Diehard 200.71240 User Manual

OPERATOR’S MANUAL

®

BATTERY CHARGER
50/15/2 Amp,
6/12 Volt,
Manual
250 Amp
ENGINE STARTER

Model No.

200.71240

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.

00-99-000853/0808

TABLE OF CONTENTS

SECTION PAGE

1. IMPORTANT SAFETY INSTRUCTIONS 1

2. PERSONAL PRECAUTIONS 2

3. PREPARING TO CHARGE 2

4. CHARGER LOCATION 3

5. DC CONNECTION PRECAUTIONS 3

6. WHEN BATTERY IS INSTALLED IN VEHICLE 3

7. WHEN BATTERY IS OUTSIDE OF VEHICLE 4

8. BATTERY CHARGING - AC CONNECTIONS 5

9. PARTS 7

10. PRODUCT FEATURES 8

11. ASSEMBLY INSTRUCTIONS 8

12. OPERATING INSTRUCTIONS 11

13. CALCULATING CHARGE TIME 12

14. USING THE ENGINE START FEATURE 14

15. MAINTENANCE INSTRUCTIONS 14

16. STORAGE INSTRUCTIONS 14

17. TROUBLESHOOTING 15

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 three years from the date of purchase, return it to any Sears
store or other DieHard outlet in the United States for free replacement.

This warranty gives you specic legal rights, and you may also have

other rights which vary from state to state.

SEARS, ROEBUCK AND CO., HOFFMAN ESTATES, IL 60179

FOR CUSTOMER ASSISTANCE OR REPLACEMENT PARTS, CALL
TOLL-FREE FROM 7 AM TO 4:30 PM CT MONDAY THROUGH FRIDAY:
1-800-SEARS-64 (1-800-732-7764)

IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL.

IMPORTANT SAFETY INSTRUCTIONS1.

SAVE THESE INSTRUCTIONS - The DieHard model 71240 Manual Bat-1.1
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 instruc­tions and precautions carefully as this manual contains important safety
and operating instructions.

WARNING: This product contains chemicals known to the State of Cali-1.2
fornia to cause cancer and birth defects or other reproductive harm. Wash
hands after handling.

Do not expose charger to rain or snow.1.3

Use of an attachment not recommended or sold by the battery charger 1.4

manufacturer may result in a risk of re, electric shock or injury to persons.

To reduce the risk of damage to electric plug or cord, pull by the plug 1.5
rather than the cord when disconnecting the charger.

An extension cord should not be used unless absolutely necessary. Use of 1.6

an improper extension cord could result in a risk of re 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 •
and;

That the wire size is large enough for the AC ampere rating of the charger •

as specied in Table 8.3.

Do not operate the charger with a damaged cord or plug; take it to a quali-1.7

ed serviceman. (Call customer service at: 800-SEARS-64).

Do not operate the charger if it has received a sharp blow, been dropped 1.8

or otherwise damaged in any way; take it to a qualied serviceman. (Call
customer service at: 800-SEARS-64).

Do not disassemble the charger; take it to a qualied serviceman when 1.9

service or repair is required. Incorrect reassembly may result in a risk of

electric shock or re. (Call customer service at: 800-SEARS-64).

To reduce the risk of electric shock, unplug the charger from the outlet 1.10
before attempting any maintenance or cleaning. Turning off the controls
will not reduce this risk.

• 1 •

WARNING – RISK OF EXPLOSIVE GASES.

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 THE INSTRUCTIONS EACH TIME
YOU USE THE CHARGER.

TO REDUCE THE RISK OF BATTERY EXPLOSION, FOLLOW THESE
INSTRUCTIONS 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.

PERSONAL PRECAUTIONS2.

Consider having someone close enough by to come to your aid when you 2.1
work near a lead-acid battery.

Have plenty of fresh water and soap nearby in case battery acid contacts 2.2
your skin, clothing or eyes.

Wear complete eye protection and clothing protection. Avoid touching your 2.3
eyes while working near the battery.

If battery acid contacts your skin or clothing, wash immediately with soap 2.4
and water. If acid enters your eye, immediately ood the eye with cold run­ning water for at least 10 minutes and get medical attention immediately.

NEVER smoke or allow a spark or ame in the vicinity of a battery or 2.5

engine.

Be extra cautious to reduce the risk of dropping a metal tool onto the bat-2.6
tery. It might spark or short-circuit the battery or other electrical part that
may cause an explosion.

Remove personal metal items such as rings, bracelets, necklaces and 2.7
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.

Use this charger for charging a LEAD-ACID battery only. It is not intended 2.8
to supply power to a low voltage electrical system other than in a starter­motor 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.

NEVER charge a frozen battery.2.9

WARNING: 2.10 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.

• 2 •

PREPARING TO CHARGE3.

If it is necessary to remove the battery from the vehicle to charge it, al-3.1

ways remove the grounded terminal from the battery rst. Make sure all of

the accessories in the vehicle are off, so as not to cause an arc.

Be sure the area around the battery is well ventilated while the battery is 3.2
being charged.

Clean the battery terminals. Be careful to keep corrosion from coming into 3.3
contact with your eyes.

Add distilled water to each cell until the battery acid reaches the level 3.4

specied by the battery manufacturer. Do not overll. For a battery without

removable cell caps, such as valve regulated lead-acid batteries, carefully
follow the manufacturer’s recharging instructions.

Study all of the battery manufacturer’s specic precautions while charging 3.5

and recommended rates of charge.

Determine the voltage of the battery by referring to the vehicle owner’s 3.6
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 at the lowest rate rst.

CHARGER LOCATION4.

Locate the charger as far away from the battery as the DC cables permit.4.1

Never place the charger directly above the battery being charged; gases 4.2
from the battery will corrode and damage the charger.

Never allow battery acid to drip onto the charger when reading the electro-4.3

lyte specic gravity or lling the battery.

Do not operate the charger in a closed-in area or restrict the ventilation in 4.4
any way.

Do not set a battery on top of the charger.4.5

DC CONNECTION PRECAUTIONS5.

Connect and disconnect the DC output clips only after setting all of the 5.1
charger switches to the “off” position and removing the AC plug from the
electrical outlet. Never allow the clips to touch each other.

Attach the clips to the battery and chassis, as indicated in steps 6.5, 6.6, 5.2

and 7.2 thru 7.4.

• 3 •

FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VE-6.
HICLE

A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION. TO
REDUCE RISK OF A SPARK NEAR BATTERY:

NEGATIVE GROUNDED SYSTEM

Position the AC and DC cables to reduce the risk of damage by the hood, 6.1
door, or moving engine parts.

Stay clear of fan blades, belts, pulleys and other parts that can cause 6.2

injury.

Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery 6.3
post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.

Determine which post of the battery is grounded (connected) to the chas-6.4
sis. 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.

For a negative-grounded vehicle, connect the POSITIVE (RED) clip from 6.5
the battery charger to the POSITIVE (POS, P, +) ungrounded post of the
battery. Connect the NEGATIVE (BLACK) clip to the vehicle chassis or

engine block 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 frame or engine block.

For a positive-grounded vehicle, connect the NEGATIVE (BLACK) clip 6.6
from the battery charger to the NEGATIVE (NEG, N, -) ungrounded post
of the battery. Connect the POSITIVE (RED) clip to the vehicle chassis or

engine block 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 frame or engine block.

When disconnecting the charger, turn all switches to off, disconnect the 6.7
AC cord, remove the clip from the vehicle chassis, and then remove the
clip from the battery terminal.

See OPERATING INSTRUCTIONS for length of charge information.6.8

• 4 •

FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. 7.

A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION.
TO REDUCE RISK OF A SPARK NEAR BATTERY:

Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery 7.1
post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.

Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to 7.2
the NEGATIVE (NEG, N, -) battery post.

Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) 7.3

post of the battery.

Position yourself and the free end of the cable you previously attached to 7.4

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.

Do not face the battery when making the nal connection.7.5

When disconnecting the charger, always do so in reverse sequence of 7.6

the connecting procedure and break the rst connection while as far away

from the battery as practical.

A marine (boat) battery must be removed and charged on shore. To 7.7

charge it onboard requires equipment specially designed for marine use.

• 5 •

BATTERY CHARGING - AC CONNECTIONS8.

For all grounded cord-connected battery chargers: 8.1

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 equipment­grounding 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 t
the outlet, have the proper outlet installed by a qualied electrician. An

improper connection can result in a risk of an electric shock.

For all grounded, cord-connected battery chargers with an input rating less 8.2

than 15-amperes and intended for use on a nominal 120-volt circuit:

This battery charger is for use on a nominal 120-volt circuit, and has a •

grounding plug that looks like the plug illustrated in sketch A in Figure 8.4.

A temporary adaptor, which looks like the adapter illustrated in sketches
B and C, may be used to connect this plug to a two-pole receptacle as
shown in sketch B if a properly grounded outlet is not available. The tem­porary adapter should be used only until a properly grounded outlet can

be installed by a qualied electrician.

DANGER – Before using an adapter as illustrated, be certain that the •
center screw of the outlet plate is grounded. The green-colored rigid
ear or lug extending from the adapter must be connected to a properly
grounded outlet – make certain it is grounded. If necessary, replace the
original outlet cover plate screw with a longer screw that will secure the
adapter ear or lug to the outlet cover plate and make a ground connec­tion to the grounded outlet.

• 6 •

Recommended minimum AWG size for extension cords for battery 8.3

25 50 100 150

(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 ampere rating is to be determined
by dividing the wattage rating by the voltage rating ± for
example:

1250 watts/125 volts = 10 amperes

Length of cord, feet (m)

AWG size of cord

AC input rating,

amperes

a

But less

than

At least

Grounding Methods

chargers:

8.4

• 7 •

PRODUCT FEATURES9.

1

2

3

4

Volt Selector Switch1.
Ammeter2.
Clamps3.
Timer4.

In case of charger malfunction, DO NOT attempt to repair charger
yourself. To arrange for charger repair, or information about custom­er replaceable parts, call 1-800-SEARS-65 (1-800-732-7764).

ASSEMBLY INSTRUCTIONS 10.

It is important to fully assemble your charger before use. Follow these

instructions for assembly:

PARTS TOOLS NEEDED

Two, 10-32, thread cutting screws

Four, 1/4-20, thread cutting screws

Two wheels
One axle
Two axle caps
Two axle brackets
One handle
One mounting foot

3/8” wrench (for mounting foot)
5/16” wrench (for wheels)

Hammer
Phillips screwdriver

TO ATTACH THE AXLE ASSEMBLY:

Remove charger from packing materials and place upside down on a at 10.1

surface. Attach mounting foot and secure with the four, 1/4-20 thread cut­ting screws.

• 8 •

Hold axle upright on oor or work surface. Then, using a hammer, tap one 10.2

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 axle caps
facing each other.

• 9 •

Place the charger on its side. Place one end of each bracket into slot, then 10.3

place the axle assembly under each bracket. Fasten the other side of the

brackets using the two, 10-32 screws provided.

To Attach Handle:10.4

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. \

• 10 •

OPERATING INSTRUCTIONS11.

Follow steps in section 6 or 7 for hookup and disconnect instructions, and 11.1

precautions.

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.

TIMER11.2 : The main function of the timer is to prevent over charging while al­lowing the 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, which is why the timer is limited to 2.25 hours. With the aid
of a battery load tester, the state of charge can be obtained within a few

seconds. For example, the average size automotive battery at a 50%

state of charge, will require 1 to 1.5 hours of charging at the 50 amp rate

to reach the full charge state. For the same battery with the timer set to its

maximum of 2.25 hours, over charging will occur, but is unlikely to cause
harm to the battery. When the charge state is unknown, start out with a
timer setting of 1 hour or less.

HOLD:11.3 This function allows continuous operation. Use when charging for

more than 2.25 hours (usually when the 2 amp charge rate is selected).

Stop charging when the battery is fully charged.

Rotary switch:11.4 Use the rotary switch to select the charge rate or engine
start setting required.

Ammeter:11.5 Indicates the amount of current measured in amperes that is

being drawn by the battery. For example, in the 50 amp charge rate, a

typical discharged battery will initially draw approximately 50 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 be­ing drawn from the charger. When cranking an engine, the starter motor
draws upwards to 250-300 amps. The meter needle will be at the extreme

right side of the start area. Sometimes, for the rst few minutes of its

charge, the battery will draw more than 50 amps; in this case, the needle
may be within, but not all the way over, to the right side of the start area.
The 2 amp charge rate may not indicate activity on the meter. The meter
does not have the resolution to display this low rate.

• 11 •

CALCULATING CHARGE TIME12.

The Chart Method12.1

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 ts 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 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 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-percent charge rate prior to recharging. Add more time for severely
discharged batteries.

CHARGE RATE/

BATTERY SIZE/RATING

CHARGING TIME - HOURS

2 AMP 50 AMP

SMALL

BATTERIES

CAR/TRUCKS

MARINE/DEEP CYCLE

Motorcycle, gar­den, tractor, etc.

200 - 315 CCA 40 - 60 RC 11 - 14 30 to 45 min.

315 - 550 CCA 60 - 85 RC 14 - 18

550 - 1000 CCA 85 - 190 RC 18 - 35 1 - 2 hours

6 - 12 AH 2 - 4 NR

12 - 32 AH 4 - 10 NR

45 min - 1

hour

80 RC 18 NR

140 RC 27 NR

160 RC 30 NR

180 RC 33 NR

• 12 •

The Hydrometer or Electronic Method12.2

To nd 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.

SPECIFIC GRAVITY PERCENT OF CHARGE

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 calculate the approximate 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:

PERCENT OF CHARGE

NEEDED

Amp Hours = Reserve Capacity + 16
2

NOTE: The Reserve Capacity can be obtained from the battery specica-
tion sheet or the owner’s manual.

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)).

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 approximate time needed, •
in hours, to bring the battery to full charge.

Add one additional hour for a deep-cycle battery.•

Example:

Amp Hour Rating x charge needed x 1.25 = hours of

Charger Setting charge

100 (AH Rating) x .50 (charge needed) x 1.25 = 6.25

50 (Charger Setting) hours

100 x .50 = 1.25 x 1.25 = 1.5625

50

You will need to charge your 100-Ampere Hour Battery for approximately
1 1/2 hours at the 50-Amp charge rate using the above example.

• 13 •

USING THE ENGINE START FEATURE13.

Set charge rate switch and timer to OFF positions.13.1

With the charger unplugged from the AC outlet, connect the charger to the 13.2

battery following instructions given in section 6 or 7.

Plug the charger AC power cord into the AC outlet, then move timer from 13.3

OFF to HOLD position.

Set the charge rate switch to the engine start position and then crank the 13.4

engine. Follow the duty cycle of your charger for proper ON / OFF times.

During extremely cold weather or when the battery is severely exhausted,
charge the battery for about 5 minutes before cranking the engine.

If the engine fails to start, charge the battery for 5 more minutes before 13.5
attempting to crank the engine again.

After the engine starts, move the charge rate switch to OFF and unplug 13.6

the AC power cord from the outlet before disconnecting DC clips.

MAINTENANCE INSTRUCTIONS14.

Before performing maintenance, unplug and disconnect battery charger 14.1

(see sections 6.7 or 7.6).

After use, use a dry cloth to wipe all battery corrosion and other dirt or oil 14.2
from terminals, cords, and the charger case.

Through routine maintenance, ensure all user installed parts are secured.14.3

STORAGE INSTRUCTIONS15.

Store charger unplugged, in an upright condition. Cord will still conduct 15.1
electricity until it is unplugged from outlet.

Store inside, in a dry, cool place (unless you’re using an on-board Marine 15.2
Charger ).

Do not store clips on handle, clipped together, on or around metal, or 15.3
clipped to cables.

• 14 •

TROUBLESHOOTING16.

PROBLEM POSSIBLE CAUSE SOLUTION/REASONS

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.

Charger makes a loud
buzz or hum.

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 250
amps for a period of 3
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.

Battery is only partially
discharged.

Transformer laminations

vibrate (buzz).

Shorted diode (hum).

Check for poor connec­tions to battery and frame.
Make sure connecting
points are clean.

Ammeter may show no
activity at the 2-amp
charge rate.

Check for open fuse or
circuit breaker supplying
AC outlet.

Check power cord and
extension cord for loose

tting plug.

Circuit breaker cycles
when current draw is
too high. Separate the
clamps. Check for worn
cables and replace if
needed.

Have battery tested by a

Sears or other qualied

service dealer.

Correct Connections.

Correct Volt/Amp Selector
setting.

Crank time varies with the
amount of current drawn.
If cranking draws more
than 250 amps, crank
time may be less than 3
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 or other qualied

service dealer.

Continue charging battery.

Continue charging. Buzz
is not abnormal.

Have charger tested by a

Sears or other qualied

service dealer.

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

• 15 •

• 16 •

• 17 •