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OWNER’S MANUAL
BATTERY 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.
00-99-000312/0306
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Table Of Contents
Warranty .................................................................... 1
Important Safety Instructions ................................. 2
Parts .......................................................................... 3
Before Using Your Battery Charger ........................ 4
Assembling your charger ..................................... 4
Plugging it in ........................................................ 5
Using an extension cord....................................... 6
Preparing your battery to be charged .................. 6
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 will show 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 Central
Time Monday through Friday. 1-800-SEARS-64 (1-800-732-7764).
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
Warranty
THREE-YEAR FULL WARRANTY
If this Battery Charger 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 specific legal rights, and you may also have other rights which vary from state to
state.
Sears, Roebuck and Co.
Hoffman Estates, IL 60179
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Important Safety Instructions
– SAVE THESE INSTRUCTIONS –
WARNING
• 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, RVs, 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.
To reduce the risk of explosion, explosive gases, or injury while
using your battery charger, follow the precautions listed below:
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 batteries
that are commonly used with home appliances.
These batteries may burst and cause personal
injury.
• 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.
Personal Safety Precautions
For your own personal safety, please follow the
following precautions:
• Do not disassemble charger. Take it to a qualified
service professional if 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.
• 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
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 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.
• 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 clean up.
• WARNING: Handling the cord on this product or
cords associated with accessories sold with this
product, may expose you to lead, a chemical known
to the State of California to cause cancer and birth
defects or other reproductive harm.
after handling.
Wash hands
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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 DieHard 71230
Item Description Part 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. Hub Cap 5200000008
11. Axle 0099000060
12. Axle Mtg. Brackets 1199004366
13. Mounting Foot 1199003352
14. Rocker Switch 3 Position 0499000052
15. Ammeter 5399100088
16. Rocker Switch 2 Position 0499000050
17. Owner's Manual 0099000312
Wiring Diagram
Wiring Diagram 71230
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Before Using Your Battery Charger
It is important to prepare your charger for use. This section will tell 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: TOOLS NEEDED:
Two 10-32 thread cutting 3/8" wrench
screws (for mounting foot)
Two 1/4-20 thread cutting 5/16" wrench
screws (for wheels)
Two wheels Hammer
One axle Phillips screwdriver
Two axle caps
Two axle brackets
One handle
One mounting foot
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 on floor or work surface. Then,
using a hammer, tap one of the plastic hubs onto
the top end of the axle. Be sure to tap the hub on
straight. Slide both wheels onto the axle with the
hubs facing inward.
continued on next page
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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.
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. 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.
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 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 grounding 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 codes and ordinances.
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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.
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.
MINIMUM RECOMMENDED EXTENSION CORD
Length of Cord, in Feet 25 50 100 150
AWG* Size of Cord 18 14 12 10
*AWG=American Wire Gauge
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 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 cell caps, no action is necessary. 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, any gases emitted from the battery 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.
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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 2position switch to the left of it. Use the 3-position
switch to select:
•
2 Amp Trickle Charge
batteries and warming large batteries. The lower the
charge rate, the longer it will take, 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 by the 2position 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 by the vehicle's charging system once
the engine starts.
— Use for charging small
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.
200A 12V
ENGINE
START
©
40A 12V
CHARGE
2A 12V
CHARGE
SELECT
VOLT/AMP SELECTOR
OFF
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.
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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 by the hood, door, or moving engine parts.
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: POSITIVE (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 parts.
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 slipping off the
posts and causing sparks.
7. 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 wall outlet.
8. Select the desired charge rate. (See "Setting the
Controls" on page 7.)
9. 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.
10. When the battery is fully charged, the AMMETER
needle will fall to about half the charge rate
selected. For specific positions, see the “Ammeter” section of “Setting the Controls” on page 7.
11. When the battery is fully charged, unplug the
charger power cord. Next, set the right-hand
switch to the OFF position.
12. Facing away from the battery, remove the charger
clamp from the chassis first, then from the battery
post or terminal.
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 off to 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 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 at least 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 will not occur directly over the
battery. (The battery cable is not provided with the
charger, but may be purchased at most automotive 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 wall
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 monitor and unplug
charger when battery is fully charged.
9. When the battery is fully charged, the AMMETER
needle will fall to about half the charge rate
selected. For specific positions, see the "Ammeter" section of "Settings the Controls" on page 7.
10. When the battery is fully charged, unplug the
charger power cord before attempting to disconnect charger clamps.
11. Facing 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 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
6-12AH
12 - 32 AH
40 - 60 RC
60 - 85 RC
85 -190 RC
80 RC
140 RC
160 RC
180 RC
• 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 batteries.
CHARGE RATE/CHARGING TIME - HOURS
2 AMP
2 - 4
4 - 10
11 - 14
14 -18
18 - 35
18
27
30
33
40 AMP
NR
NR
30 to 45 min.
45 min. to 1 hour
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.
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%
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 Capacity + 16
2
NOTE: The Reserve Capacity can be obtained from
the battery specification 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 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 % of charge needed x 1.25 = hours
Charger Setting of
charge
100 (AH Rating) x .50 (charge needed) x 1.25 = 6.25
40 (Charger Setting) hours
100 x .50 = 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 instructions for
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 selector switch to the 200 AMP START position.
3. Plug the power cord into a grounded AC wall outlet.
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 battery for about
five minutes before cranking the engine.
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
will keep the finish shiny and help prevent corrosion.
6. If the engine still does 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
position before 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.
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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 POSSIBLE CAUSE SOLUTION/REASONS
No reading on the Clamps are not making a Check for poor connections to battery and frame. Make
ammeter. good connection. sure connecting points are clean.
2-amp charge rate is Ammeter may show no activity at the 2-amp charge rate.
being used.
No reading on No power at receptacle. Check for open fuse or circuit breaker supplying AC outlet.
ammeter. Fan inside
wheel charger appears AC cord and/or extension Check power cord and extension cord for loose fitting
to not be working. cord is loose. plug.
Circuit breaker in Shorted battery clamps. Circuit breaker cycles when current draw is too high.
charger cycles on Separate the clamps.
and off with a clicking Check for worn cables and replace if needed.
sound.
Shorted battery. Have a Sears technician test the battery.
Charger leads reversed. Correct connections.
Volt/Amp Selector Switch Correct Volt/Amp Selector setting.
set to the START position.
Short start cycle Drawing more than 200 Crank time varies with the amount of current drawn. If
when cranking amps for a period of 5 cranking draws more than 200 amps, crank time may be
engine. seconds or less. less than 5 seconds.
Failure to wait for 4 Wait 4 minutes before next crank.
minutes (240 seconds)
between cranks.
Ammeter reads less Extension cord too long Use shorter or heavier gauge extension cord.
than selected charge or wire gauge too small.
rate when charging
a discharged battery. Weak cell or sulfated Sulfated battery will eventually take a normal charge if left
plate in battery. 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 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...
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
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For information about troubleshooting, call toll-free from anywhere in the
U.S.A. 7 am to 4:30 pm Central Time Monday through Friday.
1-800-SEARS-64 (1-800-732-7764).
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