PACCAR Training

EXP1000PACK1T
August, 2015
Program Objectives:
• Reduce customer downtime by
improving proper diagnostics to resolve
no-starts or poor charging conditions`
• Consistent diagnostics will support
the detail needed for program success

• Uniform testing and reporting will

deliver measureable results
Presentation Objectives
 Focus is on diagnostics for batteries along
with starters and alternators

 These test procedures will - - -

 Reduce or eliminate problem warranty claims

 Boost customer satisfaction and achieve cost
reductions by cutting service complaints

 Always start with the battery . . .

So, What’s New?
Software, Hardware and Procedures
• Software – updated to add more features

• Hardware – Longer DMM cables, new

battery test cables and a CVG module

• Procedures – battery warranties will now

include VIN and battery Serial Numbers
Tips to Remember
• Follow “Best Practices” for battery
service
• All cable connections should be clean
and tight
• Any corrosion should be cleaned before
you continue service activity
• Only use approved corrosion prevention
products when servicing
Complete Test Kit - Option #1
# EXP1000PACK1T
Software Upgrade Kit - Option #2
# ESU1000PACUPK1T
Two Test Cable Options
#A187 10’ Test Cable #A083 10’ Test Cable
with Large Clamps with Small Clamps
 More New Parts Kit
CVG Module with
J1939 Adapter

New #A087 IR
Printer with charger

New 20’ DMM Cable

for easier V-Drop
testing
System Analyzer
 Designed specifically for
professional technicians
 Menu driven Battery, Starter
and Alternator testing
 Built-in DMM with IR Temp
sensor, Scope mode, AC and
DC Volts
Getting Started
System Test - battery,
Icon for testing one starter and alternator
battery at a time test sequence w/VIN
Conductance Technology
Conductance 1. A low voltage A/C
Measurement Signal is Impressed
across the battery
terminals (VAC)

2. The A/C Current (IAC)

Response is measured

3. Conductance (G) is
calculated using
Ohm’s Law: G = IAC/VAC
Plate Surface Area
 Conductance = Scanning battery
structure inside the case, like Radar
Tips to Remember
• Battery cables are built to insulate
connections and reduce corrosion
• Testing on Stainless Steel battery bolts
will result in lower battery readings
• Final tests should be done on the lead
terminal base or on lead stud adapters
• Properly torque bolts when installing or
reinstalling cables
 Service
• The 12 Volt Lead/Acid battery is the heart
of every vehicle . . .
• If batteries are discharged or worn out,
other electrical tests may be suspect
• The PACK test result = GOOD, continue
to the starter and alternator tests
• Document results
 Battery Claims
• Any Replace decision will need both the
Battery Serial Number and the VIN

• Replace batteries per company policy

• Reassemble the Pack and continue . . .

• Results are best if you start the with

a known GOOD Battery Pack
 CVG Installation
When CVG module
installed on the J1939
CAN Bus – it lights up
and beeps

The CVG is used for

in-vehicle verification
and VIN capture
 Pack Testing
Connect test leads
to battery main
Ground and
Positive cables

When breaking the

pack – you must
remove all cables
 Ready to Test

The CVG is powered

and test cables
connected – start test

Follow the Menu

prompts and capture
all vehicle data
Pack Description
Multiple batteries in
Split pack – usually
parallel configuration
only on Kenworth
– test up to 4
Follow the Menu
Enter the number of Test option for 6 or 12
batteries volt batteries
More Menu detail
GP-31 – Standard US Flooded or Absorbed
truck batteries Glass Mat ( AGM )
Battery detail
PACK Test – enter the
CCA’s most common rating for only one
– tester has options battery, not the Pack
 Battery Test = GOOD . . .
Battery Pack Test done –
press NEXT to continue to Screen prompt will guide
Starter/Alternator tests you to the next sequence
Alternator Test
CRANKING NORMAL – Next - ALTERNATOR test
test shows average Volts, sequence starts with all
time and starter Code loads turned OFF!
Alternator Test
Tester prompt to rev
engine – hold at ~ 1500 NEXT - “Idle Engine” then
RPM, data is captured as turn on all stable loads –
test continues NO AC or wiper motor .
Alternator Test
NEXT – Rev engine to Finally, alternator
1500 RPM with loads ON electrical signature is
until it says “Back to Idle” analyzed and recorded . . .
Alternator 4 Step Test
Test is complete; Battery , Alternator DC and AC
Starter and Alternator voltage pattern results
functions are captured show NO PROBLEMS!
Check Pack Result . . . !
Just low voltage, bad Remove battery cables
battery or bad cable? - test using proper GP-
Disconnect and check! 31 Lead Stud Adapters
 Check Pack Sequence
• A “Check Pack” decision = remove all
cables and test batteries one by one
• You will need the “Battery Serial
Number” for any warranty claims
• The Serial Numbers should be visible
with all cables are removed
• Replace failed batteries per local policy
and process all valid warranty claims
Use Lead Stud Adapters!
Test each battery in You will get a separate
the Pack – detail is test result for each
necessary battery
Final details
Menu flow will change Point IR Temp sensor
if it is a non-warranty at the battery case
service
More Options
Connect all “GOOD” Continue following the
batteries and properly menu prompts . . .
torque bolts
 Detailed Testing
• Alternator test uses Digital Signal
Processing (DSP) routine and will test
new PWM alternators (show almost no
AC Ripple voltage)
• DMM Scope Mode will show alternator
DC volts and AC ripple voltage pattern
• Diagnose starting/charging circuit
condition by using Cable-Drop Test
Software Upgrade Kits
• Shops that already own a PACCAR
version of the Midtronics InTELLECT
Analyzer may purchase a software
upgrade kit from PACCAR Parts
• Kit contains a CVG Module, printer, SD
card with update software and new test
cables
• Follow the included instructions to
complete software update
Installing WiFi Pod
• Shops getting the Update Kits will need
to install the new software
• Insert the provided software SD card
with the new software to begin
• The WiFi Pod must be installed in the
bottom of the Midtronics Analyzer
• Connect the battery test clamps to a 12
volt battery to power the update
Software Update
Utility Menu is found • An instruction sheet is
in the Main Menu provided to guide you
through the software
update
• Start with the Utility
from the Main Menu
• Select the ‘Update’
icon and follow the
screen prompts
Installing Update Software
• Press ‘Yes’ to the prompt to update the
software to; rev 346D
• This update will take several minutes . . .
• Update complete - turn tester off

• Remove the update SD card and replace

the original data card back into the unit
CVG Module Mating
• Your tester will
need to be mated to
the CVG module
• The serial number
is on the back of
each CVG module
• This step is part of
the CVG setup
 CVG Module Setup
The serial number on CVG Serial Number
the back of the CVG must be matched to
can be entered the tester to work
Installing WiFi Update
“Note: Wi-Fi module is only used to
connect to the CVG module. It does not
connect to the Wi-Fi network within the
dealership.”
• From the tester Main Menu, go to Utility
• Scroll to “CVG” Icon, press “Select”
• Follow tester screen prompts while
plugged into truck J1939 Bus
The Program Begins
• With the program now loaded, the new
reporting will begin
• When in doubt – ask for help
• Maintain safe work habits
• If existing tools need repair or service,
please contact Midtronics directly
Program Objectives:
• Reduce customer downtime by
improving proper diagnostics to resolve
no-starts or poor charging conditions

• Consistent diagnostics will support the

detail needed for program success

• Uniform testing and reporting will

deliver measureable results
 Summary
• New focus on testing to deliver improved
service for our customers
• Field support is available through your
local and regional representatives
• Tool service is available from Midtronics:
• Service@midtronics.com
• 800 776-1995