Sealey PWRSTART 6000,PWRSTART 4400 Instruction Manual

INSTRUCTION MANUAL FOR:

PowerStart Power Pack
12/24V 6000 Peak Amps

MODEL No: PWRSTART 6000

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS.
USE THIS 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. PLEASE RETAIN THESE INSTRUCTIONS FOR FUTURE USE.

Thank y ou for purch asing a Seal ey prod uct.
Manufactured to a high standard this item will give you years of trouble free performance if these instructions are carefully followed and the product is correctly maintained.

1. SAFETY INSTRUCTIONS

Original Language Version

PWRSTART6000 Issue: 2 - 16/05/11

1.1. ELECTRICAL SAFETY

REGARDING DIRECT MAINS POWER USE OF THE
CHARGING UNIT. (See fig.5)
 WARNING! It is the responsibility of the owner and the
operator to read, understand and comply with the following:
You must check all electrical products, before use, to ensure
that they are safe. You must inspect power cables, plugs,
sockets and any other connectors for wear or damage. You
must ensure that the risk of electric shock is minimised by the
installation of appropriate safety devices. A Residual Current
Circuit Breaker (RCCB) should be incorporated in the main
distribution board. We also recommend that a Residual
Current Device (RCD) is used. It is particularly important to
use an RCD with portable products that are plugged into a
supply which is not protected by an RCCB. If in any doubt
consult a qualified electrician. You may obtain a Residual
Current Device by contacting your Sealey dealer. You must
also read and understand the following instructions
concerning electrical safety.

1.1.1. The Electricity at Work Act 1989 requires that all portable
electrical appliances, if used on business premises, are tested
by a qualified electrician, using a Portable Appliance Tester
(PAT), at least once a year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of
electrical appliances responsible for the safe condition of
those appliances and the safety of the appliance operators. If

in any doubt about electrical safety, contact a qualified
electrician.

1.1.3. Ensure that the insulation on all cables and on the charger
is safe before connecting it to the power supply. See 1.1.1.
and 1.1.2. and use a Portable Appliance Tester.

1.1.4. Ensure that cables are always protected against short circuit
and overload.

1.1.5. Regularly inspect the power supply cable and plug for wear or
damage and check all connections to ensure that none is loose.

1.1.6. Important: Ensure that the voltage marked on the appliance
matches the power supply to be used and that the plug is
fitted with the correct fuse - see fuse rating at (BELOW) right.

1.1.7. DO NOT pull or carry the appliance by the power cable.

1.1.8. DO NOT pull the plug from the socket by the cable.

1.1.9. DO NOT use worn or
damaged cables,
plugs or connectors.
Immediately have
any faulty item
repaired or replaced
by a qualified
electrician. When a
BS 1363/A UK 3 pin
plug is damaged, cut
the cable just above
the plug and dispose
of the plug safely.
Fit a new plug
according to the
following instructions (UK only).

a) Connect the GREEN/YELLOW earth wire to the earth
terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that
all wires have been correctly connected, that the cable
outer insulation extends beyond the cable restraint and
that the restraint is tight.

Double insulated products, which are always marked with
this symbol , are fitted with live (brown) and neutral (blue)
wires only. To rewire, connect the wires as indicated in diagram.
DO NOT connect either wire to the earth terminal.

1.2. GENERAL SAFETY

 Read the vehicle handbook to check for any specific battery
charging information.

 This unit must only be used on systems running on 12V or

24V only.

 This unit is intended for use in emergencies only. Do not use

the starter instead of the vehicle battery. Use it during start-up
operations only.

 Avoid contact with battery acid. If an operator comes into

contact with the acid, rinse affected parts immediately under
clean running water. Continue to rinse the area until medical
help arrives.
 Wear approved safety eye protection i.e. goggles (standard
spectacles are not adequate).
 WARNING!Ensure that there are no sources of flammable
ignition near the work area i.e. naked flames, cigarettes, flame
heaters, etc. as lead acid batteries produce explosive gases.

 DO NOT allow the starter terminal clamps to touch each

other when the power is on. Remember that gases are
produced which may ignite if sparks occur. To minimise
accidental contact, disconnect the mounting socket (12V/24V)
from the starter panel and place the battery clamps in the
storage pocket on the front of the unit.
 WARNING! Ensure that the work area is well ventilated as the
gases produced are flammable.

 DO NOT work alone. In case of an accident have someone at

hand to help.
 Maintain the starter in good condition (use an authorised
service agent only).

 Keep the starter clean for best and safest performance.
 Locate the starter in a suitable work area and keep the

area clean and tidy and free from unrelated materials. Ensure
adequate lighting.
 Remove ill fitting clothing. Remove ties, watches, rings and
other loose jewellery and contain long hair.
 WARNING!Disconnect the mains power before servicing or
performing any maintenance.
 Disconnect from the mains power before connecting to, or
disconnecting from, the battery.

 Clean clamps and battery terminals, removing any oxidation

before connecting the starter to the battery.

 Ensure that the correct polarity clamp is attached to the

correct terminal of the battery. POSITIVE is indicated by (+)
and may be red, NEGATIVE is indicated by (-) and may be
black. If there are no identifiable symbols, you can
distinguish the NEGATIVE battery terminal as the one which
is connected from the battery directly to the vehicle body.
(For negative earth vehicles only, for positive Earth

vehicles consult the vehicle handbook for the correct
connection procedure.)

 DO NOT use any other type of Charger Unit other than the

one supplied to charge the starter unit.

 DO NOT use the Charger Unit to charge any other

electrical item.

 DO NOT get the Charger Unit wet, or use in wet, damp

conditions (for indoor use only).

 DO NOT operate the Charger Unit if it has been dropped, or

has received a sharp knock, or is damaged. Contact an
authorised service agent.

 DO NOT try to open or dis-assemble the Charger Unit as this

may cause damage or personal injury and will invalidate your
warranty.

RECOMMENDED FUSE RATING

3 AMP

Blue
Neutral
Wire

Yellow & Green
Earth Wire

Cable
Restraint

Brown
Live
Wire

2. INTRODUCTION & SPECIFICATION

3. ASSEMBLY

4. OPERATION

WARNING! Electrical shock can cause death or injury. Avoid

touching exposed conductors of electricity. This unit is designed for
use with vehicle or boats. You will not need a host vehicle or 230VAC
power supply (Except for recharging the unit after use). You can also
use this system as a portable power source of 12VDC in remote
areas or emergencies.

4.1 Using the starter to start a vehicle.

4.1.1 Check that the starter clamps are NOT powered up by
ensuring that the mounting socket (fig.4-1) is disconnected.

4.1.2 Make sure that the ignition switch of the vehicle or boat to be
started is in the OFF position.

4.1.3 Connect the red clamp (+) to the positive terminal on the
vehicle's battery.

4.1.4 Connect the black clamp (-) to a non moving metal part of the
engine, do not connect the clamp to the negative terminal on
the battery.

4.1.5 REVERSE POLARITY WARNING. If the red light shown in
fig.3 comes on together with a buzzer, this is a warning that
there is a reverse polarity situation. Do not connect the
mounting socket to either the 12V or 24V supply until the
clamps are correctly connected as described above.

 Keep children and unauthorised persons away from the work

area.

 DO NOT use the starter for any purpose other than that

for which it is designed.

 DO NOT allow untrained persons to operate the starter.
 DO NOT get the starter wet or use in damp or wet

locations or areas where there is condensation.

 DO NOT operate the starter if it is damaged.
 DO NOT attempt to open or modify the starter.
 When not in use store in a safe, dry, child proof area. Store

under lock and key.

 DO NOT expose to direct sunlight, heat sources, or humidity.
 Ensure that the unit is in a stable position before commencing

use.

 Check the condition of cables on a regular basis and if any are

damaged have them repaired or replaced by a qualified
technician.

 Before use check for damaged parts and have any faulty

items replaced with authorised parts only. Check that the
cables are securely fastened to the starter.

 WARNING!Be vigilant and cautious during the starting

procedure as battery acid is highly corrosive and gases
can be emitted during the starting process that are flammable
and harmful to health.

 Avoid electric shocks. Be very cautious when attaching the

clamps to non-insulated conductors or bus bars. Avoid all
body contact with the surfaces of tubes, radiators and metal
power substations while testing the voltage.

g.2

g.1

3.1 ASSEMBLY.

3.1.1 HANDLE MOULDING. Attach the handle moulding to the top
of the unit as shown in fig.1 using the four M6 x 50mm bolts
provided.

3.1.2 WHEELS. Lower the unit carefully onto its front face on a
clean, non abrasive surface.

3.1.3 Slide the chrome axle tube (A) through the holes in the rear
lower corners of the cabinet so that it projects equally either
side.

3.1.4 Place a washer (B) onto each end of the axle followed by a
wheel (C).

3.1.5 Firmly press a plastic plug (D) into each open end of the axle
to retain all components.

3.1.6 FRONT CASTOR. Attach the front castor to the raised plate
on the underside of the unit using the four self tapping screws
provided. Do not over tighten.

3.1.7 Lift the unit into the upright position.

3.1.8 PLUG HANDLE. Referring to fig.2 attach the handle (A) to the
cable plug (B) in the orientation shown using the nuts, bolts
and washers provided.

4.1.6 When no buzzer sounds and the red light is OFF, plug the
mounting socket onto the 12V or 24V supply, according to the
voltage required by the vehicle to be started.

4.1.7 Turn the ignition switch (or key) of the vehicle or boat to ON.
Wait for one minute. Turn the engine over for no more then 5
to 6 seconds. If the vehicle or boat engine does not start, wait
at least 3 minutes before retrying.

g.3

Original Language Version

DESCRIPTION.
Heavy-duty steel case with composite front storage panel.
Features a high powered manufactured battery making this
model suitable for starting most vehicles. Electronic power
switch with LED indicators and 19mm digital voltage display
reduces risk of inadvertent damage by over-voltage. Heavy­ duty copper cables provide efficient power transfer. Built in trip
to prevent damage to battery or internal circuitry. Surge and
spike suppressing circuitry reduces risk of damaging vehicle’s
on-board electronics. Supplied with mains voltage recharging
pack. Supplied with two heavy-duty rear wheels and one
heavy-duty front locking castor for easy manoeuvrability.

Model No: .................................................. PWRSTART6000

Output Voltage ............................................................ 12/24V

Maximum Engine Size ..................................................600hp

Peak Amps 12V ........................................................... 6000A

Peak Amps 24V ........................................................... 3000A

Cranking Current (20º 5secs) 12V: .............................. 2000A

Cranking Current (20º 5secs) 22V: ................................ 900A

Cold Cranking Current (-18ºC 30secs) 12V: .................. 450A

Cold Cranking Current (-18ºC 30secs) 24V: .................. 350A

Cable size ................................................................... 25mm²

PWRSTART6000 Issue: 2 - 16/05/11