Sears 200.71440 User Manual

OWNER’S

MANUAL

Model No.

200.71440

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.

40/2 AMP

MANUAL BATTERY

CHARGER

200 AMP

ENGINE STARTER

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 Sears model 200.71440, Manual Battery Charger/Engine Starter, offers a wide range of features to
accommodate the needs for home or commercial use. This manual will show you how to use your charger
safely and effectively. Please read and follow these instructions and precautions carefully.

Using Your Battery Charger .................................... 7

Setting the controls ................................................ 7

Charging your battery ............................................ 8

Calculating charge time ....................................... 10

Using the engine start feature .............................. 11

Maintenance and care ......................................... 11

Troubleshooting .................................................... 12

Warranty

FULL THREE-YEAR WARRANTY

If, within three 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.

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

Sears 440 - Sch 516 9/16/95

1

Important Safety Instructions

– SAVE THESE INSTRUCTIONS –

w

! WARNING

L

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.

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 (electro-

lyte) 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.

•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.

•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 unplug-

ging 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:

•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.

Sears 440 - Sch 516 9/16/95

•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.

2

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 71440

Item

Description

Handle

1

2

Negative (BLK) cable w/clamps

3

Positive (RED) cable w/clamps

4

Power Cord

Circuit Breaker Asm

5

Rectifier Assembly

6

Transformer

7

8

Owner's Manual (not shown)

9

Wheel

10

Hub Cap

Axle

11

Axle mtg. bracket

12

Mounting Foot

13

14

Rocker Switch 3 pos.

15

Ammeter

16

Rocker Switch 2 pos.

Part Number

3599000286

3899000396

3899000410

90026096

3999000057

2299000614

93026365

0000000516

0099000080

5200000008

0099000060

1199004366

1199003352

0499000052

5399100097

0499000050

Wiring diagram

Sears 440 - Sch 516 9/16/95

3

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:

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

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.

TOOLS NEEDED:

3/8" wrench
(for mounting foot)

5/16" wrench
(for wheels)

Hammer
Phillips screwdriver

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.

Sears 440 - Sch 516 9/16/95

continued on next page

4

3. Tap the other axle cap onto the 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

L! 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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5

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.

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.

•Use the recommemnded minumum 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, 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.

Sears 440 - Sch 516 9/16/95

6

Using YUsing Y

Using Y

Using YUsing Y

To obtain the best results from your battery charger, you must know how to use it properly. This section will tell
you how to set the controls. And how you can charge a battery while it is still in the vehicle, or you can remove it
and then charge it. Follow the instructions below depending on how you choose to charge your battery.

our Battery Chargerour Battery Charger

our Battery Charger

our Battery Chargerour Battery Charger

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 swtich 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 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 2-positon
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.

40A 12V

CHARGE

©

200A 12V

ENGINE

START

VOLT/AMP SELECTOR

2A 12V

CHARGE

OFF

SELECT

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.

Sears 440 - Sch 516 9/16/95

7

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 NORMALLY

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 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. Standing 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.

Sears 440 - Sch 516 9/16/95

8

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 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 4­gauge (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 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. 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.

Sears 440 - Sch 516 9/16/95

9

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.

• 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 following chart 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.

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

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%

CHARGE RATE/CHARGING TIME - HOURS

2 AMP

2 - 4

4 - 10
11 - 14
14 - 18

18 - 35

18
27
30
33

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 40 amps).

• Multiply the result by 1.25 and you’ll have the time
need, in hours, to bring the battery to full charge.

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

40 AMP

NR

NR

1/2 - 3/4

3/4 - 1

1 - 2

NR
NR
NR
NR

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

Sears 440 - Sch 516 9/16/95

Example:

Amp Hour Rating x % of charge needed x 1.25 = hours

Charger Setting of

charge

needed

100 (AH Rating) x .50 (charge needed) x 1.25 = 1.5625

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 a little more than 1.5 hours at the 40-Amp charge
rate using the above example.

10

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 7.

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 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 battery for about
five minutes before cranking the engine.

Maintenance and careMaintenance and care

Maintenance and care

Maintenance and careMaintenance 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

7. After the engine starts, unplug the charger power

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.

for five more minutes in the 40 amp position
before cranking it again for five seconds.

cord from the outlet. Then move the right-hand
OUTPUT SELECTOR SWITCH to the OFF
position before disconnecting the battery leads.

Sears 440 - Sch 516 9/16/95

11

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

No reading on
ammeter. Fan inside
wheel charger appears
to be not 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.

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 guage too small.

Weak cell or sulfated plate
in battery.

Battery is only partially
discharged.

Check for open fuse or circuit 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.

Continue to charge battery.

Charger makes a loud
buzz or hum.

Sears 440 - Sch 516 9/16/95

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.

1-800-SEARS-64

(1-800-732-7764)

7 AM to 4:30 PM CST Monday through Friday

Continue charging. Buzz is not abnormal.

Have charger tested by qualified technician.

12

40/2 AMP

MANUAL BATTERY

OWNER’S

MANUAL

Model No.

200.71440

CHARGER

200 AMP

ENGINE STARTER

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

1-800-366-PART

When requesting service or
ordering parts, always provide
the following information:

• Product Type

• Model Number

• Part Number

• Part Description

(1-800-366-7278)

For the location of a Sears Repair
Service Center in your area

Call 24 hours a day,
7 days a week

1-800-488-1222

REPAIR SERVICES

America's Repair Specialists

0000000516-995