Chicago Electric CHICAGO ELECTRIC 38391 Installation manual

12 VOLT JUMP-START
AND POWER SUPPLY
38391
SET UP AND OPERATING INSTRUCTIONS
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©2009 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.
Note: After purchase
and before initial use
of the Jump-Start,
fully charge the Jump-
Start battery until the
DC Charging LED
turns off.
After each jump start,
fully recharge the
battery until the DC
Charging LED turns
off.
Fully charge Jump-
Start battery every 30
days to ensure long
battery life.

Page 2For technical questions, please call 1-800-444-3353.SKU 38391
SPECIFICATIONS
Start Amps 400
Peak Amps 900
Battery 12 V, Lead-Acid,
Rechargeable
Charging Current = 0.18A
Booster Cables #4 Gauge, 17” Length
Includes: 12 Volt Cigarette Lighter Charger,
AC Adapter Receptacle, Built-in Light,
Booster Cable Storage, Charge/Battery Indicators
Note: Charging performance of this tool
(if charged by line voltage) may vary
depending on variations in local line
voltage. Extension cord usage may
also affect charging performance.
Save This Manual
You will need the manual for
the safety warnings and precautions,
assembly instructions, operating and
maintenance procedures, parts list and
diagram. Keep your invoice with this
manual. Write the invoice number on the
inside of the front cover. Keep the manual
and invoice in a safe and dry place for
future reference.
SAFETY WARNINGS AND
PRECAUTIONS
WARNING: When using tool, basic safety
precautions should always be followed
to reduce the risk of personal injury and
damage to equipment.
Read all instructions before using this
tool!
1. Keep work area clean. Cluttered
areas invite injuries.
2. Observe work area conditions.
Do not use machines or power tools
in damp or wet locations. Don’t
expose to rain. Keep work area well
lighted. Do not use in the presence
of ammable gases or liquids.
3. Keep children away. Children must
never be allowed in the work area.
Do not let them handle this product.
4. Store idle equipment. When not
in use, tools must be stored in a dry
location to inhibit rust. Always lock
up tools and keep out of reach of
children.
5. Use the right tool for the job. Do
not attempt to force a small tool or
attachment to do the work of a larger
industrial tool. There are certain
applications for which this tool was
designed. It will do the job better and
more safely at the rate for which it
was intended. Do not modify this tool
and do not use this tool for a purpose
for which it was not intended.
6. Dress properly. Do not wear
loose clothing or jewelry as they
can be caught in moving parts.
Protective, electrically non-conductive
clothes and non-skid footwear are
recommended when working. Wear
restrictive hair covering to contain
long hair.
7. Wear ANSI-approved splash-
resistant safety goggles.
8. Do not overreach. Keep proper
footing and balance at all times.
9. Maintain tools with care. Keep
tools clean for better and safer
performance. Follow instructions for
lubricating and changing accessories.
Inspect tool cords periodically and, if
damaged, have them repaired by an
authorized technician. The handles
must be kept clean, dry, and free from
oil and grease at all times.

Page 3For technical questions, please call 1-800-444-3353.SKU 38391
10. Stay alert. Watch what you are
doing, use common sense. Do not
operate any tool when you are tired.
11. Check for damaged parts. Before
using any tool, any part that appears
damaged should be carefully checked
to determine that it will operate
properly and perform its intended
function. Check for alignment and
binding of moving parts; any broken
parts or mounting xtures; and any
other condition that may affect proper
operation. Any part that is damaged
should be properly repaired or
replaced by a qualied technician. Do
not use the tool if any switch does not
turn On and Off properly.
12. Replacement parts and
accessories. When servicing, use
only identical replacement parts.
Use of any other parts will void the
warranty. Only use accessories
intended for use with this tool.
13. Do not operate tool if under the
inuence of alcohol or drugs. Read
warning labels if taking prescription
medicine to determine if your
judgement or reexes are impaired
while taking drugs. If there is any
doubt, do not operate the Jump-Start.
14. Maintenance. For your safety,
maintenance should be performed
regularly by a qualied technician.
15. If you come in contact with battery
acid, immediately wash the effected
area with cool, clean water. Call for
medical assistance and continue
ushing the effected areas until
medical help arrives.
16. The ON/Off switch (See FIGURE 1,
next page) regulates power to the
clamps only. Keep it in the “Off”
position except when jumpstarting.
17. Lead-acid batteries vent hydrogen
gas during normal operation and
charging. Hydrogen is highly
ammable and explosive. Charge
batteries only in a well-ventilated
area.
18. Do not allow the red and black
clamps to come in contact with each
other or the same metal object.
19. When charging, rst connect the red
(+) clamp to the positive (+) battery
terminal.
20. Connect the negative (-) clamp to
a non-moving metal engine part for
negative ground systems.
21. Only use the charger on 12 V
systems on vehicles or boats.
22. Do not use as a replacement for a
vehicle battery.
23. The warnings, cautions, and
instructions discussed in this
instruction manual cannot cover all
possible conditions 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.
24. People with pacemakers should
consult their physician(s) before
use. Electromagnetic elds in close
proximity to heart pacemaker could
cause pacemaker interference or
pacemaker failure.

Page 4For technical questions, please call 1-800-444-3353.SKU 38391
CONTROLS AND
COMPONENTS
CHARGING
Note: After purchase and before initial
use, fully charge the Jump-Start
battery until the DC charging LED
turns off.
WARNING! The ON/Off switch (See
Figure 1) regulates power to the
clamps only. Keep it in the “Off”
position except when jumpstarting.
120 V~ Charging
1. Plug the Power Cord (5) into a wall
outlet and plug the female end of
the Power Cord into the 120V male
Charging Plug of the 120V~ Charging
Port (see Figure 2, above).
2. Before rst use, fully charge the
Jump-Start battery until the DC
Charging LED turns off.
3. After each jump start, fully
recharge the battery until the DC
Charging LED turns off. It may
take up to 48 hours to fully charge
the Jump-Start battery. Check the
progress by pressing the Voltage Test
Switch. The level of battery power
will then display on the Test Meter.
4. Fully recharge Jump Start battery
every 30 days to ensure long
battery life and reliability.
Note: The charger unit comes equipped
with an automatic shut off LED to
prevent overcharging. Leave the unit
plugged in to make sure it is charged
for emergencies.
Red
Clamp Work
Light
Black
Clamp
Test
Meter
Jump Start ON/OFF
Light
Switch
Voltage
Test
Switch
DC Charging
Light
Charging
Receptacle 120 V
Charging
Plug
(Male)
Cigarette
Lighter
Plug-In
Figure 1
Figure 2
Power
Cord (5)

Page 5For technical questions, please call 1-800-444-3353.SKU 38391
Note: The LED light will go on (when
Switch is in the OFF position) to
indicate a reverse polarity condition.
12 VDC Charging
Note: This system is equipped with a 12
VDC Cigarette Lighter Adapter so you
can charge the Jump-Start from a
vehicle or boat battery. This method
of recharging will not charge the
unit as fully as when using the 120
V~ charging method. Only use this
method in an emergency situation, as
this recharging method may shorten
the life of the Jump-Start.
5. Take out your 12 VDC Cigarette
Lighter Adapter (6). The adapter
has a cigarette lighter plug in one
end of the cord, and a round plug
on the other end. Plug the round
plug into the Recharging Receptacle
(See Figure 3). Plug the cigarette
plug into the vehicle or boat cigarette
lighter receptacle.
6. Charge the unit for the minimal time
needed (to at least 14 volts). Store
the Cigarette Lighter Adapter when
nished.
Note: Charging room temperature: 50oF
- 104oF.
OPERATION
Using the Jump-Start as a 12 VDC
power source
Warning!! The ON/Off switch (See
FIGURE 1) regulates power to the
clamps only. Keep it in the “Off”
position except when jumpstarting.
1. Insert the 12 VDC Cigarette Lighter
plug from the appliance into the 12
VDC Cigarette Lighter Receptacle on
the side of the unit.
Note: Table 2 gives approximate
operating times when beginning with
a fully charged system.
TABLE 2
12 VDC Power Source Usage Times
Appliance
Estimated
Power
(watts)
Estimated
Use
(hours)
Fluorescent Light,
Cell Phone Charger 4 50
Radio, Fan,
Depth Finder 9 26
Video Recorder/
Player, Spotlight 15 14
Small Power Tool,
Bilge Pump 24 8
Electric Cooler 48 3
Air Compressor,
Vacuum 80 2
Figure 3
Cigarette
Lighter
Adapter (5)

Page 6For technical questions, please call 1-800-444-3353.SKU 38391
If you use the Jump-Start with a
power inverter (not included) as a
120 V~ power source, Table 3 will
give you approximate times to expect
with a fully charged unit.
TABLE 3
120 V~ Power Source Usage Times
using a power inverter (not included)
Appliance
Estimated
Power
(watts)
Estimated
Use
(hours)
Spotlight, DVD
Player, Sump Pump 100 1.5
Faxes/TV’s
Small Appliances 150 1
Computers/Printers 200 0.75
Medium Power Tool,
Blender 250 0.5
Note: The appliance will be plugged into
the power inverter (not included), and
the 12 VDC Cigarette Lighter plug
from the inverter will plug into the 12
VDC Cigarette Lighter Receptacle on
the side of the unit.
Jump Starting a Vehicle
1. NOTE: Press the Light Switch to
activate Work Light in case it is
needed.
2. Attach the Red (+) Clamp (1) to the
red (+) positive battery terminal.
3. Attach the Black (-) Clamp (2) to a
non-moving metal engine part on
negative ground systems, NOT to
the negative (-) battery terminal.
4. Turn the On/Off switch to “On”.
5. Turn the ignition to “On”- Accessory
(not start) and wait a couple of
minutes.
6. Attempt to start the engine for no
more than 5-6 seconds.
7. If the vehicle does not start, wait at
least three minutes until trying again.
Repeated attempts may ood the
engine or wear out the engine starter.
If unable to start, replace the battery.
WARNING! Do not let the black and
red clamps touch each other or a
common metal conductor.
8. When the engine is running, switch
off the Jump-Start.
9. Disconnect the Black (-) Clamp and
return it to its position on the Jump-
Start. Then, disconnect the Red (+)
Clamp and return it to its position on
the Jump-Start.
10. After each jump start, fully recharge
the Jump-Start battery until the DC
Charging LED turns off.

Page 7For technical questions, please call 1-800-444-3353.SKU 38391
Recharging Using 12 VDC Supply
1. Insert the Cigarette Lighter Recharger
Plug into the Front Panel port labeled
Recharge.
2. Insert the other end of the Cigarette
Lighter Recharger Cord into the 12
VAC Cigarette lighter receptacle on
your vehicle or boat.
3. Allow the Jump Start System to
recharge for 10 hours or until
Charging LED turns off. An automatic
cut off will help prevent overcharging
the battery.
MAINTENANCE
Note: The main power switch should be
off during any maintenance. Do not
perform maintenance while charging.
1. Keep the unit clean and make sure
the clamps are free of dirt, debris, or
grease.
2. For a longer working life, protect
Jump-Start from sunlight and
moisture.
3. Lead-Acid batteries must be recycled
or disposed of properly. Do not short
terminals. Do not incinerate. Risk
of electric shock; use only in dry
location. Only use with battery packs
distributed by Harbor Freight Tools;
others may burst, causing personal
injury and/or property damage.
For additional information on battery
recycling call 1-800-822-8837.
Battery Replacement
1. Remove the eight screws around the
back panel and lift off the cover plate.
Lift out the battery.
Note: Notice how the red and black
cables connect to the old battery and
make sure to keep them in place,
connecting them to the new battery.
2. Detach the recharging wires and
jumper cables from the battery
terminals.
3. Position the replacement battery
with the label facing out, and make
sure the red (+) recharging wire
and Booster Cable is attached to
the positive (+) battery terminal.
Connect both of the recharging wires
and Booster Cables.
4. Carefully slide the battery into the
compartment without damaging the
circuit board.
5. Replace the back panel and the
screws.
Emergency Light Bulb Replacement
1. Gently squeeze the light lens/bezel
together and remove them.
2. Unscrew the bulb and replace it.
3. Snap the lens/bezel into place.

Page 8For technical questions, please call 1-800-444-3353.SKU 38391
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 QUALIFIED 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.
NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.
PARTS LIST AND ASSEMBLY DRAWING
Part Description
1 Red Clamp
2 Black Clamp
3 Light Bulb
4 Battery (Internal, not shown)
5 Power Cord
6 Cigarette Lighter Recharger
1
5
2
3
6

Page 9For technical questions, please call 1-800-444-3353.SKU 38391
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 product
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 consequential
damages, so the above limitation of exclusion may not apply to you. THIS WARRANTY
IS EXPRESSLY 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
complaint must accompany the merchandise. If our inspection veries the defect, we
will either 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 repaired 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 specic 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 • [phone]