9004a Manual - Innovative Products Of America

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Mobile Universal Trailer Tester #9004A SMART MUTT® OPERATOR’S MANUAL Uses Internal 12 Volt Motorcycle Battery. Tests Trailers Using 7 Spade, 6 Round, 5 and 4 Pin Type Connections. © 2012 Innovative Products of America®, Incorporated. All rights reserved. This material may not be reproduced, displayed, modified or distributed without the express prior written permission of the copyright holder. For permission, contact [email protected]. Innovative Products of America® Incorporated 888-786-7899 | www.ipatools.com 234 Tinker Street, Woodstock, NY 12498 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 first-hand 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 for any reason, I invite you to contact me directly via my email, [email protected] or call me at 888-786-7899. 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 to 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 better, then again, 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® www.ipatools.com Toll Free: Phone: Fax: 2 888-786-7899 845-679-4500 845-679-4600 9004A SMART MUTT® PARTS A ANTENNA WIRE ASSEMBLY B 30 AMP AMMETER GAUGE C CONTROL KNOB D CARRYING HANDLE E 7 WAY FLAT/SPADE SOCKET F FUSE HOLDER (30 AMP ATO/ATC) G POWER SWITCH H TRICKLE CHARGE INPUT I REMOTE CONTROL FOB J REMOTE CONTROL FOB BATTERY K 7 WAY FLAT TO 6 ROUND & 4/5 FLAT ADAPTER L 500 mA/12V TRICKLE CHARGER PLUG USE THE REFERENCE NUMBERS PROVIDED WHEN ORDERING PRODUCTS & PARTS ABOVE Toll Free: 888-786-7899 3 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. THE FOLLOWING SAFETY ALERT SYMBOLS ARE USED IN THIS MANUAL. 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. SYMBOL 1: Potential burn hazard. Sparks from electrical shorts can ignite flammable liquids such as fuel or oil. Heat from electrical overloads can cause fire hazards. 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 pressures used with this equipment can cause explosive failures 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 BATTERY GASES, TESTER PREPARATION AND TESTER/CHARGER LOCATION RISK OF EXPLOSION • Gases produced by a battery are highly explosive. • Wear safety goggles and protective clothing, both users and bystanders. • Use in an area having at least four air changes per hour. • Read, understand and follow all instructions for charger, battery, vehicle and any equipment used near 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, both user 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. 5 GENERAL CHARGER USE RISK OF ELECTRIC SHOCK AND FIRE • Before connecting power cord to charger, make sure controls are set to off. • DC power only. • Do not plug directly into AC wall outlet. • Do not remove or bypass the grounding pin. DC POWER ONLY Do not plug directly into AC wall outlet • Do not operate charger with damaged cord or plug. Replace cord or plug immediately. OPTIONAL CHARGER • 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. • Do not operate charger after a sharp impact, dropping 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. SPECIFICATIONS THE SMART MUTT® INCLUDES THE FOLLOWING: • Key Fob Remote with Battery • Battery Charger (500 mA) • 3-Way Trailer Socket Adapter • Antenna • Instruction Manual 6 INTERNAL BATTERY REQUIREMENTS: (Battery not included) • Internal Battery Dimensions: H: 5 3/4” L: 5 7/8” W: 3 3/8” (YUASA YTX14 or similar) • Battery Type: Lead Acid • Battery Protection: Inline 30 Amp Fuse for Overcharge Current Protection • Tester Output: Maximum output to trailer 20 Amps • Maximum Charging Input: 10 Amps SET-UP • Place the tester on a flat level surface. • Chock trailer wheels to avoid rolling. • Use the supplied battery charger or charger input no greater than 10 Amps to fully charge the internal battery of the tester. It may take up to 12 hours to charge a fully drained battery. QUICK START-UP GUIDE The SMART MUTT® uses a diagnostic program to quickly identify wiring problems for the technician. When used properly, the Tester will spot the most common causes for electrical failure before you walk around the trailer. CHECK 7 PIN CONNECTORS: Before operating the SMART MUTT®, be sure the 7 flat/spade pin connections on the right side of the unit are in good condition and pins are spread to the proper width to ensure good connections. Check the end of the 7 flat/ spade pin plug coming from the trailer. MAINTAIN 7 PIN 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 that you have a solid connection in the 7 way socket. TO PROGRAM YOUR REMOTE: Turn the SMART MUTT® on while holding down the large button on the remote, then let go after 3 seconds. Your remote is now programmed to the tester. (Up to 24 separate remotes can be purchased and programmed to one SMART MUTT®.) INITIAL POWER UP SCAN: Upon initial power up (while connected to trailer), the MUTT® checks every circuit for ground integrity and open circuits. If at any time a circuit indicator LED (e.g. clearance or brake lights) is steadily blinking immediately following power up, this is an indication of an open circuit or poor ground. An open circuit could be a cut wire, an improper pin connection, or the circuit is not available (hooked up) on that trailer. Be sure to wiggle your 7 way connectors to make sure it is not just a loose pin connection at the socket. If all the LEDs are flashing, you have a poor ground connection. 7 AVOID MISDIAGNOSIS: • Before attaching to trailer connector, make sure all sockets and pins are clean and tight. Any loose or corroded connector may cause a misdiagnosis. • Use a well-charged battery. (10 Amp max. charge rate) 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.) FUNCTIONAL DESCRIPTIONS The SMART MUTT® is a diagnostic tool for trailers wired to North American style configurations including 7 spade, 4, 5 and 6 round pin connectors. Fig. 2 - Control & Information Panel A. CONTROL KNOB (Fig. 2) Knob activates all electrical test modes and circuits to be diagnosed. • Manual Mode • Auto Cycle Mode • Warning Sound Bypass • Individual Circuit Select B. VOLTAGE INDICATOR (Fig. 2) Shows battery supply voltage integrity 8 • Green: 11.7V+ • Yellow: 11.6V • Red: 11.0V • Shutoff: 10.5 C. AUTO CYCLE INDICATOR (Fig. 2) Illuminates when Auto Cycle is engaged. Auto Cycle Mode cycles through all circuits in 5 second intervals in a clockwise rotation. To enter Auto Cycle mode, press indicator knob once. To disable Auto Cycle Mode, depress or rotate the control knob. D. GROUND INTEGRITY (Fig. 2) Large green LED above control knob indicates ground status. Ground Integrity is automatically verified when power is turned on. E. CIRCUIT INDICATORS (Fig. 2) The six small green LEDs illuminate or blink during testing phase. F. WARNING INDICATORS (Fig. 2) Flashing red LEDs indicate problems that may exist in a selected circuit. • Overload Indicator • Open Circuit Indicator • Polarity Indicator G. BACKLIT 30 AMP AMMETER (Fig. 2) Meter shows current draw of a selected circuit up to 30 Amps. H. ANTENNA (Fig 2. & Fig. 5) Receives RF signal from wireless remote. Binding post allows antenna length insertion for further distances in inclement weather. It is recommended the antenna be installed for optimum performance. Fig. 3 - Power Panel I. 12V DC BATTERY CHARGER INPUT (Fig. 3) Use for connection of trickle charger to battery. Allows float charge to be kept on battery when unit is not in use. J. POWER SELECTION SWITCH (Fig. 3) Select between internal battery or power off. • Center: OFF (battery charge in this position only) • Left: internal battery ON • Right: internal battery ON K. FUSE HOLDER (30 AMP ATO/ATC) (Fig. 3) Overload protection. The 30 Amp ATO/ATC fuse (included) is required for the Smart MUTT® to function. 9 TRAILER CONFIGURATION SET-UP The 9004A Smart MUTT is a microprocessor controlled diagnostic trailer tester specifically designed for testing lights and electric brakes on trailers with 4, 5, 6 Round pin and 7 Spade Pin type connections. Every time you power up the tester, the internal computer wants to know which type of trailer connection you are testing. Note, this phases is known as Trailer Configuration Set up and is indicated by a high speed flickering of the LEDs surrounding the control knob. If left untouched after 15 seconds, the tester will always default to a 7-spade pin configuration. However, if the user is testing a 4, 5, or 6 round Pin type trailer connection, this setting can be adjusted by rotating the control knob counterclockwise to select the desired number of circuits (as noted on the face panel). Trailer Configuration Setup is repeated each time the unit is powered up. Testing 4, 5, and 6 Round Pin Type Trailer Connections The 9004A 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 9004A 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 888-786-7899 with any technical questions. OPERATING INSTRUCTIONS This section contains information on the usage of the #9004A Mobile Universal Trailer Tester (SMART MUTT®). 7 WAY FLAT/SPADE PIN TESTING PROCEDURE To avoid false readings: • Visually inspect trailer socket for corroded and/or squeezed pins. • Bad or broken socket pins can cause false readings. Clean all connections and load socket with a dielectric grease. MANUAL TESTING MODE NOTE: Prior to any testing on the MUTT®, connect the trailer to the tester or you will receive erroneous readings. The MUTT® is to be used while connected ONLY. • Secure the 7 flat/spade cable from trailer to socket on the right side of the tester. Initial power starts a test cycle through all the LEDs. This performs the Ground Integrity test / Open Circuit test. • Check Voltage Indicator (Fig. 2-B) for green illumination. In the case of low or weak supply voltage, yellow color illuminates. Red illumination from the Voltage Indicator shows inadequate power supply. Also see Warning Indicator section (page 12). • Ground Integrity Check: When the SMART MUTT® is first turned on, notice the green lights circling the dial. This indicates the SMART 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 light flashing, this indicates an open circuit (check 10 your 7 pin connections first, then the trailer). If you do not have ground integrity, the SMART MUTT® cannot continue normal testing functions until a solid ground is established. • After the ground integrity test, the control knob (Fig. 2-A) may be rotated in either direction to select a circuit to diagnose. The corresponding circuit indicator (Fig. 2-E) illuminates, indicating the selected circuit. AUTO CYCLE MODE • After Ground Integrity has been established, momentarily push and release the control knob (Fig. 2-A). The Auto Cycle Indicator (Fig. 2-C) illuminates, showing the mode has been selected. There is a 5 second delay before power is applied to the first circuit automatically. • Power is applied by the SMART MUTT® to one circuit at a time for 5 seconds in clockwise direction, starting with the tail light indicator (Fig. 2-D). • To pause or stop the Auto Cycle mode, momentarily press and release the control knob, turning off the Auto Cycle Indicator. BYPASSING SOUND How to override warning and bypass sound: • Turn off sound by flipping the on/off switch, or hold control knob in for 5 seconds until sound is heard, then release. • To reinitiate sound, repeat processes above, or cycle power using the power switch. ALL CIRCUITS ON (OVERRIDE) Turns All Circuits On (maximum load amount 20 amps total). NOTE: Short circuit sensing is not operational in this mode. When a short circuit is found in this mode, the SMART MUTT® will not be able to identify which circuit is the cause for the short. Open Circuit sensing is not operational in this mode. There are two ways to turn All Circuits On: • Hold down control knob for 10 seconds. Listen for the second beep and release the control knob. • Hold down large button on remote control for 5 seconds, then release. All circuits will be powered at this time. • To cancel All Circuits On mode, turn selector knob or momentarily press and release large remote button. 11 REMOTE FUNCTIONS Fig. 4 - REMOTE CONTROL REMOTE PROGRAMMING With MUTT® in the Off position, hold the large button (Fig. 4-2) of the remote while simultaneously turning the MUTT® power On. Release after 2 seconds. The remote is now programmed. HOW TO USE THE WIRELESS REMOTE REMOTE MODE Follow instructions of Manual Testing Mode section prior to using the remote. • The #1 button (Fig. 4-1) cycles testing to the next circuit (clockwise). • Pressing #2 button (Fig. 4-2) activates and deactivates Auto Cycle mode. NOTE: With each press of either button, the red light (Fig. 4-3) of the remote illuminates, showing confirmation of button depression and battery integrity. Inclement weather or nearby power transformers may cause reduction in remote signal. The external antenna is included in the accessories bag. For these circumstances, the antenna can be inserted into the MUTT®’s antenna jack (Fig. 2-H). It is recommended that the antenna is installed upon set-up (Fig. 5). ANTENNA INSTALLATION Fig. 5 - ANTENNA INSTALLATION 12 WARNING INDICATORS Explanation of the diagnostic functions of the warning indicators. Fig. 6- Power Warning Indicators POWER WARNING INDICATORS VOLTAGE INDICATOR (Fig. 6) • Changes colors from green, to yellow, to red as battery voltage drops. When the battery supply voltage drops to 11V or less, the MUTT® shuts down power to all circuits and the voltage indicator flashes red. • Charging is required to continue testing. REVERSED POLARITY INDICATOR (Fig. 6) • Flashes when battery clamps have been reversed at the battery posts. • Correcting polarity of the battery terminal clamps deactivates the warning. • The MUTT® is internally protected from any damage occurring from polarity reversal. SHORT CIRCUIT PULSING AND OVERLOAD INDICATOR (Fig. 6) The MUTT® will aid the technician in troubleshooting short circuits by keeping the desired troubled circuit powered up long enough to identify the source of the problem without blowing fuses or damaging the circuit itself. • When the MUTT® identifies an amperage draw above 20 Amps for longer than 150 milliseconds, the MUTT® will automatically remove power before any damage can occur to the trailer or MUTT®. At the same time, the amperage gauge will spike, then a warning indicator will sound, while the red overload indicator illuminates. • Power will be applied repeatedly in 3 second intervals until the source of the short, or overload is removed. This will allow the technician to shake test wiring harnesses while looking for the short. 13 OPEN CIRCUIT WARNING INDICATOR (Fig. 6) The MUTT® will identify open circuits when a load is not found within the selected circuit. The MUTT® will identify circuits with loads between 100mA and 20 Amp DC as a healthy circuit. A circuit without a load or a load less than 100mA will be identified as an open circuit. CROSSED CIRCUIT WARNING CHARACTERISTICS • Red circuit indicators flash to show troubled circuits. • In the instance of crossed circuits where a circuit (or circuits) other than the selected circuit is inadvertently powered by the selected circuit, the unselected circuit indicators flash, while the selected indicator remains steady. Also known as a “backfeed”, this is caused by worn wires or improperly wired plugs on the trailer. • Some cases 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. • Crosses between brake lights and turn signals are only displayed with turn signal selection. Since the MUTT® measures the total load current and not for each circuit, it will not detect when a single circuit is disconnected in a multi-circuit condition (i.e. brake lights). It will however, properly detect the open state when checking the right or left turn signal separately. AUTO SHUTDOWN FEATURE In order to preserve battery life, the MUTT® enters a Sleep mode if inactive after 20 minutes with the power on. • A sound is emitted every 10-20 seconds to inform the operator of the condition. • Activation of any test mode takes the MUTT® out of the Sleep mode. MAINTENANCE • Dielectric grease can be used in the 7 round socket, cable and battery clamps to prevent corrosion. • Disconnect and remove battery when placing the SMART MUTT® into long term storage. • Store in a cool dry area. 14 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 plugs, the 12V wire and electric brake wire may be reversed on some trailers (particularly horse trailers). 6 PIN ROUND PLUG ADAPTER END TRAILER SIDE 7 ROUND PIN SOCKET CONFIGURATION KEYWAY TAIL ELECTRIC LIGHTS BRAKES (EB) (TM) 12 VOLT (12V) ELECTRIC TAIL BRAKES LIGHTS LEFT (EB) (TM) TURN ELECTRIC (LT) GROUND (GD) RIGHT TURN (RT) GROUND BRAKES RIGHT BACK-UP (EB) TURN LIGHTS (BU) (RT) RIGHT GROUND (GD) LEFT TURN (LT) LEFT ELECTRIC BRAKE TURN (EB) (LT) TURN (RT) KEYWAY GROUND (GD) ELECTRIC BRAKES KEYWAY CLEARANCE (EB) ELECTRIC 12 VOLTRIGHT LEFT BRAKES (12V) (EB) LEFT RIGHT TURN TURN TURN TURN(RT) (LT) (LT) (RT) RIGHT LEFT BACK-UP TURN TURN LIGHTS (BU) AUX (RT) (LT) (ABS) GROUND STOP/BRAKEELECTRIC BRAKE BACK-UP LIGHTS (BU) (EB) GROUND 7-WAY FLAT PLUG VEHICLE END BU GN Y BR WH TAIL/TAG 12 VOLT (12V) ELECTRIC BRAKE (EB) 4/5 PIN PLUG ADAPTER END BU BU GN GN Y Y BR BR WH WH 15 Limited Three Year Warranty MOBILE UNIVERSAL TRAILER TESTER #9004A SMART MUTT® Innovative Products of America® Incorporated has established a Limited Three Year Warranty Policy for the Mobile Universal Trailer Tester 9004A Series, not including any wearable parts, i.e. tires, clips, batteries, etc. Three Year Limited Warranty/Return or Replace Policy: The product is covered for three years from the date of original user purchase under the stipulations of the Standard Warranty. The product is warranted to be free from defects in workmanship or material. If there is a problem due to workmanship or material defect, Innovative Products of America® Incorporated will repair or replace the product within 24 working hours after it is received by the IPA® Repair Service Center. In the event it is determined that the product has been tampered with, or altered in any way, the warranty is void and all claims against the product will not be honored. The Warranty Repair/Return procedures require that the proof of purchase must be established (either by warranty card from the seller or by point of purchase receipt/invoice) and the manufacturer makes every attempt to return ship the product within three business days from the receipt of the returned product, freight prepaid. If it has been determined that the tool has been damaged due to misuse, Innovative Products of America® Incorporated will repair the tool at a cost we deem reasonable and these charges will be the responsibility of the user. We truly want you to be happy with our products, so if you have any questions, call us toll-free at 888-786-7899. Innovative Products of America® Incorporated 234 Tinker Street, Woodstock, NY 12498 888-786-7899 / 845-679-4500 | www.ipatools.com © 2012 Innovative Products of America®, Incorporated. All rights reserved. This material may not be reproduced, displayed, modified or distributed without the express prior written permission of the copyright holder. For permission, contact [email protected]. 009004A-MANUAL-IPA-PRINT.indd