DIEHARD 200.71460 Battery Charger Tester Engine Starter User Manual

DIEHARD 200.71460 Battery Charger Tester Engine Starter User Manual

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.

Please read this Owner’s Manual before using your Battery Charger
The Sears model 200.71460, Manual Battery Charger/Tester/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.

Important Safety Instructions

SAVE THESE INSTRUCTIONS

WARNING
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 hared as the charger cables will permit.
• Do not expose charger to rain or snow.
• Never charge a frozen battery. If battery fluid (electrolyte) becomes frozen, bring battery into a warm area to thaw before you begin charging.
• Never allow battery acid to drip on charger when reading specific gravity or filling battery. • Never set a battery on top of the charger.
• Never place charger directly above battery being charged. The gases from the battery will corrode and damage the charger.
• Never use charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause personal injury.
• Never touch the battery clamps together when the charger is energized.
• Never operate charger if it has received a hard blow, been dropped, or otherwise damaged. Take it to a qualified professional for inspection and repair.
• Be sure to position the charger power cord to prevent it from being stepped on, tripped over, or damaged.
• Never pull out the plug by the cord when unplugging the charger. Pulling on the cord may cause damage to the cord or the plug.
• Do not operate the_charger if it has a damaged power cord or plug. Have the cord replaced.

Personal Safety Precautions

For your own personal safety, please follow the following precautions:

• Wear complete eye and clothing protection when working with lead-acid batteries.
• Be sure that someone is within range of your voice to come to your aid if needed while you work with or are near a lead-acid battery.
• Have plenty of fresh water and soap nearby for use in case battery acid contacts your eyes, skin, or clothing. If this happens, wash immediately with soap and water. Then get medical attention
• Avoid touching your eyes while working with a battery. Acid particles (corrosion) may get into your eyes. If this occurs, flush eyes immediately with running cold water for at least 10 minutes. Then immediately get medical attention
• Remove all personal metal items from your body, such as rings, bracelets, necklaces, and watches while working with a lead-acid battery. A battery can produce a short circuit current high enough to weld a ring (or the like) to metal, causing a severe burn.
• Take care not to drop any metal tool or metal object onto the battery This may spark or short circuit the battery or another electrical device that may cause an explosion.
• Always operate your battery charger in an open, well ventilated area
• Never smoke or allow a spark or flame in the vicinity of the battery or engine. Batteries generate explosive gases.
• Neutralize any acid spills thoroughly with baking soda before attempting to clean up.

Parts

The exploded view of your charger shows parts, their location, and a keyed chart identifying each part by name and pert number. The wiring diagram provides additional reference for the professional repair person.

| Rpiy‹›ament Paris: uat. sâBrs t14eo
---|---
Item| Descrlpgon| Part Number
1| Plamic Cap Top| 3709001211
| Hub Cap| 5200000008
| Wheel| 0099£Q0120
4| Axle|
5| Power Cord| 00a26oso
6| Neg. (BLK} cable w/clamps|
7| Pos. (RED) cable w/clamps|
8| Circuit Breaker JOOA| 3999jXj066
Transformer
t0| Diode Assembly|
| Owners Manual (not shown)| 0000000518
11| Fan Motor|
12| Rocker Switch (Volt SaJect)| 049QXKf052
13| Voltmeter 6 & 12 volt| 5299200012
14| Front Panal Decal| 0890000556
15| Mounting Foot| 1199005112
16| Handle| 3599000262
17| Ammeter| 5399100083
18| Axle mtg. bracket| 1190£I04366
19| Timer Control Knob| 0099000096
20| Volt/rate Switch Knob| O099QXKI45
21| Timer 2 1/4HR| 0099000094
22| | 0499fXO05B

Wiring diagram

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.

To attach the axle assembly:

1. Remove charger from packing materials and place on its side on a flat surface. Attach mounting foot and secure with the two 1/4-20 thread cutting screws.

2. Hold axle upright on floor or work surface. Then, using a hammer, tap one of the plastic hubs onto the top end of the axle. Be sure to tap the hub on straight. Slide both wheels onto the axle with the hubs facing inward.
   

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

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

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 recommended minumum AWG (American Wire Gauge) to be sure that wire size is large enough for the rating of the charger

MINIMU.M .RECOMMENDED EXTENSÎON CÖRD

Length of Cord, in Feet| 25| 50| 100| 150
AWG” Size of Cord| 16| 12| 10| 8

*AWG =American Wre 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 volt/amp 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 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

Using Your Battery Charger

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.

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

VOLT/AMP SELECTOR:
Use the VOLT/AMP SELECTOR switch to select an amp charge rate and battery voltage type to match your charging needs. Read the following operating instructions for making the proper settings for charging a battery and using the ENGINE START feature.

TIMER:
The timer is designed to allow your battery to be charged for a designated amount of time. To accurately charge your battery, you must know the size of the battery in ampere hours or reserve capacity in minutes, as well as the state of charge. Since this information is often not known, the timer limit is set at 2.25 hours. This will help prevent the battery from overcharging to a point where it can be damaged. If you do not know the charge state of your battery, it is best to start out with the timer set at one hour or less.

HOLD feature:
This position overrides the timer — the charger will continue charging until the operator stops the charging process. When using HOLD, you must monitor the charging and turn the charger OFF when the battery is fully charged. OVERCHARGING may damage your battery.

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:

• The needle will be around 60 when the selector is in the 60 amp charge position. As the battery becomes charged, the reading will decrease to 25 or 30 amps at full charge. This will be your indicator to stop charging.
• With the selector switch set to the 20 amp position, the meter should display 20 amps for a discharged battery and 8 to 10 amps when the battery is fully charged.
• At the 2 amp charging rate, you may see no needle activity.

ALTERNATOR/GENERATOR TEST:

1. Set the VOLT/AMP SELECTOR switch to the OFF position.
2. Set the BATTERY TEST switch to 12 or 6 volts, according to the battery you are testing.
3. Set timer switch to the OFF position.
4. With the charger properly connected to the battery and chassis, start the engine. Read the battery test meter with the engine at a fast idle. The battery should be in a good state of charge before doing the test.
5. The voltmeter is divided into three color zones:

A. Green and Ughter Green — Charging system is good.
B. Yellow — Vehicle charging system output is low.
C. Red — Vehicle charging system is bad.

NOTE: If meter needle reads in the Red or Yellow, the charging system may have a loose belt, a faulty voltage regulator, or a worn-out alternator/generator. Additional tests may be required to find the exact cause. Take the vehicle to a qualified service center.

BATTERY TEST:
This test is based on the terminal voltage of the battery, If the battery is installed in the vehicle, make sure the engine and all accessories are turned off.

1. Set the VOLT/AMP SELECTOR to the OFF position.
2. Set the BATTERY TEST switch to 6 VOLT for 6 volt batteries or 12 VOLT for 12 volt batteries.
3. Set the timer switch to the OFF position.
4. Read lower 6 VOLT BATI’ERY section of meter for 6 volt batteries and read upper 12 VOLT BAI-rERY section for 12 volt batteries.
5. Both 6 volt and 12 volt battery sections are divided into three color zones:

A. Green — Good battery.
B, Yellow — Weak battery.
C. Red — Bad battery.

NOTE: If the meter needle is in the Red or Yellow area, the battery may only need charging. If, after charging, the needle still remains in the Red or

Yellow area, have the battery tested by a qualified technician. The meter needle may point to the lighter Green section of the meter if this test is done on a recently charged battery or a battery from a vehicle that has been operated recently.

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 grounded or connected to the chassis. THE NEGATIVE POST IS
   NORMALLY THE ONE THAT IS GROUNDED.

5. To charge s 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 an unpainted, heavy 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 an unpainted, heavy metal part of the chassis or engine block, away from the battery. Do not connect clamp to carburetor, fuel lines or sheet metal parts.
   IMPORTANT: Wear safety glasses and face away from the battery while making connections.

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 offthe posts and causing sparks.

7. Set the VOLT/AMP SELECTOR switch and timer switch to the OFF position. Next plug the power cord into a grounded AC outlet.

8. Set the VOLT/AMP SELECTOR switch to the desired charge time, from 30 to 135 minutes. If more than 135 minutes of charging time is needed, the HOLD position can be used. When using the HOLD feature, the battery being charged must be monitored closely to avoid over charging.

9. et the TIMER to the desired charge rate. (See “Setting the Controls” on pages 7 and 8, and “Calculating Charge Time” on page 11 .)

10. When the battery is fully charged in the MANUAL mode, the AMMETER pointer will fall to about half the selected charge rate. The BATTERY TEST will be in the green area of the meter. For specific positions, see the “Setting the Controls” section on pages 7 and 8.
    

11. When the battery is fully charged, first unplug the charger’s power cord. Next, turn the time switch to the OFF position. Then, standing away from the battery, remove the charger clamps in this order:

12. from the chassis connection and,

13. from the battery post.

14. Clean and store the battery charger in a dry location.

NEGATIVE GROUNDED SYSTEM

Charging your battery outside the vehicle:

1. 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) ore 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 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) ora 4- gauge (SAE) insulated 24-inch cable and, standing as far away from the battery as possible, connect the black (NEGATIVE) charger clamp to the free end of the cable. Be sure to rock the clamp back and forth to make a solid connection. IMPORTANT: Wear safety glasses and face away from the battery while you are making this final connection.

6. Make sure your charger’s VOLT/AMP SELECTOR and timer switches are inthe OFF position. Next plug the charger’s power cord into a grounded AC outlet.

7. Set the VOLT/AMP SELECTOR switch to the desired charge time, from 30 to 135 minutes, If more then 135 minutes of charging time is needed, the HOLD position can be used. When using HOLD, the battery being charged must be monitored closely to avoid over charging.

8. Set the TIMER to the desired charge position. (See “Setting the Controls” on pages 7 and 8, end “Calculating Charge Time” on page 11 for correct settings.)

9. When the battery is fully charged in the MANUAL mode, the AMMETER pointer will fall to about half the selected charge rate. The BATTERY TEST will be in the green area of the meter, For specific positions, see the “Setting the Controls” section on pages 7 and 8.

10. When the battery is fully charged, first unplug the charger power cord before attempting to disconnect charger clamps. Next, setthe right-hand switch to the OFF position.

11. Standing away from the battery, remove the charger leads. First remove the clamp from the

12. inch extension cable. Then remove the clamp from the battery post or terminal.

13. Clean and store the battery charger ine dry location.

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 prior to recharging. Add more time for severely discharged batteries.

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 GRAVITY| PERCENT OF CHARGE| PERCENT OF GMARGE NEEDED
---|---|---
1.265| 1009| 099
1.225| 75Y»| 259L
1.155| 25%| 759
1.120| 0°A| 10096

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 a full charge.

To convert Reserve Capacity to Amp Hours, divide
Reserve Capacity by 2, and add 16:

Amp Hours = Reserve Capacity + 16

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, 20 or 60 amps).
• Multiply the result by 1.25 and you’ll have the time needed, in hours, to bring the battery to full charge.
• Add one additional hour for a deep-cycle battery.

Example:
Amp Hour Rating x % of charge needed x 1.25 = hours Charger Setting of charge needed

100 (AH Ratinq) x .50 (charqe needed) x 1.25 — 3.125 20 (Charger Setting) hours 100 x .50 — 2.5 x 1.25 = 3.125 2O

You would need to charge your 100-Ampere Hour Battery for a little more than 3 hours at the 20-Amp charge rate using the above 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. Set the VOLT/AMP SELECTOR and timer switches to the OFF position. Then follow the instructions for how to connect the charger to the battery in the section “Charging your battery in the vehicle.”
2. Plug in the charger and set the VOLT/AMP SELECTOR switch — either to the “12 Volt, 250 Amp, Start” or the “6 Volt, 60 Amp/125 Amp, Start” position. Be sure the match the battery’s voltage.
3. Crank the engine for no more than five seconds. If the engine does not start, wait four minutes before cranking again.
4. During extremely cold weather, or if the battery is severely exhausted, charge the battery for about five minutes before cranking the engine.
5. If the engine still does not start, charge the battery for five more minutes before cranking it again for five seconds.
6. After the engine starts, unplug the charger power cord from the outlet. Then turn the VOLT/AMP SELECTOR switch to the OFF position before disconnecting the battery leads.

IMPORTANT : Do not try to start the engine without a battery in it. Doing so can damage the vehicle’s electrical system.

If the engine cranks but does not start, the problem is not the starting system but something else with the vehicle. STOP cranking the engine until the other problem has been identified and corrected.

Maintenance and care
A minimal amount of care can keep your battery charger working properly for years.

1. Clean the clamps each time you are finished charging. Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion.
2. Coil the input and output cords neatly when storing the charger. The cords can be wrapped around the handle of the charger. This will help prevent accidental damage to the cords and charger.
3. Occasional cleaning of the case with a soft cloth will keep the finish shiny and help prevent corrosion.

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.

for poor connections to battery and frame. Make sure connecting points are clean.
| 2-amp charge rate is being used.| Ammeter may show no activity at the 2-amp charge rate.
No reading on ammeter. Charger fan not working.| AC cord and/or extension cord is loose.
No power at receptacle.| Check power cord and extension cord for loose fitting plug.
Check Jory open fuse or circuit breaker supplying AC outlet
Circuit breaker in charger cycles on and off with a clicking sound.| Shorted battery clamps.

Shorted battery.

| 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.
| Charger leads reversed.| Correct connections.
| Volt/Amp Selector Switch set to the START pos’8ion.| Correct Volt/Amp Selector setting.
Cranking time less than 5 seconds when using ENGINE START.| Drawing more than 250 amps for a period of 5 seconds or less.| Crank time varies with the amount o1 current drawn. If cranking draws more than 250 amps, crank time may be less than 5 seconds.
| Failure to wait Jor 4 minutes (240 seconds) between cranks.| Wait 4 minutes before next crank.
Ammeter reads less than selected charge rate when charging a discharged battery.| Extension cord too long or wire gauges too small. Weak cell or sulfated plate in battery.| 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.
| Battery is only partially discharged.| Continue to charge battery.
Charger makes a loud buzz or hum.| Transformer laminations vibrate (buzz).Shouted diode (hum).| Continue charging. Buzz is not abnormal.
Have charger  teste by qualified technician.
Test meter needle| Battery severely| Continue charging battery for another two hours.
stays at the right side of the meter.| discharged. Test switch may be in the wrong position.| problem continues, consult a Sears technician. Make sure test switch is in proper 6 or 12 volt position.

Warranty

FULL FIVE-YEAR WARRANTY
If, within FIVE 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.

Seam, Roebuck and Co., Dept 817WA,
Hoffman Estates, IL 60179

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

• Product Type
• Model Number
• Part Number
• Part Description

Model No.
200.71460

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

60/20/2 AMP
MANUAL BATTERY
CHARGER
250/125 AMP
ENGINE STARTER with
BATTERY TESTER
For in form action bout troubleshooting
Call toll-free from anywhere in the U.S.A.
7 am to 4:30 pm CSTM on day through Friday
1-800-SEARS-64
(1-800-732-7764)

For the repair or replacement
parts you need
Call7 am – 7 pro,7 days week
1-800-366-PART

(1-800-366-7278)
For the locational a Sears Repair
Service Cantering you area
Call24 hours day,
7 days week
1-800-488-1222

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