Harbor Freight Tools Battery Charger 93781 User Manual

AUTOMATIC  
BATTERY CHARGER  
93781  
ASSEMBLY & OPERATING INSTRUCTIONS  
Due to continuing improvements, actual product may differ slightly from the product described herein.  
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3491 Mission Oaks Blvd., Camarillo, CA 93011  
TO PREVENT SERIOUS INjURY,  
REAd ANd UNdERSTANd ALL WARNINGS  
ANd INSTRUCTIONS BEFORE USE.  
Copyright© 2005 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.  
For technical questions and replacement parts, please call 1-800-444-3353.  
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5.  
double insulated products 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.  
6.  
7.  
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.  
do not abuse the Power Cord. Never use the Power Cord to carry the Battery Charger  
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.  
8.  
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  
9.  
Stay alert. Watch what you are doing, and use common sense when operating the  
Battery Charger. do not operate the Battery Charger while tired or under the  
influence of drugs, alcohol, or medication.  
10.  
11.  
12.  
13.  
dress properly. do not wear loose clothing or jewelry. Contain long hair. Keep your  
hair and clothing away from the Battery Charger. Loose clothes, jewelry, or long hair can  
be caught in the Battery Charger, causing personal injury.  
Use safety equipment. Always wear eye protection during assembly, use, and mainte-  
nance.  
TOOL USE ANd CARE  
do not overload the Battery Charger. Use the correct Battery Charger for your  
application. The Battery Charger will do the job better and safer at the speed and capacity  
for which it is designed.  
disconnect the Power Cord Plug from the power source before making any  
adjustments, changing accessories, or storing the Battery Charger. Such  
preventive safety measures reduce the risk of turning on the product accidentally.  
14.  
15.  
Store idle tools out of reach of children and other untrained persons. The Battery  
Charger is dangerous in the hands of untrained users.  
Maintain the Battery Charger with care. Do not use a damaged Battery Charger. Tag  
damaged Battery Charger “Do not use” until repaired.  
SERVICE  
16.  
Battery Charger service must be performed only by qualified repair personnel.  
Service or maintenance performed by unqualified personnel could result in a risk of injury.  
SKU 93781  
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SERVICE (Cont’d)  
17.  
When servicing the Battery Charger, use only identical replacement parts. Use of  
unauthorized parts or failure to follow maintenance instructions may create a risk of electric  
shock or injury.  
18.  
19.  
Always unplug the Battery Charger from its electrical outlet before performing any  
inspection, maintenance, or cleaning procedures.  
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.  
20.  
do not expose the Battery Charger equipment to rain or wet conditions. Water  
entering electrically powered equipment will increase the risk of electric shock.  
GROUNdING  
WARNING!  
Improperly connecting the grounding wire can result in the risk of electric shock. 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 Battery Charger. Never remove the  
grounding prong from the plug. 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 fit  
the outlet, have a proper outlet installed by a qualified electrician.  
GROUNdEd TOOLS:TOOLS WITH THREE PRONG PLUGS  
1.  
2.  
3.  
Tools marked with “Grounding Required” have a three wire cord and three prong grounding  
plug. The plug must be connected to a properly grounded outlet. If the Battery Charger  
should electrically malfunction or break down, grounding provides a low resistance path to  
carry electricity away from the user, reducing the risk of electric shock. (See Figure A.)  
The grounding prong in the plug is connected through the green wire inside the cord to the  
grounding system in the tool. The green wire in the cord must be the only wire connected to  
the Battery Charger’s grounding system and must never be attached to an electrically “live”  
terminal.  
(See Figure A.)  
A grounded appliance 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 following illustration. (See Figure A.)  
Figure A  
SKU 93781  
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dOUBLE INSULATEd APPLIANCES: APPLIANCES WITH TWO PRONG PLUGS  
Note: The Battery Charger has a Two Prong Plug.  
1.  
2.  
Appliances marked “Double Insulateddo 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 Figure B.)  
Double insulated tools may be used in either of the 120 volt outlets shown in the following  
illustration. (See Figure B.)  
Figure B  
EXTENSION CORdS  
1.  
2.  
Grounded appliances require a three wire extension cord. Double Insulated products can  
use either a two or three wire extension cord.  
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 Figure C, next page.)  
3.  
4.  
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 Figure C.)  
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. (See Figure C.)  
5.  
6.  
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 Figure C.)  
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.  
8.  
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.  
Protect your extension cords from sharp objects, excessive heat, and damp or wet areas.  
SKU 93781  
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RECOMMENdEd MINIMUM WIRE GAUGE FOR EXTENSION CORdS*  
EXTENSION CORd LENGTH  
NAMEPLATE  
AMPERES  
(At Full Load)  
25 Feet  
18  
50 Feet  
18  
75 Feet  
18  
100 Feet  
150 Feet  
0 - 2.0  
2.1 - 3.4  
3.5 - 5.0  
5.1 - 7.0  
18  
16  
14  
12  
16  
14  
12  
12  
18  
18  
18  
18  
18  
16  
18  
16  
14  
Specific Safety Rules for the Battery Charger  
1.  
2.  
3.  
1.  
Maintain labels and nameplates on the Battery Charger. These carry important  
information. If the labels are unreadable or missing, contact Harbor Freight Tools for  
replacement.  
Always place the Battery Charger on a dry, flat, level, sturdy nonflammable work  
surface capable of supporting the weight of the Battery Charger. Make sure to place  
the Battery Charger in a location that is out of reach of children.  
The Battery Charger is not a toy and should not be used by children.  
WARNING! Risk of explosive gases:  
Working in the vicinity of lead-acid batteries is dangerous. Batteries generate  
explosive gases during normal battery operation. For this reason, it is of utmost  
importance that each time before using this Battery Charger you read and under-  
stand all safety warnings and precautions as outlined in this manual and those  
manuals published by the battery and vehicle manufacturers and manufacturers  
of any equipment you intend to use in the vicinity of the battery.  
Personal Precautions:  
1.  
2.  
ALWAYS wear ANSI approved safety impact eye goggles when working with lead-acid  
batteries.  
Make sure someone is within range of your voice and close enough to come to  
your aid when you work near a lead-acid battery.  
SKU 93781  
For technical questions please call 1-800-444-3353.  
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3.  
Keep plenty of fresh water and soap nearby in case battery acid contacts skin,  
clothing, or eyes. Avoid touching eyes while working near a lead-acid battery. If battery  
acid contacts skin or clothing, wash immediately with soap and water. If acid enters the  
eyes, immediately flood eyes with running cold water for at least 10 minutes and get medical  
attention immediately.  
4.  
5.  
NEVER smoke or allow a spark or flame in the vicinity of a lead-acid battery or vehicle  
engine.  
Use caution to reduce the risk of dropping a metal tool onto a lead-acid battery. The  
tool may spark or short circuit the battery or other electrical part that may cause an  
explosion.  
6.  
7.  
Remove personal metal items such as rings, bracelets, necklaces, and watches when  
working with a lead-acid battery. A lead-acid battery can produce a short circuit current  
high enough to weld a ring or other metal item, causing a severe burn.  
Use the Battery Charger for charging lead-acid batteries only. This Battery Charger is  
not intended to supply power to a low voltage electrical system other than in a starter motor  
application. Do not use this Battery Charger for charging dry-cell batteries. Dry-cell  
batteries may burst and cause serious personal injury and/or property damage. NEVER  
charge a frozen battery.  
Preparing To Charge:  
1.  
2.  
If it is necessary to remove the battery from a vehicle to charge, always remove the  
grounded terminal from the battery first. Make sure all accessories in the vehicle are off,  
so as not to cause an arc.  
Make sure the area around the battery is well ventilated while the battery is being  
charged.  
3.  
4.  
Clean the battery terminals prior to charging the battery.  
Add distilled water in each cell until the battery acid reaches the level specified by the  
battery manufacturer. This helps purge excessive gas from the cells. Do not overfill. For  
a battery without cell caps, carefully follow the battery manufacturer’s recharging instruc  
tions.  
5.  
determine the voltage of the battery by referring to the vehicle owner’s manual, con-  
firm it is 12 volt.  
Charger Location:  
1.  
2.  
3.  
Always locate the Battery Charger as far away from the battery as the Charger’s dC  
cables permit.  
Never place the Battery Charger directly above the battery being charged. Gases from  
the battery will corrode and damage the Battery Charger.  
Never allow battery acid to drip on the Battery Charger.  
SKU 93781  
For technical questions please call 1-800-444-3353.  
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4.  
5.  
do not operate the Battery Charger in a closed-in area, or restrict ventilation in any  
way.  
do not set a battery on top of the Battery Charger.  
DC Connection Precautions:  
1.  
Connect and disconnect dC output clamps only after removing the AC power cord  
from the electrical outlet.  
2.  
3.  
Never allow the dC output clamps to touch each other.  
Attach the dC output clamps to the battery posts and twist or rock the clamps back  
and forth several times to make a good connection. This helps keep the clamps from  
slipping off the terminals, and helps to reduce the risk of sparking.  
To Reduce Risk Of Sparking - When The Battery Is In The Vehicle:  
1.  
2.  
3.  
4.  
Carefully position the AC input and dC output cords to reduce the risk of damage by  
hood, door, or moving engine parts.  
Stay clear of fan blades, belts, pulleys, and other moving parts that can cause  
personal injury and/or property damage.  
Check the polarity of the battery posts. A POSITIVE (+) battery post usually has a  
larger diameter than a NEGATIVE (–) battery post.  
To reduce explosion risk, never connect both Battery Charger dC output clamps  
directly to the battery.  
Symbology  
SKU 93781  
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WARNING! The warnings, precautions, and instructions discussed in this manual cannot  
cover all possible conditions and situations that may occur. The operator must understand  
that common sense and caution are factors which cannot be built into this product, but  
must be supplied by the operator.  
Unpacking  
When unpacking the Automatic Battery Charger, check to make sure parts on page 11 are included.  
If any parts are missing or broken, please call HARBOR FREIGHT TOOLS at 1-800-444-3353.  
Operation  
1. determine which post of the battery is grounded (connected) to the chassis  
of the  
vehicle.  
If the NEGATIVE (–) post is grounded to the chassis (as in most vehicles), attach the  
POSITIVE (+) DC output clamp to the POSITIVE (+) battery post and connect the NEGATIVE  
(–) DC output clamp to a clean, thick, metal area on the vehicle chassis or engine block away  
from the battery. Do not connect the NEGATIVE (–) DC output clamp to the carburetor, fuel  
lines, or thin sheet metal body parts.  
If the POSITIVE (+) post is grounded to the chassis, attach the NEGATIVE (–) DC output clamp  
to the NEGATIVE (–) battery post and connect the POSITIVE (+) DC output clamp to a clean,  
thick, metal area on the vehicle chassis or engine block away from the battery. Do not connect  
the POSITIVE (+) DC output clamp to the carburetor, fuel lines, or thin sheet metal body parts.  
2. When disconnecting the Battery Charge from the battery, turn all switches of the  
Battery Charger to their “OFF” position. Unplug the AC input power cord from its  
electrical outlet. Remove the DC output clamp from the vehicle chassis. Then, remove the  
DC output clamp from the battery.  
To Reduce Risk Of Sparking - When The Battery Is Outside The Vehicle:  
1. Check the polarity of the battery posts. A POSITIVE (+) battery post usually has a  
larger diameter than a NEGATIVE (–) battery post.  
2. Attach at least a 24 inch long, 6 gauge (AWG), insulated battery cable to the  
NEGATIVE (–) battery post-see Figure A below.  
3. Connect the POSITIVE (+) dC output clamp to the POSITIVE (+) post of the battery.  
4. Position yourself and the free end of the 24 inch long, 6 gauge (AWG), insulated  
battery cable as far away from the battery as possible. Connect the NEGATIVE (–) DC  
output clamp to the free end of the cable. Do not face the battery when making this final  
connection. (See Figure A.)  
POSITIVE (+)  
NEGATIVE (--)  
dC OUTPUT CLAMP  
dC OUTPUT CLAMP  
24 INCH, 6 GAUGE BATTERY CABLE  
FIGURE A  
(NOT INCLUdEd)  
SKU 93781  
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Note: The monitoring voltage of the Battery Charger is 10.5V; if the voltage is below 10.5V, the  
Battery Charger will not work. A battery must be properly connected to the charger to  
allow it to work. For best results, the capacity of the battery should be below 24 Ah.  
Operation (cont’d)  
1.  
2.  
Place the Battery Charger on a stable, flat surface.  
Connect the Red Charging Clamp (15) to the positive (+) terminal of the battery (if the  
Negative [–] post is grounded to the chassis, as in most vehicles) -refer to specific guidelines  
on page 9.  
3.  
4.  
5.  
Connect the Black Charging Clamp (15) to the appropriate site, depending on the specific  
usage as outlined on page 9.  
Plug the Input Power Cord (14) into the nearest 115V, grounded, electrical outlet. The  
Charging Indication Light (B) will go on when the battery is charging-see below.  
If the Reverse Polarity Indication Light (A) goes on, it indicates that an incorrect  
hookup has occurred/connections are reversed (refer to the clamping instructions on  
page 9)- see below.  
The green Full Charge Indication Light (C) signals that the battery is fully charged.  
The Battery Charger will put out a trickle charge to maintain the existing charge on the  
battery -see below.  
3
4
5
Reverse  
Polarity  
(3)  
Full Charge  
Indication  
Light (5)  
Charging Indication  
Light (4)  
6.  
7.  
Leave the Automatic Battery Charger plugged in to the nearest outlet and attached to the  
battery until the battery is to be used. Then unplug and remove the Battery Charger.  
disconnect the Charging Clamps (15) in the following order: Remove the Charging  
Clamp (15) from the chassis, then remove the dC output clamp from the battery. (Refer  
to guidelines on page 9.)  
8.  
The Battery Charger has two Storage Posts (7) on the side opposite the LED lights. Wrap all  
cords around the two Posts (7).  
SKU 93781  
For technical questions please call 1-800-444-3353.  
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Inspection, Maintenance and Cleaning  
1. Before each use inspect the general condition of the Battery Charger. Check for cracked or  
broken parts, damaged power cords, clamps, and any other condition that may affect the safe  
operation of the Battery Charger.  
2. With a dry cloth, remove any oil and residue from the Battery Charger after each use. Do not  
clean with flammable or corrosive liquids.  
3. Store in a secure, safe and dry location. Store in a location that can be locked and that is out of  
the reach of children.  
SKU 93781  
For technical questions please call 1-800-444-3353.  
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Parts List  
Quantity Part #  
Part #  
description  
description  
Quantity  
1
2
3
4
5
6
7
8
9
Front Housing Cover 1  
Back Housing Cover 1  
11  
12  
13  
Transformer  
1
1
Main Circuit Board  
Indication Light  
Circuit Board  
Input Power Cord  
Charging Clamp  
Tap Screw 2.5 X 10  
Tap Screw 3 X 12  
Handle Top Cover  
1
Handle Bottom Cover 1  
1
1
2
2
9
Handle Sleeve  
PVC Base  
Storage Posts  
Cable Clip 1  
Cable Clip 2  
1
1
2
1
1
14  
15  
16  
17  
Assembly diagram  
Note: Some parts are listed and shown for illustration purposes only and are not available  
individually as replacement parts.  
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.  
SKU 93781  
For technical questions please call 1-800-444-3353.  
Page 12  
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