Midtronics EXP HD Instruction Manual
Midtronics EXP HD Instruction Manual
Midtronics Expandable
Electrical Diagnostic Platform
INSTRUCTION ManuAl
Chapter 1: Before You Begin
We also recommend that you regster the analyzer to actvate your warranty.
Safety Precautions
Inspect the battery for damages and check the electrolyte level. If the electrolyte level is too low, replenish
it and fully charge the battery. Always use the necessary safety precautions when working with batteries to
prevent severe injury or death. Follow all manufacturers’ instructions and BCI (Battery Council International)
safety recommendations, which include the following precautions:
• Battery acid is highly corrosive. If acid enters your eyes, immediately flush them thoroughly
with running cold water for at least 15 minutes and seek medical attention. If battery acid gets
on your skin or clothing, wash immediately with water and baking soda.
• Always wear proper safety glasses or face shield when working with or around batteries.
• Keep hair, hands, and clothing as well as the analyzer cords and cables away from moving
engine parts.
• Remove any jewelry or watches before you start servicing the battery.
• Use caution when working with metallic tools to prevent sparks or short circuits.
• Never lean over a battery when testing, charging, or jump starting it.
Chapter 2: Overview
Chapter 2: Overview
The inTELLECT EXP-1000 HD tests 6- and 12-volt heavy-duty automotive and commercial batteries, and
12-volt and 24-volt charging systems. In addition to a standard single-battery test, the EXP has a test rou-
tine designed for multiple-battery vehicles and a specialized heavy-duty battery algorithm for larger batter-
ies. Other tools in the EXP include a digital multimeter with a scope, and a conductance cable drop test.
The large backlit graphical screen and icon-based user interface make diagnostics simple for the novice
and experienced electrical technician. An alphanumeric keypad with selection scrolling and soft (multifunc-
tion) keys make the EXP as easy to use as a remote control or cell phone. A memory card system allows
for upgrades, quick storage, and transfer of test data.
Case Layout
The EXP-1000 HD kit includes a hard-sided, molded carrying case. The case holds all accessories, with
room for future options.
Printer batteries
Printer paper
Cable storage
Printer charger
Side-post
stud adapters Group 31
stud adapters
Amp clamp
IR printer
Battery
test cable inTELLECT EXP
Chapter 2 : Overview
Amp clamp
6-pin RJ45
The bottom and right side of the EXP have two data ports:
Spring-loaded SD card slot for test data storage and software upgrades.
Inserting an SD Card
The SD card slot contains a plastic filler card for protection. The EXP can store test results on an SD card.
To remove the filler card, push briefly on its edge to release it and pull it from the slot.
When inserting an card, push it into the slot until it locks. The card is correctly inserted when it is not
protruding from the slot.
Chapter 2: Overview
Soft Keys
Press the two Soft Keys linked to the bot-
tom of the screen to perform the functions
displayed above them. The functions change
depending on the menu or test process. So it
may be helpful to think of the words appear-
ing above them as part of the keys. Some
of the more common soft-key functions are
SELECT, BACK, and EXIT.
POWER Button
Press the POWER button to turn the analyzer
on and off. The analyzer also turns on auto-
matically when you connect its test leads to a
battery.
Title Bar
The Title Bar shows you the name of the cur-
rent menu, test tool, utility, or function.
Selection Area
The Selection Area below the Title Bar con-
tains items you select or into which you enter
information. The area also displays instruc-
tions and warnings.
When displayed under a list of options, the You also use the Alphanumeric Keys to cre-
Directional Arrows show you which keypad ate and edit customer coupons and your shop
arrow to press to highlight a character or an contact information on printed test results, and
item in a list. manage technician IDs.
Key Character
Scroll
Box
1 $ - ( ) 1
2 a b c 2
3 d e f 3
4 g h i 4
Top Middle Last 5 j k l 5
or only screen screen
screen 6 m n o 6
Keypad Arrows 7 p q r s 7
While the Directional Arrows serve as road
signs, the Keypad Arrows are the vehicle to its 8 t u v 8
functions and features. You use the keypad to
log on, navigate to menus and options, cus- 9 w x y z 9
tomize settings, and perform tests.
0 % , . # 0
Typically, the soft key below the left half of the screen cancels your choice or returns you to the previous
screen, although the command above it may vary. (Examples: BACK and PRINT.) In a similar fashion, the
soft key below the right half of the screen confirms your choice, although the word above it may also vary
(examples: SELECT and NEXT).
Menu icons
A menu icon is a graphical representation of a function you can select, such as the Diode Icon in
the DMM Menu. To select an icon, use the LEFT or RIGHT ARROW key to highlight it. Highlighting
changes the icon to a white picture on a black background. To confirm your selection, press the
appropriate soft key.
Option Buttons
Some lists have option buttons before each item. To select an item, use the UP/DOWN ARROW keys
to move the dot to the button next to the item. You can also use the alphanumeric keypad to enter the
number preceding the option button. To confirm your selection, press the appropriate soft key.
Scrolling Lists
Scrolling lists contain items that extend above and below the screen or the selection box that contains
them. To indicate that there are more items, the symbols appear to the right of the first visible or
highlighted item on the list.
To select from the list, use the UP/DOWN ARROW keys to scroll to the item, or use the keypad to
enter your choice, and press the appropriate soft key. Scrolling increases and decreases the units by
five. To increase your scrolling speed, hold the UP or DOWN ARROW key.
Chapter 2: Overview
Alphanumeric Entry
Some selections require you to use the alphanumeric keypad. These “user-defined” selections have
a blinking horizontal line (cursor) to the right of the last character.
Use the UP/DOWN ARROW keys to highlight a line for editing. Display the character, symbol, or
number you want by rapidly pressing its key as many times as needed. If you pause, the cursor
moves to the right. To backspace, press the LEFT ARROW key. Use the RIGHT ARROW key to add
a space. Use the UP/DOWN ARROW keys to highlight a line for editing. When finished, press the
appropriate soft key to save your settings.
Chapter 2: Overview
Menu Maps
This section will help you get to your destination while letting you know what test leads you may need when
you arrive. The test leads are represented by symbols for their connectors.
Main Menu
The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons
lead directly to the function they represent, while others are menu icons that lead to two or more
functions. Menu icons are marked here with an asterisk ( ) and are mapped on the following pages.
*
Main Menu (Screen 1)
*
Optional
Tests one battery using Tests the battery pack or Allows you to view your
the battery information individual batteries (and stored test results and
you select in a series of the starting and charging print them to an optional
screens. systems. IR printer.
* *
Clamps
only
Tests both sides of a Digital multimeter with Includes a test counter,
circuit simultaneously for eight test meters, a tem- data transfer utility, the
voltage drop. Three pre- perature sensor, and EXP software version
set tests and one user- options for clamps and and serial number.
defined. probes.
DMM Menu
The DMM Menu has icons for a temperature sensor and 8 test meters, some of which require different
test leads. The available leads depend on the EXP model purchased.
METERS (Screen 1)
Measures voltage within Measures voltage within Voltage trace with time
a range of 0 to 60 Vdc. a range of 0 to 24 Vac. and frequency measure-
ments.
METERS (Screen 2)
Tests the strength of Tests the strength of the Sensor that displays tem-
the direct current flow alternating current flow perature in degrees F
through a circuit. through a circuit. or C (units you can select
in the Utilities Menu.)
METERS (Screen 3)
Probes
only
Tests a circuit for con- Tests a diode for forward Measures two signals
tinuity and resistance voltage drop. simultaneously: DC volt-
measured in ohms ( ). age and amperage.
Chapter 2: Overview
Info Menu
The Info Menu has three utilities to help you manage your test data, and track the analyzer’s usage
and history.
REPORTS
Print/View Menu
The EXP stores the last battery, system, and cable test results in its memory until you perform another
test. To review or print results before you retest, select a test type in the Print/View Menu.
REPORTS
Utility Menu
The Utilities Menu allows you customize your analyzer. Before testing, check the default values to see
which options you may want to change.
SETUP (Screen 1)
Settings to adjust date Add, edit, or delete User Allows you to add
and time. IDs using up to seven al- a custom header to
phanumeric characters. printed test results.
SETUP (Screen 2)
SETUP (Screen 3)
Allows you to select de- Sets the language of the Formats the SD card to
grees in C or F for tem- display and printouts. receive data. Also erases
perature measurements. all data on the card.
SETUP (Screen 4)
SHOP Generic header for printouts with 12 lines of text and a maximum of 17
characters per line
USERS USER01 through USER24 are placeholder IDs used to create user
names.
DISPLAY
CONTRAST LEVEL Range: 0 (lightest) to 10 (darkest). The default is set at 9.
BACKLIGHT TIME Range: 0 to 60 seconds. The default is set at 15 seconds.
LANGUAGE English is the default language. French-Canadian and Spanish are also
available.
The Utility Menu has nine utilities to customize your analyzer. Each utility described in this section is listed
in order by its icon title.
If you use the alphanumeric keypad to enter the number preceding the option button, no additional
keypress is needed to save or continue to the next step.
Clock
The CLOCK ADJUST utility has four settings. Use the UP/DOWN ARROW keys to highlight the setting
you want to change.
MODE : AM/PM
TIME : 9:07 PM
FORMAT : MMM/DD/YYYY
DATE : 6/17/6/17/2005
Mode
Use the UP/DOWN ARROW keys or press the corresponding numerical key to move the dot to the
option button of your choice or enter its number.
1. Select the 24-hour or AM/PM mode
1 24 HOUR
2 AM/PM
2. If you used the ARROW keys, press the SAVE soft key to save your setting or the
BACK soft key to return to the CLOCK ADJUST screen without saving the changes.
Time
1. Use the LEFT/RIGHT ARROWS to highlight the hour, minutes, or AM or PM. To rapidly
scroll, hold down an ARROW key.
9 : 19 PM
2. Press the SAVE soft key to save your setting or BACK to return to the CLOCK ADJUST
screen.
Format
Use the UP/DOWN ARROW keys or press the corresponding numerical key to move the dot to the
option button of your choice or enter its number.
1. Select the 24-hour or AM/PM mode
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
Chapter 3: Utility Menu
2. If you used the ARROW keys, press the SAVE soft key to save your setting or the
BACK soft key to return to the CLOCK ADJUST screen without saving the changes.
Date
1. Use the LEFT/RIGHT ARROWS to highlight the month, day, or year. To rapidly scroll,
hold down an ARROW key.
4 / 01 / 2006
2. Press the SAVE soft key to save your setting or the BACK soft key to return to the
CLOCK ADJUST screen without saving the changes.
Users
The USERS utility allows you to create and edit a USER ID with one to seven alphanumeric characters
and link it to a test counter. It also allows you to delete a USER ID and its associated test total.
2. Use the UP or DOWN ARROW keys to scroll to the ID placeholder you want to use.
Scrolling past the first line will go to the previous page. Scrolling past the fourth line will
go to the next page. To display more placeholders, continue scrolling or use the LEFT
or RIGHT ARROW key to jump up or down through the list four lines at a time.
1 USER01
2 USER02
3 USER03
4 USER04
Press the NEXT soft key to continue.
3. To clear the default characters, press the LEFT ARROW key. To add a space, move the
cursor forward by pressing the RIGHT ARROW key.
ENTER USER ID
USER01 — Blinking cursor shows the starting
location for editing
Chapter 3: Utility Menu
4. Insert a character by pressing the alphanumeric key associated with the character as
many times as needed. Press the SAVE soft key to store the new user ID in memory.
ENTER USER ID
BOB R
Deleting a User ID
1. To delete a USER ID, select:
1 ENTER NEW
2 DELETE
3 EDIT
Press the NEXT soft key to display the list of IDs.
2. Use the ARROW keys to select a USER ID as described in step 2 in Entering a New
User ID. (You cannot delete placeholder USER IDs, i.e., USER03).
1 BOB R
2 JIM F
3 PETER
4 USER04
Press the DELETE soft key.
Shop
The SHOP INFO utility allows you to create a header for your printed test results showing your business
location information. The utility’s two information screens contain eight lines of text with a maximum of 17
characters per line.
Screen 1 Screen 2
1–YOUR SHOP NAME — 5–YOUR COUNTRY —
2–1000 ANY STREET 6–YOUR PHONE NUMBER
3–YOUR TOWN, STATE
4–YOUR POSTAL CODE
To help you edit and center your header, use a pencil to write the information in the template below before
entering it into the analyzer.
2. Press the LEFT ARROW key to move the cursor backward to erase a character. To move the
cursor forward, press the RIGHT ARROW key.
3. Insert a character by pressing the key associated with the character as many times as
needed.
4. You can center text by selecting blank spaces before and after lines of text or insert spaces
between words.
5. Press the SAVE soft key to save your setting or the BACK soft key to return to the SHOP
INFO screen without saving the changes.
Chapter 3: Utility Menu
Display
The LCD OPTIONS utility allows you to adjust the contrast of the text on the display and the backlight
time.
Contrast Level
The contrast level is 0 (lightest) to 10 (darkest). To change it:
2. Press the ADJUST soft key to display the option’s numerical scroll box.
10 (1-10)
3. Press the UP or DOWN ARROW key or the corresponding numerical key to select your
preference.
4. Press the SAVE soft key to save your setting or the BACK soft key to return to the
CONTRAST LEVEL screen without saving the changes.
Backlight Time
Backlight time is from 0 to 60 seconds. To change it:
2. Press the EDIT soft key to display the option’s numerical scroll box.
60 SEC
3. Press the UP or DOWN ARROW key or the corresponding numerical key to select your
preference. To erase a character, press the LEFT ARROW key.
4. Press the SAVE soft key to save your setting or the BACK soft key to return to the
BACKLIGHT screen without saving the changes.
Chapter 3: Utility Menu
Coupon
The COUPON SELECT utility allows you to print one of the three custom coupons or messages created
in the EDIT COUPON utility.
1. Use the UP or DOWN ARROW key, or press the corresponding numerical key (1, 2) to move
the dot to the option button of your choice.
1 NO COUPON PRINTED
2 USER COUPON
2. Press the SAVE soft key to save your setting or the BACK soft key to return to the Utility
Menu without saving the changes.
Edit Coupon
The EDIT COUPON utility allows you to create a promotional coupon or message for your customers
that prints at the bottom of every test result. Its two information screens contain eight lines of text with a
maximum of 17 characters per line.
To create and edit a coupon, see the procedure under Shop in this chapter for using the keypad to enter
and backspace over characters. Use the template to plan and center your text.
Temp
The TEMP. UNITS utility enables you to set the units of measure to either Celsius or Fahrenheit.
1. Use the UP/DOWN ARROWS or press the corresponding numerical key to move the dot to
the option button of your choice.
1 DEGREES F
2 DEGREES C
Language
The LANGUAGE utility enables you to select a language for the display and printouts. To set your
preference:
1. Use the UP/DOWN ARROWS or press the corresponding numerical key to move the dot to
the option button of your choice.
1 ENGLISH
2 ESPAÑOL
3 FRANÇAIS
Format
Select this utility to format an SD card to receive data or erase all data on the card. The EXP will warn you
before formatting the disk, and ask if you want to continue.
Update
When software updates are released, this utility enables you to update the analyzer’s software using files
on an SD card.
Chapter 4: Test Preparation
• Cracked, buckled, or leaking case. If you see any of these defects, replace the battery.
• Corroded, loose, or damaged cables and connections. Repair or replace them as needed.
• Corrosion on the battery terminals, and dirt or acid on the case top. Clean the case and
terminals using a wire brush and a mixture of water and baking soda.
• Low electrolyte level. If the electrolyte level is too low, add distilled water to the level specified
by the battery manufacturer, and fully charge the battery. Do not overfill.
• Corroded or loose battery tray and hold-down fixture. Tighten or replace as needed.
The preferred battery test location is in the vehicle. However, if you plan to test out of the vehicle:
• Always disconnect the negative cable from the battery first and reconnect it last.
• Always use a carry tool or strap to lift and transport the battery.
CAUTION: To ensure accurate test results for Group 31 batteries, the clamps are designed to connect
to lead stud adapters or to the lead bases of threaded studs. Never connect the clamps directly onto the
threaded studs. When testing at side posts, always use lead terminal adapters. Do not use steel bolts.
To avoid damage, never use a wrench to tighten the adapters more than 1/4 turn. Failure to properly install
lead terminal adapters, or using adapters that are dirty or worn, may cause false test results.
At the start of the test, make sure all vehicle accessory loads are off, the key is not in the ignition, and the
doors are closed.
Logging In
Scroll to your User ID and press the NEXT soft key.
1 DAN
2 RICK J
3 JOHN G
4 USER04
To create a new User ID, scroll to a placeholder (USER01, USER02, etc.), press NEXT and select the
Users function in the Utility Menu. See “Users” on page 16 for instructions.
Chapter 4: Test Preparation
Connecting to a battery
CAUTION: Do not connect the EXP to a voltage source greater than 60 Vdc.
4. For a proper connection, rock the clamps back and forth. Both sides of the clamp must be
firmly connected before testing. If the message CHECK CONNECTION appears, clean the
terminals and/or reconnect the clamps
2. Connect the clamps to the positive (+) and negative (–) cables that lead to the starter and
chassis ground as shown. If there are multiple cables, re-test for each cable connection.
3. For a proper connection, rock the clamps back and forth. Both sides of each clamp must be
firmly connected before testing. If the message CHECK CONNECTION appears, clean the
terminals and/or reconnect the clamps.
TO GROUND
TO STARTER
Chapter 5: Battery Test
If you use the ARROW keys to select option buttons, press the NEXT soft key to continue to the next step.
If you use the alphanumeric keypad to enter the number preceding the option button, no additional key-
press is needed to save your selection. The BACK soft key returns you to the Main Menu at the start of the
test and to the previous screen as you progress.
5. Select the battery’s RATING UNITS. The units and the rating required in step 6 are printed on
the battery label. If the information is unreadable, contact the battery manufacturer.
6. Press the UP or DOWN ARROW key or use the numeric keys to select the BATTERY
RATING.
a) If CCA, scroll to the rating and press SELECT. The entry range is 100 to 3000, except for
DIN and IEC, which have a range of 100 to 1000.
500 CCA
26A17
26A19
26B17
28A19
Press the NEXT soft key to continue.
7. Aim the IR temperature sensor at the battery as instructed for an accurate temperature
measurement.
Battery Case
(Top)
Sensor
When the temperature stabilizes, press the NEXT soft key to start the test. The analyzer takes
a few seconds to evaluate the battery before displaying the results.
Chapter 5: Battery Test
In some cases the EXP may ask for additional information before it makes a decision on the
battery. See “Additional Test Requirements” on page 28 for more information.
8. If the battery decision is REPLACE or BAD CELL, the EXP-1000 HD BMP asks you to enter
the battery serial number. The number, which is located on the battery case, is needed to
generate a test code for warranty purposes. To backspace, use the LEFT ARROW key. When
finished, press the NEXT soft key to continue.
To send the results to the IR printer, align the analyzer’s IR transmitter with the printer’s receiver, and press
the PRINT soft key. To return to the Main Menu, press the END soft key.
Battery decision
Measured voltage
Measured CCA
Selected rating
Battery temperature
END becomes NEXT in the
Automotive System Test
Battery state-of-health
Battery state-of-charge
Chapter 5: Battery Test
CHARGE & RETEST Fully charge the battery using a Midtronics Diagnostic Charger and retest.
Failure to fully charge the battery before retesting may cause false
readings. If CHARGE & RETEST appears again after you fully charge the
battery, replace the battery.
REPLACE BATTERY A REPLACE BATTERY result may also mean a poor connection between
the battery and the vehicle. If you tested the battery using the SYSTEM Test,
disconnect the battery cables and retest using the BATTERY Test before
replacing it.
NOTES:
If the EXP displays 24 VOLT BATTERY after the Automotive System Test, you are attempting to test
in-vehicle both batteries in a 24-volt system. Disconnect the batteries and test them individually.
When testing at REMOTE POSTS, the EXP may need to verify a possible REPLACE result. It will give you
the option of retesting at the battery posts.
When testing at SIDE POSTS, the EXP may find that the data is inconclusive and ask you to test with side
post adapters.
Chapter 5: Battery Test
• You may be testing too close to a noise source, such as a charger or other high-current
device. If so, move away and retest.
• If you are unable to find the source of the noise, fully charge the battery and retest. If the
message appears after recharging, test the battery out of the vehicle.
The EXP may also ask you to enter the battery’s six-digit serial number, which is located on the
battery case.
After the Deep Scan Test the EXP either displays the results or gives you the option to perform the
5-Minute Discharged Battery Test. Although this test takes five minutes, it gives a more precise result
for difficult-to-diagnose batteries.
Chapter 5: Battery Test
2. Select charge current rate of the battery charger you will use for this test.
15 (10–60)
Press the NEXT soft key.
4. Make sure the charger’s power cord is disconnected and the power switch in the OFF
position.
5. Connect the charger’s clamps to the battery posts: red lead to the positive (+) terminal,
black lead to the negative (–) terminal.
6. Reconnect the analyzer’s clamps to the battery posts. Rock them back and forth so
they make good contact.
7. Connect the amp clamp to the EXP, and remove the clamp from any cables or wires.
9. Place the amp clamp around the negative (–) battery cable of the charger.
10. Plug in the charger’s power cord and turn on the charger.
The EXP begins testing while the charger applies the charge current to the battery. After the
initial boost charge, the EXP will count down the test time in minutes and seconds.
CAUTION: Do not leave the battery unattended while the charger is in operation.
11. When the test is finished, the EXP will ask you to turn off the charger and disconnect
the charger and analyzer clamps.
12. Reconnect the EXP clamps to the battery posts and press the NEXT soft key to display
the battery results.
Chapter 6: Battery and Starter System Test—Auto/Van
2. Select AUTO/VAN.
1 AUTO/VAN
2 TRUCK
Battery Test
The System Test includes a test of the battery to eliminate it as the cause of starting or charging problems.
See Chapter 5 on page 24 for the Battery Test procedure and an example of the test results.
If you are using the amp clamp (AMP CLAMP AVAILABLE), keep it clamped around the negative (–)
battery cable.
2. The EXP displays a decision on the starter system with the complete results in a series of
screens. Use the UP/DOWN ARROW keys to scroll to each screen.
To send the results to the IR printer, press the PRINT soft key. To continue testing, press the
NEXT soft key. For an example of the test results see the next page.
Chapter 6: Battery and Starter System Test—Auto/Van
NOTE: In some cases, the EXP may not detect the vehicle’s starting profile and display the soft key
options STARTED and NO START. If you select STARTED, the EXP skips to the Charging System
Test. If you select NO START, the test process ends.
Starter decision
Average cranking voltage
L o o p o h m s ( s t a r t e r Average cranking amps
loop resistance) displayed if amp clamp is used
if amp clamp used
Cranking time in seconds
X axis = Time
Starter System
Decision Recommended Action
CRANKING NORMAL The starter voltage is normal and the battery is fully charged.
LOW VOLTAGE The starter voltage is low and the battery is fully charged.
CHARGE BATTERY The starter voltage is low and the battery is discharged. Fully charge the
battery and repeat the starter system test.
REPLACE BATTERY The battery must be replaced before testing the starter.
LOW CRANKING AMPS The cranking voltage is high, but the cranking amps are low.
NO START The engine did not start and the test was aborted.
CRANKING SKIPPED The EXP did not detect the vehicle’s starting profile and skipped the Starter
Test.
2. Select AUTO/VAN.
1 AUTO/VAN
2 TRUCK
1
Press the NEXT soft key to continue.
The BACK soft key returns you to the Main Menu at the start of the test and to the previous screen
as you progress.
The EXP evaluates the battery and displays the results (page 34).
If the decision is CHECK BATTERY PACK or you selected more than one battery to test,
the EXP provides the option of testing each battery in the pack (BREAK PACK DOWN) or
continuing with the Starter Test.
Chapter 7: Battery and Starter System Test—Truck
1. Select BREAK PACK DOWN and press the NEXT soft key to continue.
3. Disconnect the battery pack, and press the NEXT soft key.
4. When prompted, connect to the first battery and press the NEXT soft key.
5. The EXP takes a few seconds to evaluate the battery. If any messages appear before the EXP
displays the results, refer to “Battery Test: Additional Test Requirements.
6. If the battery decision is REPLACE or BAD CELL, the EXP asks you to use the alphanumeric
keypad to enter the battery’s serial number. The number, which is located on the battery
case. To backspace, use the LEFT ARROW key. When finished, press the NEXT soft key to
continue.
7. When you test the last battery, the EXP displays the results. Press the DOWN ARROW key
to view the individual battery results. See an example of the results on the next page.
Chapter 7: Battery and Starter System Test—Truck
If you tested individual batteries, the EXP displays the results for each battery with a test code for
REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR transmitter with the printer’s receiver, and
press the PRINT soft key.
To continue to the Stater System Test, press the NEXT soft key.
Pack decision
2. The EXP will display one of six decisions and the results in a series of screens. Use the UP/
DOWN ARROW keys to scroll to each screen.
NOTE: In some cases, the EXP may not detect the vehicle’s starting profile and display the soft
key options STARTED and NO START. If you select STARTED, the EXP skips to the Charging
System Test. If you select NO START, the test process ends.
X axis = Time
Starting System
Decision Recommended Action
CRANKING NORMAL The starter voltage is normal and the battery is fully charged.
LOW VOLTAGE The starter voltage is low and the battery is fully charged.
CHARGE BATTERY The starter voltage is low and the battery is discharged. Fully charge
the battery and repeat the starter system test.
REPLACE BATTERY (If the battery test result was (REPLACE or BAD CELL.) The battery
must be replaced before testing the starter.
NO START The engine did not start and the test was aborted.
CRANKING SKIPPED The EXP did not detect the vehicle’s starting profile and skipped the
Starter Test.
Chapter 8: Charging System Test—Auto/Van and Truck
If you are using the amp clamp (AMP CLAMP AVAILABLE) in the TRUCK Charging System Test, keep it
clamped around the positive (+) alternator cable.
1. CHECKING FOR ALTERNATOR OUTPUT: The EXP will immediately begin testing for
alternator voltage.
2. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn off vehicle loads (blowers, interior
light, radio, etc.) and idle the engine. Press the NEXT soft key to continue.
NOTE: If necessary the analyzer will ask if you are testing a diesel engine. It will resume
testing after you make your selection.
4. REV ENGINE WITH LOADS OFF FOR 5 SECONDS: Rev the engine with the loads off.
Gradually increase the rpm until the analyzer tells you to HOLD the rev level as the bar on the
display moves to the right.
NOTE: Some 8-cylinder and older vehicles idle at a high level after starting, allowing the
analyzer to detect the rev automatically.
5. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold the rpm while the EXP takes
system measurements.
6. ENGINE REV DETECTED, IDLE ENGINE: The EXP has detected the rev. Press the NEXT
soft key.
7. TESTING ALTERNATOR AT IDLE, LOADS OFF: The analyzer will next test the engine at
idle for comparison to other readings, and then test the diode ripple. Excessive ripple usually
means one or more diodes have failed in the alternator or there is stator damage.
8. TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE ENGINE: After a few seconds, the
EXP will ask you to turn on the accessory loads. It will determine if the charging system is able
to provide enough current for the demands of the electrical system.
IMPORTANT: Turn on the high-beam headlights and the blower to high. Don’t use cyclical loads
such as air conditioning or windshield wipers.
9. TESTING ALTERNATOR AT IDLE, LOADS ON: The analyzer will determine if the charging
system is able to provide sufficient current for the demands of the vehicle’s electrical system.
10. REV ENGINE WITH LOADS ON FOR 5 SECONDS: The EXP will test the charging system
with the loads on and prompt you to rev the engine. Gradually increase the rev until the
Chapter 8: Charging System Test—Auto/Van and Truck
analyzer tells you to HOLD the rev level as the bar on the display moves to the right.
11. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold the rpm while the EXP takes
system measurements.
12. ENGINE REV DETECTED, IDLE ENGINE: The EXP has detected the rev. Press the NEXT
soft key.
13. ANALYZING CHARGING SYSTEM DATA: The EXP is completing its final analysis of the
charging system data.
14. TURN OFF LOADS AND ENGINE: Press the NEXT soft key to display the results.
Alternator decision
Loads-off DC
Loads-on DC voltage at rev
voltage at rev
Charge Code generated Loads-on current at rev
for BMP version only if amp clamp is used
Peak-to-peak
Diode waveform
AC voltage
Chapter 8: Charging System Test—Auto/Van and Truck
Charging System
Decision Action
NO PROBLEMS The system is showing normal output from the alternator. No problem detected.
NO VOLTAGE The alternator is not providing charging current to the battery.
√ Check the belts to ensure the alternator is rotating with the engine running.
Replace broken or slipping belts and retest.
√ Check all connections to and from the alternator, especially the connection to
the battery. If the connection is loose or heavily corroded, clean or replace the
cable and retest.
√ If the belts and connections are in good working condition, replace the alter-
nator. (Older vehicles use external voltage regulators, which may require only
replacement of the voltage regulator.)
LOW VOLTAGE The alternator is not providing enough current to power the system’s electrical loads
and charge the battery.
√ Check the belts to ensure the alternator is rotating with the engine running.
Replace broken or slipping belts and retest.
√ Check the connections from the alternator to the battery. If the connection is
loose or heavily corroded, clean or replace the cable and retest.
HIGH VOLTAGE The voltage output from the alternator to the battery exceeds the normal limits
of a functioning regulator.
√ Check to ensure there are no loose connections and that the ground connection
is normal. If there are no connection problems, replace the regulator. (Most
alternators have a built-in regulator requiring you to replace the alternator. In
older vehicles that use external voltage regulators, you may need to replace
only the voltage regulator.)
The regulator controls voltage output based on the battery voltage, under-
hood temperature, and vehicle loads used. In other words, it controls the
maximum voltage the system can produce based on the current needs and
amount of current that can be produced by the spinning of the rotor in the
alternator. The normal high limit of a typical automotive regulator is 14.5 volts
+/–0.5. Refer to the manufacturer specifications for the correct limit, which
may vary by vehicle type.
A high charging rate will overcharge the battery and may decrease its life and
cause it to fail. If the battery test decision is REPLACE and the charging system
test shows a HIGH OUTPUT, check the battery’s electrolyte levels. A symptom
of overcharging is battery fluid spewing through the vent caps, which causes low
electrolyte levels and will harm the battery.
Chapter 8: Charging System Test—Auto/Van and Truck
DIODE OPEN The analyzer has detected a open diode within the alternator. Replace the
alternator.
DIODE SHORT The analyzer has detected an shorted diode within the alternator. Replace
the alternator.
Chapter 9: Cable Drop Test
Default Settings
Component
Auto Van Truck
Battery Ground 80 A —
Starter Circuit 150 A 500 A
Alternator Circuit 80 A 135 A
Chassis Ground — 135 A
Other Circuit (a circuit of your choice) 10 A 10 A
The test requires two test lead connections, as shown in the illustration below.
1. Connect the battery test leads at the component’s output lead (the B+ or output screw on
the alternator) and the component’s housing as ground.
NOTE: The test requires a complete circuit. If you are testing a system with a remote solenoid, you
can test from the battery to the solenoid, but not from the battery to the starter.
IMPORTANT: For accurate results the battery should be good and fully charged before you test.
Red Red
R1
+
Component
Battery Under
Test
–
R2
Black Black
DMM Test Lead Battery Test Lead
Chapter 9: Cable Drop Test
1. To start a test, select the Cable Drop icon in the Main Menu.
2. Select AUTO/VAN.
1 AUTO/VAN
2 TRUCK
4. Use the UP/DOWN ARROWS or the keypad to select the rated amperage or output of the
circuit.
500 A
Press the NEXT soft key.
5. Follow the instructions on the display for connecting the test cables.
6. The EXP tests the circuit and displays the results. The format for the Starter Circuit results
are typical for the Cable Drop Test.
7. To print the results, align the analyzer’s IR transmitter with the printer’s receiver, and select
the PRINT soft key. To return to the Main Menu, press the END soft key.
Chapter 10: DMM (Digital Multimeter)
DC Voltmeter AC Voltmeter
The DC and AC voltmeters measures voltage between two points in a circuit. The voltmeter is connected
in parallel with the circuit.
1. Connect the DMM test lead to the analyzer’s accessories port.
3. Connect the clamps or probes in the correct polarity: red clamp or probe to positive (+);
black to negative (–).
Scope
The scope is a voltmeter that provides a graph of voltage difference as it varies over time. After you select
the scope icon, note the instructions in the next screen before proceeding. You will need them after you
press the SELECT soft key to continue:
• Press 1 on the keypad to autoscale the scope.
In the time display the horizontal axis is in seconds and the vertical axis is in volts.
In the frequency display the horizontal axis is in hertz and the vertical axis is in volts.
Press the right soft key to alternate between the options to RUN (measure and display the signal) and
HOLD (freeze the signal).
The scope allows you to print the voltage trace to the optional IR printer when you freeze the signal. Align
the analyzer’s IR transmitter with the printer’s receiver, and select the PRINT soft key.
To return to the METERS menu, press END.
Temp
The IR temperature sensor measures surface temperature within a range of –20 to 200 °F. The tool can
be used for checking the transmission for overheating, and the temperature levels of the heater and air
conditioner.
Chapter 10: DMM (Digital Multimeter)
Ohmmeter
The meter is connected in parallel with the circuit under test and uses the power supplied by the analyzer’s
internal batteries to detect open or excessive resistance.
CAUTION: Always remove power from the circuit before connecting the ohmmeter to avoid damaging the
analyzer.
1. Connect the DMM test lead to the analyzer’s accessories port.
3. Connect the clamps or probes in the correct polarity: red probe to positive (+); black to
negative (–).
Diode
This test measures the voltage drop across components, such as diodes.
1. Connect the probes test lead to the EXP’s accessories port.
3. Connect the probes in the correct polarity: red probe to positive (+); black to negative
(–).
Vdc
Range Resolution Accuracy Overload Protection
0–60 V 0.01 V 0.05% + 2 120 Vrms
Accuracies are specified from 2% to 100% of range.
Vac
Range Resolution Accuracy Overload Protection
0–24 Vac rms 0.01 Vac 0.1% + 3 120 Vrms
Accuracies are specified from 2% to 100% of range.
Adc
Range Resolution Accuracy Overload Protection
0–70 A 0.01 A ± 3% of reading ± 1A 1000 Arms
0–700 A 0.1 A ± 3% of reading ± 1A 1000 Arms
Accuracies are specified from 2% to 100% of range.
Aac
Range Resolution Accuracy Overload Protection
0–70 A 0.01 A ± 3% of reading ± 1A 1000 Arms
0–700 A 0.1A ± 3% of reading ± 1A 1000 Arms
Accuracies are specified from 2% to 100% of range.
Ohm
Range Resolution Accuracy Overload Protection
10Ω–2 M 1 2.0% + 4 120 Vrms
Continuity
Range Resolution Accuracy Overload Protection
< 10 1 2.0% + 4 120 Vrms
Diode
Range Resolution Accuracy Overload Protection
0–1.5 V 0.01 V 0.05% + 2 120 Vrms
Temperature
Range Resolution Accuracy Overload Protection
-20–200 °F 1 °F
1.0% + 5 --------
-28–93 °C 1 °C
Chapter 11: Info Menu
Totals
The TOTALS report displays the total number of battery tests in three categories. Use the UP/DOWN
ARROW keys or press the corresponding numerical key to move the dot to the option button of your
choice or enter its number.
Lifetime
LIFETIME displays the total tests performed since the EXP was first used.
User Totals
USER TOTALS displays the total tests performed by User ID, four IDs per screen.
Totals by Decision
The first screen displays the number of battery tests by decision. The second screen displays the
number of packs tests by decision.
Chapter 11: Info Menu
Clear Counters
To reset a total to 0, press the numerical key that corresponds to the number preceding a check box,
and press the NEXT soft key.
Transfer
The TRANSFER utility lets you transfer test data to a PC using an optional IR receiver and software
package.
Version
Version displays the analyzer’s software version, the date the software was released, and the serial
number of the analyzer. The utility keeps a permanent count of the number of battery tests performed since
the analyzer was first used.
Chapter 12: Print/View
To print the results, align the analyzer’s IR transmitter with the printer’s receiver, and select the PRINT
soft key. To return to the Main Menu, press the END key.
View Test
VIEW TEST allows you to view and print the results of the Battery and System Tests.
• The vehicle’s battery may be too low to power the analyzer (below 1 volt). Fully charge the
battery and retest.
To realign, press the END button to cancel the print job. Verify alignment between the analyzer
and printer; then try to print the test results again.
• Make sure the printer is on. The printer shuts off after two minutes of inactivity to conserve
the batteries. To turn the printer on, briefly press the MODE button. The green STATUS light
should turn on. Make sure you are using the Midtronics printer. Other printers may not be
compatible.
Chapter 13: Troubleshooting
• Direct sunlight interferes with infrared data transmission and receiving. If the printer is not
receiving data, remove the printer and EXP from direct sunlight. If the printed characters are
not clear or are partially missing, recharge the batteries and reprint.
Chapter 14: Testing the Cable Set
• The top teeth on the positive (RED) clamp jaw (non-cable side) and the corresponding
pin hole on the connector.
• The bottom teeth on the positive (RED) clamp jaw (cable side) and the corresponding
pin hole on the connector.
• The top teeth on the negative (BLACK) clamp jaw (non-cable side) and the corresponding
pin hole on the connector.
• The bottom teeth on the negative (BLACK) clamp jaw (cable side) and the corresponding
pin hole on the connector.
Orientation
of arrow on
cable connector TOP Teeth
RED clamp, BLACK clamp, (non-cable side)
TOP teeth TOP teeth
cable
1. Grip a pencil with the clamp as shown in the figure above. Do not grip the metal part of the
eraser or any area that may conduct current.
2. To test the connection between the TOP teeth in the RED clamp, insert a probe tip into the
connector hole designated “RED clamp, TOP teeth.”
3. On the RED clamp touch the TOP teeth (non-cable side) with the probe tip. Wiggle the
battery test cables. The resistance reading should be less than 1 .
4. Repeat the test for the BOTTOM teeth in the RED clamp (cable side). Insert a probe tip
into the connector hole designated “RED clamp, BOTTOM teeth.” Touch the teeth on the
cable side of the jaw with the other probe tip. Wiggle the battery test cables. The resistance
reading should be less than 1 .
5. Repeat the test procedure for the BLACK clamp by testing the wire circuits between the
connector and TOP and BOTTOM clamp teeth. Both readings should be less than 1 .
Chapter 15: EXP Internal Batteries