Harbor Freight Tools Battery Charger 03418 User Manual

BATTERY

CHARGER/STARTER

Model 03418

ASSEMBLY and OPERATING

INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

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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

10. Disconnect power. Unplug charger when not in use.

11. Stay alert. Watch what you are doing, use common sense. Do not operate the Charger

when you are tired.

12. 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 fixtures; and any other condition that may affect proper operation. Any part

that is damaged should be properly repaired or replaced by a qualified technician. Do

not use the tool if any switch does not turn On and Off properly.

13. Guard against electric shock. Prevent body contact with grounded surfaces such as

pipes, radiators, ranges, and refrigerator enclosures.

14. 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. Approved accessories are available from Harbor Freight

Tools.

15. Do not operate tool is under the influence of alcohol or drugs. Read warning

labels if taking prescription medicine to determine if your judgement or reflexes are

impaired while taking drugs. If there is any doubt, do not operate the Charger.

16. Use proper size and type extension cord. If an extension cord is required, it must be

of the proper size and type to supply the correct current to the tool without heating up.

Otherwise, the extension cord could melt and catch fire, or cause electrical damage to

the tool.This tool requires use of an extension cord of 0 to 10 amps capability (up to

50 feet), with wire size rated at 18 AWG. Longer extension cords require larger size

wire. If you are using the tool outdoors, use an extension cord rated for outdoor use

(signified by “WA” on the jacket).

Note: More on extension cords on page 6.

20. Maintenance. For your safety, maintenance should be performed regularly by a

qualified technician.

Note: Performance of this tool (if powered by line voltage) may vary depending on

variations in local line voltage. Extension cord usage may also affect tool performance.

Warning: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.

Unpacking

When unpacking, check to make sure the parts listed on page 11 are included. If any parts

are missing or broken, please call Harbor Freight Tools at the number on the cover of this

manual as soon as possible.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 3

Battery Charger Specific Warnings

Read all of the warnings below before operation. A failure to read and follow each of the

warnings may result in electric shock, causing serious injury or death.

Warning!! While charging, lead-acid batteries produce hydrogen gas which is extremely

flammable. They generate this gas during normal operation and, at a high level, during charging.

If any spark causes the gas to ignite, the battery could explode, sending out shrapnel-like

pieces of battery casing and extremely caustic battery acids in every direction, with extreme

force and speed. Even the slightest spark will suffice to ignite hydrogen gas. Pay strict

attention to, and follow all of the warnings, each time you use the battery charger.

Only use this charger indoors on dry, flat, stable surfaces. Any contact with water will

create an electric shock hazard resulting in serious injury or death. Never expose the

battery or charger to wet conditions. Do not stand in water or have wet hands when

contacting the battery or the charger. For water avoidance, locate all non-wheeled

chargers at least 18” off of the floor.

If charging a marine battery, do not charge on a boat or near the water. Do not charge

on a pier or a dock. The boat must be indoors, on a trailer, or you should remove the

battery from the boat and take it indoors. For marine charging, do not connect the

charger cables to the battery in the bilge or engine compartment of the boat. Follow the

boat manufacturer’s battery charging guidelines.

If the charger has defective or damaged wires, power cord, plug, or clamps, do not plug

it in and operate it. Have any damaged or defective parts repaired by a qualified

technician.

Do not alter power cord, plug, or clamps.

If the charger has been dropped or suffered a sharp blow, do not use it until it has been

checked out by a qualified service technician.

Never attempt to disassemble the battery charger. When service is needed, go to a

qualified service technician.

When wiping down or cleaning the charger, make sure the unit is unplugged from the

power outlet and not connected to a battery.

When unplugging the unit, grasp the power plug, not the power cord.

Always operate the charger in a well ventilated area.

10.

11.

Never operate the charger in close proximity to fuel tanks or gas cylinders.

Do not smoke anywhere near the charger. Do not operate the charger near any open

flame or a heat source of any kind.

12.

13.

14.

15.

16.

Do not permanently mount the battery charger to any vehicle or boat.

Never charge a frozen battery.

Never connect both charger clamps to the same post.

Do not allow the two output battery clamps to come in contact with each other.

Unless the manufacturer’s directions state otherwise, always charge the battery with

the cell caps on.

17.

Always unplug the battery charger before connecting or disconnecting battery clamps

from a battery.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 4

Battery Charger Specific Warnings (continued)

Be extra careful about dropping tools or anything metal near a charging battery as

sparks from the object may ignite the lead acid gasses.

18.

19.

20.

21.

Only charge lead acid batteries with this charger. Do not attempt to charge dry cell

household batteries as they may explode.

Position the battery charger as far away from the battery as possible. Use the full

extension length of the DC charging cables.

It is okay to rock or twist a clamp on a battery post at the time of connection. Once you

have set a clamp on a battery post, do not rock it. Rocking a clamp (other than at

original connection time) may cause sparking resulting in an explosion.

22.

Check wire and cable connections for tightness before starting a charge (before plugging

in the power cord). Loose connections cause sparks.

Reminder: Never charge in a closed compartment. The charging location must be well-

ventilated.

Battery Acid Hazards

Always wear eye protection and adequate clothing (long sleeves and long pants)

including gloves when working near battery acids.

When working with lead acid batteries, have someone in close voice proximity in case

you should need some help due to battery acid contact.

Keep a lot of fresh water and soap close by to use immediately if battery acid contacts

your skin, eyes, or clothing.

Note: If any contact with battery acid is made, you must act quickly. Immediately wash the

affected areas with soap and water. If eye contact is made, flush the eyes with running cold

water for ten minutes and then immediately get medical attention.

Fire Hazards

Use of attachments not designed for this specific model may cause a fire.

Disassembling the battery charger may cause a fire. Always have a qualified service

technician work on the battery charger.

Arcing flames and sparks are possible if you plug in the battery charger before

connecting to the battery. Always unplug the charger before battery hookup.

More Charger Warnings

Short circuits can deliver enough heat to weld a piece of metal (ie: jewelry) to your skin.

Always remove any metal or jewelry from your body or pockets before charging a battery.

Do not connect charger clamps to a battery in a vehicle when the engine is running. Do

not work on or near any vehicle when the engine is running. Moving engine parts can

cause serious injury or death.

Do not position the charger above the battery being charged or battery gases will corrode

the charger.

Do not set a battery on top of a charger.

Do not allow battery acids to come in contact with the charger.

Note: This charger is not recommended for batteries with a built in Hydrometer eye. The

reading of the built in eye will conflict with the ammeter readings.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 5

Operation

About Charging Batteries

Batteries draw as much power as they need from the charger. The charger does not force

current into the battery. When a battery is close to dead or very low charged, it will want to draw

more current. When a dead or low battery is charged, the charger’s ammeter will register at the

high end. As the battery charges, the reading will move down toward the low end, resting on

zero, when the battery is fully charged. See FIGURE 1 below.

FIGURE 1

Note: The ammeter shows the amount of current being drawn from the charger. It does not

show what the charger is capable of delivering. When the battery is fully charged and registering

zero on the ammeter, a small trickle charge will continue to move from the charger to the

battery. If you do not disconnect the charger from the battery, eventually the heat build up from

the trickle charge will cause the battery acid to boil and overcharge the battery causing damage

to the battery. You must constantly monitor battery charging progress.

Power Requirements

This charger must have a 120 volt, 60 Hertz AC (alternating current) power source fused at an

amperage greater than or equal to the input rating of this charger. Do not plug this charger in

until directed to do so in the following pages of this manual.

This charger has a 3-prong plug. The power outlet/receptacle must be grounded. If you use

an adapter (3-prong to 2-prong) to connect the plug from the charger to the outlet, the adapter

must be a properly grounded adapter and must only be used temporarily, until a qualified

electrician can install a properly grounded receptacle.

Extension cord use is determined by the input amp rating (2.2 amps) of the charger.

Minimum size (AWG rating) of a 25 foot cord is 18 gauge.

Minimum size (AWG rating) of a 50 foot cord is 18 gauge.

Minimum size (AWG rating) of a 100 foot cord is 14 gauge.

Minimum size (AWG rating) of a 150 foot cord is 12 gauge.

Never alter extension cords.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 6

Operation (continued)

Preparing the Battery

If necessary, remove the battery from the vehicle to charge it. When removing the battery,

always remove the grounded battery cable first.

Reminder: The vehicle’s engine must be OFF when removing, replacing, or charging a battery.

If necessary, add distilled water to the battery cells before charging. Read and follow

the battery manufacturer’s instruction manual. Never add water to a battery while attached

to a charger, or in close proximity to the charger. Do not overfill.

Clean battery terminals.

Check the battery manufacturer’s instructions on whether or not to have the cell caps

on when charging. If not stated, leave the cell caps on.

Determine the battery voltage from the battery or the manufacturer’s manual.

Operation Instructions

Warning! Read and understand all of the safety instructions in this manual before operating

the charger.

Warning!! If the Reverse Connect light (See FIGURE 1 on page 6) ever lights, immediately

unplug the charger and reconnect the clamps to the battery to alleviate the problem.

Connection to a battery installed in a vehicle.

Warning! The vehicle’s engine must be OFF during the entire charging process. Always read

and adhere to all the safety warnings and instructions provided in the vehicle’s manual.

Make sure the AC Power Cord (#3) is not plugged in.

Set up the charger on a flat, dry surface that allows you to position the Power Cord (#3)

and the clamp cords where they won’t be damaged by the vehicle doors, hood, or

sharp engine parts.

Note: Most vehicles are negative-grounded vehicles. Number 3 below instructs setup for

the most common negative-grounded vehicles. Number 4 below addresses the less

common positive-grounded vehicles. If you are not sure about your vehicle, check the

vehicle’s instruction manual or talk to the a qualified service technician.

Negative-grounded vehicles: The battery will have two terminals. One should be

marked POSITIVE, POS, P, OR +. The Negative terminal should be marked NEGATIVE,

NEG, N, OR -. Connect the red Clamp (#2) to the positive (ungrounded) terminal of the

battery. Connect the black Clamp (#2) to a heavy gauge metal part of your vehicle

chassis or engine block away from the battery. Do not connect to the black Clamp (#2)

to the Negative (black) terminal on the battery, fuel lines, the carburetor, or sheet metal

body parts.

Positive-grounded vehicles: The battery will have two terminals. Connect the

NEGATIVE black charger Clamp (#2) to the negative ungrounded terminal of the battery.

Connect the POSITIVE red Clamp (#2) to a heavy gauge metal part of your vehicle

chassis or engine block away from the battery. Do not connect to the NEGATIVE (black)

terminal on the battery, fuel lines, the carburetor, or sheet metal body parts.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 7

Operation (continued)

Connection to a battery outside a vehicle.

Make sure the AC Power Cord (#3) is not plugged in.

The battery will have two terminals. One should be marked POSITIVE, POS, P, OR +.

The Negative terminal should be marked NEGATIVE, NEG, N, OR -. To protect you by

keeping you further away from the battery, connect a battery cable (not included) that is

at least 24” long and #6 AWG (American Wire Gauge) to the NEGATIVE terminal of the

battery.

Connect the POSITIVE (red) Clamp (#2) from the charger to the POSITIVE terminal of

the battery.

Position yourself and the free end of the battery cable (not included) that is attached to

the NEGATIVE battery terminal, as far away as possible from the battery. While facing

away from the battery, connect the NEGATIVE (black) charger Clamp (#2) to the free

end of the battery cable (not included).

Charging

1. The charger must be set to the same voltage as the battery.

Settings:

The six volt setting (10A/6V) on the select switch is for charging medium to large 6 volt

batteries. It is a manual setting. After the battery is fully charged, the charger must be

disconnected to avoid damage. Charging time is 6 to 8 hours, and must be monitored throughout

the operation.

The two amp, 12 volt setting (2A/Auto) on the select switch is for charging small 12 volt

batteries or warming larger automotive batteries overnight to assist in cold weather starting. It

will not fully charge larger or deep cycle batteries. This setting is automatic. It will slow down

the charging rate when the battery reaches full charge. Charging time is a little longer on the

automatic setting as the unit tapers off slowly. It takes approximately 6-8 hours and it isn’t as

critical to monitor.

The ten amp, 12 volt setting (10A/12V) on the select switch is for charging medium to

large 12 volt batteries. This setting is automatic. It will slow down the charging rate when the

battery reaches full charge. Charging time is a little longer on the automatic setting as the unit

tapers off slowly. It takes approximately 6-8 hours and it isn’t as critical to monitor.

Small batteries: Lawn mower, motorcycle, or snowmobile type batteries have charge

rate limits. Always charge them on the two amp, 12 volt setting (2A/Auto) on the select switch.

Do not use this charger for charging small 6 volt batteries unless the manufacturer of the

battery states that the battery will withstand a 10 amp charge rate.

Note: More on manual charging times discussed on page 10.

Warning!! If the Reverse Connect light (see FIGURE 1) ever lights, immediately unplug the

charger and reconnect the clamps to the battery to alleviate the problem.

Note: Engine starting settings are covered on page 9.

When ready, set the select function switch (see FIGURE 1) to Charge and plug in the

charger to begin charging.

During charging, whether using the manual or automatic modes, it is important to monitor

the operation by checking the ammeter (see FIGURE 1).

Note: When the battery is charged the green charge complete light will turn on.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 8

Operation (continued)

Disconnecting after charging.

First, disconnect the charger clamp that is not attached directly to the battery. At this stage,

don’t let anything come in contact with the clamp. Then, disconnect the clamp that is in contact

with the battery terminal. Do not let the clamps touch each other while you unplug the charger.

Ammeter Readings

The ammeter shows how much charging current is drawn from the charger (to the battery).

When a dead or low battery is charged the charger’s ammeter will register at the high end. As

the battery charges, the reading will move down toward the low end, resting on zero, when the

battery is fully charged. When using the battery in engine starting mode (discussed

further down this page) the needle on the ammeter will peg toward the high end of the

ammeter.

Do not depend on reading the ammeter to approximate how long charging will take. Even at

full charge the ammeter will still be providing as much as 50 percent of the charger’s output

rating. It’s best to follow the charging times listed on page 8. Sometimes, certain conditions

such as a cold battery, a sulfated battery, or a deeply discharged Lead Calcium battery (on

many newer cars) may cause the ammeter to read near a full charge, when the charging

process is only beginning.

Note: Cold batteries (at or below 32 degrees Fahrenheit) begin charging at a low rate and

then increase as the battery warms. When the battery charges up, the rate will decrease at a

normal rate.

DEEPLY DISCHARGED LEAD-CALCIUM batteries will read out differently as they need an

activation procedure covered on page 10 of this manual.

SHORTED BATTERIES will read on the ammeter as a high end peg at the beginning of the

charging process. If after 5-10 minutes the needle does not move off of the high end, the

battery probably has a short circuit. Unplug the charger and discontinue use. Have the battery

checked by a qualified technician.

Engine Starting

Note: This charger’s high-current output can help start vehicles with weak batteries. Please

note that some of the newer vehicles with onboard computers may be damaged from this

process. Thoroughly read the vehicle owner’s manual before using this procedure.

Connect the charger to the battery as discussed in the previous operating instructions

on page 7 and 8.

Set the charger to charge the battery for 5-10 minutes according to the appropriate

charge rate for the size of the battery as explained on the previous 2 pages.

Set the select function switch (See FIGURE 1 on page 6) to Start and the select switch

(see FIGURE 1 on page 6) to 55A.

Try to start the vehicle. If it doesn’t start in 2-3 minutes, stop and wait for the vehicle to

charge for 5-10 minutes more and try again. Repeat this process until successful.

Note: If the engine continues to spin but will not start after several tries, than you may have

another problem unrelated to charging. Stop attempting to start/charge the battery until

the problem is found and corrected. Continued engine cranking may damage the

vehicle’s starter motor.

SKU 03418

For technical questions, please call 1-800-444-3353.

Page 9

Operation (continued)