Sears 28.7123 User's Manual
Contents
1. ie OPERATING INSTRUCTIONS AWARNING This battery charger must be properly assembled in accordance with the assembly instructions before it is used Charging 1 Ensure that all of the charger components are in place and in good working condition for example the plastic boots on the battery clips Make sure the electrolyte battery liquid in each cell is at the correct level Set the Output Selector Switch 2 to the OFF position Connect the battery following the precautions listed in sections 6 and 7 Connect the A C power following the precautions listed in section 8 Place the output selector switches 1 and 2 in the preferred position oP ON e For the 2A charge rate switch 1 is not used and switch 2 should be toggled up e For the 40A charge rate both switches 1 and 2 should be toggled down 6 To disconnect the charger reverse the procedure NOTE This is a manual charger and will overcharge a battery if permitted to operate for extended periods of time Monitor the charging progress often Manual Mode Be sure to monitor the charging progress and stop it when the battery is fully charged This charger is a manual charger and is not equipped with automatic shut off Not doing so may cause damage to your battery or may cause other personal property damage or personal injury Using the Engine Start feature Your battery charger can be used to jumpstart your car if the battery is low Follow these instructions2. 3 2 3 3 RISK OF CONTACT WITH BATTERY ACID BATTERY ACID IS A HIGHLY CORROSIVE SULFURIC ACID If it is necessary to remove the battery from the vehicle to charge it always remove the grounded terminal first Make sure all of the accessories in the vehicle are off to prevent arcing Be sure the area around the battery is well ventilated while the battery is being charged Clean the battery terminals before charging the battery During cleaning keep airborne corrosion from coming into contact with your eyes nose and mouth Use baking soda and water to neutralize the battery acid and help eliminate airborne corrosion Do not touch your eyes nose or mouth 236 3 4 3 5 3 6 3 7 4 4 1 4 2 4 3 4 4 4 5 5 1 5 2 Add distilled water to each cell until the battery acid reaches the level specified by the battery manufacturer Do not overfill For a battery without removable cell caps such as valve regulated lead acid batteries VRLA carefully follow the manufacturer s recharging instructions Read understand and follow all instructions for the charger battery vehicle and any equipment used near the battery and charger Study all of the battery manufacturer s specific precautions while charging and recommended rates of charge Determine the voltage of the battery by referring to the vehicle owner s manual and make sure that the output voltage selector switch is set to the correct voltage If
3. IMPORTANT READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL SAVE THESE INSTRUCTIONS The 71230 offers a wide range of features to accommodate your needs This manual will show you how to use your charger safely and effectively Please read understand and follow these instructions and precautions carefully as this manual contains important safety and operating instructions The safety messages used throughout this manual contain a signal word a message and an icon The signal word indicates the level of the hazard in a situation ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury to the operator or bystanders Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or bystanders AWARNING Indicates a potentially hazardous situation which if not avoided could result in moderate or minor injury to the operator or bystanders ACAUTION Indicates a potentially hazardous situation which if not avoided IMPORTANT could result in damage to the equipment or vehicle or property damage Safety messages in this manual contain two different sentence styles e Unnumbered sentences state the hazard e Numbered sentences state how to avoid the hazard The icon gives a graphical description of the potential hazard Pursuant to California Proposition 65 this product contains chemicals known to the State of
4. onboard requires equipment specially designed for marine use 8 GROUNDING AND AC POWER CORD CONNECTIONS AWARNING AWARNING 8 1 8 2 8 3 9 1 RISK OF ELECTRIC SHOCK OR FIRE GROUNDED OUTLET This battery charger is for use on a nominal 120 volt circuit and has a grounded plug that looks like the plug N illustrated The charger must be grounded to reduce the risk of electric shock The plug must be plugged into an outlet that is properly installed and grounded in at accordance with all local codes and ordinances The plug pins must fit the receptacle outlet Do not use with A an ungrounded system GROUNDING PIN ADANGER Never alter the AC cord or plug provided if it does not fit the outlet have a proper grounded outlet installed by a qualified electrician An improper connection can result in a risk of an electric shock or electrocution NOTE Pursuant to Canadian Regulations use of an adapter plug is not allowed in Canada Use of an adapter plug in the United States is not recommended and should not be used Recommended minimum AWG size for extension cord e 100 feet long or less use a 10 gauge extension cord e Over 100 feet long use an 8 gauge extension cord ASSEMBLY INSTRUCTIONS It is important to fully assemble your charger before use Remove all cord wraps and uncoil the cables prior to using the battery charger Follow these instructions for assembly PARTS TOOLS NEEDED 3 8 wrench fo
5. cord or plug have the cord or plug replaced immediately by a qualified service person Call customer service at 1 800 732 7764 Do not operate the charger if it has received a sharp blow been dropped or otherwise damaged in any way take it to a qualified service person Call customer service at 1 800 732 7764 Do not disassemble the charger take it to a qualified service person when service or repair is required Incorrect reassembly may result in a risk of fire or electric shock Call customer service at 1 800 732 7764 RISK OF EXPLOSIVE GASES WORKING IN THE VICINITY OF ALEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW ALL INSTRUCTIONS IN THIS MANUAL EACH TIME YOU USE THE CHARGER To reduce the risk of a battery explosion follow all instructions in this manual and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery Review the cautionary markings on these products and on the engine 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 3 PERSONAL PRECAUTIONS RISK OF EXPLOSIVE GASES NEVER smoke or allow a spark or flame in the vicinity of a battery or engine Remove personal metal items such as rings bracelets necklaces and watches when working with a lead acid battery A lead acid battery can produ
6. on how to use the ENGINE START feature AWARNING Follow all safety instructions and precautions for charging your battery Wear complete eye protection and clothing protection Charge your battery in a well ventilated area IMPORTANT Using the ENGINE START feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle s electrical system NOTE If you have charged the battery and it still will not start your car do not use the engine start feature or it could damage the vehicle s electrical system 1 Set Output Selector Switch 2 to the OFF position 2 With the charger unplugged from the A C outlet connect the charger to the battery following the instructions given in section 6 FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE Plug the charger A C power cord into the A C outlet With the charger plugged in and connected to the battery of the vehicle set the Output Selector Switch to the engine start position switch 1 up switch 2 down 5 Crank the engine until it starts or 5 seconds pass If the engine does not start wait 4 minutes before cranking again This allows the charger and battery to cool down Po NOTE During extremely cold weather or if the battery is under 2 volts charge the battery for 5 minutes before cranking the engine 6 If the engine fails to start charge the battery for 5 more minutes before attempting to crank the engine again 11 7 After the engine
7. starts move Output Selector Switch 2 to the OFF position and unplug the A C power cord before disconnecting the battery clips from the vehicle 8 Clean and store the charger in a dry location NOTE If the engine does turn over but never starts there is not a problem with the starting system there is a problem somewhere else with the vehicle STOP cranking the engine until the other problem has been diagnosed and corrected 12 CALCULATING CHARGE TIME Use the following table to more accurately determine the time it will take to bring a battery to full charge First identify where your battery fits into the chart NR means that the charger setting is NOT RECOMMENDED Find your battery s rating on the chart below and note the charge time given for each charger setting The times given are for batteries with a 50 charge prior to recharging Add more time for severely discharged batteries CHARGE RATE BATTERY SIZE RATING CHARGING MIME HOURS garden i tractor 200 315 CCA 40 60 RC 11 14 30 to 45 min CAR TRUCKS 315 550 CCA 60 85 RC 14 18 gi le 1 550 1000CCA 85 190RC 18 35 140 RC MARINE DEEP CYCLE 160 RC 180 RC 13 MAINTENANCE INSTRUCTIONS 13 1 After use and before performing maintenance unplug and disconnect the battery charger see sections 6 7 and 8 13 2 Use a dry cloth to wipe all battery corrosion and other dirt or oil from the battery clips cords and the charger case 13 3 Ensure
8. that all of the charger components are in place and in good working condition for example the plastic boots on the battery clips 13 4 Servicing does not require opening the unit as there are no user serviceable parts 13 5 All other servicing should be performed by qualified service personal 12 Store the charger unplugged in an upright position The cord will still conduct Do not store the clips on the handle clipped together on or around metal or If the charger is moved around the shop or transported to another location take care to avoid prevent damage to the cords clips and charger Failure to do so could result in personal injury or property damage 14 MOVING AND STORAGE INSTRUCTIONS 14 1 electricity until it is unplugged from the outlet 14 2 Store inside in a cool dry place 14 3 clipped to cables 14 4 15 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REASON SOLUTION No reading on the ammeter Ammeter reading stays high Ammeter reads less than selected charge rate when charging a discharged battery Charger is not plugged in No power at the receptacle Clips are not making a good connection to the battery Connections are reversed Battery is defective will not accept a charge 2 amp charge rate is being used Battery is severely discharged Wrong battery voltage Extension cord is too long or wire gauge is too small Weak cell or sulfated plate in battery Battery i
9. California to cause cancer and birth defects or N d other reproductive harm 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions AWARNING AWARNING 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 RISK OF ELECTRIC SHOCK OR FIRE Keep out of reach of children Do not expose the charger to rain or snow Use only recommended attachments Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire electric shock or injury to persons or damage to property To reduce the risk of damage to the electric plug or cord pull by the plug rather than the cord when disconnecting the charger An extension cord should not be used unless absolutely necessary Use of an improper extension cord could result in a risk of fire and electric shock If an extension cord must be used make sure e That the pins on the plug of the extension cord are the same number size and shape as those of the plug on the charger e That the extension cord is properly wired and in good electrical condition e That the wire size is large enough for the AC ampere rating of the charger as specified in section 8 To reduce the risk of electric shock unplug the charger from the outlet before attempting any maintenance or cleaning Simply turning off the controls will not reduce this risk Do not operate the charger with a damaged
10. OPERATOR S MANUAL DieHard 12V Manual Battery Charger amp Engine Starter Model No 28 71230 Read and follow all Safety Rules and Operating Instructions before Every Use of this Product SAVE THESE INSTRUCTIONS Sears Brands Management Corporation Hoffman Estates IL 60179 U S A 00 99 001012 0510 TABLE OF CONTENTS SECTION PAGE IMPORTANT SAFETY INSTRUCTIONS PERSONAL PRECAUTIONS PREPARING TO CHARGE CHARGER LOCATION DC CONNECTION PRECAUTIONS FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE GROUNDING AND AC POWER CORD CONNECTIONS ASSEMBLY INSTRUCTIONS FEATURES CONTROL PANEL OPERATING INSTRUCTIONS O N N OO A A OO WwW DY a CALCULATING CHARGE TIME 12 MAINTENANCE INSTRUCTIONS 12 MOVING AND STORAGE INSTRUCTIONS 13 TROUBLESHOOTING 13 BEFORE RETURNING FOR REPAIRS 15 DIEHARD THREE YEAR FULL WARRANTY When operated and maintained according to all supplied instructions if this DieHard product fails due to a defect in material or workmanship within 3 years from the date of purchase return it to any DieHard outlet in the United States for free replacement This warranty gives you specific legal rights and you may also have other rights which vary from state to state Sears Brands Management Corporation Hoffman Estates IL 60179 FOR CUSTOMER ASSISTANCE OR REPLACEMENT PARTS CALL TOLL FREE FROM 7 AM TO 5 PM CT MONDAY THROUGH FRIDAY 1 800 732 7764
11. ce a short circuit current high enough to weld a ring or the like to metal causing a severe burn Be extra cautious to reduce the risk of dropping a metal tool onto the battery It might spark or short circuit the battery or other electrical part that may cause an explosion Use this charger for charging LEAD ACID batteries only It is not intended to supply power to a low voltage electrical system other than in a starter motor application Do not use this battery charger for charging dry cell batteries that are commonly used with home appliances These batteries may burst and cause injury to persons and damage to property NEVER charge a frozen battery NEVER overcharge a battery Consider having someone close enough by to come to your aid when you work near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts your skin clothing or eyes Wear complete eye and body protection including safety goggles and protective clothing Avoid touching your eyes while working near the battery If battery acid contacts your skin or clothing immediately wash the area with soap and water If acid enters your eye immediately flood the eye with cold running water for at least 10 minutes and get medical attention right away If battery acid is accidentally swallowed drink milk the whites of eggs or water DO NOT induce vomiting Seek medical attention immediately PREPARING TO CHARGE AWARNING 3 1
12. circuit breaker supplying AC outlet Poor electrical connection Check power cord and extension cord for loose fitting plug The battery is connected Clips are not making a good Check for poor connection and the charger is on but is connection at battery and frame Make not charging sure connecting points are clean Rock the clips back and forth for a better connection The measured current is The charger reached the No problem this is a normal much lower than what was maximum voltage and is condition selected reducing the current 16 BEFORE RETURNING FOR REPAIRS 16 1 When a charging problem arises make certain that the battery is capable of accepting a normal charge Double check all connections the AC outlet for a full 120 volts the charger clips for correct polarity and the quality of the connections from the cables to the clips and from the clips to the battery system The clips must be clean 16 2 When a battery is very cold partially charged or sulfated it will not draw the full rated amperes from the charger It is both dangerous and damaging to a battery to force higher amperage into it than it can effectively use in recharging 16 3 When an UNKNOWN OPERATING PROBLEM arises please read this complete manual and call the customer service number for information that will usually eliminate the need for return If the above solutions do not eliminate the problem or for information about troubleshooting or
13. ptacle The charger may be overheated Battery may be severely discharged 14 The settings may be wrong Check the charger settings Have the battery checked Circuit breaker cycles when current draw is too high Check for shorted cables or clips and replace if necessary The battery may not want to accept a charge due to a run down state Allow charging to continue until battery has a chance to recover sufficiently to take a charge If more than 20 minutes stop charging and have the battery checked Shut the charger off and correct the lead connections No problem this is a normal condition Have charger checked by a qualified technician Crank time varies with the amount of current drawn If cranking draws more than the Engine Start rate crank time may be less than 5 seconds Wait 4 minutes of rest time before the next crank Check for poor connection at battery and frame Check power cord and extension cord for loose fitting plug Check for open fuse or circuit breaker supplying AC outlet The thermal protector may have tripped and needs a little longer to reset Make sure the charger vents are not blocked Wait and try again On a severely discharged battery charge for 10 to 15 minutes in the 40 amp manual rate to help assist in cranking PROBLEM POSSIBLE CAUSE REASON SOLUTION Charger will not turn on AC outlet is dead Check for open fuse or when properly connected
14. r mounting foot 5 16 wrench for mounting wheels hammer screwdriver flat blade screwdriver Phillips 9 2 Attach the Foot Remove the charger from the packing materials and place upside down on a flat surface Attach the foot and secure it with the four 4 20 thread cutting screws provided 9 3 Assemble the Wheels and Axle Hold the axle upright on the floor or work surface Then using a hammer tap one of the axle caps onto the top end of the axle Be sure to tap the axle cap on straight Slide both wheels onto the axle with the recessed hubs facing out as shown Install the second axle cap 9 4 9 5 Mount the Axle to the Charger Place one end of each bracket into the slot on the bottom of the charger Place the axle assembly under each bracket Attach the brackets using the two 10 32 thread cutting screws provided NOTE Be careful not to drop the brackets inside of the charger case J i S SS f a Y V SA GG 7 Y A SS Uf Up a XS Attach the Handle If the charger came with a plastic grip slide that onto the handle until it is centered at the top Turn the charger right side up onto its foot and wheels Align the handle so the screw holes are aligned with the screw holes on the upper back corners of the charger Attach the handle using the four Phillips head screws provided 10 FEATURES CONTROL PANEL 1 O
15. replacement parts call toll free from anywhere in the U S A 1 800 732 7764 7 00 am to 5 00 pm Central Time Monday through Friday 15 6
16. s only partially discharged 13 Plug the charger into an AC outlet Check for open fuse or circuit breaker supplying AC outlet Check for poor connection to battery and frame Make sure connection points are clean Rock the clips back and forth for a better connection Unplug the charger and reverse the clips Have battery checked Ammeter may show no activity at the 2A charge rate Continue charging battery for two more hours If problem continues have the battery checked Verify that you are charging a 12 volt lead acid battery Use a shorter or heavier gauge extension cord A sulfated battery will eventually take a normal charge if left connected If the battery will not take a charge have it checked Continue to charge the battery PROBLEM POSSIBLE CAUSE REASON SOLUTION The charger is making an audible clicking sound Charger makes a loud buzz or hum Short or no start cycle when cranking engine Circuit breaker is cycling Battery is defective Shorted battery cables or clips Severely discharged battery but otherwise it is a good battery Reverse connections at battery Transformer laminations vibrate buzz Shorted Diode Assembly or Output Rectifier Assembly hum Drawing more than the Engine Start rate Failure to wait 4 minutes between cranks Clips are not making a good connection AC cord and or extension cord is loose No power at rece
17. the charger has an adjustable charge rate charge the battery in the lowest rate first Make sure that the charger cable clips make tight connections CHARGER LOCATION AWARNING AWARNING RISK OF EXPLOSION AND pe CONTACT WITH BATTERY ACID Locate the charger as far away from the battery as the DC cables permit Never place the charger directly above the battery being charged gases from the battery will corrode and damage the charger Do not set the battery on top of the charger Never allow battery acid to drip onto the charger when reading the electrolyte specific gravity or filling the battery Do not operate the charger in a closed in area or restrict the ventilation in any way DC CONNECTION PRECAUTIONS Connect and disconnect the DC output clips only after setting all of the charger switches to the off position if applicable and removing the AC plug from the electrical outlet Never allow the clips to touch each other Attach the clips to the battery and chassis as indicated in sections 6 and 7 6 FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE AWARNING AWARNING AWARNING A SPARK NEAR THE BATTERY 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 MAY CAUSE A BATTERY EXPLOSION TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY Position the AC and DC cables to reduce the risk of damage by the hood door and moving or hot engine parts NOTE If it is necessary to close the hood d
18. trical outlet When disconnecting the charger turn all switches to off disconnect the AC cord remove the clip from the vehicle chassis and then remove the clip from the battery terminal See CALCULATING CHARGE TIME for length of charge information 5 1h FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE RISK OF A SPARK NEAR THE BATTERY A SPARK NEAR THE BATTERY AWARNING AWARNING AWARNING Ae van e EXPLOSION TO REDUCE THE 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 Check the polarity of the battery posts The POSITIVE POS P battery post usually has a larger diameter than the NEGATIVE NEG N post Attach at least a 24 inch 61 cm long 6 gauge AWG insulated battery cable to the NEGATIVE NEG N battery post Connect the POSITIVE RED charger clip to the POSITIVE POS P post of the battery Position yourself and the free end of the cable you previously attached to the NEGATIVE NEG N battery post as far away from the battery as possible then connect the NEGATIVE BLACK charger clip to the free end of the cable Do not face the battery when making the final connection Connect charger AC supply cord to electrical outlet When disconnecting the charger always do so in the reverse order of the connecting procedure and break the first connection while as far away from the battery as practical A marine boat battery must be removed and charged on shore To charge it
19. uring the charging process ensure that the hood does not touch the metal part of the battery clips or cut the insulation of the cables Stay clear of fan blades belts pulleys and other parts that can cause injury Check the polarity of the battery posts The POSITIVE POS P battery post usually has a larger diameter than the NEGATIVE NEG N post Determine which post of the battery is grounded connected to the chassis vehicle frame If the negative post is grounded to the chassis as in most vehicles see step 6 5 If the positive post is grounded to the chassis see step 6 6 For a negative grounded vehicle connect the POSITIVE RED clip from the battery charger to the POSITIVE POS P ungrounded post of the battery Connect the NEGATIVE BLACK clip to the vehicle frame or engine block at a distance away from the battery Do not connect the clip to the carburetor fuel lines or sheet metal body parts Connect to a heavy gauge metal part of the vehicle frame or engine block For a positive grounded vehicle connect the NEGATIVE BLACK clip from the battery charger to the NEGATIVE NEG N ungrounded post of the battery Connect the POSITIVE RED clip to the vehicle frame or engine block at a distance away from the battery Do not connect the clip to the carburetor fuel lines or sheet metal body parts Connect to a heavy gauge metal part of the vehicle frame or engine block Connect charger AC supply cord to elec
20. utput Selector Switch 1 2 Output Selector Switch 2 Ammeter Setting the Controls All controls for your charger are located on the front of the unit Follow these instructions to obtain the accurate charge level for your battery Output Selector Switches Two switches are used to select the rate of charge or function a 3 position switch switch 2 on the right and a 2 position switch switch 1 to the left of it e Switch 1 Use this switch to select the 200 Amp Engine Start and the 40 Amp Charge Rate Switch 2 must be in the down position Select Position when using Switch 1 e Switch 2 Use this switch to select the 2 amp Charge Rate and the OFF position Also use this switch to enable Switch 1 Note that Switch 1 is only effective when Switch 2 is set to Select Position Ammeter The Ammeter indicates the amount of current measured in amps that is being drawn by the battery As a battery takes on a charge it draws less current from the charger Correspondingly the meter will show less current being drawn by the battery When the current stops decreasing the battery is charged The start area of the meter indicates a high rate of current being drawn from the charger When cranking an engine the meter needle will be at the extreme right side of the start area The 2 amp charge rate may indicate some activity on the meter although the meter does not have the resolution to display this low rate 10
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