912 certifier manual rev. 2.0.1 8-25-2015

LITE-CHECK MODEL CERTIFIER 912OPERATIONS MANUAL

LITE-CHECK CERTIFIER FOR FMVSS/CMVSS 121-BRAKE TIMING TEST

WITH LIGHTS, AIR AND ABSREV. 2.0.1 - JANUARY 21, 2016

CAUTIONS

USE ONLY CLEAN, DRY, OIL FREE,FILTEREDAIR

►DO NOT connect the tester or release vehicle brakes without FIRST CHOCKING THE TIRES andsecurely supporting the vehicle. The trailer can move(walk) during testing.

►DO NOT weld on the vehicle while the vehicle is connected to the Tester. The Tester is groundedto the vehicle chassis and welding may damage the Tester’s circuit

►DO NOT operate other systems or electrical devices on the vehicle during brake system testing.Doing so may cause inaccurate results.

►DO NOT use the battery of the vehicle being tested as the power source for the Tester. The Tester requires a power supply independent of the vehicle being tested.

►DO NOT lengthen the existing power cord supplied on the Tester without Lite-Check approval.

►DO NOT operate the Tester drawer from a battery charger. The Tester drawer must only operatefrom an 12VDC battery or a regulated power supply such as supplied by LITE-CHECK. Batterychargers are not regulated and may damage the Tester’s electronic circuitry. If using a battery, donot charge the supply battery while the Tester power switch is on.

►Engines operating near the Tester may interfere with remote control operation. If difficulty is expe-rienced, install electrical noise suppression on the offending engine.

►Each Tester is matched to one remote control. If you experience interaction of remotes of multipletesters operated in close proximity, contact LITE-CHECK for assistance.

►For reliable remote control operation, the Tester antenna must be fully exposed.

►EMERGENCY air must be supplied to the trailer’s brakes before the 912’s SERVICE brake func-tion will operate. This prevents ‘Compounding’ and possible structural damage to brake compo-nents.

►Use only air hoses and fittings as supplied by Lite-Check. Others may produce erroneous resultsduring brake timing tests.

►In order to safely perform consistent and accurate tests, operators of the LITE-CHECK 912 mustfirst familiarize themselves with this manual, the Tester, and the brake system being tested.Should you have any questions, contact LITE-CHECK Technical Support at 800-343-8579, 7:00am – 4:00 pm, Pacific Time, Monday through Friday.

LITE-CHECK CERTIFIER 912

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What’s In This Manual

Topic , Page


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COVER……………………………………………………………………………………………..CAUTIONS…………………………………………………………………………………………What’s In This Manual…………………………………………………………………………..OVERVIEW…………………………………………………………………………………………CERTIFIER 912 COMPONENT IDENTIFICATION……………………………………………LITE-CHECK CERTIFIER 912…………………………………………………………………..

Description…………………………………………………………………………………………………….. Key Features of the Certifier 912……………………………………………………………………………. Set-up Requirements…………………………………………………………………………………………. Accessories and Options……………………………………………………………………………………..MODEL 351C HUB………………………………….………….………………….………….….. Description…………………………………………………………………………………………………….. HUB Status LEDs…………………………………………………………………………………………….. Sensor/Ports Channels LED’s - Red and Green…………………………………………………………..LITE-CHECK REMOTE CONTROL……………………………………………………………..LITE-CHECK MODEL 363 DIFFERENTIAL KIT……………………………………………… Description…………………………………………………………………………………………………….. Contains………………………………………………………………………………………………………..LITE-CHECK AIR PRESSURE SENSOR/TRANSDUCER…………………………………..SET-UP PROCEDURES…………………………………………………………………………. Shop Set-up…………………………………………………………………………………………………… CASTER INSTALLATION…………………………………………………………………………………….7-WAY CABLE WIRE/PIN DESIGNATION…………………………………………………….TESTER AIR SYSTEMS INTERNAL SENSOR CALIBRATION PROCEDURES…………

Test 1: Zeroing Pressure Self-test…………………………………………………………………………. Test 2: Altitude Re-Calibration, zeroing Tester’s interior pressure sensors…………………………… Test 3: Internal Leak Self-test………………………………………………………………………………. Calibration/Composite, 121 Timing and Air Supply Adequacy…………………………………………..TESTER OPERATION, GENERAL……………………………………………………………..

General……………………………………………………………………………………………….….……. Functions of Keys, Panel and Remote………………………………………………………………………KEYPAD OPERATION NOTES…………………………………………………….…………… Integral Keypad Operation…………………………………………………………………………………… Remote Control Operation……………………………………………………………………………………INTERPRETING PANEL DISPLAYS, INDICATORS AND ALARMS…….…………………

General………………………………………………………………………………………………………… Switch Indicators, LED……………………………………………………………………………………….. Audio Alarms…………………………………………………………………………………………………..LITE-CHECK CERTIFIER SOFTWARE……………………………………………………….. General………………………………………………………………………………………………………… Installing Your LITE-CHECK CERTIFIER Software……………………………………….………………WHAT YOU SEE ON THE GUI (912 CERTIFIER) SCREENS………….….…….………….

Main Test……………………………………………………………………………………………………….Vehicle Information……………………………………………………………………………………………

Hub Screen……………………………………………………………………………………………………. Differential Pressure Test……………………………………………………………………………………. REPORTS Screen.……………………………………………………………………………………………PERFORMING TESTS…………………………………….…….…………….….….….….…….

General Description…………………………………………………………………………………………..Vehicle Electrical Tests………………………………….….….……………………….……….

Trailer Lighting and Electrical Power Test, Manual……………………………………………………….. Trailer Lighting and Electrical Power Test, Automatically Sequenced………………………………….. Electrical Load Test……………………………………………………………………………………………

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What’s In This Manual

Topic , Page

Vehicle Air Systems Tests………………………………………………………………………Trailer or Dolly Air System Leak Test……………………………………………………………………….

Operate Vehicle Brakes for Visual inspection and Slack Adjustment……………………………………BRAKE TIMING TESTS……………………………….….………….….……….……….………

General………………………………………………………………………………………………………… Important……………………………………………….…………….….………….….………….………….. Performing Automatically Sequenced Tests……………………………………………………………….

Set-up for SERVICE Brake Apply and Release Timing Tests……………………………………………TRAILER CONNECTION……………………….……………………….…………….….………

Performing Basic Brake Apply and Release Timing Tests………………………………………………..How to Perform Air Differential Test……….….…………….……………………….……….

Set-up for SERVICE Brake Differential Pressure Tests…………………………………………………..Setup for Performing ABS Tests………….…………….…….….…….……………………..

PERFORMING ABS TESTS………………………………………………………………………………… Viewing Test Results………………………………………………………………………………………….APPENDIX……………………………………….……………….….….………………………….FMVSS - 121 REQUIREMENTS…………………………………………………………………ELECTRICAL TERMINOLOGY AND TROUBLESHOOTING……………………………….RUNNING 121 TIMING TESTS FROM THE FRONT PANEL(TROUBLESHOOTING)…..912 TROUBLESHOOTING REFERENCE GUIDE…………………………………………….REMOTE CONTROL ISSUES……………………………………………………………………

262626272727283030313333343435353637383940

Protective HoodPrinter

(Not provided by LITE-CHECK)

RemoteControl

J-Hook

ServiceAir Line

EmergencyAir Line

7-WayPlug

HubPort

Air-DrainPlugControl

Panel

AccessPanel

MonitorKeyboard

&Mouse

* All components are standard unless otherwise noted.

ElectronicDrawer

OVERVIEW


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RF Antenna(NOT VISIBLE IN THIS VIEW)

CERTIFIER 912 COMPONENT IDENTIFICATION

ITEM DESCRIPTION

Protective Hood Provides protection for the Monitor and Printer

Printer(Optional) For printing test results, NOT AVAILABLE from LITE-CHECK

RF Antenna For communication with the Remote Control

Remote Control For operation of Air, ABS and Electric tester

J-Hook For hanging HUB cable and sensors

Service Air Line To connect to Trailer Service Air

Emergency Air Line To connect to Trailer Emergency Air

7-WAY Plug To connect Tester to Trailer for electrical/ABS testing

Air Drain Plug To drain Air from the Internal Air Reservoir

HUB Port To connect Model 351C Hub to Tester

Control Panel - 912 Drawer For testing Air, ABS and Electric Systems on Trailer

Access Panel For accessing the inside of the Tester

Monitor Displays all information and results from system testing

Keyboard To enter data into the tester

Mouse To navigate through the Computer Software


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Description

► Electronic diagnostic Tester for heavy-duty trailers and dollies.► Tests 12V 7-pin lighting systems for shorts, chassis shorts, opens, and open grounds.► Tests air brake systems for leaks, proper operation, and apply/release timing (FMVSS 121).► Tests Service/control line pressure differential for trailers/dollies equipped to tow other vehicles.► Gathers and interprets 121 brake response data to tester via remote Data Acquisition Hub.► Operates via drawer-mounted control panel, remote control, or personal computer GUI.► Remote control provides convenient service brake cycling for slack adjustment verification.► Remote control allows for efficient verification of vehicle lamp operation.► Communicates with computer via Graphical User Interface (GUI).► Downloads test data, including brake timing, to the computer and allows saving or printing.► Performs all ABS tests and configuring following manufacturers procedures.► Reads and writes the following ABS manufacturers; Bendix, Haldex and Meritor-Wabco.

Key Features of the Certifier 912

► Digital display for test results.► System voltage display.► System amp-draw display.► Automatic fault alarm.► Reverse polarity protected.► Non-directional remote control provides one-person operation and testing.► Overload protection prevents vehicle-wiring damage resulting from shorts to ground.► Upgrades for future new vehicle technologies via software and/or hardware.► User friendly brake inspections, air-leak tests and 121 brake timing tests.

Set-up Requirements

Electrical power, 110 vac Compressed air, filtered, dry, 120psi @ 9scfm Computer printer (NOT AVAILABLE FROM LITE-CHECK) 3/8” air fittings for transducer connection into brake chambers(NOT PROVIDED BY LITE-CHECK)

Accessories and Options

Brake Differential Test Kit (for timing-testing dollies and trailers equipped to tow other vehicles). Model 363 Pressure Transducers w. Cable (minimum of 2 required per axle tested)


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Port from Certifier912

(18014)

Fuse Holder

Hub StatusLEDs

SensorPorts/Channels

(4 more on opposite side)

Sensor StatusLEDs

HUB Cable

Sensor

Description: Gathers data from up to eight (8) sensors, interprets that data, and transmits the result to the 912Tester. Regardless of the number of sensors ordered, all Hubs manufactured after 9/10/04 havebeen shipped with all ports pre-programmed. The HUB is connected to your tester via a HUB cable.- Maximum cable length is 45 feet. Shortercables are available to suit your application.

HUB Status LEDs

► All 4 LEDs lit: Indicates normal operation► 12 Volt Supply LED lit: Indicates 12 volt supply from tester► 5 volt on-board LED lit: Indicates correct HUB internal voltage► Sat 1 and Sat 2 lit: Solid indicates normal sensor calibration (If not, sensor voltage is out of spec)

Sensor/Ports Channels LED’s - Red and Green

► Solid green: A sensor is connected► Solid red: Test in progress► Flashing red: Test has failed

**RED LEDS WILL TURN ON DURING HUB POWER-ON AND WILL SHUT OFF AFTER DATA ISTRANSFERRED.

MODEL 351C HUBPART # 18009


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Fig. 1

Requires 4 “AA” Batteries

50 CI CanisterDifferential Manifold


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LITE-CHECK REMOTE CONTROLPART # 17028

Description: The Remote Control supplied with your 912 Tester permits operation of 13 tester functions fromup to 100 feet distance from the tester. Its 13 shape-coded buttons match those on the Tester paneland activate the same functions. The Remote Control communicates with the Tester via an FM signal, and is non-directional. Forbest operation, assure the receiving antenna on the Tester is fully exposed and not shrouded byMetal.NOTE: When replacing batteries, ensure the batteries are installed per diagram in the remote.

Failure to do so will result in battery/remote control damage.

LITE-CHECK MODEL 363 DIFFERENTIAL KITPART # 18041

Description: This kit provides additional equipment necessary to perform that portion of the 121 brake-timingtests(Differential) which applies only to converter dollies and trailers designed to tow other vehicles.

All 912 Testers contain the software or can be upgraded to perform these tests. This test com-pares the incoming Service pressure against the outgoing pressure and evaluates its difference toFMVSS 121 specifications.

Contains:► Additional atmospheric pressure sensor/transducer► 50 CI reservoir assembly-connect to rear service glad-hand

Fittings to connect #77 orifice to dolly or trailer incoming glad-hand

Fig. 2

Fig. 3 Fig. 4

#77Orifice

LITE-CHECK AIR PRESSURE SENSOR/TRANSDUCER (p/n 18038)

Description:► The 912 Tester comes standard with 2 sensors. Additional sensors are recommended for

testing additional brake chambers and as back-ups.► Air Pressure sensor/transducer with 15’ cable - PART # 18038 - interchangeable with part

supplied with Model 363 Differential Test Kit - PART # 18041.► Generally one sensor/transducer is connected to each service-brake chamber and one

emergency-brake chamber.► Other sensor/transducers are connected to the 50 CI Differential chamber at the back of the

trailer during differential testing.► Sensors are connected to Remote Hub(18009) with 15’ shielded cable and AMP connector► Do not extend without first contacting Lite-Check.► Output range is .5 to 4.5 volts, linear with pressure. Excitation is 12 volts.► Connect sensor/transducer to vehicle air with 1/4” CP-2/C1 coupler set.► If Swivel connectors are not available then use caution when connecting and disconnecting

sensors as to avoid twisting the sensor cables.


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Fig. 5

Fig. 6

CASTER INSTALLATION:

After the pallet brackets are removed, lay the cardboard used for packing onthe ground and carefully tilt the tester on its side(Fig. 7), and install the swivelcasters marked with “S” on the bottom of the tester using the suppliedfasteners at all 4 corners(Fig. 8).

SET-UP PROCEDURES

Shop Set-up (If purchased without installation & training)

Remove test station from shipping container. Verify condition and check items against content list.Notify carrier of any shipping damage or loss. Notify LITE-CHECK of any item shortages.

1. Assemble test station as per caster installation images on this page(Fig. 7 and 8).2. Connect keyboard, mouse, monitor, and optional printer(if used/not available through Lite

Check LLC.) to computer mounted inside test station. Computer is accessible with front andrear panel. Power strip for accessories is available inside test station next to the computer.

3. Connect (2) coiled airlines, 7w cable and HUB cable to test station.4. Connect HUB-to-TESTER cable and sensors to the HUB.5. Install your shop air connector to bulkhead fitting on the side of the tester. Do not connect air

at this time until self-test procedures are completed. Assure shop air supply is capable ofmaintaining 120 psi to the tester throughout all tests.

6. Connect shop 110 vac power to test station.

Follow self-test procedures listed in Pages 12 - 15

Call Lite-Check Technical Support at 800-343-8579 for assistance.


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Fig. 7

Fig. 8

7-Way Cable :

TESTER AIR SYSTEMS INTERNAL SENSOR CALIBRATIONPROCEDURES

Purpose: To check the ‘zero’ air calibration of internal sensors; re-zero if necessary(readings ap-pear inaccurate) and check tester for internal air leaks.

Note: Do not connect Tester to vehicle during any self-test.

Test 1: Zeroing Pressure Self-test:

Note: All air-lines need to be disconnected from tester. Bleed all air from air tank via drainvalve located on the lower-right side of test station. Carefully relieve all internal pressure.

1. Switch ON power to Tester. The drawer display should appear as below.

2. Cycle the and keys until the display pressures are consistent..

3. Press , the display should show ‘000’ for EMERGENCY.

4. With engaged, press , the display should show ‘000’ for SERVICE.

5. If either value is other than ‘000’, the 912 is out of calibration. Re-calibrate zero by performing the following test (Test 2 on the next page).

CIRCUIT COLOR POSITIONBrake Red 4Marker Black 2Auxiliary Blue 7Left (Turn) Yellow 3Tail Brown 6Right (Turn) Green 5

MAN.-??????? VDC 1X.XX AMP XX.XX TRAILER

7 WAY CABLE WIRE/PIN DESIGNATION


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FOR FIRST TIME SET UP, ALWAYS RUN TEST 2 (Refer to image this page)

Test 2: Altitude Re-Calibration, zeroing Tester’s interior pressure sensors:

Notes: This procedure must always be performed whenever Tester altitude is changed.► Do not open GUI Certifier Software, this test must be done via the key-pad on tester.► Leave all air-lines disconnected.► Make sure all air is drained from the Tester via drain valve.► Cycle button 2 times to make sure all the air is empty from the system.

1. Switch Tester power OFF for 10 seconds.

2. PRESS and HOLD the button and switch the tester power ON. HOLD SERVICE until display shows:

MAN.-??????? VDC 1X.XX AMP XX.XX AIR SENSOR OFFSET CLEARED 3. Switch tester power OFF for ten seconds.

4. Press and hold AIR LEAK TEST button, Switch Tester power ON. Continue to HOLD AIR LEAK TEST button until display shows:

MAN.-??????? VDC 1X.XX AMP XX.XX AIR SENSOR OFFSET STORED 5. Press ALARM MUTE to silence.

6. Press , the display should show ‘000’ on EMERGENCY.

7. Press with engaged, the display should show ‘000’ on SERVICE.

8. Repeat Test 2 if necessary. Call LITE-CHECK Technical Support if unable to resolve.

9. Turn Tester off.

Test 3: Internal Leak Self-test:

1. Connect air source, minimum pressure is 120 psi. Check that Tester glad-hands are secure and tightly blocked off. Switch tester power ON. Allow to boot (~ 30 seconds). Allow time for the air reservoir inside station to pressurize and stabilize. Press “TRACTOR” key before “Emergency” or “Service” to view 60-second timer on LCD screen.

2. Press , Tester panel display should show EMERGENCY 115 psi. ± 2 psi. Adjust air supply regulator if necessary.

3. Press ,Tester panel should show SERVICE 105 psi. + 2 psi. Adjust internal regulator

4. Press , AIR LEAK TEST. 60-second timer will countdown in upper right corner of display. Air loss from either system will be displayed real time. No loss = PASS


Connect the service gladhand to the glad hand of the50 CI canister. Connect asensor to any of the HUBPorts and the quick-discon-nect of the 50 CI canister.

Block-off the Emergencyair line from the tester.

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5. If Internal Leak Self-Test FAILS FAIL = >2 POUNDS SERVICE 5a. Repeat this test (Test 3) to verify. FAIL = >3 POUNDS EMERGENCY 5b. Perform Test 1 and Test 2 to re-zero pressure sensors.

5c. Press and to pressurize tester air system

5d. Soap-test the blocked-off glad-hands, external fittings, and internal fittings if necessary. 5e. Tighten fittings as needed. 5f. Retest. If retest fails, call LITE-CHECK for instruction.

7. Press to cancel test.

Calibration/Self-Test, Composite, 121 Timing and Air Supply Adequacy(Also refer to PDF “Lite-Check 912 Calibration and Self-Test”)

Purpose: This test verifies that the external components of the test system (air supply, hoses, fittings,glad-hands, etc.) combined with the Tester's inherent set and release times complies with the maxi-mum permissible times specified in Figure 2 of FMVSS-121, S6.1.13 as amended (Set > 0.350 sec.(+ .005 seconds) and Release > 0.700 sec. (+ .005 seconds)). Do not attempt vehicle brake tim-ing or differential tests if either of the composite times for the test system do not pass. Other-wise you run the risk of failing otherwise 'good' vehicles. If you are failing vehicles for apply andrelease timing, re-run this test to verify the test system's performance.

POWER UP computer, and connect air source. Allow for the test station reservoir to pressurize.

1. Cap the EMERGENCY glad-hand from the test stand. 2. Attach 50 CI reservoir to the Tester’s Service glad-hand connection. 3. Attach one sensor to the 50 CI reservoir by means of the quick coupler. 4. Connect this sensor to the Remote Data Acquisition Hub at a location convenient to your Tester. Use Hub port/channel-1 for simplicity. DO NOT CONNECT ADDITIONAL

SENSORS. 5. Connect the Hub to the Tester 6. Switch-on Tester power via rocker switch on front panel. After boot-up, Tester panel will

display:


7. Verify the following LED’s status►HUB STATUS LEDs (all 4) should be illuminated►The port IN USE should have a solid green LED illuminated►No other LEDs should be continuously illuminated►If the SAT1 AND SAT2 LEDs do not come on, sensor has failed calibration. Power downthe tester and change the sensor.

8. Open the LITE-CHECK GUI Certifier Software.►The following steps are required any time changes are made to sensor configuration or when the tester or PC are powered off.A. To setup the tester for testing, in the message console(lower-center of GUI) you should see

a sensor connected. Click on the VEHICLE INFO TAB, this tab is for test-specific data entry. Enter all necessary information, enter TEST1 for the VIN # and the appropriate vehicle type.


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B. You should have one pressure sensor/transducer showing in the line of text boxes at the top left of the message console. Go to the HUB Tab and select the sensor under “Location” click on CURB 1. This tells the Tester to designate this sensor as a wheel sensor and use it to run an apply/release test.

9. Go back to the MAIN TEST tab to select “Auto 121 timing test” and execute AUTOTEST. This button will change to CANCEL, and in a few seconds the Tester will begin a typical set and release timing test. 10. At test completion, the AUTOTEST button will appear and display:


11. Wait while the Tester communicates its results to the PC and its GUI. When finished, the display screen will read (MAN. - ?????” again). 12. Click on the REPORTS tab at the top of the GUI. 13. Scroll the bottom window down to see the results of this verification (timing) test.

► The set time should read 0.350 + 5 milliseconds and the release time should read 0.700 + 5 milliseconds.

· To increase the time, turn the needle valve clockwise.· To decrease the time, turn the needle valve counter clockwise.

►The open-end needle valve will adjust the release time►The right-side(from front of machine) needle valve will adjust the set time

14. Test report may be saved as a confirmation of the tester performance. To save, click on ““Save” or “Save and Print””.

TESTER OPERATION, GENERAL

General:

The system provides three means of Tester operation: The Tester’s integral key panel, the RemoteControl, and the computer’s Graphical User Interface (GUI). The Tester keypad has 16 keys; theRemote Control has 13 keys. Both sets of keys are shape-coded: i.e. the same shaped key controlsthe same function from either keyboard. The key names and functions are listed on the followingpage:


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Nat’l Highway Traffic Safety Admin., DOT

Fig. 9 Fig. 10

Functions of Keys, Panel, and Remote:

Panel Key Remote Key Action/function (In air system test mode)

EMER EMER Pressurizes trailer Emergency/Supply system (Trailer air supply).

SERVICE BRAKE Activates trailer Service/Control system

AIR LEAK- AIR LEAK- Blocks air supply to trailer and reads air loss in TEST TEST system.

Panel Key Remote Key Action/function (In electrical system test mode)

BRAKE BRAKE Tests brake light circuit

MARKER MARKER Tests marker light circuit

AUX AUX Tests auxiliary power circuit & power to ABS

LEFT LEFT Tests left turn circuit

TAIL TAIL Tests tail light circuit

RIGHT RIGHT Tests right turn circuit

Panel Key Remote Key Action/function (Special function keys)

ABS (or A) ABS (or A) ABS testing

STORED (or B) STORED (or B) Activate more than one electrical circuit

CLEAR (or C) CLEAR (or C) Used for several inputs. See display for prompts.

SELECT (or D) SELECT (or D) Selects test mode

ALL CIR-TEST (na) Automatically runs electrical test seriesMUTE (na) Silences alarm during test; resets for next operation

KEYPAD OPERATION NOTESIntegral Keypad Operation:

► Press key momentarily until the indicator LED illuminates.► Only one electrical circuit operates at one time.► Pressing a 2nd key cancels the previous key and activates that 2nd key► Pressing any key a 2nd time cancels that function.► This keypad’s actions parallel that of the Remote Control.


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Remote Control Operation:

► Press key momentarily until Remote Control’s SENDING LED illuminates. If no key actuation causes SENDING LED to illuminate then check battery and battery tabs.

BATTERIES MUST BE INSTALLED CORRECTLY TO FUNCTION PROPERLY► Only one electrical circuit operates at one time. Pressing a 2nd key cancels the previous.

Pressing any key a 2nd time cancels that function.► Remote Control’s actions parallel that of the Tester’s integral keypad.► Activating a function via the Remote Control will illuminate the respective LED on the Tester’s integral panel/keypad.► The Remote Control can be programmed to operate with only one Tester. If you

experience interference between Tester systems and remote, contact LITE-CHECK Technicalsupport for assistance.

INTERPRETING PANEL DISPLAYS, INDICATORS AND ALARMSGeneral:

The 912 Tester utilizes three on-board means of communicating with its Operator: Digital Display (LCD) Keypad switch indicating LEDs, Audio Alarm with pitch-coded sound for faults

Sample Display, Electrical Test :

7 PIN VDC 1X.XX AMP XX.XX 4-BRAKE GOOD

Sample Display, Air Loss Test:

EMER 120.00 LOSS 00.XX TIME 00 SECSERV 105.00 LOSS 00.XX

Switch Indicators, LED:

LEDs on the Keypad will be activated whether circuit is activated by remote or from the keypad► Steady light: Switch and circuit activated► Flashing light: Fault condition found in circuit being tested.

Audio Alarms:► Fault alarm (Unique pitch assigned to each specific fault type)

Pin Being TestedVoltageApplied

AmperageDrawn

Circuit BeingTested Condition

Pressure at Glad Hand

Pressure at Glad Hand

Air Loss at EmergencyGlad Hand

Air Loss at ServiceGlad Hand

ElapsedTime ofTest


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LITE-CHECK CERTIFIER SOFTWARE(PC Graphical User Interface or “GUI”)

General:

Your LITE-CHECK 912 System includes the capability to operate the Tester from the PC via theCERTIFIER software (GUI) which is loaded onto a Windows PC. This software allows convenientinsertion of vehicle data such as VIN, date, owner/purchaser’s name, shop order number, and othernon-test information into the test record so this information becomes a permanent part of the record.

Once transferred to the PC from the Tester, the test records are stored on the PC’s hard drive andcan be viewed and printed via WordPad or other text editors. Because the file extension is non-stan-dard, you must specify which text editor you wish to use as a viewer. Adobe Acrobat Reader is mostcommon.

Reports are file-named and stored by VIN number. Successive runs under a single VIN are stored asdistinct files and differentiated by a .txx file extension where xx is incremented for each successivetest. (Second run is .t02, third is .t03, etc.). The number of tests against any VIN is limited to 32.

Installing Your LITE-CHECK CERTIFIER Software:

The LITE-CHECK 912 system has the software already installed on the provided PC. Use thisprocess for installing future upgrades on the same machine or on another computer (i.e.laptop).Software backups are recommended.

Before loading the LITE-CHECK GUI, check that your computer meets the minimum recommendedspecifications.

► 2.3 GHz Pentium-4/Celeron, 256 MB RAM► 50 MB HD space► Windows 7 Professional► CD-ROM, USB port

Although the software will operate under earlier operating systems and with slower processors,performance will be most satisfactory if the PC meets these recommendations.

To prepare your computer for operating the LITE-CHECK 912 Tester via the GUI:► Use Windows Explorer or My Computer to copy the entire folders ‘CERTIFIER_X.XX’ to the

C:\ (the root directory) of your hard drive. The CERTIFIER X.XX folder contains the912Certifier.exe.

► Make a shortcut of the 912Certifier.exe► Make a shortcut to the folder labeled “Reports”► Install the “USB 232” Drivers file1. Go to “Start” menu in Windows, select “Control Panel” then Device Manager2. Select “Ports(com), right click and select “update driver”3. Locate the “USB 232” driver under the GUI folder previously copied to the C:\ drive4. You’ll need to install the driver twice(2X) for it to function properly


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WHAT YOU SEE ON THE GUI (912 CERTIFIER) SCREENS:

Main Test :

The AUTO-TEST SELECTION section which lists all the automatic tests available and provides ameans to select those tests desired to comprise a test series. Also, notice the provision forscheduling multiple runs of a single test or a test series and a status counter which shows which ofthat series of multiple runs is in progress. The AUTO SAVE and AUTO PRINT buttons control storageof test results. The AUTO TEST button initiates the automatic test(s).

AUTO ELECTRICAL – This test will momentarily step through each electrical circuitand record the data on the reports page.

AUTO ELECTRICAL LOAD – This test will turn on each electrical circuit sequentially, beginning with BRAKE. The total amperage draw for a vehicle will be displayed.

AUTO AIR LEAK – This test will display any air loss on a vehicle

AUTO 121 TIMING – This test will perform the brake response and display the results.

AUTO SAVE – This will automatically save tests results into the “Trailer Report” folder on the desktop.

AUTO PRINT – This will automatically print the test results at the completion of the test provided that there is a printer installed on the PC.

HUB POWER SUPPLIES - Presents the HUB voltages and indicates if there’s a fault► A fault will be indicated by a red led instead of green on the HUB.

` MESSAGE CONSOLE - A line showing HUB-Tester connection status, System Reboot and Clear Faults selections

Title bar

Live InformationDisplay

ManualElectricOperations

Hub PowerSupplies

5 Screen Tabsof Software

ManualAirOperations


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Message ConsoleFig. 11

Vehicle Information:► Title bar - with Certifier (GUI) Software Revision Number► Tabs for Screen Pages - for the 5 screen pages of the software► Company Name & Site Location - Company name and location of facility► Clear Record – This function will clear any lines that have data in them► Work Order(Optional) - Enter your companies Work Order Number► Add, Delete, and Clear - Control user defined fields.

CompanyName &Site Location

ClearRecord

Add, Delete andClear Fields

TitleBar

TabsForScreenPages


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WorkOrder(Optional)

Fig. 12

Hub Screen:► Title bar with Certifier (GUI) Software Revision Number► Tabs for the 5 screen pages of the software► Hub Info - Displays the number of pressure sensor/transducers the HUB found on boot-up.

-Port number(s) being used on the HUB.-LOCATION with drop down window to select transducer location on vehicle .-SET and RELEASE results from this test displayed in milliseconds.

NOTE : If Emergency is selected, the output will be in PSI.► Hub Revision - Shows HUB Software Rev.► Request Once - Reads and displays current sensor pressures and voltage at the HUB► Hub Diagnostics - Displays the selected Port, Zero pressure offset(voltage with zero pressure

applied) and Pressure in PSI.► Pressure Units - This will change the display results from PSI to Volts.► HUB Power Supplies - If field is “Red” then the problem needs to be corrected before continuing.

HubDiagnostics

HubRev.(ReferenceOnly)

HubUpdateRequest(RequestOnce)

PressureUnits

HUBPowerSupplies

TitleBar

Tabs

HubInfo


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Fig. 13

TestWindow

TitleBar

Tabs

GraphLines

RunTest

Differential Pressure Test:► Title Bar with Certifier (GUI) Software Revision Number► Tabs for the 5 screen pages of the software► Graph Lines - Sensors are automatically selected, choose Differential Psi or Diff - vs - DOT

Spec► Run Test - button will run the differential test.► Test Window - shows the results of the test in graphical form

- Scroll down to show list form


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Fig. 14

REPORTS Screen:► Title Bar with Certifier (GUI) Software Revision Number► Tabs for the 5 screen pages of the software► Two Data Blocks:

► Top block shows electrical and air results► Bottom block shows brake timing and differential results

Data from the Vehicle Info screen will be placed here, and then as each test is performed, the results will show.

► Right side Panel View Report Directory – Will take you to the “Reports” sub directory

Show Load Test Circuits – Will display each circuit load accumulation, rather than just thetotal load

Hide Diff Press Test – Option to hide the diff test resultsHide 121 Timing Test – Option to hide the 121 test resultsPressure Units – Option to change air results from PSI to kPa

Save – Will save the test report to the “Reports” directorySave and Print – Will save the test report to the “Reports” directory and print the report. (If

a printer is connected the computer)

NOTE: The test results from the 121 Brake Timing of the Emergency air system are shown in PSI(KPA).


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ViewReportDirectory

ShowLoadTest

HideDiffPressTest

Hide121TimingTest

PressureUnits

Save

Save andPrint

TitleBarTabs

DataBlocks

CurrentSoftwareVersions

Fig. 15

PERFORMING TESTS

General Description:

Your LITE-CHECK 912 Certification System performs the following tests:NOTE : Operation of these tests are covered in the following pages.

► Electrical Tests: Trailer Lighting and Power Circuit test, Manual Trailer Lighting and Power Circuit test, Automatically Sequenced Electrical Load test

► Air System Tests: Air Leak-Down Test Brake Timing (per FMVSS121) for:

SERVICE brake application and release timing SERVICE/Control signal pressure differential (vehicles which tow other vehicles)

PARK brake Trailer or Dolly Air System Leak Test Operate towed vehicle brakes for visual inspection and manual slack adjustment

► ABS: Configure and test ABS according to manufacturer specifications

The following instructions assume the Model 912 test station has been set up, calibrated, and testedaccording to the procedures in the Set-up and Self-test sections(PP 12-15 of this manual).

Vehicle Electrical Tests:

Trailer Lighting and Electrical Power Test, Manual:

1. Connect the Tester to the trailer or dolly to be tested. Use the appropriate vehicle-to-vehicle cable. Assure the connectors are securely seated in their respective receptacles.

2. Press the key corresponding to the first electrical circuit you wish to test (Example: ). You may accomplish this step from the Tester’s integral keypad, the Remote Control,

or the computer’s GUI Software (at the Tester screen). 3. Read the result on the Tester’s LCD display, computer GUI Software, or listen for Audio Alarm.

The Tester’s Drawer LCD and the GUI Main Test screen will show GOOD/FAULT condition and the Reports screen will show PASS/FAIL condition.

4. Repeat for

5. You have just performed the manual test of the trailer’s lighting and electrical power systems. 6. By use of the Remote Control, you may perform these tests while walking around the trailer to

assure that all lamps light when their circuit is activated. The Tester cannot detect non-burning lamps unless all the lamps on that circuit are out (Which gives an OPEN fault).

Nor can it detect a lamp connected to the wrong circuit. You must check this visually as you walk around.


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Trailer Lighting and Electrical Power Test, Automatically Sequenced:

1. The (or AUTO CIRCUIT TEST) feature of your 912 automatically performs the test sequence and displays a code for status of each circuit. Connected as in test

above. 2. Press ALL CIRCUIT TEST depending upon your keypad version, on the Tester’s panel. (For

operation from the GUI Software, select the “ALL CIRCUIT TEST” image.) 3. The Tester will promptly run the test sequence (which you can watch real-time on its display),

alarm for each circuit as appropriate, and show a series of 5 code letters for circuit status:

P = PASS (Good circuit)O = OPEN (Open circuit or all bulbs burned out)S = SHORT (Shorted circuit-to-circuit)G = GROUND (Open ground)C = CHASSIS (Grounded to chassis)► Displayed in order from left to right on the screen: BRAKE, MARKER, AUX, LEFT turn,

TAIL, RIGHT turn.

4. Press key again to end this test and return to the TRAILER/ready mode display.

Electrical Load Test:

1. Press STORED 2. Turn on each circuit to load them all, then the total amperage will be displayed. Auto Load Test can also be performed from the GUI. 3. Pressing STORED again will exit this feature.

CIRCUITTEST

CIRCUITTEST


25

Vehicle Air Systems Tests:

Trailer or Dolly Air System Leak Test:

This test checks for air leakage from the entire vehicle air brake system.

1. Connect test vehicle to Tester via both air hoses, Service and Emergency.

3. Press key on Tester keypad, or Remote Control. This supplies air to the trailer/dolly and releases spring or park-on-air brakes.

4. Display will show DC voltage, EMERGENCY pressure at approximately 115 psi, and SERVICE pressure at 00.00 psi.

5. Press on the Tester keypad or on the Remote Control. This pressurizes the Service air system and applies the service brakes.

6. Display will show DC voltage, EMERGENCY pressure at approximately 115 psi, and SERVICE pressure at approximately 105 psi.

7. Press key on Tester keypad or Remote Control.

8. The Tester will count down, and after a short time show a display similar to this:NOTE : Press the “TRACTOR” key to view the count-down timer.

EMER 115 LOSS 000 RESERVE 000 TIME 00 SECSERV 105 LOSS 000

Each air system is tested separately, and its pressure loss shown on the line to the right of the system’s label and present pressure. Pass if Emergency System loss < 3 psi/minute. Service

System loss < 2 psi/minute.

Operate Vehicle Brakes for Visual Inspection and Slack Adjustment

1. This test operates the test vehicle brakes allowing convenient observation of brake mechanical action and slack adjustment. Caution! Keep clear of brake components when performing steps 4 thru 8.

2. Connect test vehicle to Tester with Service and Emergency air lines and connect vehicle-to- vehicle electrical cable (7-way).

4. Press key on Tester keypad or Remote Control. This pressurizes the test vehicle’s EMERGENCY air system and releases the parking brakes (spring).

5. Note that parking brakes can be cycled via the key on the Remote Control, thus making it convenient to observe parking brake operation at the axle.


26

6. Press button on the Tester Keypad or BRAKE on the Remote Control to pressurize the SERVICE Air and apply the Service brakes.

7. Note that Service brakes can be cycled via the key on the Remote Control, thus making it convenient to observe Service brake operation at the axle. Service air cannot be activated if Emergency air system is not pressurized. (Prevents ‘Compounding’ and possible

mechanical damage to brake components.)

End of Air System Tests

BRAKE TIMING TESTS (per FMVSS-121):(Also refer to PDF “CERTIFIER 912 Brake Timing Procedures”)

General

Your Lite-Check 912 Certification System is a precision timing device capable of timing resolution toless than 1.0 millisecond(.001 seconds) for apply and release times.

Although possible to run some of these tests without use of a PC and the Certifier Software (GUI),LITE-CHECK highly recommends running them from the software. In conjunction with the Tester, theCertifier Software provides a convenient way to operate the Tester, insert non-test information intothe test record, save the complete test record, make the record readily viewable on-screen, andtransfer the record to printer or mainframe for permanent storage.

The following instructions apply to running these tests from the Certifier Software (GUI). Basic level offamiliarity with the requirements of PC computers and the Federal specification FMVSS-121 is alsoassumed.

The following instructions further assume the Tester and related equipment has been set upand selt-tested according to this instruction manual. Only invalid results can be expected if tests aremade without initial and subsequent verification of the integrity of the Testing system.

Important:

If you have not already run the Calibration/Self-Test, Composite, 121 Timing and Air SupplyAdequacy (Page 14); do so now.

Purpose: This test verifies that the external components of the test system (air supply, hoses, fittings,glad-hands, etc.) combined with the Tester's inherent set and release times complies with the maxi-mum permissible times specified in Figure 2 of FMVSS-121, S6.1.13 as amended (Set > 0.350 sec.Release > 0.700 sec.) Do not attempt vehicle brake timing or differential tests if either of thecomposite times for the test system and Tester does not pass this test. Otherwise you run therisk of failing otherwise 'good' vehicles. If you are failing vehicles for apply and release timing, re-run this test to verify the test system's performance.


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NOTE: When testing vehicles designed to tow other vehicles, ensure that at 50 CI Canister is installed on the SERVICE glad hand at the rear of the trailer being tested. No sensor is required

for this canister.


Performing Automatically Sequenced Tests:

1. Ensure that all the steps on pages 12-14 have been completed and the Testers Display Panel looks like this:


2. Ensure the tester, control panel and PC are on and functional. The HUB needs to be connect ed to the 912 with all four green LEDs illuminated on the HUB(Sat 1 and 2, 5 and 12 volt sup ply).

3. Connect the desired sensors to the the brake canisters as shown in Fig. 17 to the right. 1/2” Street Tees will be needed for

this step. Connect one sensor to the Supply line and one to the Control for each wheel end being tested.

4. Ensure the sensors are connected to the HUB making note of which sensors are connected to the Supply and Control lines for each wheel end.

5. Open the Certifier GUI if it isn’t already open and select “HUB” from the tabs at the top of the Main Tests screen .

Refer to Fig. 18 on this page.

6. Once the HUB tab has been selected, you should see a screen similar to Fig. 19 on this page. Five columns will be listed in the “Hub Info” window; Port, Sensor, Location, Set and Release. Refer to the table below for definitions.

Fig. 17

Fig. 18

Fig. 19

COLUMNHEADING DESCRIPTION

Port Sensor Location on HUB

Sensor Type of Sensor

Location Wheel End port being used

Set Measured Set Time

Release Measured Release Time

NOTE: The Set and Release time will show “0.000”at this stage as no testing has been performed yet.

28


29

Fig. 20

7. Under the “Location” column, left-click on thenecessary port to set its’ location, refer toFig. 20. If the port is connected to the emer-gency canister then select one of the “Emer”locations. Typically “Port 1” would be Emer-gency and “Port 2” would be service, thoughany port can be used in any order as long astheir locations are set on this screen. Dothis for each connected sensor.

NOTE: If only one sensor is being used, thisstep is not necessary.

Fig. 21

8. Proceed to the “Vehicle Info” tab, refer to Fig.21. In the “Test Record Info” window, enterthe Vin or Serial Number of the unit beingtested, end the Operator information, the EndCustomer and the order number.

Next, select the Vehicle Type under the “Ve-hicle Type” window. This is a drop downmenu, select the appropriate unit.

9. Return to the “Main Test” screen and selectthe desired “Auto Test” features, refer to Fig.22. “Left-click” on the boxes of the desiredfeatures then select the “Auto Test button” torun the tests. The time required to perform allthe testing varies based on the features se-lected, performing all tests should requireonly 15 minutes. The results for the selectedtests will be shown on the report at the endof the testing. Refer to the table below fordetails about each test.

Fig. 22

TEST DESCRIPTION OF TESTAuto Electrical All electrical circuits will be tested with circuit condition and amperage shownAuto Electrical Load All electrical circuits will be activated with total amperage draw shownAuto 121 Timing Performs the 121 test automatically, manual operation is not recommended

Auto Air Leak Applies air to Emergency and Service separately then together. 60 secondtimer for each test.

Auto Print Prints the results report automatically if a printer is connectedAuto Save Saves the results report automatically at the completion of testing

Set-up for SERVICE Brake Apply and Release Timing Tests:

PREPARE TEST STATIONNOTE: External sensors automatically self-calibrate without applied pressure.

1. Connect the (pressure sensor/transducers) to the mating ports on the hub. Electrically itmakes no difference which wheel transducer is connected to which remaining open Hubport/channel, so choose a consistent arrangement which makes it easy for the Tester Operatorto remember which port/channel is connected to which sensor location. Do not connect anynon-used sensors to the Hub; if you do, the Apply/Release test may ‘hang’ under certainconditions.

2. Connect the (Remote Data Hub) to the Test Station by means of the provided HUB Cable. Switch ON Tester power via rocker switch on front panel and connect supply air to

tester. Allow the air reservoir to fill. After boot-up, Tester panel will display:


3. All 4 green LEDs next to the Hub’s main connector should now be illuminated. Each port with a sensor/transducer connected to it should have its green LED at power-up for LED check

illuminated. No other LEDs should be continuously illuminated. All red LEDs will lightMomentarily

4. Start the LITE-CHECK Certifier Software from the PC’s desk-top shortcut (or from Windows Explorer by double-clicking the file, 912Certifier.exe) GUI should show this data, but may be in different formats:

TRAILER CONNECTION 1. Place the Remote Data Acquisition Hub (The red box) in a location convenient to the axles of

the vehicle to be tested BUT NOT IN FRONT OF THE TIRES.

2. Install female quick disconnects into to the Service and Emergency brake chambers to be tested, or into the airlines serving the Service and Emergency chambers. If installed into the airlines, the connection should be as close to the chamber as possible and add no flow restriction to/from the chamber.


30

Fig. 16

3. If the vehicle to be tested is equipped to tow air brake vehicles, connect the 50 CI test reservoir to the rear service glad-hand. This reservoir includes a female quick connector.

4. Connect the male quick connector of an air pressure sensor/transducer to the female quick connector at the rear end of the 50 CI reservoir installed in Step 3.

5. Connect the male quick connector of an air pressure sensor/transducer to each female quick connector you installed at the brake chambers in Step-2. These sensor/transducers have a 15’ gray shielded cable and 4-position AMP connector by which they are connected to the Remote Data Hub.

Performing Basic Brake Apply and Release Timing Tests:

These operations test Service brake application and release times for air brakes on trailers, trailersthat tow other trailers, and dollies. The following procedures assume all the foregoing set-ups andtests have been performed, and the PC is operable. Refer to pages 28 and 29 for details.

1. Assure the following data is displayed:

MAN.-??????? VDC 1X.XX AMP XX.XXTRAILER

2. Click the Hub tab at top of the Certifier Software.

3. Displayed is the port/channel number (also stenciled on the hub housing) for each sensor. The LOCATION box is your means of informing the system as to the physical test position of the sensor connected to that channel/port. By means of the arrow at right end of the LOCATION box, pull down a menu of position selections.

4. Click on the CURB or ROAD selection, which best describes the sensor’s location. (Don’t use DIFF, EMER, or REAR; these designate other tests.). SET and RELEASE boxes will autofill. If both don’t appear, you have chosen an improper location for this test.

5. Repeat the previous 2 steps for all the sensors listed.

6. Input non-data information into the test record in the Vehicle Info tab.

7. Click ‘Main Test’ tab at top of GUI screen.

8. Click check boxes for ‘Auto 121 Timing’ and ‘AutoSAVE’

9 . Verify that air supply is connected and turned on. (120 psi minimum at cart inlet)

10. Press AUTOTEST. (Button will change to CANCEL). After a moment, Tester will commence the test. The tester displays: 30 second count-down (Emergency air charge-up) 15 second count-down (Service apply timing test) 15 second count-down (Service release timing test)


31

When the GUI button changes from CANCEL to AUTOTEST, the test is complete. The display will soon show:


11. To view data from the test just completed, click ‘Reports’ tab at top of GUI.

12. Scroll down the lower window (HUB and ABS). You will see the data you manually entered, Tester serial number, software version number, and below that, columns with your 121 Service Apply/Set and Release times (Ignore the EMER.SET column and the ABS section at this time.) Because you selected AUTOSAVE, the information in both windows of this screen has been saved to the PC’s hard drive.

13. Click the Tester/ABS tab again. The test is finished. You should see this display:


14. Should you wish to repeat this test with no hardware configuration or information changes, just click AUTO TEST again. Any data for which a new test is not run will remain. Any new test will over-write earlier data in the newest test record provided “AUTO SAVE” was not selected.

NOTE : If you wish to perform another test, but with altered sensor/transducer configuration, proceed from Step-10 of the previous, Set-up section. If you wish to perform another test in which only the LOCATION information or the manually input information is to be changed,

proceed from Step-3 of this section.


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Set-up for SERVICE Brake Differential Pressure Tests:

These tests apply only to vehicles equipped to tow other air brake vehicles, such as dollies, shortsemi-trailers (for doubles and triples), and B-train front semi trailers. The test requirements are speci-fied in FMVSS-121, Paragraph S5.3.5.

The purpose of these tests is to verify the control signal passed through the rear SERVICE glad-handto the following vehicle varies no more than the permitted amount from the signal controlling thebrakes on the vehicle being tested. This permitted difference depends upon the SERVICE/Controlinput pressure to the vehicle being tested: 5 – 20 psi 1 psi difference 20 – 40 psi 2 psi difference Greater than 40 psi 5% of the input pressure

These limits apply when control pressure is increasing, is steady, or is decreasing.

These tests require attachment of the double glad-hand fitting assembly into the SERVICE line at thefront of the test vehicle.

1. Connect the differential manifold to the trailer/dolly’s nose box Service glad hand

2. The differential manifold contains the FMVSS-121 specified orifice. This orifice is 0.0180 inch-es diameter (about diameter of a pin), and limits the rate of airflow between the test vehicle andthe Tester.

3. Connect the (50 CI. canister assembly) to the trailer/dolly’s rear Service glad-hand.

4. Connect one (air sensor/transducer) to the quick disconnect on the 50 CI reservoir’s rear-most end. (This is the one of the two sensor/transducers, which has a connector, which will only connect, to the sockets at the end of the hub.) This sensor is connected to port 2 on the Remote Data Acquisition HUB.

5. Connect the other sensor to the quick disconnect on the double glad hand fitting assembly at the vehicle’s nose glad hand in Step 1. A wire extension is needed to reach the HUB located near the axle. The front sensor is connected to Remote Data Acquisition HUB Port 1.

6. Select HUB tab and locate Port 1 as Differential. Port 2 is Dolly.

7. Set up test.

8. Select AIR DIFFERENTIAL and run test. Results will automatically be displayed.


33

How to Perform Air Differential Test :

Set-up for Performing ABS Tests:

A NOREGON ADAPTOR is installed in the 912 test station for operation with the computer. Power isavailable from an internal 12V regulated power supply.

PERFORMING ABS TESTS :

► The test station is in the operational mode with power and air.

ABS configuration process.1. Connect 7w cable to trailer.

2. Press ABS or (A) key on the tester keypad or remote control which will activate power andair.

3. Open ABS program on computer for configuration and operation such as Haldex, Bendix orMeritor Toolbox Software.

4. Press the SELECT or (D) key once to charge the emergency line· This will enable the “Self Test” for the ECU valve.· This will also allow the wheels to rotate freely

5. Press the SELECT or (D) key a second time to charge the service line.· This will enable the “Sensor Test” to be performed.· The brakes can also be cycled on and off with the remote(or the “BRAKE” key on the

tester) while the operator spins the axles (see end-of-the-line test below)

6. Press the ABS or (A) key to cancel the ABS Test routine. Proceed with ABS recommended process.

NOTE: END-OF-THE-LINE test can be performed with the LITE-CHECK remote control.· Press ABS on the remote control keypad· Press the SELECT once to charge the emergency line· Press the SELECT a second time to charge the service line..· Spin wheel to the required speed and press BRAKE to apply service air· Wheel should stop if ABS is connected properly· Repeat wheel spin for wheels under ABS control.

7. Close ABS file.


34

Viewing Test Results:

1. Click the REPORTS tab. The top window displays electrical test data for the last test sequence run, and the bottom window displays the air system tests, brake timing test results, air

differential test results (pass), and ABS test (pass) for the last run.

2. These data are also stored in the directory, C:\lcgui\lctext, and can be viewed and printed viaWordPad and other text editors. (Data cannot be edited).

3. Find the appropriate file via Windows Explorer or My Computer (It will be file-named by the VIN number you entered, with an extension .txx, where xx is a number 01 - 99 designating which run it is, under that VIN).

4. Double click on the file.

5. When presented with a list of programs with which to open the file, click WordPad or your favorite text editor from the list. You should be able to view and print your results.

APPENDIX

7-Pin Wiring System, Vehicle-to-Vehicle Cable (ATA/SAE J-560b)

Pin Circuit Tester Key Color1 Ground White2 Marker MARKER Black3 L. Turn LEFT Yellow4 Brake BRAKE Red5 R. Turn RIGHT Green6 Tail Lt. TAIL Brown7 ABS/Aux. AUX Blue

35

FMVSS – 121 REQUIREMENTS

S6.1.13 Trailer Test Rig

(a) The trailer test rig shown in Figure-9 on page 15 is calibrated in accordance with the calibrationcurves shown in Figure-10 on page 15. For the requirements of S5.3.3.1 and S5.3.4.1 the pressure inthe test rig reservoir is initially set at 100 psi for the application tests and 95 psi for the release tests.

(b) The trailer test rig shown in Figure-1 is capable of increasing the pressure in a 50 CI reservoirfrom atmospheric pressure to (60) psi in 0.350 seconds measured from the first movement of theservice brake control to apply the service brake pressure, and of releasing the pressure in such areservoir from (95 to 5 psi) in 0.700 seconds, measured from the first movement of the service brake

36


ELECTRICAL TERMINOLOGY AND TROUBLESHOOTING:

Your LITE-CHECK 912 Tester uses terminology for circuit condition, which may differ from that com-monly used in your shop. Terms are:

PASS OPEN SHORT CHASSIS GROUND

PASS means: The circuit under test conducts reasonable current(measures to 50 milliamps) toground and does not leak that current into other circuits. It does not, however, prove all bulbs areworking, or that two circuits are not separately cross-wired. You must do a walk-around to determineif all bulbs are lit and that they light when the correct circuit is energized.

OPEN means: The circuit under test conducts no current to ground. There is probably a broken ordisconnected wire, an extremely corroded connection, or defective grounds that affect all loads(bulbs) on this particular circuit. A circuit will also show OPEN if all the bulbs on that circuit areburned-out or missing.

SHORT means: The circuit under test conducts current into one or more of the other circuits. Lookfor bare or abraded wires, conductors of cables, which have ‘migrated’ through melted insulation, andfrayed wires at multiple connections such as the 7-way receptacle at nose of trailer. (Note: Some mili-tary trailers use a double-diode arrangement to operate the same light filaments for both brake andturn signals. These circuits will show SHORT for a good brake-light circuit.)

CHASSIS means: The circuit under test conducts current directly to the vehicle’s chassis. (While thiscondition exists, the Tester protects the vehicle’s wiring from overload damage by cycling the circuiton and off. You may hear clicking sounds in the Tester while this is occurring. This is normal.) Lookfor abraded hot wires or cables touching the frame, chassis, or running gear components.

GROUND means: The ground circuit is open and affects all circuits. Look for broken ground wire(white) or defective connections, particularly the connection of the white ground wire to the vehicle’schassis.

Remember: Lighting circuits such as TAIL, BRAKE, and MARKER are almost always parallelcircuits; ie. loss of a load (bulb) or it’s respective circuitry does not cause the others to go outand will not necessarily cause the circuit to fail its 912 test. If you have a dead bulb on a cir-cuit of other otherwise working bulbs, you must have: a bad bulb, a bad socket, a bad groundbetween it and its chassis/ground conductor, or a break in the hot wire between it and thebulbs that are working.


37

RUNNING 121 TIMING TESTS FROM THE FRONT PANEL(TROUBLESHOOTING ONLY)

Use this procedure only for troubleshooting when there is a question as to whether the Computer, the Tester,or the Hub is the problem. These steps lead you through performing one set of Service brake application andrelease timing tests without relying upon the PC Software (GUI), and interface cable. If you get valid numbersfrom this test, you know the hub and sensors are operating properly and most likely the Tester is okay. Also,this test verifies operation of the Tester’s controller card (mother board) and input port (From the Hub), howev-er it does not examine performance of the USB portion of the communications card (output to your PC).

The following steps pre-suppose the tester has been physically connected to the test trailer or 50 cu-in testreservoir as directed under Section I-4: Set-up for Brake Timing Tests

1. Connect air source. Connect power source. 2. Set up hub and sensors. See Page 29: Set-up for SERVICE Brake Apply and Release Timing

Tests: 3. Power-up and allow the Tester to complete its boot. Display will show:


4. Acquire Hub communications: a. Press ‘D’ or “Help” on Tester panel

b. Press ‘C’ or “Clear” on Tester panel. Depending upon number of sensor/transducers andports/channels used, display will show similar to:

1-AIRSENSOR CHANS – 1EMGSET – 0.XXX 121SET – 0.XXX 121REL – 0.XXX

c. Press ‘D’ or “Help” d. Press ‘D’ or “Help” again. Display should go back to main screen.


5. Assure Tester is in TRAILER mode. If not, press TRACTOR key to toggle to TRAILER 6. Press CLEAR (or ‘C’) on Tester panel. Set/Release timing test starts (~ 1 minute) 7. When test is complete (Shows TRAILER output lines above), press ‘D’ or Help. 8. Press CLEAR (or ‘C’) on Tester panel. This brings test data to Tester display.

1 – AIRSENSOR -1EMGSET - 0.XXX 121SET - 0.XXX 121REL – 0.XXX

The 121SET and 121REL numbers are the resulting set and release times from the test which was just run(in seconds).

9. Press ‘D’ or “Help” twice to return to point for running another similar test. Remember: If you change the sensor configuration you must re-acquire communication with the HUB or switch the Drawer off and back on.


38

912 TROUBLESHOOTING REFERENCE GUIDE

HUB ISSUES

SAT1 AND OR SAT2 LED’S NOT LIT UP:

· Chances are you have a sensor that is out of spec. The external sensors are self – calibrated so if theSAT1 and SAT2 are out, try swapping out sensors. If the sensor doesn’t fix the issue then you probablyhave a bad hub board.

+5 VOLT AND +12 VOLT LED’S NOT LIT UP:

· This usually means that your hub board is bad, if you have an extra hub board tryswapping it out. If this doesn’t fix the issue call Lite-check for assistance.

HUB IS NOT COMMUNICATING WITH GUI:

· Check to make sure that two Lite-Check GUI’s are not open at the same time. If thereare two GUI’s open, only one will detect the COM port.

· Check the main 45’ hub cable for damage. If you have an extra Hub cable, turn off the drawer andswap out the hub cable. Reboot system and see if the hub is detected.

· Click on the HUB tab and try to connect using the auto connect tab.

121 TIMING ISSUES

MAX PORT PRESSURE ERROR:NOTE: Always check for error messages in the message console on the “Main Test” screen of theGUI.

· Check the service air to make sure you are at 105 PSI. If you drop below 100 PSI then then you willfail the 121 release test.

· If the service line is at about 105 then check the trailer and 912 for air-leaks and or air restrictions.

121 timing not passing:

· If your 121 timing is not passing on the release or set it is usually from an air restriction which is mostof the time on the trailer you are testing. Check for pinched lines and added valves that would cause anair restriction.

· If you think it is the 912 that is causing the 121 timing to fail, do the self-test using the 50 CI canister.Refer to page 14 for set-up. Your Times should be around .350 for your set time and .700 for releasethe tolerance can only be +.005 on each. If these numbers are too high then it could cause your 121timing to fail.


39

REMOTE CONTROL ISSUES

IF LIGHT ON REMOTE ISN’T FLASHING:

· Change batteries out. Make sure the batteries are in the right way because they can blow up and causedamage!!!

· Make sure the battery tabs are all still in contact.· If neither of the above works try opening the remote and looking at the condition of the board. If you see

anything out of the ordinary contact Lite-Check.

IF LIGHT COMES ON REMOTE BUT NO SIGNAL TO MACHINE:

· Check batteries· Open remote and check the dip switch settings, there should be 10 dip switches. The dip switches should be

the same as on the interface board which is the top board inside the drawer of the 912. The dip switches onthe remote are exactly the same as on the interface. When you open the drawer on the 912 it is the longskinny board toward the top of the drawer.

· If neither of these solutions work contact Lite-Check for assistance.

IF ABS IS NOT DETECTING PLC SIGNAL:

· Check the cables to be sure they are all hooked up correctly. Your Noregon adapter should be pluggedinto the AUX filter board inside the drawer which goes to the PLC power connector on the controllerboard (main Board).

· Make sure you power up AUX circuit or use ABS button to power up your ECU.· If neither of the above work make sure that the COM settings are correct for the

Noregon in the ABS manufacturer’s software. There are different settings for each style of Noregon.

If there are any other issues that you can’t fix please contact Lite-Check for assistance at 1-800-343-8579.


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912 certifier manual rev. 2.0.1 8-25-2015

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