Page 1
OWNER'S MANUAL
DieHard,
BATI'ERY 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.
0099000312-402
Page 2
Table Of Contents
Warranty .................................................................... 1
Important Safety Instructions ................................. 2
Parts .......................................................................... 3
Before UslngYour Battery Charger ........................ 4
Assembling your charger ..................................... 4
Plugging it in ........................................................ 5
Using an extension cord ....................................... 6
Preparing your battery to be charged .................. 6
Using Your Battery Charger ..................................... 7
Setting the controls .............................................. 7
Charging your battery .......................................... 8
Calculating charge times .................................... 10
Using the engine start feature ............................ 11
Maintenance and care ....................................... 11
Troubleshooting ..................................................... 12
Please read this Owner's Manual before using your Battery Charger
The DieHard model 71230 Manual Battery Charger/Engine Starter, offers a wide range of features to
accommodate the needs for home or light commercial use. This manual willshow you how to use Your
charger safely and effectively. Please read and follow these instructions and precautions carefully.
For information about troubleshooting, call toll-free from anywhere in the U.S.A. 7 am to 4:30 pm CT
Monday through Friday.
1-BOO-SEARS-64 (1-600-732-7764).
For repair parts or the location of a Sears Parts and Repair Center call:
1-800..4-MY-HOME = (1-800-469-4663).
Warranty
FULL THREE-YEAR WARRANTY
If, within three years from the date of purchase this battery charger fails due to a defect in material or
workmanship, RETURN IT TO THE NEAREST SEARS STORE IN THE UNITED STATES, and Sears will
repair or replace it, free of charge.
This warranty gives you specific legal rights,and you may also have other rights which vary from state to
state.
Sears, Roebuck and Co., Dept 817WA,
Hoffman Estates, IL 60179
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Important Safety Instructions
- SAVE THESE INSTRUCTIONS -
• Read all instructionsand cautions printed on the
battery charger, battery, and vehicle or equipment
using battery.
• Use charger only on lead-acid type rechargeable
batteries, such as those used in cars, trucks,
tractors, airplanes, vans, RV's, trolling motors, etc.
This charger is not intended to supply power to a
low voltage electrical system other than in an
automotive application.
• 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.
• Do not disassemble charger. Take itto a qualified
service professional ifservice or repair is required.
Incorrect assembly may result in fire or electrical
shock.
• 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.
Help us help you
Remember:
• Place charger as far away from battery being
charged as the charger cables will permit.
• Do not expose charger to rain or snow.
• 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.
• 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.
• Never use charger for charging dry-cell battades
that are commonly used with home appliances.
These batteries may burst and cause personal
injury.
Personal Safety Precautions
For your own personal safety, please follow the
following precautions:
• Wear complete eye and clothing protection when
working with lead-acid batteries.
• Be sure that someone is within range of your voice
to come to your aid ifneeded, while you work with or
are near a lead-acid battery.
• 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.
• 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 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 itto a
qualified professional for inspection and repair.
• Be sure to position the charger power cord to
prevent itfrom being stepped on, tripped over, or
damaged.
• 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.
• Do not operate the charger if it has a damaged
power cord or plug. Have the cord replaced.
• 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 shortcircuit current high enough to weld a
ring (or the like) to metal, causing a severe bum.
• 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.
• Always operate your battery charger in an open,
well ventilated area.
• Never smoke or allow a spark or flame in the vicinity
of the battery or engine. Batteries generate explo-
sive gases.
• Neutralize any acid spills thoroughly with baking
soda before attempting to clean up.
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Parts
This section shows an illustration of your battery charger. Use itto become familiar with where all the parts are
located, and what they look like.
; Item Description Pert Number
1. Handle 3599000286
2. Negative (BLK) Cable w/Clamps 3899000396
3. Positive (RED) Cable w/Clamps 3899000410
4. Power Cord 90026096
5. Circuit Breaker Assembly 3999000099
6, Rectifier Assembly 2299001081
7. Transformer 93026532
8. Fan Motor 0099000063
9. Wheel 0099000080
10. HubCap 5200000008
11. Axle 0099000060
12. Axle Mtg. Brackets 1199(X)4366
13. Mounting Foot 1199003352
14. Rocker Switch 3 Position 0499000052
15. Ammeter 5399100088
16. Reeker Switch 2 Po6ition 0499(XXX_50
17. Owner's Manual 0099000312
Wiring Diagram
ACL_R
Wiring Diagram 71230
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Before Using Your Battery Charger
It is important to prepare your charger for use. This section willtell 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:
Two 10-32 thread cutting
screws
Two 1/4-20 thread cutting
screws
Two wheels
One axle
Two axle caps
Two axle brackets
One handle
One mounting foot
TOOLS NEEDED:
3/8" wrench
(for mounting foot)
5/16" wrench
(for wheels)
Hammer
Phillips screwdriver
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 onfloor or work surface. Then,
using a hammer, tap one ofthe plastic hubs onto
the top end of the axle. Be sure to tap the hub on
straight. Slide bothwheels onto the axle with the
hubs facing inward.
am m
continued on next page
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3. Tapthe other axle cap ontothe opposite end of
the axle and place the axle assembly onto the
bottom of the charger. Place one end of the
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.
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 and align with the screw holes on the handle.
Attach the handle using the same screws.
Plugging it in
Electrical Shock Hazard
Be sure that power cord fits properly into outlet.
If not, have a qualified technician installa 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 cedes and ordinances.
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A TEMPORARY adapter may be used to connect the
charger to a two-pole outlet ifa properly grounded
outlet is not available. Use the adapter ONLY until a
properly grounded outletcan 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:
• 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.
• 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.
"AWG-_Amedcan Wire Gauge
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.
• 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.
• If you have a battery with removable cell caps, if
required, add distilledwater to each cell untilthe
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 ceil caps, no action is neces-
sary. Continue to the next step listed below.
• 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.
Wear safety glasses. See additional "Personal
Safety Precautions" on page 2.
Be sure that the area around the battery is well
ventilated while it is being charged. If ventilation is
poor, gas can be manually blown away by using a
piece of cardboard or other non-metallic material as
a fan.
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 ifall accessories in the vehicle are not
completely turned off.
NOTE: A marine battery installed in a boat must be
removed and charged on shore.
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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
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:
• 2 Amp Trickle Charge -- Use for charging small
batteries and warming large batteries. The lower the
charge rate, the longer it willtake, but the battery is
subjected to much less stress.
• OFF-- Leave the switch in the OFF Position while
connecting the charger to the battery and to the AC
power outlet,
• Select -- This setting enables you to select one of
the two charge-rate settings offered bythe 2-
position switch.
• 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 bythe 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.
40A 12V 2A 12V
CHARGE CHARGE
200A 12V_-_- SELECT
ENGINE
START
VOLT/AMP SELECTOR
AMPS
OFF
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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 bythe hood, door, or moving engine pads.
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 pads.
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 slippingoff the
posts and causing sparks.
7. Set your charger's right-hand 3-position selector
switch to the OFF position. Then plugthe
charger's power cord into a grounded AC outlet.
8. Select the desired charge rate. (See "Settingthe
Controls" on page 7.)
9. The charger will not atop 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 batteryls fully charged, unplug the
charger power cord. Next, set the right-hand
switch to the OFF position.
12. Standing away from the battery, remove the
charger clamp from the chassis first, then from
the battery post orterminal.
13. Clean and store the battery charger In a dry
location.
NEGATIVE GROUNDED SYSTEM
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Charging your battery outside the vehicle:
1. Remove the battery from vehicle, making sure to
disconnect grounded terminal first with all power
turned offto the vehicle.
2. Check the polarity ofthe 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 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 willnot 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 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 monitorand unplug
charger when battery is fully charged.
9. When the battery is fully charged, the AMMETER
needle will fall to about haft the charge rate
selected. For specific positions, see the "Amme-
ter" section of "Settingsthe Controls"on page 7.
10. When the battery is fully charged, unplug the
charger power cord before attempting to discon-
nect charger clamps.
11. Standing 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.
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Calculating charge times
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 chad.
• 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 RECOM-
MENDED.
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.
SMALL
BATTERIES
CAR/TRUCKS
Motorcycle, garden
tractor, etc.
200 - 315 CCA
315 - 550 CCA
550 - 1000 CCA
MARINE/DEEP CYCLE
6-12 AH
12 -32 AH
40 - 60 RC
60 - 85 RC
85 -190 RC
80 RC
140 RC
160 RC
180 RC
2-4
4-10
11 - 14
14 -18
18 - 35
18
27
30
33
NR
NR
V2-3A
_-1
1-2
NR
NR
NR
NR
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.
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.
To convert Reserve Capacity to Amp Hours, divide
Reserve Capacity by 2, and add 16:
Amp Hours = Reserve Caoacitv + 16
2
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).
• Multiplythe Amp Hour rating by the charge needed
(.50) and divide bythe 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.
• Add one additional hour for a deep-cycle battery.
Example:
Amp Hour Ratlno x % of charo_eneeded x 1.25 = hours
Charger Setting d
charge
100 (AH Ratlno_ x .50 (charoQ needed) x 1.25 = 6.25
40 (Charger Setting) hours
- 1.25 x 1.25 = 1.5625
40
You would need to charge your 100-Ampere Hour
Battery for approximately 1½ hours at the 40-Amp
charge rate using the above example.
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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 instructionsfor
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 in the charger.
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 batteryfor about
five minutes before cranking the engine.
6. If the engine stilldoes 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
positionbefore 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
willkeep the finish shiny and help prevent corro-
sion.
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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
No reading on the
ammeter.
No reading on
ammeter. Fan inside
wheel charger appears
to not be working.
Circuit breaker in
charger cycles on
and off with a clicking
sound.
Short start cycle
when cranking
engine.
Ammeter reads less
than selected charge
rate when charging
a discharged battery.
POSSIBLE CAUSE
Clamps are not making a
good connection.
2-amp charge rate is
being used.
No power at receptacle.
AC cord and/or extension
cord is loose.
Shorted battery clamps.
Shorted battery,
Charger leads reversed.
Volt/Amp Selector Switch
set to the START position.
Drawing more than 200
amps for a period of 5
seconds or less.
Failure to wait for 4
minutes (240 seconds)
between cranks.
Extension cord too long
or wire gauge too small.
Weak cell or sulfated
plate in battery.
SOLUTIONIREASONS
Check for poor connections to battery and frame. Make
sure connecting pointsare clean.
Ammeter may show no activity at the 2-amp charge rate.
Check for open fuse or cimuit breaker supplying AC outlet.
Check power cord and extension cord for loose fitting
plug.
Circuit breaker cycles when current draw is too high.
Separate the clamps.
Check for worn cables and replace if needed.
Have a Sears technician test the battery.
Correct connections,
Correct Volt/Amp Selector setting.
Crank time varies with the amount of current drawn. If
cranking draws more than 200 amps, crank time may be
less than 5 seconds.
Wait 4 minutes before next crank.
Use shorter or heavier gauge extension cord.
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 isonly partially Continue charging battery.
discharged.
Charger makes a loud Transformer laminations Continue charging, Buzz is not abnormal.
buzz or hum. vibrate (buzz).
Shorted diode (hum). Have charger tested by a Sears technician.
If the above solutions do not eliminate the problem...
cell toll-h_e from anywhere in the U.S.A.
1-800-SEARS-64
(1-SOO-7=:-77S4)
7 AM tO 4".30 PM CT Monday through Fdclay
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For information about troubleshooting, call toll-free from anywhere in the
U.S.A. 7 am to 4:30 pm CT Monday through Friday.
1-800-SEARS-64 (1-800-732-7764).
Forrepairpartsorthe locationofa SearsPartsand RepairCentercall:
1-800-4-MY-HOME= (t400-469-4663),
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