Operation Section
101
Use of Jumper Cables
When auxiliary start receptacles are not available,
use the following procedure.
1. Make initial determination as to failure of lift
truck to crank. Procedure applies even if lift truck
does not have diagnostic connector.
2. Place the directional control in NEUTRAL on the
stalled lift truck. Engage the parking/secondary
brake. Lower all attachments to the ground.
Move all controls to HOLD (CENTER).
3. On stalled lift truck, turn the start switch to OFF.
Turn off all accessories.
4. On stalled lift truck, turn on (close) the
disconnect switch (if equipped).
5. Move boost start lift truck near enough to stalled
lift truck for cables to reach, but DO NOT
ALLOW LIFT TRUCKS TO TOUCH.
6. Stop the engine on the boost lift truck. Or, if
using an auxiliary power source, turn off the
charging system.
7. Make sure battery caps are all in place and tight
on both lift trucks.
Typical Example of 24 Voltage
8. Connect positive (+) jumper cable (red) to
positive (+) cable terminal of discharged battery,
or battery set on the stalled lift truck. Do not
allow positive cable clamps to touch any metal
other than battery terminals.
9. Connect the other end of this positive jumper
cable (red) to positive (+) terminal of boost
battery. Use procedure of Step 8 to determine
correct terminal.
10. Connect one end of the negative (-) jumper
cable to the other terminal (negative) of the
boost battery.
11. Make final connection of negative (-) cable to the
stalled truck frame (not battery negative post)
away from battery, fuel or hydraulic lines, or
moving parts.
12. Start the engine on the boost lift truck, or
energize the charging system on the auxiliary
power source.
13. Wait a minimum of two minutes for the batteries
in the stalled lift truck to partially charge.
14. Attempt to start the stalled engine. Refer to
section on ‘Engine Starting’.
15. Immediately after starting the stalled engine,
disconnect the jumper cables in reverse order.
16. Conclude failure analysis on starting/charging
system of the stalled lift truck as required with
the engine running and charging system in
operation.
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