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OPERATOR’S MANUAL
®
BATTERY ChARGER
70/40/20/4 Amp
300 AMP
ENGINE STARTER
With Battery Tester
Model No.
200.71991
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.
00-99-000882/0808
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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. PROdUCT fEATURES 8 10. ASSEMBLY INSTRUCTIONS 8 11. OPERATING INSTRUCTIONS 10 12. ENGINE START 11 13. CALCULATING ChARGE TIME 12 14. MAINTENANCE INSTRUCTIONS 14 15. STORAGE INSTRUCTIONS 1
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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 71991 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 Do not expose
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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 ThESE STEPS WhEN BATTERY IS INSTALLEd IN v E- hICLE A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION. TO REdUCE RISK Of A SPARK NEAR 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 diameter than the NEGATI
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7. f OLLOW 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 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, +) post of t
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8. BATTERY ChARGING - AC CONNECTIONS 8.1 GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS – Charger should be grounded to reduce risk of electric shock. 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 ou
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8.2 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. f EATURES 3 4 5 1. Ammeter 2 2. Volt Meter 6 1 3. Foam Grip 7 4. Fiber Glass Clamp Rod 5. Clamps 6. Charge Rate Selector Switch 7. Timer 8 8. Wheel 10. ASSEMBLY INSTRUCTIONS IT IS IMPORTANT TO f ULLY ASSEMBLE YOUR ChARGER BEf ORE USE. fOLLOW T hESE INSTRUCTIONS f OR ASSEMBLY: ITEM QTY dESCRIPTION NO. 1 2 axle bracket 2 1 axle with pin holes TOOLS NEEdEd 3 2 wheel 4 2 screw, 10-32 x 1/2, self tapping 5/16” Wrench or Nut Driver 3/8” Wrench or Nut Driver 5 2 screw, 1/4-20 x 3/4, self ta
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10.1 First, carefully lay the charger on its front to prepare for assembly. 10.2 Assemble the foot (Item 6) using two ¼-20 screws (Item 5) and tighten securely. 10.3 Attach the two axle brackets (Item 1) using one 10-32 screw (Item 4) in each. The brackets should have one end hooked into the slot in the char- ger base. (Do not completely tighten the screws (Item 4) at this time). 10.4 Slide the axle (Item 2) into the brackets (Item 1) until centered on the char- ger. 10.5 Slide one wheel (Item
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11. OPERATING INSTRUCTIONS 11.1 TIMER The main function of the timer is to prevent over charging while allowing a 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, this is one reason why the timer was limited to 2.25 hours. With the aid of a battery load tester the state of charge can be obtained within a few seconds. Fo
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11.4 AMMETER The Ammeter indicates the amount of current measured in amperes that is being drawn by the battery. For example, in the 40 amp charge rate a typical discharged battery will initially draw approximately 40 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 200-300 amps. The meter needle
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IMPORTANT: Using the ENGINE START feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle’s electrical system. 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. 13. CALCULATING ChARGE TIME 13.1 The Chart Method Use the following table to more accurately determine the time it will tak
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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. MAINTENANCE INSTRUCTIONS 14.1 Before performing maintenance, unplug and disconnect the battery char- ger (see sections 6.7 and 7.6). 14.2 After use, use a dry cloth to wipe all battery corrosion and other dirt or oil from the clips, cords, and the charger case. 14.3 Through routine maintenance, ensure all user installed parts are secure. 14.4 Servicing does not require opening the unit, as there are no user-service- able parts. 15. STORAGE INSTRUCTIONS 15.1 Store the charger unplugged and i
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16. TROUBLEShOOTING PROBLEM POSSIBLE CAUSE SOLUTION/REASONS No reading on the ammeter. Clips are not making a good Check for poor connections to connection. battery and frame. Make sure connecting points are clean. Rock clips back and forth for a better connection. 4-amp charge rate is being Ammeter may show no activity used. at the 4-amp charge rate. Ammeter reading stays high. Battery is severely discharged. Continue charging battery for two more hours. If problem continues, have the ba
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PROBLEM POSSIBLE CAUSE SOLUTION/REASONS Short or no start cycle when Drawing more than 300 amps. Crank time varies with the cranking engine. amount of current drawn. If cranking draws more than 300 amps, crank time may be less than 3 seconds. Failure to wait 3 minutes (180 Wait 3 minutes of rest time seconds) between cranks. 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 Check power cord and exten
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