Sears Battery Charger 20071206 User Guide

OWNER’S MANUAL  
6/2 AMP  
MANUAL  
BATTERY  
CHARGER  
Model No.  
200.71206  
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.  
 
0000000508-1196  
IMPORTANT SAFETY 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.  
service or repair is required. Incorrect  
assembly may result in fire or electri-  
cal shock.  
• To reduce risk of electrical shock,  
unplug the charger from the outlet  
before attempting any maintenance or  
cleaning.  
• Use charger only on lead-acid type  
rechargeable batteries, such as those  
used in cars, trucks, tractors, air-  
planes, vans, RV’s, trolling motors,  
etc. This charger is not intended to  
supply power to a low voltage electri-  
cal system other than in an automotive  
application.  
• Always charge battery in a well  
ventilated area.  
clean up.  
• Battery chargers get hot during  
operation and must have proper  
ventilation. Air needs to flow around  
entire charger.  
• 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 set on flammable items like  
carpeting, upholstery, paper, card-  
board, etc. Will damage leather and,  
melt plastic and rubber.  
• Do not disassemble charger. Take it to  
a qualified service professional if  
HELP US HELP YOU  
Remember:  
Place charger as far away from  
battery being charged as the charger  
cables will permit.  
Never touch the battery clamps  
together when the charger is ener-  
gized.  
Do not expose charger to rain or  
snow.  
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.  
Never charge a frozen battery. If  
battery fluid (electrolyte) becomes  
frozen, bring battery into a warm area  
to thaw before you begin charging.  
Be sure to position the charger power  
cord to prevent it from being stepped  
on, tripped over, or damaged.  
Never allow battery acid to drip on  
charger when reading specific gravity  
or filling battery.  
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.  
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.  
Do not operate the charger if it has a  
damaged power cord or plug. Have  
the cord replaced.  
Never use charger for charging dry-  
 
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 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  
 
4
BEFORE USING YOUR BATTERY CHARGER  
It is important to prepare your charger for use. This section will tell you about your  
charger's electrical requirements and how to prepare a battery for charging.  
PLUGGING IT IN  
DANGER: Before using an adapter as  
illustrated, be certain that the center  
screw of the outlet plate is grounded.  
WARNING: Electrical Shock Hazard  
Be sure that power cord fits properly  
The green colored grounding clip of the  
into outlet. If not, have a qualified  
adapter must be attached by a screw to  
technician install a proper outlet. Never  
a properly grounded outlet. If unsure  
alter the AC cord or plug provided.  
whether outlet is properly grounded,  
Improper connection can result in elect-  
contact a professional electrician. If  
trical shock.  
necessary, replace the original outlet  
Your charger should be grounded to reduce  
the risk of electical shock.  
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:  
Your charger is equipped with an  
electrical cord that has an equip-  
ment grounding conductor and a  
grounding lplug desinged to be used  
on a 120 volt circuit. The plug must be  
plugged into an outlet that has been  
properly installed and grounded in acc-  
ordance with all local codes and ordin-  
ances.  
• 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.  
• Make sure that the wire size is large  
enough for its length and for the AC  
ampere rating as specified in the  
accompanying chart.  
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.  
MINIMUM RECOMMENDED EXTENSION CORD  
Length of Cord, in Feet 25  
50 100 150  
AWG* Size of Cord  
18  
18  
16 14  
*AWG=American Wire Gauge  
 
5
PREPARING YOUR BATTERY TO BE CHARGED  
cell caps while charging, and recom-  
mended rates of charge.  
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  
lead-acid battery.  
• Wear safety glasses. See additional  
"Personal Safety Precautions" on page  
4.  
• Clean the battery terminals. Be careful  
to keep corrosion from getting in or  
around your eyes.  
• 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  
• If you have a battery with removable  
cell caps, if required, add distilled water  
to each cell until the battery acid  
reaches the level recommended by the  
manufacturer. This will help purge  
excessive gases from the cells. Be  
careful not to overfill. If you have a  
sealed battery without cell caps, no  
action is necessary. Continue to the  
next step listed below.  
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.  
• Take time to read all battery  
manufacturer’s specific precautions,  
such as removing or not removing  
NOTE: A marine battery installed in a  
boat must be removed and charged on  
shore.  
USING YOUR BATTERY CHARGER  
For best results from your battery charger, learn to use it properly. This section tells  
how to set the controls and how to charge a battery in or out of the vehicle.  
rate. As the battery charges, the needle  
will fall to about 2 or 3 amps, indicating  
a charged battery.  
SETTING THE CONTROLS  
SELECTOR SWITCHES:  
A 2-way switch is used to select the 2-AMP  
or the 6-AMP charge rate.  
At the 2 amp charging rate, as the  
battery charges the needle will fall to  
about 3/4 to 1 amp indicating a charged  
battery.  
L
6 AMP  
L
2 AMP  
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 6 using the 6 amp charging  
Continued…  
 
6
When using the ENGINE START  
feature, the needle will swing into the  
Start (red) area of the scale while you  
are cranking the engine.  
The percent of charge scale is intended  
as a visual aid to help simplify reading  
the state of charge of the battery. The  
meter is scaled for use with the 10 amp  
charge rate only. For the 2 amp charge  
rate use the red triangle. The percent of  
charge is based on current drawn by the  
battery. For this reason accuracy will  
vary with the size and battery type.  
NEGATIVE GROUNDED SYSTEM  
Figure A  
Charging Your Battery  
Charging a battery in the  
vehicle:  
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 off the posts and  
causing sparks.  
7. Select the charge rate with the  
Selector Switch then plug the power cord  
into a grounded AC outlet to begin  
charging.  
8. The charger will not stop when the  
battery is fully charged. For this reason  
it is important to check charging  
progress frequently. Overcharging  
can damage a battery, you must moni-  
tor and unplug charger when battery is fully  
charged.  
9. When the battery is fully charged,  
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.  
10. When the battery is fully charged,  
unplug the charger power cord before  
attempting to disconnect charger clamps.  
11. Standing away f rom the battery, re-  
move the charger clamps in this order:  
(1) from the chassis connection and,  
(2) from the battery post or terminal.  
12. Clean and store the battery charger  
in a dry location.  
1. Arrange the power cord and  
charging leads carefully to avoid  
damage that could be caused by the  
hood,door, or moving engine parts.  
2. Keep clear of fan blades, belts,  
pulleys,and other parts that can cause  
injury.  
3. Check the polarity of the battery posts  
as indicated on the battery case: POSITIVE  
(POS, P, or +) and NEGATIVE (NEG. N or -).  
NOTE: The positive post on top-post  
batteries is usually larger than the  
negative post.  
4. Identify which battery post is ground or  
connected to the chassis. THE NEGATIVE  
POST IS NORMALLY THE ONE THAT IS  
GROUNDED. (Fig. A)  
5. To charge a negative grounded post  
system:  
Connect the red (POSITIVE) battery  
charger clamp to the ungrounded  
POSITIVE (POS, P, +) post of the battery.  
Then connect the black (NEGATIVE)  
clamp to a heavy, unpainted metal part  
of the chassis or engine block, away  
from the battery. Donot connect clamp to  
carburetor, fuel lines,or sheetmetal parts.  
To charge a positive grounded post  
system:  
Connect the black (NEGATIVE) battery  
charger clamp to the NEGATIVE (NEG, N, -)  
ungrounded post of the battery.  
Then connect the red (POSITIVE) clamp  
to a heavy, unpainted metal part  
of the chassis or engine block. Do not  
Continued...  
 
7
(NEGATIVE) lead of the charger to the free  
end of the cable. Rock the clamp to make  
a solid connection.  
Charging your battery  
outside the vehicle:  
NEGATIVE  
POSITIVE  
IMPORTANT: Wear safety glasses and  
face away from the battery while  
making this final connection.  
BATTERY  
CHARGER  
BATTERY  
+
-
6. Select the rate of charge with the Select  
or Switch then plug the power cord into a  
grounded AC outlet to begin charging.  
POWER  
CORD  
24", 6  
GAUGE  
CABLE  
7. The charger will not stop when the  
battery is fully charged. For this reason it  
is important to check charging progress  
frequently. Overcharging can damage a  
battery, you must monitor and unplug  
charger when battery is fully charged.  
TO  
GROUNDED  
POWER  
OUTLET  
Figure B  
1. Remove the battery from vehicle,  
making sure to disconnect grounded  
terminal first with all accessories  
and lights turned off in the vehicle.  
8. When the battery is fully charged,  
the AMMETER pointer will fall to about  
half the charge rateselected. For specific  
positions, refer to the “Ammeter” section in  
“Using your battery charger” on page 6.  
2. Check the polarity of the battery posts  
as indicated on the battery case: POSITIVE  
(POS, P, +) and NEGATIVE (NEG, N, -).  
9. When the battery is fully charged,  
unplug the charger power cord before  
attempting to disconnect charger clamps.  
NOTE: On top-post batteries, the  
positive battery terminal usually has a larger  
diameter post than the negative one.  
10. Stand away from the battery and  
remove thecharger leads from the  
NEGATIVE connection first, then from the  
POSITIVE battery post or terminal.  
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.  
11. Clean and store the battery charger in a  
dry location.  
4. Attach a 6-gauge (AWG) or a 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)  
or a 4-gauge (SAE) insulated 24-inch cable  
and, standing as far away from the battery as  
possible, connect the black  
 
8
CALCULATING CHARGE TIME  
The Chart Method  
Marine, or deep-cycle batteries are  
Use the following table to more accu-  
rately determine the time it will take to  
bring a battery to full charge.  
First, identify where your battery fits into  
the chart.  
usually rated in Reserve Capacity  
(RC).  
NR means that the charger setting is  
NOT RECOMMENED.  
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 Capac-  
ity (RC), Cold-Cranking Amps  
(CCA), or both.  
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-percent charge prior to recharging.  
Add more time for severely discharged  
batteries.  
CHARGE RATE/CHARGING TIME - HOURS  
BATTERY SIZE/RATING  
6 AMP  
NR  
NR  
4 - 5  
5 - 6  
6 - 12  
6
2 AMP  
2 - 4  
4 - 10  
11 - 14  
14 - 18  
18 - 35  
18  
SMALL  
BATTERIES  
6 - 12 AH  
12 - 32 AH  
40 - 60 RC  
60 - 85 RC  
85 -190 RC  
80 RC  
Motorcycle, garden  
tractor, etc.  
200 - 315 CCA  
315 - 550 CCA  
550 - 1000 CCA  
CAR/TRUCKS  
MARINE/DEEP CYCLE  
27  
140 RC  
9
30  
160 RC  
10  
33  
180 RC  
11  
The Hydrometer or Electronic Method  
To find the time needed to fully charge your battery, determine the battery’s charge  
level with a hydrometeror 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  
CHARGE NEEDED  
1.265  
1.225  
1.155  
1.120  
100%  
75%  
25%  
0%  
0%  
25%  
75%  
100%  
Continued...  
 
9
Calculating Charge Time (Continued)  
When you know the percent of charge  
and the AmpHour (AH) rating of your  
battery, you can calculate the approx-  
imate time needed to bring your battery  
to a full charge.  
(A battery at 50 percent charge that  
will be charged to 100 percent  
needs another 50 percent (.50).  
Multiply the Amp Hour rating by the  
charge needed (.50) and divide by  
the charger setting (2 or 6 amps).  
To convert Reserve Capacity to Amp  
Hour (AH) Rating, divide Reserve  
Capacity by 2, and add 16:  
Multiply the result by 1.25 and you’ll  
have the approximate time needed,  
in hours, to bring the battery to full  
charge.  
AH = Reserve Capacity + 16  
2
To calculate time needed for a  
charge:  
Add one additional hour for a deep-  
cycle battery.  
Find the percent of charge needed.  
CONVERSION EXAMPLE:  
Amp Hour Rating x % of Charge Needed x 1.25 = Hours of Charge  
(
)
Charger Setting  
or  
100 (AH Rating) x .50 (charge needed) x 1.25 = 10.4 Hours  
)
(
6 (Charger Setting)  
or  
100 x .50 8.33 x 1.25 = 10.4  
)
(
6
You would need to charge your 100-Ampere Hour Battery for approximately 10½  
hours at the 6-Amp charge rate using the above example.  
 
10  
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.  
This will help prevent accidental  
damage to the cords and charger.  
3. Occasional cleaning of the case of  
the charger with a soft cloth will  
keep the finish shiny and help  
prevent corrosion.  
 
11  
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.  
PROBLEM  
POSSIBLE CAUSE  
SOLUTION/REASONS  
Check for poor connection at battery.  
Make sure clamps and posts are clean.  
Ammeter needle will indicate little activ-  
ity at the 2-amp charge rate.  
No ammeter reading.  
Clamps not making good  
connection.  
2-amp charge rate.  
No AC power reaching charger. Check AC outlet and extension cords for  
loose fitting plug.  
Check for open fuse or circuit breaker  
supplying AC outlet.  
Circuit breaker in  
charger cycles on and  
off with a clicking  
sound.  
Separate the clamps. Circuit  
breaker cycles when current  
draw is too high. Check for worn  
cables and replace if needed.  
Shorted battery clamps.  
Have qualified Sears technician  
test the battery.  
Shorted battery.  
Correct connections.  
Charger leads reversed  
on battery.  
Ammeter reads less  
Extension cord too long or  
Use shorter or heavier extension cord.  
than selected charge wire gauge to small.  
Sulfated battery will eventually take a  
normal charge if left connected. If the  
battery will not take a charge, have it  
tested by a qualified Sears technician.  
rate when charging.  
Battery has weak cell or  
sulfated plate.  
Continue charging battery.  
Battery is only partially  
discharged.  
Continue charging. Buzz is not  
abnormal.  
Charger makes a loud Transformer laminations  
buzz or hum.  
vibrate (buzz).  
Have charger tested by qualified  
technician.  
Shorted diode (hum).  
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  
 
PARTS  
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.  
Replacement Parts List Sears 71206  
Item Description  
Part Number  
3799001402  
2299000825  
3799001382  
90026058  
1
2
3
4
5
6
7
8
Cover  
Heatsink/Diode Assembly  
Base  
AC Power Cord  
Transformer  
93026433  
Output Cable  
3899000016  
3999000044  
2299000248  
0399000007  
0399000008  
5399100090  
0499000032  
3799001392  
0899000530  
3599000240  
5181806256  
Circuit Breaker (12A)  
50A Clamp (1)  
Sleeving Red (2) required  
Sleeving Black (2) required  
Meter  
9
10  
11  
12  
13  
14  
15  
Switch SPDT  
Front Panel  
Decal  
Handle  
Screw 8-18 x 3/8" (4)  
Owner's Manual and Parts List (Not Shown) 0000000508  
 
13  
WIRING DIAGRAM  
 
14  
NOTES  
 
15  
For information about troubleshooting  
Call toll-free from anywhere in the U.S.A.  
7 am to 4:30 pm CST Monday through  
Friday 1-800-SEARS-64  
(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 a Sears Repair  
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:  
Product Type: 6/2 AMP  
Manual Battery Charger  
Model Number: 200.71206  
Part Number (See Page 13)  
Part Description (See Page 13)  
REPAIR SERVICES  
America's Repair Specialists  
 
16  

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