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Lite-Check CERTIFIER 1200 Operation Manual
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Lite-Check CERTIFIER 1200 Operation Manual

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LITE-CHECK CERTIFIER 1200
OPERATIONS MANUAL
LITE-CHECK CERTIFIER FOR
FMVSS/CMVSS 121-BRAKE TIMING TEST
WITH LIGHTS, AIR AND ABS
Version 1.0.0 Sept 25, 2019
301 N. HAVANA ST. l SPOKANE, WA 99202 l 800-343-8579
WWW.LITE-CHECK.COM

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  • Page 1 LITE-CHECK CERTIFIER 1200 OPERATIONS MANUAL LITE-CHECK CERTIFIER FOR FMVSS/CMVSS 121-BRAKE TIMING TEST WITH LIGHTS, AIR AND ABS Version 1.0.0 Sept 25, 2019 301 N. HAVANA ST. l SPOKANE, WA 99202 l 800-343-8579 WWW.LITE-CHECK.COM...
  • Page 2 This prevents ‘Compounding’ and possible structural damage to brake components. ►Use only air hoses and fittings as supplied by Lite-Check. Others may produce erroneous results during brake timing tests. ►In order to safely perform consistent and accurate tests, operators of the LITE-CHECK 1200 must first familiarize themselves with this manual, the tester, and the brake system being tested.
  • Page 3 Lite-Check CERTIFIER 1200 Operations Manual Table of Contents...
  • Page 4 Lite-Check CERTIFIER 1200 Operations Manual Table of Contents (continued) APPENDIX…………………………………………………….…….…………….….….….….……. 7-Way Wiring System, Pin Designations..…...…..…...…….……….…...…..…..………..…..….…………. Normal Power-Up Procedure..…...…..…...…….……...…..…...…...…..…..…..…..…...………………..….
  • Page 5 ► Allows test data, including brake timing, to be saved to the computer and/or to be printed. ► 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 1200 ► GUI display for test results. ► System voltage display.
  • Page 6 Lite-Check CERTIFIER 1200 Operations Manual MODEL 400 HUB AND DOLLY PART # 17190 Antenna 2 hub status LEDs Sensor Ports/Channels (4 more on opposite side) display LCD display Backlight brightness switch. Power adjustment switch. (Illuminates the LCD (Hold display.) down to power off.)
  • Page 7 The tablet communicates with the tester via Bluetooth, and is non- directional. For best operation, assure the receiving antenna on the tester is fully exposed and not shrouded by metal. LITE-CHECK MODEL 363 DIFFERENTIAL KIT, PN 18115 Differential Manifold PN 18115 This 50 CI Canister Assembly will also be used.
  • Page 8 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. On the right side of the tester, connect blue coiled hose to the “Service Air - Blue” bulkhead, connect red coiled hose to the “Emergency Air - Red”...
  • Page 9 Lite-Check CERTIFIER 1200 Operations Manual 1200 CERTIFIER SELF-TEST PROCEDURES Purpose: To check the ‘zero’ air calibration of sensors and to check the tester for internal air leaks, and to resolve any issues in them, as needed. NOTE: Do not connect Tester to vehicle during any of these self-tests.
  • Page 10 Tighten fittings and thread seal them as needed and continue. Select ”START” again (as in step 4). If this retry fails, call LITE-CHECK for assistance. If the Internal Air Leak test passes, the Tester will advance to the 121 Timing Test.
  • Page 11 Lite-Check CERTIFIER 1200 Operations Manual 121 Timing Self-Test, without a trailer or dolly: Purpose: This test verifies that the 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 >...
  • Page 12 Lite-Check CERTIFIER 1200 Operations Manual 121 Timing Self-Test, without a trailer or dolly (continued): To adjust the To adjust the SET time. RELEASE time. The SET time should read 350 - 355 milliseconds and the RELEASE time should read read 700 - 705 milliseconds.
  • Page 13 Lite-Check CERTIFIER 1200 Operations Manual Perform a Brake Air Differential Self-Test on the 1200 only, not using a Trailer or a Dolly: Nat’l Highway Traffic Safety Admin., DOT Set-up and perform the Brake Differential Self-Test: This Differential Self-Test is performed to verify your 1200 Certifier is functioning properly so that when a Differential Test is performed on an actual trailer or dolly in the future, the user will know that the results are accurate.
  • Page 14 Lite-Check CERTIFIER 1200 Operations Manual Set-up and perform the Brake Air Differential Test, with no trailer or dolly (continued): NOTE: Immediately after that glad-hand in the Diff Kit is a brass nipple which has an orifice inside to allow air flow into the Diff Kit at a specific rate. The size of the FMVSS-121 specified orifice is 0.0180 inches diameter (about diameter of a pin).
  • Page 15 Lite-Check CERTIFIER 1200 Operations Manual TESTER OPERATION, GENERAL General: The system provides two means of tester operation: The tester’s tablet PC and the computer’s Graphical User Interface (GUI). The key names and functions are listed below: Functions of Keys, Panel, and Tablet:...
  • Page 16 INTERPRETING PANEL DISPLAYS, INDICATORS AND ALARMS General: The 1200 Certifier utilizes two on-board means of communicating with its operator: 1. Graphical User Interface (GUI) of the Certifier 1200 application loaded onto the PC 2. Audio Alarm with pitch-coded sound for faults Switch Indicators, LED: Indicators on the GUI will be activated whether circuit is activated by the Tablet or from the GUI.
  • Page 17 (PC Graphical User Interface or “GUI”) General: Your LITE-CHECK 1200 System includes the capability to operate the tester from the PC via the CERTIFIER software GUI which is loaded onto a Windows PC. This software allows convenient insertion of vehicle and work data such as VIN, Customer Name and Order Number into the test record so this information becomes a permanent part of the record.
  • Page 18 3. Perform the “Normal Power-up Procedure” detailed in the Appendix which starts on page 39. 4. NOTE: The default length of time this test will take (set by Lite-Check) is 60 seconds. We generally recommend this setting not be changed. But, you may adjust it if needed by selecting the “Settings”...
  • Page 19 Lite-Check CERTIFIER 1200 Operations Manual Performing the 121 Timing Test, when attached to a trailer or dolly: PURPOSE: This test is used to verify that components of the trailer or dolly under test (air supply, hoses, fittings, glad-hands, brake cans, etc.) are in satisfactory condition to insure the tester's inherent set and release times complies with the maximum permissible times specified in FMVSS-121 for the specific type of vehicle being tested.
  • Page 20 Lite-Check CERTIFIER 1200 Operations Manual Performing the 121 Timing Test, when attached to a trailer or dolly (continued): 9. But if the 121 Timing test fails, the error will be shown which will identify the failure. The reason for the failure will be given, such as the speed at which portions of the test were completed, or for not selecting a valid sensor, etc.
  • Page 21 Lite-Check CERTIFIER 1200 Operations Manual Perform the SERVICE Brake Differential Pressure Test on a trailer or dolly: The Differential test only applies to vehicles equipped to tow other air brake vehicles, such as dollies, short semi-trailers (for doubles and triples) and B-train front semi-trailers. The test requirements are specified in FMVSS-121, Paragraph S5.3.5.
  • Page 22 1200 screen is between 100 and 105 psi. We recommend 102 psi. ► The CERTIFIER 1200 Tester is now ready to perform this test. 9. Verify or make the proper selections in the GUI to be able to run the Differential Test. First, in the “Trailer Information Panel”...
  • Page 23 6. Press the ABS 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 tablet. · Press ABS on the tablet keypad. · Press the SELECT once to charge the emergency line.
  • Page 24 Lite-Check CERTIFIER 1200 Operations Manual WHAT YOU WILL SEE ON THE 1200 CERTIFIER GUI SCREENS MAIN 1200 STARTUP SCREEN (General overview) Header Vehicle customer info Voltage and current status Select “Start” button desired tests to Activate Pressures available specific tests...
  • Page 25 ‘Controller” “Controller” Dropdown options: (Click on “Controller” to see this Controller status view.) Serial Number: The Serial Number of this Certifier 1200. Firmware Version: Level of the Firmware on the Controller Board. Input/Supply Sensor Status: Sensor status and air pressure before any changes are made by the Manifold.
  • Page 26 Lite-Check CERTIFIER 1200 Operations Manual SETUP TESTING: “Hub” dropdown Click on “Hub” to see the “Hub Status”. Hub status: NOTE: None of these are modifiable directly by the user. They are only status values reported by the Hub. HUB Connected: Indicates if the Hub is communicating with the 1200 Certifier.
  • Page 27 App will boot again to this screen, and the box will still be unchecked. Because a 3 failure would be extremely rare and unexpected, if that does happen, call Lite-Check Technical support at 1-800-343-8579 for assistance. — If the Update Firmware operation is successful, the 1200 Certifier will display a message indicating success, but again, just for a few seconds.
  • Page 28 Lite-Check CERTIFIER 1200 Operations Manual SETUP TESTING: “Settings” dropdown (Page 1 of 2) Click on Use the scroll Bar to ‘Settings” see more Setting lower to display down on this page. the data in the right side of this screenshot Click on “Unlock...
  • Page 29 Emergency Air Loss Threshold (PSI) Service Air Loss Threshold (PSI) Air Leak Test: Set your preferred values for testing. (Values originally set to logical defaults by Lite-Check.) Test Length (seconds) Default = 60. Allowable range = 10 - 600 seconds.
  • Page 30 Lite-Check CERTIFIER 1200 Operations Manual Running tests (page 1 of 3) Enter Info, select tests, start tests. Above, all tests have been selected and have started. Electrical tests will run first. Simple steps to have your 1200 run all the automatic tests, one right after the other: Connect the sensors and cables from the Hub to the differential kit and the external 50ci air tank.
  • Page 31 Lite-Check CERTIFIER 1200 Operations Manual Running Tests (page 2 of 3) Electrical Test in Progress Duration of the electrical test so far is 7 seconds. The electrical test of all circuits is in progress. The duration in time the test has run so far is 7 seconds.
  • Page 32 Lite-Check CERTIFIER 1200 Operations Manual Automatically Running Tests (page 3 of 3) Electrical done, Air Leak Started Summary bar has times of each test and the total time. Status of the currently running test. Electrical tests have completed, and the Air Leak test is in progress.
  • Page 33 Lite-Check CERTIFIER 1200 Operations Manual SENSOR SETUP FOR 121 TIMING TEST AND DIFFERENTIAL TEST After the Air Leak test passes, the “Setup Hub Sensors” popup is shown. Locate the Sensor in the list which is attached to the back of the trailer or dolly under test.
  • Page 34 Lite-Check CERTIFIER 1200 Operations Manual 121 TIMING TEST PASSED Green = Passed This snapshot shows the 121 Timing Test has passed. Values of all attached and selected sensors are displayed. Duration of the 121 Timing test is displayed. “Service Charge” and “Service Release” times are displayed.
  • Page 35 Lite-Check CERTIFIER 1200 Operations Manual Differential Test While Running Header Duration Snapshot Sensor Pressure Status Test Windows have Real-Time Results. Differential Pressure Test: ► Header bar - Additional options available in the drop downs. ► Duration snapshot values - Times of each previous test and the current Differential test are displayed.
  • Page 36 Lite-Check CERTIFIER 1200 Operations Manual PASSED DIFFERENTIAL TEST Test durations Pressure applied over the length of the test. Difference in the sensors as the test progressed This snapshot shows the Differential Test has passed. Air value supplied and the difference between the sensors in use are shown on 2 charts.
  • Page 37 Lite-Check CERTIFIER 1200 Operations Manual RESULTS of FAILED DIFFERENTIAL TEST The Air Leak test has passed, as indicated by the Green color in the Status bar at the top of the page. The Differential Test has failed and is marked in the Status bar at the top of the page.
  • Page 38 Lite-Check CERTIFIER 1200 Operations Manual This “Summary Page” is shown after the test(s) finish. Length of time for each test. Data from Data from “Customer “Trailer Information” Information in Settings. Panel” on the “Main 1200 Startup Screen” (on page 24).
  • Page 39 Lite-Check CERTIFIER 1200 Operations Manual APPENDIX 7-Way Wiring System, Pin Designations Vehicle-to-Vehicle Cable (ATA/SAE J-560b) Pin Circuit Tester Key Color Ground White Marker MARKER Black L. Turn LEFT Yellow Brake BRAKE R. Turn RIGHT Green Tail Lt. TAIL Brown ABS/Aux.

  • Page 40: Normal Power-Up Procedure

    ► Adjust the regulator on the outside of the left side of the 1200 Tester so the input pressure displayed on this screen is between 100 and 105 psi. We recommend 102 psi. ► The CERTIFIER 1200 Tester is now ready for use.