INSTRUCTION MANUAL Multi-Charger 054-3107-2 Parts missing or damaged? Questions? Toll-free Helpline 1-800-689-9928 Important: Carefully read this Instruction Manual before using this tool. Pay close attention to all Safety Instructions, Warnings, and Caution sections. Use this tool properly, and only for its intended use. Safety symbols in this Instruction Manual are used to flag possible dangers. The safety symbols and their explanations require the operator s full understanding. The safety warnings do not, by themselves, eliminate any danger, and they are not a substitute for proper accident prevention measures. This Safety Alert Symbol indicates caution, warning, or danger. Failure to obey a safety warning can result in serious injury to yourself or others. To reduce the risk of injury, fire, or electric shock, always follow the safety precautions.
TABLE OF CONTENTS Specifications... Page 2 Rules for Safe Operation... Page 2 Description... Page 4 Operation... Page 5 Troubleshooting... Page 7 Maintenance... Page 7 Exploded View & Parts List... Page 8 Warranty... Page 9 SPECIFICATIONS Charger Input 120 V ~ 60 Hz AC only Compatible batteries 054-2962-0 054-1254-2 054-3105-6 054-3104-8 054-3106-4 Charger Weight 1 lb 11 oz (0.77 kg) Optimum Charging Temperature Ni-Cd: 50 to 86 F (10 to 30 C) Li-ion: 32 to 104 F (0 to 40 C) SAFETY RULES Before operating this charger, carefully read this Operating Manual and all of the labels affixed to the tool. Keep this manual in a safe place for future reference. IMPORTANT This charger should be serviced only by a qualified service technician. READ ALL INSTRUCTIONS CAREFULLY SAVE THESE INSTRUCTIONS GENERAL SAFETY RULES WORK AREA SAFETY Keep the work area clean and well lit. Cluttered benches and dark areas invite accidents. Do not operate power tools in an explosive environment, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks, which may ignite the dust or fumes. Keep bystanders, children, and visitors away when operating power tools. Distractions can cause the operator to lose control. ELECTRICAL SAFETY The plug on the power cord must match the outlet. Page 2 054-3107-2 Multi-Charger_R12-08
Do not alter the plug in any way. Do not use an adaptor plug with a grounded power tool. Using unaltered plugs and proper outlets reduces the risk of electric shock. Avoid bodily contact with grounded surfaces, such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if the operator s body is grounded. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. Do not abuse the power cord. Never use the cord to carry the tool or to pull the plug out of an outlet. Keep the cord away from heat, oil, sharp edges, and moving parts. Damaged or entangled cords increase the risk of electric shock. Use an outdoor extension cord that is suitable for outdoor use when operating a power tool outdoors. Using the proper extension cord reduces the risk of electric shock. SERVICE This battery charger should be serviced by a qualified service technician, using identical replacement parts. This will ensure that the safety of the charger is maintained. SPECIFIC SAFETY RULES FOR THE CHARGER ѥѥwarning: To reduce the risk of electric shock or damage to the charger and the battery, charge only recommend rechargeable batteries as specifically designated on your charger. Other types of batteries may burst, causing personal injury or damage. For indoor use only. Dry location use only. Risk of fire and electric shock. Risk of injury. Charge only with Mastercraft Maximum Batteries (054-3105-6,054-2962-0, 054-1254-2, 054-3104-8, 054-3106-4). Other types of battery packs may burst, causing injury to persons and damage. Before using the battery charger, carefully read all instructions and cautionary markings in this manual, on the battery charger, on the battery, and on the tool that is powered by the battery, in order to prevent misuse of the products and possible injury or damage. Do not use the charger outdoors, and do not expose it to wet or damp conditions. Water entering the charger will increase the risk of electric shock. The use of any attachment that is not recommended or sold by the manufacturer of the battery charger may result in a risk of fire, electric shock, or personal injury. Following this rule will reduce the risk of electric shock, fire, and serious personal injury. Do not abuse the cord or the charger. Do not use the cord to carry the charger or to disconnect the charger from the outlet. Doing so may cause damage to the cord or the charger, which may create an electric shock hazard. Replace a damaged cord immediately. Verify that the cord is positioned so that it will not be stepped on, tripped over, come into contact with sharp edges or moving parts, or otherwise be subjected to damage or stress. This will reduce the risk of accidental falls, which could cause injury and damage to the cord, and may result in electric shock. 054-3107-2 Multi-Charger_R12-08 Page 3
Keep the cord and the charger away from sources of heat in order to prevent damage to the housing or the internal parts. Do not allow gasoline, oils, petroleum-based products, etc. to come into contact with plastic parts. These substances contain chemicals that can damage, weaken, or destroy plastic. In order to reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Disconnect the charger from the outlet when it is not in use. This will reduce the risk of electric shock or damage to the charger if metal items should fall into the opening. It will also help to prevent damage to the charger during a power surge. Risk of electric shock. Do not touch the uninsulated part of the output connector or an uninsulated battery terminal. DESCRIPTION KNOW YOUR CHARGER (Fig. 1) Fig. 1 Electrical contacts Charge-indicator reference label Red indicator LED Cord wrap Green indicator LED Before attempting to use this charger, become familiar with all of its operating features and safety requirements. ѥ ѥ WARNING: If any part of the charger is missing or damaged, do not operate it until the part is repaired or replaced. Failure to heed this warning could result in possible serious injury. Page 4 054-3107-2 Multi-Charger_R12-08
OPERATION CHARGING THE LI-ION BATTERY PACK A fully discharged battery pack will charge in approximately 30-60 minutes (depending on the battery s capacity and voltage) at a temperature between 32 and 104 F (between 0 and 40 C). Use only the proper charger to charge the battery pack. 1. Connect the charger to a power supply. 2. Attach the battery pack to the charger by aligning the raised ribs of Fig. 2 the battery pack with the slot in the charger and then sliding the battery pack into the charger (Fig. 2). 3. When charging, the green LED on the charger will begin to flash. 4. When charging is complete, the green LED on the charger will light up. The Power Bar LEDs will displayed if the Power Bar button is pressed while the battery pack is in the charger. 5. If it is left in the charger, the battery pack will charge fully, but it will not overcharge. CHARGING THE NI-CD BATTERY PACK A fully discharged Ni-Cd battery pack will charge in approximately 60 minutes (depending on the battery s capacity and voltage) at a temperature between 50 and 86 F (between 10 and 30 C). Use only the proper charger to charge the battery pack. 1. Connect the charger to a power supply. 2. Attach the battery pack to the charger by aligning the raised ribs of the battery pack with the slot in the charger and then sliding the battery pack into the charger (Fig. 2). 3. When charging is complete, the green LED on the charger will light up. 054-3107-2 Multi-Charger_R12-08 Page 5
LED FUNCTIONS OF THE CHARGER The charger has two LEDs; each can display red or green. The various combinations of red and green indicators and their meanings are described in. LED INDICATOR BATTERY PACK Hot/Cold Battery RED LED GREEN LED ACTION On Off Charging will not start until suitable temperature is reached Defective Flashing Off Battery pack or Charger is defective Charging Off Flashing Charging Fully Charged Off On Charging is complete Maintenance charging CHARGING A HOT BATTERY PACK If the battery pack is above the normal temperature range (149 F, 60 C for lithium battery, 113 F or 40 C for Ni-Cd battery), the red LED will light up, and the green LED will be off. The charger will automatically begin charging when the battery pack cools down. CHARGING A COLD BATTERY PACK If the battery pack is below the normal temperature range (32 F or 0 C for lithium battery, 50 F or 10 C for Ni-Cd battery), the red LED will light up, and the green LED will be off. The charger will automatically begin charging when the battery pack warms up. DIAGNOSTIC FUNCTIONS NOTE: The diagnostic function will operate only with a Li-ion battery.if the charger detects a problem, the red LED will begin flashing, and the green LED will be off. DEFECTIVE BATTERY If the LED status reads defective, remove the battery pack from the charger and then reinsert it. If the LED status reads defective a second time, try charging a different Li-ion battery pack. If a different Li-ion battery pack charges normally, dispose of the defective battery pack in compliance with local regulations. If the LED status still reads defective for a different Li-ion battery pack, the charger may be defective. Page 6 054-3107-2 Multi-Charger_R12-08
LI-ION BATTERY CHARGING If the battery pack is within the normal temperature range (32 to 104 F or 0 to 40 C), the green LED will begin flashing and the red LED will be off. The Power Bar LEDs will cycle from right to left during charging. This is part of the normal charging operation. The Power Bar LEDs will not be illuminated if the Power Bar button is pressed while the battery pack is in the charger. NI-CD BATTERY CHARGING If the battery pack is within the normal temperature range (50 to 86 F or 10 to 30 C), the green LED will begin flashing and the red LED will be off. No Power Bar lights will illuminate. LI-ION BATTERY FULL If the battery pack is within the normal temperature range, the green LED will light up, and the red LED will be off when the Li-ion battery pack is fully charged and ready to use. If it is left in the charger, the battery pack will charge fully, but it will not overcharge. The POWER BAR LEDs will not be displayed if the POWER BAR button is pressed while the battery pack is in the charger. NI-CD BATTERY FULL If the battery pack is within the normal temperature range, the green LED will light up, and the red LED will be off when the battery pack is fully charged and ready to use. If it is left in the charger, the battery pack will charge fully, but it will not overcharge. WALL-MOUNT (Fig. 3) The charger features a keyhole hanging feature for convenient storage. Screws should be installed in the wall so that the centre distance is 4-1/8in, 105mm. Use proper wall fasteners to accommodate the combined weight of the charger and the battery pack (approximately 4.0lbs/1.8kg). TROUBLE SHOOTING Fig. 3 105mm=4 1 /8 in. PROBLEM CAUSE SOLUTION The battery pack isn t charging MAINTENANCE The battery pack isn t connected to the charger Attach the battery pack to charger ѥѥwarning : Do not let brake fluids, gasoline, petroleum-based products, penetrating oil, etc. come into contact with plastic parts. These substances contain chemicals that can damage, weaken, or destroy plastic. ѥѥwarning : When servicing, use only identical replacement parts. The use of any other parts may create a hazard or cause damage to the product. 054-3107-2 Multi-Charger_R12-08 Page 7
ѥѥwarning : Use only accessories that are recommended for this battery charger by the manufacturer. Accessories that may be suitable for one tool may become hazardous when used with another tool. ѥѥwarning : To ensure safety and reliability, all repairs should be performed by a qualified service technician. EXPLODED VIEW 4 11 13 2 3 9 10 2 5 7 17 14 1 2 17 14 16 8 1 6 5 12 5 5 2 15 Page 8 054-3107-2 Multi-Charger_R12-08
PARTS LIST No. Part No. Description QTY 1 5610008000 TAPPING SCREW 4 2 5610012000 TAPPING SCREW 7 3 5610006000 TAPPING SCREW 2 4 3703987000 DUST COVER 1 5 5610218000 SCREW 6 6 3123502000 COVER 2 7 4810002000 POWER CORD & PLUG 1 8 3123425000 CLAMP SUPPORT 1 9 3123424000 LIGHT GUIDE POLE 1 10 3123423000 BLOW TUBE 1 11 3123421000 BRACKET 1 12 3123420000 LEFT HOUSING 1 13 3123419000 RIGHT HOUSING 1 14 3123422000 CLAMP 2 15 3121652000 HANDLE 1 16 3402205000 CONTACT RECEPTACLE ASSEMBLY 1 17 4890353000 PCB ASSEMBLY 1 WARRANTY 2-Year Limited Warranty This Mastercraft Maximum product is guaranteed for a period of 2 years from the date of original retail purchase against defects in workmanship and materials. Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period and if covered under this warranty, will be repaired or replaced (with the same model, or one of equal value or specification), at our option. We will bear the cost of any repair or replacement and any costs of labour relating thereto. These warranties are subject to the following conditions and limitations : a) A bill of sale verifying the purchase and purchase date must be provided; b) This warranty will not apply to any product or part thereof which is worn or broken or which has become inoperative due to abuse, misuse, accidental damage, neglect or lack of proper installation, operation or maintenance (as outlined in the applicable operating manual or operating instructions) or which is being used for industrial, professional, commercial or rental purposes; c) This warranty will not apply to normal wear and tear or to expendable parts or accessories that may be supplied with the product that are expected to become inoperative or unusable after a seasonable period of use; 054-3107-2 Multi-Charger_R12-08 Page 9
d) This warranty will not apply to routine maintenance and consumable items such as, but not limited to, fuel, lubricants, vacuum bags, blades, belts, sandpaper, bits, fluids, tune-ups or adjustments; e) This warranty will not apply where damage is caused by repairs made or attempted by others (i.e. persons not authorized by the manufacturer); f) This warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product (unless otherwise specified in writing); g) This warranty will not apply to any product or part thereof if any part from another manufacturer is installed therein or any repairs or alterations have been made or attempted by unauthorized persons; h) This warranty will not apply to normal deterioration of the exterior finish, such as, but not limited to, scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and this warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under the product manufacturer s warranty, if any. IMPORTED BY MASTERCRAFT CANADA TORONTO, CANADA M4S 2B8 Page 10 054-3107-2 Multi-Charger_R12-08