Harbor Freight Tools Battery Charger 66783 User Manual

Battery Charger/starter  
66783  
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© 2009 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.  
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4. grOunding and aC pOWer COrd COnneCtiOn instruCtiOns -  
Charger should be grounded to reduce risk of electric shock. Charger is equipped  
with an electric cord having an equipment-grounding conductor and a grounding  
plug. The plug must be plugged into an outlet that is properly installed and  
grounded in accordance with all local codes and ordinances.  
danger - never alter aC cord or plug provided - if it will not fit outlet, have  
proper outlet installed by a qualified electrician. Improper connection can result in a  
risk of an electric shock.  
This battery charger is for use on a nominal 120-volt circuit, and has a grounding  
plug that looks like the plug illustrated in sketch A in Below Figure. A temporary  
adapter, which looks like the adapter illustrated in sketch B, may be used to  
connect this plug to a two-pole receptacle as shown in sketch B if a properly  
grounded outlet is not available. The temporary adapter should be used only until a  
properly grounded outlet can be installed by a qualified electrician.  
metal screw  
Cover of grounded  
Outlet Box  
grounding  
pin  
(a)  
(B)  
danger - Before using adapter as illustrated, be certain that center screw  
of outlet plate is grounded. The green-colored rigid ear or lug extending from  
adapter must be connected to a properly grounded outlet- make certain it is  
grounded. If necessary, replace original outlet cover plate screw with a longer  
screw that will secure adapter ear or lug to outlet cover plate and make ground  
connection to grounded outlet.  
5. Do not operate this charger with a damaged cord or plug – replace the cord or plug  
immediately.  
6. Do not operate charger if it has received a sharp blow, been dropped, or otherwise  
damaged in any way; take it to a qualified serviceman.  
7. Do not disassemble charger; take it to a qualified serviceman when service or  
repair is required. Incorrect reassembly may result in a risk of electric shock or  
fire.  
8. To reduce risk of electric shock, unplug charger from outlet before attempting any  
maintenance or cleaning.  
9. Warning - risK OF eXplOsiVe gases.  
a. Working in the vicinity of a lead-acid battery is dangerous. Batteries generate  
explosive gases during normal battery operation. For this reason, it is of utmost  
reV 09b  
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importance that each time before using your charger, you read this and follow the  
instructions exactly.  
b. To reduce the risk of the battery explosion, follow these instructions and those  
published by battery manufacturer and manufacturer of any equipment you intend  
to use in vicinity of battery. Review cautionary markings on these products and on  
engine.  
11. persOnal preCautiOns  
a. Someone should be within range of your voice, or close enough to come to your  
aid, when you work near a lead-acid battery.  
b. Have plenty of fresh water and soap nearby in case battery acid contacts skin,  
clothing, or eyes.  
c. Wear complete eye protection and clothing protection. Avoid touching eyes while  
working near battery.  
d. If battery acid contacts skin or clothing, wash immediately with soap and water. If  
acid enters eye, immediately flood with running cold water for at least 10 minutes  
and get medical attention immediately.  
e. NEVER smoke or allow a spark or flame in vicinity of battery or engine.  
f. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might  
spark or short-circuit battery or other electrical part that may cause an explosion.  
g. Remove personal metal items such as rings, bracelets, necklaces, and watches  
when working near a lead-acid battery. A lead-acid battery can produce a short-  
circuit current high enough to weld a ring or the like to metal, causing a severe  
burn.  
h. Use this charger for charging LEAD-ACID batteries only. It is not intended to  
supply power to a low voltage electrical system other than in an automotive  
application. Do not use battery charger for charging dry-cell batteries that are  
commonly used with home appliances. These batteries may burst and cause  
injury to persons and damage to property.  
i. NEVER charge a frozen battery.  
12. preparing tO Charge Battery  
a. If it becomes necessary to remove the battery from the vehicle to charge, always  
remove grounded terminal from battery first. Make sure all accessories in the  
vehicle are off, so as not to cause an arc.  
b. Be sure area around battery is well ventilated while battery is being charged.  
Gases can be forcefully blown away, by using a piece of cardboard or other non-  
metallic material such as a fan.  
c. Clean battery terminals. Be careful to keep corrosion from coming in contact with  
eyes.  
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d. Add distilled water in each cell until battery acid reaches level specified by battery  
manufacturer. This helps purge excessive gas from cells. Do not overfill. For a  
battery without cell caps, carefully follow manufacturer’s recharging instructions.  
e. Study all battery manufacturer’s specific precautions such as removing or not  
removing cell caps while charging and recommended rates of charge.  
f. Determinate voltage of battery by referring to car owner’s manual and make  
sure that output voltage selector switch is set at correct voltage. If charger has  
adjustable charge rate, charge battery initially at lowest rate.  
13. Charger lOCatiOn  
a. Locate charger as far away from battery as the DC cable permits.  
b. Never place charger directly above battery being charged; gases from battery will  
corrode and damage charger.  
c. Never allow battery acid to drip on charger when reading gravity or filling battery.  
d. Do not operate charger in a closed-in area or restrict ventilation in any way.  
e. Do not set a battery on top of charger.  
14. dC COnneCtiOn preCautiOns  
a. Connect and disconnect DC output clips only after removing AC cord from electric  
outlet. Never allow clips to touch each other.  
b. Attach clips to battery and chassis as indicated in 15 (e), 15 (f), 16 (b), and 16 (d).  
15. Follow these steps when battery is installed in vehicle. A spark near battery may  
cause battery explosion. To reduce risk of a spark near battery:  
a. Position AC and DC cords to reduce the risk of damage by hood, door, or moving  
engine parts.  
b. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to  
persons.  
c. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has  
larger diameter than NEGATIVE (NEG, N, -) post.  
d. Determine which battery post is grounded (connected) to the chassis. If negative  
post is grounded to chassis (as in most vehicles), see (e). If the positive post is  
grounded to the chassis, see (f).  
e. For negative-grounded vehicle, connect POSITIVE (RED) clip from battery  
charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect  
NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do  
not connect clip to the carburetor, fuel lines, or sheet-metal body parts. Connect  
to a heavy gauge metal part of the frame or engine block.  
f. For positive-grounded vehicle, only connect NEGATIVE (BLACK) clip from  
battery charger to NEGATIVE (NEG, N, -) ungrounded post of battery. Connect  
POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Do not  
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connect clip to the carburetor, fuel lines, or sheet-metal body parts. Connect to a  
heavy gauge metal part of the frame or engine block.  
g. When disconnecting charger disconnect AC cord, remove clip from vehicle  
chassis, and then remove clip from battery terminal.  
h. See operating instructions for length of charge information.  
16. Follow these steps when battery is outside vehicle. A spark near battery may cause  
battery explosion. To reduce risk of a spark near battery:  
a. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has  
larger diameter than NEGATIVE (NEG, N, -) post.  
b. Attach at least a 24 inch long 6 gauge (AWG) insulated battery cable to  
NEGATIVE (NEG, N, -) battery post.  
c. Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.  
d. Position yourself and free end of cable as far away from battery as possible- then  
connect NEGATIVE (BLACK) charger clip to free end of the cable.  
e. Do not face battery when making final connection.  
f. When disconnecting charger, always do so in the reverse sequence of connecting  
procedure and break first connection while as far away from the battery as  
practical.  
g. A marine (boat) battery must be removed and charged on shore. To charge it on  
board requires equipment specially designed for marine use.  
saVe these instruCtiOns  
Specific Safety Rules for the Battery Charger  
1. Maintain labels and nameplates on the Battery Charger. 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  
using the Battery Charger. 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. Avoid unintentional starting. Make sure you are prepared to begin work before  
turning on the Battery Charger.  
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5.  
Always unplug the Battery Charger from its electrical outlet before  
connecting its cables to a battery, or performing and inspection,  
maintenance, or cleaning procedures.  
6. Keep extension cord off wet ground and away from water.  
7. Use this Battery Charger with lead/acid batteries only. When charging a  
maintenance-free battery, always monitor the progress of the charge by viewing  
the ammeter. Do not over charge a maintenance-free battery.  
8. Do not attempt to charge non-rechargeable or defective batteries.  
9. Keep connections and cable clamps clean and free from corrosion.  
10. Never simultaneously charge several batteries.  
11. Do not discard used batteries in the trash. Properly recycle according to local  
environmental codes.  
12. Warning: This product contains or, when used, produces 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.)  
13. Warning: People with pacemakers should consult their physician(s) before using  
this product. Electromagnetic fields in close proximity to a heart pacemaker could  
cause interference to or failure of the pacemaker.  
14. risk of explosion!  
• If you detect gas, do not adjust any switches. Do not disconnect the  
charging clamps. Immediately ventilate the room by opening windows and  
doors. Do not switch on an electrical fan. When the air has cleared of gas,  
unplug the unit from the electrical outlet.  
Charge the battery in a well-ventilated area.  
To prevent sparking due to electrostatic discharge, never wear clothes made of  
synthetic materials when charging the battery.  
• Avoid creating or working around any flames or sparks; flames or sparks can  
ignite the gasses caused by charging and cause an explosion.  
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 on the cover  
of this manual as soon as possible.  
SKU 66783  
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setup  
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 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 charge will cause the battery  
acid to boil and overcharge the battery causing damage to the battery. You  
must constantly monitor battery charging progress and if battery gets warm, stop  
charging it immediately.  
note: When charging a battery with a built-in hydrometer eye, do not depend on the  
hydrometer eye to determine the battery charge level.  
Warning! Use this charger only on flooded lead-acid batteries. Other batteries may  
be damaged or may overheat, leak, or catch fire.  
dO nOt plug this Charger in until direCted tO dO  
sO in the FOllOWing pages OF this manual.  
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of the battery. If charging a battery  
mounted in a vehicle, first remove the  
vehicle’s red cable from the battery;  
otherwise damage may occur to the  
vehicle’s electrical system. If in doubt,  
refer to the vehicle’s service manual.  
preparing the Battery  
1. If necessary, remove the battery  
from the vehicle to charge it. When  
removing the battery, disconnect the  
grounded battery cable first.  
reminder: Turn off vehicle’s engine  
before removing, replacing, or  
charging a battery.  
6. Connect the negative (black) Cable  
Clamp (2) to the negative terminal of  
the battery.  
2. 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  
7. Plug the Power Cord (3) into the  
electrical outlet.  
note: If the Red Reverse Connection  
LED is lit, the cables are connected  
to the wrong battery terminals. If this  
happens, immediately unplug the  
charger and switch the connections.  
charger, or in close proximity to the  
charger. Do not overfill.  
3. Clean battery terminals.  
8. For a quick charge assist to enable  
starting the engine, charge for 5 to 10  
minutes.  
4. 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.  
Warning! do not leave a battery  
unattended while charging.  
Charging Batteries  
9. For a full charge, leave the Battery  
Charger running. See below for a  
description of the charge modes.  
Caution: do not overcharge maintenance-  
free batteries.  
A. 12 V / 10 a Or 12 V / 2 a mOde:  
When the battery is fully  
1. Place the Battery Charger and  
battery in a well-ventilated area.  
charged, the Battery Charger will  
automatically go to standby and the  
green LED will remain lit.  
2. Determine the voltage of the battery  
from the battery labels.  
B. 6 V / 10 a mOde:  
3. Push the Select Setting switch to the  
desired battery voltage and mode.  
The Battery Charger will supply  
current to the battery at a constant  
rate. To prevent damage to  
the battery, it must be promptly  
disconnected when charging is  
complete.  
4. If charging a battery while in a  
vehicle, leave the hood open and do  
not leave the charger unattended.  
Separate the charger and battery as  
much as possible.  
note: Do not leave Battery Charger on for  
long duration without checking the  
distilled water level of the battery; do  
not allow distilled water to boil off.  
5. With the Battery Charger unplugged,  
connect the positive (red) Cable  
Clamp (2) to the positive terminal  
reV 09g; 09h  
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10. Disconnect charger and unplug the  
Power Cord (3) from the electrical  
outlet.  
use. Have the battery checked by a quali-  
fied technician.  
engine starting  
11. Disconnect the Cable Clamps from  
the battery.  
note: This charger’s high-current output  
can help start vehicles with weak  
batteries. some newer vehicles  
with onboard computers may  
ammeter readings  
The ammeter shows how much  
charging current is drawn from the  
be damaged from this process.  
Thoroughly read the vehicle owner’s  
manual before using this procedure.  
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.  
1. Connect the charger to the battery  
as discussed on pages 7 and 8, but  
leave the battery cables attached.  
2. 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.  
do not depend on reading the  
ammeter to approximate how long  
3. Set the select function switch to start  
and the select switch to 55a.  
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 monitor the battery’s charge.  
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.  
(See Figure 1 on page 6.)  
4. Try to start the vehicle. If it doesn’t  
start in 12 seconds, stop and allow  
the charger to rest for 4 minutes.  
After resting, it may be beneficial to  
charge the battery as explained in  
step 2 before attempting Repeat this  
process until successful.  
note: Cold batteries (at or below 32°  
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. Do not charge a frozen battery.  
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 vehicles  
starter.  
shOrted Batteries will read on the  
ammeter as a high end peg at the begin-  
ning 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  
reV 09b  
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maintenanCe  
Warning: unplug the Charger from its electrical outlet before performing any  
inspection, maintenance, or cleaning procedures.  
1. Before each use, inspect the general condition of the Battery Charger. Check for  
loose screws, cracked or broken parts, damaged electrical wiring, and any other  
condition that may affect its safe operation. If abnormal noise occurs, have the  
problem corrected before further use. Do not use damaged equipment.  
2. Periodically recheck all nuts, bolts, and screws for tightness.  
3. After each use, wipe down the Cable Clamps and apply a light grease.  
4. Store in a clean and dry location.  
parts list and assemBly diagram  
part  
description  
Q’ty  
1
2
3
Charger  
Clamps  
1
2
1
Power Cord  
1
3
2
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please read the FOllOWing CareFully  
WARRANTIES, EXPRESS OR IMPLIED,  
INCLUDING THE WARRANTIES OF  
MERCHANTABILITY AND FITNESS.  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS  
PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A  
REFERENCETOOLONLY. NEITHERTHE 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  
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  
STATES THATALLREPAIRSAND PARTS REPLACEMENTS of the complaint must accompany the  
SHOULD BE UNDERTAKEN BY CERTIFIEDAND LICENSED  
merchandise. If our inspection verifies  
TECHNICIANS AND NOT BY THE BUYER. THE BUYER  
the defect, we will either repair or replace  
the product at our election or we may  
elect to refund the purchase price if  
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.  
we cannot readily and quickly provide  
you with a replacement. We will return  
note: Some parts are listed and shown for  
repaired products at our expense, but if we  
illustration purposes only and are not  
determine there is no defect, or that the  
available individually as replacement  
parts.  
defect resulted from causes not within the  
scope of our warranty, then you must bear  
the cost of returning the product.  
limited 90 day Warranty  
This warranty gives you specific legal  
rights and you may also have other rights  
which vary from state to state.  
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  
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 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  
EXPRESSLY IN LIEU OF ALL OTHER  
3491 Mission Oaks Blvd. •  
PO Box 6009 • Camarillo, CA 93011 •  
(800) 444-3353  
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