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Today I used the M1008 to jump start a deuce that had totally dead batteries. I disconnected the deuce's alternator excite wire, to protect the regulator, knowing the trucks batteries probably would not take a charge.
The Deuce fired right up, so I got out and pulled the slave cable out of the receptacle and drove the truck out to the driveway to work on it.
My neighbor came over when he heard the truck running, to see what I was up to. After he left, I went out back to get the M1008 and go get some parts at the marina for another project.
I got in, started the M1008, backed up and turned around(180) and went to drive out my driveway. Just about the time I hit the driveway, I felt the right rear tire lock-up. At the same time, the truck stalled and I noticed there were no dash lights on. I was confused until I saw smoke billowing out from under the hood. That's when I remembered, I never disconnected or put away the slave cable! I jumped out and saw the cable was pulled tight( against the grill gaurd and under the rear tire). Smoke and sizzling was still occurring so I was a bit panicked and tried to pull the slave cable out of the socket but I couldn't because it was too tight and also welded to the grill guard. I got the hood up and that's when I saw what no cucv owner ever wants to see. The cable between the batteries was melted off at the terminal, but the 10 ga 12v feed wire was still connected to the rear battery negative terminal. This means 12v from the rear battery is now grounding through the 12V+ circuitry.
I gave the slave cable one more yank and broke it loose from the grill guard, leaving an arced out hole with copper wire and melted copper on it. The smoke and noises stopped.
I could see smoke near the GP relay and the drivers side alternator. I put my hand on the alternator and it was really really hot.
I was disgusted.
I looked over the damage and determined that the battery cable burned out(weak point in the 24 volt circuit). Also was obvious that a blue fusible link was missing about 2" in the middle.
I grabbed a few light gauge jumper wires and jumped the fusible link and the battery cable and turned the key on but had nothing still.
I checked my fuses and found a 20 amp fuse blown (Iirc, it was the ignition circuit). I replaced it and was happy to see I had dash lights. At some point I also noticed I did not have alt 2 light or voltmeter either.
I made a temporary repair to the fusible link, and replaced the battery cable. Cranked it up and I was rewarded with a gen 1 light on. I kinda suspected that as it was blistering hot.
I then drove it over to the garage and pulled the alternator. Opened it up and diagnosed all components and found the rectifier was bad.
I had a whole "kit" on hand, so I replaced all the internals and reinstalled the alternator.
Cranked it up and all was good. Tested all the lights and everything looks good to go.
I ordered some fusible link material and some more rebuild kits for future issues.
My slave cable was ruined, but the ends are saveable.
I just thought you guys would want to hear about this. Maybe someone else will remember to disconnect their slave cable, before driving off with it still connected. I'm pretty sure I'll remember next time.
The Deuce fired right up, so I got out and pulled the slave cable out of the receptacle and drove the truck out to the driveway to work on it.
My neighbor came over when he heard the truck running, to see what I was up to. After he left, I went out back to get the M1008 and go get some parts at the marina for another project.
I got in, started the M1008, backed up and turned around(180) and went to drive out my driveway. Just about the time I hit the driveway, I felt the right rear tire lock-up. At the same time, the truck stalled and I noticed there were no dash lights on. I was confused until I saw smoke billowing out from under the hood. That's when I remembered, I never disconnected or put away the slave cable! I jumped out and saw the cable was pulled tight( against the grill gaurd and under the rear tire). Smoke and sizzling was still occurring so I was a bit panicked and tried to pull the slave cable out of the socket but I couldn't because it was too tight and also welded to the grill guard. I got the hood up and that's when I saw what no cucv owner ever wants to see. The cable between the batteries was melted off at the terminal, but the 10 ga 12v feed wire was still connected to the rear battery negative terminal. This means 12v from the rear battery is now grounding through the 12V+ circuitry.
I gave the slave cable one more yank and broke it loose from the grill guard, leaving an arced out hole with copper wire and melted copper on it. The smoke and noises stopped.
I could see smoke near the GP relay and the drivers side alternator. I put my hand on the alternator and it was really really hot.
I was disgusted.
I looked over the damage and determined that the battery cable burned out(weak point in the 24 volt circuit). Also was obvious that a blue fusible link was missing about 2" in the middle.
I grabbed a few light gauge jumper wires and jumped the fusible link and the battery cable and turned the key on but had nothing still.
I checked my fuses and found a 20 amp fuse blown (Iirc, it was the ignition circuit). I replaced it and was happy to see I had dash lights. At some point I also noticed I did not have alt 2 light or voltmeter either.
I made a temporary repair to the fusible link, and replaced the battery cable. Cranked it up and I was rewarded with a gen 1 light on. I kinda suspected that as it was blistering hot.
I then drove it over to the garage and pulled the alternator. Opened it up and diagnosed all components and found the rectifier was bad.
I had a whole "kit" on hand, so I replaced all the internals and reinstalled the alternator.
Cranked it up and all was good. Tested all the lights and everything looks good to go.
I ordered some fusible link material and some more rebuild kits for future issues.
My slave cable was ruined, but the ends are saveable.
I just thought you guys would want to hear about this. Maybe someone else will remember to disconnect their slave cable, before driving off with it still connected. I'm pretty sure I'll remember next time.
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