Lite-Check INSPECTOR 920 User manual

INSPECTOR MODEL 920
OPERATIONS MANUAL
LITE-CHECK VEHICLE TESTER
FOR
AIR BRAKES, ELECTRICAL AND ABS
REV 2.0.3 – September 4, 2013

LITE-CHECK INSPECTOR 920
Page 2 of 36
Revision History:
Name Date Changes Version #
Gene Ambacher July 31, 2013 Initial Draft 2.0.3
Gene Ambacher September 4, 2013 Final Draft 2.0.3b

LITE-CHECK INSPECTOR 920
Page: 3 of 36
Cautions
Block vehicle wheels from movement before releasing brakes
The antenna must be fully exposed for a clear radio signal
Do not arc weld while the tester is connected to the trailor. The tester is
grounded to the chassis and will be damaged.
Do not hook up electrical devices on the same trailer that the tester is
diagnosing. The tester needs a clean power supply.
Do not lengthen existing power cord on the tester. Attach the tester
power cord directly to a 12-volt battery or a regulated power supply.
Lengthening the power cord will cause a power drop.
Be aware of voltage spikes. The tester will only operate on regulated
power. Use a 12-volt battery or LITE-CHECK 311R Regulated Power
Supply.
Using a battery charger or power converter as a power source will
damage the tester. Do not charge a battery when the battery is
connected to the tester.
The tester will not operate efficiently
below 10.5 volts and will indicate “LOW
BATTERY” (LOW BAT) 
The tester may shut down below 9.0
volts
If operating gasoline motors near the tester, be sure that they have
static suppression on the engine. Static can cause radio interference.
The emergency air must be applied before the service brakes will
operate. This prevents brake compounding.

LITE-CHECK INSPECTOR 920
Page 4 of 36
Table of Contents
Cautions.........................................................................................................................3
Table of Contents..........................................................................................................4
Introduction ...................................................................................................................7
Summary.....................................................................................................................7
Key Features of the Inspector 920...............................................................................8
Overview........................................................................................................................9
INSPECTOR 920 Component Identification................................................................9
Keyboard Layout........................................................................................................10
Equipment and Setup .................................................................................................11
What is included with the LITE-CHECK INSPECTOR 920?......................................12
Required Materials.....................................................................................................12
LITE-CHECK INSPECTOR 920 Accessories ............................................................12
Set-Up Procedures....................................................................................................13
Reminders.................................................................................................................14
Operations ...................................................................................................................14
Reading the Digital Display........................................................................................14
7-Way Pin Numbers and Circuits...............................................................................16
Remote Control ...........................................................................................................16
Operation...................................................................................................................16
Power Supply ..............................................................................................................17
Power Supply Set Up:................................................................................................17
Low Battery Messages ..............................................................................................17
7-Way Cable Test.........................................................................................................18
Trailer Test Procedures..............................................................................................18
Air Brake Testing.........................................................................................................19
Inspecting for Trailer Electrical Faults......................................................................20

LITE-CHECK INSPECTOR 920
Page: 5 of 36
Overview....................................................................................................................20
Electrical Testing .......................................................................................................20
Circuit Condition Messages.......................................................................................21
ABS Test Procedures..................................................................................................22
Initial Setup and Configuration...................................................................................22
Trailer ABS Power Supply Requirements..................................................................22
ABS Operation...........................................................................................................23
Main Menu.................................................................................................................24
Viewing Active Faults.................................................................................................24
Viewing Stored Faults................................................................................................25
Clearing Active and Stored Faults .............................................................................25
Mileage......................................................................................................................25
ECU Voltage..............................................................................................................25
Manufacturer’s Configuration.....................................................................................26
Serial Number............................................................................................................26
Special Functions ......................................................................................................26
Getting Help...............................................................................................................26
ABS Fault Identification and Troubleshooting............................................................27
Tractor Testing............................................................................................................27
Electrical Output Test ................................................................................................28
Battery/Alternator Test...............................................................................................28
Air Output Test ..........................................................................................................28
Appendix......................................................................................................................29
ABS Button Codes.....................................................................................................29
Definition of Terms.....................................................................................................32
Accessories...............................................................................................................33

LITE-CHECK INSPECTOR 920
Page 6 of 36
Warranty, Contact and Service Information..............................................................34
Shipping LITE-CHECK Products................................................................................34
Index.............................................................................................................................35

LITE-CHECK INSPECTOR 920
Page: 7 of 36
LITE-CHECK INSPECTOR 920
Diagnostic Tester
Introduction
Summary
The LITE-CHECK INSPECTOR 920 Diagnostic Test system will perform vital
diagnostics of electrical and air systems on both tractors and trailers. The INSPECTOR
software puts trailer ABS inspection, fault identification and troubleshooting support at
the fingertips of inspectors and mechanics. The LITE-CHECK INSPECTOR 920
provides your facility with an efficient tool for safety assurance and maintenance of your
heavy-duty fleet.

LITE-CHECK INSPECTOR 920
Page 8 of 36
Key Features of the Inspector 920
Remote control operation of electrical and air systems
Dynamic monitoring of electrical faults
Microprocessor-driven simultaneous monitoring of all 7-way circuits
allows direct identification of circuit conditions including: shorts,
opens, open grounds, and chassis shorts
Digital display provides fault information at the tester. Unique audible
alarms assist in troubleshooting, and repair activities at various
locations around the trailer and tractor
Regulated “Service Air” for consistent brake application and inspection
Performs one-step, air-systems leak test with built-in 60 second timer
Automatic cable test
“One-Button ABS” feature with direct access to faults present in ABS
controllers
Built-in guidance for ABS fault resolution

LITE-CHECK INSPECTOR 920
Page: 9 of 36
Overview
INSPECTOR 920 Component Identification
The LITE-CHECK INSPECTOR 920 has the following components.
Item Description
RC Antenna Antenna for use with remote control
Digital Display Displays messages on tester status and results
(see below)
Service Air Pressure Gauge Indicates service air pressure in PSI
Emergency Air Pressure Gauge Indicates emergency air pressure in PSI
Keyboard See section (below) on individual buttons
Alarm Speaker Speaker sounds different alarms for any test failure
Emergency Air Connector Port for connecting emergency air to the tester. 1/4”
air line with glad hand on one end needed.
Service Air Connector Port for connecting Service air to the tester. 1/4” air
line with glad hand on one end needed.

LITE-CHECK INSPECTOR 920
Page 10 of 36
Item Description
7-Way Cable Socket Cable socket for 7-way cable
7-Way Cable Socket (for testing) Cable socket for 7-way cable. (Used for cable
testing)
Keyboard Layout
The chart below provides a brief description of each button on the keyboard panel and
on the remote control.
Graphic Panel Button Remote Button Function
EMER.
EMER. EMER. Operates emergency air
SERVICE SERVICE Operates service air (if emergency Is
pressurized)
AIR LEAK
TEST AIR LEAK TEST Blocks air source for vehicle air leak test
BRAKE
BRAKE BRAKE Operates brake electrical circuit
MARKER MARKER Operates marker (clearance) circuit
AUXIL
AUXIL AUXIL Operates auxiliary circuit (ABS power)
LEFT LEFT Operates left turn circuit
TAIL TAIL Operates tail circuit

LITE-CHECK INSPECTOR 920
Page: 11 of 36
Graphic Panel Button Remote Button Function
RIGHT RIGHT Operates right turn circuit

ABS
BACK ABS BACK ABS Test – Initiates the ABS test routine (30
to 45 seconds). Pressing the ABS (BACK)
button at other times will display the
previous screen.
SELECT*
HELP SELECT*
HELP ABS select – Enter on selected option, or
view on screen
DOWN DOWN Move display cursor down
UP UP Move display cursor up
AUTO
CIRCUIT
TEST
N/A No longer supported
ALARM
MUTE N/A Turns alarm off during electrical test
TRACTOR
OUTPUT/
CABLE
TEST
N/A Tractor output test /Cable Test
*SELECT details: Diagnostic testers such as the INSPECTOR 920 and other
members of the LITE-CHECK family of automatic testers activate a
single circuit at a time and monitor the activity on all of the circuits
to provide computer assisted fault identification. Multiple circuits
can be activated at the same time by using the “SELECT” button on
the tester or the remote control unit. In this mode, multiple circuits
can be switched on and off, with the tester’s computer display
indicating the total current draw of all of the circuits. Press the
“SELECT” button to leave this mode.
Equipment and Setup
The LITE-CHECK Inspector 920 diagnostic tester is designed for easy operation and
setup. Some additional items are required to fully utilize all of the 920’s functions.

LITE-CHECK INSPECTOR 920
Page 12 of 36
What is included with the LITE-CHECK INSPECTOR 920?
The INSPECTOR 920 ships with the following items:
1 – LITE-CHECK INSPECTOR 920
1 – This Operations Manual
1 – Quick Reference Guide
1 – Antenna
1 – Remote Control
1 – Plastic Cover
1 – Orange Neck Pouch
Please inspect the shipment when it arrives for any missing or damaged items.
Required Materials
The following additional materials are required to operate the INSPECTOR 920:
1 – 7-way cable with 7-way plugs on both ends
2 – 1/4” air lines with glad-hands on one end
2 – Quick disconnect air connectors (male and female for tester and air lines)
1 – Filtered air regulator to provide clean 110-120psi air pressure
Note: the above Items are available in the LITE-CHECK 302A Shop Accessory
Kit (see LITE-CHECK INSPECTOR 920 Accessories below)
1 – Power supply (either a charged 12-volt battery OR a regulated power supply
(such as the LITE-CHECK 311R 12VDC Regulated Power Supply))
Warning: Power to the tester must be regulated to protect the trailer’s ABS
electronics and ensure consistent tester performance.
Mounting location or plate to secure the tester
Warning: The LITE-CHECK INSPECTOR 920 is a “diagnostic” tester that monitors the
current flow through the ground circuit to aid in identifying various fault conditions. Care
should be taken to insure that the tester’s case is not grounded to the trailer or tractor
under test. The 920 should not be supplied with power from the tractor under test when
testing and inspecting tractor/trailer combinations.
LITE-CHECK INSPECTOR 920 Accessories
Besides the items above, the following LITE-CHECK items are available to enhance the
INSPECTOR 920:

LITE-CHECK INSPECTOR 920
Page: 13 of 36
LITE-CHECK 311R 12VDC Regulated Power Supply
330A Pedal Actuator
301m Service Truck Kit
oKit Includes
2 – 20ft Air Lines
1 – 20ft 7-Way Cable With 7-Way Plugs On Both Ends
Air filter regulator for the service truck
302A Shop Accessory Kit
oKit Includes:
2 – 8ft Air Lines
1 – 8ft 7-Way Cable With 7-Way Plugs On Both Ends
1 – Filtered Air Regulator
Model 300k Shop Kit –
oKit Includes:
1 – Knock Down 4-Wheeled Cart with Air Lines
1 – 8ft 7-Way Cable With 7-Way Plugs On Both Ends
2 – 8ft Air Lines
1 – Filtered Air Regulator
Necessary hardware for an easy set-up for the shop.
Set-Up Procedures
The following steps should be taken to ensure proper setup of the INSPECTOR 920:
1. Review the Operators Manual (this manual) and the Quick Reference Guide
2. Mount the Tester securely
3. Connect the INSPECTOR 920 Tester to a 12 Volt, 20 AMP capability power
supply
Warning: A 12 volt battery charger or simple inverter cannot be used, applied
power must be clean (filtered and regulated) and capable of generating 20amp
4. Connect the air supply through a filtered regulator, to the tester on the side panel
(110 to 120 psi is recommended)
5. Connect red battery clamp or ring terminal to the positive output
6. Connect black battery clamp or ring terminal to the negative output

LITE-CHECK INSPECTOR 920
Page 14 of 36
Note: If the 920 will not operate, check if the 12 volt power line polarity is reversed.
Operations
Reading the Digital Display
The digital display on the INSPECTOR 920 includes a variety of error messages. The
following are examples only. The full list of messages is shown with the appropriate test
procedure.
Display Details
This first screen appears on the display for several
seconds
When the tester is ready, this screen will display.
The tester automatically begins in “Trailer mode.”
Reminders
Do not use battery chargers – Battery Chargers are non-regulated and may
cause damage to the ABS ECU, or the tester.
The tester will not operate reliably below 10.5 volts and will indicate a “Low
Battery” condition (LOW BAT)
The tester will completely shut down if the voltage drops below 9.0 volts
Be sure the air pressure supply is above 90psi if the tester is used for air brake
inspections (110 to 120 psi input air with regulator is recommended)

LITE-CHECK INSPECTOR 920
Page: 15 of 36
Display Details

VDC is the voltage at the tester
AMP is the circuit amperage the tester is reading
AUX, BLUE, PIN 7 indicates 7-Way PIN number
and circuits are currently being tested (see Pin
Numbers and Circuits below)
Electrical circuits will display “GOOD” if greater
than 10mA and less than 15Amps and no other
faults are found
“SHORT” – Shorted circuit fault
Fault with multiple circuits involved when a single
circuit is under test. The tester has identified
electrical activity on more than one circuit.
The panel circuit indicator lights illuminate for all
shorted circuits, and the “SHORT” fault alarm
sounds. The digital display indicates the circuit
under test, current draw, voltage and a SHORTED
circuit fault. Amperage shows the total circuit load
on the digital display.
This screen is identifying a short to the right turn
signal. The shorted circuits on the left turn signal
will be illuminated on the tester panel along with the
right turn signal.
“CHASSIS SHORT” – Ground Fault
Fault with circuit supply wire in contact with the
chassis or ground circuit.
The panel circuit indicator light is on and the
“CHASSIS” fault alarm sounds. Current to the
trailer is restricted, and the digital display shows
0.00 amperage.
This screen is identifying that the marker circuit wire
is shorted to the chassis. The tester’s software
protects the vehicle harness by pulsing the power
every 5 to 8 seconds.

LITE-CHECK INSPECTOR 920
Page 16 of 36
7-Way Pin Numbers and Circuits
7-Way Pin
Number Wire Color Circuit
4 red BRAKE
6 brown TAIL
2 black MARKER
5 green RIGHT TURN
7 blue AUXILLARY
1 white GROUND
3 yellow LEFT TURN
Remote Control
The remote control allows the vehicle inspector to operate air and electrical functions
around the vehicle and observe the responses.
Operation
Press and release the designated button
Inspect. One light circuit will be activated at a time
The Remote Control is keyed to operate one tester at a time
Remote Control operations are parallel to the panel keyboard
Range with AA batteries in good condition is over 100 feet

LITE-CHECK INSPECTOR 920
Page: 17 of 36
The sending lamp will light up when the button on the remote control is pressed
Power Supply
The tester is designed for negative ground vehicles (black-negative, red-positive). In
case of reversed battery leads on the power cable, the tester will not operate.
Power Supply Set Up:
Attach the battery cable clamps (or ring terminals) to a 12Vdc automotive battery, or a
regulated power supply (such as the LITE-CHECK 311R).
Black battery cable to negative –
Red battery cable to positive +
Turn the power switch located on the back panel of the tester on for operation.
Low Battery Messages
NOTE: The tester will not work properly if the battery is not charged to a full 12+volts.
The tester will not operate and will possibly lock up if the power is below 10.5 volts.
Notes:
Replace (4) AA batteries if the sending lamp does not illuminate
Remove the batteries using the pull strap inside the case. Do not pry them
out.
If remote controls need to be keyed to different testers, contact LITE-CHECK
for assistance
The tester antenna must be fully exposed for good test reception

LITE-CHECK INSPECTOR 920
Page 18 of 36
7-Way Cable Test
This automatically tests the 7-Way 7-pin vehicle cable.
Place tester in tractor mode (push TRACTOR OUTPUT TEST button on the
tester panel).
1. Plug in the cable in the front 7-way socket and the 7-way socket on the right side
of the tester
2. The tester will automatically read the pins and display either “PASS” or “FAIL” for
each pin in the socket
3. If there is a “FAIL” message on the digital display, the following will be indicated:
a. A blank second line in the pin sequence indicates an OPEN circuit
b. “MIS-WIRE” indicates a reversed pin
c. The same pin number on the second line indicates a “SHORT”
Trailer Test Procedures
Before beginning testing connect a 7-way cable and two 1/4” glad hands airlines from
the tester to the trailer. (Be careful to connect “service” to service and “emergency” to
emergency.
1. Ensure voltage from power source is above 10.5Vdc (anything lower may cause
faulty readings.
2. Use either the tester panel buttons or the remote control buttons
3. The tester’s panel circuit indicator lights will illuminate when the tester is
operating
4. The digital display will show the electrical status
5. The air gauges will show the air application pressure
Display Details
The tester message “LOW BATTERY” indicates
that the 12-volt battery powering the tester needs to
be recharged. The tester will display the voltage
(VDC) that is being received

LITE-CHECK INSPECTOR 920
Page: 19 of 36
Air Brake Testing
Once the INSPECTOR 920 is connected to air and power, and to the testing the air and
breaking system can begin. The Emergency Air and Service Air Gauges are similar to
the ones shown below:
1. EMER. Press the “EMER” button to apply air to the table and release the parking
brakes (source air at 110 to 120 psi)
2. Press the “SERVICE” button to set service brakes (regulated at 90 to
95psi)
3. Identify and record the current air pressure with the gauges.
4. Press the “AIR LEAK TEST” button to perform the air test. Observe the
air gauges for changes.
5. A one minute timer will start on the digital display.
6. Watch for any movement on either gauge.
a. If one gauge falls, there is an external air leak.
b. If the gauges equalize, there is an internal air leak.
7. The Emergency Gauge is allowed 3 pounds of air loss in one minute.
8. The Service Gauge is allowed 2 pounds of air loss in one minute.
a. HINT: If the gauge needles move more than one increment in one minute,
the trailer will fail DOT inspection.
b. HINT: ABS operation takes about 45 seconds to reach the main menu.
The air leak test can be performed while the ABS test is initiating. Once at

LITE-CHECK INSPECTOR 920
Page 20 of 36
the main menu, check the gauges to see if any movement of the gauge
needles has occurred.
9. Press the “EMER.” button to release the emergency air
NOTE: Emergency air must be applied before service brakes will operate. This
prevents brakes from compounding.
Inspecting for Trailer Electrical Faults
Overview
Always begin the inspection operation with a properly setup INSPECTOR 920.
Adequate air and 12-volt power should be verified before starting the test.
NOTE: Air and air connections are not required when performing electrical inspections
only.
LITE-CHECK automatic testers are programmed to concurrently monitor all of the wires
on the 7-way cable connecting the tester to the trailer. This provides immediate
feedback on the conditions of each electrical circuit under test.
Electrical faults are signaled by the tester.
Electrical circuits that have burned-out, or have damaged lamps may still have properly
operating lamps AND the circuit will not indicate a fault. The tester’s digital display can
be used to observe the current drawn by each circuit and to look for unusual variances
from the expected values.
NOTE: If more than one fault is detected, the tester will identify the faults in an order of
the hierarchy. Once the first fault is corrected, the tester will go to the next fault and so
on until all the faults have been cleared.
Electrical Testing
In normal operating mode only ONE electrical circuit will operate at a time. The digital
display will show amperage, voltage and circuit condition. The corresponding electrical
indicator LED will be lit.
1. Start at the front corner of the trailer and observe the lights. Press the button for
the circuit being tested. Each light must be visually inspected to ensure it is
good.
2. Move to the other corner of the trailer and continue the light inspection.