Chicago Electric Battery Charger 90636 User Manual

100 AMP LOAD BATTERY AND  
CHARGING SYSTEM TESTER  
90636  
OPERATING INSTRUCTIONS  
®
3491 MISSION OAKS BLVD., CAMARILLO, CA 93011  
VISIT OUR WEB SITE AT HTTP://WWW.HARBORFREIGHT.COM  
Copyright© 2003 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 and replacement parts, please call 1-800-444-3353.  
 
7. Maintain tools with care. Keep clean. Do not use a damaged tool. Tag damaged  
tools “Do not use” until repaired.  
8. Tool service must be performed only by qualified repair personnel. Service or  
maintenance performed by unqualified personnel could result in a risk of injury.  
9. Maintain labels and nameplates on this  
tool.These carry important information.  
If unreadable or missing, contact Harbor  
Freight Tools for a replacement.  
CAUTION!  
Battery acid may cause severe  
injury to eyes; always wear ANSI  
approved safety goggles. Avoid  
touching eyes while working with or  
near a battery. In case of accidental  
contact, rinse eyes with clean  
water for at least 5 minutes and  
see a doctor immediately.  
10. Always wear ANSI approved safety  
impact eye goggles and heavy work  
gloves when using this tool. Using  
personal safety devices reduce the risk  
for injury.Safety impact eye goggles and  
heavy work gloves are available from  
Harbor Freight Tools.  
11. 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 this tool in areas  
near flammable chemicals, dusts, and vapors. Do not use this product in a  
damp or wet location.  
WARNING! People with pacemakers should consult their physician(s) before  
using this product. Operation of electrical equipment in close proximity to a  
heart pacemaker could cause interference or failure of the pacemaker.  
SPECIFIC SAFETY RULES FOR THE BATTERY TESTER  
1. When connecting the Battery Cables to the battery, avoid creating sparks (always  
connect and disconnect clamps exactly as described in rule number 2, below,  
and on page 4), especially when the battery is being charged. Explosive gases  
are created during charging.Sparking could also damage the vehicle electrical  
system.  
2. Be certain of the test battery polarity before connecting the test Cable Clamps.  
The red Cable Clamp (A) goes to the positive terminal of the battery.The black  
Cable Clamp (B) goes to the negative terminal of the battery.  
3. When placing the BatteryTester in the vehicle (on the frame, engine, or fender),  
take special care that the metal housing of the Battery Tester does not come in  
contact with either terminal of the battery or other electrical connections.  
4. Do not drop the Battery Tester as it may affect proper operation.  
5. Do not smoke or have open flames near the battery.  
SKU 90636  
For technicial questions, please call 1-800-444-3353.  
Page 3  
 
6. Reversing Battery Tester Cable Clamps on the battery will damage the tester.  
7. Do not connect the BatteryTester to the battery while the battery is being charged.  
Turn the engine off before connecting.  
8. Do not touch the cooling vents on the Battery Tester immediately after testing  
the battery. They become very hot.  
UNPACKING  
When unpacking, check to make sure that all the parts are included. Refer to the  
Assembly section, and the Assembly Drawing and Parts List at the end of this manual.  
(A)  
(C)  
(D)  
(B)  
If any parts are missing or broken, please call Harbor Freight Tools at the number  
on the cover of this manual as soon as possible.  
OPERATING INSTRUCTIONS  
Testing the Battery  
CAUTION! Undercharged lead-acid batteries will freeze during cold weather.  
NEVER TEST OR CHARGE A FROZEN BATTERY.  
1. To help ensure a good connection, clean battery terminals with a solution of  
baking soda and water, and wipe the battery terminals with a cloth to remove  
any dirt and grease.  
2. Connect the red (positive) Cable Clamp (A) to the positive terminal (+) on the 6  
or 12 V lead-acid battery. (See photo above.)  
3. Connect the black (negative) Cable Clamp (B) to the negative terminal (–) on  
the battery. Turn clamps slightly to ensure a good connection.  
4. With the clamps connected, the tester’s gauge will show the battery’s current  
charge. If it is less than 12V, disconnect the battery and recharge before testing.  
If recharging will not bring the reading above 12 V the battery is defective. If it  
shows no reading, verify that the tester is connected properly. If the tester is  
connected properly, the battery is defective.  
5. Press (and hold) the Toggle Switch (C) for at least 5 seconds to simulate an  
actual load on the battery.  
SKU 90636  
For technicial questions, please call 1-800-444-3353.  
Page 4  
 
6. View the Meter Display (D) and read the battery condition. Refer to the “Battery  
Condition Analysis” section below.  
7. Release the Toggle Switch (C) and remove the Cable Clamps from the battery.  
Testing the Charging System  
Note:The engine should be at normal operating temperature during this test.  
1. Connect the Cable Clamps (A, B) to the battery as previously described.  
2. Outside, or in a well ventilated area, start the vehicle engine and run at fast idle  
speed. Never start and run the vehicle’s engine in a closed garage.  
WARNING! Avoid Carbon Monoxide poisoning.This gas comes from  
the vehicle exhaust and is colorless and odorless. It can cause  
serious injury or death if inhaled. Never run the vehicle’s engine  
inside a garage or any other enclosed space.  
3. View the Meter Display (D) and read the charging system condition (far right on  
the gauge). Refer to the “Battery Condition Analysis” section below.  
CAUTION! DO NOT press the Toggle Switch (C) during this test.  
Battery Condition Analysis  
LOAD TEST / 5 Sec.  
BATTERY CONDITION  
(Display Reading)  
Battery capacity is good. May or may not be fully charged. Check the charge state by testing the  
Specific Gravity (SG) with a Hydrometer. If SG is less than full charge, check for possible charging  
system trouble. Recharge to full level.  
OK  
(green area)  
If the Display Meter needle is steady, the battery capacity is not good. Battery may be defective or  
partly discharged. Check SG. If over 1.225, the battery is defective. If below 1.225, recharge battery  
and re-test.If there is a difference in SG between cells over 2 points (0.025), a particular cell may  
be damaged. If charging does not bring SG to full charge level, then battery is either sulfated, or  
WEAK  
(yellow area)  
has lost its active material.  
If the Display Meter needle is falling, the battery is defective or has a bad cell. For a quick check,  
BAD  
(red area)  
release the load Toggle Switch and note Display Meter reaction. If voltage recovers to its full  
potential after only a few seconds, the battery is probably defective. If the voltage recovers slowly,  
the battery may only be run down. Check SG, recharge, and re-test.  
CHARGING SYSTEM  
(white area)  
If the Display Meter needle reads OK, charging system is functional. If it falls on the low red or high  
red areas, charging system may be malfunctioning.  
SKU 90636  
For technicial questions, please call 1-800-444-3353.  
Page 5  
 
Testing the Starter  
Note:The engine should be at normal operating temperature and the battery  
should be fully charged before doing this test.  
1. Connect the Cable Clamps (A, B) to the battery as previously described.  
2. Disable the ignition so the engine will not start.(Refer to your vehicle’s manual.)  
3. Have an assistant crank the engine. Note the voltage reading during cranking.  
4. View the Meter Display (D) and read the voltage. A reading of 9 Volts or less  
indicates excessive current draw. This may be due to a poor connection, a  
failing starter, or a battery of insufficient size for the motor.  
CAUTION! DO NOT press the Toggle Switch (C) during this test.  
INSPECTION, MAINTENANCE, AND CLEANING  
1. Periodically recheck all nuts, bolts, and screws for tightness.  
2. Store in a clean and dry location.  
3. Clean the outside of the unit with a damp cloth.Never use solvents to clean any  
part of this tool. Use compressed air to blow out debris from the load vents.  
4. After each use, clean the Cable Clamps of any possible battery electrolyte.  
Apply a thin coat of silicon grease to prevent corrosion.  
REPLACEABLE PARTS  
The BatteryTester has no replaceable parts.  
PLEASE READ THE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM  
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER  
NOR 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  
STATESTHAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN  
BY CERTIFIED AND LICENSEDTECHNICIANS 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.  
REV 07/04  
SKU 90636  
For technicial questions, please call 1-800-444-3353.  
Page 6  
 

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