Harbor Freight Tools 91129 User Manual

500 AMP500 AMP

®

500 AMP

500 AMP500 AMP

LOAD TESTERLOAD TESTER

LOAD TESTER

LOAD TESTERLOAD TESTER

91129

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www .harborfreight.com

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Copyright © 2004 by Harbor F reight 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 T ools.

For technical questions and replacement parts, please call 1-800-444-3353

Specifications

Item Description

Testing Capability 12 VDC batteries, alternators, starters
Load Test Capacity 160 amp hour; Up to 1000 cold cranking

amps maximum testing; 0 ~ 500A load

Display Meters Analog, 0~16 VDC (maximum)

Analog, 0~500A; 0~160AH; 0~1000 CCA

Test Cycle 15 seconds per test with 1 minute cool

down; 3 tests in 5 minutes
Battery Cable / Clamps 3 (L) feet, copper plated clamps, # 4 AWG
Overall Dimensions 10-1/2 (W) x 9 (H) x 5 (D) inches
Weight 8.7 lbs.
Features Carrying handle and four rubber fee t

Save This Manual

You will need the manual for the saf ety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front co v er. Keep the manual and
invoice in a safe and dry place for future reference.

General Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should alwa ys be f ollowed to re­duce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or power tools in damp or wet
locations. Don’t expose to rain. Keep work area well lit. Do not use electrically
powered tools in the presence of flammable gases or liquids.

3. Keep children awa y . Children must never be allowed in the work area. Do not let
them handle machines, tools, or extension cords.

4. Store idle equipment. When not in use , tools must be stored in a dry location to
inhibit rust. Always lock up tools and keep out of reach of children.

5. Use the right tool for the job. Do not attempt to f orce a small tool or attachment to do
the work of a larger industrial tool. There are certain applications for which this tool
was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this tool and do not use this tool for a purpose for which it was
not intended.

6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictive hair co vering to contain long hair.

Page 2SKU 91129 For technical questions, please call 1-800-444-3353.

7. Use eye and ear protection. Always wear ANSI approved impact safety goggles.
Wear an ANSI approved dust mask or respirator when working around metal, wood,
and chemical dusts and mists.

8. Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across running machines.

9. Maintain tools with care. Inspect tool cords periodically and, if damaged, have them
repaired by a qualified technician. The handles must be k ept clean, dry, and free from
oil and grease at all times.

10. Disconnect power. Disconnect Load T ester from battery when not in use.

11. Stay alert. Watch what y ou are doing, use common sense . Do not operate any tool
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. Chec k f or an y brok en parts 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 short circuits. Never make contact between battery terminals with
anything metal during load testing.

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 if under the influence of alcohol or drugs. Read warning
labels if taking prescription medicine to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.

16. Maintenance. F or your saf ety, service and maintenance should be performed
regularly by a qualified technician.

17. People with pacemakers should consult their physician(s) before using this
product. Electromagnetic fields, caused by running engines, in close proximity to a
heart pacemaker could cause interference to or failure of the pacemak er.

In addition, people with pacemakers should adhere to the following:

• Caution is necessary when near the coil, spark plug cables, or distributor of a
running engine. The engine should always be off if adjustments are to be made
to the distributor .

Specific Safety Precautions for the Load Tester

1. When connecting the Battery Cables to the battery , avoid creating sparks; especially
when the battery is being charged. Explosive gases are created during charging.
Sparking could also damage the vehicle electrical system.

Page 3SKU 91129 For technical questions, please call 1-800-444-3353.

2. Do not touch the cooling vents on the Load Tester during or immediately after
testing the battery . They become v ery hot.

3. When placing the Load Tester in the vehicle’s engine compartment, take special
care that the metal housing of the Tester does not come in contact with either
terminal of the battery or other electrical connections.

4. Be certain of the test battery polarity before connecting the test Cable Clamps. The red

Cable Clamp goes to the positive terminal of the battery. The black Cable Clamp goes
to the negative terminal of the battery . Reversing Load Tester Cable Clamps on the
battery will damage the tester.

5. Do not drop the Load T ester as it ma y aff ect proper operation.

6. Do not smok e or ha v e open flames near the battery.

7. Do not connect the Load T ester to the battery while the engine is running. Turn the

engine off before connecting.

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, b ut m ust be supplied b y the operator.

Unpacking

When unpacking, check to mak e 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. If an y parts are
missing or broken, please call Harbor F reight Tools at the number on the cover of this
manual as soon as possible.

(B) Black Cable: Clamp to
Battery Negative (-) Terminal

(A) Red Cable: Clamp to
Battery Positive (+) Terminal

Page 4SKU 91129 For technical questions, please call 1-800-444-3353.

Operation

T esting the Battery

1. Wipe the battery terminals with a cloth to remove an y dirt and grease.

2. Make sure the Load Knob (C) is in the off position. Connect the red (positive) Cable

Clamp (A) to the positive terminal (+) on the 12 V battery. See photo on page 4.

3. Connect the black (negative) Cable Clamp (B) to the negative terminal (–) on the

battery .

4. Turn the Load Knob (C) clockwise until the DC ammeter reads 1/2 the Cold Crank

Amp (CCA) rating or three times the amphour (AH) capacity of the battery . The CCA
and AH rating are printed on the battery label.

Maintain load for 15 seconds to simulate an actual load on the battery. After 15
seconds has passed, the unit will sound with a beep.

5. Vie w the DC Volts Meter and read the battery condition. Ref er to the “Battery Condition

Analysis” section on the next page.

6. Turn the Load Knob (C) counterclockwise to Off, and remo v e the Cable Clamps from

the battery .

Note: Freezing temperatures affect the battery test reading. Decrease the battery rating
50 cold cranking amps for each 50°F (10°C) below freezing 30°F (0°C).

Battery T est: Green

Amps Scale

Amp Hour Scale

CCA Scale

- OK
Red - Replace

State of Charge:
Green - OK
Red - Recharge

Alternator &
Regulator T est:
Green - OK
Red - Low

Load Knob (C)

Negative
Cable (-)

Positive
Cable (+)

Page 5SKU 91129 For technical questions, please call 1-800-444-3353.

Testing the Charging System

1. Turn the Load Knob (C) counterclockwise to the Off position.

2. Connect the Cable Clamps to the battery as previously described.

Av oid Carbon Monoxide poisoning. This gas comes
from the vehicle’ s exhaust and is colorless and odorless.
It can cause SERIOUS INJURY or DEATH if inhaled.

3. Outside, or in a well ventilated area, start the vehicle engine and run at fast idle speed.

4. Vie w the DC Volt Meter and read the Alt. - Reg. condition. Refer to the “Battery
Condition Analysis” section below.

5. Turn the vehicle’s engine off, then remove the Load Tester Cable Clamps.

Battery Condition Analysis

LOAD TEST / 15 Sec.

(Display Reading)

OK

(Green area)

BAD

(Red area)

CHARGING SYSTEM

(Alt. & Reg. Test)

BATTERY CONDITION

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, chec k for possible charging syst em
trouble. Recharge to full level.
If the DC Volt Meter needle is falling, the battery is defective or has a
bad cell. For a quick check, turn the Load Knob down,
counterclockwise and note DC Volt 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 specific gravity level, recharge, and re-test.
If the DC Volt Meter needle reads OK, charging system is functional.
If it falls on the low red or high red areas, charging system may be
malfunctioning.

Page 6SKU 91129 For technical questions, please call 1-800-444-3353.

Starter Motor T est

If starting your vehicle is difficult, you may ha ve unnecessary starter motor draw , which
dramatically shortens battery life. This test identifies starter motor performance.

1. Make sure your engine is running at normal operating temperature, and that the battery
is fully charged and in good condition.

2. Connect the Red Clamp (+) to the positiv e (+) terminal post on the battery . Connect the
Black Clamp (-) to the negative (-) terminal post on the battery.

3. Turn the Load Knob (C) counterclockwise to the Off position.

4. Disab le the engine to make sure the car will not start. Refer to your vehicle’s service /
technical manual.

5. While watching the DC Volt scale (see page 6), crank the engine briefly to determine
the voltage reading during cranking.

A display reading of 9 volts or less indicates excessive current draw. This may be
caused by a bad connection of a failing starter motor , or , the battery is too small for the
vehicle’s requirements. Consult a qualified mechanic.

6. When starter motor test is complete, remov e Black Clamp (-) from battery first; then
remove Red (+) clamp .

INSPECTION, MAINTENANCE, AND CLEANING

1. Periodically check all nuts, bolts, and screws for tightness.

2. Store in a clean, dry location.

3. Clean the outside of the unit with a damp cloth. Never use solvents to clean an y parts
of this tool. Use compressed air to blow out debris from the load vents. Allow tool to

dry completely before use.

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 Carbon Pile Load Tester has no replaceable par ts.

REV 04/05

Page 7SKU 91129 For technical questions, please call 1-800-444-3353.