MODEL 6002B
OPERATOR'S MANUAL
ASSOCIATE
IMPORTANT SAFETY INSTRUCTIONS
1.
SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions for the battery charger you have
2.
CAUTION. To reduce risk of injury, charge only wet cell, lead-acid, automotive type rechargeable batteries. Other types of batteries may burst
purchased. You may need to refer to these instructions at a later date.
causing personal injury and property damage.
Do not expose the charger to rain or snow if specifically warned on the unit not to do so.
Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to
persons.
5. To reduce the risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger.
6. Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.
7. An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk of fire and electric
shock. If an extension cord must be used, make sure:
a. That the pins on the plug of extension cord are the same number, size, and shape as those of the plug on the charger;
b. That the extension cord is properly wired and in good condition; and
c. If the length of the extension cord is less than 25 feet, use a 16AWG cord, If 50 feet- 12AWG, 100 feet-10AWG, 150 feet-8AWG.
8. Do not operate the charger with a damaged cord or plug, replace them immediately.
9. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman.
10. Do not disassemble the charger unless you are qualified to work on electrical products. If not, take it to a qualified serviceman when service or
repair is required. Incorrect reassembly may result in risk of electric shock or fire.
11. To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Turning off the
controls will not reduce this risk.
3.
4.
12.
WARNING - RISK OF EXPLOSIVE GASES
a.
b.
13.
PERSONAL PRECAUTIONS
a.
b.
c.
d.
e.
f.
g.
h.
i.
14.
Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
Wear complete eye protection, and clothing protection. Avoid touching eyes while working near battery.
If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enter eyes, immediately flood eyes with running
cold water for at least 10 minutes and get medical attention immediately.
NEVER smoke or allow a spark or flame in vicinity of the battery or engine.
Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or other electrical parts
that may cause an explosion.
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 the like to metal, causing a severe burn.
Use this charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low-voltage electrical system other than
in an automotive application. Do not use this 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.
NEVER charge a frozen battery.
PREPARING TO CHARGE
a.
b.
c.
d.
e.
f.
15.
WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING
NORMAL BATTERY OPERATION. FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR
CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of
any equipment you intend to use in vicinity of the battery. Review cautionary markings on these products and on the engine.
If necessary to remove battery from 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.
Be sure the area around the battery is well ventilated while the battery is being charged. Gas can be forcefully blown away by using a
piece of cardboard or other non-metallic material as a fan.
Clean the battery terminals. Be careful to keep corrosion from coming in contact with eyes.
Add distilled water in each cell until battery acid reaches level specified by the battery manufacturer. This helps purge excessive gas
from cells. Do not overfill. For a battery without cell caps, carefully follow the manufacturer's recharging instructions.
Study all battery manufacturer's specific precautions such as removing or not removing the cell caps while charging and the
recommended rates of charge.
Determine voltage of the battery by referring to the car owner's manual and make sure that the output voltage selector switch is set at the
correct voltage. If the charger has adjustable charge rate, charge the battery initially at the lowest rate.
CHARGER LOCATION
a.
b.
c.
d.
e.
Locate the charger as far away from the battery as the DC cables permit.
Never place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.
Never allow battery acid to drop on the charger when reading the specific gravity or filling battery.
Do not operate the charger in a closed-in area, or restrict ventilation in any way.
Do not set a battery on top of the charger.
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16.
DC CONNECTION PRECAUTIONS
a.
b.
17.
Connect and disconnect the DC output clamps only after setting the charger switches to the OFF position and removing the AC cord from
the electric outlet. Never allow the clamps to touch each other.
Attach the DC clamps to the battery post and twist or rock back and forth several times to make a good connection. This tends to keep
the clamps from slipping off the terminals and helps to reduce the risk of sparking.
STOP/GO LITE INSTRUCTIONS
When used properly, the STOP/GO LITE will indicate whether clamp connections will be correct.
Connect the positive (red) clamp to the positive (POS, P, +) battery post. Touch the contact button of the
negative (black) clamp to the other battery post. Observe the L.E.D. lights in the STOP/GO LITE:
GREEN LIGHT: The first connection is correct. Make the second clamp connection per instructions.
RED LIGHT: The first connection made with the positive clamp to the battery is incorrect. Attach the
positive clamp to the other battery post and retest.
RED AND GREEN LIGHT: The battery charger is turned on. Turn the charger "OFF" and retest.
NO LIGHT: Check for a shorted or open battery. Clean any corrosion from the clamp jaws and the
battery post and retest. If still no light, use a voltmeter or other means to make certain you have properly
identified the polarity of the battery post. Then attach the clamps per instructions, disregarding the
STOP/GO LITE.
18.
FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE. A SPARK NEAR THE
BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE
BATTERY:
a.
b.
c.
d.
e.
f.
g.
h.
i.
19.
FOLLOW THESE STEPS WHEN THE BATTERY IS OUTSIDE THE VEHICLE. A SPARK NEAR THE
BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE
BATTERY:
a.
b.
c.
d.
e.
f.
g.
h.
20.
Read the section "STOP/GO LITE INSTRUCTIONS" before proceeding.
Position the AC and DC cords to reduce the risk of damage by the hood, door, or moving engine parts.
Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
Check the polarity of the battery post. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE
(NEG, N, -) post.
Determine which post of the battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most
vehicles), see item "f". If the positive post is grounded to the chassis, see item "g".
For negative-grounded vehicles, connect the POSITIVE (RED) clamp from the battery charger to the POSITIVE (POS, P, +) ungrounded
post of the battery. Touch the contact button of the STOP/GO LITE to the NEGATIVE (NEG, N, -) battery post. Interpret the light and
take appropriate action. When the green light is on, connect the NEGATIVE (BLACK) clamp to the vehicle chassis, heavy gauge metal
part of the frame, or engine block, away from the battery. Do not connect clamp to the carburetor, fuel lines, or sheet metal body parts.
For positive-grounded vehicles, connect the POSITIVE (RED) clamp from the battery charger to the POSITIVE (POS, P, +) battery post.
Touch the contact button of the STOP/GO LITE to the NEGATIVE (NEG, N, -) battery post. Interpret the light and take appropriate action.
When the green light is on, disconnect the POSITIVE (RED) clamp from the battery. Attach the NEGATIVE (BLACK) clamp from the
battery charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery. Attach the POSITIVE (RED) clamp to the vehicle chassis
or engine away from the battery. Do not connect the clamp to the carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy
gauge metal part of the frame or engine block.
When disconnecting the charger, turn the switches to OFF, disconnect the AC cord, remove the clamp from the vehicle chassis, and then
remove the clamp from the battery terminal.
See the operating instructions for length of charge information.
Read section "STOP/GO LITE INSTRUCTIONS" before proceeding.
Check the polarity of the battery post. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE
(NEG, N, -) post.
Attach at least a 24 inch long 6-gauge (AWG) insulated battery cable to the NEGATIVE (NEG, N, -) battery post.
Connect the POSITIVE (RED) charger clamp to the POSITIVE (POS, P, +) post of the battery.
Touch the contact button of the STOP/GO LITE to the free end of the battery cable. If the red light comes on, reverse the connections to
the battery and retest. When the green light comes on, position yourself and the free end of the cable as far away from the battery as
possible, then connect the NEGATIVE (BLACK) charger clamp to the free end of cable.
Do not face the battery when making the final connection.
When disconnecting the charger, always do so in reverse sequence of connecting procedure, and break the first connection while
standing as far away from the battery as practical.
A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine
use.
GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS
GROUNDING METHODS
The charger should be grounded to reduce the risk of electric shock. This
GROUNDED
charger is equipped with an electric cord having an equipment grounding
ADAPTER
OUTLET
ADAPTER
conductor and a grounding plug. The plug must be plugged into an outlet that
COVER OF GROUNDED
is properly installed and grounded in accordance with all local codes and
OUTLET BOX
ordinances.
(C)
GROUNDING
DANGER. Never alter the AC cord or plug provided - if it will not fit the
(A)
(B)
MEANS
outlet, have a 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 FIGURE (A). A temporary adapter, which looks like the adapter illustrated in FIGURE (C), may be used to
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connect this plug to a two-pole receptacle, as shown in FIGURE (B), until a properly grounded outlet can be installed by a qualified electrician.
3
DANGER. Before using an adapter as illustrated, be certain that the center screw of the outlet plate is grounded. The green-colored rigid
ear or lug extending from the adapter must be connected to a properly grounded outlet - make certain it is grounded. If necessary, replace the
original outlet cover plate screw with a longer screw that will secure the adapter ear or lug to the outlet cover plate and make ground
connection to grounded outlet.
NOTE: USE OF AN ADAPTER IS NOT ALLOWED IN CANADA. IF A GROUNDING TYPE RECEPTACLE IS NOT AVAILABLE, DO NOT
USE THIS APPLIANCE UNTIL THE PROPER OUTLET IS INSTALLED BY A QUALIFIED ELECTRICIAN.
21.
NOTE: SIDE TERMINAL TO BE USED IN POSITIVE CLAMP ONLY! For instructions for NEGATIVE clamp attachment
refer to section 18f or 18g.
Storage position
Will not get lost. Always ready to use.
22.
Extended position
Note: Pressure, when handle is squeezed,
holds adapter firm. Will not slip back.
Thrust on terminal
Note: Clamp is released and spring tension
holds adapter firm.
LENGTH OF CHARGE
a.
b.
c.
d.
Test the battery for state of charge. Do not charge if it is over 75% charged or the battery is determined to be defective.
Set beginning amps charge rate for size of battery and state of charge per charts
Charge for length of time per charge,
Discontinue charge when the specific gravity of electrolyte reaches 1.260 or above. A temperature compensating hydrometer should be
used for this reading. Discontinue charge if the battery begins to gas excessively or if the temperature of the electrolyte reaches
approximately 125°F. Do not overcharge batteries. Overcharging results in excessive water loss and eventual damage to the battery.
BATTERY SIZE TABLE
BATTERY SIZE
CHARGE RATE Vs. MINUTES CHARGE
SMALL
MEDIUM
LARGE
Ampere Hours
40
60
80+
Reserve Capacity
60
90
100+
275
350
400+
Cold Cranking Amps
0-25%
SMALL
25-50%
50-75%
STATE OF CHARGE TABLE
0-25%
STATE OF CHARGE
75%
50%
25%
DEAD
Specific Gravity
1.225
1.185
1.140
1.110
50-75%
6.2
6.05
5.95
5.9
0-25%
Open Circuit Voltage 12V
12.4
12.1
11.9
11.8
Open Circuit Voltage 24V
24.8
24.2
23.8
23.6
Open Circuit Voltage 6V
MINUTES
15 30 45 60 75 90
BATTERY SIZE %CHARGE
MEDIUM
LARGE
25-50%
45 30 30 25 25 20
A
M
P
E
R
E
S
30 20 20 15 15 10
15 10 10 10
5
5
70 50 45 40 35 30
45 30 25 20 20 20
25 15 15 10 10 10
90 55 55 50 45 45
25-50%
60 40 35 30 30 30
50-75%
30 20 20 15 15 15
ASSEMBLY INSTRUCTIONS
Attach the handle to the charger using the four screws provided. Attach the front leg to the base with the four
hex head screws provided. To attach wheels and axle to the base, tap one axle nut onto the axle with a
hammer, slide one wheel onto the axle. Push the axle through the base, place wheel on opposite side. Tap
axle nut onto the axle with a hammer.
OPERATING INSTRUCTIONS
CAUTION - This battery charger must be fully assembled before operating. Failure to do so may result in risk
of injury.
12V CRANK ASSIST
24V 18V
12V
6V
12V
HI
LO
HI
4
H L H
I O I
LO
L
2
O
2
2
3
USE OF INSTRUMENT PANEL:
The MINUTES CHARGE timer has an OFF position, a CONTINUOUS CHARGE position
and a timed charge range from 0 to 90 minutes.
a. OFF - Always make sure the timer is in the OFF position before connecting or
disconnecting the clamps from the battery. The charger will not charge with the timer in
this position.
b. CONTINUOUS CHARGE - This position is used for slow charging or parallel charging and will not turn the charger
off. Do not use this position for fast charging.
c. 0 to 90 MINUTES TIMED CHARGE - The timer will automatically turn the charger off at the end of the pre-set
charging time. Turn the timer past 20 before setting the desired time.
d. VOLTS/AMPS CHARGE SWITCHES - These switches are used to regulate the output voltage and current of the
battery charger.
INITIAL CHARGE RATE SETTING
BATTERY VOLTAGE
AMPS CHARGE
VOLTS CHARGE
6
LO
6V
12
LO
12V
18
LO
18V
24
LO
24V
VOLTS/AMPS CHARGE
4
TO CHARGE BATTERIES
Make connections to the battery per the instructions in preceding section of this manual. Determine the battery voltage and set initial charge
rate settings per chart. Turn the timer on. If a higher rate of charge is desired, turn the AMPS CHARGE switch to the appropriate 2, 3, 4 or HI
position. Always return the AMPS CHARGE switch to the LO position before advancing the VOLTS CHARGE switch.
12V CRANKING ASSIST AND BOOST STARTING
Turn off all lights and accessories in the vehicle.
Connect the charger to battery per previous instructions. Charge the battery at least five minutes. Make sure the battery is accepting current
before setting charger to crank assist. Always start on the lowest amperage crank setting. Put the switch in the "12V CRANK ASSIST"
position. Start the car with the charger connected to the battery. Follow the duty cycle on the unit. Turn the switch to OFF and remove the AC
power cord from the electric outlet before disconnecting the DC clamps.
DIESEL VEHICLES
Diesel engines have special starting requirements due to the high compression required to ignite the fuel mixture. Because of this, the starter
motors have to work harder which requires the battery to deliver a large amount of power for a period of time. Adequate voltage must be
supplied also to insure the glow plug will have enough power to preheat the chamber. When attempting to start a diesel vehicle, always fast
charge the battery at least five minutes. If time permits, charge the battery as long as possible or until the battery reaches 75% state of
charge. Make sure the battery is accepting current before setting charger to crank assist. Always start on the lowest amperage crank setting.
With the charger "ON" and attached to the battery, attempt to start the vehicle. Do not crank the engine more than 20 seconds in a five-minute
period. While allowing the starter to cool, allow the charger to continue to charge the battery.
If the vehicle has two batteries installed, read the "VEHICLES WITH TWO BATTERIES" section of this manual.
VEHICLES WITH TWO BATTERIES
Many diesel vehicles and service vehicles are equipped with two batteries. This is to provide the vehicle with greater starting power capacity
or longer reserve capacity to provide power for accessories. These batteries are wired into a parallel circuit. Because of this, it will take twice
as long to charge these batteries as indicated in the LENGTH OF CHARGE table. If one battery is charged and the other discharged, the
discharged battery should be removed from the vehicle and checked. When attaching the charger to this type of vehicle the charger should
be attached to the battery which is wired closest to the starter. This allows the charger to provide maximum starting power to the starter motor
by minimizing the voltage drop in the engine cables.
PARALLEL CHARGING
This charger may be used to parallel charge up to 10 batteries with a bus bar kit, or by using a minimum 6AWG gauge booster cables to
connect the batteries together in parallel.
CAUTION: Do not connect 6 and 12 volt batteries in parallel with each other.
CHARGING SULFATED BATTERIES
If your battery has sat in the discharged state for an extended period of time, it can become SULFATED. This usually is seen as a white
deposit near the top of the battery. The sulfate is formed when a battery with low water levels remains discharged for an extended time.
Sulfated batteries exhibit the characteristic of accepting no charge regardless of the rate of charge.
The charging method is two staged. The first stage of attempting to break down the sulfation to allow the battery to accept a charge must be
closely watched to avoid excessive charge rates as the battery begins to charge and overheat. The second stage is a slow charging to restore
the battery to full charge.
READ AND FOLLOW ALL PRECAUTIONS AND WARNINGS IN YOUR INSTRUCTION MANUAL BEFORE ATTEMPTING TO CHARGE
SULFATED BATTERIES. FAILURE TO OBSERVE THESE WARNINGS MAY RESULT IN PROPERTY DAMAGE OR SERIOUS PERSONAL
INJURY OR DEATH.
To recharge a sulfated battery:
1. Attach the battery clamps as described in the instruction manual.
2. Always use the charger’s lowest rate when turning the charger on. Set the charger to the charger’s highest rate for the voltage of the
battery being charged.
CAUTION: NEVER CHARGE A BATTERY AT VOLTAGE RATES ABOVE THAT OF THE BATTERY.
3.
The battery will show little or no amperage at the start of the charging process. This will continue until the sulfation begins to break
down.
CAUTION: AS THE SULFATION BREAKS DOWN, THE AMPERAGE MAY RAPIDLY RISE. CONSTANT
ATTENTION MUST BE OBSERVED TO PREVENT SERIOUS OVERHEATING OF THE BATTERY.
4.
5.
NOTE:
Lower the charge rate to the lowest rate for the voltage of battery being charged.
Charge the battery at this low rate until the electrolyte reaches the fully charged state as described in the tables in your instruction
manual. This may take as long as two or three days.
SOME BATTERIES MAY BE SO BADLY SULFATED THEY CAN NOT BE RESTORED TO A NORMAL OPERATING CONDITION,
REGARDLESS OF THE RATE OF CHARGE OR THE LENGTH OF TIME THE CHARGE IS APPLIED. IF THE BATTERY CANNOT
BE RESTORED TO A FULLY CHARGED CONDITION BY A SLOW CHARGING, IT SHOULD BE REPLACED.
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WIRING DIAGRAM
MODEL 6002B PARTS LIST
Front leg ................................. 610864
Wheels w/nuts (2)................... 610553
Axle w/nuts ............................. 605673
Base ....................................... 605186
Transformer............................ 611072
Rectifier .................................. 611073
Fan Blade ............................... 610189
Fan Motor ............................... 610190
AC Circuit Breaker .......................... 610397
Timer w/knob .................................. 610895
Switch w/knob................................. 605675
Amps Charge Meter........................ 605204
AC Cord .......................................... 611133
DC Cable Set.................................. 611074
DC Circuit Breaker (1) .................... 610069
Top Panel ....................................... 611132
Side Panel (1)......................... 605209
Front Panel............................. 611075
Back Panel ............................. 611076
Lid........................................... 605211
Handle .................................... 610753
Stop/Go Lite ........................... 604579
Clamps (1 pair, includes jaws) ... 6202
Jaw kit (repairs 1 clamp) ........ 610970
Parts may be purchased from your local authorized service center (see service procedure at the end of this manual). If you elect to order parts from
the factory you may do so by mail or phone. Minimum order from the factory is $25.00. Orders received that are under the minimum will not be
processed. Taxes and freight are extra and are not considered to be part of the dollar value of the order. We do not have a C.O.D. policy. Cashier
check, Money order, MasterCard or VISA are acceptable. If you use a MasterCard or VISA send only the number and expiration. DO NOT SEND
THE CARD.
MAINTENANCE INSTRUCTIONS
Worn clamps and jaws should be replaced. Worn parts can lead to poor connections and present a safety hazard. See parts list for part number of
jaw and clamp kits. Any Maintenance or repair of this unit that involves disassembly of the cabinet should be done only by a qualified serviceman.
Incorrect reassembly may result in a risk of electric shock when the unit is subsequently used.
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027-0359E.doc illustration list 6002b English
Fig
1
2
3
4
5
6
7
8
9
FILE NAME
LOGO.EPS
STOP-GO.WPG
PLUG_ENG.CXD
SIDETERM.TIF
CHRGTABL.CXD
27-520A.CXD
A4573A.CXD
PARABAT.CXD
27-359WE.CXD
DESCRIPTION
ASSOCIATED LOGO
STOP GO LITE ON BATTERY-ENGLISH
GROUNDING ADAPTER -ENGLISH
SIDE TERMINAL ADAPTER
CHARGE RATE TABLE – ENGLISH LEVEL
6001A CABINET
INSTRUMENT PANEL
PARALLEL BATTERY – ENGLISH LEVEL
6002B WIRING DIAGRAM
PUBLISHER: DO NOT REPRINT THIS PAGE
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