Manual Wheel Charger
Contents
1. Ajquiassy ajqe gt aanebay 7 1 Century Equipment 2345 Murphy Blvd Gainesville GA 305042. 10130 September 2012 Manual Wheel Charger For use with machines having Code Numbers See Below Safety Depends on You Century charging equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful K3151 1 11862 60 40 30 225 6 12 24V K3150 1 11861 60 40 2 250 6 12V W TEST K3149 1 11860 40 20 2 200 6 12V W TEST OPERATOR S MANUAL Century Equipment 2345 Murphy Blvd Gainesville GA 30504 TABLE OF CONTENTS ENGLISH ENGINE STARTING 14 SAFETY SUMMARY 3 15 SAFETY INFORMATION 3 TROUBLESHOOTING 15 SHOCK HAZARDS WIRE DIAGRAMS 16 17 EXPLOSIVE GAS HAZARDS PARTS PAGES P 712 SERIES BATTERY EXPLOSION HAZARDS 4 FIRE HAZARDS 4 BATTERY ACID HAZARDS 4 MOVING PARTS HAZARDS 4 BURN HAZARDS 4 INTRODUCTION 5 DESCRIPTION
3. 5 HOW BATTERIES CHARGE 5 SPARK PREVENTION 5 DEEPLY DISCHARGED LEAD CALCIUM BATTERIES 5 ASSEMBLY 3 6 ASSEMBLY INSTRUCTIONS 6 PREPARATION 7 CHARGER PREPARATION 7 CHARGER PLACEMENT 7 PROVIDE REQUIRED POWER 7 EXTENSION CORDS 7 BATTERY PREPARATION 7 CONTROLS AND INDICATORS 8 CONTROL SETTING INSTRUCTIONS 8 CHARGE VOLTAGE AND BAIE SELECTION 8 TIMER SWITCH SETTING 8 VOLTMETER TEST METER J ycm 8 BATTERY PERCENT OF CHARGE TEST 12 VOLT 9 ALTERNATOR TEST A2 9 PRE CHARGE BATTERY AC TIVATION MT 9 OPERATION ES 10 OPERATING INSTRUCTIONS 10 CONNECTING TO BATTERIES INSTALLED IN VEHICLES 10 CONNECTING TO BATTERIES OUTSIDE A VEHICLE 10 CHARGING INSTRUCTIONS 11 READING AN 11 CHARGING TIME INSTRUCTIONS 12 13 SAFETY SUMMARY Congratulations on the purchase of your new battery charg er We wish to acknowledge Underwriters Laboratories U L for contributing the following important safety precau tions Please read and retain these instructions for the con tinued
4. FIGURE 5 Charge Rate Selector Switch Settings 200 12 OF START 130A 12V 6V START 40A 2A 12V 12V 20A 12V 40 amp model 250A 12V START 185A 6V 6V START 60A 2A 12V 12V 40A 12V 60 amp model 60A 29 a eee 24V START 225A 12V 40A START 12V 60A OFF 12V 24V Fleet model TIMER switch allows the selection of any charging time up to 120 minutes When the selected time is up the timer automatically shuts the charger off AMMETER indicates the charging current being drawn from the charger by the battery See READING AN AMMETER in this manual VOLTMETER the voltmeter will indicate voltage whenever the charger is turned on or when the clamps are connected to a battery If connected to a battery and the unit is turned on it will read the combined voltage of the battery and the charger If there is no reading when connected to a battery check the connections and or the battery CONTROL SETTING INSTRUCTIONS CHARGE VOLTAGE AND RATE SELECTION See Figure 6 and 7 Set the RATE SELECTOR to the same voltage and charge rate that is appropriate for the size and type of battery being charged Use the battery manufacturer s specific instructions or see the guidelines below If the battery voltage is not clearly marked on the battery refer to the operator s manual for the vehicle equipment where the battery is used intended to be used Do not begin charging if the battery voltage cannot be determined Th
5. ALWAYS unplug the battery charger from the ac outlet before attempting any cleaning or maintenance Turning the charger s control s OFF alone will not remove all electricity from the charger 14 An extension cord should not be used unless absolutely necessary Use of an improper extension cord could result in a fire or electric shock If an extension cord must be used make sure that a the pins on the plug of the extension cord are the same number size and shape as those of the plug on the charger b the extension cord is properly wired and in good electrical condition and c the wire size is large enough for the length of cord as specified in the following chart Length in feet 25 50 100 150 cord AWG size 16 12 10 8 EXPLOSIVE GAS HAZARDS 1 Working in the vicinity of a lead acid battery is danger ous Batteries generate explosive gasses during normal operations and at an even higher level during charging If anything is allowed to ignite these gasses the battery may explode sending pieces of the battery and extreme ly caustic battery acid out in all directions and with extreme force Since just the slightest spark is sufficient to ignite these gasses it is of UTMOST IMPORTANCE that you read this manual and follow the instructions exactly before using your battery charger each time 2 NEVER operate this battery charger near any fuel tanks or gas cylinders This charger can produce sparks that could i
6. output cable or clamps or ac power cord plug in water or on wet surfaces 4 NEVER use this charger on a pier or dock Charger could fall in water creating an electric shock hazard 5 NEVER attempt to plug in or operate the battery charger with defective or damaged wires power cord or power cord plug Have any of these parts that are defective or damaged replaced by qualified personnel IMMEDIATELY 6 NEVER attempt to plug in the charger or operate its controls with wet hands or while standing in water 7 NEVER alter the ac power cord or power cord plug pro vided with the battery charger 8 NEVER use an attachment not recommended or sold by the battery charger manufacturer for use with this specific model battery charger 9 NEVER operate this battery charger if it has received sharp blow been dropped or similarly damaged until after being inspected and or repaired by qualified service personnel 10 NEVER disassemble this battery charger Take the bat tery charger to qualified service personnel when service or repair is needed 11 ALWAYS plug in and unplug the ac power cord by grasping the power cord plug NOT THE POWER CORD to reduce risk of damaging power cord 12 ALWAYS remove personal metal items such as rings bracelets 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 any jewelry to metal causing a severe burn 13
7. 12VLOW 12VMED 12VHIGH 24V HIGH START 200 Amp 12V K3149 1 40 2Amp 20 Amp 40 Amp 130 Amp 6V 250 Amp 12V K3150 1 60Amp 2Amp 40 Amp 60 Amp 185 Amp 6V 225 Amp 12V K3151 1 60Amp 40 Amp 60 Amp 30Amp 150 Amp 6V 12 Table 3 Length of Charge Time Chart 60 Amps BATTERY RATINGS Approx Marine Cranking Amps Approx Cold Cranking Amps Table 4 Length of Charge Time Chart 40 Amps Reserve Capacity Minutes 0 BATTERY RATINGS Approx Marine Cranking Amps BATTERY RATINGS Approx Marine Cranking Amps 13 Approx Cold Cranking Amps Approx Cold Cranking Amps Ampere Reserve Capacity Minutes Reserve Capacity Minutes MINUTES TO CHARGE 20 AMPS for the percent of charge now in the battery 0 MINUTES TO CHARGE 60 AMPS for the percent of charge now in the battery MINUTES TO CHARGE 40 AMPS for the percent of charge now in the battery 25 50 Table 6 Length of Charge Time Chart 2 Amps BATTERY RATINGS HOURS TO CHARGE Q 2 AMPS Approx Approx for the percent of charge now in the battery Marine Cold Reserve Cranking Cranking Capacity 096 25 50 Minutes NOTE 3 Setthe RATE SELECTOR to START and try to start the vehicle If the vehicle doesn t start after 3 to 4 seconds The length of charge times on these cha
8. green light on the charger will indicate the battery has become fully charged CAUTION Batteries that have 2596 charge or less can easily freeze and should be charged at once but DO NOT CHARGE A BATTERY THAT IS ALREADY FROZEN 1 Determine the present level of charge in the battery with a hydrometer or electronic percent of charge tester 2 Determine the size of the batteryin HOURS or RESERVE CAPACITY If these ratings are not printed on the battery contact your local battery dealer for this information These are the only ratings that can be used to determine length of charging time Then either use the formula in step 3 or use Table 2 plus Table 3 through Table 9 for the charging rate capabilities of this charger 3 Usethe battery rating the charge level of the battery and the amp setting to be used on the charger see Table 2 in the formula provided below EXAMPLE Battery s Present State of Charge 2596 Percent of Charge NEEDED 100 2596 75 Expressed as a Decimal 75 Amp setting on Charger 10 Amp Hour Rating of Battery 60 Hours to Reach Full Charge Hours to Reach Full Charge Hours to Reach Full Charge NOTE Ifthe battery is rate d in RESERVE CAPACITY use the following formula to convert reserve capacity to amp hours Reserve Capacity 15 5 Amp Hour Rating 2 Amp Hour Percent NEEDED Hou aS Table 2 Charge Amp Settings Model 6VHIGH
9. periods The battery can be damaged when being charged for extended periods especially at higher amperages VOLTMETER TEST METER TESTING See Figure 7 The VOLTMETER TEST METER available in some models allows additional testing to be performed In normal operation without the TEST SWITCH pressed the meter reads from 0 20 volts dc 0 and 20 are not actually seen on the meter face but are represented by the ends of the scale on the lower scale of the meter Using this part of the meter during charging the voltage should read for 6 volt batteries read 6 5 to 8 5 volts for 12 volt batteries read 13 5 to 16 5 volts If the voltmeter reads outside these voltages refer to the chart below for possible battery conditions VOLTS LOW AMPS HIGH Probable shorted Battery replace Poor Connection or Frozen Battery Battery Cold or Sulfated Reduce charge rate and charge longer After charging is complete the voltmeter should read the full charge voltage of the battery This is normally higher than the rated battery voltage To perform testing functions press the TEST SWITCH and read the top scale on the meter VOLTS LOW AMPS LOW VOLTS HIGH AMPS LOW NOTE This type of repair work is rather specialized It may require additional tests using other instruments for complete diagnosis REMEM BER The charger must be turned OFF to per form the tests If attempting to test with the charger turned ON the resu
10. safe use of your new charger This manual contains important safety information DO NOT OPERATE this equipment UNTIL YOU HAVE READ this safety summary IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS SAFETY INFORMATION The following safety information is provided as guidelines to help you operate your new battery charger under the safest possible conditions Any equipment that uses electrical power can be potentially dangerous to use when safety or safe handling instructions are not known or not followed The following safety information is provided to give the user the information necessary for safe use and operation A procedure step preceded by WARNING 15 an indication that the next step contains a procedure that might be injuri ous to a person if proper safety precautions are not heeded A procedure preceded by a CAUTION is an indication that the next step contains a procedure that might damage the equipment being used A NOTE may be used before or after a procedure step to highlight or explain something in that step SHOCK HAZARDS 1 This battery charger is intended for indoor use only Do not expose the charger to rain or snow 2 NEVER attempt to charge a marine boat battery while the boat is on or near the water A boat must be on a trailer and located indoors before attempting to charge its battery s The boat manufacturer s battery charging instructions must be followed exactly 3 NEVER set the charger
11. use for charging dry cell batteries that are commonly used with toys and home appliances These batteries may burst and cause injury to persons or damage property NEVER allow the dc output clamps to touch each other ALWAYS be extra cautious to reduce the risk of drop ping a metal object such as a tool onto or near the bat tery Doing so could produce a spark or short circuit the battery or other electrical part that could cause an explo sion ALWAYS make sure the area around a battery is well ventilated while it is being charged Gas can be forceful ly blown away by using a piece of cardboard or other non metallic material as a fan ALWAYS make sure that the ac power cord is unplugged from the ac outlet or extension cord BEFORE connecting or disconnecting the battery charger clamps to prevent arcing or burning ALWAYS locate the battery charger as far away from the battery as the dc output cables will permit ALWAYS twist or rock charger clamps back and forth several times on the battery post and the other point of connection at the time of initial connection This helps keep the clamps from slipping off their points of connec tion which helps reduce the risk of sparking DO NOT rock the clamp connected to the battery post AFTER the second connection at a point away from the battery is made or sparking may occur at the battery post ALWAYS check the cable and wire connections at the battery s for tightness BEFORE STARTIN
12. Do not plug the charger power cord into the ac power source or set any of the charger s controls until told to do so in the following instructions 1 Make sure that the ac power cord is unplugged from the ac outlet and make sure the vehicle s engine is turned off 2 Position the ac power cord and dc output cables in such a manner that they cannot be damaged by moving engine parts or the vehicle s hood or doors 3 Check the polarity of the battery terminals The POSI TIVE terminal should be marked POSITIVE POS or P The NEGATIVE terminal should be marked NEGA TIVE NEG 4 Determine whether the vehicle has a positive or negative grounded battery positive or negative cable is connected to the vehicle s chassis WARNING MOVING ENGINE PARTS CAN CAUSE SERIOUS INJURY Stay clear of fan blades belts pulleys and other moving engine parts to reduce risk of serious personal injury a Negative ground vehicles The most common type see Figure 9 Negative to Chassis Ground Positive Figure 9 Negative Ground 1 Connect the POSITIVE red clamp from the bat tery charger to the POSITIVE ungrounded termi nal of the battery 2 Connect the NEGATIVE black clamp from the battery charger to a heavy gauge metal part of the vehicle chassis or engine block away from the bat tery DO NOT connect the NEGATIVE N black charger clamp to the NEGATIVE battery terminal carburetor fuel lines or sheet me
13. ERY OR ENGINE If it is necessary to remove the battery from the vehicle to charge it make sure all accessories in the vehicle are off and ALWAYS remove the grounded cable from the battery FIRST If needed add distilled water to each cell of the battery until battery acid reaches the manufacturer s specified level DO NOT OVERFILL This helps remove excessive explosive gasses from the battery For maintenance free batteries without caps carefully follow the battery manufacturer s recharging instructions WARNING BATTERY ACID CAN CAUSE SERIOUS INJURY AND PROPERTY DAMAGE Always wear complete eye and clothing protection and avoid touching eyes while working near battery Clean battery terminals Be careful to keep corrosion from coming in contact with eyes Study all of the battery manufacturer s precautions such as whether cell caps should be left in place or removed during charging and the recommended rates of charge for the spe cific battery If you are unable to determine the battery man ufacturer s requirements for charging always charge the battery with the cell caps in place If the battery voltage cannot be determined from the infor mation on the battery itself refer to the owner s manual for the product in which the battery was installed CONTROLS AND INDICATORS CHARGE RATE SELECTOR switch is a multi position rotary switch The available settings for each charger are shown in Figure 5
14. G TO CHARGE A loose connection can cause sparks or excessive heating which could cause a battery explosion ALWAYS make sure the battery compartment is open and well ventilated before charging FIRE HAZARDS 1 NEVER use an attachment not recommended or sold by the battery charger manufacturer for use with your specif ic model charger 2 NEVER disassemble the battery charger take it to quali fied service personnel when service or repair is needed 3 ALWAYS make sure that the ac power cord is unplugged from the ac outlet or extension cord BEFORE connecting or disconnecting the battery charger clamps to prevent arcing or burning BATTERY ACID HAZARDS 1 ALWAYS have someone within range of your voice and close enough to quickly come to your aid when working near a lead acid battery 2 ALWAYS have plenty of fresh water and soap nearby in case battery acid contacts eyes skin or clothing 3 ALWAYS wear complete eye and clothing protection and avoid touching eyes while working with a battery 4 ALWAYS act QUICKLY if contact with battery acid is made If acid contacts skin or clothing wash IMMEDI ATELY with soap and water If acid enters the eye IMMEDIATELY flood the eye with running cold water for at least 10 minutes Get medical attention IMMEDIATE LY 0 MOVING PARTS HAZARDS 1 NEVER connect the battery charger clamps to a vehicle when the engine is running 2 ALWAYS stay clear of fan blades fan bel
15. TOM 3 Then replace the bottom 2 screws by screwing in part way so the handle can be move to an upright posi tion See Figure 2 FIGURE 2 REPLACE BOTTOM 2 SCREWS BY SCREWING IN PART WAY ROTATE HANDLE TO UPRIGHT POSITION 4 Align the holes of the handle with the top 2 screw holes of the charger Replace the top 2 screws which you removed in Figure1 Tighten all 4 screws secur ing the handle in the upright position See Figure 3 PREPARATION CHARGER PREPARATION CHARGER PLACEMENT Place the charger in a clean dry stable well ventilated spot as far away from the battery as the dc output cables permit NEVER place the charger directly above the battery being charged gasses from the battery will corrode and damage the charger NEVER allow battery acid to drip on the charger when reading specific gravity or filling the battery NEVER set a battery on top of the charger NEVER attempt to permanently mount this battery charger on a marine or recreational vehicle ALWAYS position the charger on the outside of a boat or recreational vehicle PROVIDE REQUIRED POWER This battery charger requires a nominal 120 volt 60 Hertz alternating current ac power source The power source must be fused at an amperage greater than or equal to the INPUT AMPS rating of this charger DO NOT PLUG THE CHARGER INTO THE AC POWER SOURCE UNTIL TOLD TO DO SO IN THE OPERATING INSTRUCTIONS WARNING ELEC
16. TRIC SHOCK CAN KILL To reduce risk of electric shock never alter ac power cord or power cord plug provided on the charger If it will not fit the outlet have a proper outlet installed by a qualified electri cian Never use an adapter The charger must be grounded to reduce risk of electric shock The charger is equipped with an electric cord that has an equipment grounding plug The plug must be plugged into an outlet that is properly installed and ground ed in accordance with all local codes and ordinances EXTENSION CORDS An extension cord should not be used unless absolutely necessary If necessary care must be taken to select an extension cord suitable for use with your specific battery charger see SHOCK HAZARDS in SAFETY SUMMARY NOTE Engine starting performance may be reduced when extension cords are used WARNING FIRE CAN KILL INJURE AND CAUSE PROPERTY DAMAGE To reduce risk of electric shock and fire never alter the ac power cord or power cord plug provided on the charg er Never alter extension cords or extension cord plugs Make sure the extension cord is properly wired and in good electrical condition Make sure the wire size American Wire Gauge or AWG of the extension cord is large enough to handle your specific charger s amperage requirements BATTERY PREPARATION WARNING BATTERY EXPLOSION CAN INJURE AND CAUSE PROPERTY DAMAGE NEVER SMOKE OR ALLOW A SPARK OR FLAME IN THE VICINITY OF THE BATT
17. e DEEPLY DISCHARGED LEAD CALCIUM BATTERIES in CHARGING TIME INSTRUCTIONS SHORTED BATTERIES When the battery being charged has a short circuit the ammeter will peg at the high amp end of the scale If after 5 to 10 minutes of charging the needle has not started to move toward lower amperages unplug the charger and discontinue charging If available use a voltmeter and read the battery voltage If the voltage is LESS THAN 12 0 volts for a 12 volt battery or LESS THAN 6 0 volts for a 6 volt battery plug the charger back in and resume charging If after another 15 to 20 min utes the ammeter has failed to move toward lower amper ages repeat the voltmeter test If the voltage has not increased the battery needs to be serviced or replaced CAUTION DO NOT USE AMMETER to determine when full charge is reached Failure to comply with this caution could cause the battery to be damaged from overcharging The battery could overheat and even explode CHARGING TIME INSTRUCTIONS Manual battery chargers need to be disconnected from a battery when the battery has reached 10096 of charge OR SOONER If this is not done the battery will overcharge resulting in possible battery damage The following instructions or the associated LENGTH CHARGE TIME CHARTS 60 amps down to 2 amps one for each charging range will allow you to determine how long it will take to bring a spec battery to full charge If the charger is so equipped a
18. e available settings are in Table 1 Small Motorcycle type 3 Amps or less mower Tractor 6 Amps or less 25 Amps or less e Maintenance free Auto 45 Amps or less or Marine Cranking Heavy duty Commercial 60 Amps or less Unless the information is supplied for the particular battery always charge small 12 volt batteries at no more than 2amps Not all of these chargers are capable of charging at 2 amps or less If your charger is one of those do not attempt to charge the small 12 volt batteries on that charger Charge only standard sized 6 and 12 volt automobile batteries on those chargers NOTE Thecharger ammeter will not taper on 6 volt settings Use charging time equations or charts only to determine the time needed to fully charge the battery TIMER SWITCH SETTING See Figure 6 and 7 Set the timer for the length of charging time required to bring the battery to full charge as determined in CHARGING TIME INSTRUCTIONS When selecting times less than 20 minutes turn timer past the 20 minute mark then back to the time desired Setting the time to charge starts the charging process To prevent overcharging do not set the timer for more time than it will take to bring the battery to full charge If the timer is turned to the eft past OFF HOLD is selected In this position the charger will remain ON indefinitely This position should be used only when charging at a low rate for extended
19. ged e Make sure you are allowing enough time for charging the battery Refer to the charging time formulas earli er in this manual 2 Ammeter shows reading but battery does not accept 15 charge a Check to see that the battery is capable of being charged It may be damaged or sulfated b Make sure you are allowing enough time for charging the battery Refer to the charging time formulas earli er in this manual 3 Vehicle will not start in engine start mode a b Unplug charger and check connections as described above Determine if charger is charging if meter indicates any amperage charger is working if no amperage is indicated wait several minutes and recheck Charger thermal protector may have tripped If engine turns over but does not start problem is with vehicle not charger Service vehicle See LIMITED WARRANTY for further information on obtain ing service 8629 22712 JIIBUYOA sa Jaye Jelg wuy T 1932919 311512 1012 ojeg L 6VLEM AOS NVESVIC C p109 aN peu Ajquassy BANISOg 219 quiessy gt 6 1 001 95 1313Ul OA ZIN 42918 E 04229 10 2 5 Bey L LSLEM 403 INVHOVIG pet quuessy ajqe 9ARnISOq
20. gnite gasses and cause an explosion 3 NEVER attempt to permanently mount this battery charger on a marine or recreational vehicle 4 NEVER attempt to connect this charger s output cables directly to the battery s in the bilge or engine compart ment of a boat Follow the boat manufacturer s battery charging instructions exactly 10 11 12 13 14 BATTERY EXPLOSION HAZARDS To reduce the risk of battery explosion read understand and follow these instructions those published by the bat tery manufacturer and those of the manufacturer of any equipment you intend to use near the battery Review cautionary markings on these products and on the engine If unable to determine the battery manufacturer s requirements for charging always charge the battery with the cell caps in place In addition make certain that any one else that uses this equipment or is a bystander in the vicinity of a charging battery understands and follows these safety instructions as well NEVER smoke or allow a spark or flame in the vicinity of the battery or engine NEVER operate the battery charger in a closed in area or restrict ventilation in any way NEVER charge a frozen battery as battery explosion can result NEVER connect BOTH battery charger clamps DIRECT LY to the two posts of the same battery See OPERA TION INSTRUCTIONS for connection procedures NEVER charge batteries other than a LEAD ACID type Especially DO NOT
21. ion yourself and the free end of the cable attached to the NEGATIVE battery terminal as far away from the battery as the cable will allow Then WHILE FACING AWAY FROM THE BATTERY connect the NEGATIVE charger clamp to the free end of the cable CHARGING INSTRUCTIONS 1 Determine the length of time necessary to charge the battery in CHARGING TIME INSTRUCTIONS but do not start the timer 2 Setall switches and the timer to OFF and connect the charger power cord into an appropriate ac outlet 3 Set charging voltage charging rate and any other func tions according to CONTROL SETTING INSTRUC TIONS 4 On models so equipped set the TIMER for the desired length of charge time BATTERY EXPLOSION CAN INJURE AND CAUSE PROPERTY DAMAGE To reduce risk of battery explosion do not overcharge a lead acid battery Follow disconnection procedure EXACTLY 5 When charging is complete turn all charger controls to OFF Then unplug the charger s ac power cord from the ac power source 6 Disconnect the charger clamp NOT attached directly to the battery first and DO NOT allow the clamp to touch anything Then disconnect the charger clamp attached to the battery terminal READING AN AMMETER The ammeter indicates the charging current being drawn from the charger by the battery As the battery becomes more fully charged the charge rate lessens and the amme ter needle moves toward the lower amp numbers on the meter During engine s
22. lts will be mean ingless Battery percent of charge test 12 volt only 1 With the charger OFF and clamps properly connected to the battery press the TEST SWITCH and read the bat tery percent of charge on the top left scale of the test meter 2 Ifthe battery has been recently charged or is in a vehicle that has been run recently there is probably a surface charge on the battery This will give a falsely high read ing on the percent of charge test Remove the SUR FACE CHARGE by turning on the vehicle headlights for three or more minutes Allow the battery to sit for one minute Retest the battery percent of charge Alternator test 12 volt only 1 With the charger OFF and clamps properly hooked to the battery start the engine and while running at fast idle press the TEST SWITCH 2 Read the alternator condition on the alternator test scale at the upper right section of the test meter The battery should be in a good state of charge before attempting this test 3 The three zones of the meter indicate the following OK Charging system is performing properly LOW Loose fan belt or voltage regulator and or alternator faulty HIGH Faulty voltage regulator or wiring harness FIGURE 6 Voltmeter Test Meter TEST SWITCHES PRE CHARGE BATTERY ACTIVATION Some modern batteries can cause charging problems if they have been deeply discharged The plates in these batteries can begin sulfating quickly forming a barrie
23. r to accepting a charge This condition will be indicated by an extremely low or zero ammeter reading A deeply discharged battery such as this may take as long as 4 to 8 hours before it will accept a charge When charging a battery with this condi tion set the RATE SELECTOR for a moderate charge rate and check on the battery every 30 minutes When the sul fate barrier has been broken through the battery will begin accepting a charge and the ammeter will register a higher normal charging rate The amount of time to charge the battery fully determined in CHARGING TIME INSTRUC TIONS begins when the battery begins accepting a charge If necessary reset the timer if your charger is so equipped to the length of charging time required after the battery begins accepting a charge FIGURE 7 CHARGE VOLTAGE AND RATE SELECTION AMMETER TIMER SWITCH SETTINGS i DC VOLTMETER 40 AMP AMD 60 AMP MODELS FIGURE 8 CHARGE VOLTAGE AND RATE SELECTION TIMER SWITCH SETTINGS VOLTS 24V FLEET MODEL OPERATION OPERATING INSTRUCTIONS ATTENTION DO NOT ATTEMPT TO OPERATE THIS BATTERY CHARGER until you have read and understood the entire SAFETY SUMMARY provided in this manual NOTE Go to ASSEMBLY in this manual before pro ceeding with the operation of your battery charger DO NOT ATTEMPT TO OPERATE THE CHARGER UNTIL ALL REQUIRED USER ASSEMBLY IS COMPLETED CONNECTING TO BATTERIES INSTALLED IN VEHICLES ATTENTION
24. rts stop and wait 3 to 4 minutes Repeat until engine starts are very accurate when using the RESERVE CAPACITY or AMPERE HOUR battery rat CAUTION ings The COLD CRANKING AMPS and Excessive continuous engine cranking can damage MARINE CRANKING AMPS ratings are vehicle starter motors approximations and vary from battery to bat tery Always follow the battery manufacturer s NOTE specific charging instructions If the engine spins but fails to start after sev Do not charge deep cycle batteries with a bat eral starting attempts there is an engine prob tery charger or setting on a charger that has lem not related to the starting system a rating of more than 25 amps Follow the Discontinue cranking the engine until the battery manufacturer s specific charging other problem is found and corrected instructions This battery charger has an internal thermal protector to prevent overheating and damage ENGINE STARTING to the battery charger If after repeated start ing attempts the ammeter registers zero out This battery charger can provide a high current output to put wait 3 to 4 minutes for the charger to help start vehicle with a weak battery However the on cool The thermal protector will automatically board computer in some vehicles can be damaged when racht and allow veu t6 continue attempting to jump start ALWAYS READ THE VEHICLE y OPERATOR S MANUAL BEFORE AUXILIARY STARTING to determine if jump star
25. t Battery Council International at 312 644 6610 and request their BATTERY SERVICE MANUAL which is avail able for a nominal charge DEEPLY DISCHARGED LEAD CALCIUM BATTERIES Many newer automotive batteries are of a lead calcium plate design When deeply discharged they may require an acti vation period before accepting a measurable charge This activation period may take as long as 4 to 8 hours If at the beginning of the charging process you notice that the ammeter if so equipped is at or near zero but you have determined that the battery is very discharged less than 25 of charge this is a good indication that an activa tion period is required see PRE CHARGE BATTERY ACTI VATION ASSEMBLY ASSEMBLY OF HANDLE AND CLAMP HOLDER FIGURE 3 Assemble the charger handle and clamp holder accord Deere GER ing to the following instructions and illustrations ee 1 Carefully remove the charger unit and all associated hardware from carton note the charger is shipped with the handle partially secured and resting in a down position on the front of the unit 2 Unscrew the top 2 screws on either side of the charger Remove the bottom 2 screws holding han dle with the washers washers will be discarded as shown in Figure 1 5 Carefully screw the clamp holder together onto the handle as shown in Figure 4 FIGURE 1 REMOVE AND DISCARD 2 WASHERS gt 90 FIGURE 4 __ _ 2 SCREWS E m om N BOT
26. tal body parts b Positive ground vehicles see Figure 10 Positive to Chassis Ground Negative Figure 10 Positive Ground 1 Connect the NEGATIVE black charger clamp to the NEGATIVE ungrounded terminal of the bat tery 2 Connect the POSITIVE red charger clamp to a heavy gauge metal part of the vehicle chassis or engine block away from the battery DO NOT con nect the POSITIVE red charger clamp to the POSITIVE battery terminal carburetor fuel lines or sheet metal body parts CONNECTING TO BATTERIES OUTSIDE A VEHICLE d 2 Make sure that the ac power cord is unplugged from the ac power source Check the polarity of the battery terminals see Figure 11 The POSITIVE terminal should be marked POSI TIVE POS or P The NEGATIVE terminal should be marked NEGATIVE NEG or Booster Cable Negative Charger Cable Positive Charger Cable From Charger Figure 11 Connecting Outside The Vehicle 10 3 Attach a battery or booster cable LEAST 24 inches long that is the same or larger wire gauge as the charg er cable to the NEGATIVE terminal of the battery WARNING BATTERY EXPLOSION CAN INJURE AND CAUSE PROPERTY DAMAGE To reduce the risk of battery explosion NEVER CON NECT BOTH BATTERY CHARGER CLAMPS DIRECTLY TO THE TWO POSTS OF A BATTERY 4 Connect the POSITIVE red charger clamp to the POSI TIVE battery terminal 5 Posit
27. tarting the ammeter will usually peg to the high amperage end of the meter There is no clear cut way to read an ammeter and deter mine exactly when charging is complete if the charger is so equipped a green light on the charger indicates battery is 11 fully charged At full charge the ammeter will still register some current draw approximately 50 of the charger s out put rating In many cases overcharging can occur if the charger is not disconnected when the battery reaches full charge or sooner Therefore it is very important that you follow the CHARGING TIME INSTRUCTIONS provided in this manual Several battery conditions can also cause the ammeter to appear to indicate a battery near full charge when in fact charging has only begun Cold Battery Sulfated Battery Deeply Discharged Lead Calcium Battery many newer automotive batteries WARNING BATTERY EXPLOSION CAN INJURE AND CAUSE PROPERTY DAMAGE To reduce risk of battery explosion check to make sure a cold battery is not frozen Battery explosion can result from attempting to charge a frozen battery COLD BATTERIES temperatures lower than 32 F or 0 C will begin charging at a low rate of charge But as the battery warms up through charging the charge rate will increase Then as the battery charges up the charge rate will decrease normally SULFATED or DEEPLY DISCHARGED LEAD CALCI UM BATTERIES require a special activation proce dure Se
28. ting can do damage to the vehicle If not read and follow these instructions CAUTION Do not try to boost start a vehicle that does not contain a battery or you may damage electrical system in the vehicle 1 Connect the battery charger to the vehicle according to OPERATING INSTRUCTIONS 2 Charge the battery for 5 to 10 minutes at the appropriate charge rate for the size of battery 14 MAINTENANCE CAUTION Make sure charger is unplugged from ac outlet before performing any cleaning or maintenance minimum amount of care can keep your battery charger working and looking good for years Clean the clamps after each use Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion Battery fluid may be neutralized with a solution of water and baking soda 1 2 Coil the input and output cables neatly after each use This will help prevent damage to the cables and the charger 3 If needed the case may be wiped clean with a soft cloth TROUBLESHOOTING 1 NoAmmeter Reading Battery does not accept charge a Make sure charger is plugged into live ac outlet b After unplugging unit check connection at battery Make sure the clamps are making good contact with the battery terminal or vehicle chassis c Check to see that the battery is capable of being charged It may be damaged or sulfated d Make sure that you have selected the proper charge voltage for the battery being char
29. to zero charge dead battery the more charging current it will want to draw When charging begins on a dead battery the chargers ammeter will regis ter toward the high end of the ammeter scale and move toward zero as the battery becomes more fully charged KEEP IN MIND the ammeter registers the amount of amperage being drawn from the charger by the battery not what the charger is capable of delivering One would expect a battery to draw zero amps when it reaches 100 charge But at 100 charge the battery will continue to draw a low level of current and convert it into heat within the battery If left connected and charging after reaching 10096 charge the battery acid will begin to boil resulting in overcharging and possible battery damage NOTE A slow bubbling sound may be heard coming from the battery during the charging process This is a normal condition and just another indicator the battery is being charged To reduce the risk of battery overcharging it is important to thoroughly read this instruction manual SPARK PREVENTION MAKE SURE no sparks or flames occur near the battery especially during charging It takes very little to ignite the explosive gasses produced by a lead acid battery Read understand and follow the safety information provided in the SAFETY SUMMARY section of this manual before attempt ing to work with or near a lead acid battery For more information about batteries and battery charging contac
30. ts pulleys and other moving engine parts when working near an engine Moving engine parts can cause severe personal injury including dismemberment 3 ALWAYS make sure that the battery charger cables and clamps are positioned so they will not come in contact with any moving engine parts 2f BURN HAZARDS a 1 NEVER lean on or rest against the engine or cooling system parts when the vehicle is running 2 ALWAYS stay clear of the cooling system engine and engine manifold These engine components get very hot and retain heat for a long time Touching any of these components can cause severe burns INTRODUCTION DESCRIPTION This battery charger is designed to handle the majority of your charging and starting needs MULTIPLE CHARGE RATES for various battery sizes High AMPERAGE ENGINE START to help start vehi cles when the battery is too weak to do the job alone An AMMETER to monitor charging progress A TIMER switch to set the desired charge time LARGE SAW TOOTH CLAMPS assure good connec tion to top or side mount battery terminals WHEEL AND HANDLE KIT for easy moving around your shop HEAVY DUTY CONSTRUCTION for long trouble free life HOW BATTERIES CHARGE A charger DOES NOT FORCE current into a battery it makes a limited amount of current available and the battery draws as much of it as it needs up to or slightly greater than the rated output current capability of the charger The closer a battery is
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