Lincoln Electric IM10130 User Manual
Manual Wheel Charger
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IM10130
September, 2012
For use with machines having Code Numbers:
Safety Depends on You
Century charging equipment
is designed and built with
safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you
act and be careful.
(See Below)
K3151-1 (11862)
60/40/30/225, 6/12/24V
K3150-1 (11861)
60/40/2/250, 6/12V
W/TEST
K3149-1 (11860)
40/20/2/200, 6/12V
W/TEST
OPERATOR’S MANUAL
Century Equipment
2345 Murphy Blvd. Gainesville, GA 30504
TABLE OF CONTENTS
ENGLISH
SAFETY SUMMARY ....................................3
SAFETY INFORMATION ........................3
SHOCK HAZARDS ............................3
EXPLOSIVE GAS HAZARDS ............3
BATTERY EXPLOSION HAZARDS ..4
FIRE HAZARDS ................................4
BATTERYACID HAZARDS................4
MOVING PARTS HAZARDS..............4
BURN HAZARDS ..............................4
INTRODUCTION ..........................................5
DESCRIPTION ........................................5
HOW BATTERIES CHARGE ..................5
SPARK PREVENTION ............................5
DEEPLY-DISCHARGED
LEAD-CALCIUM BATTERIES............5
ASSEMBLY ..................................................6
ASSEMBLY INSTRUCTIONS..................6
PREPARATION ............................................7
CHARGER PREPARATION ....................7
CHARGER PLACEMENT ..................7
PROVIDE REQUIRED POWER..............7
EXTENSION CORDS ........................7
BATTERY PREPARATION ......................7
CONTROLS AND INDICATORS ..................8
CONTROL SETTING INSTRUCTIONS ..8
CHARGE VOLTAGE AND
RATE SELECTION ............................8
TIMER SWITCH SETTING ................8
VOLTMETER/TEST METER
TESTING............................................8
BATTERY PERCENT OF CHARGE
TEST (12 VOLT ONLY)......................9
ALTERNATOR TEST
(12 VOLT ONLY) ..............................9
PRE-CHARGE BATTERY
ACTIVATION ......................................9
OPERATION ..............................................10
OPERATING INSTRUCTIONS..............10
CONNECTING TO BATTERIES
INSTALLED IN VEHICLES ..............10
CONNECTING TO BATTERIES
OUTSIDE A VEHICLE ..........................10
CHARGING INSTRUCTIONS................11
READING AN AMMETER......................11
CHARGING TIME INSTRUCTIONS.12,13
ENGINE STARTING..............................14
MAINTENANCE..........................................15
TROUBLESHOOTING ..........................15
WIRE DIAGRAM.S.................................16, 17
PARTS PAGES ......................P-712 SERIES
2
SAFETY SUMMARY
Congratulations on the purchase of your new battery charger. We wish to acknowledge Underwriters Laboratories
(U/L) for contributing the following important safety precautions. Please read and retain these instructions for the continued safe use of your new charger.
This manual contains important safety information. DO
NOT OPERATE this equipment UNTIL YOU HAVE READ
this safety summary!
IMPORTANT SAFETY INSTRUCTIONS. SAVE
THESE INSTRUCTIONS
SAFETY INFORMATION
The following safety information is provided as guidelines to
help you operate your new battery charger under the safest
possible conditions. Any equipment that uses electrical
power can be potentially dangerous to use when safety or
safe handling instructions are not known or not followed.
The following safety information is provided to give the user
the information necessary for safe use and operation.
A procedure step preceded by WARNING is an indication
that the next
ous to a person if proper safety precautions are not heeded.
A procedure preceded by a CAUTION is an indication that
the next
equipment being used.
A NOTE may be used before or after a procedure step to
highlight or explain something in that step.
step contains a procedure that might be injuri-
step contains a procedure that might damage the
11. ALWAYS plug in and unplug the ac power cord by
grasping the power cord plug, NOT THE POWER CORD,
to reduce risk of damaging power cord.
12. ALWAYS remove personal metal items such as rings,
bracelets, and watches when working with a lead-acid
battery. Alead-acid battery can produce a short circuit
current high enough to weld a ring or any jewelry to
metal causing a severe burn.
13. ALWAYS unplug the battery charger from the ac outlet
before attempting any cleaning or maintenance. Turning
the charger’s control(s) OFF, alone, will not remove all
electricity from the charger.
14. An extension cord should not be used unless absolutely
necessary. Use of an improper extension cord could
result in a fire or electric shock. If an extension cord
must be used, make sure that:
a. the pins on the plug of the extension cord are the
same number, size, and shape as those of the plug
on the charger,
b. the extension cord is properly wired and in good
electrical condition, and
c. the wire size is large enough for the length of cord as
specified in the following chart.
Length in feet: 25 50 100 150
cord AWG size: 16 12 10 8
SHOCK HAZARDS
1. This battery charger is intended for indoor use only. Do
not expose the charger to rain or snow.
2. NEVER attempt to charge a marine (boat) battery while
the boat is on or near the water. A boat must be on a
trailer and located indoors before attempting to charge its
battery(s). The boat manufacturer’s battery charging
instructions must be followed exactly.
3. NEVER set the charger, output cable or clamps, or ac
power cord plug in water or on wet surfaces.
4. NEVER use this charger on a pier or dock. Charger
could fall in water, creating an electric shock hazard.
5. NEVER attempt to plug in or operate the battery charger
with defective or damaged wires, power cord, or power
cord plug. Have any of these parts that are defective or
damaged replaced by qualified personnel IMMEDIATELY.
6. NEVER attempt to plug in the charger or operate its
controls with wet hands or while standing in water.
7. NEVER alter the ac power cord or power cord plug provided with the battery charger.
8. NEVER use an attachment not recommended or sold by
the battery charger manufacturer for use with this specific
model battery charger
9. NEVER operate this battery charger if it has received a
sharp blow, been dropped, or similarly damaged, until
after being inspected and/or repaired by qualified service
personnel.
10. NEVER disassemble this battery charger. Take the battery charger to qualified service personnel when service
or repair is needed.
EXPLOSIVE GAS HAZARDS
1. Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gasses during normal
operations and, at an even higher level, during charging.
If anything is allowed to ignite these gasses, the battery
may explode, sending pieces of the battery and extremely caustic battery acid out in all directions and with
extreme force. Since just the slightest spark is sufficient
to ignite these gasses, it is of UTMOST IMPORTANCE
that you read this manual and follow the instructions
exactly, before using your battery charger each time.
2. NEVER operate this battery charger near any fuel tanks
or gas cylinders. This charger can produce sparks that
could ignite gasses and cause an explosion.
3. NEVER attempt to permanently mount this battery
charger on a marine or recreational vehicle.
4. NEVER attempt to connect this charger’s output cables
directly to the battery(s) in the bilge or engine compartment of a boat. Follow the boat manufacturer’s battery
charging instructions exactly.
3
BATTERY EXPLOSION HAZARDS
FIRE HAZARDS
1. To reduce the risk of battery explosion, read, understand,
and follow these instructions, those published by the battery manufacturer, and those of the manufacturer of any
equipment you intend to use near the battery. Review
cautionary markings on these products and on the
engine. If unable to determine the battery manufacturer’s
requirements for charging, always charge the battery with
the cell caps in place. In addition, make certain that anyone else that uses this equipment, or is a bystander in
the vicinity of a charging battery, understands and follows
these safety instructions as well.
2. NEVER smoke or allow a spark or flame in the vicinity of
the battery or engine.
3. NEVER operate the battery charger in a closed-in area
or restrict ventilation in any way.
4. NEVER charge a frozen battery as battery explosion can
result.
5. NEVER connect BOTH battery charger clamps DIRECTLYto the two posts of the same battery. See OPERATION INSTRUCTIONS for connection procedures.
6. NEVER charge batteries other than a LEAD-ACID type.
Especially, DO NOTuse for charging dry-cell batteries
that are commonly used with toys and home appliances.
These batteries may burst and cause injury to persons or
damage property.
7. NEVER allow the dc output clamps to touch each other.
8. ALWAYS be extra cautious to reduce the risk of dropping a metal object, such as a tool, onto or near the battery. Doing so could produce a spark or short circuit the
battery or other electrical part that could cause an explosion.
9. ALWAYS make sure the area around a battery is well
ventilated while it is being charged. Gas can be forcefully blown away by using a piece of cardboard or other
non-metallic material as a fan.
10. ALWAYS make sure that the ac power cord is
unplugged from the ac outlet or extension cord BEFORE
connecting or disconnecting the battery charger clamps,
to prevent arcing or burning.
11. ALWAYS locate the battery charger as far away from the
battery as the dc output cables will permit.
12. ALWAYS twist or rock charger clamps back and forth
several times on the battery post and the other point of
connection at the time of initial connection. This helps
keep the clamps from slipping off their points of connection which helps reduce the risk of sparking. DO NOT
rock the clamp connected to the battery post AFTER the
second connection (at a point away from the battery) is
made or sparking may occur at the battery post.
13. ALWAYS check the cable and wire connections at the
battery(s) for tightness - BEFORE STARTING TO
CHARGE. Aloose connection can cause sparks or
excessive heating which could cause a battery explosion.
14. ALWAYS make sure the battery compartment is open
and well ventilated before charging.
1. NEVER use an attachment not recommended or sold by
the battery charger manufacturer for use with your specific model charger.
2. NEVER disassemble the battery charger; take it to qualified service personnel when service or repair is needed.
3. ALWAYS make sure that the ac power cord is
unplugged from the ac outlet or extension cord, BEFORE
connecting or disconnecting the battery charger clamps,
to prevent arcing or burning.
BATTERY ACID HAZARDS
1. ALWAYS have someone within range of your voice and
close enough to quickly come to your aid when working
near a lead-acid battery.
2. ALWAYS have plenty of fresh water and soap nearby in
case battery acid contacts eyes, skin, or clothing.
3. ALWAYS wear complete eye and clothing protection and
avoid touching eyes while working with a battery.
4. ALWAYS act QUICKLY if contact with battery acid is
made. If acid contacts skin or clothing, wash IMMEDIATELY with soap and water. If acid enters the eye,
IMMEDIATELY flood the eye with running cold water for
at least 10 minutes. Get medical attention IMMEDIATELY.
MOVING PARTS HAZARDS
1. NEVER connect the battery charger clamps to a vehicle
when the engine is running.
2. ALWAYS stay clear of fan blades, fan belts, pulleys and
other moving engine parts when working near an engine.
Moving engine parts can cause severe personal injury
including dismemberment.
3. ALWAYS make sure that the battery charger cables and
clamps are positioned so they will not come in contact
with any moving engine parts.
BURN HAZARDS
1. NEVER lean on or rest against the engine or cooling
system parts when the vehicle is running.
2. ALWAYS stay clear of the cooling system, engine, and
engine manifold. These engine components get very hot
and retain heat for a long time. Touching any of these
components can cause severe burns.
4
INTRODUCTION
DESCRIPTION
This battery charger is designed to handle the majority of
your charging and starting needs.
MULTIPLE CHARGE RATES for various battery sizes.
High-AMPERAGE ENGINE START to help start vehi-
cles when the battery is too weak to do the job alone.
An AMMETER to monitor charging progress
A TIMER switch to set the desired charge time.
LARGE SAW-TOOTH CLAMPS assure good connec-
tion to top or side-mount battery terminals.
WHEELAND HANDLE KIT for easy moving around
your shop.
HEAVY-DUTY CONSTRUCTION for long, trouble-free
life.
HOW BATTERIES CHARGE
A charger DOES NOT FORCE current into a battery - it
makes a limited amount of current available and the battery
draws as much of it as it needs, up to or slightly greater
than the rated output current capability of the charger.
The closer a battery is to zero charge (dead battery), the
more charging current it will want to draw. When charging
begins, on a dead battery, the chargers ammeter will register toward the high end of the ammeter scale and move
toward zero as the battery becomes more fully charged.
KEEP IN MIND, the ammeter registers the amount of
amperage being drawn from the charger by the battery, not
what the charger is capable of delivering.
One would expect a battery to draw zero amps when it
reaches 100% charge. But at 100% charge, the battery will
continue to draw a low level of current and convert it into
heat within the battery. If left connected and charging after
reaching 100% charge, the battery acid will begin to boil,
resulting in overcharging and possible battery damage.
NOTE: A slow bubbling sound may be heard coming
from the battery during the charging process.
This is a normal condition and just another
indicator the battery is being charged.
To reduce the risk of battery overcharging, it is important to
thoroughly read this instruction manual.
SPARK PREVENTION
MAKE SURE no sparks or flames occur near the battery,
especially during charging. It takes very little to ignite the
explosive gasses produced by a lead-acid battery. Read,
understand, and follow the safety information provided in the
SAFETY SUMMARY section of this manual before attempting to work with or near a lead-acid battery.
For more information about batteries and battery charging,
contact Battery Council International at (312) 644-6610, and
request their BATTERY SERVICE MANUAL, which is available for a nominal charge.
DEEPLY-DISCHARGED LEAD-CALCIUM
BATTERIES
Many newer automotive batteries are of a lead-calcium plate
design. When deeply discharged, they may require an activation period before accepting a measurable charge. This
activation period may take as long as 4 to 8 hours.
If, at the beginning of the charging process, you notice that
the ammeter (if so equipped) is at or near zero, but you
have determined that the battery is very discharged (less
than 25% of charge), this is a good indication that an activation period is required (see PRE-CHARGE BATTERY ACTIVATION).
5
ASSEMBLY OF HANDLE AND CLAMP
HOLDER
ASSEMBLY
FIGURE 3
Assemble the charger handle and clamp holder according to the following instructions and illustrations.
1. Carefully remove the charger unit and all associated
hardware from carton, note the charger is shipped
with the handle partially secured, and resting in a
down position on the front of the unit.
2. Unscrew the top 2 screws on either side of the
charger. Remove the bottom 2 screws holding handle with the washers (washers will be discarded), as
shown in Figure 1 .
FIGURE 1
REMOVE AND DISCARD
2 WASHERS
TOP
2 SCREWS
BOTTOM
2 SCREWS
HANDLE
REPLACE TOP
2 SCREWS THEN
TIGHTEN ALL 4
SCREWS
5. Carefully screw the clamp holder together onto the
handle as shown in Figure 4.
FIGURE 4
CLAMP HOLDER
3. Then replace the bottom 2 screws by screwing in part
way so the handle can be move to an upright position. (See Figure 2)
FIGURE 2
REPLACE BOTTOM
2 SCREWS BY
SCREWING IN
PAR T W AY
ROTATE HANDLE
TO UPRIGHT
POSITION
4. Align the holes of the handle with the top 2 screw
holes of the charger. Replace the top 2 screws which
you removed in Figure 1. T ighten all 4 screws secur-
ing the handle in the upright position. (See Figure 3)
HANDLE
SCREWS
6
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