September 2013
167-000505EN-A
EXP-1003 HD
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
Blank page
Contents
EXP-1003 HD
Chapter 1: Introduction & Overview 5
Personal Precautions 5
Accessories
External Connections 6
Connecting The Battery Test Cable 6
Connecting An Accessory Cable 6
Data Card 6
Conventions Used in This Manual 6
Display And Keypad 7
Data Entry Methods 8
Menu Icons 8
Option Buttons 8
Scrolling Lists 8
Scroll Boxes 8
Alphanumeric Entry 8
Menu Maps 8
Main Menu 8
DMM Menu 9
Info Menu 9
Utility Menu 9
Print/View Menu 10
Logging In 10
Creating a User ID and Setting Preferences 10
Inspecting the Battery 10
Connecting to a Battery 10
Testing Individual Batteries 10
Testing Out-of-Vehicle (Battery Test) 11
Testing the Battery Pack 11
Initial Power-up 11
5
Chapter 2: Battery Test 12
Additional Test Requirements 12
System Noise Detected 12
Unstable Battery Detected 13
Deep Scan Test 13
Battery Test Results 13
Battery Test Results 13
Chapter 3: System Test 14
Auto/Van 14
Truck 15
Auto/Van Test Results 16
Auto/Van Test Decisions 16
Truck Test Results 17
Truck Test Decisions 17
Battery Pack Test Results 17
Battery Pack Decisions 17
Additional Test Requirements 18
System Noise Detected 18
Unstable Battery Detected 18
Starter System Test 18
Starter System Test Results 18
Charging System Test 19
Charging System Test Results 19
Chapter 4: Print/View 21
View Test 21
View Cable Test 21
Chapter 5: Cable Drop Test 22
Chapter 6: DMM (Digital Multimeter) 23
DC And AC Voltmeters 23
Scope 23
DC, AC, And Volts Ammeters 23
Temp 23
Ohmmeter 23
Diode 23
Chapter 7: Info 25
Totals 25
Lifetime 25
User Totals 25
Totals by Decision 25
Clear Counters 25
Transfer 25
Version 25
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
EXP-1003 HD
Chapter 8: Utility 26
Clock 26
Mode 26
Time 26
Format 26
Date 26
Users 26
Entering A New User ID 26
Deleting A User ID 27
Editing A User 27
Shop 27
Display 27
Contrast Level 27
Backlight Time 28
Coupon 28
Edit Coupon 28
Temp 28
Language 28
Format 28
Update 28
Chapter 9: Maintenance & Troubleshooting 29
TTesting Clamp Continuity 29
Performing A Continuity Test 29
Internal Batteries 29
Battery Power Indicator 29
Replacing The Tester Batteries 29
Troubleshooting 30
The Display Does Not Turn On 30
The STATUS LED Flashes 30
Data Will Not Print 30
Appendix: Templates 31
Header And Coupon Templates 31
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Chapter 1: Introduction & Overview
Chapter 1: Introduction & OverviewEXP-1003 HD
Personal Precautions
Risk of explosive gases.
Never smoke or allow a spark or
ame in the vicinity of a battery.
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.
Wash hands after handling.
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.
Accessories
*
Inspect the battery for damage 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 ush them thoroughly with cold running
water for at least 15 minutes and seek medical attention.
If battery acid gets on your skin or clothing, wash immediately with a mixture of 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 servicing a 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.
Soft Carrying Case (Std.) Stud Adapters (Std.) A087 IR Printer
Hard Carrying Case (incl. w/Amp Kit)
DMM Probe Kit
(incl. w/Amp Kit)
A028 DMM Cable (Std.)
Printer Paper (Std.) 10’ Battery Test Cable (Std.) A018 Amp Clamp
- AMP Kit includes all shown accessories except item
*
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
(incl. w/Amp Kit)
(incl. w/Amp Kit)
Chapter 1: Introduction & Overview EXP-1003 HD
External Connections
RJ45 connector (Accessories Port) with a release lever for
accessory connections.
6-pin connector, with a locking ring, for the battery test
leads.
Temperature measurement sensor.
Data transmitter, which transmits test results to an IR
printer.
DB-9 connector for
future accessories.
Spring-loaded data card
slot for test data storage
and software upgrades.
Connecting The Battery Test Cable
Connect the battery test cable to the tester by rst aligning
the cable connector’s 6 pins with the holes on top of the tester.
Firmly insert the connector and nger-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 tester as you would a phone jack. To remove
it, press the lever and pull out the cable connector.
Data Card
The analyzer ships with a plastic insert in the data card slot to
protect it from dust and debris. To remove the plastic insert
or a data card, push briey on its edge to release it and pull it
from the slot.
When inserting a card, push it into the slot until it locks. The
card is correctly inserted when it is not protruding from the
slot. To protect the card slot and enable the analyzer to read
and write to the card, leave the card in the slot.
Conventions Used in This Manual
To help you learn how to use your Midtronics product, the
manual uses these symbols and typographical conventions:
Symbols And Typographical Conventions
Convention Description
The safety symbol indicates important
!
CAPITAL
LETTERS
SELECT The text for soft keys are in Bold capital
instructions for avoiding hazardous
conditions and personal injury.
The safety symbol with the words
CAUTION, WARNING, or DANGER
indicates instructions for avoiding
hazardous conditions and personal injury.
The wrench symbol indicates procedural
notes and helpful information.
These symbols indicate which arrow keys
on the keypad to press for a given function.
The text for screen options are in regular
capital letters.
letters.
IMPORTANT: Do not turn the locking ring more than
¾ of a turn or you will damage the tester components.
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Chapter 1: Introduction & OverviewEXP-1003 HD
Display And Keypad
The analyzer keypad and display work together to help you
quickly nd 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.
POWER Key
Press the POWER button to turn the analyzer on and
o. The analyzer also turns on automatically when you
connect its test leads to a battery.
Title Bar
The title bar shows you the name of the current menu, test
tool, utility, or function.
Selection Area
The selection area below the Title Bar contains selectable
items or dialog boxes that display information or require
a response.
Menu Screen Arrows
When displayed in menu screens, the menu screen arrows
show you which ARROW key on the keypad to press to
display other icons or screens. When displayed under a list
of options, the menu screen arrows show you which keypad
arrow to press to highlight a character or item in a list.
Scroll Bar
Another navigational aid is the scroll bar on the right side
of the screen. The position of its scroll box shows you
whether the screen is the top (or only screen), middle, or
last in a series.
Internal Batteries Status Indicator
This indicator appears in the screen’s top left corner, lets
you know the status and charge level of the analyzer’s six
(6) 1.5-volt batteries. The “X” in the top left corner of the
screen shows that the analyzer is powered by the battery
you’re testing to conserve the analyzer’s internal batteries.
Voltmeter
When you first connect the analyzer to a battery it
functions as a voltmeter. The voltage reading appears
above the left soft key until you move to other menus or
functions.
Soft Keys
Press the two soft keys linked to the bottom 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 appearing above
them as part of the keys. Some of the more common softkey functions are SELECT, BACK, and END.
Scroll
Box
Top or
only
screen
Middle
screen
Last
screen
Arrow ( ) Keys
Press to move up to the next selectable item or row.
When entering text, use to move to the previous
character.
Press to move down to the next selectable item or row.
When entering text, use to move to the next available
character.
Use or to scroll to the letters A through Z and the
numbers 0 through 9. When entering text, use to move
one space to the right and to move one space to the left.
Alphanumeric Keypad
In some cases, you can use the Alphanumeric Keypad to
enter numerical test parameters instead of scrolling to
them with the keys.
You can also use the Alphanumeric Keys to create and edit
customer coupons. The keypad includes characters for
punctuation.
To add a space, press . To add a space or insert a
character, press .
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Chapter 1: Introduction & Overview EXP-1003 HD
Refer to the following table for the characters associated
with each alphanumeric key.
Key Character
$ - ( ) 1
a b c 2
d e f 3
g h i 4
j k l 5
m n o 6
p q r s 7
t u v 8
w x y z 9
% , . # 0
Data Entry Methods
To perform a particular test or function, the tester requires
dierent types of information. This means that the methods
you use to enter information will change depending on the
type of information requested. The ve types of entry methods
are described below.
Typically, the soft key below the right half of the screen
conrms your choice, although the command above it may
vary. (Examples: SELECT, NEXT, and SAVE.) In a similar
fashion, the soft key below the left half of the screen cancels
your choice or returns you to the previous screen, although
the word above it may also vary. (Examples: BACK and END.)
Menu Icons
A menu icon is a graphical
representation of a function you
can select, such as the Battery test
Icon in the Main Menu. To select
an icon, use
it. Highlighting changes the icon
to a white picture on a black background. To conrm your
selection, press the appropriate soft key.
Option Buttons
Some lists have option buttons
before each item. To select an
item, use
to the button next to the item. To
conrm your selection, press the
appropriate soft key.
or
or
to highlight
to move the dot
Scrolling Lists
Scrolling lists contain items that
extend above and below the
screen. The first number above
the right soft key indicates
the position in the list of the
highlighted item. The second
number above the right soft key indicates the number of items
in the list.
To select an item, press or to highlight the item and press
the appropriate soft key. To advance the highlight bar up or
down four lines at a time, press or .
Scroll Boxes
Scroll boxes contain variables that
are displayed by scrolling using
arrow keys.
To select, use or to scroll to the
value, and press the appropriate
soft key. In the illustration the left directional arrow indicates
that you can press to clear all or part of the entry.
Alphanumeric Entry
Some selections require you to
alphanumeric characters. These
“user-dened” selections have a
blinking horizontal line (cursor) to
the right of the last character.
Use or to highlight a line for editing. Press SELECT to edit
the selected line. Display the character or number you want by
rapidly pressing an ARROW key as many times as needed, or
press and hold the ARROW key to rapidly scroll. To backspace,
press . Use to add a space. When nished, press the
appropriate soft key to save the text you entered.
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.
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Chapter 1: Introduction & OverviewEXP-1003 HD
Menu Icon Description
Tests one battery using the battery information
you select in a series of screens.
Tests the battery pack or individual batteries
(and the starting and charging systems.
Allows you to view your stored test results and
print them to an optional IR printer.
Tests both sides of a circuit simultaneously for
voltage drop. Three preset tests and one user-
dened.
Digital multimeter with eight test meters, a
temperature sensor, and options for clamps
and probes.
Includes a test counter, data transfer utility, the
tester software version and serial number.
Nine utilities, many of which customize your
user interface.
DMM Menu
Info Menu
The Info Menu has three utilities to help you manage
your test data, and track the analyzer’s usage and history.
Menu Icon Description
Displays the total number of test in three
categories: Lifetime of the analyzer, by User
ID, and by decision.
An optional IR software and hardware package
allows you to transfer test data to a PC.
Displays the software version, total tests from
rst use, and the serial number.
Utility Menu
The Utility Menu allows you customize your analyzer.
Before testing, check the default values to see which
options you may want to change.
Menu Icon Description
Settings to adjust date and time.
Use the DMM Menu to access the test meters, tem-
perature sensor, and probe and clamp options, some
of which require optional test leads.
Menu Icon Description
Measures voltage within a range of 0 to 60
Vdc.
Measures voltage within a range of 0 to 24
Vac.
Voltage trace with time and frequency
measurements.
Tests the strength of the direct current ow
through a circuit.
Tests the strength of the alternating current
ow through a circuit.
Sensor that displays temperature in degrees F
or C (units you can select in the Utilities Menu.)
Tests a circuit for continuity and resistance
measured in ohms (Ω).
Tests a diode for forward voltage drop.
Add, edit, or delete User IDs using up to six
alphanumeric characters.
Allows you to add a custom header to printed
test results.
Settings to adjust the screen contrast and
backlight time.
If you created a coupon with the Edit Coupon
utility, use Coupon to enable or disable the
inclusion of a coupon on printed test results.
Allows you to create and store up to three
separate coupons to be printed on test results.
Allows you to select degrees in C or F for
temperature measurements.
Sets the language of the display and printouts.
Formats the data card to receive data. Also
erases all data on the card.
Updates the analyzer software via les on a
data card.
Measures two signals simultaneously: DC
voltage and amperage.
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Chapter 1: Introduction & Overview EXP-1003 HD
Print/View Menu
The tester 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.
Menu Icon Description
Displays the last Battery and System Test
results. Sends the results to an optional IR
printer.
Displays the last Cable Drop Test result. Sends
the result to an optional IR printer.
Logging In
Scroll to a User ID and press NEXT.
1 USER01
2 USER02
3 USER03
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” for instructions.
Connecting to a Battery
Do not connect the tester to a voltage source
greater than 60 Vdc.
Testing Individual Batteries
At the start of the test, make sure all vehicle accessory loads
are o, the key is not in the ignition, and the doors are closed.
1. If the batteries have threaded studs, screw the negative (–)
stud adapter onto the negative terminal, and the positive
(+) adapter onto the positive terminal.
Failure to properly install lead terminal adapters,
or using adapters that are dirty or worn, may
cause false test results.
When testing side-post or Group 31 batteries, always use lead
terminal adapters provided with the tester—do not test at
the battery’s steel bolts. To avoid damage, never use a wrench
to tighten the adapters more than ¼ turn.
2. Connect the red clamp to the positive (+) terminal or
adapter.
Creating a User ID and Setting Preferences
When you press the POWER button, the analyzer takes a few
seconds to boot up while testing the integrity of its software. It
then displays a list of default User IDs, which are placeholders
for adding technicians to the test database. To edit the default
IDs and add up to 24 technicians, see the Utility Menu.
Before starting a test you may want to customize the use of
your tester by setting preferences in the Utility Menu. The
menu has settings for the date and time, the display contrast
and backlight time, customer coupons, languages, and more.
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. Re-
pair 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 ll up to ½ inch above the top of the
plates and fully charge the battery. Do not overll.
• Corroded or loose battery tray and hold-down xture.
Tighten or replace as needed.
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 rmly connected before
testing. If the message CHECK CONNECTION appears, clean
the terminals and/or reconnect the clamps
Clamp connection to stud adapter
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Clamp connection to stud pad
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Chapter 1: Introduction & OverviewEXP-1003 HD
Testing Out-of-Vehicle (Battery Test)
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
rst and reconnect it last.
• Always use a carry tool or strap to lift and transport the
battery.
Failure to properly install lead terminal adapters,
or using adapters that are dirty or worn, may
cause false test results.
When testing side-post or Group 31 batteries, always use lead
terminal adapters provided with the tester—do not test at
the battery’s steel bolts. To avoid damage, never use a wrench
to tighten the adapters more than ¼ turn.
Testing the Battery Pack
1. At the start of the test, make sure all vehicle accessory
loads are o, 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.
Initial Power-up
The tester is initially set up to require a default USER ID to access
the Main Menu. The rst selection screen to appear enables you
to set the language for the display and printed test results. This
option can disable. See “Options” in Utility Menu.
The Main Menu is displayed on the screen.
3. For a proper connection, rock the clamps back and forth.
Both sides of each clamp must be rmly connected before testing. If the message CHECK CONNECTION appears,
clean the terminals and/or reconnect the clamps.
To Starter
To Ground
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 2: Battery Test EXP-1003 HD
Chapter 2: Battery Test
The Battery Test function tests one battery in or out of
the vehicle and guide you through selecting battery
the test parameters and interpreting the results.
Use the BACK key to return to the Main Menu at the start of the
test or to the previous screen as you progress.
1. In the Main Menu, select the Battery Test icon.
2. Use or to s
continue or press the corresponding number key
elect the POST TYPE
and press NEXT to
.
1 TOP
2 SIDE
3. Use or to s
continue or press the corresponding number key
elect the BATTERY TYPE
and press NEXT to
.
1 GROUP 31 (BCI heavy-duty battery size)
2 4D, 8D (heavy-duty commercial batteries)
3 AUTOMOTIVE (car, van, light truck, etc.)
4. Use or to s
elect the BATTERY CHEMISTRY
and press
NEXT to continue or press the corresponding number key
1 FLOODED
2 AGM-SPIRAL
3 AGM
Rating Description Range
MCA
JIS
DIN Deutsche Industrie-Norm 100 to
SAE European labeling of CCA
IEC International Electrotechnical
EN Europa-Norm 100 to
Marine Cranking Amps: The
amount of current a battery can
provide at 32°F (0 ºC).
Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and letters.
Commission
100 to
3000
26A17 to
245H52
(72 numbers)
1000
100 to
3000
100 to
1000
1700
6. Press or to select the BATTERY RATING or use the numeric keys and press NEXT to continue.
a) If CCA, use the keypad or 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.
4 GEL
5. Use or to s
usually printed on the battery label,
elect the battery RATING UNITS, which is
and press NEXT to
continue or press the corresponding number key
information is unreadable, contact the battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
Rating Description Range
CCA
CA
Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8 ºC).
Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
100 to
3000
100 to
3000
. If the
26A17
26A19
26B17
28A19
7. If prompted, measure the ambient battery temperature
by aim the IR temperature sensor on the top of the tester
at the battery case. Once the temperature stabilizes, press
NEXT to continue the test.
Battery Case
(Top)
Sensor
Additional Test Requirements
The tester may display the following information if it
determines the need for a more decisive result.
System Noise Detected
The analyzer has detected computer, ignition noise, or
parasitic drain, and will attempt to retest. Make sure all vehicle
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loads are o, doors are closed, and the ignition is in the o
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 nd 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.
Chapter 2: Battery TestEXP-1003 HD
Battery State-
Of-Health
Battery State-
Of-Charge
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 aect 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
briey conducts a Deep Scan Test of the battery.
The tester 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 tester displays the results.
Battery Test Results
The tester displays the complete results on multiple screens.
To view the code, press
code for all REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
return to the Main Menu, press END.
NOTE: For REPLACE or BAD CELL decisions, enter the
battery serial number located on the battery case to
generate a test code for warranty purposes. When
nished, press NEXT to continue.
Battery
decision
Measured
voltage
Battery
serial
number
or . The tester will generate a test
Measured
CCA
Selected
rating
Battery
temperature
Generated
test code (for
REPLACE
decisions)
Estimated
charge time
(if needed)
Battery Test Results
Decision Recommended Action
GOOD
BATTERY
GOOD–
RECHARGE
CHARGE &
RETEST
REPLACE
BATTERY
BAD CELL–
REPLACE
JUMP START
POST
SIDE POST The analyzer has found the data was
NOTE: If the tester displays 24 VOLT BATTERY after the
Return the battery to service.
Fully charge the battery and return it to
service.
Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause false readings. If CHARGE &
RETEST appears again, replace the battery.
May also mean a poor connection between
the battery and the vehicle.
This decision indicates a bad cell within the
battery. Replace the battery.
Risk of explosive gases.
Can cause death or
serious personal injury.
Never attempt to charge a
battery with a bad cell. The
battery must be replaced.
Data was inconclusive using the remote post.
Retest at the battery terminals.
inconclusive. Retest using the side post
adapters
Automotive System Test, you are attempting to test
in-vehicle both batteries in a 24-volt system. Disconnect the batteries and test them individually.
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 3: System Test EXP-1003 HD
Chapter 3: System Test
The System Test evaluates the battery, starting and
charging systems. The System Test includes Battery
Test to eliminate it as the cause of starting or charging
problems.
The BACK key returns you to the Main Menu at the start of the
test and to the previous screen as you progress.
Auto/Van
1. Use the ARROW keys to highlight the System Test icon
and press NEXT to continue
2. Use or to s
screen
and press NEXT to continue, or press the corre-
elect AUTO/VAN at the VEHICLE TYPE
sponding number key
1 AUTO/VAN
2 TRUCK
3. Use or to s
elect the AMP CLAMP availability
NEXT to continue, or press the corresponding number key
If you select the Amp Clamp, follow the on-screen
instructions for zeroing out clamp and placing it around
the negative battery cable before proceeding.
4. Use or to s
elect the POST TYPE
continue, or press the corresponding number key
1 TOP
.
.
and press
and press NEXT to
.
Rating Description Range
CCA
CA
MCA
JIS
DIN Deutsche Industrie-Norm
SAE European labeling of CCA
IEC International Electrotechnical
EN Europa-Norm
.
7. Press or to select the BATTERY RATING or use the nu-
Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8 ºC).
Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
Marine Cranking Amps: The
amount of current a battery can
provide at 32°F (0 ºC).
Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and letters.
Commission
100 to
3000
100 to
3000
100 to
3000
26A17 to
245H52
(72 numbers)
100 to 1000
100 to 3000
100 to 1000
100 to 1700
meric keys and press NEXT to continue.
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
2 SIDE
3 JUMP START POST (Car/Van Only)
5. Use or to s
elect the BATTERY CHEMISTRY
NEXT to continue, or press the corresponding number key
1 FLOODED
2 AGM-SPIRAL
3 AGM
4 GEL
6. Use or to s
on the battery label)
the corresponding number key
elect the battery RATING UNITS (printed
and press NEXT to continue, or press
. If the information is un-
readable, contact the battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
and press
b) If JIS, scroll to the JIS number.
26A17
.
26A19
26B17
28A19
8. If prompted, measure the ambient battery temperature
by aim the IR temperature sensor on the top of the tester
at the battery case. Once the temperature stabilizes, press
NEXT to begin the test.
Battery Case
(Top)
Sensor
7 IEC
8 EN
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Chapter 3: System TestEXP-1003 HD
Truck
1. Use the ARROW keys to highlight the System Test icon
and press NEXT to continue
2. Use or to s
elect the VEHICLE TYPE
continue, or press the corresponding number key
1 AUTO/VAN
2 TRUCK
3. Use or to s
elect the battery PACK TYPE
NEXT to continue, or press the corresponding number key
1 12V PACK
2 24V PACK
4. Press or to enter the number of BATTERIES (between
2 and 6) in the pack or use the numeric keys and press
NEXT to continue.
5. If testing a 2-battery, 12 volt pack: Use or to s
the BATTERY VOLTAGE
press the corresponding number key
1 6 V
.
and press NEXT to
.
and press
2
elect
and press NEXT to continue, or
.
Rating Description Range
CCA
CA
MCA
.
JIS
DIN Deutsche Industrie-Norm
SAE European labeling of CCA
IEC International Electrotechnical
EN Europa-Norm
Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8 ºC).
Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
Marine Cranking Amps: The
amount of current a battery can
provide at 32°F (0 ºC).
Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and letters.
Commission
100 to
3000
100 to
3000
100 to
3000
26A17 to
245H52
(72 numbers)
100 to 1000
100 to 3000
100 to 1000
100 to 1700
9. Press or to select the BATTERY RATING or use the numeric keys and press NEXT to continue.
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.
2 12 V
6. Use or to s
elect the BATTERY TYPE
and press NEXT to
continue, or press the corresponding number key
1 GROUP 31
2 4D, 8D
7. Use or to s
elect the BATTERY CHEMISTRY
NEXT to continue, or press the corresponding number key
1 FLOODED
2 AGM-SPIRAL
3 AGM
4 GEL
8. Use or to s
on the battery label)
the corresponding number key
elect the battery RATING UNITS (printed
and press NEXT to continue, or press
. If the information is un-
readable, contact the battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
.
and press
675
CCA
b) If JIS, scroll to the JIS number.
26A17
26A19
26B17
.
28A19
10. If prompted, measure the ambient battery temperature
by aim the IR temperature sensor on the top of the tester
at the battery case. Once the temperature stabilizes, press
NEXT to begin the test.
Battery Case
(Top)
Sensor
If testing a 2-battery, 24-volt pack: Attach the tester clamps
to the rst battery in the pack. Press NEXT to test the
battery. When prompted, move the tester clamps to the
second battery and press NEXT to test it.
11. At the conclusion of the battery test, use the keypad to
enter the VEHICLE ID number and press NEXT to display
the test results. Press SKIP to advance past this step. The
tester will insert zeros in place of a vehicle number.
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 3: System Test EXP-1003 HD
Auto/Van Test Results
The tester displays the complete results on multiple screens.
To view the code, press
code for all REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
return to the Main Menu, press END.
NOTE: For REPLACE or BAD CELL decisions, enter the
battery serial number located on the battery case to
generate a test code for warranty purposes. When
nished, press NEXT to continue.
If the result is CHARGE & RETEST, the tester will also
display a screen showing the time needed to charge
the battery at 10, 20, and 40 A.
Battery
decision
Measured
voltage
Battery
serial
number
or . The tester will generate a test
Measured
CCA
Selected
rating
Battery
temperature
Generated
test code (for
REPLACE
decisions)
Auto/Van Test Decisions
Decision Recommended Action
GOOD
BATTERY
GOOD–
RECHARGE
CHARGE &
RETEST
REPLACE
BATTERY
BAD CELL–
REPLACE
Return the battery to service.
Fully charge the battery and return it to
service.
Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause false readings. If CHARGE &
RETEST appears again, replace the battery.
May also mean a poor connection between
the battery and the vehicle.
This decision indicates a bad cell within the
battery. Replace the battery.
Risk of explosive gases.
Can cause death or
serious personal injury.
Never attempt to charge a
battery with a bad cell. The
battery must be replaced.
JUMP START
POST
SIDE POST The analyzer has found the data was
Data was inconclusive using the remote post.
Retest at the battery terminals.
inconclusive. Retest using the side post
adapters
Battery State-
Of-Health
Battery State-
Of-Charge
Estimated
charge time
(if needed)
NOTE: If the tester 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.
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Chapter 3: System TestEXP-1003 HD
Truck Test Results
The tester displays the complete results on multiple screens.
To view the code, press
code for all REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
return to the Main Menu, press END.
NOTE: For REPLACE or BAD CELL decisions, enter the
battery serial number located on the battery case to
generate a test code for warranty purposes. When
nished, press NEXT to continue.
Pack
Decision
Batteries
In Pack
or . The tester will generate a test
Selected
rating
Battery
temperature
Vehicle ID
Results:
Battery 1
Truck Test Decisions
Decision Recommended Action
GOOD
BATTERY
GOOD–
RECHARGE
CHARGE &
RETEST
REPLACE
BATTERY
BAD CELL–
REPLACE
Return the battery to service.
Fully charge the battery and return it to
service.
Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause false readings. If CHARGE &
RETEST appears again, replace the battery.
May also mean a poor connection between
the battery and the vehicle.
This decision indicates a bad cell within the
battery. Replace the battery.
Risk of explosive gases.
Can cause death or
serious personal injury.
Never attempt to charge a
battery with a bad cell. The
battery must be replaced.
Battery Pack Test Results
The tester displays the complete results on multiple screens.
Press
or to view each screen.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
continue with the System Test, press NEXT.
Battery Pack Decisions
Results:
Battery 2
Decision Recommended Action
GOOD PACK Return the battery pack to service.
CHECK
BATTERY
PACK
24-VOLT
PACK
Break the battery pack apart and test each
battery individually.
The system being tested in-vehicle is a 24-volt
system. Disconnect the batteries and test
them individually.
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 3: System Test EXP-1003 HD
Additional Test Requirements
For a more decisive result the analyzer may ask for additional
information or further explore the battery’s condition.
System Noise Detected
The analyzer has detected computer, ignition noise, or
parasitic drain, and will attempt to retest. Make sure all vehicle
loads are o, doors are closed, and the ignition is in the o
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 nd 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.
If you are using the Amp Clamp, keep it clamped around the
negative (–) battery cable.
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 aect 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.
Starter System Test
1. Following a successful Battery Test, press NEXT to continue to the Starter System Test.
NOTE: When testing a battery pack, connect the
test cables across all the batteries in the pack.
2. Start the engine at the prompt.
NOTE: If the tester does not detect vehicle start,
STARTED and NO START options are displayed.
Select STARTED to skip to the Charging System
Test. Select NO START to end the test.
Starter System Test Results
The tester displays a decision on the starter system with the
complete results in a series of screens. Use or to scroll to
each screen. To send the results to the IR printer, press PRINT.
To continue testing, press NEXT.
Average
cranking
Starter
decision
Starter loop
resistance
(Amp Clamp
required)
Cranking
voltage
Time
Cranking current
(displayed when
Amp Clamp is
used)
Decision Recommended Action
CRANKING
NORMAL
LOW VOLTAGE The starter voltage is low and the battery is
CHARGE
BATTERY
REPLACE
BATTERY
LOW
CRANKING
AMPS
NO START The engine did not start and the test was
CRANKING
SKIPPED
The starter voltage is normal and the
battery is fully charged.
fully charged.
The starter voltage is low and the battery
is discharged. Fully charge the battery and
repeat the starter system test.
The battery must be replaced before testing
the starter.
The cranking voltage is high, but the
cranking amps are low.
aborted.
The tester did not detect the vehicle’s
starting prole and skipped the Starter Test.
voltage
Average
cranking amps
(Amp Clamp
required)
Cranking
time in
seconds
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Chapter 3: System TestEXP-1003 HD
Charging System Test
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.
1. CHECKING FOR ALTERNATOR OUTPUT: The tester will immediately begin testing for alternator voltage.
2. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn o vehicle loads (blowers, interior light, radio, etc.) and idle the
engine. Press NEXT 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.
3. REV ENGINE WITH LOADS OFF FOR 5 SECONDS: Rev the
engine with the loads o. 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.
4. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold
the rpm while the tester takes system measurements.
5. ENGINE REV DETECTED, IDLE ENGINE: The tester has detected the rev. Press NEXT.
6. 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. TESTING ALTERNATOR AT IDLE, LOADS ON: The analyzer
will determine if the charging system is able to provide
sucient current for the demands of the vehicle’s electrical system.
9. REV ENGINE WITH LOADS ON FOR 5 SECONDS: The tester will test the charging system with the loads on and
prompt you to rev the engine. Gradually increase the rev
until the analyzer tells you to HOLD the rev level as the bar
on the display moves to the right.
10. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold
the rpm while the tester takes system measurements.
11. ENGINE REV DETECTED, IDLE ENGINE: The tester has detected the rev. Press NEXT.
12. ANALYZING CHARGING SYSTEM DATA: The tester is completing its nal analysis of the charging system data.
13. TURN OFF LOADS AND ENGINE: Press NEXT to display the
results.
Charging System Test Results
The tester displays a decision on the starter system with the
complete results in a series of screens. Use or to scroll to
each screen. To send the results to the IR printer, press PRINT.
To continue testing, press NEXT.
Decision
DC Volts
at rev
Amps at rev
(Amp Clamp
required)
7. TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE ENGINE: After a few seconds, the tester 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.
Normal DC
voltage
range
Peak-to-
peak
AC voltage
Diode
waveform
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 3: System Test EXP-1003 HD
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 alternator. (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 specications 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 uid spewing through the vent
caps, which causes low electrolyte levels and will harm the battery.
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.
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Chapter 4: 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 PRINT. To return to the Main
Menu, press END.
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
Chapter 4: Print/ViewEXP-1003 HD
VIEW CABLE TEST allows you to view and print the re-
sults of the Cable Drop Test.
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 5: Cable Drop Test EXP-1003 HD
Chapter 5: 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 tester 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 1000A.
When you change the setting from the factory defaults, the
tester will store your setting in memory for your next test.
There are four preset tests for components up to 1000 amps:
Component
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
Default Settings
Auto/Van Truck
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.
3. Use or to s
elect the Cable Drop icon in the Main
Menu.
4. Use or to s
tinue, or press the corresponding number key
elect AUTO/VAN
and press NEXT to con-
.
1 AUTO/VAN
2 TRUCK
5. Use or to s
or press the corresponding number key
elect a circuit
and press NEXT to continue,
.
1 BATTERY GROUND
2 STARTER CIRCUIT
3 ALT CIRCUIT
4 CHASSIS GROUND
5 OTHER
6. Use or to s
the circuit
responding number key
elect the rated amperage or output of
and press NEXT to continue, or press the cor-
.
500 A
7. Follow the instructions on the display for connecting the
test cables.
8. The tester tests the circuit and displays the results. The
format for the Starter Circuit results are typical for the Cable Drop Test.
Voltage
drop across
Total
circuit
voltage
drop
positive side
of circuit
Voltage
drop across
negative
side of
circuit
9. To print the results, align the analyzer’s IR transmitter with
the printer’s receiver, and select PRINT. To return to the
Main Menu, press END.
Red Red
R
+
Battery
–
Black Black
DMM Test Lead
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
1
R
2
Battery Test Lead
Component
Under
Test
22
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Chapter 6: DMM (Digital Multimeter)
Chapter 6: DMM (Digital Multimeter)EXP-1003 HD
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.
A measurement that is out of the limit displays as OL. Refer to
the manufacturer specications for the correct limits, which
may vary by component or vehicle type.
1. Use the ARROW keys to highlight the DMM icon
NEXT to continue
.
and press
2. Use the ARROW keys to select the icon for the desired meter.
DC And AC Voltmeters
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 END.
1. Connect the amp clamp to the analyzer’s accessories port.
2. Select the DC Volts, AC Volts, or Volts/Amps icon.
3. Select the amp clamp range and press NEXT to continue.
The meter will zero out.
1 70 AMP MAX.
2 700 AMP MAX.
4. Place the clamp around the negative (–) cable.
5. The tester displays the measurement.
6. 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.
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.
Scope
The scope is a voltmeter that provides a graph of voltage
dierence 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 SELECT 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 SELECT.
Press the right soft key to alternate between the options to
RUN (measure and display the signal) and HOLD (freeze the
signal). 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.
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 PRINT. To
return to the METERS menu, press END.
DC, AC, And Volts Ammeters
The DC ammeter measures DC magnitude and ow of the
DC current in a circuit. The volts/amp meter simultaneously
measures charging voltage and charging current.
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 nished, press END.
6. To return to the Meters menu, press END.
Diode
This test measures the voltage drop across components, such
as diodes.
1. Connect the probe leads to the tester’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 nished, press END.
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 6: DMM (Digital Multimeter) EXP-1003 HD
The accuracy specication is dened 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 specied 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 specied 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 specied 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 specied from 2% to 100% of range.
Ohm
Range Resolution Accuracy Overload Protection
10Ω–2 M Ω 1 Ω
2.0% + 4 120 Vrms
Continuity
Range Resolution Accuracy Overload Protection
< 10 Ω 1 Ω
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
-28–93 °C
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
1 °F
1 °C
1.0% + 5 --------
24
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Chapter 7: Info
Chapter 7: InfoEXP-1003 HD
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 bat-
tery tests in three categories.
number key next to the desired option.
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
was rst used.
User Totals
USER TOTALS displays the total tests performed by User ID,
four IDs per screen.
Use
or
or press the
performed since the tester
Clear Counters
To reset a total to 0, press the number key that corresponds to
with the number preceding a check box and press NEXT.
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 rst used.
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.
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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 8: Utility EXP-1003 HD
Chapter 8: Utility
Use the Utility Menu to customize the tester—from
interface language to display contrast The utilities
also have default settings that can be user-adjusted.
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
BACKLIGHT TIME
COUPON Disabled (NO COUPON PRINTED)
EDIT COUPON Eight lines of text with 17 characters
TEMPERATURE DEGREES F (Fahrenheit)
LANGUAGE English is the default language.
Range: 0 (lightest) to 10 (darkest). The
default is set at 9.
Range: 0 to 60 seconds. The default is
set at 15 seconds.
per line.
Default: USER COUPON LINE 1
through USER COUPON LINE 8
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.
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 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
ARROW keys to highlight the setting you want to
change.
MODE : AM/PM
TIME : 9:07 PM
FORMAT : MMM/DD/YYYY
DATE : 6/17/5/17/2013
Mode
1. Use
or to select the desired Mode and press NEXT
or
press the corresponding number key.
1 24 HOUR
2 AM/PM
2. Press SAVE to save your setting or BACK to return to the
CLOCK ADJUST screen without saving.
Time
1. Use
or
to highlight the hour, minutes, or AM or PM. To
rapidly scroll, hold down an ARROW key.
9 : 19 PM
2. Press SAVE to save your setting or BACK to return to the
CLOCK ADJUST screen without saving.
Format
1. Use
or to select the desired time display Format and
press NEXT
or press the corresponding number key.
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
2. Press SAVE to save your setting or BACK key to return to
the CLOCK ADJUST screen without saving.
Date
1. Use
or
to highlight the month, day, or year. To rapidly
scroll, hold down
or
.
6 / 04 / 2013
2. Press SAVE to save your setting or BACK to return to the
CLOCK ADJUST screen without saving.
Users
Use the USERS utility to create and edit USER ID’s with
one to seven alphanumeric characters and link it to a
test counter. USER ID can also be deleted.
Entering A New User ID
1. Use
or to select ENTER NEW and press NEXT
the corresponding number key.
1 ENTER NEW
2 DELETE
3 EDIT
Press NEXT to display the list of available IDs.
or press
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
26
www.midtronics.com
Chapter 8: UtilityEXP-1003 HD
2. Use
or
to scroll to the desired ID placeholder. Scroll
past the rst line to jump to the previous page. Scroll past
the fourth line to go to the next page. Press
or
to
jump through the list four lines at a time.
Press NEXT to continue.
1 USER01
2 USER02
3 USER03
4 USER04
3. Press to clear default characters. Press to add a space.
ENTER USER ID
USER01
—
4. Insert a character by pressing the associated alphanumeric key as many times as needed. Press SAVE to store the
new user ID in memory.
ENTER USER ID
WAYNE
Deleting A User ID
1. Use
or to select DELETE and press NEXT
or press the
corresponding number key.
1 ENTER NEW
2 DELETE
3 EDIT
2. Use the ARROW keys to select a USER ID. (You cannot delete placeholder USER IDs, i.e., USER03).
1 GREG
2 WAYNE
3 GREG
4 USER04
3. Press DELETE to remove the selected user.
2. Use the ARROW keys to select a USER ID. (You cannot delete placeholder USER IDs, i.e., USER03).
1 GREG
2 WAYNE
3 GREG
4 USER04
3. Press NEXT to edit the selected user.
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
2–1000 ANY STREET 6–YOUR PHONE NUMBER
3–YOUR TOWN, STATE 7–WWW.WEBSITE.CO
4–YOUR POSTAL CODE 8–SHOP ID NUMBER
To create or overwrite a header:
1. Press
or
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 to move erase a character. Press to move the
cursor forward.
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 SAVE to save your setting or BACK to return to the
SHOP INFO screen without saving the changes.
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.
5–YOUR COUNTRY
—
—
Editing A User
1. Use
or to select EDIT and press NEXT
responding number key. A list of IDs is displayed.
1 ENTER NEW
2 DELETE
3 EDIT
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or press the cor-
Display
Use the DISPLAY option to adjust the contrast of the
text on the display and the backlight time.
Contrast Level
1. Use
27
or to select CONTRAST LEVEL and press NEXT.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 8: Utility EXP-1003 HD
2. Press ADJUST key to display the numerical scroll box.
10 (1-10)
3. Press
or
to change the value up or down, or press the
corresponding number key. The contrast level is 0 (lightest) to 10 (darkest).
4. Press SAVE to save your setting or BACK to return to the
CONTRAST LEVEL screen without saving.
Backlight Time
1. Use
or to select BACKLIGHT TIME and press NEXT.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
2. Press EDIT to display the option’s numerical scroll box.
60 SEC
3. Press
or
to change the value up or down, or press the
corresponding number key. Press to erase a character.
Backlight time is from 0 to 60 seconds.
4. Press SAVE to save your setting or BACK to return to the
BACKLIGHT TIME screen without saving.
Temp
The TEMP utility enables you to set the units of mea-
sure to either Celsius or Fahrenheit.
1. Use or to select the TEMP. UNITS and press SAVE, or
press the corresponding numbers keys and press SAVE.
1 DEGREES F
2 DEGREES C
2. Press BACK to return to the UTILITY menu without saving
any changes.
Language
The LANGUAGE utility enables you to select a language
for the display and printouts. To set your preference:
1. Use or to select the desired LANGUAGE and press
SAVE, or press the corresponding numbers keys and press
SAVE.
1 ENGLISH
2 ESPAÑOL
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
or to select the desired option and press NEXT
or
press the corresponding number key.
1 NO COUPON PRINTED
2 USER COUPON
2. Press SAVE to save your setting or BACK to return to the
Utility Menu without saving the changes.
Edit Coupon
The EDIT COUPON utility allows you to create a pro-
motional 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, use same procedure described in
the Shop section of this chapter. Use the template at the end
of this manual to plan and center your text.
3 FRANÇAIS
4 PORTUGUES
2. Press BACK to return to the UTILITY menu without saving
any changes.
Format
Select this utility to format a data card to receive data
or erase all data on the card. The tester will warn you
before formatting the disk, and ask if you want to continue.
Update
When software updates are released, this utility en-
ables you to update the analyzer’s software using les
on a data card.
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
28
www.midtronics.com
Chapter 9: Maintenance & TroubleshootingEXP-1003 HD
Chapter 9: Maintenance & Troubleshooting
Testing Clamp Continuity
If the analyzer frequently displays CHECK CLAMP CONNECTION!
you may have an intermittent open circuit in one or both of
the battery test cables.
You are testing the continuity between the clamp jaws and the
cable connector. The test is the same for clamps with one or
two sets of teeth.
This includes four dierent connections.
• The positive (Red) clamp jaw without teeth and corre-
sponding pin hole.
• The positive (Red) clamp jaw with teeth and correspond-
ing pin hole.
• The negative (Black) clamp jaw without teeth and cor-
responding pin hole.
• The negative (Black) clamp jaw with teeth and corre-
sponding pin hole.
You will need to a pencil, plastic marker or other nonconductive item to keep the test clamp jaws apart. You will
also need an ohmmeter with a good set of test probe leads.
Performing A Continuity Test
1. Grip the pencil with one of the test clamps. Do not grip
the metal part of the eraser or any other area that may
conduct electricity.
4. Repeat the test procedure for the other three cable connections. In all instances, the resistance reading should
always be less than 1 Ω.
If any of the four connections shows more than 1 Ω, contact
Midtronics Customer Service at www.midtronics.com or (630)
323-2800 to order a new set of cables.
Internal Batteries
The tester 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 Tester will display a warning
message when the batteries need replacing.
Full
Decreasing
Low
Powered
by test
battery
Top Jaw
Cable
Bottom Jaw
2. Insert one of the ohmmeter probes into one of the four
holes indicated at the tip of the cable connector. With the
tip of the other probe, touch the corresponding part of
the appropriate clamp.
Black Clamp:
Top Jaw
Black Clamp:
Bottom Jaw
Cable Connector Pin-outs
Red Clamp:
Top Jaw
Red Clamp:
Bottom Jaw
NOTE: Use a small wire or a paper clip if your ohmme-
ter probe tip is too large to insert into the connector
holes.
3. Wiggle the test cables. The resistance reading for that connection should be less than 1 Ω.
Replacing The Tester Batteries
1. Turn the tester face down.
Screw
Latch
Press
here
Slide in
this direction
2. Remove the screw.
3. Press gently on the ridges above the arrow on the battery
compartment cover.
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29
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
Chapter 9: Maintenance & Troubleshooting EXP-1003 HD
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 gure (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.
Troubleshooting
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 ana-
lyzer (below 1 volt). Fully charge the battery and retest.
• The analyzer’s 6 AA batteries may need to be replaced.
• If troubleshooting does not solve the problem, contact
Midtronics at 1-630-323-2800 to obtain service. See the
warranty information on the back cover of this manual for
more information.
The STATUS LED Flashes
When a printer fault occurs, the STATUS LED ashes. You can
identify the fault by the number of sequential ashes:
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 o after two
minutes of inactivity to conserve the batteries. To turn
the printer on, briey 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.
• Direct sunlight interferes with infrared data transmission
and receiving. If the printer is not receiving data, remove
the printer and tester from direct sunlight. If the printed
characters are not clear or are partially missing, recharge
the batteries and reprint.
• If you are unable to print after ensuring the analyzer is
functioning, the printer is on, the batteries are good, and
the IR transmitter and receiver are aligned, check the
printer manual for further instructions or call Midtronics
at 1-630-323-2800 for assistance.
If the analyzer frequently displays CHECK CLAMP CONNECTION!
there may be 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.
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
30
www.midtronics.com
Appendix: TemplatesEXP-1003 HD
Appendix: Templates
Header And Coupon Templates
To help you edit and center your coupon, use the template below to lay out your coupon information below before entering it
into the Battery Diagnostic Station.
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8
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31
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
PATENTS
This product is made by Midtronics, Inc., and is protected by one or more U.S. and foreign patents. For specic patent information,
contact Midtronics, Inc. at +1 630 323-2800.
LIMITED WARRANTY
Midtronics products are warranted to be free of defects in materials and workmanship for a period of one (1) year from date of
purchase. Midtronics will, at our option, repair or replace the unit with a re-manufactured unit. This limited warranty applies only to
Midtronics products, and does not cover any other equipment, static damage, water damage, overvoltage damage, dropping the unit,
or damage resulting from extraneous causes including owner misuse. Midtronics is not liable for any incidental or consequential
damages for breach of this warranty. The warranty is void if owner attempts to disassemble the unit or to modify the cable assembly.
SERVICE
To obtain service, contact Midtronics at 1-630-323-2800. Have your model and serial numbers ready. This rst step is critical as we will
trouble-shoot the problem(s) over the phone, and many perceived problems are in fact resolved during this step. If the problem cannot
be resolved, then the CS Agent will issue you a Return Material Authorization or RMA. This number becomes your tracking number. The
nal step is to return the unit to Midtronics freight prepaid (you pay), to the attention of the RMA number obtained.
In USA:
Midtronics, Inc.
Attn: RMA # xxxxx (this is the RMA number that you must obtain from Midtronics)
7000 Monroe St.
Willowbrook, IL 60527
If Midtronics determines that the failure was caused by misuse, alteration, accident, or abnormal condition of operation or handling,
purchaser will be billed for the repaired product and it will be returned freight prepaid with shipping & handling charges added to the
invoice. Midtronics products beyond the warranty period are subject to the repair charges in place at that time.
www.midtronics.com
Corporate Headquarters
Willowbrook, IL USA
Phone: 1.630.323.2800
Canadian Inquiries
Toll Free: +1 1 866 592 8053
Midtronics b.v.
European Headquarters
Houten, The Netherlands
Serving Europe, Africa, the Middle
East, and The Netherlands
Phone: +31 306 868 150
Midtronics China
China Operations
Shenzhen, China
Phone: +86 755 8202 2036
Midtronics India
Navi Mumbai, India
Phone: +91 22 27564103/1513
Asia/Pacíc (excluding China)
Contact Corporate Headquarters
Phone: +1.630.323.2800
167-000505EN-A 9/13 2013 ©Midtronics, Inc. All rights reserved.
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