DieHard 200.713121 User manual

OWNER'S MANUAL
®
12/2/75 AMP
FULLY AUTOMATIC
BATTERY CHARGER
ENGINE STARTER
Model No.
200.713121
CAUTION:
Before first use of charger, read this manual, and
follow all its Safety and Operating Instructions with
every charger use.
Save these instructions.
Made in U.S.A. of U.S. and imported pads.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
598-198

WARRANTY ............................................................................................................... 2
SAFETY ..................................................................................................................... 3
Important Safety Instructions .................................................................................... 3
OPERATION .............................................................................................................. 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
Using Your Battery Charger ...................................................................................... 6
Setting the controls .............................................................................................. 6
Charging your battery ........................................................................................... 8
Inside vehicle ................................................................................................... 8
Outside vehicle ............................................................................................... 9
Using the Engine Start Feature .............................................................................. 10
Calculating Charge Time ......................................................................................... 11
MAINTENANCE AND CARE .................................................................................... 12
TROUBLESHOOTING ............................................................................................ 13
PARTS ..................................................................................................................... 14
Wiring Diagram ................................................................................................. 15
Please read this Owner's Manual before using your Battery Charger
The DieHard model 200.713121, Fully Automatic Battery Charger/Engine Starter, offers
a wide range of features 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.
FULL THREE YEAR WARRANTY
Within three years from the date of purchase, this battery charger fails due to a defect in
materials or workmanship, RETURN IT TO TH E PLACE OF PURCHASE, and itwill be
repaired or replaced free ofcharge.
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
2

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.
• Usechargeronlyon lead-acidtype
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.
• 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.
• 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.
•Batterychargersget hot during
operation and must have proper
ventilation. Air needs to flow around
entirecharger.
•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 --
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 (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
will 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 tOprevent 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 orthe plug.
•Do not operate the charger if it has a
damaged power cord or plug. Have the
cord replaced.
3

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 iswithin 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 a short
circuit current high enough to weld a
ring (orthe 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.
4

It is impodant to understand your charger's requirements. This section will tell you
about your charger's electrical requirements and how to prepare abattery for
charging.
ASSEMBLING YOUR CHARGER
Included with your battery charger are
two cord wrap posts for storage of the
clamp cables.
To install, align the three tabs to
correspond 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. [_ (--Cord Wrap Cleat
PLUGGING IT IN
WARNING: Electrical Shock Hazard.
Be sure that the power cord fits properly
into the 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 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. Ifyou 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 ingood electrical
condition.
Make sure that the wire size is large
enough for its length and forthe AC
ampere rating as specified in the chart
below.
Length of Cord, In Feet 25 50 100 150
AWG* Size of Cord 18 16 12 10
*AWG=American Wire Gauge
5

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.
For batteries with removable cell caps,
ifrequired by the manufacturer, add
distilled water to each cell until the
battery acid reaches the level
recommended. 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.
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
occuring.
NOTE" A marine battery installed in a boat
must be removed and charged on shore.
•Take time to read all battery
manufacturer's specific precautions,
such as removing or not removing cell
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, how to charge a battery in or
out of a vehicle, and how to use the engine start feature.
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 6 or 12 volt.
• Use the center switch to select a
charge type_MANUAL, AUTOMATIC
DEEP CYCLE or AUTOMATIC
REGULAR.
•Use the right switch to select acharge
rate--2 AMP charge, 12 AMP charge,
or 75 AMP ENGINE START.
Battery Voltage:
Select the voltage of your battery. The
most common applications will be 12
volt.
6 VOLT 12 VOLT
6

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 isfully 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 and begin charging again
when battery requires.
• Use the AUTOMATIC REGULAR
setting for all but deep cycle batteries.
The charger will automatically stop
charging when the battery reaches
full charge and begin charging again
when battery requires.
• 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.
AUTOMATIC DEEP CYCLE
v
II.............
AUTOMATIC MANUAL
REGULAR
Charge Rate:
•Use the 2 AMP charge rate setting for
charging small batteries and warming
large batteries.The lower the charge
rate, the longer itwill take tocharge the
battery.
•Use the 12 AMP rate setting for
automotive, deep cycle and other large
batteries.
• Use the 75 AMP ENGINE START setting
only to assist in cranking the engine.
2 AMP
12AMP
ENGINE
START
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, with
the needle near 12 using the 12 amp
charging rate.
•In the MANUAL setting, as the battery
charges, the needle will fall to about 5
to 6 amps, indicating a charged
battery.
In both AUTOMATIC settings, 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
stops, and the charger, if left con-
nected, 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.
DCAMPS
CHARGE % 100 75 50 25
0 2 4 6 8 10 12
OFULL CHARGE
LED INDICATOR:
The green LED INDICATOR will glow
when the charger senses that the
battery has reached a full charge.
• When using the MANUAL charge rate,
stop charging when the LED glows and
the AMMETER needle is about 5 to 6
amps in the 12 Amp setting.
7

Fordeepcyclebatteries,youmay
wishtoallowthebatteryanotherone
ortwo hoursofchargingaftertheLED
glowsto obtainamaximumcharge.
WhenusingtheAUTOMATICcharge
rates,the LEDwill cycleon andoff
indicatingthechargerismaintaining
thebattery'sstate-of-charge.
CHARGING YOUR BA'I-rERY
Charging your battery inside
the vehicle:
1. Arrange the powercord and charg-
ing leads carefully to avoid damage
that could be caused by the hood,
door, or moving engine pads.
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 battery 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
tothe ungrounded POSITIVE
(POS, P, +) post of the battery.
Rock or twist the clamps back
and forth to make a solid connection.
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. (See
Figure A.)
To charge a positive grounded
post system: Connect the black
(NEGATIVE) battery charger clamp
to the ungrounded NEGATIVE
(NEG, N, -) post ofthe battery. Then
NEGATIVE GROUNDED SYSTEM
Figure A
.
.
.
9.
10.
connect the red (POSITIVE) 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. IMPORTANT:
Wear safety glasses and turn face
away from the battery when making
connections.
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.
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 over
charging, monitor the AMMETER
frequently when in the MANUAL mode.
Next plug the power cord into an
AC outlet.
When the battery isfully 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
page 6.
When the battery isfully charged,
unplug the charger power cord
before attempting to disconnect
charger clamps.
8

10.Whenthebatteryisfullycharged,
first unplugthechargerpowercord.
Then,standingawayfromthebattery,
removethechargerclampfromthe
chassisfirst,thenfromthe battery
post.
11. Cleanandstorethebatterycharger
inadrylocation.
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) or a 4-gauge
(SAE) insulated battery cable at least
24-inches long to the NEGATIVE
battery post. This cable willprovide a
safer connection, ifarcing and
sparking occur, itwill be at a distance
from the battery. NOTE: The battery
cable is not provided with the charger,
but may be purchased at most
automotive stores.
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.
POSRIVE
.
,
.
9.
10.
11.
12.
POWER
24", 6 GAUGE
CABLE
GROUNDED
POWER
Figure B OUTLET
For automatic charging, select
AUTOMATIC REGULAR or
AUTOMATIC DEEP CYCLE
depending on the type of battery, then
select a charge rate. The charger will
quit when the battery is fully charged
and will restart if the battery voltage
drops too low.
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 over charging;
monitor the AMMETER frequently
when in the manual mode.
Plug the power cord into an AC outlet.
When the battery isfully 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
page 6.
When the battery is fully charged,
unplug the charger power cord before
attempting to disconnect charger
clamps.
Standing away from the battery,
remove the negative lead from
the insulated cable connected to the
NEGATIVE postfirst. Then remove
the lead from the POSITIVE post.
Clean and store the charger in a
dry location.
9

Your batterychargercan 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 8.
2. Set the right hand SELECTOR
SWITCH on ENGINE START.
3. Crank the engine for no more than 5
seconds. If it does not start, wait at
least 4 minutes before cranking
again. In extreme cold or if the battery
is severely discharged, charge the
battery in the 12 amp position for about
5 minutes before cranking the engine.
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.
Ifthe engine does turn over, but never
starts up, there is not a problem with the
starting system, there is a problem
somewhere else in the vehicle. STOP
cranking the engine until the other
problem has been identified and
corrected.
10

Battery Rating Method
Use the following table to more accurately determine the time it will take to fully charge a
battery that is initially at 50% State-of-Charge. Identify your battery type and its associated
Charge Time in the table. Common battery types are:
•Small batteries, motorcycles, garden tractors, etc., are usually rated in Amp-Hours
(AH).
• Car and truck batteries, usually rated in Reserve Capacity (RC), Cold Cranking
Amps (CCA), or both.
• Marine, or deep cycle batteries, usually rated in either Amp-Hours or Reserve
Capacity (RC).
Charge Time Table for Batteries at 50% State-of-Charge
Motorcycle
and tractor
Car and
Truck
Marine and
Deep Cycle
AH
6-12
12 - 32
40
8O
95
105
RC CCA
40 -60 200 - 315
60 -85 315 -550
85-190 550- 1000
8O
14O
160
180
NA = Not Allowed. DO NOT charge at this setting
2AMP
2-4
4-10
8-11
11 - 16
16 - 35
15
26
30
33
12 AMP
NA
NA
1-2
2-3
3- 53/_
2½
4½
5
5½
75 AMP
NA
NA
NA
NA
NA
NA
NA
NA
NA
Voltmeter Method
To find the time needed to fully charge your battery, determine the battery's charge level
with a voltmeter or electronic State-of-Charge Tester. Use the table below to convert
Voltmeter and State-of-Charge readings at room temperature to the appropriate Charge
Factor. Then use the formulas that follow the table to determine the approximate Charge
Time.
Charge Factor Table
iiiiiiii_iiiiiiiili iiiiiii_iiiiiiiiii!iiiiiii;iii_i_:_iiii!iiiii_!iiiiiiiiiii:iiiiiiiiii_iii il;!i!!iiiliiii ii ii;_;ii
Voltmeter B_ _g
12 Volt Battery 6 Volt Battery
12.67 6.34 100% 0
12.45 6.22 75% 0.25
12.25 6.12 50% 0.50
12.06 6.03 25% 0.75
11.86 5.93 0% 1
11

Charge Time Needed if Amp-Hours is Known
• Find the Charge Factor for your battery in the table on page 11.
•Multiply by the Amp-Hour rating of the battery.
•Divide by the Charger Setting (either 2 Amp or 12 Amp).
•Multiply by 1.25 to get the approximate Hours Neededto bring the battery to full
charge.
Example: 15Amp-Hour (AH) Battery, 50% State-of-Charge,
2 Amp Charger Setting
[(AH x Charge Factor) ÷Charger Setting] x 1.25 = Hours Needed
(15 x 0.5 +2) x 1.25 = 4.7 Hours
Charge Time Needed if Reserve Capacity is Known
• Find the Charge Factor for your battery in the table on page 11.
•Multiply by the Reserve Capacity rating of the battery.
•Divide by the Charger Setting (either 2 Amp or 12 Amp).
•Multiply by 0,73 to get the approximate Hours Needed to bring the battery to
full charge.
Example: 95-Minute Reserve Capacity (RC) Battery, 25%
State-of-Charge, 12 Amp Charger Setting
[(RC x Charge Factor) +Charger Setting] x 0.73 =Hours Needed
[(95 x0.75) + 12] x 0.73 = 4.3 Hours
To 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.
12

Performanceproblemsoften result from little thingsthat you can fix yourself.Please
read through this chart for a possiblesolution if a problem occurs.
No ammeter reading
Circuit breaker in
charger cycles on
and off with a
clicking sound in the
MANUAL setting.
Ammeter reads less
than selected
charge rate when
charging.
Charger makes a
loud buzz or hum.
Short start cycle
when cranking
engine.
Clamps not making good
connection.
2-amp charge rate.
No AC power reaching
charger.
Shorted battery clamps.
Shorted battery.
Charger leads reversed
on battery.
Extension cord too long
or gauge too small.
Battery has weak cell or
sulfated plate.
Battery is partially
charged.
Transformer laminations
vibrate (buzz).
Shorted diode (hum).
Drawing more than 75
amps 7 seconds or less.
Failure to wait for 4
minutes (240 seconds)
between cranks.
Check for poor connection at battery. Make
sure clamps and posts are clean. Battery may
not accept an AUTOMATIC charge if severely
discharged. Use MANUAL setting, see "Using
Your Battery Charger" on page 6.
Ammeter needle will indicate little activity at the
2-amp charge rate.
Check AC outlet and extension cords for loose
fitting plug.
Check for open fuse or circuit breaker
supplying AC outlet.
Separate the clamps. Circuit breaker cycles
when current draw is too high.
Check for worn cables and replace if needed.
Have a Sears technician test the battery.
Correct connections.
! Use shorter or heavier extension cord.
Sulfated battery will eventually take a
normal charge if leftconnected. Ifthe
battery will not take a charge, have it
tested by a Sears technician.
Continue charging battery.
Continue charging. Buzz is not abnormal.
Have charger tested by qualified technician.
Crank time varies with the amount of current
drawn from the charger. If cranking draws
more than 75 amps, crank time may be less
than 7 seconds.
Wait 4minutes before next crank.
If the above solutions do not eliminate the problem,..call ton-free from anywhere in the U.S.A.
1-000-SEARS-64 • (1400-732-7764) 7 AM to 4:30 PM CST Monday through Friday
13

This section shows an illustration of your battery charger. Use it to become familiar with
where all the parts are located, and what they look like.
Item Description Part Number
1Transformer 93026483
2Diode Asm Kit 2299000976
3 PC Board Asm 2299000966
4 Circuit Breaker 3999000088
5 DC Cable Asm 3899000850
6 SCR 55A 3100300017
7 Power Cord 90026111M
Item Description
8 Handle
9 Switch-left DPDT
10 Switch - ri_lhtDPDT
11 Meter
12 Cord Wrap Cleats
13 Owner's Manual
14 Faceplate
Part Number
3599000270
0499000060
0499000068
5399100093
1199004390
0000000598
0899001076
14

(-)
i
_313_
15

For information about troubleshooting
Call toll-freefrom anywhere inthe U.S.A.
7am to 4:30 pm CST Monday through Friday
1-800-732-7764
For the repair or replacement
parts you need
Call 7 am - 7 pm, 7 days a week
1-800-366-PART
(1-800-366-7278)
For the location of an authorized
Sears Service Center in your area
Call 24 hours a day, 7 days a week
1-800-488-1222
When requesting service or
ordering parts, always provide
the following information:
•ProductType: 12/2/75 AMP
Fully Automatic Battery Charger
•Model Number: 200.713121
•Part Number (See Page 14)
•Part Description (See Page 14)