Sears 20071240 User Manual

OPERATOR’S MANUAL  
®
BATTERY ChARGER  
50/15/2 Amp,  
6/12 volt,  
Manual  
250 Amp  
ENGINE STARTER  
Model No.  
200.71240  
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.  
00-99-000853/0808  
IMPORTANT: REAd ANd SAvE ThIS SAfETY ANd INSTRUCTION MANUAL.  
1.  
IMPORTANT SAfETY INSTRUCTIONS  
1.1  
SAVE THESE INSTRUCTIONS - The DieHard model 71240 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.  
1.2  
WARNING: This product contains chemicals known to the State of Cali-  
fornia to cause cancer and birth defects or other reproductive harm. Wash  
hands after handling.  
1.3  
1.4  
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.  
1.5  
1.6  
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 8.3.  
1.7  
1.8  
Do not operate 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).  
1.9  
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).  
1.10 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.  
1 •  
wARNING – RISk Of EXPLOSIvE GASES.  
wORkING IN ThE vICINITY Of A LEAd-ACId BATTERY IS dANGER-  
OUS. BATTERIES GENERATE EXPLOSIvE GASES dURING NOR-  
MAL BATTERY 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.  
2.  
PERSONAL PRECAUTIONS  
2.1  
Consider having someone close enough by to come to your aid when you  
work near a lead-acid battery.  
2.2  
2.3  
2.4  
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.  
2.5  
2.6  
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.  
2.7  
2.8  
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 burn.  
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.  
2.9  
NEVER charge a frozen battery.  
2.10 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.  
2 •  
3.  
PREPARING TO ChARGE  
3.1  
If it is 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.  
3.2  
3.3  
3.4  
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.  
3.5  
3.6  
Study all of the battery manufacturer’s specific precautions while charging  
and recommended rates of charge.  
Determine the voltage of the battery by referring to the vehicle owner’s  
manual and make sure that the output voltage selector switch is set to the  
correct voltage. If the charger has an adjustable charge rate, charge the  
battery at the lowest rate first.  
4.  
4.1  
4.2  
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.  
4.3  
4.4  
4.5  
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.  
5.  
dC CONNECTION PRECAUTIONS  
5.1  
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.  
5.2  
Attach the clips to the battery and chassis, as indicated in steps 6.5, 6.6,  
and 7.2 thru 7.4.  
3 •  
6.  
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:  
NEGATIvE GROUNdEd SYSTEM  
6.1  
6.2  
6.3  
6.4  
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 cause  
injury.  
Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery  
post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.  
Determine which post of the battery is grounded (connected) to the 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.  
6.5  
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.  
6.6  
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.  
6.7  
6.8  
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.  
4 •  
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:  
7.1  
7.2  
7.3  
7.4  
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.  
7.5  
7.6  
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.  
7.7  
A marine (boat) battery must be removed and charged on shore. To  
charge it onboard requires equipment specially designed for marine use.  
5 •  
8.  
BATTERY ChARGING - AC CONNECTIONS  
8.1  
for all grounded cord-connected battery chargers:  
GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS  
– The charger should be grounded to reduce the risk of electric shock.  
The 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 properly 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  
improper connection can result in a risk of an electric shock.  
8.2  
For all grounded, cord-connected battery chargers with an input rating less  
than 15-amperes and intended for use on a nominal 120-volt circuit:  
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 8.4.  
A temporary adaptor, 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 an adapter as illustrated, be certain that the  
center screw of the outlet plate is grounded. The green-colored rigid  
ear or lug extending from the adapter must be connected to a properly  
grounded outlet – make certain it is grounded. If necessary, replace the  
original outlet cover plate screw with a longer screw that will secure the  
adapter ear or lug to the outlet cover plate and make a ground connec-  
tion to the grounded outlet.  
6 •  
8.3  
Recommended minimum AWG size for extension cords for battery  
chargers:  
AC input rating,  
amperesa  
AWG size of cord  
Length of cord, feet (m)  
But less  
than  
25  
(7.6)  
18  
18  
18  
18  
18  
18  
18  
16  
16  
16  
14  
14  
50  
(15.2)  
18  
18  
18  
18  
16  
16  
14  
14  
12  
12  
12  
100  
(30.5)  
18  
16  
16  
14  
14  
12  
12  
10  
10  
10  
8
150  
(45.6)  
16  
14  
14  
12  
12  
10  
10  
8
At least  
0
2
3
4
5
2
3
4
5
6
6
8
8
10  
12  
14  
16  
18  
20  
10  
12  
14  
16  
18  
8
8
8
6
12  
8
aIf the input rating of a charger is given in watts rather than in  
amperes, the corresponding ampere rating is to be determined  
by dividing the wattage rating by the voltage rating ± for  
example:  
1250 watts/125 volts = 10 amperes  
8.4  
Grounding Methods  
7 •  
9.  
PROdUCT fEATURES  
2
4
1
3
1. volt Selector Switch  
2. Ammeter  
3. Clamps  
4. Timer  
In case of charger malfunction, dO NOT attempt to repair charger  
yourself. To arrange for charger repair, or information about custom-  
er replaceable parts, call 1-800-SEARS-65 (1-800-732-7764).  
10. ASSEMBLY INSTRUCTIONS  
It is important to fully assemble your charger before use. Follow these  
instructions for assembly:  
PARTS  
TOOLS NEEdEd  
Two, 10-32, thread cutting screws  
Four, 1/4-20, thread cutting screws  
Two wheels  
3/8” wrench (for mounting foot)  
5/16” wrench (for wheels)  
Hammer  
One axle  
Phillips screwdriver  
Two axle caps  
Two axle brackets  
One handle  
One mounting foot  
TO ATTACh ThE AXLE ASSEMBLY:  
10.1 Remove charger from packing materials and place upside down on a flat  
surface. Attach mounting foot and secure with the four, 1/4-20 thread cut-  
ting screws.  
8 •  
10.2 Hold axle upright on floor or work surface. Then, using a hammer, tap one  
of the plastic axle caps onto the top end of the axle. Be sure to tap the  
axle cap on straight. Slide both wheels onto the axle with the axle caps  
facing each other.  
9 •  
10.3 Place the charger on its side. Place one end of each 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.  
10.4 To Attach 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. \  
10 •  
11. OPERATING INSTRUCTIONS  
11.1 Follow steps in section 6 or 7 for hookup and disconnect instructions, and  
precautions.  
SETTING ThE CONTROLS  
All controls for your charger are located on the front of the unit. Follow  
these instructions to obtain the accurate charge level for your battery.  
11.2 TIMER: The main function of the timer is to prevent over charging while al-  
lowing the 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, which is why the timer is 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 50 amp rate  
to reach the full charge state. For the same battery with the timer set to its  
maximum of 2.25 hours, over charging will occur, but is unlikely to cause  
harm to the battery. When the charge state is unknown, start out with a  
timer setting of 1 hour or less.  
11.3 hOLd: This function allows continuous operation. Use when charging for  
more than 2.25 hours (usually when the 2 amp charge rate is selected).  
Stop charging when the battery is fully charged.  
11.4 Rotary switch: Use the rotary switch to select the charge rate or engine  
start setting required.  
11.5 Ammeter: Indicates the amount of current measured in amperes that is  
being drawn by the battery. For example, in the 50 amp charge rate, a  
typical discharged battery will initially draw approximately 50 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 250-300 amps. The meter needle will be at the extreme  
right side of the start area. Sometimes, for the first few minutes of its  
charge, the battery will draw more than 50 amps; in this case, the needle  
may be within, but not all the way over, to the right side of the start area.  
The 2 amp charge rate may not indicate activity on the meter. The meter  
does not have the resolution to display this low rate.  
11 •  
12. CALCULATING ChARGE TIME  
12.1 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.  
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 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 rate prior to recharging. Add more time for severely  
discharged batteries.  
ChARGE RATE/  
ChARGING TIME - hOURS  
BATTERY SIZE/RATING  
2 AMP  
2 - 4  
50 AMP  
6 - 12 AH  
12 - 32 AH  
40 - 60 RC  
60 - 85 RC  
85 - 190 RC  
80 RC  
NR  
SMALL  
Motorcycle, gar-  
den, tractor, etc.  
BATTERIES  
4 - 10  
11 - 14  
14 - 18  
18 - 35  
18  
NR  
200 - 315 CCA  
315 - 550 CCA  
550 - 1000 CCA  
30 to 45 min.  
45 min - 1  
hour  
CAR/TRUCKS  
1 - 2 hours  
NR  
140 RC  
27  
NR  
MARINE/DEEP CYCLE  
160 RC  
30  
NR  
180 RC  
33  
NR  
12 •  
12.2 The hydrometer or Electronic Method  
To nd the time needed to fully charge your battery, determine the bat-  
tery’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.  
PERCENT Of ChARGE  
SPECIfIC GRAvITY  
PERCENT Of ChARGE  
NEEdEd  
1.265  
1.225  
1.155  
1.120  
100%  
75%  
25%  
0%  
0%  
25%  
75%  
100%  
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 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 approximate 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  
Charger Setting  
x
1.25  
=
hours of  
charge  
100 (AH Rating) x .50 (charge needed) x  
50 (Charger Setting)  
1.25  
=
6.25  
hours  
100 x .50 = 1.25 x 1.25 = 1.5625  
50  
You will need to charge your 100-Ampere Hour Battery for approximately  
1 1/2 hours at the 50-Amp charge rate using the above example.  
13 •  
13. USING ThE ENGINE START fEATURE  
13.1 Set charge rate switch and timer to OFF positions.  
13.2 With the charger unplugged from the AC outlet, connect the charger to the  
battery following instructions given in section 6 or 7.  
13.3 Plug the charger AC power cord into the AC outlet, then move timer from  
OFF to HOLD position.  
13.4 Set the charge rate switch to the engine start position and then crank the  
engine. Follow the duty cycle of your charger for proper ON / OFF times.  
During extremely cold weather or when the battery is severely exhausted,  
charge the battery for about 5 minutes before cranking the engine.  
13.5 If the engine fails to start, charge the battery for 5 more minutes before  
attempting to crank the engine again.  
13.6 After the engine starts, move the charge rate switch to OFF and unplug  
the AC power cord from the outlet before disconnecting DC clips.  
14. MAINTENANCE INSTRUCTIONS  
14.1 Before performing maintenance, unplug and disconnect battery charger  
(see sections 6.7 or 7.6).  
14.2 After use, use a dry cloth to wipe all battery corrosion and other dirt or oil  
from terminals, cords, and the charger case.  
14.3 Through routine maintenance, ensure all user installed parts are secured.  
15. STORAGE INSTRUCTIONS  
15.1 Store charger unplugged, in an upright condition. Cord will still conduct  
electricity until it is unplugged from outlet.  
15.2 Store inside, in a dry, cool place (unless you’re using an on-board Marine  
Charger ).  
15.3 Do not store clips on handle, clipped together, on or around metal, or  
clipped to cables.  
14 •  
16. TROUBLEShOOTING  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION/REASONS  
No reading on the am-  
meter.  
Clamps are not making a  
good connection.  
Check for poor connec-  
tions to battery and frame.  
Make sure connecting  
points are clean.  
2-amp charge rate is be-  
ing used.  
Ammeter may show no  
activity at the 2-amp  
charge rate.  
No reading on ammeter.  
Fan inside wheel charger  
appears to not be work-  
ing.  
No power at receptacle.  
Check for open fuse or  
circuit breaker supplying  
AC outlet.  
AC cord and/or extension Check power cord and  
cord is loose.  
extension cord for loose  
fitting plug.  
Circuit breaker in charger Shorted battery clamps.  
cycles on and off with a  
clicking sound.  
Circuit breaker cycles  
when current draw is  
too high. Separate the  
clamps. Check for worn  
cables and replace if  
needed.  
Shorted battery.  
Have battery tested by a  
Sears or other qualified  
service dealer.  
Charger leads reversed.  
Volt/Amp Selector Switch  
Correct Connections.  
set to the START position. Correct Volt/Amp Selector  
setting.  
Short start cycle when  
cranking engine.  
Drawing more than 250  
amps for a period of 3  
seconds or less.  
Crank time varies with the  
amount of current drawn.  
If cranking draws more  
than 250 amps, crank  
time may be less than 3  
seconds.  
Failure to wait for 4  
minutes (240 seconds)  
between cranks.  
Wait 4 minutes before  
next crank.  
Ammeter reads less than  
Extension cord too long or Use shorter or heavier  
gauge extension cord.  
selected charge rate when wire gauge too small.  
charging a discharged  
battery.  
Weak cell or sulfated plate Sulfated battery will  
in battery.  
eventually take a normal  
charge if left connected. If  
the battery will not take a  
charge, have it tested by  
a Sears or other qualified  
service dealer.  
Battery is only partially  
discharged.  
Continue charging battery.  
Charger makes a loud  
buzz or hum.  
Transformer laminations  
vibrate (buzz).  
Continue charging. Buzz  
is not abnormal.  
Shorted diode (hum).  
Have charger tested by a  
Sears or other qualified  
service dealer.  
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  
15 •  
16 •  
17 •  

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