Sears Battery Charger 20071991 User Guide

OPERATOR’S MANUAL  
®
BATTERY ChARGER  
70/40/20/4 Amp  
300 AMP  
ENGINE STARTER  
With Battery Tester  
Model No.  
200.71991  
CAUTION:  
Read and follow all Safety  
Rules and Operating Instructions  
Before Every Use of this Product.  
SAvE ThESE INSTRUCTIONS.  
Sears, Roebuck and Co., hoffman Estates, IL 60179 U.S.A.  
00-99-000882/0808  
 
TABLE Of CONTENTS  
SECTION  
PAGE  
1
1. IMPORTANT SAfETY INSTRUCTIONS  
2. PERSONAL PRECAUTIONS  
3. PREPARING TO ChARGE  
2
3
4. ChARGER LOCATION  
3
5. dC CONNECTION PRECAUTIONS  
6. WhEN BATTERY IS INSTALLEd IN vEhICLE  
7. WhEN BATTERY IS OUTSIdE vEhICLE  
8. BATTERY ChARGING - AC CONNECTIONS  
9. PROdUCT fEATURES  
3
4
5
6
8
10. ASSEMBLY INSTRUCTIONS  
11. OPERATING INSTRUCTIONS  
12. ENGINE START  
8
10  
11  
12  
14  
14  
13. CALCULATING ChARGE TIME  
14. MAINTENANCE INSTRUCTIONS  
15. STORAGE INSTRUCTIONS  
16. TROUBLEShOOTING  
14  
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 one year from the date of purchase, return it to any Sears store  
or other diehard outlet in the United States for free replacement.  
This warranty does not include fuses, which are expendable parts.  
This warranty gives you specific legal rights, and you may also have  
other rights which vary from state to state.  
Sears, Roebuck and Co., hoffman Estates, IL 60179  
fOR CUSTOMER ASSISTANCE OR REPLACEMENT PARTS,  
CALL TOLL-fREE fROM 7 AM TO 4:30 PM CT  
MONdAY ThROUGh fRIdAY: 1-800-SEARS-64 (1-800-732-7764)  
 
IMPORTANT: REAd ANd SAvE ThIS SAfETY ANd INSTRUCTION MANUAL.  
1.  
IMPORTANT SAfETY INSTRUCTIONS  
1.1  
SAVE THESE INSTRUCTIONS - The DieHard model 71991 Manual Bat-  
tery Charger, 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 instruc-  
tions and precautions carefully as this manual contains important safety  
and operating instructions.  
1.2  
1.3  
Do not expose charger to rain or snow.  
Use of an attachment not recommended or sold by the battery charger  
manufacturer may result in a risk of fire, electric shock or injury to persons.  
1.4  
1.5  
To reduce the risk of damage to electric plug or cord, pull by the plug  
rather than the cord when disconnecting the charger.  
An extension cord should not be used unless absolutely necessary. Use of  
an improper extension cord could result in a risk of fire 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  
and;  
That the wire size is large enough for the AC ampere rating of the charger  
as specified in Table 8.2.  
1.6  
1.7  
Do not operate the charger with a damaged cord or plug; take it to a quali-  
fied serviceman. (Call customer service at: 800-SEARS-64).  
Do not operate the charger if it has received a sharp blow, been dropped  
or otherwise damaged in any way; take it to a qualified serviceman. (Call  
customer service at: 800-SEARS-64).  
1.8  
1.9  
DO NOT attempt to repair product yourself. To arrange for product repair,  
or for information about customer replaceable parts, call 1-800-SEARS-64  
(1-800-732-7764).  
In case of charger malfunction, DO NOT attempt to repair the charger  
yourself. To arrange for charger repair, or for information about customer  
replaceable parts, call 1-800-SEARS-64 (1-800-732-7764)  
1.10 Do not disassemble the charger; take it to a qualified serviceman when  
service or repair is required. Incorrect reassembly may result in a risk of  
electric shock or fire. (Call customer service at: 800-SEARS-64).  
1.11 To reduce the risk of electric shock, unplug the charger from the outlet  
before attempting any maintenance or cleaning. Turning off the controls  
will not reduce this risk.  
1.12 WARNING: Pursuant to California Proposition 65, this product contains  
chemicals known to the State of California to cause cancer and birth de-  
fects or other reproductive harm.  
1 •  
 
WARNING – RISK Of EXPLOSIvE GASES.  
WORKING IN ThE vICINITY Of A LEAd-ACId BATTERY IS dANGER-  
OUS. BATTERIES GENERATE EXPLOSIvE GASES dURING NOR-  
MAL 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 BATTERY EXPLOSION, fOLLOW ThESE  
INSTRUCTIONS ANd ThOSE PUBLIShEd BY ThE BATTERY MANU-  
fACTURER 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.  
2.  
PERSONAL PRECAUTIONS  
2.1  
Consider having someone close enough by to come to your aid when you  
work near a lead-acid battery.  
2.2  
2.3  
2.4  
Have plenty of fresh water and soap nearby in case battery acid contacts  
your skin, clothing or eyes.  
Wear complete eye protection and clothing protection. Avoid touching your  
eyes while working near the battery.  
If battery acid contacts your skin or clothing, wash immediately with soap  
and water. If acid enters your eye, immediately flood the eye with cold run-  
ning water for at least 10 minutes and get medical attention immediately.  
2.5  
2.6  
NEVER smoke or allow a spark or flame in the vicinity of a battery or  
engine.  
Be extra cautious to reduce the risk of dropping a metal tool onto the bat-  
tery. It might spark or short-circuit the battery or other electrical part that  
may cause an explosion.  
2.7  
2.8  
Remove personal metal items such as rings, 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.  
Use this charger for charging a LEAD-ACID battery only. It is 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.  
2.9  
NEVER charge a frozen battery.  
2.10 WARNING: Pursuant to California Proposition 65, this product contains  
chemicals known to the State of California to cause cancer and birth de-  
fects or other reproductive harm.  
2 •  
 
3.  
PREPARING TO ChARGE  
3.1  
If it is necessary to remove the battery from the vehicle to charge it, al-  
ways remove the grounded terminal from the battery first. Make sure all of  
the accessories in the vehicle are off, so as not to cause an arc.  
3.2  
3.3  
3.4  
Be sure the area around the battery is well ventilated while the battery is  
being charged.  
Clean the battery terminals. Be careful to keep corrosion from coming into  
contact with your eyes.  
Add distilled water to each cell until the battery acid reaches the level  
specified by the battery manufacturer. Do not overfill. For a battery without  
removable cell caps, such as valve regulated lead-acid batteries, carefully  
follow the manufacturer’s recharging instructions.  
3.5  
3.6  
Study all of the battery manufacturer’s specific precautions while charging  
and recommended rates of charge.  
Determine the voltage of the battery by referring to the vehicle 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 at the lowest rate first.  
4.  
4.1  
4.2  
ChARGER LOCATION  
Locate the charger as far away from the battery as the DC cables permit.  
Never place the charger directly above the battery being charged; gases  
from the battery will corrode and damage the charger.  
4.3  
4.4  
4.5  
Never allow battery acid to drip onto the charger when reading the electro-  
lyte specific gravity or filling the battery.  
Do not operate the charger in a closed-in area or restrict the ventilation in  
any way.  
Do not set a battery on top of the charger.  
5.  
dC CONNECTION PRECAUTIONS  
5.1  
Connect and disconnect the DC output clips only after setting all of the  
charger switches to the “off” position and removing the AC plug from the  
electrical outlet. Never allow the clips to touch each other.  
5.2  
Attach the clips to the battery and chassis, as indicated in steps 6.5, 6.6,  
and 7.2 through 7.4.  
3 •  
 
6.  
fOLLOW ThESE STEPS WhEN BATTERY IS INSTALLEd IN vE-  
hICLE  
A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION. TO  
REdUCE RISK Of A SPARK NEAR BATTERY:  
NEGATIvE GROUNdEd SYSTEM  
6.1  
6.2  
6.3  
6.4  
Position the AC and DC cables to reduce the risk of damage by the hood,  
door, or moving engine parts.  
Stay clear of fan blades, belts, pulleys and other parts that can cause  
injury.  
Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery  
post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.  
Determine which post of the battery is grounded (connected) to the chas-  
sis. 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.  
6.5  
For a negative-grounded 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 carbure-  
tor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal  
part of the frame or engine block.  
6.6  
For a positive-grounded vehicle, connect the NEGATIVE (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 carbure-  
tor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal  
part of the frame or engine block.  
6.7  
6.8  
When disconnecting the charger, turn all switches to off, disconnect the  
AC cord, remove the clip from the vehicle chassis, and then remove the  
clip from the battery terminal.  
See OPERATING INSTRUCTIONS for length of charge information.  
4 •  
 
7.  
fOLLOW ThESE STEPS WhEN BATTERY IS OUTSIdE vEhICLE.  
A SPARK NEAR ThE BATTERY MAY CAUSE BATTERY EXPLOSION.  
TO REdUCE RISK Of A SPARK NEAR BATTERY:  
7.1  
7.2  
7.3  
7.4  
Check the polarity of the 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-long 6-gauge (AWG) insulated battery cable to  
the NEGATIVE (NEG, N, -) battery post.  
Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +)  
post of the battery.  
Position yourself and the free end of the cable you previously 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.  
7.5  
7.6  
Do not face the battery when making the final connection.  
When disconnecting the charger, always do so in reverse sequence of  
the connecting procedure and break the first connection while as far away  
from the battery as practical.  
7.7  
A marine (boat) battery must be removed and charged on shore. To  
charge it onboard requires equipment specially designed for marine use.  
5 •  
 
8.  
BATTERY ChARGING - AC CONNECTIONS  
8.1  
GROUNDING AND AC POWER CORD CONNECTION  
INSTRUCTIONS – Charger should be grounded to reduce risk of electric  
shock. Charger is equipped with an electric cord having an equipment-  
grounding conductor and a grounding plug. The plug must be plugged  
into an outlet that is properly installed and grounded in accordance with  
all local codes and ordinances.  
dANGER – Never alter the AC cord or plug provided - if it will not fit the  
outlet, have the proper outlet installed by a qualified electrician. An im-  
proper connection can result in a risk of an electric shock.  
This battery charger is for use on a nominal 120-volt circuit, and has a  
grounding plug that looks like the plug illustrated in sketch A in Figure 8.3.  
A temporary adapter, which looks like the adapter illustrated in sketches  
B and C, may be used to connect this plug to a two-pole receptacle as  
shown in sketch B if a properly grounded outlet is not available. The tem-  
porary adapter should be used only until a properly grounded outlet can  
be installed by a qualified electrician.  
dANGER – Before using adapter as illustrated, be certain that center  
screw of outlet plate is grounded. The green-colored rigid ear or lug ex  
tending from adapter must be connected to a properly grounded outlet–  
make certain it is grounded. If necessary, replace original outlet cover  
plate screw with a longer screw that will secure adapter ear or lug to  
outlet cover plate and make ground connection to grounded outlet.  
6 •  
 
8.2  
Recommended minimum AWG size for extension cords for battery  
chargers:  
AC input rating,  
amperesa  
AWG size of cord  
Length of cord, feet (m)  
But less  
than  
25  
(7.6)  
18  
18  
18  
18  
18  
18  
18  
16  
16  
16  
14  
14  
50  
(15.2)  
18  
18  
18  
18  
16  
16  
14  
14  
12  
12  
12  
100  
(30.5)  
18  
16  
16  
14  
14  
12  
12  
10  
10  
10  
8
150  
(45.6)  
16  
14  
14  
12  
12  
10  
10  
8
At least  
0
2
3
4
5
2
3
4
5
6
6
8
8
10  
12  
14  
16  
18  
20  
10  
12  
14  
16  
18  
8
8
8
6
12  
8
aIf the input rating of a charger is given in watts rather than in  
amperes, the corresponding ampere rating is to be determined  
by dividing the wattage rating by the voltage rating ± for  
example:  
1250 watts/125 volts = 10 amperes  
8.3  
Grounding Methods  
7 •  
 
9.  
fEATURES  
3
4
5
1. Ammeter  
2
2. Volt Meter  
3. Foam Grip  
4. Fiber Glass Clamp Rod  
5. Clamps  
6
1
7
6. Charge Rate Selector Switch  
7. Timer  
8. Wheel  
8
10. ASSEMBLY INSTRUCTIONS  
IT IS IMPORTANT TO fULLY ASSEMBLE YOUR ChARGER BEfORE  
USE. fOLLOW ThESE INSTRUCTIONS fOR ASSEMBLY:  
ITEM QTY dESCRIPTION  
NO.  
1
2
1
2
2
2
1
2
2
2
4
1
1
1
axle bracket  
2
axle with pin holes  
wheel  
TOOLS NEEdEd  
3
4
screw, 10-32 x 1/2, self tapping  
screw, 1/4-20 x 3/4, self tapping  
wheel charger foot  
hubcap, black  
5/16” Wrench or Nut Driver  
3/8” Wrench or Nut Driver  
Screwdriver (Flat Blade)  
Screwdriver (Phillips)  
Hammer  
5
6
7
8
hairpin cotter  
9
nylon washer  
10  
11  
12  
13  
screw, 8-18 x 1/2 sheet metal  
handle assembly  
fiberglass clamp rod  
foam handle grip  
8 •  
 
10.1 First, carefully lay the charger on its front to prepare for assembly.  
10.2 Assemble the foot (Item 6) using two ¼-20 screws (Item 5) and tighten  
securely.  
10.3 Attach the two axle brackets (Item 1) using one 10-32 screw (Item 4) in  
each. The brackets should have one end hooked into the slot in the char-  
ger base. (Do not completely tighten the screws (Item 4) at this time).  
10.4 Slide the axle (Item 2) into the brackets (Item 1) until centered on the char-  
ger.  
10.5 Slide one wheel (Item 3) onto the axle with the recessed hub facing out as  
shown.  
10.6 Next insert pin (Item 8) thru axle hole.  
10.7 Repeat this process for the other wheel and when both wheels have been  
pinned to axle, finish tightening the two axle bracket screws (Item 4).  
10.8 Snap hub caps (Item 7) onto each wheel to cover the pin and axle.  
10.9 Next lift the charger upright so that it rests on the wheels and foot.  
10.10 Remove the two top side screws (Item 9) from each side of the charger.  
10.11 Verify that the foam handle grip (Item 12) is on the handle assembly (Item  
10), install if needed.  
10.12 Insert the fiberglass clamp rod (Item 11) into the pierced holes on the  
inside of the handle (Item 10).  
10.13 Align the handle assembly (Item 10) with charger and reinstall the side  
screws (Item 9). Do not over tighten.  
10.14 Charger assembly is now complete. Battery clips can be clamped to the  
fiberglass rod (Item 11) for convenient storage.  
10.15 Do not attach clips to the foam area of handle as this will damage the  
foam grip.  
9 •  
 
11. OPERATING INSTRUCTIONS  
11.1 TIMER  
The main function of the timer is to prevent over charging while allowing a  
battery time to obtain a satisfactory charge. To properly set the timer you  
must know the size of the battery in ampere hours or reserve capacity in  
minutes and the state of charge. Often the state of charge is not known,  
this is one reason why the timer was limited to 2.25 hours. With the aid  
of a battery load tester the state of charge can be obtained within a few  
seconds. For example, the average size automotive battery at a 50%  
state of charge will require 1 to 1.5 hours of charging at the 40 amp rate  
to reach the full charge state. For the same battery with the timer set to its  
maximum, 2.25 hours, over charging will occur, but not likely cause harm  
to a battery that was otherwise in good condition. When the charge state  
is not known, start out with a timer setting of one hour or less, or use the  
automatic setting.  
11.2 hOLd  
This position defeats the timer function, allowing for continuous operation.  
AUTOMATIC MOdES: Put the timer in the HOLD position when the bat-  
tery charger is in one of the automatic modes, otherwise the timer will shut  
the charger off when the set time expires regardless of whether the charge  
is complete or not. The green “charged” LED will light and the fan will shut  
off when the charging is complete.  
MANUAL MOdES: Use when you want to charge more than 2.25 hours.  
Be sure to monitor the charging procedure and stop it when the battery is  
charged. Not doing so may cause damage to your battery.  
11.3 AMP RATE SELECTOR SWITCh  
Use the amp selector switch to select the charge rate or engine starting  
setting you require.  
10 •  
 
11.4 AMMETER  
The Ammeter indicates the amount of current measured in amperes that  
is being drawn by the battery. For example, in the 40 amp charge rate a  
typical discharged battery will initially draw approximately 40 amps. As  
the battery continues to charge, current will taper to 15 to 20 amps at full  
charge. The Start area of the meter indicates a high rate of current be-  
ing drawn from the charger. When cranking an engine, the starter motor  
draws upwards to 200-300 amps. The meter needle will be at the extreme  
right side of the start area. Sometimes a battery for the first few minutes  
of its charge will draw more than 70 amps, in this case the needle may  
be within, but not all the way over, to the right side of the start area. The 4  
amp charge rate may indicate some activity on the meter. The meter does  
not have the resolution to display this low rate.  
11.5 vOLTMETER  
The Voltmeter indicates the voltage at the battery terminals. Use as fol-  
lows:  
1. The charger need not be plugged into an AC outlet. The timer should  
be in the OFF position. Then connect the charger following instructions  
in Sections 6 and 7.  
2. Observe the meter indication. Keep in mind that this reading is only a  
battery voltage reading, a false surface charge may mislead you. We  
suggest that you turn on your headlights for a couple of minutes before  
you read the meter. Read a couple of minutes after you have shut the  
headlights off. If the reading is less than 10.5-volts, the battery may be  
bad or the connections at the charger may be poor. If the reading is  
10.5-volts to 12.8-volts the battery is low – recharge it. If the reading is  
above 12.8-volts the battery is charged.  
12. ENGINE START  
12.1 Set the charge rate switch and the timer to the OFF positions.  
12.2 With the charger unplugged from the AC outlet, connect the charger to the  
battery following instructions given in section 6.  
12.3 Plug the charger AC power cord into the AC outlet, and then move the  
timer from OFF to the HOLD position.  
12.4 Set the amp rate selector switch to the engine start position and then  
crank the engine until it starts or 5 seconds passes.  
NOTE: During extremely cold weather, or if the battery is under 2 volts,  
charge the battery for five minutes before cranking the engine.  
12.5 If the engine fails to start, charge the battery for 5 more minutes before  
attempting to crank the engine again.  
12.6 After the engine starts, move the amp rate selector switch to OFF and  
unplug the AC power cord from the outlet before disconnecting the battery  
clamps.  
11 •  
 
IMPORTANT: Using the ENGINE START feature WITHOUT a battery  
installed in the vehicle could cause damage to the vehicle’s electrical  
system.  
If the engine does turn over, but never starts, 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.  
13. CALCULATING ChARGE TIME  
13.1 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 – motorcycle, garden tractors, etc. – are usually rated in  
Ampere Hours (AH). For example: 6, 12, 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 RECOMMENDED.  
Find your batteries rating on the chart below 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 dis-  
charged batteries.  
ChARGE RATE/  
ChARGING TIME - hOURS  
BATTERY SIZE/RATING  
4 AMP 20 AMP 40 AMP 70 AMP  
6 - 12 AH  
12 - 32 AH  
40 - 60 RC  
60 - 85 RC  
85 - 190 RC  
80 RC  
2 - 4  
4 - 10  
11 - 14  
14 - 18  
18 - 35  
18  
NR  
NR  
NR  
NR  
NR  
NR  
SMALL  
BATTERIES  
Motorcycle, gar-  
den, tractor, etc.  
60 - 90  
min.  
30 - 40  
min.  
20 - 30  
min.  
200 - 315 CCA  
315 - 550 CCA  
550 - 1000 CCA  
CAR/  
TRUCKS  
90 - 120  
min.  
45 min -  
1 hr  
30 - 40  
min.  
2 - 3.5  
hrs.  
45 - 60  
min.  
1 - 2 hr  
1 hr  
105 min.  
NR  
NR  
NR  
NR  
2 hrs., 45 1 hr and  
min.  
140 RC  
27  
15 min  
MARINE/DEEP CYCLE  
160 RC  
30  
3 hrs.  
1.5 hrs  
180 RC  
33  
3.5 hrs.  
2 hrs  
12 •  
 
13.2 The hydrometer or Electronic Method  
To nd the time needed to fully charge your battery, determine the bat-  
tery’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.  
PERCENT Of ChARGE  
SPECIfIC GRAvITY  
PERCENT Of ChARGE  
NEEdEd  
1.265  
1.225  
1.155  
1.120  
100%  
75%  
25%  
0%  
0%  
25%  
75%  
100%  
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  
2
NOTE: The Reserve Capacity can be obtained from the battery specifica-  
tion sheet or the owner’s manual.  
To calculate time needed for a charge:  
• Find the percent 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, 15, or 60 amps).  
• Multiply the results by 1.25 and you will have the total 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  
Charger Setting  
x
1.25  
1.25  
=
=
hours of  
charge  
100 (AH Rating) x .50 (charge needed) x  
20 (Charger Setting)  
3.125  
hours  
100 x .50 2.5 x 1.25 = 3.125  
20  
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.  
13 •  
 
14. MAINTENANCE INSTRUCTIONS  
14.1 Before performing maintenance, unplug and disconnect the battery char-  
ger (see sections 6.7 and 7.6).  
14.2 After use, use a dry cloth to wipe all battery corrosion and other dirt or oil  
from the clips, cords, and the charger case.  
14.3 Through routine maintenance, ensure all user installed parts are secure.  
14.4 Servicing does not require opening the unit, as there are no user-service-  
able parts.  
15. STORAGE INSTRUCTIONS  
15.1 Store the charger unplugged and in an upright position. The cord will still  
conduct electricity until it is unplugged from the outlet.  
15.2 Store inside, in a dry, cool place (unless you are using a UL Listed, on-  
board Marine Charger).  
15.3 Store the clips on the fiberglass clamp rod. Do not store them on the  
handle, clipped together, on or around metal, or clipped to the cables.  
14 •  
 
16. TROUBLEShOOTING  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION/REASONS  
No reading on the ammeter.  
Clips are not making a good  
connection.  
Check for poor connections to  
battery and frame. Make sure  
connecting points are clean.  
Rock clips back and forth for a  
better connection.  
4-amp charge rate is being  
used.  
Ammeter may show no activity  
at the 4-amp charge rate.  
Ammeter reading stays high.  
Battery is severely discharged.  
Continue charging battery for  
two more hours. If problem  
continues, have the battery  
checked.  
Wrong battery voltage  
Verify that you are using a  
12-volt, lead-acid battery.  
Ammeter reads less than se-  
lected charge rate when charg-  
ing a discharged battery  
Extension cord is too long or  
wire gauge is too small.  
Use a shorter or heavier gauge  
extension cord.  
Weak cell or sulfated plate in  
battery.  
A sulfated battery will eventu-  
ally take a normal charge if left  
connected. If the battery will not  
take a charge, have it checked.  
Battery is only partially dis-  
charged.  
Continue to charge the battery.  
The charger is making an  
audible clicking sound.  
Circuit breaker is cycling.  
The settings may be wrong.  
Check the charger settings.  
Battery is defective.  
Shorted battery clips.  
Have the battery checked.  
Circuit breaker cycles when  
current draw is too high. Check  
for shorted cables and replace if  
necessary.  
Severely discharged battery, but Allow charging to continue until  
otherwise it is a good battery.  
battery has a chance to recover  
sufficiently to take a charge.  
If more than 20 minutes, stop  
charging and have the battery  
checked.  
Reverse connections at battery. Shut the charger off and correct  
the lead connections.  
Charger makes a loud buzz  
or hum.  
Transformer laminations vibrate No problem, this is a normal  
(buzz).  
condition.  
Shorted SCR (hum).  
Have charger tested by a Sears  
or other qualified service dealer.  
15 •  
 
PROBLEM  
POSSIBLE CAUSE  
SOLUTION/REASONS  
Short or no start cycle when  
cranking engine.  
Drawing more than 300 amps.  
Crank time varies with the  
amount of current drawn. If  
cranking draws more than 300  
amps, crank time may be less  
than 3 seconds.  
Failure to wait 3 minutes (180  
seconds) between cranks.  
Wait 3 minutes of rest time  
before the next crank.  
Clips are not making a good  
connection.  
Check for poor connection at  
battery and frame.  
AC cord and/or extension cord  
is loose.  
Check power cord and exten-  
sion cord for loose fitting plug.  
No power at receptacle.  
Check for open fuse or circuit  
breaker supplying AC outlet.  
The charger may be heated up. The thermal protector may have  
tripped and needs a little longer  
to close. Make sure the charger  
vents are not blocked. Wait and  
try again.  
Battery may be severely  
discharged.  
On a severely discharged  
battery, charge for 10 to 15 min-  
utes in the 40 amp manual rate  
to help assist in cranking.  
Charger will not turn on when  
properly connected.  
AC outlet is dead.  
Check for open fuse or circuit  
breaker supplying AC outlet.  
Poor electrical connection.  
Check power cord and exten-  
sion cord for loose fitting plug.  
The battery is connected and  
the charger is on, but is not  
charging.  
Clips are not making a good  
connection.  
Check for poor connection at  
battery and frame. Make sure  
connecting points are clean.  
Rock clips back and forth for a  
better connection.  
Battery is severely discharged.  
If your battery does not have 4  
volts, you need to switch to the  
40A Manual mode for five or ten  
minutes and then switch back to  
Automatic mode at the desired  
charge rate.  
16 •  
 
17 •  
 

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