Midtronics WALMART GR8-1150 User manual
,167587,21018/
June 2009
168-716C
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1.1 WORKING IN THE VICINITY OF A LEAD-ACID BATTERY
IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE
GASES DURING NORMAL BATTERY OPERATION, AND
WHEN DISCHARGED OR CHARGED. FOR THIS REASON,
IT IS OF UTMOST IMPORTANCE THAT BEFORE USING
YOUR CHARGER, YOU READ THIS MANUAL AND FOL-
LOW THE SAFETY AND OPERATING INSTRUCTIONS EX-
ACTLY.
1.2 To reduce risk of battery explosion, follow these safety in-
structions and those published by the battery manufac-
turer and the manufacturer of any equipment you intend
to use in the vicinity of a battery. Review cautionary mark-
ing on these products and on the engine, and on the ve-
hicle or equipment containing the battery.
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rechargeable ooded-type batteries including
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If you are uncertain as to the type of battery you are at-
tempting to charge, or the correct procedure for checking
the battery’s state of charge, contact the seller or battery
manufacturer.
1.3 Use of an attachment not recommended or sold by the
battery charger manufacturer may result in a risk of re,
electric shock, or injury to persons.
1.4 To reduce risk of damage to the electric plug and cord,
pull by the plug rather than by the cord when disconnect-
ing the charger.
1.5 Position the AC and DC leads to avoid tripping over them
and to prevent damage by hood, doors, or moving engine
parts; protect from heat, oil, and sharp edges.
1.6 Do not operate the charger if it has received a sharp blow,
been dropped or otherwise damaged in any way; take it
to a qualied service center.
1.7 Do not disassemble charger; take it to a qualied service
center when repair is required. Incorrect reassembly may
result in a risk of electric shock or re.
1.8 To reduce risk of electric shock, unplug the charger from
the AC outlet before attempting any maintenance or
cleaning. Turning o the controls will not reduce this risk.
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1.9 Connect and disconnect the battery leads only when the
AC supply cord is disconnected.
1.10
Do not overcharge the battery. (See sections 3 and 10 in
the safety instructions)
1.11
Charge the battery in a dry, well-ventilated area.
1.12
Never place articles on or around the charger, or locate
the charger in a way that will restrict the ow of cooling
air through the cabinet.
1.13
An extension cord should not be used unless absolutely
necessary. (See paragraph 4.3.)
1.14
Have a damaged cord or plug replaced immediately.
1.15
Do not expose the charger to rain or snow.
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2.1 Always have someone within range of your voice, or close
enough to come to your aid, when working around lead
acid batteries.
2.2 Have plenty of fresh water and soap nearby in case battery
acid contacts skin, clothing or eyes.
2.3 Wear complete eye protection, clothing protection, and
wear rubber soled shoes. Place damp cloth over battery
to protect against acid spray. When ground is very wet or
covered with snow, wear rubber boots. Avoid touching
eyes while working near battery.
2.4 If battery acid contacts skin or clothing, wash immediately
with soap and water. If acid enters the eye, immediately
ush with cold running water for at least 10 minutes, and
seek medical attention.
2.5 NEVER smoke or allow a spark or ame in vicinity of a bat-
tery or engine.
2.6 Be extra cautious to reduce risk of dropping a metal tool
onto the battery. It might spark or short circuit the battery
or other electrical part that may cause an explosion.
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2.7 Before working with a lead-acid battery, remove personal
metal items such as rings, bracelets, necklaces, watches,
etc. A lead-acid battery can produce a short circuit current
high enough to weld such items causing a severe burn.
2.8 CAUTION: TO REDUCE THE RISK OF INJURY, CHARGE
ONLY RECHARGEABLE LEADACID TYPE BATTERIES,
WHICH MAY INCLUDE MAINTENANCEFREE, LOW
MAINTENANCE, OR DEEPCYCLE BATTERIES. OTHER
TYPES OF BATTERIES MAY BURST CAUSING PERSON
AL INJURY AND DAMAGE.
The charger is not intended to supply power to a low-
voltage electrical system other than applications using
rechargeable, lead-acid type batteries. Do not use the
battery charger for charging dry-cell batteries commonly
used with home appliances. These batteries may burst
and cause personal injury and property damage.
2.9 NEVER charge a frozen battery; thaw it out rst.
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3.1.
If it is necessary to remove the battery from vehicle to
charge it, always remove the grounded terminal from the
battery rst. Make sure all accessories in the vehicle are o,
so as not to cause an arc.
3.2.
Be sure the area around the battery is well ventilated while
the battery is being charged. Gas can be forcefully blown
away by using a piece of cardboard or other nonmetallic
material as a fan.
3.3
Clean the battery terminals. Be careful to keep corrosion from
coming into contact with your eyes.
3.4 Add distilled water in each cell until the battery acid
reaches the level specied by the manufacturer. This helps
purge excessive gas from the cells. Do not overll. For a
battery without caps, carefully follow the manufacturer’s
recharging instructions
3.5 Study all battery manufacturer’s specic precautions such
as removing or not removing cell caps while charging and
recommended rates of charge.
3.6 Determine the voltage of the battery by referring to the
car owner’s manual and make sure that the output voltage
selector switch is set at the correct voltage. If the charger
has an adjustable charge rate, charge the battery initially
at lowest rate. If the charger has only one voltage, verify
that the battery voltage matches the voltage of charger.
For a charger not having an output voltage selector
switch, determine the voltage of the battery by referring
to car owner’s manual and make sure it matches the
output rating of the battery charger.
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4.1 The charger must be grounded to reduce risk of electric
shock. The charger is equipped with an electric cord hav-
ing an equipment grounding conductor and a ground-
ing plug. The plug must be plugged into an outlet that is
properly installed and grounded in accordance with all lo-
cal codes and ordinances.
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To avoid electrical shock or burn, never alter
the charger’s original AC cord and plug. Dis-
connect plug from outlet when charger is idle.
4.2 This battery charger is for use on a nominal 120-volt cir-
cuit and has a grounding plug that looks like the plug
illustrated in Figure A. A temporary adapter, which looks
like the adapter illustrated in Figures B and C, may be used
to connect this plug to a two-pole receptacle as shown in
Figure B, if a properly grounded outlet is not available. The
temporary adapter should be used only until a properly
grounded outlet can be installed by a qualied electri-
cian.
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Before using an adapter be certain the center
screw of the outlet plate is grounded. The rigid
ear or lug extending from the adapter must be
connected to a properly grounded outlet. Make
certain it is grounded. If necessary, replace the
original screw that secures the adapter ear or
lug to the cover plate and make the ground
connection to the grounded outlet.
USE OF AN ADAPTER IS NOT ALLOWED IN CANADA. IF A
GROUNDING-TYPE RECEPTACLE IS NOT AVAILABLE, DO
NOT USE THIS APPLIANCE UNTIL THE PROPER OUTLET IS
INSTALLED BY A QUALIFIED ELECTRICIAN.
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4.3 An extension cord should not be used unless absolutely
necessary. Use of an improper extension cord could result
in a risk of re and electric shock. If an extension cord must
be used, make sure:
a. that the pins on plugs of the extension cord are the same
number, size, and shape as those of the plug on the char-
ger;
b. that the extension cord is properly wired and in good
electrical condition;
c. that the wire size is large enough for the AC ampere rating
of charger as specied in the following table.
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5.1 Locate the charger as far away from the battery as the
charger cables permit.
5.2 Never place the charger directly above the battery being
charged; gases from the battery will corrode and damage
the charger.
5.3 Never allow battery acid to drip on the charger when tak-
ing gravity readings or lling a battery.
5.4 Operate the charger only in a well-ventilated area that is
free of dangerous vapors.
5.5 Store the charger in safe, dry location and maintain it in
perfect condition.
5.6 Do not set the battery on top of the charger or where its
acid might drip onto the charger.
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6.1 All switches should be set in the OFF position and AC cord
should be DISCONNECTED from electrical outlet before
you connect and disconnect the charger clamps. Never al-
low the clamps to touch each other.
6.2 When attaching the charger clamps, be certain to make
the best possible mechanical as well as electrical connec-
tion. This will tend to prevent the clamps from slipping o
the connections, avoid dangerous sparking, and assure
safer and more ecient charging. The clamps should be
kept clean.
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Setting the switches to “OFF” does
not always disconnect the charger
electrical circuit from the AC power
cord or the DC charger clamps.
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7.1 Before working on the vehicle, rmly apply the emergency
brake and place the gear shift to NEUTRAL—shift an auto-
matic transmission to PARK.
7.2 Locate the charger as far away from the battery as the
charger cords permit and position the AC and DC cords to
avoid stepping on or tripping over them and to prevent
damage by hood, doors, or moving engine parts.
7.3 Stay clear of fan blades, belts, pulleys, and any other parts
that can cause physical injury.
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7.4 Turn OFF all vehicle loads, including door lights, and cor-
rect any defects in the vehicle’s electrical system that may
have caused low battery.
7.5 Check the polarity of the battery posts. The POSITIVE
(POS., P, +) post usually has a larger diameter than the
NEGATIVE (NEG., N,–) post.
7.6 Determine which post of the battery is grounded (connect-
ed) to the chassis. If the negative post is grounded (as in most
vehicles), see paragraph 7.7. If the positive post is grounded,
see paragraph 7.8.
7.7 For a negative-grounded vehicle, rst connect the POSI-
TIVE (RED) clamp from the charger to the POSITIVE (POS.,
P, +) ungrounded post of the battery. Then connect the
NEGATIVE (BLACK) clamp to the vehicle chassis or engine
block away from the battery. Do not connect the clamp to
the carburetor, fuel lines, or sheet-metal body parts. Con-
nect to a heavy-gauge metal part of the frame or engine
block. When disconnecting the charger, turn all switches
to OFF, disconnect the AC cord, remove the clamp from
the vehicle chassis, and then remove the clamp from the
battery terminal.
7.8 For positive-grounded vehicle, connect the NEGATIVE
(BLACK) clamp from the charger to the NEGATIVE (NEG.,
N, –) ungrounded post of battery. Then connect the POSI-
TIVE (RED) clamp to the vehicle chassis or engine block
away from the battery. Do not connect clamp to carbu-
retor, fuel lines, or sheet-metal body parts. Connect to a
heavy gauge metal part of frame or engine block.
When disconnecting the charger, turn the switches to
OFF, disconnect the AC cord, remove the clamp from
the vehicle chassis, and then remove the clamp from the
battery terminal.
CAUTION: WHEN POSITIVE (+) POST OF VEHICLE
BATTERY IS GROUNDED, DOUBLE CHECK POLARITY.
8. FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED
IS OUTSIDE OF THE VEHICLE. A SPARK NEAR THE BATTERY
MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK
OF A SPARK NEAR THE BATTERY:
If it is necessary to remove the battery from the vehicle or
equipment, always remove the grounded terminal from
the battery rst.
WARNING: Make sure all vehicle loads are OFF to prevent a
possible arc.
8.1 Check the polarity of battery posts. POSITIVE (POS., P, +)
post usually has larger diameter than NEGATIVE (NEG., N,
–) post.
8.2 Attach at least a 60 cm (24-inch), 6-gauge insulated battery
cable to the negative (–) battery terminal.
8.3 Connect the POSITIVE (RED) charger clamp to the POSI-
TIVE (POS., P, +) post of battery.
8.4 Position yourself and the free end of cable as far away from
the battery as possible—do not face the battery when
making the nal connection—then connect the NEGA-
TIVE (BLACK) charger clamp to the free end of the cable.
8.5 When disconnecting the charger, always do so in the re-
verse sequence of the connecting procedure; break the
rst connection while staying as far away from the battery
as practical.
8.6 MARINE “BOAT” BATTERIES MUST BE REMOVED AND
CHARGED ON SHORE. TO SAFELY CHARGE THEM ON
BOARD REQUIRES EQUIPMENT ESPECIALLY DESIGNED
FOR MARINE USE.
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For safe, ecient, and accurate charging and testing, review
the safety and operating instructions in this manual before
using the Battery Diagnostic Station. In addition, follow
all manufacturers’ instructions and BCI (Battery Council
International) safety recommendations.
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Inspect the battery for damages and check the electrolyte level.
If the electrolyte level is too low, replenish it and fully charge
the battery. Always use the necessary safety precautions when
working with batteries to prevent severe injury or death.
Follow all manufacturers’ instructions and BCI (Battery Council
International) safety recommendations, which include the
following precautions:
DANGER—RISK OF EXPLOSIVE GASES: Batteries can pro-
duce a highly explosive mix of hydrogen gas and oxygen,
even when the battery is not in operation. Always work
in a well-ventilated area. Never smoke or allow a spark or
ame in the vicinity of a battery.
WARNING—REQUIRED BY CALIFORNIA PROP. 65: Bat-
tery posts, terminals, and related accessories contain lead
and lead compounds, chemicals known to the state of
California to cause cancer and birth defects or other re-
productive harm. Wash hands after handling.
Battery acid is highly corrosive. If acid enters your eyes, im-
mediately ush them thoroughly with cold running water
for at least 15 minutes and seek medical attention. If bat-
tery acid gets on your skin or clothing, wash immediately
with a mixture of water and baking soda.
Always wear proper safety glasses or face shield when
working with or around batteries.
Keep hair, hands, and clothing as well as the Battery Diag-
nostic Station cords and cables away from moving engine
parts.
Remove any jewelry or watches before you start servicing
the battery.
Use caution when working with metallic tools to prevent
sparks or short circuits.
Never lean over a battery when testing, charging, or jump
starting.
Never charge a frozen battery. Gases may form, cracking
the case, and spray out battery acid.
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To assemble the cart refer to “Instruction Sheet: Midtronics
Battery Testing Cart” and “Midtronics Battery Testing Cart
Assembly Instructions: Change to Accommodate New GR
Charge Engine” included with your shipment. The Battery
Diagnostic Station is shipped with the control module,
mounting bracket and hardware with the cables packed
separately. For easy assembly, follow these steps:
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1. Center the three holes in bottom mounting bracket over
the holes on the top of the cart. Insert the three 5/16-inch
hex-head bolts into the holes and tighten the bolts se-
curely.
2. Attach the upper mounting bracket to the bottom bracket
with the three Phillips screws as shown the illustration be-
low.
3. The upper part of the bracket has four pre-installed bolts
at each corner for mounting the control module.
4. Center the holes on the bottom of the control module with
the bolts (circled), and lower the module onto the top of
the bracket. Firmly pull the module down at an angle (ar-
rows) until the bolts are inserted securely into the slots
extending from the module’s holes.
5. Place the Charge Engine with the attached Control Mod-
ule on the cart. Connect the serial cable between the Con-
trol Module and Charge Engine (circles) and tighten the
screws on each connector.
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The two connectors for the charger cables are located on
the back of the Battery Diagnostic Station. Three screws are
included to secure the cables. To attach the cables:
1. Plug in the large connector (A), then plug in the small con-
nector (B).
2. Slide the cover (C) down the cables until it seats against
the sheet metal.
3. Insert the screws (circles) through the holes in the cover
and sheet metal. Tighten the screws securely with a small
screwdriver. (To remove the cables, use the attachment in-
structions in reverse.)
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The controls to the Battery Diagnostic Station are accessible on the front of the Control Module and the GR Charge Engine.
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Control Module
Backlit graphical display and keypad for data entry. Provides
battery analysis and controls the charge session.
Integrated Printer
Thermal printer prints test results in either English, French-
Canadian, or Spanish
Data Card Slot
For future upgrades via a data card. The slot contains a
plastic ller card for protection.
Status Light
Lights in conjunction with beeping alarm to indicate
transitions and warnings.
Serial Cable Connection: Control Module
Connects the control Module to GR Charge Engine
GR Charge Engine
Provides charge current when needed, which is regulated
by the Control Module.
ON/OFF Switch
Turns power on and o to the Battery Diagnostic Station.
Diagnostic Charger Cables and Clamps
Feed the cables into the Battery Charging Compartment
though the slot in rear of the cart before connecting the
clamps to the battery posts. For long term storage, place
the cables in the empty compartment.
Battery Charging Compartment
Enclosed area for charging a battery safely.
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Connectors for the charger cables, serial cable, and power cord are on the back of the GR Diagnostic Charge Engine. The serial
number, which you will need in order to register the Battery Diagnostic Station, is on the back of the Control Module.
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Serial Number
On bottom of label; required for product registration.
Charger Cable Connectors
Serial Cable Connection: Charge Engine
Serial cable connection between the Charge Engine
and the Control Module.
AC power cord
Connection to grounded nominal 120 V outlet.
Cable wrap
For temporary storage of cables when not in use.
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The Battery Diagnostic Station display and keypad work together to help you quickly nd and use the right tools at the right
time. The display also keeps you on track with on-screen navigation aids, directions and messages. The illustration shows how
the elements on the screen relate to the keypad.
Voltmeter
When you rst connect the cables to a battery
the Control Module functions as a voltmeter. The
voltage reading appears above the left soft key
until you start to use 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.
ARROW keys
Press the ARROW keys to scroll to numerical
values and move to menus and icons
POWER
Key
Press the POWER key to turn on the Battery
Diagnostic Station and stop (abort) a charging
session.
Title Bar
The title bar shows you the name of the current
menu, test tool, utility, or function.
Selection Area
The selection area below the Title Bar contains
selectable items or dialog boxes that display
information or require a response.
Menu Screen Arrows
When displayed in menu screens, the menu
screen arrows show you which ARROW key on
the keypad to press to display other icons or
screens. The Up and Down Menu Screen Arrows,
for example, indicate when to press the UP
( ) and DOWN ( ) ARROW keys to display the
screens above and below the current screen.
The Left and Right Menu Screen Arrows tell you
when to use the LEFT
( )
or RIGHT
( )
ARROW
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.
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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.
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Alphanumeric Keypad
In some cases, you can use the alphanumeric
keypad to enter numerical test parameters
instead of scrolling to them with the ARROW
keys.
You can also use the alphanumeric keys to create
and edit customer coupons and your shop
contact information on printed test results, and
manage User IDs.
To add a space, press the RIGHT ARROW key. To erase
a space and insert a character, press the LEFT ARROW
key.
Refer to the table below for the characters associated
with each alphanumeric key.
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M N O
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To perform a particular test or function, the Battery Diagnostic
Station requires dierent types of information. This means
that the methods you use to enter information will change
depending on the type of information requested. The six types
of entry methods are described below.
Typically, the soft key below the right half of the screen
conrms your choice, although the command above it may
vary. (Examples: SELECT, NEXT, and SAVE.) In a similar fashion,
the soft key below the left half of the returns you to the
previous screen or enables you to print results, although the
word above it may also vary. (Examples: BACK and PRINT.)
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A menu icon is a graphical
representation of a function
you can select, such as the
Diagnostic Icon in the Main
Menu. 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 conrm your selection, press the
appropriate soft key.
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Some lists have option buttons
before each item. To select an
item, use the UP ( ) or DOWN
( ) ARROW keys to move the
dot to the button next to the
item. To conrm your selection,
press the appropriate soft key.
You can also use the alphanumeric keypad to enter the
number preceding the option button of your choice. No
additional keypress is needed to proceed.
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Scrolling lists contain items that
extend above and below the
screen. The rst number above
the right soft key indicates
the position in the list of the
highlighted item. The second
number above the right soft key indicates the number of items
in the list.
To select an item, the UP ( ) or DOWN ( ) ARROW key to
highlight the item, and press the appropriate soft key.
To move the highlight bar up four lines at a time, press the
LEFT
( )
ARROW.
To
move the highlight bar down four lines at
a time,
press the
RIGHT
( )
ARROW key.
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Some selections require you to
use the alphanumeric keypad.
These “user-dened” selections
have a blinking horizontal line
(cursor) to the right of the last
character.
Use the UP or DOWN ARROW keys to highlight a line for
editing. Display the character, symbol, or number you want
by rapidly pressing its key as many times as needed. If you
pause, the cursor moves to the right. To backspace, press the
LEFT ARROW
key. Use the RIGHT ARROW key to add a space.
Use the UP/DOWN ARROW keys to highlight a line for editing.
When nished, press the appropriate soft key to save your
settings.
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Value boxes contain items
that extend above and below
the selection box that contain
them. To indicate that there are
more values, the symbols
appear to the right of the box.
To select, use the UP or DOWN ARROW key to scroll to the
value, or use the keypad to enter the value directly, and press
the appropriate soft key. In the illustration the left directional
arrow indicates that you can press the
LEFT ARROW key
to
clear all or part of the entry.)
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This section contains a graphical representation of the menu structure with brief descriptions of the utilities in each menu.
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The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons lead directly to the
function they represent, while others are menu icons that lead to two or more options. Menu icons marked with an asterisk (*)
are mapped on the following pages.
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Provides a list of topics and denitions. Also includes Midtronics Customer Service phone
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The Info Menu has utilities to allow you to view and print test results, track the usage and history of your Battery Diagnostic
Station, and manage test data.
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The Admin / Utility Menu lets you customize options in the user interface to suit your needs. Before using the Battery Diagnostic
Station for the rst time, check the default values to see what options you may want to change, add, or delete.
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Updates the software via les on a data card.
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The Admin / Utility Menu has several utilities that customize the user interface. The utilities have default settings that you can
change, depending on your requirements.
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The CLOCK ADJUST utility has four settings. Use the
UP or DOWN ARROW key to highlight the setting
you want to change. Although the date and time have
been set at the factory, you may want to make adjust-
ments based your time zone or Daylight Saving Time.
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Use the UP or DOWN ARROW key, or press the corresponding
numerical key (1 or 2) to move the dot to the option button of
your choice.
1. Select the or 24-hour or 12-hour (AM/PM) clock.
1
24 HOUR
2 AM/PM
2. If you used the ARROW keys, press the SAVE soft key to
save your setting or the BACK soft key to return to the
CLOCK ADJUST screen without saving the changes.
If you use the alphanumeric keypad to enter the number
preceding the option button, no additional keypress is
needed to save your selection.
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1. Use the LEFT or RIGHT ARROW keys to highlight the hour,
minutes, or AM or PM. To rapidly scroll, hold down an UP
or DOWN ARROW key.
30
2. Press the SAVE soft key to save your setting, or press the
BACK soft key to return to the CLOCK ADJUST screen.
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Use the UP or DOWN ARROW or press the corresponding
numerical key (1 or 2) to move the dot to the option
button of your choice.
1. Select the format of the date.
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
2. If you used the ARROW keys, press the SAVE soft key to
save your setting or the BACK soft key to return to the
CLOCK ADJUST screen without saving the changes.
If you use the alphanumeric keypad to enter the number
preceding the option button, no additional keypress is needed
to save your selection.
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1. Use the LEFT or RIGHT ARROW key to highlight the
month, day, or year. To rapidly scroll, hold down an UP or
DOWN ARROW key.
2. Press the SAVE soft key to save your setting or the BACK
soft key to return to the CLOCK ADJUST screen without
saving the changes.
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