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Battery Management Innovation
VAS 6161
Vehicle Battery and
Electrical Diagnostic Platform
For testing 6 and 12-volt automotive batteries and
12- and 24-volt charging systems
INSTRUCTION MANUAL
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Contents
Contents
Chapter 1: Before You Begin ..................................................................................................7
Starting the tester for the rst time ..................................................................................................................7
Safety ...........................................................................................................................................................................7
General Precautions ........................................................................................................................................................7
Conventions Used in This Manual .....................................................................................................................8
Utilisation in accordance with „intended purpose“ ....................................................................................8
Disposal.......................................................................................................................................................................8
Chapter 2: Description ..........................................................................................................9
Connections and Data Ports ...............................................................................................................................9
Connecting the Battery Test Cable ................................................................................................................. 10
Removing and Inserting the Data Card ........................................................................................................ 10
Display and Keypad ............................................................................................................................................. 11
Data Entry Methods ............................................................................................................................................. 12
Menu icons ......................................................................................................................................................................12
Option Buttons ...............................................................................................................................................................12
Scrolling Lists .................................................................................................................................................................. 12
Alphanumeric Entries ..................................................................................................................................................12
Menu Maps ............................................................................................................................................................. 13
Main Menu ....................................................................................................................................................................... 13
Info Menu .........................................................................................................................................................................14
Print/View Menu ............................................................................................................................................................ 14
Utilities Menu..................................................................................................................................................................15
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Contents
Chapter 3: Test Preparation ................................................................................................ 16
Inspecting the Battery ........................................................................................................................................ 16
Testing Out-of-Vehicle ........................................................................................................................................ 16
Testing In-Vehicle ................................................................................................................................................. 16
Connecting the Battery Test Cable ................................................................................................................. 16
Setting User Preferences .................................................................................................................................... 17
Chapter 4: Battery Testing .................................................................................................. 18
Warranty mode ..................................................................................................................................................... 18
Service mode ......................................................................................................................................................... 19
Maintenance mode .............................................................................................................................................20
Additional tester messages .............................................................................................................................. 21
Surface Charge ............................................................................................................................................................... 21
System Noise ...................................................................................................................................................................21
Deep Scan Test ...............................................................................................................................................................21
Battery Test Results for Warranty test and Service Mode ....................................................................... 22
Battery Test Results for Maintenance Mode ............................................................................................... 22
Chapter 5: Dynamic Response Test .................................................................................... 23
Test Routine ............................................................................................................................................................ 23
Chapter 6: System Test ........................................................................................................ 24
Battery Test ............................................................................................................................................................. 24
Starter Test ..............................................................................................................................................................24
Alternator Test .......................................................................................................................................................25
Alternator Test Results .................................................................................................................................................26
Chapter 7: QC Test................................................................................................................ 29
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Contents
Chapter 8: Utilities ............................................................................................................... 32
Con g Tester .......................................................................................................................................................... 32
Display ...................................................................................................................................................................... 33
Language ................................................................................................................................................................ 34
Shop .......................................................................................................................................................................... 35
Coupon .................................................................................................................................................................... 35
Edit Coupon ............................................................................................................................................................ 36
Format Disk ............................................................................................................................................................. 36
Update ...................................................................................................................................................................... 36
Battery List (for QC Mode) ................................................................................................................................. 36
Chapter 9: Info Menu ...........................................................................................................37
Totals ......................................................................................................................................................................... 37
Transfer ..................................................................................................................................................................... 37
Version info ............................................................................................................................................................. 37
Chapter 10: Print/View ........................................................................................................ 38
View Test .................................................................................................................................................................. 38
View QC Test ........................................................................................................................................................... 38
Chapter 11: Troubleshooting .............................................................................................. 39
Problems with the display ................................................................................................................................. 39
Data Will Not Print ................................................................................................................................................ 39
Chapter 12: Tester Internal Batteries ................................................................................. 40
Battery Power Indicator .....................................................................................................................................40
Replacing the Tester Batteries.......................................................................................................................... 40
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Contents
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Chapter 1: Before You Start
Chapter 1: Before You Begin
Starting the tester for the rst time
When the tester is rst used the operator is asked to enter a couple of items. Items such as dealer ID and
Region are used to set-up speci c utilities such as date/time stamps and hour indication.
Changes can be made afterwards by going in to the Utility Menu and selecting CONFIG TESTER.
Safety
Because of the possibility of personal injury, always use extreme caution when working with batteries.
Follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations.
General Precautions
• DANGER—RISK OF EXPLOSIVE GASES: Batteries can produce a highly explosive mix of
hydrogen gas and oxygen, even when the battery is not in operation. Always work in a wellventilated area. Never smoke or allow a spark or flame in the vicinity of a battery.
• WARNING—REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals known to the state of California to
cause cancer and birth defects or other reproductive harm. Wash hands after handling.
• Battery acid is highly corrosive. If acid enters your eyes, immediately flush them thoroughly with
running cold water for at least 15 minutes and seek medical attention. If battery acid gets on
your skin or clothing, wash immediately with water and baking soda.
• Always wear proper safety glasses or face shield when working with or around batteries.
• Keep hair, hands, and clothing as well as the analyzer cords and cables away from moving engine
parts.
• Remove any jewelry or watches before you start servicing the battery.
• Use caution when working with metallic tools to prevent sparks or short circuits.
• Never lean over a battery when testing, charging or jump starting it.
The tester is manufactured in line with the latest state of the art and according to recognised safety standards.
If used incorrectly or misused, however, it can cause
- injury or death to the user or a third party,
- damage to the tester and other material assets belonging to the operator,
- inefficient operation of the tester.
All persons involved in commissioning, operating, maintaining and servicing the tester must
- be suitably qualified,
- have knowledge of and experience in dealing with testers and batteries and
- read and follow these operating instructions carefully.
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Chapter 1: Before You Start
Conventions Used in This Manual
To help you learn how to use your analyzer, the manual uses these symbols and typographical conventions:
!
CAUTION
UP ARROW
POST TYPE
The safety symbol followed by the word WARNING or CAUTION indicates
instructions for avoiding hazardous conditions and personal injury.
The word CAUTION without the safety symbol indicates instructions for avoiding
equipment damage.
The wrench symbol indicates procedural notes and helpful information.
The text for keypad buttons and soft-key functions are in bold capital letters.
The text for screen options are in regular capital letters.
Utilisation in accordance with „intended purpose“
The tester is to be used exclusively for its intended purpose. Utilisation for any other purpose, or in any
other manner, shall be deemed to be „not in accordance with the intended purpose“. The manufacturer is
not liable for any damage, inadequate or incorrect results arising out of such misuse.
Utilisation in accordance with the “intended purpose” also comprises
- carefully reading and obeying all operating instructions and safety and danger notices
- performing all stipulated inspection and servicing work.
- following all instructions from the battery and vehicle manufacturers.
Disposal
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation as national law, electrical equipment that has
reached the end of its life must be collected separately and returned to an approved
recycling facility Any device that you no longer require must be returned to our agent,
or nd out about the approved collection and recycling facilities in your area. Ignoring
this European Directive may have potentially adverse a ects on the environment and
your health!
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Chapter 2: Description
Connections and Data Ports
Chapter 2: Description
Integrated thermal printer
Release lever for door to paper compartment
Paper slot
LCD screen with Main Menu
Accessories port
6-pin
connector
Control Panel: keypad and power button
6-pin connector for the battery test cable
Spring-loaded data card slot for test data
storage and software upgrades.
Infrared temperature sensor with a range of
-28 °C to +93 °C (-20 °F to +200 °F).
Data transmitter: sends test results to a PC
using an optional hardware and software kit
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Chapter 2: Description
Connecting the Battery Test Cable
CAUTION: To prevent damage to the analyzer’s circuitry, do not connect the analyzer to a voltage
source greater than 30 Vdc.
To connect the battery test cable to the analyzer align the arrow on the cable connector with the arrows on
the analyzer’s housing. Hold the part of the cable connector as shown and rmly insert the connector into
analyzer’s six-pin receptacle. Do not twist.
To avoid damaging the battery test cable, always hold the ridged part of the cable connector (as shown in
the photo) when inserting and removing the cable.
Arrows
Hold the cable
connector here
Removing and Inserting the Data Card
The analyzer ships with a plastic insert in the data card slot to protect it from dust and debris. To remove the
plastic insert or a data card, push brie y on its edge to release it and pull it from the slot.
When inserting a card, push it into the slot until it locks. The card is correctly inserted when it is not
protruding from the slot. To protect the card slot and enable the analyzer to read and write to the card,
leave the card in the slot.
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Chapter 2: Description
Display and Keypad
The keypad and display work together to help you quickly nd and use the right tools at the right time. The
display also keeps you on track with on-screen navigation aids, directions and messages.
POWER Key
Press the POWER button to turn the analyzer on and
o . The analyzer also turns on automatically when you
connect its test leads to a battery.
Title Bar
The title bar shows you the name of the current menu,
test tool, utility, or function.
Selection Area
The selection area below the Title Bar contains selectable
items or dialog boxes that display information or require
a response.
Internal Batteries Status Indicator
This indicator appears in the screen’s top left corner, lets
you know the status and charge level of the analyzer’s six
1.5-volt batteries. The X in the top left corner of the screen
shows that the analyzer is powered by the battery you’re
testing to conserve the analyzer’s internal batteries.
Voltmeter
When you rst connect the analyzer to a battery it functions
as a voltmeter. The voltage reading appears above the left
soft key until you move to other menus or functions.
Soft Keys
Press the two Soft Keys linked to the bottom of the screen
to perform the functions displayed above them. The
functions change depending on the menu or test process.
So it may be helpful to think of the words appearing above
them as part of the keys. Some of the more common softkey functions are SELECT, BACK, and END.
Menu Screen Arrows
When displayed in menu screens, the menu screen
arrows show you which ARROW key on the keypad to
press to display other icons or screens. The Up and Down
Menu Screen Arrows, for example, indicate when to
press the UP (
the screens above and below the current screen.
he Left and Right Menu Screen Arrows tell you when to
T
use the LEFT
icon.
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.
ARROW keys
Press the UP ARROW key to move up to the next
selectable item or row. When entering text, use the UP
ARROW key to move to the previous character.
) and DOWN ( ) ARROW keys to display
( )
or RIGHT
( )
ARROW keys to select an
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Chapter 2: Description
Data Entry Methods
To perform a particular test or function, the tester will ask for di erent types of information. This means that
the methods you use to enter information will change depending on the type of information requested. The
four types of entry methods are described below.
Typically, the soft key below the right half of the screen con rms your choice, although the word above it
may vary. In a similar fashion, the soft key below the left half of the screen cancels your choice or returns you
to the previous screen, although the word above it may also vary.
Menu icons
A menu icon is a graphical representation of a function you can select. To select an icon, use the LEFT or
RIGHT ARROW key to highlight it. Highlighting changes the icon to a white picture on a black background.
To co n rm your selection, press the appropriate soft key.
Option Buttons
Some lists have option buttons before each item. To select an item, use the UP/DOWN ARROW keys to move
the dot into the button next to the item you want. You can also use the alphanumeric keypad to enter the
number preceding the option button. To con rm your selection, press the appropriate soft key.
Scrolling Lists
Scrolling lists contain items that extend above and below the screen or the selection box that contains them.
To indicate that there are more items, the symbols
appear to the right of the rst visible or highlighted
item on the list.
To select from this type of list, use the
UP/DOWN ARROW keys to scroll to the item, or use the keypad to
enter your choice, and press the appropriate soft key.
Alphanumeric Entries
Even though the tester does not use an alphanumeric keypad it is possible to enter alphanumeric values.
When applicable the alphanumeric values appear on the display. Use the UP/DOWN or LEFT/RIGHT ARROW
keys to scroll and con rm this with the > key. To return one or more steps use the < key.
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Chapter 2: Description
Menu Maps
This section will help you get to your destination while letting you know what test leads you may need when
you arrive. The test leads are represented by symbols for their connectors.
Main Menu
The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons lead
directly to the function they represent, while others are menu icons that lead to two or more functions.
Menu icons are marked here with an asterisk (
) and are mapped on the following pages.
*
MAIN MENU (Screen 1)
Tests a battery for Warranty purposes using the battery information you select
in a series of screens.
*
Enables you to view your
stored test results and
print them to the internal
printer.
Tests a battery in regular Service, this includes the possibility to perform the starting and
charging systems.
MAIN MENU (Screen 2)
Quality Control Mode for
testing Stock batteries or
compound batteries.
Tests vehicles on compount/
ports or at dealer before delivery to the customer.
*
Includes a test counter,
data transfer utility and
displays the tester software versions.
*
Utilities, many of which
customize your user interface in the tester.
MAIN MENU (Screen 3)
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Chapter 2: Description
Info Menu
REPORTS
Displays the total number
of Tests performed since
the tester was rst used.
to Main Menu an icon
An optional IR software
and hardware package enables you to transfer test
data to a PC.
Displays the software version, total tests from rst
use, and the serial number.
Print/View Menu
The tester stores the last test results in its memory until you perform another test. To review or print results
before you retest, select a test type in the Print/View Menu.
REPORTS
Displays the last Test results. The results can be
printed to the integrated
printer.
to Main Menu an icon
Displays the last Quality Control Test result. Sends the result to the integrated printer.
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Utilities Menu
The Utilities Menu lets you customize your analyzer to suit your needs.
SETUP (Screen 1)
Chapter 2: Description
Configur the tester by
selecting several speci c
functions
Settings to adjust the
screen contrast and backlight time.
Sets the language of the
display and printouts.
to Main Menu an icon
SETUP (Screen 2)
Enables you to add a custom header to printed test
results.
If you’ve created a coupon
in the Edit Coupon utility,
use Coupon to turn it on
Enables you to create a
coupon at the bottom of
printed test results.
and o .
to Main Menu an icon
SETUP (Screen 3)
Formas the SD card to receive data. Also erases all
data on the card.
to Main Menu
Enable you to Update the
software in the tester with
a speci c SD Card
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Setup Quality Control
Mode speci c items
an icon
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Chapter 3: Test Preparation
Chapter 3: Test Preparation
Inspecting the Battery
Before starting the test visually inspect the battery for:
• Cracked, buckled, or leaking case. If you see any of these defects, replace the battery.
• Corroded, loose, or damaged cables and connections. Repair or replace them as needed.
• Corrosion on the battery terminals, and dirt or acid on the case top. Clean the case and terminals
using a wire brush and a mixture of water and baking soda.
• Low electrolyte level. If the electrolyte level is too low, add distilled water to fill up and fully
charge the battery. Do not overfill.
• Corroded or loose battery tray and hold-down fixture. Tighten or replace as needed.
Testing Out-of-Vehicle
The preferred battery test location is in the vehicle. However, if you plan to test out of the vehicle:
• Always disconnect the negative cable from the battery first and reconnect it last.
• Always use a carry tool or strap to lift and transport the battery.
Testing In-Vehicle
The preferred test position is at the battery posts.
At the start of the test, make sure all vehicle accessory loads are o , the key is not in the ignition, and
the doors are closed. If systems in the vehicle are still active it might lead to a SYSTEM NOISE message, the
tester will automatically continue to test the battery until the noise is gone.
Connecting the Battery Test Cable
CAUTION: Do not connect the tester to a voltage source greater than 30 Vdc.
Connect the clamps to the battery: the red clamp to the positive (+) terminal and the black clamp to the
negative (–) terminal.
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Chapter 3: Test Preparation
If you connect the clamps in the wrong polarity (positive to negative or negative to positive), the tester
displays CLAMPS REVERSED! Reconnect the clamps correctly.
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 tester will display the message CHECK CONNECTION. If the
message reappears after you have correctly reconnected the clamps, clean the terminals and reconnect.
Setting User Preferences
Before starting your test you may want to customize the use of your analyzer by setting preferences in the
Utility Menu. The menu has settings for the display’s date and time, the contrast and backlight time, a utility
to customize printouts, among others.
To conserve the analyzer’s internal batteries, the tester will turn o after 30 seconds of inactivity.
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Chapter 4: Battery Test
Chapter 4: Battery Testing
The tester will guide you through the steps of selecting your battery test parameters and interpreting the
results. Before you start the test, review the instructions in Chapter 3: Test Preparation.
Warranty mode
This test mode is speci cally designed for warranty claims. At the end of the test the tester can create a
testcode that is needed when the claim is issued.
1. Select the battery LOCATION.
OUT OF VEHICLE
IN VEHICLE
Press the
NEXT soft key to continue. The BACK soft key returns you to the Main Menu.
2. Select the POST TYPE. (IN-VEHICLE)
TOP POST
JUMP START POST
Press the
NEXT soft key to continue.
3. Select the VEHICLE (JUMP START POST)
TOUAREG
TOUAREG V10 TDI
By selecting a vehicle the tester will use a pre-de ned compensation factor to overcome the extra
resistance caused by the JUMP START POST cable. Selecting the wrong vehicle can lead to incorrect
measurements.
Press the
NEXT soft key to continue.
4. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
5. Select the BATTERY TYPE
REGULAR
AGM
2 * 6V SPIRAL
GEL
Press the
6. Press the
NEXT soft key to continue.
UP/DOWN ARROW keys to select the battery rating or in the case of JIS, the part
number.
Press the
NEXT soft key to start the test.
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Chapter 4: Battery Test
Service mode
This test mode is speci cally designed for vehicles that are in service.
1. Select the TEST LOCATION
TOP POST
JUMP START POST
Press the
NEXT soft key to continue.
2. Select the VEHICLE (JUMP START POST)
TOUAREG
TOUAREG V10 TDI
By selecting a vehicle the tester will use a pre-de ned compensation factor to overcome the extra
resistance caused by the JUMP START POST cable. Selecting the wrong vehicle can lead to incorrect
measurements.
Press the
NEXT soft key to continue.
3. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
4. Select the BATTERY TYPE
REGULAR
AGM
2 * 6V SPIRAL
GEL
Press the
NEXT soft key to continue.
5. Select the RATING UNITS
CCA
JIS
DIN
SAE
IEC
EN
Press the
6. Press the
NEXT soft key to continue.
UP/DOWN ARROW keys to select the battery rating or in the case of JIS, the part
number.
Press the
NEXT soft key to start the test.
For the next few seconds the tester will display the word
battery.
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TESTING and a stopwatch while it evaluates the
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Chapter 4: Battery Test
Maintenance mode
This test mode is speci cally designed for new vehicles that are stored on a compound, in a port or at the
dealer storage before delivery to the customer.
1. POWERING UP SCANNER....
2. Scan the VIN bar code
When it’s impossible to scan the VIN code press the
NEXT soft key to enter it manually.
3. Select the TEST LOCATION
TOP POST
JUMP START POST
Press the
NEXT soft key to continue.
4. Select the VEHICLE (JUMP START POST)
TOUAREG
TOUAREG V10 TDI
By selecting a vehicle the tester will use a pre-de ned compensation factor to overcome the extra
resistance caused by the JUMP START POST cable. Selecting the wrong vehicle can lead to incorrect
measurements.
Press the
NEXT soft key to continue.
5. Scan the BATTERY VIN bar code
When it’s impossible to scan the VIN code press the
NEXT soft key to select it from a pre-de ned
list.
6. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
For the next few seconds the tester will display the word
battery.
TESTING and a stopwatch while it evaluates the
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Chapter 4: Battery Test
Additional tester messages
Surface Charge
The battery can hold a surface charge if the engine has been running or after the battery has been charged.
The tester may prompt you to remove the surface charge before it displays a test result.
1. Follow the instructions indicating when to turn the headlights on and off (IN-VEHICLE)
2. The tester will resume testing after it detects that the surface charge is removed.
System Noise
To perform a correct measurement the tester requires the vehicle to be in rest. After the car has been driven
some vehicle speci c systems might still be active in the background. The tester will detect this and displays
the message SYSTEM NOISE. When this message appears switch o all consumers(radio, airconditioning)
and remove the key from the ignition. As soon as there is no more activity in the vehicle the tester will
continue testing and display the test result.
Deep Scan Test
In some cases the tester 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. This test will typically be performed on batteries that are in a low state of charge.
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Chapter 4: Battery Test
Battery Test Results for Warranty test and Service Mode
After the test the tester will display the battery decisions with the complete results in a series of screens. Use
the UP/DOWN ARROW keys to scroll through each result. To print the results press the PRINT soft key. To
return to the Main Menu, press the
Battery decision
Temperature indication
Decision Recommended Action
GOOD BATTERY Return the battery to service
GOOD–RECHARGE Fully charge the battery and return it to service
CHARGE & RETEST Fully charge the battery and retest. Failure to fully charge the battery
END soft key.
Measured voltage
Measured capacity
rating units
Rating units you selected
for the test
Battery Decisions and Recommendations
before retesting may cause false readings. If
CHARGE & RETEST appears
again after you fully charge the battery, replace the battery
REPLACE BATTERY Replace the battery. A
REPLACE BATTERY result may also mean a poor
connection between the battery cables and the battery. After disconnecting
the battery cables, retest the battery using the out-of-vehicle test before
replacing it
BAD CELL–REPLACE Replace the battery and retest
FROZEN BATTERY Thaw the battery and retest
REMOTE POST The decision is based on a measurement on the JUMP START POST. Advise
is to retest directly on battery post
Battery Test Results for Maintenance Mode
Decision Recommended Action
GOOD BATTERY Return the battery to service
CHARGE BATTERY Fully charge the battery and return it to service
CHARGE INSTANTLY Immediately fully charge the battery and retest.
MARK AS DEFECT Mark this battery as DEFECT and replace it from the vehicle
REMOTE POST Replace the battery and retest
FROZEN BATTERY Thaw the battery and retest
REMOTE POST The decision is based on a measurement on the JUMP START POST. Advise
is to retest directly on battery post
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Chapter 5: Dynamic Reponse Test
Chapter 5: Dynamic Response Test
This test is an in-vehicle test in which a deeply-discharged battery can be diagnosed in minutes instead of
the hours needed to charge it. The tester displays the option to perform the test after a deep scan and before
it arrives at the battery decision.
The test requires an:
• Amp clamp
Test Routine
1. AMP clamp available
YES
NO
Press the
NEXT soft key to continue.
2. Place the Amp clamp around the negative wire.
Press the
NEXT soft key to continue.
3. Start vehicle.
4. Tester is checking alternator for output.
5. Turn all vehicles loads off, idle engine.
6. Enter the charge current coming from the alternator (See Amp clamp display).
Press the
NEXT soft key to continue.
7. Alternator voltage and current is checked and 5 minute procedure starts.
8. At the end of the 5 minute procedure enter the final charge current from the alternator (See
Amp clamp display).
As of this point onwards the tester will perform the alternator test. For more detail please see the chapter
SYSTEM TEST
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Chapter 6: System Test
Chapter 6: 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 System Test includes 3 tests that provide a complete diagnosis of the vehicle’s electrical system:
• BATTERY TEST
• STARTER TEST
• ALTERNATOR TEST
Battery Test
The System Test includes a test of the battery to eliminate it as the cause of starting or charging problems.
Starter Test
1. Start the engine at the prompt.
2. The tester will display one of the starter decisions with the complete results in a series of screens.
Use the UP/DOWN ARROW keys to scroll to each screen.
To continue testing, press the
NOTE: In some cases, the tester may not detect the vehicle’s starting pro le. It will display the
soft key options
skipped. If you select NO START, the test process ends.
Decision Action
CRANKING NORMAL The starter voltage is normal and the battery is fully charged.
LOW VOLTAGE The starter voltage is low and the battery is fully charged.
CHARGE BATTERY The starter voltage is low and the battery is discharged. Fully charge the
REPLACE BATTERY (If the battery test result was (REPLACE or BAD CELL.) The battery must be
STARTED and NO START. If you select STARTED, the alternator test will be
battery and repeat the starter system test.
replaced before testing the starter.
NEXT soft key.
NO START The engine didn’t start and the test was aborted.
CRANKING SKIPPED The Tester didn’t detect the vehicle’s starting pro le and skipped the Starter
Test.
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Chapter 6: System Test
Starter decision
Average cranking
voltage
Cranking time in
milliseconds
X axis = time
Alternator Test
1. ANALYZING CHARGING SYSTEM DATA: After you press the NEXT soft key to begin the alternator
test, the Tester will immediately begin testing for alternator voltage.
2. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn off vehicle loads (blowers, interior light, radio,
etc.) and idle the engine. Press the
NEXT soft key to continue.
NOTE: If necessary the analyzer will ask if you are testing a diesel engine. It will resume
testing after you make your selection.
3.
REV ENGINE WITH LOADS OFF FOR 5 SECONDS: Rev the engine with the loads off. Gradually
increase the rpm until the analyzer tells you to HOLD the rev level as the bar on the display
crosses the rpm target line.
4. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold the rpm while the Tester takes system
measurements.
5. ENGINE REV DETECTED, IDLE ENGINE: The Tester has detected the rev. Press the
NEXT soft key to
continue.
6.
TESTING ALTERNATOR AT IDLE, LOADS OFF: The analyzer will next test the engine at idle for
comparison to other readings, and then test the diode ripple. Excessive ripple usually means one
or more diodes have failed in the alternator or there is stator damage.
7.
TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE ENGINE: After a few seconds, the Tester will
ask you to turn on the accessory loads. It will determine if the charging system is able to provide
enough current for the demands of the electrical system.
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Chapter 6: System Test
IMPORTANT: Turn on the high-beam headlights, the blower to high and the rear defogger. Don’t
use cyclical loads such as air conditioning or windshield wipers.
8. TESTING ALTERNATOR AT IDLE, LOADS ON: The analyzer will determine if the charging system is
able to provide sufficient current for the demands of the vehicle’s electrical system.
9. REV ENGINE WITH LOADS ON FOR 5 SECONDS: The Tester will test the charging system with the
loads on and prompt you to rev the engine. Gradually increase the rev until the analyzer tells
you to HOLD the rev level as the bar on the display crosses the rpm target line.
10. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold the rpm while the Tester takes system
measurements.
11. ENGINE REV DETECTED, IDLE ENGINE: The Tester has detected the rev. Press the
NEXT soft key
to continue.
12. ANALYZING CHARGING SYSTEM DATA: The Tester is completing its final analysis of the charging
system data.
13. TURN OFF LOADS AND ENGINE: Press the
NEXT soft key to display the results.
Alternator Test Results
Alternator decision
Loads-o DC voltage at rev
Normal DC voltage range
Loads-on DC voltage at rev
Bar graph showing DC voltage
within normal range with loads
on and o
Peak-to-peak AC voltage
Graph of diode waveform
Figure 16: NO PROBLEMS Alternator Result
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Chapter 6: System Test
Decision Action
NO PROBLEMS
The system is showing normal output from the alternator. No problem detected.
Table 3: Alternator Decisions and Recommendations
NO OUTPUT
LOW OUTPUT
HIGH OUTPUT
The alternator is not providing charging current to the battery.
√ Check the belts to ensure the alternator is rotating with the engine running.
Replace broken or slipping belts and retest.
√ Check all connections to and from the alternator, especially the connection
to the battery . If the connection is loose or heavily corroded, clean or replace
the cable and retest.
√ If the belts and connections are in good working condition, replace the alterna-
tor. (Older vehicles use external voltage regulators, which may require only
replacement of the voltage regulator.)
The alternator is not providing enough current to power the system’s electrical
loads and charge the battery.
√ Check the belts to ensure the alternator is rotating with the engine running.
Replace broken or slipping belts and retest.
√ Check the connections from the alternator to the battery. If the connection is
loose or heavily corroded, clean or replace the cable and retest.
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.)
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Page 28
Chapter 6: System Test
Table 4: Diode Decisions and Recommendations
Decision Action
EXCESSIVE RIPPLE One or more diodes in the alternator aren’t functioning or there’s stator
damage, which is shown by an excessive amount of AC ripple current supplied
to the battery.
√ Make sure the alternator mounting is sturdy and that the belts are in
good shape and functioning properly. If the mounting and belts are
good, replace the alternator.
OPEN PHASE The Tester has detected an open phase within the alternator. Replace the
alternator.
OPEN DIODE The Tester has detected a open diode within the alternator. Replace the
alternator.
SHORTED DIODE The Tester has detected an shorted diode within the alternator. Replace the
alternator.
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Page 29
Chapter 7: QC Test
Chapter 7: QC Test
The tester has the ability to test multiple batteries one after the other without having to input the battery
rating / settings.
There are two types of QC tests: the STOCK CONTROL or the COMPOUND TEST.
STOCK CONTROL is meant for batteries standing in a warehouse or on a pallet where as COMPOUND TESTING
is done when the battery is in the vehicle.
STOCK CONTROL
1. The first screen shows you the amount of tests performed. Once you press both the arrow keys
you reset the test counter.
2. Select the BATTERY TYPE
REGULAR
AGM
2 * 6V SPIRAL
GEL
Press the
NEXT soft key to continue.
3. Select the RATING UNITS
CCA
JIS
DIN
SAE
IEC
EN
Press the
4. Press the
NEXT soft key to continue.
UP/DOWN ARROW keys to select the battery rating or in the case of JIS, the part
number.
Press the
NEXT soft key to start the test.
5. Enter the minimum voltage.
6. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
The tester will now test the battery.
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Chapter 7: QC Test
COMPOUND MODE
1. The first screen shows you the amount of tests performed. Once you press both the arrow keys
you reset the test counter. At the same time you have the possibility to enter a batch name for
the coming measurements. This can be useful when you measure multiple vehicles that belong
to a specific batch.
All the battery information is stored on the data card linked to the entered batch name.
2. Select the TEST LOCATION
TOP POST
JUMP START POST
Press the
NEXT soft key to continue.
Select the BATTERY TYPE
3. Select the SELECTION
MANUAL
PRE-SELECTION
Press the
NEXT soft key to continue.
4. Select the BATTERY TYPE
REGULAR
AGM
2 * 6V SPIRAL
GEL
Press the
NEXT soft key to continue.
5. Select the RATING UNITS
CCA
JIS
DIN
SAE
IEC
EN
Press the
NEXT soft key to continue.
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Chapter 7: QC Test
6. Press the UP/DOWN ARROW keys to select the battery rating or in the case of JIS, the part
number.
Press the
NEXT soft key to start the test.
5. Enter the minimum voltage.
6. Select the TEMPERATURE.
Aim the tester 2 inches (5 cm) from the sides or top of the battery case. As soon as the temperature
reading is stable the operator can press NEXT
The tester will now test the battery.
After the test you can save the test result accompanied by VIN code information either by using the barcode
reader or manual input.
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Chapter 8: Utilities
The Utility Menu allows you to easily set up your analyzer:
Con g Tester
TIME : 15:23
MODE : 24 HOUR
DATE :
FORMAT :
TEMP. UNITS C
WRITE FAIL ASK
BARCODE READER YES
REGION OTHER
DEALER-ID 12345678
Chapter 8: Utilities
M23/02/2009
6/17/DDDD/MM/YYYY
Time
1. Use the LEFT/RIGHT ARROWS to highlight the hour, minutes. To rapidly scroll, hold down an
ARROW key.
9 : 19 PM
2. Press the SAVE soft key to save your setting or BACK to return to the ADJUST screen.
Mode
Use the LEFT/RIGHT ARROWS to select the option of your choice.
1. Select the 24-hour or AM/PM mode
2. Press the OK soft key to save your setting
Date
Date cannot be changed.
Format
Use the UP/DOWN ARROWS to select the desired option.
1. MM/DD/YYY (month/day/year) or DD/MM/YYY (day/month/year)
2. Press the OK soft key to save your setting.
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Chapter 8: Utilities
Temp. units
1. Use the LEFT/RIGHT ARROWS to select either Celsius or Fahrenheit as temperature indication.
Write fail
After each measurement the test results are stored on the data card. In case the data cannot be stored on
to the card you can select the way this is noti ed to the operator.
ASK (operator is asked if it is ok to continue even when results are not stored)
FORCE (measurements can only continue when data card is entered)
IGNORE (measurement is not stored and operator not notified)
Barcode reader
Switch barcode reader use ON or OFF. When set to o the tester will not ask for the reader.
Region
Indicate where the tester is being used. USA, CANADA or OTHER
Dealer-Id
Depending where the tester is used there is a pre-de ned format for the dealer-id.
Display
The LCD OPTIONS utility enables you to adjust the contrast of the text on the display and the backlight
time.
Contrast Level
The contrast level is 0 (lightest) to 10 (darkest). To change it:
1. Press the
2. Press the LEFT/RIGHT ARROW key to display the option’s numerical scroll box.
UP or DOWN ARROW to highlight the option.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
10
(1-10)
3. Press the UP/DOWN ARROW keys to select your preference.
4. Press the
LEVEL screen without saving the changes.
SAVE soft key to save your setting or the BACK soft key to return to the CONTRAST
• 33 •
Page 34
Backlight Time
Backlight time is from 0 to 60 seconds. To change it:
Chapter 8: Utilities
1. Press the
UP or DOWN ARROW to highlight the option.
CONTRAST LEVEL 10
BACKLIGHT TIME 60
2. Press the LEFT/RIGHT ARROW key to display the option’s numerical scroll box.
60
SEC
3. Press the UP/DOWN ARROW keys to select your preference.
4. Press the
SAVE soft key to save your setting or the BACK soft key to return to the BACKLIGHT
screen without saving the changes.
Language
The LANGUAGE utility enables you to select a language for the display and printouts. To set your
preference:
1. Use the
selection of 24 languages.
UP/DOWN ARROWS to move the dot to the option button of your choice. There is a
2. Press the
NEXT soft key to save your setting.
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Chapter 8: Utilities
Shop
The SHOP INFO utility enables you to create a header for your printed test results showing your business
location information. Its two information screens contain eight lines of text with up to 16 characters on each
line.
Screen 1
1–YOUR SHOP NAME
2–1000 ANY STREET
3–YOUR TOWN, STATE
4–YOUR POSTAL CODE
—
Screen 2
5–YOUR COUNTRY
6–YOUR PHONE NUMBER
7–WWW.WEBSITE.COM
8–YOUR SHOP ID NUMBER
—
To create or overwrite a header:
1. Press the
UP or DOWN ARROW to highlight the line you want to change.
2. Press SELECT to activate the line for editing, move the cursor backward to erase a character,
press the
LEFT ARROW key; to move the cursor forward, press the RIGHT ARROW key.
3. Insert a character by pressing the key associated with the character as many times as needed.
4. You can center text by selecting blank spaces before and after lines of text or insert spaces
between words.
5. Press the
SAVE soft key to save your setting or the BACK soft key to return to the SHOP INFO
screen without saving the changes.
Coupon
The COUPON SELECT utility enables and disables the printing of the custom coupon you’ve created in the
EDIT COUPON utility.
1. Use the
2. Press the
SELECT screen without saving the changes.
UP/DOWN ARROWS to move the dot to the option button of your choice.
NEXT soft key to save your setting or the BACK soft key to return to the COUPON
• 35 •
Page 36
Chapter 8: Utilities
Edit Coupon
The EDIT COUPON utility enables you to create a promotional coupon for your customers that prints at the
bottom of every test result. Its two information screens contain eight lines of text with up to 16 characters
each. The editing process is the same as when you create a header for your test results printouts. See the
SHOP utility for more information.
Format Disk
Select this utility to format a data card to receive data or erase all data on the card. The Tester will warn you
before formatting the disk and ask you if you want to continue. When a new blank data card is used you
always have to use this function before the tester can write to the card.
Update
As software updates become available you’ll be able to use this utility to update the Tester software using
les on an SD card. The use of a special formatted disk is required for this action.
FIRMWARE (use this option when new software becomes available from Midtronics)
SAVE CONFIG (the tester will store the workshop address to the data card, file name is CONFIG.CSV)
LOAD CONFIG (after new software is uploaded you can reload the workshop details to the tester)
1. Connect the tester to a 12V battery to ensure the tester does not switch off during the proces
2. Insert the disc in the tester
3. Select one of the options and follow the instructions on the screen
4. When finished the tester will prompt you to remove the card and reboot the tester
Battery List (for QC Mode)
In this function you can add, delete battery information that is used for the various battery tests.
BATTERY LIST
From this menu you can add or delete batteries that you can select in the MAINTENANCE MODE or
QC mode. When you add a battery you must have the BATTERY PRODUCER, BATTERY TYPE, BATTERY RATING, BATTERY CCA, BATTERY CAPACITY, GOOD LIMIT, CHARGE&RETEST LIMIT, REPLACE
LIMIT
VW PARTNUMBER
From this menu you can add or delete VW partnumbers that correspond to the VW batteries.
IMPORT LIST
When VW delivers new battery information it can be uploaded with this function. It will have the
same e ect as the above mentioned steps but than in a more simple way.
EXPORT LIST
To view the current battery and partnumber information use the EXPORT function to send the
information to the data card.
• 36 •
Page 37
Chapter 9: Info Menu
Chapter 9: Info Menu
The Info Menu has 3 utilities to help you manage your test data and track the usage and history of your
analyzer.
Totals
The TOTALS report displays the total number of battery tests by decision performed since the Tester was rst
used. The other option is to clear all the counters from the tester.
Transfer
The TRANSFER utility lets you transfer test data to a PC using an optional IR receiver/software package.
Version info
Version info displays the software version, the database version, the total tests performed and the serial
number. The utility keeps a permant count of the number of battery tests performed since the analyzer was
rst used.
• 37 •
Page 38
Chapter 10: Print/View
Chapter 10: Print/View
The Print/View Menu enables you to view and print the results of the tests performed before you perform
another test and overwrite the results in memory.
View Test
VIEW TEST gives you the option of viewing and printing all available test results. To return to the Main Menu,
press the
View QC Test
VIEW QC TEST gives you the option of viewing and printing all results of the Quality Control Test. To print
the results press the PRINT soft key.
To return to the Main Menu, press the END key.
END key. To print the results press the PRINT key.
• 38 •
Page 39
Chapter 11: Troubleshooting
Chapter 11: Troubleshooting
If you have problems with the display or printer try these troubleshooting suggestions:
Problems with the display
The display does not turn on:
• Check the connection to the battery.
• The analyzer’s internal batteries may need to be replaced.
The display ickers or is dim:
• The contrast may need to be adjusted in the Utility menu.
• The analyzer’s internal batteries may need to be replaced.
Data Will Not Print
The internal printer will not print
• The analyzer must be connected to the vehicle battery to print to the internal printer.
• The vehicle battery may be too low to power the printer. (Battery with at least 11.5 volts)
• Verify that the paper is properly installed
• Verify that the paper sensor is clean and undamaged
• 39 •
Page 40
Chapter 12: Tester Internal Batteries
Chapter 12: Tester Internal Batteries
The Tester uses 6 AA, 1.5-volt batteries (alkaline recommended) to allow testing of batteries down to
1 volt and supply power while the menu is active. The analyzer can test batteries down to 5.5 volts when the
internal batteries are not functioning.
Battery Power Indicator
The square in the upper left corner of the display indicates the charge level of the battery pack. The square is
black when the battery pack is fully charged. It gradually changes to white as the charge level declines. The
Tester will display a warning message when the batteries need replacing.
Full Powered by
Decreasing Low
Figure 7: Power Level Indicator for AA Batteries
Replacing the Tester Batteries
1. Turn the Tester face down.
2. Use a Philips screwdriver to remove the screw securing the
door to the battery compartment.
3. Lift the door at the tab and place it aside.
4. Remove the discharged batteries.
5. Insert new batteries as shown, make sure the positive and
negative terminals are positioned correctly.
test battery
6. Reposition the door on the battery compartment.
7. Reinsert and tighten the screw.
• 40 •
Page 41
Patents, Limited Warranty, Service
PATENTS
The EXP Expandable Electrical Diagnostic Platform is made in the U.S.A. by Midtronics, Inc. and is protected
by one or more of the following U.S. Patents: 4,816,768; 4,825,170; 4,881,038; 4,912,416; 5,572,136;
5,585,728; 5,592,093; 5,757,192; 5,821,756; 5,831,435; 5,914,605; 6,051,976; 6,091,245; 6,163,156; 6,249,124;
6,304,087; 6,310,481; 6,316,914; 6,323,650; 6,351,102; 6,359,441; 6,363,303; 6,392,414; 6,441,585; 6,445,158;
6,456,045; 6,469,511; 6,534,993; 6,544,078; 6,556,019; 6,566,883; 6,586,941; 6,707,303. Canadian Patents:
1,295,680; 1,280,164. United Kingdom Patent: 0,672,248; 0,417,173. German Patent: 693 25 388.6; 689 23
281.0-08; 93 21 638.6. And other U.S. and Foreign patents issued and pending. This product may utilize
technology exclusively licensed to Midtronics, Inc. by Johnson Controls, Inc. and/or Motorola, Inc.
LIMITED WARRANTY
This analyzer is warranted to be free of defects in materials and workmanship for a period of two years
from date of purchase. Midtronics will, at our option, repair or replace the unit with a remanufactured unit.
This limited warranty applies only to the analyzer, and does not cover any other equipment, static damage,
water damage, overvoltage damage, dropping the unit, or damage resulting from extraneous causes
including owner misuse. Midtronics is not liable for any incidental or consequential damages for breach
of this warranty. The warranty is void if owner attempts to disassemble the unit or to modify the cable
assembly.
167-000113A-GB 4/09 ©Midtronics, Inc.
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