Craftsman Diehard Battery Charger Maintainer Owners Manual

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0099000999-03

Model No.

28.71219

OPERATOR’S MANUAL

Battery Charger

Read and follow all Safety

Rules and Operating Instructions

before Every Use of this Product.

SAVE THESE INSTRUCTIONS.

Sears Brands Management Corporation,

Hoffman Estates, IL 60179 U.S.A.

• 2 •

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 3

years from the date of purchase, return it to any 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 Brands Management Corporation, Hoffman Estates, IL 60179

FOR CUSTOMER ASSISTANCE OR REPLACEMENT PARTS,

CALL TOLL-FREE FROM 7 AM TO 5 PM CT

MONDAY THROUGH FRIDAY: 1-800-732-7764

IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION

MANUAL.

SAVE THESE INSTRUCTIONS – This manual will show you how to

use your charger safely and effectively. Please read, understand and

follow these instructions and precautions carefully, as this manual

contains important safety and operating instructions. The safety

messages used throughout this manual contain a signal word, a

message and an icon.

The signal word indicates the level of the hazard in a situation.

Indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury to the operator

or bystanders.

Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury to the

operator or bystanders.

Indicates a potentially hazardous situation which, if not

avoided, could result in moderate or minor injury to the

operator or bystanders.

Indicates a potentially hazardous situation which, if not

avoided, could result in damage to the equipment or

vehicle or property damage.

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. Wash hands

before handling.

• 3 •

IMPORTANT SAFETY INSTRUCTIONS – 1.

SAVE THESE INSTRUCTIONS. This manual contains

important safety and operating instructions.

RISK OF ELECTRIC SHOCK OR FIRE.

Keep out of reach of children.1.1

Do not expose the charger to rain or 1.2

snow.

Use only recommended attachments. 1.3

Use of an attachment not recommended or sold by the battery

charger manufacturer may result in a risk of re, electric shock

or injury to persons or damage to property.

To reduce the risk of damage to the electric plug or cord, pull by 1.4

the plug rather than the cord when disconnecting the charger.

An extension cord should not be used unless absolutely 1.5

necessary. Use of 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.

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

the charger as specied in section 8.

To reduce the risk of electric shock, unplug the charger from the 1.6

outlet before attempting any maintenance or cleaning. Simply

turning off the controls will not reduce this risk.

Do not operate the charger with a damaged cord or plug; have 1.7

the cord or plug replaced immediately by a qualied service

person. (Call customer service at 1-800-732-7764.)

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

dropped or otherwise damaged in any way; take it to a qualied

service person. (Call customer service at 1-800-732-7764.)

Do not disassemble the charger; take it to a qualied service 1.9

person when service or repair is required. Incorrect reassembly

may result in a risk of re or electric shock. (Call customer

service at 1-800-732-7764.)

• 4 •

RISK OF EXPLOSIVE GASES.

WORKING IN THE VICINITY OF A LEAD-1.10

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 a battery explosion, follow these 1.11

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.

This charger employs parts, such as switches and circuit 1.12

breakers, that tend to produce arcs and sparks. If used in a

garage, locate this charger 18 inches or more above oor level.

PERSONAL PRECAUTIONS2.

RISK OF EXPLOSIVE GASES.

NEVER smoke or allow a spark or ame in the 2.1

vicinity of a battery or engine.

Remove personal metal items such as rings, 2.2

bracelets, necklaces and 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.

Be extra cautious, to reduce the risk of dropping a metal tool 2.3

onto the battery. It might spark or short-circuit the battery or

other electrical part that may cause an explosion.

Use this charger for charging LEAD-ACID batteries only. It is 2.4

not intended to supply power to a low voltage electrical system

other than in a starter-motor 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.2.5

NEVER overcharge a battery.2.6

• 5 •

Consider having someone nearby to come to your aid when you 2.7

work near a lead-acid battery.

Have plenty of fresh water and soap nearby in case battery acid 2.8

contacts your skin, clothing or eyes.

Wear complete eye and body protection, including safety 2.9

goggles and protective clothing. Avoid touching your eyes while

working near the battery.

If battery acid contacts your skin or clothing, immediately 2.10

wash the area with soap and water. If acid enters your eye,

immediately ood the eye with cold running water for at least 10

minutes and get medical attention right away.

If battery acid is accidentally swallowed, drink milk, the whites of 2.11

eggs or water. DO NOT induce vomiting. Seek medical

attention immediately.

PREPARING TO CHARGE3.

RISK OF CONTACT WITH BATTERY ACID.

BATTERY ACID IS A HIGHLY CORROSIVE

SULFURIC ACID.

If it is necessary to remove the battery 3.1

from the vehicle to charge it, always remove

the grounded terminal rst. Make sure all of

the accessories in the vehicle are off to prevent arcing.

Be sure the area around the battery is well ventilated while the 3.2

battery is being charged.

Clean the battery terminals before charging the battery. During 3.3

cleaning, keep airborne corrosion from coming into contact

with your eyes, nose and mouth. Use baking soda and water to

neutralize the battery acid and help eliminate airborne corrosion.

Do not touch your eyes, nose or mouth.

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

level specied by the battery manufacturer. Do not overll. For

a battery without removable cell caps, such as valve regulated

lead acid batteries (VRLA), carefully follow the manufacturer’s

recharging instructions.

Read, understand and follow all instructions for the charger, 3.5

battery, vehicle and any equipment used near the battery

• 6 •

and charger. Study all of the battery manufacturer’s specic

precautions while charging and recommended rates of charge.

Determine the voltage of the battery by referring to the vehicle 3.6

owner’s 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 in the lowest rate rst.

Make sure that the charger cable clips make tight connections.3.7

CHARGER LOCATION4.

RISK OF EXPLOSION

AND CONTACT WITH

BATTERY ACID.

Locate the charger as far 4.1

away from the battery as the

DC cables permit.

Never place the charger directly above the battery being charged; 4.2

gases from the battery will corrode and damage the charger.

Do not set the battery on top of the charger.4.3

Never allow battery acid to drip onto the charger when reading 4.4

the electrolyte specic gravity or lling the battery.

Do not operate the charger in a closed-in area or restrict the 4.5

ventilation in any way.

DC CONNECTION PRECAUTIONS5.

Connect and disconnect the DC output clips only after setting 5.1

all of the charger switches to the “off” position (if applicable) 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 5.2

sections 6 and 7.

FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED 6.

IN VEHICLE.

A SPARK NEAR THE

BATTERY MAY CAUSE A

BATTERY EXPLOSION. TO

REDUCE THE RISK OF A

SPARK NEAR THE BATTERY:

• 7 •

Position the AC and DC cables to reduce the risk of damage 6.1

by the hood, door and moving or hot engine parts. NOTE: If it

is necessary to close the hood during the charging process,

ensure that the hood does not touch the metal part of the battery

clips or cut the insulation of the cables.

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

cause injury.

Check the polarity of the battery posts. The POSITIVE (POS, 6.3

P, +) battery post usually has a larger diameter than the

NEGATIVE (NEG, N, -) post.

Determine which post of the battery is grounded (connected) to 6.4

the chassis. 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 6.5

vehicle, connect the

POSITIVE (RED) clip

from 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 6.6

(BLACK) clip 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.

Connect charger AC supply cord to electrical outlet.6.7

NEGATIVE GROUNDED SYSTEM

• 8 •

When disconnecting the charger, turn all switches to off (if 6.8

applicable), disconnect the AC cord, remove the clip from the

vehicle chassis and then remove the clip from the

battery terminal.

See CALCULATING CHARGE TIME for length of 6.9

charge information.

FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE 7.

VEHICLE.

A SPARK NEAR THE

BATTERY MAY CAUSE A

BATTERY EXPLOSION. TO

REDUCE THE RISK OF A

SPARK NEAR THE BATTERY:

Check the polarity of the 7.1

battery posts. The POSITIVE

(POS, P, +) battery post usually

has a larger diameter than the

NEGATIVE (NEG, N, -) post.

Attach at least a 24-inch (61 7.2

cm) long 6-gauge (AWG)

insulated battery cable to the NEGATIVE (NEG, N, -) battery post.

Connect the POSITIVE (RED) charger clip to the POSITIVE 7.3

(POS, P, +) post of the battery.

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

attached to 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

Connect charger AC supply cord to electrical outlet.7.6

When disconnecting the charger, always do so in the reverse 7.7

order of 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. 7.8

To charge it onboard requires equipment specially designed for

marine use.

• 9 •

AC POWER CORD CONNECTIONS8.

RISK OF ELECTRIC SHOCK OR FIRE.

This battery charger is for use on a 8.1

nominal 120-volt circuit. The plug must

be plugged into an outlet that is properly

installed in accordance with all local codes

and ordinances. The plug pins must t the receptacle (outlet).

8.2 Never alter the AC cord or plug provided – if it does

not t the outlet, have a proper outlet installed by a qualied

electrician. An improper connection can result in a risk of an

electric shock or electrocution. NOTE: Pursuant to Canadian

Regulations, use of an adapter plug is not allowed in Canada.

Use of an adapter plug in the United States is not recommended

and should not be used.

Recommended minimum AWG size for extension cord:8.3

100 feet long or less – use an 18 gauge extension cord.•

Over 100 feet long – use a 16 gauge extension cord.•

ASSEMBLY INSTRUCTIONS9.

Remove all cord wraps and uncoil the cables prior to using the

battery charger.

FEATURES/CONTROL PANEL 10.

1

2

3

4

5

7

1

3

2

4

4

5

6

6

Amp/Volt Selector Switch1.

Battery Status LEDs2.

AC Power cord 3.

Battery Clamp Cable Assembly4.

Ring Terminal Cable Assembly5.

12V Plug Cable Assembly6.

Charger Quick-Connect Cable7.

• 10 •

Amp/Volt Selector Switch10.1

2A, 12V

AMP/VOLT

SELECTOR

4A, 6V

LED Display10.2

CHECK BATTERY (red) LED lit: Indicates the battery is not properly

connected to the charger.

CHECK BATTERY (red) LED blinking: Indicates the charger is in

abort mode.

CHARGING (yellow) LED lit: Indicates the charger is charging

the battery.

CHARGED (green) LED lit: Indicates the battery is fully charged and

the charger is in maintain mode.

NOTE: See the Operating Instructions section for a complete

description of the charger modes.

OPERATING INSTRUCTIONS11.

This battery charger must be properly assembled in

accordance with the assembly instructions before it is used.

The charger does not have an On/Off switch. Plug the 71219 into

a 120V AC electrical wall outlet only after battery connections have

been made and the Amp/Volt selector switch has been set.

NOTE: This charger is equipped with an auto-start feature. It will not

supply current to the battery clips until a battery is properly connected.

Meaning, the clips will not spark if touched together.

Charging

Ensure that all of the charger components are in place and in 1.

good working condition, for example, the plastic boots on the

battery clips.

Connect the battery following the connection instructions 2.

described in Using the Quick-Disconnect Cable

Connectors section.

• 11 •

Set the Amp/Volt Selector switch to the proper setting for the 3.

battery being charged.

Connect the AC power following the precautions listed in 4.

section 8.

If you’ve connected everything correctly, the CHARGING 5.

(yellow) LED should be lit indicating that the charger is

charging. If the CHARGING (yellow) LED does not light or if

the CHECK BATTERY (red) LED is lit, check the connections

or have the battery checked/replaced.

USING THE QUICK-DISCONNECT CABLE CONNECTORS

Connect any of the three output cable assemblies to the charger in

seconds. Make sure to place the charger on a dry, non-

ammable surface.

NOTE: Never connect the clamp and ring terminal connectors

together for use in other applications, such as external battery or

other power source charging, or to extend the output cable length, as

reverse polarity and/or overcharge conditions will occur.

50 AMP BATTERY CLIPS

Connect the end of the charger output cable to the end of the 1.

50 Amp Battery clips cable.

Follow the steps in sections 6 and 7 to connect the output 2.

clips to the battery.

After a good electrical connection is made to the battery, plug 3.

the power cord into a 120V AC electrical wall outlet. Make

sure to place the charger on a dry, non-ammable surface.

PERMANENT RING CONNECTORS

The ring connectors permanently attach to the battery providing easy

access to quickly charge your battery. This application is appropriate

for motorcycles, lawn tractors, ATVs and snowmobiles.

To permanently attach to a battery, loosen and remove each 1.

nut from the bolt at the battery terminal.

Connect the red POSITIVE connector ring to the POSITIVE 2.

battery terminal.

Connect the black NEGATIVE connector ring to the 3.

NEGATIVE battery terminal.

Replace and tighten the nuts to secure. 4.

• 12 •

Connect the cable to the end of the charger output cord. 5.

Take care to keep the wires and plug away from metal and

moving parts.

Plug the charger power cord into a 120V AC electrical 6.

wall outlet. Make sure to place the charger on a dry,

non-ammable surface.

12V ACCESSORY PLUG

Charge or maintain your battery without lifting the hood.

Connect the end of the 12V Accessory Plug Cable Quick-1.

Connect to the charger.

Insert the 12V accessory plug into the 12V accessory outlet.2.

Route the power cord from the charger through the vehicle’s 3.

open window.

Plug the charger power cord into a 120V AC electrical 4.

wall outlet. Make sure to place the charger on a dry, non-

ammable surface.

If the vehicle’s ignition key has to be on in order for the 5.

accessory outlet to supply/receive power, turn the key on.

Battery Connection Indicator

If the charger does not detect a properly connected battery, the

CHECK BATTERY (red) LED will light continuously until such

a battery is detected. Charging will not begin while the CHECK

BATTERY (red) LED is on. When charging begins, the CHARGING

(yellow) LED will be lit.

Completion of Charge

Charge completion is indicated by the CHARGED (green) LED. When

lit, the charger has stopped charging and switched to the Maintain

Mode of operation.

Maintain Mode (Float-Mode Monitoring)

When the CHARGED (green) LED is lit, the charger has started

Maintain Mode. In this mode, the charger keeps the battery

fully charged.

NOTE: If the charger has to provide its maximum maintain current for

a continuous 12 hour period, it will go into Abort Mode (see Aborted

Charge section). This is usually caused by a drain on the battery or

• 13 •

the battery could be bad. Make sure there are no loads on the battery.

If there are, remove them. If there are none, have the battery checked

or replaced.

Maintaining a Battery

The 71219 is a battery maintainer that maintains both 6 and 12 volt

batteries, keeping them at full charge. It can charge small batteries

and maintain both small and large batteries. If you are maintaining

a fully charged large battery, you will be properly utilizing the battery

charger. However, if you were to use this battery charger to charge a

large battery, such as a marine deep cycle battery, that was not fully

charged, you may lose some of the battery’s capacity. This would

cause the large battery to be unable to hold a charge and become

useless. Therefore, we do not recommend charging a large battery

with this unit.

NOTE: The maintain mode technology utilized in DieHard’s chargers

allows you to safely charge and maintain a healthy battery for

extended periods of time. However, problems with the battery,

electrical problems in the vehicle, improper connections or other

unanticipated conditions could cause excessive current draws. As

such, occasionally monitoring your battery and the charging process

is recommended.

Desulfation Mode

If the battery is left discharged for an extended period of time, it could

become sulfated and not accept a normal charge. If the charger

detects a sulfated battery, the charger will switch to a special mode of

operation designed for such batteries. If successful, normal charging

will resume after the battery is desulfated. Desulfation could take up

to 8 hours. If desulfation fails, charging will abort and the CHARGING

(yellow) LED will blink.

Aborted Charge

If charging can not be completed normally, charging will abort. When

charging aborts, the charger’s output is shut off and the CHECK

BATTERY (red) LED will blink. To reset after an aborted charge, unplug

the charger from the outlet, wait a few moments and plug it back in.

BATTERY PERCENT AND CHARGE TIMES12.

This charger adjusts the charging current in order to charge the

battery completely, efciently and safely.

This battery charger has a rated output of 2 and 4 amperes.

• 14 •

Charging Times12.1

Battery Condition

2 Amp, 12 Volt Battery 50% Discharged 100% Discharged

Ampere Hour Battery

Capacity

Approximate Average Charge Time in

Hours

10 3.2 6.2

12 4.0 7.5

20 6.4 12.4

Battery Condition

4 Amp, 6 Volt Battery 50% Discharged 100% Discharged

Ampere Hour Battery

Capacity

Approximate Average Charge Time in

Hours

10 1.6 3.2

12 2.0 4.0

20 3.2 6.4

MAINTENANCE INSTRUCTIONS13.

After use and before performing maintenance, unplug and 13.1

disconnect the battery charger (see sections 6, 7 and 8).

Use a dry cloth to wipe all battery corrosion and other dirt or oil 13.2

from the terminals, cords, and the charger case.

Ensure that all of the charger components are in place and in good 13.3

working condition, including the plastic boots on the battery clips.

Servicing does not require opening the unit, as there are no 13.4

user-serviceable parts.

All other servicing should be performed by qualied service 13.5

personnel.

• 15 •

MOVING AND STORAGE INSTRUCTIONS14.

Store the charger unplugged, in an upright condition. The AC cord 14.1

will still conduct electricity until it is unplugged from the outlet.

Store inside, in a dry, cool place.14.2

Do not store the clips on or around metal, clipped together or 14.3

clipped to cables.

If the charger is moved around the shop or transported to 14.4

another location, take care to avoid/prevent damage to the

cords, clips and charger. Failure to do so could result in personal

injury or property damage.

TROUBLESHOOTING15.

PROBLEM POSSIBLE CAUSE REASON/SOLUTION

Charger will

not turn on

when properly

connected, and

no LEDs are lit.

AC outlet is dead.

Poor electrical

connection.

Check for an open

fuse or circuit breaker

supplying the AC outlet.

Check the power cord

and extension cord for a

loose tting plug.

CHECK

BATTERY (red)

LED is lit.

Reverse connections at

battery.

Battery voltage is too low.

Battery is not properly

connected to the

charger.

Unplug the charger

and correct the lead

connections.

This charger has an

automatic start feature.

If the battery voltage

is under 0.2 Volts, the

charger will not detect

it and will not start the

charging process. Have

the battery checked/

replaced.

Make sure the

connections from the

battery connector cable

to the battery and to the

charger are tight.

• 16 •

PROBLEM POSSIBLE CAUSE REASON/SOLUTION

CHECK

BATTERY (red)

LED is blinking

Charger is in abort

mode.

See “Aborted Charge”

in the OPERATING

INSTRUCTIONS

Section.

Battery clips

do not spark

when touched

together.

The charger is equipped

with an auto-start feature.

It will not supply current

to the battery clips until

a battery is properly

connected. Meaning,

the clips will not spark if

touched together.

No problem; this is a

normal condition.

BEFORE RETURNING FOR REPAIRS16.

When a charging problem arises, make certain that the battery 16.1

is capable of accepting a normal charge. Double check all

connections, the AC outlet for a full 120 volts, the charger clips

for correct polarity and the quality of the connections from the

cables to the clips and from the clips to the battery system. The

clips must be clean.

When an UNKNOWN OPERATING PROBLEM arises, please 16.2

read the complete manual and call the customer service number

for information that will usually eliminate the need for return.

If the above solutions do not eliminate the problem or

for information about troubleshooting or replacement parts,

call toll-free from anywhere in the U.S.A.

1-800-732-7764

7:00 am to 5:00 pm Central Time Monday through Friday