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EXP- 800
INNOVATION TECHNOLOGY QUALITY WORLDWIDE
INNOVATION TECHNOLOGY QUALITY WORLDWIDE
Battery & Electrical
July 2008
168-547A
Diagnostic Analyzer
For testing 6 and 12-volt automotive batteries
and 12- and 24-volt charging systems
INSTRUCTION MANUAL
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blank page behind cover
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Contents
ContentsEXP-800
Chapter 1: Before You Begin 5
Safety Reminder 5
Personal Precautions 5
Chapter 2: Overview 6
Connections and Data Ports 6
Connecting the Battery Test Cable 7
Removing and Inserting the Data Card 7
Display and Keypad 8
Data Entry Methods 10
Menu Icons 10
Option Buttons 10
Scrolling Lists 10
Scroll Boxes 10
Alphanumeric Entry 10
Menu Structure 11
Main Menu 11
Info Menu 11
Admin/Utility Menu 12
Chapter 3: Getting Started 13
Logging In for the First Time 13
Bootup 13
Entering Your Store ID Number and Zip Code 13
Logging in as an Unregistered User 13
Adding a User 13
Disabling the Login Screens 13
Chapter 4: Admin/Utility Menu 14
Clock 15
Mode 15
Time 15
Format 15
Date 15
Shop 16
Users 16
Entering a New User ID 16
Deleting a User ID 17
Display 17
Contrast Level 17
Backlight Time 17
Coupon 17
Edit Coupon 18
Temp 18
Track Calls 18
Language 19
Admin 19
Options 19
Clear Test Totals 19
Reset Defaults 19
Store ID# 19
Format Disk 20
Update 20
Chapter 5: Test Preparation 21
Inspecting the Battery 21
Testing Out-of-Vehicle (Battery Test) 21
Testing In-Vehicle (System Test) 21
Connecting to the Battery 21
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Contents EXP-800
Chapter 6: Battery Test 22
Additional Test Requirements and Messages 23
System Noise Detected 23
Unstable Battery Detected 23
Deep Scan Test 23
Voltage Out of Range 23
Battery Test Results 23
State of Health (SOH) 24
Chapter 7: System Test 25
Battery Test 25
Starter System Test 25
Charging System Test 26
Chapter 8: PDI Battery Test 28
Selecting Test Parameters 28
Printing Test Results 28
When the EXP displays a total of 100 Tests 28
Chapter 10: Printing Test Results 30
Changing the Paper in the Internal Printer 30
Chapter 11: Troubleshooting 31
Problems with the Display 31
Problems with the Internal Printer 31
Chapter 12: Test Cable Maintenance 32
Cleaning the Clamps 32
Handling the Test Cables 32
Storing Test Cables 32
Testing Resistance in the Cable Set 33
Test Procedure 33
Chapter 13: EXP Internal Batteries 34
Battery Power Indicator 34
Replacing the Internal Batteries 34
Chapter 9: Info Menu 29
View Test 29
View PDI Test 29
Totals 29
Transfer 29
Version 29
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Chapter 1: Before You Begin
Chapter 1: Before You BeginEXP-800
Safety Reminder
!
For safe, ecient, and accurate testing, review the safety
and operating instructions in this manual before using the
analyzer. In addition, follow all manufacturers’ instructions and
BCI (Battery Council International) safety recommendations.
Personal 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 pro-
duce 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
ame in the vicinity of a battery.
Battery acid is highly corrosive. If acid enters your eyes, im-
mediately 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 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.
WARNING—REQUIRED BY CALIFORNIA PROP. 65: Bat-
tery 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.
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Chapter 2: Overview EXP-800
Chapter 2: Overview
This chapter describes the analyzer’s hardware and software interface. The components include test leads and connectors, and
the display and keypad. The user interface comprises the software menus, test options, and utilities.
Connections and Data Ports
Integrated thermal printer
Release lever for door to paper compart-
ment
Paper slot
LCD screen with Main Menu
Control Panel: keypad and power button
6-pin connector for the battery test cable
(see the next page for detail)
Spring-loaded data card slot for test data
storage and software upgrades.
Infrared temperature sensor with a range of
-28 °C to +93 °C (-20 °F to +200 °F).
Data transmitter: sends test results to a PC
using an optional hardware and software
kit
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Chapter 2: OverviewEXP-800
Connecting the Battery Test Cable
CAUTION: To prevent damage to the analyzer’s
!
circuitry, do not connect the analyzer to a voltage
source greater than 30 Vdc.
To connect the battery test cable to the analyzer align the
arrow on the cable connector with the arrows on the analyzer’s
housing. Hold the part of the cable connector as shown and
rmly insert the connector into analyzer’s six-pin receptacle.
Do not twist.
To avoid damaging the battery test cable, always hold the
ridged part of the cable connector (as shown in the photo)
when inserting and removing the cable.
Arrows
Removing and Inserting the 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.
Hold the
cable
connector
here
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Chapter 2: Overview EXP-800
Display and Keypad
The EXP display and keypad 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 shows how the elements on the
screen relate to the keypad.
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 soft-key
functions are SELECT, BACK, and END.
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.
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 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.
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. The Up and Down Menu Screen Arrows,
for example, indicate when to press the UP
( ) and DOWN ( ) ARROW keys to display the
screens above and below the current screen.
he Left and Right Menu Screen Arrows tell you
T
when to use the LEFT
( )
or RIGHT
( )
ARROW
keys to select an icon.
Voltmeter
When you rst 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.
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.
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Chapter 2: OverviewEXP-800
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.
Scroll
Box
Top or
only
screen
Middle
screen
Last
screen
ARROW keys
Press the UP ARROW key to move up to the next
selectable item or row. When entering text, use
the UP ARROW key to move to the previous
character.
Press the DOWN ARROW key to move down to
the next selectable item or row. When entering
text, use the DOWN ARROW key to move to the
next available character.
Use the UP and DOWN ARROW keys to scroll to
the letters A through Z, numbers 0 through 9, and
the following symbols:
! ” # $ % & ’ ( ) * + , - . / : ; < =
> ? @
When entering text, use the RIGHT ARROW key
to move one space to the right.
Use the LEFT ARROW key to move one space to
the left.
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Chapter 2: Overview EXP-800
Data Entry Methods
To perform a particular test or function, the EXP 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 the
highlight 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 the UP or DOWN ARROW key to move the dot to the
button next to the item. To conrm your selection, press the
appropriate soft key.
LEFT ARROW
or
RIGHT ARROW
key to
Scrolling Lists
Scrolling lists contain items that extend above and below the
screen. The rst 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 the UP or DOWN ARROW key to
highlight the item and press the appropriate soft key.
To move the highlight bar up four lines at a time, press the
LEFT ARROW
To
move the highlight bar down four lines at a time,
key.
press the
RIGHT ARROW key.
Scroll Boxes
Scroll boxes contain variables that are displayed by scrolling
using arrow keys.
To select, use the UP or DOWN ARROW key to scroll to the
value, and press the appropriate soft key. In the illustration
the left directional arrow indicates that you can press the
ARROW key
to clear all or part of the entry.)
LEFT
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 the UP or DOWN ARROW keys to highlight a line for
editing. Press the SELECT soft key 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 the
ARROW
key. Use the RIGHT ARROW key to add a space. When
nished, press the appropriate soft key to save the text you
entered.
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LEFT
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EXP-800
Chapter 2: Overview
Menu Structure
This section contains a graphical representation of the menu structure with brief descriptions of the utilities in each menu.
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 options. Menu icons marked with an asterisk (*)
are mapped on the following pages.
Menu Icon Description
Tests a battery using the battery information you select in a series of screens.
Tests a battery, and the starting and charging systems.
Enables you to test up to 100 batteries in succession without re-entering battery information
each time. Frees up inventory space by weeding out defective batteries.
Utility to view and print test results, a test counter, a data transfer utility, and information on the
*
analyzer software version and serial number.
*
Info Menu
The Info Menu has utilities to allow you to view and print test results, track the usage and history of your analyzer, and manage
test data.
Menu Icon Description
Provides access to the Utility Menu, which allows you to customize the analyzer and
administrative functions that include setting passwords.
Provides tips for troubleshooting problems with the printer, the cables, and loss of power. Also
includes Midtronics Customer Service phone numbers.
Displays the last battery test results. Sends the results to the internal printer.
Reports menu that includes the following type of test totals: Battery, System, Totals by User ID,
and Totals by Decision
A future optional accessory consists of an IR software and hardware package that will enable
you to transfer test data to a PC.
View and print the results of the last test of new batteries in inventory.
Displays the software version, and the serial number.
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Chapter 2: Overview EXP-800
Admin/Utility Menu
The Admin/Utility Menu lets you customize your analyzer for your needs. Before using the analyzer for the rst time, check the
default values to see what options you may want to change, add, or delete.
Menu Icon Description
Settings to adjust the date and time.
Allows you to add a custom header to printed test results.
Add, edit, or delete User IDs.
Settings to adjust the screen contrast and backlight time.
If you’ve created a coupon in the Edit Coupon utility, use Coupon to enable or disable.
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.
Stores test results on the data card when enabled (ON).
Sets the language of the display and printouts.
Allows you to enable or disable the user login screen, clear test totals, address header printing
and restore defaults.
Allows you to change your store ID number and includes the number on printed results.
Formats the data card to receive data. Also erases all data on the card.
Updates the analyzer software via les on a data card.
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Chapter 3: Getting Started
Chapter 3: Getting StartedEXP-800
The EXP is initially set up to require a default USER ID to access
the Main Menu. The instructions in this section show you how
to log in for the rst time, enter your store ID and zip code
(required only once), and adjust optional settings.
Logging In for the First Time
When you turn on the EXP, it takes approximately eight
seconds to boot up while testing the integrity of its software.
Bootup
The rst selection screen to appear enables you to set the
language for the display and printed test results. You can
disable this option in the Admin/Utility Menu. See “Options”
on page 19.
1. Use the UP or DOWN ARROW key to move the dot to the
option button of your choice (1, 2, or 3).
1 ENGLISH
2 ESPAÑOL
3 FRANÇAIS
2. Press the NEXT soft key to continue.
Logging in as an Unregistered User
The default setting requires a user name to display the Main
Menu. You can log in as an unregistered user or you can create
a new user ID.
To log in as an unregistered user, press the NEXT soft key to
selected the highlighted UNREG.
0 UNREG
1 ADD USER
Adding a User
1. Use the DOWN ARROW key to scroll to ADD USER. Press
the NEXT soft key to continue.
0 UNREG
1 ADD USER
2. Use the UP or DOWN ARROW key to scroll to the ID place-
holder you want to use. Scrolling past the rst line displays
the previous screen. Scrolling past the fourth line displays
the next screen. To display more placeholders, continue
scrolling or use the LEFT or RIGHT ARROW key to jump
up or down through the list ve lines at a time. Press the
NEXT soft key to continue.
Entering Your Store ID Number and Zip Code
The next screen asks you to enter your store ID number.
1. Display a number by pressing the UP or DOWN ARROW
key as many times as needed.
ENTER STORE ID#
2. Press the NEXT soft key to continue.
3. Use the UP or DOWN ARROW key to enter your store’s zip
code.
ENTER ZIP CODE
4. Press the NEXT soft key to continue.
The next time you log in, you will not be asked for your store ID
and zip code. The analyzer saves stores them in memory until
you change them using the STORE ID# option in the Admin/
Utility Menu.
1 USER01
2 USER02
3 USER03
4 USER04
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
4. Display a character by pressing UP or DOWN ARROW key
as many times as needed. Press the SAVE soft key.
ENTER USER ID
DAN L
Disabling the Login Screens
You can disable and enable the login screens in the Admin/
Utility Menu. See “Options” on page 19.
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Chapter 4: Admin/Utility Menu EXP-800
Chapter 4: Admin/Utility Menu
The Admin/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. The most
important function is the ADMIN (administrative) function, which controls user access.
Table 1:
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 USER48 are placeholder IDs used to create user names.
DISPLAY
Utility Default Settings
CONTRAST LEVEL
BACKLIGHT TIME
COUPON Disabled (NO COUPON PRINTED)
EDIT COUPON Eight lines of text with 17 characters per line.
TEMPERATURE DEGREES F (Fahrenheit)
TRACK CALLS Tracking OFF
LANGUAGE English (French-Canadian and Spanish are available). You can select the language when
ADMIN
OPTIONS
1-USER ID User login screen enabled (ON)
2-UNREG. USER Unregistered user accessibility enabled (ON)
3-PRINTER HEADER Prints address header (OFF)
4-ADMIN PIN Administrator PIN enabled (OFF)
5-DATE CODE Require battery date code (OFF)
6, 7, 8-SCREEN INPUT Display user-dened text elds (OFF)
Range: 0 (lightest) to 10 (darkest). The default is set at 9.
Range: 0 to 60 seconds. The default is set at 15 seconds.
Default: USER COUPON LINE 1 through USER COUPON LINE 8
the EXP boots up and when you print test results.
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EXP-800
Chapter 4: Admin/Utility Menu
Clock
The CLOCK ADJUST utility has four settings. Use the
UP or DOWN ARROW key to highlight the setting
you want to change. Although the date and time
have been set at the factory, you may want to make
adjustments based your time zone or Daylight Saving Time.
MODE : AM/PM
TIME : 9:07 AM
FORMAT : /MM/DD/YYYY
DATE : /11/29/2006
Mode
Use the UP or DOWN ARROW key to move the dot to the
option button of your choice (1 or 2).
1. Select the or 24-hour or 12-hour (AM/PM) clock.
1 24 HOUR
2 AM/PM
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.
Format
Use the UP or DOWN ARROW to move the dot to the option
button of your choice (1 or 2).
1. Select the format of the date.
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
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.
Date
1. Use the LEFT or RIGHT ARROW key to highlight the
month, day, or year. To rapidly scroll, hold down an UP or
DOWN ARROW key.
6 / 17 / 2005
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.
Time
1. Use the LEFT or RIGHT ARROW keys to highlight the hour,
minutes, or AM or PM. To rapidly scroll, hold down an UP
or DOWN ARROW key.
9 : 19 PM
2. Press the SAVE soft key to save your setting, or press the
BACK soft key to return to the CLOCK ADJUST screen.
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Chapter 4: Admin/Utility Menu EXP-800
Shop
The SHOP INFO utility allows you to create a header
for your printed test results with your business location information. Its three information screens
contain 12 lines of text with a maximum of 17 characters per line.
To create or overwrite a header:
1. Press the UP or DOWN ARROW to highlight the line you
want to change. Press the SELECT soft key to edit the selected line. The cursor blinks to the right of the last character in the line. (The cursor is not visible if all character
spaces are lled.)
2. To erase a character, press the LEFT ARROW key.
3. Display a character by pressing the UP or DOWN ARROW
key as many times as needed. You can center text by inserting blank spaces with the RIGHT ARROW key.
IMPORTANT: Be sure to erase any default characters on un-
used lines by pressing the LEFT ARROW key.
4. To save your text on the selected line, press the SAVE soft
key.
NOTE: The right soft key displays SELECT when
you highlight a line for editing and SAVE when
you edit the line. To exit the edit mode of the selected line without saving the changes, press the
BACK soft key.
Screen 1
1–YOUR SHOP NAME
2–1000 ANY STREET
3–YOUR TOWN, STATE
4–YOUR ZIP CODE
5–YOUR COUNTRY
—
6–YOUR PHONE NUMBER
7–WWW.WEBSITE.COM
8–
Screen 2
—
To help you edit and center your header, use a pencil to write the information in the template below before entering it into the
EXP.
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8
Users
The USERS utility allows you to create and edit a
USER ID with 1 to 7 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
Header Template
2. Use the UP or DOWN ARROW keys to scroll to the ID
placeholder you want to use. Scrolling past the rst line
displays the previous screen. Scrolling past the fourth line
displays the next screen. To display more placeholders,
continue scrolling or use the LEFT or RIGHT ARROW key
to jump up or down through the list ve lines at a time.
1 USER01
2 USER02
3 USER03
4 USER04
Press the NEXT soft key to continue.
Press the NEXT soft key to display the list of available IDs.
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Chapter 4: Admin/Utility MenuEXP-800
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
4. Display a character by pressing the UP or DOWN ARROW
key as many times as needed. Press the SAVE soft key.
ENTER USER ID
DAN L
Deleting a User ID
NOTE: You cannot delete placeholder USER IDs
(i.e., USER03).
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.
3. Press the UP or DOWN ARROW 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 LCD OPTIONS screen without saving the changes.
Backlight Time
Backlight time is from 0 to 30 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 ADJUST soft key to display the option’s numerical scroll box.
15 SEC
3. Press the UP or DOWN ARROW 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 LCD OPTIONS screen without saving the changes.
2. Use the ARROW keys to select a USER ID as described in
step 2 in Entering a New User ID.
1 ANDY
2 JIM F
3 USER03
4 USER04
Press the DELETE soft key to continue.
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
Coupon
The COUPON utility allows you to enable and dis-
able the custom coupons or message created in
the EDIT COUPON utility. You also have the option
of having no coupon print.
1.
Use the UP or DOWN ARROW key to move the dot to the
option button of your choice (1 or 2).
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.
2. Press the ADJUST soft key to display the option’s numerical scroll box.
9 (1-10)
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Chapter 4: Admin/Utility Menu EXP-800
Edit Coupon
To create and edit a coupon, see the procedure under “Shop”
in this chapter for using the keypad to enter and backspace
The EDIT COUPON utility allows you to create and
over characters.
store a promotional coupon or message on the
printed test results you give tor your customers.
The utility’s two information screens contain eight
lines of text with a maximum of 17 characters per
line. To enable and disable the inclusion of the text
on your test results, use the COUPON utility.
To help you edit and center your coupon, use a pencil to write the information in the template below before entering it into the
analyzer.
Coupon Template
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 7
Line 8
Temp
The TEMP. UNITS utility allows you to set the units
of measurement to either Fahrenheit or Celsius. To
set your preference:
1.
Use the UP or DOWN ARROW key to move the dot to
the option button of your choice (1 or 2).
1 DEGREES F
2 DEGREES C
2. Press the SAVE soft key to save your setting or the BACK
soft key to return to the Admin/Utility Menu without saving the changes.
Track Calls
The TRACK CALLS utility stores the test results and
test codes by date as an .xml (Extensible Markup
Language) le in a folder named ”XML” on the data
card before the EXP prints the results.
requires a data card reader (not included) to read
or transfer the le to a PC.
You can open the le
in Microsoft® Internet Explorer®. The data in the le
is separated by tags (identiers enclosed in angle
brackets) that dene the data.
This utility
NOTE: To avoid corrupting the le, copy rather
than move the le to your PC.
The default setting for the utility is OFF. To set your preference:
1. Use the UP or DOWN ARROW key to move the dot to the
option button of your choice (1 or 2).
1 TRACKING OFF
2 TRACKING ON
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.
NOTE: Over time disk access slows as the format
card reaches its capacity. To free up card space,
transfer the les to a PC and reformat the card to
permanently erase data no longer needed.
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Chapter 4: Admin/Utility MenuEXP-800
Language
The LANGUAGE utility allows you to select a lan-
guage for the display and printouts. You can override the selection when the EXP displays the language option after you turn it on or print results.
To set your preference:
1. Use the UP or DOWN ARROW key to move the dot to the op-
tion button of your choice (1, 2, or 3).
1 ENGLISH
2 ESPAÑOL
3 FRANÇAIS
2. Press the SAVE soft key to save your setting or the BACK
soft key to return to the Admin/Utility Menu without saving the changes.
Admin
This section explains how to use the Admin Utility
to control User ID access to the EXP. It also describes
functions that clear test totals and restore settings
to factory defaults.
4 – LANGUAGE
Select this setting to enable (ON) or disable (OFF) the
language selection option when the EXP boots up.
5 – DATE CODE
Select this setting to enable (ON) to require the entry of a
battery date code
6, 7. 8 – SCREEN INPUT
Select this setting to enable (ON) to display user-dened
text elds
Clear Test Totals
This function allows you to clear the test totals by User ID and
battery test decision. The analyzer veries that you want the
counter reset to 0 before it continues.
NOTE: This will not clear the lifetime test total
available in the VERSION information screen.
Reset Defaults
This function allows you to reset Administrative options to
their original settings. It will clear all registered users and
restrict access to the EXP.
Select the ADMIN icon to display a list of administrative
functions:
1 OPTIONS
2 CLEAR TEST TOTALS
3 RESET DEFAULTS
Options
In the OPTIONS section there are three functions that allow
you to control user access to the Main Menu and Admin/Utility
Menu. Each option is easily enabled or disabled by turning it
ON or OFF. To save your settings after each selection, press the
SAVE soft key. To return to the administrative functions list
without saving, press the BACK soft key.
1 – USER ID
Select this setting to enable (ON) or disable (OFF) the
USER ID login screen.
2 – UNREG. USER
Select this setting to enable (ON) or disable (OFF)
unregistered login access to the analyzer when option
1 – USER ID is ON.
Option Default Settings
1 – USER ID ON
2 – UNREG. USER ON
3 – PRINT HEADER OFF
4 – LANGUAGE ON
5 – DATE CODE OFF
6, 7, 8 – SCREEN INPUTS OFF
Store ID#
The next screen asks you to enter your store ID
number.
1. Insert a character by pressing the UP or DOWN ARROW
key as many times as needed.
ENTER STORE ID#
2. Press the NEXT soft key to continue.
3 – PRINT HEADER
Select this setting to enable (ON) or disable (OFF) the
address header on the printout.
3. Use the UP or DOWN ARROW key to enter your store’s zip
code, and press the SAVE soft key.
ENTER ZIP CODE
19
Page 20
Chapter 4: Admin/Utility Menu
Format Disk
Select this utility to format an data card to receive
data or erase all data on the card. The analyzer will
warn you before formatting the disk and ask if you
want to continue.
Update
When software updates become available for the
EXP, this utility walks you though the quick process
of updating the analyzer’s software using a data
card.
EXP-800
20
Page 21
Chapter 5: Test Preparation
Chapter 5: Test PreparationEXP-800
Inspecting the Battery
Before starting the test visually inspect the battery for:
• Cracked,buckled,orleakingcase.Ifyouseeanyofthese
defects, replace the battery.
• Corroded,loose,ordamagedcablesandconnections.Repair or replace them as needed.
• Corrosiononthebatteryterminals,anddirtoracidonthe
case top. Clean the case and terminals using a wire brush
and a mixture of water and baking soda.
• Lowelectrolytelevel.Iftheelectrolytelevelistoolow,add
distilled water to ll up to 1/2 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.
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.
• Alwaysuse acarry toolor straptolift andtransport the
battery.
Testing In-Vehicle (System Test)
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 preferred test position is at the battery posts. If you must
test at a remote-post location, it should have both a positive
and negative post. Otherwise, you must remove the battery
and perform a System Test.
At the start of the test, place the vehicle transmission in PARK,
make sure all vehicle accessory loads are o, the key is not in
the ignition, and the doors are closed.
Connecting to the Battery
Connect the red clamp to the positive (+) terminal and the
black clamp to the negative (–) terminal.
If you connect the clamps in the wrong polarity (red to
negative or black to positive), the analyzer displays CLAMPS
REVERSED! Reconnect the clamps.
To make sure both sides of the clamps are gripping the
terminals, rock the each clamp back and forth. A poor
connection will prevent testing, and the analyzer displays
the message CHECK CONNECTION. If the message reappears
after you have correctly reconnected the clamps, clean the
terminals and reconnect
CAUTION: When testing side-post or Group 31
!
batteries, always use lead terminal adapters provided with the EXP—do not test at the battery’s
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.
21
Page 22
Chapter 6: Battery Test EXP-800
Chapter 6: Battery Test
The Battery Test analyzes a battery not connected to a vehicle.
The EXP guides you through the steps of selecting your
battery test parameters and interpreting the results. Before
you start the test, review the instructions in Chapter 5: Test
Preparation on page 21.
IMPORTANT: When you start a new test, the last test results in
memory are overwritten. Remember to record or print
the results if you need to retain them.
If you use the ARROW keys to select option buttons, press the
NEXT soft key to continue to the next step.
1. In the Main Menu select the Battery test icon.
2. Use the UP or DOWN ARROW key to enter the battery
date code, which is printed on the battery label. Enter the
date in the format MM/YY (for example, 01/06 for January 2006) and press NEXT. If the date code is unavailable,
press NEXT to continue.
IF AVAILABLE, ENTER
THE BATTERY DATE CODE
NEXT IF UNKNOWN
5. Select the BATTERY TYPE.
1 AUTOMOTIVE (default)
2 MARINE BATTERY
3 MOTORCYCLE
4 GROUP31
5 COMMERCIAL_4D/8D
6 LAWN & GARDEN
Press the NEXT soft key to continue.
If you select MOTORCYCLE as the battery type, the analyzer
asks for the battery part number. Scroll to the part number
(128 available). To increase your scrolling speed, hold the UP
or DOWN ARROW key, or use the LEFT or RIGHT ARROW key
to move up or down four part numbers at a time. Press ENTER
and continue the test at step 7 to determine the battery
temperature.
6. If you selected AGM as the battery type in step 5, select
the type of plate construction.
1 REGULAR FLOODED
2 AGM
3 AGM SPIRAL
MM/YY
3. Select the location of the battery.
1 OUT OF VEHICLE (not connected to the vehicle)
2 IN VEHICLE (connect to the vehicle)
Press the NEXT soft key to continue.
4. Select the POST TYPE. The REMOTE option appears for the
IN VEHICLE test.
1 TOP POST
2 SIDE POST
3 JUMP START POST (appears for System Test)
Press the NEXT soft key to continue.
4 GEL
Press the NEXT soft key to continue.
7. Select the battery’s rating units. The rating units and rating information required in the next step are printed on
the battery label. If the information is unreadable, contact
the battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
Press the NEXT soft key to continue.
22
Page 23
Chapter 6: Battery TestEXP-800
Table 2:
Battery Rating Systems
Rating
System Description Range
CCA Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8
ºC).
CA Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
MCA Marin e Cr anking Amps: T h e
amount of current a battery can
provide at 32°F (0 ºC).
JIS Japanese Industrial Standard:
(sh o w n on a ba t t e ry a s a
co mbin atio n of n umbe rs and
letters.
DIN (A) Deutsche Industrie-Norm 100 to 1000
SAE (A) European labeling of CCA 100 to 3000
IEC (A) I nter n ation al Ele c trote chnic al
Commission
EN (A) Europa-Norm 100 to 1700
100 to 3000
100 to 3000
100 to 3000
72 nu m b e r s
from 26A17 to
245H52
100 to 1000
8 Press an UP or DOWN ARROW key to select the BATTERY
RATING. Press ENTER.
If you select JIS, the analyzer asks for the JIS part number. Scroll
to the part number. To increase your scrolling speed, hold the
UP or DOWN ARROW key, or use the LEFT or RIGHT ARROW
key to move up or down four part numbers at a time. Press
ENTER to continue.
9. Hold the analyzer two inches above the battery case so
that the IR temperature sensor on the underside of the EXP
can approximate the battery temperature. Press NEXT to
continue.
Additional Test Requirements and Messages
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.
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:
• Youmaybetestingtooclosetoanoisesource,suchasa
charger or other high-current device. If so, move away 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 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 conduct a Deep Scan Test
for a few seconds to determine whether the battery should be
replaced or if it has a chance to be recovered.
Voltage Out of Range
The analyzer has detected two 12-volt batteries connected in
series. Disconnect the batteries and test them individually.
Battery Test Results
IMPORTANT: To print results the EXP must be connected to a
battery measuring 11.50 to 16.00 volts.
The EXP prints the results before displaying the battery
decision with an analysis in a series of screens. The analysis
includes the battery state-of-health (SOH). See Table 3 on the
next page for an explanation of the battery decisions.
NOTE: When the option TRACK CALLS is enabled,
the EXP writes the results to the data card.
Use the UP or DOWN ARROW key to scroll to each screen. To
return to the Main Menu, press the END soft key. If you are
performing a System Test, press the NEXT key to continue with
the Starter System Test.
Battery
decision
Measured
voltage
Battery
tempera-
ture
Test Code
for all
decisions
Estimated
charge time
if charging
needed
Measured
CCA
Selected
rating
• 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.
• Disconnectthebatterycablesandretest.
23
Page 24
Chapter 6: Battery Test EXP-800
State of Health (SOH)
The battery’s state of health represents its general condition,
and therefore its ability to deliver the specied performance
compared with a fresh battery.
Although a poor state-of-health can be the result of defects
in construction, it is most often caused by normal wear, which
As the battery approaches end of life, its deterioration
accelerates until it nally fails to start the vehicle. Before failing,
the battery may start the vehicle under normal conditions
but may not be able to operate in more extreme conditions.
Extreme heat or cold could expose a weak battery and cause
it to fail.
depends on vehicle needs, climate, and operating conditions.
These cause irreversible physical and chemical changes within
the battery until it can no longer hold a charge and supply
the power to start the car and provide auxiliary power to the
electrical system.
Table 3:
Decision Recommended Action
GOOD BATTERY Return the battery to service.
GOOD–RECHARGE Fully charge the battery and return it to service.
CHARGE REQUIRED 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 REQUIRED appears again
after you fully charge the battery, replace the battery.
Battery Decisions
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 IN-VEHICLE Test, disconnect the battery cables and
retest using the OUT-OF-VEHICLE 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.
OK-REPLACE SOON The battery may fail under extreme climate conditions. A REPLACE battery result may also mean
a poor connection between the battery and the battery terminal connectors. If you tested the
battery using the
VEHICLE Test
24 VOLT BATTERY 24-volt battery detected. You are attempting to test in-vehicle both batteries in a 24-volt system.
Disconnect the batteries and test them individually.
IN-VEHICLE Test
before replacing it.
, disconnect the battery cables and retest using the
OUT-OF-
NOTES: When testing at remote posts, the ana-
lyzer 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 analyzer may nd
that the data is inconclusive and instruct you to
test with side post adapters.
24
Page 25
Chapter 7: System Test
Chapter 7: System TestEXP-800
The system test rst evaluates the battery, then the starting
and charging systems.
IMPORTANT: When you start a new test, the last test results in
memory are overwritten. Remember to record or print
the results if you need to retain them.
Battery Test
The System Test includes a test of the battery to eliminate it as
the cause of starting or charging problems. See Chapter 6 on
page 22 for the Battery Test procedure.
Starter System Test
The performance of the starter and charging systems depends
on the battery’s condition. It is important that the battery is
good and fully charged before any further system testing.
1. In the Main Menu select the Battery test icon.
3. The analyzer displays one of six decisions and the results
in a series of screens.
NOTE: In some cases, the analyzer may not de-
tect the vehicle’s starting prole and display the
soft key options STARTED and NO START. If you
select STARTED, the analyzer skips to the Charging System Test. If you select NO START, the test
process ends.
Starter System Test Results
The results include the battery analysis. Use the UP or DOWN
ARROW key to scroll to each screen. See Table 4 for on the
next page for an explanation of the starter system decisions.
To continue testing, press the NEXT soft key.
Average
Starter
decision
cranking
voltage
Cranking
time in mil-
liseconds
2. Start the engine at the prompt. If after the vehicle started
and the results do not appear after approximately 25 seconds, press the NO START soft key.
X axis = time
Table 4:
Starting System Decision 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 using a
Midtronics Diagnostic Charger and retest the starter system.
REPLACE BATTERY Replace the battery and retest before testing the alternator test..
NO START The engine did not start and the test was aborted.
Starter System Decisions
25
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Chapter 7: System Test EXP-800
Charging System Test
When you press NEXT in any test result screen, the analyzer
proceeds to the Charging System Test.
1. CHECKING FOR ALTERNATOR OUTPUT: The analyzer is 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 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.
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 analyzer takes system measurements.
5. ENGINE REV DETECTED, IDLE ENGINE: The analyzer has detected the rev. Press the NEXT soft key.
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.
7.
TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE ENGINE: After a few seconds, the analyzer 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.
10. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold
the rpm while the analyzer takes system measurements.
11. ENGINE REV DETECTED, IDLE ENGINE: The analyzer has detected the rev. Press the NEXT soft key.
12. ANALYZING CHARGING SYSTEM DATA: The analyzer is
completing its nal analysis of the charging system data.
13. TURN OFF LOADS AND ENGINE: Press the NEXT soft key
to display the results. See Table 5 on the next page for an
explanation for the test decisions.
NOTE: When the option TRACK CALLS is enabled,
the EXP writes the results to the data card.
Charging System Test Results
Alternator
Loads-off
DC voltage
at rev
Normal DC
voltage
range
Peak-topeak AC
voltage
decision
Loads-on
DC voltage
at rev
Bar graph
showing
DC voltage
within
normal
range with
loads on and
off
Graph
of diode
waveform
IMPORTANT: Turn on the high-beam headlights and the blower
to high. Do not use cyclical loads such as air conditioning or windshield wipers.
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 analyzer 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.
26
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Chapter 7: System TestEXP-800
Table 5:
Charging
System
Decision Action
NO
PROBLEMS
NO OUTPUT The alternator is not providing charging current to the battery.
LOW OUTPUT The alternator is not providing enough current to power the system’s electrical loads and charge the
HIGH OUTPUT The voltage output from the alternator to the battery exceeds the normal limits of a functioning
The system is showing normal output from the alternator. No problem detected.
√ 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.)
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.
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.
Charging System Decisions
Diode Decision Action
EXCESSIVE
RIPPLE
OPEN PHASE The analyzer has detected an open phase within the alternator. Replace the alternator.
OPEN DIODE The analyzer has detected a open diode within the alternator. Replace the alternator.
SHORTED
DIODE
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.
The analyzer has detected an shorted diode within the alternator. Replace the alternator.
Table 6:
Diode Decisions
27
Page 28
Chapter 8: New Battery Test EXP-800
Chapter 8: PDI Battery Test
The PDI Battery Test in the Main Menu enables you to quickly
check new batteries in your inventory. The test can verify up
to 100 batteries in succession using the CCA rating and units
or JIS part number that you provide. This test diers from the
Battery Test in that the decision is either pass or fail. Neither
decision will tell you that a battery is bad, but rather that the
measured voltage and CCA fall in or out of your requirements.
IMPORTANT: The New Battery Test does not produce a test
code.
Selecting Test Parameters
1. Select the New Battery Test icon in the Main Menu.
2. The EXP displays the total number of PDI Tests completed
out of 100. To clear the results from memory and reset the
total to 0, simultaneously press the LEFT and RIGHT AR-
ROW keys. Press the NEXT soft key to continue.
Printing Test Results
1. To print the test results for an individual battery, use the
UP or DOWN ARROW key to scroll to the screen showing
the battery that was tested. Select the PRINT soft key.
2. Select option 1 to print the screen result of the selected
battery. Select option 2 to print the results of all the batteries listed by the order in which they were tested. Press
NEXT.
1 PDI BATTERY
2 PDI SUMMARY
PDI BATTERY
PDI SUMMARY
IMPORTANT: Be sure to monitor the number of tests per-
formed and be ready to print the results as the number
approaches 100. When the limit is reached you will no
longer be able to test until you clear all results from
memory.
3.
Enter the information required in steps 6 through 9 in “Chapter 6: Battery Test” on pages 22 and 23.
4. For the next few seconds the EXP evaluates the battery,
writes the results to the data card, and displays the results
starting from the last battery tested. To view a previous
result for a battery, use the UP or DOWN ARROW key to
scroll to the screen showing the battery that was tested.
Example of
displayed results
for a test of two
batteries
When the EXP displays a total of 100 Tests
The analyzer will not be able to continue inventory testing
until you clear all tests from its memory.
NOTE: To retain a record, use the PRINT soft key
to print the results.
To clear the results and reset the counter to 0:
1. Select the EXIT soft key to return to the Main Menu.
2. Select the New Battery Test icon.
3. In the INVENTORY STAT screen press the LEFT and RIGHT
ARROW key simultaneously to clear the results and reset
the counter to 0.
5. To continue testing, connect to the next battery. The analyzer starts the test automatically using the same parameters. To test another type of battery press END, then follow
steps 1 through 3 above.
28
Page 29
EXP-800
Chapter 9: Info Menu
Chapter 9: Info Menu
The Info Menu has several types of reports to help you manage
your test data and track the usage and history of your analyzer.
All the reports can be displayed and sent to an optional
handheld or to the analyzer’s internal printer. It also has a
utility to transfer test data to a PC using an optional IR receiver
and software package. In the Main Menu, select the Info icon.
View Test
This report displays the results of the Battery and
System Tests. See “Battery Test Results” on page
23, “Starter System Test Results” on page 25 and
“Charging System Test Results” on page 26.
View PDI Test
This report displays and prints the results for an in-
dividual battery or for all batteries tested using the
PDI Battery Test on page 28.
1. To print the test results for an individual battery, use the
UP or DOWN ARROW key to scroll to the screen showing the order in which the battery was tested. Select the
PRINT soft key.
Totals
The TOTALS menu shows the total number of tests
in four categories since the totals were reset to
zero. Use the UP or DOWN ARROW key to move the
dot to the option button of your choice (1, 2, 3, or
4). See the screen illustrations on the next page.
1 TOTALS
2
USER TOTALS
3
SYSTEM TEST
TOTALS displays the
total number of battery
tests performed OUT OF
VEHICLE and IN VEHICLE
since the EXP was rst
used. The IN-VEHICLE total
includes tests performed by
selecting the SYSTEM icon.
USER TOTALS displays
the total number of tests
performed by user including
the unregistered users.
SYSTEM TEST displays the
total number of Starting and
Charging Test decisions.
2. Select option 1 to print the screen result of the selected
battery. Select option 2 to print the results of all the batteries listed by the date and order in which they were tested. Select the PRINT soft key.
1 PDI BATTERY
2 PDI SUMMARY
4
TOTALS BY DECISION
Transfer
The TRANSFER utility lets you transfer test data to a
PC using an optional IR receiver and software package. The list of test codes is also sent to the data
card if the card is inserted into the EXP.
Version
Version displays the analyzer’s software version, the
software release date, the analyzer serial number.
The utility keeps a permanent count of the number
of battery tests performed since the analyzer was
rst used.
TOTALS BY DECISION
displays the total number of
tests by battery decision.
29
Page 30
Chapter 10: Printing Test Results EXP-800
Chapter 10: Printing Test Results
If you are using the EXP internal printer, keep the clamps
connected to the battery during the printing process. After a
test the results automatically print.
NOTE: When the option TRACK CALLS is enabled,
the EXP writes the results to the data card.
To print a second copy of the results:
1. Press the PRINT soft key.
2. Select the language for the printed results. Use the UP/
DOWN ARROWS to move the dot to the option button of
your choice (1, 2, or 3).
1 ENGLISH
2 ESPAÑOL
3 FRANÇAIS
3. Press the NEXT soft key to continue.
Changing the Paper in the Internal Printer
The internal printer is shipped with a roll of thermal printing
paper installed in the paper compartment. The roll size is 2-1/4
inches wide by 1-7/8 inch in diameter. Replacement rolls are
available at most oce supply stores.
The analyzer uses only thermal printing paper. Below are four
major oce supply stores that carry thermal paper:
Store Part Number Phone
Ofce Depot 209-653-271 800-463-3768
Ofce Max 20121146 800-283-7674
Quill 856607 800-789-1331
Staples 531236 800-378-2753
To replace the paper roll:
1. Unlock the printer door by gently pressing down on the
red lever.
2. Lift the printer door and remove the spent roll.
Push the lever in this direction
Paper sensor
3. Place a new roll of paper in the compartment. As the diagram in the paper compartment indicates, the paper feeds
from the bottom of the roll.
4. Pull the paper forward so that it extends past the serrated
edge of the paper slot.
5. Close the door and make sure the lever locks securely. For
a clean tear, pull the paper along the serrated edge. Do
not pull the paper straight out of the printer.
NOTE: Due to production variances some paper
roll diameters may be too large. Please remove
paper from roll to recommended 1-7/8 inch diameter. DO NOT force cover to close if roll is too
large.
30
Page 31
Chapter 11: Troubleshooting
Chapter 11: TroubleshootingEXP-800
In addition to the troubleshooting suggestions in this chapter,
the EXP Help Menu provides tips on troubleshooting
problems with the printer, the cables, and loss of power.
It also includes Midtronics Customer Service phone
numbers.
Problems with the Display
The display does not turn on:
• Checktheconnectiontothebattery.
• Theanalyzer’sinternalbatteriesmayneedtobereplaced.
See “Chapter 13: EXP Internal Batteries” on page 34.
The display ickers or is dim:
• Thecontrastmayneedtobe adjustedintheAdmin/Utility menu. Highlight the Display icon and press ENTER. Use
the UP or DOWN ARROW key to scroll the contrast value to
10.
• Theanalyzer’sinternalbatteriesmayneedtobereplaced.
See “Chapter 13: EXP Internal Batteries” on page 34.
Problems with the Internal Printer
The internal printer will not print
• Theanalyzermustbeconnectedtothevehiclebatteryto
print to the internal printer. Check the clamp connections
to the battery.
• Thevehiclebatterymaybetoolowtopowerthe printer.
Connect to a battery with at least 11.5 volts.
• Verifythatthepaperisproperlyinstalled.
• Verifythatthepapersensoriscleanandundamaged(see
page 30).
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Chapter 12: Test Cable Maintenance EXP-800
Chapter 12: Test Cable Maintenance
The test cables that come with your analyzer are consumable
items. Cables are like tires in that the more you use them and
the harder you drive them, the shorter their useful life. Here
are a few things you can do to protect your test cables from
damage and premature wear:
Cleaning the Clamps
• Thegrease,dirt,andsulfationthatbuilduponbatteryterminals are highly corrosive and can damage the clamps
over time. Before connecting the clamps, ensure accurate
test readings and protect the clamps by cleaning the battery case and terminals using a wire brush and a mixture
of water and baking soda.
• Periodically clean the clamps using a mixture of baking
soda and water, or a mild hand-soap, and a small bristle
brush.
• Toprotect the clamps fromoil anddirt,clipthem to the
back of the analyzer as shown.
Storing Test Cables
• Neverwrapthecablesaroundtheanalyzer;thisputsunnecessary strain on the test cables.
Because the test cables are the “tires” of the analyzer, they
have a certain life expectancy and will wear out eventually.
However, the abuse examples cited above are not covered
under warranty. To ensure the best performance and longest
life of the test cables, attach and remove them with care, and
carry the analyzer and cables together.
If an inspection or a change in test results indicate that the test
cables need to be replaced, please call Midtronics Customer
Service at 1-800-776-1995.
Handling the Test Cables
• Alwaysconnectanddisconnecttheclampstothebattery
by opening and closing the clamps. Never pull on the test
cables to remove the battery clamps. Pulling can damage
the Y-junction, the cables, and the clamps to the extent
that the analyzer may produce lower-than-expected conductance readings or fail completely.
• Nevercarrytheanalyzerbythe cables.Carryingtheanalyzer or swinging it by the cables puts unnecessary strain
on the cables and can result in premature failure. Handle
the analyzer with care to get the maximum use from the
product.
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Page 33
Chapter 12: Test Cable MaintenanceEXP-800
Testing Resistance in 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.
Test Procedure
You are testing the continuity of the following end points:
• Thepositive(REDclampjawwithout teeth and itscorresponding pin hole.
• The positive (RED) clamp jaw with teeth and its corresponding pin hole.
• Thenegative(black)clampjawwithoutteethanditscorresponding pin hole.
• The negative (black)clamp jaw withteethand itscorresponding pin hole.
1. Grip a pencil with the clamp as shown in the gure Con-
tacts for Clamp Jaws. Do not grip the metal part of the
eraser or any area that may conduct current.
2. Insert a probe tip into the hole designated “NO TEETH” for
the color (BLACK or RED) of the clamp you are testing as
shown in the gure “Contacts for Cable Connector.”
Orientation of
arrow on cable
connector
RED clamp,
NO teeth
BLACK clamp,
TEETH
Contacts for Cable Connector
Contact point for
testing at “NO
TEETH”
Contact point for
testing at “TEETH”
Contacts for Small Clamp
BLACK clamp,
NO teeth
RED clamp,
TEETH
3. Touch the toothless jaw of the clamp with the other probe
tip. Wiggle the battery test cables. The resistance reading
should be less than 1 Ω.
4. Repeat the test for the “TEETH” side of the circuit, this time
touching the jaw with teeth. Insert the other probe tip
into the “teeth” pin hole. Wiggle the battery test cables.
The resistance reading should be less than 11 Ω.
33
Page 34
Chapter 13: EXP Internal Batteries
Chapter 13: EXP Internal Batteries
EXP-800
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.
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 vehicle
battery
Replacing the Internal Batteries
1. Turn the analyzer face down.
2. Use a Philips screwdriver to remove the screw securing
the door to the battery compartment.
Remove the screw
and lift the tab
3. Lift the door at the tab and place it aside.
4. Remove the discharged batteries.
5. Insert new batteries as shown. Make sure the positive and
negative terminals are positioned correctly.
6. Reposition the door on the battery compartment.
7. Reinsert and tighten the screw.
34
Page 35
35
Page 36
PATENTS
The EXP-800 Battery & Electrical Diagnostic Analyzer is made in the U.S.A. by Midtronics, Inc. and is protected by one or more
ofthefollowingU.S.Patents:4,816,768; 4,825,170; 4,881,038; 4,912,416; 5,572,136; 5,585,728; 5,592,093; 5,757,192; 5,821,756;
5,831,435;5,914,605;6,051,976;6,091,245;6,163,156;6,249,124;6,304,087;6,310,481;6,316,914;6,323,650;6,351,102;6,359,441;
6,363,303;6,392,414;6,441,585;6,445,158;6,456,045;6,469,511;6,534,993;6,544,078;6,556,019;6,566,883;6,586,941;6,707,303.
Canadian Patents: 1,295,680; 1,280,164. United Kingdom Patent: 0,672,248;0,417,173. German Patent:693 25388.6; 689 23
281.0-08;9321638.6.AndotherU.S.andForeignpatentsissuedandpending.Thisproductmayutilizetechnologyexclusively
licensed to Midtronics, Inc. by Johnson Controls, Inc. and/or Motorola, Inc.
LIMITED WARRANTY
This analyzer is warranted to be free of defects in materials and workmanship for a period of one year from date of purchase.
EXP-800 cables are warranted to be free of defects in materials and workmanship for a period of 9 months from date of purchase.
Midtronics will, at our option, repair or replace the unit with a remanufactured unit. This limited warranty applies only to the
EXP-800 analyzer, 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 for a Return Authorization number, and return the unit to Midtronics freight prepaid,
Attention: RA# ________. Midtronics will service the analyzer and reship the next scheduled business day following receipt,
using the same type carrier and service as received. 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 freight charges added to the invoice. Battery analyzers beyond the warranty period are subject to the repair
charges in eect at that time. Optional remanufacturing service is available to return the tester to like-new condition. Out-ofwarranty repairs will carry a 3-month warranty. Remanufactured units purchased from Midtronics are covered by a 6-month
warranty.
www.midtronics.com
Corporate Headquarters
Willowbrook, IL USA
Midtronics b.v.
European Headquarters
Serving Europe, Africa, the Middle
East and The Netherlands
Phone: +31 306 868 150
Fax: +31 306 868 158
E-Mail: [email protected]
European Sales Locations
IJsselstein, The Netherlands
Paris, France
Dusseldorf, Germany
168-547A 7/08 2008 Midtronics, Inc. All rights reserved.
Midtronics China Oce
China Operations
Shenzhen, China
Phone: +86 755 8202 2037
Fax: +86 755 8202 2039
E-Mail: [email protected]
Asia/Pacic (excluding China)
Contact Corporate Headquarters at
+1.630.323.2800 or
E-Mail: [email protected]
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