IPA 9005A User Manual

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Page 1

Mobile Universal Trailer Tester

SUPER MUTT

OPERATOR’S MANUAL

HEAD

#9005A

Innovative Products of America® Incorporated

888-786-7899 • 234 Tinker Street, Woodstock, NY 12498 • www.ipatools.com

modied or distributed without the express prior written permission of the copyright holder. For permission, contact [email protected].

Page 2

LETTER FROM THE PRESIDENT OF IPA

My name is Peter Vinci and I am the president of IPA®. I would like to 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 rsthand 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 rst 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: 888-786-7899 Phone: 845-679-4500 Fax: 845-679-4600

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9005A SUPER MUTT® DELUXE PARTS

RED AIR HOSE

#7900AP-18AS

BLUE AIR HOSE #7900AP-23AS

FEMALE 2 PRONG PLUG POWER

ADAPTER WITH ALLIGATOR CLIPS

#9005A-4AS

Qty. 3 - #MUT-RAS

CONTROL FOB

#7900K-34B

CONTROL FOB BATTERY

(12V Alkaline Energizer AE or A23)

5 FT. CABLE 7 ROUND

PIN #7900K-1

10 FT. CHASSIS GROUND CABLE

#7900K-2BCHAS

CHARGER

#CH0001

Regulator

7900K-1 5 FT. TRAILER CABLE ASSEMBLY

7900K-17 30 AMP AMMETER GAUGE

MUT-RAS REMOTE CONTROL FOB (QTY. 3)

7900K-79AS ANTENNA WIRE ASSEMBLY

7900K-8Z 7 ROUND ZINC SOCKET SOLID PIN

7900AP-18AS RED AIR HOSE ASSEMBLY

7900AP-11 6 FT. STRAIGHT RED AIR HOSE

7900AP-5 GLADHAND, RED EMERGENCY

7900AP-23AS BLUE AIR HOSE ASSEMBLY

7900AP-12 6 FT. STRAIGHT BLUE AIR HOSE

7900AP-6 GLADHAND, BLUE SERVICE

7900AP-14 SOLENOID VALVE 4-WAY 12V DC

7900AP-31 0-160 PSI 2 IN. PANEL MOUNT GAUGE

9005-4AS FEMALE 2 PRONG PLUG POWER ADAPTER WITH ALLIGATOR CLIPS

CHR0001 BATTERY CHARGER

9008-4R FACE SHIELD

ANTENNA

#7900K-79AS

AVAILABLE ADAPTERS:

#7900A-5 7 ROUND

TO 7 FLAT ADAPTER

#8000 7 WAY FLAT TO 6 ROUND & 4/5

FLAT ADAPTER

USE THE REFERENCE NUMBERS PROVIDED WHEN ORDERING

PRODUCTS & PARTS ABOVE

Toll Free: 888-786-7899

Page 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.

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 ammable liquids such as fuel or oil. Heat from electrical overloads can cause re hazards.

SYMBOL 2: Potential electrical hazard. Batteries have enough electrical energy

potential to ignite ammable 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 re hazard. Use caution with ammable liquids such as fuel and oil. Electrical shorts can ignite ammable liquids and wiring.

SYMBOL 8: Important information is stated.

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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 rst.

• 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 specied 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, ush 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.

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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.

• Do not operate charger with damaged cord or plug. Replace cord or plug immediately.

• 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.

• 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, 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 re 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.

DC POWER ONLY

Do not plug directly into

AC wall outlet

Page 7

QUICK SET-UP GUIDE

NOTE: The Super MUTT eliminate guesswork and make your job easier. As a general rule, if something is wrong with your trailer’s electrical system, the MUTT LEDs to indicate the problem. Air brake testing is straightforward, but should be operated only AFTER reading the instruction manual. Both Lights and Air Brakes can be operated by remote control.

1. CHOCK ALL WHEELS BEFORE TESTING BRAKES.

2. INSTALL A FULLY CHARGED 12 VOLT DC BATTERY in the battery compartment

of your Super MUTT

3. INSTALL THE ANTENNA (in the included accessories bag) into the MUTT antenna jack (see Fig. 3, pg. 15).

4. PROGRAM THE REMOTE by holding down the large button of remote and simultaneously turning the MUTT seconds. The remote control is programmed once the start-up sequence has

nished and the Ground Integrity light on the MUTT

small button on the remote for Air Brake operation will also be programmed at this time.

5. CHECK 7 PIN CONNECTORS on both sides of the MUTT to make sure the pins are spread to the proper width and greased. This ensures a solid connection.

6. CONDITION 7 PIN CONNECTORS: Use dielectric grease on all connections to avoid corrosion. If a bad connection exists at the terminal junction, you may get an erroneous reading or the MUTT

have a solid connection in the 7-way socket (perform cable test).

7. CONNECT THE OUTPUT side of the 7-way pin cable to the trailer being tested.

Connect shop air into the clean air source. Optimum test pressure is 100 psi (do not exceed 120 psi). Connect the red air hose to the Emergency Side (left) Air Out

connection on the front of the MUTT Service Side Air Out connection. Finally, connect each of the appropriate glad hand connectors to the corresponding trailer connection.

8. OPTIMUM TESTING PRESSURE is 100 psi.

HEAD is an advanced diagnostic tool designed to

will beep and blink

Deluxe Head. (See pg. 9 - Choosing a Battery).

power On. Release the large button after 2

remains solid green. The

before operating

will not work properly. Make sure that you

. Then connect the blue air hose to the

Page 8

QUICK REFERENCE GUIDE

OPERATION AND TESTING

ELECTRICAL TESTING

1. CABLE TESTING: It is always recommended that you use the cable tester to

verify that the MUTT

trailer testing. To perform the Cable Test, insert both ends of the 7-way pin cable

one in each receptacle on the MUTT

MUTT

on to verify the continuity between both ends of the cable. Look for the

solid green light verifying Ground Integrity and note if there are any green circuit LEDs blinking. Note that each circuit is tested upon start up as well as ground fault check. Solid LEDs mean good connection and blinking LEDs indicate an

open circuit or poor continuity. The cable tester can also be used to inspect all trailer cables.

2. GROUND INTEGRITY: When the MUTT

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, it indicates a poor cable connection

or bad ground. Individual blinking lights indicate an open circuit. (Refer to pg. 11, K)

3. CIRCUIT PROBLEM INDICATION: As you turn the MUTT

each circuit, a steady green light veries 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

4. LOW DRAW LED TRAILERS: The MUTT

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 additional load.

5. 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.

6. ALL CIRCUITS ON: All circuits can be turned on at one time by pressing/holding the large remote button for ve seconds. To cancel, press and release the large button on the remote.

AIR BRAKE TESTING (See detailed instructions on page 19-21)

1. AIR BRAKE TESTING: Main power must be on.

2. LEAK DOWN TEST: To conduct leak down test on the Service and Emergency

line air circuits, open the Emergency Side ball valve to charge the circuit with air, then close ball valve and note any pressure drop. Any pressure drop on the gauge

is an indication of a leak in the circuit. Repeat leak down test on the Service Side.

3. ACTUATE BRAKES: Push the selector switch to left, then by using the remote control and in real time, actuate the brake servos. This feature allows you to see the slacker adjustments and the push rod travel in real time.

’s 7-way round pin cable is in proper working order before

’s side. Once the cable is installed, turn the

is rst turned on, Ground Integrity and

control knob to test

will sound if there is a problem.

will identify any circuit drawing less

Page 9

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 Service Side and close ball valve on the Emergency Side. There should be no increase in PSI on the Emergency Side. Then reverse procedure and charge the Emergency Side and close ball valve on the Service Side. No air should leak into the Service Side.

NOTE: Be certain to CHOCK ALL TRAILER WHEELS before conducting

trailer testing.

CHOOSING A BATTERY

(Manufacturer’s Suggested Replacement: YUSA #YTX14 or Equivalent)

• Battery Voltage: 12/24 V DC

• Battery Type: Lead Acid

• Battery Compartment Dimensions: 5 7/8” L x 5 3/4” H x 3 3/8” W

• Battery Protection: Inline 30 amp Fuse for Overcharge

INSTALLING AN INTERNAL BATTERY:

1. Remove the four 8-32 x 1/4” Phillips head screws in the back of the MUTT®.

2. Slide out the battery tray.

3. Place the battery into the tray with the battery terminals facing the front of the

unit. Attach the ring terminal on the red wire to the positive side of the battery and tighten securely.

4. Cover positive terminal with the red boot.

5. Attach the ring terminal of the black wire to the negative battery terminal.

6. Carefully slide the tray into the tester. Use caution - DO NOT ALLOW the

positive battery terminal to contact the unit.

7. Reinstall screws to secure.

AVOID MISDIAGNOSIS

• Before attaching to the trailer connector, make sure all sockets and pins are clean

and tight.

• Any loose or corroded connections may cause a misdiagnosis or show a fault.

• Use a well-charged battery.

Page 10

OPERATING INSTRUCTIONS

This section contains information on the usage of the #9005A Series Mobile Universal Trailer Tester. (MUTT®)

FUNCTIONAL DESCRIPTIONS

The Mobile Universal Trailer Tester (MUTT®) is a eet maintenance and a diagnostic aid for trailer electrical operations wired to North American style 7 round pin conguration.

Fig. 1: Control and Information Panel

The following describes the Testing Panel (Fig. 1).

A. AIR CONTROL SWITCH

Select between Emergency, Remote and Service Side air control.

Left: REMOTE

Center: EMERGENCY

Right: SERVICE

B. POWER SOURCE SWITCH

Select between Internal Battery, External Power, or Power Off.

Center: OFF (battery charge in this position only)

Up: Installed Battery ON

Down: External Power ON (power supply is an optional accessory)

C. 12V DC BATTERY TRICKLE CHARGE INPUT

Use for connection of trickle charger to battery (charger not included).

Allows oat charge to be kept on battery when unit is not in use.

D. 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.

Page 11

E. BACKLIT 30 AMP AMMETER

Meter shows current draw of a selected circuit up to 30 amps.

F. 30 AMP FUSE SOCKET

Overload protection.

G. MUTE SWITCH

Flip switch up to mute alert sounds.

H. TROUBLE WARNING INDICATORS

Flashing red LEDs indicate problems that may exist in a selected circuit.

• Overload Indicator

• Open Circuit Indicator

• Reversed (Battery) Polarity Indicator

I. AUTO CYCLE INDICATOR

Illuminates when Auto Cycle is engaged.

Auto Cycle tests all circuits in ve second intervals in clockwise rotation. (You cannot access Auto Cycle mode when in Auxiliary or Brake mode). To enter Auto Cycle

mode, press Control Knob once and then a second time to cancel Auto mode.

J. VOLTAGE INDICATOR

Shows supplied battery voltage integrity.

Operating Voltage Range: 12/24 volt DC

K. GROUND INTEGRITY

Large green LED above the Control Knob indicates ground status.

Ground Integrity is automatically veried when power is turned on. If a ground fault is indicated, attach the supplied 10 ft. ground cord 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.

L. 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

• Brake Light Exercise Mode

M. CIRCUIT INDICATORS

The small green LEDs illuminate or blink in testing phase.

N. CHASSIS GROUND OUTLET

Insert supplied ground cable into this socket for trailers using the frame or body for ground connection instead of ground pin in harness.

Page 12

ELECTRICAL/LIGHT TESTING PROCEDURES

7 ROUND PIN TRAILER TESTER

MANUAL MODE

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. Prior to any MUTT erroneous readings. The MUTT trailer or while cable testing.

2. Secure battery connections to tester.

3. Make sure the remote key fob has been programmed (Pg. 14).

4. Insert the provided 7-way round cable to the socket on the right side of the tester.

5. Before testing trailer lights, test the 7-way pin cable with the socket on the left

side of the MUTT

6. Using the red power selection switch (Fig. 1-B, Pg. 10), select Power Source.

7. Check Voltage Indicator (Fig. 1-J, Pg. 10) 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

(Pg. 16).

8. Initial power starts a test cycle through all the LEDs. This performs the Ground

Integrity test.

9. Ground Integrity Test: When the MUTT

circling the dial. This indicates the MUTT

a lack of ground, all the green lights begin to ash to alert you to the ground problem. If you only see one green LED ashing, this indicates an Open Circuit (check your 7-way pin connections rst, then the trailer). If you do not have Ground Integrity, the MUTT ground is established. To troubleshoot, rst you need to understand the type of ground being used on your particular trailer. There are two types: The rst type

is wired with each light receptacle grounded by the ground return wire leading back through the 7-way round pin plug at the front of the trailer; the second type is chassis ground where the light receptacles are grounded directly to the trailer chassis.

9a. If the trailer is grounded through the plug, the technician needs to locate

the source of this poor ground. Some systems use both wire and chassis ground.

Suggestion: Check the 7-way plug sockets and pin contacts FIRST for

loose or broken connections.

9b. If the trailer lights are chassis grounded, use the following instructions.

testing, connect the 7-way pin connector or you will receive

(cable tester).

is intended to be used while connected to a

is rst turned on, notice the green lights

testing for Ground Integrity. If there is

cannot continue normal testing functions until a solid

Page 13

Your MUTT® comes supplied with a 10 ft. ground cable accessory. Plug in

the 10 ft. ground cable to the MUTT

Chassis Ground outlet (Fig. 1-N, Pg.

10). Then using the alligator clip, attach the other end of the ground cable to

the chassis of the trailer. This effectively grounds your trailer and allows testing to continue.

10. After the Ground Integrity test, the control knob (Fig. 1-L, Pg. 10) may be rotated in either direction to select a circuit to diagnose. The corresponding Circuit Indicator (Fig. 1-M, Pg. 10) illuminates indicating 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. 1-L, Pg. 10). The Auto Cycle Indicator (Fig. 1-I, Pg. 10) illuminates.

2. Power is applied by the MUTT

to one circuit at a time for ve seconds in a

clockwise direction starting from the Ground Integrity Indicator (Fig. 1-K, Pg. 10).

3. A ve second delay commences before power is applied to the rst circuit

automatically.

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 warning sound:

• Flip the Mute switch up to disable audible alerts, or press the control knob

(Fig. 1-L, Pg. 10) for ve seconds. Mute can not be accessed when AUX or Brake Circuits are selected.

• To restore sound, return the switch to down position and/or cycle power using the

Power Source switch.

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 remote for ve seconds. On trailers using incandescent bulbs, All Circuits On will typically result in an overload because the amperage draw will exceed the allowed 20 amp maximum.

NOTE: Short Circuit sensing is operational in this mode. If a short circuit is found in this mode, the MUTT short. Open Circuit sensing is not operational.

• To cancel All Circuits On mode, turn the selector knob or press and release the

large remote button.

will not be able to identify which circuit is the cause of the

Page 14

REMOTE FUNCTIONS

REMOTE PROGRAMMING

With MUTT® in the OFF position, hold down the large button (Fig. 2-1) on the remote while simultaneously turning the MUTT

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 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.

Open Emergency ball valve and charge circuit with

100 psi. Use the small button on the remote to actuate Service Side.

3. REMOTE CONFIRMATION INDICATOR

Red light illuminates to conrm that a button has been pressed to indicate

Battery Remote Power.

NOTE: With each press of either button, the red light (Fig. 2-3) of the remote illuminates, showing the conrmation of button depression and battery integrity of

the remote. Inclement weather, nearby power transformers and closely parked trailers may cause reduction in the remote signal.

The antenna wire (included in the accessories bag) can be inserted into the MUTT® antenna jack (Fig. 1-D). It is recommended that the antenna is installed upon set-up (Fig.5). 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 in. 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 a Duracell MN21 battery can be used.

power On. Release after two seconds. The

Fig. 2: Remote Control

WARNING: Be careful when using remote controls in multi-bay shops where another MUTT programmed to multiple MUTT remote is being held down at the same time another MUTT

may be in operation. One remote may be inadvertently

s. This can happen when the large button on a

is being powered up, effectively programming one remote to two units. To avoid this, be sure any other MUTT control can only be synchronized to a MUTT

users alert you when they power up their units. A remote

during the power-up phase.

Page 15

ANTENNA INSTALLATION

See Fig. 3 for installation of the Antenna (included in the accessories bag)

Fig. 3: Antenna Installation

WARNING INDICATORS

Explanation of the diagnostic functions of the warning indicators.

Fig. 4: Warning Indicators

Page 16

POWER TO TESTER 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 ashes red. Charging or replacing the battery is required to continue testing.

• Between 10V-11V, the indicator is RED, showing the battery is too low.

• Between 11V-12V, the indicator is YELLOW, showing the battery is low.

REVERSED POLARITY INDICATOR

• 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.

RED TRAILER WARNING INDICATORS

These signals indicate a fault.

OVERLOAD INDICATOR

• When the MUTT direct short, the indicator ashes 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

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 ashes

and sounds.

confronts a constant amperage draw above 20 amps or a

goes into Pulsar Mode.

CROSSED CIRCUIT WARNING CHARACTERISTICS

• Green Circuit Indicators ash 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 ash 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 specic wiring schematics for the unit in question.

GROUND INTEGRITY WARNING

(With the Use of Chassis Ground Cable)

Ground Integrity has been explained in the Testing Procedure (Pg. 12, Section 9). When the MUTT

is rst 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, it indicates a poor cable connection or a bad ground. Individual blinking lights indicate an open circuit.

Page 17

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 10-20 seconds to inform the operator of the condition.

• Activation of any test mode takes the MUTT

out of Sleep mode.

CABLE TESTING

The MUTT® has a special cable feature to test 7-way round pin cables for continuity. The cable testing feature can be used to test a tractor’s cable or the supplied MUTT cable. It is recommended that all cables be tested prior to the MUTT

operation.

TEST PROCEDURE

PRIOR TO CABLE TESTING:

To avoid erroneous fault, be certain the 7 pins in each plug are clean and spread to the proper size.

• Insert each end of the cable into both side connectors on the MUTT push the cable ends in rmly until they reach the bottom of the connector.

• Turn main power switch to desired power supply.

• Once the power is selected, the green lights around the control knob will blink and disappear one at a time until only the Ground Integrity light remains solid

green. Once the initial check has been performed, poor cable conditions will be shown by a blinking light for the problem circuit.

• If the cable has an open circuit or continuity problem, the corresponding circuit ashes repeatedly.

• Further testing can be performed by selecting each circuit individually via the control knob or remote. When an open circuit is detected, the LED for the circuit will ash and an audible alert will be heard.

NOTE: Always check the MUTT

connector pins at the side of the MUTT® for proper

expansion. Over time, the pins may bend in slightly resulting in a poor connection

between the connector and the cable ends. A at head screwdriver can be used to

expand the pins until the a tight connection is made.

. Be sure to

Page 18

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 PRE-TEST PROCEDURES STEPS 1 THROUGH 7 (PAGE 19). FAILURE TO FULLY UNDERSTAND THESE WARNINGS CAN RESULT IN MINOR TO SERIOUS INJURY AND POSSIBLY DEATH.

SHOP AIR IN on side of MUTT

Fig. 5: Air Brake Panel

AIR PANEL (Fig. 5)

A. Emergency Side – Air Out to

Red Hose

B. Emergency Side – Gauge

C. Emergency Side – Ball Valve

D. Air Regulator – Knob

E. Service Side – Ball Valve

F. Service Side – Gauge

G. Service Side – Air Out to Blue Hose

Page 19

AIR BRAKE PRE-TEST PROCEDURE

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. 1-B, Pg. 10) to the middle

Off position.

4. Move Air Control rocker switch (Fig. 1-A, Pg. 10) to the middle Emergency setting.

5. Turn both Emergency Side and Service Side ball valves (Fig. 5-C & E) to the Closed position.

6. If using an external power source, connect it to the 20 amp External Power Input socket (on the side of the MUTT

7. Attach red gladhand hose from the MUTT

Side air system and attach the blue gladhand hose to Service Side. Now you can connect your shop air to the Shop Air inlet on the right side of the unit. Connect an

air regulator where needed.

NOTE: To set the air regulator, pull and turn knob (Fig. 5-D)

directly to your trailer’s Emergency

DO NOT EXCEED 120 PSI.

LEAK DOWN TESTING

EMERGENCY SIDE – MANUAL LEAK DOWN TEST

1. Connect shop air to Shop Air inlet (on the side of the unit). Look for any signs of

air leaks on test unit. Air leaks could result in faulty test results and may not allow the MUTT

2. Turn Emergency Side (red) ball valve (Fig. 5-C) to the Open position – this air charges the Emergency Side.

3. Once air has lled the Emergency Side, turn ball valve (Fig. 5-C) to Closed position to begin leak down test.

4. Note any PSI drop after stabilization of pressure.

5. Look for air loss according to your local code or test by noting consistent air drop

over time. If air pressure continues to drop, you can turn air supply back on Emergency Side (Fig. 5-C) and begin to look for the leak by inspecting air system, if an unacceptable air pressure loss is observed.

6. Once the Emergency Side air passes the leak down test, a leak down test on the Service Side can now be performed.

SERVICE SIDE – MANUAL LEAK DOWN TEST

1. Press Air Control rocker switch to the right Service position (located on upper

panel). Turn power switch to desired the power source.

2. Turn the Service Side (blue) ball valve (Fig. 5-E) to the Open position.

3. Once the Service Side (Fig. 5-F) gauge reects the desired pressure, then turn the

ball valve to the Closed position to begin leak down test.

4. Note any PSI drop after stabilization of pressure.

to work properly.

WARNING: Pressurizing Emergency Side will release the brakes.

Page 20

5. Look for air loss according to your local code or test by noting consistent air drop

over time. If air pressure continues to drop, you can turn air supply back on the Service Side (Fig. 5-E, Pg. 18) and begin to look for the leak by inspecting air system if an unacceptable air pressure loss is observed.

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 the inspection and service of the air brake system. When operating the Service Side via remote, the Emergency Side must be precharged with

the ball valve in the Open position. If the Emergency Side has insufcient pressure,

the Service Side brakes will not actuate.

WARNING: Remember to sufciently chock/block the wheels of the trailer

before operation to prevent the trailer from rolling. Trailers should always be

parked on a at/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. Push red air control switch to the Emergency Side position.

2. Turn Emergency Side valve to the Open position.

3. Charge Emergency Side with desired air pressure.

4. Turn Service Side valve to the Open position.

5. Move red air control switch to Remote position (The smaller button on the wireless

remote controls the air ow when pressed).

6. Point the remote in the general direction of the MUTT® (Install antenna for

improved range).

7. Press small button once to engage the service air brakes.

8. Press small button again to disengage the brakes.

9. Repeat as necessary.

Page 21

ADDITIONAL TESTING PROCEDURES

There are many safety and operational functions to test on a trailer, but there are a few which are widely viewed as VERY important. With this tester, these tests can be performed without the truck or tractor, quickly, accurately, and in most cases, with only one person. Below are a few common system checks that can be

performed using the MUTT

• Leak Down Testing on both Service Side and Emergency Side.

• One man leak and shake testing throughout the trailer.

• Push rod travel measurements.

• Slacker adjustment reading specic to manufacturer’s specs on

brake chamber and proper operation notes.

• Even brake pressure activation.

• One man wheel off ground testing for brake strength and operation.

• Accessing ABS codes.

MAINTENANCE AND STORAGE

• Switch power off, remove all power cables, and disconnect battery before cleaning.

• Wipe surfaces down with a well-wrung, soft, damp cloth.

• Diluted dishwashing liquid or similar substance can be used in the dampened

cloth if necessary.

• Dielectric grease can be used in 7-way round socket and cable, as well as battery clamps, to prevent corrosion.

• Disconnect and remove battery when placing the MUTT

• Store in a cool dry area.

into long-term storage.

Page 22

TYPICAL TRAILER WIRING

12 VOLT (12V)

BACK-UP LIGHTS (BU)

ELECTRIC BRAKE

ELECTRIC BRAKES (EB)

KEYWAY

RIGHT TURN (RT)

LEFT TURN (LT)

GROUND

GROUND (GD)

TAIL/TAG

LEFT TURN (LT)

CLEARANCE

AUX (ABS)

STOP/BRAKE

RIGHT TURN (RT)

12 VOLT (12V)

BACK-UP LIGHTS (BU)

ELECTRIC BRAKE (EB)

ELECTRIC BRAKES (EB)

KEYWAY

RIGHT TURN (RT)

LEFT TURN (LT)

GROUND

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).

Trailer Wiring

ELECTRIC BRAKES (EB)

BACK-UP LIGHTS (BU)

6-WAY ROUND PIN PLUG

ADAPTER END

TAIL LIGHTS (TM)

RIGHT TURN (RT)

12V

7-WAY FLAT PIN PLUG

VEHICLE END

ELECTRIC BRAKES (EB)

LEFT TURN (LT)

GROUND

ELECTRIC BRAKE (EB)

GROUND (GD)

LEFT TURN (LT)

12 VOLT (12V)

RIGHT TURN (RT)

TRAILER SIDE 7-WAY ROUND PIN

SOCKET CONFIGURATION

GROUND (GD)

CLEARANCE

LEFT TURN (LT)

AUX (ABS)

STOP/BRAKE

4/5 PIN PLUG

ADAPTER END

RIGHT

TURN &

BRAKES

BU GN Y BR WH

BACK -UP

LIGHTS

LEFT

TURN &

BRAKE

TAIL LIGHTS

TAIL/TAG

RIGHT TURN (RT)

GROUND

Page 23

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

the 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 faults that have occurred but do not presently exist. Active faults can be cleared only after repairs are completed.

The ECU signals a malfunction by lighting both the internal and external indicator

lamp when a fault exists. 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 rst 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 ve 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 AUX or Brake light circuit, then press the control knob to ash either the Brake or AUX line to access the trailer blink codes. Other methods include applying and removing power to the AUX or brake circuit in sequence with the ABS manufacturer’s specications. Consult the ABS system of manufacturer’s manual for detailed

instructions.

The diagnostic chart (pg. 24-29) references some of the ABS codes and the method for releasing them from the CPU utilizing the SUPER MUTT

’s auxiliary circuit.

Page 24

WABCO BLINK CODES

Select AUX circuit, depress control knob to ash brake lights in sequence.

Blink Code

Problem

Area

Sensor BUI

Sensor YEI

Sensor BU2

Sensor YE2

External ABS Modulator Valve

Internal modulator failure inlet valve #2

Internal modulator failure inlet valve #1

Action

Determine sensor location. Check sensor installation. Make necessary repairs.

Determine sensor location. Check senor installation. Make necessary repairs.

Determine sensor location. Check sensor installation. Make necessary repairs.

Verify proper electrical modulator installation.

Check power supply. Make necessary corrections.

Verify proper installation. If code continues, contact Meritor WABCO for assistance.

For diagnostic and troubleshooting assistance, call Meritor WABCO at 1-800-535-5560

Internal modulator failure inlet valve

Power Supply

ECU Failure

SAE JI 708 Failure

SAE J2497

(PLC) Failure

Generic I/O Failure

Verify proper installation. If code continues, contact Meritor WABCO for assistance.

Verify proper electrical installation. Check power supply.

Make necessary corrections.

Verify proper installation. If code continues, contact Meritor WABCO for assistance.

Internal failure, contact Meritor WABCO

Verify proper electrical installation. Check power supply.

Make necessary corrections.

Page 25

HALDEX BLINK CODES

Select brake circuit, depress control knob to ash AUX in sequence.

Item Flash Count

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

System OK (with vehicle 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.

Explanation

Possible Causes

ABS is operational Displays “00”

when traveling > 6 MPH

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.

Actual Fault

PLC

Select

X X

PLC

Select

System OK (No Active Fault)

ABS ECU is fully operational. Dis-

plays “07” vehicle is stationary

X X

Page 26

Fault Code

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.

Explanation

Possible Causes

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 exension continuity and

connections. Replace sensor and/ or sensor cable.

Inspect exciter teeth for minor damage or teeth lled with

debris.

Verify all exciters have the same

number of teeth.

Verify sensor and valve wiring/

plumbing is correct.

See side by side axle by axle congurations.

PLC

Select

PLC

Select

Page 27

Fault Code

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.

Explanation

Possible Causes

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 abut 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 ex- citer 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 by axle congurations.

PLC

Select

PLC

Select

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.

Page 28

Fault Code

Slow wheel recovery on Red valve channel.

Slow wheel recovery on Blue valve channel.

Slow wheel recovery on Yellow valve channel.

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.

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.

Dump solenoid Short circuit to ground on

Yellow valve channel.

Explanation

Possible Causes

For a 2M System, verify sensor and valve wiring/plumbing is correct. (See Side-By-Side and Axle-By-Axle congurations). Slow brake release, foundation

brake mechanical faults, dry bushings, broken ABS valve, restricted piping. Check for kinks

and blockage etc., incorrect airlines, wiring.

Modulator valve solenoid failure, solenoid connection, or valve cable damage. The most likely causes include: a bad solenoid or a 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 hardward as required

and retest.

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 contact-

ing the trailer.

Disconnect the indicated solenoid and check the resistance at the solenoid pins.

PLC

Select

PLC

Select

Page 29

Fault Code

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.

Dump solenoid out shorted to Permanent

Power on Red valve channel.

Dump solenoid out shorted to Permanent

Power on Blue valve channel.

Dump solenoid out shorted to Permanent

Power on Yellow valve channel.

Low supply voltage fault. This code is not

stored in memory.

No internal ABS ECU solenoid voltage

available.

Explanation

Possible Causes

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.

If solenoid checks good and 8089 code still exists, check ECU.

Verify 12 V DC power source.

Do Not Use Battery Charger as Power Supply. ECU minimum

operating voltage is 8.5 V DC.

Verify permanent power is

present.

PLC

Select

X X

PLC

Select

Power input over voltage fault.

Short circuit on ABS ECU internal relay.

ABS Corrupt Memory

Verify 12 VDC power source.

Do Not Use Battery Charger as Power Supply. ECU maximum

operating voltage is 16.0 VDC.

Replace ECU

X X

Page 30

SERIAL #

Locate your serial number on the unit and record it above. Please be sure to send in your warranty card.

NOTES

Page 31

OPTIONAL ACCESSORIES &