blue channel speed sensor S2A has low sensor output. Yellow channel speed sensor S2B has low sensor output. Blue channel speed sensor S3A has low sensor output. Yellow channel speed sensor S3B gap too large. Gap should be kept to a minimum. Sensor or spring clip is worn or not properly adjusted, wiring open or short circuit, wheel bearing not properly adjusted (these faults will only occur at speeds of greater than 6 mph). Measure the AC voltage at the sensor in question while rotating the wheel at a rate of about one revolution every two seconds. The output should be at least 200 millivolts (0.2 VAC). If this is not the case, push in the sensor until it touches the exciter and rotate the wheel again. If this doesn t correct the problem, then the sensor and the sensor block clip should be replaced. If sensor extensions are used verify extension continuity and connections. Replace sensor and/ or sensor cable. Inspect exciter teeth for minor damage or teeth filled with debris. Verify all exciters have the same number of teeth. Verify sensor and valve wiring/ plumbing is correct. See side-by-side and axle-byaxle configurations. 27

28 Fault Code Explanation Possible Causes PLC Select 1M PLC Select 2M Red channel wheel speed sensor S1A has an erratic output voltage. Red channel wheel speed sensor S1B has an erratic output voltage. Blue channel wheel speed sensor S2A has an erratic output voltage. Yellow channel wheel speed sensor S2B has an erratic output voltage. Blue channel wheel speed sensor S3A has an erratic output voltage. Yellow channel wheel speed sensor S3B has an erratic output voltage. Loose sensor, connection, bracket or exciter, damaged exciter, sensor is not properly adjusted or has worn cable insulation, or worn sensor block clip, wheel bearing failure, wheel bearing is not properly adjusted (these faults will only occur at speeds greater than 6 mph). Measure the AC voltage at the sensor in question while rotating the wheel at a rate of about one rotation every two seconds. The output should be at least 200 millivolts (0.2 VAC). If this is not the case, push in the sensor until it touches the exciter and rotate the wheel again. If this doesn t correct the problem, then the sensor should be replaced. Verify the tire and wheel size is large enough for 100 tooth exciter ring. If these faults re-occur at the same speed, inspect the exciter ring for damage. Smaller wheels and tires require 80 tooth exciter rings. Reference Tire Scale Factor Chart. Verify sensor and valve wiring/ plumbing is correct. See side-by-side and axle-byaxle configurations. Occurs only when vehicle is stationary Auxiliary channel 1 fault (digital channel 1) output only. Auxiliary channel 2 fault (digital channel 2) output only. Auxiliary channel 3 fault (digital channel 3) output only. Auxiliary channel 4 fault (digital channel 4) output only. Auxiliary channel 5 fault (digital channel 5) output only. PLC Select 2M Plus (ABS Auxiliary Codes) Note: These codes are only used with PLC Select 2M Plus ABS that supports trailer Auxiliaries. Auxiliary Channel has an open circuit or the ECU (Electronic Control Unit) has an auxiliary device connected and is not programmed to be. Note: These codes do not affect ABS performance and do not illuminate the tractor trailer ABS warning lamps. 28

29 Fault Code Explanation Possible Causes PLC Select 1M PLC Select 2M Slow wheel recovery on Red valve channel. Slow wheel recovery on Blue valve channel. Slow wheel recovery on Yellow valve channel. For a 2M System, verify sensor and valve wiring/plumbing is correct. (See side-by-side and axle-by-axle configurations.) Slow brake release, foundation brake mechanical faults, dry bushings, broken ABS valve, restricted piping. Check for kinks and blockage etc., incorrect airlines, wiring Hold solenoid Open circuit on Red valve channel. Hold solenoid Open circuit on Blue valve channel. Hold solenoid Open circuit on Yellow valve channel. Dump solenoid Open circuit on Red valve channel. Dump solenoid Open circuit on Blue valve channel. Dump solenoid Open circuit on Yellow valve channel. Modulator valve solenoid failure, solenoid connection, or valve cable damage. The most likely causes include a bad solenoid or loose solenoid connection. Disconnect the indicated solenoid and check the resistance at the solenoid pins. Check the female terminals on the connector for excessive pin spread or corrosion. Replace defective hardware as required and retest Hold solenoid Short circuit to ground on Red valve channel. Hold solenoid Short circuit to ground on Blue valve channel. Hold solenoid Short circuit to ground on Yellow valve channel. Dump solenoid Short circuit to ground on Red valve channel. Dump solenoid Short circuit to ground on Blue valve channel. Modulator valve solenoid failure, or value cable damage. The most likely causes include: a damaged cable or solenoid. An example of this is a worn or chafed cable that has exposed wires contacting the trailer. Disconnect the indicated solenoid and check the resistance at the solenoid pins. 79 Dump solenoid Short circuit to ground on Yellow valve channel. 29

30 Fault Code Explanation Possible Causes PLC Select 1M PLC Select 2M Output leakage or poor insulation on any of the valve channels. Hold solenoid short circuit to Permanent Power on Red valve channel. Hold solenoid short circuit to Permanent Power on Blue valve channel. Hold solenoid short circuit to Permanent Power on Yellow valve channel. Modulator valve solenoid failure or valve cable damage. Indicates that the solenoid or its cable has a short circuit to positive power (12 volts DC). The most likely cause is a damaged cable or solenoid. Disconnect the indicated solenoid and check the resistance at the solenoid pins Dump solenoid out shorted to Permanent Power on Red valve channel. Dump solenoid out shorted to Permanent Power on Blue valve channel. If solenoid checks good and code still exists, check ECU. 89 Dump solenoid out shorted to Permanent Power on Yellow valve channel. 90 Low supply voltage fault. This code is not stored in memory. Verify 12 V DC power source. Do Not Use Battery Charger as Power Supply. ECU minimum operating voltage is 8.5 V DC. 91 No internal ABS ECU solenoid voltage available. Verify permanent power is present. 92 Power input over voltage fault. Verify 12 VDC power source. Do Not Use Battery Charger as Power Supply. ECU maximum operating voltage is 16.0 VDC. 93 Short circuit on ABS ECU internal relay. 99 ABS Corrupt Memory. Replace ECU. 9A ABS Corrupt Memory. 30