iPA SMART MUTT 9004A User manual

Innovative Products of America®Incorporated
888-786-7899 • 234 Tinker Street, Woodstock, NY 12498 • www.ipatools.com
Portable Unit for
Light-Duty Trailer Lights and Electric Brakes
OPERATOR’S MANUAL
Mobile Universal Trailer Tester
SMART MUTT®(7 Spade Pin)
#9004A

1
LETTER FROM THE PRESIDENT OF IPA®
My name is Peter Vinci and I am the president of IPA®. I would like to thank you for
your interest in IPA®’s product line and share my commitment to you, our products
and our policies. In today’s world, we have all experienced the lack of service and
consideration demonstrated by many companies after you buy their products. They
say whatever they can to make the sale, and then it’s like pulling teeth to get any
service response out of them. I know this myself rsthand and because of this, I
want to be sure that your experience with IPA®meets your expectations and that
IPA®never disappoints you with our service or customer response.
To prove my commitment to you, if for any reason, you are not happy with one of our
products – or more importantly, with the response from our customer service depart-
ment, or any member of the IPA®team – I invite you to contact me directly via my
email, [email protected] or call me at 888-786-7899. Your satisfaction is more im-
portant to me than the sale itself. We will not be in business for long if we don’t make
you completely happy with our products and service. I want IPA®to be different and
be known for its quality and service.
With that said, please take a look at our product line. You will see innovative rst time
products that were created to help you do your job faster and better than before.
I would also like to invite you to critique our products. If you can think of a better way
to make them or changes that will make them work better, please contact me directly
and I will be sure to look into it. If you have an innovation and would like some
feedback, give me a call.
From all of us at IPA®, we thank you for taking the time to review our product line and
wish you and your family the very best of everything.
Peter Vinci
President
IPA®
www.ipatools.com
Toll Free: 888-786-7899
Phone: [phone]
Fax: [phone]

2
TABLE OF CONTENTS
PART 1: IMPORTANT SAFETY INSTRUCTIONS 3
PART 2: WHAT’S INCLUDED 6
PART 3: CONTROLS AND PANELS 7
PART 4: SET-UP 8
4.1 Choosing a Battery 8
PART 5: PRETESTING CHECKLIST 9
PART 6: GENERAL CONTROLS & OPERATIONS 10
6.1 Initial Startup and Shutdown 10
6.2 Auto Shutdown Feature 10
6.3 Using the 3-Button Remote Control 11
PART 7: ELECTRICAL/LIGHTING TESTING 12
7.1 Selecting a Circuit 12
Auto-Cycle Mode 12
7.2 Ground Integrity Test 13
7.3 Fault Indication 13
Open Circuit 13
Crossed Circuits 14
Short/Overloaded Circuit 14
7.4 Activating Hazard Lights 15
7.5 All Circuits On (Override) Mode 15
7.6 Electric Brake Testing 16
PART 8: TYPICAL TRAILER WIRING 17
PART 9: MAINTENANCE AND STORAGE 17
PART 10: OPTIONAL ACCESSORIES AND
RELATED PRODUCTS 18

3
PART 1: IMPORTANT SAFETY INSTRUCTIONS
IT IS IMPORTANT TO READ, UNDERSTAND AND FOLLOW ALL SAFETY
MESSAGES AND INSTRUCTIONS PRINTED IN THIS MANUAL AND ON THE
EQUIPMENT BEFORE OPERATING. IF SAFETY INFORMATION IS NOT HEEDED,
SERIOUS INJURY OR DEATH TO THE OPERATOR OR BYSTANDERS MAY OCCUR.
DANGER
Indicates a hazardous situation, if not avoided, will result in death or serious injury.
The possible hazards are shown in the adjoining symbols or explained in the text.
WARNING
Indicates a hazardous situation, if not avoided, could result in death or serious injury.
The possible hazards are shown in the adjoining symbols or explained in the text.
CAUTION
Indicates a hazardous situation, if not avoided, may result in minor or major injury.
The possible hazards are shown in the adjoining symbols or explained in the text.
THE FOLLOWING SAFETY ALERT SYMBOLS ARE USED IN THIS MANUAL.
SYMBOL 1: Potential burn hazard. Sparks from electrical shorts can ignite
ammable liquids such as fuel or oil. Heat from electrical overloads can cause re
hazards.
SYMBOL 2: Potential electrical hazard. Batteries have enough electrical energy
potential to ignite ammable liquids such as fuel or oil. Wire overloads can cause
electrical failures. Shock hazard exists.
SYMBOL 3: Potential explosive air hazard. Pneumatic pressures used with this
equipment can cause explosive failures on damaged equipment.
SYMBOL 4: Potential eye hazard. Wear OSHA approved safety glasses. Battery
acid and high air pressures create hazardous situations for eyes.
SYMBOL 5: Potential chemical burn hazard. Wear protective gloves. Battery acid
is corrosive and can cause skin damage.
SYMBOL 6: Potential electrical hazard. Electrical energy can cause heat and
burn hazards.
SYMBOL 7: Potential re hazard. Use caution with ammable liquids such as fuel
and oil. Electrical shorts can ignite ammable liquids and wiring.
SYMBOL 8: Important information is stated.

4
BATTERY GASES, TESTER PREPARATION
AND TESTER/CHARGER LOCATION
RISK OF EXPLOSION
• Gases produced by a battery are highly explosive.
• Wear safety goggles and protective clothing, both
users and bystanders.
• Use in an area having at least four air changes per hour.
• Read, understand and follow all instructions for charger, battery, vehicle and any
equipment used near battery and charger.
• Do not smoke, strike a match, place metal tools on battery or cause a spark in
the vicinity of the battery. When removing battery cables, remove the ground
cable rst.
• Clean terminals before charging battery. During cleaning, keep corrosive particles
from eyes, nose and mouth. Use baking soda and water to neutralize acid and
help eliminate airborne corrosion.
• Never allow clamps on charger cables to touch each other.
• Do not expose tester or charger to rain, snow or wet conditions.
• Do not allow battery gases or acid to contact MUTT®cabinet. Do not place
charger directly above or below battery.
• Fill battery to level specied by battery manufacturer using distilled water.
• Do not remove cell caps while charging per manufacturer’s instructions.
• Make sure tester cable clamps make tight connections.
• Battery explosion can cause injury.

5
GENERAL CHARGER USE
RISK OF ELECTRIC SHOCK AND FIRE
• Before connecting charger to unit, make sure
controls are set to OFF.
• Do not remove or bypass the grounding pin.
• Do not operate charger with damaged cord or plug.
Replace cord or plug immediately if damage occurs.
• Position power cord and charger cables away from the hood, doors and hot or
moving engine parts where they could be damaged.
• Unplug power cord by grasping and pulling on the plug, rather than the cord
when disconnecting charger from outlet.
• Charger power cord uses equipment-grounding conductor and a grounding plug.
Plug only into a 120V AC outlet that is correctly installed and grounded in
accordance with all ordinances and local codes.
• Unplug power cord from outlet before cleaning or maintaining tester and charger.
Turning off controls does not reduce the risk of electric shock.
• Do not operate charger after a sharp impact, drop or any other damage. Do not
disassemble charger.
• Use only recommended attachments.
• Do not charge a frozen battery.
• Do not overcharge a battery.
• Use charger only on lead-acid automotive batteries. Do not use charger for
charging dry cell batteries.
• Electric shock or re can cause injury.
RISK OF ENTANGLEMENT
• Keep yourself, clothing and battery charger leads clear of moving parts such as
fan blades, pulleys, hood and doors.
• Moving parts can cause injury.
RISK OF BURNS
• Batteries can produce short circuit current high enough to weld jewelry such
as rings, bracelets and watches. You must remove them before working near
batteries.
• Short circuits can cause injury.
DO NOT
Plug Directly Into
AC Wall Outlet

6
PART 2: WHAT’S INCLUDED
Use the Provided Reference Numbers When
Ordering Products and Parts Above
Toll Free: 888-786-7899
INCLUDED PARTS AND ACCESSORIES:
AUTO
CYCLE VOLTAGE INDICATOR
Trailer Pin
Selection LED
4 Pin
Mode
5 Pin
Mode
6 Pin
Mode
7 Pin
Mode
T
o
S
e
t
P
i
n
M
o
d
e
ELECTRIC
BRAKE
BACK-UP
LIGHTS
GROUND
INTEGRITY
12V/
AUX
RIGHT
TURN
LEFT
TURN
TAIL
LIGHTS
BRAKE
LIGHTS
PIN CONFIGURATIONS
7-WAY SPADE PLUG
TRAILER END
4/5 PIN PLUG
TRAILER END
6 ROUND PLUG
TRAILER END
BACK-UP
LIGHTS
(BU)
ELECTRIC
BRAKE (BK)
ELECTRIC
BRAKE
ELECTRIC
BRAKE (EB)
TAIL LIGHTS
(TM)
TAIL
LIGHTS
(TM)
TAIL
LIGHTS
GROUND
GROUND
GROUND
(GD)
RIGHT
TURN/
BRAKE
(RT)
RIGHT
TURN/
BRAKE
LEFT
TURN/
BRAKE
RIGHT
TURN/
BRAKE (RT)
LEFT
TURN/
BRAKE
(LT)
LEFT
TURN/
BRAKE (LT)
12VOLT
(12V)
12VOLT
(12V)
10 20 300
3-BUTTON REMOTE
CONTROL FOB (Qty. 1 Included)
#MUT-RM3-9004A
3-WAY TRAILER ADAPTER
#8000
500mA BATTERY CHARGER
#CHR0001

PART 3: CONTROLS AND PANELS
An overview of the MUTT®’s controls, inputs, outputs and their functions.
A. BACKLIT 30 AMP AMMETER
Meter shows current draw of a selected circuit up to 30 amps.
B. TROUBLE WARNING INDICATORS
Flashing red LEDs indicate problems that may exist in a selected circuit. This includes
the Overload Indicator, Open Circuit Indicator, and Reversed (Battery) Polarity Indicator.
C. POWER SOURCE SWITCH
Select between Power On or Power Off.
D. 12V DC BATTERY TRICKLE CHARGER INPUT (CIGARETTE SOCKET)
For connecting the trickle charger to the MUTT�®s internal battery (battery not included).
E. AUTO CYCLE INDICATOR
Illuminates when Auto Cycle Mode is engaged.
F. VOLTAGE INDICATOR
Shows supplied battery voltage integrity. Operating Voltage Range: 12/24 volt DC.
G. GROUND INTEGRITY
A large green LED above the control knob indicates ground status. Ground
integrity is automatically veried when power is turned on.
H. CONTROL KNOB
Knob activates all electrical test modes and circuits to be diagnosed.
I. CIRCUIT INDICATORS
The small green LEDs illuminate or blink in testing phases.
K. 30 AMP FUSE SOCKET
Overload protection.
L. 7 WAY FLAT/SPADE SOCKET
A receptacle used to connect your 7 Spade Pin Trailer to the MUTT®to test elec-
trical circuits.
7
L
AUTO
CYCLE VOLTAGE INDICATOR
Trailer Pin
Selection LED
4 Pin
Mode
5 Pin
Mode
6 Pin
Mode
7 Pin
Mode
T
o
S
e
t
P
i
n
M
o
d
e
ELECTRIC
BRAKE
BACK-UP
LIGHTS
GROUND
INTEGRITY
12V/
AUX
RIGHT
TURN
LEFT
TURN
TAIL
LIGHTS
BRAKE
LIGHTS
PIN CONFIGURATIONS
7-WAY SPADE PLUG
TRAILER END
4/5 PIN PLUG
TRAILER END
6 ROUND PLUG
TRAILER END
BACK-UP
LIGHTS
(BU)
ELECTRIC
BRAKE (BK)
ELECTRIC
BRAKE
ELECTRIC
BRAKE (EB)
TAIL LIGHTS
(TM)
TAIL
LIGHTS
(TM)
TAIL
LIGHTS
GROUND
GROUND
GROUND
(GD)
RIGHT
TURN/
BRAKE
(RT)
RIGHT
TURN/
BRAKE
LEFT
TURN/
BRAKE
RIGHT
TURN/
BRAKE (RT)
LEFT
TURN/
BRAKE
(LT)
LEFT
TURN/
BRAKE (LT)
12VOLT
(12V)
12VOLT
(12V) 10 20 300
Electrical Control Panel
E
G
H
F
A
B
C
DI
KRight Side

8
PART 4: SET-UP
4.1 CHOOSING A BATTERY
(Manufacturer’s Suggested Replacement: YUASA #YTX14 or Group 14 Equivalent)
• Battery Voltage: 12/24V DC
• Battery Type: Lead-Acid
• Battery Compartment Dimensions: 5 7/8" L x 5 3/4" H x 3 3/8" W
• Battery Protection: In-line 30 amp Fuse for Overcharge
INSTALLING AN INTERNAL BATTERY
1. Remove the four 8/32" x 1/4" Phillips head screws in
the back of the MUTT®.
2. Slide out the battery tray.
3. Place the battery onto the tray with the battery terminals facing the front of the
unit. Attach the ring terminal on the red wire to the positive side of the battery and
tighten securely.
4. Cover positive terminal with the red boot.
5. Attach the ring terminal of the black wire to the negative battery terminal.
6. Carefully slide the tray into the tester. Use caution – DO NOT ALLOW the positive
battery terminal to contact the unit.
7. Reinstall screws to secure.
DO NOT
Use 24 Volts on a Trailer
Wired for 12 Volts!

9
PART 5: PRETESTING CHECKLIST
The pretesting checklist should always be completed prior to using the MUTT®
UNIT PLACEMENT
• Place the tester on a at, level surface.
MAINTAIN CONNECTORS
Dielectric grease should be used on all connections to avoid corrosion. If a bad
connection exists at the terminal junction, you may get an erroneous reading and the
MUTT®will not work properly.
• Make sure you have a solid connection in the socket.
• Be certain the 7 pins in each plug are clean and spread to the proper size.
• Always check the MUTT®connector pins at the side of the MUTT®for proper
expansion. Over time, the pins may bend in slightly resulting in a poor connection
between the connector and the cable ends. A at head screwdriver can be used
to expand the pins until a tight connection is made.
TRAILER CONFIGURATION SET-UP
The 9004A Smart MUTT®is a microprocessor controlled
diagnostic trailer tester specically designed for testing
lights and electric brakes on trailers with 4, 5, 6 round pin
and 7 spade pin type connections. Every time you power
up the tester, the internal computer wants to know which
type of trailer connection you are testing. Note, this phase
is known as Trailer Conguration Set-Up and is indicated by a high speed icker-
ing of the LEDs surrounding the control knob. If left untouched after 15 seconds,
the tester will always default to a 7 spade pin conguration. However, if the user is
testing a 4, 5 or 6 round pin type trailer connection, this setting can be adjusted by
rotating the control knob counterclockwise to select the desired number of circuits
(as noted on the face panel). Trailer Conguration Set-Up is repeated each time the
unit is powered up.
Testing 4, 5 and 6 Round Pin Type Trailer Connections
The 9004A is hard wired to a 7 spade pin connector, located on the side of the tester.
Each unit is supplied with a plug-in adapter, which will adapt the 9004A to 4, 5 and
6 round pin type connections. To test trailers with these types of connections, the
adapter must be plugged in line between the tester and the trailer. The instructions
above for Trailer Conguration Set-Up should be used for more efcient and accu-
rate testing.
Call 888-786-7899 with any technical questions.