Harbor Freight Tools 90636 User Manual

100 AMP LOAD BA100 AMP LOAD BA

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100 AMP LOAD BA

100 AMP LOAD BA100 AMP LOAD BA

CHARGING SYSTEM TESTERCHARGING SYSTEM TESTER

CHARGING SYSTEM TESTER

CHARGING SYSTEM TESTERCHARGING SYSTEM TESTER

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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.

SPECIFICATIONS

Item Description

Capability 6 and 12 VDC battery tester with

charging system output

Load Test Capacity 100 amps; 50~1000 cold cranking

amps
Display Meter Analog, 0~16 VDC (maximum)
Test Cycle 10 seconds per test with 1 minute cool

down; 3 tests in 5 minutes
Battery Cable / Clamps 16-3/4 inch; Copper plated clamps
Overall Dimensions 12-3/4 (L) x 6 (W) x 3 (D) inches
Features Carrying handle and four rubber feet

Save This Manual

You will need the manual f or the saf ety warnings and precautions, operating and
maintenance procedures. Keep your invoice with this man ual in a saf e and dry
place for future reference .

SAFETY PRECAUTIONS

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instruc­tions listed below may result in electric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

1. Keep your w ork area clean and well lit. Cluttered benches and dark areas in vite
accidents.

2. Do not operate power tools in e xplosive atmospheres, such as in the presence
of flammable liquids, gases, or dust. Power tools create sparks which may
ignite the dust or fumes.

3. Keep bystanders, children, and visitors away while operating a power tool.
Distractions can cause you to lose control. Protect others in the work area from
debris such as chips and sparks. Provide barriers or shields as needed.

4. Do not force the tool. Use the correct tool f or y our application. The correct tool
will do the job better and safer at the rate f or which it is designed.

5. Do not use the power tool if the P ower Switch does not turn it on or off. Any tool
that cannot be controlled with the Power Switch is dangerous and must be
replaced.

6. Store idle tools out of reach of children and other untrained persons. Tools are
dangerous in the hands of untrained users.

SKU 90636 For technicial questions, please call 1-800-444-3353. Page 2

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 perf ormed 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.

10. Always wear ANSI approved safety
impact eye goggles and heavy work
gloves when using this tool. Using
personal safety de vices reduce the risk
for injury . Safety impact eye goggles and

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 .

CAUTION!

Battery acid may cause severe

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. Alw ays 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.

W ARNING! 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, a void 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 v ehicle electrical
system.

2. Be certain of the test battery polarity before connecting the test Cab le 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 Battery Tester in the vehicle (on the frame, engine, or f ender),
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 hav e open flames near the battery.

SKU 90636 For technicial questions, please call 1-800-444-3353. Page 3

6. Rev ersing Battery Tester Cable Clamps on the battery will damage the tester.

7. Do not connect the Battery T ester 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 par ts are included. Refer to the
Assembly section, and the Assembly Dra wing and Parts List at the end of this manual.

(A)

(D)

If any parts are missing or broken, please call Harbor Freight Tools at the number
on the cover of this manual as soon as possib le .

(C)

(B)

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 batter y 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 positiv e terminal (+) on the 6
or 12 V lead-acid battery. (See photo abo v e.)

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 12 V, disconnect the battery and recharge before testing.
If recharging will not bring the reading above 12 V the battery is def ective . 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 fr om

the vehicle exhaust and is colorless and odorless. It can cause
serious injury or death if inhaled. Never run the vehic le’s engine
inside a garage or any other enclosed space.

3. View the Meter Displa y (D) and read the charging system condition (far right on
the gauge). Ref er to the “Battery Condition Analysis” section below.

CAUTION! DO NOT press the T oggle Switc h (C) during this test.

Battery Condition Analysis

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SKU 90636 For technicial questions, please call 1-800-444-3353. Page 5

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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. (Ref er to your vehicle’ s manual.)

3. Have an assistant cr ank the engine. Note the v oltage 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 T oggle Switc h (C) during this test.

INSPECTION, MAINTENANCE, AND CLEANING

1. Periodically recheck all n uts , 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 solv ents to clean any
part of this tool. Use compressed air to blow out debris from the load v ents.

4. After each use, clean the Cable Clamps of any possible battery electrolyte.
Apply a thin coat of silicon grease to prev ent corrosion.

REPLACEABLE PARTS

The Battery Tester has no replaceable parts.

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THE 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
ST ATES THA T ALL REPAIRS AND P ARTS REPLACEMENTS SHOULD BE UNDER T AKEN
BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE B UYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS T O 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