Stanley J5C09 Power Station (Jump Starter and Air Compress/Tire Inflator) Power Adapter Replacement

ID: 153076

Description: My Stanley J5C09 power station (jump starter...

Steps:

  1. The most likely failure on this device is a dead battery. But, you also might have a failed power adapter.
  2. Plug in the power cord.
  3. Check the indicator lights. The "low" light should be on. If it's not, chances are that the power adapter has failed.
  4. If the "low" light is on, this isn't the repair guide for you. Something other than the power adapter has failed.
  5. Important: Turn the power switch to off! Unplug and remove the power cord.
  6. Remove the screws from the outside edges of the rear of the power station case. (No need to remove the screws that hold the compressor module to the case.)
  7. Gently pull the two halves of the case apart. Feed the jumper wire cables into the case so there is room to open it.
  8. Remove the two screws holding the power adapter in place.
  9. Cut the power adapter wires, leaving about 1" on the power adapter side. Strip about 1/4" inch of the insulation on the two wires coming out of the power adapter.
  10. Check the power adapter with your multimeter.
  11. Set the multmeter to DC volts.
  12. Connect the multimeter probes to the two wires coming out of the power adapter.
  13. Plug in the power adapter.
  14. Is the meter showing 13 volts DC or more? If so, you power adapter is probably OK. There's some other reason your power station isn't charging. This guide won't help.
  15. You could simply drill a hole somewhere in the power station case to mount the barrel connector
  16. Or, you could 3D-print a plate to neatly cover up the hold where the power adapter was originally.
  17. The 3D design is on thingiverse.com
  18. https://www.thingiverse.com/thing:550616...
  19. Print it. No supports needed.
    20. Step image
  20. Place the power jack plate into the case in the hold where the power adapter was.
  21. You may need to trim the plate to fit the case.
  22. Drill small holes into the case to match the (4) holes in the plate.
  23. Use (4x) 2mm x 5mm sheet metal screws to attach the plate to the case.
    24. Step image
  24. Strip the wires that used to connect to the power adapter, about 1/4".
  25. The wire with the "- - -" stripe pattern is the negative. Connect this to the barrel jack terminal that is connected to the outer ring of the jack.
  26. Connect the other wire to the terminal connect to the center pin.
  27. Use your multimeter's continuity test feature to verify the barrel jack connections.
  28. Solder the wires to the barrel jack.
  29. Remove the nut from the barrel jack
  30. Insert the barrel jack into the plate
  31. Tighten the barrel jack nut.
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