Lite-Check INSPECTOR 920 Operation Manual Download

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INSPECTOR MODEL 920

OPERATIONS MANUAL

LITE-CHECK VEHICLE TESTER

FOR

AIR BRAKES, ELECTRICAL AND ABS

REV 2.0.3 –

September 4, 2013

Summary of Contents for INSPECTOR 920

Page 1: ...INSPECTOR MODEL 920 OPERATIONS MANUAL LITE CHECK VEHICLE TESTER FOR AIR BRAKES ELECTRICAL AND ABS REV 2 0 3 September 4 2013 ...

Page 2: ...LITE CHECK INSPECTOR 920 Page 2 of 36 Revision History Name Date Changes Version Gene Ambacher July 31 2013 Initial Draft 2 0 3 Gene Ambacher September 4 2013 Final Draft 2 0 3b ...

Page 3: ...power supply Lengthening the power cord will cause a power drop Be aware of voltage spikes The tester will only operate on regulated power Use a 12 volt battery or LITE CHECK 311R Regulated Power Supply Using a battery charger or power converter as a power source will damage the tester Do not charge a battery when the battery is connected to the tester The tester will not operate efficiently below...

Page 4: ...p 11 What is included with the LITE CHECK INSPECTOR 920 12 Required Materials 12 LITE CHECK INSPECTOR 920 Accessories 12 Set Up Procedures 13 Reminders 14 Operations 14 Reading the Digital Display 14 7 Way Pin Numbers and Circuits 16 Remote Control 16 Operation 16 Power Supply 17 Power Supply Set Up 17 Low Battery Messages 17 7 Way Cable Test 18 Trailer Test Procedures 18 Air Brake Testing 19 Insp...

Page 5: ...Main Menu 24 Viewing Active Faults 24 Viewing Stored Faults 25 Clearing Active and Stored Faults 25 Mileage 25 ECU Voltage 25 Manufacturer s Configuration 26 Serial Number 26 Special Functions 26 Getting Help 26 ABS Fault Identification and Troubleshooting 27 Tractor Testing 27 Electrical Output Test 28 Battery Alternator Test 28 Air Output Test 28 Appendix 29 ABS Button Codes 29 Definition of Ter...

Page 6: ...LITE CHECK INSPECTOR 920 Page 6 of 36 Warranty Contact and Service Information 34 Shipping LITE CHECK Products 34 Index 35 ...

Page 7: ...orm vital diagnostics of electrical and air systems on both tractors and trailers The INSPECTOR software puts trailer ABS inspection fault identification and troubleshooting support at the fingertips of inspectors and mechanics The LITE CHECK INSPECTOR 920 provides your facility with an efficient tool for safety assurance and maintenance of your heavy duty fleet ...

Page 8: ...ts opens open grounds and chassis shorts Digital display provides fault information at the tester Unique audible alarms assist in troubleshooting and repair activities at various locations around the trailer and tractor Regulated Service Air for consistent brake application and inspection Performs one step air systems leak test with built in 60 second timer Automatic cable test One Button ABS feat...

Page 9: ... Service Air Pressure Gauge Indicates service air pressure in PSI Emergency Air Pressure Gauge Indicates emergency air pressure in PSI Keyboard See section below on individual buttons Alarm Speaker Speaker sounds different alarms for any test failure Emergency Air Connector Port for connecting emergency air to the tester 1 4 air line with glad hand on one end needed Service Air Connector Port for ...

Page 10: ...rd panel and on the remote control Graphic Panel Button Remote Button Function EMER EMER EMER Operates emergency air SERVICE SERVICE Operates service air if emergency Is pressurized AIR LEAK TEST AIR LEAK TEST Blocks air source for vehicle air leak test BRAKE BRAKE BRAKE Operates brake electrical circuit MARKER MARKER Operates marker clearance circuit AUXIL AUXIL AUXIL Operates auxiliary circuit A...

Page 11: ...ble Test SELECT details Diagnostic testers such as the INSPECTOR 920 and other members of the LITE CHECK family of automatic testers activate a single circuit at a time and monitor the activity on all of the circuits to provide computer assisted fault identification Multiple circuits can be activated at the same time by using the SELECT button on the tester or the remote control unit In this mode ...

Page 12: ...ITE CHECK 302A Shop Accessory Kit see LITE CHECK INSPECTOR 920 Accessories below 1 Power supply either a charged 12 volt battery OR a regulated power supply such as the LITE CHECK 311R 12VDC Regulated Power Supply Warning Power to the tester must be regulated to protect the trailer s ABS electronics and ensure consistent tester performance Mounting location or plate to secure the tester Warning Th...

Page 13: ...gulator Necessary hardware for an easy set up for the shop Set Up Procedures The following steps should be taken to ensure proper setup of the INSPECTOR 920 1 Review the Operators Manual this manual and the Quick Reference Guide 2 Mount the Tester securely 3 Connect the INSPECTOR 920 Tester to a 12 Volt 20 AMP capability power supply Warning A 12 volt battery charger or simple inverter cannot be u...

Page 14: ...rs on the display for several seconds When the tester is ready this screen will display The tester automatically begins in Trailer mode Reminders Do not use battery chargers Battery Chargers are non regulated and may cause damage to the ABS ECU or the tester The tester will not operate reliably below 10 5 volts and will indicate a Low Battery condition LOW BAT The tester will completely shut down ...

Page 15: ... and the SHORT fault alarm sounds The digital display indicates the circuit under test current draw voltage and a SHORTED circuit fault Amperage shows the total circuit load on the digital display This screen is identifying a short to the right turn signal The shorted circuits on the left turn signal will be illuminated on the tester panel along with the right turn signal CHASSIS SHORT Ground Faul...

Page 16: ...Control The remote control allows the vehicle inspector to operate air and electrical functions around the vehicle and observe the responses Operation Press and release the designated button Inspect One light circuit will be activated at a time The Remote Control is keyed to operate one tester at a time Remote Control operations are parallel to the panel keyboard Range with AA batteries in good co...

Page 17: ... 311R Black battery cable to negative Red battery cable to positive Turn the power switch located on the back panel of the tester on for operation Low Battery Messages NOTE The tester will not work properly if the battery is not charged to a full 12 volts The tester will not operate and will possibly lock up if the power is below 10 5 volts Notes Replace 4 AA batteries if the sending lamp does not...

Page 18: ...in number on the second line indicates a SHORT Trailer Test Procedures Before beginning testing connect a 7 way cable and two 1 4 glad hands airlines from the tester to the trailer Be careful to connect service to service and emergency to emergency 1 Ensure voltage from power source is above 10 5Vdc anything lower may cause faulty readings 2 Use either the tester panel buttons or the remote contro...

Page 19: ...he gauges 4 Press the AIR LEAK TEST button to perform the air test Observe the air gauges for changes 5 A one minute timer will start on the digital display 6 Watch for any movement on either gauge a If one gauge falls there is an external air leak b If the gauges equalize there is an internal air leak 7 The Emergency Gauge is allowed 3 pounds of air loss in one minute 8 The Service Gauge is allow...

Page 20: ...al faults are signaled by the tester Electrical circuits that have burned out or have damaged lamps may still have properly operating lamps AND the circuit will not indicate a fault The tester s digital display can be used to observe the current drawn by each circuit and to look for unusual variances from the expected values NOTE If more than one fault is detected the tester will identify the faul...

Page 21: ...is on and the OPEN fault alarm sounds The digital display indicates the circuit under test current draw voltage and an OPEN circuit fault SHORT Circuit wires are in contact The panel circuit indicator lights illuminate for all shorted circuits and the SHORT fault alarm sounds The digital display indicates the circuit under test current draw voltage and a SHORTED circuit fault CHASSIS SHORT Circuit...

Page 22: ...t NOTE If more than one fault is detected the tester will first identify the faults based on the hierarchy below Once the first fault is corrected the tester will go to the next fault and so on Fault Detection Hierarchy 1 Chassis Short 2 Open Ground 3 Short 4 Open 5 Good ABS Test Procedures Initial Setup and Configuration Before beginning ABS testing be sure these steps are followed Trailer ABS Po...

Page 23: ...ester voltage and amperage 6 Press SELECT button to cancel the test ABS Operation Warning If the trailer being tested has multiple ECUs before beginning the ABS test procedure disconnect all but one ECU Run the ABS test procedure using the steps below When completed disconnect the first ECU and reconnect the next one Now repeat the test procedure with the next ECU NOTE All ABS notes are for the Me...

Page 24: ...s the ABS menu Use the UP and DOWN buttons to navigate the menu The cursor on the display will move up and down indicating which option selected Press the SELECT button to choose a menu option Move the cursor to the bottom of the digital display and pressing the DOWN button once more will display additional menu options Viewing Active Faults View an active fault by using the DOWN button to the VIE...

Page 25: ...P button to return to the previous fault Clearing Active and Stored Faults Move the cursor UP or DOWN to select ACTIVE FAULTS or STORED FAULTS press the SELECT button to clear the faults from the ECU s memory Mileage This option displays the odometer mileage and trip mileage for the trailer if the ECU manufacturer supports it Press the SELECT button to reset the trip mileage ECU Voltage This optio...

Page 26: ...el Speed can be checked This display shows the speed of the trailer s wheels Depending on the manufacturer wheel speed will display in RPMs or MPH This function requires the trailer to be jacked up and the wheels spun manually NOTE The S in S1A and S1B indicates a sensor on the Halidex ECU Getting Help Pressing the SELECT HELP button while the screen is displaying information on a fault will open ...

Page 27: ...es Haldex TRS Yes Yes Yes Yes Bendex MC 30 Yes Yes Yes Yes Bendex TABS 6 Standard Yes Yes Yes Yes Bendex TABS 6 Single Channel Yes Yes Yes Yes Bendex TABS 6 Multi Channel Yes Yes Yes Yes 1 Exit ABS mode to cycle power and clear faults All information and directions were obtained directly from each of the above ABS OEMs The LITE CHECK process conforms to each OEM s procedure NOTE If the INSPECTOR 9...

Page 28: ...e front port on the INSPECTOR 920 3 Turn the tractor ignition button to the ON position The AUXIL circuit LED will light and the battery voltage will appear on the digital display 4 Start the tractor s engine and the alternator voltage will be appear on the digital display Erratic voltage may indicate a faulty alternator Air Output Test NOTE The INSPECTOR 920 may be powered ON or OFF for this test...

Page 29: ...wn UP Move display cursor up The menu items are explained below View Active Faults o Press SELECT to view active faults o Press the DOWN button to see detailed fault information o Press the SELECT to display the help screen for this fault this displays the factory solution for this fault Use the DOWN UP buttons to scroll through the Help Information o Press ABS BACK to return to the fault o Press ...

Page 30: ...ress ABS BACK again to return to the menu Clear Faults o Press SELECT to clear faults o Use the UP DOWN buttons to choose active or stored faults o Press SELECT to clear either Active or stored faults Mileage o Press SELECT to display trip and total mileage o Press SELECT to reset the trip odometer o Press ABS BACK to return to the menu Note Use the DOWN button to move to the second menu screen VI...

Page 31: ...ration and Vin o Press ABS BACK to return to the menu Serial Number o Press SELECT to display the ECU serial number o Press ABS BACK to return to the menu Special Functions o Press SELECT to display the Special Functions menu o Note Manufacturers may have other special functions o Press SELECT to display the Trailer s wheel speed o The wheels must be manually spun to view actual speeds o Press ABS...

Page 32: ...display with all the circuit indicator lights flashing and alarm sounding OPEN GROUND The ground wire is not connected showing an incomplete circuit A fault message will appear with the circuit indicators flashing and alarm sounding CHASSIS Shorted circuit wire is in contact with the chassis A fault message will appear with the circuit indicators flashing and alarm sounding ABS Glossary ABS Anti l...

Page 33: ...iously but does not presently exist 3 Intermittent a fault which comes and goes usually with certain driving conditions Accessories LITE CHECK 311R 12VDC Regulated Power Supply 330A Pedal Actuator 301m Service Truck Kit o Kit Includes 2 20ft Air Lines 1 20ft 7 Way Cable With 7 Way Plugs On Both Ends Air filter regulator for the service truck 302A Shop Accessory Kit o Kit Includes 2 8ft Air Lines 1...

Page 34: ...es are available Testers and power supplies have a serial number attached to the device for tracking purposes Questions concerning operation and service may be addressed to LITE CHECK by calling 1 800 343 8579 during normal business hours Pacific Time Zone Shipping LITE CHECK Products Please follow these instructions for shipping LITE CHECK testers and products to minimize damage 1 Remove all air ...

Page 35: ...n 34 cursor 24 29 digital display 9 14 down 11 24 25 27 29 30 ecu 22 23 24 25 26 27 31 32 33 electrical faults 20 electrical output test 27 28 electronic control unit 23 emer 10 20 emergency air 3 9 10 20 28 emergency gauge 19 fault detection hierarchy 22 fault identification and troubleshooting27 filtered air regulator 13 33 gauges 19 getting help 26 glad hands 12 good faults repaired 22 ground 1...

Page 36: ...hipping 34 shop accessory kit 12 13 33 short 15 18 21 32 special functions 26 31 stored 25 tail 10 16 23 tmc recommended practice 141 22 tractor output 11 18 28 tractor testing 27 trailer mode 14 up 11 24 25 27 29 30 vdc 15 18 22 viewing active faults 24 viewing stored faults 25 voltage 3 15 18 20 21 22 23 25 26 28 31 voltage spikes 3 wabco 27 warranty 34 wheel speed 26 wire color 16 ...

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