Sears 20071231 User Manual

OWNER’S MANUAL  
®
BATTERY 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.  
00-99-000312/0306  
Important Safety Instructions  
– SAVE THESE INSTRUCTIONS –  
To reduce the risk of explosion, explosive gases, or injury while  
using your battery charger, follow the precautions listed below:  
WARNING  
• 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, RVs, 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 recom-  
mended by the manufacturer may result in fire,  
electric shock, or injury.  
Wear complete eye and clothing protection when  
working with lead-acid batteries.  
Help us help you  
Remember:  
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.  
Place charger as far away from battery being  
charged as the charger cables will permit.  
Do not expose charger to rain or snow.  
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.  
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.  
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.  
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.  
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.  
Never use charger for charging dry-cell batteries  
that are commonly used with home appliances.  
These batteries may burst and cause personal  
injury.  
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.  
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.  
Always operate your battery charger in an open,  
well ventilated area.  
Be sure to position the charger power cord to  
prevent it from being stepped on, tripped over, or  
damaged.  
Never smoke or allow a spark or flame in the vicinity  
of the battery or engine. Batteries generate explo-  
sive gases.  
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.  
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.  
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:  
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.  
Replacement Parts List DieHard 71230  
Item  
1.  
Description  
Part Number  
3599000286  
3899000396  
3899000410  
90026096  
Handle  
2.  
Negative (BLK) Cable w/Clamps  
Positive (RED) Cable w/Clamps  
Power Cord  
3.  
4.  
5.  
Circuit Breaker Assembly  
RectifierAssembly  
Transformer  
3999000099  
2299001081  
93026532  
6.  
7.  
8.  
FanMotor  
0099000063  
0099000080  
5200000008  
0099000060  
1199004366  
1199003352  
0499000052  
5399100088  
0499000050  
0099000312  
9.  
Wheel  
10.  
11.  
12.  
13.  
14.  
15.  
16.  
17.  
Hub Cap  
Axle  
Axle Mtg. Brackets  
MountingFoot  
Rocker Switch 3 Position  
Ammeter  
Rocker Switch 2 Position  
Owner'sManual  
Wiring Diagram  
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 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.  
continued on next page  
4
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.  
Plugging it in  
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.  
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: 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 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:  
MINIMUM RECOMMENDED EXTENSION CORD  
Length of Cord, in Feet  
25  
50  
100 150  
• 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* Size of Cord  
18  
14  
12 10  
*AWG=American 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 guide-  
lines 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, 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 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.  
• 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.  
• 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.  
NOTE: A marine battery installed in a boat must be  
removed and charged on shore.  
6
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  
200A 12V  
ENGINE  
START  
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:  
2A 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  
OFF — Leave the switch in the OFF Position while  
connecting the charger to the battery and to the AC  
power outlet.  
40A 12V  
CHARGE  
SELECT  
Select — This setting enables you to select one of  
the two charge-rate settings offered by the 2-  
position 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.  
When cranking the engine while using the ENGINE  
START feature, the needle will swing into the Start  
(red) area of the scale.  
7
Charging Your Battery  
Charging your battery in the vehicle:  
1. Arrange the power cord and charging leads  
carefully in order to avoid damage that could be  
caused by the hood, door, or moving engine parts.  
2. Keep clear of the fan blades, belts, pulleys, and  
other parts that can cause injury.  
3. Check the polarity of the battery posts using the  
identification marks on the battery case: POSI-  
TIVE (POS, P, +) and NEGATIVE (NEG, N, -).  
4. Identify which battery post is ground or connected  
to the chassis. THE NEGATIVE POST IS NOR-  
MALLY THE ONE THAT IS GROUNDED.  
5. To charge a negative grounded post system:  
Connect the red (POSITIVE) charger clamp to the  
ungrounded POSITIVE (POS, P, +) post of the  
battery. Next, connect the black (NEGATIVE)  
clamp to a heavy unpainted metal part of the  
chassis or engine block, away from the battery. Do  
not connect clamp to carburetor, fuel lines, or  
sheet metal parts.  
NEGATIVE GROUNDED SYSTEM  
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 wall outlet.  
8. Select the desired charge rate. (See "Setting the  
Controls" on page 7.)  
9. The charger will not stop when the battery is fully  
charged. For this reason it is important to check  
charging progress frequently. Overcharging can  
damage a battery, you must monitor and unplug  
charger when battery is fully charged.  
10. When the battery is fully charged, the AMMETER  
needle will fall to about half the charge rate  
selected. For specific positions, see the “Amme-  
ter” section of “Setting the Controls” on page 7.  
11. When the battery is fully charged, unplug the  
charger power cord. Next, set the right-hand  
switch to the OFF position.  
12. Facing 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.  
8
Charging your battery outside the vehicle:  
1. Remove the battery from vehicle, making sure to  
disconnect grounded terminal first with all power  
turned off to the vehicle.  
2. Check the polarity of the battery posts as indicated  
on the battery case: POSITIVE (POS, P, +) and  
NEGATIVE (NEG, N, -).  
NOTE: On top-post batteries, the positive battery  
terminal usually has a larger diameter than the  
negative one.  
3. Connect the red (POSITIVE) charger clamp to the  
POSITIVE post of the battery. Be sure to rock the  
clip back and forth to make a solid connection.  
4. Attach 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  
arcing and sparking will not occur directly over the  
battery. (The battery cable is not provided with the  
charger, but may be purchased at most automo-  
tive accessory outlets.)  
5. Take the other end of the 6-gauge (AWG) or a 4-  
gauge (SAE) insulated 24-inch cable and, 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 wall  
outlet.  
7. Select the desired charge rate. (See "Setting the  
Controls" on page 7.)  
8. The charger will not stop when the battery is fully  
charged. For this reason it is important to check  
charging progress frequently. Overcharging can  
damage a battery, you must monitor and unplug  
charger when battery is fully charged.  
9. When the battery is fully charged, the AMMETER  
needle will fall to about half the charge rate  
selected. For specific positions, see the "Amme-  
ter" section of "Settings the Controls" on page 7.  
10. When the battery is fully charged, unplug the  
charger power cord before attempting to discon-  
nect charger clamps.  
11. Facing 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 chart.  
NR means that the charger setting is NOT RECOM-  
MENDED.  
• 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 batter-  
ies.  
• Batteries in cars and smaller trucks are usually rated  
in Reserve Capacity (RC), Cold-Cranking Amps  
(CCA), or both.  
CHARGE RATE/CHARGING TIME - HOURS  
BATTERY SIZE/RATING  
2 AMP  
2 - 4  
4 - 10  
11 - 14  
14 -18  
18 - 35  
18  
40 AMP  
Motorcycle, garden  
tractor, etc.  
6 - 12 AH  
12 - 32 AH  
40 - 60 RC  
60 - 85 RC  
85 -190 RC  
80 RC  
NR  
SMALL  
BATTERIES  
NR  
200 - 315 CCA  
315 - 550 CCA  
550 - 1000 CCA  
30 to 45 min.  
CAR/TRUCKS  
45 min. to 1 hour  
1 - 2  
NR  
NR  
NR  
NR  
MARINE/DEEP CYCLE  
140 RC  
27  
160 RC  
30  
180 RC  
33  
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 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.  
SPECIFIC  
GRAVITY OF CHARGE  
PERCENT  
PERCENT OF  
CHARGE NEEDED  
• Add one additional hour for a deep-cycle battery.  
1.265  
1.225  
1.155  
1.120  
100%  
75%  
25%  
0%  
0%  
25%  
75%  
100%  
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  
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.  
100 x .50 = 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 Capacity + 16  
2
NOTE: The Reserve Capacity can be obtained from  
the battery specification sheet or the owner's manual.  
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 selec-  
tor switch to the 200 AMP START position.  
3. Plug the power cord into a grounded AC wall outlet.  
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.  
6. If the engine still does not start, charge the battery  
for five more minutes in the 40 AMP position  
before cranking it again for five seconds.  
7. After the engine starts, unplug the charger power  
cord from the outlet. Then move the right-hand  
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.  
Maintenance and care  
A minimal amount of care can keep your battery  
charger working properly for years.  
1. Clean the clamps each time you are finished  
charging. Wipe off any battery fluid that may have  
come in contact with the clamps to prevent  
corrosion.  
2. Coil the input and output cords neatly when storing  
the charger. The cords can be wrapped around  
the handle of the charger. This will help prevent  
accidental damage to the cords and charger.  
3. Occasional cleaning of the case with a soft cloth  
will keep the finish shiny and help prevent corro-  
sion.  
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.  
Clamps are not making a Check for poor connections to battery and frame. Make  
good connection.  
sure connecting points are clean.  
2-amp charge rate is  
being used.  
Ammeter may show no activity at the 2-amp charge rate.  
No reading on  
No power at receptacle.  
Check for open fuse or circuit breaker supplying AC outlet.  
ammeter. Fan inside  
wheel charger appears AC cord and/or extension Check power cord and extension cord for loose fitting  
to not be working.  
cord is loose.  
plug.  
Circuit breaker in  
charger cycles on  
and off with a clicking  
sound.  
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.  
Correct connections.  
Charger leads reversed.  
Volt/Amp Selector Switch Correct Volt/Amp Selector setting.  
set to the START position.  
Short start cycle  
when cranking  
engine.  
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.  
Ammeter reads less  
than selected charge  
rate when charging  
a discharged battery.  
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.  
Charger makes a loud Transformer laminations  
Continue charging. Buzz is not abnormal.  
Have charger tested by a Sears technician.  
buzz or hum.  
vibrate (buzz).  
Shorted diode (hum).  
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  
12  
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).  
13  

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