Midtronics GR8-1202 User Manual

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April 2013

167-000497EN-A

GR8-1202

Multitasking Battery And

Electrical Diagnostic Station

INSTRUCTION MANUAL

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GR8-1202

Contents

Safety Guidelines 5

General Safety Precautions 5 Personal Precautions 5 Preparing To Charge The Battery 6 Grounding & Power Cord Connections 6 Charger Location 7 DC Connection Precautions 7 Installing The Battery 7 Connecting To The Battery 8

Chapter 1: Introduction & Overview 9

Safety Reminder 9 Safety Precautions 9 Assembling the GR8 9

Attaching the Control Module 9

Installing the Multitasker Module 10 Front of GR8 11 Back of GR8 11 Control Module Keypad 12 Data Entry Methods 13

Menu Icons 13

Option Buttons 13

Scrolling Lists 13

Alphanumeric Entry 13

Value Boxes 13 Main Menu 13 Info Menu 14 DMM Menu 14 Setup Menu 14 Setting User Preferences 15 Help Menu 15 Multitasking 15

Wireless Multitasking 15

Procedure Example 15 Inspecting the Battery 15 Testing Out-of-Vehicle (Battery Test) 15 Testing In-Vehicle (System Test) 16 Connecting to the Battery 16 Initial Power-up 16

Selecting A Language 16

Chapter 2: Battery Test 17

Test Requirements 17 Additional Test Requirements 18

System Noise Detected 18 Unstable Battery Detected 18

Deep Scan Test 18 Battery Test Results 18 State of Health 19 State-of-Charge 19

Chapter 3: Diagnostic Charging 20

Charging Modes 21

Initial Analysis 21

Deep Scan Test 21

Diagnostic Mode 21

Aborting a Charge Session 21

Completing a Charge Session 22

Diagnostic Charge Results 22

Top-Off Mode 22

Chapter 4: System Test 23

Starter Test 23

Starter System Test Results 23 Charging System Test 24 Key-Off Draw 24

Charging System Test Results 25

Chapter 5: ECM Power Supply 26

Chapter 6: Jump Start 27

Chapter 7: Manual Charging 28

Chapter 8: Info Menu 30

View Test Battery 30 View Test Charger 30 View Cable Test 30 View Inventory Test 30 Totals 30 Transfer 31 View Wireless 31 Version 31

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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Contents

GR8-1202

Chapter 9: Cable Drop Test 32

Cable Drop Test 32

Battery Ground Test 32 Battery Ground Test Results 32

Starter Circuit 33

Starter Circuit Test Results 33

Alternator Circuit 33

Alternator Circuit Test Results 33

Other Circuit 34

Other Circuit Test Results 34

Chapter 10: Key Off Draw 35

Chapter 11: Digital Multimeter (DMM) 36

Ohm Meter 36 Diode 36 Scope 37 DC and AC Volts/Amp 37

Multimeter Specications 38

Chapter 12: Inventory Test 39

Selecting Test Parameters 39

Printing Test Results 39 Clearing Test Results 39

Chapter 13: Setup 40

Clock 40

Mode 40 Time 40 Format 40

Date 40 Shop 40 Users 41

Entering A New User ID 41

Deleting A User ID 41

Editing A User ID 41

Info Upload 41 Display 42

Contrast Level 42 Coupon 42 Edit Coupon 42 Track Calls 42 Language 43 Admin 43

Options 43

Clear Test Totals 43

Reset Defaults 43 Select 43 Update 43 Format 43 Buzzer 44 User Screen 44 Wireless 44

Chapter 14: Maintenance / Troubleshooting 45

Help 45

Terms/Denitions 45

Troubleshooting 45

Service Info 45 Test Messages 45 Replacing the Paper Roll 45 Control Module Internal Batteries 46

Battery Power Indicator 46

Replacing the Internal Batteries 46 Test Cable Maintenance 46 Attaching the Charger Cables 46 Error Messages 47

Appendix 48

Header Template 48 Coupon Template 48

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GR8-1202

Safety Guidelines

1 General Safety Precautions

1. IMPORTANT SAFETY INSTRUCTIONS. IT IS OF UTMOST

IMPORTANCE THAT BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE SAFETY AND OPERATING INSTRUCTIONS EXACTLY. SAVE THESE

INSTRUCTIONS.

Risk of explosive gases

Batteries generate explosive gases during normal operation, and when discharged or charged.

1.1 To reduce risk of battery explosion, follow these safety instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery. Review cautionary marking on these products and on the engine, and on the vehicle or equipment containing the battery.

Safety Guidelines

Remove marine “boat” batteries and charge them on shore.

Charging marine batteries on-board requires specially designed equipment for marine use.

1.8

Connect and disconnect the battery leads only when the

AC supply cord is disconnected.

1.9

Do not overcharge the battery. (See sections 3 and 10 in

the safety instructions)

1.10

Charge the battery in a dry, well-ventilated area.

1.11

Never place articles on or around the charger, or locate

the charger in a way that will restrict the ow of cooling air through the cabinet.

1.12

An extension cord should not be used unless absolutely necessary. (See paragraph 4.3.)

1.13 Have a damaged cord or plug replaced immediately.

Charging a non-rechargeable battery may cause the battery to burst.

To reduce the risk of injury, only charge rechargeable lead-acid type batteries including maintenance-free, low-maintenance, or deep-cycle batteries.

If you are uncertain as to the type of battery you are attempting to charge, or the correct procedure for checking the battery’s state of charge, contact the seller or battery manufacturer.

1.2 Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of re, electric shock, or injury to persons.

1.3 To reduce risk of damage to the electric plug and cord, pull by the plug rather than by the cord when disconnecting the charger.

1.4 Position the AC and DC leads to avoid tripping over them and prevent damage by hood, doors, or moving engine parts; protect from heat, oil, and sharp edges.

1.5 Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way; take it to a qualied service center.

1.6 Do not disassemble charger; take it to a qualied service center when repair is required. Incorrect reassembly may result in a risk of electric shock or re.

1.7 To reduce risk of electric shock, unplug the charger from the AC outlet before attempting any maintenance or cleaning. Turning o the controls will not reduce this risk.

1.14

Do not expose the charger to rain or snow.

2 Personal Precautions

2.1 Always have someone within range of your voice to come to your aid when working around lead acid batteries.

2.2 Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.

2.3 Wear complete eye and clothing protection, as well as rubber soled shoes. Place damp cloth over battery to protect against acid spray. When ground is very wet or covered with snow, wear rubber boots. Avoid touching eyes while working near battery.

2.4 If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately ush with cold running water for at least 10 minutes and seek medical attention.

2.5 NEVER smoke or allow a spark or ame in vicinity of a battery or engine.

2.6 Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short circuit the battery or other electrical part that may cause an explosion.

2.7 Before working with a lead-acid battery, remove personal metal items such as rings, bracelets, necklaces, watches, etc. A lead-acid battery can produce a short circuit current high enough to weld such items causing a severe burn.

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Safety Guidelines

GR8-1202

Non-rechargeable batteries may burst when charging causing personal injury and damage.

To avoid electrical shock or burn, never alter the charger’s original AC cord and plug. Disconnect plug from outlet when charger is idle.

2.8 The charger is not intended to supply power to a lowvoltage electrical system other than applications using rechargeable, lead-acid type batteries. Do not use the battery charger for charging dry-cell batteries commonly used with home appliances. These batteries may burst and cause personal injury and property damage.

2.9 NEVER charge a frozen battery; thaw it out rst.

3 Preparing To Charge The Battery

3.1

If it is necessary to remove the battery from vehicle to charge it, always remove the grounded terminal from the battery rst. Make sure all accessories in the vehicle are o, so as not to cause an arc.

3.2

Be sure the area around the battery is well ventilated while the battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan.

3.3

Clean the battery terminals. Be careful to keep corrosion from coming into contact with your eyes.

3.4 Add distilled water in each cell until the battery acid reaches the level specied by the manufacturer. This helps purge excessive gas from the cells. Do not overll. For a battery without caps, carefully follow the manufacturer’s recharging instructions

3.5 Study all battery manufacturer’s specic precautions such as removing or not removing cell caps while charging and recommended rates of charge.

Hazardous voltage. An improper connection can result in electric shock

To avoid electrical shock or burn, never alter the charger’s original AC cord and plug. Disconnect plug from outlet when charger is idle.

IF THE PLUG DOES NOT FIT THE OUTLET, HAVE A QUALIFIED ELECTRICIAN INSTALL A PROPER OUTLET.

4.2

This battery charger is for use on a nominal 120-volt circuit and has a grounding plug that looks like the plug illustrated in Figure A. A temporary adapter, which looks like the adapter illustrated in Figures B and C, may be used to connect this plug to a two-pole receptacle as shown in Figure B, if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualied electrician.

Hazardous voltage. An improper connection can result in electric shock

Before using an adapter be certain the center screw of the outlet plate is grounded. The rigid ear or lug extending from the adapter must be connected to a properly grounded outlet. Make certain it is grounded. If necessary, replace the original screw that secures the adapter ear or lug to the cover plate and make the ground connection to the grounded outlet.

USE OF AN ADAPTER IS NOT ALLOWED IN CANADA. IF A GROUNDING-TYPE RECEPTACLE IS NOT AVAILABLE, DO NOT USE THIS APPLIANCE UNTIL THE PROPER OUTLET IS INSTALLED BY A QUALIFIED ELECTRICIAN.

3.6 Determine the voltage of the battery by referring to the car owner’s manual and make sure that the output voltage selector switch is set at the correct voltage. If the charger has an adjustable charge rate, charge the battery initially at lowest rate. If the charger has only one voltage, verify that the battery voltage matches the voltage of charger.

For a charger not having an output voltage selector switch, determine the voltage of the battery by referring to car owner’s manual and make sure it matches the output rating of the battery charger.

4. Grounding & Power Cord Connections

4.1 The charger must be grounded to reduce risk of electric shock. The charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

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4.3 An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk of re and electric shock. If an extension cord must be used, make sure:

a. that the pins on plugs of the extension cord are the

same number, size, and shape as those of the plug on the charger;

b. that the extension cord is properly wired and in good

electrical condition;

c. that the wire size is large enough for the AC ampere

rating of charger as specied in the following table.

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GR8-1202

Safety Guidelines

Recommended minimum AWG* size for extension cords for battery chargers

AC input rating amperes AWG* size of cord

Length of cord, feet (m)

Equal or greater than: But less than:

25 (7.6) 50 (15.2) 100 (30.5) 150 (45.6)

8 10 18 14 12 10

10 12 16 14 10 8

12 14 16 12 10 8

14 16 16 12 10 8

16 18 14 12 8 8

*American Wire Gauge

5. Charger Location

5.1 Locate the charger as far away from the battery as the charger cables permit.

5.2 Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.

5.3 Never allow battery acid to drip on the charger when taking gravity readings or lling a battery.

5.4 Operate the charger only in a well-ventilated area that is free of dangerous vapors.

5.5 Store the charger in safe, dry location and maintain it in perfect condition.

5.6 Do not set the battery on top of the charger or where its acid might drip onto the charger.

6. DC Connection Precautions

6.1

All switches should be set in the OFF position and AC cord should be DISCONNECTED from electrical outlet before you connect and disconnect the charger clamps. Never allow the clamps to touch each other.

6.2 When attaching the charger clamps, be certain to make the best possible mechanical as well as electrical connection. This will tend to prevent the clamps from slipping o the connections, avoid dangerous sparking, and assure safer and more ecient charging. The clamps should be kept clean.

Hazardous voltage. Can cause death or serious personal injury.

Setting the switches to “OFF” does not always disconnect the charger electrical circuit from the AC power cord or the DC charger clamps.

7. Installing The Battery

Risk of explosive gases.

A spark near the battery may cause a battery explosion. Follow these steps when the battery is installed in the vehicle to reduce the risk of explosion.

7.1 Before working on the vehicle, rmly apply the emergency brake and place the gear shift to NEUTRAL—shift an automatic transmission to PARK.

7.2 Locate the charger as far away from the battery as the charger cords permit and position the AC and DC cords to avoid stepping on or tripping over them and to prevent damage by hood, doors, or moving engine parts.

7.3 Stay clear of fan blades, belts, pulleys, and any other parts that can cause physical injury.

7.4 Turn OFF all vehicle loads, including door lights, and cor- rect any defects in the vehicle’s electrical system that may have caused low battery.

7.5 Check the polarity of the battery posts. The POSITIVE

(POS., P, +) post usually has a larger diameter than the NEGATIVE (NEG., N,–) post.

7.6 Determine which post of the battery is grounded (connected) to the chassis. If the negative post is grounded (as in most vehicles), see paragraph 7.7. If the positive post is grounded, see paragraph 7.8.

7.7 For a negative-grounded vehicle, rst connect the POSI-

TIVE (RED) clamp from the charger to the POSITIVE (POS., P, +) ungrounded post of the battery. Then connect the NEGATIVE (BLACK) clamp to the NEGATIVE (NEG., N,–) post of the battery. Do not connect the clamp to the

carburetor, fuel lines, or sheet-metal body parts. When disconnecting the charger, turn all switches to OFF, discon- nect the AC cord, remove the clamp from the NEGATIVE battery terminal, and then remove the clamp from the POSITIVE battery terminal.

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Safety Guidelines

GR8-1202

7.8 For positive-grounded vehicle, connect the NEGATIVE (BLACK) clamp from the charger to the NEGATIVE (NEG., N, –) ungrounded post of battery. Then connect the POSI- TIVE (RED) clamp to the POSITIVE (POS., P, +) post of the

battery. Do not connect clamp to carburetor, fuel lines, or sheet-metal body parts.

When disconnecting the charger, turn the switches to

OFF, disconnect the AC cord, remove the clamp from the POSITIVE battery terminal, and then remove the clamp from the NEGATIVE battery terminal.

CAUTION: WHEN POSITIVE (+) POST OF VEHICLE BATTERY IS GROUNDED, DOUBLE CHECK POLARITY.

8. Connecting To The Battery

8.1 If it is necessary to remove the battery from the vehicle or equipment, always remove the grounded terminal from the battery rst.

Risk of explosive gases. Can cause death or serious personal injury.

Always work in a well-ventilated area. 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.

8.1

Check the polarity of battery posts. POSITIVE (POS., P, +) post usually has larger diameter than NEGATIVE (NEG., N, –) post.

8.2 When disconnecting the charger, always do so in the reverse sequence of the connecting procedure; break the rst connection while staying as far away from the battery as practical.

8.3 MARINE “BOAT” BATTERIES MUST BE REMOVED AND

CHARGED ON SHORE. TO SAFELY CHARGE THEM ON BOARD REQUIRES EQUIPMENT ESPECIALLY DESIGNED FOR MARINE USE.

Risk of explosive gases.

Make sure all vehicle loads are OFF to prevent a possible arc..

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GR8-1202

Chapter 1: Introduction & Overview

Safety Reminder

For safe, ecient, and accurate charging and testing, review the safety and operating instructions in this manual before using the analyzer. In addition, follow all manufacturer instructions and BCI (Battery Council International) safety recommendations.

Safety Precautions

Inspect the battery for damages and check the electrolyte level. If the electrolyte level is too low, replenish it and fully charge the battery. Always use the necessary safety precautions when working with batteries to prevent severe injury or death. Follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations, which include the following precautions:

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..

Chapter 1: Introduction & Overview

Conventions Used in This Manual

To help you learn how to use your GR8, the manual uses these symbols and typographical conventions:

Convention

CAUTION

ARROW

CAPITAL LETTERS

The safety symbol indicates instructions for avoiding hazardous conditions and personal injury.

The word CAUTION indicates instructions for avoiding equipment damage.

The wrench symbol indicates procedural notes and helpful information.

The text for keypad buttons are in Bold capital letters.

The text for screen options are in regular capital letters.

The text for soft keys are in Bold capital letters.

Description

Assembling the GR8

The GR8 control module, multitasking module, and mounting bracket are these steps:

packaged separately. For easy assembly, follow

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.

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.

Never charge a frozen battery. Gases may form, cracking



the case, and spray out battery acid.

Attaching the Control Module

1. The hardware to attach the control module’s mounting bracket to the GR8 is installed on the top of the charger. There are three bolts with one at washer, one lock washer, and one hex nut per bolt. Remove the washers and hex nuts, and set them aside.

Pre-installed

bolts for the

control module

mounting

bracket.

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Chapter 1: Introduction & Overview

GR8-1202

2. Center the three holes in mounting bracket over the bolts, and lower the bracket onto the charger. Reinstall the hardware in this order: the at washer rst, the lock washer next, and the hex nut last. Tighten the nuts securely.

Control Module

mounting bracket

3. Center the holes on the bottom of the control module with the bolts, and lower the module onto the top of the bracket. Firmly pull the module down at an angle until the bolts are inserted securely into the slots extending from the module’s holes.

Installing the Multitasker Module

The GR8-1202 comes with a bracket to hold the multitasker module.

1. Place the multitasker module in the bracket. Connect one of the serial cables between port B of the multitasker and the cart.

Charge

Port B

Cart

2. Connect the other serial cable between the control module and port A of the multitasker.

Control Module

Port A

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GR8-1202

Chapter 1: Introduction & Overview

Front of GR8











Back of GR8















 STATUS light

Lights in conjunction with beeping alarm to indicate transitions and warnings

 Control Module

Backlit graphical display and keypad for data entry.

 Data Card slot

For data storage and future software updates.

 Multitasker Module

Allows GR8 to test battery and electrical systems while charging an additional battery.

 ON/OFF Switch

Turns power on and o to the GR8.

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Serial number label

(for control module)

 Battery and System test cable connector

 AMP Clamp Connector

For use with amp clamp

 Cable wrap

For storing cables when not in use.

 Charger cable connectors

 Serial number label

(for charger)

 AC power cord

Connection to grounded nominal 120 V outlet. Display and Keypad

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Chapter 1: Introduction & Overview

GR8-1202

Control Module Keypad

















 Menu Screen Arrows (tu)

When displayed, the 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.

Some screens also indicate the page order with a notation such as P1/3 (page 1 of 3).

Scroll

Box

Top or

only

screen

Middle screen

Last

screen



 Voltmeter

When you rst connect the GR8 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 to perform the functions displayed above them. These functions will change depending on the menu or test process.

 ARROW Keys

Press the ARROW keys to scroll to numerical values and move to menus and icons.

 POWER Key

Press the POWER key to turn the control module ON and OFF.

 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.

 Alphanumeric Keypad

In some cases, you can use the alphanumeric keypad to enter numerical test parameters instead of scrolling to them with the ARROW keys. You can also use the alphanumeric keys to create and edit customer coupons and your shop contact information on printed test results, and manage User IDs.

To add a space, press u. To erase a space and insert a character, press t.

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

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GR8-1202

Chapter 1: Introduction & Overview

Data Entry Methods

Typically, the soft key below the right half of the screen conrms your choice. The soft key below the left half of the screen cancels your choice or returns you to the previous screen.

Menu Icons

A menu icon is a graphical representation of a function can select, such as the DC Amp Meter Test Icon in the DMM Menu. To select an icon, use t or u to highlight it. Highlighting changes the icon to a white picture on a black background. To conrm your selection, press the appropriate soft key.

Option Buttons

Some lists have option buttons before each item. To select an item, use  or  to move the dot to the button next to the item. To conrm your selection, press the appropriate soft key.

You can also use the alphanumeric keypad to enter the number preceding the option button of your choice. No additional keypress is needed to proceed.

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. use  or  to highlight the item, and press the appropriate soft key. To move the highlight bar up five lines at a time, press

t. To

move the highlight bar down ve lines at a time,

you

To select an item,

press u

Value Boxes

Value boxes contain items that extend above and below the selection box that contain them. To indicate that there are more values, the symbols appear to the right of the box. To select, use  or  to scroll to the value, or use the keypad to enter the value directly, and press the appropriate soft key. In the illustration the left directional arrow indicates that you can press t to clear all or part of the entry.

Main Menu

Icon Description

Tests a battery using the battery information you select in a series of screens.

Automatically tests, charges, and provides battery decision using the information you select in a series of screens.

Tests a battery, and the starting and charging systems.

Tests and maintains battery voltage at 13.5 volts to provide uninterrupted reprogramming of ECMs and retain vehicle system settings.

Makes high output current available to boost charge an in-vehicle battery and assist in starting the engine.

Provides a timed charge that ranges from 5 to 120 minutes or a continuous charge that ends when you press the STOP key.

View and print test results, total test counters, data transfer, software version and date, and GR8 serial number for the Control Module.

Test the voltage drop of circuits.

Test the amount of current draw on the battery when

the ignition and all accessories are off.

Alphanumeric Entry

Some selections require you to use the alphanumeric keypad. These “user-defined” selections have a blinking horizontal line (cursor) to the right of the last character.

Use  or  to highlight a line for editing. Display the character, symbol, or number you want by rapidly pressing its key as many times as needed. If you pause, the cursor moves to the right. To backspace, press t. Use u to add a space. Use  or  to highlight a line for editing. When nished, press the appropriate soft key to save your settings.

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Digital multimeter with 4 test meters.

Enables you to test up to 100 batteries in succession without re-entering battery information each time.

The Setup Menu lets you customize options in the GR8 to suit your needs.

Provides a list of topics and denitions. Also includes

Midtronics Customer Service phone numbers.

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GR8-1202

Info Menu

Selecting the Info Menu lets you view the test results for the Battery, Charger, and Cable Test. This menu also allows you to select Totals, Transfer results and view Software Version information.

Icon Description

Displays the last Battery results. Sends the results to the printer.

Displays the last Charger results. Sends the results to the printer.

Displays the last Cable Drop Test result. Sends the result to the printer.

View and Print the results from the last inventory test.

Display total results from the tester or charger.

Transfers test results and counters to an IR receiver and data card.

Setup Menu

The Setup Menu has several functions to customize

the use of your GR8—from the language of the user interface to the contrast of the display.

Icon Description

Settings to adjust the time.

Enables you to add a custom header to printed test results.

Add, edit, or delete User IDs.

Updates Shop, Coupon, User, and Screen information on the GR8 using a data card.

Settings to adjust the screen contrast and backlight time.

Use this option to turn Coupon printing on or off.

Displays wireless communication quality and channel being used.

Lists the software version, version date, and serial number.

DMM Menu

Selecting the Info Menu lets you view the test results for the Battery and Charger. This menu also allows you to select Totals, Transfer results and view Software Version information.

Icon Description

Tests a circuit for continuity and resistance

measured in ohms (Ω).

Tests a diode for forward voltage drop.

Voltage trace with time and frequency measurements.

Displays the last DC test results. Sends the results to the printer.

Enables you to create a coupon at the bottom of printed test results.

Stores test results on the data card when enabled (ON). (Data card reader required)

Sets the language of the display and printouts.

Offers additional administration options such as showing the user ID and headers for printouts.

Select built-in printer or an external lR printer.

Updates the GR8 software using les on an

data card.

Formats the data card to receive data. Also erases all data on the card.

Allows you to turn the buzzer OFF. Default is ON.

User-dened questions with the answers stored in data les on the data card.

Displays the last AC test results. Sends the results to the printer.

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Optimize wireless communication between the Multitasker and Control Module.

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GR8-1202

Chapter 1: Introduction & Overview

Setting User Preferences

Before starting your test you may want to customize the use of your GR8 by setting preferences in the Setup Menu under the Admin icon. This menu has settings for time, contrast, customizing printouts for the optional IR printer, and several other settings.

Help Menu

The GR8 provides a Help Menu with a glossary of test-

related denitions that you may want to review prior to testing.

This menu also provides troubleshooting information and phone numbers for Midtronics Customer Service, in case you encounter a problem and/or need technical assistance.

See Chapter 14: Maintenance & Troubleshooting for more information about the Help function.

Multitasking

The GR8-1202 Multitasking Battery Diagnostic Station is capable of doing two jobs at once. Historically a charger or tester could only perform one function at a time. The GR81202 Multitasking Battery Diagnostic Station has the ability to charge or test the battery and the electrical system of a vehicle independently while a second battery is being charged.

Wireless Multitasking

The Multitasker communicates with the control module using RF radio signals. Once a charge session has begun, the control module can be disconnected and removed to test another vehicle in the service bay—thus, acting as two tools in one. The Multitasker will control the charge session when the control module is removed. The charge session can be monitored with the control module even when it is not connected however, internal AA battery life will be reduced. Long-term monitoring of a charge session should be done while connected to the Multitasker.

Procedure Example

Select CONTINUE, swap out the tester cables for the charging cables, and the controller will now analyze the battery for the optimal charging conditions Once the charge process has started you can go back to the main menu and continue to run system tests while the charger is charging.

Starting with the battery test is recommended so that a good battery decision can quickly be reached. While the charger can also be used and will reach the same decision, it is designed to determine the optimum charging method for a battery and therefore will take longer before reaching a decision. The same holds true for a bad cell or other physical aws that will cause a replace battery decision.

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 low, add dis- tilled water to ll up to ½ above the top of the plates and fully charge the battery. Do not overll.

• 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.

• Always use a carry tool or strap to lift and transport the battery.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8.

The best way to utilize the multitasking feature is by rst testing a battery using the Battery Test or System Test with the associated battery test cables that come from the top of the controller. If the test decision for the battery is one that requires a charge then the controller will ask you if you want to charge the battery.

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Do not test at the battery’s steel bolts.

Failure to properly install lead terminal adapters, or using adapters that are dirty or worn, may cause false test results. Always use lead terminal adapters provided with the GR8 when testing side-post or Group 31 batteries.

IMPORTANT:

wrench

To avoid damage, never use a

to tighten the adapters more than ¼

turn.

IMPORTANT:

There must be a formatted data card installed in the GR8 in order for it to work properly.

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Chapter 1: Introduction & Overview

GR8-1202

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 testing clamps to the battery in accordance with all precautions and safety instructions. Do not connect either

clamp to the vehicle’s chassis.

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 sounds an alarm and displays CLAMPS REVERSED! Reverse the clamps and reconnect the clamps to the battery.

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 will display the message CHECK CONNECTION. If the message reappears after you have correctly reconnected the clamps, clean the terminals and reconnect.

Initial Power-up

When you turn on the charger, it will initially display the GR1202 logo on the screen while testing the internal software integrity.

Selecting A Language

After the logo appears, the rst selection screen to appear enables you to temporarily set the language for the display and printed test results.

1. Use  or  to select the LANGUAGE you want the tool to use as the default language and press NEXT, or press the corresponding number key.

1  ENGLISH

2  ESPAÑOL

3  FRANÇAIS

2. Press SAVE to save your settings and continue to Main Menu.

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GR8-1202

Chapter 2: Battery Test

Test Requirements

The GR8 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 1: Introduction & Overview.

NOTE: 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.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the small clamps from the GR8 control module when performing a Battery Test.

If you use the ARROW keys to select option buttons, press NEXT to continue to the next step.

1. In the Main Menu select the BATTERY TEST icon.

2. Use  or  to select the battery LOCATION and press NEXT to continue, or press the corresponding number key.

1  OUT OF VEHICLE

2  IN VEHICLE

3. Use  or  to select the battery POST TYPE and press NEXT to continue, or press the corresponding number key. The JUMP START POST option will only appear when IN VEHICLE testing has been selected.

1.  TOP POST

4. Use  or  to select the battery APPLICATION, or press the corresponding number key and press NEXT to continue.

1  AUTOMOTIVE

2  MARINE BATTERY

3  MOTORCYCLE

4  GROUP 31

5  COMMERCIAL – 4D/8D

6  LAWN AND GARDEN

7  AG/TRACTOR

5. Use  or  to select the BATTERY TYPE, or press the corresponding number key and press NEXT to continue.

1  REGULAR

2  AGM

3  AGM/SPIRAL

4  GEL

NOTE: The BATTERY TYPE options will vary de-

pending on the APPLICATION selected in the previous step.

6. Use  or  to select the battery RATING UNITS, or press the corresponding number key and press NEXT to continue.

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  SIDE POST

3  JUMP START POST

NOTE: If the measured battery voltage is below

7.5 V, you will be prompted to select between a 6 and 12 volt battery.

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2  CA

3  JIS

4  DIN

5  SAE

6  IEC

7  EN

8  MCA

If you select JIS, the analyzer will ask for the JIS part number. Scroll to the part number. To increase your scrolling speed, hold  or , or use t or u to move up or down four part numbers at a time.

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Chapter 2: Battery Test

GR8-1202

Ratings Description Range

CCA Cold Cranking Amps (specied

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).

JIS Japanese Industrial Standard:

(shown on a battery as a combination of numbers and letters.

DIN Deutsche Industrie-Norm 100 to 1000

SAE European labeling of CCA 100 to 3000

IEC International Electrotechnical

Commission

EN Europa-Norm 100 to 1700

MCA Marine Cranking Amps: The

amount of current a battery can provide at 32°F (0 ºC).

7. Use  or  to enter responding number keys.

the BATTERY RATING,

Scrolling increases and decreas-

100 to 3000

72 numbers from 26A17 to 245H52

100 to 1000

100 to 3000

or press the cor-

es the units by 5. To increase your scrolling speed, hold down  or . Use t to backspace digit by digit.

500

CCA

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 aect 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 will then conduct a Dynamic Scan Test of the battery for a few seconds while displaying a battery being scanned.

Battery Test Results

After the test, the analyzer displays a battery decision with an analysis in a series of screens. The analysis includes the battery state-of-health and state-of-charge.

Use

 or  Menu, press END. If you are performing a System Test, press NEXT to continue with the Starter System Test.

to scroll to each screen. To return to the Main

Additional Test Requirements

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

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.

Battery

decision

Measured

voltage

Selected

rating

Measured

rating

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GR8-1202

Chapter 2: Battery Test

Decision Recommended Action

GOOD BATTERY Return the battery to service.

GOOD–RECHARGE Fully charge the battery and return it to

service.

OK - REPLACE SOON

CHARGE & RETEST

REPLACE BATTERY

BAD CELL– REPLACE

SIDE POST TEST Test data was inconclusive using

JUMP START POST Data was inconclusive using the

24V 24-volt battery detected. You are

The battery may fail under extreme climate conditions. The battery result may also mean a poor connection between the battery and the vehicle. If you tested the battery in vehicle, disconnect the battery cables and retest using the Battery Test before replacing it.

Fully charge and test the battery using a Midtronics Diagnostic Charger.

Disconnect the battery cables and replace the battery.

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.

the side post. Retest using side post adapters.

jump start post. Retest at the battery terminals.

attempting to test in-vehicle both batteries in a 24-volt system. Disconnect the batteries and test them individually.

State-of-Charge

The State-of-Charge is one of several important factors that aect the battery’s ability to crank an engine. It is a measure of the available capacity remaining of a battery expressed as a percentage of its original rated capacity. During testing, the GR8 accurately detects a battery’s State-of-Charge and indicates this as part of the test results.

State of Health

The battery’s state of health represents its general condition, and therefore its ability to deliver the specied 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 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. 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.

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Chapter 3: Diagnostic Charging

GR8-1202

Chapter 3: Diagnostic Charging

The GR8 1202 battery analyzer and diagnostic char-

ger will determine the internal condition of a battery before attempting to apply a charge to it.

The charger applies an AC signal at a known frequency across the terminals and measures the internal conductance to determine battery health before attempting to charge.

Before you start the test, review the instructions in Chapter 1: Introduction & Overview.

NOTE: 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.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the large clamps from the GR8 charge engine when performing diagnostic charging.

Before performing a diagnostic charge on a battery installed in a vehicle, make sure all vehicle accessory loads are o, the key is not in the ignition, and the doors are closed.

Use the following procedure to perform a diagnostic charge on a battery.

1. If connected, remove the small clamps from the battery terminals.

2. Connect the large clamps from the charge engine to the battery terminals.

3. From the Main Menu, highlight the DIAGNOSTIC icon and press the SELECT key.

4. Use  or  to select the battery LOCATION and press NEXT to continue, or press the corresponding number key.

1  OUT OF VEHICLE

6. Use  or  to select the battery APPLICATION, or press the corresponding number key and press NEXT to continue.

1  AUTOMOTIVE

2  MARINE BATTERY

3  MOTORCYCLE

4  GROUP 31

5  COMMERCIAL – 4D/8D

6  LAWN AND GARDEN

7  AG/TRACTOR

7. Use  or  to select the BATTERY TYPE, or press the corresponding number key and press NEXT to continue.

1  REGULAR

2  AGM

3  AGM/SPIRAL

4  GEL

NOTE: The BATTERY TYPE options will vary de-

pending on the APPLICATION selected in the previous step..

8. Use  or  to select the battery RATING UNITS, or press the corresponding number key and press NEXT to continue.

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  JIS

2  IN VEHICLE

5. Use  or  to select the battery POST TYPE and press NEXT to continue, or press the corresponding number key. The JUMP START POST option will only appear when IN VEHICLE testing has been selected.

1.  TOP POST

2  SIDE POST

3  JUMP START POST

NOTE: If the measured battery voltage is below

7.5 V, you will be prompted to select between a 6 and 12 volt battery.

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4  DIN

5  SAE

6  IEC

7  EN

8  MCA

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GR8-1202

Chapter 3: Diagnostic Charging

Ratings Description Range

CCA Cold Cranking Amps (specied

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).

JIS Japanese Industrial Standard:

(shown on a battery as a combination of numbers and letters.

DIN Deutsche Industrie-Norm 100 to 1000

SAE European labeling of CCA 100 to 3000

IEC International Electrotechnical

Commission

EN Europa-Norm 100 to 1700

MCA Marine Cranking Amps: The

amount of current a battery can provide at 32°F (0 ºC).

100 to 3000

72 numbers from 26A17 to 245H52

100 to 1000

100 to 3000

9. Using the keypad or the  or  keys to select the BATTERY RATING and press NEXT to begin the charging process.

CCA

After the Deep Scan Test the GR8 will either display the results or give you the option to perform the 5-Minute Discharged Battery Test. Although this test takes several minutes, it gives a more precise result for dicult-to-diagnose batteries. The decision tree of the test is shown below.

Diagnostic Mode

Once the GR8 determines that the battery is good, needs charging, and is safe to charge, it proceeds to Diagnostic Charge Mode. During the charging session, the GR8 provides updates of the charging voltage, charging current, remaining time to charge, charging mode, and the amount of charge replenished into the battery in amp-hours. The GR8 continues to test the battery throughout Diagnostic Mode and may determine at some point that the battery needs to be replaced.

NOTE:

The actual time needed to charge the battery may be less than the estimated time depending on the battery’s charge acceptance.

When the battery requires testing, the display alternates between the CHARGING and TESTING screens. The TESTING screens represent a two-step process.

Step 1: The GR8 applies an electrical load and tests the bat-

tery’s response.

Charging Modes

Diagnostic Charging has four modes (Initial Analysis, Deep Scan Test, Diagnostic Mode, Top-O Mode) that the GR8 may use to determine the State-of-Health of the battery while bringing it to a full State-of-Charge.

Initial Analysis

The GR8 rst analyzes the battery and may make a decision: GOOD BATTERY, REPLACE BATTERY, or REPLACE-BAD CELL. For diagnostic charge analysis, progress is shown by the left to right movement of a progress bar.

Deep Scan Test

In some cases the GR8 may need to further analyze the battery to determine whether the battery should be replaced or it has a signicant chance to be recovered. It will then conduct a Deep Scan Test of the battery for a few seconds.

Step 2: The GR8 measures the battery’s CCA.

The Estimated time only appears when the charger is in DIAGNOSTIC mode and after the ve -minute printout.

This mode occurs automatically at the end of the charge cycle to allow the charger to ll a good battery to capacity. TopO Mode ends when the battery’s acceptance of the charge current goes below 2 amps, or when you press the STOP button.

Aborting a Charge Session

If you need to abort the charging session, press and hold the

STOP key until the charging session is aborted. After aborting,

select NEXT to return to the Main Menu.

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Chapter 3: Diagnostic Charging

GR8-1202

Completing a Charge Session

The charge session is complete when the proper amount of charge is put back into the battery or the remaining estimated time to charge counts down to zero.

If the GR8 nds that the battery is bad before the end of the estimated time to charge, it displays the decision REPLACE BATTERY or BAD CELL-REPLACE and the results.

If charging at the side posts or jump start posts and the test data is inconclusive, the GR8 displays the decision JUMP START POST or SIDE POST TEST. A JUMP START POST decision prompts you to test at the battery. A SIDE POST TEST decision prompts you to test using the side post adapters.

When the decision is GOOD BATTERY, the GR8 gives you the option of topping o the battery’s charge level before it displays the results.

Diagnostic Charge Results

Use

 or 

to scroll to each screen. To return to the Main

Menu, press EXIT. To print, press PRINT.

Measured

Battery

decision

Maximum

Charging Time

Replaced

AMP Hours

voltage

Measured

capacity

Selected

rating

Diagnostic Charging Decisions

Battery Decision Recommended Action

GOOD BATTERY Return the battery to service.

OK-REPLACE SOON The battery may fail under extreme

climate conditions. The battery result may also mean a poor connection between the battery and the vehicle and the battery. If you tested the battery using the System test, disconnect the battery cables and retest using the Battery Test before replacing it.

REPLACE BATTERY Before replacing the battery make

sure battery cables and connections are clean and solid. If they are loose or corroded, clean and tighten, then retest.

BAD CELL - REPLACE Replace the battery. This decision

indicates a bad cell within the battery.

WARNING: Charging a

battery with a bad cell is dangerous!

Top-Off Mode

Following the Diagnostic Charge Mode process the GR8 will prompt you to stop the process or continue on in Top-O Mode. After two minutes the GR8 will automatically enter TopO mode if there is no user input.

Good

Replace

Range

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Range

Press STOP to end the TOP OFF MODE and return to the Main Menu. Press MENU to return to the Main Menu while the TOP OFF MODE continues in the background.

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GR8-1202

Chapter 4: System Test

The GR8 guides you through the steps of selecting the System Test parameters and interpreting the results. Before you start the test, review the instructions in Chapter 1: Introduction & Overview.

NOTE: 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.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the small clamps from the GR8 control module when performing a System Test.

If you use the ARROW keys to select option buttons, press NEXT to continue to the next step.

1. In the Main Menu select the SYSTEM TEST icon.

2. If you using the AMP CLAMP option, select AVAILABLE. If you are not using the AMP CLAMP, select NOT AVAILABLE.

Starter System Test Results

Average cranking

voltage

Average cranking

current if amp clamp is used

Cranking time

in seconds

Y axis = System

performance:

cranking voltage

X axis = Time

1  AVAILABLE

2  NOT AVAILABLE

If you are using the amp clamp, plug it into the Control Module and follow the procedure for setting it to zero.

NOTE: Select AMP CLAMP if you want to perform

a Key-O Draw test as part of the System Test.

3. Follow the procedure outlined in Chapter 2: Battery Test.

Starter Test

1. Following a successful battery test, start the vehicle’s engine when prompted.

2. The GR8 will display 1 of 8 starter decisions with the complete results in a series of screens. Use each screen.

To print, press the PRINT key. To continue testing, press NEXT.

NOTE: In some cases, the GR8 may not detect the

vehicle’s starting prole and will display the options STARTED and NO START. Select STARTED, to continue with an alternator test. Select NO START to end the test process.

 or 

to scroll to

Starting System Decisions

Decision Action Recommended

CRANKING NORMAL

LOW VOLTAGE The starter voltage is low and the battery is

CHARGE BATTERY

REPLACE BATTERY

NO START The engine didn’t start and the test was

CRANKING SKIPPED

SIDE POST TEST

JUMP START POST

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.

(If the battery test result was (REPLACE or BAD CELL.) The battery must be replaced before testing the starter.

aborted.

The GR8 didn’t detect the vehicle’s starting

prole and skipped the Starter Test.

Test Data was inconclusive using the side post. Retest using side post adapters.

Data was inconclusive using the jump start post. Retest at the battery terminals.

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Chapter 4: System Test

GR8-1202

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 NEXT to continue.

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, older vehicles and pulse

modulated alternators can prevent the analyzer from detecting the engine 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. If the engine rev is not detected, select NEXT to skip the engine rev or END to end the test and return to the Main Menu.

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 sucient 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.

If the engine rev is not detected, select NEXT to try again or END to end the test and return to the Main Menu.

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 NEXT to continue.

12. ANALYZING CHARGING SYSTEM DATA: The analyzer is completing its nal analysis of the charging system data.

13. TURN OFF LOADS AND ENGINE: Press NEXT to display the results.

Key-Off Draw

If an Amp Clamp was connected to the Control Module during the System Test, you will be prompted to perform a Key-O Draw test after the vehicle's engine has been shutdown.

If you choose to perform the test, follow the procedure describe in Chapter 10: Key-O Draw.

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.

IMPORTANT:

Turn on the high-beam headlights and the blower to high. Do not use cyclical loads such as air conditioning or windshield wipers.

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GR8-1202

Chapter 4: System Test

Charging System Test Results

Loads-off

DC voltage

at rev

Normal DC

voltage

range

Peak-to-peak

AC voltage

Diode Decisions

Diode

Decision

EXCESSIVE RIPPLE

OPEN PHASE

OPEN DIODE

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 open phase within the alternator. Replace the alternator.

The analyzer has detected a open diode within the alternator. Replace the alternator.

The analyzer has detected an shorted diode within the alternator. Replace the alternator.

Action

Decision

Loads-on

DC voltage

at rev

Bar graph of

DC voltage

within

normal

range (loads

on and off)

Graph

of diode

waveform

Charging

System

Decision

NO PROBLEMS

NO VOLTAGE

LOW VOLTAGE

HIGH VOLTAGE

Charging System Decisions

Action

The system is showing normal output from the alternator. No problem detected.

The alternator is not providing charging voltage 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.)

The alternator is not providing enough voltage 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.

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 specications 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.

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Chapter 5: ECM Power Supply

GR8-1202

Chapter 5: ECM Power Supply

The ECM Power Supply function tests and maintains

battery voltage in the vehicle at 13.5 volts to allow for uninterrupted reprogramming of vehicle computers, retain vehicle system settings, or simply to maintain battery voltage.

Select the SETUP icon on the Main Menu to modify this setting.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the large clamps from the GR8 charge engine when using the ECM Power Supply mode.

IMPORTANT: Before starting Power Supply Mode,

verify that all vehicle loads are o and the key is not in the ignition.

NOTE: Start the Power Supply Mode to begin the con-

trol module reprogramming process.

1. If connected, remove the small tester clamps from the battery terminals and connect the large charger clamps.

2. In the Main Menu use the ARROW keys to highlight the ECM POWER SUPPLY icon and press NEXT.

3. Use

 or 

to select the BATTERY TYPE and press NEXT,

or press the corresponding number key.

1  REGULAR

2  AGM

4. Before entering the ECM Power Supply function, the GR8 will test the battery to determine if it needs to be charged rst.

NOTE: If you choose to charge the battery, you will need to restart the ECM Power Supply function once the battery has been successfully charged.

NOTE:

The GR8 tests the battery to determine if it is safe to charge. If a detective battery is detected, the GR8 will beep, the status light will ash, and a warning displayed indicating that the battery is unsafe to charge. Press

EXIT

to return to the Main

Menu.

5. If the battery is safe to charge, the GR8 begins maintaining the battery voltage at 13.5 volts.

NOTE: Amperage uctuates in response to the

vehicle’s demands. If the voltage drops below the 12.8, the GR8 displays a warning and raises the voltage to the set point.

6. When nished servicing the vehicle, press the STOP button or the OFF switch, unplug the power cord and disconnect the clamps.

3  AGM SPIRAL

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GR8-1202

Chapter 6: Jump Start

This charging mode makes high output current avail-

able to boost charge an in-vehicle battery as well as assist in starting the engine. If you need to abort at any time, press the STOP key.

Select the SETUP icon on the Main Menu to change this setting.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the large clamps from the GR8 charge engine when performing a jump start.

1. In the Main Menu, highlight the JUMP START icon and press NEXT.

NOTE:

EXIT

to return to the Main

Menu.

3. If the battery is safe to charge, the GR8 will prompt you to press NEXT to begin the boost charge

4. The GR8 begins boost-charging. Do not crank the engine at this time.

5. When the GR8 displays “CRANK ENGINE NOW,“ beeps and ashes the status light, you can crank the engine for up to ve seconds.

6. When the GR8 displays “JUMP START COMPLETE,” press the

STOP key. (The alarm sounds every second until you press STOP.)

2. Use

 or 

to select the BATTERY TYPE and press NEXT,

or press the corresponding number key.

1  REGULAR

2  AGM

3  AGM SPIRAL

NOTE: The BATTERY TYPE options will vary de-

pending on the APPLICATION selected in the previous step..

The BACK key returns you to the Main Menu at the start of the test and to the previous screen as you progress.

NOTE: If you use the ARROW keys to select op-

tion buttons, press NEXT to continue to the next step. If you use the alphanumeric keypad to enter the number preceding the option button, no additional keypress is needed.

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Chapter 7: Manual Charging

GR8-1202

Chapter 7: Manual Charging

The GR8 charges the battery based on the current

limit or voltage limit, and charge duration that you select.

Select the SETUP icon on the Main Menu to change this setting.

Charging after the battery is fully charged can result in excessive battery temperature

Overcharging will “gas” the battery and boil o electrolytes, shortening battery life. Monitor the battery’s Stateof-Charge and temperature to avoid overcharging.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the large clamps from the GR8 charge engine when performing manual charging.

1. In the Main Menu, highlight the MANUAL icon and press the NEXT key.

2. Use  or  to select the battery LOCATION and press NEXT to continue, or press the corresponding number key.

1  OUT OF VEHICLE

2  IN VEHICLE

4. Use

 or 

to select the LIMIT TYPE, or press the corresponding numerical key (1 or 2) to move the dot to the option button of your choice.

1  LIMIT CURRENT

2  LIMIT VOLTAGE

Press NEXT. The BACK key returns you to the Main Menu at the start of the test and to the previous screen as you progress.

NOTE:

If you use the ARROW keys to select option buttons, press NEXT continue to the next step. If you use the alphanumeric keypad to enter the number preceding the option button, no additional keypress is needed.

5. You can set limits using VOLTAGE or CURRENT.

If your limit type is CURRENT, select the maximum amperage (1 to 60 amps). When in doubt, start with a low charging current.

Press NEXT.

50 AMPS

If your limit-type is VOLTAGE, select the maximum voltage. The range for Regular-type batteries is 12.7 to 15.3 V; AGM is 12.7 to 14.4 V. Press NEXT.

Press NEXT. The BACK key returns you to the Main Menu at the start of the test and to the previous screen as you progress.

3. Use

 or 

to select the BATTERY TYPE and press NEXT

ton continue, or press the corresponding number key.

1  REGULAR

2  AGM

3  AGM SPIRAL

12.40 VOLTAGE

6. Select a charge duration from 5 to 120 minutes. For durations longer than 120 minutes, select Continuous charging.

To select a timed charge when “CONTINUOUS” is displayed, use the key pad to enter a duration 5 and 120 minutes.

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GR8-1202

Continuous charging stops when you press the STOP key.

Timed Charge Continuous Charge Selection Screen Selection Screen

Chapter 7: Manual Charging

NOTE:

7. If the battery is safe to charge, the GR8 will begin charging at the selected levels. The illustration shows an example of the information displayed during timed charging.

NOTE:

If Continuous charge is selected, charging

time is not displayed.

8. When Manual Mode ends, the GR8 displays the total charging time for Continuous and Timed Charging, the amp hours replaced, and the charging mode.

The alarm sounds every 30 seconds until you disconnect

the clamps, or press

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Chapter 8: Info Menu

GR8-1202

Chapter 8: Info Menu

The Info Menu has three utilities to help you print and

view your test data and track the usage and history of your GR8. The Info menu also allows you to view total history and transfer information to another machine.

The Print/View Menu enables you to view and print the results of the Battery and System Tests before you perform another test and overwrite the results in memory.

View Test Battery

VIEW TEST BATTERY gives you the option of viewing

and printing the results of the Battery and System Tests. Select PRINT to print and END to return to the Main Menu key.

View Test Charger

VIEW TEST CHARGER gives you the option of viewing

and printing the results of the Charger Test. To print the results, select PRINT. To return to the Main Menu, press END.

View Cable Test

2. Use

 or 

to select the specic type of totals and press

NEXT.

1  LIFETIME

2  USER TOTALS

3  LAST 100 LOG

4  TOTALS BY DECISION

5  SYSTEM TEST ( Tester Totals only)

Tester And Charger Totals Screens

Tester Totals Charger Totals

Lifetime Totals

VIEW CABLE TEST gives you the option of viewing and

printing the results of the last performed Cable Drop Test.

Results from previous tests are not saved and are therefore not viewable. To print the results select PRINT. Press END to return to the Main Menu.

View Inventory Test

This report displays and prints the results for an in-

dividual battery or for all batteries tested using the Inventory Test.

Totals

TOTALS gives you the option of viewing the results

of tester and charger tests in several dierent ways including lifetime, user totals, last 100 performed, by decision, and by system test. Press END to return to the Main Menu.

1. Use

 or 

to select the battery TOTALS and press NEXT

to continue, or press the corresponding number key.

1  TESTER TOTALS

2  CHARGER TOTALS

User Totals

Last 100 Log

Totals By Decision

N/A

System Test

3. To print the results select PRINT. To abort the printout press END.

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Transfer

TRANSFER is an optional accessory that consists of an

IR software and hardware package that will enable you to transfer test data to a PC.

View Wireless

Displays communication quality and channel being

used for wireless communication between the control head and the multitasking module. Press BACK to return to the Info menu.

1. Use  or  to highlight the VIEW WIRELESS icon and press NEXT. The WIRELESS screen is displayed.

2. Use the t or u to display the dBm for each channel.

Chapter 8: Info Menu

3. To print the results select PRINT.

4. To abort the printout press END.

Version

VERSION displays the GR8 software version, the date

the software was released, and the serial number of the control module. The utility also allows you to print the information.

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Chapter 9: Cable Drop Test

Battery Test Lead

GR8-1202

Chapter 9: Cable Drop Test

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 voltage 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’s no need to run the engine. The Cable Drop Test uses Midtronics’ conductance technology to send a signal through the circuit at the component under test. The GR8 then simultaneously calculates voltage drop on the positive (+) and negative (–) sides of any circuit as well as the total voltage drop. The amperage range for each of the four tests is 0 to 1000 A. When you change the setting from the factory defaults, the GR8 will store your setting in memory for your next test.

There are three preset tests:

• BATTERY GROUND

• STARTER CIRCUIT

• ALTERNATOR CIRCUIT

A fourth test, OTHER CIRCUIT, tests other grounds and circuits against your specied amperage capacity.

The test requires two test lead connections, as shown in the gure below.

• Battery test leads at the component’s output lead (the B+ or output screw on the alternator) and the component’s housing as ground.

• DMM test leads at the battery terminals

To begin, select the Cable Drop Test icon in the Main Menu and follow the instructions on the display.

IMPORTANT: For accurate results the battery should

be good and fully charged before you perform a test.

Battery Ground Test

The Battery Ground Test measures the voltage drop for the ground strap.

1. SELECT CIRCUIT: Use  or  to select BATTERY GROUND and press NEXT to continue, or press the corresponding number key.

1  BATTERY GROUND

2  STARTER CIRCUIT

3  ALT CIRCUIT

4  OTHER

2. SET AMPS: Use

 or 

to select the rated amperage of the starter circuit and press NEXT to continue, or use the numeric keypad. The default is 80 A.

80 A

3. Connect the main clamps (battery test leads) to the battery and ground: positive (+) clamp to the battery’s positive post; negative (–) clamp to the vehicle chassis.

4. Connect the DMM cable to the battery posts: positive (+) clamp to the positive post; negative clamp (–) to the negative post.

For the next few seconds the GR8 will display the word TESTING and a stopwatch while it evaluates the battery ground.

NOTE: The test requires a complete circuit. If you’re

testing a system with a remote solenoid, you can test from the battery to the solenoid, but not from the battery to the starter.

Red Red

Battery

–

Black Black

DMM Test Lead

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Component

Under

Test

Battery Ground Test Results

If there is a problem, the decision is CLEAN AND RETEST OR REPLACE. To print the results, select PRINT. To return to the Main Menu, press the END key.

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GR8-1202

Chapter 9: Cable Drop Test

Starter Circuit

The Starter Circuit Test measures the voltage drop of the starter circuit.

1. SELECT CIRCUIT: and press NEXT to continue, or press the corresponding number key.

1  BATTERY GROUND

2  STARTER CIRCUIT 3  ALT CIRCUIT

4  OTHER

2. SET AMPS: Use the starter circuit and press NEXT to continue, or use the numeric keypad. The default is 150 A.

3. Connect the positive (+) clamp of the battery test leads to the starter’s battery terminal stud. Connect the negative (–) clamp to the starter’s housing.

4. Connect the positive (+) DMM clamp to the battery’s positive (+) post. Connect the negative clamp (–) to the battery’s (–) negative post.

For the next few seconds the GR8 will display the word TESTING and a stopwatch while it evaluates the battery ground.

Use  or  to select STARTER CIRCUIT

 or 

to select the rated amperage of

150 A

Alternator Circuit

The Alternator Circuit Test measures the voltage drop of the alternator circuit.

1. SELECT CIRCUIT: NEXT to continue, or press the corresponding number key.

1  BATTERY GROUND

2  STARTER CIRCUIT

3  ALT CIRCUIT

4  OTHER

2. SET AMPS: Use the starter circuit and press NEXT to continue, or use the numeric keypad. The default is 80 A.

3. Connect the positive (+) clamp of the battery test leads to the alternator’s output stud (B+). Connect the negative (–) clamp to the alternator’s housing.

4. Connect the positive (+) DMM clamp to the battery’s positive (+) post. Connect the negative clamp (–) to the battery’s (–) negative post.

For the next few seconds the GR8 will display the word TESTING and a stopwatch while it evaluates the battery ground.

Use  or  to select ALT CIRCUIT and press

 or 

to select the rated amperage of

80 A

Starter Circuit Test Results

If there is a problem, the decision is CLEAN AND RETEST OR REPLACE. To print the results, select PRINT. To return to the Main Menu, press END.

Alternator Circuit Test Results

If there is a problem, the decision is CLEAN AND RETEST OR REPLACE. To print the results, select PRINT. To return to the Main Menu, press END.

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Chapter 9: Cable Drop Test

Other Circuit

This test enables you to measure voltage drop across other components.

1. SELECT CIRCUIT: NEXT to continue, or press the corresponding number key.

1  BATTERY GROUND

2  STARTER CIRCUIT

3  ALT CIRCUIT

4  OTHER

Use  or  to select OTHER and press

GR8-1202

2. SET AMPS:

Use

 or 

to select the rated amperage of the starter circuit and press NEXT to continue, or use the numeric keypad.

The default is 10 A.

10 A

3. Connect the positive (+) clamp of the battery test leads to the component’s positive terminal (+). Connect the negative (–) clamp to the component’s negative (–) terminal.

4. Connect the positive (+) DMM clamp to the battery’s positive (+) post. Connect the negative clamp (–) to the bat-

tery’s (–) negative post.

For the next few seconds the GR8 will display the word TESTING and a stopwatch while it evaluates the battery ground.

Other Circuit Test Results

If there is a problem, the decision is CLEAN AND RETEST OR REPLACE. To print the results, select PRINT . To return to the Main Menu, press the END key.

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GR8-1202

Chapter 10: Key Off Draw

Key O Draw is used to determine the amount of cur-

rent being pulled from the battery when the ignition and all accessories are o.

Select the SETUP icon on the Main Menu to change this setting.

NOTE: The Amp Clamp is required to perform a Key

O Draw test.

1. In the Main Menu, highlight the KEY OFF DRAW icon and press NEXT.

2. Attach the connector end of Amp Clamp cable to the top of the GR8 Control Module. Make sure the clamp itself is not around any wires before proceeding.

3. Press NEXT to set the Amp Clamp value to zero.

4. Turn o the engine and all electric loads Remove any leads connected to the accessory sockets and close the vehicle’s doors.

5. Place the Amp Clamp around the negative (-) battery cable making sure the arrow on the clamp is pointing away from the battery.

7. The Key O Draw results are displayed when the analyzer has completed the test.

Amp Range Action

.250 - below Acceptable Amp range .251 - .499 Check manufacturers specications

.500 - above Key Off Draw is excessive

6. Press NEXT to begin testing.

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Chapter 11: Digital Multimeter (DMM)

GR8-1202

Chapter 11: Digital Multimeter (DMM)

The digital metering functions are versatile enough to

test everything from a vehicle’s entire electrical system to a board-level component:

• Scope

• Ohmmeter

• Diode Drop

• DC and AC Volts/Amp

NOTE: The DMM function requires the optional DMM

Clamps, DMM Clamps and Probes or Amp Clamp.

The DMM’s infrared temperature sensor also enables you to determine the surface temperature of components before you service them or as a diagnostic aid. Specications for each tool are listed at the end of this chapter.

Select the DMM icon to display its METERS menu. The tools in this menu are available in a series of three screens.

A measurement that is out of the limit displays as OL. Refer to the manufacturer specications for the correct limits, which may vary by component or vehicle type.

Ohm Meter

NOTE: The Ohm Meter function requires the optional

DMM Clamps, or DMM Clamps and Probes.

The meter is connected in parallel with the circuit un-

der test and uses the power supplied by the internal batteries in the Control Module to detect open or excessive resistance.

Always remove power from the circuit before connecting the ohmmeter to avoid damaging the Control Module.

1. Connect the DMM test lead to the accessories port on the Control Module.

2. Select the meter’s icon.

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

4. The meter will autorange and display the measurement.

5. When nished, press END.

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the small clamps from the GR8 control module when using the DMM.

6. To return to the METERS menu, press END.

Diode

NOTE: The Ohm Meter function requires the optional

DMM Clamps, or DMM Clamps and Probes.

This test measures the voltage drop across compo-

nents, such as diodes.

1. Connect the probes t the Control Module.

2. Select the meter’s icon.

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

4. The meter will autorange and display the measurement.

5. When nished, press END.

est lead to the accessories port on

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Chapter 11: Digital Multimeter (DMM)

Scope

NOTE: The Scope function requires the optional DMM

Clamps, or DMM Clamps and Probes.

The scope is a voltmeter that provides a graph of volt-

age dierence as it varies over time. After you select the SCOPE icon, note the instructions in the next screen before proceeding. You’ll need them after you press NEXT:

• Press 1 on the keypad to autoscale the time display.

• Press 3 on the keypad for the time display.

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

Press NEXT to continue.

In the time display the horizontal axis is in seconds and the vertical axis is in volts.

In the frequency display the horizontal axis is in hertz and the vertical axis is in volts.

Press the right soft key to alte RUN (measure and display the signal) and HOLD (freeze the signal).

The scope enables you to print the voltage trace to the printer when you freeze the signal. To print, press PRINT.

To return to the METERS menu, press END.

rnate between the options to

DC and AC Volts/Amp

The volts/amp meter simultaneously voltage and charging current.

NOTE: The Volts/Amp function requires the optional

Amp Clamp

1. Connect the amp clamp lead to the Control Module accessories port.

2. Select the meter’s icon.

3. Select the amp clamp range.

1  70 AMP MAX.

2  700 AMP MAX.

Press NEXT to continue.

4. The meter will zero itself and display the amperage and voltage measurements.

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

6. Connect the battery test cable to the GR8.

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

8. The GR8 will display the measurement.

9. To return to the METERS menu, press END.

measures charging

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Chapter 11: Digital Multimeter (DMM)

Multimeter Specications

The accuracy specication is dened 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 specied 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 specied 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 specied from 2% to 100% of range.

GR8-1202

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 specied from 2% to 100% of range.

Ohm

Range Resolution Accuracy Overload Protection

10Ω–2 MΩ 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 1 °F 1.0% + 5 --------

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GR8-1202

Chapter 12: Inventory Test

Use the Inventory Test in the Main Menu to quickly

check batteries in inventory. The test can verify up to 100 batteries in succession using the user-specied battery rating along with the minimum voltage limit.

This test diers from the Battery Test in that the decision is either "Good" or "Needs Charge". Neither decision indicates a battery is bad, but that the measured voltage and CCA fall in or out of the entered parameters.

Chapter 12: Inventory Test

Example of

displayed results

for a test of two

batteries

Do not connect both sets of clamps to the same battery at the same time.

Connecting both sets of clamps to the same battery at the same time may damage the GR8. Only use the small clamps from the GR8 control module when performing Inventory Test.

NOTE: The Inventory Test option does not pro-

duce a test code.

Selecting Test Parameters

1. Select the Inventory Test icon in the Main Menu.

2. The tester displays the total number of Inventory Tests completed out of 100. To clear the results from memory and reset the total to 0, simultaneously press t and u. Press NEXT to continue.

IMPORTANT: Be sure to monitor the number of

tests performed 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 4 through 7 in the Battery Test section of this manual.

4. Enter the BATTERY RATING voltage (between 12.20 - 12.80v).

5. For the next few seconds the tester 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  or  to scroll to the screen showing the battery that was tested.

6. 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.

Printing Test Results

1. To print the test results for an individual battery, use  or  to scroll to the screen showing the battery that was tested. Select PRINT.

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 PRINT to print the results.

1  INVENTORY BATTERY

2  INVENTORY SUMMARY

Clearing Test Results

The analyzer will not be able to continue inventory testing until you clear all tests from its memory.

NOTE: To retain a record, use PRINT to print the results.

To clear the results and reset the counter to 0:

1. Press EXIT to return to the Main Menu.

2. Select the Inventory Battery Test icon.

3. In the INVENTORY STAT screen press t and u simultane- ously to clear the results and reset the counter to 0.

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Chapter 13: Setup

GR8-1202

Chapter 13: Setup

Clock

The CLOCK ADJUST utility has four settings. Use



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 : /11/29/2012

Mode

1. Use  or  to highlight the MODE function and press ADJUST to continue.

2. Use  or  to select the CLOCK ADJUST and press NEXT to continue, or press the corresponding number key.

1  24 HOUR

2  AM/PM

3. If you used the ARROW keys, press SAVE to save your set- ting or BACK to return to the CLOCK ADJUST screen without saving the changes.

If you use the alphanumeric keypad to enter the number preceding the option button, no additional keypress is needed to save your selection.

Time

1. Use  or  to highlight the TIME function and press ADJUST.

2. Use

t or u

to highlight the hour, minutes, or AM or PM. To

rapidly scroll, hold down

9 : 19 PM

 or 

3. Press SAVE to save your setting, or press BACK to return to the CLOCK ADJUST screen.

Format

1. Use  or  to highlight the FORMAT function and press ADJUST to continue.

2. Use  or  to select the DATE ADJUST and press NEXT to continue, or press the corresponding number key.

 or

3. Press SAVE to save your setting or BACK to return to the CLOCK ADJUST screen without saving the changes.

If you use the alphanumeric keypad to enter the number preceding the option button, no additional keypress is needed to save your selection.

Date

1. Use

t or 

to highlight the month, day, or year. To rapidly

scroll, hold down

 or 

3 / 28 / 2012

2. Press SAVE to save your setting or BACK to return to the CLOCK ADJUST screen without saving the changes.

Shop

When the Admin option 3-PRINT HEADER is selected,

the SHOP INFO utility allows you to create a header for your printed test results. Its three information screens contain 12 lines of text with a maximum of 17 characters per line.

Header information can be manually created or uploaded from a data card.

To manually create or overwrite a header:

1. Select MANUAL EDIT and press NEXT.

2. Press

3. To erase a character, press t.

4. Insert a character by pressing the alphanumeric key asso-

5. Press SAVE to save your setting or BACK to return to the

 or 

to highlight the line you want to change. The cursor blinks to the right of the last character in the line. (The cursor is not visible if all character spaces are lled.)

ciated with the character as many times as needed. You can center text by inserting blank spaces with the u key. If you pause momentarily, the cursor will automatically move to the right.

IMPORTANT: Be sure to erase any default charac-

ters on unused lines by pressing t.

SHOP INFO screen without saving the changes.

Screen 1

1–YOUR SHOP NAME

2–1000 ANY ST.

3–YOUR TOWN, STATE

4–YOUR POSTAL CODE

5–YOUR COUNTRY

—

6–YOUR PHONE NUMBER

7–WWW.WEBSITE.COM

8–

Screen 2

—

1  MM/DD/YYYY (month/day/year)

2  DD/MM/YYYY (day/month/year)

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Use the template in the Appendix of this manual to edit and center your header.

www.midtronics.com

GR8-1202

Chapter 13: Setup

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.

Default setting for USER ID is o. Select the ADMIN icon to turn this feature on.

Entering A New User ID

1. Use  or  to highlight ENTER NEW and press NEXT to continue, or press the corresponding number key.

1  ENTER NEW

2  DELETE

3  EDIT

2. Use

3. To clear the default characters, press t. To add a space,

 or 

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

to jump up or down through the list ve lines at a time.

1 USER01

2 USER02

3 USER03

4 USER04

t or

Press NEXT to continue.

move the cursor forward by pressing u.

ENTER USER ID

USER01

2. Use

 or 

to jump up or down through the list ve lines at a time.

1 MARK

2 GARY

3 USER03

4 USER04

t or

Press DELETE to remove the ID and continue.

Editing A User ID

1. Use  or  to highlight EDIT and press NEXT to continue, or press the corresponding number key.

1  ENTER NEW

2  DELETE

3  EDIT

2. Use

 or 

to jump up or down through the list ve lines at a time.

1 MARK

2 GARY

3 GREG

4 USER04

t or

Press SELECT to continue.

3. Edit the selected User ID.

4. Insert a character by pressing the alphanumeric key associated with the character as many times as needed. Press SAVE.

ENTER USER ID

MARK

Deleting A User ID

NOTE: You cannot delete placeholder USER IDs (i.e.,

USER03).

1. Use  or  to highlight DELETE and press NEXT to continue, or press the corresponding number key.

1  ENTER NEW

2  DELETE

3  EDIT

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4. Press SAVE to save your changes.

Info Upload

Using a data card loaded into the Control Module,

the INFO UPLOAD utility updates Shop, Coupon, User, and Screen information on the GR8.

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Chapter 13: Setup

GR8-1202

Display

The LCD CONTRAST 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

 or 

to highlight the option.

CONTRAST LEVEL 10

2. Press ADJUST to display the option’s numerical scroll box.

9 (1-10)

3. Press

 or 

to select your preference, or the correspond-

ing numerical keys. To erase a character, press t.

4. Press SAVE to save your setting or BACK to return to the LCD OPTIONS screen without saving the changes.

Coupon

The COUPON utility allows you to enable and disable

the custom coupons or message created in the EDIT COUPON utility. You also have the option of having no coupon print.

1. Use  or  to select the COUPON SELECT option and press NEXT to continue, or press the corresponding number key.

1  NO USER COUPON PRINTED

Edit Coupon

The EDIT COUPON utility allows you to create and

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 create and edit a coupon, see the procedure under “Shop” in this chapter for using the keypad to enter and backspace over characters.

To help you edit and center your coupon, use a pencil to write the information in the template in the Appendix of this manual.

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.

This utility requires a standard data card reader (not included) to read or transfer the le to a PC.

NOTE: To avoid corrupting the le, copy rather than

move the le to your PC.

The default is OFF. To set your preference:

1. Use  or  to select the TRACKING and press NEXT to continue, or press the corresponding number key.

1  TRACKING OFF

2  USER COUPON

2. If you used the ARROW keys, press SAVE to save your set- ting or BACK to return to the Setup Menu without saving the changes.

If you use the alphanumeric keypad to enter the number preceding the option button, no additional keypress is needed to save your selection.

2  TRACKING ON

2. If you have used the ARROW keys, press SAVE to save your setting or BACK to return to the Setup Menu without saving the changes.

If you use the alphanumeric keypad to enter the number preceding the option button, no additional keypress is needed to save your selection

NOTE: Over time disk access slows as the data 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.

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

www.midtronics.com

GR8-1202

Chapter 13: Setup

Language

The LANGUAGE utility allows you to select a language

for the display and printouts. You can override the selection when the Battery Diagnostic Station displays the language option after you turn it on or print results.

To set your preference:

1. Use  or  to select the LANGUAGE option and press NEXT to continue, or press the corresponding number key.

1  ENGLISH

2  ESPAÑOL

3  FRANÇAIS

2. If you used the ARROW keys, press SAVE to save your set- ting or BACK to return to the Setup Menu without saving the changes.

Admin

This section explains how to use the Admin Menu to

control User ID access to the tester. It also describes functions that clear test totals and restore settings to factory defaults.

Use  or  to select an ADMIN option and press NEXT to continue, or press the corresponding number key

1  OPTIONS

4 – DATE CODE

Enable this setting to require a battery date code be entered for all batteries being tested.

5 – CARD MESSAGE

Enable this option to require a Start Up Data Card Message.

6, 7, 8 – SCREEN INPUT

Select this setting to enable (ON) to display user-dened text elds (Default is o).

Clear Test Totals

This function allows you to clear the test totals by User ID and battery test decision. The Battery Diagnostic Station veries that you want the counter reset to 0 before it continues.

NOTE: This will not clear the lifetime test total avail-

able 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.

Option Default Settings

1 – USER ID ON

2 – UNREG. USER ON

3 – PRINT HEADER ON

2  ENABLE BMIS

3  CLEAR TEST TOTALS

4  RESET DEFAULTS

Options

In the OPTIONS section there are four functions that allow you to control user access to the Main Menu and Setup Menu. Each option is easily enabled or disabled by turning it ON or OFF. To save your settings after each selection, press SAVE. To return to the administrative functions list without saving, press BACK.

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 Battery Diagnostic Station.

3 – PRINT HEADER

Select this setting to enables or disable printing of the header you created using the Shop Utility.

Select

Use this option to print test results using the printer

built into the Control Module, an external IR printer or disable the printer function completely.

Update

When software updates become available for the Bat-

tery Diagnostic Station, this utility walks you though the quick process of updating the Battery Diagnostic Station software using a data card.

Format

Select this utility to format an data card to receive

data or erase all data on the card. The charger will warn you before formatting the disk and ask if you want to continue.

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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Chapter 13: Setup

GR8-1202

Buzzer

The BUZZER utility allows you to enable or disable the

beep that warns you if the clamps are connected improperly and alerts you to other errors.

1. Use  or  to select a BUZZER option and press NEXT to continue, or press the corresponding number key

1  OFF

2  ON

2. Press SAVE to save your setting or BACK to return to the Setup Menu without saving the changes.

User Screen

This utility allows you to customize screen informa-

tion. Data may be entered manually or using a data card. To use a data card, insert the data card in to the data slot and select Data Card. Data will be uploaded automatically and tester will return to Setup Menu.

1. Select the input screen by pressing as needed:

1  INPUT SCREEN 1

2  INPUT SCREEN 2

3  INPUT SCREEN 3

Press NEXT to continue.

 or 

as many times

4. Use

 or 

to move to the line you want to edit.

SCREEN OPTIONS

1 - 1

2 - 2

3 - 3

4 -

Press SELECT to continue.

5. Use

 or 

to move the cursor. Use the keypad to enter

the desired alphanumeric characters on each line.

1 - USER OPTION LINE 1

2 -

3 -

4 -

Press SAVE to continue.

Wireless

Scans for interference and recommends the best

channel for wireless communication. Make sure the Control Module is connected to the Charge Engine before running the scan.

2. Use

 or 

to scroll to the method for data entry you

want to use.

1  MANUAL EDIT

2  DATA CARD

Press NEXT to continue.

3. Insert a character by pressing

 or 

as many times as needed. To add a space, move the cursor forward by pressing u.

ENTER SCREEN TITLE

Press NEXT to continue.

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

www.midtronics.com

GR8-1202

Chapter 14: Maintenance / Troubleshooting

Help

The Help Menu has four functions to aid in the use of

your analyzer including: Terms/Denitions, Troubleshooting and Service Info.

Terms/Denitions

The TERMS/DEFINITIONS option provides definitions for several terms used by the GR8-1202 battery diagnostic station. To use this feature:

1. In the Help Menu, select the TERMS/DEFINITIONS option and press ENTER.

1  TERMS/DEFINITIONS

2  TROUBLESHOOTING

3  SERVICE INFO.

2. Use  or  or use the keypad to highlight the term of your choice.

1 - REGULAR

2 - AGM

3 - AGM SPIRAL

4 - GEL

Press ENTER to view the denition.

3. Use  or  to scroll through and read the full text denition.

4. Press BACK to return to the list of terms.

Test Messages

The table below will help you troubleshoot test messages. If troubleshooting does not solve the problem, call Midtronics Customer Service at 1-630-323-2800.

Message Explanation

System Noise Detected

Unstable Battery Detected

The GR8 has detected computer, ignition noise, or parasitic drain, and will attempt to retest. Make sure all vehicle loads are off, doors are closed, and the ignition is in the off position. The GR8 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.

A battery that is weak, or that has just been charged, may retain enough electrical activity to be detected by the GR8 and will adversely affect the test results. A fully charged battery should stabilize quickly, after which the GR8 will automatically retest. Weak batteries should be charged and retested. If the battery is fully charged, check the clamp connections.

Troubleshooting

The TROUBLESHOOTING option provides guidance to common questions or issues that may arise in using the station.

1. In the Help Menu, use  to select the TROUBLESHOOTING option and press ENTER to continue.

1 - PRINTER HELP

2 - CABLE PROBLEMS

2. Use  or  to read the full text description.

Press BACK to return to the previous screen.

Service Info

The SERVICE INFO option lists contact phone numbers for technical assistance and service issues.

www.midtronics.com

Replacing the Paper Roll

The printer uses thermal paper in a roll with the dimensions

2.25 in x 85 ft. (57 mm x 25.9 m). Replacement rolls can usually be purchased through many oce supply stores.

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Chapter 14: Maintenance / Troubleshooting

GR8-1202

Control Module Internal Batteries

The Control Module 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 Control Module will display a warning message when the internal batteries need to be replaced.

Full Decreasing Low Using vehicle

battery or AC

power.

Replacing the Internal Batteries

1. Turn the Control Module face down.

2. Use a Phillips screwdriver to remove the screw securing the door to the battery compartment.

5. Remove the discharged batteries.

6. Insert new batteries as shown. Make sure the positive and negative terminals are positioned correctly.

7. Insert the door’s tabs into the slots on the Control Module and slide the door closed.

8. Re-insert and tighten the screw.

Test Cable Maintenance

Here are a few things you can do to protect your test cables from damage and premature wear:

• The grease, dirt, and sulfation that build up on battery ter- minals 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.

• Clean the battery terminals. If stud adapters are required, fasten them with the proper tool. Do not use the battery clamps to tighten adapters.

Battery door hold

down screw

3. Press on the ridges above the arrow on the battery compartment cover.

4. Slide the door in the direction of the arrow and remove the door.

Slide door

in this

direction.

• Never remove the clamps from a battery to abort an ac- tive charging session. Always press the red STOP button before removing the clamps.

• Do not leave the clamps laying in battery acid.

• Hang the clamps on the cable wrap on the back of the GR8 when not in use.

Attaching the Charger Cables

The connector for the charger cables is located on the back of the GR8. Three (3) screws are included to secure the cables. To attach the cables:

1. Plug the small connector into the small socket (A) on the back of the Battery Diagnostic Station.

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

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GR8-1202

Chapter 14: Maintenance / Troubleshooting

2. Plug the large connector (B) into the large socket while placing the protective cover (C) against the back of the Diagnostic Station.

3. Insert the screws through the holes in the cover (circled) and Diagnostic Station sheet metal and securely tighten the screws with a #2 Phillips head screwdriver.

The installation is now complete.

Error Messages

The table below will help you troubleshoot test messages. If troubleshooting does not solve the problem, call Midtronics Customer Service at 1-630-323-2800.

MESSAGE Option EXPLANATION

VOLTAGE OUT OF RANGE!

VALID RANGE

0 TO 16 VOLTS

INVALID

NUMERIC

ENTRY

INTERNAL MEMORY ERROR!

CALL MIDTRONICS CUSTOMER

SERVICE

1-630-323-2800

REVERSE CONNECTION!

CHECK POLARITY

OF CLAMPS.

CONNECT RED CLAMP TO BATTERY

POSITIVE (+) POST, CONNECT BLACK

CLAMP TO BATTERY NEGATIVE (-) POST!

CHARGER FAULT!

CHECK CLAMPS! CHECK SERIAL CABLE!

BATTERY POWER TOO LOW TO

USE PRINTER. CONNECT TO FULLY

CHARGED BATTERY TO PRINT

RESULTS.

11.50V TO 16.00V

CHARGER ERROR

IS CHARGER TURNED ON?

ARE CABLES CONNECTED?

Attention light ashes at 0.5

second intervals.

Less than 100 CCA or invalid

date entry can cause this

error.

Attention light ashes at .5

second intervals.

Attention light ashes at 0.5

second intervals

At power up or when reverse

connection is made. For

charger this can only occur

at main menu or in a charger

test screen

Clamp not connected

Attention light ashes at 0.5

second intervals

Attention light ashes at 0.5

second intervals

Does not print and display

this message if clamps are

not connected

This occurs if the

bridge cannot talk

to the charger.

Tool detects incorrect voltage in battery test.

Any edit box entry that exceeds the limits.

Upon power up the tool detects a checksum error

Tool will return to state that threw the error if the connection becomes valid. For charger both the bridge and Control Module will sound a steady tone until the error is corrected.

Tool will return to state that threw the error if the connection becomes valid

Charger reported a fatal error.

Screen will be displayed for 3 seconds and then tool will return to viewing screen where print initiated from.

Make sure the charger is turned and the cables are connected. Also make sure the Multitasker module is receiving power and is properly connected between the Control Module and the charger.

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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Appendix

GR8-1202

Appendix

Header Template

To help you edit and center your header, use a pencil to write the information in the template below before entering it into the GR8.

Line 1

Line 2

Line 3

Line 4

Line 5

Line 6

Line 7

Line 8

Coupon Template

To help you edit and center your header, use a pencil to write the information in the template below before entering it into the GR8.

Line 1

Line 2

Line 3

Line 4

Line 5

Line 6

Line 7

Line 8

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

www.midtronics.com

GR8-1202

Appendix

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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

Appendix

GR8-1202

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527

www.midtronics.com

GR8-1202

Appendix

www.midtronics.com

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 specic 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.

Midtronics GR8-1202 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual