Usage:
Reference: Truck Engine News, May 1987, Page 4, "Testing The Starter On The Engine. " Truck Engine News, May 1987, Page 3, "Alternator/Generator Output Test On Engine. " Truck Engine News, April 1989, Page 6, "Cause And Effects Of Low Batter Voltage On Electric Starters. " Truck Engine News, March 1989, Page 5, "Preventive Maintenance For Batteries. "
Reference: Special Instruction, SEHS7633, "Battery Test Procedure. "
The procedures that follow apply to systems of any voltage and either positive or negative ground.
Engine Starting With Jumper Cables
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Batteries give off flammable fumes that can explode. This can result in personal injury.
Prevent sparks near the batteries. They could cause vapors to explode. Do not allow jumper cable ends to contact each other or the truck.
Add water if necessary to cover the plates in batteries on the stalled engine.
Always thaw a frozen battery before jump starting. Frozen batteries may explode causing personal injury.
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 an engine with jumper cables.
Incorrect jump procedures can cause an explosion resulting in personal injury.
Always connect battery positive (+) to battery positive (+) and battery negative ( -) to battery negative (-).
Jump only with a battery source and with the same voltage as the stalled engine.
Turn off all lights and accessories on the stalled truck. Otherwise, they will operate when the jump source is connected.
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When starting from another truck, make sure the trucks do not touch. This could prevent damage to engine bearings and electrical circuits. Turn on (close) the disconnect switch on the stalled engine prior to the jump connection to prevent damage to electrical components. Severely discharged maintenance free batteries might not fully recharge by the alternator alone after jump starting. They should be charged to the correct voltage by a battery charger. Many batteries thought to be unusable, are only discharged. Recharge and load test to confirm true battery condition. Use only equal voltage for jump starting. Use of a higher voltage can damage the electrical system. Refer to Special Instruction, SEHS7633, Battery Test Procedure, for complete testing and charging information.
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Engine Starting With Jump (formerly Called "Auxiliary ") Start Receptacles
Some Caterpillar products may be equipped with jump start receptacles as standard equipment. All other products can be equipped with a parts service receptacle. A permanent receptacle is then always available for jump starting.
Two mating cable assemblies are also available to jump the stalled engine from another truck also equipped with this receptacle or an auxiliary power pack. Your Caterpillar dealer can provide the correct cables in lengths for your application.
1. Make initial determination as to failure of the stalled machine to crank. Refer to Secial Instruction SEHS7768 on use of 6V2150 Starting/Charging Analyzer Group. This procedure applies even if the engine does not have a diagnostic connector.
2. Place the transmission control in NEUTRAL on the stalled truck. Engage the parking/secondary brake.
3. Turn the start switch to OFF on the stalled engine. Turn off all accessories.
4. Turn on (close) the disconnect switch (if equipped) on the stalled engine.
5. Assure the batteries in the stalled engine are not frozen and that electrolyte is above the plates in all cells.
6. Move the jump start source near enough to the stalled engine for cables to reach, but DO NOT ALLOW MACHINES TO TOUCH.
7. Stop the engine on the jump source, or if using an auxiliary power source, turn off the charging system.
8. On the stalled engine, connect the appropriate jump start cable to the jump start receptacle.
9. Connect the other end of this cable to the jump start receptacle of the jump source.
10. Start the engine on the jump source. Or, energize the charging system on the auxiliary power source.
11. Wait a minimum of two minutes for the batteries in the stalled engine to partially charge.
12. Attempt to start the stalled engine. Refer to the beginning of "Engine Starting" in the Operation And Maintenance Manual.
13. Immediately after starting the stalled engine, disconnect the jump start cable from the JUMP SOURCE.
14. Disconnect the other end of this cable from the stalled engine.
15. Conclude failure analysis on starting/charging system of the stalled engine as required, now that the engine is running and charging system is operating.
Use Of Jumper Cables
When jump start receptacles (formerly called "auxiliary ") are not available, use the following procedure.
1. Make initial determination as to failure of engine to crank. Refer to Special Instruction SEHS7768 on use of 6V2150 Starting/Charging Analyzer Group. This procedure applies even if the engine does not have a diagnostic connector.
2. Place the transmission control in NEUTRAL on the stalled truck. Engage the parking/secondary brake.
3. On stalled engine, turn the start switch to OFF. Turn off all accessories.
4. On stalled engine, turn on (close) the disconnect switch (if equipped).
5. Move jump source near enough to the stalled engine for cables to reach, but DO NOT ALLOW TRUCKS TO TOUCH.
6. Stop the engine on the jump source. Or, if using an auxiliary power source, turn off the charging system.
7. Make sure that water covers the plates in the batteries and that the batteries are not frozen in the stalled engine. Make sure battery caps are all in place and tight on both engines.
8. Connect the positive (+) jumper cable (red) to the positive (+) cable terminal of the discharged battery, or battery set on the stalled engine. Do not allow positive cable clamps to touch any metal other than the battery terminals.
NOTE: Batteries in series may be located 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 engine as the starter.
NOTE: On engines with two sets (two in each fender) of two batteries (four total), connect to either set as per above procedure.
9. Connect the other end of this positive jumper cable (red) to the positive (+) terminal of the jump battery. Use the procedure in Step 8 to determine the correct terminal.
10. Connect one end of the negative (-) jumper cable to the negative ( -) terminal of the jump source as follows:
- 12 Volt Systems: use the negative (-) terminal of the jump battery.
- 24 Volt Systems: use the jump battery negative (-) terminal (connected to the disconnect switch) in the same battery set as used in Step 9.
11. Make final connection of the negative (- ) cable to the stalled engine (not battery negative post) after answering the following:
Question:
Does the stalled engine have a battery-cable size [00 gauge wire is 11.6 mm (.46 ") in diameter] ground connection from the starter negative post to frame (typical 24 Volt system)?
NOTE: Engines with a small battery-cable size ground connection [6 gauge wire is 6.5 mm (.26 ") in diameter] from the starter negative post to the engine block do not fulfill this requirement.
- Yes - connect to frame (not battery negative post) away from battery, fuel or hydraulic lines, or moving parts.
- No - connect to starter negative post (typical 24 Volt system) or engine block if starter negative post does not exist (typical 12 Volt systems) away from battery, fuel or hydraulic lines.
12. Start the engine on the jump source. Or, energize the charging system on the auxiliary power source.
13. Wait a minimum of two minutes for the batteries in the stalled engine to partially charge.
14. Attempt to start the stalled engine. Refer to section on "Engine Starting" in the Operation And Maintenance Manual.
15. Immediately after starting the stalled engine, disconnect the jumper cables in reverse order.
16. Conclude failure analysis on starting/charging system of stalled engine as required now that engine is running and charging system is in operation.