exp-800 ni · exp-800 analyzer, and does not cover any other equipment, static damage, water...

Battery & Electrical Diagnostic Analyzer

For testing 12-volt automotive batteries and 12-volt charging systems

EXP-800 NI

May 2011167-006EN-D

INSTRUCTION MANUAL

Blank page behind cover

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527www.midtronics.com 3

EXP-800 NI

Contents

Chapter 1: Before You Begin 5Safety Reminder 5Personal Precautions 5

Chapter 2: Overview 6Connections and Data Ports 6Connecting the Battery Test Cable 6Removing and Inserting the Data Card 6Display and Keypad 7Data Entry Methods 7

Menu Icons 8Option Buttons 8Scrolling Lists 8Scroll Boxes 8Alphanumeric Entry 8

Menu Structure 8Main Menu 8Admin Menu 9Info Menu 9

Chapter 3: Getting Started 10Select Language. 10Select A Dealership 10Adjust The Clock 10Enter A ZIP Code 10User ID 10

Chapter 4: Test Preparation 11Inspecting the Battery 11Testing Out-of-Vehicle (Battery Test) 11Testing In-Vehicle (System Test) 11Connecting to the Battery 11

Chapter 5: Check-In 12Performing A Check-In Test 12

Chapter 6: Customer Delivery 13Performing A Customer Delivery Test 13

Chapter 7: OK Verify 14Battery Test 14

Initial Analysis 14Deep Scan Test 14Battery Test Results 15

Starter Test 15Starter System Test Results 15

Charging System Test 16Charging System Test Results 16

Chapter 8: Roadside 18Battery Test 18




Chapter 9: Inventory Test 22Selecting Test Parameters 22Printing Additional Test Results 22Clearing Test Totals 22

Chapter 10: Battery Test 23Test Procedure 23

Initial Analysis 23Deep Scan Test 23Battery Test Results 24State of Health (SOH) 24

Chapter 11: System Test 25Battery Test 25




Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 www.midtronics.com4

EXP-800 NI

Chapter 12: Info Menu 29View Test 29Totals 29Transfer 29Check-In 29View Inventory 30Customer Delivery 30Version 30

Chapter 13: Admin Menu 31Clock 31

Mode 31Time 31Format 31

Shop 31Users 32

Creating A New User ID 32Deleting A User ID 32Editing a User ID 33

Display 33Contrast Level 33Backlight Time 33

Temp 33Language 34Admin 34

Options 34Change Admin PIN 34Clear Test Totals 34Reset Defaults 34

Format Disk 34Update 34Logos 34

Chapter 14: Maintenance & Troubleshooting 35Printer Paper 35

Replacing Printer Paper 35Problems with the Internal Printer 35

Test Cable Maintenance 35Cleaning the Clamps 35Handling the Test Cables 36Storing Test Cables 36Testing Resistance in the Cable Set 36Test Procedure 36

Internal Batteries 37Power Indicator 37Replacing The Internal Batteries 37

Problems with the Display 37

Appendix A 38Shop Header Template 38


EXP-800 NI Chapter 1: Before You Begin

! Safety ReminderFor safe, efficient, and accurate testing, review the safety and operating instructions in this manual before using the analyzer. In addition, follow all manufacturers’ instructions and BCI (Battery Council International) safety recommendations.

Personal PrecautionsInspect 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:

Battery acid is highly corrosive. If acid enters your eyes, immediately flush 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 imme-diately 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.

Risk of explosive gases. Never smoke or allow a spark or flame in the vicinity of a battery.Batteries can produce a highly explosive mix of hydrogen gas and oxygen, even when the battery is not in operation. Always work in a well-ventilated area.

Wash hands after handling.REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.

Chapter 1: Before You Begin

Conventions Used in This ManualTo help you learn how to use your Midtronics product, the manual uses these symbols and typographical conventions:

Symbols And Typographical Conventions

Convention Description

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

The safety symbol with the words CAUTION, WARNING, or DANGER indicates instructions for avoiding hazardous conditions and personal injury.

CAUTION The word CAUTION indicates instructions for avoiding equipment damage.

The wrench symbol indicates procedural notes and helpful information.

UP ARROW The text for keypad buttons are in BOLD capital letters.

CAPITAL LETTERS The text for screen options are in regular capital letters.

BACK ARROW The text for soft keys are in Bold capital letters.


EXP-800 NIChapter 2: Overview

Chapter 2: Overview

This chapter describes the analyzer’s hardware and software interface. The components include test leads and connectors, and the display and keypad. The user interface comprises the software menus, test options, and utilities.

Connections and Data Ports

Integrated thermal printer

Release lever for door to paper compartment

Paper slot

LCD screen with Main Menu

Control Panel: keypad and power button

6-pin connector for the battery test cable (see the next page for detail)

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

Infrared temperature sensor with a range of -28 °C to +93 °C (-20 °F to +200 °F)

Data transmitter: sends test results to a PC using an op-tional hardware and software kit

Connecting the Battery Test Cable

To prevent damage to the analyzer’s circuitry, do not connect the analyzer to a voltage source greater than 30 Vdc.

T o c o n n e c t t h e 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 firmly 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.

Removing and Inserting the Data CardThe analyzer ships with a plastic insert in the data card slot to protect it from dust and debris. To remove the plastic insert or an data card, push briefly on its edge to release it and pull it from the slot.

When inserting a card, push it into the slot until it locks. The card is correctly inserted when it is not protruding from the slot. To protect the card slot and enable the analyzer to read and write to the card, leave the card in the slot.

Hold the cable

connector here

Arrows


EXP-800 NI Chapter 2: Overview

Display and Keypad

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

Internal Batteries Status IndicatorThis 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.

VoltmeterWhen you first connect the analyzer to a battery it functions as a voltmeter. The voltage reading appears above the left soft key until you move to other menus or functions.

Soft KeysPress the two Soft Keys linked to the bottom of the screen to perform the functions displayed above them. The functions change depending on the menu or test process. So it may be helpful to think of the words appearing above them as part of the keys. Some of the more common soft-key functions are SELECT, BACK, and END.

POWER KeyPress the POWER button to turn the analyzer on and off. 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 AreaThe selection area below the Title Bar contains selectable items or dialog boxes that display information or require a response.

Menu Screen ArrowsWhen 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 or keys to display the screens above and below the current screen.

The Left and Right Menu Screen Arrows tell you when to use the or keys to select an 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 BarAnother 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.

Top or only

screen

Middle screen

Last screen

Scroll Box

Arrow ( ) keys

Data Entry MethodsTo perform a particular test or function, the tester requires different types of information. This means that the methods you use to enter information will change depending on the type of information requested. The five types of entry methods are described below.

Typically, the soft key below the right half of the screen confirms your choice, although the command above it may vary. (Examples: SELECT, NEXT, and SAVE.) In a similar fashion, the soft key below the left half of the screen cancels your choice or returns you to the previous screen, although the word above it may also vary. (Examples: BACK and END.)


EXP-800 NIChapter 2: Overview

Menu IconsA menu icon is a graphical representation of a function you can select, such as the Battery test Icon in the Main Menu. To select an icon, use or to highlight it. Highlighting changes the icon to a white picture on a black background. To confirm your selection, press the appropriate soft key.

Option ButtonsSome 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 confirm your selection, press the appropriate soft key.

Scrolling ListsScrolling lists contain items that extend above and below the screen. The first number above the right soft key indicates the position in the list of the highlighted item. The second number above the right soft key indicates the number of items in the list.

To select an item, press or to highlight the item and press the appropriate soft key.

To move the highlight bar up four lines at a time, press . To move the highlight bar down four lines at a time, press .

Scroll BoxesScroll boxes contain variables that are displayed by scrolling using arrow keys.

To select, use or to scroll to the value, and press the appropriate soft key. In the illustration the left directional arrow indicates that you can press to clear all or part of the entry.

Alphanumeric EntrySome selections require you to use alphanumeric characters. T h e s e “ u s e r - d e f i n e d ” selections have a blinking horizontal line (cursor) to the right of the last character.

Use or to highlight a line for editing. Press the SELECT soft key to edit the selected line. Display the character or number you want by rapidly pressing an arrow key as many times as needed, or press and hold the arrow key to rapidly

scroll. To backspace, press . Use to add a space. When finished, press the appropriate soft key to save the text you entered.

Menu StructureThis section contains a graphical representation of the menu structure with brief descriptions of the utilities in each menu.

Main MenuThe 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 lead to two or more options.

Menu Icon Description

Check In is done when the vehicle comes off the truck at delivery (new vehicles delivered to the dealer). Output Includes Warranty CodeFor use after a sale to verify the battery and electrical system of a vehicle is working properly before delivery to a customer. Output Includes Warranty CodeVerifies the battery and electrical system of a vehicle brought in for service is working properly prior to returning to the customer. Output Includes Warranty CodeFor testing the battery, starter, and charging systems of vehicles requiring roadside assistance. Output Includes Warranty Code

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

Tests a battery, either in a vehicle or out, using battery information you select in a series of screens. Output Includes Warranty CodeTests the battery starting and charging systems of a vehicle. A test code is generated for all completed tests. Output Includes Warranty CodeUtility to view and print test results, a test counter, a data transfer utility, and information on the analyzer software version and serial number.Provides access to the Admin Menu, which allows you to customize the analyzer and administrative functions that include setting passwords.Provides tips for troubleshooting problems with the printer, the cables, and loss of power. Also includes Midtronics Customer Service phone numbers.


EXP-800 NI Chapter 2: Overview

Admin Menu

The Admin Menu lets you customize your analyzer for your needs. Before using the analyzer for the first time, check the default values to see what options you may want to change, add, or delete.


Settings to adjust the date and time.

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

Add, edit, or delete User IDs.

Settings to adjust the screen contrast and backlight time.

Allows you to select degrees in C or F for temperature measurements.

Sets the language of the display and printouts.

Allows you to enable or disable the user login screen, clear test totals, address header printing and restore defaults.

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

Updates the analyzer software via files on a data card.

Select your type of dealership; Nissan or Infiniti.

Info Menu

The Info Menu has utilities to allow you to view and print test results, track the usage and history of your analyzer, and manage test data.


Displays the last battery test results. Sends the results to the internal printer.

Reports menu that includes the following type of test totals: Battery, System, Totals by User ID, and Totals by Decision.

A future optional accessory consists of an IR software and hardware package that will enable you to transfer test data to a PC.

View and print the results from the last performed Check-In test.

View and print the results of the last 100 inventory tests.

View and print the results from the last performed Customer Delivery test.

Displays the software version, and the serial number.


EXP-800 NIChapter 3: Getting Started

The instructions in this section will help you quickly put your tester to work. Once you turn on the tester, it can take 8 to 10 seconds to power up while testing the integrity of its software.

Select Language.1. Use or to select which language should be used on

the tester screen.

1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS

2. Press NEXT to continue.

Select A DealershipSelect which logo should appear at the top of your printed test results.

1. Use the or to select the correct logo.

1 NISSAN

2 INFINITI


Adjust The Clock

NOTE: The tester date is preset and cannot be adjust-ed in the field.

IMPORTANT: Incorrectly adjusting the tester clock can invalidate battery warranty claims.

1. Use or to highlight the hour, minutes, or AM or PM. Use or to adjust the time setting. Hold down either button to rapidly scroll.

9 : 33 PM

2. Press SAVE to save your settings and continue.

Enter A ZIP Code1. Use the or key to highlight the each digit of the 5 dig-

its ZIP code. To rapidly scroll through the numbers, hold down the key.

ZIP CODE ENTER ZIP CODE

0 1 2 3 4 5 6 7 8 9BACKSPACE

2. Use or to highlight the desired number in the char-acter map and press the SELECT key to select it. The char-acter appears in the box above the character map. Repeat this process to complete the line.

Highlight BACKSPACE to backspace and make corrections.

Highlight SAVE to save the zip code and proceed to the next screen.

User IDThe tester has been initially set up to require a default USER ID to access the Main Menu. This function enables you to select the user name of the person performing the tests. Up to 8 user names can be created and stored.

NOTE: You can disable and enable User ID login by selecting the options in Chapter 13: Admin Menu.

1. From the Admin Menu highlight the USERS icon and press SELECT.

2. Use or to select ENTER NEW.

1 ENTER NEW

2 DELETE

3 EDIT


4. A list of eight (8) user placeholders are displayed in the USERS screen.

Use or to scroll to a specific placeholder ID. Scrolling up from the first line or down from the last line displays the next screen of placeholders. You can also use the or key to jump up or down through the list four lines at a time.

Highlight the line you want to change and press SELECT.

5. A four-row alphanumeric character map is displayed be-low the line you want to change.

USER 10 1 2 3 4 5 6 7 8 9

A B C D E F G H I J K L MN O P Q R S T U V W X Y Z

BACKSPACE

Use the arrow keys to highlight individual characters you want to include and press SELECT to add them to your line of text. To add a space in your line of text, select the blank space next to the number “9”.

6. Press SAVE to save your edited line and return to the USERS screen. Repeat the process to create new user IDs.

Chapter 3: Getting Started


EXP-800 NI Chapter 4: Test Preparation

Inspecting the BatteryBefore starting the test visually inspect the battery for:

• Cracked,buckled,orleakingcase.Ifyouseeanyofthesedefects, replace the battery.

• Corroded,loose,ordamagedcablesandconnections.Re-pair or replace them as needed.

• Corrosiononthebatteryterminals,anddirtoracidonthecase 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 to ½ inch above the top of the plates 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 (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 batteryfirst and reconnect it last.

• Alwaysuseacarry toolorstrap to liftandtransport thebattery.

Failure to properly install lead terminal adapters, or using adapters that are dirty or worn, may cause false test results.When testing side-post or Group 31 batteries, always use lead terminal adapters provided with the tester—do not test at the battery’s steel bolts. To avoid damage, never use a wrench to tighten the adapters more than ¼ turn.

Testing 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.

At the start of the test, place the vehicle transmission in PARK, make sure all vehicle accessory loads are off, the key is not in the ignition, and the doors are closed.

Connecting to the BatteryConnect the red clamp to the positive (+) terminal and the black clamp to the negative (–) terminal.

If you connect the clamps in the wrong polarity (red to negative or black to positive), the analyzer displays CLAMPS REVERSED! Reconnect the clamps.

To make sure both sides of the clamps are gripping the terminals, rock the each clamp back and forth. A poor connection will prevent testing, and the analyzer displays the message CHECK CONNECTION. If the message reappears after you have correctly reconnected the clamps, clean the terminals and reconnect.

Chapter 4: Test Preparation


EXP-800 NIChapter 5: Check-In

The Check-In function enables you to quickly check-in new vehicles as they arrive at your dealership for the first time.

A unique test code is generated showing that the vehicle was properly tested before being placed in dealer inventory. On average this test will take approximately 10 to 15 seconds to complete.

Performing A Check-In Test1. Select the CHECK-IN icon in the Main Menu.

2. Enter the last 8 alphanumeric digits of the VIN for the ve-hicle being tested and press NEXT to continue.

Use the arrow keys to highlight individual characters and numbers of the VIN and press SELECT to add them to your line of text. When finished press NEXT to continue.

NOTE: You must enter the VIN before a Check-In test can be performed.

3. The Check-In test now begins. When complete the re-sults are printed out and displayed on the Control Module screen once the test has been completed.

Battery Decisions: Check-In

Decision Recommended Action

GOOD BATTERY Return the battery to service.

USE GR8 OR IDLE CHRG FOR 30MIN & RETEST

Charge the battery your Midtronics diagnostic charger and retest the battery. Failure to do so may cause a false test result.

REPLACE The battery has tested bad and should be pulled from your inventory.

4. If the decision is GOOD, the vehicle is ready for delivery to the customer

For a USE GR8 OR IDLE CHRG FOR 30MIN & RESTEST decision, the battery state of charge is low and will need to be charged and retested. If the idle charge method is used, start the engine and turn the wipers ON then OFF. This will cause the ECM to energize the alternator and begin charging. Allow the engine to idle with no electrical load for 30 minutes and then retest the battery condition.

For a REPLACE decision, remove the battery and replace it with a good battery before delivering the vehicle to the customer.

NOTE: After the Check-In test is complete the result-ing printout will contain all relevant test codes for the entire process. All results screens will then be shown on the tester.

Chapter 5: Check-In


EXP-800 NI Chapter 6: Customer Delivery

The Customer Deliver function enables you to quickly perform a final battery test before delivering a new vehicle to your customer.

This test generates a unique test code to show that the vehicle was tested prior to customer delivery and that the battery was in good working order. On average this test will take approximately 10 to 15 seconds to complete.

Performing A Customer Delivery Test1. Select the Customer Delivery icon in the Main Menu.



NOTE: You must enter the VIN before a Custom-er Delivery test can be performed.

3. The Customer Delivery test now begins. The results are printed out and displayed on the Control Module screen once the test has been completed.

Battery Decisions: Customer Delivery




Charge the battery before testing. Failure to do so may cause a false test result.


4. If the decision is GOOD, the vehicle is ready for delivery to the customer

For a USE GR8 OR IDLE CHRG FOR 30MIN & RESTEST decision, the battery state of charge is low and will need to be charged and retested. If the idle charge method is used, start the engine and turn the wipers ON then OFF. This will cause the ECM to energize the alternator and begin charging. Allow the engine to idle with no electrical load for 30 minutes and then retest the battery condition.

For a REPLACE decision, remove the battery and replace it with a good battery before delivering the vehicle to the customer.

NOTE: After the Customer Delivery test is complete the resulting printout will contain all relevant test codes for the entire process. All results screens will then be shown on the tester.

Chapter 6: Customer Delivery


EXP-800 NIChapter 7: OK Verify

The OK Verify function enables you to verify that the battery and electrical system of a vehicle brought in for service is working properly prior to returning it to your customer.

NOTE: While this testing procedure is identical to a System Test, OK Verify creates a unique test code that is generated for warranty purposes.

Battery Test1. In the Main Menu, highlight the OK Verify icon and press

NEXT.

2. If using the AMP CLAMP, select AVAILABLE and calibrate it according to the onscreen instruction. Otherwise if you are not using the AMP CLAMP, select NOT AVAILABLE.

NOT AVAILABLE

AVAILABLE

3. Enter the last 8 alphanumeric digits of the VIN for the ve-hicle being tested and press NEXT.


4. Select the Nissan or Infiniti VEHICLE MODEL. Use or to highlight the correct model. Use or to quickly scroll the screen up or down. Press NEXT to continue.

200SX240SX300ZX350Z

NOTE: If you are testing a vehicle that is not a Nissan or Infiniti model, highlight OTHER NISSAN or OTHER INFINITI and press NEXT to continue.

5. Determine if the battery being tested is the original that came with the vehicle when it was new.

For Nissan/Infiniti vehicles with the original battery: For models with more than one original battery size available, you may be prompted to select from a list of

available options. Use or to highlight the correct option and press NEXT to continue.

For Nissan/Infiniti vehicles without the original battery: Use the keypad to enter the battery CCA value or use or to scroll to the correct value. Press NEXT to continue.

For other vehicles: you will be asked if the vehicle’s VIN begins with the letter “J”. If YES, select the battery model by JIS number from a list displayed on the screen. Use or to highlight the correct model. Use or to quickly scroll the screen up or down. Press NEXT to continue.

If NO, use the keypad to enter the battery CCA value or use or to scroll to the correct value and press NEXT to continue.

500 CCA

6. The Temperature screen will appear.

Hold the IR temperature sensor on bottom of the Control Module two inches above the battery case to approximate the battery temperature.

7. Press NEXT to begin the System Test.

Initial AnalysisThe analysis in progress is shown by a stopwatch.

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

After the Deep Scan Test the GR8 will either display the results or give you the option to perform the 10-Minute Discharged Battery Test. Although this test takes several minutes, it gives a more precise result for difficult-to-diagnose batteries.

Chapter 7: OK Verify


EXP-800 NI Chapter 7: OK Verify

Battery Test ResultsTest results are displayed in two screens. Use or to scroll to each screen. To return to the Main Menu, press EXIT. To print, press the PRINT key.

Screen 1 of 2

Measured voltage

Measured capacity

Selected rating

Temperature

Battery decision

Screen 2 of 2

Pass/Fail threshold. Shaded are indicates a REPLACE decision.

Battery Test Decisions



CHARGE REQUIRED

Fully charge the battery. Failure to fully charge the battery before testing may cause false readings.

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.

24 VOLT BATTERY

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

Starter TestIf you are using the amp clamp, keep it clamped around the negative (–) battery cable.

1. Start the engine at the prompt.

2. The GR8 will display 1 of 8 starter decisions with the com-plete results in a series of screens similar to those shown on the right. Use or to scroll to each screen.

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

NOTE: If the GR8 does not detect a starting pro-file, the options are STARTED and NO START. Se-lect STARTED to continue with the alternator test. Selecting NO START will end the test.

Starter System Test Results

Screen 1 of 2

Average cranking voltage

Average cranking current if amp clamp is used

Cranking time in seconds

Screen 2 of 2

Y axis = System performance:

cranking voltage

X axis = Time

Starter System Decisions and Recommendations


CRANKING NORMAL

The starter voltage is normal and the battery is fully charged.

LOW CRANKING AMPS

The measured amperage is low when starting the vehicle. Only measured when the Amp Clamp is used during the test.

LOW VOLTAGE The starter voltage is low and the battery is fully charged.

CHARGE BATTERY

The starter voltage is low and the battery is discharged. Fully charge the battery and repeat the starter system test.

REPLACE BATTERY

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

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

CRANKING SKIPPED

The GR8 didn’t detect the vehicle’s starting profile and skipped the Starter Test.

SIDE POST TEST

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

JUMP START POST

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


EXP-800 NIChapter 7: OK Verify

Charging System TestWhen you press NEXT in any test result screen, the analyzer proceeds to the Charging System Test.

1. CHECKING FOR ALTERNATOR OUTPUT: The analyzer is test-ing for alternator voltage.

2. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn off ve-hicle loads (blowers, interior light, radio, etc.) and idle the engine. Press NEXT to continue.

NOTE: If necessary the analyzer will ask if you are testing a diesel engine. It will resume testing after you make your selection.

3. REV ENGINE WITH LOADS OFF FOR 5 SECONDS: Rev the engine with the loads off. Gradually increase the rpm until the analyzer tells you to HOLD the rev level as the bar on the display moves to the right.

NOTE: Cold engines, 8-cylinder engines and old-er vehicles will idle at a high level after starting, not allowing the analyzer to detect the rev auto-matically.

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 de-tected the rev. Press NEXT 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 alter-nator or there is stator damage.

7. TURN HIGH BEAMS AND BLOWER MOTOR ON, IDLE EN-GINE: 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.

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 ana-lyzer 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.



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

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

Charging System Test Results

1. Use the or key to scroll to each screen.

2. To print, press the PRINT key. Press END to return to the Main Menu.

Screen 1 of 3

DecisionLoads-off DC voltage

at rev Loads-on DC voltage

at rev

Screen 2 of 3

Normal DC voltage range

Bar graph of DC voltage

within normal

range (loads on and off)

Screen 3 of 3

Graph of diode

waveform

Peak-to-peak AC voltage

NOTE: After the OK Verify test is complete the result-ing printout will contain all relevant test codes for the entire process. All results screens will then be shown on the tester.


EXP-800 NI Chapter 7: OK Verify

Charging System Decisions

Charging System

DecisionAction

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

NO VOLTAGE 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.)

LOW VOLTAGE 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.

HIGH VOLTAGE The voltage output from the alternator to the battery exceeds the normal limits of a functioning regulator.√ Check to ensure there are no loose connections and that the ground connection is normal. If there are

no connection problems, replace the regulator. (Most alternators have a built-in regulator requiring you to replace the alternator. In older vehicles that use external voltage regulators, you may need to replace only the voltage regulator.)

The regulator controls voltage output based on the battery voltage, under-hood temperature, and vehicle loads used. In other words, it controls the maximum voltage the system can produce based on the current needs and amount of current that can be produced by the spinning of the rotor in the alternator. The normal high limit of a typical automotive regulator is 14.5 volts +/–0.5. Refer to the manufacturer specifications for the correct limit, which may vary by vehicle type.A high charging rate will overcharge the battery and may decrease its life and cause it to fail. If the battery test decision is REPLACE and the charging system test shows a HIGH OUTPUT, check the battery’s electrolyte levels. A symptom of overcharging is battery fluid spewing through the vent caps, which causes low electrolyte levels and will harm the battery.

Diode Decisions

Diode Decision Action

EXCESSIVE RIPPLE

One or more diodes in the alternator are not functioning or there is stator damage, which is shown by an excessive amount of AC ripple current supplied to the battery. √ Make sure the alternator mounting is sturdy and that the belts are in good shape and functioning properly.

If the mounting and belts are good, replace the alternator.

OPEN PHASE The analyzer has detected an open phase within the alternator. Replace the alternator.

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

SHORTED DIODE

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


EXP-800 NIChapter 8: Roadside

The ROADSIDE function enables you to verify that the battery and electrical system of a vehicle not brought in for service is working properly prior to returning it to your customer after battery replacement during a roadside repair.

NOTE: While this testing procedure is identical to a System Test, a unique test code is generated for war-ranty purposes.

Battery Test1. In the Main Menu, highlight the ROADSIDE icon and press

NEXT.


NOT AVAILABLE

AVAILABLE




200SX

240SX

300ZX

350Z


5. For Nissan/Infiniti vehicles without the original battery: Use the keypad to enter the battery CCA value or use or to scroll to the correct value. Press NEXT to continue.

For other vehicles: You will be asked if the vehicle’s VIN begins with the letter “J”. If YES, select the battery model by JIS number from a list displayed on the screen. Use or to highlight the correct model. Use or to quickly scroll the screen up or down. Press NEXT to continue.


500 CCA







Chapter 8: Roadside


EXP-800 NI Chapter 8: Roadside


Screen 1 of 2

Measured voltage

Measured capacity

Selected rating

Temperature

Battery decision

Screen 2 of 2





CHARGE REQUIRED


REPLACE BATTERY


24 VOLT BATTERY




2. The GR8 will display 1 of 8 starter decisions with the com-plete results in a series of screens similar to those shown on the right. Use the or key to scroll to each screen.



Starter System Test Results

Screen 1 of 2




Screen 2 of 2


cranking voltage

X axis = Time



CRANKING NORMAL


LOW CRANKING AMPS


LOW VOLTAGE The starter voltage is low and the battery is fully charged.

CHARGE BATTERY


REPLACE BATTERY



CRANKING SKIPPED


SIDE POST TEST


JUMP START POST



EXP-800 NIChapter 8: Roadside





















Screen 1 of 3


at rev

Loads-off current at rev if amp clamp is

used

Loads-on DC voltage

at revLoads-on current at rev if amp clamp is

used

Screen 2 of 3



within normal


Screen 3 of 3

Graph of diode

waveform


NOTE: After the Roadside test is complete the result-ing printout will contain all relevant test codes for the entire process. All results screens will then be shown on the tester.


EXP-800 NI Chapter 8: Roadside


Charging System

DecisionAction


NO VOLTAGE 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








The regulator controls voltage output based on the battery voltage, under-hood temperature, and vehicle loads used. In other words, it controls the maximum voltage the system can produce based on the current needs and amount of current that can be produced by the spinning of the rotor in the alternator. The normal high limit of a typical automotive regulator is 14.5 volts +/–0.5. Refer to the manufacturer specifications for the correct limit, which may vary by vehicle type. A high charging rate will overcharge the battery and may decrease its life and cause it to fail. If the battery test decision is REPLACE and the charging system test shows a HIGH OUTPUT, check the battery’s electrolyte levels. A symptom of overcharging is battery fluid spewing through the vent caps, which causes low electrolyte levels and will harm the battery.

Diode Decisions


EXCESSIVE RIPPLE

One or more diodes in the alternator are not functioning or there is stator damage, which is shown by an excessive amount of AC ripple current supplied to the battery. √ Make sure the alternator mounting is sturdy and that the belts are in good shape and functioning properly.




SHORTED DIODE



EXP-800 NIChapter 9: Inventory Test

The Inventory Test in the Main Menu enables you to quickly check vehicles that have been in your inven-tory for an extended period of time.

You can test the batteries in up to 50 vehicles in succession without re-entering the battery information each time. It differs from the Battery Test in that the decision is either pass or fail. Neither decision will tell you if a battery is bad, but rather that the measured voltage and CCA fall in or out of specification.

Selecting Test Parameters1. Select the Inventory Test icon in the Main Menu.

The INVENTORY STATS screen is displayed on the Control Module screen.

IMPORTANT: Be sure to monitor the number of tests performed and be ready to print the test result the totals as the number approaches 50. When the limit is reached you will no longer be able to test until you clear all results from memory.



NOTE: Entering the VIN is optional when per-forming an Inventory Test.

3. The Inventory Test now begins. On average this test will take approximately 5 to 10 seconds to complete. The re-sults are printed out and displayed on the Control Module screen once the test has been completed.

Use or to view previous battery results.

Battery Decisions: Inventory Test

Decision Recommended ActionGOOD Return the battery to service.


Charge the battery before testing. Failure to do so may cause a false test result.


4. Connect the clamps to the next battery to continue test-ing identical battery types. The analyzer will begin auto-matically using the same parameters. To test another type of battery press END, then follow steps 1 and 2.

Printing Additional Test ResultsYou can print additional results for individual tested batteries or a summary of the last 100 batteries tested using the Inventory Test.

1. For individual battery test results, use or to scroll to the specific Inventory Test result screen you want to print.

2. Select PRINT.

3. Use or to select INVENTORY PRINT.

1 INVENTORY BATTERY

2 INVENTORY SUMMARY

4. Use or to select the LANGUAGE of the printout.

1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS

The Inventory Test results are now printed out.

5. To print additional copies press PRINT. Press END to re-turn to the Main Menu.

Clearing Test Totals1. Select the Inventory Test icon in the Main Menu.

The INVENTORY STATS screen is displayed on the Control Module screen.

2. Press and at the same time to erase the Inventory Test totals from Control Module memory.

Chapter 9: Inventory Test


EXP-800 NI Chapter 10: Battery Test

Test Procedure

The Battery Test lets you test the condition and state-of-health of a battery either in or out of a vehicle. Re-view the instructions in Chapter 3: Test Preparation before beginning this test.

IMPORTANT: When you start a new test, the last test results in memory are overwritten. Remember to re-cord or print the results if you need to retain them..

If you use the arrow keys to select option buttons and press NEXT to continue to the next step.

1. In the Main Menu, highlight the Battery Test icon and press NEXT.


NOT AVAILABLE

AVAILABLE




200SX

240SX

300ZX

350Z



For Nissan/Infiniti vehicles with the original battery: For models with more than one original battery size available, you may be prompted to select from a list of available options. Use or to highlight the correct option and press NEXT to continue.




500 CCA






Chapter 10: Battery Test


EXP-800 NIChapter 10: Battery Test



Use the or key to scroll to each screen. To return to the Main Menu, press END.

Battery decision

Measured voltage

Selected rating

Battery temperature

Measured rating

State of Health (SOH)The battery’s state of health represents its general condition, and therefore its ability to deliver the specified 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 finally 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.



GOOD–RECHARGE

Fully charge the battery and return it to service.

GOOD-MARGINAL

The battery may fail under extreme climate conditions. A MARGINAL 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.

CHARGE REQUIRED

Fully charge the battery using a Midtronics Diagnostic Charger and retest. Failure to fully charge the battery before retesting may cause false readings. If CHARGE REQUIRED appears again after you fully charge the battery, replace the battery.

REPLACE BATTERY

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

BAD CELL–REPLACE

Replace the battery.WARNING: Do not charge the battery. Charging a battery with one or more bad cells could cause an explosion and serious harm to the user.

24 VOLT BATTERY


Notes:

When testing at remote posts, the analyzer may need to verify a possible REPLACE result. It will give you the option of retesting at the battery posts.

When testing at side posts, the analyzer may find that the data is inconclusive and instruct you to test with side post adapters.


EXP-800 NI Chapter 11: System Test

The System Test includes the option of using an amp clamp. Under this mode, a Starter Test provides a di-agnosis of the vehicle’s electrical system.

You also have the option of viewing or printing the results at the end of each test, or at the end of the entire test sequence.

IMPORTANT: Battery test code, starter code and charge code are only provided at the end of a com-plete system test.

Battery TestBefore beginning the STARTER TEST the system will guide you through a battery test first.

1. In the Main Menu, highlight the SYSTEM TEST icon and press NEXT.


NOT AVAILABLE

AVAILABLE




200SX

240SX

300ZX

350Z



For Nissan/Infiniti vehicles with the original battery: For models with more than one original battery size available, you may be prompted to select from a list of available options. Use or to highlight the correct option and press NEXT to continue.




500 CCA





Chapter 11: System Test


EXP-800 NIChapter 11: System Test




Screen 1 of 2

Measured voltage

Measured capacity

Selected rating

Temperature

Battery decision

Screen 2 of 2





CHARGE REQUIRED


REPLACE BATTERY


24 VOLT BATTERY




2. The GR8 will display 1 of 9 starter decisions with the com-plete results in a series of screens similar to those shown on the right. Use the or key to scroll to each screen.



Starter System Test ResultsScreen 1 of 2




Screen 2 of 2


cranking voltage

X axis = Time



CRANKING NORMAL


LOW CRANKING AMPS


LOW VOLTAGE

The starter voltage is low and the battery is fully charged.

CHARGE BATTERY


REPLACE BATTERY



EXP-800 NI Chapter 11: System Test



CRANKING SKIPPED


SIDE POST TEST


JUMP START POST






















Screen 1 of 3


at rev

Loads-off current at

rev if amp clamp

is used

Loads-on DC voltage

at revLoads-on current at

rev if amp clamp

is used

Screen 2 of 3



within normal


Screen 3 of 3

Graph of diode

waveform


NOTE: After the Charging System Test is complete the resulting printout will contain all relevant test codes for the entire SYSTEM TEST process. All results screens will then be shown on the tester.


EXP-800 NIChapter 11: System Test


Charging System

DecisionAction


NO VOLTAGE 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








The regulator controls voltage output based on the battery voltage, under-hood temperature, and vehicle loads used. In other words, it controls the maximum voltage the system can produce based on the current needs and amount of current that can be produced by the spinning of the rotor in the alternator. The normal high limit of a typical automotive regulator is 14.5 volts +/–0.5. Refer to the manufacturer specifications for the correct limit, which may vary by vehicle type.A high charging rate will overcharge the battery and may decrease its life and cause it to fail. If the battery test decision is REPLACE and the charging system test shows a HIGH OUTPUT, check the battery’s electrolyte levels. A symptom of overcharging is battery fluid spewing through the vent caps, which causes low electrolyte levels and will harm the battery.

Diode Decisions


EXCESSIVE RIPPLE

One or more diodes in the alternator are not functioning or there is stator damage, which is shown by an excessive amount of AC ripple current supplied to the battery.√ Make sure the alternator mounting is sturdy and that the belts are in good shape and functioning properly.




SHORTED DIODE



EXP-800 NI Chapter 12: 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 View Menu enables you to view and print the results of the Battery, System, and Cable Drop Tests before you perform another test and overwrite the results in memory. Check-In and Customer Delivery test results are also overwritten every time a test is performed.

View Test

VIEW TEST BATTERY gives you the option of viewing and printing the results of the Battery and System Tests. Press END to return to the Main Menu.

1. To print the results select PRINT.


1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS

The test results are now printed out. To abort the printout press END.

Totals

TOTALS gives you the option of viewing the results of tester and charger tests in several different 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 specific totals you want to view and press NEXT.

1 DAILY

2 MONTHLY

3 PREVIOUS MONTH

4 TOTALS

5 SYSTEM



1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS

The test result screens are now printed out. To abort the printout press END.

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. Press END to return to the Main Menu.

Check-In

CHECK-IN lets you view the results from the last new vehicle Check-In test including the test code. Results from previous tests are not saved and are therefore not viewable. Press END to return to the Main Menu.

Chapter 12: Info Menu


EXP-800 NIChapter 12: Info Menu



1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS


View Inventory

This report displays and prints the results for an in-dividual battery or for all batteries tested using the Inventory Test (see Chapter 10: Inventory Test). Press END to return to the Main Menu.

1. For individual battery test results, use or to scroll to the specific Inventory Test result screen you want to print.

2. Select the PRINT key.

3. Use or to select INVENTORY PRINT.

1 BATTERY

2 SUMMARY


1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS

The Inventory Test results are now printed out.

5. To print additional copies press PRINT. Press END to re-turn to the Main Menu.

Customer Delivery

CUSTOMER DELIVERY lets you view the latest test re-sult from the last customer delivery test performed including the test code. Press END to return to the Main Menu.



1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS


Version

VERSION displays the software version loaded into the tester, the date the software was released, and the serial number of the control module. You can also print the information. Press BACK to return to the Info menu.

1. Use or to highlight the VERSION icon and press NEXT. The VERSION INFO screen is displayed.

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



1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS



EXP-800 NI Chapter 13: Admin Menu

Chapter 13: Admin Menu

The Admin Menu has several utilities that customize the tester. From the language of the user interface to the contrast of the text on the display. The utili-ties here have default settings that you can change, depending on your requirements. The most impor-tant function is the ADMIN (administrative) function, which controls user access.

Setup Function Default Settings

CLOCKMODE

TIME

FORMAT

AM/PMThe current Central Standard TimeMM/DD/YYYY (month/day/year)

SHOP Generic header for printouts with 12 lines of text and a maximum of 17 characters per line.

USERS USER 1 through USER 8 are placeholder IDs used to create user names.

DISPLAYCONTRAST LEVEL

BACKLIGHT TIME

Range: 0 (lightest) to 10 (darkest). The default is set at 9.Range: 0 to 60 seconds. The default is set at 15 seconds.

TEMPERATURE DEGREES F (Fahrenheit)

LANGUAGE English (French-Canadian and Spanish are available). The language can also be selected at startup.

ADMINOPTIONS

1-USER ID

2-PRINTER HEADER

3-ADMIN PIN

User login screen enabled (ON)Prints address header (OFF)Administrator PIN enabled (OFF)

Clock The CLOCK ADJUST utility has three settings. Use the or key to highlight the setting you want to change.

Although the time has been set at the factory, you may want to make adjustments based your time zone or Daylight Saving Time. The actual date cannot be changed.

MODE : AM/PMTIME : 9:07 AMFORMAT : /MM/DD/YYYY

NOTE: The tester date is preset and cannot be adjust-ed in the field.

ModeUse the or key to move the dot to the option button of your choice (1 or 2).

1. Select the or 24-hour or 12-hour (AM/PM) clock.

1 24 HOUR

2 AM/PM

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

Time

IMPORTANT: Incorrectly adjusting the tester clock can invalidate battery warranty claims.

1. Use the or keys to highlight the hour, minutes, or AM or PM. To rapidly scroll, hold down an or key.

9 : 19 PM

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

FormatUse the or to move the dot to the option button of your choice (1 or 2).

1. Select the format of the date.

1 MM/DD/YYYY (month/day/year)

2 DD/MM/YYYY (day/month/year)

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

Shop

The SHOP utility allows you to create a header for your printed test results with your business location information when the Admin option 3-PRINT HEADER is selected.

You can create your own header or load one from a data card. If you choose to create your own, use the template in Appendix A at the back of this manual to lay everything out before entering it into your tester.

1. Select MANUAL EDIT and press NEXT.

1 MANUAL EDIT

2 DATA CARD


EXP-800 NIChapter 13: Admin Menu

2. The first SHOP INFO screen is displayed.

1–YOUR SHOP NAME

2–ADDRESS

3–ADDRESS

4–ADDRESS

Three information screens contain 12 lines of text with a maximum of 17 characters per line.

Screen 1 Screen 2 Screen 31–YOUR SHOP NAME 5–ADDRESS 9–ADDRESS

2–ADDRESS 6–ADDRESS 10–ADDRESS

3–ADDRESS 7–ADDRESS 11–PHONE NUMBER

4–ADDRESS 8–ADDRESS 12–WEBSITE

Press or to highlight the line you want to change and press SELECT.

3. A six-row alphanumeric character map is displayed below the line you want to change.

YOUR SHOP NAME0 1 2 3 4 5 6 7 8 9


! “ # $ % & ‘ ( ) * +, - . / : ; < = > ? @

BACKSPACE

NOTE: Due to the size of the tester screen only four rows of the character map can be displayed at one time. To view the hidden rows of the char-acter map use or to scroll the character map up or down.


4. Press SAVE to save your edited line and return to the SHOP INFO screen. Repeat the process to edit the addi-tional lines of your shop information.

Users

The USERS utility allows you to create and edit up to eight USER ID’s that are linked to the individual test counters. You can also delete a USER ID and its associ-ated test total.

Creating A New User ID1. From the Admin Menu highlight the USERS icon and press

SELECT.

2. Use or to select ENTER NEW.

1 ENTER NEW

2 DELETE

3 EDIT

Press NEXT to continue.

3. A list of user placeholders are displayed.

1 USER 12 USER 23 USER 34 USER 45 USER 56 USER 67 USER 78 USER 8

Use or to scroll to a specific placeholder ID. Scrolling up from the first line or down from the last line displays the next screen of placeholders. You can also use the or key to jump up or down through the list four lines at a time.

Highlight the line you want to change and press SELECT.


YOUR SHOP NAME0 1 2 3 4 5 6 7 8 9


BACKSPACE



Deleting A User ID

NOTE: You cannot delete placeholder text (i.e., USER01, USER02, USER03).

1. Use or to select DELETE.

1 ENTER NEW

2 DELETE

3 EDIT



EXP-800 NI Chapter 13: Admin Menu

2. Use or to select a USER ID you want to delete.

1 RYAN

2 TOM

3 GREG

4 USER 4

Press DELETE to continue.

3. Press YES to confirm the deletion.

Editing a User IDThis function can also be used to change a USER PIN.

1. Use or to select EDIT.

1 ENTER NEW

2 DELETE

3 EDIT


2. Use or to select a USER ID you want to edit.

1 RYAN

2 TOM

3 GREG

4 USER 4

Press SELECT to continue.

3. To clear the characters, press the key. To add a space, move the cursor forward by pressing the key.

ENTER USER ID

RYAN

Press SAVE.


RYAN0 1 2 3 4 5 6 7 8 9


BACKSPACE



Display

The LCD OPTIONS utility allows you to adjust the con-trast of the text on the display and the backlight time.

Contrast LevelThe contrast level is 0 (lightest) to 10 (darkest). To change it:

1. Press the or key to highlight the option.

CONTRAST LEVEL 10BACKLIGHT TIME 60

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

9 (1-10)

3. Press the or key to select your preference. To erase a character, press the key.

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

Backlight TimeBacklight time is from 0 to 60 seconds. To change it:

1. Press the or key to highlight the option.

CONTRAST LEVEL 10BACKLIGHT TIME 60

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

15 SEC

3. Press the or key to select your preference. To erase a character, press the key.

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

Temp

The TEMP. UNITS utility allows you to set the units of measurement to either Fahrenheit or Celsius. To set your preference:

1. Use the or key to move the dot to the option button of your choice (1 or 2).

1 DEGREES F

2 DEGREES C

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


EXP-800 NIChapter 13: Admin Menu

Language

The LANGUAGE utility allows you to select a language for the display and printouts. You can override the se-lection when the tester displays the language option after you turn it on or print results.

To set your preference:

1. Use the or key to move the dot to the option button of your choice (1, 2, or 3).

1 ENGLISH

2 ESPAÑOL

3 FRANÇAIS

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

Admin

This section explains how to use the Admin to control User ID access to the tester. It also describes functions that clear test totals and restore settings to factory de-faults.

Select the ADMIN icon to display a list of administrative functions:

1 OPTIONS

2 CHANGE ADMIN PIN

3 CLEAR TEST TOTALS

4 RESET DEFAULTS

OptionsIn the OPTIONS section there are four functions that allow you to control user access to the Main Menu and Admin 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 – PRINTER HEADER

Select this setting to enable (ON) printing the address header on the printout

3 - LANGUAGE

Select this option to disable the language question each time the analyzer is turned on.

4 – ADMIN PIN

Select this setting to enable (ON) password protection for ADMIN mode

Change Admin PINUsing the arrow keys, this function allows users with Administrative rights to create or change their 2 digit PIN.

Clear Test TotalsThis function allows you to clear the test totals by User ID and battery test decision. The analyzer verifies 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 DefaultsSelecting Reset Defaults will reset Admin Options to their original preset defaults. All registered users will be cleared.

Format Disk

Select this utility to format an data card to receive data or erase all data on the card. The analyzer will warn you before formatting the disk and ask if you want to continue.

Update

When software updates become available for the tes-ter, this utility lets you quickly update the internal soft-ware using an SD-type data card.

Logos

This utility allows you to select logos that will appear at the top of your printed test results.


EXP-800 NI Chapter 14: Maintenance & Troubleshooting

Printer PaperThe internal printer is shipped with a roll of thermal printing paper installed in the paper compartment. The roll size is 2¼ inches wide by 17/8 inch in diameter.

The analyzer uses only thermal printing paper which is available at most office supply stores. The following are three major stores that carry the recommended paper:

Store Part Number PhoneOffice Depot 209-653-271 800-463-3768

Office Max 20121146 800-283-7674

Quill 856607 800-789-1331

Replacing Printer Paper1. Unlock the printer door by gently pressing down on the

red lever.

2. Lift the printer door and remove the spent roll.Push the lever in this direction

Paper sensor

3. Place a new roll of paper in the compartment. As the diagram in the paper compartment indicates, the paper feeds from the bottom of the roll.

4. Pull the paper forward so that it extends past the serrated edge of the paper slot.

5. Close the door and make sure the lever locks securely. For a clean tear, pull the paper along the serrated edge. Do not pull the paper straight out of the printer.

Problems with the Internal PrinterThe internal printer will not print

• Theanalyzermustbeconnectedtothevehiclebatterytoprint to the internal printer. Check the clamp connections to the battery.

• Thevehiclebatterymaybetoolowtopowertheprinter.Connect to a battery with at least 11.5 volts.

• Verifythatthepaperisproperlyinstalled.

• Verifythatthepapersensoriscleanandundamaged.

Test Cable MaintenanceThe test cables that come with your analyzer are consumable items. Cables are like tires in that the more you use them and the harder you drive them, the shorter their useful life. Here are a few things you can do to protect your test cables from damage and premature wear:

Cleaning the Clamps• Thegrease,dirt,andsulfationthatbuilduponbatteryter-

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 bat-tery 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.

• Toprotecttheclampsfromoilanddirt,clipthemtotheback of the analyzer as shown.

Chapter 14: Maintenance & Troubleshooting


EXP-800 NIChapter 14: Maintenance & Troubleshooting

Handling the Test Cables• Alwaysconnectanddisconnecttheclampstothebattery

by opening and closing the clamps. Never pull on the test cables to remove the battery clamps. Pulling can damage the Y-junction, the cables, and the clamps to the extent that the analyzer may produce lower-than-expected con-ductance readings or fail completely.

• Nevercarrytheanalyzerbythecables.Carryingtheana-lyzer or swinging it by the cables puts unnecessary strain on the cables and can result in premature failure. Handle the analyzer with care to get the maximum use from the product.

Storing Test Cables• Never wrap the cables around the analyzer; this puts un-

necessary strain on the test cables.

Because the test cables are the “tires” of the analyzer, they have a certain life expectancy and will wear out eventually. However, the abuse examples cited above are not covered under warranty. To ensure the best performance and longest life of the test cables, attach and remove them with care, and carry the analyzer and cables together.

If an inspection or a change in test results indicate that the test cables need to be replaced, please call Midtronics Customer Service at 1-800-776-1995.

Testing Resistance in the Cable SetIf the analyzer frequently displays CHECK CLAMP CONNECTION! you may have an intermittent open circuit along one or both of the battery test cables. You can check the circuit with a simple test. The test requires an ohmmeter and a wire or paper clip if the ohmmeter probes are too large to insert into the pin holes. You will also need to a pencil or plastic marker to keep the clamp jaws apart.

Test ProcedureYou are testing the continuity of the following end points:

• Thepositive(REDclampjawwithoutteethanditscorre-sponding pin hole.

• The positive (RED) clamp jaw with teeth and its corre-sponding pin hole.

• Thenegative(black)clampjawwithoutteethanditscor-responding pin hole.

• Thenegative (black)clamp jawwithteethand itscorre-sponding pin hole.

1. Grip a pencil with the clamp as shown in the figure Con-tacts for Clamp Jaws. Do not grip the metal part of the eraser or any area that may conduct current.

2. Insert a probe tip into the hole designated “NO TEETH” for the color (BLACK or RED) of the clamp you are testing as shown in the figure “Contacts for Cable Connector.”

3. Touch the toothless jaw of the clamp with the other probe tip. Wiggle the battery test cables. The resistance reading should be less than 11Ω.

4. Repeat the test for the “TEETH” side of the circuit, this time touching the jaw with teeth. Insert the other probe tip into the “teeth” pin hole. Wiggle the battery test cables. The resistance reading should be less than 11 Ω.

In addition to the troubleshooting suggestions in this chapter, the tester Help Menu provides tips on troubleshooting problems with the printer, the cables, and loss of power. It also includes Midtronics customer service phone numbers.

Contacts for Cable Connector

Orientation of arrow on cable

connector

BLACK clamp, NO TEETH

RED clamp, NO TEETH

RED clamp, TEETH

BLACK clamp, TEETH

Contacts for Small Clamp

Contact point for testing at NO TEETH

Contact point for testing at TEETH


EXP-800 NI Chapter 14: Maintenance & Troubleshooting

Internal BatteriesThe tester uses six AA, 1.5-volt batteries (alkaline recommended) to allow testing of batteries down to 1 volt and supply power while the menu is active.

Power IndicatorThe 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 vehicle

battery

Decreasing Low

Replacing The Internal Batteries1. Turn the analyzer face down.

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

Remove the screw and lift the tab

3. Lift the door at the tab and place it aside.

4. Remove the discharged batteries.

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

6. Reposition the door on the battery compartment.

7. Reinsert and tighten the screw.

Problems with the DisplayThe display does not turn on:

• Checktheconnectiontothebattery.

• Theanalyzer’sinternalbatteriesmayneedtobereplaced.

The display flickers or is dim:

• ThecontrastmayneedtobeadjustedintheAdminMenu.Highlight the Display icon and press ENTER. Use or to scroll the contrast value to 10.

• Theanalyzer’sinternalbatteriesmayneedtobereplaced.


EXP-800 NIAppendix A

Shop Header TemplateTo help you edit and center your coupon, use the template below to lay out your shop information below before entering it into your battery tester.

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Appendix A

PATENTSThe EXP-800 NI is made by Midtronics, Inc., and is protected by one or more U.S. and foreign patents. For specific patent information, contact Midtronics, Inc. at +1 630 323-2800.

LIMITED WARRANTYThis analyzer is warranted to be free of defects in materials and workmanship for a period of two years from date of purchase. EXP-800 cables are warranted to be free of defects in materials and workmanship for a period of one year from date of purchase. Midtronics will, at our option, repair or replace the unit with a remanufactured unit. This limited warranty applies only to the EXP-800 analyzer, and does not cover any other equipment, static damage, water damage, overvoltage damage, dropping the unit, or damage resulting from extraneous causes including owner misuse. Midtronics is not liable for any incidental or consequential damages for breach of this warranty. The warranty is void if owner attempts to disassemble the unit or to modify the cable assembly.

SERVICETo obtain service, contact Midtronics for a Return Authorization number, and return the unit to Midtronics freight prepaid, Attention: RA# ________. Midtronics will service the analyzer and reship the next scheduled business day following receipt, using the same type carrier and service as received. If Midtronics determines that the failure was caused by misuse, alteration, accident, or abnormal condition of operation or handling, purchaser will be billed for the repaired product and it will be returned freight prepaid with freight charges added to the invoice. Battery analyzers beyond the warranty period are subject to the repair charges in effect at that time. Optional remanufacturing service is available to return the tester to like-new condition. Out-of-warranty repairs will carry a 3-month warranty. Remanufactured units purchased from Midtronics are covered by a 6-month warranty.

167-006EN-D 5/11 ©2011 Midtronics, Inc. All rights reserved.

exp-800 ni · exp-800 analyzer, and does not cover any other equipment, static damage, water...

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