Chicago Electric Automobile Battery Charger 96157 User Manual

5 in 1 portable power pack  
Model 96157  
operation instructions  
Diagrams within this manual may not be drawn proportionally.  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
®
Distributed exclusively by Harbor Freight Tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Read this material before using this product.  
Failure to do so can result in serious injury.  
SaVe THiS manual.  
©
®
Copyright 2007 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 or replacement parts, please call 1-800-444-3353.  
 
4.  
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.  
5.  
6.  
Do not expose the power pack to rain or wet conditions. Water entering the  
Power Pack will increase the risk of electric shock.  
stay alert. Watch what you are doing, and use common sense when operating  
the Power Pack. Do not use the Power Pack while tired or under the influence of  
drugs, alcohol, or medication. A moment of inattention while operating power tools  
may result in serious personal injury.  
7.  
use safety equipment. Always wear ANSI-approved eye protection. Dust mask,  
nonskid safety shoes, hard hat, or hearing protection must be used for appropriate  
conditions.  
8.  
Do not force the power pack. Use the correct tool for your application. The cor-  
rect tool will do the job better and safer at the rate for which it is designed. Do not  
force the tool and do not use the tool for a purpose for which it is not intended.  
9.  
Do not use the power pack if the power switch does not turn it on or off. Any  
tool that cannot be controlled with the Power Switch is dangerous and must be  
replaced.  
10.  
Disconnect the power pack from the power source before making any ad-  
justments, changing accessories, or storing the tool. Such preventive safety  
measures reduce the risk of starting the tool accidentally.  
11.  
12.  
13.  
store idle tools out of reach of children and other untrained persons. Tools  
are dangerous in the hands of untrained users.  
Maintain labels and nameplates on the tool. These carry important information.  
If unreadable or missing, contact Harbor Freight Tools for a replacement.  
people with pacemakers should consult their physician(s) before use. Elec-  
tromagnetic fields in close proximity to heart pacemaker could cause pacemaker  
interference or pacemaker failure.  
14.  
warninG:this product contains lead, which is 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.)  
15.  
16.  
17.  
avoid contact with battery acid. If splashed, immediately wash effected area  
with clean water. Continue washing area until medical help arrives.  
connect cables to proper polarities. Connect black cable to negative body ground  
and red cable to positive battery terminal.  
Do not allow the black and red clamps to touch. Injury to the operator or prop-  
erty damage can occur if this happens.  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
18.  
19.  
For emergency use only. Do not use this system in the place of a vehicle battery.  
Only use to jump start the vehicle.  
lead acid batteries generate additional hydrogen gas when charging. Hydro-  
gen gas is explosive. Only use the Jump-start System in a well-ventilated area. Do  
not allow smoking in the area.  
20.  
never exceed the maximum charging time of the power pack. Maximum AC  
charge time is 48 hours. Maximum DC charge time is 24 hours.  
serVice  
1.  
2.  
Tool service must be performed only by qualified repair personnel. Service or main-  
tenance performed by unqualified personnel could result in a risk of injury.  
When servicing a tool, use only identical replacement parts. Follow instructions  
in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of un-  
authorized parts or failure to follow maintenance instructions may create a risk of  
electric shock or injury.  
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.  
operation instructions  
note: For additional information regarding the parts listed in the following pages, refer to  
the Assembly Diagram near the end of this manual.  
charging the power pack  
note: Before initial use, it is necessary to completely charge the Power Pack. Initial  
charge time when using an AC outlet is 48 hours. Initial charge time when using a  
DC outlet is 24 hours. Always charge on concrete or tile, not on surfaces that are  
flammable or surfaces that could get heat damaged.  
1.  
Press and hold the Battery Status Button (23) on the front of the unit to check the  
battery power level: 13 - 15 Volts is ready for use, 12 Volts needs to be charged,  
less than 12 Volts should be charged immediately.  
2.  
Turn the Jump-start Power Switch (18) on the back of the unit to the “OFF” posi-  
tion.  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
AC Adapter (30)  
DC Adapter (31)  
3.  
to charge from an ac power source. After the initial charge, use only the AC  
Adapter (30) provided with the unit. Plug first into any standard 120V socket, and  
then into Power Pack. Allow up to 34 hours for the unit to fully charge. The pack  
must not be continually charged for over 34 hours at a time.  
4.  
5.  
6.  
When the Power Pack is fully charged, unplug from the 120V socket and unit. Do  
not exceed the maximum ac charge time of 34 hours.  
to charge from a Dc power source, plug the DC Adapter (31) into any 12V outlet  
and then into the AC/DC charging jack on the front of the unit.  
After the initial charge, fully charging the Power Pack by a DC connection will take  
about 12 hours. Do not exceed the maximum Dc charge time of 12 hours.  
note: The Charging Indicator light will illuminate when the Power Pack is charging with  
both AC or DC input. the charging indicator light will not turn off when the  
charging is complete. The Voltmeter (10) must be checked periodically when  
charging and the Power Pack must be unplugged when the unit is fully charged.  
Do not oVercHarGe.  
work light  
To turn on the L.E.D. Work Light (13), push the Work Light Switch (25) to the “ON”  
position. Turn Work Light Switch to “OFF” position when done.  
Jump-starting  
note: Read the vehicle owner’s manual prior to using the Power Pack to jump-start the  
vehicle.  
1.  
Turn off the ignition switch of the vehicle and all accessories (lights, radio etc.) of  
the vehicle off.  
2.  
Turn all switches on the Power Pack off.  
caution: Do not touch Positive and Negative Battery Clamps together.  
3.  
Connect the red Positive Battery Clamp (27) to the vehicle’s positive battery ter-  
minal.  
REV 08a  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
4.  
5.  
Connect the black Negative Battery Clamp (28) to a non-moving metal part  
of the vehicle. Do not connect to tHe neGatiVe terMinal oF tHe  
batterY.  
The Connection Indicator Light (17) will glow green if a correct connection has  
been made. If the Connection Indicator Light turns red, review, and change the  
connections.  
6.  
7.  
8.  
When the correct connection has been made, turn the Jump-start Power Switch  
(18) to the “ON” position.  
Start vehicle. If vehicle does not start, wait an additional 3 minutes before trying  
again. Failure to wait 3 minutes may damage the power pack.  
After vehicle is started, remove the black Negative Battery Clamp first, and then  
the red Positive Battery Clamp.  
air compressor  
1.  
2.  
3.  
Open Compartment Door (5) on the back of the unit and pull out the air hose.  
Check proper inflation level for the object that is being inflated.  
Lift lever on air nozzle and connect the appropriate adapter (stored in the same  
area as the air hose and nozzle) for your intended use. Move lever down to lock  
adapter in place.  
4.  
5.  
6.  
Turn Air Compressor Switch (24) to “ON” position. (“0”=OFF, 1”=ON)  
Watch the Compressor Gauge (15) on the front of the unit to avoid over-inflation.  
When the object reaches the proper inflation level, turn off Air Compressor and  
disconnect hose. Do not overinate any object.  
ac inverter  
1.  
Before connecting the Inverter, make sure the Inverter/Fan Switch (26) is in the  
“OFF” position. (Push on “0” portion of the switch)  
2.  
3.  
Plug the appliance into an AC Socket (29) of the Power Pack.  
Press the Inverter/Fan Switch to theONposition. If the inverter is working correctly,  
the light underneath the Inverter/Fan Switch will illuminate green.  
4.  
5.  
Turn on the appliance, if the light remains on, the system is functioning normally. If  
the light turns off, immediately turn off the appliance and the inverter and see the  
Troubleshooting Guide” section of the manual.  
Monitor voltage use, so that the Power Pack does not drain completely.  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
Fan  
Turn the Inverter/Fan Switch (26) to the “ON” position, turn off when finished.  
12 Volt Dc  
1.  
2.  
Remove the 12V DC Socket Cover (11, 12) and plug in a 12 Volt accessory.  
Monitor voltage use, so that the Power Pack does not run out of power.  
battery Disposal  
1.  
Disposal: The Power Pack uses a lead-acid battery. Do not attempt to replace  
battery. Remove all screws from case and open. Disposing of Power Pack must  
comply with the standards for hazardous waste disposal in your area. Contact your  
local city government office for the nearest hazardous waste disposal area in your  
community.  
inspection, Maintenance, anD cleaninG  
1.  
2.  
warninG! Make sure the Power Switch of the tool is in its “OFF” position and  
that the tool is unplugged from its electrical outlet before performing any inspection,  
maintenance, or cleaning procedures.  
beFore eacH use, inspect the general condition of the tool. Check for loose  
screws, misalignment or binding of moving parts, cracked or broken parts, dam-  
aged 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.  
please reaD tHe FollowinG careFullY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEM-  
BLY 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 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.  
record products 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 available  
individually as replacement parts.  
REV 08j  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
troublesHootinG  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
liMiteD 90 DaY warrantY  
Harbor FreightTools Co.makes every effort to assure that its products meet high quality and durabil-  
ity 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 facili-  
ties, 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 WAR-  
RANTIES 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 merchan-  
dise. If our inspection verifies 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 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  
parts list  
part  
1
Description  
Main Body (Front)  
part  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
Description  
Jump-start Power Switch  
Positive Cable  
2
Main Body (Back)  
Positive Clamp Holder  
Negative Clamp Holder  
Compartment Door  
Back Panel  
3
Negative Cable  
4
Fan/Inverter  
5
Battery  
6
Battery Status Button  
Air Compressor Switch  
Work Light Switch  
Inverter/Fan Switch  
Positive Battery Clamp  
Negative Battery Clamp  
AC Socket  
7
Front Panel  
8
Transparent Panel  
12V 40A Fuse  
9
10  
11  
12  
13  
14  
15  
16  
17  
Voltmeter  
DC Socket Cover  
DC Socket  
L.E.D. Work Light  
Air Compressor  
Compressor Gauge  
PCB - Inverter  
AC Adapter  
DC Charger  
3 Air Nozzle Adapters (not shown)  
Connection Indicator  
note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts.  
REV 08a  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
asseMblY DiaGraM  
REV 08a  
SKU 96157  
For technical questions, please call 1-800-444-3353.  
Page 10  
 

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