Associated 6036B Operator's Manual

SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the battery tester you have purchased. You may need to refer to these instruction at a later date. CAUTION: The electrolyte in automotive batteries is sulfuric acid, which is capable of causing severe damage to skin, eyes, and clothing. When contact with a) Eyes: Force open and flood with cool running water at least for 10 minutes, then see a doctor. Never use eyes drops or other medication before seeing a doctor b) Remove contaminated clothing and flood skin for at least 10 minutes with clear, cool water. While batteries are being charged or tested, an explosive gas mixture forms inside each cell. Some of this gas escape through the vent holes in the filler caps and ma condition. Sparks or flames igniting this gas mixture will burn back through the vent hole and explode inside the battery cell. Such an explosion is dangerous not only electrolyte which would spray onto anything in the vicinity. TO PREVENT EXPLOSIONS: a) Use well ventilated areas for charging and testing batteries. b) Add distilled water in each cell until battery acid reaches level specified by battery manufacture. This helps purge excessive gas from cells. Do not over-fill. For a manufacturer’s instructions. c) Allow no smoking, sparks or open flames near batteries being charged, tested or batteries recently charged and to be tested. WARNING - RISK OF EXPLOSIVE GASES. a) Working in vicinity of lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation. For this reason, it is of utmost importa instructions exactly each time you use this battery tester. b) To reduce the risk of battery explosions, follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend to marking on these products and on the engine. c) Do not break live electrical circuits at the terminals of batteries because a spark may occur at that point causing an explosion. Always turn battery chargers or te the clamps from the battery terminals. PERSONAL PRECAUTIONS: a) Wear complete protection and avoid touching eyes while working near battery. b) For acid contact on skin or clothing, remove clothing and wash skin immediately with soap and water. For acid in eye, immediately flood eye with running cold w attention immediately. Never use eye drops or other medication before seeing a doctor. c) NEVER smoke or allow a spark or flame in the vicinity of battery or engine. d) Be extra cautious to reduce risk of dropping a metal tool onto a battery. The tool may spark or short-circuit the battery or other electrical parts which may cause e) Remove 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- or the like to metal, and cause severe burn. f) Spilled acid: Neutralize with a solution of baking soda ( 1 pound per gallon of cold water ) or household ammonia (1 pint per gallon of cold water)

1. To remove the unit from the carton, grasp the side handles in the packing and pull both the packing and the unit out of the carton. Remove the internal packing from the unit and return it to the carton. Set the carton and internal packing aside for future use. 2. Hold onto the knob to keep the shaft from spinning after it is unlocked. Loosen the set screw in the locking collar with the 3/32 hex wrench provided. DO NOT remove the set screw from the locking collar. Allow the shaft to back out slowly until it stops. (Locking down the carbon stack helps to prevent the carbon disk and ceramic tubes from breaking during shipping, or anytime the unit needs to be transported.) NOTE: When shipping or transporting the unit, be sure to lock the shaft down by turning the knob all the way down and tightening the the locking collar set screw with the 3/32 hex wrench provided. ATTACHING THE 6036B TO OPTIONAL 6038 UTILITY CART If you have also purchased the optional two wheel utility cart model 6038 the two pieces are assembled as follows. 1. Set the 6036B on top of the cart with the front of the unit facing away from the handle. Align the two holes in t mounting plate with the threaded inserts in the bottom of the tester. 2. Insert the spade bolt through the hole in the mounting plate and thread the spade bolt into the insert as shown. PREPARING TO TEST a) When necessary to remove battery from vehicle for testing, always remove ground terminal first. Make sure all accessories in the vehicle are turned off, so as not to cause an arc. b) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes. c) Determine the cold cranking amps (CCA) rating of battery by referring to car owner’s manual or label on battery TESTER LOCATION a) Locate tester as far away from battery as DC cables permit. b) Never allow battery acid to drip on tester or other items when handling a hydrometer, reading specific gravity or filling a battery. c) Do not set a battery on top of the tester. d) Position cables to reduce risk of danger by hood, door or moving engine parts. e) Stay clear of fan blades, belts, pulleys, and other parts that can cause personal injuries. f) Do not block air passaging through the tester. CONNECTIONS AND PRECAUTIONS a) Connect and disconnect DC output clamps only after setting fan switch to “Automatic” position, and the LOAD CONTROL knob is counter-clockwise (CCW.) as b) When attaching clamps to battery posts, twist or rock clamp back and forth several times to make a good connection. This tends to prevent the clamps from slip sparking. NOTE: Either when receiving the unit new or when the unit has been sitting around awhile. The carbon stacks in the unit will collect moisture from the air and will n need to be pre-loaded, by turning the knob to a 100 amps and holding the knob for 5 to 10 seconds and releasing the knob (Do this on a good battery that y might be in the carbon stacks and prevents the carbons from cracking during normal operation. Note: If a lot of water or steam come out of the unit, do this out. OPERATING INSTRUCTIONS 1. Visually inspect batteries for obvious damage. Do not test a battery if post are loose, case is cracked or fluid level is below the top of the plates. With “maintena instructions for checking water level. Do not test a frozen battery. 2. Be sure Voltmeter and Ammeter pointers are zeroed. Zero meters by adjusting screw on face of meter until meter points to zero. 3. See connection precautions before connecting or disconnecting clamp prior to test. 4. Depress FAN switch to “Automatic” and the fan will automatically turn on as the LOAD CONTROL on top of tester is turned clockwise, and automatically go to o clockwise. 5. Connect RED clamp to POSITIVE (POS, +, P) battery post and BLACK clamp to NEGATIVE (NEG, -, N) battery post. NOTE: Depress FAN switch to “Manual” and the fan will run for as long as the tester is connected to a battery. DO NOT CONNECT OR DISCONNECT FR

KNOB counter-clockwise as far as possible. Fan will automatically be OFF and then the clamps may safely be removed from battery. 6. DETERMINE STATE OF CHARGE OF BATTERY a) Adjust LOAD CONTROL knob clockwise (CW) to 100 amps for 3 seconds. Adjust LOAD CONTROL knob counter-clockwise until the meter reads zero. Read b) Results: 1. Pointer in green zone - proceed to LOAD TESTER. 2. Pointer in red zone to left of green zone - battery is tool low to test. Recharge & repeat procedure. c) Green band indicates a battery that is at least 75% charged. 7. LOAD TEST a) Figure the value of one-half of Cold Cranking Amps (CCA) rating of battery to be tested. b) Adjust “LOAD CONTROL” knob to the one-half of the battery’s cold cranking amperage (CCA) rating using AMPERES LOAD meter as a reference. Hold this r amperage will probably change due to resistance changes in the cables, carbons and the battery. Readjust the LOAD CONTROL during this 15 seconds interv of 15 seconds and with the load on, read the battery’s voltage on the volt scale. TURN THE LOAD CONTROL KNOB COUNTER-CLOCKWISE AS FAR AS c) The voltage reading obtained from a battery changes in relation to the temperature of the battery and also in relation to the amperage being drawn from the batte given here and on the face of the tester gives the minimum voltage that should be obtained for the test procedure given. i.e.: The outside temperature is 60 degre good battery is 9.5 at 60 degrees F. When at the end of the 15 second test you find that the battery’s voltage is equal to or greater than 9.5, the battery is good. defective. In some cases a six volt battery is to be tested. To do this simply divide the minimum volts of the chart by two to obtain the voltage reference to be used. When smoke is emitted from any cell of the battery, the battery is defective regardless of the test indications BATTERY TEMPERATURE COMPENSATION 15 SECOND LOAD TEST °C 21� 16 10 4 -1 -7 -12 -18 °F 70� 60 50 40 30 20 10 0 MIN. VOLTS 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5 8. STRESS TEST: a) To determine if a battery is adequate for an application, a stress test may be applied to a battery. Determine the maximum current draw, minimum acceptable vo which the battery is to be installed. b) Run a load test at the determined current and time and check that the battery voltage is above the minimum required. APPLICATION DATA: ALTERNATOR TEST: Be sure that the battery in the car, test is good. Start engine with tester connected to the battery. The charging voltage of the alternator sho zone. If the pointer is in the red zone to the left of the green zone, the voltage is too low to fully charge the battery. If the pointer is in the red zone to the right of the g the battery. NOTE: In very cold weather, the alternator may read above 14.8 VDC. Check owner’s service manual. STARTER CURRENT TEST:Connect tester to battery. Be sure battery is fully charged. Ground the ignition, by removing the coil cable from the distributor cap. Gro wire to prevent arcing of high- voltage spark that could cause a fire, someone getting shocked, or damage to the ignition system. (On GM car with HEI ignition, simply terminal on the distributor.) Turn ignition switch on and allow starter to run for 5 seconds. Read the voltage on the VOLT scale while cranking. With car circuit off an adjust LOAD CONTROL knob to give VOLTMETER reading the same as measured while cranking engine. Read Amps on ammeter and the reading is the starting c VOLTMETER: The tester may be used as a voltmeter to troubleshoot electrical problems on any 6 or 12 volt vehicle. Read voltages on volt scale. NOTE: A static charge may build-up on the meter face, causing the needle to be off zero. For the meter to read correctly, this charge must be neutralized. Spray “Static Guard” or equivalent on the meter or wipe with a cloth dampened with soap and water. WIRING DIAGRAM

VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610334 SHUNT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610335 BRACKET & NUT ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610337 TOP PLATE ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610338 CARBON STACK W/CERAMIC TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610871 CERAMIC TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610872 Parts may be purchased from your local authorized service depot listed in the Service Procedure Manual supplied with your products. If you elect to order parts from the factory, you may do so by mail or by phone. Minimum orders from the factory is $25.00. Orders received that are under the minimum will not be processed. Taxes and freight are extra and are not considered to be part of the dollar value of the order. We DO NOT have a C.O.D. policy. Casher checks, Money order, Master Card, or Visa are acceptable. If you use a Master or Visa Card, send only the number an the expiration date. DO NOT SEND THE CARD. ASSOCIATED EQUIPMENT CORPORATION 5110 Brown Avenue Saint Louis, Missouri 63115 (314) 385-5178 W1644 Rev.11/97 027-0293 FIG. PLT. FILE NAME DESCRIPTION 1 LOGO.EPS LOGO 2 27293-2.PLT LOCK-DOWN 3 27293-3.plt assembly view of tester to cart 4 B2844.PLT WIRING DIAGRAM