Chicago Electric 65834 User Manual

BATTERY CHARGER  
WITH LCD DISPLAY  
65834  
SET uP AnD OPERATInG InSTRuCTIOnS  
®
Distributed exclusively by Harbor Freight Tools .  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Read this material before using this product.  
Failure to do so can result in serious injury.  
SAVE THIS mAnuAL.  
©
®
Copyright 2008 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.  
an increased risk of electric shock if  
your body is grounded.  
adjustments, changing accesso-  
ries, or storing the product.  
c.Do not expose this product to rain  
or wet conditions. Water entering  
this product will increase the risk of  
electric shock.  
c.Store this product out of the reach  
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.  
d.Do not abuse the Power Cord.  
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.  
d.maintain this product. Check for  
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.  
e.This product for use indoors only.  
f. If operating this product in a damp  
location is unavoidable, use a  
Ground Fault Circuit Interrupter  
(GFCI) protected supply. Use of  
a GFCI reduces the risk of electric  
shock.  
e.use this product and its acces-  
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.  
3. Personal safety  
a.Stay alert, watch what you are do-  
ing and use common sense when  
using this product. Do not use this  
product while you are tired or un-  
der the influence of drugs, alcohol  
or medication. A moment of inatten-  
tion while operating this product may  
result in serious personal injury.  
5. Service  
a.Have your Battery Charger ser-  
viced by a qualified repair person  
using only identical replacement  
parts. This will ensure that the safety  
of the product is maintained.  
b.Do not overreach. Keep proper  
footing and balance at all times.  
This enables better control of the  
power tool in unexpected situations.  
Specific Safety Warnings:  
1. Maintain labels and nameplates on  
the Battery Charger. These carry  
important safety information. If un-  
readable or missing, contact Harbor  
Freight Tools for a replacement.  
4. Product use and care  
a.Do not force this product. use the  
correct product for your applica-  
tion. The correct product will do the  
job better and safer at the rate for  
which it was designed.  
2. Wear ANSI-approved safety goggles  
during set up and use of the Battery  
Charger.  
b.Disconnect this product from its  
power source before making any  
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Page 3  
3. Do not start a vehicle or turn on a  
mobile unit when connected to the  
Battery Charger.  
• Avoid operating alone.  
• Do not use with power switch locked  
on.  
• Properly maintain and inspect to  
avoid electrical shock.  
4. When the battery is being charged in  
the 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  
• Any power cord must be properly  
grounded. Ground Fault Circuit Inter-  
rupter (GFCI) should also be imple-  
mented – it prevents sustained elec-  
trical shock.  
vehicle. Do not connect to the carbu- 12. WARNING: Handling the Power Cord  
retor or fuel lines.  
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.)  
5. Charge in a well ventilated area. Ex-  
plosive gases may be produced dur-  
ing charging. Do not smoke, cause  
sparks, or strike matches near the  
battery when charging.  
6. Always refer to the user manual of  
the battery for charging instructions  
and precautions prior to using the  
Battery Charger.  
13. The warnings, precautions, and in-  
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.  
7. Avoid unintentional starting. Prepare  
to begin work before turning on the  
unit.  
8. Do not leave the Battery Charger  
unattended when it is plugged into an  
electrical outlet. Unplug the Power  
Cord from its power source before  
leaving.  
SAVE THESE  
InSTRuCTIOnS.  
9. Do not reverse the polarity of the  
Cable Clamps or vehicle battery.  
10. This product is not a toy. Keep it out  
of reach of children.  
11. People with pacemakers should  
consult their physician(s) before use.  
Electromagnetic fields in close prox-  
imity to heart pacemaker could cause  
pacemaker interference or pacemak-  
er failure. In addition, people with  
pacemakers should:  
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Page 4  
“live” terminal.  
(See 3-Prong Plug and Outlet.)  
GROunDInG  
TO PREVEnT  
ELECTRIC SHOCK  
AnD DEATH FROm  
InCORRECT GROunDInG  
WIRE COnnECTIOn:  
3. The tool 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  
preceding illustration.  
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. Do not use the  
(See 3-Prong Plug and Outlet.)  
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.  
3-PROnG PLuG & OuTLET  
ExTEnSIOn CORDS  
Grounded Tools. Tools with  
Three Prong Plugs:  
1. Grounded tools require a three wire  
extension cord.  
1. Tools marked with “Grounding Re-  
quired” have a three wire cord and  
three prong grounding plug. The  
plug must be connected to a properly  
grounded outlet. If the tool should  
electrically malfunction or break  
down, grounding provides a low re-  
sistance path to carry electricity away  
from the user, reducing the risk of  
electric shock.  
2. As the distance from the supply outlet  
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.)  
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. (See Table A.)  
(See 3-Prong Plug and Outlet.)  
2. The grounding prong in the plug is  
connected through the green wire in-  
side the cord to the grounding system  
in the tool. The green wire in the cord  
must be the only wire connected to  
the tool’s grounding system and must  
never be attached to an electrically  
4. When using more than one exten-  
sion cord to make up the total length,  
make sure each cord contains at  
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Page 5  
least the minimum wire size required.  
(See Table A.)  
PRODuCT SPECIFICATIOnS  
120 VAC / 60 Hz  
Power Cord: 18 AWG x 3C SVT  
Electrical  
Power Plug: 3-Prong, Non-Polarized  
Requirements  
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. (See Table A.)  
Output Voltage: 14.4VDC Maximum  
Output Current: 6 Amps Maximum  
6VDC or 12VDC Lead-Acid Batteries Only.  
(3Ah to 48Ah Charger Capacity)  
Indoor Use Only  
Product  
Applications  
Three Error Codes Display:  
“E01” = Wrong Polarity  
6. Make sure the extension cord is prop-  
erly wired and in good electrical con-  
dition. Always replace a damaged  
extension cord or have it repaired by  
a qualified electrician before using.  
“E02” = Disconnected During Charging  
“E03” = Damaged Battery or  
Not a 6V or 12V Battery  
Battery Status Display:  
Empty = No Battery/No Connection  
One Bar = Battery Connected  
Features  
Four Bars = Fully Charged  
Flashing Bars = Battery Charging  
4-Stage Charging Symbol Indicates  
2 Amp, 4 Amp, 6 Amp, or Auto  
Push Button Starts Charging  
Display Shows Charging Voltage  
RECOmmEnDED mInImum WIRE  
GAuGE FOR ExTEnSIOn CORDS*  
(120 VOLT)  
ExTEnSIOn CORD  
Accessories  
Battery Cable Clamps (Qty. 2)  
nAmEPLATE  
LEnGTH  
AmPERES  
(at full load)  
0 – 2.0  
2.1 – 3.4  
18  
18  
18  
18  
18  
14  
12  
18  
18  
18  
16  
14  
12  
10  
18  
18  
16  
14  
12  
10  
-
18  
16  
14  
12  
10  
-
16  
14  
12  
12  
-
unPACKInG  
3.5 – 5.0  
5.1 – 7.0  
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.  
7.1 – 12.0  
12.1 – 16.0  
16.1 – 20.0  
-
-
-
* Based on limiting the line  
voltage drop to five volts at  
150% of the rated amperes.  
TABLE A  
SYmBOLOGY  
OPERATInG InSTRuCTIOnS  
Double Insulated  
Read the EnTIRE ImPORTAnT  
SAFETY InFORmATIOn section  
at the beginning of this manual  
before set up or use of this  
product.  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
V~  
A
TO PREVEnT  
SERIOuS InJuRY FROm ACCIDEnTAL  
OPERATIOn:  
unplug the Battery Charger from its  
power source before performing any  
inspection, maintenance, or cleaning  
procedures.  
Amperes  
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
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Page 6  
4. Battery Selection: Press “6V or  
12V” for the battery type that is to be  
charged. (See Figure A.)  
Display Features:  
1. Power Switch: Press “ON/OFF”  
to start charging. Press “ON/OFF”  
again to stop charging.  
5. LCD Display of Battery: The LCD  
will indicate the battery type (6V or  
12V) that has been selected. (See  
Figure A.)  
(See Figure A.)  
2. Charging Rate Selection: Press  
“AMPS SELECTION” button to set  
charging current. (See Figure A.)  
6. LCD Display of Voltage: Before  
connecting the battery, the LCD will  
display “00.0V”. After connecting  
the battery, the LCD will display the  
battery voltage. During charging, the  
LCD will display the charging voltage.  
(See Figure A.)  
3. LCD Display of Charging Current:  
The LCD will indicate charging cur-  
rent (2 Amp, 4 Amp, 6 Amp, or Auto)  
that has been selected.  
(See Figure A.)  
BATTERY  
SELECTIOn  
CHARGInG  
SPEED  
SELECTIOn  
POSITIVE (+)  
BATTERY CLAmP  
nEGATIVE (--)  
BATTERY CLAmP  
POWER  
SWITCH  
LCD DISPLAY  
FEATuRInG:  
* CHARGInG CuRREnT  
*BATTERY TYPE  
*BATTERY STATuS  
*SOunD ALARm  
*VOLTAGE  
*ERROR SIGnAL  
FIGuRE A  
2. If battery is disconnected during  
charging, the LCD will display “E02”.  
(See Below.)  
Error Signals:  
1. Under improper polarity, the LCD will  
display “E01”. (See Below.)  
SKU 65834  
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Page 7  
3. If the battery is not 6 volt or 12 volt,  
or the battery is damaged, the LCD  
will display “E03”. (See Below.)  
4. If the battery is in the process of  
charging, the LCD will display the fol-  
lowing: (See Below.)  
Battery Status  
1. If the battery is not connected, the  
LCD will display the following:  
(See Below.)  
Sound Alarms:  
1. A continuous “beep” indicates wrong  
polarity, disconnection during charg-  
ing, wrong type of battery, dead or  
improper battery connection.  
2. If the battery is connected, the LCD  
will display the following:  
(See Below.)  
2. A short “beep” occurs each time a  
button is pressed.  
3. A short “beep” occurs when connect-  
ing or disconnecting the battery.  
The Charging Process:  
1. Remove the battery caps from the  
vehicle’s battery to allow any excess  
gas to escape and prevent bursting of  
the battery.  
3. If the battery is fully charged, the LCD  
will display the following:  
2. Check and top off the battery’s liquid.  
(See next illustration.)  
3. When the battery being charged is in  
the vehicle, verify that the ignition is  
off. Connect the positive  
(RED with +) Battery Clamp to the  
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Page 8  
positive (+ or P) terminal of the bat-  
tery. Connect the negative (BLACK  
with --) Battery Clamp to an unpaint-  
ed, solid metal portion of the vehicle.  
Do not connect to the carburetor or  
fuel lines.  
tery Charger will then turn to the next  
charging stage under constant volt-  
age.  
If “AUTO” is selected, the Battery  
Charger starts charging from 2 Amps  
until the charging voltage is raised up  
to 7.2V volts for a 6 volt battery (mo-  
torcycle) or up to 14.4V volts for a 12  
volt battery (automobile). The Battery  
Charger then turns to the next charg-  
ing stage (float charging).  
4. After the Battery Clamps are con-  
nected, slightly rotate the Clamps to  
remove any dirt or oxidation layer to  
ensure proper contact.  
5. Plug the Power Cord of the Battery  
Charger into the nearest 120 volt,  
grounded, electrical outlet.  
2. Constant voltage stage: The Battery  
Charger outputs a constant charging  
voltage of 7.2 volts for a 6 volt battery  
or 14.4 volts for a 12 volt battery. The  
charging current gradually decreases  
until it is less than 1 Amp and turns to  
the next floating charging stage.  
6. To select the charging speed: Press  
the “AMPS SELECTION” button for  
maximum charging current.  
(See Figure A and Below.)  
3. Floating charging stage: The battery  
is fully charged and ready to use.  
The LCD Display shows the battery  
signal which indicates the battery is  
fully charged. The Battery Charger  
outputs a constant safe voltage of 6.8  
volts for a 6 volt battery or 13.6 volts  
for a 12 volt battery for floating charg-  
ing.  
Recommended Charging Current  
Charging  
Current  
2 Amp  
4 Amp  
6 Amp  
Battery  
Capacity  
3 ~ 20 Ah  
6 ~ 36 Ah  
12 ~ 48 Ah  
7. To select the battery voltage: Press  
the “BATTERY SELECTION” button  
(either 6V or 12V). (See Figure A.)  
8. To start the charging process: Press  
the “ON/OFF” Power Switch. There  
is a short “beep” sound to indicate the  
charging has started.  
Disconnecting the Battery  
Charger and Battery:  
(See Figure A.)  
1. Once the battery is fully charged, dis-  
connect the Power Cord of the Bat-  
tery Charger from its electrical outlet.  
The Charging Stages:  
2. Disconnect the negative (BLACK  
with --) Battery Clamp from its un-  
painted, solid metal portion of the  
vehicle. Then disconnect the positive  
(RED with +) Cable Clamp (7) from  
the positive (+ or P) terminal of the  
battery.  
1. The constant charging stage: Press  
the “ON/OFF” Power Switch. The  
Battery Charger will run under the  
charging current selected until the  
charging voltage is raised up to 7.2  
volts for a 6 volt battery or up to 14.4  
volts for a 12 volt battery. The Bat-  
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Page 9  
(RED with +) Battery Clamp from the  
positive (+ or P) terminal of the bat-  
tery.  
aclean, soft cloth for best perfor-  
mance. Do not use solvents, acid, or  
alkali products.  
3. Replace the battery caps on the bat- 4. WARnInG! If the Power Cord is  
tery.  
damaged, it must be replaced only  
by a qualified service technician.  
mAInTEnAnCE AnD  
PLEASE READ THE  
FOLLOWInG CAREFuLLY  
SERVICInG  
Procedures not specifically  
explained in this manual  
must be performed only by a  
qualified technician.  
THE MANUFACTURER AND/OR  
DISTRIBUTOR HAS PROVIDED THE  
PARTS LIST AND ASSEMBLY DIAGRAM  
IN THIS MANUAL AS A REFERENCE  
TOOL ONLY. NEITHER THE  
TO PREVEnT  
SERIOuS InJuRY  
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.  
FROm ACCIDEnTAL  
OPERATIOn OR PRODuCT  
FAILuRE:  
unplug the Power Cord 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  
1. BEFORE EACH USE, inspect the  
general condition of the Battery  
Charger and its accessories. Check  
for cracked or broken parts, damaged  
electrical wiring, and any other condi-  
tion that may affect its safe operation.  
3. AFTER USE, clean the surface of  
the Battery Charger periodically with  
SKU 65834  
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Page 10  
TROuBLESHOOTInG  
Problem  
Display  
Possible Causes  
Possible Solutions  
Battery Charger  
will not charge.  
1. Screen is not  
turned on.  
1. No AC power input.  
1. Check the plug and power source.  
The push buttons 1. Screen displays  
1. The battery is not connected. 1. Check the battery connections.  
do not work.  
00.0V.  
2. Screen displays  
E01.  
2. The polarity connection is  
wrong.  
2. Make sure the polarity is correct.  
There is a  
continuous  
“beep” sound.  
1. Screen displays  
E02.  
1. The battery is disconnected  
during charging.  
1. Check the battery connection. Then  
resume charging.  
2. Screen displays  
E03.  
2. The battery is not 6V or 12V.  
2. Make sure battery is 6V or 12V.  
3. The battery is too low in  
voltage. (6V battery is less  
than 5.2V; 12V battery is less  
than 10.5V)  
3. If the battery is deeply discharged, wait  
for a while until it automatically turns back  
above 5.2V for a 6V battery or above 10.5V  
for a 12V battery.  
4. The battery is damaged.  
4. If the battery is in low voltage status for a  
long time, then it is possibly damaged and  
needs to be replaced with a new battery.  
Abnormal  
situation.  
1. No display  
on screen, or  
abnormal display  
on screen.  
1. AC power supply is not  
stable. Battery has hidden  
defect which prevents the  
Battery Charger from normal  
resetting.  
1. Disconnect the power supply, then  
reconnect again. If the faulty situation  
occurs during charging, try another similar  
battery to determine if it is a battery  
problem or power supply problem.  
Follow all safety precautions whenever diagnosing or servicing this  
product. Disconnect power supply before service.  
PARTS LIST  
Part #  
Description  
Upper Housing  
Qty. Part #  
Description  
Sticker  
Qty.  
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
Lower Housing  
Socket  
1
3
Battery Selection Button  
Charging Speed Selection Button  
Power Switch  
Radiator Board (B)  
Rivet  
1
4
2
5
Welding Slice  
Screw (M3 x 6)  
Nut (M3)  
1
6
Decorative Board  
Screen Cover  
1
7
1
8
Label  
Screw (M3 x 6)  
Nut (M3)  
2
9
LCD  
2
10  
11  
12  
13  
14  
15  
Back Board  
Screw (ST2 x 4)  
Screw (ST2 x 4)  
Screw (ST3 x 5)  
Power Cord  
4
Display Feature Circuit Board  
Main Function Circuit Board  
Key Board Function Circuit Board  
Key Board Spring  
Radiator Board (A)  
4
3
1
Battery Clamp  
Screw (ST3 x 30)  
2
4
SKU 65834  
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Page 11  
ASSEmBLY DIAGRAm  
SKU 65834  
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Page 12  
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 verifies 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 specific 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.  
SKU 65834  
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Page 13  

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