PWM Power Pro Online User Guide
Contents
1. PWM POWER PRO User Guide 2014 Hickok Inc All rights reserved All rights reserved No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical without written permission from Hickok Hickok assumes no responsibility for use of this equipment by untrained or unauthorized persons Printed in the United States of America Safety Information Before using this equipment carefully read understand and follow instructions and safety messages on equipment and in this guide This guide cannot anticipate or provide advice and cautions for all situations encountered by technicians With this in mind always follow and refer to the manuals provided by the manufacturer of the vehicle or equipment being tested or used for all information and testing procedures whenever diagnosing repairing or operating such vehicle or equipment Failure to follow the instructions cautions and warnings provided here as well as those provided by the vehicle and equipment manufacturers can result in fire explosion bodily injury and property damage In addition to the information listed below additional warnings and cautions are listed throughout the guide Please read them carefully Fuel vapors are toxic and explosive which can cause severe injury or death Use proper ventilation to avoid breathing fuel vapors Minimize contact with the skin with the use of gloves such as nitrile glove2. position and the PWM Control Knob to OFF Connect the tester s power cable to the battery The tester will power up and perform a self test Once the test is completed the LED Readout displays a zero N 3 Connect the male spade terminal to a test lead 4 Plug the test lead into the output jack 5 Remove the fuse or relay and connect the output lead to the component side of the fuse or relay per the vehicle s shop manual 6 Set the Output Polarity Switch to and rotate the PWM Control knob to increase or decrease the amount desired to test the component The amount of current the component is drawing is displayed in the LED Readout 7 Make note of the results and refer to the specifications listed in the vehicle s shop manual to determine the course of action needed for repairs Using the Power Pro This procedure uses the same hookup as the Fuse Box Testing Procedure Total Circuit Demand Testing amp Hookup Procedure 1 Set the Output Polarity Switch to the OFF position and the PWM Control Knob to OFF Connect the tester s power cable to the battery The tester will power up and perform a self test Once the test is completed the LED Readout displays a zero Connect the male spade terminal to a test lead Plug the test lead into the output jack Remove the fuse or relay and set the Output Polarity Switch to and rotate the PWM Control knob to 100 Probe the component side of the s
3. sole discretion of the manufacturer This warranty does not cover expendable parts such as batteries nor does it cover shipping or handling In addition manufacturer is not liable for any loss or damage to product during shipping In the event it is determined that the product has been tampered with or altered in any way this warranty is void and all claims against the product will not be honored All warranty claims must be submitted as outlined by the manufacturer and shall be processed in accordance with the manufacturer s established warranty claim procedures These procedures include provisions that proof of purchase must be established by either warranty card from the seller or by point of purchase receipt and that the manufacturer will make every attempt to return ship the product within one business day from receipt of the returned product freight prepaid In addition all maintenance procedures as outlined by the product manuals should be followed for the warranty to be kept in force Should the product not be used in accordance with procedures as specified or if the product otherwise fails outside of the warranty the manufacturer reserves the right to make such judgment and the party returning the product will be notified that written notification will be necessary to repair the product at a cost which the manufacturer deems as reasonable The product will then be shipped back to the customer COD or as the manufacturer deems appropr
4. ck is open The tester is still usable but you must run a separate ground jumper To correct the error the tester must be sent in to Hickok Waekon for service 05 Timed Out To protect the vehicle the Auto off time varies with the current Specifications Power Supply 11 18 VDC Operating Current lt 100mA Output Current Ground Jack Current Display PWM Rate PWM Range Over Temperature Over Current Continuous On Time 0 40A high side low side drive 0 40A unprotected 0 40A 0 1A steps 15kHz 0 100 duty Heat Sink gt 120 F output disabled gt 40A output disabled 2 minutes 40 amps 10 minutes 20 amps 25 minutes 10 amps 30 minutes 5 amps Warranty Subject to the conditions that follow and are noted below this product is warranted to be free from defects in material and workmanship under proper use and in accordance with the manufacturer s written recommendation and specifications for a period designated below on all products This product carries a one year limited warranty The manufacturer s obligation under this warranty is limited to unaltered products returned to the manufacturer by the initial end user of the new products Therefore this warranty does not cover any products resold by the end user to third parties nor any reconditioned products sold as such by the manufacturer The sole remedy for any such defect shall be the repair or replacement of the product at the
5. erosassrersnerorsnecnseaveneraserorenerorsnseses 4 Using the Controls and Connections jssera maia cnciginoeoeiior ana coca coniorninimacons o 5 Using the PWM Power PFO oc co co G0 0000966666666669666666 6 Two Wire Testing amp Hookup Procedure amina caisenei cmi esemutarasennesea a rnisseuniniao 6 One Wire Hookup Testing amp Hookup Procedure irmas 7 Fuse Box Testing amp Hookup Procedure usas antas idas ad 8 Total Circuit Demand Testing amp HOOKUP Procedure 9 Error Codes amp Specifications PR sia zszsssac T Error COGS G66 cec00 10660000080 046661 0k0 a a TA T S 10 SGC CATIONS 226266156 0xv6081A g1 18x40 EERE E AAEN 10 Contact Informat OI c cccc c5 SSSS516658566665555sssssssssssse 11 Warranty ga ga ad do gang s sgt 136a6at238686235124s035055065 852550s6 vee 12 Overview PWM Power Pro Components 2 3 ft 40A Test Leads Tester 2 Removable Power Clips E RS oe 2 Alligator Clips or ES 2 Female Spade Terminal Probes 1 Male Spade Terminal Probes Tester Used along with the supplied adapters connects to the suspect component stand alone or on vehicle providing power and measuring current draw The tester controls the selected Duty Cycle PWM to the component while monitoring current usage Power Cable with Banana jacks When used along with the Removable Power Clips connects to the vehicle s battery to supply
6. iate This is the only authorized manufacturer s warranty and is in lieu of all other expressed or implied warranties or representations including but not limited to any implied warranties of merchantability or fitness or any other obligations on the part of the manufacturer In no event will the manufacturer be liable for business interruptions loss of profit personal injury costs of delays or any special indirect incidental or consequential damages costs or losses 061014
7. ing at any duty cycle Also when there is an error it displays a two digit error code see the rear panel of the tester for a listing of error codes or refer to the Error Code section in this guide for details Load Polarity Output Switch Sets the drive polarity of the output jack and enables the PWM control knob Heat Sink Used to dissipate heat generated during testing Ground Jack Connect the black test lead here Supplies ground for components that need a two wire hookup Error LED Lights to indicate an error and that the output jack has been disabled Also the LED readout displays the error code See the rear panel of the tester for a listing of error codes or refer to the Error Code section in this guide for details PWM Control Knob Sets the duty cycle of the supply delivered to the output jack for variable load current Using the PWM Power Pro Two Wire Testing amp Hookup Procedure Use this procedure for any of the following conditions Procedure 1 Red Test Lead Tester Bench testing Component is still connected to the vehicle but is disconnected from the vehicle s harness Component Vehicle Harness IMPORTANT The tester GROUND JACK is not protected If connected to the battery s positive terminal it will fail and become inoperable see Error Code 04 Set the Output Polarity Switch to the OFF position and the PWM Control Knob to OFF Connect the tester s power cab
8. le to the battery The tester will power up and perform a self test Once the test is completed the LED Readout displays a zero Note If the unit becomes unresponsive remove and reconnect the power cable connections to the battery Select the probes or clips that most closely mates to the components and then connect to the test leads Plug the red test lead into the output jack and the black test lead into the ground jack IMPORTANT To avoid possible damage do not let the tips of the leads touch once they are connected to the tester Disconnect the component from the circuit and connect the positive and negative leads to the component per the vehicle s shop manual Set the Output Polarity Switch to and rotate the PWM Control knob to increase or decrease the amount desired to test the component The amount of current the component is drawing is displayed in the LED Readout For best duty cycle control on smaller loads lt 2A connect one side of the component to power and the other side to the output jack Set the lead polarity to minus Forreversing motors such as power windows and locks reverse the test leads to drive the motor in the opposite direction Make note of the results and refer to the specifications listed in the vehicle s shop manual to determine the course of action needed for repairs Using the Power Pro One Wire Hookup Testing amp Hookup Procedure Use this
9. power to the tester Banana jacks also allow you to use an alternate power source Note Once it is connected to power the tester turns on automatically and performs a self test the LED Readout and the Error LED briefly turn on If the PWM Power Pro does not perform a self test check the battery voltage and or polarity of the power cable hookup to the vehicle battery 40A Test Leads 1 red and 1 black Use along with one of the supplied flex probe adapters or clips to connect the tester to the component you are testing Flex Probe Adapters and Clips 2 female spade terminal probes 1 male spade terminal probes and 2 alligator clips are included The probes are used along with the leads to connect to the component you are testing Optional 77202 Spade Flex Probe Kit and 77203 Round Flex Probe Kit not shown Both kits contain an assortment of terminal probes to provide for a larger coverage of connectors Overview Using the Controls and Connections Heat Sink Output Jack Ground Jack LED Readout Error LED PWM Control Knob Load Polarity Output Switch CAUTION The Heat Sink can become extremely hot during use Therefore avoid contact with your skin or any of the vehicle s components Output Jack Connect the red test lead here Outputs power or ground to drive the components that already have one side tied to the vehicle wiring LED Readout Displays the average current amperage the component is us
10. procedure for P Tester in circuit testing a OUTPUT component connected to a harness Vehicle Component Harness Procedure 1 Set the Output Polarity Switch to the OFF position and the PWM Control Knob to OFF 2 Connect the tester s power cable to the battery The tester will power up and perform a self test Once the test is completed the LED Readout displays a zero Note If the unit becomes unresponsive remove and reconnect the power cable connections to the battery 3 Select the probe that most closely mates to the component s harness and connect it to a test lead 4 Plug the test lead into the output jack 5 Connect the output lead to the component by back probing the drive side of the component per the vehicle s shop manual 6 Set the Output Polarity Switch to or based on the component s circuit operation per the vehicle s shop manual and rotate the PWM Control knob to increase or decrease the amount desired to test the component The amount of current the component is drawing is displayed in the LED Readout 7 Make note of the results and refer to the specifications listed in the vehicle s shop manual to determine the course of action needed for repairs Using the Power Pro Fuse Box Testing amp Hookup Procedure Use this procedure for Test Lead fuse box relay testing A too Fuse Relay Component Box Tester Procedure 1 Set the Output Polarity Switch to the OFF
11. s when there is possibility of getting methanol fuel on your hands If the skin is directly exposed wash the area immediately and change any clothes that have become wet with fuel Always wear approved safety glasses when testing Should fuel get into eyes flush eyes immediately with water and consult your physician Vehicles emit flammable vapors which can ignite Keep flames sparks cigarettes and other ignition sources away from the vehicle at all times In case of fire never use water to fight flames caused by methanol or methanol blended gasoline This will cause the flames to spread instead of extinguishing them Use a dry chemical extinguisher to fight flames preferably one marked ABC though BC is acceptable A foam extinguisher is acceptable only if it is ARF grade which is resistant to alcohol Before beginning any tests make sure the test environment is safe and the vehicle meets these conditions e Test area should be well ventilated Vehicle should be in park Wheels should be blocked Engine should be at normal operating temperature Vehicle should have normal exhaust flow Keep all tester cables clear of exhaust manifolds and radiator fan blades Use caution when testing on a vehicle while the engine is running surfaces may become hot electric cooling fans may turn on unexpectedly etc Contents Overview OO 4 PWM Power Pro COMPONENNG ssssescsesesesecosessenesns
12. uspect circuit fuse or relay with all of the component s turned on or off as desired Determine the demand by reading the amps displayed in the LED Readout Make note of the results and refer to the specifications listed in the vehicle s shop manual to determine the course of action needed for repairs Error Codes amp Specifications Error Codes Error codes are indicated by the lit Red LED located on the front of the tester along with a two digit code displayed in the LED Readout Use the following chart to determine the cause of the error code and the course of action you need to take To clear an error code set the Load Polarity switch to the OFF position Error Code Required Action 01 Over Temperature Turn the tester off and allow to cool Prolonged high current usage can cause overheating as well as damage to the load under test CAUTION The Heat Sink can become extremely hot during use Therefore avoid contact with your skin or any of the vehicle s components 02 Over Current Excessive current draw may be caused by high start up demand on the component being tested Start from 0 and slowly increase the current Over Current can also be caused by failing component or excessive testing run time 03 Low Battery The tester detected low battery voltage Check the vehicle s battery and or connections 04 Ground Jack Inoperable The tester detected at power up that the ground ja
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