MAN Truck & Bus AG

Technical Information sheet

Published on: 31.05.2012 Issued by: SASPC Number: 399902a

Information sheet type Work instruction

Subject Jump starting
Validity As of the date of publication until withdrawn or replaced
Worldwide
Distribution This Information sheet will be made available on the Internet (MAN After Sales
Portal). In line with Euro 6 (RMI) regulations, all workshops can access this
Information sheet.
This Information sheet will be made available to the MAN service organisation
on the MAN Intranet/Extranet.
Replaces 399902

Vehicle(s) affected All

Component(s) affected Electrical system, batteries

Problem When jump starting vehicles, users continue to make mistakes that damage
the batteries and/or components of the electrical system, in particular
electronic components.
Cause The information in the Operator's Manuals is not observed closely enough.
Remedy It has become apparent that we should refresh the knowledge on the correct
jump starting procedure. For example, to prevent damage to the vehicle
electrical system, in particular to electronic components, the Operator's
Manuals for TG series vehicles have been provided with corresponding inlays
from November 2011. MAN sales subsidiaries and MAN importers shall inform
the owners of older vehicles in a customer letter.
The content of the customer letter is to match the information provided on page
1 of the Annex to this Technical Information sheet. The Annex of this Technical
Information sheet also contains a summary of the most important information
from the Operator's Manuals.
If required, please advise your customers appropriately. We recommend
providing customers with the Annex to this Technical Information sheet.
This may be done by providing copies in the outlet areas frequented by
customers or by attaching a copy of the document to the invoice.
Create a Service Support Desk request if the batteries have been subjected
to reverse polarity.
The request must be assigned to the HQ2-Support-Team-Electrical-system-
electronics-intarder-TP-GSR group directly by workshops within Germany
and for workshops outside Germany it must be assigned to the HQ2-Support-
Team-Electrical-system-electronics-intarder-TP-GSR group via the responsible
national organisation.

Yours faithfully,
MAN Truck & Bus AG ppa G. Ziegler i.V. J. Thomas

Annex 399902aen
Page 1 of 1
Jump starting
Important information
Dear customer,
Dear driver,
In the course of a vehicle's life it is almost impossible to prevent the vehicle battery from going flat when the
vehicle is not on your premises or in the workshop. This is often dealt with by jump starting using another
battery or vehicle.
It is a well known fact that reverse polarity during jump starting can severely damage the battery or even
cause it to explode.
However, it may be new to you that the jump start leads must be connected only when the ignition is off and
that a certain sequence must be adhered to when connecting the leads and also during the subsequent jump
start.
Non-observance may result in severe damage to electronic components or failure of such
components. In extremely unfortunate circumstances this may also cause damage by scorching
or fire.
Please observe the comprehensive information contained in your Operator's Manual to prevent
personal/vehicle damage. Please also forward this information to your drivers and your workshop personnel.
The following contains a summary of the most important information from the Operator's Manual.

General information
If it is not possible to start your engine due to the low battery charge, there is the possibility to start the
engine using jump start leads and connecting them to another vehicle's batteries.
Use jump start leads with a minimum cross-section of 35 mm².
To prevent any negative effects on the battery life the batteries must be fully charged before jump
starting.

CAUTION
Risk of explosion!
An explosive mixture of hydrogen and oxygen may form around the batteries. Sparks may ignite this mixture.
This may result in severe injuries.
Ensure the area around the batteries and the location where you are jump starting are well ventilated
before jump starting and during (dis)connection of the jump start leads.

IMPORTANT!
Risk of damage!
Risk of damage to electronic components.
For this reason:
To jump start, use batteries with the same nominal voltage (2x12 V in series = 24 V) only.
The capacity (Ah) of the batteries providing the current must not be significantly below the capacity of the
batteries receiving the current.
Jump starting devices may only be used for jump starting if the device manufacturer has supplied a
clearance certificate stating that using the device will not result in overvoltage or voltage peaks in the
vehicle electric system (12 V or 24 V).
Connect the jump start leads only if the ignition is off. If the ignition is on and voltage peaks or even
reverse polarity occur, there is a significantly higher risk of severe damage to electronic components.
Such damage may have a delayed effect and, in the worst case, may cause control unit malfunctions
or damage caused by scorching or fire.
If you have connected the leads incorrectly by accident (connecting a positive terminal with a
negative terminal or connecting negative and positive terminals in reverse), check whether
components have been damaged. For this purpose, please contact an MAN service workshop.

Annex to 399902aen
Page 1 of 2
Procedure for jump starting using jump start leads
The vehicle providing the current (donor vehicle) and the vehicle receiving the current (receiving vehicle)
must not come into contact with each other. If the vehicles are in contact with each other, it is possible
that a current may already flow upon connecting one of the two jump start leads.
Switch off the engine of the donor vehicle and switch off the ignition.
If the vehicle has an electrical or mechanical main battery switch: switch off the main battery switch.
Switch off the ignition of the receiving vehicle.
If the vehicle has an electrical or mechanical main battery switch: switch off the main battery switch.
During the following steps, ensure that the positive and negative terminals do not come into contact with
each other or with any vehicle components.
Connect jump start leads with a minimum cross-section of 35 mm² in
the sequence shown in the figure. Ensure the terminals are well Batteries providing
connected. current for jump starting
IMPORTANT! ("donor batteries")
Risk of damage! 2
Risk of damage to all conductive 4
+
components (in the electrical system - +
or any other components, such as - –
cable pulls).
Do not connect the negative cable to +
the vehicle frame.
In MAN vehicles, ground connection 1
is not via the frame but via separate 3
+
ground cables. - +
-
Switch on the main battery switch of the
donor vehicle and the receiving vehicle
(if fitted).
Batteries that require
Start the engine of the donor vehicle. current for jump starting
Start the engine of the receiving vehicle.
Actuate the starter motor for a maximum of 15 seconds.
If the engine has not started after 15 seconds, wait approximately 2 minutes before re-attempting to jump
start.
Switch off the engine of the donor vehicle after the engine of the receiving vehicle has started.
Disconnect the jump start leads in reverse order.

Annex to 399902aen
Page 2 of 2