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Failure to properly service the batteries may cause 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 the 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. When using jumper cables, always connect the positive (+) jumper cable to the positive (+) battery terminal first. Next, connect the negative (-) jumper cable to the frame away from the batteries. Follow the procedure in the Operation and Maintenance Manual. Jump start only with an energy source of 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 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. |
Use of Jump Start Cables
If the machine is equipped with an auxiliary start receptacle, use the auxiliary start receptacle. When the auxiliary start receptacle is not available, use the following procedure.
Reference: For more information concerning the auxiliary start receptacle, refer to the Operation and Maintenance Manual, "Engine Starting with Auxiliary Start Receptacle" in this publication.
- Use 6V-2150 Starting and Charging Analyzer in order to determine the cause of the failure of the engine to start. Use this procedure if the machine does not have a diagnostic connector.
Reference: Refer to Special Instruction, SEHS776, 8, "Use of a 6V-2150 Starting and Charging Analyzer Group" for further information.
- Move the transmission direction and speed control to the NEUTRAL position on the stalled machine. Engage the parking brake. Move all controls to the HOLD position.
- On the stalled machine, turn the engine start switch to the OFF position. Turn off all accessories.
- On the 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 on the machine that is being used as the electrical source. If you are using an auxiliary power source, turn off the charging system.
- Check the battery caps for correct placement and for correct tightness. Make these checks on both machines. Make sure the batteries in the stalled machine are not frozen. Check the batteries for low electrolyte.
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| Illustration 1 | g00899858 |
- Connect the positive jump start cable to the positive cable terminal of the discharged battery. Do not allow positive cable clamps to touch 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 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 two minutes.
- Attempt to start the stalled engine.
Reference: For more information on starting the engine, refer to the Operation and Maintenance Manual, "Engine Starting" for the machine that is being serviced.
- 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.