Chicago Electric 91045 Assembly And Operating Instructions Manual

Brand: Chicago Electric

Model: 91045

Type: Assembly And Operating Instructions Manual

JUMPSTJUMPST

JUMPST

ARAR

TER AND DCTER AND DC

TER AND DC

POWER SOURCEPOWER SOURCE

POWER SOURCE

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 MISSION OAKS BLVD., CAMARILLO, CA 93011

VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM

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

91045

Page 2SKU 91045

SPECIFICATIONS

Item Description

Power Output 12 VDC, 300 amps (cranking); 700 amps (peak)

Battery Type 12 VDC, 12 AH, sealed acid battery; UL listed

Charging Internal

Battery

Charges using a 120 VAC power cord and

internal power supply

Battery Cables # 8 AWG, 18 inches; 200 amp, copper plated

cable clamps

LED Indicators Red = less than 50% charge; also on while

charging; Yellow = 50% to 75% charge; Green =

full charge;

Overall Dimensions 6-1/2 (W) x 7-3/4 (L) x 8-7/8 (H) inches

Accessories Power adapter cable enables powering of

devices using 12 VDC. DC socket has a 15 amp

overload circuit breaker (reset on back of unit)

Weight 12 lbs.

SAVE THIS MANUAL

You will need the manual for the safety warnings and precautions, assembly instructions,

operating and maintenance procedures, parts list and diagram. Keep your invoice with this

manual. Write the invoice number on the inside of the front cover. Keep the manual and

invoice in a safe and dry place for future reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instruc-

tions listed below may result in electric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

Work Area

1. Keep your work area clean and well lit. Cluttered benches and dark areas invite

accidents.

2. Do not operate Jumpstarter 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 the Jumpstarter.

Distractions can cause you to lose control.

Page 3SKU 91045

Electrical Safety

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. Do not expose power tools to rain or wet conditions. Water entering a power tool will

increase the risk of electric shock.

6. Grounded tools must be plugged into an outlet properly installed and grounded in

accordance with all codes and ordinances. Never remove the grounding prong or

modify the plug in any way. Do not use any adapter plugs. Check with a qualified

electrician if you are in doubt as to whether the outlet is properly grounded. If the

tools should electrically malfunction or break down, grounding provides a low

resistance path to carry electricity away from the user.

7. Double insulated tools are equipped with a polarized plug (one blade is wider than the

other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully

in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to

install a polarized outlet. Do not change the plug in any way. Double insulation

eliminates the need for the three wire grounded power cord and grounded power

supply system.

8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull the

Plug from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or

moving parts. Replace damaged Power Cords immediately. Damaged Power Cords

increase the risk of electric shock.

9. When operating a power tool outside, use an outdoor extension cord marked “W-A” or

“W”. These extension cords are rated for outdoor use, and reduce the risk of electric

shock.

Personal Safety

10. Stay alert. Watch what you are doing, and use common sense when operating this

product. Do not use 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.

11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your

hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair

can be caught in moving parts.

12. Do not overreach. Keep proper footing and balance at all times. Proper footing and

balance enables better control of the product in unexpected situations.

13. Use safety equipment. Always wear eye protection. A dust mask, non-skid safety

shoes, hard hat, or hearing protection must be used for all appropriate conditions.

Page 4SKU 91045

Tool Use and Care

14. Disconnect the Power Cord Plug from the power source before making any

adjustments, changing accessories, or storing the product.

15. Store this product out of reach of children and other untrained persons. Tools are

dangerous in the hands of untrained users.

16. Use only accessories that are recommended by the manufacturer for your model.

Accessories that may be suitable for one tool may become hazardous when used on

another tool.

Service

17. Service for this product must be performed only by qualified repair personnel. Service

or maintenance performed by unqualified personnel could result in a risk of injury.

18. When servicing a tool, use only identical replacement parts. Follow instructions in the

“Inspection, Maintenance, And Cleaning”

section of this manual. Use of unauthorized

parts or failure to follow maintenance instructions may create a risk of electric shock

or injury.

SPECIFIC SAFETY RULES FOR THE JUMPSTARTER

1. Maintain labels and nameplates on the Jumpstarter. These carry important

information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

2. Always wear safety impact eye goggles and heavy work gloves when working on or

around lead-acid batteries. Using personal safety devices reduce the risk for injury.

Safety impact eye goggles and heavy work gloves are available from Harbor Freight

Tools.

3. 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 a power tool in areas near flammable

chemicals, dusts, and vapors. Do not use this product in a damp or wet location.

4. Always unplug the Jumpstarter from its electrical outlet before performing any

inspection, maintenance, or cleaning procedures.

5. Avoid contact with Battery Acid. If splashed, immediately wash effected area with

clean water. Continue washing area until medical help arrives.

6. Turn vehicle ignition off before making cable connections.

7. Connect cables to proper polarities. Connect the red cable to the positive battery

terminal, and the black cable to an unpainted negative body ground (for a negative

grounded system).

8. Keep clear of fan blades, belts, pulleys, and other moving parts of the engine that may

cause injury, or damage to the Jumpstarter.

Page 5SKU 91045

9. Use Jumpstarter in well ventilated areas. Do not attempt to jump start vehicle around

flammable gases or liquids.

10. Do not allow the Black and Red clamps to touch. If this happens it can melt clamps or

other metal objects. Place them only on the corresponding battery terminals and

ground. When finished jumpstarting the engine, immediately secure each clamp to the

plastic grips on the back of the unit.

11. Use only with vehicles and boats with 12 volt electrical systems.

12. Jumpstarter for emergency use only. Only use to jump start your vehicle. Do not use

this system in the place of a vehicle battery.

13. Never leave the vehicle unattended while jumpstarting the engine. Remove the keys

from the vehicle.

14. Keep extension cord off the ground and away from water when recharging the unit.

15. Always connect the Line Cord to a Ground Fault Circuit Interrupter (GFCI) protected

electrical outlet.

16. Do not attempt to jump start a vehicle while recharging the unit’s internal battery.

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.)

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 FOR POWERING AN APPLIANCE

1. Before using this tool to power an appliance or electrical device make sure the appliance/

electrical device uses 12VDC power.

2. Never attempt to power an external appliance or electrical device while also attempting

to jump start a vehicle engine.

3. When not powering an appliance, remove the appliance vehicle adapter cord from the

Jumpstarter Accessory Socket and store it.

BATTERY PRECAUTIONS

1. Read all instructions and warnings on the Jumpstarter before charging it’s battery.

2. To avoid accidents, charge the supplied internal battery only. Do not replace with a

different type of battery.

3. Do not expose the battery to rain or wet conditions.

4. To avoid damage of cable and plug, never pull the cable to disconnect the

Jumpstarter.

5. Do not use the Jumpstarter if the cables or plugs are damaged.

(1)

Page 6SKU 91045

6. Repairs should be carried out by a qualified technician.

7. Do not touch the battery poles with any conductive source.

8. If the internal battery is removed, do not store the battery in a box with other metal

objects.

9. Do not throw the battery in a fire or in the general trash. Contact your local hazardous

waste disposal authority for proper disposal.

10. Do not drain the battery completely before recharging. Recharge fully.

11. Always recharge the internal battery (6) when Jumpstarter performance begins to

diminish. Severe heat is most destructive to a battery; the more heat generated, the

faster the battery loses power. A battery that gets too hot can be permanently

damaged. Never over-discharge a battery by using the Jumpstarter to the point of

complete discharge. When the Jumpstarter performance begins to diminish, stop

using it and recharge the battery for optimal performance.

12. Recharge the battery monthly even if not used.

GROUNDING

Note: This product comes with a two-prong, polarized plug.

WARNING!

Improperly connecting the grounding wire can result in the risk of electric

shock. Check with a qualfified 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.

Double Insulated Tools: Tools with Two Prong Plugs

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 Laboratories, Inc., the Canadian Standard Association, and the

National Electrical Code. (See illustration below.)

Double insulated tools may be used in either of the 120 volt outlets shown in the following

illustrations.

Page 7SKU 91045

EXTENSION CORDS

Grounded

tools require a three wire extension cord.

Double Insulated

tools can use

either a two or three wire extension cord.

2. As the distance from the supply outlet increases, you must use a heavier gauge

extension cord. Using extension cords with inadequately sized wire causes a serious

drop in voltage, resulting in loss of power and possible tool damage. (See Table

below.)

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.

4. When using more than one extension cord to make up the total length, make sure

each cord contains at least the minimum wire size required.

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.

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.

7. Make sure your extension cord is properly wired and in good electrical condition.

Always replace a damaged extension cord or have it repaired by a qualified electrician

before using it.

8. Protect your extension cords from sharp objects, excessive heat, and damp or wet

areas.

RECOMMENDED MINIMUM WIRE GAUGE FOR 120 VAC EXTENSION CORDS*

NAMEPLATE

AMPERES

(At Full Load)

EXTENSION CORD LENGTH

Feet

100

Feet

150

Feet

0 – 2.0 18 18 18 18 16

2.1 – 3.4 18 18 18 16 14

3.5 – 5.0 18 18 16 14 12

5.1 – 7.0 18 16 14 12 12

7.1 – 12.0 18 14 12 10 -

12.1 – 16.0 14 12 10 - -

16.1 – 20.0 12 10 - - -

* Based on limiting the line voltage drop to five volts at 150% of the rated amperes.

Page 8SKU 91045

SYMBOLOGY

UNPACKING

When unpacking, check to make sure that all the parts are included. Refer to the Assembly

section, and the Assembly Drawing and Parts List at the end of this manual.

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.

Charging Line Cord (5)

Accessory

Power

Cord (20)

Jumpstarter Unit

Page 9SKU 91045

OPERATING INSTRUCTIONS

Controls and Indicators

Item Description

Red Button Press to check (internal) battery status. Lights LEDs.

Red LED Indicators Indicates (internal) battery has 50% or less charge. Recharge

required. Charging LED lights when recharging.

Yellow LED Indicator Indicates (internal) battery has 50% to 75% charge. Usable,

but recharge.

Green LED Indicators Indicates (internal) battery fully charged.

Lights when charging is complete.

Reset Button Press to reset when accessory appliance pulls more than 15

amps current. Located on back of unit.

Charging the Internal Battery

Recharge the internal Battery (6) when new, after each use, and every three months

whether used or not.

1. Set the Jumpstarter upright in a well ventilated area, away from combustible materials.

2. Plug the Charging Line Cord (5) into the side of the Jumpstarter.

(See photo at right.)

3. Insert the Charging Line Cord plug into an electrical outlet or

proper extension cord.

The red LED will be lit during charging. When fully charged, the

green LED will light, and the red LED will go out.

The charger will automatically go into a “float charge” mode, and continue while

connected to the electrical outlet.

4. Unplug the Charging Line Cord (5) from the electrical outlet or extension cord and the

Jumpstarter.

5. Store the Charging Line Cord in the Jumpstarter box.

6. Press the Status Test Button (15) to verify that the internal Battery (6) is fully charged.

Status Test Button (15)

Status LEDs

Charging LED

Charged LED

REV 09/04

Page 10SKU 91045

Jumpstarting an Engine

1. Turn the engine ignition key to Off position.

2. Place the Jumpstarter on a stable surface near the engine battery, and away from

moving engine parts.

Caution: Do not touch the Jumpstarter red cable clamp to the black cable clamp. This

short circuits the Jumpstarter and may damage the internal Battery (6).

3. Connect the red (+) cable clamp to the positive terminal of the engine battery. Move

the clamp so that it digs into the terminal for a good connection.

4. Connect the black (–) cable clamp to the engine or unpainted chassis surface.

Do not connect to an engine part that will turn or move when the engine is

started.

Do not connect to the negative battery terminal.

5. Turn the engine ignition key to the On position and crank the engine.

If the engine does not immediately start, wait three minutes and try again.

6. After the engine starts, first remove the black (–) cable clamp from the engine battery

and secure it to the plastic tab on the back of the Jumpstarter. Do the same for the

red (+) cable clamp.

7. Recharge the Jumpstarter as described on the previous page.

8. Place the Jumpstarter (upright) in its factory box and store in a clean, dry, and cool

environment.

Using the Jumpstarter to Power an Appliance

The Jumpstarter can be used to power any appliance (up to around 80

watts) that uses 12 VDC as its power source.

1. Plug the appliance vehicle adapter cord (cigarette lighter plug) into

the Jumpstarter Accessory Socket (4).

Turn on the appliance. A four watt appliance will operate about 20

hours. An 80 watt appliance will operate for about one hour. After

use, check the internal Battery (6) status. Recharge if necessary.

2. Optionally, use the supplied Accessory Power Cord (20) to power

electronic devices that use 12 VDC as its power source.

(Example: Lap Top Computers, electronic keyboards, electric

shavers) (See photo at right.)

3. When finished, remove the appliance adapter cord and store the Jumpstarter.

(20)

(4)

Page 11SKU 91045

INSPECTION, MAINTENANCE, AND CLEANING

WARNING! Make sure the Charging Line Cord is unplugged from its electrical outlet

before performing any inspection, maintenance, or cleaning procedures.

1. Before each use, inspect the general condition of the Jumpstarter. 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. If

abnormal noise or vibration occurs, have the problem corrected before further use. Do

not use damaged equipment.

2. After the internal Battery (6) in the Jumpstarter has expired, it should be recycled.

Some States require this recycling. Contact your local solid waste authority for

recycling information. Battery replacement should only be done by a qualified

technician.

Warning: Do not dispose of battery by fire. This could result in an explosion. Before

disposing of battery, cover exposed terminals with heavy duty electrical tape to

prevent shorting. Do not expose battery to intense heat or fire as this could cause

an explosion.

4. Store the Jumpstarter in a clean and dry location at room temperature.

5. Clean cable clamps after each use.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM 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 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.

Page 12SKU 91045

PARTS LIST

Part # Description Qty.

1 Case(front) 1

2 Accessory socket assy. 1

3 Accessory socket cap 1

4 Accessory socket block 1

5 Charging Line Cord 1

6 12V/12AH battery 1

7 Warning label 1

8 Case (rear) 1

9PCB 1

10 Circuit breaker 1

11 Handle 1

12 Charger 1

13 Charger fixed block 1

14 Clamp and cable assy 2

15 Status Test Button 1

16 Panel sticker 1

17 Sticker 1

18 Recharge indicator label 1

19 Screws (not shown) -

20 Accessory Power Cord 1

ASSEMBLY DRAWING

NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as re-

placement parts.

Chicago Electric 91045 Assembly And Operating Instructions Manual

Chicago Electric 91045 Assembly And Operating Instructions Manual

Chicago Electric 91045 Assembly And Operating Instructions Manual

Related papers

Other documents