April 2013 167-000497EN-A GR8-1202 Multitasking Battery And Electrical Diagnostic Station INSTRUCTION MANUAL This page intentionally left blank. GR8-1202 Contents Contents Safety Guidelines 5 Chapter 2: Battery Test 17 General Safety Precautions 5 Test Requirements 17 Personal Precautions 5 Additional Test Requirements 18 Preparing To Charge The Battery 6 System Noise Detected 18 Grounding & Power Cord Connections 6 Unstable Battery Detected 18 Charger Location 7 Deep Scan Test 18 DC Connection Precautions 7 Battery Test Results 18 Installing The Battery 7 State of Health 19 Connecting To The Battery 8 State-of-Charge 19 Chapter 1: Introduction & Overview 9 Chapter 3: Diagnostic Charging 20 Safety Reminder 9 Charging Modes 21 Safety Precautions 9 Initial Analysis 21 Assembling the GR8 9 Deep Scan Test 21 Attaching the Control Module 9 Diagnostic Mode 21 Installing the Multitasker Module 10 Aborting a Charge Session 21 Front of GR8 11 Completing a Charge Session 22 Back of GR8 11 Diagnostic Charge Results 22 Control Module Keypad 12 Top-Off Mode 22 Data Entry Methods 13 Menu Icons 13 Chapter 4: System Test 23 Option Buttons 13 Starter Test 23 Scrolling Lists 13 Starter System Test Results 23 Alphanumeric Entry 13 Charging System Test 24 Value Boxes 13 Key-Off Draw 24 Main Menu 13 Charging System Test Results 25 Info Menu 14 Chapter 5: ECM Power Supply 26 DMM Menu 14 Setup Menu 14 Chapter 6: Jump Start 27 Setting User Preferences 15 Help Menu 15 Chapter 7: Manual Charging 28 Multitasking 15 Wireless Multitasking 15 Chapter 8: Info Menu 30 Procedure Example 15 View Test Battery 30 Inspecting the Battery 15 View Test Charger 30 Testing Out-of-Vehicle (Battery Test) 15 View Cable Test 30 Testing In-Vehicle (System Test) 16 View Inventory Test 30 Connecting to the Battery 16 Totals 30 Initial Power-up 16 Transfer 31 Selecting A Language 16 View Wireless 31 Version 31 www.midtronics.com 3 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Contents GR8-1202 Chapter 9: Cable Drop Test 32 Info Upload 41 Cable Drop Test 32 Display 42 Battery Ground Test 32 Contrast Level 42 Battery Ground Test Results 32 Coupon 42 Starter Circuit 33 Edit Coupon 42 Starter Circuit Test Results 33 Track Calls 42 Alternator Circuit 33 Language 43 Alternator Circuit Test Results 33 Admin 43 Other Circuit 34 Options 43 Other Circuit Test Results 34 Clear Test Totals 43 Reset Defaults 43 Chapter 10: Key Off Draw 35 Select 43 Update 43 Chapter 11: Digital Multimeter (DMM) 36 Format 43 Ohm Meter 36 Buzzer 44 Diode 36 User Screen 44 Scope 37 Wireless 44 DC and AC Volts/Amp 37 Multimeter Specifications 38 Chapter 14: Maintenance / Troubleshooting 45 Help 45 Chapter 12: Inventory Test 39 Terms/Definitions 45 Selecting Test Parameters 39 Troubleshooting 45 Printing Test Results 39 Service Info 45 Clearing Test Results 39 Test Messages 45 Replacing the Paper Roll 45 Chapter 13: Setup 40 Control Module Internal Batteries 46 Clock 40 Battery Power Indicator 46 Mode 40 Replacing the Internal Batteries 46 Time 40 Test Cable Maintenance 46 Format 40 Attaching the Charger Cables 46 Date 40 Error Messages 47 Shop 40 Users 41 Appendix 48 Entering A New User ID 41 Header Template 48 Deleting A User ID 41 Coupon Template 48 Editing A User ID 41 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 4 www.midtronics.com GR8-1202 Safety Guidelines Safety Guidelines 1 General Safety Precautions 1. IMPORTANT SAFETY INSTRUCTIONS. IT IS OF UTMOST IMPORTANCE THAT BEFORE USING YOUR CHARGER, Remove marine “boat” batteries and charge YOU READ THIS MANUAL AND FOLLOW THE SAFETY them on shore. AND OPERATING INSTRUCTIONS EXACTLY. SAVE THESE Charging marine batteries on-board requires specially INSTRUCTIONS. designed equipment for marine use. 1.8 Connect and disconnect the battery leads only when the AC supply cord is disconnected. Risk of explosive gases 1.9 Do not overcharge the battery. (See sections 3 and 10 in Batteries generate explosive gases during normal opera- the safety instructions) tion, and when discharged or charged. 1.10 Charge the battery in a dry, well-ventilated area. 1.1 To reduce risk of battery explosion, follow these safety in- 1.11 Never place articles on or around the charger, or locate structions and those published by the battery manufac- the charger in a way that will restrict the flow of cooling turer and the manufacturer of any equipment you intend air through the cabinet. to use in the vicinity of a battery. Review cautionary mark- ing on these products and on the engine, and on the ve- 1.12 An extension cord should not be used unless absolutely hicle or equipment containing the battery. necessary. (See paragraph 4.3.) 1.13 Have a damaged cord or plug replaced immediately. 1.14 Do not expose the charger to rain or snow. Charging a non-rechargeable battery may cause the battery to burst. To reduce the risk of injury, only charge rechargeable 2 Personal Precautions lead-acid type batteries including maintenance-free, 2.1 Always have someone within range of your voice to come low-maintenance, or deep-cycle batteries. to your aid when working around lead acid batteries. If you are uncertain as to the type of battery you are 2.2 Have plenty of fresh water and soap nearby in case battery attempting to charge, or the correct procedure for checking acid contacts skin, clothing or eyes. the battery’s state of charge, contact the seller or battery manufacturer. 2.3 Wear complete eye and clothing protection, as well as rub- ber soled shoes. Place damp cloth over battery to protect 1.2 Use of an attachment not recommended or sold by the against acid spray. When ground is very wet or covered battery charger manufacturer may result in a risk of fire, with snow, wear rubber boots. Avoid touching eyes while electric shock, or injury to persons. working near battery. 1.3 To reduce risk of damage to the electric plug and cord, 2.4 If battery acid contacts skin or clothing, wash immediately pull by the plug rather than by the cord when disconnect- with soap and water. If acid enters the eye, immediately ing the charger. flush with cold running water for at least 10 minutes and seek medical attention. 1.4 Position the AC and DC leads to avoid tripping over them and prevent damage by hood, doors, or moving engine 2.5 NEVER smoke or allow a spark or flame in vicinity of a bat- parts; protect from heat, oil, and sharp edges. tery or engine. 1.5 Do not operate the charger if it has received a sharp blow, 2.6 Be extra cautious to reduce risk of dropping a metal tool been dropped or otherwise damaged in any way; take it onto the battery. It might spark or short circuit the battery to a qualified service center. or other electrical part that may cause an explosion. 1.6 Do not disassemble charger; take it to a qualified service 2.7 Before working with a lead-acid battery, remove personal center when repair is required. Incorrect reassembly may metal items such as rings, bracelets, necklaces, watches, result in a risk of electric shock or fire. etc. A lead-acid battery can produce a short circuit current high enough to weld such items causing a severe burn. 1.7 To reduce risk of electric shock, unplug the charger from the AC outlet before attempting any maintenance or cleaning. Turning off the controls will not reduce this risk. www.midtronics.com 5 Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60527 Safety Guidelines GR8-1202 Non-rechargeable batteries may burst when Hazardous voltage. charging causing personal injury and damage. An improper connection can result in To avoid electrical shock or burn, never alter the charger’s electric shock original AC cord and plug. Disconnect plug from outlet To avoid electrical shock or burn, never alter when charger is idle. the charger’s original AC cord and plug. Dis- connect plug from outlet when charger is idle. 2.8 The charger is not intended to supply power to a low- voltage electrical system other than applications using IF THE PLUG DOES NOT FIT THE OUTLET, HAVE A rechargeable, lead-acid type batteries. Do not use the QUALIFIED ELECTRICIAN INSTALL A PROPER OUTLET. battery charger for charging dry-cell batteries commonly 4.2 This battery charger is for use on a nominal 120-volt cir- used with home appliances. These batteries may burst cuit and has a grounding plug that looks like the plug il- and cause personal injury and property damage. lustrated in Figure A. A temporary adapter, which looks like 2.9 NEVER charge a frozen battery; thaw it out first. 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 3 Preparing To Charge The Battery temporary adapter should be used only until a properly 3.1 If it is necessary to remove the battery from vehicle to grounded outlet can be installed by a qualified electrician. charge it, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc. 3.2 Be sure the area around the battery is well ventilated while Hazardous voltage. An improper connection can result in the battery is being charged. Gas can be forcefully blown electric shock away by using a piece of cardboard or other nonmetallic Before using an adapter be certain the center material as a fan.