Wheel Charger Owner`s Manual
Contents
1. 14 Charging Instr ctlorts oce edet ev etta 15 leading AMMO en nde ee eia eee 15 Charging Time IMStmi Con Em 16 Engine yee i U4 de Perera EET 19 Maintenance IESU 20 Troubleshooting FOU NS SIO e O 21 Limited Warranty 21 INTRODUCTION Description This battery charger is designed to handle the majority of your charging and starting needs e Multiple Charge Rates for various battery sizes High Amperage Engine Start to help start vehicles when the battery is too weak to do the job alone Ammeter to monitor charging progress Timer Switch to set the desired charge time Large Saw Tooth Clamps assure good connection to top or side mount battery terminals Wheel and Handle Kit for easy moving around your shop Heavy Duty Christie Tough 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 to zero capacity dead battery the more charging2. AX WARNING Moving Parts Hazards 1 2 NEVER connect the battery charger clamps to a vehicle when the engine is running ALWAYS stay clear of fan blades fan belts pulleys and other moving engine parts when working near an engine Moving engine parts can cause severe personal injury including dismemberment ALWAYS make sure that the battery charger cables and clamps are positioned so they will not come in contact with any moving engine parts NEVER wear loose clothing or long hair around moving parts because they may get caught and cause severe injury or death A WARNING Burn Hazards 1 2 NEVER lean on or rest against the engine or cooling system parts when the vehicle is running 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 PERSONAL PRECAUTIONS 1 e Someone should be within range of your voice or close enough to come to your aid when you work near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection Avoid touching eyes while working near battery If battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immediately flood eye with running cold water for at least 10 minutes and get medical attentio
3. Eu RD edu EM ded 8 Deeply discharged Lead Calcium 42 44 000 00000000 8 Spaik PrevehltiOli eii 8 Assembly hire E EE 9 Preparation Charger Placement i i eios edad o bL esee 10 Provide Required PONSI aep oru cutee tex nes tha oun RR Ru rue Rx NEA E PENNS AEPA EREEREER ATEAN 10 Extension COL OS 10 Battery Prep arao RE DE 11 Controls and Indicators Control Setting IMStrucCtiOns E 12 Charge Voltage and Rate Selecto Mirris idilar aani sn nte ne nnns sin 12 Charging Rate Settings by 12 12 Bicis iesus RM MT 13 Polarity Proctection E e 13 Pre Charge Battery 13 Operation Operating INSIRUCTIONS e D Le 14 Connecting to Batteries Installed 14 Connecting to Batteries Outside a
4. Clore Automotive will at it s option refund the original purchase price or supply a replacement unit Transformer Rectifier All Other Parts FREE Service Labor Model No Warranty Period Warranty Period Warranty Period QWC 5 Years 2 Years 1 Year FDC 10 Years 5 Years 1 Year Excludes cables and clamps THE TERMS OF THE CLORE AUTOMOTIVE LIMITED WARRANTY CONSTITUTE THE BUYER S SOLE AND EXCLUSIVE REMEDY THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THIS EXPRESS WARRANTY AFTER THE WARRANTY PERIOD ALL RISK OF LOSS FROM WHATEVER REASON SHALL BE PUT UPON THE PURCHASER CLORE AUTOMOTIVE SHALL NOT BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCES LIABILITY IF ANY SHALL NEVER EXCEED THE PURCHASE PRICE OF THIS MACHINE REGARDLESS OF WHETHER LIABILITY IS PREDICATED UPON BREACH OF WARRANTY EXPRESS OR IMPLIED NEGLIGENCE STRICT TORT OR ANY OTHER THEORY This warranty extends to each person who acquires lawful ownership within the warranty period but is void if the product has in Clore Automotive s sole judgement been abused altered misused or improperly packaged and damaged when returned for repair This warranty applies to the product only and does not apply to any accessory items included with the product which are subject to wear from usage the replacement or repair of these items shall be at the expense of the owner Some states do not permit the l
5. 5 Polarity Protec Booster Automatic Reverse r the USA ttery Charge Made in paten Positive Polarity Protection Clore Automotive Kansas City MO 64161 www cloreautomotive com 913 310 1050 2012 Clore Automotive 842 189 000 B
6. contain liquid acids which are amm hazardous if spilled WARNING This product contains chemicals including lead known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling WARNING Shock Hazards 1 2 10 11 12 13 14 WARNING Risk of Explosive Gases 1 NEVER store the charger outdoors always store indoors when not in use When charger is used outdoors extreme care must be taken to ensure that any electrical connections such as extension cords are properly shielded from exposure to rain snow and moisture 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 NEVER set the charger output cable or clamps or ac power cord plug in water or on wet surfaces NEVER use this charger on a pier or dock Charger could fall in water creating an electric shock hazard 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 NEVER attempt to plug in the charger or operate its controls with wet hands or while standing in water NEVER alter the ac power cord or power cord plug provide
7. AUTOMOTIVE PRODUCTS Wheel Charger Owner s Manual Booster rger protection larity inthe US AT 6 12 24 VOLT FLEET DUTY Battery Charger Booster ection Polarity Prot utomatic Reverse A Made in the USA Includes information on Christie Model Nos QWC and FDC AWARNING Failure to follow instructions may cause damage or explosion always shield eyes Read entire instruction manual before use Warning This product contains chemicals including lead known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling Congratulations on the purchase of your new battery charger We wish to acknowledge Underwriters Laboratories U L for contributing the following important safety precautions Please read and retain these instructions for the continued safe use of your new charger This manual contains important safety information DO NOT OPERATE this equipment UNTIL YOU HAVE READ this safety summary SAFETY SUMMARY IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS AWARNING Read these instructions completely before using the Battery Charger and save them for future reference Before using the Battery Charger to charge a battery read these instructions and the instruction manual safety information provided by the car truck boat or equipment manufacturer Following all manufacturers instructions and safety procedure
8. 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 extremely 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 To reduce the risk of battery explosion follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of battery Review cautionary markings on these products and on engine NEVER operate this battery charger near any fuel tanks or gas cylinders This charger can produce sparks that could ignite gasses and cause an explosion NEVER attempt to permanently mount this battery charger on a marine or recreational vehicle NEVER attempt to connect this charger s output cables directly to the battery s in the bilge or engine compartment of a boat Follow the boat manufacturer s battery charging instructions exactly A WARNING Battery Explosion Hazards W 1 9 NEVER connect both battery charger clamps directly to the two posts of the same battery See Operation Instructions for connection procedures NEVER allow the DC output clamps to touch each other ALWAYS be extra cautious to reduce the risk
9. ad and understood the entire Safety Summary provided in this manual Note Go to Assembly in this manual before proceeding with the operation of your battery charger Do not attempt to operate the charger until all required user assembly is completed WARNING Connect and disconnect DC output clamps only after setting any charger switches to the OFF position and removing AC cord from electric outlet Never allow clamps to touch each other Connecting to Batteries Installed in Vehicles 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 POSITIVE terminal should be marked POSITIVE POS or P The NEGATIVE terminal should be marked NEGATIVE NEG or 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 most common see Figure 5 eee 1 Connect the POS red clamp from the battery charger to the POS Chassis aroun ungrounded terminal of the battery 2 Connect the NEG black clamp
10. age See Safety Summary pages 2 4 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 specific battery If you are unable to determine the battery manufacturer s requirements for charging always charge the battery with cell caps in place If the battery voltage cannot be determined from the information on the battery itself refer to the owner s manual for the product in which the battery was installed 11 CONTROLS AND INDICATORS Charge Rate Selector switch is a multiposition rotary switch This switch is used to set both the charging voltage and rate of charge hi med lo Charging Indicator LED is a status light This LED will light whenever the charger is charging 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 This switch also has a hold position which will keep the charger ON until turned OFF See Timer Switch Setting in this section for more details Ammeter indicates the charging current being drawn from the charger by the battery See Reading an Ammeter in this manual Polarity Protection Switch is a bi positio
11. are approximations and vary from battery to battery Always follow the battery manufacturer s specific charging instructions Do not charge deep cycle batteries with a battery charger or setting on a charger that has a rating of more than 20 amps Follow the battery manufacturer s specific charging instructions Engine Starting This battery charger can provide a high current output to help start a vehicle with a weak battery However the onboard computer in some vehicles can be damaged when attempting to jumpstart ALWAYS READ THE VEHICLE OPERATOR S MANUAL BEFORE AUXILIARY STARTING to determine if jumpstarting can do damage to the vehicle If not read and follow these instructions CAUTION Do not attempt to boost start a vehicle that does not contain a battery or you may damage electrical systems in the vehicle 1 Connect the battery charger to the vehicle according to Operating Instructions 2 Confirm vehicle voltage and ensure that all settings used during the jump starting process conform to that voltage 3 Charge the battery for 5 to 10 minutes at the appropriate charge rate for the size of battery 4 Set the Rate Selector to HI setting for applicable voltage and try to start the vehicle If the vehicle doesn t start after 3 to 4 seconds stop and wait 3 to 4 minutes Repeat until engine starts CAUTION Excessive continuous engine cranking can damage vehicle starter motors Note If the engine spins but fails to start af
12. current it will want to draw When charging begins on a dead battery the charger s ammeter will register toward the high end of the 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 100 charge the battery acid will begin to boil may produce acid vapor and get hot resulting in overcharging and possible battery damage Note A slow intermittent bubbling sound may be heard coming from the battery during the charging process This is anormal 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 Deeply Discharged Lead Calcium Batteries Many newer automotive batteries are of a lead calcium plate design When deeply discharged they may require an activation 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 is at or near zero but you have determined that the battery is very discharged less than 25 of c
13. d with the battery charger NEVER use an attachment not recommended or sold by Clore Automotive for use with this specific model battery charger Use of such attachment may result in risk of fire electric shock or injury to persons NEVER operate this battery charger if it has received a sharp blow been dropped or similarly damaged until after being inspected and or repaired by qualified service personnel NEVER disassemble this battery charger Take the battery charger to qualified service personnel when Service or repair is needed 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 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 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 That pins on plug of extension cord are the same number size and shape as those of plug on charger b That extension cord is properly wired and in good electrical condition and c That the wire size is large enough for the length of cord as specified below Length of cord in feet 25 50 100 150 AWG size of cord 16 12 10 8 Working in the vicinity of a lead acid battery is dangerous
14. el of charge in the battery with a hydrometer or electronic percent of charge tester 2 Determine the size of the battery in Amp 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 Use the 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 Amp Hour Percent Rating of X of Charge Hours Battery NEEDED X 125 to Charge Amp Setting Selected On Charger Example Battery s Present State of Charge 25 Percent of Charge Needed 100 25 75 Decimal 75 Amp Setting on Charger 10 80 78 X 1 25 Hours to Reach Full Charge 45 10 X 1 25 Hours to Reach Full Charge 4 5 X 1 25 Hours to Reach Full Charge Reserve capaety 15 5 Amp Hour Rating Amp Hour Rating of Battery 60 Note If the battery is rated in Reserve Capacity use the following formula to convert reserve capacity to amp hours 16 BATTERY RATINGS Approx Marine Cranking Amps BATTER Y RATINGS Approx Marine Cranking Amps BATTERY RATINGS Approx Marine Cranking Amps Approx Cold Cranking Amps Approx Cold Cranking Amps Approx Co
15. from the battery charger to a heavy gauge metal part of the vehicle chassis or engine block away from the battery DO NOT connect the NEG charger clamp to the NEG battery terminal carburetor fuel lines or sheet metal body parts b Positive Ground Vehicles 1 Connect the NEG black charger clamp to the NEG ungrounded terminal of the battery Positive 2 Connect the POS red charger clamp to a heavy gauge metal part Figure 5 Negative of the vehicle chassis or engine block away from the battery DO NOT connect the POS red charger clamp to the POS battery terminal carburetor fuel lines or sheet metal body parts Connecting to Batteries Outside a Vehicle Make sure that the AC power cord is unplugged from the AC outlet 2 Check the polarity of the battery terminals see Figure 6 The POSITIVE terminal should be marked POSITIVE POS or P The NEGATIVE terminal should be marked NEGATIVE NEG or N 3 Attach a battery or booster cable AT LEAST 24 inches long that is the same or larger wire gauge as the charger 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 connect both battery charger clamps directly to the two posts of a battery 4 Connect the POS red charger clamp to the POS battery terminal 5 Position yourself and the free end of the cable attached to the NEG battery terminal as far away from the bat
16. harge this is a good indication that an activation period is required see Pre Charge Battery Activation 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 during the charging process Read understand and follow the safety information provided in the Safety Summary section of this manual before attempting to work with or near a lead acid battery For more information about batteries and battery charging contact Battery Council International at 312 644 6610 and request their Battery Service Manual which is available for a nominal charge ASSEMBLY Charger Assembly 1 Carefully remove the charger unit and all associated hardware from carton 2 Attached handle onto back of cabinet using two 2 1 bolts 3 Remove the plywood packing base by remove three 3 sheet metal screws 4 Thread and tighten one 1 axle cap on the axle and slide on one 1 wheel Push axle through holes in the side bottom of cabinet Slide on other wheel and thread and tighten on other axle cap 5 Mount the front foot onto bottom of charger base using two 2 1 2 bolts PREPARATION Charger Placement Place the charger in a clean dry stable well ventilated spot as far from the battery as the DC output cables permit NEVER place the charger directly above the battery being charged gasses from the battery w
17. ill corrode and damage the charger NEVER allow battery acid to drip on the charger when reading specific gravity or filling the battery NEVER place a battery on top of the charger NEVER attempt to permanently mount this battery charger on a marine or recreational vehicle NEVER position the charger on the outside of a boat or recreational vehicle Provide Required Power This battery charger requires a nominal alternating current ac power source according to the chart below Model No AC Power Supply Required QWC 120V 60Hz FDC 120V 60Hz QWC2 230V 50 60Hz FDC2 230V 50 60Hz 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 ELECTRIC SHOCK CAN KILL See complete warning on page 3 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 electrician 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 AC outlet that is properly installed and grounded in accordance with all local codes and ordinances Extension Cords Note Engine starting performance may be reduced when extension cords are used An e
18. imitation of warranties or limitation of consequential or incidental damages so the above disclaimer and limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN SERVICE UNDER THIS WARRANTY Bring or send to the nearest Clore Automotive Authorized Warranty Service Center along with a copy of your purchase receipt or call Technical Service at 800 328 2921 To locate the nearest Clore Automotive Authorized Warranty Service Center go to www cloreautomotive com If this product fails within the first 30 days after retail purchase due to a defect in material or workmanship return it to your place of purchase for an exchange A valid dated sales receipt is required to obtain service under this warranty Registering Your Purchase For best service and to receive periodic product updates follow the instructions below to register your purchase Please visit www cloreregistration com Click on the Christie logo Complete the information in the web form and click submit It s that easy For answers to questions concerning use out of warranty service or warranty service information on this or other Clore Automotive products contact Clore Automotive Technical Service 800 328 2921 913 310 1050 www cloreautomotive com 21 AUTOMOTIVE PRODUCTS Wheel Charger Owner s Manual enmisTIE FLEET DUTY Battery aide tion
19. ld Cranking Amps Length of Charge Time Chart 70 Amps MINUTES TO CHARGE 70 AMPS Reserve Capacity Minutes for the percent of charge now in the battery Length of Charge Time Chart 60 Amps Reserve Capacity Minutes Reserve Capacity Minutes 15 100 MINUTES TO CHARGE 60 AMPS for the percent of charge now in the battery 50 MINUTES TO CHARGE 40 AMPS for the percent of charge now in the battery 17 BATTERY RATINGS Approx Marine Cranking Amps BATTERY RATINGS Approx Marine Cranking Amps Approx Cold Cranking Amps Approx Cold Cranking Amps Length of Charge Time Chart 30 Ams MINUTES TO CHARGE 30 AMPS for the percent of charge now in the battery Reserve Capacity Minutes Length of Charge Time Chart 20 Amps MINUTES TO CHARGE 20 AMPS for the percent of charge now in the battery Reserve Capacity Minutes 18 25 50 75 Length of Charge Time Chart 10 Amps BATTERY RATINGS MINUTES TO CHARGE 10 AMPS Approx Approx for the percent of charge now in the battery Marine Cold Reserve Cranking Cranking Capacity 0 25 50 Amps Amps Minutes Note The length of charge times on these charts are very accurate when using the Reserve Capacity or Ampere Hour battery ratings The Cold Cranking Amps and Marine Cranking Amps ratings
20. n immediately NEVER smoke or allow a spark or flame in vicinity of battery or engine Be extra cautious to reduce risk of dropping a metal tool onto battery It might spark or short circuit battery or other electrical part that may cause explosion 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 circuit current high enough to weld a ring or other jewelry to metal causing a severe burn Use charger for charging LEAD ACID batteries only It is not intended to supply power to a low voltage electrical system other than in a starter motor application 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 NEVER charge a frozen battery as battery explosion can result TABLE OF CONTENTS Safety Summary Safety 2 ELTE 3 Explosive Gas HaZands E 3 Battery IEXPIOSIOM mL 4 MOVING Parts HaZardS n 4 A ZANAS EP NM 4 Personal 6 22 2 5 Introduction lere EU 8 How Batteries Charge esci nde t ntt ag
21. n switch This switch is used to engage or disengage the automatic reverse polarity protection feature on this charger Control Setting Instructions Charge Voltage and Rate Selection Set the Rate Selector to the 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 Deep cycle 20 Amps or less Maintenance free Automotive or Marine Cranking 45 Amps or less Heavy duty Commercial 80 Amps or less Charging Rate Settings by Model Model No 6V Lo 6VMed 6VHi 12V Lo 12V Med 12V Hi 24V Lo 24V Med 24V Hi 20A 30A 40 40A 70A FDC 40A 60A 40A 70A 10A 20A 40A Charging Indicator LED This LED will light whenever the charger is in active charging mode In addition the internal cooling fan should start whenever the unit is charging NEVER operate the charger if the fan is not running while the Charging Indicator LED is lit Timer Switch Setting 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 Se
22. of dropping a metal object such as a tool onto or near the battery Doing so could produce a spark or short circuit the battery or other electrical part that could cause an explosion NEVER operate the battery charger in a closed in area or restrict ventilation in any way ALWAYS make sure the area around a battery is well ventilated while it is being charged Gas can be forcefully 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 connection 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 starting to charge A loose connection can cause sparks or excessive heating which could cause a battery explosion 10 ALWAYS make sure the battery compartment is open and well ventilated before charging
23. ort 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 minutes the ammeter has failed to move toward lower amperages repeat the voltmeter test If the voltage has not increased the battery needs to be serviced or replaced CAUTION Do not use an 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 15 Charging Time Instructions Manual battery chargers need to be disconnected from a battery when the battery has reached 100 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 of 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 specific battery to full charge 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 lev
24. otection Switch in Controls and Indicators section 4 Make sure that you have selected the proper charge voltage for the battery being charged 5 Make sure you are allowing enough time for charging the battery Refer to the charging time formulas earlier in this manual Ammeter shows reading but battery does not accept charge 1 Check to see that the battery is capable of being charged it may be damaged or sulfated See Polarity Protection Switch in Controls and Indicators section 2 Make sure you are allowing enough time for charging the battery Refer to the charging time formulas earlier in this manual Vehicle will not start in engine start mode 1 Unplug charger and check connections as described above 2 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 3 If engine turns over but does not start problem is with vehicle not charger Service vehicle See Limited Warranty for further information on obtaining service LIMITED WARRANTY Clore Automotive L L C warrants that for the periods outlined in the table below from the date of original retail purchase of the entire unit it will repair at no charge for parts and labor as noted this product if proven defective in material or workmanship If after reasonable efforts by Clore Automotive the product is deemed not repairable
25. r still does not charge and the Charging Indicator LED is lit press the Polarity Bypass Switch and release This switch provides a slight charge to the battery so that the automatic polarity protection circuit can correctly identify the positive terminal and permit the charger to begin charging If there is still no charging current the battery is probably defective or sulfated and cannot be charged Pre Charge Battery Activation Some modern batteries can cause charging problems if they have been deeply discharged The plates in such batteries can begin sulfating quickly forming a barrier 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 condition set the Rate Selector for a moderate charge rate and check on the battery every 30 minutes When the sulfate 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 Instructions begins when the battery begins accepting a charge If necessary reset the timer to the length of charging time required after the battery begins accepting a charge 13 OPERATION Operating Instructions ATTENTION Do not attempt to operate this battery charger until you have re
26. s will reduce the risk of accident Working around lead acid batteries may be dangerous Lead acid batteries release explosive gases during normal operation charging and jump starting Carefully read and follow these instructions for safe use Always follow the specific instructions in this manual and on the Battery Charger each time you use the Battery Charger All lead acid batteries car truck and boat produce hydrogen gas which may violently explode in the presence of fire or sparks Do not smoke use matches or a cigarette lighter while near batteries Do not handle the battery while wearing vinyl clothing because static electricity sparks are generated when vinyl clothing is rubbed Review all cautionary material on the Battery Charger and in the engine compartment Always wear eye protection appropriate protective clothing and other safety equipment when working near lead acid batteries Do not touch eyes while working on or around lead acid batteries Always store clamps away from each other or common conductors Improper storage of clamps may cause the clamps to come in contact with each other or a common conductor which would be hazardous if the charger was plugged into an AC outlet Use extreme care while working within the engine compartment because moving parts may cause severe injury Read and follow all safety instructions published in the vehicle s Owner s Manual E Batteries being charged with the Battery Charger unit likely
27. ter several starting attempts there is an engine problem not related to the starting system Discontinue cranking the engine until the other problem is found and corrected This battery charger has an internal thermal protector to prevent overheating and damage to the battery charger If after repeated starting attempts the ammeter registers zero output wait 3 to 4 minutes for the charger to cool The thermal protector will automatically reset and allow you to continue 19 MAINTENANCE CAUTION Make sure charger is unplugged from AC outlet before performing any cleaning or maintenance A minimum amount of care can keep your battery charger working and looking good for years 1 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 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 No ammeter reading battery does not accept charge 1 Make sure charger is plugged into live AC outlet 2 After unplugging unit check connection at battery Make sure the clamps are making good contact with the battery terminal or vehicle chassis 3 Check to see that the battery is capable of being charged it may be damaged or sulfated See Polarity Pr
28. tery as the cable will allow Then WHILE FACING AWAY FROM THE BATTERY connect the NEGATIVE charger clamp to the free end of the cable 14 Booster Cable Negative A Charger Positive Charger Cable Figure 6 Connecting Outside a Vehicle Charging Instructions Note A marine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use 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 functions according to Control Setting Instructions 4 On models so equipped set the Timer for the desired length of charge time WARNING 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 bat
29. tery becomes more fully charged the charge rate lessens and the ammeter needle moves toward the lower range on the meter During engine starting the ammeter will usually peg to the high amperage end of the meter There is no clear cut way to read an ammeter and determine exactly when charging is complete At full charge the ammeter will still register some current draw approximately 5096 of the charger s output 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 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 WARNING Battery explosion can injure and cause property damage To reduce the 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 Sulfated or Deeply Discharged Lead Calcium Batteries require a special activation procedure See Pre Charge Battery Activation page 13 Shorted Batteries When the battery being charged has a sh
30. tting 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 left 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 periods The battery can be damaged when being charged for extended periods especially at higher amperages Polarity Protection Switch The charger is equipped with automatic polarity protection and will not charge if the charging clamps are improperly connected to a battery reversing positive and vehicle ground This feature is designed to prevent damage to vehicle electronics due to an improper connection The protection circuit is electronic and extremely sensititive However if the battery to be charged is too discharged below 1 5 Volts to energize the polarity protection circuit charging current will not flow as indicated on the Ammeter 12 If the charging light is ON but current does not flow the clamp connections may be reversed or a poor contact has been made to the battery Turn the charger OFF and disconnect the ac power supply Check all vehicle connections See Connecting to Batteries Installed in a Vehicle If all vehicle connections are correct and there is good contact at the battery connection reconnect ac power supply and restart the charging process If the charge
31. xtension 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 WARNING Fire can kill injure and cause property damage See Safety Summary pages 2 4 To reduce risk of electric shock and fire never alter the AC power cord or power cord plug provided on the charger 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 10 Battery Preparation WARNING Battery explosion can injure and cause property damage Never smoke or allow a spark or flame in the vicinity of the battery or engine See Safety Summary pages 2 4 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 dam
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