Chicago Electric 99857 User's Manual
Contents
1. parts This will ensure that the safety of the Battery Charger is maintained Battery Charger Safety Warnings 1 For technical questions please call 1 800 444 3353 Maintain labels and nameplates on the tool These carry important safety information If unreadable or miss ing contact Harbor Freight Tools for a replacement Avoid contact with battery acid If splashed unplug Battery Charger and immediately wash effected area with clean water Turn vehicle OFF and allow to cool before plugging in Battery Charger Remove keys from vehicle ignition before plugging in Battery Charger Before operation check to be sure Battery Charger cables are connect ed to the correct battery posts Red must be connected to the Positive terminal Black cable must be con nected to the Negative terminal Keep Output Wires 12 and Power Cable 8 clear of fan fan belt pul leys and any other moving parts of the engine Only use Battery Charger in a well ventilated area to prevent build up of explosive gasses Do not allow the Red and Black ter minals of the Battery Charger or the vehicle battery cables to touch Do not allow the Red cables to touch the frame or any metal part of the ve hicle Contact can cause an electrical short resulting in sparks burn injury or damage to property Only use in 12 VDC systems Do not use in any other voltage system Page 4 9 Do not attempt to start or jump a vehicle with2. C 5 under the battery to hold the Charger in place 7 Be sure the Battery Charger is firmly attached and will not come loose during normal vehicle use or during a sudden stop Periodically check the Charger to be sure it is still firmly at tached A loose Battery Charger can become damaged or damage vehicle components 8 Be sure the vehicle ignition switch is in the OFF position Using the vehicle battery clamp bolts attach the round connectors of the Output Wires 12 SKU 99857 For technical questions please call 1 800 444 3353 to the battery Be sure the Red Out put Wire is attached to the Positive terminal and the Black Output wire is attached to the Negative terminal Be sure all connections are tight Keep Output Wires 12 and Power Cable 8 clear of fan fan belt pul leys and any other moving parts of the engine Functions When plugged in this Battery Char ger will charge a 12 VDC battery and maintain the charge You can see the state of charge by observing the LED lights on the Charger 3 Stage Charging This charger automatically works in three stages depending on the con dition of your battery Page 9 2 1st stage Constant Current When the battery is severely discharged the Charger applies Constant Cur rent This stage speedily charges the battery while protecting against damage loss of Hydrogen or even explosion The battery is charged toa gt maximum of 14 8 Vo
3. consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESS LY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the com plaint must accompany the merchandise If our inspection verifies the defect we will ei ther repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return re paired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 99857 For technical questions please call 1 800 444 3353 Page 14
4. which if in any way Do not use any adapt not avoided could result in er plugs with grounded Battery minor or moderate injury Chargers Unmodified plugs and SKU 99857 For technical questions please call 1 800 444 3353 Page 2 SKU 99857 matching outlets will reduce risk of electric shock b Avoid body contact with grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is grounded c Do not expose Battery Chargers to rain or wet conditions Water enter ing a Battery Charger will increase the risk of electric shock d Do not abuse the cord Never use the cord for carrying pulling or unplugging the Battery Char ger Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords in crease the risk of electric shock e When operating a Battery Charger outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock Th If operating a Battery Charger in a damp location is unavoidable use a Ground Fault Circuit Interrupter GFCI protected supply Use of a GFCI reduces the risk of electric shock Personal safety a Stay alert watch what you are do ing and use common sense when operating a Battery Charger Do not use a Battery Charger while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operat
5. ELECTRIC hace 1 5 AMP ELECTRONIC ONBOARD BATTERY CHARGER Werl 99857 SET UP AND OPERATING INSTRUCTIONS Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our website at http www harborfreight com Read this material before using this product Failure to do so can result in serious injury SAVE THIS MANUAL Copyright 2008 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included For technical questions or replacement parts please call 1 800 444 3353 SAVE THIS MANUAL Mebi NOTICE is used to address practices Keep this manual for the safety warn not related to personal injury ings and precautions assembly operat ing inspection maintenance and cleaning CAUTION without procedures Write the product s serial CAUTION the safety alert number in the back of the manual near the symbol is used to address assembly diagram or month and year of practices not related to purchase if product has no number Keep personal injury this manual and the receipt in a safe and dry place for future reference
6. General Battery Charger Safety Warnings IMPORTANT SAFETY f WARNING Read all safety warnings and instructions INFORMATION __ Failure to follow the warnings and instructions may result in electric shock fire and or serious injury Save all warnings and instructions for future reference In this manual on the labeling and all other information provid ed with this product This is the safety alert The term Battery Charger in the symbol It is used to alert warnings refers to your mains you to potential personal operated corded Battery Charger injury hazards Obey all safety messages that 1 Work area safety follow this symbol to avoid a Keep work area clean and well lit possible injury or death Cluttered or dark areas invite acci dents DANGER indicates b Do not operate Battery Chargers in 44 DANGER a hazardous explosive atmospheres such as in situation which if not the presence of flammable liquids avoided will result in death or gases or dust Battery Chargers serious injury create sparks which may ignite the dust or fumes AWARNING Hab ids a c Keep children and bystanders hazardous situation which if away while operating a Battery not avoided could result in Charger Distractions can cause you death or serious injury to lose control CAUTION used 2 Electrical safety ACAUTION with the safety a Battery Charger plug must match alert symbol indicates a the outlet Never modify the plug hazardous situation
7. LIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO PARTS LIST e 1 s PowerCable 1 9 feeca a SKU 99857 For technical questions please call 1 800 444 3353 Page 12 ASSEMBLY DIAGRAM SKU 99857 For technical questions please call 1 800 444 3353 Page 13 LIMITED 90 DAY WARRANTY Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that this prod uct is free from defects in materials and workmanship for the period of 90 days from the date of purchase This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities criminal activity improper installation normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or
8. d tools may be used in either of the 120 volt outlets shown in the preceding illustration See dition Always replace a damaged extension cord or have it repaired by a qualified electrician before using it Outlets for 2 Prong Plug g Plug 8 Protect the extension cords from sharp objects excessive heat and damp or wet areas RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS 120 240 VOLT EXTENSION CORD NAMEPLATE LENGTH ction RE lo N Extension Cords 1 Grounded tools require a three wire extension cord Double Insulated tools can use either a two or three wire extension cord 2 As the distance from the supply outlet increases you must use a heavier gauge extension cord Using exten sion cords with inadequately sized wire Causes a serious drop in voltage resulting in loss of power and pos sible tool damage See Table A at full load PES o co co rw rara pet ve es NINI RIO ik P 3 The smaller the gauge number of the wire the greater the capacity of the cord For example a 14 gauge cord can carry a higher current than a 16 gauge cord See Table A Based on limiting the line voltage drop to five volts at 150 of the rated amperes TABLE A 4 When using more than one exten Symbology sion cord to make up the total length make sure each cord contains at Double Insulated least the minimum wire size required See Table A EG Canadian Standa
9. e Battery Chargers out of the reach of children and do not allow persons unfamiliar with the Page 3 Battery Charger or these instruc tions to operate the Battery Char ger Battery Chargers are dangerous in the hands of untrained users d Maintain Battery Chargers Check D RV b a SKU 99857 for breakage of parts and any other condition that may affect the Battery Charger s operation If damaged have the Battery Char ger repaired before use Many ac cidents are caused by poorly main tained Battery Chargers Use the Battery Charger in ac cordance with these instructions taking into account the working conditions and the work to be per formed Use of the Battery Charger for operations different from those intended could result in a hazardous situation Battery use and care When battery is not in use keep away other metal objects like paper clips coins keys nails screws or other small metal ob jects that can make a connec tion from one terminal to another Shorting the battery terminals togeth er may cause burns or a fire Under abusive conditions liquid may be ejected from the battery avoid contact If contact acciden tally occurs flush with water If liquid contacts eyes additionally seek medical help Liquid ejected from the battery may cause irritation or burns Service Have your Battery Charger ser viced by a qualified repair person using only identical replacement
10. e engine is OFF the engine is cool and the key is re moved from the ignition 2 Never Jump or attempt to start the vehicle while the Battery Charger is plugged in 3 Do not attempt to charge a damaged or dead battery with this tool This charger is designed to top off and maintain vehicle batteries at or near 12 VDC Attempting to charge dam aged or discharged batteries with this tool may cause the battery or the charger to overheat possibly causing damage or explosion 4 Plug your extension cord into the Power Cable 8 Plug the extension cord into a GFCI protected 120 VAC outlet 5 Observe the LED lights on the char ger to determine the operational sta tus of the circuit and the charger Page 10 LED ON Condition Cleaning and Maintenance Color OFF Green OFF Charger is not operating BEFORE EACH USE inspect the general Reg OFF Check connections and status condition of the Charger Check for loose of 120 VAC circuit emm ON 120 VAC is present and char SCTEWS misalignment or binding of moving Yellow ON ger is operating parts cracked or broken parts damaged Reg m electrical wiring and any other condition that may affect its safe operation ON 120 VAC is present Battery is OFF fully charged Yellow OFF Green ON OFF Battery Voltage is under 9V 1 AFTER USE clean external surfaces Red ON of the tool with clean cloth Yellow OFF 2 AWARNING If the supply cord of this Battery Charge
11. ing Battery Chargers may result in seri ous personal injury b Use personal protective equip ment Always wear eye protection Safety equipment such as dust mask For technical questions please call 1 800 444 3353 non skid safety shoes hard hat or hearing protection used for appropri ate conditions will reduce personal injuries c Do not overreach Keep proper footing and balance at all times This enables better control of the Battery Charger in unexpected situa tions d Dress properly Do not wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts e Only use safety equipment that has been approved by an appropri ate standards agency Unapproved safety equipment may not provide adequate protection Eye protection must be ANSI approved and breath ing protection must be NIOSH ap proved for the specific hazards in the work area Battery Charger use and care a Do not force the Battery Charger Use the correct Battery Charger for your application The correct Battery Charger will do the job better and safer at the rate for which it was designed b Disconnect the plug from the pow er source from the Battery Charger before making any adjustments changing accessories or storing Battery Chargers Such preventive safety measures reduce the risk of starting the Battery Charger acciden tally c Store idl
12. it prevents sustained elec trical shock WARNING Handling the cord on this product will expose you to lead a chemical known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling Califor nia Health amp Safety Code 8 25249 5 et seq WARNING The brass components of this product contain lead a chemi cal known to the State of California to cause birth defects or other repro ductive harm California Health amp Safety code 25249 5 et seq The warnings precautions and in structions discussed in this instruction manual cannot cover all possible con ditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator SAVE THESE INSTRUCTIONS Page 5 SKU 99857 GROUNDING TO PREVENT AWARNING ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE CONNECTION Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Do not modify the power cord plug provided with the tool Never remove the grounding prong from the plug Do not use the tool if the power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician Grounded Tools Tools with Three P
13. lts DC 3 2nd Stage Constant Voltage This is a speed charge cycle for batteries nearly full It will top off the battery at 14 8 Volts DC utilizing a 200 mA trickle charge 4 3rd stage Floating Constant Volt age This stage maintains a fully charged battery in its best condition by constantly applying small ticks of charge The battery will never fall below 13 5 Volts DC OPERATING INSTRUCTIONS Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product A Tool Set Up SERIOUS INJ SERIOUS INJURY Use only an appropriate extension cord in good condition to operate this Battery Charger See pages 6 and 7 of this manual for information on safe use of extension cords SKU 99857 For technical questions please call 1 800 444 3353 Work Piece and Work Area Set Up 1 Designate a work area that is clean ventilated and well lit The work area must not allow access by children or pets to prevent injury and distraction Route the power cord along a safe route to reach the work area without creating a tripping hazard or exposing the power cord to possible damage The power cord must reach the work area with enough extra length to al low free movement while working 3 To prevent electrical shock avoid moisture or water in the work area General Operating Instructions 1 Be sure the vehicl
14. r is damaged it must be replaced only by a quali fied service technician 6 Periodically check the Battery Char ger during operation to be sure it does not overheat 7 Before starting or operating the ve hicle unplug and put away the exten sion cord MAINTENANCE AND SERVICING Procedures not specifically A explained in this manual must be performed only by a qualified technician SERIOUS INJURY FROM TOOL FAILURE Do not use damaged equipment If abnormal heat occurs or Charger overheats have the problem corrected before further use SKU 99857 For technical questions please call 1 800 444 3353 Page 11 Troubleshooting Possible Causes Likely Solutions Tool will not 1 No power at outlet 1 Check power at outlet operate LED 2 Cord not connected 2 Check that cord is plugged in lights off LED lights on 1 Loose or dirty connection at 1 Check connections Clean and re tighten but tool does not battery terminals charge battery l Follow all safety precautions whenever diagnosing or servicing the MIA tool Disconnect power supply before service PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUA
15. rds Association 5 If you are using one extension cord beso than m tool add the Underwriters Laboratories Inc nameplate amperes and use the sum to determine the required minimum V Volts Altemating Current cord size See Table A No Load Revolutions per Minute Ng xxxx min RPM 6 Ifyou are using an extension cord outdoors make sure it is marked with the suffix W A W in Canada to indicate it is acceptable for outdoor use 7T Make sure the extension cord is prop erly wired and in good electrical con SKU 99857 For technical questions please call 1 800 444 3353 Page 7 SPECIFICATIONS Electrical Requirements 120 V 60 Hz Output Voltage 12 VDC 1 5 Amps Charging Method 3 Stage trickle charge Red Yellow and Status Indicators Green LED lights On Off trickle Overload Protection charging with Thermal Overload Protection Additional Protection Shor Cleat ang Polarity Protection UNPACKING When unpacking check to make sure that the item is intact and undamaged If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible INSTRUCTIONS FOR PUTTING INTO USE Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product SERIOUS INJ SERIOUS INJURY FROM ACCIDENTAL OPERATION Unplug the tool f
16. rom its electrical outlet and disconnect from battery before assembling or making any adjustments to the tool SKU 99857 For technical questions please call 1 800 444 3353 Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual Mounting 1 The Battery Charger must be mount ed near the battery in the engine compartment of the vehicle 2 Leave at least 2 7 clearance in front of the Output Wires 12 Plug 3 You can mount the Charger on the vehicle engine compartment wall near the battery or you can mount it on a bracket held in place by the bat tery Bracket B 6 Bracket A 9 Figure 1 Side View with Brackets Front View with Brackets j 5 4 For Engine Compartment Wall mounting mark and predrill wall us ing Bracket A 9 or Bracket B 6 as a template See Figure 1 above Be Page 8 sure that there are no wires hoses or other components behind the wall that will be damaged by drilling Use Brackets A and B to grip the Battery Charger Attach to the compartment wall using two Self Tapping Screws 12 5 For mounting under the battery as semble Brackets A B and C 9 6 and 5 as shown in Figure 2 below Bracket A 9 Side View of Brackets Assembly Slide Bracket C 5 DN under Battery p Bracket B 6 Figure 2 e mt Attach Output Wires to Battery Terminals 6 Slide Bracket
17. rong Plugs S NER mA 3 Prong Plug and Outlet Tools marked with Grounding Re quired have a three wire cord and three prong grounding plug The plug must be connected to a properly grounded outlet If the tool should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user reducing the risk of electric shock See 3 Prong Plug and Outlet The grounding prong in the plug is connected through the green wire in side the cord to the grounding system in the tool The green wire in the cord must be the only wire connected to the tool s grounding system and must never be attached to an electrically live terminal See 3 Prong Plug and Outlet The tool must be plugged into an appropriate outlet properly installed and grounded in accordance with all codes and ordinances The plug and outlet should look like those in the preceding illustration See 3 Prong Plug and Outlet Double Insulated Tools Tools with Two Prong Plugs S S Outlets for 2 Prong Plug Tools marked Double Insulated do not require grounding They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Labora tories Inc the Canadian Standard Association and the National Electri cal Code See Outlets for 2 Prong Plug For technical questions please call 1 800 444 3353 Page 6 Double insulate
18. this Battery Charger plugged in Do not use this Battery Charger to charge a dead damaged or severely discharged battery This charger is designed to top off and maintain a battery at or near 12 VDC 10 Do not leave the Charger unattended when it is plugged into an electrical outlet Unplug the Charger from its electrical outlet before leaving TT The battery charger may get hot during use The charger s heat can build up to unsafe levels and create a fire hazard if it does not receive adequate ventilation due to an electrical fault or if it is used in a hot environment Do not place the charger on a flam mable surface Do not obstruct any vents on the charger Especially avoid placing the charger on car pets and rugs they are not only flammable but they also obstruct vents under the charger 12 This product is not a toy Keep it out of reach of children 13 People with pacemakers should consult their physician s before use Electromagnetic fields in close prox imity to heart pacemaker could cause pacemaker interference or pacemak er failure In addition people with pacemakers should Avoid operating alone Do not use with power switch locked on Properly maintain and inspect to avoid electrical shock Any power cord must be properly grounded Ground Fault Circuit Inter SKU 99857 14 For technical questions please call 1 800 444 3353 rupter GFCI should also be imple mented
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