Midtronics EXP-1003 HD User manual

INSTRUCTION MANUAL
September 2013
167-000505EN-A
EXP-1003 HD
Expandable Electrical
Diagnostic Platform
For testing 6- and 12-volt
heavy-duty, automotive,
and commercial batteries,
and 12-volt and 24-volt
charging systems.

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Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527
www.midtronics.com 3
EXP-1003 HD
Chapter 1: Introduction & Overview 5
Personal Precautions 5
Accessories 5
External Connections 6
Connecting The Battery Test Cable 6
Connecting An Accessory Cable 6
Data Card 6
Conventions Used in This Manual 6
Display And Keypad 7
Data Entry Methods 8
Menu Icons 8
Option Buttons 8
Scrolling Lists 8
Scroll Boxes 8
Alphanumeric Entry 8
Menu Maps 8
Main Menu 8
DMM Menu 9
Info Menu 9
Utility Menu 9
Print/View Menu 10
Logging In 10
Creating a User ID and Setting Preferences 10
Inspecting the Battery 10
Connecting to a Battery 10
Testing Individual Batteries 10
Testing Out-of-Vehicle (Battery Test) 11
Testing the Battery Pack 11
Initial Power-up 11
Chapter 2: Battery Test 12
Additional Test Requirements 12
System Noise Detected 12
Unstable Battery Detected 13
Deep Scan Test 13
Battery Test Results 13
Battery Test Results 13
Chapter 3: System Test 14
Auto/Van 14
Truck 15
Auto/Van Test Results 16
Auto/Van Test Decisions 16
Truck Test Results 17
Truck Test Decisions 17
Battery Pack Test Results 17
Battery Pack Decisions 17
Additional Test Requirements 18
System Noise Detected 18
Unstable Battery Detected 18
Starter System Test 18
Starter System Test Results 18
Charging System Test 19
Charging System Test Results 19
Chapter 4: Print/View 21
View Test 21
View Cable Test 21
Chapter 5: Cable Drop Test 22
Chapter 6: DMM (Digital Multimeter) 23
DC And AC Voltmeters 23
Scope 23
DC, AC, And Volts Ammeters 23
Temp 23
Ohmmeter 23
Diode 23
Chapter 7: Info 25
Totals 25
Lifetime 25
User Totals 25
Totals by Decision 25
Clear Counters 25
Transfer 25
Version 25
Contents

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EXP-1003 HD
Chapter 8: Utility 26
Clock 26
Mode 26
Time 26
Format 26
Date 26
Users 26
Entering A New User ID 26
Deleting A User ID 27
Editing A User 27
Shop 27
Display 27
Contrast Level 27
Backlight Time 28
Coupon 28
Edit Coupon 28
Temp 28
Language 28
Format 28
Update 28
Chapter 9: Maintenance & Troubleshooting 29
TTesting Clamp Continuity 29
Performing A Continuity Test 29
Internal Batteries 29
Battery Power Indicator 29
Replacing The Tester Batteries 29
Troubleshooting 30
The Display Does Not Turn On 30
The STATUS LED Flashes 30
Data Will Not Print 30
Appendix: Templates 31
Header And Coupon Templates 31

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Chapter 1: Introduction & OverviewEXP-1003 HD
Personal Precautions
Risk of explosive gases.
Never smoke or allow a spark or
ame in the vicinity of a battery.
Batteries can produce a highly explosive mix
of hydrogen gas and oxygen, even when the
battery is not in operation. Always work in a
well-ventilated area.
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.
Inspect the battery for damage 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 ush them thoroughly with cold running
water for at least 15 minutes and seek medical attention.
If battery acid gets on your skin or clothing, wash 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 servicing a 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.
Chapter 1: Introduction & Overview
Accessories *







Soft Carrying Case (Std.) Stud Adapters (Std.) A087 IR Printer (incl. w/Amp Kit)
 Hard Carrying Case (incl. w/Amp Kit) DMM Probe Kit (incl. w/Amp Kit) A028 DMM Cable (Std.)
Printer Paper (Std.) 10’ Battery Test Cable (Std.) A018 Amp Clamp (incl. w/Amp Kit)
*- AMP Kit includes all shown accessories except item 
.

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Chapter 1: Introduction & Overview EXP-1003 HD
External Connections




RJ45 connector (Accessories Port) with a release lever for
accessory connections.

6-pin connector, with a locking ring, for the battery test
leads.

Temperature measurement sensor.

Data transmitter, which transmits test results to an IR
printer.


DB-9 connector for
future accessories.

Spring-loaded data card
slot for test data storage
and software upgrades.
Connecting The Battery Test Cable
Connect the battery test cable to the tester by rst aligning
the cable connector’s 6 pins with the holes on top of the tester.
Firmly insert the connector and nger-tighten the locking ring.
IMPORTANT: Do not turn the locking ring more than
¾ of a turn or you will damage the tester components.
Connecting An Accessory Cable
If you are using an accessory cable, plug it into the accessories
port on top of the tester as you would a phone jack. To remove
it, press the lever and pull out the cable connector.
Data Card
The analyzer ships with a plastic insert in the data card slot to
protect it from dust and debris. To remove the plastic insert
or a data card, push briey on its edge to release it and pull it
from the slot.
When inserting a card, push it into the slot until it locks. The
card is correctly inserted when it is not protruding from the
slot. To protect the card slot and enable the analyzer to read
and write to the card, leave the card in the slot.
Conventions Used in This Manual
To 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 important
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.
The wrench symbol indicates procedural
notes and helpful information.
  These symbols indicate which arrow keys
on the keypad to press for a given function.
CAPITAL
LETTERS
The text for screen options are in regular
capital letters.
SELECT The text for soft keys are in Bold capital
letters.

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Chapter 1: Introduction & OverviewEXP-1003 HD
Display And Keypad
The analyzer keypad and display work together to help you
quickly nd and use the right tools at the right time. The
display also keeps you on track with on-screen navigation aids,
directions, and messages. The illustration below shows how
the elements on the screen relate to the keypad.










Internal Batteries Status Indicator
This indicator appears in the screen’s top left corner, lets
you know the status and charge level of the analyzer’s six
(6) 1.5-volt batteries. The “X” in the top left corner of the
screen shows that the analyzer is powered by the battery
you’re testing to conserve the analyzer’s internal batteries.
Voltmeter
When you 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 Keys
Press the two soft keys linked to the bottom of the screen
to perform the functions displayed above them. The
functions change depending on the menu or test process.
So it may be helpful to think of the words appearing above
them as part of the keys. Some of the more common soft-
key functions are SELECT, BACK, and END.
POWER Key
Press the POWER button to turn the analyzer on and
o. The analyzer also turns on automatically when you
connect its test leads to a battery.
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. When displayed under a list
of options, the menu screen arrows show you which keypad
arrow to press to highlight a character or item in a list.
Scroll Bar
Another navigational aid is the scroll bar on the right side
of the screen. The position of its scroll box shows you
whether the screen is the top (or only screen), middle, or
last in a series.
Top or
only
screen
Middle
screen
Last
screen
Scroll
Box
Arrow () Keys
Press to move up to the next selectable item or row.
When entering text, use to move to the previous
character.
Press to move down to the next selectable item or row.
When entering text, use to move to the next available
character.
Use or to scroll to the letters A through Z and the
numbers 0 through 9. When entering text, use to move
one space to the right and to move one space to the left.
Alphanumeric Keypad
In some cases, you can use the Alphanumeric Keypad to
enter numerical test parameters instead of scrolling to
them with the   keys.
You can also use the Alphanumeric Keys to create and edit
customer coupons. The keypad includes characters for
punctuation.
To add a space, press . To add a space or insert a
character, press .

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Chapter 1: Introduction & Overview EXP-1003 HD
Refer to the following table for the characters associated
with each alphanumeric key.
Key Character
$ - ( ) 1
a b c 2
d e f 3
g h i 4
j k l 5
m n o 6
p q r s 7
t u v 8
w x y z 9
% , . # 0
Data Entry Methods
To perform a particular test or function, the tester requires
dierent types of information. This means that the methods
you use to enter information will change depending on the
type of information requested. The ve types of entry methods
are described below.
Typically, the soft key below the right half of the screen
conrms your choice, although the command above it may
vary. (Examples: SELECT, NEXT, and SAVE.) In a similar
fashion, the soft key below the left half of the screen cancels
your choice or returns you to the previous screen, although
the word above it may also vary. (Examples: BACK and END.)
Menu Icons
A menu icon is a graphical
representation of a function you
can select, such as the Battery test
Icon in the Main Menu. To select
an icon, use  or to highlight
it. Highlighting changes the icon
to a white picture on a black background. To conrm your
selection, press the appropriate soft key.
Option Buttons
Some lists have option buttons
before each item. To select an
item, use or  to move the dot
to the button next to the item. To
conrm your selection, press the
appropriate soft key.
Scrolling Lists
Scrolling 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 advance the highlight bar up or
down four lines at a time, press or .
Scroll Boxes
Scroll boxes contain variables that
are displayed by scrolling using
arrow keys.
To select,use ortoscrolltothe
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 Entry
Some selections require you to
alphanumeric characters. These
“user-dened” selections have a
blinking horizontal line (cursor) to
the right of the last character.
Use or to highlight a line for editing. Press SELECT 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 nished, press the
appropriate soft key to save the text you entered.
Menu Maps
This section will help you get to your destination while letting
you know what test leads you may need when you arrive. The
test leads are represented by symbols for their connectors.
Main Menu
The Main Menu is the starting point for all tools and utilities,
which are depicted as icons. Some icons lead directly to the
function they represent, while others are menu icons that lead
to two or more functions.

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Chapter 1: Introduction & OverviewEXP-1003 HD
Menu Icon Description
Tests one battery using the battery information
you select in a series of screens.
Tests the battery pack or individual batteries
(and the starting and charging systems.
Allows you to view your stored test results and
print them to an optional IR printer.
Tests both sides of a circuit simultaneously for
voltage drop. Three preset tests and one user-
dened.
Digital multimeter with eight test meters, a
temperature sensor, and options for clamps
and probes.
Includes a test counter, data transfer utility, the
tester software version and serial number.
Nine utilities, many of which customize your
user interface.
DMM Menu
Use the DMM Menu to access the test meters, tem-
perature sensor, and probe and clamp options, some
of which require optional test leads.
Menu Icon Description
Measures voltage within a range of 0 to 60
Vdc.
Measures voltage within a range of 0 to 24
Vac.
Voltage trace with time and frequency
measurements.
Tests the strength of the direct current ow
through a circuit.
Tests the strength of the alternating current
ow through a circuit.
Sensor that displays temperature in degrees F
or C (units you can select in the Utilities Menu.)
Tests a circuit for continuity and resistance
measured in ohms (Ω).
Tests a diode for forward voltage drop.
Measures two signals simultaneously: DC
voltage and amperage.
Info Menu
The Info Menu has three utilities to help you manage
your test data, and track the analyzer’s usage and his-
tory.
Menu Icon Description
Displays the total number of test in three
categories: Lifetime of the analyzer, by User
ID, and by decision.
An optional IR software and hardware package
allows you to transfer test data to a PC.
Displays the software version, total tests from
rst use, and the serial number.
Utility Menu
The Utility Menu allows you customize your analyzer.
Before testing, check the default values to see which
options you may want to change.
Menu Icon Description
Settings to adjust date and time.
Add, edit, or delete User IDs using up to six
alphanumeric characters.
Allows you to add a custom header to printed
test results.
Settings to adjust the screen contrast and
backlight time.
If you created a coupon with the Edit Coupon
utility, use Coupon to enable or disable the
inclusion of a coupon on printed test results.
Allows you to create and store up to three
separate coupons to be printed on test results.
Allows you to select degrees in C or F for
temperature measurements.
Sets the language of the display and printouts.
Formats the data card to receive data. Also
erases all data on the card.
Updates the analyzer software via les on a
data card.

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Chapter 1: Introduction & Overview EXP-1003 HD
Print/View Menu
The tester stores the last battery, system, and cable
test results in its memory until you perform another
test. To review or print results before you retest, select
a test type in the Print/View Menu.
Menu Icon Description
Displays the last Battery and System Test
results. Sends the results to an optional IR
printer.
Displays the last Cable Drop Test result. Sends
the result to an optional IR printer.
Logging In
Scroll to a User ID and press NEXT.
1USER01
2USER02
3USER03
4USER04
To create a new User ID, scroll to a placeholder (USER01,
USER02, etc.), press NEXT and select the Users function in the
Utility Menu. See “Users”for instructions.
Creating a User ID and Setting Preferences
When you press the POWER button, the analyzer takes a few
seconds to boot up while testing the integrity of its software. It
then displays a list of default User IDs, which are placeholders
for adding technicians to the test database. To edit the default
IDs and add up to 24 technicians, see the Utility Menu.
Before starting a test you may want to customize the use of
your tester by setting preferences in the Utility Menu. The
menu has settings for the date and time, the display contrast
and backlight time, customer coupons, languages, and more.
Inspecting the Battery
Before starting the test visually inspect the battery for:
•Cracked, buckled, or leaking case. If you see any of these
defects, replace the battery.
•Corroded, loose, or damaged cables and connections. Re-
pair or replace them as needed.
•Corrosion on the battery terminals, and dirt or acid on the
case top. Clean the case and terminals using a wire brush
and a mixture of water and baking soda.
•Low electrolyte level. If the electrolyte level is too low,
add distilled water to ll up to ½ inch above the top of the
plates and fully charge the battery. Do not overll.
•Corroded or loose battery tray and hold-down xture.
Tighten or replace as needed.
Connecting to a Battery
Do not connect the tester to a voltage source
greater than 60 Vdc.
Testing Individual Batteries
At the start of the test, make sure all vehicle accessory loads
are o, the key is not in the ignition, and the doors are closed.
1. If the batteries have threaded studs, screw the negative (–)
stud adapter onto the negative terminal, and the positive
(+) adapter onto the positive terminal.
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.
2. Connect the red clamp to the positive (+) terminal or
adapter.
3. Connect the black clamp to the negative (–) terminal or
adapter.
4. For a proper connection, rock the clamps back and forth.
Both sides of the clamp must be rmly connected before
testing. If the message CHECK CONNECTION appears, clean
the terminals and/or reconnect the clamps
Clamp connection to stud adapter
Clamp connection to stud pad

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Chapter 1: Introduction & OverviewEXP-1003 HD
Testing Out-of-Vehicle (Battery Test)
The preferred battery test location is in the vehicle. However, if
you plan to test out of the vehicle:
•Always disconnect the negative cable from the battery
rst and reconnect it last.
•Always use a carry tool or strap to lift and transport the
battery.
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 the Battery Pack
1. At the start of the test, make sure all vehicle accessory
loads are o, the key is not in the ignition, and the doors
are closed.
2. Connect the clamps to the positive (+) and negative (–) ca-
bles that lead to the starter and chassis ground as shown.
If there are multiple cables, re-test for each cable connec-
tion.
3. For a proper connection, rock the clamps back and forth.
Both sides of each clamp must be rmly connected be-
fore testing. If the message CHECK CONNECTION appears,
clean the terminals and/or reconnect the clamps.
To Starter
To Ground
Initial Power-up
The tester is initially set up to require a default USER ID to access
the Main Menu. The rst selection screen to appear enables you
to set the language for the display and printed test results. This
option can disable. See “Options”in Utility Menu.
The Main Menu is displayed on the screen.

Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 www.midtronics.com
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Chapter 2: Battery Test EXP-1003 HD
The Battery Test function tests one battery in or out of
the vehicle and guide you through selecting battery
the test parameters and interpreting the results.
Use the BACK key to return to the Main Menu at the start of the
test or to the previous screen as you progress.
1. In the Main Menu, select the Battery Test icon.
2. Use or to s elect the POST TYPE and press NEXT to
continue or press the corresponding number key .
1 TOP
2 SIDE
3. Use or to s elect the BATTERY TYPE and press NEXT to
continue or press the corresponding number key .
1 GROUP 31 (BCI heavy-duty battery size)
2 4D, 8D (heavy-duty commercial batteries)
3 AUTOMOTIVE (car, van, light truck, etc.)
4. Use or to s elect the BATTERY CHEMISTRY and press
NEXT to continue or press the corresponding number key .
1 FLOODED
2 AGM-SPIRAL
3 AGM
4 GEL
5. Use or to s elect the battery RATING UNITS, which is
usually printed on the battery label, and press NEXT to
continue or press the corresponding number key . If the
information is unreadable, contact the battery manufac-
turer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
Rating Description Range
CCA Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8 ºC).
100 to
3000
CA Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
100 to
3000
Rating Description Range
MCA Marine Cranking Amps: The
amount of current a battery can
provide at 32°F (0 ºC).
100 to
3000
JIS Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and letters.
26A17 to
245H52
(72 numbers)
DIN Deutsche Industrie-Norm 100 to
1000
SAE European labeling of CCA 100 to
3000
IEC International Electrotechnical
Commission
100 to
1000
EN Europa-Norm 100 to
1700
6. Press or to select the BATTERY RATING or use the nu-
meric keys and press NEXT to continue.
a) If CCA, use the keypad or scroll to the rating and
press SELECT. The entry range is 100 to 3000, except
for DIN and IEC, which have a range of 100 to 1000.
500 CCA
b) If JIS, scroll to the JIS number.
26A17
26A19
26B17
28A19
7. If prompted, measure the ambient battery temperature
by aim the IR temperature sensor on the top of the tester
at the battery case. Once the temperature stabilizes, press
NEXT to continue the test.
Battery Case
(Top)
Sensor
Additional Test Requirements
The tester may display the following information if it
determines the need for a more decisive result.
System Noise Detected
The analyzer has detected computer, ignition noise, or
parasitic drain, and will attempt to retest. Make sure all vehicle
Chapter 2: Battery Test

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Chapter 2: Battery TestEXP-1003 HD
loads are o, doors are closed, and the ignition is in the o
position. The analyzer will automatically retest when it no
longer detects system noise. If the message reappears:
•You may be testing too close to a noise source, such as
a charger or other high-current device. If so, move away
and retest.
•If you are unable to nd the source of the noise, fully
charge the battery and retest. If the message appears after
recharging, test the battery out of the vehicle.
•Disconnect the battery cables and retest.
Unstable Battery Detected
A battery that is weak, or that has just been charged, may retain
enough electrical activity to be detected by the analyzer and will
adversely aect the test results. A fully charged battery should
stabilize quickly, after which the analyzer will automatically
retest. Weak batteries should be charged and retested. If the
battery is fully charged, check the clamp connections.
Deep Scan Test
In some cases the analyzer may need to further analyze a
deeply discharged battery to determine whether the battery
should be replaced or if it has a chance to be recovered. It then
briey conducts a Deep Scan Test of the battery.
The tester may also ask you to enter the battery’s six-digit
serial number, which is located on the battery case. After the
Deep Scan Test the tester displays the results.
Battery Test Results
The tester displays the complete results on multiple screens.
To view the code, press or . The tester will generate a test
code for all REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
return to the Main Menu, press END.
NOTE: For REPLACE or BAD CELL decisions, enter the
battery serial number located on the battery case to
generate a test code for warranty purposes. When
nished, press NEXT to continue.
Battery
decision
Measured
voltage
Selected
rating
Battery
temperature
Measured
CCA
Generated
test code (for
REPLACE
decisions)
Battery
serial
number
Battery State-
Of-Health
Battery State-
Of-Charge
Estimated
charge time
(if needed)
Battery Test Results
Decision Recommended Action
GOOD
BATTERY
Return the battery to service.
GOOD–
RECHARGE
Fully charge the battery and return it to
service.
CHARGE &
RETEST
Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause false readings. If CHARGE &
RETEST appears again, replace the battery.
REPLACE
BATTERY
May also mean a poor connection between
the battery and the vehicle.
BAD CELL–
REPLACE
This decision indicates a bad cell within the
battery. Replace the battery.
Risk of explosive gases.
Can cause death or
serious personal injury.
Never attempt to charge a
battery with a bad cell. The
battery must be replaced.
JUMP START
POST
Data was inconclusive using the remote post.
Retest at the battery terminals.
SIDE POST The analyzer has found the data was
inconclusive. Retest using the side post
adapters
NOTE: If the tester displays 24 VOLT BATTERY after the
Automotive System Test, you are attempting to test
in-vehicle both batteries in a 24-volt system. Discon-
nect the batteries and test them individually.

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Chapter 3: System Test EXP-1003 HD
The System Test evaluates the battery, starting and
charging systems. The System Test includes Battery
Test to eliminate it as the cause of starting or charging
problems.
The BACK key returns you to the Main Menu at the start of the
test and to the previous screen as you progress.
Auto/Van
1. Use the ARROW keys to highlight the System Test icon
and press NEXT to continue .
2. Use or to s elect AUTO/VAN at the VEHICLE TYPE
screen and press NEXT to continue, or press the corre-
sponding number key .
1 AUTO/VAN
2 TRUCK
3. Use or to s elect the AMP CLAMP availability and press
NEXT to continue, or press the corresponding number key .
If you select the Amp Clamp, follow the on-screen
instructions for zeroing out clamp and placing it around
the negative battery cable before proceeding.
4. Use or to s elect the POST TYPE and press NEXT to
continue, or press the corresponding number key .
1 TOP
2 SIDE
3 JUMP START POST (Car/Van Only)
5. Use or to s elect the BATTERY CHEMISTRY and press
NEXT to continue, or press the corresponding number key .
1 FLOODED
2 AGM-SPIRAL
3 AGM
4 GEL
6. Use or to s elect the battery RATING UNITS ( printed
on the battery label) and press NEXT to continue, or press
the corresponding number key . If the information is un-
readable, contact the battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
Rating Description Range
CCA Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8 ºC).
100 to
3000
CA Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
100 to
3000
MCA Marine Cranking Amps: The
amount of current a battery can
provide at 32°F (0 ºC).
100 to
3000
JIS Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and letters.
26A17 to
245H52
(72 numbers)
DIN Deutsche Industrie-Norm 100 to 1000
SAE European labeling of CCA 100 to 3000
IEC International Electrotechnical
Commission
100 to 1000
EN Europa-Norm 100 to 1700
7. Press or to select the BATTERY RATING or use the nu-
meric keys and press NEXT to continue.
a) If CCA, scroll to the rating and press SELECT. The
entry range is 100 to 3000, except for DIN and IEC,
which have a range of 100 to 1000.
500 CCA
b) If JIS, scroll to the JIS number.
26A17
26A19
26B17
28A19
8. If prompted, measure the ambient battery temperature
by aim the IR temperature sensor on the top of the tester
at the battery case. Once the temperature stabilizes, press
NEXT to begin the test.
Battery Case
(Top)
Sensor
Chapter 3: System Test

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Chapter 3: System TestEXP-1003 HD
Truck
1. Use the ARROW keys to highlight the System Test icon
and press NEXT to continue .
2. Use or to s elect the VEHICLE TYPE and press NEXT to
continue, or press the corresponding number key .
1 AUTO/VAN
2 TRUCK
3. Use or to s elect the battery PACK TYPE and press
NEXT to continue, or press the corresponding number key .
1 12V PACK
2 24V PACK
4. Press or to enter the number of BATTERIES (between
2 and 6) in the pack or use the numeric keys and press
NEXT to continue.
2
5. If testing a 2-battery, 12 volt pack: Use or to s elect
the BATTERY VOLTAGE and press NEXT to continue, or
press the corresponding number key .
1 6 V
2 12 V
6. Use or to s elect the BATTERY TYPE and press NEXT to
continue, or press the corresponding number key .
1 GROUP 31
2 4D, 8D
7. Use or to s elect the BATTERY CHEMISTRY and press
NEXT to continue, or press the corresponding number key .
1 FLOODED
2 AGM-SPIRAL
3 AGM
4 GEL
8. Use or to s elect the battery RATING UNITS ( printed
on the battery label) and press NEXT to continue, or press
the corresponding number key . If the information is un-
readable, contact the battery manufacturer.
1 CCA
2 CA
3 MCA
4 JIS
5 DIN
6 SAE
7 IEC
8 EN
Rating Description Range
CCA Cold Cranking Amps (specied
by SAE): The amount of current a
battery can provide at 0 ºF (–17.8 ºC).
100 to
3000
CA Cranking Amps: The amount of
current a battery can provide at
32°F (0 ºC).
100 to
3000
MCA Marine Cranking Amps: The
amount of current a battery can
provide at 32°F (0 ºC).
100 to
3000
JIS Japanese Industrial Standard:
(shown on a battery as a
combination of numbers and letters.
26A17 to
245H52
(72 numbers)
DIN Deutsche Industrie-Norm 100 to 1000
SAE European labeling of CCA 100 to 3000
IEC International Electrotechnical
Commission
100 to 1000
EN Europa-Norm 100 to 1700
9. Press or to select the BATTERY RATING or use the nu-
meric keys and press NEXT to continue.
a) If CCA, scroll to the rating and press SELECT. The
entry range is 100 to 3000, except for DIN and IEC,
which have a range of 100 to 1000.
675 CCA
b) If JIS, scroll to the JIS number.
26A17
26A19
26B17
28A19
10. If prompted, measure the ambient battery temperature
by aim the IR temperature sensor on the top of the tester
at the battery case. Once the temperature stabilizes, press
NEXT to begin the test.
Battery Case
(Top)
Sensor
If testing a 2-battery, 24-volt pack: Attach the tester clamps
to the rst battery in the pack. Press NEXT to test the
battery. When prompted, move the tester clamps to the
second battery and press NEXT to test it.
11. At the conclusion of the battery test, use the keypad to
enter the VEHICLE ID number and press NEXT to display
the test results. Press SKIP to advance past this step. The
tester will insert zeros in place of a vehicle number.

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Chapter 3: System Test EXP-1003 HD
Auto/Van Test Results
The tester displays the complete results on multiple screens.
To view the code, press or . The tester will generate a test
code for all REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
return to the Main Menu, press END.
NOTE: For REPLACE or BAD CELL decisions, enter the
battery serial number located on the battery case to
generate a test code for warranty purposes. When
nished, press NEXT to continue.
If the result is CHARGE & RETEST, the tester will also
display a screen showing the time needed to charge
the battery at 10, 20, and 40 A.
Battery
decision
Measured
voltage
Selected
rating
Battery
temperature
Measured
CCA
Generated
test code (for
REPLACE
decisions)
Battery
serial
number
Battery State-
Of-Health
Battery State-
Of-Charge
Estimated
charge time
(if needed)
Auto/Van Test Decisions
Decision Recommended Action
GOOD
BATTERY
Return the battery to service.
GOOD–
RECHARGE
Fully charge the battery and return it to
service.
CHARGE &
RETEST
Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause false readings. If CHARGE &
RETEST appears again, replace the battery.
REPLACE
BATTERY
May also mean a poor connection between
the battery and the vehicle.
BAD CELL–
REPLACE
This decision indicates a bad cell within the
battery. Replace the battery.
Risk of explosive gases.
Can cause death or
serious personal injury.
Never attempt to charge a
battery with a bad cell. The
battery must be replaced.
JUMP START
POST
Data was inconclusive using the remote post.
Retest at the battery terminals.
SIDE POST The analyzer has found the data was
inconclusive. Retest using the side post
adapters
NOTE: If the tester displays 24 VOLT BATTERY after the
Automotive System Test, you are attempting to test
in-vehicle both batteries in a 24-volt system. Discon-
nect the batteries and test them individually.

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Chapter 3: System TestEXP-1003 HD
Truck Test Results
The tester displays the complete results on multiple screens.
To view the code, press or . The tester will generate a test
code for all REPLACE decisions.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
return to the Main Menu, press END.
NOTE: For REPLACE or BAD CELL decisions, enter the
battery serial number located on the battery case to
generate a test code for warranty purposes. When
nished, press NEXT to continue.
Pack
Decision Selected
rating
Battery
temperature
Batteries
In Pack
Vehicle ID
Results:
Battery 1
Results:
Battery 2
Truck Test Decisions
Decision Recommended Action
GOOD
BATTERY
Return the battery to service.
GOOD–
RECHARGE
Fully charge the battery and return it to
service.
CHARGE &
RETEST
Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause false readings. If CHARGE &
RETEST appears again, replace the battery.
REPLACE
BATTERY
May also mean a poor connection between
the battery and the vehicle.
BAD CELL–
REPLACE
This decision indicates a bad cell within the
battery. Replace the battery.
Risk of explosive gases.
Can cause death or
serious personal injury.
Never attempt to charge a
battery with a bad cell. The
battery must be replaced.
Battery Pack Test Results
The tester displays the complete results on multiple screens.
Press or to view each screen.
To send the results to the IR printer, align the analyzer’s IR
transmitter with the printer’s receiver, and press PRINT. To
continue with the System Test, press NEXT.
Battery Pack Decisions
Decision Recommended Action
GOOD PACK Return the battery pack to service.
CHECK
BATTERY
PACK
Break the battery pack apart and test each
battery individually.
24-VOLT
PACK
The system being tested in-vehicle is a 24-volt
system. Disconnect the batteries and test
them individually.

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Chapter 3: System Test EXP-1003 HD
Additional Test Requirements
For a more decisive result the analyzer may ask for additional
information or further explore the battery’s condition.
System Noise Detected
The analyzer has detected computer, ignition noise, or
parasitic drain, and will attempt to retest. Make sure all vehicle
loads are o, doors are closed, and the ignition is in the o
position. The analyzer will automatically retest when it no
longer detects system noise. If the message reappears:
•You may be testing too close to a noise source, such as
a charger or other high-current device. If so, move away
and retest.
•If you are unable to nd the source of the noise, fully
charge the battery and retest. If the message appears after
recharging, test the battery out of the vehicle.
•Disconnect the battery cables and retest.
If you are using the Amp Clamp, keep it clamped around the
negative (–) battery cable.
Unstable Battery Detected
A battery that is weak, or that has just been charged, may
retain enough electrical activity to be detected by the analyzer
and will adversely aect the test results. A fully charged
battery should stabilize quickly, after which the analyzer
will automatically retest. Weak batteries should be charged
and retested. If the battery is fully charged, check the clamp
connections.
Starter System Test
1. Following a successful Battery Test, press NEXT to contin-
ue to the Starter System Test.
NOTE: When testing a battery pack, connect the
test cables across all the batteries in the pack.
2. Start the engine at the prompt.
NOTE: If the tester does not detect vehicle start,
STARTED and NO START options are displayed.
Select STARTED to skip to the Charging System
Test. Select NO START to end the test.
Starter System Test Results
The tester displays a decision on the starter system with the
complete results in a series of screens. Use or to scroll to
each screen. To send the results to the IR printer, press PRINT.
To continue testing, press NEXT.
Average
cranking
voltage
Cranking
time in
seconds
Starter
decision
Starter loop
resistance
(Amp Clamp
required)
Average
cranking amps
(Amp Clamp
required)
Cranking
voltage
Time
Cranking current
(displayed when
Amp Clamp is
used)
Decision Recommended Action
CRANKING
NORMAL
The starter voltage is normal and the
battery is fully charged.
LOW VOLTAGE The starter voltage is low and the battery is
fully charged.
CHARGE
BATTERY
The starter voltage is low and the battery
is discharged. Fully charge the battery and
repeat the starter system test.
REPLACE
BATTERY
The battery must be replaced before testing
the starter.
LOW
CRANKING
AMPS
The cranking voltage is high, but the
cranking amps are low.
NO START The engine did not start and the test was
aborted.
CRANKING
SKIPPED
The tester did not detect the vehicle’s
starting prole and skipped the Starter Test.

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Chapter 3: System TestEXP-1003 HD
Charging System Test
If you are using the amp clamp (AMP CLAMP AVAILABLE) in the
AUTO/VAN Charging System Test, keep it clamped around the
negative (–) battery cable.
1. CHECKING FOR ALTERNATOR OUTPUT: The tester will im-
mediately begin testing for alternator voltage.
2. TURN ALL VEHICLE LOADS OFF, IDLE ENGINE: Turn o 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 o. Gradually increase the rpm until
the analyzer tells you to HOLD the rev level as the bar on
the display moves to the right.
NOTE: Some 8-cylinder and older vehicles idle at
a high level after starting, allowing the analyzer
to detect the rev automatically.
4. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold
the rpm while the tester takes system measurements.
5. ENGINE REV DETECTED, IDLE ENGINE: The tester has de-
tected the rev. Press NEXT.
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 tester will ask you to turn on
the accessory loads. It will determine if the charging sys-
tem 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. Don’t use cyclical loads
such as air conditioning or windshield wipers.
8. TESTING ALTERNATOR AT IDLE, LOADS ON: The analyzer
will determine if the charging system is able to provide
sucient current for the demands of the vehicle’s electri-
cal system.
9. REV ENGINE WITH LOADS ON FOR 5 SECONDS: The tes-
ter 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.
10. ACQUIRING DATA....HOLD ENGINE RPM: Continue to hold
the rpm while the tester takes system measurements.
11. ENGINE REV DETECTED, IDLE ENGINE: The tester has de-
tected the rev. Press NEXT.
12. ANALYZING CHARGING SYSTEM DATA: The tester is com-
pleting its nal analysis of the charging system data.
13. TURN OFF LOADS AND ENGINE: Press NEXT to display the
results.
Charging System Test Results
The tester displays a decision on the starter system with the
complete results in a series of screens. Use or to scroll to
each screen. To send the results to the IR printer, press PRINT.
To continue testing, press NEXT.
Decision
DC Volts
at rev
Amps at rev
(Amp Clamp
required)
Normal DC
voltage
range
Diode
waveform
Peak-to-
peak
AC voltage

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Chapter 3: System Test EXP-1003 HD
Charging System
Decision Action
NO PROBLEMS The system is showing normal output from the alternator. No problem detected.
NO VOLTAGE The alternator is not providing charging current to the battery.
√Check the belts to ensure the alternator is rotating with the engine running. Replace broken or
slipping belts and retest.
√Check all connections to and from the alternator, especially the connection to the battery. If the
connection is loose or heavily corroded, clean or replace the cable and retest.
√If the belts and connections are in good working condition, replace the alternator. (Older
vehicles use external voltage regulators, which may require only replacement of the voltage
regulator.)
LOW VOLTAGE The alternator is not providing enough current to power the system’s electrical loads and charge the
battery.
√Check the belts to ensure the alternator is rotating with the engine running. Replace broken or
slipping belts and retest.
√Check the connections from the alternator to the battery. If the connection is loose or heavily
corroded, clean or replace the cable and retest.
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 specications for the correct limit, which may vary by vehicle type.
A high charging rate will overcharge the battery and may decrease its life and cause it to fail. If the
battery test decision is REPLACE and the charging system test shows a HIGH OUTPUT, check
the battery’s electrolyte levels. A symptom of overcharging is battery uid spewing through the vent
caps, which causes low electrolyte levels and will harm the battery.
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.
DIODE OPEN The analyzer has detected a open diode within the alternator. Replace the alternator.
DIODE SHORT The analyzer has detected an shorted diode within the alternator. Replace the alternator.