Midtronics MDX-650 MILITARY User manual

INSTRUCTION MANUAL
MDX-650 MILITARY
Battery Conductance and
Electrical System Analyzer
For 6 & 12-volt automotive starting batteries
and 12 & 24-volt starting/charging systems

MDX-650 MILITARY
Introduction & Overview
Safety Guidelines
Because of the possibility of personal injury, always use extreme caution when
working with batteries. Follow all BCI (Battery Council International) safety
recommendations.
Wash hands after handling.
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.
Capabilities
The MDX-650 MILITARY Battery Conductance and Electrical System Analyzer
tests 6 & 12-volt regular ooded, AGM at plate, AGM spiral, and gel batteries,
as well as 12 & 24-volt starting and charging systems for passenger cars, light
trucks and military vehicles. It displays the test results in seconds and features a
built-in printer to provide customers with a copy of the results.
Additional features include the ability to:
•test batteries from rated from 100 to 2000 CCA
•detect bad cells
•protect against reverse polarity
•test discharged batteries
•test multiple rating systems (CCA, CA, JIS)
•provide a user interface with English, Spanish, and French-Canadian as the
selectable language

MDX-650 MILITARY
Display and Keypad
When you rst connect the MDX-650 MILITARY to a battery, it functions as a
voltmeter until you press .
IMPORTANT: If you connect the tester to a voltage source greater
than 30 Vdc, you may damage the tester’s circuitry.
The menu-driven display will then guide you step by step through the test
process. Use the keypad buttons to scroll to and select options in the menu.
To turn o the tester when not connected to the battery, briey press and hold
the button.
User Interface
 pq Arrows
Use these keys
to choose test
parameters and scroll
to menu options.
Next
Use this button to
make selections.
6Back/Print
Use this button to
move to the previous
screen or move back
one space when
creating custom
headers.
Also used
to print out test
results with an IR
printer.
Menu
Use to access the
Main Menu options
of the tester.
For information
about the options,
see “Options Menu”.
MDX-650 MILITARY


Display Showing
Battery Result


IR
Output
Decision
Measured
rating
Measured
voltage
Selected
rating
Button
Toolbar

MDX-650 MILITARY
Options Menu
Procedure
1. Press to access the Options Menu.
2. Use por qto move to the line you want to edit.
3. Press to make the highlighted line editable.
4. Use por qto select the character for that cursor location.
5. Press to move to the next location.
6. Press to return to the Options Menu.
Option Explanation
VIEW / PRINT
RESULTS
Press 6to display the previous test result or to print
the results.
QC MODE A quick test to check battery inventory.
EXPORT DATA Export the last test result to an IR Reader program.
(under development)
PERFORM TEST Begin the Battery Test procedure.
LANGUAGE
SELECTION
Select a language for the tester.
(Default: English)
SET ADDRESS Enter the address to display on the top of the printout.
(Limit: 8 lines, 21 characters per line)
TIME Select 24-hour or AM/PM and set the time.
(Default: AM/PM)
DATE Select the date format as well as set the correct date.
(Default: MM/DD/YYYY)
COUNTER Clear or display battery and system test by results.
CONTRAST Adjust the contrast setting of the tester display.
(Default: 10)
TEMPERATURE
UNITS
Select the temperature units Degrees F or Degrees C
(Default: Degrees F)
VOLTMETER Automatically test battery voltage when the clamps are
rst connected to the battery terminals. Press to
continue testing the battery. Press 6to return to the
menu. (Default: ON)

MDX-650 MILITARY
Preparations Before the Test
Before connecting the tester, clean the battery posts or side terminals with
a wire brush and a mixture of baking soda and water. When testing side-
post batteries, install and tighten lead terminal adapters. A set of adapters is
included with the tester.
IMPORTANT: Do not test at steel bolts. For OUT-OF-VEHICLE testing,
failure to install terminal adapters or installing terminal adapters that
are worn or dirty may result in inaccurate test results. To avoid dam-
age, never use a wrench to tighten the adapters more than ¼ turn.
If you are testing in the vehicle, make sure all accessory loads are o, the key is
not in the ignition, and the doors are closed.
Connecting the Tester
•Connect the red clamp to the positive (+) terminal and the black clamp to
the negative (–) terminal.
•For a proper connection, rock the clamps back and forth. The tester re-
quires that both sides of each clamp be rmly connected before testing. A
poor connection will produce a CHECK CONNECTION or WIGGLE CLAMPS
message. If the message appears, clean the terminals and reconnect the
clamps.
•The preferred test position is at the battery terminals. If the battery is not
accessible, you may test at the jumper post; however, the available power
measurement may be lower than the actual value.

MDX-650 MILITARY
Battery & System Test
When you rst connect the tester to the battery, it functions as a voltmeter
until you press to start the test. This function can be turned o through the
Options Menu.
After you press , scroll to each parameter using por q and press to select.
If any messages appear during the test, see the section “Test Messages”.
1. BAT. LOCATION: Scroll to and select IN VEHICLE or OUT OF VEHICLE for a
battery not connected to a vehicle. Following an IN VEHICLE test you will be
prompted to test the starting and charging systems.
IMPORTANT: The performance of the starting and charging systems
depends on the battery’s condition. It is important that the battery is
good and fully charged before any further system testing.
2. POST TYPE: (In-Vehicle only) Scroll to TOP POST, SIDE POST or JUMP START
POST where applicable.
3. APPLICATION: Scroll to and select AUTOMOTIVE, COMMERCIAL -4D/8D, 6T,
or GROUP 31.
4. BATTERY TYPE: Scroll to and select REGULAR FLOODED, AGM FLAT PLATE,
AGM SPIRAL, or GEL where applicable.
5. BATTERY STANDARD: Scroll to and select the battery’s rating system. Not
all rating systems are available for each application.
Standard Description Range
CCA Cold Cranking Amps, as specied by SAE. The
most common rating for cranking batteries at 0 ºF
(–17.8 ºC).
100–2000
CA Cranking Amps: Current available at 32 ºF (0 ºC) 100-2000
JIS#
Japanese Industrial Standard, shown on a battery as
a combination of numbers and letters.
26A17
thru
245H52
6. BATTERY RATING: Scroll to and select the rating units. Hold down por q
to increase the scrolling speed.

MDX-650 MILITARY
7. Press to start test. After several seconds the tester displays the decision
on the battery’s condition and the measured voltage. The tester also dis-
plays your selected battery rating and the rating units.
GOOD BATTERY
VOLTS
MEASURED
RATING
12.50V
465 CCA
500 CCA
6

Decision
Measured
CCA
Measured
voltage
Selected
rating
Decision Interpretation
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 inaccurate results. If CHARGE & RETEST
appears again after you fully charge the battery,
replace the battery.
REPLACE BATTERY Replace the battery and retest. A REPLACE
BATTERY result may also mean a poor connection
between the battery cables and the battery. After
disconnecting the battery cables, retest the battery
using the out-of-vehicle test before replacing it.
BAD CELL-
REPLACE
Replace the battery and retest.
24 VOLT SYSTEM 24-volt system detected. Disconnect batteries and
test individually.
READY TO INSTALL Battery has just been activated and is ready to
install in vehicle (Motorcycle only)
NEEDS CHARGE
Fully charge battery and retest using BEFORE
DELIVERY. (Motorcycle only)
Failure to fully charge the battery before retesting
may cause false readings.
8. Press to proceed with the starter test, 6to print the test results or
to return to the Options Menu.
NOTE: For an in-vehicle test, the display alternates between the
test results and the message PRESS FOR STARTER TEST.
IMPORTANT: The MDX-650 MILITARY retains the results of the last test
only. When you start a new test, the last results are overwritten.

MDX-650 MILITARY
Starter System Test
IMPORTANT: 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.
Once you have completed an in-vehicle test, the display alternates between
the battery test results and the message PRESS FOR STARTER TEST.
1. Press to proceed with the starter test.
2. Start the engine when prompted.
3. The tester displays the decision on the starter system, cranking voltage,
and cranking time in milliseconds.
STARTER SYSTEM
DECISION
CRANKING
TIME
10.20V
718mS
6

Starter
Decision
Cranking
time in
milliseconds
Average
cranking
voltage
Decision Interpretation
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
Battery must be replaced before the starting system can
be tested.
NO START No vehicle start detected.
CRANKING
SKIPPED
A start was not detected.
4. Press to proceed with the charging system test, 6 button to print the
test results, to return to the Options Menu.
NOTE: For an in-vehicle test, the display alternates between the
test results and the message PRESS FOR CHARGING TEST.

MDX-650 MILITARY
Charging System Test
Once you have completed an in-vehicle test, the display alternates between
the battery test results and the message PRESS FOR CHARGING TEST. Press
to proceed with the charging test.
Following the on-screen prompts:
1. Rev the engine.
2. Turn on high beams headlights and the blower fan.
3. Rev engine with loads on.
4. Idle engine and turn o loads.
5. The Charging System decision is displayed at the end of the procedure.
CHARGING SYSTEM
DECISION
NO LOAD
14.29V
LOADED
14.25V
6

Alternator
Decision
Loads-off
DC Voltage
at rev
Loads-on
DC Voltage
at rev
Decision Interpretation
NO PROBLEMS System is showing normal output from the alternator.
NO OUTPUT No alternator output detected.
√ 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 OUTPUT Alternator not providing sufcient 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.

MDX-650 MILITARY
Decision Interpretation
HIGH OUTPUT Alternator voltage output exceeds the normal limits.
√ Make sure there are no loose connections and
the ground connection is normal. If there are no
connection problems, replace the regulator. Most
alternators have a built-in regulator that requires
replacing the alternator. In older vehicles that
use external voltage regulators, you may need to
replace only the voltage regulator.
EXCESSIVE
RIPPLE
Excessive AC ripple detected.
√ One or more diodes in the alternator is not
functioning or there is stator damage.
6. Press 6to print the test results or to return to the Options Menu.
Test Messages
For a more decisive result, the tester may prompt you for additional
information. The messages in the following table may appear before the tester
can display a result.
Test Message Interpretation
BAT. TEMPERATURE
Select ambient temperature above or below 32 ºF (0 ºC)
CHARGE STATE Select before or after battery has been charged.
SURFACE CHARGE
DETECTED
Remove the surface charge before it begins testing.
Testing will resume after charge has been removed.
CHECK
CONNECTION
One or both clamps are not making proper contact with
the battery terminals.
ENGINE REV NOT
DETECTED PRESS
WHILE REVVING
Tester has not detected an increase in engine rpm
REVERSE
CONNECTION
Clamps are connected in the wrong polarity:
positive to negative or negative to positive.
SYSTEM NOISE
CHECK LOADS
In-vehicle testing. Tester has detected computer, ignition
noise or parasitic drain. Make sure all vehicle loads are
off including open doors and ignition switch.
UNSTABLE
BATTERY
Out-of-vehicle. Weak battery, should be charged and
retested.
WIGGLE
CLAMPS
Clamps are not making good contact with
battery terminals

MDX-650 MILITARY
Error Messages
Error Message Interpretation
BATTERY POWER TOO
LOW TO USE PRINTER.
CONNECT TO FULLY
CHARGED BATTERY
11.50 TO 16.00V
Battery being tested has fallen below 9 volts.
Connect to a fully charged battery to use the
printer.
CONNECT TO
12V BATTERY
Tester is not connected to the battery
LOW INTERNAL AA
BATTERIES. REPLACE
AA BATTERIES SOON!
Internal AA batteries are low and need to be
replaced. See “Maintenance & Troubleshooting”
section.
NON 12 VOLT SYSTEM
DETECTED
System being tested is not 12-volts.
PRINTER DOOR OPEN.
CLOSE DOOR AND TRY
TO PRINT AGAIN
Door covering printer paper is not secure.
PRINTER OUT OF PAPER
REPLACE WITH THERMAL
PRINTER PAPER.
2.5 IN. DIA. MAX.
2.25 IN. WIDE MAX
Printer is out of thermal paper. Replace with new
roll. See “Maintenance & Troubleshooting” section.
QC DATA MEMORY FULL
PRINT RESULTS OR
CLEAR MEMORY.
QC mode memory is full. Select QC mode from the
Options Menu to clear the memory.

MDX-650 MILITARY
Maintenance & Troubleshooting
Changing The Cable Assembly
1. Identify the circled screw.
2. Remove the screw.
3. Grasp the housing and rmly pull the cable assembly from housing.
4. To attach a new cable, align the cable and tester housings and push to-
gether. Insert the screw and tighten.

MDX-650 MILITARY
Troubleshooting the Display
If the display does not turn on:
•Check the connection to the vehicle battery.
•The vehicle battery may be too low (below 1 volt) to power the analyzer.
Fully charge the battery and retest.
•The analyzer’s AA batteries may need to be replaced. (alkaline recom-
mended).
•If the analyzer does not power on when you press and hold the button,
replace the AA batteries.
Replacing the Battery
The MDX-650 MILITARY can test down to 5.5 volts when the unit’s internal
batteries are not functioning. The tester displays LOW INTERNAL AA BATTERIES,
REPLACE AA BATTERIES SOON! when the internal AA batteries need to be
replaced.
NOTE: Setup information will be retained while you change the
internal batteries.
Use the following procedure to remove and replace the internal AA batteries.
1. Turn the tester face down.
2. Remove the screw securing the battery compartment cover using a small
Phillips screwdriver.
3. Lift the door o and remove the discharged battery.
4. Insert fresh AA batteries making sure the positive and negative terminals
are positioned correctly.
5. Reposition the cover and tighten the screw.