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DUOVOLT JUMP START BOX
USER & INSTALLATION GUIDE
Revision: A
REF: QSF-030
Issue: D
Merlin Equipment Ltd
Hill Barton Industrial Estate
Exeter, Devon, EX5 1SA
T: +44 (0) 1202 697979
Merlin Power Systems
332-4 West Montauk Highway
New York NY11946
United States of America
T: +1 (631) 594 5102
www.merlinequipment.com
Merlin Equipment Ltd
Jump Start Box– User and Installation Guide
Clyst Court
United Kingdom
Hampton Bays
Page: 1 of 15
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Summary of Contents for Merlin DUOVOLT JumpStart
- Page 1 DUOVOLT JUMP START BOX USER & INSTALLATION GUIDE Revision: A Merlin Equipment Ltd Clyst Court Hill Barton Industrial Estate Exeter, Devon, EX5 1SA United Kingdom T: +44 (0) 1202 697979 Merlin Power Systems 332-4 West Montauk Highway Hampton Bays New York NY11946...
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Page 2: Warning
If you are in anyway unsure about any aspect of the installation or use of Jump Start Box, contact your Dealer or Merlin Power Systems for advice. -
Page 3: Precautions
• MAINTENANCE. If you have problems or suspect device failures DO NOT attempt to repair the unit yourself. Return it to your Dealer or Merlin for servicing. REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box–... -
Page 4: Approvals And Conformity
Jump Start Box complies with RoHS (Reduction of Hazardous Substances) Directive 2011/65/EC. At the end of life, Jump Start Box should be disposed of as normal electrical waste. Signed: James Hortop Managing Director Merlin Equipment Limited REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide... -
Page 5: Introduction
INTRODUCTION Thank you for choosing Merlin Jump Start Box! Please take the time to read and understand this manual before installation and use. The DuoVolt Jump Start Box is designed to allow fleet service providers the ability to jump start 24V vehicles from 12V service vans. -
Page 6: Table Of Contents
NOTES ............................12 DUO VOLT JUMP START BOX OPERATION .................. 13 AFTER INSTALLATION .......................14 PRODUCT SPECIFICATIONS .......................14 PRODUCT ACCESSORIES ......................14 WARRANTY ..........................15 REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide Page: 6 of 15... -
Page 7: Identification Of System Components
Control Switch & Loom: A control switch and loom are provided for remote control of the Jump Start Box. Control Switch Assembly. REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide Page: 7 of 15... - Page 8 Warning! Incorrectly connected cables may damage Jump Start Box or vehicle electrics and will invalidate the Warranty. REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide Page: 8 of 15...
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Page 9: Installation
/ design Engineer. Ensure all cables are routed away from vehicle control devices and are suitably fixed and secured. Cables and wiring should not be installed above vehicle access points. REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide Page: 9 of 15... -
Page 10: Jump Start Box Installation
The Jump Start Box has 4. No fixing locations accessible from inside the enclosure. These are dimensioned as below: Ensure that the unit is securely mounted to the vehicle using suitable bolts, washers and nuts. REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide Page: 10 of 15... -
Page 11: Wiring Schematics
High current cables must have a current rating higher than that of the associated fuse. • Diagram shows typical split charge device contactor. Merlin recommends the use of SmartBank Pro as the device can be inhibited when Jump Start Box is operating in 24V mode. -
Page 12: Notes
Ensuring that the Control Switch is in the ‘Off’ position, connect the batteries. Care should be taken to ensure that tools are not shorted between live terminals and vehicle chassis. REF: QSF-030 Merlin Equipment Ltd Issue: D Jump Start Box– User and Installation Guide... -
Page 13: Duo Volt Jump Start Box Operation
‘Off’ or ‘24V’ position. Merlin recommends use of SmartBank Pro as a split charge device as this can be inhibited when Jump Start Box is operating in 24V mode. -
Page 14: After Installation
AFTER INSTALLATION If you are unsure about any aspect please consult a suitably qualified engineer, your Dealer or Merlin Equipment Ltd before commissioning the unit. PRODUCT SPECIFICATIONS Jump Start Box Part Number(s) 19-7500 ECU Maximum Dimensions excluding cabling (W x L x H) -
Page 15: Warranty
If your product requires troubleshooting or warranty service, contact your merchant. If you are unable to contact your merchant, or the merchant is unable to provide service, contact Merlin directly at: Merlin Equipment Ltd, Clyst Court, Hill Barton Industrial Estate, Exeter, Devon, EX5 1SA, United Kingdom. Tel: +44 (0) 1202 697979.
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