Safety rst About the SkelStartTM
Engine Start Module
The SkelStart ESM enables drivers to start a vehicle
engine in situations where the engine cannot be
started by normal batteries owing to, for example,
extreme weather conditions or aged batteries, or
where there is insufcient power in the batteries
to start the engine. The SkelStartTM ESM is able to
supply sufcient power to start the engine even
at −40 °C. SkelStart comes with stud terminals,
possible to have with standard battery posts.
What do you need
for installation?
The additional materials that may be needed for
installation are listed below. These items are not
included with the SkelStartTM ESM, but may be
necessary for isolating other vehicle electronic
non-starting loads from the starter system.
+bolt, washer, nut (M8)
+electrical insulation material (heat shrink)
for proper insulation
+cable to connect other vehicle electronic
non-starting loads to the positive (+)
battery terminal
+standard shop tools
WARNING
Installing the
SkelStartTM ESMs
Mounting location
SkelStartTM installation requires the installation of
a bracket or a shelf on which to place the ESM. The
shelf must be in a safe location, away from any direct
heat sources.
The Starter
Positive (+) Terminal
Status Button
Status Indicator (LED) Fig 1. SkelStartTM ESM
Electrical installation
Do not connect cables from the battery
to the starter (S+) terminal of the ESM.
Cable selection
For SkelStart ESM installation, the following
new cables required:From SkelStart S+
(output) terminal to high current starter
distribution terminal block.From high current
starter distribution terminal block to starter
terminal.From SkelStart B+ (input plus)
terminal to battery + terminal.From SkelStart
B- (input negative) terminal to the ground.
Cable thickness from Distribution Terminal Block to the
Starter "+" solenoid
Sp - cable thickness (mm²)
I - starter peak current (A)
t - starting time (sec)
Cable thickness from SkelStart output (S+) terminal to
Distribution Terminal Block
Pre-installation checks
Before installation of the SkelStartTM ESM, you
need to remove all the cables from the vehicle
batteries. The vehicle batteries need to be
charged. Clean the battery terminals to remove
any corrosion or grease.
Length of cable (m) 4.5–6 6.1–7.5 7.5–9 9.1–12
Cable size (mm2)35 50 50 70
Electrical connection identication
32
SkelStartTM specications
Specications Unit SkelStartTM 24V
Charged full Voltage V 28.2
Rated Capacitance, initial F1,600
Resistance* mΩ0.46
Maximum Peak Current
(for 0,4s duration)*
A19,803
Maximum Stored Energy Wh 176.5
CCA* A6,033
Peak Power* kW 430
Charging current A max. 80
Charging voltage range V 18-32
Recharge time FROM 0 V min 10
Net mass* kg 42.5
The battery
Positive (+) Terminal
The battery
Negative (-) Terminal
(ground connection)
Wiring instructions
1. Before installation, remove all the cables from the
vehicle batteries.
NOTE: Do not connect the SkelStartTM
before instructed to do so!
2. Most vehicle manufacturers connect the alternator
and other vehicle power cables to the starter
solenoid’s positive terminal. Therefore, all the cables
connected to the Starter Solenoid’s positive terminal
need to be removed (Fig. 2 cables 1, 2, 3 - cable 3 can
consist several cables). Note: the starter can include
an integrated magnetic switch, in which case the
short cable from the magnetic switch to the starter
can remain connected to the positive starter terminal.
3. The cables removed from the positive starter
solenoid terminal should be connected using a
terminal block or a nut–bolt connection (use spring
washer or locknut). This connection will then have
to be isolated from the rest of the vehicle and
mounted securely. This can be achieved by bundling
the cables together using cable ties and covering the
connection with heat shrink (Fig 3. cables 1,2,3).
Note: the connection must be fully isolated from
the mass of the truck and should be secured in such
a way that vibration, abrasion or corrosion cannot
cause a short circuit.
4. Construct a new cables to connect the SkelStartTM
S+ terminals to the high current distribution
terminal block. Make sure that the terminal block is
securely isolated from surroundings. (Fig. 3 cable
4). The recommended cable size from SkelStart to
distribution terminal block - based on the length
of the total cable - can be found in the table above
"Cable thickness from SkelStart output (S+) terminal
to Distribution Terminal Block".
k - factor depending on the protective
conductor material PVC-insulated
copper conductor, constant: 143
Sp = √(I² x t) / k
SKELSTART ESM IS NOT A BATTERY
HIGH CURRENT HAZARD
DO NOT CONNECT CABLES FROM
THE BATTERY TO THE STARTER (S+)
TERMINAL OF THE SKELSTART ESM
DO NOT CONNECT IN REVERSE POLARITY
DO NOT JUMP-START
DO NOT DROP THE SKELSTART ESM
DO NOT SHORT CIRCUIT
* Values given based on individual SkelStart. Connection between
devices not included.
All calculations are based on 1 second ESR.
