Tools Featured in this Teardown

Introduction

The main thing that usually breaks on a jump starter is the battery. These units usually contain a lead acid battery with a finite lifespan. It is possible and simple to replace but usually not financially worth doing. If the unit does not hold a charge but functions while it is plugged in then it is most likely a faulty battery.

This teardown is not a repair guide. To repair your Jump Starter Power Station, use our service manual.

Power Station Jump Starter Model PS1100 The bad battery could be replaced to restore it to full functionality.
  • Power Station Jump Starter

  • Model PS1100

  • The bad battery could be replaced to restore it to full functionality.

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Opening it up reveals the Lead battery, AC/DC converter, 12V DC input, switch, back of circuit board, back of light. Additional bells and whistles are sometimes added (lights, switches, compressors, power jacks, etc.)  Some have AC power jacks which require a DC/AC converter which is more expensive than an AD/DC converter. Additional bells and whistles are sometimes added (lights, switches, compressors, power jacks, etc.)  Some have AC power jacks which require a DC/AC converter which is more expensive than an AD/DC converter.
  • Opening it up reveals the Lead battery, AC/DC converter, 12V DC input, switch, back of circuit board, back of light.

    • Additional bells and whistles are sometimes added (lights, switches, compressors, power jacks, etc.) Some have AC power jacks which require a DC/AC converter which is more expensive than an AD/DC converter.

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The battery to the left is the culprit of the dead power supply.  A jump starter is nothing more than a small car battery with some wires. Any 12V battery with the same dimensions should work as a replacement
  • The battery to the left is the culprit of the dead power supply. A jump starter is nothing more than a small car battery with some wires.

  • Any 12V battery with the same dimensions should work as a replacement

    • This is a Lead 12V 17AmpHours battery made by Pilot battery Co. Ltd.

    • Model PL17-12

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Both power inputs.  AC/DC converter and DC 12V input. The designers of this jump starter simply purchased an aftermarket AC/DC adapter and built it in.
  • Both power inputs. AC/DC converter and DC 12V input.

  • The designers of this jump starter simply purchased an aftermarket AC/DC adapter and built it in.

    • The adapter has an input of 120V (typical outlet voltage) and an output of 15V (perfect for charging a 12V battery).

  • Left - DC Power Jack, Right - Thermal Relay for safety and protection

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Circuit board with your typical LEDs, Resistors, Transistors (black half circles), IC chips (long black), Capacitors (disks and cyliders), buttons (right middle) Power Rectifier (left middle square), Diodes (small black, bar on one side), Piezo Speaker (large and round, bottom) Light with 5 LED's Big Switch to handle 12V
  • Circuit board with your typical LEDs, Resistors, Transistors (black half circles), IC chips (long black), Capacitors (disks and cyliders), buttons (right middle) Power Rectifier (left middle square), Diodes (small black, bar on one side), Piezo Speaker (large and round, bottom)

  • Light with 5 LED's

  • Big Switch to handle 12V

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The back module is the compressor.  It will still function normally by application of a 12v power supply. I did not disassemble the compressor.  I will bolt a plexiglass cover over the top and solder a 12v car adapter to run it as an emergency compressor
  • The back module is the compressor. It will still function normally by application of a 12v power supply.

    • I did not disassemble the compressor. I will bolt a plexiglass cover over the top and solder a 12v car adapter to run it as an emergency compressor

  • I have a walk through on recycling the compressor on instructables.com

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Brent Olsen

Member since: 07/26/2011

351 Reputation

1 Guide authored

13 Comments

where can i find more information on the circuit? plan to add a switch to my jumpstarter to either charge the internal battery or an external battery...

would that 700mA handle a 65Ah battery if i simply attach a device like that to that slightly bigger battery?

gcb - Reply

i like this article,thanks for sharing,i bought one before and it was good,i think we all need car jump starter,i would like to recommend one oem jump starter factory,http://www.mairpower.com

MAIR POWER - Reply

I have one of these that the ac adapter has come loose from the main board. is there a possibility that you could post a photo of exactly where the adapter solders onto the main board?

Phillip Duke - Reply

can I use a 12V 18Amp

pjfz80 - Reply

To charge the battery? The back of the unit will say what the "input" should be.

Brent Olsen -

helpful article any chance on getting the dimension of the battery I do not see PL17-12 but many like it. the dimension would be helpful

Edward Ginsberg - Reply

Thanks for the information, I was able to purchase a 6FM-18 battery that was a perfect fit and it is all up and running, great help from your post.

Edward Ginsberg - Reply

What is the peak amp output this will start a vehicle with is it 1100 peak amps? as in the model number

Edward Ginsberg - Reply

My compressor will not come on. It can on one time then makes a noise but does not put out compressor air, any ideas?

trdnface - Reply

Thanks for this tutorial. it was very helpful.

iweld Alexander - Reply

was using my unit as an air compressor. the unit shut off in just a few minutes and now nothing will come on. no led display

Ronnie Laws - Reply

The air compessor hose nozzle which connects to the tire valve stem broke off in my PS1100. Any idea where I can find a replacement part?

Mike Fatah - Reply

I am 99% sure that you will never find that part. any of these components aren't really meant to be replaced. Things like the battery or the ac-dc converter you can find because they just used off-the-shelf parts. You could probably find that size hose but you would have to find a way to seal/crimp it onto the air nozzle on the other end.

Brent Olsen - Reply

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