Sears 200.71231 User's Manual
Contents
1. CD WA Plugging it in A WARNING 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 Your charger is equipped with an electrical cord that 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 ee A TEMPORARY adapter may be used to connect the charger to a two pole 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 A WARNING Improper adapter con nection can result in electrical shock 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 metal screw to a properly grounded outlet If unsure whether outlet is properly grounded contact a professional electrician If necessary 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 an2. Weak cell or sulfated plate in battery Battery is only partially discharged Transformer laminations vibrate buzz Shorted diode hum Check for poor connections to battery and frame Make sure connecting points are clean Ammeter may show no activity at the 2 amp charge rate Check for open fuse or circuit breaker supplying AC outlet Check power cord and extension cord for loose fitting plug Circuit breaker cycles when current draw is too high Separate the clamps Check for worn cables and replace if needed Have a Sears technician test the battery Correct connections Correct Volt Amp Selector setting Crank time varies with the amount of current drawn If cranking draws more than 200 amps crank time may be less than 5 seconds Wait 4 minutes before next crank Use shorter or heavier gauge extension cord Sulfated battery will eventually take a normal charge if left connected If the battery will not take a charge have it tested by a Sears technician Continue charging battery Continue charging Buzz is not abnormal Have charger tested by a Sears 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 Central Time Monday through Friday For information about troubleshooting call toll free from anywhere in the U S A 7 am to 4 30 pm Central Time Monday through Friday 1 800 SEARS 64
3. 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 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 Use only 3 conductor grounded extension cord when necessary Check that the extension cord is properly wired and in good electrical condition Use the recommended minimum 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 25 50 100 150 18 14 12 10 AWG Size of Cord AWG American Wire Gauge Preparing your battery to be charged It is important that you read and follow these guide lines while you are preparing to charge your battery 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 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 Take time to read all battery manufacturer s specific precautions such as removing or not removing
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5. OWNER S MANUAL DieHard BATTERY CHARGER 40 2 Amp Manual 200 Amp ENGINE STARTER DieHard MANUAL Model No 200 71230 CAUTION Read all Safety Rules and Operating Instructions and follow them with each use of this product Sears Roebuck and Co Hoffman Estates IL 60179 U S A 00 99 000312 0306 Table Of Contents Warranty un 2cciccccccneniccecceccnnnitieeceeennniiteceeeennntiieeeeeennntiier 1 Using Your Battery Charger ccceessssseeerees 7 Important Safety Instructions csseeeeseeees 2 Setting the controls ececeeeeeeeeeeteeeeeeeetteeeee 7 PIS aaa wees cece ease cee en ees nacseeerevtevecuecuecess 3 Charging your battery ccccsseeeesestteeeeeeeeees 8 Before Using Your Battery Charger s 1se0e 4 Calculating charge times ccceeeeeeseeeeeeees 10 Assembling your Charger eecsseeeeeeeeenneeeeeeeee 4 Using the engine start feature eee 11 PLUGGING TIN escran 5 Maintenance and Care oo eeeeeeeeeeeeeenneeeeeeeeeees 11 Using an extension COrd ssec 6 Troubleshooting cceecseeeeeeeeeeeneeeeeeeeeeeeeseeeeens 12 Preparing your battery to be charged 6 Please read this Owner s Manual before using your Battery Charger The DieHard model 71230 Manual Battery Charger Engine Starter offers a wide range of features to accommodate the needs for home or light commercial use This manual will show you how to use yo
6. 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 Take the other end of the 6 gauge AWG or a 4 gauge SAE insulated 24 inch cable and standing 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 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 wall outlet Select the desired charge rate See Setting the Controls on page 7 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 When the battery is fully charged the AMMETER needle will fall to about half the charge rate selected For specific positions see the Amme ter section of Settings the Controls on page 7 When the battery is fully charged unplug the charger power cord before attempting to discon nect charger clamps Facing away from the battery remove the charger leads Remove the NEGATIVE clamp first then from the POSITIVE battery post or terminal Clean and store the batter
7. cell caps while charging and recommended rates of charge Wear safety glasses See additional Personal Safety Precautions on page 2 Be sure that the area around the battery is well ventilated while it is being charged If ventilation is poor any gases emitted from the battery 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 tells how to set the controls and how to charge a battery in and out of the vehicle 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 OUTPUT SELECTOR SWITCHES Two switches are used to select the rate of charge or function a 3 position switch on the right and a 2 position switch to the left of it Use the 3 position switch to select e 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
8. charger to rain or snow Never charge a frozen battery If battery fluid electrolyte becomes frozen bring battery into a warm area to thaw before you begin charging Never allow battery acid to drip on charger when reading specific gravity or filling battery Never set a battery on top of the charger Never place charger directly above battery being charged The gases from the battery will corrode and damage the charger Never use charger for charging dry cell batteries that are commonly used with home appliances These batteries may burst and cause personal injury Never touch the battery clamps together when the charger is energized Never operate charger if it has received a hard blow been dropped or otherwise damaged Take it to a qualified professional for inspection and repair Be sure to position the charger power cord to prevent it from being stepped on tripped over or damaged Never pull out the plug by the cord when unplugging 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 Personal Safety Precautions For your own personal safety please follow the following precautions 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 repa
9. eep cycle batteries are usually rated in Reserve Capacity RC e NR means that the charger setting is NOT RECOM MENDED 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 percent charge Add more time for totally discharged batter ies CHARGE RATE CHARGING TIME HOURS 40 AMP D 30 to 45 min 14 18 45 min to 1 hour 18 35 Djv N I D wo ao Zz D 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 percent needs another 50 percent 50 Multiply the Amp Hour rating by the charge needed 50 and divide by the charger setting 2 or 10 amps Multiply the result by 1 25 and you ll have the 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 of charge needed x 1 25 hours Charger Setting of charge 100 AH Rating x 50 charge needed x 1 25 6 25 40 Charger Setting hours 100 x 50 1 25 x 1 25 1 5625 40 You would need to charge your 100 Ampere Hour Battery for approximately 11 2 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 6 If the engine still does not start charge the battery car if the battery is low F
10. he battery or engine Batteries generate explo sive gases Neutralize any acid spills thoroughly with baking soda before attempting to clean up WARNING Handling the cord on this product or cords associated with accessories sold with this product may expose you to lead a chemical known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 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 DieHard 71230 Item Description Part Number 1 Handle 3599000286 A Negative BLK Cable w Clamps 3899000396 Positive RED Cable w Clamps 3899000410 Power Cord 90026096 5 Circuit Breaker Assembly 3999000099 Rectifier Assembly 2299001081 Transformer 93026532 Fan Motor 0099000063 Wheel 0099000080 Axle 0099000060 12 Axle Mtg Brackets 1199004366 13 Mounting Foot 1199003352 14 Rocker Switch 3 Position 0499000052 15 Ammeter 5399100088 16 Rocker Switch 2 Position 0499000050 17 Owner s Manual 0099000312 Wiring Diagram NEG BLACK BAT CABLE THROUGH POS RED UPPER BAT CABLE XFORMER 532 i CIRCUIT BREAKER Wiring Diagram 71230 3 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 connec
11. ir is required Incorrect assembly may result in fire or electrical shock To reduce risk of electrical shock unplug the charger from the outlet before attempting any maintenance or cleaning Always charge battery in a well ventilated area 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 Have plenty of fresh water and soap nearby for use in case battery acid contacts your eyes skin or clothing If this happens wash immediately with soap and water Then get medical attention 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 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 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 Always operate your battery charger in an open well ventilated area Never smoke or allow a spark or flame in the vicinity of t
12. lamps each time you are finished charging Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion 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 Occasional cleaning of the case with a soft cloth will keep the finish shiny and help prevent corro sion 11 Troubleshooting Performance problems often result from little things that you can fix yourself Please read through this table for a possible solution if a problem occurs PROBLEM POSSIBLE CAUSE SOLUTION REASONS No reading on the ammeter No reading on ammeter Fan inside wheel charger appears to not be working Circuit breaker in charger cycles on and off with a clicking sound Short start cycle when cranking engine Ammeter reads less than selected charge rate when charging a discharged battery Charger makes a loud buzz or hum Clamps are not making a good connection 2 amp charge rate is being used No power at receptacle AC cord and or extension cord is loose Shorted battery clamps Shorted battery Charger leads reversed Volt Amp Selector Switch set to the START position Drawing more than 200 amps for a period of 5 seconds or less Failure to wait for 4 minutes 240 seconds between cranks Extension cord too long or wire gauge too small
13. much less stress e OFF Leave the switch in the OFF Position while connecting the charger to the battery and to the AC power outlet Select This setting enables you to select one of the two charge rate settings offered by the 2 position 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 amount of amperes being drawn by the battery When you first start charging a battery the reading will be high with the needle near 40 at the 40 AMP CHARGE rate As the battery charges the needle will fall to about 15 to 20 amps indicating a charged battery 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 200A 12V ENGINE 2A 12V START CHARGE f 7 40A 12V SELECT CHARGE VOLT AMP SELECTOR O 10 20 30 40 E E E E Charging Your Battery Ch 1 arging your battery in the vehicle 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 Keep clear of the fan blades belts pulleys and othe
14. ollow these instructions on for five more minutes in the 40 AMP position how to use the engine start feature before cranking it again for five seconds 1 Set the right hand OUTPUT SELECTOR switch to 7 After the engine starts unplug the charger power the OFF position Then follow the instructions for cord from the outlet Then move the right hand connecting the charger to the battery in the SELECTOR SWITCH to the OFF section Charging your battery in the vehicle see position before disconnecting the battery leads page 8 IMPORTANT Do not try to start the engine without a Once Wie Chalger 15 connected set Ne rignthand battery in it You could cause damage to the electrical selector switch to SELECT and set the left selec tor switch to the 200 AMP START position See Plug the power cord into a grounded AC wall outlet If the engine does turn over but never starts up there Crank the engine for no more than five seconds is not a problem with the starting system there is a If the engine does not start wait four minutes problem somewhere else with the vehicle STOP before cranking again cranking the engine until the other problem has been During extremely cold weather or if the battery is diagnosed and corrected severely exhausted charge the battery for about five minutes before cranking the engine Maintenance and care A minimal amount of care can keep your battery charger working properly for years E Clean the c
15. ortant to check charging progress frequently Overcharging can damage a battery you must monitor and unplug charger when battery is fully charged When the battery is fully charged the AMMETER needle will fall to about half the charge rate selected For specific positions see the Amme ter section of Setting the Controls on page 7 When the battery is fully charged unplug the charger power cord Next set the right hand switch to the OFF position Facing away from the battery remove the charger clamp from the chassis first then from the battery post or terminal Clean and store the battery charger in a dry location NEGATIVE GROUNDED SYSTEM Charging your battery outside the vehicle 1 10 11 12 Remove the battery from vehicle making sure to disconnect grounded terminal first with all power turned off to the vehicle 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 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 Attach at least 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
16. r parts that can cause injury Check the polarity of the battery posts using the identification marks on the battery case POSI TIVE POS P and NEGATIVE NEG N Identify which battery post is ground or connected to the chassis THE NEGATIVE POST IS NOR MALLY THE ONE THAT IS GROUNDED 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 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 connect clamp to carburetor fuel lines or sheet metal parts 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 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 wall outlet Select the desired charge rate See Setting the Controls on page 7 The charger will not stop when the battery is fully charged For this reason it is imp
17. t 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 y f f 2 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 Be sure to tap the hub on straight Slide both wheels onto the axle with the hubs facing inward PEPEEEEEEEDV RELY TOUT continued on next page 3 Place the charger on its side Place one end of each bracket into slot then place the axle assem bly 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 Align the handle so the screw holes are aligned with the screw holes on each side of the wheel charger Attach the handle using the same screws MAG PTET Ty LNA
18. ur charger safely and effectively Please read and follow these instructions and precautions carefully For information about troubleshooting call toll free from anywhere in the U S A 7 am to 4 30 pm Central Time Monday through Friday 1 800 SEARS 64 1 800 732 7764 Warranty THREE YEAR FULL WARRANTY If this Battery Charger fails due to a defect in material or workmanship within three years from the date of purchase RETURN IT TO ANY SEARS STORE or OTHER 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 Roebuck and Co Hoffman Estates IL 60179 Important Safety Instructions SAVE THESE INSTRUCTIONS A WARNING e Read all instructions and cautions printed on the battery charger battery and vehicle or equipment using battery Use charger only on lead acid type rechargeable batteries such as those used in cars trucks tractors airplanes vans RVs trolling motors etc This charger is not intended to supply power to a low voltage electrical system other than in an automotive application 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 Place charger as far away from battery being charged as the charger cables will permit Do not expose
19. y charger in a dry location Positive Negative Calculating charge times 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 e 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 SMALL Motorcycle garden 6 12 AH BATTERIES tractor etc 12 32 AH 4 10 11 14 27 20 180 RC MARINE DEEP CYCLE 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 GRAVITY 1 265 1 225 1 155 1 120 PERCENT PERCENT OF OF CHARGE CHARGE NEEDED 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 NOTE The Reserve Capacity can be obtained from the battery specification sheet or the owner s manual e Marine or d
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