Battery management and jumpstarting

Safety procedures on mines and quarry’s

Battery management and jumpstarting:


This work instruction is to be followed in the event of jump starting flat TMM batteries.

The document is applicable to the garage staff only, because only competent mechanics are

Allowed to jump start flat batteries. This document will also supply guidelines to ensure that

TMM batteries remain in optimal working condition as to ensure that they, as far as

possible, do not require charging through the process of jump starting.

Work instruction & responsibilities

Jump Starting of TMM

TMM will only be jump started using a battery cart. Carry out pre-start checks on the

Battery cart before use, in particular focus on the following:

  • Make sure batteries on the battery-cart are charged to its full capacity.
  • Check that all battery cables and links are tight and in their appropriate place.
  • Check that all battery filler plugs are fitted.
  • Check battery-cart tires and tow bar for fitness.
  • Use the relevant PPE (face shield or safety goggles, gloves and leather apron )


Once the pre-start checks are completed, proceed to defective machine or equipment. The battery cart must only be towed using a LDV.

Once at the defective TMM, make contact with the Team leader/driver of the defective machine and together complete a mini risk assessment.

Particular focus through the risk assessment must be placed on the prevailing traffic, possible battery explosion or wrong connections and the interaction of people

And TMM involved during the jump start process.

In the event of a TMM that is parked in the road or in areas of high traffic volume, red hazard triangles must be placed in front and at the rear of the defective TMM and stop blocks must be used to prevent inadvertent movement. The battery cart must be parked as close to the side of the flat battery of the defective TMM as possible, the Team Leader must act as spotter when positioning the battery cart.

Once the battery cart is in position, determine the voltage capacity of the defective TMM and/or of the flat battery and ensure all clamps are securely fitted to the battery poles.

Also determine whether the electrical system is coupled is “series” or “parallel” and ensure that the electrolyte levels (if possible), are correct. Proceed to fit the extension cables on the batteries on the cart and to the batteries of the defective TMM. The “live” cables must be connected first and then the “earth” cables. Ensure that the extension cables are fitted tightly, positive to positive and negative to negative in a “series” system.

Once the cables are all appropriately connected, all people involved in the jump start process must stand clear of the area before the defective TMM is started. This is to keep people involved at a safe distance in the event of battery explosions or sparks.

Once people are clear, the defective machine can be started. Proceed in removing the cables once the defective TMM is running, starting with the “earth” cable first. The garage staff then needs to determine the cause of the flat battery and remedial action needs to be taken in order to prevent repeat battery failures. In addition, the batteries on the battery cart needs to be recharged at the garage for further use.

Battery Management of TMM’s

All competent mechanics at garage and drivers operating TMM must ensure that the batteries remain in optimal operating condition. The following measures must be taken to ensure that:

  • All radio’s, lights and air-conditioners, etc. Must be switched off when the engine of the TMM is not running.
  • When TMM start showing signs related to difficulty starting, the driver must report

this to the Team Leader, which in turn must report it to the garage. The garage staff then needs to investigate and if required must replace the battery to prevent it from becoming completely flat.

  • The condition of batteries must be assessed during every OEM specified maintenance schedule by the garage staff (aspect such as battery water, corrosive terminals, voltage output, acid build up on terminals, etc.)
  • Batteries are only allowed to be stored at the battery store in the garage. Flat
  • Batteries needs to be stored separately from new batteries and the storage area must be clearly labelled in order to differentiate new from old.
  • Batteries that were jump started must undergo a voltage test to ascertain if it needs replacing.


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