Caterpillar 271-8590 Analyzer Group (24 Volt) Tool Operating Manual NEHS0973 - PDF DOWNLOAD

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TOOL OPERATING MANUAL 271-8590 Analyzer Group (24 Volt) European Union Compliant, CE marked SMCS: 1401, 785

NEHS0973 May 2007

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Important Safety Information

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

Think Safety Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions.

An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”.

The Safety Alert “WARNING” label is shown below.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

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Contents

Literature Information

Literature Information Safety Section . . . . . . . . . . . . . . . . . . . . . . . 3 General Information Section . . . . . . . . . . . . 3 Operation Section . . . . . . . . . . . . . . . . . . . . 3 Safety Section Safety Icon Nomenclature . . . . . . . . . . . . . . . 4 Personal Protection/Important Information . . . 4 Prohibited Action . . . . . . . . . . . . . . . . . . . . . 4 Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 4 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 4 Personal Protection . . . . . . . . . . . . . . . . . . . 4 Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 5 General Information Section Component Identification. . . . . . . . . . . . . . . . 6 271-8587 Test Lead with Battery Clamps . . 8 225-8266 Amp Probe (Optional) . . . . . . . . . 8 271-8585 Printer (Optional) . . . . . . . . . . . . . 8 Software Overview . . . . . . . . . . . . . . . . . . . . . 8 Replacement Parts . . . . . . . . . . . . . . . . . . . . 9 Operation Section Battery and System Tests . . . . . . . . . . . . . . 10 Pretest Steps . . . . . . . . . . . . . . . . . . . . . . . 10 In-Vehicle Battery and Electrical System Test . . . . . . . . . . . . . . . . . . . . . . . 11 Out-of-Vehicle Battery Test . . . . . . . . . . . . 17 Quick Test (Battery) . . . . . . . . . . . . . . . . . . . 20 Understanding Test Results. . . . . . . . . . . . . 23 Battery Test Results . . . . . . . . . . . . . . . . . . 23 System Test Results . . . . . . . . . . . . . . . . . . 23 More Functions Menu . . . . . . . . . . . . . . . . . 24 Pretest Steps . . . . . . . . . . . . . . . . . . . . . . . 24 Multimeter Test. . . . . . . . . . . . . . . . . . . . . . 24 View Last Test Results . . . . . . . . . . . . . . . . 25 Set Time/Date . . . . . . . . . . . . . . . . . . . . . . 26 Software Update . . . . . . . . . . . . . . . . . . . . 28 Unit Version . . . . . . . . . . . . . . . . . . . . . . . . 28 Test Counters . . . . . . . . . . . . . . . . . . . . . . . 29 Edit Header or Footer . . . . . . . . . . . . . . . . 29 AMP Probe Setup . . . . . . . . . . . . . . . . . . . 30 Stored Tests . . . . . . . . . . . . . . . . . . . . . . . . 31 Manual Crank Data . . . . . . . . . . . . . . . . . . 33 ACC Load Test. . . . . . . . . . . . . . . . . . . . . . 34 Additional Display Screens . . . . . . . . . . . . . 36 Manufacturer’s Limited Warranty . . . . . . . . . 39 Repair Service . . . . . . . . . . . . . . . . . . . . . . 39

This manual should be stored with the tool group.

This manual contains safety information, operation instructions, and maintenance information.

Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.

Safety Section The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section The General Information section describes tooling functions and features. It provides useful information on individual parts, additional tooling, and resources.

Operation Section The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.

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Safety Section

Safety Warnings

Safety Icon Nomenclature

Personal Protection

WARNING

Personal Protection/Important Information

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools.

Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

Read the manual Ear protection Eye protection

Prohibited Action No liquid around electrical components

To prevent possible damage to your hearing, always wear ear protection when working around noise generating tools or equipment.

No smoking

Hazard Avoidance Battery explosion hazard

To avoid eye injury, always wear protective glasses. Make sure no one can be injured by flying objects or debris when working on a component.

Electrocution hazard Entanglement hazard (hands)

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

Explosion hazard Fire hazard Poison gas hazard

Personal injury can result from slips, trips, or falls.

DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

Protective guards Safety alert symbol Slipping hazard Tripping hazard Ventilate

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Hazard Avoidance

WARNING

WARNING

Do not use test leads if the insulation is damaged or if metal is exposed. Do not remove test leads while a test is running. Do not touch the test leads, tips, or the circuit being tested.

Keep service area well ventilated or attach a building exhaust removal system to the engine exhaust system. Engines produce carbon monoxide, an odorless, poisonous gas that causes slower reaction time and can lead to serious injury or death.

NOTICE

Do not drive the vehicle and operate the tester at the same time.

Any distractions may cause an accident. One person should drive the vehicle while another person operates the tester.

To prevent damage to the electronic equipment when disconnecting battery cables: 1. Turn the ignition, all accessories, and loads OFF. 2. Close the operator cab doors.

Maintain adequate clearance around moving components or belts during testing.

Moving components and belts can catch loose clothing, body parts, or test equipment, and cause serious damage or personal injury.

3. Remove the negative battery cable.

4. Remove the positive cable.

Batteries contain sulfuric acid and produce explosive gases that can result in serious injury. Stand back from the battery during testing. To prevent ignition of gases, keep lighted cigarettes, sparks, flames, and other ignition sources away from the battery at all times.

Do not test a frozen battery, as it may explode. Allow the battery to warm up before testing.

Do not spray liquids on the tester. Liquids may enter the tester and cause permanent damage to the electrical components.

Flammable liquids may cause an explosion.

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Component Identification

General Information Section

The top of the tester has the following features.

1.. RJ45 Port - connects a personal computer (PC) for updating the internal software.

2.. Test Lead Port - connects the battery clamp test lead.

3. Infrared Lights - outputs signals to an infrared printer for printing test results.

4.. Red and Black Jacks - connects an optional amp probe for using the multimeter function.

NOTICE Use only the amp probes described in this guide; do not use these jacks for any other leads.

The 271-8590 Analyzer Group (24-Volt) is a portable, hand-held tool that tests the condition of 6-Volt or 12-Volt batteries, as well as 6-Volt, 12-Volt, or 24-Volt battery packs.

The tester also tests the machine’s starting/charging system. In addition, the analyzer group has a multimeter function for use with optional amp probes and has a printing function for use with an optional printer.

The analyzer group tests conventional (flooded lead acid) and absorbed glass mat (AGM) batteries within 50 to 4000 Cold Cranking Amp (CCA), Cranking Amp (CA), Amp Hours (A-HR), Japanese Industrial Standard (JIS), or German-Deutsches Institut für Normung (DIN) capacity ratings.

Top View Features.

The 271-8590 Analyzer Group (24-Volt) includes the following: • Carrying Case • NEHS0973 Tool Operating Manual • Analyzer Group (24-Volt) • Test Lead with Battery Clamps • Side Post Terminals • Amp Probes (optional) • Printer (optional)

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7.. Security Cable Connector - used to attach a security cable for protection against theft, loss, or dropping.

The front and back of the tester have the following features.

5.. Digital Display - displays up to four lines of test instructions and results.

6.. Keypad - has the following keys: a. MENU - returns the display to the “Main Menu” screen. b. Up and Down Arrows - scrolls up and down on a screen or within a data field for making selections on the screen. c. GO - executes a screen command and advances to the next screen or step in a procedure. d. OFF - turns the tester OFF when it is not connected to a battery.

8.. Battery Compartment - holds one 9-Volt battery.

e. ON - turns the tester ON when it is not connected to a battery. (When properly connected to a battery, the tester turns ON automatically.)

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271-8587 Test Lead with Battery Clamps

271-8585 Printer (Optional)

The test lead has the following features.

The printer is an infrared printer for use in North America. For information about the printer, refer to the documentation provided with the optional printer.

1.. Connector - connects to the top of the tester, Test Lead Port (2).

2.. 4.6 m (15 ft) cable.

3.. Black Clamp - connects to a battery’s negative terminal.

4.. Red Clamp - connects to a battery’s positive terminal.

Software Overview When the tester is turned ON, the first screen in the digital display is the “Main Menu” screen shown below.

225-8266 Amp Probe (Optional) The optional amp probe is available for use with the tester’s multimeter function. It is a range-selectable amp probe used for current drain tests.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

In Vehicle (In Machine): tests a 6-Volt, 12-Volt, or 24-Volt system that is installed in a machine. This test determines the battery’s condition and then continues with a test of the machine’s starting/charging system. The test results include the battery condition, the condition of the charging system, starting system, and diodes. For additional instructions, refer to the In-Vehicle Battery and Electrical System Test section in this manual.

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Out-of-Vehicle (Out-of-Machine): tests a 6-Volt or 12-Volt battery that is not installed in a machine. This test determines the battery’s condition and displays the results (good, bad, etc.) along with the battery’s open circuit voltage (OCV). For additional instructions, refer to the Out-of-Vehicle Battery Test section in this manual.

Replacement Parts Part

Quick Test: determines the condition of a 6-Volt, 12-Volt, or 24-Volt battery or battery pack, and displays the open circuit voltage (OCV), cold cranking amps (CCA), cranking amps (CA), ampere hours (A-HR), and German-Deutsches Institut für Normung (DIN), as applicable. For additional instructions, refer to the Quick Test (Battery) section in this manual.

Part Number

Cable Battery Clamps

271-8587

Carrying Case with Foam Insert

281-1950

Analyzer Only

271-8589

Optional Printer Group

271-8585

Optional Amp Probe

225-8266

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at: U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

More Functions: has the following options: • Multimeter - determines the battery voltage and electrical current.

• View Last Test - displays the results of the last test performed.

• Set Time/Date - lets you set a date and time for printing test results.

• Software Update - when properly connected to a PC, updates the software.

• Unit Version - displays information about the software, such as name, version number, etc.

• Test Counters - displays the number of tests and resets these counters to zero.

• Edit Header/Footer - adds information for printing of test results, such as shop name or a specific message.

• Amp Probe Setup - turns ON (or OFF) the amp probe for multimeter testing.

• Stored Tests - stores the results for up to 13 tests for later review.

• Manual Crank Data - displays live amps, maximum amps, live volts, and minimum volts during engine cranking.

• Accessory Load Test - checks the capacity of the alternator at idle with accessory loads applied.

For additional instructions, refer to the More Functions Menu section in this manual.

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e. If testing a battery installed in a machine, turn OFF all electrical sources that may drain current from the battery.

For example, turn the ignition key OFF and all accessories and other loads OFF.

Operation Section Battery and System Tests This chapter includes the following sections: • Pretest Steps

2.. Install a 1U-9534 9-Volt Battery in the tester’s battery compartment. (To open the compartment, slide the cover toward the bottom of the tester.)

• In-Machine Battery and Electrical System Test • Out-of-Machine Battery Test • Quick Test (Battery)

3.. Connect the test lead to test lead port (2) on the top of the tester. (See photograph on page 6.) Finger-tighten the connector’s screws.

• Understanding Test Results

Pretest Steps

4.. Attach the test lead’s clamps to the battery’s terminals: red to positive (+) and black to negative (-).

WARNING To prevent personal injury when connecting and disconnecting cables to the positive terminal, be very careful not to contact the battery hold downs. Arcing will occur if the positive clamp simultaneously contacts both the positive terminal and the battery hold down.

NOTE: The tester turns ON automatically when properly connected to the battery. If it does not turn ON, check the battery connections. Both clamps must make solid contact with the terminals.

5.. Continue with the appropriate test steps, as explained in the following sections.

1.. Check the following: a.. If the battery being tested is frozen, let it warm up before testing. b.. Make sure the terminals of the battery being tested are clean and dry; brush and clean gently, if necessary. c.. Before testing, let the battery stabilize for three minutes after being removed from a battery charger or an operating machine. Otherwise, let the battery stabilize one minute before testing. d. If testing a battery installed in a machine, make sure the connection between the battery terminals and cables is not oxidized or loose. This condition could cause cranking and charging problems and may provide false test results.

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3.. Use the Up and Down Arrow keys to select the correct charging system, and then press the GO key. This displays a question about the status of the battery.

In-Vehicle Battery and Electrical System Test The in-vehicle test is a 35 second test to determine the condition of the battery and the starting (cranking) system, diodes, and charging system.

1.. After following the Pretest Steps, the following screen should appear. This displays the Main Menu on the tester.

Known Good Battery?

YES ↑

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

4.. Determine the status of the battery, if known:

← GO

• If the battery is known to be good, press the Up Arrow key. This will skip the remaining questions about the battery and go to the start of the actual test.

Proceed to Step 11.

2.. Use the Up and Down Arrow keys to select IN-VEHICLE, and then press the GO key. This displays the “Select Charging System” screen.

Select Charging Sys: 12 Volts 6 Volts 24 Volts

NO ↓

← GO

NOTE: The word GO indicates the selected item.

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6.. Select the battery type.

• If the status of the battery is not known, press the Down Arrow key. This displays the “Number/Type of Battery” screen.

Select Battery Type CONVENTIONAL ← GO AGM/GELL/OPTIMA ↓ Change Batt. Type

NUMBER/TYPE OF BATT 1 X 12 VOLT BATT ← GO 2 X 12 VOLT BATTS 3 X 12 VOLT BATTS ↓

• If the battery is conventional (flooded lead acid), press the GO key.

• If the battery is AGM, GELL, or OPTIMA, press the Down Arrow key, and then press the GO key.

• The possible selections continue beyond the first screen. Use the Down Arrow key to view all of the possible selections.

7.. At the “Select Units” screen, use the Down Arrow key to select a capacity rating for the test. GO indicates the selected line.

NUMBER/TYPE OF BATT 4 X 12 VOLT BATTS ← GO 2 X 6 VOLT BATTS 4 X 6 VOLT BATTS ↑

SELECT UNITS CCA ← GO A-HR CA/MCA DIN Change ↓ JIS

5.. Use the Down Arrow key to select the correct number(s) and type(s) of batteries, and then press the GO key.

NOTE: The battery’s capacity rating is usually found on the battery’s label. Use one of the following ratings: • CCA

- cold cranking ampere rating

• CA/MCA - cranking ampere/marine cranking ampere rating

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• A-HR

- ampere hours

• DIN

- German-Deutsches Institut für Normung

• JIS

- Japanese Industrial Standard

8.. After selecting a capacity rating, press the GO key. This displays a screen for entering the capacity rating. Use the Up and Down Arrow keys and adjust the rating until it matches the rating on the battery’s label.

Press the GO key.

10. Press the GO key to perform the battery pack test. If the battery pack is good, go to Step 11.

NOTE: If the battery pack is determined to be low, the screen pictured below will be displayed and the tester will begin the Quick Idle test. Follow the on-screen prompts to complete the Quick Idle test.

NOTE: Do not use the rating reported by the Quick test because it is typically higher than the printed rating for a newer battery.

Start The Engine Run At Idle Speed GO = Continue ↑ = No-Start

Enter Rated CCA For One Batt.

700 ← GO ↑ ↓ To Change Value

NOTE: If the engine does not start, press the Up Arrow key. The tester will proceed to the individual battery tests.

NOTE: If a battery pack being tested has different CCA rated batteries, disassemble the pack and test each battery individually.

11.. Wait for the screen to display “IS THIS AN AIR-START VEHICLE?” If testing an air-start vehicle, press the Up Arrow key for “Yes.” If it is not an air-start vehicle, press the Down Arrow key for “No.”

9.. The battery’s open-circuit voltage (OCV) should now be displayed.

Press GO

12.30V

IS THIS AN AIR-START VEHICLE? YES ↑

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NO ↓

13.. The test will start and the following screens will display.

12.. The “Start Vehicle” screen should now be displayed. Start the engine and then press the GO key.

AN INCREASE IN RPM WILL BE REQUIRED PRESS GO

START VEHICLE AND TURN OFF LOADS AC, R-DEFOG, ETC ‘GO’ IF NO START ‘MENU’ NOTE: If the engine does not start, press the MENU key. This displays the battery test results, as described in Step 14. Charge the battery(s) or use a booster battery to provide power.

RUN ENGINE ABOVE 1500 RPM NOW AND MAINTAIN FOR 15 SECONDS.

BAT. GOOD OCV 12.43 CCA 642 GO=PRINT

MAINTAIN SPEED VOLTS = 14.41 V

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14.. If the battery and system test is good, the first screen displays the battery test results. Press the Down Arrow key to display the next screen.

LOADING SYSTEM VOLTS = 14.31 V

BATTERY/PACK GOOD MORE ↓

GO=PRINT

NOTE: Other possible results for the first screen include No Start Condition, Charging Volts Too Low, Bat. Good/Low Charge, Bat. Bad, and Bat. Charge and Retest.

WITH ENGINE IDLING, TURN ON ALL OF THE ELECTRICAL ACC/LOADS PRESS GO

15.. The second screen of test results displays charging system test results, which includes load and no load voltages, and the test results for the charging system.

TEST COMPLETE TURN ENGINE OFF

CHG.LOAD V= 14.31 CHG.NO LOAD V= 14.40 CHG. VOLTS GOOD MORE ↓ BACK ↑ GO=PRINT

NOTE: The test results appear on several screens. They may include special messages, readings, or condition results. To view each screen, use the Down Arrow key. The following steps are examples from a good battery and system. For test result descriptions, refer to the Understanding Test Results section in this manual.

NOTE: Possible charging Volts results are Good or Charging System Needs Repair.

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18.. The fourth screen of test results displays the loaded system test results. Press the Down Arrow key to display the next screen, or the Up Arrow to review the previous screen(s).

16.. Press the Down Arrow key to display the next screen, or the Up Arrow to review the previous screen(s).

17.. The third screen of test results displays the condition of the diodes. Press the Down Arrow key to display the next screen, or the Up Arrow to review the previous screen(s).

ACC. LOAD V= 14.21 ACC. LOAD VOLTS GOOD DIODES

GOOD

MORE ↓

BACK ↑

MORE ↓ GO=PRINT

BACK ↑

GO=PRINT

NOTE: Possible accessory load results are Good or Low.

NOTE: Possible diode results are Good, Bad, or NA.

19.. The final screen of test results displays the cranking voltage (voltage during starting) and condition. Use the Up Arrow to review previous screen(s), print test results, or return to the Main Menu using the following steps.

CRANKING V= 9.90 GOOD BACK ↑

GO=PRINT

NOTE: Possible cranking voltage results are Good or Low.

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20.. If an optional printer is available, print the test results. For details, refer to the instructions included with the printer.

Out-of-Vehicle Battery Test The Out-of-Vehicle test takes about 13 seconds to determine if the battery is good, has a low charge, or is bad. The test shows the battery condition even if the battery is discharged down to 1 Volt state of charge.

21.. To end the test and return to the Main Menu, press the MENU key. Select another test or disconnect the clamps from the battery.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

1.. Complete the steps in “Pretest Steps.” This displays the Main Menu on the tester.

← GO IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

22.. Press the OFF key to turn the tester OFF. (The tester turns OFF automatically after a few minutes of inactivity.)

← GO

NOTE: The word GO indicates the selected item.

2.. Use the Up and Down Arrow keys to select OUT-OF-VEHICLE, and then press the GO key. This displays the “Select Battery Type” screen.

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5.. Use the Down Arrow key to select a capacity rating for the test. The word GO indicates the selected line.

3.. Select one of the following: • If the battery is conventional (flooded lead acid), press the GO key.

• If the battery is AGM, GELL, or OPTIMA, press the Down Arrow key, and then press the GO key.

SELECT UNITS CCA ← GO A-HR CA/MCA DIN Change ↓ JIS Select Battery Type ← GO CONVENTIONAL AGM/GELL/OPTIMA ↓ Change Batt. Type

NOTE: The battery’s capacity rating is usually found on the battery’s label. Use one of the following ratings: • CCA

4.. This screen displays the battery’s open-circuit voltage (OCV). Press the GO key.

Press GO

- cold cranking ampere rating

• CA/MCA - cranking ampere/marine cranking ampere rating • A-HR

- ampere hours

• DIN

- German-Deutsches Institut für Normung

• JIS

- Japanese Industrial Standard

6.. Use the Up and Down Arrow keys, and adjust the rating until it matches the rating on the battery’s label.

12.30V

NOTE: If the tester senses abnormal conditions, such as very low voltage, other screens may display. Respond to any questions, as necessary.

Enter Rated CCA For One Batt.

700 ← GO ↑ ↓ To Change Value NOTE: Do not use the CCA rating reported by the Quick Test because it is typically higher than the printed rating for a newer battery.

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7.. Press the GO key to begin the load and recovery part of the test. The screen displays FIRST LOAD ON,, SECOND LOAD ON,, RECOVERY PERIOD, and then WORKING as the analyzer applies two medium loads to the battery, followed by a recovery period, and then displays the battery condition.

12V CCA WORKING

NOTE: If the tester senses abnormal conditions, such as a cold battery, other screens may display. Respond to any questions, as necessary.

FIRST LOAD ON 12.248V 2

BELOW 32 DEG F ?

YES ↑ NO ↓ SECOND LOAD ON 12.004V 2

RECOVERY PERIOD 12.220V 3

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8.. When the test is complete, the screen displays the battery condition, the open-circuit voltage (OCV), and the cold cranking amps (CCA).

Quick Test (Battery) The Quick Test is a short procedure to determine the battery voltage and actual Cold Cranking Amperes (CCA), Cranking Ampere rating (CA), Ampere Hours (A-HR), and German-Deutsches Institut für Normung (DIN), if applicable.

1.. Complete the steps in “Pretest Steps.” This displays the Main Menu on the tester.

BAT. OCV.

GOOD 12.69 CCA

726

GO=PRINT NOTE: For some capacity ratings, the A-HR reading appears instead of the CCA reading.

For the JIS capacity rating, the JIS code displays.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

9.. Analyze the test results. For descriptions of possible test results, refer to the “Understanding Test Results” section in this manual.

← GO

NOTE: The word GO indicates the selected item.

10.. If an optional printer is available, print the test results. For details, refer to the instructions included with the printer.

WARNING To prevent personal injury when connecting and disconnecting cables to the positive terminal, be very careful not to contact battery hold downs. Arcing will occur if the positive clamp simultaneously contacts both the positive terminal and the battery hold down.

11.. To end the test and return to the Main Menu, press the MENU key.

12.. Select another test or disconnect the clamps from the battery. Press the OFF key to turn the tester OFF. (The tester turns OFF automatically after a few minutes of inactivity.)

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2.. Use the Up and Down Arrow keys to select QUICK TEST, and then press the GO key. This displays the “Select Battery Type” screen.

5.. Use the Down Arrow key to select the charging system type for the test. The word GO indicates the selected line.

SELECT CCA TYPE 12V CCA 6V CCA 24V CCA

Select Battery Type CONVENTIONAL ← GO AGM/GELL/OPTIMA ↓ Change Batt. Type

← GO

6.. Press the GO key to begin the test. The screen display shows WORKING as the analyzer determines the battery’s capacity.

3.. Select one of the following: • If the battery is conventional (flooded lead acid), press the GO key.

• If the battery is AGM, GELL, or OPTIMA, press the Down Arrow key, and then press the GO key.

4.. This screen displays the battery’s open-circuit voltage (OCV). Press the GO key.

12V CCA WORKING

NOTE: If the tester senses abnormal conditions, such as a cold battery, other screens may display. Respond to any questions, as necessary.

Press GO

12.30V

BELOW 32 DEG F ?

YES ↑

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NO ↓

7.. When the test is complete, the screen displays the open-circuit voltage (OCV) and the cold cranking amps (CCA).

OCV ↓ DIN OCV ↓ CCA

12.44 642

9.. To end the test and return to the Main Menu, press the MENU key.

10.. Select another test or disconnect the clamps from the battery.

8.. Repeatedly pressing the Down Arrow key will change the second line to cranking amps (CA), then ampere hours (AHR), German-Deutsches Institut für Normung (DIN), then back to CCA.

OCV ↓ CA

12.44 802

OCV ↓ AHR

12.44 80

12.44 362

11.. Press the OFF key to turn the tester OFF. (The tester turns OFF automatically after a few minutes of inactivity.)

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Understanding Test Results

System Test Results

This section includes descriptions for test results and tips for solving problems.

Charge Battery and Retest System: indicates the battery either has a low charge or is almost fully discharged and must be charged before running any tests.

Battery Test Results Bat. Good: the battery is in good condition and can hold a charge. This also indicates that the charging system, cranking system, and diode test will be unaffected by the battery condition.

Service Batteries as Required and Retest System: indicates battery is bad and must be replaced before running any tests.

Diodes Good: indicates the rectifier diodes are good.

Bat. Good/Low Charge: the battery is in good condition but needs to be charged.

(The battery charge is above 15%, but not close to the full nominal capacity.)

Diodes Bad: indicates the diode pack or alternator needs to be replaced.

Bat. Charge & Retest: the battery is almost fully discharged and the battery condition cannot be determined. (The battery charge is below 15% of the nominal capacity.)

Charge the battery and repeat the test.

NOTE: To prevent an erroneous diode test, the tester should not be used to test diodes unless the battery condition is good.

Bat. Bad: the battery is in bad condition and most likely will not hold enough of a charge for reliable engine starting. Replace the battery.

Charging System Good: indicates the charging system is in good condition.

Charging Volts Too Low/High Charging System Needs Repair: indicates the charging system voltages are too low/high.

The charging system is faulty. If the no load voltage is too low, the battery test result may be Good/Low Charge.

NOTE: A bad battery can mask other charging system problems that will be caught when tested with a good battery. For example, a bad battery could make the diodes test bad.

Cranking Good: indicates the starting system is in good condition.

No Start Condition: indicates the battery is bad or needs recharging. This result may also appear if the battery is too small for the machine, if the starter motor is defective, or if the cranking resistance is excessive. Make sure the battery size is correct and there are no starter or engine problems.

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2. Use the Down Arrow key to select More Functions and press GO to display the More Functions Menu.

More Functions Menu This section includes the following information: • Pretest Steps • Multimeter Test • View Last Test Results • Set Time/Date • Software Update • Unit Version

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

• Test Counters • Edit Header or Footer • Amp Probe Setup

← GO

• Stored Tests NOTE: The word GO indicates the selected item.

• Manual Crank Data • Accessory Load Test

Pretest Steps

3.. Select MULTIMETER, and then press the GO key. This displays a reminder message about the probe setup and then displays the multimeter screen (if the amp probe is enabled).

Refer to the Pretest Steps in “Battery and System Tests” section.

Multimeter Test The More Functions, Multimeter option quickly checks a battery’s voltage, and with optional amp probes, tests the electrical current for the ranges of 0.1mV/Amp, 1mV/Amp, 10mV/Amp, and 100mV/Amp. To complete the multimeter test, follow these steps: 1.. Follow the instructions in “Pretest Steps” and “AMP Probe Setup” sections in this manual. This displays the Main Menu.

MULTIMETER ← GO VIEW LAST TEST SET TIME/DATE SOFTWARE UPDATE

REMEMBER TO TURN ON AND ZERO THE AMP PROBE

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4.. This screen displays the voltage, amperes, maximum amperes, and the selected amp probe range. Select either of the following: • Press the Up Arrow key to reset (clear) the Max Amps readings to zeros.

• Repeatedly press the Down Arrow key to change the range. Possible options are 0.1mV/A, 1mV/A, 10mV/A, and 100mV/A.

MULTIMETER ← GO VIEW LAST TEST SET TIME/DATE SOFTWARE UPDATE 6.. Turn OFF the amp probe.

7.. Select another test or disconnect the clamps and the amp probe from the battery.

VOLTS:14.284 Amps: 7 Max Amps: 7 Clr ↑ Amp Probe: 100mV/A ↓

8.. Press the OFF key to turn the tester OFF. (The tester turns OFF automatically after a few minutes of inactivity.)

View Last Test Results The More Functions, View Last Test option displays the test results of the last test performed.

5.. When finished with the multimeter tests, press the MENU key. This displays a reminder message if the amp probe is enabled, and then displays the More Functions Menu.

1.. If necessary, press the ON key to turn the tester ON and display the main menu. (If the tester is already ON, press the MENU key to display the Main Menu.)

2.. Use the Down Arrow key to select MORE FUNCTIONS, and then press the GO key.

REMEMBER TO TURN OFF THE AMP PROBE IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

NOTE: The word GO indicates the selected item.

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3.. Use the Up and Down Arrow keys to select VIEW LAST TEST, and then press the GO key.

Set Time/Date The More Functions, Set Time/Date option lets you include a date and time when printing the test results.

1.. Press the ON key to turn the tester ON. This displays the Main Menu.

2.. Use the Down Arrow key to select MORE FUNCTIONS, and then press the GO key.

MULTIMETER VIEW LAST TEST ← GO SET TIME/DATE SOFTWARE UPDATE 4.. If necessary, use the Down Arrow key to scroll through the test results.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

NOTE: The word GO indicates the selected item.

BAT. OCV.

3.. Select SET TIME/DATE, and then press the GO key.

GOOD 12.69 CCA 726 GO=PRINT

5.. If an optional printer is available, print the test results. For details, refer to the instructions included with the printer.

6.. To return to the Main Menu, press the MENU key.

MULTIMETER VIEW LAST TEST SET TIME/DATE ← GO SOFTWARE UPDATE

7.. Either select another test or disconnect the clamps from the battery (if connected).

8.. Press the OFF key to turn the tester OFF. (The tester turns OFF automatically after a few minutes of inactivity.)

NOTE: Because the tester shuts off automatically after a few minutes, it may be helpful to connect the tester to a battery before performing the steps in this section. (To do this, refer to “Pretest Steps” section.)

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4.. Press the GO key to advance to the Year screen or press the MENU key to exit. This displays the “Set Year” screen.

Set Date

↑↓

18

Set Hour

↑↓

:9

Set Date/Time 01/18/07 29:28 MENU to exit 5.. Use the Up and Down Arrow keys to set the year, and then press the GO key.

Repeat this for each of the next screens that appear for the Month, Date, Hour, and Minutes.

Set Year

↑ ↓ 2007

Set Minute ↑ ↓

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6.. When finished, the display returns to the More Functions Menu. Press the MENU key to return to the Main Menu.

Set Month

↑

01

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3.. Use the Down Arrow key to select UNIT VERSION, and then press the GO key.

This displays the Version information.

Software Update The More Functions, Software Update option allows the software to be updated.

Instructions will be provided as updates become available.

MULTIMETER VIEW LAST TEST SET TIME/DATE SOFTWARE UPDATE

VIEW LAST TEST SET TIME/DATE SOFTWARE UPDATE UNIT VERSION ← GO

← GO

Unit Version The More Functions, Set Version option displays information about the software, such as name, version number, etc.

1.. Press the ON key to turn the tester ON. This displays the Main Menu.

SABRE HP Heavy V1.01 Program PN-532995 REVISION A 08/05/05 Press GO to continue

2.. Use the Down Arrow key to select MORE FUNCTIONS, and then press the GO key.

4.. Press the GO key to return to the More Functions Menu.

5.. Press the MENU key to return to the Main Menu.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

NOTE: The word GO indicates the selected item.

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Test Counters The More Functions, Test Counters option displays the number of System Tests, Battery Tests, and Quick Tests that have been done with the tester and lets you reset the counters to zero.

1.. Press the ON key to turn the tester on. This displays the Main Menu.

System Tests Battery Tests Quick Tests Press ↓ to clear

NOTE: The word GO indicates the selected item.

022 006 010

4.. To reset all the counters to zeros (000), press the Down Arrow key.

2.. Use the Down Arrow key to select MORE FUNCTIONS, and then press the GO key.

5.. When finished, press the MENU key twice to return to the Main Menu.

Edit Header or Footer The More Functions, Edit Header or Footer function customizes information printed on test results, such as shop information or messages to customers.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

1.. Press the ON key to turn the tester ON. This displays the Main Menu.

2.. Use the Down Arrow key to select MORE FUNCTIONS, then press the GO key. This displays the More Functions Menu.

← GO

3.. Use the Down Arrow key to select TEST COUNTERS, and then press the GO key.

This displays the test counts.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

SET TIME/DATE SOFTWARE UPDATE UNIT VERSION TEST COUNTERS ← GO

← GO

NOTE: The word GO indicates the selected item.

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w key until 3.. Repeatedly press the Down Arrow EDIT HEADER/FOOTER shows on the screen and is selected. Press the GO key.

This displays the “Edit Header/Footer” screen.

5.. Enter the desired text, as follows: a.. Press (and hold down) the Up Arrow key until the desired letter or number appears. (After using the Up Arrow key, you can also use the Down Arrow key.) b.. Press the GO key to move to the next space. (Two blinking dots indicate the currently selected space.) c.. Repeat Steps a. and b. until the text is entered.

SOFTWARE UPDATE UNIT VERSION TEST COUNTERS EDIT HEAD/FOOTR ← GO

NOTE: To leave a space blank, press the GO key. To move to the next line, press the GO key.

6.. When finished, press the MENU key twice to return to the Main Menu.

4.. Select one of the following: • To edit header information, press the Up Arrow key.

AMP Probe Setup

• To edit footer information, press the Down Arrow key.

To use the optional amp probes with the Multimeter function, first set up the amp probe connected to the tester.

NOTE: If the amp probe is not set up, the Multimeter function displays only the battery voltage.

1. Follow the instructions in “Pretest Steps” sections in this manual. This displays the Main Menu.

↑ TO EDIT HEADER ↓ TO EDIT FOOTER ‘MENU’ TO EXIT NOW

NOTE: The 225-8266 Clamp-On Ammeter, LCD Display will not display the fast current spike that occurs during cranking. The analyzer, when used with the 225-8266 Ammeter, will display the fast current spike that occurs during cranking.

NOTE: Header information appears at the top of a printed report; footer information appears at the bottom of a printed report.

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4.. The bottom line of the screen shows the amp probe’s status. The status must be set to ENABLED. If necessary, press the Up Arrow key to change the status to ENABLED.

2. Use the Down Arrow key to select MORE FUNCTIONS, and then press the GO key.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

Amp Probe Setup Enable Amp Probe ↑ Disable Amp Probe ↓ Amp probe: DISABLED

NOTE: The word GO indicates the selected item.

5.. Press the MENU key twice to return to the Main Menu.

3.. Repeatedly press the Down Arrow key until AMP PROBE SETUP shows on the screen and is selected. Press the GO key.

Stored Tests The More Functions, Stored Tests option stores up to 13 tests that can be reviewed later.

To view stored test results, follow these steps: 1.. Press the ON key to turn the tester on. This displays the Main Menu.

2.. Use the Down Arrow key to select MORE FUNCTIONS, and then press the GO key.

UNIT VERSION TEST COUNTERS EDIT HEAD/FOOTR AMP PROBE SETUP

← GO

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

NOTE: The word GO indicates the selected item.

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3.. Repeatedly press the Down Arrow key until STORED TESTS shows on the screen and is selected. Press the GO key.

The “View Stored Tests” screen shows the number of stored tests, the number of the currently selected test, and the date and time of the currently selected test. Use the Up (or Down) Arrow key to select the test number to view, and then press the GO key. This displays the results for the selected test.

TEST COUNTERS EDIT HEAD/FOOTR AMP PROBE SETUP STORED TESTS ← GO

View Stored Tests Number of tests: 13 View test: 01 ↑ ↓ GO Dated: 01/18/07 28:48

4.. Complete one of the following: • To view a stored test, press the Up Arrow key. This displays the “View Stored Tests” screen.

NOTE: If the results have more than one screen, use the Down Arrow key to scroll to the next screen(s). Optionally, press the GO key to print the test results.

5.. To clear the stored tests, press the Down Arrow key. This displays the “Clear Stored Tests” screen.

STORED TESTS View Stored Tests ↑ Clear Stored Tests ↓ Press MENU to exit

Clear Stored Tests Press ↑ to clear ALL stored tests or MENU to exit.

NOTE: Press the MENU key to return to the Main Menu without clearing stored tests.

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3.. Repeatedly press the Down Arrow key until MANUAL CRANK DATA shows on the screen and is selected. Press the GO key.

6.. To clear all the stored tests, press the Up Arrow key. The message, “ALL TESTS CLEARED” appears on the screen. Use the MENU key to return to previous screens.

EDIT HEAD/FOOTR AMP PROBE SETUP STORED TESTS MANUAL CRANK DATA

Clear Stored Tests ALL TESTS CLEARED Press MENU to exit

← GO

4.. Follow the on-screen instructions and turn off all loads (lights, radios, A/C, etc.), and then press the GO key.

Manual Crank Data The More Functions, Manual Crank Data option displays data acquired during engine cranking.

To view manual crank data, follow these steps: 1.. Press the ON key to turn the tester ON. This displays the Main Menu.

2.. Use the Down Arrow key to select More Functions, and then press the GO key.

This displays the More Functions Menu.

TURN OFF ALL LOADS: LIGHTS, RADIOS, A/C, ETC. Press GO NOTE: If the amp probe is enabled, you will see a prompt reminding you to turn ON and zero the amp probe.

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS

← GO

NOTE: The word GO indicates the selected item.

REMEMBER TO TURN ON AND ZERO THE AMP PROBE

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w key to select More 2.. Use the Down Arrow Functions, and then press the GO key.

This displays the More Functions Menu.

5.. The Manual Crank Data includes fixed readings for maximum amps and minimum volts (the readings on the right), and live amps and live volts (displayed on the left).

Use the Up Arrow key to clear the crank data, or the Down Arrow key to toggle the amp probe units display (options include 0.1mV/Amp, 1mV/Amp, 10mV/Amp, and 100mV/Amp).

IN VEHICLE OUT OF VEHICLE QUICK TEST MORE FUNCTIONS 12.3 V CRANK 12.3 V 7A CRANK 7A Clear Crank Data ↑ Amp Probe: 100 mV/A ↓

← GO

NOTE: The word GO indicates the selected item.

3.. Repeatedly press the Down Arrow key until ACC LOAD TEST shows on the screen and is selected. Press the GO key. This displays the first “ACC Load Test” screen.

6.. Press the MENU key twice to return to the Main Menu.

ACC Load Test The More Functions, ACC Load Test option checks the output of the alternator at idle and under electrical loads.

To perform the ACC Load Test, follow these steps:

AMP PROBE SETUP STORED TESTS MANUAL CRANK DATA ACC LOAD TEST ← GO

1.. Press the ON key to turn the tester ON. This displays the Main Menu.

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6.. Follow the on-screen instructions to turn OFF all of the electrical/accessory loads and turn OFF the engine. This displays the test results.

4.. Follow the on-screen instructions to start the engine and let it idle for 20 seconds, and then press the GO key. This displays the next instruction in the ACC Load Test.

TEST COMPLETE! TURN OFF ALL OF THE ELECTRICAL ACC/LOADS AND TURN OFF ENGINE

START THE ENGINE AND LET IT IDLE FOR 20 SECONDS PRESS GO 5.. Follow the on-screen instructions to turn ON all of the electrical/accessory loads, and then press the GO key. This performs the test.

ACC. LOAD V= 14.249 ACC. LOAD VOLTS OK GO=Print WITH ENGINE IDLING, TURN ON ALL OF THE ELECTRICAL ACC/LOADS PRESS GO

NOTE: Possible ACC Load Test results are OK and Low. 7.. If an optional printer is available, print the test results. For details, refer to the instructions included with the printer.

8.. To end the test and return to the Main Menu, press the MENU key twice.

9.. Select another test or disconnect the clamps from the battery. Press the OFF key to turn the tester OFF. (The tester turns OFF automatically after a few minutes of inactivity.)

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Additional Display Screens Other display screens may appear during testing. Some possible display screens are shown in this section.

BATT. 1 CHRG&RETST MORE ↓

GO=PRINT

BAT. CHARGE & RETEST OCV 8.91 CCA 0 GO=PRINT

BATT. 1 BAD MORE ↓

GO=PRINT

BATT. 1 GOOD/LOW CHG MORE ↓

GO=PRINT

BAT. BAD OCV 12.48 CCA 473 GO=PRINT BAT. GOOD/LOW CHARGE OCV 12.30 CCA 642 GO=PRINT

36

HAS BATTERY BEEN CHARGED ONCE?

BAT. GOOD OCV 12.69 CCA 726

YES ↑

GO=PRINT

BATT. 1 GOOD BATT. 2 BAD MORE ↓

NO ↓

CONNECT TESTER TO BATTERY 1 THEN PRESS GO

GO=PRINT

CONNECT TESTER TO BATTERY 2 THEN PRESS GO

SERVICE BATTERIES AS REQUIRED AND RETEST SYSTEM. BACK ↑ GO=PRINT

37

NO START CONDITION BATTERY PACK GOOD

SERVICE CHARGING SYSTEM AND CHARGE BATTERY PACK. MORE ↓ GO=PRINT

MORE ↓

GO=PRINT

CRANKING V = N/A RETEST THE SYSTEM BACK ↑ GO=PRINT BACK ↑ GO=PRINT

Turn OFF The Engine Then Press GO To Continue

38

Order Information

Manufacturer’s Limited Warranty

Replacement and optional parts can be ordered from your Caterpillar Parts Systems authorized dealer.

THIS WARRANTY IS EXPRESSLY LIMITED TO ORIGINAL RETAIL BUYERS OF THE MANUFACTURER’S ELECTRONIC DIAGNOSTIC TOOLS (“UNITS”).

Technical Service If you have any questions on the operation of the product, please call:

The Manufacturer’s Units are warranted against defects in materials and workmanship for three years (36 months) from date of delivery. Cables are warranted against defects in materials and workmanship for 90 days (3 months) from date of delivery. This warranty does not cover any Unit that has been abused, altered, used for a purpose other than that for which it was intended, or used in a manner inconsistent with instructions regarding use.

The sole and exclusive remedy for any Unit found to be defective is repair or replacement, at the option of the Manufacturer. In no event shall the Manufacturer be liable for any direct, indirect, special, incidental or consequential damages (including lost profit) whether based on warranty, contract, tort, or any other legal theory. The existence of a defect shall be determined by the Manufacturer in accordance with procedures established by the Manufacturer. No one is authorized to make any statement or representation altering the terms of this warranty.

CAT Dealer Service Tool Division dealerservicetool_hotline@cat.com 800-542-8665 (USA) 800-541-8665 (Illinois) 800-523-8665 (Canada) 309-675-6277 (Outside USA) 309-494-1355 (Fax)

Repair Service When sending your electronic product in for repair, please include the following information: • company name • contact name • telephone number • description of the problem • proof-of-purchase for warranty repairs • preferred method of payment for non-warranty repairs

Disclaimer THE ABOVE WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

For non-warranty repairs, payment can be made with Visa, Master Card, or with approved credit terms. To receive a credit application, please fax your request to the Credit Department at 800-962-8734.

Software

Send the unit to: SPX Service Solutions 2300 Park Drive Owatonna, MN 55060-0994 RGA: Repair Dept.

Unit software is proprietary, confidential information protected under copyright law.

Users have no right in or title to Unit software other than a limited right of use revocable by the Manufacturer. Unit software may not be transferred or disclosed without the written consent of the Manufacturer. Unit software may not be copied except in ordinary backup procedures.

39

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

©2007 Caterpillar All Rights Reserved

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NEHS0973 Printed in U.S.A.