Diehard 20071224 User Manual BATTERY CHARGER Manuals And Guides L0303006

DIEHARD Battery charger Manual L0303006 DIEHARD Battery charger Owner's Manual, DIEHARD Battery charger installation guides

200.71224 L0303006

User Manual: Diehard 20071224 20071224 DIEHARD BATTERY CHARGER - Manuals and Guides View the owners manual for your DIEHARD BATTERY CHARGER #20071224. Home:Automotive Parts:Diehard Parts:Diehard BATTERY CHARGER Manual

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Page Count: 16

OWNER'S MANUAL

DieHard,.

Battery Charger

1512Amp

Fully Automatic

Microprocessor Controlled

Engine Starter

100 Amp

Model No.

200.71224

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.

0099000303-602

WARRANTY .............................................................................................................. 2

IMPORTANT SAFETY INSTRUCTIONS .................................................................. 3

PERSONAL SAFETY PRECAUTIONS .................................................................... 4

BEFORE USING YOUR BATTERY CHARGER ....................................................... 5

Assembling your charger ................................................................................... 5

Plugging it in ....................................................................................................... 5

Using an extension cord ..................................................................................... 5

PREPARING YOUR BATTERY TO BE CHARGED ................................................. 6

CHARGING TIPS ...................................................................................................... 6

USING YOUR BATTERY CHARGER ....................................................................... 7

CONTROL PANEL .................................................................................................... 9

CHARGING YOUR BATTERY ._.............................................................................. 10

Inside vehicle .................................................................................................... 10

Outside vehicle ................................................................................................. 11

Using Engine Start ............................................................................................ 11

ESTIMATING CHARGE TIME ................................................................................ 12

MAINTENANCE AND CARE .................................................................................. 13

TROUBLESHOOTING ............................................................................................ 14

PARTS ..................................................................................................................... 15

WIRING DIAGRAM ................................................................................................. 16

Please read this Owner's Manual before using your Battery Charger

The DieHard model 71224, Fully Automatic Battery Charger/Engine Starter, offers

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 CT Monday through Friday.

1-800-SEARS-64 (1-800-732-7764).

FULL THREE YEAR WARRANTY

If, within three years from the date of purchase this battery charger fails due to a

defect in material or workmanship, simply return the charger to the place of purchase

and it will be replaced 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

WARNING:To reducethe 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, air-

planes, vans, RV's, trolling motors,

etc. This charger is not intended to

supply power to a low voltage

electrical system.

• Use only attachments recommended

or sold by Sears. The use of attach-

ments not recommended by Sears

may result in fire, electric shock, or

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.

• Battery chargers get hot during

operation and must have proper

ventilation. Air needs to flow around

entire charger.

• Do not set charger on flammable

materials like carpeting, upholstery,

paper, cardboard, etc. Charger may

damage leather and melt plastic and

rubber.

HELP US HELP YOU --

Remembe_

•Place charger as far away from the

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 like radios,

stereos, remote controls, etc. These

batteries may burst and cause

personal injury.

•Never touch the battery clamps

together when the charger is on. You

could cause a spark.

• 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.

For your own personalsafety,pleasefollowthe followingprecautions:

• 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.

Abattery can produce ashort circuit

current high enough to weld aring (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.

It is important to understand your charger's requirements. This section will tell you

about your charger's electrical requirements and how to prepare a battery for

charging.

ASSEMBLING YOUR CHARGER

Included with your battery charger are two

cord wrap cleats for storage of the clamp

cables.

To install, align the three tabs to corre-

spond with the three receptacles and push

until you hear a snap.

Wrap clamp cord after unplugging the

power cord and store your charger in a

dry location.

PLUGGING IT IN

Your charger requires a 120V AC

receptacle installed according to all

local codes and ordinances.

[_) ('-Cord Wrap Cleat

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 that the pins on charger's

power cord fit firmly into the extension

cord, and that the extension cord fits

firmly into the receptacle.

• 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

chart below.

......... !ii!i!!i iii ....... ii ¸ ! iiiiiil

Length of Cord, inFeet 25 50 100 150

AWG* Size of Cord 18 16 12 10

*AWG-AmericanWireGauge

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.

• For batteries with removable vent

caps, if required, add distilled water to

each cell until the battery acid

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 with non-removable

vent caps, no action is necessary.

• Take time to read all battery

manufacturer's specific precautions,

such as removing or not removing

vent 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 it is necessary to remove the battery

from the vehicle to charge it, always

remove the grounded terminal from

the battery first. Turn off all vehicle

accessories to avoid sparks from

occurring.

NOTE: A marine battery installed in a

boat must be removed and charged on

shore.

Read the following pages before using your charger. The tips below serve only as a

guide for specific situations.

If your vehicle won't start: You don't

need to fully charge a battery to start

your vehicle. If the charger won't start

your vehicle using the 100 Amp Start

rate, try charging the battery using the

15 Amp rate for 10 or 15 minutes. That

should charge the battery enough to

allow the 100A Start rate to start the

vehicle. If the vehicle will then be

operated continuously for an extended

period (such as a long drive), the

vehicle could charge the battery back to

normal during that pedod. If the vehicle

will only be operated for a short period

(short drive), the battery might need to

be charged again before it could start

the vehicle.

Reviving your battery: If you only

wish to charge your battery enough to

operate your vehicle, you dQn't need to

wait for the entire charging process to

be completed. When the charger

displays three Battery Status LEDs (see

pages 8, 9, and 12), the battery has

been charged as much as by most

chargers. The vehicle should then start

and operate normally.

Completing an interrupted charge: If

the charging process has been inter-

rupted and restarted after three Battery

Status LEDs were lit, the charger will

go straight to Maintain Mode (see

pages 7 & 9). However, if the original

charge was started using 15 Amps, the

charge can often be completed using 2

Amps.

For bestresultsfromyour batterycharger,learnto use it properly.This sectiontellshow

to set the controlsand how to charge a battery in and out of a vehicle.

TOUCH PAD

BUTTONS

2 AMP

CHARGE RATE

BATTERY TYPE

BAlrlrERY STATUS

I--] I--I1--11--1

CHECK CHARGED

LEDs

2 Amp charge rate: Intended for

charging of small batteries such as

those commonly used in garden

tractors, snowmobiles and motorcycles.

It is not to be used as a trickle charger

for larger batteries.

15 Amp charge rate: Use for charging

automotive batteries, marine starter

batteries and deep cycle batteries. Not

intended for industrial applications and

very large batteries where 20 amp and

greater charge rates are required.

100 Amp engine start: Provides 100

amps for cranking an engine with a

weak or run down battery. Always use in

combination with abattery.

Charging: Both the 2 and 15 amp

charge rates perform an automatic

charge function. Dudng the first few

seconds of operation, an analytical

check of the battery is performed. If the

charger does not detect a properly

connected battery, the red "check" LED

will light continuously until such a "

battery is detected. If a battery will not

accept a normal charge, the charger

will switch to a special mode of

operation designed for such batteries.

Indication of this special mode is the

flashing of the first amber LED in the

charge status display. If successful,

normal charging will resume. If not, a

red LED will blink indicating that

charging has been aborted. When the

amber LED is on but not flashing,

normal charging is in progress. Charge

completion is indicated by a green

LED; at this point the charger has

switched to the Maintain Mode of

operation.

Maintain Mode: When the green LED is

lit, the charger has started Maintain

Mode. This mode of operation is also

known as Float-Mode Monitoring. In this

mode, the charger keeps the battery

fully charged by delivering a small

current, when necessary.

Battery types: The charger offers a se-

lection of three different types of batteries:

• Type 1 most Low-Maintenance, AGM

and Gel Cell batteries;

Type 2Deep Cycle and Maintenance-

Free batteries;

• Type 3 Deep cycle batteries with a

built-in 'eye-type' charge indicator.

With the exception of AGM and gel cell

batteries, all other battery types may or

may not have vent caps. Vent caps are

located on top of the battery and provide

a means to add distilled water when

needed. Batteries should be marked

with their type. If charging a battery that

is not marked, check the manual of the

item that uses the battery. If the battery

type is unknown, use the Type 1

position. Make sure the battery complies

with the safety instructions on page 3.

Engine cranking: When the 100A

Start rate is selected, the charger waits

until the engine is actually being

cranked before delivering 100 amps for

engine start. Note: The charger

delivers a charge of 3 to 7 amps while

waiting for the engine to be cranked and

will reset if the engine is not cranked

within 15 minutes. Cranking is allowed

for up to 3 seconds, then the charger

shuts down for a 4 minute cool down

period. During the cool down period the

Start LED will blink. After 4 minutes, the

Start LED will light continuously,

indicating that another crank cycle can

be performed.

Battery Status LEDs: The status of the

battery is indicated by arow of six

LED's. The first LED is red; it will light

under the following conditions:

1. The charger is not connected to a bat-

tery. Red LED lights continuously.

2. The charger is reverse-connected to a

battery. Red LED lights continuously.

3. The charge cycle was not completed

within 24 hours. Red LED blinks.

4. The battery could not be charged in a

normal manner. This could be due to a

battery with a partially shorted or open

cell, sulfated battery plates or electro-

lyte out of balance. Red LED blinks.

The next four LED's are amber. First,

only the leftmost amber LED will light.

Then two, then three, and eventually all

four amber LED's will light. Refer to

"Estimating Charge Time" on page 12

for more information.

The sixth LED is green and lights to indi-

cate that charging is complete. When the

green LED lights, the amber LED's will turn

off and the charger starts Maintain Mode.

See the Control Panel table on the next

page.

Setup and Operating: Follow all safety

and connecting procedures in this

manual. Located above each button on

the control pad is an amber LED that

lights to indicate that the selection is

active.

When first plugged in, the charger will

automatically default to the 2 AMP /

TYPE 1 position. You may then select

the charge rate and battery type. For

example, if you're charging a large 12-

volt deep cycle battery, press the

buttons labeled 15 AMP and TYPE 2.

Note: If you press a charge rate or

battery type button after charging has

started, the charger will restart the

charging process. Refer to "Estimating

Charge Time" on page 12 for more

information.

When selecting the Start position, you

do not have to select a battery type. All

indicator lights will turn off except for the

light above the Start button. The red

LED will also light if a properly con-

nected battery has not been detected.

¢.D

MODEL 71224

X indicates panel lights that continuously glow.

B indicates panel lights that blink on and off.

Initial power up

Battery REVERSED or NOT connected

Normal battery detected, charge started

Sulfated battery detected, charge started

Charging 0% to 25% completed

Charging 20% to 50% completed

Charging 35% to 90% completed

Charging 75% to 100% completed

Charge complete, Maintain Mode started

Engine Start, cranking or ready to crank

Engine Start, 4minute rest period

Charge aborted

I D CH4nr_'_eou_'ruD

user selected

CHECK

BATrERv STATUS

DDDDDI'-]

-- CHARGED

user selected

X X

XXX

X X X X

IMPORTANT: Follow all safety instruc-

tions and precautions when charging

your battery. Wear complete eye

protection and clothing protection.

Charge your battery in a well-ventilated

area.

Charging your battery in the vehicle:

1. Avoid personal injury by keeping

clear of fan blades, belts, pulleys and

other engine parts.

2. Avoid damaging the charger by

keeping the power cord and output

cords away from the hood, door or

moving engine parts.

3. Note the polarity of the battery posts

by checking the identification marks

on the battery: POSITIVE (POS, P or

+) and NEGATIVE (NEG, N or -). The

positive post is usually larger than

the negative post.

4. Identify which battery post is

grounded or connected to the

chassis. THIS IS NORMALLY THE

NEGATIVE POST.

NEGATIVE GROUNDED SYSTEM

5. Connecting to a negative-

grounded system: Connect the red

(POSITIVE) output clamp to the

POSITIVE post of the battery. Rock

and twist the clamp back and forth to

be sure asolid electrical connection

is made. Then connect the black

(NEGATIVE) output clamp to a

heavy, unpainted metal part of the

chassis or engine block, away from

the battery (see figure above). DO

NOT connect clamp to negative

battery post, carburetor, fuel line or

sheet metal part.

Connecting to a positive-grounded

system: Connect the black (NEGA-

TIVE) output clamp to the NEGA-

TIVE post of the battery. Rock and

twist the clamp back and forth to be

sure asolid electrical connection is

made. Then connect the red (POSI-

TIVE) output clamp to a heavy,

unpainted metal part of the chassis

or engine block, away from the

battery. DO NOT connect clamp to

positive battery post, carburetor, fuel

line or sheet metal part.

Plug power cord into an AC outlet.

The charger will set to the default

state of 2 AMP charge rate and Type

1 for battery type.

Press the appropriate control buttons

to select the desired charge rate and

battery type. Within a few- seconds,

the red LED should go out and the

charging process should start. If the

red LED does not go out, check for

correct cable connection.

To disconnect the charger, unplug

the charger power cord before

attempting to disconnect the output

clamps. Then, standing away from

the battery, remove the output clamp

from the chassis or engine block.

Finally, remove the output clamp

from the battery post.

Clean and store the charger in a dry

location.

Charging your battery removed from

the vehicle:

PosrrlvE NEGATIVE

'CHARGER

POWER

CORD

24",6 GAUGE

CABLE

GROUNDED

POWER

OUTLET

1. Note the polarity of the battery posts

by checking the identification marks

on the battery: POSITIVE (POS, P or

+) and NEGATIVE (NEG, N or -). The

positive post is usually larger than

the negative post.

2. Attach at least a 24-inch-long 6-

gauge (AWG) insulated battery cable

to NEGATIVE (NEG, N or-) battery

post. Rock and twist the clamp back

and forth to be sure a solid electrical

connection is made.

3. Connect the red (POSITIVE) output

clamp to the POSITIVE battery post.

Rock and twist the clamp back and

forth to be sure a solid electrical

connection is made.

4. Position yourself as far away from

the battery as possible, and then

connect the black (NEGATIVE)

output clamp to the free end of the

cable.

5. Plug the power cord into an AC

outlet. The charger will set to the

default state of 2AMP charge rate

and Type 1 for battery type.

6. Press the appropriate control buttons

to select the desired charge rate and

battery type. Within a few seconds,

the red LED should go out and the

charging process should start. If the

red LED does not go out, check for

correct cable connection.

To disconnect the charger, unplug

the charger power cord before

attempting to disconnect the charger

clamps. Then, standing away from

the battery, remove the output clamp

from the NEGATIVE battery post.

Finally, remove the output clamp

from the POSITIVE battery post.

Clean and store the charger in a dry

location.

USING ENGINE START

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.

IMPORTANT: Follow all safety instruc-

tions and precautions when charging

your battery. Wear complete eye

protection and clothing protection.

Charge your battery in a well-ventilated

area.

IMPORTANT: Using the ENGINE

START feature WITHOUT a battery

installed in the vehicle could cause

damage to the vehicle's electrical

system.

1. With the charger plugged in and

connected to the battery of the

vehicle, press the 100 AMP touch

pad. Only the 100 AMP indicator

lamp should be lit.

Crank the engine for no more than 3

seconds. If engine does not start, let

rest for 4 minutes before cranking

again.

After the engine starts, unplug the

power cord before disconnecting the

output clamps from the battery.

Clean and store the charger in a dry

location.

This charger adjusts the charging time in order to charge the battery completely,

efficiently, and safely. The microprocessor automatically makes all necessary

calculations. However, this section includes guidelines that can be used to estimate

charging time.

The duration of the charging process

depends on each of three factors.

1. Battery state: A battery that has only

been slightly discharged could be

charged in only a few hours. How-

ever, the same battery could take 24

hours to charge if it is very weak.

Battery state can be estimated by

using a voltmeter to measure the

battery voltage or by using a State-

of-Charge Tester. The lower the

reading, the longer the charging

process will take.

2. Battery rating: A higher rated battery

will take much longer to charge than

a lower rated battery under the same

conditions. A battery's rating may be

indicated in Ampere hours (Ah),

Reserve Capacity (RC), or Cold

Cranking Amps (CCA). The lower the

rating, the quicker the charging will

be completed. For example, a very

small battery might be rated for 6 Ah

and charge in 4 hours, but a very

large battery might be rated for 100

Ah and require 24 hours to charge

completely.

3. Charge rate: The charge rate is

measured in amps. This charger

provides charge rates of 2 Amps and

15 Amps. Note: the 100 Amp rate is

intended for Engine Start only, NOT

continuous charging. A higher

charge rate results in a faster charge.

Note: The 2 Amp rate might be, too

low to charge a higher rated battery

within the 24 hour time limit the

charger allows. However, some

smaller batteries, such as motor-

cycle and tractor batteries, have a

maximum recommended charge rate

much less than 15 Amps. Such

batteries should be charged using

the 2 Amp setting.

This charger starts charging at the

selected rate (2 or 15 Amps) and

eventually reduces the charge rate in a

precisely controlled manner. After the

charging process has started, the

Battery Status LEDs can be used to

estimate the charge time as explained

below.

•Fled LED: Checking for properly

connected battery, not charging (no

output).

•1 Amber LED: Battery detected,

charging started, 3 to 10 seconds

from start.

2 Amber LED$: Charging roughly

20% to 25% complete, 1 to 5 hours

from start.

•3 Amber LEDs: Charging roughly

35% to 50% complete, 3to 7 hours

from start. Battery charged enough

for use in vehicle. Note: If charging is

restarted after this point, the charger

may go straight to Maintain Mode

(Green LED).

•4 Amber LEDs: One or two hours

left, battery virtually "good as new", 4

to 13 hours from start.

Green LED: Charge complete,

battery at maximum charge state, 5to

14 hours from start.

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 corro-

sion.

Performance problems often can be corrected by the user. Please read through this

chart for a possible solutions to common problems.

PROBLEM POSSIBLE CAUSE SOLUTION

Indicator lights are lit in The charger may be Return to place of

an errat c manner not defective, purchase for a

]explained in the "Using replacement.

Your Battery Charger"

section.

The red abort light always

flashes before the battery

is charged.

Engine crank time is less

than specified.

The green full charge light

turns on a few minutes

after connecting to the

battery.

This will happen if the

battery did not reach full

charge within 24 hours.

May be due to a very large

battery or a bank of

batteries requiring more

than what a 15 Amp

charger can deliver within

24 hours. The battery may

also be bad.

Starter motor may be

drawing more than 100

Amps.

The battery may be fully

charged or recently

charged leaving the

battery voltage high

enough to make the

charger think the battery

is fully charged.

Reset the charger by

unplugging it or briefly

disconnecting the negative

battery clip. Select the

desired charge rate and

battery type again, if

necessary,

Charge the battery at the

15 Amp rate for 10 to 15

minutes then crank the

engine.

If the battery is in a vehicle

turn the headlights on for a

few minutes to reduce the

battery voltage and try

charging again:

For information about troubleshooting, call toll-free from anywhere in the

U.S.A. 7 am to 4:30 pm CT Monday through Friday.

1-800-SEARS-64 (1-800-732-7764).

This section shows an illustration of your battery charger. Use it to become

familiar with part locations and appearance.

Item Description

1, Transformer

2, SCR ControlModule

3. Screw 8-18 xl/2"(4)

4. Touch Pad Control Board

5. Circuit Breaker

6. Output Cables

Part Number

93026557

2299001160

5199000274

2299001191

3999000104

2299001205

Item Description

7. AC Power Cord

8. Handle

9. Faceplate

10. CordCleat

Owner'sManual

Part Number

90026135

3599000270

0899001570

1199004390

0099000303

For information about troubleshooting, call toll-free from anywhere in the

U.S.A. 7 am to 4:30 pm CT Monday through Friday.

1-800-SEAFIS-64 (1-800-732-7764).

Diehard 20071224 User Manual BATTERY CHARGER Manuals And Guides L0303006

DIEHARD Battery charger Manual L0303006 DIEHARD Battery charger Owner's Manual, DIEHARD Battery charger installation guides

200.71224 L0303006

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