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Reference: Service Magazine, SEBD1764, 4 May 1987, "Testing The Starter On The Engine"
Reference: Service Magazine, SEBD1764, 4 May 1987, "Alternator/Generator Output Test On Engine"
Reference: Service Magazine, SEBD1964, 1 May 1989, "Cause And Effects Of Low Battery Voltage On Electric Starters"
Reference: Service Magazine, SEBD1960, 27 March 1989, "Preventive Maintenance For Batteries"
Reference: Special Instruction, SEHS7633, "Battery Test Procedure"
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Never "hotwire" or short across the starter terminals! Hotwiring or shorting across the starter terminals could bypass the engine neutral start system, damage the electrical system, and result in unexpected machine motion or behavior. This could cause personal injury or death. |
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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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After determining the voltage of the starting system, please review the applicable notice for your machine.
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Ensure that the machine that is used as an electrical source does not touch the stalled machine. This could prevent damage to engine bearings and electrical circuits. Turn on the disconnect switch on the electrical source. This will help to prevent damage to electrical components on the stalled machine. This machine has a 24 volt starting system. Use only equal voltage for jump starting. Use of a higher voltage will damage the electrical system. 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. Refer to Special Instruction, SEHS7633, "Battery Test Procedure" for complete information about testing and about charging. This document is available from your Caterpillar dealer. |
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This machine has a 12 volt starting system. Use only equal voltage for jump starting. Use of a higher voltage damages the electrical system. |
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.
The procedure that follows applies to systems of any voltage and either positive ground or negative ground systems.
Note: If there are any questions regarding the proper jump starting procedures, consult your authorized dealer for guidance.
- Determine the reason that the engine fails to crank.
- Engage the parking brake on the stalled machine. Move the transmission control into the NEUTRAL position. Move the hoist control into the HOLD position.
- Turn the engine start switch key on the stalled machine to the OFF position. Turn off all accessories.
- Turn the battery disconnect switch on the stalled machine to the ON position.
- Move the machine that is being used as an electrical source near the stalled machine in order for the jump start cables to reach the stalled machine.
Do not allow the machines to contact each other.
- 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.
- Ensure that the battery caps on both machines are tight. Ensure that the battery caps on both machines are correctly placed. Ensure that the batteries in the stalled machine are not frozen. Make sure that the batteries have enough electrolyte.
- 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 starting motor.
Do not allow the positive cable clamps to contact any other metal except for the battery terminals.
- Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.
- Connect one negative end of the jump start cable to the negative cable terminal of the electrical source.
- Finally, connect the other negative end of the jump start cable to the frame of the stalled machine. Do not connect the negative end of the jump start cable to the negative terminal on the battery.
Do not allow the jump start cables to contact any of the following components: fuel lines, hydraulic lines and moving parts.
- Start the engine of the machine that is being used as an electrical source, or energize the charging system on the auxiliary power source.
- 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.
- Attempt to start the stalled engine.
- Immediately after you start the stalled engine, disconnect the jump start cables in reverse order.
- Conclude the failure analysis on the starting system of the stalled machine and/or on the charging system of the stalled machine.