NEHS1270 TesLite and LoadProCables {0374, 0599, 0709, 0734} Caterpillar

Caterpillar Products

All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

European Union Compliant, CE marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by a “Safety Alert Symbol” followed by a “Signal Word” such as “DANGER”,“WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that can cause product damage are identified by "NOTICE" labels on the product and in this publication.

Literature Information

Store this manual with the tool group.

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, extra tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Service Parts Section

The Service Parts Section describes tooling replacement parts and part number availability.

General Information Section

Introduction

These voltmeter leads were manufactured by two different suppliers. The older leads are yellow and are manufactured by TesLite. The newer leads are red and manufactured by LoadPro. The two manufacturers use different load resistors therefore the tables have different values. The part number for each manufacturer is the same (275-9936).

Using the TesLite Voltmeter Leads with your Digital Voltmeter

Note: This is not a special tool. This is a set of normal Voltmeter leads that have a special function of locating corrosion in wiring. Remove your normal voltmeter leads and install these. The TesLite Voltmeter Leads work with any digital voltmeter with standard banana plugs.

Basic TesLite Operation

1. Read voltage like you normally do.

2. Push button

3. Read voltage again.

4. Did voltage drop? If yes, there is a problem in the wire.

5. If the voltage did not drop, the wire is clean.

6. See page 5 for specific resistances.

Testing for Corrosion in the Positive

Illustration 2	g06057233

1. Use the positive Teslite® Probe in the Red side of the circuit.

2. Use the Tesliteleads just like a test light - black to ground, and test with theTeslite probe.

3. Break the circuit at connectors as needed to test each segment.

4. Depress the Teslite button with each voltage test.

5. Any drop in voltage indicates a problem in the circuit.

TesliteVoltmeter Leads are a powered test light. If you are looking for a corrosion problem in positive, clip the black lead to ground and check the positive wires with the Teslite probe. If you are looking for a ground problem, clip the Teslite probe to a clean voltage source and check the ground connections and wires with the black probe.

Testing for Corrosion in the Negative

Illustration 3	g06057242

Note: Attach the Teslite Probe to a clean voltage supply.

1. Use the Teslite leads just like a powered test light. Connect the Teslite probe to a clean voltage supply.

2. Use the black probe in the ground circuit to check for a bad ground. Break the circuit as needed to test each segment.

3. Depress the Teslite button with each voltage test.

4. A constant voltage means that the ground is clean.

5. A drop in voltage means that the ground is corroded.

Use the RED lead in the RED side (positive) and the BLACK lead in the BLACK (negative) side. Using the Teslite Probe in ground wires does not work.

Best Test for Determining if you have Circuit Corrosion (Resistance - Ω)

1. Remove the load component from the circuit.

2. Insert both the Teslite probe and the negative probe into the connector.

3. Read the voltage according to the manufacturer instructions.

4. Depress the Teslite probe button (max 5 - 8 sec).

5. If the system voltage remains, the circuit is clean.

6. If the voltage drops, there is corrosion.

7. Move the black probe to a clean machine ground and repeat the test.

8. If the repeat test voltage drops, the corrosion is in the positive.

9. If the drop goes away, the corrosion is in the ground.

Illustration 4	g06057263

SteadyPin™System shown above.

Illustration 5	g06057275

Illustration 6	g06059398

Troubleshooting Guide

Warranty

Limited lifetime warranty. If your Teslite leads fail from manufacturer defect, ship to Brighter Ideas, LLC for inspection and replacement. Leads that have been damaged in use cannot be replaced under warranty.

General Information

Teslite Voltmeter leads are designed to replace the load in an electrical circuit so a load test (voltage drop test) can be made with the component removed. This is the best way to make the initial test.

The normal drop in a clean circuit varies, and you will need to develop a sense of how much drop constitutes a fault. A drop of 0.5V in a 12V system is an effective resistance of 5Ω.

Things to Consider

The digital VOLTmeter function in the multimeter is the best diagnostic tool you can use. The system voltage is more powerful than the 3V that the ohmmeter supplies. Testing with voltage drop is more accurate and easier.

Do not use the Teslite Probe (positive) in the negative side of the circuit. You may inadvertently operate a component switched in ground.

Testing your Teslite Leads

Install your Teslite Leads into your digital meter, and set the meter to measure Ohms (Ω). Do not touch leads together. Depress the Teslite button. Your meter should read 95Ω - 105Ω. If the reading is outside of this range, or reads 0Ω or 0LΩ, your Teslite leads are not working. Contact Cat Dealer Service Tools for warranty replacement.

Warnings and Cautions

1. Primarily designed as a replacement for the component.

2. Do not use the Teslite Probe (positive) in the negative side of the circuit. You may inadvertently operate a component switched in ground. Know where you are.

3. Use on 28.5V (DC or AC) only. Maximum 5 - 8 seconds per test.

4. Not for computer (ECM) INPUT circuits. This tool has been tested successfully and will test computer (ECM) sensor driver circuits (B+ and Gnd/Return).

5. Not designed for high-voltage circuits.

6. Do not use positive TesLite probe in the negative side of the circuit. Use the BLACK lead on ground with Teslite probe energized (powered "test light" mode).

7. Use only with Digital Voltmeter

8. Teslite will not function with AMMETER or OHMMETER.

How to Calculate TesLite Amp Draw

1. Measure your TesLite voltage.

2. Divide by 100. This is the mA draw.

3. Example - 5VDC divided by 100 = 50mA

How to Calculate Actual Circuit Resistance (See "Advanced Testing")

1. Measure the actual system voltage.

2. Measure TesLite

3. Divide TesLite Voltage by 100. This is the TesLite Amperage.

4. Subtract voltage 2 from voltage 1. This is the corrosion voltage drop.

5. Divide corrosion voltage drop by TesLite Amperage. This is the corrosion resistance (Ω) V divided by A equals Ω.

6. Multiply the corrosion resistance Ω by your normal circuit amperage. This is the actual voltage drop.

Your Ω(Corrosion) for Your System Voltages TesLite

Teslite Voltage is read with Teslite button depressed.

Teslite Process Notes

There are only 3 faults that can occur in a single wire; Open, Short-to-ground, and High Resistance.

1. Do you read system voltage with both probes in the load connector? If you do, then you cannot have an OPEN or SHORT-TO-GROUND.

2. If you do read system voltage, push the Teslite button. Does the voltage drop? If yes, you have corrosion. If no, then the wire is clean.

3. If the voltage drops, move the black probe to a clean ground. Repeat the test. If the voltage stays up, corrosion in ground. If the voltage drops again, corrosion in positive.

4. If you read GHOST voltage, you have an OPEN. Move the black lead to a clean ground. If the voltage rises, the OPEN is negative. If the GHOST Voltage remains, then the OPEN is in the positive.

5. If you read TRUE ZERO voltage (0.000V), you have SHORT-TO-GROUND.

Using LOADpro Dynamic Meter Leads with your Digital Voltmeter

This is not a special tool. This is a set of normal VoltMeter leads that have a function of locating high resistance in wiring by applying a 40mA/V dynamic load with every voltage test. Remove your normal voltmeter leads and install these. The Loadpro works with any digital voltmeter with standard banana plugs.

General Information

Loadpro Voltmeter Leads are designed to replace the load in an electrical circuit so a load test (voltage drop test) can be made with the component removed. This is the best way to make the initial test.

The normal drop in a clean circuit varies, and you will need to develop a sense of how much drop constitutes a fault. A drop of 0.5V in a 12V system is an effective resistance of 5Ω.

Things to Consider

The digital Voltmeter function in the multimeter is the best diagnostic tool you can use. The system voltage is more powerful than the 3V that the ohmmeter supplies. Testing with voltage drop is more accurate and easier.

Do not use the Loadpro Probe (positive) in the negative side of the circuit. You may inadvertently operate a component switched in ground.

Testing your LoadPro Leads

Install your Loadpro Leads into your digital meter, and set the meter to measure Ohms Ω. Do not touch the leads together. Depress the Loadpro button. Your meter should read approximately 25Ω. If the reading is outside of this range, or reads 0Ω, or 0LΩ, your Loadpro Leads are not working. Contact a reputable dealer for warranty service.

Notice

1. The Loadpro is primarily designed as a replacement for the component.

2. Do not use the Loadpro Probe (positive) in the negative side of the circuit. You may inadvertently operate a component switched in ground. Know where you are.

3. Use up to 28.5V (DC or AC) only. Maximum 5 - 8 seconds per test. Prolonged use may overheat or damage the Loadpro.

4. The Loadpro is not for computer (ECM) INPUT circuits. This tool has been tested successfully and will test computer ( ECM) sensor driver circuits (B+ and Gnd/Return).

5. The Loadpro is not designed for high-voltage circuits.

6. Do not use positive Loadpro Probe (positive) in the negative side of the circuit. Use the BLACK lead on ground with Loadpro probe energized (powered "test light" mode).

7. Use only with the Digital Voltmeter.

8. Loadpro will not function with AMMETER or OHMMETER.

How to Calculate Loadpro Amp Draw

1. Measure the Loadpro voltage.

2. Divide by 100. This is the mA draw.

3. Example: 5VDC ÷ 100 = 50mA

How to Calculate the Actual Circuit Resistance (Refer to section on Advanced Testing)

1. Measure the actual system voltage.

2. Measure the Loadpro voltage.

3. Divide the Loadpro Voltage by 100. This is the Loadpro Amperage.

4. Subtract voltage 2 from voltage 1. This is the resistance voltage drop by Loadpro Amperage. This is the resistance voltage drop.

5. Divide resistance voltage drop byLoadpro Amperage. This is the circuit resistance Ω. V ÷A=Ω

6. Multiply the circuit resistance Ω by the normal circuit amperage. This is the actual voltage drop.

Basic System Test Procedure

There are only 3 faults that can occur in a single wire: Open, Short-to-ground, and High resistance.

Show/hide table

Illustration 7	g06084310

1. Disconnect the load component (light bulb, etc.) from the wiring harness.

2. Insert both the Loadpro probe and the negative probe into the wiring harness connector. Refer to the diagram below for polarity.

3. Read system voltage and compare to manufacturer specifications. Zero (0.000) volts is a Short-to-ground in the positive circuit. GHOST voltage is an open circuit in either the positive or the negative circuit. To determine if the OPEN is on the positive or negative circuit, move the black lead to a known good ground. If the voltage rises to manufacturer specifications, the OPEN is in the ground side of the circuit. If the GHOST voltage remains, then the OPEN is in the positive side. SYSTEM voltage, the circuit is complete, but may have HIGH RESISTANCE.

4. To test for high resistance in the positive or negative circuit, depress Loadpro probe button (maximum of 5 to 8 seconds). If the system voltage does not change or drops very little, the wiring is good. If the voltage drops, there is HIGH RESISTANCE in the wiring circuit.

5. To determine if the HIGH RESISTANCE is on the positive or negative circuit, move the black probe to a known good ground and repeat step #4. If the voltage drops, then the resistance is in the positive side of the circuit. If system voltage is present, then the resistance is in the ground side of the circuit.

   Note: Ghost Voltage. When the DMM is set to the lowest DC Millivolts scale, the reading appears to float around and shows random readings. This happens because the test circuit is "open" Touch the test probes together and the DMM reading will ZERO itself. When you touch the DMM test probes together, you have "closed" the test circuit. Using this characteristic of DMM can help you to find open circuits.

Testing for Resistance in the Positive

Show/hide table

Illustration 8	g06084320

1. Use the positive Loadpro Probe in the RED side of the circuit.

2. Use the Loadpro Leads just like a test light - black to ground, and test with the Loadpro Probe.

3. Break the circuit at the connectors as needed to test each segment.

4. Depress the Loadpro button with each voltage test.

5. Any drop in voltage indicates a problem (high resistance in the circuit).

Note: Think of the Loadpro Voltmeter Leads as a "powered test light". If you are looking for a big resistance problem (corrosion) in positive, clip the black lead to ground and check the positive wires with the Loadpro probe. If you are looking for a ground problem, clip the Loadpro probe to a clean voltage source, and check the ground connections and wires with the black probe.

Testing for Resistance in the Negative

Show/hide table

Illustration 9	g06084329

1. Use the Loadpro Leads just like a powered test light. Connect the Loadpro probe to a clean voltage supply.

2. Use the black probe in the ground circuit to check for a "bad ground". Break the circuit as needed to test each segment.

3. Depress the Loadpro button with each voltage test.

4. A constant voltage means that the ground is clean.

5. A drop in voltage means that the ground has high resistance (corrosion).

Use the RED lead in the RED side (positive) and the BLACK lead in the BLACK (negative) side.

Using the Loadpro Probe (positive) in ground wires does not work.

Attach the Loadpro Probe to a clean voltage supply.

Ω(Corrosion) for System Voltages

Loadpro Voltage is read with the Loadpro button depressed.

Warranty Information

This product is warranted to be free from defects for one year. If this product fails during the first 12 months due to faulty materials or workmanship, it will be repaired or replaced free of charge, at the discretion of the manufacturer.

For warranty and service coverage, return this product to your dealer for processing and evaluation, or return it directly to:

Defective units being returned to your dealer or to the factory should include proof of purchase date.

Any testers that do not function due to misuse or abuse will be subject to "out of warranty" service charges.