Schumacher PSW-22 User Manual

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Models / Modelos / Modèles: PSW-22, PSW-2035, PSW-2550, PSW-3060, PSW-61224

OWNER’S MANUAL

Manual del usuario

GUIDE D’UTILISATION

Manual Battery Charger Cargador de Batería Manual Chargeur de Batterie Manuel

DO NOT RETURN THIS PRODUCT TO THE STORE!

Call Customer Service for Assistance: 800-621-5485

¡NO LO DEVUELVA este producto A LA TIENDA!

Llame a Servicios al Cliente para Asistencia: 800-621-5485

NE PAS RETOURNER LE PRODUIT AU MAGASIN!

Appeler le service clientèle pour l’assistance: 800-621-5485

READ THE ENTIRE MANUAL BEFORE USING THIS PRODUCT. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.

LEA EL MANUAL COMPLETO ANTES DE UTILIZAR ESTE PRODUCTO. CUALQUIER FALLA PODRÍA RESULTAR EN SERIAS LESIONES O PODRÍA SER MORTAL.

LIRE ENTIÈREMENT LE GUIDE AVANT D’UTILISER CE PRODUIT.

L’ÉCHEC DE FAIRE AINSI PEUT S’ENSUIVRE DANS LA BLESSURE SÉRIEUSE OU LA MORT.

0099001270-00

IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL.

SAVE THESE INSTRUCTIONS – This manual will show you how to use your charger safely and effectively. Please read, understand and follow these instructions and precautions carefully, as this manual contains important safety and operating instructions. The safety messages used throughout this manual contain a signal word, a message and an icon.

The signal word indicates the level of the hazard in a situation.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or bystanders.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to the operator or bystanders.

Indicates a potentially hazardous situation which, if not avoided, could result in moderate or minor injury to the operator or bystanders.

Indicates a potentially hazardous situation which, if not avoided, could result in damage to the equipment or vehicle or property damage.

Pursuant to California Proposition 65, this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

1.IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS.

This manual contains important safety and operating instructions.

RISK OF ELECTRIC SHOCK OR FIRE.

1.1Keep out of reach of children.

1.2Do not expose the charger to rain or snow.

1.3Use only recommended attachments. Use of an attachment not recommended or sold by Schumacher® Electric Corporation

may result in a risk of fire, electric shock or injury to persons or damage to property.

1.4To reduce the risk of damage to the electric plug or cord, pull by the plug rather than the cord when disconnecting the charger.

1.5An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk of fire and electric shock. If an extension cord must be used, make sure:

•That the pins on the plug of the extension cord are the same number, size and shape as those of the plug on the charger.

•That the extension cord is properly wired and in good electrical condition.

•That the wire size is large enough for the AC ampere rating of the charger as specified in section 8.

1.6To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Simply turning off the controls will not reduce this risk.

1.7Do not operate the charger with a damaged cord or plug; have the cord or plug replaced immediately by a qualified service person. (Call customer service at 1-800-621-5485.)

1.8Do not operate the charger if it has received a sharp blow, been dropped or otherwise damaged in any way; take it to a qualified service person. (Call customer service at 1-800-621-5485.)

1.9Do not disassemble the charger; take it to a qualified service person when service or repair is required. Incorrect reassembly may result in a risk of fire or electric shock. (Call customer service at 1-800-621-5485.)

•2 •

RISK OF EXPLOSIVE GASES.

1.10 WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER.

1.11To reduce the risk of a battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery. Review the cautionary markings on these products and on the engine.

1.12This charger employs parts, such as switches and circuit breakers, that tend to produce arcs and sparks. If used in a garage, locate this charger 18 inches (46 cm) or more above floor level.

2.PERSONAL PRECAUTIONS

RISK OF EXPLOSIVE GASES.

2.1NEVER smoke or allow a spark or flame in the vicinity of a battery or engine.

2.2Remove personal metal items such as rings, bracelets, necklaces and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.

2.3Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or other electrical part that may cause an explosion.

2.4Use this charger for charging LEAD-ACID batteries only. It is not intended to supply power to a low voltage electrical system other than in a starter-motor application. Do not use this battery charger for charging dry-cell batteries that are commonly used with home

appliances. These batteries may burst and cause injury to persons and damage to property.

2.5NEVER charge a frozen battery.

2.6NEVER overcharge a battery.

2.7Consider having someone nearby to come to your aid when you work near a lead-acid battery.

2.8Have plenty of fresh water and soap nearby, in case battery acid contacts your skin, clothing or eyes.

2.9Wear complete eye and body protection, including safety goggles and protective clothing. Avoid touching your eyes while working near the battery.

2.10If battery acid contacts your skin or clothing, immediately wash the area with soap and water. If acid enters your eye, immediately flood the eye with cold running water for at least 10 minutes and get medical attention right away.

2.11If battery acid is accidentally swallowed, drink milk, the whites of eggs or water. DO NOT induce vomiting. Seek medical attention immediately.

3.PREPARING TO CHARGE

RISK OF CONTACT WITH BATTERY ACID. BATTERY ACID IS A

HIGHLY CORROSIVE SULFURIC ACID.

3.1If it is necessary to remove the battery from the vehicle to charge it, always remove the grounded terminal first. Make sure all of the accessories in the vehicle are off to prevent arcing.

3.2Be sure the area around the battery is well ventilated while the battery is being charged.

3.3Clean the battery terminals before charging the battery. During cleaning, keep airborne corrosion from coming into contact with your eyes, nose and mouth. Use baking soda and water to neutralize the battery acid and help eliminate airborne corrosion. Do not touch your eyes, nose or mouth.

3.4Add distilled water to each cell until the battery acid reaches the level specified by the battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve regulated lead acid batteries (VRLA), carefully follow the manufacturer’s recharging instructions.

3.5Read, understand and follow all instructions for the charger, battery, vehicle and any equipment used near the battery and charger. Study all of the battery manufacturer’s specific precautions while charging and recommended rates of charge.

•3 •

3.6Determine the voltage of the battery by referring to the vehicle owner’s manual and make sure that the output voltage selector switch is set to the correct voltage. If the charger has an adjustable charge rate, charge the battery in the lowest rate first.

3.7Make sure that the charger cable clips make tight connections.

4.CHARGER LOCATION

RISK OF EXPLOSION AND CONTACT WITH

BATTERY ACID.

4.1Locate the charger as far away from the battery as the DC cables permit.

4.2Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.

4.3Do not set the battery on top of the charger.

4.4Never allow battery acid to drip onto the charger when reading the electrolyte specific gravity or filling the battery.

4.5Do not operate the charger in a closed-in area or restrict the ventilation in any way.

5.DC CONNECTION PRECAUTIONS

5.1Connect and disconnect the DC output clips only after setting all of the charger switches to the “off” position (if applicable) and removing the AC plug from the electrical outlet.

Never allow the clips to touch each other.

5.2Attach the clips to the battery and chassis, as indicated in sections 6 and 7.

6.FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE.

A SPARK NEAR THE BATTERY MAY CAUSE A

BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

6.1 Position the AC and DC cables to reduce the risk of damage by the hood, door and moving or hot engine parts. NOTE: If it is necessary to close the

hood during the charging process, ensure that the hood does not touch the metal part of the battery clips or cut the insulation of the cables.

6.2Stay clear of fan blades, belts, pulleys and other parts that can cause injury.

6.3Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.

6.4Determine which post of the battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most vehicles), see step 6.5. If the positive post is grounded to the chassis, see step 6.6.

6.5For a negative-grounded vehicle, connect the POSITIVE (RED) clip from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect the NEGATIVE (BLACK) clip to the vehicle chassis or engine block away from the battery.

Do not connect the clip to the carburetor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

6.6For a positive-grounded vehicle, connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery. Connect the POSITIVE (RED) clip to the vehicle chassis or engine block away from the battery. Do not connect the clip to the carburetor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

6.7Connect charger AC supply cord to electrical outlet.

6.8When disconnecting the charger, turn all switches to off, disconnect the AC cord, remove the clip from the vehicle chassis and then remove the clip from the battery terminal.

6.9See CALCULATING CHARGE TIME for length of charge information.

•4 •

7.FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE.

A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

7.1 Check the polarity of the battery posts. The

POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.

7.2Attach at least a 24-inch (61 cm) long 6-gauge (AWG) insulated battery cable to the NEGATIVE (NEG, N, -) battery post.

7.3Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) post of the battery.

7.4Position yourself and the free end of the cable you previously attached to the NEGATIVE

(NEG, N, -) battery post as far away from the battery as possible – then connect the NEGATIVE (BLACK) charger clip to the free end of the cable.

7.5Do not face the battery when making the final connection. As stated in 7.4, face away from the battery when connecting the negative clip to the cable.

7.6Connect charger AC supply cord to electrical outlet.

7.7When disconnecting the charger, always do so in the reverse order of the connecting procedure and break the first connection while as far away from the battery as practical.

7.8A marine (boat) battery must be removed and charged on shore. To charge it onboard requires equipment specially designed for marine use.

8.grounding and ac power cord connections

RISK OF ELECTRIC SHOCK OR FIRE.

8.1 This battery charger is for use on a nominal 120-volt circuit and has a grounded plug that looks like the plug illustrated. The charger must be grounded to reduce the risk of electric shock. The plug must be plugged into an outlet

that is properly installed and grounded in accordance with all local codes and ordinances. The plug pins must fit the receptacle (outlet).

Do not use with an ungrounded system.

8.2 Never alter the AC cord or plug provided – if it does not fit the outlet, have a proper grounded outlet installed by a qualified electrician. An improper connection can result in a risk of an electric shock or electrocution. NOTE: Pursuant to Canadian Regulations, use of an adapter plug is not allowed in Canada. Use of an adapter plug in the United States is not recommended and should not be used.

8.3Recommended minimum AWG size for extension cord:

•100 feet (30.5 meters) long or less – use a 10 gauge (6 mm2) extension cord.

•Over 100 feet (30.5 meters) long – use an 8 gauge (10 mm2) extension cord.

• 5 •

9.FEATURES

5	3				5	3	4
	4		5		5		4
			5
1		10	9		2
1		10			11
				1	11		6
				1
					1
	6				1
	6						7
	7						7
	7
	8			8			8
	8

	PSW-22			PSW-2035		PSW-2550
5	3	4		3	1.	Ammeter
5	3	4	5	3	2.	Voltmeter
			5	4	2.	Voltmeter
					3.	Foam Grip
2					4.	Fiber Glass Clamp Rod
2					5.	Clamps
11			1		5.	Clamps
1		6	1	6	6.	Charge Rate Selector Switch
1		7		6	7.	Timer
		7		7	8.	Wheel
12					9.	Off/Charge Rate Toggle Switch
		8		8	10.	Engine Start/Charge Rate
						Toggle Switch
					11.	Voltage Selector Switch
					12.	Battery Load Tester Switch
	PSW-3060			PSW-61224

10.ASSEMBLY INSTRUCTIONS

Wheel Charger Assembly Instructions for PSW-2035

10.1It is important to fully assemble your charger before use. Remove all cord wraps and uncoil the cables prior to using the battery charger. Follow these instructions for assembly.

	PARTS	TOOLS NEEDED
(2)	10-32, thread cutting screws	3/8" wrench (for mounting foot)
(4)	¼-20, thread cutting screws	5/16" wrench (for mounting wheels)
(4)	Phillips head sheet metal screws	1/4" wrench (for mounting handle)
(2) wheels		hammer
(1) axle		screwdriver (flat blade)
(2) axle caps		screwdriver (Phillips)
(2) axle brackets
(1) handle
(1) foot

• 6 •

Attach the Foot: Remove the charger from the packing materials and place upside down on a flat surface. Attach the foot and secure it with the four ¼-20 thread cutting screws provided.

Assemble the Wheels and Axle: Hold the axle upright on the floor or work surface. Then, using a hammer, tap one of the axle caps onto the top end of the axle. Be sure to tap the axle cap on straight. Slide both wheels onto the axle with the recessed hubs facing out as shown. Install the second axle cap.

Mount the Axle to the Charger:

Place one end of each bracket into the slot on the bottom of the charger. Place the axle assembly under each bracket. Attach the brackets using the two, 10-32 thread cutting screws provided.

NOTE: Be careful not to drop the brackets inside of the charger case.

Attach the Handle: If the charger came with a plastic grip, slide that onto the handle until it is centered at the top. Turn the charger right side up onto its foot and wheels. Align the handle so the screw holes are aligned with the screw holes on the upper back corners

of the charger. Attach the handle using the four Phillips head screws provided.

Wheel Charger Assembly Instructions for PSW-22, PSW-2550, PSW-3060 and PSW-61224

10.2It is important to fully assemble your charger before use. Follow these instructions for assembly.

Item		PARTS	TOOLS NEEDED
1	(2) axle brackets		3/8" wrench (for mounting foot)
2	(1) axle with pin holes		5/16" wrench (for mounting wheels)
3	(2) wheels		1/4" wrench (for mounting handle)
4	(2)	10-32, thread cutting screws	hammer
5	(2)	¼-20, thread cutting screws	screwdriver (flat blade)
6	(1) foot		screwdriver (Phillips)
7	(2) axle caps
8	(2) hairpin cotter
9	(4)	8-18 sheet metal screws
10	(1) handle
11	(1) fiberglass clamp rod
12	(1) foam handle grip

• 7 •

1.Carefully lay the charger on its front to prepare for assembly.

2.Assemble the foot (Item 6) using two ¼-20 screws (Item 5) and tighten securely.

3.Attach the two axle brackets (Item 1) using one 10-32 screw (Item 4) in each. The brackets should have one end hooked into the slot in the charger base. Be careful not to drop the brackets inside of the charger case. Do not completely tighten the screws (Item 4) at this time.

4.Slide the axle (Item 2) into the brackets (Item 1) until centered on the charger.

5.Slide one wheel (Item 3) onto the axle with the recessed hub facing out as shown.

6.Insert the pin (Item 8) through the axle hole.

7.Repeat this process for the other wheel and when both wheels have been pinned to the axle, finish tightening the two axle bracket screws (Item 4).

8.Snap the axle caps (Item 7) onto each wheel to cover the pin and axle.

9.Lift the charger upright so that it rests on the wheels and foot.

10.Remove the two top side screws (Item 9) from each side of the charger.

11.Verify that the foam handle grip (Item 12) is on the handle assembly (Item 10). Install it if needed.

12.Insert the fiberglass clamp rod (Item 11) into the pierced holes on the inside of the handle (Item 10).

13.Align the handle assembly (Item 10) with the charger and reinstall the side screws (Item 9). Do not over tighten.

14.The charger assembly is now complete. The battery clips can be clamped to the fiberglass rod (Item 11) for convenient storage.

15.Do not attach the clips to the foam area of the handle; this will damage the foam grip.

11.CONTROL PANEL

Note: Not all controls are available on all models.

Timer

•Timer Setting: The timer allows you to set a specified time for charging. After the timer expires, the charger stops charging your battery. The main function of the timer is to prevent over charging while allowing a battery time to obtain a satisfactory charge. To properly set the timer, you must know the size of the battery in ampere hours or reserve capacity in minutes and the state of charge. It is important that you determine the appropriate state of charge of your battery as specified in Section 13 and set the timer accordingly.

•Hold: This position defeats the timer function, allowing for continuous operation. Put the timer in the HOLD position when you want to charge more than 2¼ hours. Be sure to monitor the charging progress and stop it when the battery is charged. Not doing so may cause damage to your battery or may cause other personal property damage or personal injury.

•8 •

Ammeter

The Ammeter indicates the amount of current, measured in amps, that is being drawn by the battery. As a battery takes on a charge, it draws less current from the charger. Correspondingly, the meter will show less current being drawn by the battery. When the

current stops decreasing, the battery is charged. The 2 amp charge rate may indicate some activity on the meter, although the meter does not have the resolution to display this low rate.

Voltmeter

The voltmeter indicates the voltage at the battery terminals. The charger need not be plugged into an AC outlet. The timer should be in the OFF position. Then connect the charger following the instructions in sections 6 and 7. Observe the meter indication.

Keep in mind that this reading is only a battery voltage reading, a false surface charge may mislead you. We suggest that you turn on the headlights for a couple of minutes before you read the meter. Read it a couple of minutes after you have shut the headlights off. If the reading is less than 10.5-volts, the battery may be bad or the connection at the charger may be poor. If the reading is 10.5-volts to 12.8-volts, the battery is low – recharge it. If the reading is above 12.8-volts, the battery is charged.

Charge Rate Selector Switch

Use the Charge Rate selector switch to select the charge rate or engine starting setting you require.

•1.5A, 2A, 4A and 5A Slow Charge Rate – Intended for charging small batteries such as those commonly used in garden tractors, snowmobiles and motorcycles.

•10A, 20A, 30A and 35A Fast and 40A, 60A, 65A and 80A Rapid Charge Rate –

Use for charging automotive, marine and deep-cycle batteries. Not intended for industrial applications.

•125A, 180A, 200A, 225A, 250A and 300A Engine Start – Provides high amperage for cranking an engine with a weak or run down battery. Always use in combination with a battery.

Model PSW-2035 employs 2 toggle switches:

•Switch #1 – Use this switch to select the 200 Amp Engine Start and the 35 Amp

Charge Rate. Switch #2 must be in the down position (Select Position) when using

Switch #1.

•Switch #2 – Use this switch to select the 2 amp Charge Rate and the OFF position.

Also, use to select use of Switch #1. Note that Switch #1 is only effective when Switch #2 is set to “Select Position.”

Model PSW-61224 employs a 7-position rotary switch.

•You may select the output voltages of 6, 12, or 24 volts for charging the batteries of those voltages or battery combinations connected in series (not parallel) in which the sum of the battery voltages adds up to the range selected. Each voltage range offers a high or low amp charge rate. The higher charge rate is more suitable for fast charging a battery to the point where it will start a vehicle, the lower (slower) charge rate is more suitable for fully charging (restoring) a battery. (See the Input/Output Chart on the Battery Charger.)

Voltage Selector Switch

Use this switch to set the scale of the voltmeter to either 6 volt and 12 volt DC to match the battery or batteries being charged. NOTE: This does not change the output voltage of the charger.

Battery Load Tester Switch (Model PSW-3060 only)

Use this switch to apply a load to the battery when testing it. (See Using the Battery Load Tester Feature section.)

12.OPERATING INSTRUCTIONS Charging (Model PSW-2035)

1.Ensure that all of the charger components are in place and in good working condition, including the plastic boots on the battery clips. Make sure the electrolyte

(battery liquid) in each cell is at the correct level.

2.Set the charge rate selector switch (switch #2) to the OFF position.

3.Connect the battery following the precautions listed in Sections 6 and 7.

4.Connect the AC power following the precautions listed in Section 8.

5.Place the charge rate selector switches (switch #1 and #2) in the preferred position.

•9 •

•For the 2A charge rate, switch #1 is not used and switch #2 should be toggled up.

•For the 35A charge rate, both switches (#1 and #2) should be toggled down.

6.To disconnect the charger, reverse the procedure.

NOTE: This is a manual charger and will overcharge a battery if permitted to operate for extended periods of time. Monitor the charging often.

Charging (Models PSW-22, PSW 2550, PSW-3060 and PSW-61224)

1.Ensure that all of the charger components are in place and in good working condition, including the plastic boots on the battery clips. Make sure the electrolyte

(battery liquid) in each cell is at the correct level.

2.Set the charge rate selector switch to the OFF position.

3.Connect the battery following the precautions listed in Sections 6 and 7.

4.Connect the AC power following the precautions listed in Section 8.

5.Set the voltage selector switch (if equipped) to the correct voltage for the battery type you are charging.

6.Place the charge rate selector switch in the preferred position.

7.Turn the timer to the selected charge time.

8.To disconnect the charger, reverse the procedure.

NOTE: This is a manual charger and will overcharge a battery if permitted to operate for extended periods of time. Monitor the charging often.

Using the Engine Start feature

Your battery charger can be used to jumpstart your car if the battery is low. Follow these instructions on how to use the ENGINE START feature.

Follow all safety instructions and precautions for charging your battery. Wear complete eye protection and clothing protection. Charge your battery in a wellventilated area.

Using the ENGINE START feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle’s electrical system. NOTE: If you have charged the battery and it still will not start your car, do not use the engine start feature, or it could damage the vehicle’s electrical system.

1.Set the charge rate switch and the timer to the OFF position.

2.With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in Section 6 (FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE).

3.Plug the charger AC power cord into the AC outlet, and then move the timer switch from OFF to the HOLD position.

4.With the charger plugged in and connected to the battery of the vehicle, set the charge rate selector switch to the engine start position.

NOTE: For Model PSW-2035, switch #1 should be toggled up and switch #2 should be toggled down.

5.Crank the engine until it starts or 3.5 seconds pass. If the engine does not start, wait 3 minutes before cranking again. This allows the charger and battery to cool down.

NOTE: During extremely cold weather, or if the battery is under 2 volts, charge the battery for 5 minutes before cranking the engine.

6.If the engine fails to start, charge the battery for 5 more minutes before attempting to crank the engine again.

7.After the engine starts, move the charge rate selector switch to the OFF position and unplug the AC power cord before disconnecting the battery clips from the vehicle.

8.Clean and store the charger in a dry location.

NOTE: If the engine does turn over but never starts, there is not a problem with the starting system; there is a problem somewhere else with the vehicle. STOP cranking the engine until the other problem has been diagnosed and corrected.

• 10 •

Using the Battery Voltage Tester

Overview

This battery charger has a built-in voltmeter to test your battery’s state of charge. A recently charged battery could have a temporarily high voltage due to what is known as “surface charge”. The voltage of such a battery will gradually drop during the period immediately after the charging system is disengaged. Consequently, the tester could display inconsistent values for such a battery. For a more accurate reading, the surface charge should be removed by temporarily creating a load on the battery, such as by turning on lights or other accessories for a couple of minutes before you read the display. Read it a couple of minutes after you have shut the headlights off.

Testing Sequence: There are five basic steps required to test the battery state of charge:

1.With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in Sections 6 and 7.

2.Select the correct setting of the meter (6V or 12V) to match the battery to be tested.

3.Set the charge rate switch and the timer to the OFF position.

4.Plug the charger AC power cord into the AC outlet, following the instructions given in Section 8.

5.Read the voltage on the voltmeter.

Using the Alternator Performance Tester

Overview

This battery charger has a built-in alternator tester that displays an estimate of the alternator’s relative output compared to normal alternators. The alternator % values displayed should be taken as a general reference, not a precise diagnosis. The alternator tester functions the same as the built-in battery voltage tester (see previous section for details) with a few differences.

Testing Sequence: There are five basic steps required to operate this unit as an alternator tester:

1.With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in Sections 6 and 7.

2.Select the correct setting of the meter (6V or 12V) to match the battery to be tested.

3.Set the charge rate switch and the timer to the OFF position.

4.Start the vehicle and turn on the vehicle’s headlights. Read the voltage on the voltmeter.

Using the Battery Load Tester Feature (PSW-3060 only) Overview

Load testing is the process of putting demand on a system or device and measuring its response.

Testing Sequence: There are five basic steps required to load test a battery.

1.Confirm that the charger is not plugged in.

2.Select the correct setting of the meter (6V or 12V) to match the battery to be tested.

3.Set the charge rate switch and the timer to the OFF position.

4.Connect the battery following the precautions listed in Sections 6 and 7.

5.Press the Load Switch to LOAD ON for 10 seconds while reading the voltmeter.

Green – Indicates the battery capacity is OK. The battery may or may not be fully charged. Check the specific gravity to determine the state of charge. If the specific gravity shows less than a full charge, check for an electrical drain on the battery or for possible charging system problems. Recharge the battery to full charge.

Yellow or Red, but the needle remains steady – Indicates that the battery capacity is not satisfactory. The battery may be either defective or not fully charged. Check the specific gravity of the battery to see which condition exists. If charging does not bring the battery up to a full charge, the battery should be replaced.

Yellow or Red, but the needle continues to fall – Indicates the battery may be defective or rundown. Release the load switch, and note the voltmeter reaction. Voltage recovery into the green or above within seconds indicates a defective battery. A slow recovery indicates a rundown condition. For best results, check the specific gravity of the battery.

• 11 •

General Charging Notes

Fan: The charger is designed to control its cooling fan for efficient operation.

Consequentially, it is normal for the fan to start and stop when maintaining a fully charged battery. Keep the area near the charger clear of obstructions to allow the fan to operate efficiently.

Voltage: The voltage displayed during charging is the charging voltage and is usually higher than the battery’s resting voltage.

13.CALCULATING CHARGE TIME

Use the table below to more accurately determine the time it will take to bring a battery to full charge. First, identify where your battery fits into the chart.

NR means that the charger setting is NOT RECOMMENDED.

Find your battery’s rating on the chart, and note the charge time given for each charger setting. The times given are for batteries with a 50% charge prior to recharging. Add more time for severely discharged batteries.

BATTERY SIZE/RATING

CHARGE RATE/CHARGING TIME - HOURS

1.5 - 2

4 - 5

AMP

6 - 12 AH

2 - 5

1 - 2

Motorcycle,

hrs.

SMALL

garden,

3¾ -

BATTERIES

12 - 32

2 - 5

tractor, etc.

13½

hrs.

200 - 315

40 - 60

11¼ -

5½

2¼ - 3

1 - 1½

¾ - 1

40 - 50

½ - ¾

23 - 29

17 - 22

- 7¼

CCA

hrs.

hr.

min.

hrs.

min.

hrs.

CAR/

315 - 550

60 - 85

7¼

3 - 3¾

1½ - 2

1 - 1¼

50 - 60

¾ - 1

29 - 37

22 - 28

- 9¼

TRUCK

CCA

hrs.

min.

hr.

min.

hrs.

550 - 1000

85 - 190

9¼ -

3¾ - 7

2 - 3½

1¼

1 - 2

1 - 1¾

37 - 70

28 - 52

17½

- 2¼

CCA

hrs.

min.

hrs.

80 RC

8¾

3½

1¾

hrs.

140 RC

5½

2¾

hrs.

MARINE/DEEP CYCLE

160 RC

6 hrs.

3 hrs.

180 RC

6½

3¼

hrs.

14. MAINTENANCE INSTRUCTIONS

14.1 After use and before performing maintenance, unplug and disconnect the battery charger (see Sections 6, 7 and 8).

14.2 Use a dry cloth to wipe all battery corrosion and other dirt or oil from the terminals, cords, and the charger case.

14.3 Ensure that all of the charger components are in place and in good working condition, including the plastic boots on the battery clips.

14.4 Servicing does not require opening the unit, as there are no user-serviceable parts.

15. STORAGE INSTRUCTIONS

15.1Store the charger unplugged, in an upright position. The cord will still conduct electricity until it is unplugged from the outlet.

15.2Store inside, in a cool, dry place.

15.3Store the clips on the fiberglass clamp rod. Do not store them on the handle, clipped together, on or around metal, or clipped to the cables.

•12 •

16.TROUBLESHOOTING

PROBLEM	POSSIBLE CAUSE	REASON/SOLUTION
No reading on the	Charger is not plugged in.	Plug the charger into an AC
ammeter.		outlet.
	No power at the receptacle.	Check for open fuse or circuit
		breaker supplying AC outlet.
	Clips are not making a good	Check for poor connection to
	connection to the battery.	battery and frame. Make sure
		connection points are clean.
		Rock clips back and forth for a
		better connection.
	Connections are reversed.	Unplug the charger and reverse
		the clips.
	Battery is defective (will not	Have battery checked.
	accept a charge).
	1.5, 2, 4 or 5 amp charge rate is	Ammeter may show no activity at
	being used.	the 1.5A, 2A, 4A or 5A charge rate.
Ammeter reading stays high.	Battery is severely discharged.	Continue charging battery for two
		more hours. If problem continues,
		have the battery checked.
	Wrong battery voltage.	Verify the voltage settings on the
		charger are correct.
Ammeter reads less than	Extension cord is too long or wire	Use a shorter or heavier gauge
selected charge rate when	gauge is too small.	extension cord.
charging a discharged	Weak cell or sulfated plate in	A sulfated battery will eventually
battery.	Weak cell or sulfated plate in	A sulfated battery will eventually
	battery.	take a normal charge if left
		connected. If the battery will not
		take a charge, have it checked.
	Battery is only partially discharged.	Continue to charge the battery.

The charger is making an	Circuit breaker is cycling.	The settings may be wrong.
audible clicking sound.		Check the charger settings.
	Battery is defective.	Have the battery checked.
	Shorted battery cables or clips.	Circuit breaker cycles when
		current draw is too high. Check for
		shorted cables or clips and replace
		if necessary.
	Severely discharged battery, but	The battery may not want to
	otherwise it is a good battery.	accept a charge due to a run-
		down state. Allow charging to
		continue until battery has a
		chance to recover sufficiently to
		take a charge. If more than 20
		minutes, stop charging and have
		the battery checked.
	Reverse connections at battery.	Shut the charger off and correct
		the lead connections.

• 13 •

PROBLEM	POSSIBLE CAUSE	REASON/SOLUTION
Charger makes a loud buzz	Transformer laminations vibrate	No problem; this is a normal
or hum.	(buzz).	condition.
	Shorted Diode Assembly or	Have charger checked by a
	Output Rectifier Assembly (hum).	qualified technician.
Short or no start cycle	Drawing more than the charger’s	Crank time varies with the
when cranking engine.	rated amps.	amount of current drawn. If
		cranking draws more than the
		charger’s rated amps, crank time
		may be less than 3 seconds.
	Failure to wait 3 minutes (180	Wait 3 minutes of rest time before
	seconds) between cranks.	the next crank.
	Clips are not making a good	Check for poor connection at
	connection.	battery and frame.
	AC cord and/or extension cord	Check power cord and extension
	is loose.	cord for loose fitting plug.
	No power at receptacle.	Check for open fuse or circuit
		breaker supplying AC outlet.
	The charger may be overheated.	The thermal protector may have
		tripped and needs a little longer
		to reset. Make sure the charger
		vents are not blocked. Wait and
		try again.
	Battery may be severely	On a severely discharged battery,
	discharged.	charge for 10 to 15 minutes in the
		manual charge rate to help assist
		in cranking.
Charger will not turn on	AC outlet is dead.	Check for open fuse or circuit
when properly connected.		breaker supplying AC outlet.
	Poor electrical connection.	Check power cord and extension
		cord for loose fitting plug.
The battery is connected	Clips are not making a good	Check for poor connection at
and the charger is on, but	connection.	battery and frame. Make sure
is not charging.		connecting points are clean.
		Rock clips back and forth for a
		better connection.

• 14 •

17.BEFORE RETURNING FOR REPAIRS

17.1When a charging problem arises, make certain that the battery is capable of accepting a normal charge. Double check all connections, the AC outlet for a full 120-volts, the charger clips for correct polarity and the quality of the connections from the cables to the clips and from the clips to the battery system. The clips must be clean.

17.2When a battery is very cold, partially charged or sulfated, it will not draw the full rated amperes from the charger. It is both dangerous and damaging to a battery to force higher amperage into it than it can effectively use in recharging.

17.3When an UNKNOWN OPERATING PROBLEM arises, please read the complete manual and call the customer service number for information that will usually eliminate the need for return.

If the above solutions do not eliminate the problem or for information about troubleshooting or replacement parts, call toll-free from anywhere in the U.S.A.

1-800-621-5485

7:00 am to 5:00 pm Central Time Monday thru Friday

18.LIMITED WARRANTY

Warranty not valid in Mexico.

SCHUMACHER ELECTRIC CORPORATION, 801 BUSINESS CENTER DRIVE, MOUNT PROSPECT, IL 60056-2179, MAKES THIS LIMITED WARRANTY TO THE ORIGINAL RETAIL PURCHASER OF THIS PRODUCT. THIS LIMITED WARRANTY IS NOT TRANSFERABLE OR ASSIGNABLE.

Schumacher Electric Corporation (the “Manufacturer”) warrants this battery charger for 3 years from the date of purchase at retail against defective material or workmanship that may occur under normal use and care. If your unit is not free from defective material or workmanship, Manufacturer’s obligation under this warranty is solely to repair or replace your product with a new or reconditioned unit at the option of the Manufacturer. It is the obligation of the purchaser to forward the unit, along with proof of purchase and mailing charges prepaid to the Manufacturer or its authorized representatives in order for repair or replacement to occur.

Manufacturer does not provide any warranty for any accessories used with this product that are not manufactured by Schumacher Electric Corporation and approved for use with this product. This Limited Warranty is void if the product is misused, subjected to careless handling, repaired, or modified by anyone other than Manufacturer or if this unit is resold through an unauthorized retailer.

Manufacturer makes no other warranties, including, but not limited to, express, implied or statutory warranties, including without limitation, any implied warranty of merchantability or implied warranty of fitness for a particular purpose. Further,

Manufacturer shall not be liable for any incidental, special or consequential damage claims incurred by purchasers, users or others associated with this product, including, but not limited to, lost profits, revenues, anticipated sales, business opportunities, goodwill, business interruption and any other injury or damage. Any and all such warranties, other than the limited warranty included herein, are hereby expressly disclaimed and excluded. Some states do not allow the exclusion or limitation of incidental or consequential damages or length of implied warranty, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and it is possible you may have other rights which vary from this warranty.

• 15 •

THIS LIMITED WARRANTY IS THE ONLY EXPRESS LIMITED WARRANTY AND THE MANUFACTURER NEITHER ASSUMES OR AUTHORIZES ANYONE TO ASSUME OR MAKE ANY OTHER OBLIGATION TOWARDS THE PRODUCT OTHER THAN THIS WARRANTY.

Schumacher Electric Corporation Customer Service 1-800-621-5485

Monday – Friday 7:00 a.m. to 5:00 p.m. CST

Schumacher® and the Schumacher Logo® are registered trademarks of Schumacher Electric Corporation.

To activate the warranty, please fill in the warranty registration card on page 17 and mail it in, OR go to www.batterychargers.com to register your product online.

DO NOT RETURN THIS PRODUCT TO THE STORE!

Call Customer Service for assistance: 800-621-5485

• 16 •

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