MODEL 6006
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 14AWG 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.
1
16.
DC CONNECTION PRECAUTIONS
a.
b.
17.
FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE. A SPARK NEAR THE
BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE
BATTERY:
a.
b.
c.
d.
e.
f.
g.
h.
18.
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 "e". If the positive post is grounded to the chassis, see item "f".
For negative-grounded vehicles, connect the POSITIVE (RED) clamp from the battery charger to the POSITIVE (POS, P, +) ungrounded
post of the battery. 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 to the carburetor, fuel lines, or sheet metal body parts.
For positive-grounded vehicles, connect 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 block away from the battery. Do not
connect the clamp to the carburetor, fuel lines, or sheet-metal body parts.
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.
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.
19.
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.
Check the polarity of the battery post. The POSITIVE (POS, P, +) 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.
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
The charger should be grounded to reduce the risk of electric shock. This 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 the AC cord or plug provided - if it will not fit the 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 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.
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.
2
20. NOTE: SIDE TERMINAL
refer to section 17e or 17f.
TO BE USED IN POSITIVE CLAMP ONLY! For instructions for NEGATIVE clamp attachment
Storage position
Will not get lost. Always ready to use.
21.
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
CHARGE RATE Vs. MINUTES CHARGE
SMALL
MEDIUM
LARGE
Ampere Hours
40
60
80+
Reserve Capacity
60
90
100+
BATTERY SIZE
Cold Cranking Amps
275
350
0-25
SMALL
400+
25-50
50-75
STATE OF CHARGE TABLE
STATE OF CHARGE
Specific Gravity
75%
50%
0-25
25%
DEAD
1.225 1.185 1.140
1.110
50-75
0-25
Open Circuit Voltage-6 V.
6.2
6.05
5.95
5.9
Open Circuit Voltage-12 V.
12.4
12.1
11.9
11.8
Open Circuit Voltage-24 V.
24.8
24.2
23.8
23.6
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 with the whitewall facing out. 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.
USE OF INSTRUMENT PANEL:
The CHARGE TIME 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 preset charging time. Turn the timer past 20 before setting the desired time.
TO CHARGE BATTERIES
Make connections to the battery per the instructions in previous sections of this manual.
Determine if the battery is 6, 12 or 24 volts and then set the CHARGE VOLTAGE switch to 6V for a 6 volt battery, 12LO for a 12 volt battery or 24V
for a 24 volt battery.
Turn the timer on and read the AMPERES meter.
If a higher rate of charge is desired for charging 12 volt batteries, set the CHARGE VOLTAGE switch to the 12HI position.
Set the timer to the desired minutes charge.
DO NOT USE THE 12V START POSITION TO CHARGE BATTERIES.
3
12V CRANKING ASSIST
Turn off all the lights and accessories in the stalled vehicle.
Connect the charger to the battery per previous instructions.
Set the CHARGE VOLTAGE switch to the 12HI position.
Charge the battery on 12HI for at least five minutes. Make sure the battery is accepting current before setting charger to 12V START.
Set the switch in the 12V START position. Start the vehicle with the charger connected to the battery.
NOTE: Do not crank the engine more than 20 seconds in any five minute period; excessive cranking may overheat and damage the starter.
DO NOT USE THE 12V START POSITION TO CHARGE BATTERIES.
If the vehicle fails to start, return the CHARGE VOLTAGE switch to the 12HI position.
While waiting for the starter to cool, allow the charger to continue to charge the battery.
Turn the timer to the OFF position before disconnecting the 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 12V START. 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. Lower the charge rate to the lowest rate for the voltage of battery being charged.
5. 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.
NOTE: 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.
4
WIRING DIAGRAM
MODEL 6006 PARTS LIST
Item
Description
Part No.
1
Front leg ................................................... 605671
2
Wheels w/nuts .......................................... 605672
3
Axle w/nuts ............................................... 610052
4
Transformer .............................................. 610862
5
Rectifier .................................................... 610850
6
Fan Blade ................................................. 610189
7
Fan Motor ................................................. 610190
8
Timer w/knob ............................................ 610895
9
Ammeter ................................................... 605204
10
DC Circuit Breaker ................................... 610536
11
DC Cable set ............................................ 611084
12
Handle ...................................................... 610753
13
AC Cord.................................................... 610696
14
Switch w/knob........................................... 611083
15
Clamps (1pair, includes jaws) ....................... 6202
16
Jaw Kit (repairs 1 clamp) .......................... 610970
17
Front Panel .............................................. 611085
18
Right Side Panel ....................................... 611032
19
Back Panel ............................................... 610977
20
Pointer Knob-Switch ................................. 603147
21
AC Circuit Breaker .................................... 610397
22
Pointer Knob-Timer................................... 610930
Not shown
Top Panel ................................................. 611011
Left Side Panel ......................................... 611031
Base ......................................................... 610054
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.
5
027-0521E.doc illustration list 6006 English
Fig
1
2
3
4
5
6
7
8
FILE NAME
LOGO.EPS
EXTERNAL_BATTERY.WPG
PLUG-ENG.PLT
SIDETERM.TIF
ENGLSTBL.PLT
27-385A.CXD
27-521WE.CXD
27-800-2.CXD
DESCRIPTION
ASSOCIATED LOGO
BATTERY W/CABLE EXTENSION
GROUNDING ADAPTER -ENGLISH
SIDE TERMINAL ADAPTER
CHARGE RATE TABLE - ENGLISH
ASSEMBLY DRAWING
WIRING DIAGRAM
PARTS LIST EXPLODED ASSEMBLY
REVISION RECORD
10/05 Pg. 2: added external battery drawing. Pg. 3: removed axle washer from assembly instructions. Pg. 4: “12V START” was “crank assist
“ in sections “12V Cranking Assist” and “Diesel Vehicles”. Pg. 5: rectifier 610850 was 610100. Added exploded assembly drawing
to parts list.
PUBLISHER: DO NOT REPRINT THIS PAGE
6