Schumacher Battery Charger 9500A User Guide

OWNER'S MANUAL  
MODEL 9500A  
Read Rules for  
Safe Operations  
and Instruction  
Carefully  
Fully Automatic 6 & 12 volt  
2 amp / 15 amp / 40 amp  
Battery Charger with  
125 amp / 250 amp Engine Start  
WORKING IN 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 EACH TIME BEFORE USING YOUR  
CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.  
GENERAL BATTERY SAFETY  
A
1. Before you use your battery charger, be sure to read all  
10. Do not use an extension cord unless absolutely necessary.  
Use of an improper extension cord could result in fire or  
electric shock. If an extension cord must be used, make  
sure that:  
instructions and cautions printed on:  
• Battery Charger  
• Battery  
• Vehicle or unit using battery  
• Pins on plug of extension cord are the same number, size,  
and shape as those of the plug on the charger.  
• Extension cord is properly wired and in good electrical  
condition.  
• Wire size is large enough for AC ampere rating of charger,  
as specified below:  
2. Use battery charger on LEAD ACID type rechargeable bat-  
teries only, such as used in trucks, autos, tractors, airplanes,  
trolling motors, vans, RV's, etc. Charger is not intended to  
supply power to a low-voltage electrical system other than  
in an automotive application.  
_____________________________________________  
WARNING: Do not use 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.  
Length of cord (feet): 25 50 100 150  
AWG size of cord:  
16 12 10  
8
(American Wire Gauge)  
_____________________________________________  
3. Use only attachments recommended or sold by manufac-  
turer. Use of non-recommended attachments may result in  
fire, electric shock, or injury.  
4. When disconnecting the battery charger, pull by the plug  
not by the cord. Pulling on the cord may cause damage to  
cord or plug.  
5. Locate battery power cord so it cannot be stepped on,  
tripped over, or subjected to damage or stress.  
6. Do not operate charger with damaged cord or plug. Have  
cord replaced immediately.  
7. Do not operate charger if it has received a sharp blow, been  
dropped, or otherwise damaged in any way. Take it to a  
qualified professional for inspection and repair.  
8. Do not disassemble charger. Take it to a qualified profes-  
sional when service or repair is required. Incorrect reas-  
sembly may result in electric shock or fire.  
11. Always charge battery in a well ventilated area. NEVER  
operate in a closed-in or restricted area without adequate  
ventilation because of risk of explosive gases.  
12. Locate charger as far away from battery as DC charger  
cables permit.  
13. Do not expose charger to rain or snow.  
14. NEVER charge a frozen battery. If battery fluid (electrolyte)  
is frozen, bring into a warm area to thaw before charging.  
15. NEVER allow battery acid to drip on charger when reading  
specific gravity or filling battery.  
16. NEVER set a battery on top of charger.  
17. NEVER place charger directly above battery being charged.  
Gases from battery will corrode and damage charger.  
18. NEVER touch the battery clips together when the charger  
is energized.  
9. To reduce risk of electric shock, unplug charger from outlet  
before attempting any maintenance or cleaning.  
• IMPORTANT SAFETY INSTRUCTIONS •  
• SAVE THESE INSTRUCTIONS •  
ELECTRIC CORPORATION  
801 BUSINESS CENTER DRIVE • MOUNT PROSPECT, ILLINOIS 60056-2179  
Send Warranty Product Repairs to: P.O. Box 280 • 1025 East ThompsonAvenue, Hoopeston, IL 60942  
Call Customer Service if you have questions: 1-800-621-5485  
471-499  
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OPERATING INSTRUCTIONS: CHARGING BATTERY IN VEHICLE  
F.  
When charging battery in the vehicle, take care to determine the battery type and which post is grounded. To reduce risk of a spark  
near battery, follow these steps when battery is installed in vehicle. WARNING: A spark near battery may cause battery explosion.  
WARNING: Do not connect clip to carburetor, fuel lines, or sheet-  
metal body parts. NOTE: Attach clips to battery post and twist  
or rock back and forth several times to make a good connec-  
tion. This tends to keep clips from slipping off terminals and  
helps to reduce risk of sparking.  
1. Position AC power cord and DC charging cords to reduce  
risk of damage by hood, door, or moving engine parts.  
2. Stay clear of fan blades, belts, pulleys, and other parts that  
can cause injury.  
3. Check polarity of battery posts. Battery case will be marked  
by each post: POSITIVE (POS, P, +) and NEGATIVE (NEG,  
N, -). NOTE: The positive battery post usually has a larger  
diameter than the negative post.  
6. Connect the AC power cord and then make the desired  
charger settings, (See Battery Charging-section H).  
7. Observe the meter for proper response, if something does  
not look right, refer to the trouble shooting section of this  
manual.  
4. Determine which post of battery is ground (connected) to  
chassis.  
NOTE: The negative post is normally grounded.  
8. When the battery is fully charged, unplug the charger from  
the AC outlet.  
9. When the battery is charged and the charger is unplugged:  
(1) Remove clip from the vehicle chassis, then  
(2) Remove clip from the battery post, in that order.  
NEGATIVE GROUNDED POST  
5A. For negative-grounded vehicle, connect POSITIVE (RED)  
clip from battery charger to POSITIVE (POS, P, +) ungrounded  
post of battery. Connect NEGATIVE (BLACK) clip to vehicle  
chassis or engine block away from battery. Connect to a heavy  
gauge metal part of the frame or engine block.  
POSITIVE GROUNDED POST  
5B. For positive-grounded vehicle, connect NEGATIVE  
(BLACK) clip from battery charger to NEGATIVE (NEG, N, -)  
ungrounded post of battery. Connect POSITIVE (RED) clip to  
vehicle chassis or engine block away from battery. Connect to a  
heavy gauge unpainted metal part of the frame or engine block.  
G. OPERATING INSTRUCTIONS: CHARGING BATTERY OUT OF VEHICLE  
When charging battery out of vehicle, take care to determine the battery type. To reduce risk of a spark near battery, follow these steps  
when battery is outside vehicle. WARNING: A spark near the battery may cause battery explosion. WARNING: When removing battery  
from vehicle or boat, disconnect grounded pole first. When disconnecting, make sure all accessories are off, so as not to cause an arc.  
(NOTE: A marine (boat) battery must be removed and charged on shore. (To charge on board requires special equipment designed for  
marine use.) WARNING: When reinstalling battery, attach the ground post first.  
24" CABLE  
1. Check polarity of battery posts. Battery case will be marked  
by each post: POSITIVE (POS, P, +) and NEGATIVE (NEG,  
N, -). NOTE: The positive battery post usually has a larger  
diameter than the negative post.  
2. Attach a 24-inch long (or longer) 6-gauge (AWG) insulated  
battery cable to NEGATIVE (NEG, N, -) battery post.  
(The 24" lead is not supplied. You may purchase at most  
automotive stores.)  
3. Connect POSITIVE (RED) charger clip to POSITIVE (POS,  
P, +) post battery. Rock clip back and forth to make good  
7. When battery is fully charged, unplug charger from AC out-  
let.  
8. When battery is fully charged and the charger is unplugged:  
(1) Remove clip from end of the Negative end of cable,  
then  
connection.  
4. Position yourself and free end of 24 inch cable as far away  
from battery as possible. Then connect NEGATIVE (BLACK)  
charger clip to free end of cable.  
WARNING: Do not face battery when making final con-  
nection. Rock clip back and forth to make a good connec-  
tion.  
(2) Remove clip from Positive battery post, in that order.  
9. Clean and store battery charger.  
5. Connect the AC power cord and then make the desired  
charger settings. (See Battery Charging-section H).  
6. Observe the meter for proper response, if something does  
not look right, refer to the troubleshooting section of this  
manual.  
WARNING: Be sure area around the battery is well venti-  
lated while battery is being charged. Gas can be forcefully  
blown away by using a piece of cardboard or other non-  
metallic material as a fan.  
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CHARGER CONTROLS  
Power ON/OFF Switch  
Use this switch to apply AC line volts to the charger.  
Always connect and disconnect leads with this switch in the  
OFF position.  
OFF  
6V  
ON  
POWER  
CHARGE RATE  
2
TIME  
TESTER  
VOLTS  
AMPS  
Battery Voltage Select 6V / 12V  
RESET  
LOW  
MEDIUM  
HIGH  
AMP  
250 AMP 12 VOLT  
125 AMP 6VOLT  
The 6 volt position should be used for charging 6 volt batteries.  
The 12 volt position should be used for charging 12 volt batter-  
ies.  
12V  
15  
AUTOMATIC  
MANUAL  
AMP  
ENGINE  
START  
BATTERY  
40  
AMP  
TOUCH PAD SELECTIONS  
TESTER: The SE-9500A charger may used as a tester to: 1) test  
voltage of the battery, 2) test the vehicle's charging system which  
includes the alternator. Note: If the charging voltage measures  
greater than 16 volts, check both the alternator and voltage regu-  
lator. (Consult your vehicle's owner's manual before testing the  
regulator.)  
AUTO (Automatic): After turning on the charger, by switching  
the Power switch to the ON setting, press AUTO, then the de-  
sired CHARGE RATE. You do not not have to select TIME, as the  
charger will do this itself in the AUTO mode.  
MANUAL: The charger defaults to MANUAL when first turned on  
without the need to press the MANUAL button. If you have started  
charging in the automatic mode and wish to change to MANUAL,  
set the CHARGE RATE to the desired rate, 2, 15, or 40 amps and  
then set the TIME to the time you wish to charge the battery.  
To operate tester, press RESET, then press TESTER. The meter  
will display the voltage of the battery. If the engine is running, the  
charger will display the voltage of the alternator.  
START: (Engine Start) DO NOT try to crank a vehicle without a  
battery in it, you may damage the vehicle electrical system.  
CHARGE RATE SELECTIONS  
The START button, when pressed, selects 125 amps cranking  
assist for a 6 volt battery or 250 amps cranking assist for a 12  
volt battery. (See section I for more detailed instructions)  
Three charge rates are provided for your selection. 2 amp, 15  
amp and 40 amp. See the recommended uses in the battery  
charging chart, (Section H). Press the desired CHARGE RATE  
after selecting MANUAL or AUTO (Automatic) charge.  
METER: The meter is a digital display type. The following dis-  
plays will be displayed on the meter:  
TIME (timer) The timer has 3 clocks. You may set the time up to  
the maximum hours allowed.  
____ A  
____ V  
Charge Rate in amps  
Voltage reading of battery or charge  
RATE  
2 AMPS  
18 Hours  
1 Hour  
15 AMPS  
14 Hours  
1 Hour  
40 AMPS  
5 Hours  
1/2 Hour  
RDY — Charger is ready for cranking  
Maximum  
Time  
WAIT  
FULL  
MAN  
Wait until the charger is ready to crank again  
Battery is charged.  
Charger is in the MANUAL mode  
Charger is in the AUTOMATIC mode  
Increment  
Settings  
AUTO  
Chk Bat indicates a problem with battery or connections  
OFF — Set time has expired (MANUAL MODE)  
Charge rate chart  
You must press and repress the TIME button to advance the  
time.  
Once you have begun charging, the time remaining may be  
displayed by simply pressing the TIME button.  
Charge Rate  
Charge Time:  
Hours  
Recommended  
Uses  
RESET: Use RESET to stop charging and to change to an alter-  
nate charge method. Press RESET, then select the new charge  
method, set the new CHARGE RATE, and set charge TIME if you  
have changed from AUTO (Automatic) to Manual. If you do not  
set the time, the charger will default to the maximum time al-  
lowed for the CHARGE RATE selected.  
2 AMPS  
3-6 HOURS  
Small batteries,such as those  
used on motorcycles, jet skis  
lawn tractors, and snowmobiles.  
15 AMPS  
40 AMPS  
2 - 6 HOURS  
Cars, trucks, RV's, vans,  
trolling motors, and marine  
batteries.  
VOLT/AMP: The charger meter will display the voltage when  
initially turned on. If you wish to display the amps, press the  
VOLT/AMP button. Press the VOLT/AMP button again to restore  
the voltage reading.  
1 - 3 HOURS  
Large lead acid batteries Cars,  
trucks, RV's, vans  
construction equipment.  
ENGINE  
START  
Duty cycle  
3 seconds ON  
300 seconds OFF  
Cranking assist helps turn  
engines when battery power  
is low.  
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H.  
BATTERY CHARGING  
1. First connect the charger to the battery following instructions in section F and G.  
2. Plug the charger power cord into AC outlet.  
3. Set battery voltage switch to match the battery voltage, then switch the power switch to ON.  
4. Select mode of operation, either MANUAL or AUTO (Automatic).  
The charger begins in the MANUAL mode when first started, by default. If you wish to charge in the MANUAL mode, set the CHARGE  
RATE and then the desired TIME of charge. If you select AUTO (Automatic), select your desired CHARGE RATE, 2, 15, OR 40 amps.  
(See charge rate chart). The TIME does not have to be set in the AUTO (Automatic) mode.  
5. Charging will now begin. By default, the meter will display the battery voltage. If you want amps displayed, simply press the VOLT/  
AMP button.  
6. If you selected MANUAL, you have the option of setting the time the battery will charge. If you do not set a time the maximum time  
allowed for the charge rate selected will be automatically chosen by default. (See explanation of timer).  
The TIMER has three clocks, one for each charge rate. For the 40 amp rate, the maximum time setting is 5 hours, set in increments of  
1/2 hour. The 15 amp rate has a maximum time setting of 14 hours and the 2 amp setting has a maximum time setting of 18 hours. Both  
the 10 amp and the 2 amp are set with time increments of 1 hour. You must press and depress the TIME button to advance the TIME  
setting. Once you have begun charging, pressing the TIME button will tell you the remaining charge time.  
If the battery is deeply discharged, below 1.5 volts, you must start the charging in the MANUAL mode and in the 2 amp setting. This will  
bring the battery voltage up high enough to allow you to use the other features of the charger. You may use your voltmeter to read the  
battery voltage.  
I.  
ENGINE START  
Engine Start:  
ONLY ACTIVE IN THE MANUAL MODE. DO NOT CRANK ENGINE IN THE AUTOMATIC MODE.  
1. Connect the charger to the battery following the instructions in sections F and G.  
2. Plug the charger power cord into the 120 v 60 hz AC outlet.  
3. Set the battery voltage selector switch to match the voltage of the battery, then switch the power switch to the ON position.  
4. The charger will be in the MANUAL mode, indicated by MAN on the meter display.  
5. Press START button and observe RDY on the display meter. The charger is now ready to have the engine cranked.  
6. Crank the engine. Cranking is limited to 5 seconds, then automatically switches to the 15 amp charge rate for 5 minutes. The meter  
will display WAIT. After the five minutes have expired, the meter will again display RDY and you may crank the engine once more.  
Repeat until engine starts.  
DO NOT try to crank a vehicle without a battery, as you may damage the vehicle's electrical system.  
If the engine spins, but fails to start after several cranking attempts, there is a problem other than the starting system. Stop cranking the  
engine until the other problem is found and corrected.  
CAUTION: Excessive continuous cranking can damage a starter motor.  
J.  
CHARGING TIME REQUIRED  
The automatic charging circuit will prevent overcharging a battery. When full charge is reached, the charging to the battery will be turned off and  
the meter will display FULL.  
When charging in the MANUAL mode, you must monitor the charging of the battery. Select theAMP display on the meter. When the amp reading is about  
one half of the set charge rate, the battery is fully charged, stop the charging and disconnect from the battery. Overcharging can occur when using  
the MANUAL mode. Refer to the Charge Rate Chart on page 4 and charging time formula below.  
Determine the charge level of your battery with a hydrometer or electronic percent of charge tester. Determine the ampere hour rating of your battery. It  
may be on the battery information label. If the battery is rated in Reserve Capacity, convert to ampere hour rating using the following formula:  
Ampere Hour rating = (Reserve Capacity) + 16  
(2)  
Example: AH rating = (168 Reserve Capacity) + 16  
(2)  
or AH = 100  
Use the following formula to determine the time of charge required: (AH x % of charge needed) divided by amp setting of the charger, times  
1.25 = hours of charge:  
Example: State of charge of the battery is 50%  
Percent of charge needed is 100% - 50% = 50% (.50 decimal)  
Ampere rating of the battery is 100AH  
Charger setting is  
10 amps  
100 x .50  
10  
=
x 1.25  
=
6.25 hours of charge needed  
+ 1.00 hour more if charging a deep cycle battery  
7.25 hours total for a deep cycle battery.  
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K.  
INDICATIONS OF A FULLY CHARGED BATTERY  
A hydrometer reading of the specific gravity of the electrolyte (fluid) of the battery in good condition should be between 1.25 and 1.28.  
When a battery reaches 80-85% of full charge, bubbles will appear on the surface of the fluid. As the battery nears full charge, bubbling  
will become more vigorous.  
The digital display Meter will display FULL when the battery is completely charged.  
L.  
ASSEMBLY INSTRUCTIONS  
Wheel Charger assembly instructions:  
NOTE: Unit must be fully assembled before operating.  
HUBS MUST  
FACE IN  
PARTS:  
TOOLS NECESSARY:  
5/16" wrench  
Hammer  
Fig. C  
4
1
2
2
2
1
10-32 thread cutting screws  
mounting foot  
wheels  
axle caps  
axle brackets  
handle  
Screwdriver  
BRACKET  
First place the charger on its side.  
Next mount the mounting foot FIG. A with (2) 10-32 screws.  
Next pound the axle firmly into an axle cap using a hammer,
Next slide the wheels onto the axle, hubs must face in, FIG. C.  
Next pound the other axle cap onto the other end of the axle.  
Fig. D  
Fig. E  
Next place the axle assembly onto the bottom of the charger as shows in figure FIG. C. Mount the axle to the bottom of the charger using  
the two 10-32 thread cutting screws as shown in Fig. D (these screws require a 5/16" wrench.)  
Next turn the battery charger right side up onto its foot and wheels.  
Remove the two top screws from each side of the charger, line up the handle and reinstall the screws. FIG. E.  
M.  
TROUBLESHOOTING  
1. No meter reading  
A. Make sure that the charger is plugged into the AC outlet.  
B. Make sure that the AC outlet is "LIVE." Check by plugging in a lamp.  
2. Meter displays CHK BAT  
A. Have a serviceman, at your neighborhood garage, check that the battery is capable of taking a charge, it may be damaged or  
sulfated.  
B. Make sure you have selected the proper charge voltage for the battery being charged.  
C. After unplugging charger, check the connections at the battery. Make sure the clips are making good contact.  
D. If the battery voltage is below 1.5 volts and you were charging in automatic, the display will read CHK BAT. Try to bring the battery  
voltage up above the needed 1.5 volts by selecting the MANUAL mode and the 2 amp setting. This should bring the battery voltage  
to the needed voltage in a few minutes.  
3. Vehicle will not start in ENGINE START  
A. Unplug the charger and check the connections at the battery.  
B. You must wait until the meter read "RDY." The charger may still be in the "WAIT" mode.  
C. The thermal protector may have tripped and needs a little longer to close. Wait a little longer and retry.  
D. If the engine turns over, but doesn't start, the problem is with the vehicle, not the charger. Have the vehicle problem resolved  
before you try to crank the engine again.  
N.  
WARRANTY  
SCHUMACHER ELECTRIC CORPORATION, 801 BUSINESS CENTER DRIVE, MOUNT  
THIS IS THE ONLY EXPRESS LIMITED WARRANTY AND THE MANUFACTURER NEI-  
THERASSUMES NORAUTHORIZESANYONE TOASSUME OR MAKEANY OTHER OBLIGATION  
TOWARDS THE PRODUCT OTHER THAN THIS EXPRESS LIMITED WARRANTY. THE MANU-  
FACTURER MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PURPOSE OF  
THIS PRODUCTAND EXPRESSLY EXCLUDES SUCH FROM THIS LIMITED WARRANTY.  
SOME STATES DO NOTALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR  
CONSEQUENTIAL DAMAGES OR LENGTH OF IMPLIED WARRANTY SO THE ABOVE LIMITA-  
TIONS OR EXCLUSIONS MAYNOTAPPLYTO YOU.  
PROSPECT, ILLINOIS 60056-2179 MAKES THIS LIMITED WARRANTY TO THE ORIGINAL  
PURCHASER AT RETAIL OF THIS PRODUCT. THIS LIMITED WARRANTY IS NOT TRANS-  
FERABLE.  
Schumacher Electric Corporation warrants this battery charger for five years from date of  
purchase at retail 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 changes prepaid to the manufac-  
turer or its authorized representative.  
This limited warranty is void if the product is misuse, subjected to careless handling, or  
repaired by anyone other than the manufacturer or its authorized representative.  
The manufacturer makes no warranty other than this limited warranty and expressly excludes  
any implied warranty including any warranty for consequential damages.  
THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTSANDYOU MAYALSO HAVE OTHER  
RIGHTS WHICH VARYFROM STATE TO STATE  
471-1197  
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NOTES  
471-499  
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• IMPORTANT SAFETY INSTRUCTIONS •  
• SAVE THESE INSTRUCTIONS •  
ELECTRIC CORP.  
801 BUSINESS CENTER DRIVE • MOUNT PROSPECT, ILLINOIS 60056-2179  
471-1197  
8
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