Sears 287123 User Manual

OPERatOR’S MaNUaL  
12v Manual Battery charger  
& Engine Starter  
Model No.  
28.71230  
Read and follow all Safety  
Rules and Operating Instructions  
before Every Use of this Product.  
SavE thESE INStRUctIONS.  
Sears Brands Management corporation, hoffman Estates, IL 60179 U.S.a.  
00-99-001012/0510  
taBLE Of cONtENtS  
SEctION  
PagE  
IMPORTANT SAFETY INSTRUCTIONS  
PERSONAL PRECAUTIONS  
PREPARING TO CHARGE  
2
3
3
4
4
CHARGER LOCATION  
DC CONNECTION PRECAUTIONS  
FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE  
FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE  
GROUNDING AND AC POWER CORD CONNECTIONS  
ASSEMBLY INSTRUCTIONS  
5
6
7
7
FEATURES/CONTROL PANEL  
10  
11  
12  
12  
13  
13  
15  
OPERATING INSTRUCTIONS  
CALCULATING CHARGE TIME  
MAINTENANCE INSTRUCTIONS  
MOVING AND STORAGE INSTRUCTIONS  
TROUBLESHOOTING  
BEFORE RETURNING FOR REPAIRS  
DIEhaRD thREE-YEaR fULL WaRRaNtY  
When operated and maintained according to all supplied instructions, if this DieHard  
product fails due to a defect in material or workmanship within 3 years from the date  
of purchase, return it to any 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 Brands Management Corporation, Hoffman Estates, IL 60179  
fOR cUStOMER aSSIStaNcE OR REPLacEMENt PaRtS,  
caLL tOLL-fREE fROM 7 aM tO 5 PM ct  
MONDaY thROUgh fRIDaY: 1-800-732-7764  
IMPORtaNt: REaD aND SavE thIS SafEtY aND INStRUctION MaNUaL.  
SavE thESE INStRUctIONS – The 71230 offers a wide range of features  
to accommodate your needs. This manual will show you how to use your  
charger safely and effectively. Please read, understand and follow these  
instructions and precautions carefully, as this manual contains important safety  
and operating instructions. The safety messages used throughout this manual  
contain a signal word, a message and an icon.  
The signal word indicates the level of the hazard in a situation.  
Indicates an imminently hazardous situation which, if not avoided,  
will result in death or serious injury to the operator or bystanders.  
Indicates a potentially hazardous situation which, if not avoided,  
could result in death or serious injury to the operator or bystanders.  
Indicates a potentially hazardous situation which, if not avoided,  
could result in moderate or minor injury to the operator  
or bystanders.  
Indicates a potentially hazardous situation which, if not avoided,  
could result in damage to the equipment or vehicle or  
property damage.  
Safety messages in this manual contain two different sentence styles.  
Unnumbered sentences state the hazard.  
Numbered sentences state how to avoid the hazard.  
The icon gives a graphical description of the potential hazard.  
Pursuant to California Proposition 65, this product contains chemicals  
known to the State of California to cause cancer and birth defects or  
other reproductive harm.  
1 •  
1.  
IMPORtaNt SafEtY INStRUctIONS - SavE thESE INStRUctIONS -  
This manual contains important safety and operating instructions  
RISK Of ELEctRIc ShOcK OR fIRE.  
1.1  
1.2  
1.3  
Keep out of reach of children.  
Do not expose the charger to rain or snow.  
Use only recommended attachments. 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 or damage to property.  
1.4  
1.5  
To reduce the risk of damage to the 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.  
That the wire size is large enough for the AC ampere rating of the charger  
as specified in section 8.  
1.6  
1.7  
1.8  
1.9  
to reduce the risk of electric shock, unplug the charger from the outlet  
before attempting any maintenance or cleaning. Simply turning off the  
controls will not reduce this risk.  
Do not operate the charger with a damaged cord or plug; have the cord or plug  
replaced immediately by a qualified service person. (Call customer service at:  
1-800-732-7764.)  
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 service person. (Call  
customer service at: 1-800-732-7764.)  
Do not disassemble the charger; take it to a qualified service person when  
service or repair is required. Incorrect reassembly may result in a risk of fire or  
electric shock. (Call customer service at: 1-800-732-7764.)  
RISK Of EXPLOSIvE gaSES.  
1.10 WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.  
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY  
OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT  
YOU FOLLOW ALL INSTRUCTIONS IN THIS MANUAL EACH TIME YOU  
USE THE CHARGER.  
1.11 To reduce the risk of a battery explosion, follow all instructions in this manual  
and those published by the battery manufacturer 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 •  
2.  
PERSONaL PREcaUtIONS  
RISK Of EXPLOSIvE gaSES.  
2.1  
2.2  
NEVER smoke or allow a spark or flame in the vicinity of a battery or engine.  
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.  
2.3  
2.4  
Be extra cautious to reduce the risk of dropping a metal tool onto the battery.  
It might spark or short-circuit the battery or other electrical part that may cause  
an explosion.  
Use this charger for charging LEAD-ACID batteries 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.  
2.5  
2.6  
2.7  
NEVER charge a frozen battery.  
NEVER overcharge a battery.  
Consider having someone close enough by to come to your aid when you work  
near a lead-acid battery.  
2.8  
2.9  
Have plenty of fresh water and soap nearby in case battery acid contacts your  
skin, clothing or eyes.  
Wear complete eye and body protection, including safety goggles and  
protective clothing. Avoid touching your eyes while working near the battery.  
2.10 If battery acid contacts your skin or clothing, immediately wash the area with  
soap and water. If acid enters your eye, immediately flood the eye with cold  
running water for at least 10 minutes and get medical attention right away.  
2.11 If battery acid is accidentally swallowed, drink milk, the whites of eggs or water.  
DO NOT induce vomiting. Seek medical attention immediately.  
3.  
PREPaRINg tO chaRgE  
RISK Of cONtact WIth BattERY acID.  
BattERY acID IS a hIghLY cORROSIvE  
SULfURIc acID.  
3.1  
If it is necessary to remove the battery from the vehicle to charge it, always  
remove the grounded terminal first. Make sure all of the accessories in the  
vehicle are off to prevent arcing.  
3.2  
3.3  
Be sure the area around the battery is well ventilated while the battery is  
being charged.  
Clean the battery terminals before charging the battery. During cleaning, keep  
airborne corrosion from coming into contact with your eyes, nose and mouth.  
Use baking soda and water to neutralize the battery acid and help eliminate  
airborne corrosion. Do not touch your eyes, nose or mouth.  
3 •  
3.4  
3.5  
3.6  
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 (VRLA), carefully follow  
the manufacturer’s recharging instructions.  
Read, understand and follow all instructions for the charger, battery, vehicle  
and any equipment used near the battery and charger. 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 in the  
lowest rate first.  
3.7  
4.  
Make sure that the charger cable clips make tight connections.  
chaRgER LOcatION  
RISK Of EXPLOSION aND  
cONtact WIth BattERY acID.  
4.1  
4.2  
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  
Do not set the battery on top of the charger.  
Never allow battery acid to drip onto the charger when reading the electrolyte  
specific gravity or filling the battery.  
4.5  
Do not operate the charger in a closed-in area or restrict the ventilation in  
any way.  
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 (if applicable) 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 sections 6 and 7.  
4 •  
6.  
fOLLOW thESE StEPS WhEN BattERY IS INStaLLED IN vEhIcLE  
a SPaRK NEaR thE BattERY  
MaY caUSE a BattERY  
EXPLOSION. tO REDUcE thE  
RISK Of a SPaRK NEaR  
thE BattERY:  
NEgatIvE gROUNDED SYStEM  
6.1  
Position the AC and DC cables to reduce the risk of damage by the hood, door  
and moving or hot engine parts. NOTE: If it is necessary to close the hood  
during the charging process, ensure that the hood does not touch the metal  
part of the battery clips or cut the insulation of the cables.  
6.2  
6.3  
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.  
6.4  
Determine which post of the battery is grounded (connected) to the chassis  
(vehicle frame). 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 frame or engine block at a  
distance away from the battery. Do not connect the clip to the carburetor, fuel  
lines or sheet-metal body parts. Connect to a heavy gauge metal part of the  
vehicle 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 frame or engine block at a  
distance away from the battery. Do not connect the clip to the carburetor, fuel  
lines or sheet-metal body parts. Connect to a heavy gauge metal part of the  
vehicle frame or engine block.  
6.7  
6.8  
Connect charger AC supply cord to electrical outlet.  
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.  
6.9  
See CALCULATING CHARGE TIME for length of charge information.  
5 •  
7.  
fOLLOW thESE StEPS WhEN BattERY IS OUtSIDE vEhIcLE  
a SPaRK NEaR thE BattERY  
MaY caUSE a BattERY  
EXPLOSION. tO REDUcE thE  
RISK Of a SPaRK NEaR thE  
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 (61 cm) 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  
7.7  
Do not face the battery when making the final connection.  
Connect charger AC supply cord to electrical outlet.  
When disconnecting the charger, always do so in the reverse order of the  
connecting procedure and break the first connection while as far away from the  
battery as practical.  
7.8  
A marine (boat) battery must be removed and charged on shore. To charge it  
onboard requires equipment specially designed for marine use.  
6 •  
8.  
gROUNDINg aND ac POWER cORD cONNEctIONS  
RISK Of ELEctRIc ShOcK OR fIRE.  
8.1  
This battery charger is for use on a nominal 120-volt  
circuit and has a grounded plug that looks like the plug  
illustrated. The charger must be grounded to reduce  
the risk of electric shock. The plug must be plugged  
into an outlet that is properly installed and grounded in  
accordance with all local codes and ordinances. The  
plug pins must fit the receptacle (outlet). Do not use with  
an ungrounded system.  
8.2  
8.3  
Never alter the AC cord or plug provided – if it does not fit  
the outlet, have a proper grounded outlet installed by a qualified electrician. An  
improper connection can result in a risk of an electric shock or electrocution.  
NOtE: Pursuant to Canadian Regulations, use of an adapter plug is not  
allowed in Canada. Use of an adapter plug in the United States is not  
recommended and should not be used.  
Recommended minimum AWG size for extension cord:  
100 feet long or less - use a 10 gauge extension cord.  
• Over 100 feet long - use an 8 gauge extension cord.  
9.  
aSSEMBLY INStRUctIONS  
9.1  
It is important to fully assemble your charger before use. Remove all cord  
wraps and uncoil the cables prior to using the battery charger. Follow these  
instructions for assembly.  
PaRtS  
tOOLS NEEDED  
(2) 10-32, thread cutting screws  
(4) ¼-20, thread cutting screws  
3/8” wrench (for mounting foot)  
5/16” wrench (for mounting wheels)  
(4) Phillips head sheet metal screws hammer  
(2) wheels  
(1) axle  
screwdriver (flat blade)  
screwdriver (Phillips)  
(2) axle caps  
(2) axle brackets  
(1) handle  
(1) foot  
7 •  
9.2  
attach the foot: Remove the charger from the packing materials and place  
upside down on a flat surface. Attach the foot and secure it with the four ¼-20  
thread cutting screws provided.  
9.3  
assemble the Wheels and axle: Hold the axle upright on the floor or work  
surface. Then, using a hammer, tap one of the 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 recessed hubs facing out as shown. Install the second axle cap.  
8 •  
9.4  
Mount the axle to the charger: Place one end of each bracket into the slot  
on the bottom of the charger. Place the axle assembly under each bracket.  
Attach the brackets using the two, 10-32 thread cutting screws provided.  
NOtE: Be careful not to drop the brackets inside of the charger case.  
9.5  
attach the handle: If the charger came with a plastic grip, slide that onto the  
handle until it is centered at the top. Turn the charger right side up onto its foot  
and wheels. Align the handle so the screw holes are aligned with the screw  
holes on the upper back corners of the charger. Attach the handle using the  
four Phillips head screws provided.  
9 •  
10. fEatURES/cONtROL PaNEL  
1
2
3
1. Output  
Selector  
Switch #1  
2. Output  
Selector  
Switch #2  
3. Ammeter  
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.  
Output Selector Switches:  
Two switches are used to select the rate of charge or function; a 3-position  
switch (switch #2) on the right, and a 2-position switch (switch #1) to the  
left of it.  
Switch #1 - Use this switch to select the 200 Amp Engine Start and the 40  
Amp Charge Rate. Switch #2 must be in the down position (Select Position)  
when using Switch #1.  
Switch #2 - Use this switch to select the 2 amp Charge Rate and the OFF  
position. Also, use this switch to enable Switch #1. Note that Switch #1 is  
only effective when Switch #2 is set to “Select Position.”  
ammeter  
The Ammeter indicates the amount of current, measured in amps, that is being  
drawn by the battery. As a battery takes on a charge, it draws less current from  
the charger. Correspondingly the meter will show less current being drawn by  
the battery. When the current stops decreasing, the battery is charged. The  
start area of the meter indicates a high rate of current being drawn from the  
charger. When cranking an engine, the meter needle will be at the extreme  
right side of the start area. The 2 amp charge rate may indicate some activity  
on the meter, although the meter does not have the resolution to display this  
low rate.  
10 •  
11. OPERatINg INStRUctIONS  
This battery charger must be properly assembled in  
accordance with the assembly instructions before it is used.  
charging  
1. Ensure that all of the charger components are in place and in good working  
condition, for example, the plastic boots on the battery clips. Make sure the  
electrolyte (battery liquid) in each cell is at the correct level.  
2. Set the Output Selector Switch #2 to the OFF position.  
3. Connect the battery following the precautions listed in sections 6 and 7.  
4. Connect the A.C. power following the precautions listed in section 8.  
5. Place the output selector switches #1 and #2 in the preferred position.  
For the 2A charge rate, switch #1 is not used and switch #2 should be  
toggled up.  
For the 40A charge rate, both switches #1 and #2 should be toggled down.  
6. To disconnect the charger, reverse the procedure.  
NOtE: this is a manual charger and will overcharge a battery if  
permitted to operate for extended periods of time. Monitor the charging  
progress often.  
Manual Mode  
Be sure to monitor the charging progress and stop it when the battery is fully  
charged. This charger is a manual charger and is not equipped with automatic  
shut off. Not doing so may cause damage to your battery or may cause other  
personal property damage or personal injury.  
Using the Engine Start feature  
Your battery charger can be used to jumpstart your car if the battery is low.  
Follow these instructions on how to use the ENGINE START feature.  
Follow all safety instructions and precautions for charging  
your battery. Wear complete eye protection and clothing protection. Charge  
your battery in a well-ventilated area.  
Using the ENGINE START feature WITHOUT a battery  
installed in the vehicle could cause damage to the vehicle’s electrical system.  
NOTE: If you have charged the battery and it still will not start your car, do not  
use the engine start feature, or it could damage the vehicle’s electrical system.  
1. Set Output Selector Switch #2 to the OFF position.  
2. With the charger unplugged from the A.C. outlet, connect the charger to  
the battery following the instructions given in section 6: FOLLOW THESE  
STEPS WHEN BATTERY IS INSTALLED IN VEHICLE.  
3. Plug the charger A.C. power cord into the A.C. outlet.  
4. With the charger plugged in and connected to the battery of the vehicle, set  
the Output Selector Switch to the engine start position (switch #1 up, switch  
#2 down).  
5. Crank the engine until it starts or 5 seconds pass. If the engine does not  
start, wait 4 minutes before cranking again. This allows the charger and  
battery to cool down.  
NOtE: During extremely cold weather, or if the battery is under 2 volts, charge  
the battery for 5 minutes before cranking the engine.  
6. If the engine fails to start, charge the battery for 5 more minutes before  
attempting to crank the engine again.  
11 •  
7. After the engine starts, move Output Selector Switch #2 to the OFF position  
and unplug the A.C. power cord before disconnecting the battery clips from  
the vehicle.  
8. Clean and store the charger in a dry location.  
NOtE: If the engine does turn over but never starts, 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.  
12. caLcULatINg chaRgE tIME  
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.  
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% charge  
prior to recharging. Add more time for severely discharged batteries.  
chaRgE RatE/  
chaRgINg tIME - hOURS  
BattERY SIZE/RatINg  
2 aMP  
2 - 4  
40 aMP  
NR  
Motorcycle,  
garden, tractor,  
etc.  
6 - 12 AH  
12 - 32 AH  
40 - 60 RC  
SMALL  
BATTERIES  
4 - 10  
11 - 14  
NR  
200 - 315 CCA  
315 - 550 CCA  
550 - 1000 CCA  
30 to 45 min.  
45 min - 1  
hour  
CAR/TRUCKS  
60 - 85 RC  
14 - 18  
85 - 190 RC  
80 RC  
18 - 35  
18  
1 - 2 hours  
NR  
140 RC  
160 RC  
180 RC  
27  
NR  
MARINE/DEEP CYCLE  
30  
NR  
33  
NR  
13. MaINtENaNcE INStRUctIONS  
13.1 After use and before performing maintenance, unplug and disconnect the  
battery charger (see sections 6, 7 and 8).  
13.2 Use a dry cloth to wipe all battery corrosion and other dirt or oil from the  
battery clips, cords, and the charger case.  
13.3 Ensure that all of the charger components are in place and in good working  
condition, for example, the plastic boots on the battery clips.  
13.4 Servicing does not require opening the unit, as there are no user-  
serviceable parts.  
13.5 All other servicing should be performed by qualified service personal.  
12 •  
14. MOvINg aND StORagE INStRUctIONS  
14.1 Store the charger unplugged, in an upright position. The cord will still conduct  
electricity until it is unplugged from the outlet.  
14.2 Store inside, in a cool, dry place.  
14.3 Do not store the clips on the handle, clipped together, on or around metal, or  
clipped to cables.  
14.4 If the charger is moved around the shop or transported to another location,  
take care to avoid/prevent damage to the cords, clips and charger. Failure to  
do so could result in personal injury or property damage.  
15. tROUBLEShOOtINg  
PROBLEM  
POSSIBLE caUSE  
REaSON/SOLUtION  
No reading on the ammeter. Charger is not plugged in.  
Plug the charger into an AC  
outlet.  
No power at the receptacle. Check for open fuse or  
circuit breaker supplying AC  
outlet.  
Clips are not making a good Check for poor connection  
connection to the battery.  
to battery and frame. Make  
sure connection points  
are clean. Rock the clips  
back and forth for a better  
connection.  
Connections are reversed.  
Unplug the charger and  
reverse the clips.  
Battery is defective (will not Have battery checked.  
accept a charge).  
2 amp charge rate is being  
used.  
Ammeter may show no  
activity at the 2A charge rate.  
Ammeter reading stays  
high.  
Battery is severely  
discharged.  
Continue charging battery for  
two more hours. If problem  
continues have the battery  
checked.  
Wrong battery voltage.  
Verify that you are charging  
a 12 volt lead-acid battery.  
Ammeter reads less than  
selected charge rate when  
charging a discharged  
battery.  
Extension cord is too long or Use a shorter or heavier  
wire gauge is too small.  
gauge extension cord.  
Weak cell or sulfated plate  
in battery.  
A sulfated battery will  
eventually take a normal  
charge if left connected. If  
the battery will not take a  
charge, have it checked.  
Battery is only partially  
discharged.  
Continue to charge the  
battery.  
13 •  
PROBLEM  
POSSIBLE caUSE  
REaSON/SOLUtION  
The charger is making an  
audible clicking sound.  
Circuit breaker is cycling.  
The settings may be wrong.  
Check the charger settings.  
Battery is defective.  
Have the battery checked.  
Shorted battery cables or  
clips.  
Circuit breaker cycles when  
current draw is too high.  
Check for shorted cables  
or clips and replace if  
necessary.  
Severely discharged battery, The battery may not want  
but otherwise it is a good  
battery.  
to accept a charge due to  
a run-down state. Allow  
charging to continue until  
battery has a chance to  
recover sufficiently to take  
a charge. If more than 20  
minutes, stop charging and  
have the battery checked.  
Reverse connections at  
battery.  
Shut the charger off and  
correct the lead connections.  
Charger makes a loud buzz Transformer laminations  
or hum. vibrate (buzz).  
No problem, this is a normal  
condition.  
Shorted Diode Assembly or Have charger checked by a  
Output Rectifier Assembly  
(hum).  
qualified technician.  
Short or no start cycle when Drawing more than the  
Crank time varies with the  
amount of current drawn. If  
cranking draws more than  
the Engine Start rate, crank  
time may be less than 5  
seconds.  
cranking engine.  
Engine Start rate.  
Failure to wait 4 minutes  
between cranks.  
Wait 4 minutes of rest time  
before the next crank.  
Clips are not making a good Check for poor connection at  
connection.  
battery and frame.  
AC cord and/or extension  
cord is loose.  
Check power cord and  
extension cord for loose  
fitting plug.  
No power at receptacle.  
Check for open fuse or  
circuit breaker supplying AC  
outlet.  
The charger may be  
overheated.  
The thermal protector may  
have tripped and needs a  
little longer to reset. Make  
sure the charger vents are  
not blocked. Wait and try  
again.  
Battery may be severely  
discharged.  
On a severely discharged  
battery, charge for 10 to  
15 minutes in the 40 amp  
manual rate to help assist in  
cranking.  
14 •  
PROBLEM  
POSSIBLE caUSE  
REaSON/SOLUtION  
Charger will not turn on  
when properly connected.  
AC outlet is dead.  
Check for open fuse or  
circuit breaker supplying AC  
outlet.  
Poor electrical connection.  
Check power cord and  
extension cord for loose  
fitting plug.  
The battery is connected  
Clips are not making a good Check for poor connection  
and the charger is on, but is connection.  
not charging.  
at battery and frame. Make  
sure connecting points  
are clean. Rock the clips  
back and forth for a better  
connection.  
The measured current is  
much lower than what was  
selected.  
The charger reached the  
maximum voltage and is  
reducing the current.  
No problem, this is a normal  
condition.  
16. BEfORE REtURNINg fOR REPaIRS  
16.1 When a charging problem arises, make certain that the battery is capable  
of accepting a normal charge. Double check all connections, the AC outlet  
for a full 120 volts, the charger clips for correct polarity and the quality of  
the connections from the cables to the clips and from the clips to the battery  
system. The clips must be clean.  
16.2 When a battery is very cold, partially charged or sulfated, it will not draw the  
full rated amperes from the charger. It is both dangerous and damaging to a  
battery to force higher amperage into it than it can effectively use  
in recharging.  
16.3 When an UNKNOWN OPERATING PROBLEM arises, please read this  
complete manual and call the customer service number for information that will  
usually eliminate the need for return.  
If the above solutions do not eliminate the problem, or for information about troubleshooting  
or replacement parts, call toll-free from anywhere in the U.S.A.  
1-800-732-7764  
7:00 am to 5:00 pm Central Time Monday through Friday  
15 •  

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