The connection of battery cables to a battery and the disconnection of battery cables from a battery may cause an explosion which may result in injury or death. The connection and the disconnection of other electrical equipment may also cause an explosion which may result in injury or death. The procedures for the connection and the disconnection of battery cables and other electrical equipment should only be performed in a nonexplosive atmosphere.
Improper jump start cable connections can cause an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the engine.
Note: If possible, first diagnose the reason for the starting failure. Refer to Troubleshooting, "Engine Will Not Crank and Engine Cranks But Will Not Start" for further information. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine by using another battery with jump-start cables. The condition of the battery can be rechecked after the engine has been switched OFF.
Ensure that a 12 VDC or 24 VDC battery source is used to start the engine. Never attempt to start an engine from an external power source such as electric welding equipment, which has a voltage that is unsuitable for engine starting and will damage the electrical system.
Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system.
Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove first.
Turn all electrical accessories OFF before attaching the jump start cables.
Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.
- Turn the start switch on the stalled engine to the OFF position. Turn off all the engines accessories.
- Connect one positive end of the jump-start cable to the positive cable terminal of the discharged battery. 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. Connect the other negative end of the jump-start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries.
Note: The engine ECM must be powered before the starting motor is operated or damage can occur.
- Start the engine in the normal operating procedure. Refer to this Operation and Maintenance Manual, "Starting the Engine".
- Immediately after the engine is started, disconnect the jump-start cables in reverse order.
After jump starting, the alternator may not be able to recharge fully batteries that are severely discharged. The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, "Battery - Replace" and Testing and Adjusting Manual, "Battery - Test".