Sealey PBIW4600 User manual

SCHUMACHER 500/1500HP 12/24V WHEELED
ROADSTART® EMERGENCY JUMP STARTER
MODEL NO’S: PBIW4600, PBIW6200
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions,
and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE
THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
1. SAFETY
1.1. GENERAL SAFETY
Modern vehicles contain extensive electronic systems. You are required to check with the vehicle manufacturer, for any
 specicinstructionsregardingtheuseofthistypeofequipmentoneachvehicle.
No liability will be accepted for damage/injury, where this product is not used in accordance with all instructions.
PLEASE SAVE THIS OWNER’S MANUAL AND READ BEFORE EACH USE.
9This manual will explain how to use the unit safely and effectively. Please read and follow these instructions and precautions carefully.
9If someone else uses the Roadstart, make they are well informed on how to use it safely, and have read and understood the operating
instructions. The longevity of the Roadstart depends on it.
9Charge the Roadstart’s internal battery immediately after purchase, after each use and as often as possible. It is highly recommended
to leave the Roadstart permanently connected to the automatic charger.
9Read the entire manual before using this product. Failure to do so could result in serious injury or death.
9Keep out of reach of children.
9This Roadstart is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack
of experience and knowledge, unless they have been given supervision or instruction concerning the use of the Roadstart by a person
responsible for their safety.
9This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental
capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in
a safe way and understand the hazards involved.
9Children shall not play with the appliance.
8DO NOT put ngers or hands into the product.
8DO NOT expose the Roadstart to rain or snow.
9 Use only recommended attachments. Use of an attachment not recommended or sold by Sealey may result in a risk of re, electric
shock or injury to persons or damage to property.
9To reduce the risk of damage to the electric plug or cord, pull by the plug rather than the cord when disconnecting the Roadstart.
9To reduce the risk of electric shock, unplug the Roadstart charger from the outlet before attempting any maintenance or cleaning.
Simply turning off the controls will not reduce this risk.
8DO NOT operate the Roadstart or charger with a damaged output cable; have the damaged part replaced immediately by a qualied
service person.
9 If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualied persons in order to avoid
a hazard.
8NEVER wait until the Roadstart is completely discharged before recharging.
8DO NOT operate the Roadstart if it has received a sharp blow, been dropped or otherwise damaged in any way; take it to a qualied
service person.
8DO NOT disassemble the Roadstart or charger; take it to a qualied service person when service or repair is required. Incorrect
reassembly may result in a risk of re or electric shock.
RISK OF EXPLOSIVE GASES. PREVENT FLAMES AND SPARKS. PROVIDE ADEQUATE VENTILATION DURING CHARGING.
WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES
DURING NORMAL OPERATION. FOR THIS REASON, IT IS IMPORTANT THAT YOU FOLLOW THESE INSTRUCTIONS EACH
TIME YOU USE THE ROADSTART.
9The Roadstart must be placed in a well-ventilated area.
9To reduce the risk of a battery explosion, follow these instructions and those 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.
1.2. PERSONAL PRECAUTIONS
RISK OF EXPLOSIVE GASES. A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK
OF A SPARK NEAR THE BATTERY:
9 NEVER smoke or allow a spark or ame in the vicinity of a battery or engine.
8DO NOT permit the internal battery of the Roadstart to freeze. Never charge a frozen battery.
Warning!
Original Language Version
© Jack Sealey Limited
Refer to
instruction
manual
Do not expose
to rain
Use in a well
ventilated area
Corrosive
substance
Keep away
from sparks
and ame -
battery could
emit explosive
gases
Wear eye
protection
Wear
protective
clothing
PBIW4600, PBIW6200 | Issue:2 (6) 04/11/19

Original Language Version
© Jack Sealey Limited
9When charging the internal battery, work in a well ventilated area and do not restrict the ventilation in any way.
9Be sure the area around the battery is well ventilated while the Roadstart is being used.
9Remove personal metal items such as rings, bracelets, necklaces and watches when 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.
9Be extra cautious, to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or other
electrical part that may cause an explosion.
9To prevent sparking, NEVER allow clamps to touch together or contact the same piece of metal.
9Consider having someone close enough by to come to your aid when you work near a lead-acid battery.
9Have plenty of fresh water and soap nearby in case battery acid contacts your skin, clothing or eyes.
9Wear complete eye and body protection, including safety goggles and protective clothing. Avoid touching your eyes while working near
the battery.
9 If battery acid contacts your skin or clothing, immediately wash the area with soap and 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.
9If battery acid is accidentally swallowed, drink milk, the whites of eggs or water. DO NOT induce vomiting. Seek medical attention
immediately.
2. INTRODUCTION
High performance (2x 23Ah PBIW4600, 2 x 32Ah PBIW6200) AGM battery, specially formulated to jump-start up to 1500hp diesel vehicles.
Rotomolded high durability casing with lifetime warranty. Patented 4A microprocessor controlled speed charging and thermal runaway
protection. Unlike other Roadstart packs, can be left safely on charge continuously. Audible warning signals if the unit has been turned on for too
long without being connected to a battery and reverse polarity. Isolating rotary on/off switch and analogue display showing the internal battery
level. 12V Output socket can be used as a memory saver as well as for powering accessories such as mini compressors. Ventilation system
vents gases directly out of the casing via a ‘Whistle’ outlet, warning the user of a potential issue. A fuse integrated in the (+) clamp provides
short-circuit and overload protection. Heavy-duty clamps with a braided link between each jaw for maximum power transmission. Curved clamps
provide easier access to awkward battery terminals.
3. SPECIFICATION
4. FEATURES
4.1. DESCRIPTION
1. Reverse polarity buzzer
2. 12V outlet, protected by 16A external circuit breaker
3. 500A fuse
4. Voltmeter
5. Push button for voltmeter
6. Voltage selector
7. Charger input plug
4.2. VOLTMETER
4.2.1. Press the button to show the charge level of the Roadstart.
4.2.2. Half an hour after disconnecting the charger from the Roadstart, the voltmeter must indicate about 13 volt for a full charge.
4.3. ALTERNATOR TESTING
4.3.1. After starting rev the engine to 2000 rpm, leave the Roadstart connected to the vehicle and press the voltmeter push button. The
voltmeter must indicate between 14 and 14.4 volt if the alternator is functioning correctly.
4.3.2.
Model no PBIW4600 PBIW6200
Auxiliary output 1 x 12V 1 x 12V
Cable and clamp length 1.4m 1.4m
Peak amps 4600A (12V), 2300A (24V) 6200A (12V), 3100A (24V)
Starting current 1800A/900A 2400/1200A
Voltage 12/24V 12/24V
PBIW4600, PBIW6200 | Issue:2 (6) 04/11/19

4.4. RECHARGING, see Section 8 also.
4.4.1. NEVER wait until the Roadstart is completely discharged before recharging.
4.4.2. A fully automatic and intelligent charger AC 230V is provided with the Roadstart. Connect the charger to the mains AC 230V, then
connect the charger to the Roadstart via the recharge plug. The Roadstart can be left permanently connected to the automatic charger,
to maintain correct charge level.
5. PREPARATION FOR USE
WARNING! Risk of contact with battery acid. Battery acid is a highly corrosive sulphuric acid.
5.1. Clean the battery terminals before using the Roadstart. During cleaning, keep airborne 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.
5.2. Read, understand and follow all instructions for the Roadstart, battery, vehicle and any equipment used near the battery and the
Roadstart.
5.3. Determine the voltage of the battery by referring to the vehicle owner’s manual and make sure that the output voltage of the Roadstart
is correct.
5.4. Make sure that the Roadstart cable clamps make tight connections.
5.5. CONNECTION TO A BATTERY
A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE
BATTERY:
5.5.1. Attach the output cables to the battery and chassis as indicated below. Never allow the output clamps to touch each other.
5.5.2. Position the cables to reduce the risk of damage by the engine cover, door and moving or hot engine parts.
NOTE: If it is necessary to close the bonnet during the jump starting process, ensure that the bonnet does not touch the metal part of
the battery clamps or cut the insulation of the cables.
5.5.3. Stay clear of fan blades, belts, pulleys and other parts that can cause injury.
5.5.4. Determine which post of the battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most
vehicles), see step 5.5. If the positive post is grounded to the chassis, see step 5.5.7.
5.5.5. For a negative-grounded vehicle, connect rst the POSITIVE (RED) clamp from the Roadstart to the POSITIVE (POS, P, +)
unearthed post of the battery. Then connect the NEGATIVE (BLACK) clamp to the vehicle chassis or engine block away from the
battery. DO NOT connect the clamp to the carburettor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the
chassis frame or engine block.
5.5.6. When disconnecting the Roadstart, rst remove the clamp from the vehicle chassis, then remove the clamp from the battery terminal,
in that order.
5.5.7. In the rare event that the vehicle is positive-grounded, connect the NEGATIVE (BLACK) clamp from the Roadstart to the NEGATIVE
(NEG, N, -) ungrounded post of the battery. Connect the POSITIVE (RED) clamp to the vehicle chassis or engine block away from the
battery. DO NOT connect the clamp to the carburettor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the
frame or engine block.
6. OPERATION
6.1. TO START A VEHICLE
6.1.1. THE VOLTAGE SELECTOR MUST BE DISCONNECTED !, FIG.1.
6.1.2. HOW TO CONNECT YOUR ROADSTART
IMPORTANT: Refer to section 6.8 risk of Explosion
6.1.2.1. 12VJUMPSTARTING,g.2
Connect the red clamp (+) to the positive terminal (+) of the battery, then connect the Black clamp (-) to the negative terminal of the
battery.
fig.1fig.2
Original Language Version
© Jack Sealey Limited PBIW4600, PBIW6200 | Issue:2 (6) 04/11/19

6.1.2.2. 24V JUMP STARTING
NOTE: Read point 6.2 detection of 24V
IF THE BATTERIES ARE SIDE BY SIDE,g.3
Connect the red clamp (+) to the positive terminal (+) of the battery, then connect the Black clamp (-) to the negative (-) terminal of the
other battery.
IF THE BATTERIES ARE ON BOTH SIDES OF THE VEHICLE,g.4
Connect the Red clamp (+) to the positive terminal (+) of the battery, then connect the black clamp (-) to the negative terminal (-) or to
the mass of the vehicle.
6.1.3. VOLTAGESELECTION,g.5
6.1.3.1. Select the correct voltage, for the vehicle to be jump started.
NOTE: From this moment on there is voltage to the clamps.
6.1.4. START THE ENGINE
6.1.4.1. Turn the ignition key for a maximum of 3 - 8 seconds. Wait for a further minute before attempting to start again.
6.1.5. DISCONNECTION,g.6
6.1.5.1. Disconnect the black (-) clamp rst followed by the red (+) clamp.
6.1.6. DISCONNECTIONOFTHEVOLTAGESELECTOR,g.7
6.1.7. After starting disconnect the voltage selector.
6.1.8. STORAGE,g.7seealsoSection7
6.1.9. Return the clamps to their support posts.
6.1.10. RECHARGING,g.8,seealsoSection8
6.1.10.1. Recharge the Roadstart immediately after use.
fig.6
fig.7fig.8
fig.5
fig.3
fig.4
Original Language Version
© Jack Sealey Limited

6.2. 24V VEHICLES - DETECTION OF 24V
6.2.1. Detection of 24 volt on a vehicle where the cables are not visible or where the batteries are located on both sides of the engine bay
(large types of engines), is as follows, g.9.
6.2.1.1. Use a voltmeter in position DC: connect the negative to the chassis of the vehicle and the positive to the positive post of a battery.
6.2.1.2. If the voltmeter indicates 12V, you are NOT connected on the right battery.
6.2.1.3. If the voltmeter meter indicates 24V the correct battery has been selected, g.10 and 10A. Connect the cargo booster clamps to the
same points, observing correct polarity.
6.3. REVERSE POLARITY
6.3.1. If the polarity is reversed, the buzzer will give a warning signal under the following conditions:
- if the remaining voltage in the batteries of the vehicle, is at least 4v.
- if the voltage connector is not connected.
6.4. STARTING ATTEMPTS
8DO NOT crank for more than 3-8 seconds, wait for a further 1 minute before making a second attempt.
The reasons are:
1. To allow the voltage of the Roadstart to build up again.
2. To allow gasses inside the batteries to disperse.
3. To allow the batteries to cool down.
NOTE: If you do not wait and /or the starting attempt is too long, you risk losing power, performance is reduced by the second attempt
and there is a risk of the fuse melting (blowing).
If after 3 attempts the engine does not start, if may be necessary to identify a further cause of the breakdown.
NOTE: if the Roadstart is fully charged and the starter turns slowly, the vehicle’s battery or that of the Roadstart, may need to be
inspected for a short circuit.
6.5. Never connect the Roadstart to a battery or a starter motor which is in short circuit.
6.6. Never disconnect the Roadstart whilst running the engine when there is no battery in the vehicle or when the vehicle’s battery is at 0
volt. This may cause failure of the diodes in the alternator.
6.7. Never connect the Roadstart in short circuit, for example:
1. By connecting the red clamp (+) to the negative terminal of the battery and black clamp (-) to the vehicle’s chassis, g.11.
THE REVERSE POLARITY SIGNAL WILL NOT OPERATE BECAUSE THIS IS NOT A REVERSE POLARITY.
Batteries side by side
Batteries located on both sides of the vehicle
fig.9
fig.10
fig.11
fig.10A
Original Language Version
© Jack Sealey Limited
9
9
8
PBIW4600, PBIW6200 | Issue:2 (6) 04/11/19

2. By connecting the clamps on the positive and negative terminal of the 2 batteries which are connected together in the 24V vehicle,
g.12.
6.8. RISK OF EXPLOSION
6.8.1. Never connect the Roadstart on a 24V vehicle when you have selected the 12V voltage.
6.8.2. If this mistake is made, do not disconnect the voltage selector, because this may cause a spark. It is recommended to disconnect
one of the clamps of the vehicle’s battery, to move away from the Roadstart and to wait some minutes while the hydrogen escapes
from the Roadstart. Contact supplier immediately.
6.9. PROTECTION, g.13.
6.9.1. Roadstart is equipped with an internal 500A fuse located inside the positive clamp. It can blow following a short circuit or a too long
starting attempt.
6.9.2. Test fuse with an external voltmeter if it is suspected that it has blown.
7. STORAGE
7.1. Store the Roadstart in an upright position, inside, in a cool, dry, child free place.
7.2. Always make sure the Roadstart is fully charged before storing. When not in use, it is highly recommended to leave the
Roadstart on charge with its original charger.
8DO NOT use and/or store the Roadstart in or on any area or surface where damage could occur if the internal battery should
unexpectedly leak acid.
7.3. Clamps must be stored on their support posts, ensuring they do not come into contact with any metallic surface.
8. RECHARGING
8.1. PREVENTING PREMATURE FAILURE OF THE BATTERIES
Note: Correct recharging of the batteries increases the Roadstart’s efciency and its lifespan.
8.1.1. The Roadstart must be put on permanent charge between use.
8.1.2. Never recharge the Roadstart 12/24V via the cigarette lighter plug of the Roadstart.
The cigarette lighter plug (outlet 12V) is only connected to one battery and is just provided for the connection of a portable lamp 12V
(maximum 16A) or all other 12V accessories.
8.1.3. Never completely discharge the Roadstart’s batteries because:
The batteries do not have a memory effect.
Danger of irreversible sulphation.
8.1.4. During the charge, the clamps must never touch a metallic surface. One or several poles in the charging plug may melt.
8.2. CHARGER CONTROL PANEL g.14
8.2.1. Press Start/Stop button to begin charging. If button is not pressed charging
should begin in 10 minutes.
8.2.2. Power LED (green) lit: connected to mains supply.
8.2.3. Charging LED (orange) lit: Roadstart battery is charging.
8.2.4. ChargingLED(orange)ashing:Roadstart battery is not charging because
charger has detected a problem.
8.2.5. Battery defect LED (red) will also light:
Reasons:
1. Battery voltage below 10V after 2 hours of charging - battery may be
defective. Make sure there are no loads on the battery, if there
are remove them. If there are no loads have the battery checked or replaced.
Desulphation unsuccessful - Battery may be defective have battery checked
or replaced.
2. Battery is sulphated - Charger is in desulphation mode. Continue charging
for 24 hours. If not successful have battery checked or replaced.
Lack of progress is detected and battery voltage is below 14.2V. The battery
may be overheated. If so allow to cool down. Have battery checked or
replaced.
Battery voltage drops to below 12.2V in Maintain Mode. The battery will not hold a charge.
May be caused by a drain on the battery or the battery could be bad. Make sure there are no loads on
the battery. If there are remove them. If not have the battery checked or replaced.
8.2.6. Charged/Maintaining LED (green) pulsing: The Roadstart battery is fully charged. The charger moves into oat charging mode to
maintain the battery capacity.
8.2.7. ReversepolarityLED(red)ashing: not applicable as Roadstart has a charging plug.
Original Language Version
© Jack Sealey Limited
fig.12 fig.13
fig.14

Original Language Version
© Jack Sealey Limited
SealeyGroup,KempsonWay,SuffolkBusinessPark,BuryStEdmunds,Suffolk.IP327AR
01284757500 01284703534 [e-mail] www.sealey.co.uk
BATTERY REMOVAL
Under the Waste Batteries and Accumulators Regulations 2009, Jack Sealey Ltd are required to inform potential purchasers of products
containing batteries (as defined within these regulations), that they are registered with Valpak’s registered compliance scheme. Jack
Sealey Ltd Batteries Producer Registration Number (BPRN) is BPRN00705.
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
WEEE REGULATIONS
Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment
(WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid
waste authority for recycling information.
PROBLEM POSSIBLE CAUSE REASON/SOLUTION
The Roadstart won’t jump start car. Clamps are not making a good connection
to the battery.
The Roadstart battery is not charged.
The vehicle’s battery is defective.
The fuse has blown.
Check for poor connection to battery and
chassis. Make sure connection points are
clean. Rock clamps back and forth for a
better connection.
Check the battery charge status by
pressing the button on the front of the
Roadstart.
Have the battery checked.
Replace the power fuse.
Roadstart will not power 12V device. The 12V device is not turned on.
The 16A fuse has been triggered.
Roadstart battery is not charged.
Turn on the 12V device.
Push the 16A fuse button to turn it back
on, see 4.1 point 2.
Check the battery charge status by
pressing the button on the front of the
Roadstart.
The battery in the Roadstart won’t hold a
charge.
The battery is bad (will not accept a
charge).
Have the battery checked.
The green POWER LED does not light
when charger is properly connected.
Mains outlet dead.
Poor electrical connection.
Check for open fuse or circuit breaker at
the supplying AC outlet.
Check power cord and extension cord for
a loose tting plug.
The red BATTERY DEFECT LED is lit and
yellow/orange CHARGING LED is ashing
rapidly.
The battery voltage is still under 10V after
2 hours of charging.
(or)
In maintain mode, the output current is
more than 1.5A for 12 hours.
Desulphation was unsuccessful.
The battery may be defective. Make sure
there are no loads on the battery. If there
are, remove them. If there are none, have
the battery checked or replaced.
The battery may be defective. Have it
checked or replaced.
9. TROUBLESHOOTING
PBIW4600, PBIW6200 | Issue:2 (6) 04/11/19