Chicago Electric 65042 Set Up And Operating Instructions Manual

Brand: Chicago Electric

Model: 65042

Type: Set Up And Operating Instructions Manual

Chicago Electric 65042 is a high-frequency battery charger with 6 amp and 3-stage charging capabilities. You can use it to charge batteries in vehicles or other devices, as it comes with clamps for connecting to battery terminals and is suitable for outdoor use with an extension cord marked "W-A". The charger is equipped with safety features such as protection against sparks and reversed polarity, and it also has a built-in cooling fan to prevent overheating. Additionally, it has a compact design and a lightweight construction, making it portable and easy to use in various settings.

HIGH FREQUENCY

BATTERY CHARGER

3-STAGE / 6 AMP

65042

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.

2008 by Harbor Freight Tools

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.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 2

SAVE THIS MANUAL

Keep this manual for the safety warn-

ings and precautions, assembly, operating,

inspection, maintenance and cleaning pro-

cedures. Write the product’s serial number

in the back of the manual (or month and

year of purchase if product has no num-

ber). Keep this manual and the receipt in

a safe and dry place for future reference.

IMPORTANT SAFETY

INFORMATION

In this manual, on the labeling,

and all other information provid-

ed with this product:

This is the safety alert

symbol. It is used to alert

you to potential personal

injury hazards. Obey all

safety messages that

follow this symbol to avoid

possible injury or death.

DANGER indicates

a hazardous

situation which, if not

avoided, will result in death or

serious injury.

WARNING

indicates a

hazardous situation which, if

not avoided, could result in

death or serious injury.

CAUTION, used

with the safety

alert symbol, indicates a

hazardous situation which, if

not avoided, could result in

minor or moderate injury.

NOTICE is used to

address practices

not related to personal injury.

CAUTION, without

the safety alert

symbol, is used to address

practices not related to

personal injury.

General Safety Warnings

WARNING Read all safety

warnings and instructions.

Failure to follow the warnings and

instructions may result in electric

shock, re and/or serious injury.

Save all warnings and

instructions for future reference.

Work area safety1.

Keep work area clean and well lit. a.

Cluttered or dark areas invite acci-

dents.

Do not operate this product in b.

explosive atmospheres, such as in

the presence of ammable liquids,

gases or dust. This product can cre-

ate sparks which may ignite the dust

or fumes.

Keep children and bystanders c.

away while operating this product.

Distractions can cause you to lose

control.

Electrical safety2.

The Power Cord Plug must match a.

the outlet. Never modify the Plug

in any way. Unmodied plugs and

matching outlets will reduce risk of

electric shock.

Avoid body contact with grounded b.

surfaces such as pipes, radiators,

ranges and refrigerators. There is

SKU 65042 For technical questions, please call 1-800-444-3353. Page 3

an increased risk of electric shock if

your body is grounded.

Do not expose this product to rain c.

or wet conditions. Water entering

this product will increase the risk of

electric shock.

Do not abuse the Power Cord. d.

Never use the Cord for carrying,

pulling or unplugging this prod-

uct. Keep the Cord away from

heat, oil, sharp edges or moving

parts. Damaged or entangled cords

increase the risk of electric shock.

When operating this product out-e.

doors, use an extension cord suit-

able for outdoor use. Use of a cord

suitable for outdoor use reduces the

risk of electric shock.

If operating this product in a damp f.

location is unavoidable, use a

Ground Fault Circuit Interrupter

(GFCI) protected supply. Use of

a GFCI reduces the risk of electric

shock.

Personal safety3.

Stay alert, watch what you are do-a.

ing and use common sense when

using this product. Do not use this

product while you are tired or un-

der the inuence of drugs, alcohol

or medication. A moment of inatten-

tion while operating this product may

result in serious personal injury.

Do not overreach. Keep proper b.

footing and balance at all times.

This enables better control of the

power tool in unexpected situations.

Product use and care4.

Do not force this product. Use the a.

correct product for your applica-

tion. The correct product will do the

job better and safer at the rate for

which it was designed.

Disconnect this product from its b.

power source before making any

adjustments, changing accesso-

ries, or storing the product.

Store this product out of the reach c.

of children and do not allow per-

sons unfamiliar with this product

or these instructions to operate

the unit. Electrically powered prod-

ucts are dangerous in the hands of

untrained users.

Maintain this product. Check for d.

breakage of parts and any other

condition that may affect this

product’s operation. If damaged,

have the unit repaired before use.

Many accidents are caused by poorly

maintained products.

Use this product and its acces-e.

sories in accordance with these

instructions, taking into account

the working conditions and the

work to be performed. Use of this

product for operations different from

those intended could result in a haz-

ardous situation.

Service5.

Have your Battery Charger ser-a.

viced by a qualied repair person

using only identical replacement

parts. This will ensure that the safety

of the product is maintained.

Specic Safety Warnings

Maintain labels and nameplates on 1.

the Battery Charger. These carry

important safety information. If un-

readable or missing, contact Harbor

Freight Tools for a replacement.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 4

Wear ANSI-approved safety goggles 2.

during set up and use of the Battery

Charger.

Do not start a vehicle or turn on a 3.

device when connected to the Battery

Charger.

To begin charging a battery in a 4.

vehicle, verify that the ignition is off.

Connect the positive (RED with +)

Cable Clamp to the positive (+ or

P) terminal of the battery. Connect

the negative (BLACK with --) to an

unpainted, solid metal portion of the

vehicle. Do not connect to the carbu-

retor or fuel lines or to the negative

terminal of the battery.

CAUTION: Harbor Freight Tools is 5.

not responsible for any damage to

mobile units being charged with the

High Frequency Battery Charger.

Refer to the mobile unit manufactur-

er’s charging instructions for the unit.

Overcharging may damage the mo-

bile unit.

Charge in a well ventilated area. Ex-6.

plosive gases may be produced dur-

ing charging. Do not smoke, cause

sparks, or strike matches near the

battery when charging.

Always refer to the user manual of 7.

the battery and/or mobile unit for

charging instructions and precautions

prior to using the Battery Charger.

Do not leave the Battery Charger 8.

unattended when it is plugged into an

electrical outlet. Unplug the Power

Cord from its power source before

leaving.

Do not reverse the polarity of the 9.

Cable Clamps, mobile unit, or vehicle

battery.

This product is not a toy. Keep it out 10.

of reach of children.

People with pacemakers should 11.

consult their physician(s) before use.

Electromagnetic elds in close prox-

imity to heart pacemaker could cause

pacemaker interference or pacemak-

er failure. In addition, people with

pacemakers should:

• 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-

rupter (GFCI) should also be imple-

mented – it prevents sustained elec-

trical shock.

WARNING: Handling the Power Cord 12.

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.

(California Health & Safety Code §

25249.5, et seq.)

The warnings, precautions, and in-13.

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.

SAVE THESE

INSTRUCTIONS.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 5

DOUBLE INSULATED TOOLS:

TOOLS WITH TWO PRONG

PLUGS

Tools marked “Double Insulated” do 1.

not require grounding. They have

a special double insulation system

which satises 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.)

Double insulated tools may be used 2.

in either of the 120 volt outlets shown

in the preceding illustration. (See

Outlets for 2-Prong Plug.)

EXTENSION CORDS

Grounded1. tools require a three wire

extension cord. Double Insulated

tools can use either a two or three

wire extension cord.

As the distance from the supply outlet 2.

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.

(See Table A.)

The smaller the gauge number of the 3.

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.)

When using more than one exten-4.

sion cord to make up the total length,

make sure each cord contains at

least the minimum wire size required.

(See Table A.)

If you are using one extension cord 5.

for more than one tool, add the

nameplate amperes and use the sum

to determine the required minimum

cord size. (See Table A.)

If you are using an extension cord 6.

outdoors, make sure it is marked with

the sufx “W-A” (“W” in Canada) to

indicate it is acceptable for outdoor

use.

Make sure the extension cord is prop-7.

erly wired and in good electrical con-

dition. Always replace a damaged

extension cord or have it repaired by

a qualied electrician before using.

RECOMMENDED MINIMUM WIRE

GAUGE FOR EXTENSION CORDS*

(120 VOLT)

NAMEPLATE

AMPERES

(at full load)

EXTENSION CORD

LENGTH

25’

50’

75’

100’

150’

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 - - -

TABLE A

* Based on limiting the line

voltage drop to ve volts at

150% of the rated amperes.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 6

GROUNDING

TO PREVENT

ELECTRIC SHOCK

AND DEATH FROM

INCORRECT GROUNDING

WIRE CONNECTION:

Check with a qualied

electrician if you are in doubt

as to whether the outlet is

properly grounded. Do not

modify the Power Cord Plug

provided with the Battery

Charger. Do not use the

Battery Charger if the Power

Cord or Plug is damaged. If

damaged, have it repaired by

a service facility before use. If

the Plug will not t the outlet,

have a proper outlet installed

by a qualied electrician.

SYMBOLOGY

Double Insulated

Canadian Standards Association

Underwriters Laboratories, Inc.

Volts Alternating Current

Amperes

xxxx/min.

No Load Revolutions per Minute

(RPM)

PRODUCT SPECIFICATIONS

Product

Applications

Designed to charge most 6 volt DC and 12 volt

DC vehicle batteries. Also designed to charge

mobile units such as PSP’s, iPODS, MP3’s,

and cell phones.

Power Input

120 VAC / 60 Hz (Household Current)

12 VDC (Cigarette Lighter Receptacle)

Power

Output

6/12 VDC (Fast: 6 ADC / Slow: 2 ADC)

(USB Terminal: 5V/0.5A)

Power Cord

Plug Type

2-Prong, Polarized

Battery

Capacity

Maximum 120 Ah

Features

Automatic 3-Step Charging:

(Constant Current, Constant Voltage, Floating).

Overload & Polarity Reversal Protection.

5 LED Indicators for:

(Slow Charge, Fast Charge, 6V, 12V, USB).

Accessories

12 VDC Plug (Qty. 1)

Battery Cable Clamps (Qty. 2)

Plug Adapters (Qty. 8)

Fuse F3A250V

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.

OPERATING INSTRUCTIONS

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.

TO PREVENT

SERIOUS INJURY FROM ACCIDENTAL

OPERATION:

Unplug the Battery Charger from its

power source before performing any

inspection, maintenance, or cleaning

procedures.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 7

To Charge A 6 VDC or 12 VDC Vehicle

Battery Using 120 VAC Household Cur-

rent:

Remove the battery caps from the 1.

vehicle’s battery to allow any excess

gas to escape and prevent bursting of

the battery.

Check and top off the battery’s liquid.2.

Connect the Cable Clamp (7) wires to 3.

the Output Wire of the Battery Char-

ger. (See Figure A.)

When the battery being charged 4.

is in the vehicle, verify that the

ignition is off. Connect the positive

(RED with +) Cable Clamp (7) to the

positive (+ or P) terminal of the bat-

tery. Connect the negative (BLACK

with --) Cable Clamp (7) to an un-

painted, solid metal portion of the

vehicle. Do not connect to the carbu-

retor or fuel lines.

(See Figure A.)

After the Cable Clamps (7) are con-5.

nected, slightly rotate the clamps to

remove any dirt or oxidation layer to

ensure proper contact.

Plug the Power Cord (5) of the Bat-6.

tery Charger into the nearest 120

volt, grounded, electrical outlet.

(See Figure A.)

Press the Voltage Button on the Bat-7.

tery Charger which coincides with the

battery being charged.

Select either the “FAST” or “SLOW” 8.

charge rate on the Battery Charger.

Then press “ENTER” to start. The

L.E.D. Light will illuminate (without

twinkling) to indicate normal charging.

NOTE: This Battery Charger is suit-9.

able for 12 volt batteries (residual

voltage more than 8 volt) or 6 volt

batteries (residual voltage more than

4 volt). If the residual voltage is lower

than that listed above, the Battery

Charger will not output.

When the “FULL” L.E.D. light illumi-10.

nates, the battery is fully charged.

Once the battery is fully charged, 11.

disconnect the Power Cord (5) of the

Battery Charger from its electrical

outlet. (See Figure A.)

Disconnect the negative (BLACK 12.

with --) Cable Clamp (7) from its

unpainted, solid metal portion of the

vehicle. Then disconnect the positive

(RED with +) Cable Clamp (7) from

the positive (+ or P) terminal of the

battery.

Replace the battery caps on the bat-13.

tery.

To Charge A 6 VDC or 12 VDC Vehicle

Battery Using The 12 VDC Plug:

Follow the previous instructions. 1.

However, DO NOT use the 120 volt

Power Cord (5) of the Battery Char-

ger. Instead, plug the 12 VDC Plug

(11) into another vehicle’s cigarette

lighter receptacle for 12 VDC input

power. (See Figure A.)

To Charge A Mobile Unit Using The USB

Receptacle:

NOTE: For this application, either the 1.

120 VAC Power Cord (5) or the 12

VDC Plug (11) may be used as input

power.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 8

Select the proper Plug Adapter (10) 2.

for the mobile unit. Then connect

the Adapter to the Output Wire of the

Battery Charger. (See Figure A.)

Plug the Plug Adapter (10) into the 3.

mobile unit’s charging intake recep-

tacle. (See Figure A.)

IMPORTANT: Refer to the mobile 4.

unit manufacturer’s recommended

charge time for the unit. Do not

overcharge. Overcharging may

damage the mobile unit.

Once the mobile unit is fully charged, 5.

disconnect the 120 VAC Power Cord

(5), or 12 VDC Plug (11) from its

power source. (See Figure A.)

Disconnect the Plug Adapter (10) of 6.

the Battery Charger from the mobile

unit. (See Figure A.)

FIGURE A

12 VDC PLUG

(11)

120 VAC

POWER PLUG

(5)

OUTPUT

WIRE

CABLE CLAMPS

(7)

VEHICLE

BATTERY

OUTPUT

WIRE

PLUG

ADAPTER

(10)

MAINTENANCE AND

SERVICING

Procedures not specically

explained in this manual must

be performed only by a qualied

technician.

TO PREVENT

SERIOUS INJURY

FROM ACCIDENTAL

OPERATION OR PRODUCT

FAILURE:

Unplug the 120 VAC Power

Cord (5) or 12 VDC Plug (11)

from its electrical outlet before

performing any inspection,

maintenance, or cleaning

procedures.

Do not use damaged

equipment. If abnormal noise,

heat, or vibration occurs have

the problem corrected before

further use.

Inspection, Maintenance, and

Cleaning

BEFORE EACH USE, inspect the 1.

general condition of the Battery Char-

ger and its accessories. Check for

cracked or broken parts, damaged

electrical wiring, and any other condi-

tion that may affect its safe operation.

TO REPLACE THE FUSE: Unscrew 2.

and remove the Cap on the 12 VDC

Plug (11). Remove the old Fuse, and

replace with a new F3A 250V Fuse.

Then screw the Cap back onto the 12

VDC Plug. (See Figure A.)

AFTER USE,3. clean the surface of the

Battery Charger periodically with a

clean, soft cloth for best performance.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 9

TROUBLESHOOTING

Problem Possible Causes Possible Solutions

Battery Charger

will not charge.

No AC or DC power at power 1.

source.

AC or DC cord and/or plug 2.

not connected.

Cable clamps not properly 3.

connected.

Using improper plug adapter.4.

Battery residual voltage is 5.

less than 8 volts for 12 volt

battery or 4 volts for 6 volt

battery.

Check AC or DC power at power source.1.

Check that AC or DC cord and/or plug is 2.

plugged in.

Check that Cable clamps are properly 3.

connected.

Check that proper plug adapter is being 4.

used.

Make sure Battery residual voltage is 5. more

than 8 volts for 12 volt battery or 4 volts for 6

volt battery.

Follow all safety precautions whenever diagnosing or servicing this

product. 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.

Do not use solvents, acid, or alkali prod-

ucts.

WARNING! If the 120 VAC Power 4.

Cord (5) or 12 VDC Plug Cord is dam-

aged, it must be replaced only by

a qualied service technician.

SKU 65042 For technical questions, please call 1-800-444-3353. Page 10

PARTS LIST & ASSEMBLY DIAGRAM

Part # Description Part # Description

1 Top Cover 7 Cable Clamps

2 Transformer 8 Bottom Cover

3 VMOSFET 9 PCB Control

4 Electro Magnet 10 Plug Adapters

5 Power Cord 11 12 VDC Plug

6 USB Receptacle 12 Fuse (F3A 250V)

11 & 12

SKU 65042 For technical questions, please call 1-800-444-3353. Page 11

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 veries 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 specic 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.

Chicago Electric 65042 Set Up And Operating Instructions Manual

Chicago Electric 65042 Set Up And Operating Instructions Manual

Chicago Electric 65042 Set Up And Operating Instructions Manual

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