6/2 AMP
MANUAL
BATTERY
CHARGER
Model No.
200.71206
OWNER’S MANUAL
SAFETY
OPERATION
MAINTENANCE
CAUTION:
Read and Follow All Safety
Rules and Operating Instructions Before Every
Use of this Product.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
0000000508-1196
1
TROUBLESHOOTING
PARTS
TABLE OF CONTENTS
Warranty ...................................................................................................... 2
Important Safety Instructions ....................................................................3
Before Using Your Battery Charger .......................................................... 5
Plugging it in ............................................................................................ 5
Using an extension cord .......................................................................... 5
Preparing your battery to be charged ...................................................... 6
Using Your Battery Charger ...................................................................... 6
Setting the controls ..................................................................................6
Charging your battery .............................................................................. 7
Calculating charge time ........................................................................... 9
Using the engine start feature ................................................................ 11
OPERATION SAFETY
Maintenance and care ........................................................................... 11
Troubleshooting ....................................................................................... 12
Parts .......................................................................................................... 13
Wiring Diagram ......................................................................................... 14
Please read this Owner's Manual before using your Battery Charger
The Sears model 200.71206, Manual Battery Charger, offers a wide range of
MAINTENANCEPARTS
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.
WARRANWARRAN
WARRAN
WARRANWARRAN
FULL TWO-YEAR WARRANTY
If, within two years from the date of purchase this battery charger fails due to a
defect in materials or workmanship, simply RETURN IT TO THE NEAREST
SEARS STORE IN THE UNITED STATES, and Sears will repair or replace it, free
of charge.
TROUBLESHOOTING
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
TT
YY
T
Y
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2
IMPORTANT SAFETY INSTRUCTIONS
WARNING: To reduce the risk of explosion, explosive gases, or injury while using
your battery charger, follow the precautions listed below:
• Read all instructions and 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 recommended by the
manufacturer may result in fire,
electric shock, or injury.
• Do not disassemble charger. Take it to
a qualified service professional if
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-
service 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.
clean up.
• Battery chargers get hot during
operation and must have proper
ventilation. Air needs to flow around
entire charger.
• Do not set on flammable items like
carpeting, upholstery, paper, cardboard, etc. Will damage leather and,
melt plastic and rubber.
• 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.
• Be sure to position the charger power
cord to prevent it from 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.
3
SAFETY
OPERATION
MAINTENANCE
TROUBLESHOOTING
PARTS
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 if
needed 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
OPERATION SAFETY
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.
Remove all personal metal items
MAINTENANCEPARTS
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.
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.
TROUBLESHOOTING
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 explosive
gases.
Neutralize any acid spills thoroughly
with baking soda before attempting to
4
BEFORE USING YOUR BATTERY CHARGER
It is important to prepare your charger for use. This section will tell you about your
charger's electrical requirements and how to prepare a battery for charging.
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 electtrical shock.
Your charger should be grounded to reduce
the risk of electical shock.
Your charger is equipped with an
electrical cord that has an equipment grounding conductor and a
grounding lplug desinged 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.
DANGER: 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 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.
• Make sure that the wire size is large
enough for its length and for the AC
ampere rating as specified in the
accompanying chart.
SAFETY
OPERATION
MAINTENANCE
TROUBLESHOOTING
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.
MINIMUM RECOMMENDED EXTENSION CORD
Length of Cord, in Feet 25 50 100 150
AWG* Size of Cord 18 18 16 14
*AWG=American Wire Gauge
5
PARTS
PREPARING YOUR BATTERY TO BE CHARGED
It is important that you read and follow
these guidelines 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 distilled water
to each cell until the battery acid
OPERATION SAFETY
reaches the level recommended 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 necessary. Continue to the
next step listed below.
• Take time to read all battery
manufacturer’s specific precautions,
MAINTENANCEPARTS
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
4.
• 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 if
all accessories in the vehicle are not
completely turned off.
NOTE: A marine battery installed in a
boat must be removed and charged on
shore.
USING YOUR BATTERY CHARGER
For best results from your battery charger, learn to use it properly. This section tells
how to set the controls and how to charge a battery in or out of the vehicle.
SETTING THE CONTROLS
SELECTOR SWITCHES:
A 2-way switch is used to select the 2-AMP
or the 6-AMP charge rate.
TROUBLESHOOTING
LL
6 AMP 2 AMP
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 6 using the 6 amp charging
rate. As the battery charges, the needle
will fall to about 2 or 3 amps, indicating
a charged battery.
At the 2 amp charging rate, as the
battery charges the needle will fall to
about 3/4 to 1 amp indicating a charged
battery.
Continued…
6
When using the ENGINE START
feature, the needle will swing into the
Start (red)
are cranking the engine.
The percent of charge scale is intended
as a visual aid to help simplify reading
the state of charge of the battery. The
meter is scaled for use with the 10 amp
charge rate only. For the 2 amp charge
rate use the red triangle. The percent of
charge is based on current drawn by the
battery. For this reason accuracy will
vary with the size and battery type.
area of the scale while you
Charging Your Battery
SAFETY
NEGATIVE GROUNDED SYSTEM
Figure A
Charging a battery in the
vehicle:
1. Arrange the power cord and
charging leads carefully to avoid
damage that could be caused by the
hood,door, or moving engine parts.
2. Keep clear of fan blades, belts,
pulleys,and other parts that can cause
injury.
3. Check the polarity of the battery posts
as indicated on the battery case: POSITIVE
(POS, P, or +) and NEGATIVE (NEG. N or -).
NOTE: The positive post on top-post
batteries is usually larger than the
negative post.
4. Identify which battery post is ground or
connected to the chassis. THE NEGATIVE
POST IS NORMALLY THE ONE THAT IS
GROUNDED. (Fig. A)
5. To charge a negative grounded post
system:
Connect the red (POSITIVE) battery
charger clamp to the ungrounded
POSITIVE (POS, P, +) post of the battery.
Then connect the black (NEGATIVE)
clamp to a heavy, unpainted metal part
of the chassis or engine block, away
from the battery. Donot connect clamp to
carburetor, fuel lines,or sheetmetal parts.
To charge a positive grounded post
system:
Connect the black (NEGATIVE) battery
charger clamp to the NEGATIVE (NEG, N, -)
ungrounded post of the battery.
Then connect the red (POSITIVE) clamp
to a heavy, unpainted metal part
of the chassis or engine block. Do not
connect clamp to carburetor, fuel lines,
or sheet metal parts. IMPORTANT: Wear
safety glasses and face away from
the battery while making connections.
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. Select the charge rate with the
Selector Switch then plug the power cord
into a grounded AC outlet to begin
charging.
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 pointer will fall to about
half the charge rate selected. For specific
positions, refer to the “Ammeter” section
in “Using your battery charger” on page 6.
10. When the battery is fully charged,
unplug the charger power cord before
attempting to disconnect charger clamps.
11. Standing away f rom the battery, remove the charger clamps in this order:
(1) from the chassis connection and,
(2) from the battery post or terminal.
12. Clean and store the battery charger
in a dry location.
Continued...
7
OPERATION
MAINTENANCE
TROUBLESHOOTING
PARTS
Charging your battery
outside the vehicle:
(NEGATIVE) lead of the charger to the free
end of the cable. Rock the clamp to make
a solid connection.
24", 6
GAUGE
CABLE
NEGATIVE
BATTERY
CHARGER
GROUNDED
POSITIVE
BATTERY
+ -
Figure B
OPERATION SAFETY
1. Remove the battery from vehicle,
making sure to disconnect grounded
terminal first with all accessories
and lights turned off in 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
MAINTENANCEPARTS
diameter post 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 arcing and
sparking will occur away from the battery.
TROUBLESHOOTING
(The battery cable is not provided with
the charger, but may be purchased at most
automotive accessory outlets.)
POWER
CORD
TO
POWER
OUTLET
IMPORTANT: Wear safety glasses and
face away from the battery while
making this final connection.
6. Select the rate of charge with the Select
or Switch then plug the power cord into a
grounded AC outlet to begin charging.
7. 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.
8. When the battery is fully charged,
the AMMETER pointer will fall to about
half the charge rateselected. For specific
positions, refer to the “Ammeter” section in
“Using your battery charger” on page 6.
9. When the battery is fully charged,
unplug the charger power cord before
attempting to disconnect charger clamps.
10. Stand away from the battery and
remove thecharger leads from the
NEGATIVE connection first, then from the
POSITIVE battery post or terminal.
11. Clean and store the battery charger in a
dry location.
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
8
CALCULATING CHARGE TIME
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 cars and smaller trucks
are usually rated in Reserve Capacity (RC), Cold-Cranking Amps
(CCA), or both.
BATTERY SIZE/RATING
SMALL
BATTERIES
CAR/TRUCKS
MARINE/DEEP CYCLE
Motorcycle, garden
tractor, etc.
200 - 315 CCA
315 - 550 CCA
550 - 1000 CCA
• Marine, or deep-cycle batteries are
usually rated in Reserve Capacity
(RC).
• NR means that the charger setting is
NOT RECOMMENED.
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 prior to recharging.
Add more time for severely discharged
batteries.
CHARGE RATE/CHARGING TIME - HOURS
6 AMP
NR
NR
4 - 5
5 - 6
6 - 12
6
9
10
11
6-12AH
12 - 32 AH
40 - 60 RC
60 - 85 RC
85 -190 RC
80 RC
140 RC
160 RC
180 RC
2 AMP
2 - 4
4 - 10
11 - 14
14 - 18
18 - 35
18
27
30
33
SAFETY
OPERATION
MAINTENANCE
The Hydrometer or Electronic Method
To find the time needed to fully charge your battery, determine the battery’s charge
level with a hydrometeror electronic Percent-of-Charge Tester. The following table
will help you convert hydrometer readings to percent of charge values.
SPECIFIC PERCENT PERCENT OF
GRAVITY OF CHARGE CHARGE NEEDED
1.265 100% 0%
1.225 75% 25%
1.155 25% 75%
1.120 0% 100%
Continued...
9
TROUBLESHOOTING
PARTS
Calculating Charge Time (Continued)
When you know the percent of charge
and the AmpHour (AH) rating of your
battery, you can calculate the approximate time needed to bring your battery
to a full charge.
(A battery at 50 percent charge that
will be charged to 100 percent
needs another 50 percent (.50).
To convert Reserve Capacity to Amp
Hour (AH) Rating, divide Reserve
Capacity by 2, and add 16:
Reserve Capacity + 16
AH =
2
To calculate time needed for a
charge:
OPERATION SAFETY
• Find the percent of charge needed.
CONVERSION EXAMPLE:
Amp Hour Rating x % of Charge Needed x 1.25 = Hours of Charge
(
Charger Setting
MAINTENANCEPARTS
100 (AH Rating) x .50 (charge needed) x 1.25 = 10.4 Hours
6 (Charger Setting)
(
• Multiply the Amp Hour rating by the
charge needed (.50) and divide by
the charger setting (2 or 6 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 deepcycle battery.
)
or
)
or
100 x .50 8.33 x 1.25 = 10.4
(
6
You would need to charge your 100-Ampere Hour Battery for approximately 10½
TROUBLESHOOTING
hours at the 6-Amp charge rate using the above example.
)
10
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.
This will help prevent accidental
damage to the cords and charger.
3. Occasional cleaning of the case of
the charger with a soft cloth will
keep the finish shiny and help
prevent corrosion.
SAFETY
OPERATION
MAINTENANCE
11
TROUBLESHOOTING
PARTS
TROUBLESHOOTING
Performance problems often result from little things that you can fix yourself. Please
read through this chart for a possible solution if a problem occurs.
PROBLEM POSSIBLE CAUSE SOLUTION/REASONS
No ammeter reading.
OPERATION SAFETY
Circuit breaker in
charger cycles on and
off with a clicking
sound.
MAINTENANCEPARTS
Ammeter reads less
than selected charge
rate when charging.
Clamps not making good
connection.
2-amp charge rate.
No AC power reaching charger.
Shorted battery clamps.
Shorted battery.
Charger leads reversed
on battery.
Extension cord too long or
wire gauge to small.
Battery has weak cell or
sulfated plate.
Check for poor connection at battery.
Make sure clamps and posts are clean.
Ammeter needle will indicate little activity at the 2-amp charge rate.
Check AC outlet and extension cords for
loose fitting plug.
Check for open fuse or circuit breaker
supplying AC outlet.
Separate the clamps. Circuit
breaker cycles when current
draw is too high. Check for worn
cables and replace if needed.
Have qualified Sears technician
test the battery.
Correct connections.
Use shorter or heavier 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 qualified Sears technician.
Battery is only partially
discharged.
TROUBLESHOOTING
Charger makes a loud
buzz or hum.
Transformer laminations
vibrate (buzz).
Shorted diode (hum).
If the above solutions do not eliminate the problem...
call toll-free from anywhere in the U.S.A.
7 AM to 4:30 PM CST Monday through Friday
Continue charging battery.
Continue charging. Buzz is not
abnormal.
Have charger tested by qualified
technician.
1-800-SEARS-64
(1-800-732-7764)
12
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 Sears 71206
Description Part Number
Item
Cover 3799001402
1
Heatsink/Diode Assembly 2299000825
2
3
Base 3799001382
4
AC Power Cord 90026058
5
Transformer 93026433
Output Cable 3899000016
6
Circuit Breaker (12A) 3999000044
7
50A Clamp (1) 2299000248
8
Sleeving Red (2) required 0399000007
Sleeving Black (2) required 0399000008
9
Meter 5399100090
Switch SPDT 0499000032
10
Front Panel 3799001392
11
Decal 0899000530
12
13
Handle 3599000240
14
Screw 8-18 x 3/8" (4) 5181806256
15
Owner's Manual and Parts List (Not Shown) 0000000508
SAFETY
OPERATION
MAINTENANCE
13
TROUBLESHOOTING
PARTS
OPERATION SAFETY
WIRING DIAGRAM
MAINTENANCEPARTS
TROUBLESHOOTING
14
NOTES
SAFETY
OPERATION
15
MAINTENANCE
TROUBLESHOOTING
PARTS
For information about troubleshooting
Call toll-free from anywhere in the U.S.A.
7 am to 4:30 pm CST Monday through
Friday 1-800-SEARS-64
(1-800-732-7764)
For the repair or replacement
parts you need
Call 7 am - 7 pm, 7 days a week
OPERATION SAFETY
1-800-366-PART
(1-800-366-7278)
For the location of a Sears Repair
Service Center in your area
MAINTENANCEPARTS
Call 24 hours a day,
7 days a week
1-800-488-1222
When requesting service or
ordering parts, always provide
the following information:
TROUBLESHOOTING
Product Type: 6/2 AMP
Manual Battery Charger
Model Number: 200.71206
Part Number (See Page 13)
Part Description (See Page 13)
REPAIR SERVICES
America's Repair Specialists
16
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