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OPERATOR’S MANUAL
®
BATTERY ChARGER
40/20 Amp
Manual
200 Amp
ENGINE STARTER
Model No.
200.71230
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.
00-99-000880/0808
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TABLE Of CONTENTS SECTION PAGE 1. IMPORTANT SAfETY INSTRUCTIONS 1 2. PERSONAL PRECAUTIONS 2 3. PREPARING TO ChARGE 3 4. ChARGER LOCATION 3 5. dC CONNECTION PRECAUTIONS 3 6. whEN BATTERY IS INSTALLEd IN vEhICLE 4 7. whEN BATTERY IS OUTSIdE vEhICLE 5 8. BATTERY ChARGING - AC CONNECTIONS 6 9. PARTS 5 10. fEATURES 9 11. ASSEMBLY INSTRUCTIONS 9 12. OPERATING INSTRUCTIONS 12 13. CALCULATING ChARGE TIME 13 14. USING ThE ENGINE START fEATURE 15 15. MAINTENANCE INSTRUCTIONS 15
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IMPORTANT: REAd ANd SAvE ThIS SAfETY ANd INSTRUCTION MANUAL. 1. IMPORTANT SAf ETY INSTRUCTIONS 1.1 SAVE THESE INSTRUCTIONS - The DieHard model 71230 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
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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 - f ACTURER ANd ThE MANUf ACTURER Of ANY EQUIPMENT YOU INTENd TO USE IN ThE vICINITY Of ThE BATTERY. REvIEw ThE
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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 Be sure the area around the battery is well ventilated while the battery is being charged. 3.3 Clean the battery terminals. Be careful to keep corrosion from coming into contact with your eyes. 3.4 Add distilled water to each cell until the battery
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6. f OLLOw T hESE STEPS wh EN BATTERY IS INSTALLEd IN vEhICLE. A SPARK NEAR ThE BATTERY MAY CAUSE A BATTERY EXPLO- SION. 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, or moving engine parts. 6.2 Stay clear of fan blades, belts, pulleys and other parts that can cause injury. 6.3 Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diamete
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7. f OLLOw T hESE STEPS wh EN BATTERY IS OUTSIdE vEhICLE. A SPARK NEAR ThE BATTERY MAY CAUSE A BATTERY EXPLO- SION. TO REdUCE ThE RISK Of A SPARK NEAR ThE BATTERY: 7.1 Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N, -) post. 7.2 Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to the NEGATIVE (NEG, N, -) battery post. 7.3 Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P,
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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 p
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8.3 Recommended minimum AWG size for extension cords for battery chargers: AC input rating, AWG size of cord a Length of cord, feet (m) amperes But less 25 50 100 150 At least than (7.6) (15.2) (30.5) (45.6) 0 2 18 18 18 16 2 3 18 18 16 14 3 4 18 18 16 14 4 5 18 18 14 12 5 6 18 16 14 12 6 8 18 16 12 10 8 10 18 14 12 10 10 12 16 14 10 8 12 14 16 12 10 8 14 16 16 12 10 8 16 18 14 12 8 8 18 20 14 12 8 6 a If the input rating of a charger is given in watts rather than in amperes, the corresponding
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9. PARTS The Sears service centers offer the following replacement parts for your battery charger. If you are having trouble with your battery charger, please contact a qualified service person to diagnose and/or repair your unit. It is not recommended that the consumer service the internal components of the battery charger, as improper handling or repair could lead to shock, electrocution, damage to the charger, or result in fire. As such, please con- tact 1-800-SEARS-64 for troubleshootin
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10. f EATURES 2 1 3 1. Output Selector Switches 2. Ameter 3. Clamps 4. Wheels 4 11. 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 3/8” wrench (for mounting foot) Four, 1/4-20, thread cutting scews 5/16” wrench (for wheels) Two wheels Hammer One axle Phillips screwdriver Two axle caps Two axle brackets One handle One mounting foot • 9 •
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11.1 To attach the axle assembly: 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. 11.2 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 recessed hubs facing out as shown. Install the second axle cap. • 10 •
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11.3 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. 11.4 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. • 11 •
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12. OPERATING INSTRUCTIONS 200A 12V 2A 12V ENGINE CHARGE START OFF 40A 12V SELECT CHARGE VOLT/AMP SELECTOR 12.1 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. 12.2 Output Selector Switches: Two switches are used to select the rate of charge or function; a 3-posi- tion switch on the right, and a 2-position switch to the left of it. Use the 3-position switch to select: • 2 Am
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The 2 amp charge rate may not indicate activity on the meter. The meter does not have the resolution to display this low rate. 13. CALCULATING ChARGE TIME 13.1 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
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13.2 The hydrometer or Electronic Method To find 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 GRA vITY PERCENT Of ChARGE NEEdEd 1.265 100% 0% 1.225 75% 25% 1.155 25% 75% 1.120 0% 100% When you know the percent of charge and the Amp Hour (AH) rating of your battery, you can calcul
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14. USING ThE ENGINE START f EATURE 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. 14.1 Set the right-hand OUTPUT SELECTOR switch to the OFF position. Then follow the instructions for connecting the charger to the battery in the Op- erating Instructions section. 14.2 Once the charger is connected, set the right-hand selector switch to SE- LECT and set the left selector switch to the 200 AMP START
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17. TROUBLEShOOTING PROBLEM POSSIBLE CAUSE SOLUTION/REASONS No reading on the am- Clamps are not making a Check for poor connec- meter. good connection. tions to battery and frame. Make sure connecting points are clean. Rock clips back and forth for a better connection. 2-amp charge rate is be- Ammeter may show no ing used. activity at the 2-amp charge rate. No reading on ammeter. No power at receptacle. Check for open fuse or Fan inside wheel charger circuit breaker supplying appears to
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PROBLEM POSSIBLE CAUSE SOLUTION/REASONS Ammeter reads less than Extension cord too long or Use shorter or heavier selected charge rate when wire gauge too small. gauge extension cord. 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 technician. Battery is only partially Continue charging battery. discharged. Charger makes a loud Tr
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