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Midtronics EXP HD Instruction Manual

The document describes a battery management device called the Midtronics EXP-1000 HD. It can test 6- and 12-volt heavy-duty, automotive, and commercial batteries as well as 12-volt and 24-volt charging systems. The device has a large graphical screen and icon-based interface to simplify diagnostics. It comes in a hard-sided carrying case with accessories like test cables and can store test data on an SD card.

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0% found this document useful (0 votes)
405 views52 pages

Midtronics EXP HD Instruction Manual

The document describes a battery management device called the Midtronics EXP-1000 HD. It can test 6- and 12-volt heavy-duty, automotive, and commercial batteries as well as 12-volt and 24-volt charging systems. The device has a large graphical screen and icon-based interface to simplify diagnostics. It comes in a hard-sided carrying case with accessories like test cables and can store test data on an SD card.

Uploaded by

Zeck
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Battery Management Innovation

Midtronics Expandable
Electrical Diagnostic Platform

For testing 6- and 12-volt


heavy-duty, automotive,
and commercial batteries,
and 12-volt and 24-volt
charging systems.

INSTRUCTION ManuAl
Chapter 1: Before You Begin

Chapter 1: Before You Begin


For safe, efficient, and accurate testing, review the safety and operating instructions in this manual before
using the analyzer.

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:

• DANGER—RISK OF EXPLOSIVE GASES: Batteries can produce a highly explosive mix of


hydrogen gas and oxygen, even when the battery is not in operation. Always work in a well-
ventilated area. Never smoke or allow a spark or flame in the vicinity of a battery.

• WARNING—REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related


accessories contain lead and lead compounds, chemicals known to the state of California to
cause cancer and birth defects or other reproductive harm. Wash hands after handling.

• 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

Test Leads, Connections, and Data Ports


The top of the EXP has two connectors for test cables:

RJ45 connector (Accessories Port) with a


release lever for accessory test cable.

6-pin connector, with a locking ring, for the


battery test leads.

In addition, the top-left corner of the EXP has two IR data


ports:

Temperature measurement sensor.

Data transmitter, which transmits test results to


an IR printer

Standard and optional test cables include:

Heavy duty battery test cable


(15-foot)

Amp clamp
6-pin RJ45

DMM (Digital Multimeter)


cable

Banana Jack adapter


and probes
Chapter 2 : Overview

The bottom and right side of the EXP have two data ports:

DB-9 connector for future expandability.

Spring-loaded SD card slot for test data storage and software upgrades.

Connecting the Battery Test Cable


Connect the battery test cable to the EXP by first aligning the cable connector’s 6 holes with the 6 pins on
top of the EXP. Firmly insert the connector and finger-tighten the locking ring.

Connecting an Accessory Cable


If you are using an accessory cable, plug it into the accessories port on top of the EXP as you would a
phone jack. To remove it, press the lever and pull out the cable connector.

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

Display and Keypad


The analyzer keypad and display work together to help you quickly find and use the right tools at the right
time. The display also keeps you on track with on-screen navigation aids, directions, and messages. The
illustration below shows how the elements on the screen relate to the keypad.

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.

Status Indicator: EXP Internal Batteries Directional Arrows


This indicator appears in the screen’s top left When displayed in menu screens, the Direc-
corner. It lets you know the status and charge tional Arrows show you which ARROW key
level of the analyzer’s six 1.5 volt batteries. on the keypad to press to display other icons
The X in the indicator shows that the EXP is or screens. The Up and Down Directional Ar-
powered by the battery you are testing, a fea- rows, for example, let you know when to press
ture which conserves the internal batteries. the UP and DOWN ARROW keys to display
the screens above and below the current
screen.
Voltmeter
When you first connect the analyzer to a bat- The Left and Right Directional Arrows tell you
tery it functions as a voltmeter. The voltage when to use the LEFT or RIGHT ARROW
reading appears above the left soft key until keys to select an icon.
you move to other menus or functions.
Chapter 2: Overview

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.

To add a space, press the RIGHT ARROW


Scroll Bar key. To erase a space and insert a character,
Another navigational aid is the Scroll Bar on press the LEFT ARROW key.
the right side of the screen. The position of Refer to the table below for the characters as-
its scroll box shows you whether the screen sociated with each alphanumeric key.
is the top (or only screen), middle, or last in a
series. Keypad Character Assignment

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

Alphanumeric Keypad Backspace


In some cases, you can use the Alphanumeric
Keypad to enter numerical test parameters Space
instead of scrolling to them with the ARROW
keys.
Chapter 2: Overview

Data Entry Methods


To perform a particular test or function, the EXP will ask for different types of information. This means that
the methods you use to enter information will change depending on the type of information requested. The
four types of entry methods are described below.

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.

Main Menu (Screen 2)

* *
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.

Main Menu (Screen 3)

* Required test leads

Nine utilities, many of


Battery Amp Cable
which customize your test clamp drop
user interface.
Chapter 2: Overview

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.

Required test leads

Battery Amp DMM


test clamp clamps or
probes

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

Displays the total num- An optional IR software Displays the software


ber of test in three cat- and hardware package version, total tests from
egories: Lifetime of the allows you to transfer first use, and the serial
analyzer, by User ID, test data to a PC. number.
and by decision.

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

Displays the last Battery Displays the last Cable


and System Test results. Drop Test result. Sends
Sends the results to an the result to an optional
optional IR printer. IR printer.
Chapter 2: Overview

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)

Settings to adjust the If you created a coupon Allows you to create


screen contrast and with the Edit Coupon and store up to three
backlight time. utility, use Coupon to separate coupons to be
enable or disable the printed on test results.
inclusion of a coupon on
printed test results.

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)

Updates the analyzer


software via files on an
SD card.
Chapter 3: Utility Menu

Chapter 3: Utility Menu


The Utility Menu has several utilities that customize the EXP—from the language of the user interface to the
contrast of the text on the display. The utilities have default settings that you can change, depending on your
requirements.

Setup Function Default Settings


CLOCK
TIME The current Central Standard Time
MODE AM
DATE Current
FORMAT MM/DD/YYYY (month/day/year)

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.

COUPON Disabled (NO COUPON PRINTED)

EDIT COUPON Eight lines of text with 17 characters per line.


Default: USER COUPON LINE 1 through USER COUPON LINE 8

TEMPERATURE DEGREES F (Fahrenheit)

LANGUAGE English is the default language. French-Canadian and Spanish are also
available.

1. In the Main Menu, select the Utility icon.

2. Select the icon of the utility you want to adjust.


Chapter 3: Utility Menu

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.

Entering a New User ID


1. To create a USER ID, select:
1 ENTER NEW
2 DELETE
3 EDIT
Press the NEXT soft key to display the list of available IDs.

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.

Edit (Editing a User ID)


1. To edit a USER ID, select:
1 ENTER NEW
2 DELETE
3 EDIT
Press the NEXT soft key to display the list of IDs.

2. Follow steps 2, 3 , and 4 in “Entering a New User ID” above.


Chapter 3: Utility Menu

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.

Header and Coupon Template


Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8

To create or overwrite a header:


1. Press the UP or DOWN ARROW to highlight the line you want to change. The cursor will be
blinking to the right of the last character in the line.

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:

1. Press the UP or DOWN ARROW key to highlight the option.


CONTRAST LEVEL 10
BACKLIGHT TIME 60

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:

1. Press the UP or DOWN ARROW key to highlight the option.


CONTRAST LEVEL 10
BACKLIGHT TIME 60

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.

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 DEGREES F
2 DEGREES C

2. Press the SAVE soft key to save your setting.


Chapter 3: Utility Menu

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

2. Press the SAVE soft key to save your setting.

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

Chapter 4: Test Preparation

Inspecting the Battery


Before starting the test visually inspect the battery for:

• 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.

Testing Individual Batteries


1. If the batteries have threaded studs, screw the negative (–) stud adapter onto the negative
terminal, and the positive (+) adapter onto the positive terminal.

2. Connect the red clamp to the positive (+) terminal or adapter.

3. Connect the black clamp to the negative (–) terminal or adapter.

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

Clamp connection to stud adapter Clamp connection to stud pad

Testing the Battery Pack


1. 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.

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

Chapter 5: Battery Test


The Battery Test function tests one battery in or out of the vehicle. To test the battery pack the analyzer will
guide you through the steps of selecting your battery test parameters and interpreting the results. Before
you start the test, review the instructions in “Test Preparation.”

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.

1. In the Main Menu, select the Battery Test icon.

2. Select the POST TYPE.


1 TOP
2 SIDE
3 REMOTE (appears only for the Automotive System Test)

Press the NEXT soft key to continue.

3. Select the BATTERY TYPE.

1 GROUP 31 (BCI heavy-duty battery size)


2 4D, 8D (heavy-duty commercial batteries)
3 AUTOMOTIVE (car, van, light truck, etc.)

Press the NEXT soft key to continue.

4. Select the BATTERY CHEMISTRY.

1 REGULAR/AUTO (flooded lead-acid)


2 AGM-SPIRAL (Absorbed Glass Mat: non-spillable, shaped like a six-pack)
3 AGM-OTHER (non-spillable, standard shape)
4 GEL (VRLA with gelified electrolyte)

Press the NEXT soft key to continue.


Chapter 5: Battery Test

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.

1 CCA (Cold Cranking Amps)


2 CA (Cranking Amps)
3 MCA (Marine Cranking Amps)
4 JIS (Japanese Industrial Standard)
5 DIN (Deutsch Industry Norm)
6 SAE (Society of Automotive Engineers)
7 IEC (International Electrotechnical Commission)
8 EN (European Norm)
Press the NEXT soft key to continue.

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

b) If JIS, scroll to the JIS number.

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.

Battery Test Results


The EXP displays the complete results on multiple screens. The EXP-1000 HD BMP generates a test code
for REPLACE decisions. To view the code, press the UP or DOWN ARROW key.

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 serial number


Test code generated for REPLACE
decisions for warranty purposes
(BMP version only. )

Battery state-of-health

Estimated charge time if


charging needed

Battery state-of-charge
Chapter 5: Battery Test

Battery Decision Recommended Action

GOOD BATTERY Return the battery to service.

GOOD–RECHARGE Fully charge the battery and return it to service.

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.

BAD CELL–REPLACE Replace the battery.

WARNING: Do not charge the battery. Charging a battery with


one or more bad cells could cause an explosion and serious
harm to the user.

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

Additional Test Requirements


For a more decisive result the analyzer may ask for additional information or further explore the battery’s
condition. The following messages and instructions may appear before the analyzer displays the results
of your test.

System Noise Detected


The analyzer has detected computer, ignition noise, or parasitic drain, and will attempt to retest. Make
sure all vehicle loads are off, doors are closed, and the ignition is in the off position. The analyzer will
automatically retest when it no longer detects system noise. If the message reappears:

• 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.

• Disconnect the battery cables and retest.

Unstable Battery Detected


A battery that is weak, or that has just been charged, may retain enough electrical activity to be
detected by the analyzer and will adversely affect the test results. A fully charged battery should
stabilize quickly, after which the analyzer will automatically retest. Weak batteries should be charged
and retested. If the battery is fully charged, check the clamp connections.

Deep Scan Test


In some cases the analyzer may need to further analyze a deeply discharged battery to determine
whether the battery should be replaced or if it has a chance to be recovered. It then briefly conducts
a Deep Scan Test of the battery.

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

5-Minute Discharged Battery Test


During this test a deeply discharged battery is diagnosed in minutes, eliminating the need to charge
the battery for hours in advance. The EXP displays this test option after the Deep Scan Test and
before it arrives at the battery decision.
The test requires an external high-current charger. The use of an amp clamp is preferred but not
required.
1. If you are using an amp clamp, connect it to the analyzer’s accessories port and
select AMP CLAMP AVAILABLE.
1 AVAILABLE
2 NOT AVAILABLE
Press the NEXT soft key to continue.

2. Select charge current rate of the battery charger you will use for this test.

15 (10–60)
Press the NEXT soft key.

3. Disconnect the analyzer’s clamps from the battery posts.

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.

8. Press the NEXT soft key to zero out the clamp.

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

Chapter 6: Battery and Starter System Test—Auto/Van


The System test evaluates the battery, starting and charging systems. Before the test, inspect the
alternator drive belt. A belt that is glazed or worn, or lacks the proper tension, will prevent the engine
from achieving the rpm levels needed for the test.

1. In the Main Menu, select the System Test icon.

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.

Starter System Test


1. Start the engine at the prompt.

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

Auto/Van Starter System Test Results


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 testing, press the NEXT soft key.

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

Y axis = system performance:


cranking voltage

X axis = Time

Y axis = system performance:


Cranking current is displayed
if amp clamp is used

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.

Refer to page 36 for the Charging System Test.


Chapter 7: Battery and Starter System Test—Truck

Chapter 7: Battery and Starter System Test—Truck


Before starting the test, inspect the alternator drive belt. A belt that is glazed or worn, or lacks the proper
tension, will prevent the engine from achieving the rpm levels needed for the test.
The System Test first evaluates the battery pack (with up to 6 batteries), then the starter and charging
systems. The Charging System Test has the option of using the amp clamp to measure charging current.

Battery Pack Test


The test is designed to give you a quick approximation of the pack’s state of health and its capability to
deliver current. If the analyzer determines that the pack has a low state of charge, it will provide the option
of testing the batteries individually or skipping to the System Test.

1. In the Main Menu, select the System Test icon.

2. Select AUTO/VAN.
1 AUTO/VAN
2 TRUCK

3. Enter the number of batteries in the pack (up to six).

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.

4. Follow steps 3 to 8 in the Battery Test section starting on page 24.

5. When prompted, enter the vehicle VIN.

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

Break Pack Down


If you choose to test individual batteries, the EXP uses the parameters from the pack test and prompts you
through the steps of disconnecting the pack, testing each battery, and reconnecting.

To test individual batteries after a CHECK BATTERY PACK decision:

1. Select BREAK PACK DOWN and press the NEXT soft key to continue.

2. Disconnect the EXP from the battery posts.

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

Battery Pack Test Results


If the result is GOOD PACK, the EXP continues to the Starter System Test. The EXP generates a Pack
Code for all decisions.

If you tested individual batteries, the EXP displays the results for each battery with a test code for
REPLACE decisions.

To view the complete results, press the UP or DOWN ARROW key.

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

Selected number of Selected rating


batteries in the pack Battery temperature

Pack Code for REPLACE decisions

Results for a test of two


batteries, with serial
numbers and test codes
for REPLACE decisions
Chapter 7: Battery and Starter System Test—Truck

Truck Starter System Test


The performance of the starting and charging systems depends on the battery’s condition. It is important
that the battery or pack is good and fully charged before any further system testing.

1. Start the engine at the prompt.

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.

Starter System Test Results


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 testing, press the NEXT soft key.

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.

Average cranking voltage


Starter decision

Cranking time in seconds

Y axis = system performance:


cranking voltage

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

Chapter 8: Charging System Test—Auto/Van and Truck


If you are using the amp clamp (AMP CLAMP AVAILABLE) in the AUTO/VAN Charging System Test, keep
it clamped around the negative (–) battery cable.

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.

Charging System Test Results—Auto/Van and Truck

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

Normal DC Bar graph showing DC


voltage range voltage within normal range
with loads on and off

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 Decision Action


EXCESSIVE RIPPLE One or more diodes in the alternator are not functioning or there is stator
damage, which is shown by an excessive amount of AC ripple current
supplied to the battery.
√ Make sure the alternator mounting is sturdy and that the belts are in good
shape and functioning properly. If the mounting and belts are good, replace
the alternator.
OPEN PHASE The analyzer has detected an open phase within the alternator. Replace the
alternator.

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

Chapter 9: Cable Drop Test


If the test results for the starter or charging systems indicate that there may be a problem, you may want
to perform the Cable Drop Test to determine if it is due to worn cables or bad connections between the
battery and the alternator or starter. Worn cables or bad connections create higher resistance, which
causes a drop across the circuit. The voltage drop reduces current carrying capability that displays the
same symptoms as a weak alternator or starter and causes premature battery failure.
There is no need to run the engine. The Cable Drop Test uses Midtronics’ conductance technology to
send a signal through the circuit to the component under test. The EXP then simultaneously calculates
voltage drop on the positive (+) and negative (–) sides of the circuit as well as the total voltage drop. The
amperage range for each of the four tests is 0 to 1000 A. When you change the setting from the factory
defaults, the EXP will store your setting in memory for your next test.
There are four preset tests for components up to 1000 amps:

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.

2. Connect the DMM test leads at the battery terminals.

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

3. Use the UP/DOWN ARROWS or the numerical keypad to select a circuit.


1 STARTER CIRCUIT
2 ALT CIRCUIT
3 CHASSIS GROUND
4 OTHER
Press the NEXT soft key to continue.

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.

Total circuit voltage drop


Voltage drop across
positive side of circuit

Voltage drop across


negative side of circuit

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)

Chapter 10: DMM (Digital Multimeter)


The DMM’s infrared temperature sensor also allows you to determine the surface temperature of
components before you service them or as a diagnostic aid. Specifications for each tool are listed at the
table at the end of this chapter.
A measurement that is out of the limit displays as OL. Refer to the manufacturer specifications for the
correct limits, which may vary by component or vehicle type.

1. In the Main Menu, select the DMM icon.

2. Select the icon of the meter you want to use.

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.

2. Select the DC Volts or AC Volts icon.

3. Connect the clamps or probes in the correct polarity: red clamp or probe to positive (+);
black to negative (–).

4. The meter autoranges and displays the measurement.

5. To return to the METERS menu, press the END soft key.

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.

• Press 3 on the keypad for the time display.

• Press 4 on the keypad for the FFT (frequency) display.

Press the SELECT soft key.


Chapter 10: DMM (Digital Multimeter)

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.

DC Ammeter AC Ammeter Volts/Ammeter


The DC ammeter measures DC magnitude and flow of the DC current in a circuit. The volts/amp meter
simultaneously measures charging voltage and charging current.

1. Connect the amp clamp lead to the analyzer’s accessories port.

2. Select the DC Volts, AC Volts, or Volts/Amps icon.

3. Select the amp clamp range.


1 70 AMP MAX.
2 700 AMP MAX.
Press the NEXT soft key to continue.

4. The meter zeros itself.

5. Place the clamp’s jaws around the negative (–) cable.

6. The EXP displays the measurement.

7. To return to the METERS menu, press the END soft key.

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.

2. Select the Ohm Meter icon.

3. Connect the clamps or probes in the correct polarity: red probe to positive (+); black to
negative (–).

4. The meter will autorange and display the measurement.

5. When finished, press the END soft key.

6. To return to the Meters menu, press the END soft key.

Diode
This test measures the voltage drop across components, such as diodes.
1. Connect the probes test lead to the EXP’s accessories port.

2. Select the meter’s icon.

3. Connect the probes in the correct polarity: red probe to positive (+); black to negative
(–).

4. The meter will autorange and display the measurement.

5. When finished, press the END soft key.


Chapter 10: DMM (Digital Multimeter)

The accuracy specification is defined as ± (n% reading + [count * resolution]) at 77 °F.

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

Chapter 11: Info Menu


The Info Menu has three utilities to help you manage your test data and track the usage and history of your
analyzer.

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.

1. In the Main Menu, select the Totals icon.

2. Select the icon of the report or function you want to use.

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

Chapter 12: Print/View


The Print/View Menu allows you to view and print the results of the Battery, System, and Cable Drop Tests.
The results of the last test are stored in memory until the next test is performed.

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.

1. In the Main Menu, select the Print/View icon.

2. Select the icon of the report or function you want to use.

View Test
VIEW TEST allows you to view and print the results of the Battery and System Tests.

View Cable Test


VIEW CABLE TEST allows you to view and print the results of the Cable Drop Test.
Chapter 13: Troubleshooting

Chapter 13: Troubleshooting


If you have problems with the display or the Midtronics printer, try these troubleshooting suggestions:

The Display Does Not Turn On


• Check the connection to the vehicle battery.

• Press the POWER button.

• The vehicle’s battery may be too low to power the analyzer (below 1 volt). Fully charge the
battery and retest.

• The analyzer ’s 6 AA batteries may need to be replaced. Follow the directions in


“Chapter 15: EXP Internal Batteries” on page 52, and replace the batteries (alkaline
recommended).

The STATUS LED Flashes


When a printer fault occurs, the STATUS LED flashes. You can identify the fault by the number of sequential
flashes:
Printer STATUS LED
Sequence Condition Solution
* * * No paper Insert new paper
** ** ** Thermal head too hot Allow head to cool
*** *** *** Batteries weak Recharge printer
batteries for 16 hours

Data Will Not Print


• If the IR transmitter and receiver are not aligned, all the data may not print. The infrared
ports on the top of the analyzer and on the printer below the MODE button should be pointed
directly at each other. The maximum distance for reliable transmission between the ports is
17 in (45 cm).

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

Chapter 14: Testing the Cable Set


If the analyzer frequently displays CHECK CLAMP CONNECTION! you may have an intermittent open
circuit along one or both of the battery test cables. You can check the circuit with a simple test. The test
requires an ohmmeter and a wire or paper clip if the ohmmeter probes are too large to insert into the pin
holes. You will also need to a pencil or plastic marker to keep the clamp jaws apart. The test is the same
for cable sets with clamps having two or one set of teeth.

Test Procedure for Heavy Duty Clamps


You are testing the continuity of the following end points on the test cable:

• 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

BLACK clamp, RED clamp


BOTTOM teeth BOTTOM teeth BOTTOM Teeth
(cable side)

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

Chapter 15: EXP Internal Batteries


The EXP uses six AA, 1.5-volt batteries (alkaline recommended) to allow testing of batteries down to
1 volt and supply power while the menu is active. The analyzer can test batteries down to 5.5 volts when
the internal batteries are not functioning.

Battery Power Indicator


The square in the upper left corner of the display indicates the charge level of the battery pack. The square
is black when the battery pack is fully charged. It gradually changes to white as the charge level declines.
The EXP will display a warning message when the batteries need replacing.

Full Decreasing Low Powered


by test
battery

Replacing the EXP Batteries


Press here Slide in
1. Turn the EXP face down. Screw Latch
this direction

2. Remove the screw.

3. Press gently on the ridges above the


arrow on the battery compartment
cover.

4. Slide the cover in the direction of the


arrow and remove the cover.

5. Remove the discharged batteries.

6. Insert new batteries as shown in the


figure (right). Make sure the positive
and negative terminals are positioned
correctly.

7. Insert the battery door tabs into the


slots on the analyzer and slide the door
closed, making sure the latch locks.

8. Insert and tighten the screw.

Automotive Diagnostic & Test Tools

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