NAPA Battery Charging& Testing Procedures

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S A F E T Y F I R S T !

WARNING: Follow all safety instructions when handling batteries! Always wear safety glasses and a face shield when working on or near batteries.

Safety Comes First: Before starting any of the following procedures, read and follow all safety information. Read Instruction Manual before proceeding.

All batteries generate explosive hydrogen gas. Keep sparks, flames and cigarettes away from batteries atall times. Do not connect or disconnect “live” circuits. To avoid creating sparks, always turn chargingand testing equipment off before attaching or removing clamps. ALWAYS DISCONNECT GROUNDED CABLE FIRST AND CONNECT IT LAST TO PREVENT DANGEROUS SPARKS.Perform all work in a well ventilated area. Never lean directly over a battery while boosting, testing or charging it.

PROTECT YOUR EYES!Batteries contain corrosive sulfuric acid that can destroy clothing and burn the skin. Neutralize acid spillswith a paste made of baking soda and water or large quantities of water. BE CAREFUL!

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In order to assure safe and accurate battery testing all steps must be followed in their entirety and in their specified order!

VISUAL CHECK:A. Visual inspection.

An external inspection of the battery may reveal signs of the cause of failure.1. Do the terminals show signs of having been hammered, twisted, or driven down into the cover?

Do side terminals show signs of over-torquing? Over-torquing can cause internal damage that can't be seen.

2. Does the container or cover show signs of stress, damage, or high temperature?Does the container or cover have worn areas indicating vibration damage?

3. Are the ends of the battery pushed out? This can indicate plate growth.B. Inspect terminals.

(Look for: corrosion, loose or broken posts or moisture and dirt around terminals.)

C. Inspect for cracks in the case.D. If the battery has a hole in the case or a

post is broken, it is not a warranty battery.E. Inspect for loose hold-downs

(If battery is in vehicle only)

IF ANY OF THESE ITEMS APPEAR, IT IS NOT A WARRANTY BATTERY AND CREDIT WILL NOT BE ISSUED.

S T E P 1

A. Prepare CONNECTIONS for testing battery: Use a post brush to clean battery posts. Neutralize any corrosion with abaking soda/water paste or battery cleaner spray. Scrape or brush off the residue and wash the area with clean water.

B. Make sure adapter and tester clampCONNECTIONS ARE TIGHT.NOTE: All SIDE TERMINAL POSTSmust use a proper Side Terminal Charging Post to ensure the best testing and charging results.

THREADED STUD TERMINALSmust use a properGroup 31 Charging Poststo ensure the best testing and charging results.

DO NOT USE Battery Bolt Extenders or BatteryBolts for testing or charging batteries. This willcause the tester to give an inaccurate reading.

DO NOT USE Stainless Steel Nuts or the ThreadedStud for testing or charging batteries. This willcause the tester to give an inaccurate reading.

Bolt ExtendersBattery Bolts

S T E P 2

Threaded Stud4

S T E P 3

TESTING THE BATTERY:A. Connect tester by hooking up red clamp to battery’s positive post.

Hook up black clamp to battery’s negative post.B. Enter the required testing information based on tester being used.C. If the tester indicates "Charge & Re-Test" battery proceed to Step 4.

NOTE: If battery needs charging, it is NOT a warranty battery.

If the tester indicates "Replace" or "Bad Cell" battery, this is a warrantable battery. Follow the proper warranty procedures.

If the tester indicates a "Good" battery proceed to Step 5.

NOTE: CONTACT YOUR ESG OR TOOLEQUIPMENT REPRESENTATIVE FORPROPER EQUIPMENT GUIDANCE TOTEST AND CHARGE BATTERIES.

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TIME (MINUTES) TO RECHARGE A SINGLE BATTERY

C. After charging has been completed, retest battery on tester (See Step 3).D. If the tester again displays "Charge & Re-Test", warrant battery, following proper warranty procedures.

If tester displays "Bad Cell" or "Replace Battery", warrant battery following proper warranty procedures. If tester displays "Good Battery", proceed to step 5.

VoltageState

Approx. Battery Charging Time*Standard of

To Full Charge at 80°F / 27°CBattery Charge Maximum Rate at

6-Volt 12-Volt 50 Amps 30 Amps 20 Amps 10 Amps 2 Amps6.3 12.6 100% – FULL CHARGE–6.2 12.4 75% 20 min. 35 min. 48 min. 90 min. 7.5 hrs.6.1 12.2 50% 45 min. 75 min. 95 min. 180 min. 15 hrs.6.0 12.0 25% 65 min. 115 min. 145 min. 280 min. 22.5 hrs.5.9 11.8 0% 85 min. 150 min. 195 min. 370 min. 30 hrs.

NOTE: CONTACT YOUR ESG OR TOOL EQUIPMENT REPRESENTATIVE FORPROPER EQUIPMENT GUIDANCE TO TEST AND CHARGE BATTERIES.

S T E P 4

A. If tester displayed “Charge & Re-Test”, remove battery from tester. B. Charge battery based on the chart below.

IMPORTANT: NEVER OVERCHARGE BATTERIES!

EXCESSIVE CHARGING WILL SHORTEN BATTERY LIFE.

* Charging time depends upon battery age, temperature, capacity,

and efficiency of charger.

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If the battery tested “Good”, ask questions to find the true cause of the customer’s problem.

1. What is the year/age of the vehicle? a. Battery not charging in vehicle due to faulty alternator, loose belt, poor cables or connections.

(NOTE: recommend a charging systems check)• In-Store check if proper equipment available• If not available, recommend qualified installer

2. What is the Make and Model of your vehicle? a. Possible incorrect battery for the application.

3. How is your vehicle used?a. Was the vehicle idle for a long length of time?

4. Have you installed any additional accessory items?a. Possible electrical drain.

5. Is the engine cranking slowly?a. Faulty starting system.

6. Has the battery gone dead in the past?a. User left interior lights or headlights on.

S T E P 5

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P O T E N T I A L E L E C T R I C A L P R O B L E M S

Charger doesn’t appear to power up:

• Make sure unit is plugged in and turned on.

• Check the power to unit. Make sure power cord and plug is not damaged or obstructed.

• Check power to outlet. It is possible that circuit breakers need attention.

“Check Connection” displayed on unit:

• If terminal adapters are used, make sure they are making a good connection (complete lead-to-lead contact).

• Check tester cable to clamp connection (tight, no corrosion, etc.)

• Make sure tester clamps are making good contact with battery post and terminal ends.

Form No. 1775 . © 2011. Printed in U.S.A.

T R O U B L E S H O O T I N G G U I D E