Diehard 20071315 User Manual BATTERY CHARGER Manuals And Guides L0305327
DIEHARD Battery charger Manual L0305327 DIEHARD Battery charger Owner's Manual, DIEHARD Battery charger installation guides
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Die Hard
OWNER'S
MANUAL
Model No.
200.71315
CAUTION:
Read and Follow AH Safety
Rules and Operating Instructions
Before Every Use ofthis Product.
15/2/125 AMP
FULLY AUTOMATIC
BATTERY CHARGER
ENGINE STARTER
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Table Of Contents
Warranty .................................................................. 1
Important Safety Instructions .................................. 2
Parts ......................................................................... 3
Before Using Your Battery Charger ........................ 4
Plugging it in .......................................................... 4
Using an extension cord ........................................ 4
Preparing your battery to be charged .................... 4
Using Your Battery Charger .................................... 5
Setting the controls ................................................ 5
Charging your battery ............................................ 7
Calculating charge time ......................................... 9
Using the engine start feature ............................. 10
Maintenance and care ......................................... 10
Troubleshooting ..................................................... 11
Please read this Owner's Manual before using your Battery Charger
The Sears model 200.71315, Fully Automatic 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.
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 work-
manship, 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.
Seam, Roebuck and Co., Dept 817WA,
Hoffman Estates, IL 60179
Important Safety Instructions
- SAVE THESE INSTRUCTIONS -
•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, trac-
tors, airplanes, vans, RV's, trolling motors, etc.
This charger is not intended to supply power to
alow voltage electrical system other than in an
automotive application.
•Use only attachments recommended or sold by
manufacturer. The use of attachments not recom-
mended by the manufacturer 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.
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.
•Never touch the battery clamps together when the
charger is energized.
•Never operate charger if it has received ahard 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 follow-
ing 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 cloth-
ing. 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 ashort 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.
Parts
This section shows an illustrationof your battery charger. Use it to become familiar with where all the parts are
located, and what they look like.
Item DescrlpUon Pert Number
1 CaseCover 3799001420
2Heatsinkassembly 2299000851S
3CaseBottom 3799001410
4 ACUnecord 90026086
5 Transformer 93026405
OutputCordsetBlack 3899000398
7OutputCordRed 3899000394
8 CircuitBreaker(2req) 3999000086
9 Meter 5399100094
10 Switch(Left) 0499000000
11 Swtich(Center) 0499000062
12 Switch(Right) 0499060061
13 Faceplate 0899000536
14 HandJe 3599000270
15 SCRModule 2299000852
16 Owner'sManeal 0000000514
Wiring diagram
9
12
f
Before Using Your Battery Charger
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.
Plugging it in
Your charger requires a 120V receptacle installed
according to all local codes and ordinances.
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 accompanying chart.
Length of Cord, in Feet 25 50 100 150
AWG* Size of Cord 18 18 16 14
*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 or 6 volt lead-acid
battery. Set the selector switch to match the voltage
rating of the battery to be charged.
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 recommended by the
manufacturer. This will help purge excessive gases
from the cells. Be careful not to overfill. If you have
asealed 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 ff all accessories in the vehicle are not
completely turned off.
NOTE: A marine battery installed in a boat must be
removed and charged on shore.
Using Your Battery Charger
For best results from your battery charger, learn to use it properly. This section will tell you how to set the con-
trols, how to charge a battery in or out of a vehicle, and how to use the ENGINE START features.
Setting the Controls
All controls are located on the front of the charger.
Follow these instructions to obtain the correct charge
level for your battery.
SELECTOR SWITCHES:
Your charger has three switches:
•Use the left switch to match the battery voltage--
either 6or 12 volt.
•Use the center switch to select a charge type_
MANUAL, AUTOMATIC DEEP CYCLE or AUTO-
MATIC REGULAR.
•Use the right switch to select acharge rate_2 AMP
charge, 15 AMP charge, or 125 AMP ENGINE
START feature.
Battery Voltage:
Select the voltage of your battery. The most common
applications will be 12 volt.
Charge Type:
•Use the MANUAL setting only if you check the
charging progress frequently. The charger will not
stop charging when the battery reaches full charge,
possibly damaging the battery if left on too long.
You must monitor and unplug the charger when
battery is fully charged.
•Use the AUTOMATIC DEEP-CYCLE setting for all
deep-cycle battery charging. The charger will
automatically stop charging when the battery
reaches full charge.
•Use the AUTOMATIC REGULAR setting for all but
deep-cycle batteries and for a sevedy discharged
battery. The charger will automatically stop charg-
ing when the battery reaches full charge.
• A severely discharged battery may not have enough
charge to start the control circuit in an AUTOMATIC
setting. In this case, charge on MANUAL until the
battery has enough charge to accept an
AUTOMATIC setting.
Charge Rate:
° Use the 2 AMP charge rate setting for charging
small batteries and warming large batteries.The
lower the charge rate, the longer it will take to
charge the battery.
• Use the 15 AMP rate setting for automotive, deep
cycle and other large batteries.
•Use the 125 AMP ENGINE START setting only to
assist in cranking the engine.
6 VOLT 12VOLT
II
MANUAL AUTOMATIC
DEEP
CYCLE
II
2 AMP 15AMP
II
AUTOMATIC
REGULAR
ENGINE
START
5
AMMETER:
Theammeter indicates the measured amount of
amperes being drawn by the battery. When you first
start charging abattery, the reading will be high, with
the needle near 15 using the 15 amp charging rate.
In the MANUAL setting, as the battery charges, the
needle will fall to about 7 or 8amps, indicating a
charged battery.
In either AUTOMATIC setting, the needle will fall to
zero and the charger will shut off when the
charger's control circuit senses a full charge. A
freshly charged battery's voltage will drop shortly
after charging, and the charger, if left connected,
may resume charging. This off-and-on cycling will
continue until the battery's voltage no longer drops
enough to restart the charger.
•At the 2 amp charging 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.
LED INDICATORS:
Two LED INDICATORS provide information on the state
of charge by glowing steadily or blinking at different
intervals.
GREEN, FAST BLINK:
When the charger is charging a battery, the green LED
INDICATOR will blink rapidly approximately 4 times per
second.
GREEN, STEADY:
In AUTOMATIC, the green LED INDICATOR will glow
and the meter needle will be at zero, when the charger
has completed the charging cycle.
In MANUAL mode, YOU MUST monitor the charging
and stop the charging when the meter indicates about
half the selected rate, 2or 15 amps. The charger has a
safety timer designed into the control, stopping the
charge upon reaching amaximum permitted time.
See chart to right.
GREEN, SLOW BLINK:
The charger will be in the MAINTAIN mode when the
slow blinking green LED INDICATOR is operating. This
occurs only in the AUTOMATIC charging positions after
the end of the AUTOMATIC charging cycle, approxi-
mately 2 times per second.
RED, STEADY:
When the red LED INDICATOR glows steadily, it means
that the charger has not sensed abattery. The leads
may be reversed on the battery posts or one or both
connections may not be making a solid contact. Check
your connections.
DC AMPS
0 5 10 15
• • • •
•FULL CHECK •
CHARGE BATI'ERY
Rate,._,_ :,_M_mdm:Tlme,
2A 20 HRS.
15A 16 HRS.
RED, SLOW BLINK:
If, after a pre-set number of hours, the charger fails to
fully charge abattery, it will give up and the red LED
INDICATOR will blink slowly to tell you that something
is wrong with the battery, approximately 2 times per
second.
RED, FAST BLINK:
A rapid blinking red LED INDICATOR informs you that
the charger cannot operate with your control setting.
For example the controls are set on 12V.
AUTOMATIC REGULAR, and ENGINE START. The
ENGINE START feature will operate only in the
MANUAL mode--the red LED INDICATOR will blink
rapidly, approximately 4 times per second.
6
Charging Your Battery
Charging a battery in the vehicle:
1. Arrange the power cord and charging leads carefully
to avoid damage that could be caused by the hood,
door, or moving engine parts.
2. Keep clear of fan blades, belts, pulleys, and other
parts that can cause injury.
3. Check the polarity of the battery posts as indicated
on the battery case: POSITIVE (POS, P, or +) and
NEGATIVE (NEG. N or -). NOTE: The positive post
on top-post batteries is usually larger than the
negative post.
4. Identify which battery post is ground or connected to
the chassis. THE NEGATIVE POST IS
NORMALLY THE ONE THAT IS GROUNDED.
5. To charge a negative grounded post system:
Connect the red (POSITIVE) battery charger clamp
to the ungrounded POSITIVE (POS, P, +) post of
the battery. Then connect the black (NEGATIVE)
clamp to a heavy, unpainted metal part of the
chassis or engine block, away from the battery. 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. For automatic charging, select AUTOMATIC DEEP
CYCLE or AUTOMATIC REGULAR as a charge type
then select a charge rate. The charger will stop
charging when the battery is fully charged.
8. For manual charging, select MANUAL as a charge
type then select a charge rate. The charger will not
stop charging when the battery is fully charged--you
must monitor and unplug charger when battery is
fully charged. Avoid overcharging, monitor the
AMMETER frequently when in the MANUAL mode.
9. Next plug the power cord into an AC outlet.
10. When the battery is fully charged, in the MANUAL
mode, the AMMETER pointer will fall to about half
the charge rate selected. For specific positions,
refer to the "Ammeter" section in "Using your battery
charger" on a page 6.
11. When the battery is fully charged, unplug the charger
power cord before attempting to disconnect charger
clamps.
12. Standing away from the battery, remove the charger
clamps In this order: (1) from the chassis
connection and, (2) from the battery post or terminal.
13. Clean and store the battery charger in a dry location.
\
NEGATIVE GROUNDED SYSTEM
7
Charging your battery outside the vehicle:
t. Remove the battery from vehicle, making sure to
disconnect grounded terminal first with all accessories
and lights turned off in the vehicle.
2. Check the polarity of the battery posts as indicated
on the battery case: POSITIVE (POS, P, +) and
NEGATIVE (NEG, N, -).
NOTE: On top-post batteries, the positive battery
terminal usually has a larger diameter post than the
negative one.
3. Connect the red (POSITIVE) charger clamp to the
POSITIVE post of the battery. Be sure to rock the
clip back and forth to make a solid connection.
4. Attach a 6-gauge (AWG) or a4-gauge (SAE)
insulated battery cable of at least 24-inches in
length to the NEGATIVE battery post. This cable
will provide a safer connection because arcing and
sparking will occur away from the battery. (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 of the charger
to the free end of the cable. Rock the clamp to
make a solid connection.
IMPORTANT: Wear safety glasses and face away
from the battery while making this final connection.
6. For automatic charging, select AUTOMATIC
REGULAR or AUTOMATIC DEEP CYCLE depending
on the type of battery, then select acharge rate.
The charger will quit when the battery is fully charged
and will restart if the battery voltage drops too low.
7. For manual charging, select MANUAL as a charge
type then select a charge rate. The charger will not
stop charging when the battery is fully charged --
you must monitor and unplug charger when battery
is fully charged. Avoid overcharging, monitor the
AMMETER frequently when in the Manual mode.
8. Next plug the power cord into an AC outlet.
9. When the battery is fully charged in the MANUAL
mode, the AMMETER pointer wUlfall to about half
the charge rate selected. For specific positions,
refer to the "Ammeter" section in "Using your battery
charger" on page 6.
10. When the battery is fully charged, unplug the
charger power cord before attempting to disconnect
charger clamps.
11. Stand away from the battery and remove remove
the charger leads from the NEGATIVE connections
first, then from the battery post or terminal.
12. Clean and store the charger in a dry location.
POSITWE
BATTERY
NEGA_VE
24",6 GAUGE
CABLE
BATTERYCHARGER
CORD
TO
POWER
OUTLET
Calculating charge time
The Chart Method
Use the following chart to estimate charge time when
charging in the MANUAL Mode. First, identity 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, or 12 to 32 AH etc.
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
RECOMMENED.
Find your battery's rating on the chart to the right and
note the charge time given for each charger setting.
The times given are for batteries with a 50-percent
charge prior to recharging. Add more time for severely
discharged batteries.
SMALL
BATI'ERIES
CAR/TRUCKS
Motorcycle, garden
tractor, etc.
200 - 315 CCA
315 - 550 CCA
550 - 1000 CCA
MARINE/DEEP CYCLE
6-12AH
12 -32 AH
40 - 60 RC
60 - 85 RC
85 -190 RC
80 RC
140 RC
180 RC
180 RC
2-4
4-10
11 -14
14-18
18-35
18
27
3O
33
NR
NR
11/2- 2
2 - 21/2
21/2- 41/2
21/2
31/2
4
41/2
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 below will help you convert hydrometer readings to
percent of charge values.
When you know the percent of charge and the Amp
Hour (AH) rating of your battery, you can calculate the
approximate time needed to bring your battery to afull
charge.
To convert Reserve Capacity to Amp Hours, divide
Reserve Capacity by 2, and add 16:
Amp Hours = Reserve Capacity + 16
2
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 15 amps).
•Multiply the result by 1.25 and you'll have the
approximate time needed, in hours, to bring the
battery to full charge.
Add one additional hour for a deep-cycle battery.
Example:
Amp Hour Rating x charge needed x1.25 =hours
Charger Setting of
charge
100 (AH Ratinq) x .50 (charqe needed) x1.25 = 4.163
15 (Charger Setting) hours
1_.5 = 3.33 x 1.25 = 4.163
15
You would need to charge your 100-Ampere Hour Battery
for alittle more than 4 hours at the 15-amp charge rate
in this example.
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. Connect the charger to the battery and vehicle as
instructed in the "Charging your battery" section on
page 7.
2. Set the right-hand SELECTOR SWITCH to ENGINE
START.
3. Crank the engine for no more than 5 seconds.
If it does not start, wait st least 4minutes before
cranking again. In extreme cold or if the battery is
severely discharged, charge the battery for about 5
minutes before cranking the engine.
I
4. After the engine starts, unplug the charger power
cord from the AC outlet. Then disconnect the
charger from the battery.
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.
Maintenance and care
Aminimal amount of care can keep your battery
charger working properly for years.
1. Clean the clamps each time you are finished
charging. Wipe off any battery fluid that may have
come in contact with the clamps to prevent
corrosion.
2. Coil the input and output cords neatly when storing
the charger. This will help prevent accidental
damage to the cords and charger.
3. Occasional cleaning of the case of the charger with
a soft cloth will keep the finish shiny and help
prevent corrosion.
10
Troubleshooting
Performance problems often result from little things that you can fix yourself. Please read through this char for a
3ossible solution if a problem occurs.
P0SSiBLE CAUSE
PROBLEM
No ammeter reading.
Circuit breaker in
charger cycles on and
off with a clicking
sound MANUAL
mode.
Ammeter reads less
than selected charge
rate when charging.
Charger makes a loud
buzz.
ShoR star cycle
when cranking
engine.
Clamps not making good
connection.
2-amp charge rate.
AC cord and/or extension
cord is loose.
No power at receptacle.
ShoRed battery clamps.
Shorted battery.
Charger leads reversed
on battery.
Extension cord too long or i
gauge to small.
Weak cell or sulfated
plate.
Battery is only partially
charged.
Transformer lamination
buzz.
Drawing more than 125
amps for 5 seconds or
less.
Failure to wait for 4 minute
(240) seconds) between
cranks.
The red LED should be glowing steadily. Check for poor
connection at battery. Make sure clamps and posts are clean.
Ammeter needle will show little or no activity at the 2-amp
charge rate.
Check power cord and extension cord for loose tilting plug.
Check for open fuse or circuit breaker supplying AC outlet.
Circuit breaker cycles when current draw is too high.
Check for shorted cables and replace if needed.
The red LED should be blinking slowly. Have a qualified
technician test the battery.
The red LED should be glowing steadily. Correct connec-
tions to battery.
Use shorter or heavier extension cord.
Sulfated battery will eventually take a normal charge if left
connected. If the battery will not take a charge, the red
LED should be blinking slowly. Have a Sears technician
test the battery.
Continue charging battery.
Continue charging buzz is not abnormal.
Crank time varies with the amount of current drawn from
the charger. If cranking draws more than 125 amps, crank
time may be less than 5 seconds.
Wait 4 minutes before next prank.
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
11
Notes
12
SE/AURS
OWNER'S
MANUAL
Model No.
200.71315
When requesting service or
ordering parts, always provide
the following information:
•Product Type
•Model Number
•Part Number
• Part Description
0000000514-995
15/2/125 AMP
FULLY AUTOMATIC
BATTERY CHARGER
ENGINE STARTER
Forinformationabouttroubleshooting
Calltoll-freefromanywhereintheU.S.A.
7 amto 4:30 pmCSTMondaythroughFriday
1-800-SEARS-64
(1-800-732-7764)
Forthe repairorreplacement
partsyouneed
Call7 am- 7 pro,7 daysa week
1-800-366-PART
(1-800-366-7278)
Forthe locationof a SearsRepair..._
ServiceCenterinyourarea
Call24 hoursa day,
7 daysaweek
1-800-488-1222
8EARS
America's Repair Specialists
