Sears 200.71991 User's Manual
Contents
1. Shorted battery clips Severely discharged battery but otherwise it is a good battery Reverse connections at battery Transformer laminations vibrate buzz Shorted SCR hum 15 Check for poor connections to battery and frame Make sure connecting points are clean Rock clips back and forth for a better connection Ammeter may show no activity at the 4 amp charge rate Continue charging battery for two more hours If problem continues have the battery checked Verify that you are using a 12 volt lead acid battery Use a shorter or heavier gauge extension cord A sulfated battery will eventu ally take a normal charge if left connected If the battery will not take a charge have it checked Continue to charge the battery 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 and replace if necessary 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 tested by a Sears or other qualified service dealer PROBLEM Short or no start cycle when cranking engine Charger will not turn on when properly connected The battery is connected and the charg2. 3 AMP RATE SELECTOR SWITCH Use the amp selector switch to select the charge rate or engine starting setting you require 10 11 4 11 5 12 12 1 12 2 12 3 12 4 12 5 12 6 AMMETER The Ammeter indicates the amount of current measured in amperes that is being drawn by the battery For example in the 40 amp charge rate a typical discharged battery will initially draw approximately 40 amps As the battery continues to charge current will taper to 15 to 20 amps at full charge The Start area of the meter indicates a high rate of current be ing drawn from the charger When cranking an engine the starter motor draws upwards to 200 300 amps The meter needle will be at the extreme right side of the start area Sometimes a battery for the first few minutes of its charge will draw more than 70 amps in this case the needle may be within but not all the way over to the right side of the start area The 4 amp charge rate may indicate some activity on the meter The meter does not have the resolution to display this low rate VOLTMETER The Voltmeter indicates the voltage at the battery terminals Use as fol lows 1 The charger need not be plugged into an AC outlet The timer should be in the OFF position Then connect the charger following instructions in Sections 6 and 7 2 Observe the meter indication Keep in mind that this reading is only a battery voltage reading a false surface charge may mislead you We sug
3. 7 FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION TO REDUCE RISK OF A SPARK NEAR BATTERY Negative Positive 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 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 When disconnecting the charger always do so in reverse sequence 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 onboard requires equipment specially designed for marine use 8 1 BATTERY CHARGING AC CONNECTIONS GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS Charger should be grounded to reduce risk of electric shock Charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an outlet that is proper
4. 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 CALCULATING CHARGE TIME The Chart Method 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 Small batteries motorcycle garden tractors etc are usually rated in Ampere Hours AH For example 6 12 32 AH etc Batteries in cars and smaller trucks are usually rated in Reserve Capacity RC Cold Cranking Amps CCA or both Marine or deep cycle batteries are usually rated in Reserve Capacity RC NR means that the charger setting is NOT RECOMMENDED Find your batteries rating on the chart below and note the charge time given for each charger setting The times given are for batteries with a 50 percent charge prior to recharging Add more time for severely dis charged batteries CHARGE RATE BATTERY SIZE RATING ETE TIME HOURS SMALL Motorcycle gar BATTERIES den tractor etc 12 32 AH 4 10 NR NR 60 90 30 40 20 30 CAR TRUCKS 90 120 45min 30 40 2 3 5 45 60 550 1000 CCA 85 190 RC 18 35 2 hrs 45 1 hr and MARINE DEEP CYCLE 12 4 13 2 The Hydrometer or Electronic Method To find the time needed to fully charge your battery determine the bat tery s charge level with a hydrometer or electron
5. or ten minutes and then switch back to Automatic mode at the desired charge rate 17 5
6. AINTENANCE INSTRUCTIONS Before performing maintenance unplug and disconnect the battery char ger see sections 6 7 and 7 6 After use use a dry cloth to wipe all battery corrosion and other dirt or oil from the clips cords and the charger case Through routine maintenance ensure all user installed parts are secure Servicing does not require opening the unit as there are no user service able parts STORAGE INSTRUCTIONS Store the charger unplugged and in an upright position The cord will still conduct electricity until it is unplugged from the outlet Store inside in a dry cool place unless you are using a UL Listed on board Marine Charger Store the clips on the fiberglass clamp rod Do not store them on the handle clipped together on or around metal or clipped to the cables 14 16 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION REASONS No reading on the ammeter Ammeter reading stays high Ammeter reads less than se lected charge rate when charg ing a discharged battery The charger is making an audible clicking sound Charger makes a loud buzz or hum Clips are not making a good connection 4 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 is only partially dis charged Circuit breaker is cycling Battery is defective
7. LL TOLL FREE FROM 7 AM TO 4 30 PM CT MONDAY THROUGH FRIDAY 1 800 SEARS 64 1 800 732 7764 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 IMPORTANT READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS The DieHard model 71991 Manual Bat tery Charger offers a wide range of features to accommodate the needs for home or light commercial use This manual will show you how to use your charger safely and effectively Please read and follow these instruc tions and precautions carefully as this manual contains important safety and operating instructions Do not expose charger to rain or snow 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 To reduce the risk of damage to 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 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 That the extension cord is properly wired and in good electrical condition and That the wire size is large enough for the AC ampere rating of the charger as specified in Table 8 2 Do not opera
8. OPERATOR S MANUAL DieHard BATTERY CHARGER 70 40 20 4 Amp 300 AMP ENGINE STARTER With Battery Tester Model No 200 71991 CAUTION Read and follow all Safety Rules and Operating Instructions Before Every Use of this Product SAVE THESE INSTRUCTIONS Sears Roebuck and Co Hoffman Estates IL 60179 U S A 00 99 000882 0808 TABLE OF CONTENTS SECTION PAGE 1 IMPORTANT SAFETY INSTRUCTIONS 1 2 PERSONAL PRECAUTIONS 2 3 PREPARING TO CHARGE 3 4 CHARGER LOCATION 3 5 DC CONNECTION PRECAUTIONS 3 6 WHEN BATTERY IS INSTALLED IN VEHICLE 4 7 WHEN BATTERY IS OUTSIDE VEHICLE 5 8 BATTERY CHARGING AC CONNECTIONS 6 9 PRODUCT FEATURES 8 10 ASSEMBLY INSTRUCTIONS 8 11 OPERATING INSTRUCTIONS 10 12 ENGINE START 11 13 CALCULATING CHARGE TIME 12 14 MAINTENANCE INSTRUCTIONS 14 15 STORAGE INSTRUCTIONS 14 16 TROUBLESHOOTING 14 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 one year from the date of purchase return it to any Sears store or other DieHard outlet in the United States for free replacement This warranty does not include fuses which are expendable parts This warranty gives you specific legal rights and you may also have other rights which vary from state to state Sears Roebuck and Co Hoffman Estates IL 60179 FOR CUSTOMER ASSISTANCE OR REPLACEMENT PARTS CA
9. TERY OPERATION FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER TO REDUCE THE RISK OF BATTERY EXPLOSION FOLLOW THESE INSTRUCTIONS AND THOSE PUBLISHED BY THE BATTERY MANU FACTURER 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 PERSONAL PRECAUTIONS 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 protection and clothing protection Avoid touching your eyes while working near the battery If battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye immediately flood the eye with cold run ning water for at least 10 minutes and get medical attention immediately NEVER smoke or allow a spark or flame in the vicinity of a battery or engine Be extra cautious to reduce the risk of dropping a metal tool onto the bat tery It might spark or short circuit the battery or other electrical part that may cause an explosion Remove personal metal items such as rings bracelets necklaces and watches when working with a lead acid battery A lead acid battery can produce a short circuit current high enough to weld a ring or the like to metal causing a severe bur
10. er is on but is not charging POSSIBLE CAUSE SOLUTION REASONS Drawing more than 300 amps Failure to wait 3 minutes 180 seconds between cranks Clips are not making a good connection AC cord and or extension cord is loose No power at receptacle The charger may be heated up Battery may be severely discharged AC outlet is dead Poor electrical connection Clips are not making a good connection Battery is severely discharged 16 Crank time varies with the amount of current drawn If cranking draws more than 300 amps crank time may be less than 3 seconds Wait 3 minutes of rest time before the next crank Check for poor connection at battery and frame Check power cord and exten sion 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 close Make sure the charger vents are not blocked Wait and try again On a severely discharged battery charge for 10 to 15 min utes in the 40 amp manual rate to help assist in cranking Check for open fuse or circuit breaker supplying AC outlet Check power cord and exten sion cord for loose fitting plug Check for poor connection at battery and frame Make sure connecting points are clean Rock clips back and forth for a better connection If your battery does not have 4 volts you need to switch to the 40A Manual mode for five
11. g while allowing a battery time to obtain a satisfactory charge To properly set the timer you must know the size of the battery in ampere hours or reserve capacity in minutes and the state of charge Often the state of charge is not known this is one reason why the timer was limited to 2 25 hours With the aid of a battery load tester the state of charge can be obtained within a few seconds For example the average size automotive battery at a 50 state of charge will require 1 to 1 5 hours of charging at the 40 amp rate to reach the full charge state For the same battery with the timer set to its maximum 2 25 hours over charging will occur but not likely cause harm to a battery that was otherwise in good condition When the charge state is not known start out with a timer setting of one hour or less or use the automatic setting 11 2 HOLD This position defeats the timer function allowing for continuous operation AUTOMATIC MODES Put the timer in the HOLD position when the bat tery charger is in one of the automatic modes otherwise the timer will shut the charger off when the set time expires regardless of whether the charge is complete or not The green charged LED will light and the fan will shut off when the charging is complete MANUAL MODES Use when you want to charge more than 2 25 hours Be sure to monitor the charging procedure and stop it when the battery is charged Not doing so may cause damage to your battery 11
12. gest that you turn on your headlights for a couple of minutes before you read the meter Read a couple of minutes after you have shut the headlights off If the reading is less than 10 5 volts the battery may be bad or the connections at the charger may be poor If the reading is 10 5 volts to 12 8 volts the battery is low recharge it If the reading is above 12 8 volts the battery is charged ENGINE START Set the charge rate switch and the timer to the OFF positions With the charger unplugged from the AC outlet connect the charger to the battery following instructions given in section 6 Plug the charger AC power cord into the AC outlet and then move the timer from OFF to the HOLD position Set the amp rate selector switch to the engine start position and then crank the engine until it starts or 5 seconds passes NOTE During extremely cold weather or if the battery is under 2 volts charge the battery for five minutes before cranking the engine If the engine fails to start charge the battery for 5 more minutes before attempting to crank the engine again After the engine starts move the amp rate selector switch to OFF and unplug the AC power cord from the outlet before disconnecting the battery clamps 11 13 13 1 IMPORTANT Using the ENGINE START feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle s electrical system If the engine does turn over but never starts there is not
13. ic Percent of Charge Tester The following table will help you convert hydrometer readings to percent of charge values SPECIFIC GRAVITY PERCENT OF CHARGE PERCENT OF CHARGE When you know the percent of charge and the Amp Hour AH rating of your battery you can calculate the approximate time needed to bring your battery to a full charge To convert Reserve Capacity to Amp Hours divide Reserve Capacity by 2 and add 16 Amp Hours Reserve Capacity 16 2 NOTE The Reserve Capacity can be obtained from the battery specifica tion sheet or the owner s manual To calculate time needed for a charge Find the percent charge needed A battery at 50 percent charge that will be charged to 100 percent needs another 50 percent 50 Multiply the Amp Hour rating by the charge needed 50 and divide by the charger setting 2 15 or 60 amps Multiply the results by 1 25 and you will have the total time needed in hours to bring the battery to full charge Add one additional hour for a deep cycle battery Example Amp Hour Rating x charge needed x 1 25 hours of Charger Setting charge 100 AH Rating x 50 charge needed x 1 25 3 125 20 Charger Setting hours 100x 50 2 5x 1 25 3 125 20 You would need to charge your 100 Ampere Hour Battery for a little more than 3 hours at the 20 Amp charge rate using the above example 13 14 14 1 14 2 14 3 14 4 15 15 1 15 2 15 3 M
14. ly installed and grounded in accordance with all local codes and ordinances DANGER Never alter the AC cord or plug provided if it will not fit the outlet have the proper outlet installed by a qualified electrician An im proper connection can result in a risk of an electric shock This battery charger is for use on a nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated in sketch A in Figure 8 3 A temporary adapter which looks like the adapter illustrated in sketches B and C may be used to connect this plug to a two pole receptacle as shown in sketch B if a properly grounded outlet is not available The tem porary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician DANGER Before using adapter as illustrated be certain that center screw of outlet plate is grounded The green colored rigid ear or lug ex tending from adapter must be connected to a properly grounded outlet make certain it is grounded If necessary replace original outlet cover plate screw with a longer screw that will secure adapter ear or lug to outlet cover plate and make ground connection to grounded outlet 8 2 Recommended minimum AWG size for extension cords for battery chargers AC input rating AWG size of cord amperes Length of cord feet m lf the input rating of a charger is given in watts rather than in amperes the corresponding ampere rating is
15. n Use this charger for charging a LEAD ACID battery 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 WARNING Pursuant to California Proposition 65 this product contains chemicals known to the State of California to cause cancer and birth de fects or other reproductive harm 3 1 3 2 3 3 3 4 3 5 3 6 4 1 4 2 4 3 4 4 4 5 5 1 5 2 PREPARING TO CHARGE If itis necessary to remove the battery from the vehicle to charge it al ways remove the grounded terminal from the battery first Make sure all of the accessories in the vehicle are off so as not to cause an arc Be sure the area around the battery is well ventilated while the battery is being charged Clean the battery terminals Be careful to keep corrosion from coming into contact with your eyes 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 carefully follow the manufacturer s recharging instructions Study all of the battery manufacturer s specific precautions while charging and recommended rate
16. o the slot in the char ger base Do not completely tighten the screws Item 4 at this time Slide the axle Item 2 into the brackets Item 1 until centered on the char ger Slide one wheel Item 3 onto the axle with the recessed hub facing out as shown Next insert pin Item 8 thru axle hole Repeat this process for the other wheel and when both wheels have been pinned to axle finish tightening the two axle bracket screws Item 4 Snap hub caps Item 7 onto each wheel to cover the pin and axle Next lift the charger upright so that it rests on the wheels and foot Remove the two top side screws Item 9 from each side of the charger Verify that the foam handle grip Item 12 is on the handle assembly Item 10 install if needed Insert the fiberglass clamp rod Item 11 into the pierced holes on the inside of the handle Item 10 Align the handle assembly Item 10 with charger and reinstall the side screws Item 9 Do not over tighten Charger assembly is now complete Battery clips can be clamped to the fiberglass rod Item 11 for convenient storage Do not attach clips to the foam area of handle as this will damage the foam grip 11 OPERATING INSTRUCTIONS VOLT AMP SELECTOR 12V 70A 5V 12V n START 300A 29 79 40 jo 9 NNI ye we f UR se Boon i 1735 120 CHARGE TIME MINUTES Manual operation Must be monitorod 11 1 TIMER The main function of the timer is to prevent over chargin
17. s 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 the charger has an adjustable charge rate charge the battery at the lowest rate first CHARGER LOCATION 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 Never allow battery acid to drip onto the charger when reading the electro lyte specific gravity or filling the battery Do not operate the charger in a closed in area or restrict the ventilation in any way Do not set a battery on top of the charger DC CONNECTION PRECAUTIONS Connect and disconnect the DC output clips only after setting all of the charger switches to the off position 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 steps 6 5 6 6 and 7 2 through 7 4 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VE HICLE A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION TO REDUCE RISK OF A SPARK NEAR BATTERY Position the AC and DC cables to reduce the risk of damage by the hood door or moving engine parts Stay clear of fan blades belts pulleys and other parts that can cau
18. se 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 chas sis 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 chassis or engine block away from the battery Do not connect the clip to the carbure tor fuel lines or sheet metal body parts Connect to a heavy gauge metal part of the 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 chassis or engine block away from the battery Do not connect the clip to the carbure tor fuel lines or sheet metal body parts Connect to a heavy gauge metal part of the frame or engine block 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 OPERATING INSTRUCTIONS for length of charge information s s 7 7 1 7 2 7 3 7 4 7 5 7 6 7
19. te the charger with a damaged cord or plug take it to a quali fied serviceman Call customer service at 800 SEARS 64 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 serviceman Call customer service at 800 SEARS 64 DO NOT attempt to repair product yourself To arrange for product repair or for information about customer replaceable parts call 1 800 SEARS 64 1 800 732 7764 In case of charger malfunction DO NOT attempt to repair the charger yourself To arrange for charger repair or for information about customer replaceable parts call 1 800 SEARS 64 1 800 732 7764 Do not disassemble the charger take it to a qualified serviceman when service or repair is required Incorrect reassembly may result in a risk of electric shock or fire Call customer service at 800 SEARS 64 To reduce the risk of electric shock unplug the charger from the outlet before attempting any maintenance or cleaning Turning off the controls will not reduce this risk WARNING Pursuant to California Proposition 65 this product contains chemicals known to the State of California to cause cancer and birth de fects or other reproductive harm aqe 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 WARNING RISK OF EXPLOSIVE GASES WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGER OUS BATTERIES GENERATE EXPLOSIVE GASES DURING NOR MAL BAT
20. to be determined by dividing the wattage rating by the voltage rating for example 1250 watts 125 volts 10 amperes 8 3 Grounding Methods d METAL SCREW F 1 COVER OF GROUNDED OUTLET BOX GROUNDING PIN A B ADAPTER E gt o GROUNDING MEANS GROUNDING C PIN D gt AA210 9 10 FEATURES Ammeter Volt Meter Foam Grip Fiber Glass Clamp Rod Clamps Charge Rate Selector Switch Timer Wheel ONOARWN ASSEMBLY INSTRUCTIONS IT IS IMPORTANT TO FULLY ASSEMBLE YOUR CHARGER BEFORE USE FOLLOW THESE INSTRUCTIONS FOR ASSEMBLY m M QTY DESCRIPTION axle bracket axle with pin holes TOOLS NEEDED screw 10 32 x 1 2 self tapping 5 16 Wrench or Nut Driver screw 1 4 20 x 3 4 self tapping 3 8 Wrench or Nut Driver wheel charger foot Screwdriver Flat Blade Screwdriver Phillips hubcap black Hammer hairpin cotter screw 8 18 x 1 2 sheet metal handle assembly fiberglass clamp rod foam handle grip dd e o _ e J e 2 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12 10 13 10 14 10 15 WA WMA WA First carefully lay the charger on its front to prepare for assembly Assemble the foot Item 6 using two 20 screws Item 5 and tighten securely Attach the two axle brackets Item 1 using one 10 32 screw Item 4 in each The brackets should have one end hooked int
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