OWNER'S MANUAL
DieHard,
BATI'ERY CHARGER
40/2 Amp
Manual
200 Amp
ENGINE STARTER
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.
0099000312-402
Table Of Contents
Warranty ....................................................................
1
Using Your Battery Charger .....................................
7
Important Safety Instructions .................................
2
Setting the controls ..............................................
7
Parts ..........................................................................
3
Charging your battery ..........................................
8
Before UslngYour Battery Charger ........................ 4
Calculating charge times ....................................
10
Assembling your charger .....................................
Using the engine start feature ............................
Maintenance and care .......................................
11
11
4
Plugging it in ........................................................
5
Using an extension cord .......................................
6
Troubleshooting
.....................................................
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 Your
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 CT
Monday through Friday.
1 -BOO-SEARS-64 (1-600-732-7764).
For repair parts or the location of a Sears Parts and Repair Center call:
1-800..4-MY-HOME = (1-800-469-4663).
Warranty
FULL THREE-YEAR
WARRANTY
If, within three years from the date of purchase this battery charger fails due to a defect in material or
workmanship, RETURN IT TO THE NEAREST SEARS STORE IN THE UNITED STATES, and Sears will
repair or replace it, free of charge.
This warranty 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
12
Important
Safety Instructions
- SAVE THESE INSTRUCTIONS
• Read all instructions and cautions printed on the
battery charger, battery, and vehicle or equipment
using battery.
-
• 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.
• Use charger only on lead-acid type rechargeable
batteries, such as those used in cars, trucks,
tractors, 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.
• 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.
• Use only attachments recommended or sold by
manufacturer. The use of attachments not recommended 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.
• Never touch the battery clamps together when the
charger is energized.
• Do not expose charger to rain or snow.
• 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.
• Never charge a frozen battery. If battery fluid
(electrolyte) becomes frozen, bring battery into a
warm area to thaw before you begin charging.
• Be sure to position the charger power cord to
prevent it from being stepped on, tripped over, or
damaged.
• Never allow battery acid to drip on charger when
reading specific gravity or filling battery.
• 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.
• 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.
• Do not operate the charger if it has a damaged
power cord or plug. Have the cord replaced.
• Never use charger for charging dry-cell battades
that are commonly used with home appliances.
These batteries may burst and cause personal
injury.
Personal
Safety
• 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 bum.
Precautions
For your own personal safety, please follow the
following precautions:
• Wear complete eye and clothing protection when
working with lead-acid batteries.
• 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.
• 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.
• Always operate your battery charger in an open,
well ventilated area.
• Never smoke or allow a spark or flame in the vicinity
of the battery or engine. Batteries generate explosive gases.
• 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.
• Neutralize any acid spills thoroughly with baking
soda before attempting to clean up.
2
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.
; Item
1.
Description
Handle
Pert Number
3599000286
2.
Negative (BLK) Cable w/Clamps
3899000396
3.
Positive (RED) Cable w/Clamps
3899000410
4.
Power Cord
5.
Circuit Breaker Assembly
3999000099
6,
Rectifier Assembly
2299001081
7.
Transformer
8.
Fan Motor
0099000063
9.
Wheel
0099000080
10.
HubCap
5200000008
11.
Axle
0099000060
12.
Axle Mtg. Brackets
1199(X)4366
13.
Mounting Foot
1199003352
14.
Rocker Switch 3 Position
0499000052
15.
Ammeter
5399100088
16.
Reeker Switch 2 Po6ition
0499(XXX_50
17.
Owner's Manual
0099000312
Wiring
90026096
93026532
Diagram
ACL_R
Wiring
Diagram
3
71230
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
screws
3/8" wrench
(for mounting foot)
Two 1/4-20 thread cutting
screws
5/16" wrench
(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.
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.
am
m
continued on next page
4
3. Tapthe
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.
Plugging
it in
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 grounding 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 cedes and ordinances.
5
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.
,_
WARNING:
nection
Improper
adapter con-
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
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:
• 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.
"AWG-_Amedcan
Wire Gauge
• 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.
Preparing
your
battery
to be charged
It is important that you read and follow these guidelines while you are preparing to charge your battery.
Wear safety glasses. See additional "Personal
Safety Precautions" on page 2.
• 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.
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 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 ceil caps, no action is necessary. Continue to the next step listed below.
• 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.
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 2position switch to the left of it. Use the 3-position
switch to select:
40A 12V
CHARGE
• 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.
• OFF-- Leave the switch in the OFF Position while
connecting the charger to the battery and to the AC
power outlet,
2A 12V
CHARGE
OFF
200A 12V_-_-
SELECT
ENGINE
START
• Select -- This setting enables you to select one of
the two charge-rate settings offered by the 2position switch.
VOLT/AMP SELECTOR
• Use the 40 Amp Charge rate for a fast charge.
• 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.
AMPS
When cranking the engine while using the ENGINE
START feature, the needle will swing into the Start
(red) area of the scale.
7
Charging
Charging
Your Battery
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 pads.
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 pads.
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.
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 atop 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 batteryls 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 charger In a dry
location.
NEGATIVE
8
GROUNDED
SYSTEM
Charging
1.
your battery outside
the vehicle:
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 automotive accessory outlets.)
5. Take the other end of the 6-gauge (AWG) or a 4gauge (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.
6. 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.
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 haft 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.
9
Calculating
charge
times
The Chart Method
• Marine, or deep-cycle batteries are usually rated in
Reserve Capacity (RC).
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 chad.
• NR means that the charger setting is NOT RECOMMENDED.
• Small batteries -- motorcycles, garden tractors, etc.
-- are usually rated in Ampere Hours (AH). For
example: 6 to 12 AH, or 12 to 32 AH.
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 batteries.
• Batteries in cars and smaller trucks are usually rated
in Reserve Capacity (RC), Cold-Cranking Amps
(CCA), or both.
SMALL
BATTERIES
CAR/TRUCKS
MARINE/DEEP
Motorcycle, garden
tractor, etc.
6-12 AH
2-4
NR
NR
12 -32 AH
4-10
200 - 315 CCA
40 - 60 RC
11 - 14
V2-3A
315 - 550 CCA
60 - 85 RC
14 -18
_-1
550 - 1000 CCA
85 -190 RC
18 - 35
1-2
80 RC
18
NR
140 RC
27
NR
160 RC
30
NR
180 RC
33
NR
CYCLE
To calculate time needed for a charge:
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.
• 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 bythe 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 Ratlno x % of charo_eneeded x 1.25 = hours
Charger Setting
d
charge
100 (AH Ratlno_ x .50 (charoQ needed) x 1.25 = 6.25
40 (Charger Setting)
hours
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.
- 1.25 x 1.25 = 1.5625
40
To convert Reserve Capacity to Amp Hours, divide
Reserve Capacity by 2, and add 16:
You would need to charge your 100-Ampere Hour
Battery for approximately 1½ hours at the 40-Amp
charge rate using the above example.
Amp Hours = Reserve Caoacitv + 16
2
10
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 8.
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.
3. Plug in the charger.
4. 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 before cranking the engine.
Maintenance
6.
7.
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.
After the engine starts, unplug the charger power
cord from the outlet. Then move the right-hand
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.
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 corrosion.
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
SOLUTIONIREASONS
No reading on the
ammeter.
Clamps are not making a
good connection.
Check for poor connections to battery and frame. Make
sure connecting points are clean.
2-amp charge rate is
being used.
Ammeter may show no activity at the 2-amp charge rate.
No power at receptacle.
Check for open fuse or cimuit breaker supplying AC outlet.
AC cord and/or extension
cord is loose.
Check power cord and extension cord for loose fitting
plug.
Shorted battery clamps.
Circuit breaker cycles when current draw is too high.
Separate the clamps.
Check for worn cables and replace if needed.
Shorted battery,
Have a Sears technician test the battery.
Charger leads reversed.
Correct connections,
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.
Volt/Amp Selector Switch Correct Volt/Amp Selector setting.
set to the START position.
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.
Drawing more than 200
amps for a period of 5
seconds or less.
Crank time varies with the amount of current drawn. If
cranking draws more than 200 amps, crank time may be
less than 5 seconds.
Failure to wait for 4
minutes (240 seconds)
between cranks.
Wait 4 minutes before next crank.
Extension cord too long
or wire gauge too small.
Use shorter or heavier gauge extension cord.
Weak cell or sulfated
plate in battery.
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.
Battery is only partially
discharged.
Continue charging battery.
Transformer laminations
vibrate (buzz).
Continue charging, Buzz is not abnormal.
Shorted diode (hum).
Have charger tested by a Sears technician.
If the above solutions do not eliminate the problem...
cell toll-h_e from anywhere in the U.S.A.
1-800-SEARS-64
(1-SOO-7=:-77S4)
7 AM tO 4".30 PM CT Monday through Fdclay
12
For information about troubleshooting, call toll-free from anywhere in the
U.S.A. 7 am to 4:30 pm CT Monday through Friday.
1-800-SEARS-64 (1-800-732-7764).
For repair parts or the locationof a Sears Partsand Repair Center call:
1-800-4-MY-HOME= (t400-469-4663),