Chicago Electric 90636 User manual

100 AMP LOAD BA100 AMP LOAD BA
100 AMP LOAD BA100 AMP LOAD BA
100 AMP LOAD BATTERTTER
TTERTTER
TTERY ANDY AND
Y ANDY AND
Y AND
CHARGING SYSTEM TESTERCHARGING SYSTEM TESTER
CHARGING SYSTEM TESTERCHARGING SYSTEM TESTER
CHARGING SYSTEM TESTER
OPERATING INSTRUCTIONS
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011
VISIT OURWEB SITE AT HTTP://WWW.HARBORFREIGHT.COM
Copyright©2003 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.
®
90636

SKU 90636 For technicial questions, please call 1-800-444-3353. Page 2
SPECIFICATIONS
Item Description
Capability 6 and 12 VDC battery tester with
charging system output
Load Test Capacity 100 amps; 50~1000 cold cranking
amps
Display Meter Analog, 0~16 VDC (maximum)
Test Cycle 10 seconds per test with 1 minute cool
down; 3 tests in 5 minutes
Battery Cable / Clamps 16-3/4 inch; Copper plated clamps
Overall Dimensions 12-3/4 (L) x 6 (W) x 3 (D) inches
Features Carrying handle and four rubber feet
SaveThis Manual
You will need the manual for the safety warnings and precautions, operating and
maintenance procedures. Keep your invoice with this manual in a safe and dry
place for future reference.
SAFETY PRECAUTIONS
WARNING!
READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instruc-
tions listed below may result in electric shock, fire, and/or serious injury.
SAVETHESE INSTRUCTIONS
1. Keepyourworkarea cleanandwelllit. Cluttered benchesand darkareas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.
3. Keep bystanders, children, and visitors away while operating a power tool.
Distractionscancause you tolosecontrol. Protect othersin thework areafrom
debris such as chips and sparks. Provide barriers or shields as needed.
4. Do not force the tool. Use the correct tool for your application. The correct tool
will do the job better and safer at the rate for which it is designed.
5. Donot use thepowertool if thePowerSwitch doesnot turn iton or off. Anytool
that cannot be controlled with the Power Switch is dangerous and must be
replaced.
6. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.

SKU 90636 For technicial questions, please call 1-800-444-3353. Page 3
7. Maintaintools withcare. Keepclean. Donotuse adamagedtool. Tagdamaged
tools “Do not use”until repaired.
8. Tool service must be performed only by qualified repair personnel. Service or
maintenanceperformed byunqualifiedpersonnel could resultin a risk of injury.
9. Maintain labels and nameplates on this
tool.Thesecarryimportant information.
Ifunreadableormissing, contactHarbor
FreightTools for a replacement.
10. Always wear ANSI approved safety
impact eye goggles and heavy work
gloves when using this tool. Using
personal safety devices reduce the risk
for injury.Safetyimpacteyegogglesand
heavy work gloves are available from
Harbor FreightTools.
11. 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 this tool in areas
near flammable chemicals, dusts, and vapors. Do not use this product in a
damp or wet location.
WARNING! People with pacemakers should consult their physician(s) before
using this product. Operation of electrical equipment in close proximity to a
heart pacemaker could cause interference or failure of the pacemaker.
SPECIFIC SAFETY RULES FORTHE BATTERYTESTER
1. WhenconnectingtheBatteryCablestothebattery,avoidcreatingsparks(always
connect and disconnect clamps exactly as described in rule number 2, below,
and on page 4), especially when the battery is being charged.Explosive gases
are created during charging.Sparking could also damage the vehicle electrical
system.
2. Be certain of the test battery polarity before connecting the test Cable Clamps.
The red Cable Clamp (A) goes to the positive terminal of the battery.The black
Cable Clamp (B) goes to the negative terminal of the battery.
3. Whenplacing theBatteryTesterin thevehicle(on the frame,engine,orfender),
take special care that the metal housing of the BatteryTester does not come in
contact with either terminal of the battery or other electrical connections.
4. Do not drop the Battery Tester as it may affect proper operation.
5. Do not smoke or have open flames near the battery.
CAUTION!
Battery acid may cause severe
injury to eyes; always wear ANSI
approved safety goggles. Avoid
touching eyes while working with or
nearabattery. In caseof accidental
contact, rinse eyes with clean
water for at least 5 minutes and
see a doctor immediately.

SKU 90636 For technicial questions, please call 1-800-444-3353. Page 4
UNPACKING
When unpacking, check to make sure that all the parts are included. Refer to the
Assemblysection,andtheAssemblyDrawingandPartsListattheend ofthismanual.
If any parts are missing or broken, please call Harbor FreightTools at the number
on the cover of this manual as soon as possible.
6. Reversing Battery Tester Cable Clamps on the battery will damage the tester.
7. DonotconnecttheBatteryTestertothebatterywhilethebatteryisbeingcharged.
Turn the engine off before connecting.
8. Do not touch the cooling vents on the Battery Tester immediately after testing
the battery.They become very hot.
(A)
(B)
(C)
(D)
OPERATING INSTRUCTIONS
Testing the Battery
CAUTION! Undercharged lead-acid batteries will freeze during cold weather.
NEVERTEST OR CHARGE A FROZEN BATTERY.
1. To help ensure a good connection, clean battery terminals with a solution of
baking soda and water, and wipe the battery terminals with a cloth to remove
any dirt and grease.
2. Connect the red (positive) Cable Clamp (A) to the positive terminal (+) on the 6
or 12V lead-acid battery.(See photo above.)
3. Connect the black (negative) Cable Clamp (B) to the negative terminal (–) on
the battery. Turn clamps slightly to ensure a good connection.
4. With the clamps connected, the tester’s gauge will show the battery’s current
charge. Ifitis lessthan12V,disconnectthe batteryandrecharge beforetesting.
If recharging will not bring the reading above 12 V the battery is defective. If it
shows no reading, verify that the tester is connected properly. If the tester is
connected properly, the battery is defective.
5. Press (and hold) the Toggle Switch (C) for at least 5 seconds to simulate an
actual load on the battery.

SKU 90636 For technicial questions, please call 1-800-444-3353. Page 5
6. View the Meter Display (D) and read the battery condition.Refer to the“Battery
Condition Analysis”section below.
7. Release theToggle Switch (C) and remove the Cable Clamps from the battery.
Testing the Charging System
Note:The engine should be at normal operating temperature during this test.
1. Connect the Cable Clamps (A, B) to the battery as previously described.
2. Outside, or in a well ventilated area, start the vehicle engine and run at fast idle
speed. Never start and run the vehicle’s engine in a closed garage.
WARNING!Avoid Carbon Monoxide poisoning.This gas comes from
the vehicle exhaust and is colorless and odorless.It can cause
seriousinjuryor death if inhaled. Neverrun the vehicle’s engine
inside a garage or any other enclosed space.
3. Viewthe MeterDisplay(D) and readthe charging systemcondition (farrighton
the gauge).Refer to the“Battery Condition Analysis” section below.
CAUTION! DO NOT press theToggle Switch (C) during this test.
Battery Condition Analysis
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SKU 90636 For technicial questions, please call 1-800-444-3353. Page 6
INSPECTION, MAINTENANCE, AND CLEANING
1. Periodically recheck all nuts, bolts, and screws for tightness.
2. Store in a clean and dry location.
3. Cleanthe outsideof the unitwith a dampcloth.Never use solventsto clean any
part of this tool.Use compressed air to blow out debris from the load vents.
4. After each use, clean the Cable Clamps of any possible battery electrolyte.
Apply a thin coat of silicon grease to prevent corrosion.
REPLACEABLE PARTS
The BatteryTester has no replaceable parts.
Testing the Starter
Note:The engine should be at normal operating temperature and the battery
should be fully charged before doing this test.
1. Connect the Cable Clamps (A, B) to the battery as previously described.
2. Disablethe ignition sothe enginewill not start.(Referto yourvehicle’smanual.)
3. Have an assistant crank the engine. Note the voltage reading during cranking.
4. View the Meter Display (D) and read the voltage. A reading of 9 Volts or less
indicates excessive current draw. This may be due to a poor connection, a
failing starter, or a battery of insufficient size for the motor.
CAUTION! DO NOT press theToggle Switch (C) during this test.
REV 07/04
PLEASE READTHE FOLLOWING CAREFULLY
THEMANUFACTURERAND/ORDISTRIBUTOR HASPROVIDEDTHEPARTSDIAGRAM
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
STATESTHATALL REPAIRSANDPARTSREPLACEMENTSSHOULD BEUNDERTAKEN
BYCERTIFIEDAND LICENSEDTECHNICIANS ANDNOT BYTHE BUYER.THEBUYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRSTOTHE
ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF
HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.