ARTER AND DC POWER SOURCE

JUMPSTAR ARTER AND DC POWER SOURCE 91045 ASSEMBLY AND 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 Power Output Battery Type Charging Internal Battery Battery Cables LED Indicators Overall Dimensions Accessories Weight Description 12 VDC, 300 amps (cranking); 700 amps (peak) 12 VDC, 12 AH, sealed acid battery; UL listed Charges using a 120 VAC power cord and internal power supply # 8 AWG, 18 inches; 200 amp, copper plated cable clamps Red = less than 50% charge; also on while charging; Yellow = 50% to 75% charge; Green = full charge; 6-1/2 (W) x 7-3/4 (L) x 8-7/8 (H) inches Power adapter cable enables powering of devices using 12 VDC. DC socket has a 15 amp overload circuit breaker (reset on back of unit) 12 lbs. SAVE THIS MANUAL You will need the manual for the safety 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 cover. Keep the manual and invoice in a safe and dry place for future reference. GENERAL SAFETY RULES 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 Work Area 1. Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. 2. Do not operate Jumpstarter in explosive 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 the Jumpstarter. Distractions can cause you to lose control. Page 2

Electrical Safety 4. Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is grounded. 5. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. 6. Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. If the tools should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user. 7. Double insulated tools are equipped with a polarized plug (one blade is wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation eliminates the need for the three wire grounded power cord and grounded power supply system. 8. Do not abuse the Power Cord. Never use the Power Cord to carry the tools or pull the Plug from an outlet. Keep the Power Cord away from heat, oil, sharp edges, or moving parts. Replace damaged Power Cords immediately. Damaged Power Cords increase the risk of electric shock. 9. When operating a power tool outside, use an outdoor extension cord marked W-A or W. These extension cords are rated for outdoor use, and reduce the risk of electric shock. Personal Safety 10. Stay alert. Watch what you are doing, and use common sense when operating this product. Do not use while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury. 11. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. 12. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the product in unexpected situations. 13. Use safety equipment. Always wear eye protection. A dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for all appropriate conditions. Page 3

Tool Use and Care 14. Disconnect the Power Cord Plug from the power source before making any adjustments, changing accessories, or storing the product. 15. Store this product out of reach of children and other untrained persons. Tools are dangerous in the hands of untrained users. 16. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool. Service 17. Service for this product must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. 18. When servicing a tool, use only identical replacement parts. Follow instructions in the Inspection, Maintenance, And Cleaning section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury. SPECIFIC SAFETY RULES FOR THE JUMPSTARTER 1. Maintain labels and nameplates on the Jumpstarter. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 2. Always wear safety impact eye goggles and heavy work gloves when working on or around lead-acid batteries. Using personal safety devices reduce the risk for injury. Safety impact eye goggles and heavy work gloves are available from Harbor Freight Tools. 3. 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 a power tool in areas near flammable chemicals, dusts, and vapors. Do not use this product in a damp or wet location. 4. Always unplug the Jumpstarter from its electrical outlet before performing any inspection, maintenance, or cleaning procedures. 5. Avoid contact with Battery Acid. If splashed, immediately wash effected area with clean water. Continue washing area until medical help arrives. 6. Turn vehicle ignition off before making cable connections. 7. Connect cables to proper polarities. Connect the red cable to the positive battery terminal, and the black cable to an unpainted negative body ground (for a negative grounded system). 8. Keep clear of fan blades, belts, pulleys, and other moving parts of the engine that may cause injury, or damage to the Jumpstarter. Page 4

9. Use Jumpstarter in well ventilated areas. Do not attempt to jump start vehicle around flammable gases or liquids. 10. Do not allow the Black and Red clamps to touch. If this happens it can melt clamps or other metal objects. Place them only on the corresponding battery terminals and ground. When finished jumpstarting the engine, immediately secure each clamp to the plastic grips on the back of the unit. 11. Use only with vehicles and boats with 12 volt electrical systems. 12. Jumpstarter for emergency use only. Only use to jump start your vehicle. Do not use this system in the place of a vehicle battery. 13. Never leave the vehicle unattended while jumpstarting the engine. Remove the keys from the vehicle. 14. Keep extension cord off the ground and away from water when recharging the unit. 15. Always connect the Line Cord to a Ground Fault Circuit Interrupter (GFCI) protected electrical outlet. 16. Do not attempt to jump start a vehicle while recharging the unit s internal battery. WARNING! This product contains lead, which is a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code 25249.5, et seq.) 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 POWERING AN APPLIANCE 1. Before using this tool to power an appliance or electrical device make sure the appliance/ electrical device uses 12VDC power. 2. Never attempt to power an external appliance or electrical device while also attempting to jump start a vehicle engine. 3. When not powering an appliance, remove the appliance vehicle adapter cord from the Jumpstarter Accessory Socket and store it. BATTERY PRECAUTIONS (1) 1. Read all instructions and warnings on the Jumpstarter before charging it s battery. 2. To avoid accidents, charge the supplied internal battery only. Do not replace with a different type of battery. 3. Do not expose the battery to rain or wet conditions. 4. To avoid damage of cable and plug, never pull the cable to disconnect the Jumpstarter. 5. Do not use the Jumpstarter if the cables or plugs are damaged. Page 5

6. Repairs should be carried out by a qualified technician. 7. Do not touch the battery poles with any conductive source. 8. If the internal battery is removed, do not store the battery in a box with other metal objects. 9. Do not throw the battery in a fire or in the general trash. Contact your local hazardous waste disposal authority for proper disposal. 10. Do not drain the battery completely before recharging. Recharge fully. 11. Always recharge the internal battery (6) when Jumpstarter performance begins to diminish. Severe heat is most destructive to a battery; the more heat generated, the faster the battery loses power. A battery that gets too hot can be permanently damaged. Never over-discharge a battery by using the Jumpstarter to the point of complete discharge. When the Jumpstarter performance begins to diminish, stop using it and recharge the battery for optimal performance. 12. Recharge the battery monthly even if not used. GROUNDING Note: This product comes with a two-prong, polarized plug. WARNING! Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualfified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the power cord plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician. Double Insulated Tools: Tools with Two Prong Plugs Tools marked Double Insulated do not require grounding. They have a special double insulation system which satisfies OSHA requirements and complies with the applicable standards of Underwriters Laboratories, Inc., the Canadian Standard Association, and the National Electrical Code. (See illustration below.) Double insulated tools may be used in either of the 120 volt outlets shown in the following illustrations. Page 6

EXTENSION CORDS 1. Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord. 2. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage. (See Table below.) 3. The smaller the gauge number of the wire, the greater the capacity of the cord. For example, a 14 gauge cord can carry a higher current than a 16 gauge cord. 4. When using more than one extension cord to make up the total length, make sure each cord contains at least the minimum wire size required. 5. If you are using one extension cord for more than one tool, add the nameplate amperes and use the sum to determine the required minimum cord size. 6. If you are using an extension cord outdoors, make sure it is marked with the suffix W- A ( W in Canada) to indicate it is acceptable for outdoor use. 7. Make sure your extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualified electrician before using it. 8. Protect your extension cords from sharp objects, excessive heat, and damp or wet areas. RECOMMENDED MINIMUM WIRE GAUGE FOR 120 VAC EXTENSION CORDS* NAMEPLATE AMPERES EXTENSION CORD LENGTH (At Full Load) 25 Feet 50 Feet 75 Feet 100 Feet 150 Feet 0 2.0 18 18 18 18 16 2.1 3.4 18 18 18 16 14 3.5 5.0 18 18 16 14 12 5.1 7.0 18 16 14 12 12 7.1 12.0 18 14 12 10-12.1 16.0 14 12 10 - - 16.1 20.0 12 10 - - - * Based on limiting the line voltage drop to five volts at 150% of the rated amperes. Page 7

SYMBOLOGY 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. Jumpstarter Unit Charging Line Cord (5) Accessory Power Cord (20) 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. Page 8

OPERATING INSTRUCTIONS Controls and Indicators Item Red Button Red LED Indicators Yellow LED Indicator Green LED Indicators Description Press to check (internal) battery status. Lights LEDs. Indicates (internal) battery has 50% or less charge. Recharge required. Charging LED lights when recharging. Indicates (internal) battery has 50% to 75% charge. Usable, but recharge. Indicates (internal) battery fully charged. Lights when charging is complete. Reset Button Press to reset when accessory appliance pulls more than 15 amps current. Located on back of unit. Status LEDs Charging LED Charged LED Status Test Button (15) Charging the Internal Battery Recharge the internal Battery (6) when new, after each use, and every three months whether used or not. 1. Set the Jumpstarter upright in a well ventilated area, away from combustible materials. 2. Plug the Charging Line Cord (5) into the side of the Jumpstarter. (See photo at right.) 3. Insert the Charging Line Cord plug into an electrical outlet or proper extension cord. The red LED will be lit during charging. When fully charged, the green LED will light, and the red LED will go out. The charger will automatically go into a float charge mode, and continue while connected to the electrical outlet. 4. Unplug the Charging Line Cord (5) from the electrical outlet or extension cord and the Jumpstarter. 5. Store the Charging Line Cord in the Jumpstarter box. 6. Press the Status Test Button (15) to verify that the internal Battery (6) is fully charged. Page 9 REV 09/04

Jumpstarting an Engine 1. Turn the engine ignition key to Off position. 2. Place the Jumpstarter on a stable surface near the engine battery, and away from moving engine parts. Caution: Do not touch the Jumpstarter red cable clamp to the black cable clamp. This short circuits the Jumpstarter and may damage the internal Battery (6). 3. Connect the red (+) cable clamp to the positive terminal of the engine battery. Move the clamp so that it digs into the terminal for a good connection. 4. Connect the black ( ) cable clamp to the engine or unpainted chassis surface. Do not connect to an engine part that will turn or move when the engine is started. Do not connect to the negative battery terminal. 5. Turn the engine ignition key to the On position and crank the engine. If the engine does not immediately start, wait three minutes and try again. 6. After the engine starts, first remove the black ( ) cable clamp from the engine battery and secure it to the plastic tab on the back of the Jumpstarter. Do the same for the red (+) cable clamp. 7. Recharge the Jumpstarter as described on the previous page. 8. Place the Jumpstarter (upright) in its factory box and store in a clean, dry, and cool environment. Using the Jumpstarter to Power an Appliance The Jumpstarter can be used to power any appliance (up to around 80 watts) that uses 12 VDC as its power source. 1. Plug the appliance vehicle adapter cord (cigarette lighter plug) into the Jumpstarter Accessory Socket (4). Turn on the appliance. A four watt appliance will operate about 20 hours. An 80 watt appliance will operate for about one hour. After use, check the internal Battery (6) status. Recharge if necessary. 2. Optionally, use the supplied Accessory Power Cord (20) to power electronic devices that use 12 VDC as its power source. (Example: Lap Top Computers, electronic keyboards, electric shavers) (See photo at right.) 3. When finished, remove the appliance adapter cord and store the Jumpstarter. (20) (4) Page 10

INSPECTION, MAINTENANCE, AND CLEANING WARNING! Make sure the Charging Line Cord is unplugged from its electrical outlet before performing any inspection, maintenance, or cleaning procedures. 1. Before each use, inspect the general condition of the Jumpstarter. Check for loose screws, misalignment or binding of moving parts, cracked or broken parts, damaged electrical wiring, and any other condition that may affect its safe operation. If abnormal noise or vibration occurs, have the problem corrected before further use. Do not use damaged equipment. 2. After the internal Battery (6) in the Jumpstarter has expired, it should be recycled. Some States require this recycling. Contact your local solid waste authority for recycling information. Battery replacement should only be done by a qualified technician. Warning: Do not dispose of battery by fire. This could result in an explosion. Before disposing of battery, cover exposed terminals with heavy duty electrical tape to prevent shorting. Do not expose battery to intense heat or fire as this could cause an explosion. 4. Store the Jumpstarter in a clean and dry location at room temperature. 5. Clean cable clamps after each use. PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED 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 STATES THAT 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 PARTS THERETO. Page 11

PARTS LIST Part # Description Qty. 1 Case(front) 1 2 Accessory socket assy. 1 3 Accessory socket cap 1 4 Accessory socket block 1 5 Charging Line Cord 1 6 12V/12AH battery 1 7 Warning label 1 8 Case (rear) 1 9 PCB 1 10 Circuit breaker 1 11 Handle 1 12 Charger 1 13 Charger fixed block 1 14 Clamp and cable assy 2 15 Status Test Button 1 16 Panel sticker 1 17 Sticker 1 18 Recharge indicator label 1 19 Screws (not shown) - 20 Accessory Power Cord 1 NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. ASSEMBLY DRAWING Page 12