DIGITAL BATTERY TESTER WITH CCA SET CODE 92903 ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at http://www.harborfreight.com Copyright© 2005 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 Battery Capacity Maximum Capacity Battery Cable Length Test Cycle Overall Dimensions

12 Volts DC, 125 Amps Load Capability 300 - 1000 CCA Testing Capacity 16” Long 10 Second Test, 1 Min. Cool Down 3 Tests in 5 Min. Maximum 11-1/4” x 6-1/2” x 2-1/2”

Save This Manual You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, and parts list illustration. 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.

Safety Warnings and Precautions WARNING: When using tool, basic safety precautions should always be followed 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 the Battery Tester 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 away. Children must never be allowed in the work area. Do not let them handle the Battery Tester.

4.

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

5.

Use the right product for the job. Do not attempt to force a small Battery Tester to do the work of a larger industrial Battery Tester. There are certain applications for which this Battery Tester was designed. It will do the job better and more safely at the rate for which it was intended. Do not modify this Battery Tester and do not use this Battery Tester 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 the Battery Tester. Protective, electrically non-conductive clothes and non-skid footwear are recommended when working. Wear restrictive hair covering to contain long hair.

7.

Use eye and ear protection. Always wear ANSI approved impact safety goggles. Wear a full face shield when working with battery acid. 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. REV 07d

SKU 92903

For technical questions, please call 1-800-444-3353

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9.

Maintain tools with care. Keep the Battery Tester clean for better and safer performance. Follow instructions for changing accessories. Inspect product cords periodically, and if damaged, have them repaired by an authorized technician. The handles must be kept clean, dry, and free from oil and grease at all times.

10.

Disconnect power. Disconnect from battery when not in use.

11.

Avoid unintentional starting. Be sure the Test Start Button is not depressed when not in use.

12.

Stay alert. Watch what you are doing, use common sense. Do not operate any product when you are tired.

13.

Check for damaged parts. Before using any product, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting fixtures; 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 product if any button does not turn On and Off properly.

14.

Guard against electric shock. Prevent body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerator enclosures.

15.

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.

16.

Do not operate product 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 product.

17.

Maintenance. For your safety, service and maintenance should be performed regularly by a qualified technician.

18.

Beware of hot surfaces. The cables, clamps, and batteries may become hot during use. Avoid touching without exercising care to avoid harm and injury.

19.

Avoid extreme heat. Do not create smoke, flames, or sparks near batteries. Battery acid is extremely explosive.

20.

Test Start Button Warnings. Release the Test Start Button before connecting, disconnecting, or rocking clamps. Do not depress the Test Start Button for longer than ten seconds.

21.

CARBON MONOXIDE WARNING: Only operate a vehicle in a well-ventilated area. Do not operate an engine in a garage or enclosed structure. Running engines produce carbon monoxide, a colorless, odorless gas, that is deadly if inhaled. Caution!! This Battery Tester becomes very hot during use. Touching it will result in serious burns.

SKU 92903

For technical questions, please call 1-800-444-3353

Page 3

Caution!! Keep this Battery Tester a safe distance from any flammable products. The extreme heat generated from this unit combined with a close proximity to flammable materials can result in fire. Warning: In case of accidental contact, rinse eyes with cool water for five minutes and contact a doctor immediately. WARNING: Always read and adhere to all warnings and instructions provided by the manufacturer of the battery being tested. Lead acid batteries produce explosive gases during normal operation, which can be ignited by a spark. Make sure you work in a properly ventilated area. WARNING: This product contains or, when used, produces 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. Electromagnetic fields in close proximity to a heart pacemaker could cause interference to or failure of the pacemaker.

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, but must be supplied by the operator.

Unpacking When unpacking, check to make sure that the product is intact and undamaged. 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.

SKU 92903

For technical questions, please call 1-800-444-3353

Page 4

Operation Caution!! This Battery Tester becomes very hot during use. Touching it will result in serious burns.

FIGURE 1 Positive Clamp (RED)

Note: CCA stands for Cold Cranking Amps, the amount a battery can deliver in 30 sec. at zero degrees F.

Set CCA

LED Window Test Start

Negative Clamp (BLACK)

TESTING THE BATTERY Note: The temperature of the battery will affect the testing data. It will test lower when cold than when warm. Never test or charge a frozen battery. Caution! Wear rubber gloves (not included) whenever working with the Battery Tester or batteries. Note: Before any testing, make sure to clean the battery contacts. 1.

Make sure the vehicle is not running. Connect the Red Clamp (+) to the positive (+) terminal post on the battery. Connect the Black Clamp (-) to the negative (-) terminal post on the battery. Adjust the Set CCA button to correspond with the CCA of the battery. Push the CCA button (in increments of 100) until the CCA that matches your battery appears. See FIGURE 1. Round your Battery CCA number DOWN.

2.

Check the Battery Tester LED Window (See FIGURE 1) to determine effectiveness of charge. If the Battery Tester does not register and no display is seen, double check that the Clamps are connected to the proper terminal posts. Make certain a clean connection has been made between the Clamps and terminal posts.

3.

Hold the Test Start button until a solid and consistent measurement is indicated by the Battery Tester. A tone should sound once an acceptable reading is attained. Within ten seconds, while continuing to hold the button, read the meter. Do not test more than three times in a five minute period. Allow one minute for cool down between tests. Note: Do not activate the Test Start button for more than ten seconds. Note: If a battery does not have the charge expected, have a qualified technician check the specific gravity. There may be an electrical drain or charging system trouble. If charging does not raise the specific gravity, you may have a defective battery. REV 04/05

SKU 92903

For technical questions, please call 1-800-444-3353

Page 5

Operation (continued) Analyzing test results by color display: The Battery Tester will measure battery output/charge in two ways. The three lights above the LED Window (See FIGURE 1) will indicate a color telling you the general condition of the battery. Red = Bad, No Charge, or Completely Discharged Yellow = Weak, Needs Recharging Green = Good or Normal - Has Existing Charge Analyzing test results by Voltage Reading: The LED Window will display a number along with the color. Green = Greater than 10.7 V - Battery is fully charged Yellow = Between 9.0 and 10.7 V - Battery is undercharged Red = Less Than 9.0 V - Battery is uncharged and possibly damaged 4.

If the battery is without significant charge, charge it and check it again under load. The battery should measure 75% of Open-Circuit Voltage. 75% can be considered fully charged. If the charging rate reaches at least 75%, but fails to reach 75% during the load test, it needs replacing. Refer to the table below for 12 Volt battery percentages: Open Circuit Voltage (V): Less than 11.7V Battery Charge Percentage 0%

5.

12V 20%

12.2V 50%

12.4V 75%

12.4V+ 100%

When test is complete, remove Black Clamp (-) from battery first; then remove Red Clamp (+).

TESTING THE CHARGING SYSTEM - Alternator / Regulator Output: Warning: When testing a system in a car/truck, the vehicle must be on a flat, dry surface. The transmission must be in park and the emergency brake engaged. 1.

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

2.

With the engine off, check the Battery Tester LED Window (See FIGURE 1) to determine effectiveness of charge. Without using the Test Start Button, If the Battery Tester does not register and no display is seen, double check that the Clamps are connected to the proper terminal posts. Make certain a clean connection has been made between the Clamps and terminal posts.

3.

Start the engine and let it run. Without using the Test Start Button, observe the voltage readout when the engine speed reaches between 1200 to 1500 RPM (normal idle speed).

4.

Determine battery charge based on color indicators and voltage as described above. If the battery registers below 75 percent or the readout is not constant, you may have an alternator/regulator problem. See a qualified service technician.

5.

When charging system test is complete, remove Black Clamp (-) from battery first; then remove Red Clamp (+). REV 04/05

SKU 92903

For technical questions, please call 1-800-444-3353

Page 6

STARTER MOTOR TEST If starting your vehicle is difficult, you may have 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.

2.

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

3.

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

4.

While watching the LED window, 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 an authorized service technician.

5.

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

DISPLAY CODES Code

Situation

Possible Meanings/Causes

EF1

Load test

Tester/relay defective. Discontinue use and have a qualified technician service.

-L-

Star t of test During load test

Battery voltage less than 12 volts. Battery voltage less than 7 volts, battery defective.

Maintenance 1.

Keep the Clamps clean and clear of dirt, grease, or debris.

2.

Store and use in a dry environment away from any heat sources.

REV 10/05

SKU 92903

For technical questions, please call 1-800-444-3353

Page 7

Parts List Illustration

Positive Clamp (RED)

Set CCA

Negative Clamp (BLACK)

Note: CCA stands for Cold Cranking Amps

LED Window Test Start

NO REPLACEMENT PARTS ARE AVAILABLE FOR THIS PRODUCT.

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. NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts.

SKU 92903

For technical questions, please call 1-800-444-3353

Page 8