Schumacher 85-8100 User Manual
85-8100
Professional
Battery
Charger/Tester
INSTRUCTION MANUAL
English p. 1
Français p. 19
Español p. 39
00-99-000613/1106
TABLE OF CONTENTS
1. IMPORTANT SAFETY INSTRUCTIONS .....................................................................................4
2. PERSONAL PRECAUTIONS ......................................................................................................5
3. ATTACHING THE HANDLE, GROUNDING AND AC POWER CORD CONNECTION ..............6
4. PREPARING TO CHARGE THE BATTERY ................................................................................8
5. CHARGER LOCATION ...............................................................................................................8
6. DC CONNECTION PRECAUTIONS ...........................................................................................8
7. CHARGER FEATURES AND CONTROLS .................................................................................9
8. BASIC OPERATION ....................................................................................................................11
9. PROCEDURE FOR A BATTERY INSTALLED IN THE VEHICLE ...............................................12
10. PROCEDURE FOR A BATTERY OUTSIDE THE VEHICLE .......................................................13
11. ELECTRICAL CONDITION OF THE BATTERY ..........................................................................13
12. BATTERY CHARGING FORMULA .............................................................................................14
13. MULTIPLE BATTERY CHARGING ............................................................................................15
14. STARTER AND CHARGING SYSTEMS TEST PROCEDURES ................................................15
15. MAINTENANCE INSTRUCTIONS ..............................................................................................17
16. TROUBLESHOOTING ................................................................................................................17
17. LIMITED WARRANTY .................................................................................................................17
18. CUSTOMER SERVICE ...............................................................................................................18
CHARGING TIME CHART
12 V Battery
Type
Small
Automotive
Regular
Automotive
Deep Cycle
Heavy Duty
RC = Reserve Capacity SOC = State-of-Charge hrs = Hours min = Minutes
RC
Minutes
60 <11.7 0 60 6 hrs 4 hrs 115 min 85 min
60 11.7-12.0 25 45 4 hrs 3 hrs 85 min 65 min
60 12.0-12.2 50 30 3 hrs 115 min 1 hr 45 min
60 12.2-12.4 75 15 85 min 1 hr 30 min 20 min
120 <11.7 0 90 9 hrs 6 hrs 3 hrs 2 hrs
120 11.7-12.0 25 70 7 hrs 5 hrs 2 hrs 105 min
120 12.0-12.2 50 50 5 hrs 3 hrs 95 min 70 min
120 12.2-12.4 75 20 2 hrs 95 min 50 min 35 min
180 <11.7 0 130 13 hrs 9 hrs 4 hrs 3 hrs
180 11.7-12.0 25 100 10 hrs 7 hrs 3 hrs 2 hrs
180 12.0-12.2 50 70 7 hrs 4 hrs 2 hrs 100 min
180 12.2-12.4 75 30 3 hrs 2 hrs 65 min 50 min
240 <11.7 0 170 17 hrs 11 hrs 6 hrs 4 hrs
240 11.7-12.0 25 130 13 hrs 8 hrs 4 hrs 3 hrs
240 12.0-12.2 50 80 8 hrs 6 hrs 3 hrs 2 hrs
240 12.2-12.4 75 40 4 hrs 3 hrs 85 min 65 min
- A - - B - - C -
Battery
Voltage% SOC
Amp
Hrs
10 Amp 15 Amp 30 Amp 40 Amp
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Instruction Manual
NAPA 85-8100 Digital Wheel Charger
WARNING: Handling the cord on this product or cords associated with
accessories sold with this product, may expose you to lead, a chemical
known to the State of California to cause cancer and birth defects or
other reproductive harm. Wash hands after handling.
CAUTION: Charger must be fully assembled before operating. See section 3 for instructions.
1. IMPORTANT SAFETY INSTRUCTIONS
READ AND SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT AND
OPERATING INSTRUCTIONS.
WARNING: RISK OF EXPLOSIVE GAS.
1.1 WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. Batteries generate
explosive gases during normal battery operation, and when discharged or charged. For this reason, IT IS OF UTMOST IMPORTANCE THAT BEFORE USING YOUR CHARGER, YOU READ
THIS MANUAL AND FOLLOW THE SAFETY AND OPERATING INSTRUCTIONS EXACTLY.
1.2 To reduce risk of battery explosion, follow these safety instructions and those published by the
battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of
a battery. Review cautionary marking on these products and on engine, and on vehicle or equipment containing the battery.
1.3 CAUTION: To reduce risk of injury, CHARGE ONLY RECHARGEABLE LEAD-ACID TYPE
BATTERIES which may include maintenance-free, low-maintenance or deep-cycle batteries. OTHER TYPES OF BATTERIES MAY BURST causing personal injury and damage.
If you are uncertain as to the type of battery you are attempting to charge, or the correct proce-
dure for checking the battery’s state-of-charge, contact the seller or battery manufacturer.
1.4 Use of an attachment not recommended or sold by the battery charger manufacturer may result in
a risk of re, electric shock, or injury to persons.
1.5 To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting the charger.
1.6 Position AC and DC leads to avoid tripping over them and to prevent damage by hood, doors, or
moving engine parts; protect from heat, oil, and sharp edges.
1.7 Do not operate charger if it has received a sharp blow, been dropped or otherwise damaged in
any way; take it to a qualied service center.
1.8 Do not disassemble NAPA Digital Wheel Charger; take it to a qualied service center when repair
is required. Incorrect reassembly may result in a risk of electric shock or re.
1.9 To reduce risk of electric shock, unplug charger from the AC outlet before attempting any maintenance or cleaning. Turning off the controls will not reduce this risk.
▪ ▪
1.10 MARINE “BOAT” BATTERIES MUST BE REMOVED AND CHARGED ON SHORE. To safely
charge them on board requires equipment especially designed for marine use.
1.11 Connect and disconnect battery leads (clamps) only when AC supply cord is unplugged.
1.12 Do not overcharge battery (see Sections 8–12 and/or refer to the Charging Time Chart on the
Quick Reference Guide or Table of Contents page).
1.13 When charging a battery, locate in a dry, well-ventilated area.
1.14 Never place articles on or around charger, or locate the NAPA Digital Wheel Charger in such a
way that will restrict the ow of cooling air through the cabinet.
1.15 An extension cord should not be used unless absolutely necessary (see paragraph 3.4).
1.16 Have a damaged cord or plug replaced immediately.
1.17 Do not expose the NAPA Digital Wheel Charger to rain or snow.
2. PERSONAL PRECAUTIONS
2.1 Always have someone within range of your voice, or close enough to come to your aid, when
working around lead acid batteries.
2.2 Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
2.3 Wear complete eye protection, clothing protection, and wear rubber soled shoes. Place damp
cloth over battery to protect against acid spray. When ground is very wet or covered with snow,
wear rubber boots. Avoid touching eyes while working near battery.
2.4 If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye,
immediately ush with running cold water for at least 10 minutes and seek medical attention.
2.5 NEVER smoke or allow a spark or ame in vicinity of battery or engine.
2.6 Be extra cautious to reduce risk of dropping a metal tool onto a battery. It might spark or short
circuit the battery or other electrical part that may cause an explosion.
2.7 Before working with a lead acid battery, remove personal metal items such as rings, bracelets,
necklaces, watches, etc. A lead acid battery can produce a short circuit current high enough to
weld such items, causing a severe burn.
2.8 CAUTION: TO REDUCE THE RISK OF INJURY, CHARGE ONLY RECHARGEABLE LEAD
ACID TYPE BATTERIES WHICH MAY INCLUDE MAINTENANCE FREE, LOW MAINTENANCE, OR DEEP CYCLE BATTERIES. OTHER TYPES OF BATTERIES MAY BURST, CAUSING PERSONAL INJURY AND DAMAGE.
The NAPA Digital Wheel Charger is not intended to supply power to a low-voltage electrical sys-
tem other than applications using rechargeable, lead-acid type batteries. Do not use this battery
charger for charging dry-cell batteries commonly used with home appliances. These batteries may
burst and cause personal injury and property damage.
2.9 NEVER charge a frozen battery; thaw it out rst.
▪ ▪
3. ATTACHING THE HANDLE, GROUNDING AND AC POWER CORD CONNECTION
3.1 ATTACHING THE CHARGER HANDLE
CAUTION: The charger must be fully assembled before operating.
a. Locate the handle and four screws provided. The charger comes with one of two types of
handles.
b. Remove the top two screws at the rear from both sides of the charger.
c. Straddle the handle over the charger and align the mounting holes. Make sure the handle is
ush with the edge of the charger (see drawing.)
d. Attach the handle with the four screws and tighten securely.
Notice offset of
holes to orient
handle correctly.
3.2 The charger must be grounded to reduce risk of electric shock. The NAPA Digital Wheel
Charger is equipped with an electric cord having an equipment grounding conductor and a
grounding plug, which must be plugged into an outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
DANGER: NEVER ALTER CHARGER’S ORIGINAL AC CORD AND PLUG. IF THE PLUG
DOES NOT FIT OUTLET, HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED
ELECTRICIAN. IMPROPER CONNECTION CAN RESULT IN THE RISK OF AN ELECTRIC
SHOCK. ALWAYS KEEP CHARGER UNPLUGGED FROM OUTLET WHEN CHARGER IS
IDLE.
▪ ▪
3.3 This NAPA Digital Wheel Charger is for use on a nominal 120-volt circuit and has a grounding
plug that looks like the plug illustrated below (A). A temporary adapter, which looks like the adapter illustrated in (B) and (C), may be used to connect this plug to a two-pole receptacle as shown in
(B), if a properly grounded outlet is not available. The temporary adapter should be used only until
properly grounded outlet can be installed by a qualied electrician.
DANGER: BEFORE USING ADAPTER AS ILLUSTRATED, BE CERTAIN THAT CENTER
SCREW OF OUTLET PLATE IS GROUNDED. The green-colored rigid ear or lug extending from
adapter must be connected to a properly grounded outlet: make certain it is grounded. If necessary, replace original outlet cover plate screw with a longer screw that will secure adapter ear or
lug to cover plate and make ground connection to grounded outlet.
USE OF AN ADAPTER IS NOT ALLOWED IN CANADA. IF A GROUNDING-TYPE RECEPTACLE
IS NOT AVAILABLE, DO NOT USE THIS CHARGER UNTIL THE PROPER OUTLET IS INSTALLED
BY A QUALIFIED ELECTRICIAN.
3.4 An extension cord should not be used unless absolutely necessary. Use of improper extension
cord could result in a risk of re and electric shock. If extension cord must be used, make sure:
a. that pins on plugs of extension cord are the same number, size, and shape as those of plug
on the NAPA Digital Wheel Charger;
b. that extension cord is properly wired and in good electrical condition;
c. that wire size is large enough for AC ampere rating of charger as specied in the following
table.
Recommended minimum AWG* size for
extension cords for battery chargers
AC input rating, amperes AWG size of cord
Equal to or
greater than:
But less than: Length of cord, in feet (meters)
25 (7.6) 50 (15.2) 100 (30.5) 150 (45.6)
12 14 16 12 10 8
*American Wire Gauge
▪ ▪
4. PREPARING TO CHARGE BATTERY
4.1 If necessary to remove battery from vehicle to charge, always remove grounded terminal from
battery rst. Make sure all accessories in the vehicle are OFF, so as not to cause an arc.
4.2 Be sure area around battery is well-ventilated while battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan.
4.3 Clean battery terminals. Be careful to keep corrosion from coming into contact with your eyes.
. Add distilled water in each cell until battery acid reaches level specied by manufacturer. This
helps purge excessive gas from cells. Do not overll. For a battery without caps, carefully follow
the manufacturer’s recharging instructions.
. Study all battery manufacturer’s specic precautions such as removing or not removing cell caps
while charging and recommended rates of charge.
4.6 Determine voltage of battery by referring to car owner’s manual, and make sure that it matches
the output rating of the charger.
5. CHARGER LOCATION
5.1 Locate the NAPA Digital Wheel Charger as far away from battery as charger cables permit.
5.2 Never place charger directly above battery being charged; gases from battery will corrode and
damage charger.
. Never allow battery acid to drip on the charger when taking gravity readings or lling a battery.
5.4 Operate charger only in a well-ventilated area, free of dangerous vapors.
5.5 Store charger in a safe, dry location and maintain in perfect condition.
5.6 Do not set battery on top of charger, or where its acid might drip onto the charger.
6. DC CONNECTION PRECAUTIONS
6.1 All switches should be set in OFF position and AC cord should be UNPLUGGED from electrical
outlet before you connect and disconnect charger clamps.
6.2 Never allow clamps to touch each other.
6.3 When attaching charger clamps, be certain to make the best possible mechanical as well as electrical connection. This will tend to prevent clamps from slipping off connections, avoid dangerous
sparking, and assure safer and more efcient charging. Clamps should be kept clean.
CAUTION: SETTING SWITCHES TO OFF DOES NOT ALWAYS DISCONNECT CHARGER
ELECTRICAL CIRCUIT FROM AC POWER CORD OR DC CHARGER CLAMPS. MAKE SURE
CHARGER IS UNPLUGGED AND UNCLAMPED WHENEVER IT IS NOT IN USE.
▪ 8 ▪
7. CHARGER FEATURES AND CONTROLS
VOLTS
AMP-HRS.
AMPS.
TIME
TEMPS
TIEMPO
TEST / PRUEBA
OK
CHARGE
CARG
A
SELECT
SÉLECT.
SELEC.
FUNCTION
FONCTION
FUNCTIÓN
BAT. START. ALT.
V
A
Ah
PASS
FAIL
HOLD
CONT.
ESPERA
OFF
ARRÊT
APAGADA
30 MIN
45 MIN
15 MIN
60 MIN
75 MIN
90 MIN
105 MIN
120 MIN
PRUEBA
TEST
The NAPA 85-8100 Wheel Charger is a fully functional wheel charger with a unique digital inter-
face module that allows users to perform battery charge acceptance, starter, and alternator tests.
7.1 CONTROL CENTER FEATURES
Multi-purpose numerical LED display
functions as Voltmeter, Ammeter, Amp
The Digital Test and
Hour Accumulator, and Timer.
Charge display module
displays volts, amps, amp
hours, and charge time
units as indicated via
green LEDs.
Pass/Fail LEDs indicate
test results via a green
LED for PASS and a
red LED for FAIL.
Control Center Panel
The Select button gives
the user the ability to
select the display outputs, depending on what
is desired.
The Function button
allows users to change
the operation from
Charging to test modes
(Battery Charge
Acceptance, Starter, or
Alternator test).
NOTE: The multi-purpose LED display changes function according to how the charger is being used:
As an AMMETER, it indicates the amount of amps owing from charger into battery.
It keeps track of all accumulated amp hours during a test.
It serves as a VOLTMETER, indicating live voltage as soon as clamps are attached.
During TIMER operations, it shows either remaining time or elapsed time.
7.2 TIMER SWITCH
The Timer switch on the upper-right turns ON
the charger by setting a time. This must be done
before the charger is plugged in.
The OFF position disconnects the output of the
charger. By rotating the dial clockwise the output
is turned ON for a duration of time determined
by the number of minutes at which the dial is set.
The HOLD function can be used if charging times
longer than 120 minutes are required. While in the
timing phase, the output can be turned off by rotating the dial counterclockwise to the OFF position.
NOTE: There is no sound when the Timer completes, except for a soft click.
When determining charging time, refer to section 12. If the charger is plugged in when the Timer is
set, the internal fan will spin. A faint ticking sound is heard while the Timer runs.
▪ ▪
Timer Switch
7.3 RATE/VOLTAGE CONTROL SWITCH
12 V, 60 AMP
BOOST CHARGE
CHARGE D’APPOINT
CARGA DE REFUERZO
12 V, 200 AMP
ENGINE START
DÉMARRAGE
ARRANQUE
12 V
2 AMP
OFF
ARRÊT
APAGADA
TEST / PRUEBA
12 V, 40 AMP
The Rate/Voltage Control switch on the
upper-left controls the voltage and current.
Ensure that the voltage setting selected
matches the voltage of the battery intended for charging.
Select the amperage rate that suites your
application as described below:
Rate/Voltage Control Switch
SLOW CHARGE (Continuous)
2 AMP: For trickle-charging automotive size batteries, and slow overnight charging of low rated
batteries used in motorcycles, snowmobiles, lawn and garden tractors, etc.
FAST CHARGE (Continuous)
40 AMP: For charging automotive style, regular and deep-cycle batteries.
BOOST CHARGE & ENGINE START (Duty Cycle)
60 AMP: For brief, high output charging. Follow BOOST CHARGE ratings (min/max, On/Off
times) on charger’s front label. Refer to Quick Reference Guide for more details.
200 AMP: For automotive engine starting/cranking assist only. Follow ENGINE START ratings
(min/max, on/off times) on charger’s label. Refer to the Quick Reference Guide and paragraph 7.4
for more details.
WARNING: At higher AMP rates, it becomes easier to boil and overcharge the battery. DO
NOT LEAVE THE CHARGER UNATTENDED. Refer to the battery manufacturer’s charging
instructions. Use the Charging Time Chart on the Table of Contents page, or the calculation
in Section 12, to determine how long to charge. DO NOT LEAVE ON BOOST CHARGE ANY
LONGER THAN NECESSARY or damage to battery will result.
7.4 ENGINE START
The ENGINE START setting provides a high current suitable for crank-assist/starting a vehicle
that will not start due to a discharged battery. Use the step-by-step instructions of the Quick Refer-
ence Guide or use the following procedure. With the rate selector switch set to a fast charge (not
boost) setting (40 AMP), charge battery for 5 minutes. After 5 minutes of charge, select the ENGINE START position (200 AMP), set the timer to the HOLD position. Attempt to start the engine
using the ignition key.
If the engine fails to start within 3 to 5 seconds, stop cranking. Return charger to the fast charge
setting (40 AMP), and charge battery for another 5 minutes.
If the engine fails to start after a second or third attempt, disconnect the charger. Before replacing
the battery, use a battery tester to test it.
▪ 10 ▪
DO NOT attempt to start a vehicle without the battery properly installed. Damage may result
to the vehicle’s electrical system.
7.5 OVERLOAD PROTECTION
The charger uses an output circuit breaker and a thermal breaker to prevent overheating and
damage to the charger and the vehicle. If after repeated starting attempts, the charger does not
indicate any output on its meter, it may be because one of the two breakers has opened. If the
output breaker opens due to excessive current, a popping noise will be heard. It will automatically
reset itself in a few minutes. If the thermal breaker opens, it will automatically reset itself in about
15 to 30 minutes. Output over-voltage will show as 19.9 and the FAIL LED will light.
7.6 Display and Accuracy
Voltage
• Open circuit voltage between 12.0–13.0 is displayed to 0.1 V and is accurate to +/- 0.1 V at
DC levels.
•
Open circuit voltage below 12.0 or above 13.0 is displayed to 0.1 V and is accurate to +/- 2%.
• Charging voltage is displayed to 0.1 V and is accurate to +/- 2%.
Current
• Below 10 A, current is displayed to 0.1 A and is accurate to +/- 0.3 A.
• At 10 A or above, current is displayed to 0.1 A and is accurate to +/- 5%
Amp Hours
• Amp Hours are measured in whole units and represent the charge sent to the battery
NOTE: This is NOT a measurement of actual battery amp hours, but a running display
of how many amp hours the battery is currently accumulating.
Charge Time
• In Battery Test Mode, the timer displays a countdown timer from 15 minutes to zero.
• In Battery Charge Mode, the timer displays a total elapsed time.
8. BASIC OPERATION
8.1 BATTERY CHARGE ACCEPTANCE TEST
NOTE: This is NOT the same as a conductance test, for which the battery
analyzers mentioned in paragraph 7.4 are used.
a. With charger unplugged, set both dials to test mode (point to white battery illustration
boxes on each dial).
b. Hook the cables to battery, red to positive (+) post and black to negative (-) post. (If polarity
is reversed, attaching the second clamp will cause a spark. Reverse the clamps.) The
battery voltage will appear on the front panel display, and the PASS/FAIL LEDs will blink
alternatively until the 15 minute test time elapses.
▪ 11 ▪
NOTE: If charger detects more than 20 volts, the red FAIL light will illuminate and
the display will show 19.9. This may show on the display in BOOST CHARGE
mode.
c. Plug charger into outlet, and the battery test will automatically begin. Because the
test starts the instant the charger is plugged in, be sure to PLUG THE CHARGER IN
AS SOON AS POSSIBLE AFTER HOOKING CABLES TO BATTERY.
It is suggested that you stay near the charger for the rst 1 minutes or so to monitor test results.
If the battery FAILS, it is not recommended to attempt to continue charging a failed battery.
NOTE: To determine the difference between a BAD battery and one that fails simply
because it does not accept a charge, run another test with a dedicated battery tester.
The NAPA 85-8100 Digital Wheel Charger is not meant to replace a conductance battery
tester. Remove the battery from the charger for at least 4 hours before doing a
conductance test.
8.2 BATTERY CHARGE (See section 12 for more information)
Testing is part of the charging process. Once the initial 15-minute test has completed and the bat-
tery has passed, more time can be added to the Timer dial to nish charging.
NOTE: Even if the test is interrupted, the digital timer will keep track of all time that has passed
so the test can be picked up again at any time.
NOTE: Because the NAPA 85-8100 is a manual charger, charging will continue for as long as
the timer is active, even after the 15-minute digital test has completed. Extended charge times
can be potentially dangerous—so only set timer for slightly over 15 minutes.
Continue to charge until charge current drops to 12 amps or less, the target amp-hour value has
been reached, or the charge voltage exceeds 16 V.
Stop charging immediately if battery emits vapor or is hot (≥125 ˚F) to the touch.
9. FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN THE VEHICLE. A
SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE
THE RISK OF A SPARK NEAR THE BATTERY:
.1 Before working on vehicle, rmly apply emergency brake and place gear shift to NEUTRAL—shift
an automatic transmission to PARK.
9.2 Locate the NAPA Digital Wheel Charger as far away from battery as charger cords permit and
position AC and DC cords to avoid stepping on or tripping over them and to prevent damage by
hood, doors, or moving engine parts.
. Stay clear of fan blades, belts, pulleys, and any other parts that can cause physical injury.
9.4 Turn OFF all vehicle loads, including door lights, and correct any defects in car’s electrical system
that may have caused low battery.
9.5 Check polarity of battery posts. The POSITIVE (POS., P, +) post usually has a larger diameter
than the NEGATIVE (NEG., N,–) post.
9.6 Determine which post of battery is grounded (connected) to chassis. If negative post is grounded
(as in most vehicles), see paragraph 9.7. If positive post is grounded, see paragraph 9.8.
. For negative-grounded vehicle, rst connect POSITIVE (red) clamp from charger to POSITIVE
(POS., P, +) ungrounded post of battery. Then connect NEGATIVE (BLACK) clamp to vehicle
chassis or engine block away from battery. Do not connect clamp to carburetor, fuel lines, or
▪ 12 ▪
sheet-metal body parts. Connect to a heavy gauge metal part of frame or engine block. When disconnecting charger, turn switches to OFF, disconnect AC cord, remove clamp from vehicle chassis, and then remove clamp from battery terminal.
9.8 For positive-grounded vehicle, connect NEGATIVE (BLACK) clamp from charger to NEGATIVE
(NEG., N, –) ungrounded post of battery. Then connect POSITIVE (RED) clamp to vehicle chassis
or engine block away from battery. Do not connect clamp to carburetor, fuel lines, or sheet-metal
body parts. Connect to a heavy gauge metal part of frame or engine block.
When disconnecting the NAPA Digital Wheel Charger, turn switches to OFF, disconnect AC cord,
remove clamp from vehicle chassis, and then remove clamp from battery terminal.
CAUTION: When positive (+) post of vehicle battery is grounded, double-check polarity.
9.9 See the Charging Time Chart on the Table of Contents page.
10. FOLLOW THESE STEPS WHEN THE BATTERY IS OUTSIDE THE VEHICLE. A SPARK
NEAR THE BATTERY MAY CAUSE AN EXPLOSION. TO REDUCE THE RISK OF A
SPARK NEAR THE BATTERY:
If necessary to remove the battery from the vehicle or equipment, always remove the grounded
terminal from battery rst.
WARNING: MAKE SURE ALL VEHICLE LOADS ARE OFF TO PREVENT A POSSIBLE ARC.
10.1 Check polarity of battery posts. POSITIVE (POS., P, +) post usually has larger diameter than
NEGATIVE (NEG., N, –) post.
10.2 Attach at least a 24-inch, 6-gauge insulated battery cable to NEGATIVE (NEG., N, –) battery post.
10.3 Connect POSITIVE (RED) charger clamp to POSITIVE (POS., P, +) post of battery.
10. Position yourself, and free end of cable, as far away from battery as possible—do not face battery when
making nal connection—then connect NEGATIVE (BLACK) charger clamp to free end of cable.
10.5 When disconnecting the charger, always do so in reverse sequence of connecting procedure;
break rst connection while staying as far away from battery as practical.
10.6 MARINE “BOAT” BATTERIES MUST BE REMOVED AND CHARGED ON SHORE. To safely
charge them on board requires equipment especially designed for marine use.
11. ELECTRICAL CONDITION OF THE BATTERY
11.1 The state-of-charge of rellable-top batteries can be checked by using a hydrometer. A hydro-
meter is a bulb-type syringe which is used to extract a small quantity of the electrolyte from each
battery cell. A oat in the hydrometer barrel indicates the specic gravity of the electrolyte. This
specic gravity reading indicates the battery’s state-of-charge at a given temperature, as shown in
the following table:
▪ 1 ▪
**Initial specic gravity readings vary, depending on battery type and
manufacturer. Contact the seller or manufacturer of the battery for this
specication.
11.2 The state-of-charge of sealed-top (maintenance-free and recombination-type) batteries must be
checked with a high resolution voltage tester.
11.3 If uncertain about type of battery you will be charging, or the correct procedure for checking the
battery’s state-of-charge, contact the seller or manufacturer of the battery.
11.4 The temperature of the battery, and the equipment the battery is used with, has a dramatic effect
on battery efciency and system power requirements. For example, at 0 oF (–18 oC), a battery
is operating at 0% of its rated efciency, while the engine it is attempting to start requires over
twice as much power as would be necessary at 80 o F (27 oF).
12. BATTERY CHARGING FORMULA
12.1 Determine battery’s state-of-charge by following the instructions and chart in Section 11, connect
charger as per instructions in Section 9 and/or 10.
12.2 From the Charging Time Chart (located on the Table of Contents page and also on the Quick
Reference Guide), pick the ROW which has the Reserve Capacity rating and measured battery
voltage that is closest to the battery being charged. Follow across the row until you are under the
desired charging rate. This value indicates the approximate time required to recharge the battery.
NOTE: As a manual charger, the NAPA 85-8100 will continue to charge for as long
as the Timer is selected. This is potentially dangerous, as battery thermal runaway
and gassing are not detected. For this reason, only set the Timer for slightly over
the needed time to perform a charge. More time can always be added later, as the
Timer keeps track of accumulated time and charge.
12.3 An alternative method for calculating the time required to recharge a battery in good condition is
to follow this formula:
(reserve capacity in minutes) + 15.5 = amp hour capacity
2
(amp hour capacity) x (percent of charge needed) = time in hours
charger amp rate setting
(time in hours) x (recharge factor of 1.25) = recharge time
Example: Suppose a battery has an RC of 120 minutes and is discharged down to 25%.
We need to put in 75% more charge and we want to use our charger’s 40 AMP charge setting:
▪ 1 ▪
120 minutes + 15.5 = 75.5 amp hours *
2
(75.5 amp hours) x (0.75) = time = 1.4 hours
40-amp charge rate
Then: (1.4 hours) x (recharge factor of 1.25) = 1.76 hours or 106 minutes recharge time.
* NOTE: The NAPA 85-8100
calculates the amp hours for you,
visible on the display panel.
13. MULTIPLE BATTERY CHARGING
13.1 PARALLEL CHARGING
Batteries of the same type and voltage rating may be connected in parallel for maintenance charging.
Charge time increases in proportion to the number of batteries. Rate of charge decreases in the same
proportion.
Example: Charging two batteries in parallel will take twice as long, since each battery receives one-half
the amount of charge showing on the ammeter.
Thus, if the ammeter shows a 40-amp charge, each battery will be getting a 20-amp charge (assuming
both batteries have a similar rating, state-of-charge, etc.).
Example of Parallel Connection
14. STARTER AND CHARGING SYSTEMS TEST PROCEDURES
14.1 If doing both tests, the Starter test must run rst, before the Alternator test.
Ensure that the charger remains UNPLUGGED for the entire duration of either test.
Plugging in the charger will automatically start charging the battery, and suspend the Starter or
Alternator test in progress. Any charging current detected will make the FAIL LED come on by
default, and invalidate test results.
NOTE: Starter and Alternator tests will become disabled and not run while
charging is taking place.
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14.2 STARTER SYSTEM TEST PROCEDURE
a. WIth charger UNPLUGGED, connect the tester clamps to the battery as it is
situated in the vehicle: red to the positive(+) terminal, black to the negative (–)
terminal. Rock each clamp back and forth to make a good connection.
NOTE: The battery must be good and fully charged for this test.
b. Only the live voltage will appear on the LED, unless the charger is plugged in, in which
case the charge current is displayed and the FAIL LED is lit. The Starter test will be
bypassed if attempting to select it, until current is removed. UNPLUG the charger. The
PASS/FAIL LEDs will alternate blinking until a crank event is detected.
c. Start the vehicle.
d. Observe the nal cranking voltage that appears on the LED:
If the Volts reading is greater than 9.6 volts, the Starting System is OK. The PASS
LED will light.
If the Volts reading is less than 9.6 volts, there is a Starting System problem. The
FAIL LED will light. Check connections, wiring, and starter.
NOTE: If charge voltage exceeds 19.9v, the FAIL LED lights to highlight a potentially
dangerous situation.
14.3 CHARGING SYSTEM (ALTERNATOR) TEST PROCEDURE
The Alternator test is normally selected AFTER the crank (Starter) test. If continuing
from a Starter test, with the vehicle still running, press the Function button to move
from Starter to Alternator test.
a. Connect the tester clamps to the battery: red to positive (+) terminal, black to negative
(–) terminal, if they are not already connected. Rock each clamp back and forth to make
a good connection. NOTE: The battery must be good and fully charged for this test.
b. Only voltage will appear on the LED, unless the charger is plugged in, in which case the
charge current is displayed and the FAIL LED is lit. The Alternator test will be invalidated
until current is removed. UNPLUG the charger.
c. Rev the engine at 2000 rpm for 15 seconds. The PASS/FAIL LEDs will indicate the
result immediately. But as this is a semi-live result that will retain the highest measured
value, it is recommended to wait until this peak voltage stabilizes. If the value drifts into
the pass region, the PASS LED will light. If the value further drifts up and out of the pass
region, then the FAIL LED will stay lit.
d. Observe the volts reading that appears on the LED:
If the Volts reading is between 13.3 and 15.5 volts, the Charging System is OK.
The PASS LED will light.
If the Volts reading is greater than 15.5 volts, there is a Charging System Problem.
The FAIL LED will light. Check regulator.
If the Volts reading is less than 13.3 volts there is a Charging System Problem.
The FAIL LED will light. Check connections, wiring, and starter.
NOTE: If charge voltage exceeds 19.9v, the FAIL LED lights to highlight a potentially
dangerous situation.
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15. MAINTENANCE INSTRUCTIONS
The charger is designed and built with high quality materials requiring only a minimum amount of care:
1.1 Clamps should be cleaned each time the charger is used to prevent corrosion from battery uid.
15.2 Cords should be coiled when the charger is not being used to prevent damage.
1. Other servicing should be performed by qualied service personnel.
16. TROUBLESHOOTING
16.1 No amperage reading while charging a known good battery (voltage will still show):
a. Check AC outlet to be sure it is live.
b. Check connections to battery.
c. A circuit breaker may have opened. Refer to Section 9.5.
d. Ensure that all operating instructions were followed.
16.2 Certain battery conditions can cause meter to indicate incorrectly—including cold, sulphated,
or damaged batteries.
16.3 A Starter or Alternator test appears to fail. Conrm that the charger was left unplugged for
the entire duration of these tests. If charger is left unattended while running a Starter or Alternator
test and someone should happen to plug it in, the test will automatically be disabled and results
will not be valid.
16.4 Display panel blanks out after a test. This may happen if the 15-minute test has been allowed
to run unattended for more than 20 minutes or so, and indicates the battery was either
1) not able to accept a charge and is probably BAD, or
2) was completely discharged.
Repeat the battery test, and be there to monitor results when timer shuts off at 15 minutes. If
battery still shows FAIL and/or the display shuts down again after several seconds, then the
battery cannot even hold enough power to run the monitor display. It is likely unable to accept a
charge and should be considered BAD. See Section 8.1.
17. LIMITED WARRANTY
SCHUMACHER ELECTRIC CORPORATION, 801 BUSINESS CENTER DRIVE, MOUNT
PROSPECT, ILLINOIS, 60056-2179 MAKES THIS LIMITED WARRANTY TO THE
ORIGINAL PURCHASER AT RETAIL OF THIS PRODUCT. THIS LIMITED WARRANTY IS
NOT TRANSFERABLE.
Schumacher Electric Corporation warrants this battery charger against defective material
or workmanship. If such should occur, the unit will be repaired or replaced at the option
of the manufacturer. It is the obligation of the purchaser to forward the unit together with
proof of purchase, transportation and / or mailing charges prepaid to the manufacturer or its
authorized representative. This limited warranty is void if the product is misused, subjected
to careless handling, or repaired by anyone other than the factory or other authorized factory
representative. The manufacturer makes no warranty other than this limited warranty and
expressly excludes any implied warranty including any warranty for consequential damages.
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