Sears 200.7144 User's Manual
Contents
1. e NR means that the charger setting is NOT RECOMMENDED Find your battery s rating on the following chart and note the charge time given for each charger setting The times given are for batteries with a 50 percent charge Add more time for totally discharged batteries CHARGE RATE CHARGING TIME HOURS SMALL BATTERIES Motorcycle garden tractor etc 12 32 AH 4 10 NR 200 315 CCA 40 60 RC 11 14 1 2 3 4 CAR TRUCKS 315 550 CCA 550 1000 CCA 80 RC 60 85 RC 85 190 RC 14 18 3 4 4 18 35 1 2 18 NR MARINE DEEP CYCLE 140 RC 160 RC 180 RC The Hydrometer or Electronic Method To find the time needed to fully charge your battery determine the battery s charge level with a hydrometer or electronic Percent of Charge Tester The following table will help you convert hydrometer readings to percent of charge values SPECIFIC PERCENT PERCENT OF GRAVITY OF CHARGE CHARGE NEEDED 1 265 100 0 25 1 225 75 When you know the percent of charge and the Amp Hour AH rating of your battery you can calculate the 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 Sears 440 Sch 516 9 16 95 27 NR 30 NR 33 NR To calculate time needed for a charge e Find the percent of charge needed A battery at 50 percent charge that will be charged to 100 perc2. BLK cable w clamps 3899000396 3 Positive RED cable w clamps 3899000410 4 Power Cord 90026096 5 Circuit Breaker Asm 3999000057 6 Rectifier Assembly 2299000614 7 Transformer 93026365 8 Owner s Manual not shown 0000000516 9 Wheel 0099000080 10 Hub Cap 5200000008 1 Axle 0099000060 12 Axle mtg bracket 1199004366 13 Mounting Foot 1199003352 14 Rocker Switch 3 pos 0499000052 15 Ammeter 5399100097 16 Rocker Switch 2 pos 0499000050 Wiring diagram Sears 440 Sch 516 9 16 95 Before Using Your Battery Charger It is important to prepare your charger for use This section will tell you how to assemble the charger ground and connect the power cord and prepare to charge a battery Assembling your charger It is important to fully assemble your charger before use Follow these instructions for easy assembly PARTS TOOLS NEEDED Two 10 32 thread cutting 3 8 wrench screws for mounting foot Two 1 4 20 thread cutting 5 16 wrench screws for wheels Two wheels Hammer One axle Phillips screwdriver Two axle caps Two axle brackets One handle One mounting foot To attach the axle assembly 1 Remove charger from packing materials and place upside down on a flat surface Attach mounting foot and secure with the two 1 4 20 thread cutting screws ASS XA N Hold axle upright on floor or work surface Then using a hammer tap one of the plastic hubs onto the top end of the axle B
3. SEARS OWNER S MANUAL Model No 200 71440 40 2 AMP MANUAL BATTERY CHARGER 200 AMP CAUTION ENGINE STARTER Read and Follow All Safety Rules and Operating Instructions Before Every Use of this Product Sears Roebuck and Co Hoffman Estates IL 60179 U S A Table Of Contents Wa Ta L1 a MP OETPEPEPP PEET OAE T TET AEA T ANTT 1 Using Your Battery Charger Setting the controls m Charging your battery Before Using Your Battery Charger sseessee 4 Calculating charge time Assembling your charger Using the engine start feature Maintenance and care Important Safety Instructions Plugging it in Using an extension Cord sc sseceeseeseeseesteeeeeeeteeee 6 Troubleshooting 12 Preparing your battery to be charged 0 6 Please read this Owner s Manual before using your Battery Charger The Sears model 200 71440 Manual Battery Charger Engine Starter offers a wide range of features to accommodate the needs for home or commercial use This manual will show you how to use your charger safely and effectively Please read and follow these instructions and precautions carefully Warranty FULL THREE YEAR WARRANTY If within three years from the date of purchase this battery charger fails due to a defect in materials or work manship simply RETURN IT TO THE NEAREST SEARS STORE IN THE UNITED STATES and Sears will repair or replace it free of charge This warran
4. a grounded AC outlet 7 Select the desired charge rate See Setting the Controls on page 7 8 The charger will not stop when the battery is fully charged For this reason it is important to check charging progress frequently Overcharging can damage a battery you must monitor and unplug charger when battery is fully charged 9 When the battery is fully charged the AMMETER needle will fall to about half the charge rate selected For specific positions see the Ammeter section of Settings the Controls on page 7 10 When the battery is fully charged unplug the charger power cord before attempting to disconnect charger clamps 11 Standing away from the battery remove the charger leads Remove the NEGATIVE clamp first then from the POSITIVE battery post or terminal 12 Clean and store the battery charger in a dry location Sears 440 Sch 516 9 16 95 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 motorcycles garden tractors etc are usually rated in Ampere Hours AH For example 6 to 12 AH or 12 to 32 AH e Batteries in cars and smaller trucks are usually rated in Reserve Capacity RC Cold Cranking Amps CCA or both BATTERY SIZE RATING e Marine or deep cycle batteries are usually rated in Reserve Capacity RC
5. arger in a dry location Sears 440 Sch 516 9 16 95 Charging your battery outside the vehicle 1 Remove the battery from vehicle making sure to disconnect grounded terminal first with all power turned off to the vehicle 2 Check the polarity of the battery posts as indicated on the battery case POSITIVE POS P and NEGATIVE NEG N NOTE On top post batteries the positive battery terminal usually has a larger diameter than the negative one 3 Connect the red POSITIVE charger clamp to the POSITIVE post of the battery Be sure to rock the clip back and forth to make a solid connection 4 Attach a 6 gauge AWG or a 4 gauge SAE insulated battery cable of at least 24 inches in length to the NEGATIVE battery post This cable will provide a safer connection because any arcing and sparking will not occur directly over the battery The battery cable is not provided with the charger but may be purchased at most automo tive accessory outlets 5 Take the other end of the 6 gauge AWG or a 4 gauge SAE insulated 24 inch cable and stand ing as far away from the battery as possible connect the black NEGATIVE lead to the free end of the cable Be sure to rock the clamp to make a solid connection IMPORTANT Wear safety glasses and face away from the battery while making the final connection 6 Set your charger s right hand 3 position selector switch to the OFF position Then plug the charger s power cord into
6. ate when charging a Weak cell or sulfated plate Sulfated battery will eventually take a normal charge if left discharged battery in battery connected If the battery will not take a charge have it tested by a Sears technician Battery is only partially Continue to charge battery discharged Charger makes a loud Transformer laminations Continue charging Buzz is not abnormal buzz or hum vibrate buzz Shorted diode hum Have charger tested by qualified technician If the above solutions do not eliminate the problem call toll free from anywhere in the U S A 1 800 SEARS 64 1 800 732 7764 7 AM to 4 30 PM CST Monday through Friday 12 Sears 440 Sch 516 9 16 95 SEARS OWNER S MANUAL Model No 200 71440 When requesting service or ordering parts always provide the following information Product Type Model Number Part Number Part Description 0000000516 995 40 2 AMP MANUAL BATTERY CHARGER 200 AMP ENGINE STARTER For information about troubleshooting Call toll free from anywhere in the U S A 7 am to 4 30 pm CST Monday through Friday 1 800 SEARS 64 1 800 732 7764 For the repair or replacement parts you need Call 7 am 7 pm 7 days a week 1 800 366 PART 1 800 366 7278 For the location of a Sears Repair Service Center in your area Call 24 hours a day 7 days a week 1 800 488 1222 SEARS America s Repair Specialists
7. charge a positive grounded post system Connect the black NEGATIVE charger clamp to the ungrounded NEGATIVE NEG N post of the battery Then connect the red POSITIVE clamp to a heavy unpainted metal part of the chassis or engine block away from the battery Do not con nect clamp to carburetor fuel lines or sheet metal parts 6 Connect the clamp to the battery post and twist or rock back and forth to make a solid connection This will help keep the clamps from slipping off the posts and causing sparks 7 Set your charger s right hand 3 position selector switch to the OFF position Then plug the charger s power cord into a grounded AC outlet 8 Select the desired charge rate See Setting the Controls on page 7 9 The charger will not stop when the battery is fully charged For this reason it is important to check charging progress frequently Overcharging can damage a battery you must monitor and unplug charger when battery is fully charged 10 When the battery is fully charged the AMMETER needle will fall to about half the charge rate selected For specific positions see the Ammeter section of Setting the Controls on page 7 11 When the battery is fully charged unplug the charger power cord Next set the right hand switch to the OFF position 12 Standing away from the battery remove the charger clamp from the chassis first then from the battery post or terminal 13 Clean and store the battery ch
8. e sure to tap the hub on straight Slide both wheels onto the axle with the hubs facing inward FUE TTAAELLD LOT TACT AV ETLAY UL continued on next page Sears 440 Sch 516 9 16 95 3 Tap the other axle cap onto the opposite end of the axle and place the axle assembly onto the bottom of the charger Place one end of the bracket into slot then place the axle assembly under each bracket Fasten the other side of the brackets using the two 10 32 screws provided To attach the handle Turn the charger right side up onto its foot and wheels Remove the two top screws from each side of the charger and align with the screw holes on the handle Attach the handle using the same screws h gu Plugging it in AWARNING Electrical Shock Hazard Be sure that power cord fits properly into outlet If not have a qualified technician install a proper outlet Never alter the AC cord or plug provided Improper connection can result in electrical shock Your charger should be grounded to reduce the risk of electrical shock M Your charger is equipped with an electrical cord that D has an equipment grounding conductor and a ground ing plug designed to be used on a 120 volt circuit The plug must be plugged into an outlet that has been properly installed and grounded in accordance with all local codes and ordinances Sears 440 Sch 516 9 16 95 A TEMPORARY adapter may be used to connect the charger to a two p
9. efore cranking the engine Ro Maintenance and care A minimal amount of care can keep your battery charger working properly for years 1 Clean the clamps each time you are finished charging Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion 2 Coil the input and output cords neatly when storing the charger The cords can be wrapped around the handle of the charger This will help prevent accidental damage to the cords and charger 3 Occasional cleaning of the case with a soft cloth will keep the finish shiny and help prevent corro sion Sears 440 Sch 516 9 16 95 6 If the engine still does not start charge the battery for five more minutes in the 40 amp position before cranking it again for five seconds 7 After the engine starts unplug the charger power cord from the outlet Then move the right hand OUTPUT SELECTOR SWITCH to the OFF position before disconnecting the battery leads IMPORTANT Do not try to start the engine without a battery in it You could cause damage to the electrical system If the engine does turn over but never starts up 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 Troubleshooting Performance problems often result from little things that you can fix yourself Please read through this chart for a possible so
10. ent needs another 50 percent 50 e Multiply the Amp Hour rating by the charge needed 50 and divide by the charger setting 2 or 40 amps e Multiply the result by 1 25 and you ll have the time need in hours to bring the battery to full charge e Add one more hour for a deep cycle battery Example Amp Hour Rating x of charge needed x 1 25 hours Charger Setting of charge needed 100 AH Rating x 50 charge needed x 1 25 1 5625 40 Charger Setting hours 100 x 50 1 25 x 1 25 1 5625 40 You would need to charge your 100 Ampere Hour Bat tery for a little more than 1 5 hours at the 40 Amp charge rate using the above example Using the engine start feature Your battery charger can be used to jump start your car if the battery is low Follow these instructions on how to use the engine start feature 1 Set the right hand OUTPUT SELECTOR switch to the OFF position Then follow the instructions for connecting the charger to the battery in the section Charging your battery in the vehicle see page 7 2 Once the charger is connected set the right hand selector switch to SELECT and set the left selector switch to the 200 AMP START position Plug in the charger Crank the engine for no more than five seconds If the engine does not start wait four minutes before cranking again 5 During extremely cold weather or if the battery is severely exhausted charge the battery for about five minutes b
11. g to charge your battery e Make sure that you have a 12 volt lead acid battery Clean the battery terminals Be careful to keep corrosion from getting in or around your eyes e If you have a battery with removable cell caps if required add distilled water to each cell until the battery acid reaches the level indicated by the manufacturer This will help purge excessive gases from the cells Be careful not to overfill If you have a sealed battery without cell caps no action is neces sary Continue to the next step listed below e Take time to read all battery manufacturer s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge Sears 440 Sch 516 9 16 95 e Wear safety glasses See additional Personal Safety Precautions on page 2 e Be sure that the area around the battery is well ventilated while it is being charged If ventilation is poor gas can be manually blown away by using a piece of cardboard or other non metallic material as a fan If it is necessary to remove the battery from the vehicle to charge it always remove the grounded terminal from the battery first A spark may be caused if all accessories in the vehicle are not completely turned off NOTE A marine battery installed in a boat must be removed and charged on shore Using Your Battery Charger To obtain the best results from your battery charger you must know how to use it properly This section
12. lution if a problem occurs PROBLEM POSSIBLE CAUSE SOLUTION REASONS No reading on the Clamps are not making a Check for poor connections to battery and frame Make ammeter good connection sure connecting points are clean 2 amp charge rate is being Ammeter may show no activity at the 2 amp charge rate used No reading on No power at receptacle Check for open fuse or circuit breaker supplying AC outlet ammeter Fan inside wheel charger appears AC cord and or extension Check power cord and extension cord for loose fitting to be not working cord is loose plug Circuit breaker in Shorted battery clamps Circuit breaker cycles when current draw is too high charger cycles on and Separate the clamps off with a clicking Check for worn cables and replace if needed sound Shorted battery Have a Sears technician test the battery Charger leads reversed Correct connections Volt Amp Selector Switch Correct Volt Amp Selector setting set to the START position Short start cycle Drawing more than 200 Crank time varies with the amount of current drawn If when cranking amps for a period of 5 cranking draws more than 200 amps crank time may be engine seconds or less less than 5 seconds Failure to wait for 4 Wait 4 minutes before next crank minutes 240 seconds between cranks Ammeter reads less Extension cord too long or Use shorter or heavier gauge extension cord than selected charge wire guage too small r
13. ole outlet if a properly grounded outlet is not available Use the adapter ONLY until a properly grounded outlet can be installed by a qualified electrician DANGER Before using an adapter as illustrated be certain that the center screw of the outlet plate is grounded The green colored grounding clip of the adapter must be attached by a screw to a properly grounded outlet If unsure whether outlet is properly grounded contact a professional electrician If neces sary replace the original outlet cover screw with a longer one that will secure the grounding clip to the outlet cover and make a ground connection to the grounded outlet Using an extension cord The use of an extension cord is not recommended If you must use an extension cord please make sure that you follow these guidelines e Make sure 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 Use only 3 conductor grounded extension cord when necessary e Check that the extension cord is properly wired and in good electrical condition e Use the recommemnded minumum AWG American Wire Gauge to be sure that wire size is large enough for the rating of the charger MINIMUM RECOMMENDED EXTENSION CORD Length of Cord in Feet AWG Size of Cord AWG American Wire Gauge Preparing your battery to be charged It is important that you read and follow these guidelines while you are preparin
14. rate charger if it has received a hard blow been dropped or otherwise damaged Take it to a qualified professional for inspection and repair e Be sure to position the charger power cord to prevent it from being stepped on tripped over or damaged e Never pull out the plug by the cord when unplug ging the charger Pulling on the cord may cause damage to the cord or the plug Do not operate the charger if it has a damaged power cord or plug Have the cord replaced e Remove all personal metal items from your body such as rings bracelets necklaces and watches while working with a lead acid battery A battery can produce a short circuit current high enough to weld a ring or the like to metal causing a severe burn e Take care not to drop any metal tool or metal object onto the battery This may spark or short circuit the battery or another electrical device that may cause an explosion e Always operate your battery charger in an open well ventilated area e Never smoke or allow a spark or flame in the vicinity of the battery or engine Batteries generate explosive gases e Neutralize any acid spills thoroughly with baking soda before attempting to clean up Parts This section shows an illustration of your battery charger Use it to become familiar with where all the parts are located and what they look like Replacement Parts List Sears 71440 Item Description Part Number 1 Handle 3599000286 2 Negative
15. teries that are commonly used with home appliances These batteries may burst and cause personal injury Personal Safety Precautions For your own personal safety please follow the follow ing precautions e Wear complete eye and clothing protection when working with lead acid batteries Be sure that someone is within range of your voice to come to your aid if needed while you work with or are near a lead acid battery e Have plenty of fresh water and soap nearby for use in case battery acid contacts your eyes skin or cloth ing If this happens wash immediately with soap and water Then get medical attention e Avoid touching your eyes while working with a battery Acid particles corrosion may get into your eyes If this occurs flush eyes immediately with running cold water for at least 10 minutes Then immediately get medical attention Sears 440 Sch 516 9 16 95 To reduce the risk of explosion explosive gases or injury while using your battery charger follow the precautions listed below Do not disassemble charger Take it to a qualified service professional if service or repair is required Incorrect assembly may result in fire or electrical shock e To reduce risk of electrical shock unplug the charger from the outlet before attempting any maintenance or cleaning e Always charge battery in a well ventilated area e Never touch the battery clamps together when the charger is energized e Never ope
16. ty gives you specific legal rights and you may also have other rights which vary from state to state Sears Roebuck and Co Dept 817WA Hoffman Estates IL 60179 Sears 440 Sch 516 9 16 95 Important Safety Instructions SAVE THESE INSTRUCTIONS FINAN e Read all instructions and cautions printed on the battery charger battery and vehicle or equipment using battery e Use charger only on lead acid type rechargeable batteries such as those used in cars trucks trac tors airplanes vans RV s trolling motors etc This charger is not intended to supply power to a low voltage electrical system other than in an automotive application e Use only attachments recommended or sold by manufacturer The use of attachments not recom mended by the manufacturer may result in fire electric shock or injury Help us help you Remember e Place charger as far away from battery being charged as the charger cables will permit e Do not expose charger to rain or snow e Never charge a frozen battery If battery fluid electro lyte becomes frozen bring battery into a warm area to thaw before you begin charging e Never allow battery acid to drip on charger when reading specific gravity or filling battery e Never set a battery on top of the charger e Never place charger directly above battery being charged The gases from the battery will corrode and damage the charger e Never use charger for charging dry cell bat
17. unt of amperes being drawn by the battery When you first start charging a battery the reading will be high with o 19 20 30 o the needle near 40 at the 40 AMP CHARGE rate As the battery charges the needle will fall to about 15 to AR 20 amps indicating a charged battery QHARGING START At the 2 AMP CHARGE rate you will notice very little needle movement When cranking the engine while using the ENGINE START feature the needle will swing into the Start red area of the scale VOLT AMP SELECTOR Sears 440 Sch 516 9 16 95 Charging Your Battery Charging your battery in the vehicle 1 Arrange the power cord and charging leads carefully in order to avoid damage that could be caused by the hood door or moving engine parts 2 Keep clear of the fan blades belts pulleys and other parts that can cause injury 3 Check the polarity of the battery posts using the identification marks on the battery case POSITIVE POS P and NEGATIVE NEG N 4 Identify which battery post is ground or connected to the chassis THE NEGATIVE POST IS NORMALLY THE ONE THAT IS GROUNDED 5 To charge a negative grounded post system Connect the red POSITIVE charger clamp to the ungrounded POSITIVE POS P post of the battery Next connect the black NEGATIVE clamp to a heavy unpainted metal part of the chassis or engine block away from the battery Do not connect clamp to carburetor fuel lines or sheet metal parts To
18. will tell you how to set the controls And how you can charge a battery while it is still in the vehicle or you can remove it and then charge it Follow the instructions below depending on how you choose to charge your battery Setting the controls All the controls for your charger are located on the front of the unit Follow these instructions to obtain the accurate charge level for your battery 40A 12V 2A 12V OUTPUT SELECTOR SWITCHES CHARGE CHARGE Two switches are used to select the rate of charge or function a 3 position switch on the right and a 2 position swtich to the left of it Use the 3 position switch to select OFF 2 Amp Trickle Charge Use for charging small batteries and warming large batteries The lower the charge rate the longer it will take but the battery is subjected to much less stress 200A 12V SELECT e OFF Leave the switch in the OFF Position while ENGINE connecting the charger to the battery and to the AC START power outlet Select This setting enables you to select one of the two charge rate settings offered by the 2 positon switch e Use the 40 Amp Charge rate for a fast charge e Use the 200 Amp Engine Start for cranking the engine Remember that little or no charging has been done by the charger and unless your trip is quite long your battery will still need further charging by the vehicle s charging system once the engine starts AMMETER The AMMETER indicates the measured amo
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