8E/ 8

OWNER'S
MANUAL

Model No.
200,71440

40/2 AMP
MANUAL BATTERY
CHARGER
200 AMP
CAUTION:
ENGINE STARTER
Read and Follow Al! Safety
Rules and Operating Instructions
Before Every Useof this Product.

Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.

Table Of Contents
Warranty .................................................................. 1 Using Your Battery Charger .................................... 7
Important Safety Instructions .................................. 2 Setting the controls ................................................ 7
Parts ......................................................................... 3 Charging your battery ............................................ 8
Before Using Your Battery Charger ........................ 4 Calculating charge time ....................................... 10
Assembling your charger ....................................... 4 Using the engine start feature .............................. 11
Plugging it in .......................................................... 5 Maintenance and care ......................................... 11
Using an extension cord ........................................ 6 Troubleshooting ..................................................... 12

Preparing your battery to be charged .................... 6

Please read this Owner's Manual before using your Battery Charger

The Sears model 200.71440, Manual Battery Charger/Engine Starter, offers a wide range of features to
accommodate the needs for home or commercial use. This manual will show you how to use your charger
safely and effectively. Please read and follow these instructions and precautions carefully.

Warranty
FULL THREE-YEAR WARRANTY

If, within three years from the date of purchase this battery charger fails due to a defect in materials or work-
manship, simply RETURN IT TO THE NEAREST SEARS STORE IN THE UNITED STATES, and Sears will
repair or replace it, free of charge.

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
Important Safety Instructions
- SAVE THESE INSTRUCTIONS -

• Read all instructions and cautions printed on the • De not disassemble charger. Take it to a qualified
battery charger, battery, and vehicle or equipment service professional if service or repair is required.
using battery. Incorrect assembly may result in fire or electrical
• Use charger only on lead-acid type rechargeable shock.
batteries, such as those used in cars, trucks, trac- • To reduce risk of electrical shock, unplug the
tors, airplanes, vans, RV's, trolling motors, etc. charger from the outlet before attempting any
This charger is not intended to supply power to maintenance or cleaning.
a low voltage electrical system other than in an • Always charge battery in a well ventilated area.
automotive application.
• 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
• Never touch the battery clamps together when the
charged as the charger cables will permit.
charger is energized.
• Do not expose charger to rain or snow.
• Never operate charger if it has received a hard blow,
• Never charge a frozen battery. If battery fluid (electro-
been dropped, or otherwise damaged. Take it to a
lyte) becomes frozen, bring battery into a warm area qualified professional for inspection and repair.
to thaw before you begin charging.
• Be sure to position the charger power cord to
• Never allow battery acid to drip on charger when
prevent it from being stepped on, tripped over, or
reading specific gravity or filling battery.
damaged.
• Never set a battery on top of the charger. • Never pull out the plug by the cord when unplug-
• Never place charger directly above battery being ging the charger. Pulling on the cord may cause
charged. The gases from the battery will corrode damage to the cord or the plug.
and damage the charger.
• Do not operate the charger if it has a damaged
• Never use charger for charging dry-cell batteries that power cord or plug. Flave the cord replaced.
are commonly used with home appliances. These
batteries may burst and cause personal injury.

Personal Safety Precautions

For your own personal safety, please follow the follow- • Remove all personal metal items from your body,
ing precautions: such as rings, bracelets, necklaces, and watches
• Wear complete eye and clothing protection when while working with a lead-acid battery A battery can
working with lead-acid batteries. produce a short circuit current high enough to weld
• Be sure that someone is within range of your voice a ring (or the like) to metal, causing a severe burn.
to come to your aid if needed while you work with or • Take care not to drop any metal tool or metal object
are near a lead-acid battery. onto the battery. This may spark or short circuit the
• Have plenty of fresh water and soap nearby for use battery or another electrical device that may cause
in case battery acid contacts your eyes, skin, or cloth- an explosion.
ing. If this happens, wash immediately with soap and • Always operate your battery charger in an open, well
water. Then get medical attention. ventilated area.
• Avoid touching your eyes while working with a • Never smoke or allow a spark or flame in the vicinity
battery. Acid particles (corrosion) may get into your of the battery or engine. Batteries generate explosive
eyes. If this occurs, flush eyes immediately with gases.
running cold water for at least 10 minutes. Then • Neutralize any acid spills thoroughly with baking
immediately get medical attention. soda before attempting to clean up.

2
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 Description Part Number
1 Handle 3599000286
2 Negative (BLK) cable w/clamps 3899000396 4

3 Positive (RED) cable w/clamps 3899000410

4 Power Cord 90026096
5 Circuit Breaker Asm 3999000057
6 Rectifier Assembly 2299000614
7 Transformer 93026365
8 Owner's Manual (not shown) 0000000516
9 Wheel 0099000080
10 Hub Cap 5200000008
11 Axle 0099000060
12 Axle mtg, bracket 1199004366
13 Mounting Foot 1199003352
14 Rocker Switch 3 pos. 0499000052
15 Ammeter 5399100097 13
12
16 Rocker Switch 2 pos. 0499000050

14

Wiring diagram

3
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:

Two 10-32 thread cutting 3/8" wrench
screws (for mounting foot)
Two 1/4-20 thread cutting 5/16" wrench
screws (for wheels)
Two wheels Hammer
One axle Phillips screwdriver
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 II II
hubs facing inward.

continued on next page

4
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.

4'
ji
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

Electrical Shock Hazard

Be sure that power cord fits properly into outlet.
If not, have a qualified technician install a proper
outtet. 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.

5
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. 11111
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 (Xl
adapter must be attached by a screw to a properly _,.....dw
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.
• Usa 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.

Length of Cord, in Feel 25 50 100 150

AWG* Size of Cord 18 14 12 10

*AWG = American Wice Gauge

Preparing your battery to be charged

It is important that you read and follow these guidelines • Wear safety glasses. See additional "Personal
while you are preparing to charge your battery. Safety Precautions" on page 2.
• Make sure that you have a 12 volt lead-acid battery. Be sure that the area around the battery is well
Clean the battery terminals. Be careful to keep ventilated while it is being charged. If ventilation is
corrosion from getting in or around your eyes. poor, gas can be manually blown away by using a
• If you have a battery with removable cell caps, if piece of cardboard or other non-metallic material as
required, add distilled water to each cell until the a fan.
battery acid reaches the level indicated by the If it is necessary to remove the battery from the
manufacturer. This will help purge excessive gases vehicle to charge it, always remove the grounded
from the cells. Be careful not to overfill. If you have a terminal from the battery first. A spark may be
sealed battery without cell caps, no action is neces- caused if all accessories in the vehicle are not
sary. Continue to the next step listed below. completely turned off.
• Take time to read all battery manufacturer's specific NOTE: A marine battery installed in a boat must be
precautions, such as removing or not removing removed and charged on shore.
cell caps while charging, and recommended rates
of charge.

6
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 2A 12V
OUTPUT SELECTOR SWITCHES CHARGE CHARGE

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 200A_12V_'L. SELEC_T
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 ENGINE
connecting the charger to the battery and to the AC START
power outlet.
• Select -- This setting enables you to select one of
VOLT/AMP SELECTOR
the two charge-rate settings offered by the 2-positon
switch.
• 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.
AMPS
When cranking the engine while using the ENGINE
START feature, the needle will swing into the Start
(red) area of the scale.

7
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.

8
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 topopost 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.

9
Calculating charge time
The Chart Method
"Use the following table to more accurately determine • Marine, or deep-cycle batteries are usually rated in
the time it will take to bring a battery to full charge. Reserve Capacity (RC).
First, identify where your battery fits into the chart. • NR means that the charger setting is NOT
Small batteries -- motorcycles, garden tractors, etc. RECOMMENDED.
-- are usually rated in Ampere Hours (AH). For Find your battery's rating on the following chart and
example; 6 to 12 AH, or 12 to 32 AH. note the charge time given for each charger setting.
Batteries in cars and smaller trucks are usually rated The times given are for batteries with a 50-percent
in Reserve Capacity (RC), Cold-Cranking Amps charge. Add more time for totally discharged batteries.
(CCA), or both.

CHARGE RATE/CHARGING TIME - HOURS

BATrERY SIZE/RATING
2 AMP 40 AMP
SMALL Motorcycle, garden 6-12AH 2-4 NR
BAFFERIES tractor, etc. 12-32 AH 4-10 NR
20O - 315 CCA 40 - 60 RC 11 -14 1/2- 3/4
CAR_RUCKS 315 - 550 CCA 60 - 85 RC 14-18 3/4- 1
550 - 1000 CCA 85 -190 RC 18 - 35 1-2
8O RC 18 NR
MARINE/DEEP CYCLE
140 RC 27 NR
160 RC 30 NR
180 RC 33 NR

The Hydrometer or Electronic Method To calculate time needed for a charge:

To find the time needed to fully charge your battery, Find the percent of charge needed. (A battery at
determine the battery's charge level with a hydrometer 50 percent charge that will be charged to 100
or electronic Percent-of-Charge Tester. The following percent needs another 50 percent (.50).
table will help you convert hydrometer readings to Multiply the Amp Hour rati6g by the charge
3ercent of charge values. needed (.50) and divide by the charger setting (2
or 40 amps).
SPECIFIC PERCENT PERCENT OF • Multiply the result by 1.25 and you'll have the time
G_V TY OF CHARGE CHARGE NEEDED need, in hours, to bring the battery to full charge.
• Add one more hour for a deep-cycle battery.
1.265 100% 0%

1.225 75% 25% Example:

Amp Hour Rating x % of charqe needed x 1.25 = hours
1,155 25% 75%
Charger Setting of
1.120 0% 100% charge
needed

When you know the percent of charge and the Amp 100 {AH Rating) x .50 (charqe needed) x 1.25 = 1.5625
Hour (AH) rating of your battery, you can calculate the 40 (Charger Setting) hours
time needed to bring your battery to a full charge.
To convert Reserve Capacity to Amp Hours, divide 100 x :50 = 1.25 x 1.25 = 1.5625
Reserve Capacity by 2, and add 16: 40

Amp Hours = Reserve Capacity + 16 You would need to charge your 100-Ampere Hour Bat-
2 tery for a littlemore than 1.5 hours atthe 40-Amp charge
rate using the above example.

10
Using the engine start feature
Your battery charger can be used to jump-start your 6. If the engine still does not start, charge the battery
car if the battery is low. Follow these instructions on for five more minutes in the 40 amp position
how to use the engine start feature. before cranking it again for five seconds.
1. Set the right-hand OUTPUT SELECTOR switch to 7. After the engine starts, unplug the charger power
the OFF position. Then follow the instructions for cord from the outlet. Then move the right-hand
connecting the charger to the battery in the OUTPUT SELECTOR SWITCH to the OFF
section "Charging your battery in the vehicle" see position before disconnecting the battery leads.
page 7.
2. Once the charger is connected, set the right-hand IMPORTANT: Do not try to start the engine without a
selector switch to SELECT and set the left selector battery in it. You could cause damage to the electrical
switch to the 200 AMP START position. system.
3. Plug in the charger,
4. Crank the engine for no more than five seconds. If the engine does turn over, but never starts up, there
If the engine does not start, wait four minutes is not a problem with the starting system, there is a
before cranking again. problem somewhere else with the vehicle. STOP
5. During extremely cold weather, or if the battery is cranking the engine until the other problem has been
severely exhausted, charge the battery for about diagnosed and corrected.
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
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 Clamps are not making a Check for poor connections to battery and frame. Make
ammeter, good connection, 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 AC cord and/or extension Check power cord and extension cord for loose fitting
to be not working, cord is loose, plug.

Circuit breaker in Shorted battery clamps. Circuit breaker cycles when current draw is too high.
charger cycles on and Separate the clamps.
off with a clicking Check for worn cables and replace if needed.
sound,
Shorted battery. Have a Sears technician test the battery.
Charger leads reversed. Correct connections.

Volt/Amp Selector Switch Correct Volt/Amp Selector setting.

set to the START position.

Short start cycle Drawing more than 200 Crank time varies with the amount of current drawn. If
when cranking amps for a period of 5 cranking draws more than 200 amps, crank time may be
engine. seconds or less. less than 5 seconds.
Failure to wait for 4 Wait 4 minutes before next crank,
minutes (240 seconds)
between cranks.

Ammeter reads less Extension cord too long or Use shorter or heavier gauge extension cord.
than selected charge wire guage too small.
rate when charging a Weak cell or sulfated plate Sulfated battery will eventually take a normal charge if left
discharged battery. in battery. connected. If the battery will not take a charge, have it
tested by a Sears technician.
Battery is only partially Continue to charge battery.
discharged.

Charger makes a loud Transformer laminations Continue charging. Buzz is not abnormal.
buzz or hum. vibrate (buzz),
Shorted diode (hum). Have charger tested by qualified technician.

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
 SEE/AIRS MANUAL
40/2
BATTERY
AMP

OWNER'S CHARGER
MANUAL 200 AMP
ENGINE STARTER
Model No.
200.71440
Forinformationabouttroubleshooting
Calltoll-freefromanywhereinthe U.S.A.
7 am to 4:30 pm CSTMondaythrough Friday
1-800-SEARS-64
(1-800-732-7764)

Forthe repairor replacement

partsyouneed
Call7 am - 7 pm, 7 days a week
1-800-366-PART
(1-800-366-7278)

Forthe locationof a SearsRepair

ServiceCenterin your-area
Call24 hoursa day,
7 daysa week
1-800-488-1222

When requesting service or

ordering parts, always provide
the following information:

• Product Type
SE/ARS
• Model Number
• Part Number America's Repair Specialists

• Part Description

0000000516-995