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Failure to properly service the batteries may cause peronal 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. |
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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. This machine has a 24 volt starting system. 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. |
When auxiliary start receptacles are not available, use the following procedure.
- Determine the reason that the engine will not start. Refer to Special Instruction, REHS0354, "Charging System Troubleshooting".
- Move the direction/speed control to the P position on the stalled machine. Move the hoist control to the HOLD position.
- On a stalled machine, turn the start switch key to the OFF position. Turn off the accessories.
- On a stalled machine, turn the battery disconnect switch to the ON position.
- Move the machines together in order for the cables to reach. DO NOT ALLOW THE MACHINES TO CONTACT EACH OTHER.
- Stop the engine of the machine that is being used as an electrical source. When you use an auxiliary power source, turn off the charging system.
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Illustration 1 g03663462 - Check the battery caps for correct placement and for correct tightness. Make these checks on both machines. Make sure that the batteries in the stalled machine are not frozen. Check the batteries for low electrolyte.
- Connect the positive jump-start cable to the positive cable terminal of the discharged battery.
Do not allow positive cable clamps to contact any metal except for battery terminals.
- Batteries in series may be in separate compartments. Use the terminal that is connected to the starter solenoid. This battery is normally on the same side of the machine as the starter.
- Connect the positive jump-start cable to the positive terminal of the electrical source. Use the procedure from Step 9 in order to determine the correct terminal.
- Connect one end of the negative jump-start cable to the negative terminal of the electrical source.
- Make the final connection. Connect the negative cable to the frame of the stalled machine. Make this connection away from the battery, the fuel, the hydraulic lines, or moving parts.
- Start the engine on the machine that is the electrical source. Also, you can energize the charging system on the auxiliary power source.
- Allow the electrical source to charge the batteries for 2 minutes.
- Attempt to start the stalled engine. Refer to Operation and Maintenance Manual, "Engine Starting". See the beginning of this topic.
- Immediately after the stalled engine starts, disconnect the jump-start cables in reverse order.
- Conclude with a failure analysis on the starting charging system. Check the stalled machine, as required. Check the machine when the engine is running and the charging system is in operation.
