operator`s manual

operator`s manual
OPERATOR’S MANUAL
MANUAL Battery Charger
2 Amp, 12 Volt
6 Amp, 6, 12 Volt
Model No.
89023
CAUTION:
Read and follow all Safety
Rules and Operating Instructions
Before Every Use of this Product.
Save these instructions.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
0099001048-01
Plus Start 2-Year Full Warranty
When operated and maintained according to all supplied instructions, if this Plus Start product
fails due to a defect in material or workmanship within 2 years from the date of purchase, return
it to any Kmart store in the United States for free replacement.
This warranty gives you specific legal rights, and you may also have other rights which vary
from state to state.
Sears, Roebuck and Co., Hoffman Estates, IL 60179
For customer assistance or replacement parts,
call toll-free from 7 am to 5:00 pm CT
Monday through Friday: 1-800-SEARS-64 (1-800-732-7764)
IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL.
SAVE THESE INSTRUCTIONS – This manual will show you how to use your charger
safely and effectively. Please read, understand and follow these instructions and
precautions carefully, as this manual contains important safety and operating instructions.
The safety messages used throughout this manual contain a signal word, a message and
an icon.
Indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury to the operator or bystanders.
Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury to the operator or bystanders.
Indicates a potentially hazardous situation which, if not avoided, could result
in moderate or minor injury to the operator or bystanders.
Indicates a potentially hazardous situation which, if not avoided, could result
in damage to the equipment or vehicle or property damage.
Pursuant to California Proposition 65, this product contains chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
1.
1.4
1.5
1.6
1.7
1.8
1.9
IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS.
This manual contains important safety and operating instructions.
RISK OF ELECTRIC SHOCK OR FIRE.
1.1
Keep out of reach of children.
1.2
Do not expose the charger to rain or snow.
1.3
Use only recommended attachments. 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 or damage to property.
To reduce the risk of damage to the electric plug or cord, pull by the plug rather than the
cord when disconnecting the charger.
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:
• That the pins on the plug of the extension cord are the same number, size and shape
as those of the plug on the charger.
• That the extension cord is properly wired and in good electrical condition.
• That the wire size is large enough for the AC ampere rating of the charger as specified
in Section 8.
To reduce the risk of electric shock, unplug the charger from the outlet before attempting
any maintenance or cleaning. Simply turning off the controls will not reduce this risk.
Do not operate the charger with a damaged cord or plug; take it to a qualified service
person. (Call customer service at 1-800-732-7764.)
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 service person. (Call customer service at
1-800-732-7764.)
Do not disassemble the charger; take it to a qualified service person when service or
repair is required. Incorrect reassembly may result in a risk of fire or electric shock.
(Call customer service at 1-800-732-7764.)
•1•
RISK OF EXPLOSIVE GASES.
1.10 WORKING IN THE 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 YOU FOLLOW THE INSTRUCTIONS EACH TIME
YOU USE THE CHARGER.
1.11 To reduce the risk of a battery explosion, follow these instructions and those published by
the battery manufacturer and the manufacturer of any equipment you intend to use in the
vicinity of the battery. Review the cautionary markings on these products and on the engine.
1.12 This charger employs parts, such as switches and circuit breakers, that tend to produce
arcs and sparks. If used in a garage, locate this charger 18 inches (46 cm) or more
above floor level.
2.
PERSONAL PRECAUTIONS
RISK OF EXPLOSIVE GASES.
2.1
NEVER smoke or allow a spark or flame in the vicinity of a battery
or engine.
2.2
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.
2.3
Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might
spark or short-circuit the battery or other electrical part that may cause an explosion.
2.4
Use this charger for charging LEAD-ACID batteries only. It 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 that are commonly used with
home appliances. These batteries may burst and cause injury to persons and damage
to property.
2.5
NEVER charge a frozen battery.
2.6
NEVER overcharge a battery.
2.7
Consider having someone nearby to come to your aid when you work near a
lead-acid battery.
2.8
Have plenty of fresh water and soap nearby in case battery acid contacts your skin,
clothing or eyes.
2.9
Wear complete eye and body protection, including safety goggles and protective
clothing. Avoid touching your eyes while working near the battery.
2.10 If battery acid contacts your skin or clothing, immediately wash the area with soap and
water. If acid enters your eye, immediately flood the eye with cold running water for at
least 10 minutes and get medical attention right away.
2.11 If battery acid is accidentally swallowed, drink milk, the whites of eggs or water. DO NOT
induce vomiting. Seek medical attention immediately.
•2•
3.
3.3
3.4
3.5
3.6
3.7
4.
4.3
4.4
4.5
5.
5.1
5.2
PREPARING TO CHARGE
RISK OF CONTACT WITH BATTERY ACID. BATTERY ACID
IS A HIGHLY CORROSIVE SULFURIC ACID.
3.1
If it is necessary to remove the battery from the vehicle to
charge it, always remove the grounded terminal first. Make sure
all of the accessories in the vehicle are off, to prevent arcing.
3.2
Be sure the area around the battery is well ventilated
while the battery is being charged.
Clean the battery terminals before charging the battery. During cleaning, keep airborne
corrosion from coming into contact with your eyes, nose and mouth. Use baking soda
and water to neutralize the battery acid and help eliminate airborne corrosion. Do not
touch your eyes, nose or mouth.
Add distilled water to each cell until the battery acid reaches the level specified by the
battery manufacturer. Do not overfill. For a battery without removable cell caps, such
as valve regulated lead acid batteries (VRLA), carefully follow the manufacturer’s
recharging instructions.
Read, understand and follow all instructions for the charger, battery, vehicle and any
equipment used near the battery and charger. Study all of the battery manufacturer’s
specific precautions while charging and recommended rates of charge.
Determine the voltage of the battery by referring to the vehicle owner’s manual and
make sure that the output voltage selector switch is set to the correct voltage. If the
charger has an adjustable charge rate, charge the battery in the lowest rate first.
Make sure that the charger cable clips make tight connections.
CHARGER LOCATION
RISK OF EXPLOSION AND CONTACT WITH
BATTERY ACID.
4.1
Locate the charger as far away from the
battery as the DC cables permit.
4.2
Never place the charger directly above
the battery being charged; gases from the
battery will corrode and damage the charger.
Do not set the battery on top of the charger.
Never allow battery acid to drip onto the charger when reading the electrolyte specific
gravity or filling the battery.
Do not operate the charger in a closed-in area or restrict the ventilation in any way.
DC CONNECTION PRECAUTIONS
Connect and disconnect the DC output clips only after setting all of the charger switches
to the “off” position and removing the AC plug from the electrical outlet. Never allow the
clips to touch each other.
Attach the clips to the battery and chassis, as indicated in steps 6.5, 6.6 and 7.2
through 7.4.
•3•
6.
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE.
A SPARK NEAR THE BATTERY MAY CAUSE
A BATTERY EXPLOSION. TO REDUCE THE
RISK OF A SPARK NEAR THE BATTERY:
6.1
Position the AC and DC cables to
reduce the risk of damage by the hood, door
and moving or hot engine parts. NOTE: If it is
necessary to close the hood during the charging process, ensure that the hood does not
touch the metal part of the battery clips or cut the insulation of the cables.
Stay clear of fan blades, belts, pulleys and other parts that can cause injury.
Check the polarity of the battery posts. 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 step 6.5. If the
positive post is grounded to the chassis, see step 6.6.
For a negative-grounded vehicle, connect the
POSITIVE (RED) clip from the battery charger
to the POSITIVE (POS, P, +) ungrounded post
of the battery. Connect the NEGATIVE (BLACK)
clip to the vehicle chassis or engine block away
from the battery. Do not connect the clip to the
carburetor, fuel lines or sheet-metal body parts.
Connect to a heavy gauge metal part of the
frame or engine block.
For a positive-grounded vehicle, connect the
NEGATIVE (BLACK) clip from the battery
charger to the NEGATIVE (NEG, N, -)
ungrounded post of the battery. Connect the
POSITIVE (RED) clip to the vehicle chassis
NEGATIVE GROUNDED SYSTEM
or engine block away from the battery. Do not
connect the clip to the carburetor, fuel lines or sheet-metal body parts.
Connect to a heavy gauge metal part of the frame or engine block.
Connect charger AC supply cord to electrical outlet.
When disconnecting the charger, turn all switches to off, disconnect the AC cord, remove
the clip from the vehicle chassis and then remove the clip from the battery terminal.
See CALCULATING CHARGE TIME for length of charge information.
•4•
7.
7.2
7.3
7.4
7.5
7.6
7.7
7.8
8.
FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE.
A SPARK NEAR THE BATTERY MAY CAUSE
A BATTERY EXPLOSION. TO REDUCE THE
RISK OF A SPARK NEAR THE BATTERY:
7.1
Check the polarity of the battery posts.
The POSITIVE (POS, P, +) battery post usually
has a larger diameter than the NEGATIVE
(NEG, N, -) post.
Attach at least a 24-inch (61 cm) long 6-gauge (AWG) insulated battery cable to the
NEGATIVE (NEG, N, -) battery post.
Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) post of the battery.
Position yourself and the free end of the cable
you previously attached to the NEGATIVE
(NEG, N, -) battery post as far away from
the battery as possible, then connect the
NEGATIVE (BLACK) charger clip to the free
end of the cable.
Do not face the battery when making the final
connection. As stated in 7.4, face away from
the battery when connecting the negative clip
to the cable.
Connect charger AC supply cord to electrical outlet.
When disconnecting the charger, always do so in the reverse order of the connecting
procedure and break the first connection while as far away from the battery as practical.
A marine (boat) battery must be removed and charged on shore. To charge it onboard
requires equipment specially designed for marine use.
grounding and ac power cord connections
8.1
This battery charger is for use on a nominal 120-volt circuit and
has a grounded plug that looks like the plug illustrated. The
charger must be grounded to reduce the risk of electric shock.
The plug must be plugged into an outlet that is properly installed
and grounded in accordance with all local codes and ordinances.
The plug pins must fit the receptacle (outlet). Do not use with an
ungrounded system.
8.2
Never alter the AC cord or plug provided – if it
does not fit the outlet, have a proper grounded outlet installed by a
qualified electrician.
An improper connection can result in a risk of an electric shock or electrocution.
NOTE: Pursuant to Canadian Regulations, use of an adapter plug is not allowed in Canada.
Use of an adapter plug in the United States is not recommended and should not be used.
Recommended minimum AWG size for extension cord:
• 100 feet long (30.5 m) or less – use an 16 gauge (1.5 mm2) extension cord.
• Over 100 feet long (30.5 m) – use a 14 gauge (2.5 mm2) extension cord.
8.3
9.
ASSEMBLY INSTRUCTIONS
Remove all cord wraps and uncoil the cables prior to using the battery charger.
•5•
10.
CONTROL PANEL
Ammeter
The Ammeter indicates the amount of current, measured in amps, that is being drawn
by the battery. As a battery takes on a charge, it draws less current from the charger.
Correspondingly, the meter will show less current being drawn by the battery. When the
current stops decreasing, the battery is charged.
The 2 amp charge rate may indicate some activity on the meter, although the meter
does not have the resolution to display this low rate. For the 2 amp charge rate, a
triangle has been provided. Its accuracy has been calibrated for use with small batteries.
• Percent of Charge
The percent of charge scale is intended as a visual aid to help simplify reading the
state of charge. The percent of charge is based on the current drawn by the battery.
For this reason, accuracy will vary with the size and battery type. This means that the
indication for a fully charged large battery may be slightly less than 100%.
Charge Rate Selector Switch (Voltage/Amp Selector)
Use this switch to set the maximum charge rate to one of the following.
• 2A Slow Charge Rate – Intended for charging small batteries such as those commonly
used in garden tractors, snow mobiles and motorcycles. The 2A rate can be used to
warm or trickle charge larger batteries.
• 6A Fast Charge Rate – Use for charging automotive, marine and deep-cycle batteries.
NOTE: This charger is not recommended for 8 or 16 volt systems.
11.
OPERATING INSTRUCTIONS
This battery charger must be properly assembled in accordance with the
assembly instructions before it is used.
This is a manual charger. Be sure to monitor the charging process and
stop it when the battery is charged. Not doing so may cause damage to your battery or
result in other property damage or personal injury.
The charger does not have an ON/OFF switch. The On and Off commands are
controlled by plugging the 89023 into a 120V AC electrical wall outlet only after the
battery connections have been made and the CHARGE RATE SELECTOR switch has
been set.
Charging
1. Ensure that all of the charger components are in place and in good working
condition, for example, the plastic boots on the battery clips.
2. Connect the battery, following the precautions listed in Sections 6 and 7.
3. Select the appropriate settings for your battery.
4. Connect the AC power, following the precautions listed in Section 8. Make sure
to place the charger on a dry, non-flammable surface, like metal or concrete.
5. To disconnect, reverse the above procedure.
• Indication of a Fully Charged Battery:
A hydrometer reading of the specific gravity of the electrolyte (fluid) of a battery in
good condition should be between 1.250 and 1.285. When a battery reaches 80 to
85% of a full charge, bubbles will appear on the surface of the fluid. As the battery
nears full charge, the bubbling will become more active. At no time during the charge
cycle should there be any sign of vigorous bubbling of the battery fluid.
Manual Charging Mode
When a manual charge is performed, the charger will continue to charge and will not
shut off. You must keep a visual check on the ammeter to determine when the battery
is charged. Be sure to monitor the charging process and stop it when the battery is
charged. Not doing so may cause damage to your battery or result in other property
damage or personal injury.
•6•
12.
CALCULATING CHARGE TIME
Use the following table to accurately determine the time it will take to bring a battery to
full charge. First, identify where your battery fits into the chart.
CCA is the Cold Cranking Amp rating of the battery.
RC is the Reserve Capacity rating of the battery.
AH is the Amp Hour capacity of the battery.
NR means that the charger setting is NOT RECOMMENDED.
Find your battery’s rating on the chart below and note the charge time given for each
charger setting. The times given are for batteries with a 50% charge prior to recharging.
Add more time for severely discharged batteries.
CHARGE RATE/
CHARGING TIME
BATTERY SIZE/RATING
SMALL
BATTERIES
CARS/
TRUCKS
2 AMP
6 AMP
Motorcycle,
garden,
tractor, etc.
6 - 12 AH
2 - 4 hrs
45 min - 1¼ hrs
12 - 32 AH
4 - 10 hrs
1¼ – 3½ hrs
200 - 315
CCA
40 - 60 RC
11¼ - 14½ hrs
3¾ – 4¾ hrs
315 - 550
CCA
60 - 85 RC
NR
4¾ – 6 hrs
550 - 1000
CCA
80 - 190 RC
NR
6 – 11½ hrs
6 hrs
MARINE/DEEP CYCLE
13.
80 RC
NR
140 RC
NR
9 hrs
160 RC
NR
10 hrs
180 RC
NR
11 hrs
MAINTENANCE INSTRUCTIONS
13.1 Before performing maintenance, unplug and disconnect the battery charger
(see Sections 6, 7 and 8).
13.2 Use a dry cloth to wipe all battery corrosion and other dirt or oil from the battery clips,
cords and the charger case.
13.3 Ensure that all of the charger components are in place and in good working condition,
for example, the plastic boots on the battery clips.
13.4 Servicing does not require opening the unit, as there are no user-serviceable parts.
13.5 All other servicing should be performed by qualified service personnel.
14.
STORAGE INSTRUCTIONS
14.1 Store charger unplugged, in an upright position. The cord will still conduct electricity until
it is unplugged from the outlet.
14.2 Store inside, in a cool, dry place (unless you’re using an on-board Marine Charger).
14.3 Do not store the clips on the handle, clipped together, on or around metal, or clipped
to cables.
14.4 If the charger is moved around the shop or transported to another location, take care to
avoid/prevent damage to the cords, clips and charger. Failure to do so could result in
personal injury or property damage.
•7•
15.
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
REASON/SOLUTION
No reading on the
ammeter.
Charger is not plugged in.
Plug the charger into an AC outlet.
No power at the receptacle.
Check for open fuse or circuit
breaker supplying AC outlet.
Clips are not making a good
connection to the battery.
Check for poor connection to
battery and frame. Make sure
connection points are clean. Rock
clips back and forth for a better
connection.
Connections are reversed.
Unplug the charger and reverse
the clips.
Battery is defective (will not
accept a charge).
Have battery checked.
2 amp charge rate is being used.
Ammeter may show no activity at
the 2A charge rate.
Battery is severely discharged.
Continue charging battery for two
more hours. If problem continues,
have the battery checked.
Wrong battery voltage.
Verify the voltage settings on the
charger are correct.
AC outlet is dead.
Check for open fuse or circuit
breaker supplying AC outlet.
Poor electrical connection.
Check power cord and extension
cord for loose fitting plug.
Ammeter reading stays
high.
Charger will not turn
on when properly
connected.
The battery is connected Clips are not making a good
and the charger is on, but connection.
is not charging.
Check for poor connection at
battery and frame. Make sure
connecting points are clean. Rock
clips back and forth for a better
connection.
Ammeter reads less
than selected charge
rate when charging a
discharged battery
Extension cord is too long or wire
gauge is too small.
Use a shorter or heavier gauge
extension cord.
Weak cell or sulfated plate in
battery.
A sulfated battery will eventually
take a normal charge if left
connected. If the battery will not
take a charge, have it checked.
•8•
PROBLEM
POSSIBLE CAUSE
The charger is making an Circuit breaker is cycling.
audible clicking sound.
Charger makes a loud
buzz or hum.
16.
REASON/SOLUTION
The settings may be wrong.
Check the charger settings.
Battery is defective.
Have the battery checked.
Shorted battery cables or clips.
Circuit breaker cycles when
current draw is too high. Check
for shorted cables or clips and
replace if necessary.
Severely discharged battery, but
otherwise it is a good battery.
The battery may not want to accept
a charge due to a run-down state.
Allow charging to continue until
battery has a chance to recover
sufficiently to take a charge. If more
than 20 minutes, stop charging and
have the battery checked.
Reverse connections at battery.
Shut the charger off and correct
the lead connections.
Transformer laminations vibrate
(buzz).
No problem; this is a normal
condition.
Shorted Diode Assembly or Output
Rectifier Assembly (hum).
Have charger checked by a
qualified technician.
BEFORE RETURNING FOR REPAIR or replacement
16.1 When a charging problem arises, make certain that the battery is capable of accepting
a normal charge. Use a good battery to double check all connections, AC outlet for a full
120-volts, charger clips for correct polarity and the quality of the connections from the
cables to the clips and from the clips to the battery system. The clips must be clean.
16.2 When a battery is very cold, partially charged or sulfated, it will not draw the full rated
amperes from the charger. It is both dangerous and damaging to a battery to force
higher amperage into it than it can effectively use in recharging.
16.3 When an UNKNOWN OPERATING PROBLEM arises, please read the complete manual
and call the customer service number for information that will usually eliminate the need
for return.
If the above solutions do not eliminate the problem, or for information about troubleshooting
or replacement parts, call toll-free from anywhere in the U.S.A.
1-800-732-7764
7:00 a.m. to 5:00 p.m. Central Time, Monday thru Friday
•9•
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement