Chicago Electric 91325 User manual

BABA
BABA
BATTERTTER
TTERTTER
TTERY CHARGERY CHARGER
Y CHARGERY CHARGER
Y CHARGER
WITH AUTO CUTWITH AUTO CUT
WITH AUTO CUTWITH AUTO CUT
WITH AUTO CUT-OFF-OFF
-OFF-OFF
-OFF
12/24 VOL12/24 VOL
12/24 VOL12/24 VOL
12/24 VOLTT
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ASSEMBLY AND OPERATING INSTRUCTIONS
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011
VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM
Copyright©2004 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.
For technical questions and replacement parts, please call 1-800-444-3353.
TO HELP PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
91325

SKU 91325 For technical questions, please call 1-800-444-3353. Page 2
IMPORTANT SAFEGUARDS
IMPORTANT SAFETY INSTRUCTIONS
1. “SAVE THESE INSTRUCTIONS” - This manual contains important safety and operating
instructions for battery charger Model: 91325.
2. Do not expose charger to rain or snow.
3. Use of an attachment not recommended or sold by the battery charger manufacturer may
result in a risk of fire, electric shock, or injury to persons.
4. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when
disconnecting charger. An extension cord should not be used unless absolutely
necessary.
5. Use of improper extension cord could result in a risk of fire and electric shock. If extension
cord must be used, make sure:
(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.
(c) That wire size is large enough for AC ampere rating of charger.
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SKU 91325 For technical questions, please call 1-800-444-3353. Page 3
MINIMUM AWG WIRE SIZE FOR EXTENSION CORDS FOR THIS BATTERY CHARGER
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5205001051
0< 2<I81818161
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6< 8<I81612101
8< 01<I81412101
01< 2
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21< 41<I6121018
41< 61<I6121018
6. Do not operate this charger with a damaged cord or plug – replace the cord or plug
immediately.
7. Do not operate charger if it has received a sharp blow, been dropped, or otherwise
damaged in any way; take it to a qualified serviceman.
8. Do not disassemble charger; take it to a qualified serviceman when service or repair is
required. Incorrect reassembly may result in a risk of electric shock or fire.
9. To reduce risk of electric shock, unplug charger from outlet before attempting any
maintenance or cleaning.
10. WARNING - RISK OF EXPLOSIVE GASES.
(a) Working in the vicinity of a lead-acid battery is dangerous. Batteries generate
explosive gases during normal battery operation. For this reason, it is of utmost
importance that each time before using your charger, you read this and follow the
instructions exactly.
(b) To reduce the risk of the 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.
11. PERSONAL PRECAUTIONS
(a) Someone should be within range of your voice, or close enough to come to your aid,
when you work near a lead-acid battery.
(b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing,
or eyes.
(c) Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.
(d) If battery acid contacts skin or clothing, wash immediately with soap and water. If
acid enters eye, immediately flood with running cold water for at least 10 minutes
and get medical attention immediately.

SKU 91325 For technical questions, please call 1-800-444-3353. Page 4
(e) NEVER smoke or allow a spark or flame in vicinity of battery or engine.
(f) 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 an explosion.
(g) Remove personal metal items such as rings, bracelets, necklaces, and watches
when working near a lead-acid battery. A lead-acid battery can produce a short-
circuit current high enough to weld a ring or the like to metal, causing a severe burn.
(h) Use this charger for charging LEAD-ACID batteries only. It is not intended to supply
power to a low voltage electrical system other than in an automotive 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.
(i) NEVER charge a frozen battery.
12. PREPARING TO CHARGE BATTERY
(a) If it becomes necessary to remove the battery from the vehicle to charge, always
remove grounded terminal from battery first. Make sure all accessories in the vehicle
are off, so as not to cause an arc.
(b) Be sure area around battery is well ventilated while battery is being charged. Gases
can be forcefully blown away, by using a piece of cardboard or other non-metallic
material such as a fan.
(c) Clean battery terminals. Be careful to keep corrosion from coming in contact with
eyes.
(d) Add distilled water in each cell until battery acid reaches level specified by battery
manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery
without cell caps, carefully follow manufacturer’s recharging instructions.
(e) Study all battery manufacturer’s specific precautions such as removing or not
removing cell caps while charging and recommended rates of charge.
(f) Determinate voltage of battery by referring to car owner’s manual and make sure
that output voltage selector switch is set at correct voltage. If charger has adjustable
charge rate, charge battery initially at lowest rate.
13. CHARGER LOCATION
(a) Locate charger as far away from battery as the DC cable permits.
(b) Never place charger directly above battery being charged; gases from battery will
corrode and damage charger.
(c) Never allow battery acid to drip on charger when reading gravity or filling battery.
(d) Do not operate charger in a closed-in area or restrict ventilation in any way.
(e) Do not set a battery on top of charger.
14. DC CONNECTION PRECAUTIONS
(a) Connect and disconnect DC output clips only after setting any charger switches to
off position and removing AC cord from electric outlet. Never allow clips to touch
each other.
(b) Attach clips to battery and chassis as indicated in 15 (e), 15 (f), 16 (b), and 16 (d).

SKU 91325 For technical questions, please call 1-800-444-3353. Page 5
15. Follow these steps when battery is installed in vehicle. A spark near battery may cause
battery explosion. To reduce risk of a spark near battery:
(a) Position AC and DC cords to reduce the risk of damage by hood, door, or moving
engine parts.
(b) Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to
persons.
(c) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger
diameter than NEGATIVE (NEG, N, -) post.
(d) Determine which battery post is grounded (connected) to the chassis. If negative
post is grounded to chassis (as in most vehicles), see (e). If the positive post is
grounded to the chassis, see (f).
(e) For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger
to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK)
clip to vehicle chassis or engine block away from battery. Do not connect clip to the
carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal
part of the frame or engine block.
(f) For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger
to NEGATIVE (NEG, N, -) ungrounded post of battery. Connect POSITIVE (RED)
clip to vehicle chassis or engine block away from battery. Do not connect clip to the
carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal
part of the frame or engine block.
(g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip
from vehicle chassis, and then remove clip from battery terminal.
(h) See operating instructions for length of charge information.
16. Follow these steps when battery is outside vehicle. A spark near battery may cause
battery explosion. To reduce risk of a spark near battery:
(a) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger
diameter than NEGATIVE (NEG, N, -) post.
(b) Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE
(NEG, N, -) battery post.
(c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.
(d) Position yourself and free end of cable as far away from battery as possible- then
connect NEGATIVE (BLACK) charger clip to free end of the cable.
(e) Do not face battery when making final connection.
(f) When disconnecting charger, always do so in the reverse sequence of connecting
procedure and break first connection while as far away from the battery as practical.
(g) A marine (boat) battery must be removed and charged on shore. To charge it on
board requires equipment specially designed for marine use.
SAVE THESE INSTRUCTIONS

SKU 91325 For technical questions, please call 1-800-444-3353. Page 6
Specific Safety Rules for the Battery Charger
1. Maintain labels and nameplates on the Battery Charger.These carry important information.
If unreadable or missing, contact Harbor Freight Tools for a replacement.
2. Always wear safety impact eye goggles and heavy work gloves when using the
Battery Charger. Using personal safety devices reduce the risk for injury. Safety
impact eye goggles and heavy work gloves are available from Harbor Freight
Tools.
3. Maintain a safe working environment. Keep the work area well lit. Make sure there is
adequate surrounding workspace. Always keep the work area free of obstructions, grease,
oil, trash, and other debris. Do not use a power tool in areas near flammable chemicals,
dusts, and vapors. Do not use this product in a damp or wet location.
4. Avoid unintentional starting. Make sure you are prepared to begin work before turning
on the Battery Charger.
5. Always unplug the Battery Charger from its electrical outlet before connecting
its cables to a battery, or performing and inspection, maintenance, or cleaning
procedures.
6. Keep extension cord off wet ground and away from water.
7. Use this Battery Charger with lead/acid batteries only. When charging a maintenance-
free battery, always monitor the progress of the charge by viewing the ammeter. Do not
over charge a maintenance-free battery.
8. Do not attempt to charge non-rechargeable or defective batteries.
9. Keep connections and cable clamps clean and free from corrosion.
10. Never simultaneously charge several batteries.
11. Do not discard used batteries in the trash. Properly recycle according to local
environmental codes.
12. Do not attempt to charge a 6 volt battery.

SKU 91325 For technical questions, please call 1-800-444-3353. Page 7
13. Risk of Explosion!
• If you detect gas, do not switch off the unit. Do not disconnect the charg-
ing clamps. Immediately ventilate the room by opening windows and doors.
Do not switch on an electrical fan. When the air has cleared of gas, unplug
the unit from the electrical outlet.
• Charge the battery in a well-ventilated area.
• To prevent sparking due to electrostatic discharge, never wear clothes made of
synthetic materials when charging the battery.
• Avoid creating or working around any flames or sparks; flames or sparks can
ignite the gasses caused by charging and cause an explosion.
This product contains or, when used, produces a chemical known to
the State of California to cause cancer and birth defects or other reproductive harm.
(California Health & Safety Code 25249.5, et seq.)
People with pacemakers should consult their physician(s) before us-
ing this product. Operation of electrical equipment in close proximity to a heart pace-
maker could cause interference to or failure of the pacemaker.
ASSEMBLY INSTRUCTIONS
1. When unpacking, check to make sure that all the parts are included. Refer to the Assembly
Drawing and Parts List at the end of this manual. If any parts are missing or broken,
please call Harbor Freight Tools at the number on the cover of this manual as soon as
possible.
2. This product comes pre-assembled. No additional assembly is necessary.

SKU 91325 For technical questions, please call 1-800-444-3353. Page 8
OPERATING INSTRUCTIONS
Controls and Indicators
Caution: Do not overcharge maintenance-free batteries. Do not try to start the engine
with the Battery Charger connected to the battery.
1. Place the Battery Charger and battery in a well-ventilated area.
2. Determine the voltage of the battery from the battery labels.
3. Push the Auto / Manual switch to the desired mode. Push the Select Function Switch to
the battery voltage: 12 or 24V.
4. If charging a battery while in a vehicle, leave the hood open and do not leave the charger
unattended. Separate the charger and battery as much as possible.
5. If the battery is not a maintenance-free type battery, unscrew the cell caps and fill each
cell to the full indicator with distilled water. Replace caps.
Ammeter (8)
Cable Clamps (3)
Reverse Cable Clamp
Connection LED Charge Complete
LED
Auto / Manual
Switch
Off / 12V (10 A) / 24V (5 A)
Switch
Power Cable (15)
REV 08/04

SKU 91325 For technical questions, please call 1-800-444-3353. Page 9
6. With the Battery Charger unplugged, connect the positive (red) Cable Clamp (3) to the
positive terminal of the battery.
If charging a battery mounted in a vehicle, first remove the vehicle’s red cable from the
battery; otherwise damage may occur to the vehicle’s electrical system. If in doubt, refer
to the vehicle’s service manual.
7. Connect the negative (black) Cable Clamp (3) to the negative terminal of the battery.
8. Plug the Power Cord (15) into the electrical outlet.
9. Note: If the Red Reversed Connection LED is lit, the cables are connected to the wrong
terminals of the battery. If this happens, immediately switch off the charger, unplug it, and
switch the connections.
For a quick charge assist to enable starting the engine, charge for 5 to 10 minutes.
For a full charge, leave the Battery Charger running. If the charger is in manual mode, it
MUST be monitored and shut off when the battery is charged; NEVER leave a battery
unattended while charging. IF THE CHARGER IS IN AUTOMATIC MODE, when the
battery is fully charged the Battery Charger will automatically shut down, and the green
LED will remain lit.
Optionally, only with the battery removed from the vehicle and the CHARGER IN
AUTOMATIC MODE, the Battery Charger can be left on while connected to the battery.
When the battery becomes weak, the Battery Charger will automatically turn on. When
the battery is once again charged, the Battery Charger will automatically shut off. It will,
however, keep sensing the charge of the battery. Note: Do not leave Battery Charger on
for long duration without checking the distilled water level of the battery; do not allow
distilled water to boil off. Note: Do not leave a charging battery unattended.
10. When finished charging the battery, push the Function Switch to the Off position and
unplug the Power Cord (15) from the electrical outlet.
11. Disconnect the Cable Clamps from the battery.
MAINTENANCE INSTRUCTION
1. Before each use, inspect the general condition of the Battery Charger. Check for loose
screws, misalignment or binding of moving parts, cracked or broken parts, damaged
electrical wiring, and any other condition that may affect its safe operation. If abnormal
noise or vibration occurs, have the problem corrected before further use. Do not use
damaged equipment.
2. Periodically recheck all nuts, bolts, and screws for tightness.
3. After each use wipe down the Cable Clamps and apply a light grease.
4. Store in a clean and dry location.
Make sure the Power Switch of the Battery Charger is in its “OFF” po-
sition and that the unit is unplugged from its electrical outlet before performing any
inspection, maintenance, or cleaning procedures.
REV 08/04

SKU 91325 For technical questions, please call 1-800-444-3353. Page 10
NOTE: Some parts are listed and shown
for illustration purposes only and are not
available individually as replacement
parts.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR 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 QUALI-
FIED 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
Part Description Qty.
1 Handle 1
2 Cover 1
3 Clamps, Cable 2
4 Nut, Six Head 1
5 Washer, Outer Tooth 1
6 Rectifier Assembly 1
7 Circuit Breaker 1
7A Washer, Flat 1
7B Pin 1
8 Ammeter 1
9 PCB 1
10 Transformer 1
11 Base 1
12 Switch, Slide 1
13 Switch, Slide 1
14 Rivet 2
15 Power Cable 1
16 Switch 1
17 Rivet, Power Cable 1
18 Label 1
19 Washer 1
20 Washer, Inner Tooth 1
21 Pin 2

SKU 91325 For technical questions, please call 1-800-444-3353. Page 11
ASSEMBLY DRAWING