Forney 52726 User manual

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52726
300–200–60–30–2 AMP • 6 & 12 VOLT • BATTERY CHARGER
MANUAL OPERATION WITH ENGINE START
POWER TO GET THE JOB DONE
OWNER’S MANUAL
• 300A for Emergency Engine Start at 12V
• 200A for Emergency Engine Start at 6V
• 60A Rapid Charge
• 30A Fast Charge
• 2A Trickle Charge
• Fan Cooled
• Rotary Switch for Ease-of-Use & Accuracy
• Timer with Hold for Continuous Charging
• Reverse Hookup & Short Circuit Protection
• Overheat Protection
• ETL certified
• 5-3-1 Warranty with “Advanced
Replacement”

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IMPORTANT SAFETY INSTRUCTIONS
IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL
1. Keep out of reach of children.
2. Do not expose the charger to rain or snow.
3. Use only recommended attachments. Use of an
attachment not recommended or sold by Forney
Industries, Inc. may result in a risk of fire, electric
shock or injury to persons or damage to property.
4. To reduce the risk of damage to the electric plug or
cord, pull by the plug rather than the cord when
disconnecting the charger.
5. An extension cord should not be used unless
absolutely necessary. Use of an improper
extension cord could result in a risk of fire and
electric shock. If an extension cord must be used,
make sure:
• That the pins on the plug of the extension cord
are the same number, size and shape as those
of the plug on the charger.
• That the extension cord is properly wired and in
good electrical condition.
• That the wire size is large enough for the A.C.
ampere rating of the charger as specified
in Section "BATTERY CHARGING – A.C.
CONNECTIONS".
6. To reduce the risk of electric shock, unplug the
charger from the outlet before attempting any
maintenance or cleaning. Simply turning off the
controls will not reduce this risk.
7. 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 the like to metal, causing a severe burn.
8. Do not operate the charger with a damaged cord
or plug; take it to a qualified service person.
9. Do not operate the charger if it has received a
sharp blow, been dropped or otherwise damaged
in any way; take it to a qualified service person.
10. Do not disassemble the charger; take it to a
qualified service person when service or repair is
required. Incorrect reassembly may result in a risk
of fire or electric shock.
SAVE THESE INSTRUCTIONS – The Wheel Chargers offers a wide range of features to accommodate your needs.
This manual will show you how to use your charger safely and effectively. Please read, understand and follow
these instructions and precautions carefully, as this manual contains important safety and operating instructions.
This product may contain chemicals known to the State of California to cause cancer, birth defects and
other reproductive harm (CA. Prop 65). Wash hands after use.

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PERSONAL PRECAUTIONS
PREPARING TO CHARGE
1. 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 you follow the
instructions each time you use the charger.
2. To reduce the risk of a battery explosion, follow
these instructions and those published by the
battery manufacturer and the manufacturer of any
equipment you intend to use in the vicinity of the
battery. Review the cautionary markings on these
products and on the engine.
3. NEVER smoke or allow a spark or flame in the
vicinity of a battery or engine.
4. Be extra cautious to reduce the risk of dropping a
1. Consider having someone close enough by to come
to your aid when you work near a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case
battery acid contacts your skin, clothing or eyes.
3. Wear complete eye and body protection, including
safety goggles and protective clothing. Avoid
touching your eyes while working near the battery.
4. If battery acid contacts your skin or clothing,
immediately wash the area with soap and water.
If acid enters your eye, immediately flood the eye
with cold running water for at least 10 minutes
and get medical attention right away.
5. If battery acid is accidentally swallowed, drink
milk, the whites of eggs or water. DO NOT induce
vomiting. Seek medical attention immediately.
6. If it is necessary to remove the battery from the
vehicle to charge it, always remove the grounded
terminal first. Make sure all of the accessories in
the vehicle are off to prevent arcing.
7. Be sure the area around the battery is well
ventilated while the battery is being charged.
8. Clean the battery terminals before charging the
metal tool onto the battery. It might spark or short-
circuit the battery or other electrical part that may
cause an explosion.
5. 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 a starter-
motor application. Do not use this 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.
6. NEVER charge a frozen battery.
7. NEVER overcharge a battery.
battery. During cleaning, keep airborne corrosion
from coming into contact with your eyes, nose and
mouth. Use baking soda and water to neutralize
the battery acid and help eliminate airborne
corrosion. Do not touch your eyes, nose or mouth.
9. Add distilled water to each cell until the battery
acid reaches the level specified by the battery
manufacturer. Do not overfill. For a battery without
removable cell caps, such as valve regulated
lead acid batteries (VRLA), carefully follow the
manufacturer’s recharging instructions.
10. Read, understand and follow all instructions for
the charger, battery, vehicle and any equipment
used near the battery and charger. Study all of the
battery manufacturer’s specific precautions while
charging and recommended rates of charge.
11. Determine the voltage of the battery by referring to
the vehicle owner’s manual and make sure that the
output voltage selector switch is set to the correct
voltage. If the charger has an adjustable charge
rate, charge the battery in the lowest rate first.
12. Make sure that the charger cable clips make tight
connections.
CHARGER LOCATION
1. Locate the charger as far away from the battery
as the DC cables permit.
2. Never place the charger directly above the
battery being charged; gases from the battery
will corrode and damage the charger.
3. Do not set the battery on top of the charger.
4. Never allow battery acid to drip onto the charger
when reading the electrolyte specific gravity or
filling the battery.
5. Do not operate the charger in a closed-in area or
restrict the ventilation in any way.

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FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE
FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE
1. Position the A.C. and D.C. cables to reduce the
risk of damage by the hood, door and moving or
hot engine parts. NOTE: If it is necessary to close
the hood during the charging process, ensure
that the hood does not touch the metal part of the
battery clips or cut the insulation of the cables.
2. Stay clear of fan blades, belts, pulleys and other
parts that can cause injury.
3. Check the polarity of the battery posts. The POSITIVE
(POS, P, +) battery post usually has a larger
diameter then the NEGATIVE (NEG, N, -) post.
4. Determine which post of the battery is grounded
(connected) to the chassis. If the negative post is
grounded to the chassis (as in most vehicles). If the
positive post is grounded to the chassis.
5. For a negative-grounded vehicle, connect the
POSITIVE (RED) clip from the battery charger to
the POSITIVE (POS, P, +) ungrounded post of the
battery. Connect the NEGATIVE (BLACK) clip to
1. Check the polarity of the battery posts. The POSITIVE
(POS, P, +) battery post usually has a larger diameter
than the NEGATIVE (NEG, N, -) post.
2. Attach at least a 24-inch (61 cm) long 6-gauge
(AWG) insulated battery cable to the NEGATIVE
(NEG, N, -) battery post.
3. Connect the POSITIVE (RED) charger clip to the
POSITIVE (POS, P, +) post of the battery.
4. Position yourself and the free end of the cable you
previously attached to the NEGATIVE (NEG, N,
-) battery post as far away from the battery as
possible – then connect the NEGATIVE (BLACK)
charger clip to the free end of the cable.
5. Do not face the battery when making the final
connection.
6. When disconnecting the charger, always do so in
the reverse order of the connecting procedure and
the vehicle chassis or engine block away from the
battery. Do not connect the clip to the carburetor, fuel
lines or sheet-metal body parts. Connect to a heavy
gauge metal part of the frame or engine block.
6. For a positive-grounded vehicle, connect the
NEGATIVE (BLACK) clip from the battery charger
to the NEGATIVE (NEG, N, -) ungrounded post
of the battery. Connect the POSITIVE (RED) clip to
the vehicle chassis or engine block away from the
battery. Do not connect the clip to the carburetor, fuel
lines or sheet-metal body parts. Connect to a heavy
gauge metal part of the frame or engine block.
7. When disconnecting the charger, turn all switches
to off, disconnect the A.C. cord, remove the clip
from the vehicle chassis and then remove the clip
from the battery terminal.
8. See CALCULATING CHARGE TIME for length of
charge information.
break the first connection while as far away from
the battery as practical.
7. A marine (boat) battery must be removed and
charged on shore. To charge it onboard requires
equipment specially designed for marine use.
CHARGER LOCATION
1. Connect and disconnect the DC output clips only after setting all of the charger switches to the “off” position
and removing the A.C. plug from the electrical outlet. Never allow the clips to touch each other.
2. Attach the clips to the battery and chassis.
+ –
NEGATIVE
POSITIVE
BATTERY
BATTERY
CHARGER

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BATTERY CHARGING – A.C. CONNECTIONS
1. This battery charger is for use on a nominal 120-
volt circuit and has a grounded plug that looks like
the plug illustrated. The charger must be grounded
to reduce the risk of electric shock. The plug must be
plugged into an outlet that is properly installed and
grounded in accordance with all local codes and
ordinances. The plug pins must fit the receptacle
(outlet). Do not use with an ungrounded system.
2. Never alter the A.C. cord or plug provided – if it
does not fit the outlet, have a proper grounded
outlet installed by a qualified electrician. An
improper connection can result in a risk of an
electric shock or electrocution.
3. NOTE: Pursuant to Canadian Regulations, use of
an adapter plug is not allowed in Canada. Use
A.C. Input Rating, Amperes* Awg Size of Cord Length of Cord, Feet (m)
At Least But Less Than 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.6)
0 2 18 18 18 16
2 3 18 18 16 14
3 4 18 18 16 14
4 5 18 18 14 12
5 6 18 16 14 12
6 8 18 16 12 10
810 18 14 12 10
10 12 16 14 10 8
12 14 16 12 10 8
14 16 16 12 8 8
16 18 14 12 8 8
18 20 14 12 8 6
*If the input rating of a charger is given in watts rather than in amperes, the corresponding ampere rating is to
be determined by dividing the wattage rating by the voltage rating - for example:
1200 watts/120 volts = 10 amperes
of an adapter plug in the United States is not
recommended.
4. Recommended minimum AWG size for extension cord:
GROUNDING PIN
GROUNDED OUTLET
(A)

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Wheel Charger Assembly Instructions:
NOTE: Charger must be assembled before operating
Parts Tools
(2)10-32 screws 5/16" wrench
(2) 1/4-20 screws 3/8" wrench
(2) wheels Hammer
(2) axle caps Screwdriver
(1) handle
(1) mounting foot
(1) axle
Tools necessary
1. First place the charger on it side.
2. Next mount the mounting foot FIG. A with (2) 1/4-20 screws, or FIG. F with (2) 10-32 screws.
3. Next pound the axle firmly into an axle cap using a hammer FIG. B.
4. Slide one wheel onto the axle with hub facing in, as shown in FIG. C.
5. Poke above assembly thru holes in charger back until axle sticks out of the other end.
6. Turn charger on its other side.
7. Slide wheel and pound cap onto the axle end.
8. Next turn the charger right side up onto its foot and wheels.
9. Remove the (2) top screws from each side of the charger, line up the handle and reinstall the screws FIG. E.
ASSEMBLY INSTRUCTIONS
CONTROL PANEL
Charge Rate Selector Switch
Use the Charge Rate selector switch to select the
charge rate or engine starting setting you require.
• 2A Slow Charge Rate – Intended for charging small
batteries such as those commonly used in garden
tractors, snow mobiles and motorcycles.
• 30A Fast and 60A Rapid Charge Rate – Use
for charging automotive, marine and deep-cycle
batteries. Not intended for industrial applications.
• 200A and 300A Engine Start – Provides 200 or 300
amps for cranking an engine with a weak or run down
battery. Always use in combination with a battery.
Timer
• Timer Setting: The timer allows you to set a specified
time for charging. After the timer expires, the charger
stops charging your battery. The main function of
the timer is to prevent over charging while allowing
a battery time to obtain a satisfactory charge. To
properly set the timer, you must know the size of
the battery in ampere hours or reserve capacity in
minutes and the state of charge. It is important that
you determine the appropriate state of charge of
your battery as specified in Section "CALCULATING
CHARGE TIME" and set the timer accordingly.
• Hold: This position defeats the timer function,
allowing for continuous operation. Be sure to
monitor the charging progress and stop it when
the battery is charged. Not doing so may cause
damage to your battery or may cause other
personal property damage or personal injury.
Ammeter
The Ammeter indicates the amount of current,
measured in amps, that is being drawn by the battery.
As a battery takes on a charge, it draws less current
from the charger. Correspondingly, the meter will show
less current being drawn by the battery. When the
current stops decreasing, the battery is charged. The
start area of the meter indicates a high rate of current
being drawn from the charger. When cranking an
engine, the meter needle will be at the extreme right
side of the start area. The 2 amp charge rate may
indicate some activity on the meter, although the meter
does not have the resolution to display this low rate.

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OPERATING INSTRUCTIONS
Charging
1. Ensure that all of the charger components are in
place and in good working condition, including
the plastic boots on the battery clips.
2. Connect the battery following the precautions
listed in sections "FOLLOW THESE STEPS
WHEN BATTERY IS INSTALLED IN VEHICLE"
and "FOLLOW THESE STEPS WHEN BATTERY IS
OUTSIDE VEHICLE".
3. Select the appropriate settings for your battery.
4. Connect the A.C. power following the precautions
listed in section "BATTERY CHARGING – A.C.
CONNECTIONS".
5. Turn the charger on. (If necessary)
Using the Engine Start feature
Your battery charger can be used to jump start your
car if the battery is low. Follow these instructions on
how to use the ENGINE START feature. WARNING:
Follow all safety instructions and precautions for
charging your battery. Wear complete eye protection
and clothing protection. Charge your battery in a well-
ventilated area. IMPORTANT: Using the ENGINE START
feature WITHOUT a battery installed in the vehicle
could cause damage to the vehicle’s electrical system.
NOTE: If you have charged the battery and it still will
not start your car, do not use the engine start feature,
or it could damage the vehicle’s electrical system.
1. Set the charge rate switch and the timer to the OFF
position.
2. With the charger unplugged from the A.C. outlet,
connect the charger to the battery following the
instructions given in Section "FOLLOW THESE STEPS
WHEN THE BATTERY IS INSTALLED IN A VEHICLE".
3. Plug the charger A.C. power cord into the A.C.
outlet, and then move the timer switch from OFF to
the HOLD position.
4. With the charger plugged in and connected to the
battery of the vehicle, set the charge rate selector
switch to the engine start position.
5. Crank the engine until it starts or 5 seconds pass.
If the engine does not start, wait 3 minutes before
cranking again. This allows the charger and
battery to cool down.
NOTE: During extremely cold weather, or if the battery
is under 2 volts, charge the battery for 5 minutes
before cranking the engine.
6. If the engine fails to start, charge the battery for
5 more minutes before attempting to crank the
engine again.
7. After the engine starts, move the charge rate
selector switch and timer to the off position and
unplug the A.C. power cord before disconnecting
the battery clips from the vehicle.
8. Clean and store the charger in a dry location.
NOTE: If the engine does turn over but never starts,
there is not a problem with the starting system; there
is a problem somewhere else with the vehicle. STOP
cranking the engine until the other problem has been
diagnosed and corrected.
General Charging Notes
Fan: It is normal for the fan to be on all the time. Keep
the area near the charger clear of obstructions to allow
the fan to operate efficiently.

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CALCULATING CHARGE TIME
The Hydrometer or Electronic Method
To find the time needed to fully charge your battery, determine the battery’s charge level with a hydrometer or electronic
Percent-of-Charge Tester. The following table will help you convert hydrometer readings to percent of charge values.
SPECIFIC GRAVITY PERCENT OF CHARGE PERCENT OF CHARGE NEEDED
1.265 100% 0%
1.225 75% 25%
1.155 25% 75%
1.120 0% 100%
When you know the percent of charge and the Amp Hour (AH) rating of your battery, you can calculate the
approximate time needed to bring your battery to a full charge.
To convert Reserve Capacity to Amp Hours, divide Reserve Capacity by 2, and add 16:
Example:
Amp Hour Rating = Reserve Capacity/2 + 16
NOTE: The Reserve Capacity can be obtained from the battery specification sheet or the owner’s manual.
To calculate the time needed for a charge:
1. Find the percent of charge needed. (A battery at 50 percent charge that will be charged to 100 percent needs
another 50 percent (.50)).
2. Multiply the Amp Hour Rating by the charge needed (.50) and divide by the charge rate.
3. Multiply the results by 1.25 and you will have the total time needed, in hours, to bring the battery to full charge.
4. Add an additional hour for a deep-cycle battery.
Example:
(Amp Hour Rating x % of charge needed)/Charger Setting x 1.25 = hours of charge
(100 (Ah Rating) x .50 (charge needed))/20 (Charger Setting) x 1.25 = 3.125 hours
(100 x .50)/20 x 1.25 = 3.125
You would need to charge your 100-Ampere Hour Battery for a little more than 3 hours at the 20-Amp charge
rate using the above example.
The Chart Method
Use the following table to more accurately determine the time it will take to bring a battery to full charge. First,
identify where your battery fits into the chart.
NR means that the charger setting is NOT RECOMMENDED.
Find your battery’s rating on the chart below, and note the charge time given for each charger setting. The times
given are for batteries with a 50% charge prior to recharging. Add more time for severely discharged batteries.

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BATTERY SIZE/RATING CHARGE RATE/CHARGING TIME - HOURS
2 AMP 5 AMP 10 AMP 15 AMP 20 AMP 30 AMP 35 AMP 40 AMP 50 AMP 60 AMP 80 AMP
SMALL BATTERIES
Motorcycle, Garden Tractor, etc.
6 - 12 AH 2 - 3¾
hrs.
¾ - 1½ hrs.
NR NR NR NR NR NR NR NR NR
12 - 32 AH 3¾ - 10
hrs.
1½ - 4 hrs.
NR NR NR NR NR NR NR NR NR
CAR/TRUCKS 200 - 315
CCA
40 - 60 RC 11¼ -
14½ hrs.
4½ - 5¾ hrs.
2¼ - 3 hrs.
1½ - 2 hrs.
1 - 1½ hrs.
¾ - 1 hrs.
40 - 50 min.
½ - ¾ hrs.
25 - 35 min.
23 - 29 min.
17 - 22 min.
315 - 550 CCA
60 - 85 RC 14½ -
18¼ hrs.
5¾ - 7½ hrs.
3 - 3¾ hrs.
2 - 2½ hrs.
1½ - 2 hrs.
1 - 1¼ hrs.
50 - 60 min.
¾ - 1 hrs.
½. - ¾ hrs.
29 - 37 min.
22 - 28 min.
550 - 1000 CCA
85 - 190 RC 18¼ -
34¾ hrs.
7½ - 14 hrs.
3¾ - 7 hrs.
2½ - 4½ hrs.
2 - 3½ hrs.
1¼ - 2¼ hrs.
1 - 2 hrs. 1 - 1¾
hrs.
¾ - 1½ hrs.
37 - 70 min.
28 - 52 min.
MARINE/ DEEP CYCLE
80 RC 17½ hrs 7 hrs. 3½ hrs. 2¼ hrs. 1¾ hrs. NR NR NR NR NR NR 140 RC 27 hrs. 10¾ hrs. 5½ hrs. 3½ hrs. 2¾ hrs. NR NR NR NR NR NR 160 RC 30 hrs. 12 hrs. 6 hrs. 4 hrs. 3 hrs. NR NR NR NR NR NR 180 RC 33 hrs. 13¼ hrs. 6½ hrs. 4½ hrs. 3¼ hrs. NR NR NR NR NR NR

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MAINTENANCE INSTRUCTIONS
STORAGE INSTRUCTIONS
1. After use and before performing maintenance,
unplug and disconnect the battery charger.
2. Use a dry cloth to wipe all battery corrosion and
other dirt or oil from the terminals, cords, and the
charger case.
1. Store the charger unplugged, in an upright position.
The cord will still conduct electricity until it is
unplugged from the outlet.
2. Store inside, in a cool, dry place.
3. Ensure that all of the charger components are in
place and in good working condition, including the
plastic boots on the battery clips.
4. Servicing does not require opening the unit, as there
are no user-serviceable parts.
3. Do not store the clips on the handle, clipped together,
on or around metal, or clipped to cables.
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
No reading on the
ammeter.
Charger is not plugged in.
No power at the receptacle.
Clips are not making a good connection to
the battery.
Connections are reversed.
Battery is defective (will not accept a charge).
2 amp charge rate is being used.
Plug the charger into an A.C. outlet.
Check for open fuse or circuit breaker supplying
A.C. outlet.
Check for poor connection to battery and frame.
Make sure connection points are clean. Rock clips
back and forth for a better connection.
Unplug the charger and reverse the clips.
Have battery checked.
Ammeter may show no activity at the 2A charge rate.
Ammeter reading stays
high.
Battery is severely discharged.
Wrong battery voltage.
Continue charging battery for two more hours. If
problem continues have the battery checked.
Verify the voltage settings or output ratings on the
charger are correct.
Ammeter reads less than
selected charge rate when
charging a discharged
battery
Extension cord is too long or wire gauge
is too small.
Weak cell or sulfated plate in battery.
Battery is only partially discharged.
Use a shorter or heavier gauge extension cord.
A sulfated battery will eventually take a normal
charge if left connected. If the battery will not take
a charge, have it checked.
Continue to charge the battery.