Harbor Freight Tools Battery Charger 03418 User Manual

BATTERY  
CHARGER/STARTER  
Model 03418  
ASSEMBLY and OPERATING  
INSTRUCTIONS  
®
3491 Mission Oaks Blvd., Camarillo, CA 93011  
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 and replacement parts, please call 1-800-444-3353  
 
10. Disconnect power. Unplug charger when not in use.  
11. Stay alert. Watch what you are doing, use common sense. Do not operate the Charger  
when you are tired.  
12. Check for damaged parts. Before using any tool, any part that appears damaged  
should be carefully checked to determine that it will operate properly and perform its  
intended function. Check for alignment and binding of moving parts; any broken parts  
or mounting fixtures; and any other condition that may affect proper operation. Any part  
that is damaged should be properly repaired or replaced by a qualified technician. Do  
not use the tool if any switch does not turn On and Off properly.  
13. Guard against electric shock. Prevent body contact with grounded surfaces such as  
pipes, radiators, ranges, and refrigerator enclosures.  
14. Replacement parts and accessories. When servicing, use only identical  
replacement parts. Use of any other parts will void the warranty. Only use accessories  
intended for use with this tool. Approved accessories are available from Harbor Freight  
Tools.  
15. Do not operate tool is under the influence of alcohol or drugs. Read warning  
labels if taking prescription medicine to determine if your judgement or reflexes are  
impaired while taking drugs. If there is any doubt, do not operate the Charger.  
16. Use proper size and type extension cord. If an extension cord is required, it must be  
of the proper size and type to supply the correct current to the tool without heating up.  
Otherwise, the extension cord could melt and catch fire, or cause electrical damage to  
the tool.This tool requires use of an extension cord of 0 to 10 amps capability (up to  
50 feet), with wire size rated at 18 AWG. Longer extension cords require larger size  
wire. If you are using the tool outdoors, use an extension cord rated for outdoor use  
(signified by “WA” on the jacket).  
Note: More on extension cords on page 6.  
20. Maintenance. For your safety, maintenance should be performed regularly by a  
qualified technician.  
Note: Performance of this tool (if powered by line voltage) may vary depending on  
variations in local line voltage. Extension cord usage may also affect tool performance.  
Warning:The warnings, cautions, and instructions discussed in this instruction 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.  
Unpacking  
When unpacking, check to make sure the parts listed on page 11 are included. 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.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 3  
 
Battery Charger Specific Warnings  
Read all of the warnings below before operation. A failure to read and follow each of the  
warnings may result in electric shock, causing serious injury or death.  
Warning!! While charging, lead-acid batteries produce hydrogen gas which is extremely  
flammable. They generate this gas during normal operation and, at a high level, during charging.  
If any spark causes the gas to ignite, the battery could explode, sending out shrapnel-like  
pieces of battery casing and extremely caustic battery acids in every direction, with extreme  
force and speed. Even the slightest spark will suffice to ignite hydrogen gas. Pay strict  
attention to, and follow all of the warnings, each time you use the battery charger.  
1.  
2.  
3.  
Only use this charger indoors on dry, flat, stable surfaces. Any contact with water will  
create an electric shock hazard resulting in serious injury or death. Never expose the  
battery or charger to wet conditions. Do not stand in water or have wet hands when  
contacting the battery or the charger. For water avoidance, locate all non-wheeled  
chargers at least 18” off of the floor.  
If charging a marine battery, do not charge on a boat or near the water. Do not charge  
on a pier or a dock. The boat must be indoors, on a trailer, or you should remove the  
battery from the boat and take it indoors. For marine charging, do not connect the  
charger cables to the battery in the bilge or engine compartment of the boat. Follow the  
boat manufacturer’s battery charging guidelines.  
If the charger has defective or damaged wires, power cord, plug, or clamps, do not plug  
it in and operate it. Have any damaged or defective parts repaired by a qualified  
technician.  
4.  
5.  
Do not alter power cord, plug, or clamps.  
If the charger has been dropped or suffered a sharp blow, do not use it until it has been  
checked out by a qualified service technician.  
6.  
7.  
Never attempt to disassemble the battery charger. When service is needed, go to a  
qualified service technician.  
When wiping down or cleaning the charger, make sure the unit is unplugged from the  
power outlet and not connected to a battery.  
8.  
When unplugging the unit, grasp the power plug, not the power cord.  
Always operate the charger in a well ventilated area.  
9.  
10.  
11.  
Never operate the charger in close proximity to fuel tanks or gas cylinders.  
Do not smoke anywhere near the charger. Do not operate the charger near any open  
flame or a heat source of any kind.  
12.  
13.  
14.  
15.  
16.  
Do not permanently mount the battery charger to any vehicle or boat.  
Never charge a frozen battery.  
Never connect both charger clamps to the same post.  
Do not allow the two output battery clamps to come in contact with each other.  
Unless the manufacturer’s directions state otherwise, always charge the battery with  
the cell caps on.  
17.  
Always unplug the battery charger before connecting or disconnecting battery clamps  
from a battery.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 4  
 
Battery Charger Specific Warnings (continued)  
Be extra careful about dropping tools or anything metal near a charging battery as  
sparks from the object may ignite the lead acid gasses.  
18.  
19.  
20.  
21.  
Only charge lead acid batteries with this charger. Do not attempt to charge dry cell  
household batteries as they may explode.  
Position the battery charger as far away from the battery as possible. Use the full  
extension length of the DC charging cables.  
It is okay to rock or twist a clamp on a battery post at the time of connection. Once you  
have set a clamp on a battery post, do not rock it. Rocking a clamp (other than at  
original connection time) may cause sparking resulting in an explosion.  
22.  
Check wire and cable connections for tightness before starting a charge (before plugging  
in the power cord). Loose connections cause sparks.  
Reminder: Never charge in a closed compartment. The charging location must be well-  
ventilated.  
Battery Acid Hazards  
1.  
2.  
3.  
Always wear eye protection and adequate clothing (long sleeves and long pants)  
including gloves when working near battery acids.  
When working with lead acid batteries, have someone in close voice proximity in case  
you should need some help due to battery acid contact.  
Keep a lot of fresh water and soap close by to use immediately if battery acid contacts  
your skin, eyes, or clothing.  
Note: If any contact with battery acid is made, you must act quickly. Immediately wash the  
affected areas with soap and water. If eye contact is made, flush the eyes with running cold  
water for ten minutes and then immediately get medical attention.  
Fire Hazards  
1.  
2.  
Use of attachments not designed for this specific model may cause a fire.  
Disassembling the battery charger may cause a fire. Always have a qualified service  
technician work on the battery charger.  
3.  
Arcing flames and sparks are possible if you plug in the battery charger before  
connecting to the battery. Always unplug the charger before battery hookup.  
More Charger Warnings  
1.  
Short circuits can deliver enough heat to weld a piece of metal (ie: jewelry) to your skin.  
Always remove any metal or jewelry from your body or pockets before charging a battery.  
2.  
Do not connect charger clamps to a battery in a vehicle when the engine is running. Do  
not work on or near any vehicle when the engine is running. Moving engine parts can  
cause serious injury or death.  
3.  
Do not position the charger above the battery being charged or battery gases will corrode  
the charger.  
4.  
5.  
Do not set a battery on top of a charger.  
Do not allow battery acids to come in contact with the charger.  
Note: This charger is not recommended for batteries with a built in Hydrometer eye. The  
reading of the built in eye will conflict with the ammeter readings.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
Operation  
About Charging Batteries  
Batteries draw as much power as they need from the charger. The charger does not force  
current into the battery. When a battery is close to dead or very low charged, it will want to draw  
more current. When a dead or low battery is charged, the charger’s ammeter will register at the  
high end. As the battery charges, the reading will move down toward the low end, resting on  
zero, when the battery is fully charged. See FIGURE 1 below.  
FIGURE 1  
Note: The ammeter shows the amount of current being drawn from the charger. It does not  
show what the charger is capable of delivering. When the battery is fully charged and registering  
zero on the ammeter, a small trickle charge will continue to move from the charger to the  
battery. If you do not disconnect the charger from the battery, eventually the heat build up from  
the trickle charge will cause the battery acid to boil and overcharge the battery causing damage  
to the battery. You must constantly monitor battery charging progress.  
Power Requirements  
This charger must have a 120 volt, 60 Hertz AC (alternating current) power source fused at an  
amperage greater than or equal to the input rating of this charger. Do not plug this charger in  
until directed to do so in the following pages of this manual.  
This charger has a 3-prong plug. The power outlet/receptacle must be grounded. If you use  
an adapter (3-prong to 2-prong) to connect the plug from the charger to the outlet, the adapter  
must be a properly grounded adapter and must only be used temporarily, until a qualified  
electrician can install a properly grounded receptacle.  
Extension cord use is determined by the input amp rating (2.2 amps) of the charger.  
Minimum size (AWG rating) of a 25 foot cord is 18 gauge.  
Minimum size (AWG rating) of a 50 foot cord is 18 gauge.  
Minimum size (AWG rating) of a 100 foot cord is 14 gauge.  
Minimum size (AWG rating) of a 150 foot cord is 12 gauge.  
Never alter extension cords.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 6  
 
Operation (continued)  
Preparing the Battery  
1.  
If necessary, remove the battery from the vehicle to charge it. When removing the battery,  
always remove the grounded battery cable first.  
Reminder: The vehicle’s engine must be OFF when removing, replacing, or charging a battery.  
2.  
If necessary, add distilled water to the battery cells before charging. Read and follow  
the battery manufacturer’s instruction manual. Never add water to a battery while attached  
to a charger, or in close proximity to the charger. Do not overfill.  
3.  
4.  
Clean battery terminals.  
Check the battery manufacturer’s instructions on whether or not to have the cell caps  
on when charging. If not stated, leave the cell caps on.  
5.  
Determine the battery voltage from the battery or the manufacturer’s manual.  
Operation Instructions  
Warning! Read and understand all of the safety instructions in this manual before operating  
the charger.  
Warning!! If the Reverse Connect light (See FIGURE 1 on page 6) ever lights, immediately  
unplug the charger and reconnect the clamps to the battery to alleviate the problem.  
Connection to a battery installed in a vehicle.  
Warning! The vehicle’s engine must be OFF during the entire charging process. Always read  
and adhere to all the safety warnings and instructions provided in the vehicle’s manual.  
1.  
2.  
Make sure the AC Power Cord (#3) is not plugged in.  
Set up the charger on a flat, dry surface that allows you to position the Power Cord (#3)  
and the clamp cords where they won’t be damaged by the vehicle doors, hood, or  
sharp engine parts.  
Note: Most vehicles are negative-grounded vehicles. Number 3 below instructs setup for  
the most common negative-grounded vehicles. Number 4 below addresses the less  
common positive-grounded vehicles. If you are not sure about your vehicle, check the  
vehicle’s instruction manual or talk to the a qualified service technician.  
3.  
Negative-grounded vehicles: The battery will have two terminals. One should be  
marked POSITIVE, POS, P, OR +. The Negative terminal should be marked NEGATIVE,  
NEG, N, OR -. Connect the red Clamp (#2) to the positive (ungrounded) terminal of the  
battery. Connect the black Clamp (#2) to a heavy gauge metal part of your vehicle  
chassis or engine block away from the battery. Do not connect to the black Clamp (#2)  
to the Negative (black) terminal on the battery, fuel lines, the carburetor, or sheet metal  
body parts.  
4.  
Positive-grounded vehicles: The battery will have two terminals. Connect the  
NEGATIVE black charger Clamp (#2) to the negative ungrounded terminal of the battery.  
Connect the POSITIVE red Clamp (#2) to a heavy gauge metal part of your vehicle  
chassis or engine block away from the battery. Do not connect to the NEGATIVE (black)  
terminal on the battery, fuel lines, the carburetor, or sheet metal body parts.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
Operation (continued)  
Connection to a battery outside a vehicle.  
1.  
2.  
Make sure the AC Power Cord (#3) is not plugged in.  
The battery will have two terminals. One should be marked POSITIVE, POS, P, OR +.  
The Negative terminal should be marked NEGATIVE, NEG, N, OR -. To protect you by  
keeping you further away from the battery, connect a battery cable (not included) that is  
at least 24” long and #6 AWG (American Wire Gauge) to the NEGATIVE terminal of the  
battery.  
3.  
4.  
Connect the POSITIVE (red) Clamp (#2) from the charger to the POSITIVE terminal of  
the battery.  
Position yourself and the free end of the battery cable (not included) that is attached to  
the NEGATIVE battery terminal, as far away as possible from the battery. While facing  
away from the battery, connect the NEGATIVE (black) charger Clamp (#2) to the free  
end of the battery cable (not included).  
Charging  
1. The charger must be set to the same voltage as the battery.  
Settings:  
The six volt setting (10A/6V) on the select switch is for charging medium to large 6 volt  
batteries. It is a manual setting. After the battery is fully charged, the charger must be  
disconnected to avoid damage. Charging time is 6 to 8 hours, and must be monitored throughout  
the operation.  
The two amp, 12 volt setting (2A/Auto) on the select switch is for charging small 12 volt  
batteries or warming larger automotive batteries overnight to assist in cold weather starting. It  
will not fully charge larger or deep cycle batteries. This setting is automatic. It will slow down  
the charging rate when the battery reaches full charge. Charging time is a little longer on the  
automatic setting as the unit tapers off slowly. It takes approximately 6-8 hours and it isn’t as  
critical to monitor.  
The ten amp, 12 volt setting (10A/12V) on the select switch is for charging medium to  
large 12 volt batteries. This setting is automatic. It will slow down the charging rate when the  
battery reaches full charge. Charging time is a little longer on the automatic setting as the unit  
tapers off slowly. It takes approximately 6-8 hours and it isn’t as critical to monitor.  
Small batteries: Lawn mower, motorcycle, or snowmobile type batteries have charge  
rate limits. Always charge them on the two amp, 12 volt setting (2A/Auto) on the select switch.  
Do not use this charger for charging small 6 volt batteries unless the manufacturer of the  
battery states that the battery will withstand a 10 amp charge rate.  
Note: More on manual charging times discussed on page 10.  
Warning!! If the Reverse Connect light (see FIGURE 1) ever lights, immediately unplug the  
charger and reconnect the clamps to the battery to alleviate the problem.  
Note: Engine starting settings are covered on page 9.  
2.  
When ready, set the select function switch (see FIGURE 1) to Charge and plug in the  
charger to begin charging.  
3.  
During charging, whether using the manual or automatic modes, it is important to monitor  
the operation by checking the ammeter (see FIGURE 1).  
Note: When the battery is charged the green charge complete light will turn on.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 8  
 
Operation (continued)  
Disconnecting after charging.  
First, disconnect the charger clamp that is not attached directly to the battery. At this stage,  
don’t let anything come in contact with the clamp. Then, disconnect the clamp that is in contact  
with the battery terminal. Do not let the clamps touch each other while you unplug the charger.  
Ammeter Readings  
The ammeter shows how much charging current is drawn from the charger (to the battery).  
When a dead or low battery is charged the charger’s ammeter will register at the high end. As  
the battery charges, the reading will move down toward the low end, resting on zero, when the  
battery is fully charged. When using the battery in engine starting mode (discussed  
further down this page) the needle on the ammeter will peg toward the high end of the  
ammeter.  
Do not depend on reading the ammeter to approximate how long charging will take. Even at  
full charge the ammeter will still be providing as much as 50 percent of the charger’s output  
rating. It’s best to follow the charging times listed on page 8. Sometimes, certain conditions  
such as a cold battery, a sulfated battery, or a deeply discharged Lead Calcium battery (on  
many newer cars) may cause the ammeter to read near a full charge, when the charging  
process is only beginning.  
Note: Cold batteries (at or below 32 degrees Fahrenheit) begin charging at a low rate and  
then increase as the battery warms. When the battery charges up, the rate will decrease at a  
normal rate.  
DEEPLY DISCHARGED LEAD-CALCIUM batteries will read out differently as they need an  
activation procedure covered on page 10 of this manual.  
SHORTED BATTERIES will read on the ammeter as a high end peg at the beginning of the  
charging process. If after 5-10 minutes the needle does not move off of the high end, the  
battery probably has a short circuit. Unplug the charger and discontinue use. Have the battery  
checked by a qualified technician.  
Engine Starting  
Note: This charger’s high-current output can help start vehicles with weak batteries. Please  
note that some of the newer vehicles with onboard computers may be damaged from this  
process. Thoroughly read the vehicle owner’s manual before using this procedure.  
1.  
2.  
3.  
4.  
Connect the charger to the battery as discussed in the previous operating instructions  
on page 7 and 8.  
Set the charger to charge the battery for 5-10 minutes according to the appropriate  
charge rate for the size of the battery as explained on the previous 2 pages.  
Set the select function switch (See FIGURE 1 on page 6) to Start and the select switch  
(see FIGURE 1 on page 6) to 55A.  
Try to start the vehicle. If it doesn’t start in 2-3 minutes, stop and wait for the vehicle to  
charge for 5-10 minutes more and try again. Repeat this process until successful.  
Note: If the engine continues to spin but will not start after several tries, than you may have  
another problem unrelated to charging. Stop attempting to start/charge the battery until  
the problem is found and corrected. Continued engine cranking may damage the  
vehicle’s starter motor.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
Operation (continued)  
More on charging times.  
1.  
When using a manual mode for charging, you can check the present level of a battery  
by using a hydrometer or electronic percent-of-charge tester (not included). Be sure to  
read and follow all of the instructions in the manual for these testing tools.  
Note: Batteries that are only 25% charged or lower can easily freeze.  
2.  
When you determine the percent of charge needed, you can determine the batteries  
needed charging time by using the formula below. First you will need to know the  
AMPERE HOURS or RESERVE CAPACITY. If it is not listed on the battery, check with  
the manufacturer of the battery.  
Formula: Amp Hour Rating x Percent of Change Needed  
X 1.25 = hours to charge  
Amp Setting Selected on Charger  
Example:  
Battery state of charge = 25%  
Battery needs  
= 75% or .75  
Amp setting on charger = 10  
Amp hour rating of battery = 60  
60 times .75 divided by 10 = 4.5  
4.5 times 1.25 = 5.6 hours needed to charge.  
DEEPLY DISCHARGED LEAD-CALCIUM batteries on many of the newer vehicles may  
require an activation period when deeply discharged. This period may last from 4-8 hours. If  
you notice that the ammeter needle is at or near zero at the beginning of the charging  
process, your battery is less than 25% charged and needs to be activated or pre-charged.  
You know it needs pre-charge activation when the ammeter reads zero and neither the Charge  
Complete or the Reverse Connect lights are lit. Pre-charge activation is needed if the battery  
is already known to be dead and the Charge Complete light is on. If the Charge complete  
light is lit, do not attempt pre-charge activation until the battery is tested with a hydrometer  
or other testing methods and found to be low or dead. If you determine that the battery  
needs pre-charge activation, take it to a qualified service technician.  
Troubleshooting  
No Ammeter Reading:  
1.  
2.  
3.  
4.  
5.  
Make sure the charger is plugged in.  
Unplug the unit and check all of the connections making sure clean contact is made.  
Check that the battery isn’t damaged and incapable of being charged.  
Double check that you have selected the correct settings.  
Make sure you allow enough charging time.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 10  
 
Parts List and Assembly Drawing  
Part No.  
Description  
Charger  
Clamps (2)  
Power Cord  
1
2
3
Maintenance  
Always unplug the unit before attempting any maintenance.  
1.  
Clean the clamps after each use and remove any battery fluid with a solution of water  
and baking soda.  
2.  
3.  
To prevent damage to the cable wires and the power cord, coil them after each use.  
Wipe the case down with a soft cloth.  
PLEASE READTHE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS  
MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE 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 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 PARTSTHERETO.  
NOTE: Some parts are listed and shown for illustration purposes only and are not available indi-  
vidually as replacement parts.  
SKU 03418  
For technical questions, please call 1-800-444-3353.  
Page 11  
 

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