Engine Starting with Jump Start Cables
------ WARNING! ------
Batteries give off flammable fumes that can explode resulting in personal injury.
Prevent sparks near the batteries. They could cause vapors to explode. Do not allow the jump start cable ends to contact each other or the machine.
Do not smoke when checking battery electrolyte levels.
Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.
Always wear eye protection when starting a machine with jump start cables.
Improper jump start procedures can cause an explosion resulting in personal injury.
Always connect the battery positive (+) to battery positive (+) and the battery negative (−) to battery negative (−).
Jump start only with an energy source with the same voltage as the stalled machine.
Turn off all lights and accessories on the stalled machine. Otherwise, they will operate when the energy source is connected.
When starting from another machine, make sure that the machines do not touch. This could prevent damage to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to the boost connection to prevent damage to electrical components on the stalled machine.
Severely discharged maintenance free batteries do not fully recharge from the alternator after jump starting. The batteries must be charged to proper voltage with a battery charger. Many batteries thought to be unusable are still rechargeable.
Use only equal voltage for starting. Check the battery and starter voltage rating of your machine. Use only the same voltage for jump starting. Use of a welder or higher voltage damages the electrical system.
Refer to Special Instruction, Battery Test Procedure, SEHS7633, available from your Caterpillar dealer, for complete testing and charging information.
Severely discharged maintenance free batteries will not fully recharge from the alternator alone after you jump start the machine. The batteries must be charged to the proper voltage with a battery charger. Many batteries that are considered to be unusable can still be recharged by this method.
Refer to Special Instruction, SEHS7633, "Battery Test Procedure" for complete information about testing and about charging. This document is available from your Caterpillar dealer.
When auxiliary starting receptacles are not available, use the following procedure.
1. Determine the reason that the engine will not crank. See Special Instruction, SEHS7768 for instructions about the use of a 6V-2150 Starting/Charging Analyzer. This is still a valid procedure if the machine does not have a diagnostic connector.
2. Engage the parking brake on the stalled machine. Place the transmission into neutral. Lower the equipment to the ground. Move all controls to the HOLD position.
3. Turn the start switch on the stalled machine to the OFF position. Turn off all accessories.
4. Turn the battery disconnect switch on the stalled machine to the ON position.
5. Move the machine that is being used as an electrical source near the stalled machine so that the jump start cables reach the stalled machine. Do not allow the machines to contact each other.
6. Stop the engine of the machine that is being used as an electrical source. If you are using an auxiliary power source, turn off the charging system.
7. Ensure that battery caps on both machines are tight and correctly placed. Ensure that batteries in the stalled machine are not frozen. Make sure that the batteries have enough electrolyte.
8. The positive ends of the jump start cable are red. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Some machines have battery sets.
Note: Batteries that are in series may be in separate compartments. Use the terminal that is connected to the starter solenoid. This battery or battery set is normally on the same side of the machine as the starter. The positive ends of the jump start cable are red. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Do not allow the positive cable clamps to contact any metal except for the battery terminals.
9. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.
10. Connect one negative end of the jump start cable to the negative cable terminal of the electrical source.
Note: In 24 volt battery systems, the negative cable terminal of the electrical source is connected to the battery disconnect switch in the same battery set that is used in Step 9.
11. Finally, connect the other negative end of the jump start cable to the frame of the stalled machine. Do not connect the jump start cable to the battery post. Do not allow the jump start cables to contact the battery cables, the fuel lines, the hydraulic lines, or any moving parts.
12. Start the engine of the machine that is being used as an electrical source or energize the charging system on the auxiliary power source.
13. Wait at least two minutes before you attempt to start the stalled machine. This will allow the batteries in the stalled machine to partially charge.
14. Attempt to start the stalled engine. See your machine's Operation and Maintenance Manual, "Starting Above 0°C (+32°F)" for the correct starting procedure.
15. Immediately after you start the stalled engine, disconnect the jump start cables in reverse order.
16. Conclude the failure analysis on the starting system of the stalled machine and/or on the charging system of the stalled machine.
Prevent sparks near the batteries. They could cause vapors to explode. Do not allow the jump start cable ends to contact each other or the machine.
Do not smoke when checking battery electrolyte levels.
Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.
Always wear eye protection when starting a machine with jump start cables.
Improper jump start procedures can cause an explosion resulting in personal injury.
Always connect the battery positive (+) to battery positive (+) and the battery negative (−) to battery negative (−).
Jump start only with an energy source with the same voltage as the stalled machine.
Turn off all lights and accessories on the stalled machine. Otherwise, they will operate when the energy source is connected.
NOTICE
When starting from another machine, make sure that the machines do not touch. This could prevent damage to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to the boost connection to prevent damage to electrical components on the stalled machine.
Severely discharged maintenance free batteries do not fully recharge from the alternator after jump starting. The batteries must be charged to proper voltage with a battery charger. Many batteries thought to be unusable are still rechargeable.
Use only equal voltage for starting. Check the battery and starter voltage rating of your machine. Use only the same voltage for jump starting. Use of a welder or higher voltage damages the electrical system.
Refer to Special Instruction, Battery Test Procedure, SEHS7633, available from your Caterpillar dealer, for complete testing and charging information.
Severely discharged maintenance free batteries will not fully recharge from the alternator alone after you jump start the machine. The batteries must be charged to the proper voltage with a battery charger. Many batteries that are considered to be unusable can still be recharged by this method.
Refer to Special Instruction, SEHS7633, "Battery Test Procedure" for complete information about testing and about charging. This document is available from your Caterpillar dealer.
When auxiliary starting receptacles are not available, use the following procedure.
1. Determine the reason that the engine will not crank. See Special Instruction, SEHS7768 for instructions about the use of a 6V-2150 Starting/Charging Analyzer. This is still a valid procedure if the machine does not have a diagnostic connector.
2. Engage the parking brake on the stalled machine. Place the transmission into neutral. Lower the equipment to the ground. Move all controls to the HOLD position.
3. Turn the start switch on the stalled machine to the OFF position. Turn off all accessories.
4. Turn the battery disconnect switch on the stalled machine to the ON position.
5. Move the machine that is being used as an electrical source near the stalled machine so that the jump start cables reach the stalled machine. Do not allow the machines to contact each other.
6. Stop the engine of the machine that is being used as an electrical source. If you are using an auxiliary power source, turn off the charging system.
7. Ensure that battery caps on both machines are tight and correctly placed. Ensure that batteries in the stalled machine are not frozen. Make sure that the batteries have enough electrolyte.
8. The positive ends of the jump start cable are red. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Some machines have battery sets.
Note: Batteries that are in series may be in separate compartments. Use the terminal that is connected to the starter solenoid. This battery or battery set is normally on the same side of the machine as the starter. The positive ends of the jump start cable are red. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Do not allow the positive cable clamps to contact any metal except for the battery terminals.
9. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.
10. Connect one negative end of the jump start cable to the negative cable terminal of the electrical source.
Note: In 24 volt battery systems, the negative cable terminal of the electrical source is connected to the battery disconnect switch in the same battery set that is used in Step 9.
11. Finally, connect the other negative end of the jump start cable to the frame of the stalled machine. Do not connect the jump start cable to the battery post. Do not allow the jump start cables to contact the battery cables, the fuel lines, the hydraulic lines, or any moving parts.
12. Start the engine of the machine that is being used as an electrical source or energize the charging system on the auxiliary power source.
13. Wait at least two minutes before you attempt to start the stalled machine. This will allow the batteries in the stalled machine to partially charge.
14. Attempt to start the stalled engine. See your machine's Operation and Maintenance Manual, "Starting Above 0°C (+32°F)" for the correct starting procedure.
15. Immediately after you start the stalled engine, disconnect the jump start cables in reverse order.
16. Conclude the failure analysis on the starting system of the stalled machine and/or on the charging system of the stalled machine.
