Chicago Electric Battery Charger 99857 User Manual

1.5 Amp ElEctronic  
onboArd bAttEry chArgEr  
99857  
SEt up And opErAting inStructionS  
®
distributed exclusively by harbor Freight tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
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 2008 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.  
 
matching outlets will reduce risk of  
electric shock.  
non-skid safety shoes, hard hat, or  
hearing protection used for appropri-  
ate conditions will reduce personal  
injuries.  
b.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.  
c.do not overreach. Keep proper  
footing and balance at all times.  
This enables better control of the  
Battery Charger in unexpected situa-  
tions.  
c.do not expose battery chargers to  
rain or wet conditions. Water enter-  
ing a Battery Charger will increase  
the risk of electric shock.  
d.dress properly. do not wear loose  
clothing or jewelry. Keep your  
hair, clothing and gloves away  
from moving parts. Loose clothes,  
jewelry or long hair can be caught in  
moving parts.  
d.do not abuse the cord. never  
use the cord for carrying, pulling  
or unplugging the battery char-  
ger. Keep cord away from heat,  
oil, sharp edges or moving parts.  
Damaged or entangled cords in-  
crease the risk of electric shock.  
e.only use safety equipment that  
has been approved by an appropri-  
ate standards agency. Unapproved  
safety equipment may not provide  
adequate protection. Eye protection  
must be ANSI-approved and breath-  
ing protection must be NIOSH-ap-  
proved for the specific hazards in the  
work area.  
e.When operating a battery charger  
outdoors, use an extension cord  
suitable for outdoor use. Use of a  
cord suitable for outdoor use reduces  
the risk of electric shock.  
f. if operating a battery charger in a  
damp location is unavoidable, use 4. battery charger use and care  
a ground Fault circuit interrupter  
a.do not force the battery charger.  
(gFci) protected supply. Use of  
use the correct battery charger  
a GFCI reduces the risk of electric  
for your application. The correct  
Battery Charger will do the job better  
shock.  
and safer at the rate for which it was  
designed.  
3. personal safety  
a.Stay alert, watch what you are do-  
b.disconnect the plug from the pow-  
ing and use common sense when  
er source from the battery charger  
operating a battery charger. do  
before making any adjustments,  
not use a battery charger while  
changing accessories, or storing  
you are tired or under the influence  
battery chargers. Such preventive  
of drugs, alcohol or medication. A  
safety measures reduce the risk of  
moment of inattention while operating  
starting the Battery Charger acciden-  
Battery Chargers may result in seri-  
tally.  
ous personal injury.  
c.Store idle battery chargers out of  
b.use personal protective equip-  
the reach of children and do not  
ment. Always wear eye protection.  
allow persons unfamiliar with the  
Safety equipment such as dust mask,  
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Page 3  
 
battery charger or these instruc-  
tions to operate the battery char-  
ger. Battery Chargers are dangerous  
in the hands of untrained users.  
parts. This will ensure that the safety  
of the Battery Charger is maintained.  
battery charger Safety Warnings  
d.maintain battery chargers. check  
for breakage of parts and any  
other condition that may affect the  
battery charger’s operation. if  
damaged, have the battery char-  
ger repaired before use. Many ac-  
cidents are caused by poorly main-  
tained Battery Chargers.  
1. Maintain labels and nameplates on  
the tool. These carry important safety  
information. If unreadable or miss-  
ing, contact Harbor Freight Tools for a  
replacement.  
2. Avoid contact with battery acid. If  
splashed, unplug Battery Charger  
and immediately wash effected area  
with clean water.  
e.use the battery charger in ac-  
cordance with these instructions,  
taking into account the working  
conditions and the work to be per-  
formed. Use of the Battery Charger  
for operations different from those  
intended could result in a hazardous  
situation.  
3. Turn vehicle OFF and allow to cool  
before plugging in Battery Charger.  
Remove keys from vehicle ignition  
before plugging in Battery Charger.  
4. Before operation, check to be sure  
Battery Charger cables are connect-  
ed to the correct battery posts. Red  
must be connected to the Positive (+)  
terminal. Black cable must be con-  
nected to the Negative (-) terminal.  
5. battery use and care  
a.When battery is not in use, keep  
away other metal objects, like  
paper clips, coins, keys, nails,  
screws or other small metal ob-  
jects, that can make a connec-  
tion from one terminal to another.  
Shorting the battery terminals togeth-  
er may cause burns or a fire.  
5. Keep Output Wires (12) and Power  
Cable (8) clear of fan, fan belt, pul-  
leys and any other moving parts of  
the engine.  
6. Only use Battery Charger in a well  
ventilated area to prevent build up of  
explosive gasses.  
b.under abusive conditions, liquid  
may be ejected from the battery;  
avoid contact. if contact acciden-  
tally occurs, flush with water. If  
liquid contacts eyes, additionally  
seek medical help. Liquid ejected  
from the battery may cause irritation  
or burns.  
7. Do not allow the Red and Black ter-  
minals of the Battery Charger or the  
vehicle battery cables to touch. Do  
not allow the Red cables to touch the  
frame or any metal part of the ve-  
hicle. Contact can cause an electrical  
short resulting in sparks, burn injury  
or damage to property.  
6. Service  
a.have your battery charger ser-  
viced by a qualified repair person  
using only identical replacement  
8. Only use in 12 VDC systems. Do not  
use in any other voltage system.  
SKU 99857  
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Page 4  
 
9. Do not attempt to start or jump a  
vehicle with this Battery Charger  
plugged in. Do not use this Battery  
Charger to charge a dead, damaged  
or severely discharged battery. This  
charger is designed to “top off” and  
maintain a battery at or near 12 VDC.  
rupter (GFCI) should also be imple-  
mented – it prevents sustained elec-  
trical shock.  
14. WARNING: Handling the cord on  
this product will expose you to lead,  
a chemical known to the State of  
California to cause cancer, and birth  
defects or other reproductive harm.  
Wash hands after handling. (Califor-  
nia Health & Safety Code § 25249.5,  
et seq.)  
10. Do not leave the Charger unattended  
when it is plugged into an electrical  
outlet. Unplug the Charger from its  
electrical outlet before leaving.  
11.  
The battery charger may  
get hot during use. The  
charger’s heat can build  
15. WARNING: The brass components  
of this product contain lead, a chemi-  
cal known to the State of California  
to cause birth defects (or other repro-  
ductive harm). (California Health &  
Safety code 25249.5, et seq.)  
up to unsafe levels and  
create a fire hazard if it does not  
receive adequate ventilation, due to  
an electrical fault, or if it is used in a  
hot environment.  
Do not place the charger on a flam-  
mable surface. Do not obstruct any  
vents on the charger. Especially  
avoid placing the charger on car-  
pets and rugs; they are not only  
flammable, but they also obstruct  
vents under the charger.  
16. The warnings, precautions, and in-  
structions discussed in this instruction  
manual cannot cover all possible con-  
ditions 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.  
12. This product is not a toy. Keep it out  
of reach of children.  
SAVE thESE  
13. People with pacemakers should  
consult their physician(s) before use.  
Electromagnetic fields in close prox-  
imity to heart pacemaker could cause  
pacemaker interference or pacemak-  
er failure. In addition, people with  
pacemakers should:  
inStructionS.  
• Avoid operating alone.  
• Do not use with power switch locked  
on.  
• Properly maintain and inspect to  
avoid electrical shock.  
• Any power cord must be properly  
grounded. Ground Fault Circuit Inter-  
SKU 99857  
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Page 5  
 
of electric shock. (See 3-prong plug  
and outlet.)  
grounding  
to prEVEnt  
ElEctric ShocK  
And dEAth From  
incorrEct grounding  
WirE connEction:  
2. The grounding prong in the plug is  
connected through the green wire in-  
side the cord to the grounding system  
in the tool. The green wire in the cord  
must be the only wire connected to  
the tool’s grounding system and must  
never be attached to an electrically  
“live” terminal. (See 3-prong plug  
and outlet.)  
Check with a qualified  
electrician if you are in doubt  
as to whether the outlet is  
properly grounded. do not  
modify the power cord plug  
provided with the tool. never  
remove the grounding prong  
from the plug. do not use the  
tool if the power cord or plug  
is damaged. if damaged, have  
it repaired by a service facility  
before use. if the plug will not  
fit the outlet, have a proper  
outlet installed by a qualified  
electrician.  
3. The tool must be plugged into an  
appropriate outlet, properly installed  
and grounded in accordance with all  
codes and ordinances. The plug and  
outlet should look like those in the  
preceding illustration. (See 3-prong  
plug and outlet.)  
double insulated tools: tools  
with two prong plugs  
grounded tools: tools with three  
prong plugs  
1. Tools marked “Double Insulated” do  
not require grounding. They have  
a special double insulation system  
which satisfies OSHA requirements  
and complies with the applicable  
standards of Underwriters Labora-  
tories, Inc., the Canadian Standard  
Association, and the National Electri-  
cal Code. (See outlets for 2-prong  
plug.)  
1. Tools marked with “Grounding Re-  
quired” have a three wire cord and  
three prong grounding plug. The  
plug must be connected to a properly  
grounded outlet. If the tool should  
electrically malfunction or break  
down, grounding provides a low  
resistance path to carry electricity  
away from the user, reducing the risk  
SKU 99857  
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Page 6  
 
2. Double insulated tools may be used  
in either of the 120 volt outlets shown  
in the preceding illustration. (See  
outlets for 2-prong plug.)  
dition. Always replace a damaged  
extension cord or have it repaired by  
a qualified electrician before using it.  
8. Protect the extension cords from  
sharp objects, excessive heat, and  
damp or wet areas.  
Extension cords  
1. Grounded tools require a three wire  
extension cord. Double Insulated  
tools can use either a two or three  
wire extension cord.  
rEcommEndEd minimum WirE  
gAugE For EXtEnSion cordS*  
(120/240 Volt)  
EXtEnSion cord  
nAmEplAtE  
lEngth  
2. As the distance from the supply outlet  
increases, you must use a heavier  
gauge extension cord. Using exten-  
sion cords with inadequately sized  
wire causes a serious drop in voltage,  
resulting in loss of power and pos-  
sible tool damage.  
AmpErES  
(at full load)  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
3.5 – 5.0  
5.1 – 7.0  
(See table A.)  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
3. The smaller the gauge number of the  
wire, the greater the capacity of the  
cord. For example, a 14 gauge cord  
can carry a higher current than a 16  
gauge cord. (See table A.)  
-
-
* based on limiting the line  
voltage drop to five volts at  
150% of the rated amperes.  
tAblE A  
Symbology  
4. When using more than one exten-  
sion cord to make up the total length,  
make sure each cord contains at  
least the minimum wire size required.  
(See table A.)  
Double Insulated  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
Amperes  
5. If you are using one extension cord  
for more than one tool, add the  
nameplate amperes and use the sum  
to determine the required minimum  
cord size. (See table A.)  
V~  
A
6. If you are using an extension cord  
outdoors, make sure it is marked with  
the suffix “W-A” (“W” in Canada) to  
indicate it is acceptable for outdoor  
use.  
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
7. Make sure the extension cord is prop-  
erly wired and in good electrical con-  
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Page 7  
 
note: For additional information regarding  
the parts listed in the following pages,  
refer to the Assembly Diagram near  
the end of this manual.  
SpEciFicAtionS  
Electrical Requirements 120 V~ / 60 Hz  
Output Voltage  
12 VDC / 1.5 Amps  
Charging Method  
3-Stage trickle charge  
mounting  
Red, Yellow and  
Green LED lights  
Status Indicators  
1. The Battery Charger must be mount-  
ed near the battery in the engine  
compartment of the vehicle.  
On / Off trickle  
charging with Thermal  
Overload Protection  
Overload Protection  
Additional Protection  
Short Circuit and  
Polarity Protection  
2. Leave at least 2-½” clearance in front  
of the Output Wires (12) Plug.  
3. You can mount the Charger on the  
vehicle engine compartment wall  
near the battery, or you can mount it  
on a bracket held in place by the bat-  
tery.  
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.  
Bracket B (6)  
inStructionS For  
putting into uSE  
Bracket A (9)  
read the EntirE importAnt  
SAFEty inFormAtion  
section at the beginning of this  
manual including all text under  
subheadings therein before set  
up or use of this product.  
Side View with Brackets  
Front View with Brackets  
to prEVEnt  
SEriouS injury  
From AccidEntAl  
opErAtion:  
unplug the tool from its  
electrical outlet and  
disconnect from battery  
before assembling or making  
any adjustments to the tool.  
4. For Engine Compartment Wall  
mounting, mark and predrill wall us-  
ing Bracket A (9) or Bracket B (6) as  
a template. See Figure 1 above. Be  
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Page 8  
 
sure that there are no wires, hoses  
or other components behind the wall  
that will be damaged by drilling. Use  
Brackets A and B to grip the Battery  
Charger. Attach to the compartment  
wall using two Self Tapping Screws  
(12).  
to the battery. Be sure the Red Out-  
put Wire is attached to the Positive  
(+) terminal and the Black Output  
wire is attached to the Negative (-)  
terminal. Be sure all connections are  
tight.  
9. Keep Output Wires (12) and Power  
Cable (8) clear of fan, fan belt, pul-  
leys and any other moving parts of  
the engine.  
5. For mounting under the battery, as-  
semble Brackets A, B and C (9, 6 and  
5) as shown in Figure 2 below.  
Bracket A (9)  
Side View of Brackets  
Assembly  
Functions  
1. When plugged in, this Battery Char-  
ger will charge a 12 VDC battery, and  
maintain the charge. You can see the  
state of charge by observing the LED  
lights on the Charger.  
Slide Bracket C (5)  
under Battery  
Bracket B (6)  
3 Stage charging  
1. This charger automatically works in  
three stages, depending on the con-  
dition of your battery.  
Attach Output Wires  
to Battery Terminals.  
6. Slide Bracket C (5) under the battery  
to hold the Charger in place.  
7. Be sure the Battery Charger is firmly  
attached and will not come loose  
during normal vehicle use or during a  
sudden stop. Periodically check the  
Charger to be sure it is still firmly at-  
tached. A loose Battery Charger can  
become damaged, or damage vehicle  
components.  
8. Be sure the vehicle ignition switch is  
in the OFF position. Using the vehicle  
battery clamp bolts, attach the round  
connectors of the Output Wires (12)  
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Page 9  
 
2. 1st stage: Constant Current. When  
the battery is severely discharged,  
the Charger applies Constant Cur-  
rent. This stage speedily charges  
the battery while protecting against  
damage, loss of Hydrogen or even  
explosion. The battery is charged to a  
maximum of 14.8 Volts DC.  
Work piece and Work Area Set up  
1. Designate a work area that is clean,  
ventilated and well-lit. The work area  
must not allow access by children or  
pets to prevent injury and distraction.  
2. Route the power cord along a safe  
route to reach the work area without  
creating a tripping hazard or exposing  
the power cord to possible damage.  
The power cord must reach the work  
area with enough extra length to al-  
low free movement while working.  
3. 2nd Stage: Constant Voltage. This  
is a speed charge cycle for batteries  
nearly full. It will top off the battery  
at 14.8 Volts DC, utilizing a 200 mA  
trickle charge.  
3. To prevent electrical shock, avoid  
moisture or water in the work area.  
4. 3rd stage: Floating Constant Volt-  
age. This stage maintains a fully  
charged battery in its best condition  
by constantly applying small “ticks”  
of charge. The battery will never fall  
below 13.5 Volts DC.  
general operating instructions  
1. Be sure the vehicle engine is OFF,  
the engine is cool and the key is re-  
moved from the ignition.  
opErAting inStructionS  
2. Never “Jump” or attempt to start the  
vehicle while the Battery Charger is  
plugged in.  
read the EntirE importAnt  
SAFEty inFormAtion  
section at the beginning of this  
manual including all text under  
subheadings therein before set  
up or use of this product.  
3. Do not attempt to charge a damaged  
or “dead” battery with this tool. This  
charger is designed to “top off” and  
maintain vehicle batteries at or near  
12 VDC. Attempting to charge dam-  
aged or discharged batteries with  
this tool may cause the battery or the  
charger to overheat, possibly causing  
damage or explosion.  
tool Set up  
to prEVEnt  
SEriouS injury:  
use only an appropriate  
extension cord in good  
condition to operate this  
battery charger.  
4. Plug your extension cord into the  
Power Cable (8). Plug the extension  
cord into a GFCI protected 120 VAC  
outlet.  
See pages 6 and 7 of this  
manual for information on safe  
use of extension cords.  
5. Observe the LED lights on the char-  
ger to determine the operational sta-  
tus of the circuit and the charger.  
SKU 99857  
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Page 10  
 
cleaning and maintenance.  
lEd  
color  
on /  
oFF  
condition  
Green  
Red  
OFF  
OFF  
Charger is not operating.  
Check connections and status  
of 120 VAC circuit.  
bEForE EAch uSE, inspect the general  
condition of the 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.  
Green  
Yellow  
Red  
ON  
ON  
OFF  
120 VAC is present and char-  
ger is operating.  
Green  
Red  
Yellow  
ON  
OFF  
OFF  
120 VAC is present. Battery is  
fully charged.  
1. AFtEr uSE, clean external surfaces  
Green  
Red  
Yellow  
ON/OFF Battery Voltage is under 9V.  
ON  
OFF  
of the tool with clean cloth.  
2.  
WArning! if the supply cord of  
this battery charger is damaged, it  
must be replaced only by a quali-  
fied service technician.  
6. Periodically check the Battery Char-  
ger during operation to be sure it  
does not overheat.  
7. Before starting or operating the ve-  
hicle, unplug and put away the exten-  
sion cord.  
mAintEnAncE And  
SErVicing  
Procedures not specifically  
explained in this manual  
must be performed only by a  
qualified technician.  
to prEVEnt  
SEriouS injury  
From tool FAilurE:  
do not use damaged  
equipment. if abnormal heat  
occurs, or charger overheats,  
have the problem corrected  
before further use.  
SKU 99857  
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Page 11  
 
troubleshooting  
problem  
possible causes  
likely Solutions  
Tool will not  
1. No power at outlet.  
1. Check power at outlet.  
operate. LED  
lights off.  
2. Cord not connected.  
2. Check that cord is plugged in.  
LED lights on,  
but tool does not  
charge battery  
1. Loose or dirty connection at  
battery terminals.  
1. Check connections. Clean and re-tighten.  
Follow all safety precautions whenever diagnosing or servicing the  
tool. disconnect power supply before service.  
plEASE rEAd thE FolloWing cArEFully  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY  
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.  
pArtS liSt  
part  
1
description  
Qty.  
LED Light  
3
1
1
1
1
1
1
1
1
4
1
1
2
Top Cover  
3
Radiator  
4
Printed Circuit Board  
Bracket C  
5
6
Bracket B  
7
Bottom Cover  
Power Cable  
Bracket A  
8
9
10  
11  
12  
2.5 x 12 Self Tapping Screws  
Transformer  
Output Wires  
SKU 99857  
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Page 12  
 
ASSEmbly diAgrAm  
SKU 99857  
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Page 13  
 
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 prod-  
uct 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 ExPRESS-  
LY 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 com-  
plaint must accompany the merchandise. If our inspection verifies the defect, we will ei-  
ther 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 re-  
paired 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  
record product’s 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 avail-  
able individually as replacement parts.  
SKU 99857  
For technical questions, please call 1-800-444-3353.  
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