Harbor Freight Tools Battery Charger 92775 User Manual

MULTI-BATTERY CHARGING STATION  
Model 92775  
OPERATING INSTRUCTIONS  
®
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 or replacement parts, please call 1-800-444-3353.  
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WORK AREA  
1.  
2.  
Keep your work area clean and well lit. Cluttered benches and dark areas  
invite accidents.  
Do not operate power equipment in explosive atmospheres, such as in the  
presence of flammable liquids, gases, or dust. Power equipment creates  
sparks which may ignite flammables.  
3.  
Keep bystanders, children, and visitors away while operating power equip-  
ment. Distractions can cause you to lose control. Protect others in the work  
area.  
PERSONAL SAFETY  
1.  
Stay alert. Watch what you are doing, and use common sense when oper-  
ating power equipment. Do not use power equipment while tired or under  
the influence of drugs, alcohol, or medication. A moment of inattention while  
operating power equipment may result in serious personal injury.  
2.  
3.  
4.  
5.  
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.  
Avoid accidental starting. Make sure the Power Switch of the Charger is in  
its “OFF” position before plugging the Power Cord Plug into an electrical  
outlet. Plugging in with the Power Switch “ON” invites accidents.  
Do not overreach. Keep proper footing and balance at all times. Proper  
footing and balance enables better control of the Charger in unexpected  
situations.  
Use safety equipment. Always wear ANSI approved safety impact eye  
goggles when using the Charger.  
TOOL USE AND CARE  
1.  
Do not force the equipment. Use the correct equipment for your  
application. The correct equipment will do the job better and safer at the rate for  
which it is designed. Do not use small equipment, tools, or attachments to do the  
work of larger industrial equipment, tools, or attachments. Do not use this  
product for a purpose for which it was not intended.  
SKU 92775  
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2.  
3.  
Do not use the Charger if any of the Control Panel components do not  
work properly. Any equipment with a faulty Control Panel is dangerous and  
must be replaced.  
Before making any adjustments, changing accessories, or storing the  
Charger, make sure all Switches on its Control Panel are in their “OFF”  
positions. Such preventive safety measures reduce the risk of starting the  
equipment accidentally.  
4.  
5.  
Store idle equipment out of reach of children and other untrained persons.  
Power equipment is dangerous in the hands of children and untrained users.  
Maintain equipment with care. Do not use damaged equipment. Tag damaged  
equipment “Do not use” until repaired.  
6.  
7.  
Check for misalignment or binding of moving parts, breakage of parts, and  
any other condition that may affect the Charger’s operation. If damaged,  
have the Charger serviced before using. Many accidents are caused by  
poorly maintained equipment.  
Use only accessories that are recommended by the manufacturer for your  
model. Accessories that may be suitable for one Charger may become  
hazardous when used on another Charger.  
SERVICE  
1.  
2.  
Equipment service must be performed only by qualified repair personnel.  
Service or maintenance performed by unqualified personnel could result in a risk  
of injury.  
When servicing equipment, 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.  
SAVE THESE INSTRUCTIONS  
SKU 92775  
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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 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.  
GROUNDED TOOLS: TOOLS WITH THREE PRONG PLUGS  
1.  
Tools and equipment 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 tool or equipment 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.)  
2.  
3.  
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 tool’s grounding system and must never be attached  
to an electrically “live” terminal. (See Figure A.)  
Your 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 that in the following illustration. (See Figure A.)  
3-PRONG PLUG  
120 VOLT, GROUNDED,  
ELECTRICAL OUTLET.  
FIGURE A  
SKU 92775  
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EXTENSION CORDS  
1.  
2.  
Grounded tools and equipment require a 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 and  
equipment damage. (See Figure B.)  
3.  
4.  
5.  
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 B.)  
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 B.)  
If you are using one extension cord for more than one tool or equipment, add the  
nameplate amperes and use the sum to determine the required minimum cord  
size. (See Figure B.)  
6.  
7.  
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.  
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.  
RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*  
(120 VOLT)  
NAMEPLATE  
AMPERES  
EXTENSION CORD LENGTH  
(At Full Load)  
25  
FEET  
18  
18  
18  
18  
16  
14  
12  
50  
FEET  
18  
18  
18  
16  
14  
12  
10  
75  
FEET  
18  
18  
16  
14  
12  
10  
-
100  
FEET  
18  
16  
14  
12  
10  
-
150  
FEET  
0-2.0  
2.1-3.4  
3.5-5.0  
16  
14  
12  
12  
-
5.1-7.0  
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.  
FIGURE B  
SKU 92775  
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SYMBOLOGY  
Double Insulated  
Canadian Standards  
Association  
Underwriters Laboratories,  
Incorporated  
Volts  
Alternating Current  
V ~  
A
Amperes  
No Load  
Revolutions Per Minute (RPM)  
no  
xxxx/min.  
FIGURE C  
SPECIFIC SAFETY RULES  
1.  
2.  
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 the Charger in  
areas near flammable chemicals, dusts, and vapors.  
Maintain labels and nameplates on the Charger. These carry important  
information. If unreadable or missing, contact Harbor Freight Tools for a  
replacement.  
3.  
4.  
To avoid electrical shock, never start or run the Charger in the rain. Never  
allow water or other liquids to leak inside the body of the Charger.  
Do not pull the Charger by its Power Cord or Charger Cables, or pull the  
Power Cord or Charger Cables around sharp corners or edges. Keep the  
Power Cord and Charger Cables away from heated surfaces.  
5.  
6.  
Avoid unintentional starting. Make sure you are prepared to begin work  
before turning on any of the Switches on the Control Panel of the Charger.  
Do not stand on the Charger. Standing on the Charger may cause it to tip,  
causing personal injury and/or product damage.  
SKU 92775  
For technical questions, please call 1-800-444-3353  
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7.  
Never leave the Charger unattended when any of its Switches on the Control  
Panel are left in their “ON” position. Make sure all Switches are in their “OFF”  
position before leaving.  
8 .  
Make sure to read and understand all instructions and safety  
precautions as outlined in the manufacturer’s manual for the battery  
that will be charged.  
9.  
Never allow the Red and Black Charger Clamps to touch each other or the  
same metal object.  
10.  
11.  
Always connect the Black Charger Clamp of the Charger to the negative (--)  
terminal on the battery.  
Always connect the Red Charger Clamp of the Charger to the positive (+)  
terminal on the battery.  
12.  
13.  
When connecting the Charger Clamps to the terminals on a battery, always  
connect the Red Charger Clamp first, then connect the Black Charger  
Clamp. When disconnecting the Charger Clamps, always disconnect the Black  
Charger Clamp first, then disconnect the Red Charger Clamp.  
Make all Charger Clamp connections before plugging the Charger’s Power  
Cord Plug into a 120 volt, grounded, electrical outlet and turning on the  
Power Switch.  
14.  
Avoid working alone. If an accident occurs, an assistant can bring help.  
15.  
Always wear clothing and eye protection. When working on or around  
lead acid batteries, always wear ANSI approved safety impact eye goggles,  
work gloves and long sleeve shirt and trousers.  
16.  
WARNING! Lead acid batteries generate hydrogen gas during normal  
operation, and even more gas is generated when the battery is charging.  
Hydrogen gas is explosive, poisonous to breathe, and highly flammable. To  
reduce the risk of battery explosion, follow all instructions in this manual and  
those warnings and instructions published by the battery manufacturer.  
17.  
18.  
19.  
Use the Charger in a well ventilated area. Do not attempt to charge battery  
around flammable gases or liquids. If necessary, wear an ANSI approved  
breathing respirator to avoid hydrogen gas fumes.  
Use this Charger only with lead acid, rechargeable type batteries. Remove  
the battery caps to check liquid level inside battery. If liquid is not present, or if  
liquid appears to be frozen, do not attempt to charge the battery.  
Proper Battery Care: Battery leakage may occur under extreme usage or  
temperature conditions. If battery fluid comes in contact with skin, wash with soap  
SKU 92775  
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and water and rinse with lemon juice and vinegar. If the fluid comes into contact  
with the eyes, flush with water for several minutes and contact a doctor  
immediately. Never burn the battery, as it can explode in a fire. Do not charge a  
leaking battery. Contact local solid waste authorities for instructions on correct  
disposal or recycling of old batteries.  
20.  
21.  
Performance of the Charger (if powered by line voltage) may vary  
depending on variations in local line voltage. Extension cord usage may  
also affect equipment performance.  
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 or failure of the pacemaker. In addition,  
people with pacemakers should adhere to the following: Avoid operating power  
equipment alone. Don’t use a power equipment with the power switch(s) locked  
on. Properly maintain and inspect all power equipment before use to avoid  
electrical shock.  
22.  
WARNING! The warnings and precautions discussed in this manual cannot  
cover all possible conditions 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  
CONTROL PANEL FEATURES  
FIGURE D  
CHARGING  
CURRENT SELECTOR (1)  
POWER ON (2)  
BATTERY CHARGING (3)  
BATTERY CHARGED (4)  
LOW BATTERY (5)  
POWER SWITCH (6)  
SKU 92775  
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1.  
Charging Current Selector (1): The Charging Current Selector is used for  
selecting a charging current of either 0.25 AMPs, 0.50 AMPs, or 0.90 AMPs  
depending upon the 12 volt battery that is to be charged. Use a digital voltmeter  
(not included) to determine the voltage of the battery. Check the battery  
manufacturer’s recommended charging current. Then, set the Charging  
Current Selector to the appropriate Amperage. (See Figure D.)  
2.  
3.  
Power On (2): When illuminated, the Power On feature indicates the Battery  
Charger is on and ready for use. (See Figure D.)  
Battery Charging (3): After properly connecting the Charger Clamps to the  
battery, selecting the correct charging current, and turning on the Batter Charger,  
the Battery Charging feature will illuminate indicating proper functioning of the  
Battery Charger. If the Battery Charging feature does not illuminate, the voltage  
of the battery is below 9 volts, and the battery will not charge. (See Figure D.)  
4.  
5.  
6.  
Battery Charged (4): When illuminated, the Battery Charged feature indicates  
the battery is fully charged and may then be disconnected from the Battery  
Charger. (See Figure D.)  
Low Battery (5): When illuminated, the Low Battery feature indicates the battery  
connected will not be charged as its voltage is below 9 volts. The battery should  
be recycled according to local guidelines. (See Figure D.)  
Power Switch (6): Always properly connect the Charger Clamps to the battery,  
and select the correct charging current before turning the Power Switch to its  
“ON” position. Once the battery(s) is charged, turn the Power Switch to its  
“OFF” position. Then disconnect the Charger Clamps, and remove the  
battery(s). (See Figure D.)  
7.  
Charger Clamps: Never allow the Red and Black Charger Clamps to touch  
each other or the same metal object. Always connect the Black Charger Clamp  
of the Charger to the negative (--) terminal on the battery. Always connect the  
Red Charger Clamp of the Charger to the positive (+) terminal on the battery.  
When connecting the Charger Clamps to the terminals on a battery, always  
connect the Red Charger Clamp first, then connect the Black Charger Clamp.  
When disconnecting the Charger Clamps, always disconnect the Black Charger  
Clamp first, then disconnect the Red Charger Clamp. Make all Charger Clamp  
connections before plugging the Charger’s Power Cord Plug into a 120 volt,  
grounded, electrical outlet and turning on the Power Switch.  
8.  
Internal 12 Volt Relay (8): The Battery Charger features an internal 12 Volt  
Relay to protect the Battery Charger from a short circuit and reverse polarity.  
The 12 Volt Relay will not connect the battery to the Battery Charger unless the  
battery voltage is more than 9 volts and connected to the proper polarity.  
SKU 92775  
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9.  
3 AMP Fuse (9): The 3 AMP Fuse is located on the rear panel of the Battery  
Charger. In the event the Power On (2) feature on any of the six separate cir  
cuits does not illuminate, turn Power Switch(es) (6) to the “OFF” positions and  
unplug the Battery Charger from its electrical outlet. Temporarily remove the  
Fuse Cap. Pull out and remove the 3 AMP Fuse to check for a melted wire  
strand within the Fuse. If necessary, insert a new 3 AMP Fuse into the Fuse  
Holder. Then replace the Fuse Cap. Plug the Power Cord of the Battery Charger  
into its electrical outlet, and turn the Power Switch(es) to the “ON” position to  
resume battery charging.  
OPERATING INSTRUCTIONS  
To Charge A Battery:  
1.  
2.  
The Battery Charger features six separate circuits that allow the unit to charge up  
to six batteries at once.  
To charge a battery, pull out the sliding Shelf on the Battery Charger, and place  
the battery on the Shelf. Connect the Charger Clamps (7) as discussed in  
Step #7, page 10.  
3.  
4.  
5.  
6.  
7.  
Set the Current Selector (1) to the appropriate amperage (0.25, 0.50, or 0.90  
AMPs). (See Figure D.)  
Plug the Power Cord of the Battery Charger into the nearest 120 volt, grounded,  
electrical outlet.  
Turn the Power Switch (6) (for the circuit you are using) to its “ON” position.  
(See Figure D.)  
When illuminated, the Battery Charged (4) feature will indicate the battery is fully  
charged. (See Figure D.)  
Once the battery is fully charged, turn off the Power Switch (6). Unplug the  
Battery Charger from its electrical outlet. Then disconnect the Charger Clamps  
(7) as discussed in Step #7, page 10. (See Figure D.)  
8.  
When finished using the Battery Charger, make sure to store the Battery Charger  
in a clean, dry, safe location out of reach of children and other unauthorized  
people.  
SKU 92775  
For technical questions, please call 1-800-444-3353  
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INSPECTION, MAINTENANCE, AND CLEANING  
1.  
2.  
WARNING! Before performing any inspection, maintenance, or cleaning  
procedures, make sure all Switches on the Control Panel are in their “OFF”  
positions and the Charger is disconnected from its electrical outlet. Such  
preventive safety measures reduce the risk of starting the equipment accidentally.  
Before each use: Inspect the general condition of the Charger. Check for  
misalignment or binding of moving parts, cracked or broken parts, damaged  
electrical cables, 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.  
3.  
4.  
Battery precautions: Never burn batteries, as they can explode in a fire. Do  
not charge leaking batteries. If liquid is not present, or if liquid appears to be  
frozen, do not attempt to charge the battery. Contact local solid waste authorities  
for instructions on correct disposal or recycling of the battery.  
To clean: Clean the exterior of the Charger thoroughly with a clean, wet cloth  
and a mild detergent. Do not introduce any liquid into the interior of the Charger.  
Do not use solvents. Do not immerse any part of the Charger in liquids.  
5.  
6.  
When storing: Store the Charger in a safe, dry, location out of reach of children  
and untrained users.  
NOTE: The parts listed and shown in this manual are for illustration purposes  
only, and are not available individually as replacement parts.  
7.  
WARNING! All maintenance, service, and repairs not listed in this  
manual are only to be attempted by a qualified technician.  
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.  
SKU 92775  
For technical questions, please call 1-800-444-3353  
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