DieHard 28.71221 User manual

OPERATOR’S MANUAL
Model No.
28.71221
00-99-001008/01
12V Manual Battery Charger
Read and follow all Safety
Rules and Operating Instructions
before Every Use of this Product.
SAVE THESE INSTRUCTIONS.
Sears Brands Management Corporation, Hoffman Estates, IL 60179 U.S.A.

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 3 years from the date
of purchase, return it to any DieHard outlet in the United States for free replacement.
This warranty gives you specic legal rights, and you may also have other rights
which vary from state to state.
Sears Brands Management Corporation, Hoffman Estates, IL 60179
FOR CUSTOMER ASSISTANCE OR REPLACEMENT PARTS,
CALL TOLL-FREE FROM 7 AM TO 5 PM CT
MONDAY THROUGH FRIDAY: 1-800-732-7764
TABLE OF CONTENTS
SECTION PAGE
IMPORTANT SAFETY INSTRUCTIONS 1
PERSONAL PRECAUTIONS 2
PREPARING TO CHARGE 3
CHARGER LOCATION 3
DC CONNECTION PRECAUTIONS 4
FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE 4
FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE 5
GROUNDING AND AC POWER CORD CONNECTIONS 5
ASSEMBLY INSTRUCTIONS 6
FEATURES/CONTROL PANEL 6
OPERATING INSTRUCTIONS 6
CALCULATING CHARGE TIME 7
MAINTENANCE INSTRUCTIONS 7
MOVING AND STORAGE INSTRUCTIONS 8
TROUBLESHOOTING 8
BEFORE RETURNING FOR REPAIRS 9

•1 •
IMPORTANT: READ AND SAVE THIS SAFETY AND INSTRUCTION MANUAL.
SAVE THESE INSTRUCTIONS – The 71221 offers a wide range of features to
accommodate your needs. This manual will show you how to use your charger safely
and effectively. Please read, understand and follow these instructions and precautions
carefully, as this manual contains important safety and operating instructions. The safety
messages used throughout this manual contain a signal word, a message and an icon.
The signal word indicates the level of the hazard in a situation.
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury to the operator or bystanders.
Indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury to the operator or bystanders.
Indicates a potentially hazardous situation which, if not avoided, could result
in moderate or minor injury to the operator
or bystanders.
Indicates a potentially hazardous situation which, if not avoided, could result
in damage to the equipment or vehicle or
property damage.
Safety messages in this manual contain two different sentence styles.
Unnumbered sentences state the hazard.•
Numbered sentences state how to avoid the hazard.•
The icon gives a graphical description of the potential hazard.
Pursuant to California Proposition 65, this product contains chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS -1.
This manual contains important safety and operating instructions
RISK OF ELECTRIC SHOCK OR FIRE.
Keep out of reach of children.1.1
Do not expose the charger to rain or snow.1.2
Use only recommended attachments. Use of an attachment not recommended or sold1.3
by the battery charger manufacturer may result in a risk of re, electric shock or injury to
persons or damage to property.
To reduce the risk of damage to the electric plug or cord, pull by the plug rather than the1.4
cord when disconnecting the charger.
An extension cord should not be used unless absolutely necessary. Use of an improper1.5
extension cord could result in a risk of re 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.•
That the wire size is large enough for the AC ampere rating of the charger as•
specied in section 8.

•2 •
To reduce the risk of electric shock, unplug the charger from the outlet before attempting1.6
any maintenance or cleaning. Simply turning off the controls will not reduce this risk.
Do not operate the charger with a damaged cord or plug; have the cord or plug replaced1.7
immediately by a qualied service person. (Call customer service at: 1-800-732-7764.)
Do not operate the charger if it has received a sharp blow, been dropped or otherwise1.8
damaged in any way; take it to a qualied service person. (Call customer service at:
1-800-732-7764.)
Do not disassemble the charger; take it to a qualied service person when service or 1.9
repair is required. Incorrect reassembly may result in a risk of re or electric shock. (Call
customer service at: 1-800-732-7764.)
RISK OF EXPLOSIVE GASES.
WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.1.10
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY
OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT
YOU FOLLOW ALL INSTRUCTIONS IN THIS MANUAL EACH TIME YOU USE
THE CHARGER.
To reduce the risk of a battery explosion, follow all instructions in this manual and those1.11
published by the battery manufacturer 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.
This charger employs parts, such as switches and circuit breakers, that tend to produce1.12
arcs and sparks. If used in a garage, locate this charger 18 inches or more above
oor level.
PERSONAL PRECAUTIONS2.
RISK OF EXPLOSIVE GASES.
NEVER smoke or allow a spark or ame in the vicinity of a battery or engine.2.1
Remove personal metal items such as rings, bracelets, necklaces and watches when2.2
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.
Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might2.3
spark or short-circuit the battery or other electrical part that may cause an explosion.
Use this charger for charging LEAD-ACID batteries only. It is not intended to supply2.4
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.
NEVER charge a frozen battery.2.5
NEVER overcharge a battery.2.6
Consider having someone close enough by to come to your aid when you work near a2.7
lead-acid battery.
Have plenty of fresh water and soap nearby in case battery acid contacts your skin,2.8
clothing or eyes.

•3 •
Wear complete eye and body protection, including safety goggles and protective2.9
clothing. Avoid touching your eyes while working near the battery.
If battery acid contacts your skin or clothing, immediately wash the area with soap and2.10
water. If acid enters your eye, immediately ood the eye with cold running water for at
least 10 minutes and get medical attention right away.
If battery acid is accidentally swallowed, drink milk, the whites of eggs or water. DO NOT2.11
induce vomiting. Seek medical attention immediately.
PREPARING TO CHARGE3.
RISK OF CONTACT WITH BATTERY ACID. BATTERY ACID
IS A HIGHLY CORROSIVE SULFURIC ACID.
If it is necessary to remove the battery from the vehicle to charge it, always remove the3.1
grounded terminal rst. Make sure all of the accessories in the vehicle are off to
prevent arcing.
Be sure the area around the battery is well ventilated while the battery is3.2
being charged.
Clean the battery terminals before charging the battery. During cleaning, keep airborne3.3
corrosion from coming into contact with your eyes, nose and mouth. Use baking soda
and water to neutralize the battery acid and help eliminate airborne corrosion. Do not
touch your eyes, nose or mouth.
Add distilled water to each cell until the battery acid reaches the level specied by the 3.4
battery manufacturer. Do not overll. For a battery without removable cell caps, such
as valve regulated lead acid batteries (VRLA), carefully follow the manufacturer’s
recharging instructions.
Read, understand and follow all instructions for the charger, battery, vehicle and any3.5
equipment used near the battery and charger. Study all of the battery manufacturer’s
specic precautions while charging and recommended rates of charge.
Determine the voltage of the battery by referring to the vehicle owner’s manual and 3.6
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 in the lowest rate rst.
Make sure that the charger cable clips make tight connections.3.7
CHARGER LOCATION4.
RISK OF EXPLOSION AND CONTACT WITH
BATTERY ACID.
Locate the charger as far away from the battery as the DC cables permit.4.1
Never place the charger directly above the battery being charged; gases from the4.2
battery will corrode and damage the charger.
Do not set the battery on top of the charger.4.3
Never allow battery acid to drip onto the charger when reading the electrolyte specic 4.4
gravity or lling the battery.
Do not operate the charger in a closed-in area or restrict the ventilation in any way.4.5

•4 •
DC CONNECTION PRECAUTIONS5.
Connect and disconnect the DC output clips only after setting all of the charger switches5.1
to the “off” position (if applicable) and removing the AC plug from the electrical outlet.
Never allow the clips to touch each other.
Attach the clips to the battery and chassis, as indicated in sections 6 and 7.5.2
FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE6.
A SPARK NEAR THE BATTERY MAY CAUSE
A BATTERY EXPLOSION. TO REDUCE THE
RISK OF A SPARK NEAR THE BATTERY:
NEGATIVE GROUNDED SYSTEM
Position the AC and DC cables to reduce the risk of damage by the hood, door and6.1
moving or hot engine parts. NOTE: If it is necessary to close the hood during the
charging process, ensure that the hood does not touch the metal part of the battery clips
or cut the insulation of the cables.
Stay clear of fan blades, belts, pulleys and other parts that can cause injury.6.2
Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually 6.3
has a larger diameter than the NEGATIVE (NEG, N, -) post.
Determine which post of the battery is grounded (connected) to the chassis (vehicle 6.4
frame). 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.
For a negative-grounded vehicle, connect the POSITIVE (RED) clip from the battery 6.5
charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect the
NEGATIVE (BLACK) clip to the vehicle frame or engine block at a distance away from
the battery. Do not connect the clip to the carburetor, fuel lines or sheet-metal body
parts. Connect to a heavy gauge metal part of the vehicle frame or engine block.
For a positive-grounded vehicle, connect the NEGATIVE (BLACK) clip from the battery 6.6
charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery. Connect the
POSITIVE (RED) clip to the vehicle frame or engine block at a distance away from the
battery. Do not connect the clip to the carburetor, fuel lines or sheet-metal body parts.
Connect to a heavy gauge metal part of the vehicle frame or engine block.
Connect charger AC supply cord to electrical outlet.6.7
When disconnecting the charger, turn all switches to off, disconnect the AC cord, remove6.8
the clip from the vehicle chassis and then remove the clip from the battery terminal.
See CALCULATING CHARGE TIME for length of charge information.6.9

•5 •
FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE7.
A SPARK NEAR THE BATTERY MAY CAUSE
A BATTERY EXPLOSION. TO REDUCE THE
RISK OF A SPARK NEAR THE BATTERY:
Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually 7.1
has a larger diameter than the NEGATIVE (NEG, N, -) post.
Attach at least a 24-inch (61 cm) long 6-gauge (AWG) insulated battery cable to the 7.2
NEGATIVE (NEG, N, -) battery post.
Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) post of 7.3
the battery.
Position yourself and the free end of the cable you previously attached to the NEGATIVE7.4
(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.
Do not face the battery when making the nal connection.7.5
Connect charger AC supply cord to electrical outlet.7.6
When disconnecting the charger, always do so in the reverse order of the connecting7.7
procedure and break the rst connection while as far away from the battery as practical.
A marine (boat) battery must be removed and charged on shore. To charge it onboard 7.8
requires equipment specially designed for marine use.
GROUNDING AND AC POWER CORD CONNECTIONS8.
RISK OF ELECTRIC SHOCK OR FIRE.
This battery charger is for use on a nominal 120-volt circuit and8.1
has a grounded plug that looks like the plug illustrated. The
charger must be grounded to reduce the risk of electric shock.
The plug must be plugged into an outlet that is properly installed
and grounded in accordance with all local codes and ordinances.
The plug pins must t the receptacle (outlet). Do not use with an
ungrounded system.
8.2 Never alter the AC cord or plug provided – if it does not t the outlet,
have a proper grounded outlet installed by a qualied electrician. An improper
connection can result in a risk of an electric shock or electrocution.
NOTE: Pursuant to Canadian Regulations, use of an adapter plug is not allowed in
Canada. Use of an adapter plug in the United States is not recommended and should
not be used.

•6 •
Recommended minimum AWG size for extension cord:8.3
100 feet long or less - use a 16 gauge extension cord.•
Over 100 feet long - use a 14 gauge extension cord.•
ASSEMBLY INSTRUCTIONS9.
Remove all cord wraps and uncoil the cables prior to using the battery charger.
FEATURES/CONTROL PANEL10.
Ammeter1.
Charge Rate Selector Switch2.
Battery Clips3.
12
3
Setting the controls
All of the controls for your charger are located on the front of the charger. Read these
instructions to properly set the charger controls.
Ammeter
The Ammeter indicates the amount of current, measured in amps, that is being drawn
by the battery. As a battery takes on a charge, it draws less current from the charger.
Correspondingly, the meter will show less current being drawn by the battery. When the
current stops decreasing, the battery is charged.
The 2 amp charge rate may indicate some activity on the meter, although the meter
does not have the resolution to display this low rate. For the 2 amp charge rate, a
triangle has been provided. Its accuracy has been calibrated for use with small batteries.
Percent of Charge•
The percent of charge is based on the current drawn by the battery. For this reason,
accuracy will vary with the size and battery type.
Charge Rate Selector Switch:
Use the Charge Rate Selector switch to select the charge rate setting you require.
OPERATING INSTRUCTIONS11.
This battery charger must be properly assembled in accordance with
the assembly instructions before it is used.
The charger does not have an On/Off switch. The On and Off commands are controlled
by plugging the 71221 into a 120V AC electrical wall outlet only after the battery
connections have been made.
NOTE: Once the charger is plugged in, the battery clips are live. Make sure they are
properly connected to the battery before plugging the charger into an AC outlet or it
could cause a short circuit that may cause personal injury and/or property damage.

•7 •
Charging
Ensure that all of the charger components are in place and in good working1.
condition, for example, the plastic boots on the battery clips.
Connect the battery following the precautions listed in sections 6 and 7.2.
Select the appropriate settings for your battery.3.
Connect the AC power following the precautions listed in section 8. Make sure to4.
place the charger on a dry, non-ammable surface like metal or concrete.
To disconnect the charger, reverse the above procedure.5.
Manual Charging
When a Manual Charge is performed, the charger will continue to charge and will not
shut off. You must keep a visual check on the ammeter to determine when the battery
is charged. Be sure to monitor the charging process and stop it when the battery is
charged. Not doing so may cause damage to your battery or result in other property
damage or personal injury.
CALCULATING CHARGE TIME12.
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 ts into the chart.
CCA = Cold Cranking Amps
RC = Reserve Capacity
AH = Amp Hour
NR means that the charger setting is NOT RECOMMENDED.
Find your battery’s rating on the chart below, and note the charge time given for each
charger setting. The times given are for batteries with a 50% charge prior to recharging.
Add more time for severely discharged batteries.
BATTERY SIZE/RATING CHARGE RATE/CHARGING TIME
2 AMP 10 AMP
SMALL
BATTERIES
Motorcycle,
garden,
tractor, etc.
6 - 12 AH 2 - 4 hrs NR
12 - 32 AH 4 - 10 hrs NR
CARS/
TRUCKS
200 - 315 CCA 40 - 60 RC 11 ¼ - 14 ½ hrs 2¼ – 3 hrs
315 - 550 CCA 60 - 85 RC 14 ½ - 18 ¼ hrs 3 – 3¾ hrs
550 - 1000 CCA 80 - 190 RC 18 ¼ - 34 ¾ hrs 3¾ – 7 hrs
MARINE/DEEP CYCLE
80 RC 17 ½ hrs 3½ hrs
140 RC 27 hrs 5½ hrs
160 RC 30 hrs 6 hrs
180 RC 33 hrs 6¾ hrs
MAINTENANCE INSTRUCTIONS13.
After use and before performing maintenance, unplug and disconnect the battery13.1
charger (see sections 6, 7 and 8).
Use a dry cloth to wipe all battery corrosion and other dirt or oil from the battery clips,13.2
cords, and the charger case.
Ensure that all of the charger components are in place and in good working condition,13.3
for example, the plastic boots on the battery clips.
Servicing does not require opening the unit, as there are no user-serviceable parts.13.4
All other servicing should be performed by qualied service personal.13.5

•8 •
MOVING AND STORAGE INSTRUCTIONS14.
Store the charger unplugged, in an upright position. The cord will still conduct electricity14.1
until it is unplugged from the outlet.
Store inside, in a cool, dry place.14.2
Do not store the clips on the handle, clipped together, on or around metal, or clipped14.3
to cables.
If the charger is moved around the shop or transported to another location, take care to14.4
avoid/prevent damage to the cords, clips and charger. Failure to do so could result in
personal injury or property damage.
TROUBLESHOOTING15.
PROBLEM POSSIBLE CAUSE REASON/SOLUTION
The charger will not turn on,
there is no reading on the
ammeter or the charger is
not charging the battery.
Charger is not plugged in.
No power at the receptacle.
Poor electrical connection.
Clips are not making a good
connection to the battery.
Connections are reversed.
Battery is defective (will not
accept a charge).
2 amp charge rate is being
used.
Plug the charger into an AC
outlet.
Check for open fuse or circuit
breaker supplying AC outlet.
Check power cord and
extension cord for loose tting
plug.
Check for poor connection to
battery and frame. Make sure
connection points are clean.
Rock the clips back and forth
for a better connection.
Unplug the charger and
reverse the clips.
Have battery checked.
Ammeter may show no activity
at the 2A charge rate.
Ammeter reading stays high. Battery is severely
discharged.
Wrong battery voltage.
Continue charging battery for
two more hours. If problem
continues have the battery
checked.
Verify that the voltage settings
on the charger are correct.
Ammeter reads less than
selected charge rate when
charging a discharged
battery.
Extension cord is too long or
wire gauge is too small.
Weak cell or sulfated plate in
battery.
Battery is only partially
discharged.
Use a shorter or heavier
gauge extension cord.
If the battery will not take a
charge, have it checked.
Continue to charge the
battery.

•9 •
PROBLEM POSSIBLE CAUSE REASON/SOLUTION
The charger is making an
audible clicking sound.
Circuit breaker is cycling.
Battery is defective.
Shorted battery cables or
clips.
Severely discharged battery,
but otherwise it is a good
battery.
Reverse connections at
battery.
The settings may be wrong.
Check the charger settings.
Have the battery checked.
Circuit breaker cycles when
current draw is too high.
Check for shorted cables or
clips and replace if necessary.
The battery may not want to
accept a charge due to a run-
down state. Allow charging to
continue until battery has a
chance to recover sufciently
to take a charge. If more than
20 minutes, stop charging and
have the battery checked.
Shut the charger off and
correct the lead connections.
Charger makes a noticable
buzz or hum.
Transformer laminations
vibrate (buzz).
No problem, this is a normal
condition.
BEFORE RETURNING FOR REPAIRS16.
When a charging problem arises, make certain that the battery is capable of accepting16.1
a normal charge. Double check all connections, the AC outlet for a full 120 volts, the
charger clips for correct polarity and the quality of the connections from the cables to the
clips and from the clips to the battery system. The clips must be clean.
When a battery is very cold, partially charged or sulfated, it will not draw the full rated16.2
amperes from the charger. It is both dangerous and damaging to a battery to force
higher amperage into it than it can effectively use in recharging.
When an UNKNOWN OPERATING PROBLEM arises, please read this complete16.3
manual and call the customer service number for information that will usually eliminate
the need for return.
If the above solutions do not eliminate the problem, or for information about troubleshootingor
replacement parts, call toll-free from anywhere in the U.S.A.
1-800-732-7764
7:00 am to 5:00 pm Central Time Monday through Friday