Schumacher PST-1000 User Manual
OWNER’S MANUAL
Model: PST-1000
Carbon Pile Charging System Analyzer
For 6 and 12 Volt Batteries
ELECTRIC CORPORATION
MT. PROSPECT, IL 60056
Send Warranty Product Repairs To:
Customer Returns
P.O. Box 280
1025 E. Thompson Avenue
Hoopeston, IL 60942-0280
Questions? Call Customer Service
1-800-621-5485
00-99-000443/1004
PST-1000 IMPORTANT OPERATING & SAFETY NOTES
READ BEFORE PROCEEDING WITH TESTS
1. Always work in a well ventilated area. Never start a vehicle’s
engine in an enclosed area.
2. Never smoke or allow any other open flame to come within
25 feet of the vehicle being tested.
3. Always insure that everyone within close proximity of the
vehicle being tested is correctly wearing approved safety /
protective glasses before proceeding with any testing or
adjustments.
4. Always insure that the vehicle’s engine is turned OFF when
connecting or disconnecting any and all test equipment.
5. Always exercise extreme caution to insure that hands, arms,
clothing and tester leads are kept well away from all moving
engine parts.
6. Because the battery may produce highly explosive gases, it
is extremely important that you carefully observe the following
precautions:
A. DO NOT smoke or allow any other open flame or spark
within 25 feet of the battery.
B. NEVER DIRECTLY CONNECT THE POSITIVE AND
NEGATIVE battery posts with any single conductive
material such as a screwdriver, jumper lead, etc. , as this
will cause a short circuit and spark which could result in
an explosion.
7. Battery acid and corrosion can be extremely dangerous and
MUST BE DEALT WITH VERY CAREFULLY.
A. DO NOT allow battery acid or corrosion to come in direct
contact with skin or eyes. If it does, thoroughly wash skin
with warm, soapy water IMMEDIATELY and/or rinse eyes
with clear water for 15 – 20 minute. CONTACT
PHYSICIAN IMMEDIATELY.
B. Extreme caution must be exercised to avoid ingestion of
battery acid or corrosion. If ingestion does occur, drink
large quantities of milk, (DO NOT INDUCE VOMITING).
CONTACT PHYSICIAN IMMEDIATELY.
8. Tremendous back pressure can be developed in the radiator,
and taking the radiator cap off improperly can result in a
sudden release of scalding hot fluid, and subsequent serious
burns. You MUST refer to proper vehicle manufacturer’s
service manual for correct procedure.
9. Before working on a vehicle set the brakes and block the
wheels. Beware of automatic parking brake release. Due to
the inherent dangers with even the simplest automotive
maintenance procedures, the manufacturer and all
parties involved in the distribution and/or sale of this
automotive test product will NOT be held liable or
responsible, wholly OR partially, for ANY injuries,
damages or claims resulting from the performance of
testing or adjustment procedures included in this
instruction guide and/or the use of this automotive test
product.
10. Avoid electrical shocks caused by getting too close to live
ignition wires or touching the coil TACH terminal. A person’s
reaction near a running engine can be more damaging than
the shock itself.
11. Keep spark producing devices at least 18" (0.5m) above the
floor to reduce the hazard of igniting gasoline vapor.
12. Route test leads away from belts and pulleys before starting
engine to avoid damage and possible injury.
13. Remove finger rings and metal wrist bands. They can short
on active current sources and become very hot from electric
current passage and cause sever burns.
The charging system Analyzer is a rugged, professional quality
tool designed for extra heavy duty use. The convenient hook up
and test sequence allows a complete check in minutes of the:
Battery Alternator/Generator
Starter motor Voltage Regulator
Starter Solenoid All Interconnecting cables
With 6 to 24 volts batteries, it is a portable digital readout analyzer.
OUTSTANDING FEATURES OF THE CHARGING SYSTEM
ANALYZER ARE:
A. Rugged Construction: Designed for an extra heavy duty use
and maximum reliability.
B. Convenient Hook Up: All connections simply clamp on; no
time consuming cable disconnection are required on most
vehicles.
C. Large easy to read 3/4-inch digital displays for both amps
and volts:
1. Voltage Scale ±4V – ±16V for battery, ±0V – ±199.9V for
EXT
2. Current Scales ±0 – ±1999A
3. Good/Bad LED for Alternator Diodes
D. 12,000 watts Carbon pile for battery load testing.
E. An easy control carbon pile load, an inductive “Hall-effect”
amp probe which is plug-in replaceable, a beeping signal for
“time-out”, a high efficiency cooling fan and extra heavy duty
battery terminal clamps and cables
ANALYZER FEATURES
BATTERY CABLES
The Battery Cables do three things:
1. They conduct power to the analyzer from the battery under
test. The analyzer will measure accurately for voltages from
±4 to ±16 volts and ±0 – ±1000 Amps at the battery clamps.
2. They carry the 12,000 watts of resistance load from the
carbon pile stack.
3. They provide battery voltage reading connections when the
display selector is on the battery volts position.
Note: Each load cable has a voltage sensor wire which is independent of the extra heavy cable. The battery clamps are color
coded: Red for battery POS (+) and Black for battery NEG (-).
VOLTS DISPLAY AND SELECTOR
This liquid crystal display shows the voltage selected by the switch
below. A ±16.0 volt range with 0.1 volt steps are provided for
Battery Volts and External ±199.9V. If more than ±199.9 volts
are applied, the display will show “1”.
2
EXTERNAL VOLTS LEADS (1 mg ohms)
These leads may be used for measuring any DC voltage on a
vehicle when the test selector switch is placed in External position. The voltmeter circuit is isolated and has an automatic polarity indication. Typical applications are for measuring load voltages and cable connection voltage drops.
AMPS DISPLAY
The display shows the amperage sensed by the Amp Probe. The
readout is in 1 amp steps and has a working range up to ±1999
Amps.
AMP PROBE LEAD AND ZERO KNOB
The inductive Amp Probe senses current in a wire without having
to disturb any connections. Place the wire through the opening
and check that the probe jaws close fully. The + - sign on the
probe indicates the direction of conventional currents, which will
give a positive display reading. Reversed currents will show a
minus sign. For example, if the probe is on a negative ground
alternator output wire with the + sign towards the alternator, the
reading will be positive. Switch to 1000A position and use the
zero auto adjust knob (on probe top) to cancel offset before probe
hookup.
Note: The probe works by sensing magnetism around a wire. To
avoid errors keep it away from the back of the alternator and
other strong magnets. Probe uses a 9 volt battery inside of the
back.
DIODE/STATOR LAMP
This lamp will be on steady when there is alternator output of at
least 20 amps and excessive “ripple” is detected in the battery
cable. Ignore momentary flashes. Alternator output with ripple
current are usually caused by a bad diode or stator winding.
LOAD CONTROL KNOB
This load is suitable for 6 to 24 volt automotive battery systems.
The Load control knob is used to adjust the battery test current.
The load is a carbon pile capable of drawing 1000 Amps. Draws
of over 100 amps must be limited to 15 seconds with a minimum
of 60 seconds off between tests to avoid heat buildup. The fan
will come on when the test load reaches 50 amps and will remain
on until the temperature drops below 60°C. If the fan air feels
warm, allow it to run after testing to reduce the damaging effects
of high temperatures.
ANALYZER HOOK UP
All of the test procedures of a vehicle’s equipment presume that
the battery will perform well enough.
The battery test should
always be completed before performing other diagnostic
tests.
General specifications given in this manual are for 6–12 volts
systems and give satisfactory performance references for most
vehicles. However, there are some vehicles which will require
the actual vehicle manufacturer’s service specification values for
more accurate test conclusions.
When hooking up the analyzer, always do the following steps:
1. Be sure the load knob is turned to OFF before connecting
the analyzer cables to the battery. Take note of the safety
precautions on the front page of this manual.
2. Connect the analyzer Battery Clamps to the battery terminals;
Red to positive (+), Black to negative (-) They may be reversed
to get a minus volts reading. The clamp jaw from each cable
must have a solid connection to the battery terminal to assure
good voltage measurements and to prevent arching during
adapter attachment or high current load testing.
3. Set the volts (source) selector to Battery Volts. The analyzer
will show the battery voltage. The display will work from ±4.0
to ±16.0 volts so that 6 to 12 volt batteries can be tested.
4. With the Amps Probe jaws closed and not around any wires,
switch to the “1000A” position and push the Zero Amps Knob
until the Amps Display reads “000”.
NOTE
This manual assumes that Negative Ground battery systems
are being tested since Positive Ground batteries exist only
on antique or unusual vehicles. This affects the circuit
troubleshooting procedures.
BATTERY CAUTION
1. Always wear safety glasses when working around batteries.
2. Do not break live circuits at the battery terminals.
3. Avoid accidentally shorting the insulated battery terminal to
any ground metal. Never put a wrench on a live battery
terminal. Severe burns may result. Always disconnect the
battery chassis ground cable first.
AVOID DANGEROUS SPARKS
Always turn the Load Knob “OFF” before connecting or moving the battery clamps.
LOAD-ON LAMP
When the lamp is lighted, the carbon pile is drawing at last 50
amps from the battery and it is a reminder to turn off the load
when the test is complete or before changing battery connections.
Note: The Load-On lamp will not be bright enough to see during
6V battery tests.
TIMER BEEPER AND TIME OUT LAMP
When the Load-On lamp begins lighting, an internal timer waits
15 seconds and then begins sounding an audible beep and the
“Time-Out” lamp illuminates. Both are reminders to turn off the
load before removing or moving the battery cable clamps from
the battery.
BATTERY TESTING
The battery test has three steps:
I. Visual Inspection
II. State of Charge Check
III. Load Test
A battery must be tested with a load to determine its ability to
perform. Specific gravity or open circle voltage tests do not completely gauge a battery’s performance.
Sealed batteries can be tested like open vent batteries except for
the specific gravity test.
VISUAL INSPECTION
1. Corroded or damaged cable connectors.
2. Loose or damaged battery posts.
3. Damaged battery cases which allow the loss of electrolyte.
4. The battery fluid must completely cover the cell plates in all
cells. If water is added to the battery before specific gravity
3
readings are taken, the battery should be charged five minutes
to stimulate mixing. (Refer to battery manufacturer’s
instructions regarding removal of vent caps while charging
battery).
ELECTROLYTE CAUTION
Battery electrolyte is SULFURIC ACID. It can eat holes in
clothes and skin. Flush spills with water.
STATE OF CHARGE CHECK
By Specific Gravity (open vent battery only)
Sample, measure and return the electrolyte from each cell with a
hydrometer.
1. The specific gravity should be at least 1.230 in all cells. If
not, charge the battery. If charging the battery does not bring
the specific gravity up to 1.230, then the battery should be
replaced.
2. The specific gravity readings should not vary more than 50
points (.050) between all cells. If the difference is greater,
replace the battery.
By Open Circuit Voltage (any lead-acid battery)
Measure the open circuit (no load) stabilized voltage. A stabilized
battery has no “surface charge”, which means that the electrolyte has had a chance to remix and shed gas bubbles after current flow has stopped.
Open Circuit Volts 12.6 12.4 12.2 12.0
% of Charge 100 75 50 25
If the measured voltage is less than 12.4 volts, first recharge the
battery. With a low % of charge, performance will be reduced
and any load test results may be invalid.
LOAD TEST
A battery must have the capability to crank an engine while maintaining enough voltage to power the ignition. To give consistent
results, these tests require that a battery be at least 75% charged
and must not have been heavily used within the last 10 minutes.
The standard battery performance test is based on battery ratings provided by the manufacturer. If the test load amperage is
known, use it, otherwise use one of the following:
1. Cold Cranking Amperes at 0°F. (CCA) - When using CCA,
divide the given value by 2 to obtain the load. FOR example,
1000 CCA divided by 2 equals a 500 amperes test load.
2. Ampere Hour Rating (Ah) - If only the Ampere Hour rating is
known, multiply the value by 3 to obtain the load. For example,
a 200 Ah battery times 3 equals a 600 amperes load.
3. BATTERY WATTS - When only the battery rating in watts is
known then use Table 1 (below) as a guide to determine
what battery load or cranking amps would be normal. FOR
EXAMPLE: A battery load or cranking amps for a battery
rated at 2400 watts would be 125 to 200 amps.
TABLE 1
Battery Load or
Engine Cubic Cubic Cranking Amp Watt
Size Inches Centimeters Rating
Small 100 to 200 1600 to 2400 100-150 Amps 1200 to 1800
Medium 200 to 350 2400 to 5600 125-200 Amps 1500 to 2400
Large 350 to 500 5600 to 8000 175-300 Amps 2100 to 3600
Ratings can be found on the battery, in the vehicle manual or in a
replacement battery application guide. In the battery performance
load test, the rated amperage is drawn from the battery for 15
seconds while watching the battery voltage. At 70°F and higher,
a good battery will maintain an output of 9.6 volts or more during
the load testing period (4.8 volts for 6 volt battery). When a battery is cooler than 70°F, the output voltage requirement is reduced to give equivalent test conclusions per the following
(Table 2):
Table 2 ELECTROLYTE TEMP MINIMUM
–°F– –°C– LOADED VOLTS
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 -1 9.1
20 -7 8.9
10 -12 .7
0 -18 8.5
NOTE: DIVIDE MINIMUM TEST VOLTAGE IN HALF FOR 6 VOLT
BATTERIES.
LOAD TEST CAUTION
If the amperes display goes out while loading a battery, the
voltage has fallen below 4.0 volts. TURN THE LOAD OFF IMMEDIATELY.
The battery could become overheated. If a battery smokes
while being loaded, immediately discontinue using it. It is
not safe.
Zero Amp Meter. Then Place AMP PROBE around either analyzer cable.
BLACK
CHASSIS
RED
BATTERY
Figure 1
Connection for LOAD TEST
1. Have the Load knob turned to “OFF” before connecting.
2. Connect analyzer Battery Clamps to battery terminals, Red
to POS (+), Black to NEG (-) the cables can be reverse.
Wiggle clamps to be sure that the clamp jaws make good
contact with battery terminals.
3. Set the Volts Selector to “Battery Volts”. The analyzer should
show battery voltage over 12.4V. (6.2V)
4
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