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The importance of a car Battery Tester

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The electric charge that your battery carries will not last a century. It can only carry so much electric charge for a specified amount of time and sooner or later it will discharge. In most cases, it is quite difficult to tell how much electric charge you have left.

The 21st century cars are modern machines and fully loaded with high technology gadgets such as GPS navigation, LCD screens, DVD players and can be connected to Bluetooth devices. How all this latest car technology can handle by car battery which is installed in car electrical system. You may have all these top-of-the-line automobile extras but if your battery is dead, so are they.

Why do you need a car battery tester?

Testing of batteries in a short comprehensive test is the dream of testing devices.

State-of-health is not measured but estimated based on available symptoms. If the symptoms are not well defined or obvious then a reliable measurement is not possible. When testing a battery and trying to determine the state of health you must consider

Capacity, ability to store energy.

Internal resistance, ability to deliver current.

Self-discharge, cell integrity and health

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Batteries are presented for assessment in a variety of conditions, and a good charge can easily mask a symptom allowing a weak battery to perform well. Likewise, a strong battery with low charge shares similarities with a battery that exhibits capacity loss. Battery characteristics are also swayed by a recent charge, discharge, or long storage. These characteristics need to be considered while testing batteries.

The top indicator of a battery health is capacity, a measurement that represents energy storage. A new battery should deliver 100 percent of the rated capacity. This means a 10Ah pack should deliver Ten amps for 1 hour. If the battery fails to perform after 20 minutes for example, then the capacity is only 33 percent. Capacity defines end of battery life.

Lead acid starts at about 85 percent and increases in capacity through use before the long and gradual decrease begins Lithium-ion starts at peak and begins its decline immediately, but at a very slow pace. Nickel-based batteries need several charge/discharge cycles to reach full capacity when new or after a long storage.

Manufacturers typically provide specifications based on a new battery. Unfortunately, this performance only represents a new cell and not represent a battery in real-life situations, because degradation begins from the day the battery is made. The decrease in performance only becomes visible once the battery has been used many times and daily routines are being taken for granted.

“It is difficult to know when to replace a battery, some are replaced too early, but most are kept too long.”

Knowing when to replace a battery

This is difficult for many battery users. When asked, many reply with confusion. Many are not familiar with the term capacity as a measurement of battery life, and fewer know that capacity is used as a threshold for replacing batteries. In many scenarios, battery problems only become apparent with increased breakdowns, which may be caused by a lack of battery maintenance.

Battery replacement depends on the application. Using battery Analysers typically set the replacement threshold at 80 percent capacity. In some applications you can keep the battery longer than others and cost benefit decisions need to be made in different situations. Hand tools for example may go as low as 60 percent and still provide a full day’s use, whereas a battery in a car will still start the car at 40 percent capacity.

With batteries you need to plan for a worst-case scenario, while manufacturers include some reserve when specifying battery life and capacity, the amount is seldom clearly defined. In critical applications then tighter tolerances should be used and the battery must be replaced sooner than when a sudden failure can be tolerated.

Medical and military applications are considered critical and batteries are often replaced too soon. Rather than testing them, battery manufacturers prefer to use a cycle count or a date stamp to mandate retirement. To cover all eventualities, the service duration on a date stamp is often limited to 2 or 3 years.

In some medical applications it has been observed that many batteries have more than 90 percent capacity left when the mandatory 2-year date-stamp expires, replacing perfectly good batteries prematurely. Despite this apparent waste, this has been mandated in this field because a survey says that “up to 50 percent of service calls in hospitals surveyed relate to battery issues.”

Some batteries and portable devices include a fuel gauge that shows the remaining energy. A full charge always shows 100 percent, whether the battery is new or faded. This creates a false sense of security by anticipating that a faded battery showing fully charge will deliver the same runtime as a new one. Batteries with fuel gauges only indicate State of charge and not the capacity, and this is based usually on Battery Voltage.

“Battery failure is not only limited to portable devices.” 

More than 40 percent of all roadside car failures are battery-related, and that each third breakdown involves either a discharged or defective battery. Additionally, only a few starter batteries reach the average age of five years, and this applies to all cars. These statistics was derived from a study that covered more than four million breakdowns in Europe. The study only included newer cars; service-prone vehicles more than 6 years old were excluded.

The Battery Council International reports similar results. A 2010 study revealed that grid-related failures had increased by 9 percent from 5 years earlier. Experts suspect that higher electrical demands in modern vehicles lead to higher failure rates.

Battery failure in Japan is the largest single complaint among new car owners. The average car is driven 13km per day and mostly in congested cities. The most common reason for battery failure is undercharge, developing sulfation.

A manufacturer of luxury cars in Europe reported that one in two starter batteries returned under warranty had no problem. A European manufacturer of high-quality starter batteries stated that factory defects account for only 5 to 7 percent of all warranty claims. Battery failure during the warranty period is seldom a factory defect, driving habits are the main culprits. A careful assessment with advanced battery test instruments capable of looking at various failure symptoms can greatly reduce warranty claims.

“The mobile phone industry experiences similar battery warranty issues.” 

Nine out of ten batteries returned are said to have no problems. Rather than trouble-shooting a customer complaint because of lower than expected runtime, the technician simply replaces the battery, in turn leads to repeat complaints.  

The challenge of Battery Testing

The key problem lies in the difficulty of testing batteries, and this applies to repair shops, retail outlets, and service garages. There is a significant shortfall in a reliable method of estimating the state-of-charge, which is based mostly on voltage and charge counting. Assessing capacity, is the leading health indicator of a battery! Measuring the open circuit voltage and checking the internal resistance do not provide conclusive evidence of battery state-of-health.

A dead battery is easy to check and most testers are 100 percent accurate. The challenge comes in evaluating a battery in the 80–100 percent performance range while in use. Most service and repair workshops struggle to introduce good battery test procedures. This is mostly due to the unavailability of suitable technology that can assess a battery on the go.

There is a lot of hype and effort put into the super battery, but this improved battery is incomplete without being able to check performance while in service. Improving performance and reliability does not rest in a better battery alone, but in tracking the performance as it ages.

Car batteries 

Have so much improvement over the years, but the technology is still basically the same. Not until we are stranded in some place because we can’t start the car, do we even think of our car battery. A modern car battery voltage tester can warn of impending battery failure and may even diagnose alternator problems; thus evaluate and determine the course of action that needs to be taken.

Battery tester 

Uses the adjustable load test as gauge to decide whether your battery is still usable or need to be discarded and replaced. These testers measure the voltage drop when a voltage load that is half the battery’s CCA rating is used. And how does it work? The load is applied for about 15 seconds and the voltage drop is measured. Make sure that when you do this test the ambient temperature is not below 20⁰C. If the drop reading does not fall below 9.6 volts, then your battery is ideally conditioned, and is therefore, considered good. To illustrate this, let’s take an example: You have a battery of Cold Cranking Amp (CCA) rating of 600; if you apply 300 amps load for 15 seconds and the measured voltage does not fall below 9.6 volts then the battery is good. It is also possible to use a car battery tester in opposing temperature conditions, but only if you compensate for the difference in calculations.

This accurate method of testing is exactly how the AutoTest® BST-380 Battery System Tester evaluates a battery. It not only gives a complete view of battery health, but is a conveniently portable, easy to use battery analysis tool designed for automotive service, fleet maintenance and breakdown assist diagnostic use. Taking the guess work out of battery diagnosis alerting you to replace batteries before they fail.

The Battery System Tester is a professional quality unit that tests all 12V auto batteries, including new auxiliary batteries for hybrids.

It uses advanced conductance testing technology to easily, quickly and accurately measure the actual cold cranking amps capability of the vehicle starting battery, the health of the battery itself, and common faults in the vehicle starting system and charging system. It can help maintenance personnel to identify problems quickly and accurately, thus leading to efficient vehicle repair.

AutoTest® Battery System Tester Functions:

  • User friendly
  • Built in Printer for an instant printout
  • Test 12V/24V/30V batteries
  • 100-2000 CCA (cold cranking amps)
  • Polarity Reverse Protection
  • Testing standards include a majority of the world’s battery standards, CCa, BCi, Ca, mCa, JiS, Din, ieC, en, Sae and G
  • Stores 100 test results
  • In-built real time clocks
  • Registered Australian Made and Owned

Test Functions:

  • Battery Test
  • Charging System Test
  • Start System Test
  • Maximum Load Test
  • Cranking Mode
  • QC Mode

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Published in Australian Diesel Mechanic Magazine February 2021 – Issue 54

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FAQ – Autostop Maxi

Where is the user manual?

The user manual is stored inside the USB drive that came in the box as a PDF file. The manual can be download from AutoTest Product website as well.

My screen is too dark/light.

Adjust the contrast by using the ‘O’ menu command and pressing the up or down arrows. Refer to your manual for more information.

My Brake Meter turns off when printing.

Charge the battery.

How often should I charge my battery?

It is okay to leave the unit on charge all the time.

My brake tester will not take charge.

Check that the charge light is on. Measure the output voltage of the charge. Batteries normally have a life of 2-3 years. If the problem persists, call our Service Team.

My brake meter does not print out the results after the test.

After a test, press Y to print out the results. If the results displayed are not correct, press NO and repeat the test. Call our Service Team if the problem persists.

The paper won’t feed.

Wrong paper type – replace the paper roll. Clean dust and dirt from the printer with a dry brush.

Does my printer need oiling?

No. Under no circumstances should you oil your printer, this will void your warranty.

How long does my printer ribbon last?

The ribbon should be changed with every second roll of paper.

 

Where do I buy paper and ribbons?

From the online shop on our website or your local distributor. A paper pack consists of 2 paper rolls and 1ribbon.

Can I replace or repair my pedal sensor?

No. Each sensor is individually calibrated; this must be done by Service Team.

I need to push the brake pedal very hard to get the AutoStop brake tester to work.

Call our Service Team, and a technician will help you to adjust the meter.

Every test has the same pedal force reading. The pedal sensor wire is broken. Send the meter back for repair to AutoTest Products, or via your local distributor.

The plastic cap on my load cell is loose.

The cap should be loose for correct operation.

The speed reading is much higher than the speed I was travelling.

The brake meter was not firmly secured in the car – repeat the test.

The speed reading is much lower than the speed I was travelling.

The sensors may need adjustments – turn the brake meter off, then on again to perform a self-check.

Call the Service Team if the problem persists.

What sort of stop is required?

A moderate stop from approximately 35 km/h is best. Do not skid the vehicle, as this will provide poor results.

How often do I need to calibrate my AutoStop Brake Tester?

Maxi – 2 years.

How long does it take to calibrate my Brake Meter?

It may take one business day to calibrate (excluding shipping and repairs).

Where do I send my AutoStop Brake Tester for calibration?

Send it to AutoTest Products or through your local distributor.

What should I send when my AutoStop Brake Tester needs service and calibration?

Please send your brake meter, charger, business card

and up to date contact details.

Can I hire a replacement brake tester while mine is repaired or calibrated?

Yes, we require a bond paid by credit card and

dispatch will be same day.Contact us for the hire forms.

Why is the distance shown on the meter different to that measured with a tape measure?

AutoStop brake meters measure deceleration (braking efficiency) directly (which is the design parameter used in original homologation) to an accuracy of 2%. Distance is calculated by the meter in its internal computer using the average deceleration measurement, time to stop (from the internal real time clock – accuracy 1.0%) and the assumption that the final speed is zero. The double integration process involved in the mathematics compounds these measurement accuracies and dependent on the shape of the deceleration versus time trace can generate a different result. The difference will be much less than that obtained from using any peak deceleration instrument such as a Tapley meter. The difference is due solely to the mathematics and is not a function of the AutoStop meter. Regulators in certain jurisdictions still use “distance to stop” – because in the 70’s and 80’s direct measurement of braking efficiency to an accuracy of 2%. The regulations will “catch-up” eventually.

Can I store two tester ID numbers in the meter?

No, only one ID can be stored. Please press “N” on the Examiner ID prompt to reset it.

How long does my warranty last?

12 months parts and labour. 3 months parts and labour for repairs.

My time or date is incorrect.

If the time is incorrect by one hour, check the daylight saving setting. Otherwise, contact us and a technician will assist you.

How do I get the latest version of the download software for my brake meter? The latest version of the download software is available for free download on our website.

My download software / datalogger isn’t working.

Check that all cables are connected securely and are not damaged. If you are running Windows 2000, you must use the new Windows-based software, since the old MS-DOS data logging software is not compatible. You can download the latest download software free from AutoTest website.

How do I clear the datalogger?

At the Ready > prompt, press “L” to enter the datalogger menu. Press “C” at the datalogger menu to wipe all saved test data.

Why is the speed wrong?

The device is not fastened properly, or has been turned on before fastening in the test position. Figure 1 shows correct test position. Needs to be seat belted into the passenger seat with the lid open and closer to the windscreen, not resting on the back

of the chair. Alternatively, you can place on the floor of the passenger seat facing the same direction.

Never hold on your lap for the test, between your legs, or on the floor of the driver’s side

 

 

Figure 1: AutoStop brake meter in position ready for testing. Secure in position before turning on and starting any testing.

 

I’ve lost my manual. Where can I get a copy?

You can download the latest version of our product manuals on the AutoTest website.

How do I change units from % to G?

At “ready” press “x” then “A”, pressing “A” repeatedly will toggle between units.

How do I change to daylight saving?

At ready press “T” then “D”, an asterisk will be displayed beside the time indicating Daylight saving.

How to check battery level?

Press “B” at Ready > screen.

Why does the screen show prelude and not register a brake test?

Please check pedal sensor reading. Press “c” at Ready>. Press “c” again, screen should show 0.XX N. Press on pedal sensor and see if the reading goes up accordingly. If there is a delay or the reading is not rising, please contact us.

I’ve lost the License code for using my Brake Meter with the Data logging software.

Please contact our service department with the unit’s serial number at the ready and they will assist you in generating a new code.

 

Why the Brake Meter turns off while printing, even it has been charged overnight?

The battery is not holding charge and needs to be replaced. Send it in to us for a replcement.

The charging light is not tuning on when I plug in the charger.

The charging socket may be damaged, or the LED may be blown. Send it in to us for repair. Please also send in with the charger you are using.

The Brake meter turns off in the middle of a test or print out, but it shows 100% battery.

The battery is not holding charge and needs to be replaced. Send it in to us for a replacement.

Why the keypad shows 12V input but I need to use a 14V charger?

That means 12V non-regulated. It should be shown as 14V if the charger output is regulated. We recommend using the charger that came with the Brake Meter only. Never use a 12V regulated charger, it will drain the battery. You can purchase a new charger through our website or your local distributor.

The charging light is not going off even when the battery is fully charged.

The charging light only indicate if a charger is plugged in, it won’t change according to the battery level.

My computer does not recognise my brake meter when plugged in via USB.

Please install the USB drivers included with the Brake Meter software, these are located in the ‘USB drivers’ sub-folder of the main folder where the datalogger was installed to (Typically: C:\Program Files (x86)\AutoTest\ Maxi and Heavy Datalogger).

Please contact us for further assistance if this still doesn’t recognise your Brake Meter.

How do I find which Comm Port number my Brake Meter was assigned?

Open ‘Device Manager’ and expand ‘Ports(Com & LPT)’. Search the list of devices for ‘USB Serial Device’ and to the right of its name will be the Com port number.

How do I use my Brake Meter with serial connection with newer desktops or laptops that don’t have a serial ports?

It is still possible to use a Brake Meter with serial connection on newer PCs that lack serial ports by using a USB-to-serial converter. Compatibility with individal converters may vary however and AutoTest can only offer minimal support in assisting you when using one.

 

How do I change the display views for km / mph, the unit of acceleration, graph mode etc? Refer to the manual, Section 4.

Brake meter will not turn on

Battery may be flat- charge unit for 12 to 16 hours. Battery charger has failed – check battery charger output with multimeter, also check condition of fittings. Battery or internal electronics have failed – return unit for servicing.

Brake meter does not record keypad input

Battery may be flat- refer below.

Brake meter turns itself off during use

Battery may be flat- refer below.

No printout

Out of paper = remove printer cover plate and check paper roll. Refer manual Section 4.

Printout illegible or hard to read

Printer ribbon needs replacing- Refer manual Section 5.

“Time out” displayed on printout

Unit not secured into position properly.Foot has been lifted from pedal before vehicle has stopped.

 

“MEM FAILED” is displayed when Brake Meter is switched ON.

Internal flash memory is not responding or it is faulty. Swtich off the unit and return it for servicing.

“Format Mme? Y/N” is displayed when Brake Meter is switched ON.

Internal flash memory is corrupt or unreadable.Press ‘N’ key to skip formatting. Switch off the unit and return it for servicing. Note: If ‘Y’ key is pressed, all existing data might get erased.

“Reset All? Y/N” displayed when unit is switched ON.

Clock memory is corrupt. Clock battery may be flat. Do NOT press ‘Y’. Press ‘N’and switch off the unit and return the unit for serviing.

“Accelero Fail” displayed when unit is switched ON.

Accelerometer chip is faulty. Return the unit for servicing.

FAQ – AutoTest Bluetooth Printer

How do I turn the power on my printer?

Press and hold the POWER button down for 2-3 seconds, or until the power indicator light turns red.

 

Why is the red light on my printer flashing?

When the printer is on, but has been inactive for a time, the red light will flash as the printer has en- tered power saving mode. To print again, press the Power button and the red light will stop flashing.

Why isn’t the Bluetooth printer connecting?

When connecting, it can take up to 20 seconds for the printer to pair. You will see the blue light flash- ing when it is paired. Restart the Bluetooth printer and make sure it is charged up.

My print-outs are faded. What should I do?

This means that the printer is almost flat. Charge your printer, and it will print darker.

 

What does the blue blinking light on my printer mean?

That the battery is almost flat. This means you must charge the device. (If the printer is charging, refer to the question below).

Can I use the printer while charging it?

Yes. While the printer is charging the blue light will turn on. When the printer is off the light will be solid. When the printer is turned on while charging the blue light will flash.

How do I correctly charge my printer?

 

Refer to your Printer User Manual point 3.2.7 BATTERY CHARGING on your USB, or download from our website – https://autotest.net.au/product/autostop-mini-plus-brake-meter/

 

FAQ – AutoLight

AutoLight won’t Turn on.

Firstly, ensure batteries are correctly inserted. If they are, they may be flat. Replace the batteries. If the light tester will still not turn on, please contact our service department.


 

AutoLight won’t stay on.

The lamp only stays illuminated for approx. 3 secs, then a result is shown.


The light globe is not working.

Return unit for servicing.

 

AutoLight turns itself off during use.

The batteries may be flat. Replace them.

 

My AutoLight briefly flashed an incorrect reading and switched off quicker than normal.

The batteries in your unit are low and don’t have enough charge to power the unit. Please replace BOTH with 9-volt batteries.

 

How long does a battery last?

Many hundreds of Tests.

 

Can I use a rechargeable battery?

No. Rechargeable batteries have lower voltage and are not suitable.

 

How often do I need to calibrate my AutoLight Tester?

Every 12 months.

 

How long does it take to calibrate my AutoLight?

It may take one business day to calibrate (Excluding shipping and any repairs).

 

Where do I send my AutoLight for calibration?

Send it to AutoTest Products (see contacts) or your local distributor.

 

What should I send when my AutoLight needs service and calibration?

Please send the device, a business card and updated contact details.

 

How long does the warranty last?

12 months parts and labour.3 months parts and labour for repairs.

 

Can I get a longer cord?

Yes. A longer cord can be purchased as an optional extra, which is double in length. The unit must be recalibrated after the modification.

FAQ – AutoTest Headlight Align

Where is the manual for the Headlight Align?

The manual for the Headlight Align is on the USB that is included with the unit. Additionally, it can be downloaded from our website.

I’m having dificulties assembling my Headlight Align?

Refer to the manual and follow the steps starting from Page 9, where the Fig 1 shows all the parts / pieces. You may also call us if you need further help.

 

FAQ – AutoStop Mini Plus

Where is the user manual?

The user manual is stored inside the USB drive that came in with the unit. The manual can also be downloaded on AutoTest Product website.

How to change daylight saving time?

Go to “View Clock?” and Press number “1” to toggle daylight saving. If the time is out, please contact us.

Can I change the batteries?

No. The batteries are soldered on the circuit board. Please send the unit to us if your batteries are faulty.

Why does the unit turn off once connected to the charger?

This is normal. Please turn off the meter before putting it to charge.

I need the data logging software for the AutoStop Mini, not the Mini Plus and I can’t find it on your website.

The AutoStop Mini has been superseded by the Mini Plus and we no longer have a product page for it. Please contact our service department and they will arrange a download link for you.

How often do I need to calibrate?

Mini Plus -1 Year

How do I know when to calibrate my Mini Plus?

Calibration due date is shown on the screen & shown on every test print out.

 

FAQ – AutoGas (Gas Analyser)

If the AutoTest Emissions Tester installer shows the following message: “The wizard was interrupted before AutoTest Emissions Tester could be completely installed.”

 

  1. Go to the Program Files directory on the C Drive

  2. Find the AutoTest folder

  3. Right click on the folder

  4. Click on the “Security” tab

  5. For your user account which should be under your name or administrator click on the “Edit” button

  6. Under the “permissions for everyone” list, tick “Allow” for “full control” and “modify”

  7. Click Apply and ok

  8. The installer should now work

How often does the Gas Analyser need to be calibrated?

 

Every 12 months. Send it directly to us, or via your local distributor for recalibration.

 

Can the Gas Analyser connect to the computer using USB?

 

The Gas Analyser needs to be connected to the PC via the supplied cable. Earlier cables are RS232 and will need an RS232 to USB adapter to plug into a USB port. Current cables connect directly through the USB port to the Gas Analyser.

Where is the user manual?

The user manual is stored inside the USB that came in the box. The manual can also be downloaded from our website.

Where do I buy the paper?

You can purchase a paper pack through our website or your local distributor. A paper pack consists of 4 paper rolls.

Can I buy more filters?

Yes. You can purchase these directly through our website.

Can I replace sensors by myself?

 

No. The Gas Analyser needs to be recalibrated after changing any sensors. Please contact AutoTest Products.

 

FAQ – AutoStop Suspension Meter

Why does the unit turn off once connected to the charger?

This is normal. Please turn off the meter before putting it to charge.

Can I change the batteries?

No. The batteries are soldered on the circuit board. Please send to AutoTest Products if your products are faulty.


FAQ – AutoStop BTS380 Battery System Tester

The Battery tester is tuning on and off.

The cable is broken. Send it to AutoTest Products or via your local distributor for repair.

Where do I buy my paper?

You can purchase a paper pack through our website or your local distributor. A paper pack consists of 9 paper rolls.


FAQ – AutoStop Heavy

  Where is the user manual?

The user manual is stored inside the USB drive that came in the box as a PDF file. The manual can be downloaded from AutoTest Product website as well.

My screen is too dark/light.

Adjust the contrast by using the ‘O’ menu command and pressing the up or down arrows. Refer to your manual for more information.

My Brake Meter turns off when printing.

Charge the battery.

How often should I charge my battery?

It is okay to leave the unit on charge all the time.

My brake tester will not take charge.

Check that the charge light is on. Measure the output voltage of the charge. Batteries normally have a life of 2-3 years. If the problem persists, call our Service Team.

My brake meter does not print out the results after the test.

After a test, press Y to print out the results. If the results displayed are not correct, press NO and repeat the test. Call our Service Team if the problem persists.

The paper won’t feed.

Wrong paper type – replace the paper roll. Clean dust and dirt from the printer with a dry brush.

Does my printer need oiling?

No. Under no circumstances should you oil your printer, this will void your warranty.

How long does my printer ribbon last?

The ribbon should be changed with every second roll of paper.

Where do I buy paper and ribbons?

From the online shop on our website or your local distributor. A paper pack consists of 2 paper rolls and 1 ribbon.

Can I replace or repair my pedal sensor?

No. Each sensor is individually calibrated; this must be done by Service Team.

 

I need to push the brake pedal very hard to get the AutoStop brake tester to work.

Call our Service Team, and a technician will help you to adjust the meter.

Every test has the same pedal force reading. The pedal sensor wire is broken. Send the meter back for repair to AutoTest Products, or via your local distributor.

The plastic cap on my load cell is loose.

The cap should be loose for correct operation.

The speed reading is much higher than the speed I was travelling.

The brake meter was not firmly secured in the car – repeat the test.

The speed reading is much lower than the speed I was travelling.

The sensors may need adjustments – turn the brake meter off, then on again to perform a self-check.

Call the Service Team if the problem persists.

What sort of stop is required?

A moderate stop from approximately 35 km/h is best. Do not skid the vehicle, as this will provide poor results.

How often do I need to calibrate my AutoStop Brake Tester?

Heavy – 1 Year.

How long does it take to calibrate my Brake Meter?

It may take one business day to calibrate (excluding shipping and repairs).

Where do I send my AutoStop Brake Tester for calibration?

Send it to AutoTest Products or through your local distributor.

What should I send when my AutoStop Brake Tester needs service and calibration?

Please send your brake meter, charger, business card

and up to date contact details.

Can I hire a replacement brake tester while mine is repaired or calibrated?

Yes, we require a bond paid by credit card and

dispatch will be same day. Contact us for the hire forms.

Why is the distance shown on the meter different to that measured with a tape measure?

AutoStop brake meters measure deceleration (braking efficiency) directly (which is the design parameter used in original homologation) to an accuracy of 2%. Distance is calculated by the meter in its internal computer using the average deceleration measurement, time to stop (from the internal real time clock – accuracy 1.0%) and the assumption that the final speed is zero. The double integration process involved in the mathematics compounds these measurement accuracies and dependent on the shape of the deceleration versus time trace can generate a different result. The difference will be much less than that obtained from using any peak deceleration instrument such as a Tapley meter. The difference is due solely to the mathematics and is not a function of the AutoStop Meter. Regulators in certain jurisdictions still use “distance to stop” – because in the 70’s and 80’s direct measurement of braking efficiency to an accuracy of 2%. The regulations will “catch-up” eventually.

Can I store two tester ID numbers in the meter?

No, only one ID can be stored. Please press “N” on the Examiner ID prompt to reset it.

How long does my warranty last?

12 months parts and labour. 3 months parts and labour for repairs.

My time or date is incorrect.

If the time is incorrect by one hour, check the daylight saving setting. Otherwise, contact us

and a technician will assist you.

 

How do I get the latest version of the download software for my brake meter? The latest version of the download software is available for free download on our website.

 

My download software / datalogger isn’t working.

Check that all cables are connected securely and are not damaged. If you are running Windows 2000, you must use the new Windows-based software, since the old MS-DOS data logging software is not compatible. You can download the latest download software free from AutoTest website.

 

How do I clear the datalogger?

At the Ready > prompt, press “L” to enter the datalogger menu. Press “C” at the datalogger menu to wipe all saved test data

 

Why is the speed wrong?

The device is not fastened properly, or has been turned on before fastening in the test position. Figure 1 shows correct test position. Needs to be seat belted into the passenger seat with the lid open and closer to the windscreen, not resting on the back

of the chair. Alternatively, you can place on the floor of the passenger seat facing the same direction.

Never hold on your lap for the test, between your legs, or on the floor of the driver’s side

 

Figure 1: AutoStop brake meter in position ready for testing. Secure in position before turning on and starting any testing.

I’ve lost my manual. Where can I get a copy?

You can download the latest version of our product manuals on the AutoTest website.

How do I change units from % to G?

At “ready” press “x” then “A”, pressing “A” repeatedly will toggle between units.

How do I change to daylight saving?

At ready press “T” then “D”, an asterisk will be displayed beside the time indicating Daylight saving.

How to check battery level?

Press “B” at Ready> screen.

Why does the screen show prelude and not register a brake test?

Please check pedal sensor reading. Press “c” at Ready>. Press “c” again, screen should show 0.XX N. Press on pedal sensor and see if the reading goes up accordingly. If there is a delay or the reading is not rising, please contact us.

I’ve lost the License code for using my Brake Meter with the Data logging software.

Please contact our service department with the unit’s serial number at the ready and they will assist you in generating a new code.

 

Why the Brake Meter turns off while printing, even it has been charged overnight?

The battery is not holding charge and needs to be replaced. Send it in to us for a replacement.

The charging light is not tuning on when I plug in the charger.

The charging socket may be damaged, or the LED may be blown. Send it in to us for repair. Please also send in with the charger you are using.

The Brake meter turns off in the middle of a test or print out, but it shows 100% battery.

The battery is not holding charge and needs to be replaced. Send it in to us for a replacement.

Why the keypad shows 12V Input but I need to use a 14V charger?

That means 12V non-regulated. It should be shown as 14v if the charger output is regulated. We recommend using the charger that came with the Brake meter only. Never use a 12v regulated charger, it will drain the battery. You can purchase a new charger through our website or your local distributor.

The charging light is not going off even when the battery is fully charged.

The charging light only indicate if a charger is plugged in, it won’t change according to the battery level.

My computer does not recognise my Brake Meter when plugged in via USB.

Please install the USB drivers included with the Brake Meter software, these are located in the ‘USB drivers’ sub-folder of the main folder where the datalogger was installed to (Typically: C:\Program Files (x86)\AutoTest\ Maxi and Heavy Datalogger).

Please contact us for further assistance if this still doesn’t recognise your Brake Meter.

How do I find which Comm Port number my Brake Meter was assigned?

Open ‘Device Manager’ and expand ‘Ports (Com & LPT)’. Search the list of devices for ‘USB Serial Device’ and to the right of its name will be the Com port number.

How do I use my Brake Meter with serial connection with newer desktops or laptops that don’t have a serial ports?

It is still possible to use a Brake Meter with serial connection on newer PCs that lack serial ports by using a USB-to-serial converter. Compatibility with individual converters may vary however and AutoTest can only offer minimal support in assisting you when using one.

How do I change the display views for km / mph, the unit of acceleration, graph mode etc? Refer to the manual, Section 4.

 

 

Brake meter will not turn on

Battery may be flat- charge unit for 12 to 16 hours. Battery charger has failed – check battery charger output with multimeter, also check condition of fittings. Battery or internal electronics have failed – return unit for servicing.

Brake meter does not record keypad input

Battery may be flat- refer below.

Brake meter turns itself off during use

Battery may be flat- refer below.

No printout

Out of paper = remove printer cover plate and check paper roll. Refer manual Section 4.

Printout illegible or hard to read

Printer ribbon needs replacing- Refer manual Section 5.

“Time out” displayed on printout

Unit not secured into position properly. Foot has been lifted from pedal before vehicle has stopped.

“MEM FAILED” is displayed when Brake Meter is switched ON.

Internal flash memory is not responding or it is faulty. Swtich off the unit and return it for servicing.

“Format Mme? Y/N” is displayed when Brake Meter is switched ON.

Internal flash memory is corrupt or unreadable.Press ‘N’ key to skip formatting. Switch off the unit and return it for servicing. Note: If ‘Y’ key is pressed, all existing data might get erased.

“Reset All? Y/N” displayed when unit is switched ON.

Clock memory is corrupt. Clock battery may be flat. Do NOT press ‘Y’. Press ‘N’ and switch off the unit and return the unit for servicing.

“Accelero Fail” displayed when unit is switched ON.

Accelerometer chip is faulty. Return the unit for servicing.

 

FAQ – Workshop Pro 10

IMPORTANT THINGS TO KNOW

READ YOUR MANUAL INC. ACTIVATION STEPS – This can be found in the USB stick provided in the box, or on our website.

You need to be connected to Wi-Fi to activate your license

New users must activate their license through the Workshop Manager App

You cannot renew your license until it has expired.

 

BLUETOOTH PRINTER:

  • To turn on, hold ON button for a few seconds.

  • Follow prompts in BrakePro app to connect and print.

HOW TO TAKE A SCREEN SHOT OF YOUR RESULTS:

  • Hold Power button and Volume Down button at the same time for a couple of seconds.

  • This screen shot will be saved on the tablet. Go to FILES app and click on IMAGES tab. Then click on the SCREEN SHOT folder at the top to find your image.

  • You can email this image if you set up your emails on this tablet.



When the BrakePro app starts, it shows “Looking for GPS Signal’ for a long time and I can’t use the unit.

Your unit is having trouble acquiring a signal, take the unit outside. Alternatively connect your unit to a Wi-Fi network to assist in establishing a connection, this can reduce start up time considerably.

 

My brake software is expired. How do I reactivate it?

Through the Workshop Manager App. You will need to make sure you have downloaded it, and refreshed the app, as well as the Brake Pro app. You will need to calibrate and pay for your license every 12-months.

 

How do I know what version of software I have?

Go to: SETTINGS > ABOUT > VERSION

(See Fig 1 below)

 

Where can I find my Serial Number?

Go to: SETTINGS > ABOUT > TABLET SERIAL

(See Fig 1 below)

 

When should I calibrate my Workshop Pro? Calibration is required yearly. Every time you renew the license. This can be done yourself through Workshop

Manager app.

*IN NSW YOU MUST SEND YOUR WORKSHOP PRO AND PEDAL EFFORT SENSOR TO US FOR YEARLY CALIBRATION.

 

When do I need to send in my Workshop Pro? You do not need to*. If you are having issues with the Workshop Pro (i.e. Won’t charge or won’t turn on),

you can take the device to your nearest Distributor. Alternatively, call our service line ( 3 8840 3016 ) for advice before sending your unit back.

My unit prompts me to update the BrakePro app but shows an error when it tries to install.

Contact Service Team and they’ll walk you through this issue.

When activating my unit, I get an error such as ‘Address field too long’ or similar.

Please check your address. If the address is very long you may need to abbreviate it. Do not use special characters such as commas or slashes, as these will trigger errors. Just leave a space in their place when possible

 


Figure 1: The About screen shows your softwear version number, tablet serial number, android ID, and your GPS location zone.

 

Figure 2: Workshop Pro in position ready for testing. If the unit is moving in the seat, place on the floor of the passenger seat. Supplied velcro will secure in place.

 

The app is running slowly when sorting out stored tests.

Please clean up tests regularly by transferring them to the computer using the USB cable.

 

The time on my unit is wrong, how do I fix this? Change the time to AUTOMATIC if you had changed it manually. If it’s on network time but still incorrect, connect

to a network to get the updated time.

The time zone may be wrong, so swipe up on the bottom of the screen and press the circle button. Once you’re on the home screen swipe on the middle of the screen to open up the list of apps. Open ‘Settings’ and scroll down to select System Settings. Then select Date & Time. Switch off Automatic Time Zone if it’s on and then set correct Time Zone manually if that is wrong.

My results are in the wrong units, how do I change them?

Open Settings from the Brake Pro app’s main menu and then select Test Results Settings. Choose your desired Units and then press either the house or gears icons to save your choice. You can also change the units for decelaration on the test results screen by pressing on the decelaration readings and choosing from the menu that pops up.

Why am I getting a speed error?

The Workshop Pro is moving relative to the vehicle.

This is a common error when the unit is not secured properly to the vehicle. See Figure 2 on previous page. The supplied Velcro will stop your Workshop Pro from moving,when attached to the carpet floor on the passenger side of the vehicle.

Never hold in your hand for the test, or between your legs, or on the floor of the driver’s side.

How do I delete a saved result?

To delete individual saved test results, open Database on the main App menu. Hold your finger down on the test you want deleted and it will be highlighted in red. You can then select multiple tests to be deleted. Click the trash can in top right corner to delete the selected tests.