OWNER’S
MANUAL
Model No.
200.71440
40/2 AMP
MANUAL BATTERY
CHARGER
200 AMP
ENGINE STARTER
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.
Important Safety Instructions
– SAVE THESE INSTRUCTIONS –
w
To reduce the risk of explosion, explosive gases, or injury while
using your battery charger, follow the precautions listed below:
L! WARNING
•Read all instructions and cautions printed on the
battery charger, battery, and vehicle or equipment
using battery.
•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.
•Use charger only on lead-acid type rechargeable
batteries, such as those used in cars, trucks, trac-
tors, airplanes, vans, RV’s, trolling motors, etc.
This charger is not intended to supply power to
a low voltage electrical system other than in an
automotive application.
•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.
•Use only attachments recommended or sold by
manufacturer. The use of attachments not recom-
mended by the manufacturer may result in fire,
electric shock, or injury.
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 (electro-
lyte) 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 touch the battery clamps together when the
charger is energized.
•Never operate charger if it has received a hard blow,
been dropped, or otherwise damaged. Take it to a
qualified professional for inspection and repair.
•Be sure to position the charger power cord to
prevent it from being stepped on, tripped over, or
damaged.
•Never pull out the plug by the cord when unplug-
ging 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.
•Never use charger for charging dry-cell batteries that
are commonly used with home appliances. These
batteries may burst and cause personal injury.
•Do not operate the charger if it has a damaged
power cord or plug. Have the cord replaced.
Personal Safety Precautions
For your own personal safety, please follow the follow-
ing 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 cloth-
ing. If this happens, wash immediately with soap and
water. Then get medical attention.
•Remove all personal metal items from your body,
such as rings, bracelets, necklaces, and watches
while working with a lead-acid battery. A battery can
produce a short circuit current high enough to weld
a ring (or the like) to metal, causing a severe burn.
•Take care not to drop any metal tool or metal object
onto the battery. This may spark or short circuit the
battery or another electrical device that may cause
an explosion.
•Always operate your battery charger in an open, well
ventilated area.
•Never smoke or allow a spark or flame in the vicinity
of the battery or engine. Batteries generate explosive
gases.
•Neutralize any acid spills thoroughly with baking
soda before attempting to clean up.
•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.
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Sears 440 - Sch 516 9/16/95
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 71440
Item
1
Description
Part Number
3599000286
3899000396
3899000410
90026096
Handle
2
Negative (BLK) cable w/clamps
Positive (RED) cable w/clamps
Power Cord
3
4
5
Circuit Breaker Asm
Rectifier Assembly
Transformer
3999000057
2299000614
93026365
6
7
8
Owner's Manual (not shown)
Wheel
0000000516
0099000080
5200000008
0099000060
1199004366
1199003352
0499000052
5399100097
0499000050
9
10
11
12
13
14
15
16
Hub Cap
Axle
Axle mtg. bracket
Mounting Foot
Rocker Switch 3 pos.
Ammeter
Rocker Switch 2 pos.
Wiring diagram
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Sears 440 - Sch 516 9/16/95
Before Using Your Battery Charger
It is important to prepare your charger for use. This section will tell you how to assemble the charger, ground
and connect the power cord, and prepare to charge a battery.
Assembling your charger
It is important to fully assemble your charger before
use. Follow these instructions for easy assembly.
PARTS:
TOOLS NEEDED:
3/8" wrench
(for mounting foot)
Two 10-32 thread cutting
screws
5/16" wrench
(for wheels)
Two 1/4-20 thread cutting
screws
Hammer
Two wheels
Phillips screwdriver
One axle
Two axle caps
Two axle brackets
One handle
One mounting foot
To attach the axle assembly:
1. Remove charger from packing materials and place
upside down on a flat surface. Attach mounting foot
and secure with the two 1/4-20 thread cutting
screws.
2. Hold axle upright on floor or work surface. Then,
using a hammer, tap one of the plastic hubs onto
the top end of the axle. Be sure to tap the hub on
straight. Slide both wheels onto the axle with the
hubs facing inward.
continued on next page
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Sears 440 - Sch 516 9/16/95
3. Tap the other axle cap onto the opposite end of the
axle and place the axle assembly onto the bottom of
the charger. Place one end of the bracket into slot,
then place the axle assembly under each bracket.
Fasten the other side of the brackets using the two
10-32 screws provided.
To attach the handle:
Turn the charger right side up onto its foot and wheels.
Remove the two top screws from each side of the
charger and align with the screw holes on the handle.
Attach the handle using the same screws.
Plugging it in
L! WARNING
Electrical Shock Hazard
Be sure that power cord fits properly into outlet.
If not, have a qualified technician install a proper
outlet. Never alter the AC cord or plug provided.
Improper connection can result in electrical shock.
Your charger should be grounded to reduce the risk
of electrical shock.
Your charger is equipped with an electrical cord that
has an equipment grounding conductor and a ground-
ing plug designed to be used on a 120 volt circuit. The
plug must be plugged into an outlet that has been
properly installed and grounded in accordance with all
local codes and ordinances.
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Sears 440 - Sch 516 9/16/95
A TEMPORARY adapter may be used to connect the
charger to a two-pole outlet if a properly grounded
outlet is not available. Use the adapter ONLY until a
properly grounded outlet can be installed by a qualified
electrician.
DANGER: Before using an adapter as illustrated, be
certain that the center screw of the outlet plate is
grounded. The green colored grounding clip of the
adapter must be attached by a screw to a properly
grounded outlet. If unsure whether outlet is properly
grounded, contact a professional electrician. If neces-
sary, replace the original outlet cover screw with a
longer one that will secure the grounding clip to the
outlet cover and make a ground connection to the
grounded outlet.
Using an extension cord
The use of an extension cord is not recommended. If
you must use an extension cord, please make sure
that you follow these guidelines:
•Make sure the pins on the plug of the extension cord
are the same number, size, and shape as those of the
plug on the charger.
• Use only 3-conductor (grounded) extension cord
when necessary.
•Check that the extension cord is properly wired and
in good electrical condition.
•Use the recommemnded minumum AWG (American
Wire Gauge) to be sure that wire size is large enough
for the rating of the charger.
MINIMUM RECOMMENDED EXTENSION CORD
Length of Cord, in Feet 25
50
14
100
12
150
10
AWG* Size of Cord
18
*AWG=American Wire Gauge
Preparing your battery to be charged
It is important that you read and follow these guidelines
while you are preparing to charge your battery.
• Wear safety glasses. See additional "Personal
Safety Precautions" on page 2.
•Make sure that you have a 12 volt lead-acid battery.
Clean the battery terminals. Be careful to keep
corrosion from getting in or around your eyes.
•If you have a battery with removable cell caps, if
required, add distilled water to each cell until the
battery acid reaches the level indicated by the
manufacturer. This will help purge excessive gases
from the cells. Be careful not to overfill. If you have a
sealed battery without cell caps, no action is neces-
sary. Continue to the next step listed below.
• Be sure that the area around the battery is well
ventilated while it is being charged. If ventilation is
poor, gas can be manually blown away by using a
piece of cardboard or other non-metallic material as
a fan.
• If it is necessary to remove the battery from the
vehicle to charge it, always remove the grounded
terminal from the battery first. A spark may be
caused if all accessories in the vehicle are not
completely turned off.
•Take time to read all battery manufacturer’s specific
precautions, such as removing or not removing
cell caps while charging, and recommended rates
of charge.
NOTE: A marine battery installed in a boat must be
removed and charged on shore.
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Sears 440 - Sch 516 9/16/95
Using Your Battery Charger
To obtain the best results from your battery charger, you must know how to use it properly. This section will tell
you how to set the controls. And how you can charge a battery while it is still in the vehicle, or you can remove it
and then charge it. Follow the instructions below depending on how you choose to charge your battery.
Setting the controls
All the controls for your charger are located on the
front of the unit. Follow these instructions to obtain the
accurate charge level for your battery
40A 12V
CHARGE
2A 12V
CHARGE
.
OUTPUT SELECTOR SWITCHES
Two switches are used to select the rate of charge or
function—a 3-position switch on the right, and a 2-
position swtich to the left of it. Use the 3-position
switch to select:
©
OFF
• 2 Amp Trickle Charge — Use for charging small
batteries and warming large batteries. The lower the
charge rate, the longer it will take, but the battery is
subjected to much less stress.
• OFF — Leave the switch in the OFF Position while
connecting the charger to the battery and to the AC
power outlet.
SELECT
200A 12V
ENGINE
START
• Select — This setting enables you to select one of
the two charge-rate settings offered by the 2-positon
switch.
VOLT/AMP SELECTOR
• Use the 40 Amp Charge rate for a fast charge.
• Use the 200 Amp Engine Start for cranking the
engine. Remember that little or no charging has
been done by the charger and, unless your trip
is quite long, your battery will still need further
charging by the vehicle's charging system once
the engine starts.
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 40 at the 40 AMP CHARGE rate. As
the battery charges, the needle will fall to about 15 to
20 amps, indicating a charged battery.
At the 2 AMP CHARGE 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.
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Sears 440 - Sch 516 9/16/95
Charging Your Battery
Charging your battery in the vehicle:
1. Arrange the power cord and charging leads
carefully in order to avoid damage that could be
caused by the hood, door, or moving engine parts.
2. Keep clear of the fan blades, belts, pulleys, and
other parts that can cause injury.
3. Check the polarity of the battery posts using the
identification marks on the battery case: POSITIVE
(POS, P, +) and NEGATIVE (NEG, N, -).
4. Identify which battery post is 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) charger clamp to the
ungrounded POSITIVE (POS, P, +) post of the
battery. Next, 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.
To charge a positive grounded post system:
Connect the black (NEGATIVE) charger clamp to the
ungrounded NEGATIVE (NEG, N, -) post of the
battery. Then connect the red (POSITIVE) clamp to
a heavy unpainted metal part of the chassis or
engine block, away from the battery. Do not con-
nect clamp to carburetor, fuel lines or sheet metal
parts.
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. Set your charger's right-hand 3-position selector
switch to the OFF position. Then plug the charger's
power cord into a grounded AC outlet.
8. Select the desired charge rate. (See "Setting the
Controls" on page 7.)
9. 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.
10. When the battery is fully charged, the AMMETER
needle will fall to about half the charge rate selected.
For specific positions, see the “Ammeter” section of
“Setting the Controls” on page 7.
11. When the battery is fully charged, unplug the
charger power cord. Next, set the right-hand switch
to the OFF position.
12. Standing away from the battery, remove the charger
clamp from the chassis first, then from the battery
post or terminal.
13. Clean and store the battery charger in a dry location.
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Sears 440 - Sch 516 9/16/95
Charging your battery outside the vehicle:
1. Remove the battery from vehicle, making sure to
disconnect grounded terminal first with all power
turned off to 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 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 of at least 24-inches in
length to the NEGATIVE battery post. This cable
will provide a safer connection because any arcing
and sparking will not occur directly over the
battery. (The battery cable is not provided with the
charger, but may be purchased at most automo-
tive accessory outlets.)
5. Take the other end of the 6-gauge (AWG) or a 4-
gauge (SAE) insulated 24-inch cable and, stand-
ing as far away from the battery as possible,
connect the black (NEGATIVE) lead to the free
end of the cable. Be sure to rock the clamp to
make a solid connection. IMPORTANT: Wear
safety glasses and face away from the battery
while making the final connection.
6. Set your charger's right-hand 3-position selector
switch to the OFF position. Then plug the
charger's power cord into a grounded AC outlet.
7. Select the desired charge rate. (See "Setting the
Controls" on page 7.)
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 monitor and unplug
charger when battery is fully charged.
9. When the battery is fully charged, the AMMETER
needle will fall to about half the charge rate
selected. For specific positions, see the "Ammeter"
section of "Settings the Controls" on page 7.
10. When the battery is fully charged, unplug the
charger power cord before attempting to
disconnect charger clamps.
11. Standing away from the battery, remove the
charger leads. Remove the NEGATIVE clamp first,
then from the POSITIVE battery post or terminal.
12. Clean and store the battery charger in a dry
location.
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Sears 440 - Sch 516 9/16/95
Calculating charge time
The Chart Method
• Marine, or deep-cycle batteries are usually rated in
Reserve Capacity (RC).
• NR means that the charger setting is NOT
Use the following table to more accurately determine
the time it will take to bring a battery to full charge.
First, identify where your battery fits into the chart.
• Small batteries — motorcycles, garden tractors, etc.
— are usually rated in Ampere Hours (AH). For
example; 6 to 12 AH, or 12 to 32 AH.
RECOMMENDED.
Find your battery’s rating on the following chart and
note the charge time given for each charger setting.
The times given are for batteries with a 50-percent
charge. Add more time for totally discharged batteries.
• Batteries in cars and smaller trucks are usually rated
in Reserve Capacity (RC), Cold-Cranking Amps
(CCA), or both.
CHARGE RATE/CHARGING TIME - HOURS
BATTERYSIZE/RATING
2 AMP
2 - 4
4 - 10
11 - 14
14 - 18
18 - 35
18
40 AMP
NR
6 - 12 AH
SMALL
BATTERIES
Motorcycle, garden
tractor, etc.
12 - 32 AH
40 - 60 RC
60 - 85 RC
85 -190 RC
80 RC
NR
200 - 315 CCA
315 - 550 CCA
550 - 1000 CCA
1/2 - 3/4
3/4 - 1
1 - 2
NR
CAR/TRUCKS
MARINE/DEEPCYCLE
140 RC
27
NR
160 RC
30
NR
180 RC
33
NR
To calculate time needed for a charge:
The Hydrometer or Electronic Method
To find the time needed to fully charge your battery,
determine the battery’s charge level with a hydrometer
or electronic Percent-of-Charge Tester. The following
table will help you convert hydrometer readings to
percent of charge values.
•
Find the percent of charge needed. (A battery at
50 percent charge that will be charged to 100
percent needs another 50 percent (.50).
Multiply the Amp Hour rating by the charge
needed (.50) and divide by the charger setting (2
or 40 amps).
•
•
•
Multiply the result by 1.25 and you’ll have the time
need, in hours, to bring the battery to full charge.
Add one more hour for a deep-cycle battery.
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%
Example:
Amp Hour Rating x % of charge needed x 1.25 = hours
Charger Setting
of
charge
needed
100 (AH Rating) x .50 (charge needed) x 1.25 = 1.5625
When you know the percent of charge and the Amp
Hour (AH) rating of your battery, you can calculate the
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:
40 (Charger Setting)
hours
100 x .50 = 1.25 x 1.25 = 1.5625
40
You would need to charge your 100-Ampere Hour Bat-
tery for a little more than 1.5 hours at the 40-Amp charge
rate using the above example.
Amp Hours = Reserve Capacity + 16
2
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Sears 440 - Sch 516 9/16/95
Using the engine start feature
6. If the engine still does not start, charge the battery
Your battery charger can be used to jump-start your
car if the battery is low. Follow these instructions on
how to use the engine start feature.
for five more minutes in the 40 amp position
before cranking it again for five seconds.
7. After the engine starts, unplug the charger power
cord from the outlet. Then move the right-hand
OUTPUT SELECTOR SWITCH to the OFF
1. Set the right-hand OUTPUT SELECTOR switch to
the OFF position. Then follow the instructions for
connecting the charger to the battery in the
section “Charging your battery in the vehicle” see
page 7.
position before disconnecting the battery leads.
IMPORTANT: Do not try to start the engine without a
battery in it. You could cause damage to the electrical
system.
2. Once the charger is connected, set the right-hand
selector switch to SELECT and set the left selector
switch to the 200 AMP START position.
3. Plug in the charger.
If the engine does turn over, but never starts up, 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.
4. Crank the engine for no more than five seconds.
If the engine does not start, wait four minutes
before cranking again.
5. During extremely cold weather, or if the battery is
severely exhausted, charge the battery for about
five minutes before cranking the engine.
Maintenance and care
A minimal amount of care can keep your battery
charger working properly for years.
1. Clean the clamps each time you are finished
charging. Wipe off any battery fluid that may have
come in contact with the clamps to prevent
corrosion.
2. Coil the input and output cords neatly when
storing the charger. The cords can be wrapped
around the handle of the charger. This will help
prevent accidental damage to the cords and
charger.
3. Occasional cleaning of the case with a soft cloth
will keep the finish shiny and help prevent corro-
sion.
11
Sears 440 - Sch 516 9/16/95
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
No reading on the
ammeter.
Clamps are not making a
good connection.
Check for poor connections to battery and frame. Make
sure connecting points are clean.
2-amp charge rate is being Ammeter may show no activity at the 2-amp charge rate.
used.
No reading on
No power at receptacle
Check for open fuse or circuit breaker supplying AC outlet.
ammeter. Fan inside
wheel charger appears
to be not working.
AC cord and/or extension
cord is loose.
Check power cord and extension cord for loose fitting
plug.
Circuit breaker in
charger cycles on and
off with a clicking
sound.
Circuit breaker cycles when current draw is too high.
Separate the clamps.
Check for worn cables and replace if needed.
Shorted battery clamps.
Have a Sears technician test the battery.
Correct connections.
Shorted battery.
Charger leads reversed.
Correct Volt/Amp Selector setting.
Volt/Amp Selector Switch
set to the START position.
Short start cycle
when cranking
engine.
Drawing more than 200
amps for a period of 5
seconds or less.
Crank time varies with the amount of current drawn. If
cranking draws more than 200 amps, crank time may be
less than 5 seconds.
Failure to wait for 4
minutes (240 seconds)
between cranks.
Wait 4 minutes before next crank.
Ammeter reads less
than selected charge
rate when charging a
discharged battery.
Extension cord too long or
wire guage too small.
Use shorter or heavier gauge extension cord.
Sulfated battery will eventually take a normal charge if left
connected. If the battery will not take a charge, have it
tested by a Sears technician.
Weak cell or sulfated plate
in battery.
Continue to charge battery.
Battery is only partially
discharged.
Continue charging. Buzz is not abnormal.
Have charger tested by qualified technician.
Transformer laminations
vibrate (buzz).
Charger makes a loud
buzz or hum.
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
12
Sears 440 - Sch 516 9/16/95
40/2 AMP
MANUAL BATTERY
CHARGER
200 AMP
ENGINE STARTER
OWNER’S
MANUAL
Model No.
200.71440
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
• Model Number
• Part Number
REPAIR SERVICES
America's Repair Specialists
• Part Description
0000000516-995
|