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Battery Test Procedure (1401) : Shutdown SIS
Battery Test Procedure (1401) : Shutdown SIS
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Shutdown SIS
Previous Screen
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Special Instruction
Battery Test Procedure{1401}
Media Number -SEHS7633-06
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Introduction
This instruction provides the necessary information in order to test the following battery types:
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A new battery
The procedures and the tests refer to batteries of the following types:
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Caterpillar Premium
Procedures and/or tests will specify the types of batteries and voltages.
Identify the battery before you use any procedure or before you perform any test. Ensure that the battery
type and the battery voltage are known.
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Special Instruction, SEHS9249, "Use Of The 4C-4911 Battery Load Tester For 6, 8 and 12 Volt
Lead Acid Batteries."
Safety Precautions
Handling Batteries And Battery Acid
All lead-acid batteries contain sulfuric acid which can burn the skin and
clothing. Always wear a face shield and protective clothing when
working on or near batteries.
Note: When you are working with acid or when you are adding electrolyte to a battery, wear a face
shield and protective clothing in order to prevent contact with the battery electrolyte.
If an accident occurs use the following antidotes:
Eyes - If electrolyte is splashed into the eyes, proceed with the following steps:
1. Force the eyes open. Flood the eyes with cool, clean water for at least 15 minutes.
2. Seek immediate medical attention.
Internal - If electrolyte is consumed, proceed with the following steps:
1. Immediately drink large quantities of water or milk.
2. After you drink the milk or the water, drink one of the following liquids:
{
Milk of magnesia
Beaten eggs
Vegetable oil
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Charging a Battery
Do not attempt to charge a battery that has ice in any of the cells.
Charging a battery in this condition can cause an explosion that may
result in personal injury or death.
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Cleaning Case for the Battery And Cleaning Case for the Battery
Terminal Post
Cleaning Case for the Battery
In order to prevent a leakage path (a type of short circuit), clean the top surface of the battery and the
terminal posts of the battery.
A leakage path can cause electrical components and electrical systems to appear as functioning even
though the disconnect switch (if equipped) is in the OFF position. The electrical system can also include
the Engine Monitoring System (EMS).
A battery can be slippery and difficult to handle if an acid film exists. An acid film can corrode the
battery posts and the cable connections.
Batteries can be cleaned with one of the following solutions:
Baking Soda - Combine 0.1 kg (0.2 lb) of baking soda with 1 L (1.1 qt) of clean water.
Ammonia - Combine 0.1 kg (0.2 lb) of ammonia soda with 1 L (1.1 qt) of clean water.
Remove the cleaning solution from the battery and neutralize the battery by rinsing the battery with
clean water.
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If a corroded terminal post has a nonconductive coating, you cannot clean the terminal with a cleaning
solution or with a cleaning brush.
Use a fine grit sandpaper to remove the nonconductive coating if the terminal posts are corroded.
NOTICE
Clean the battery terminal post(s) surface until the surface has a
bright, shiny appearance.
DO NOT remove any more material than necessary, or the cable
terminal may not fit properly.
The REQUIRED AC power source must match the AVAILABLE AC power source.
For 12 volt batteries, use a charger that is rated at 70 amperes. For 6 volt batteries, use a charger
that is rated at 110 amperes.
Continuous shorting (touching) of the charger's output lead wiring should not damage the battery
charger.
Use a charger that has a relay for polarity protection. This will prevent damage to the charger if
the battery is connected in reverse.
Charging overloads into the RED charging zone on the output meter should not damage the
battery charger.
Use a battery charger with at least three switchable charge rate settings or a continuous variable
output rate.
This feature permits the charger to work with all three Caterpillar battery types and voltages. A high 6
volt rate can be used on an 8 volt battery.
The continuous variable rate permits a charging current near the values that are required. The continuous
variable rate allows the current to be reduced if a battery overheats or a battery creates excessive
gassing.
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Use the recommended tools or the equivalent tools when you are testing a battery for warranty
consideration.
Record the results of the test on the correct Battery Test Sheet.
Refer to ""Recommended Tools And Special Instructions" " in this publication.
If there is external visible damage in the area of the leak, then replace the battery at the customer's
expense.
If the battery is eroded in areas that were in contact with the hold-downs, then replace the battery at the
customer's expense.
NOTICE
Find the cause of the failure before you install a new battery. Failure to
do so could result in damage to the replacement battery.
Use distilled water or use any clean water that is safe to drink.
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Refer to ""Battery Case Cleaning And Battery Terminal Post Cleaning" " in this publication.
Note: If an installed battery fails the test, remove the cables and retest the battery.
If the battery is installed, the connections between the batteries MUST be removed in order to test the
following systems:
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If the "RED Bad Cell" indicator illuminates, the cells are not good.
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If the battery is within the warranty period, replace the battery that is under waranty.
If the battery is beyond the warranty period then replace the battery at the customer's expense.
Turn the "Tester Functions" dial to the "B - Battery Condition" position.
If the GREEN "OK to Test" indicator illuminates, the condition of the battery can be read on the
meter.
Turn the "Battery Rating/Cold Crank Amps" dial to the Cold Cranking Amp position.
Note: For Caterpillar batteries, if the rating (CCA) is not shown on the label for the battery, refer to,
PEHP2001, "Specifications For Caterpillar Batteries".
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If meter (B) indicates in the GREEN area, the battery is in good condition. Continue to Test "CVolts".
If meter (B) indicates in the RED area, and the battery is within the warranty period, replace the
battery that is under warranty.
If the battery is beyond the warranty period, replace the battery at the customer's expense.
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If the "OK to Test" indicator does NOT illuminate, then the battery condition can NOT be read on
meter (B).
Charge the battery for 4 hours at the full charging rate or charge the battery for 8 hours at half the
charging rate. Refer to Table 2.
Note: The charging rate will usually change with time. Check the charging rate periodically. Stay near
the recommended rate. If the battery becomes warm or the smell of acid becomes noticeable, reduce the
charging rate.
If the battery will not accept at least half of the charging rate within the first 15 minutes of charging then
the battery has failed. Replace the battery.
Note: After charging is complete, check the battery on the Test "B - Battery Condition" again. If the
"OK to Test - Test B" indicator does not come on, the battery has failed.
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If the battery is within the warranty period, then replace the battery that is under warranty.
If the battery is beyond the warranty period, then replace the battery at the customer's expense.
If the "OK to Test - Test B" indicator comes on, the battery condition can be read on meter (B).
Turn the "Battery Rating/Cold Crank Amp" dial to the Cold Cranking Amp position. Read the
"Battery Condition" on meter (B).
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If meter (B) indicates in the GREEN area, the battery is in good condition and no replacement is
necessary.
If meter (B) indicates in the RED area replace the battery that is under warranty.
If the battery is beyond the warranty period, then replace the battery at the customer's expense.
The voltage of the battery is measured with "Test C". This test determines if the battery must be
recharged. Before you can return the battery to service this test must be done.
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If the needle is beyond the YELLOW "DISCHARGED" range, return the battery to service.
Charging is not necessary.
If the needle is within the YELLOW "DISCHARGED" range, charge the battery.
If the needle is near the right side of the YELLOW "DISCHARGED" range, less charging will be
required. After you charge the battery, proceed to Test "D - Cranking Power".
Check the meter. There must be enough power in order to crank the engine.
Meter (D) should have a reading of at least 90 percent of the rating (CCA).
For example, a battery with a rating of 1000 (CCA) should be recharged until meter (D) is at least
900 (CCA).
Continue charging the battery until meter (D) has a reading of at least 90 percent of the rating
(CCA).
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Illustration 1
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g00658592
The 177-2330 Battery Analyzer will test any 6 volt battery or 12 volt battery with any of the following
capacities:
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The test can be completed in 20 seconds. The test determines whether the battery is good, whether the
battery is bad or whether the battery needs to be recharged. The battery analyzer will test the condition
of a battery that is discharged as low as one volt.
Operating Instruction
Battery cables and battery terminals should be clean before the analyzer is connected. Clean all dirty
parts and/or corroded parts with a wire brush, if necessary.
1. Clamp the BLACK lead to the negative (-) battery terminal on the machine.
2. Clamp the RED lead to the positive (+) battery terminal on the machine.
3. To ensure a good connection on all sides of each clamp, move the clamps back and forth.
Test Procedure
Before a battery is tested, turn the ignition to the OFF position. Turn all accessories and loads to the
OFF position. Allow the battery to stabilize for one minute before you begin the battery test. If the
battery was recently recharged, allow the battery to stabilize for three minutes before you begin the
battery test.
1. If the battery is less than 0 C (32 F), press the "MODE" key in order to select the "Cold Battery
Test". If the battery is frozen, allow the battery to warm up to above freezing before you test the
battery.
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Do not test a frozen battery, it may explode. Allow the battery to warm
up above 0 C (32 F) before attempting any testing.
2. Follow the directions on the Display Screen:
a. Connect the battery analyzer clamps to the battery and press the "GO" key.
Illustration 2
Battery Test Start Screen
g00644085
b. Select the battery voltage (6 volt or 12 volt). This message is displayed only if the actual
battery voltage is less than 6 volts.
Illustration 3
Low Voltage Display Screen
g00644100
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Illustration 4
Cold Battery Test Display Screen
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g00644104
3. Press the "GO" key in order to begin testing. Two loads are placed on the battery. A short
recovery time takes place before the finish of the test.
4. Press the "MODE" key. Select one of the following battery Amp Rating choices:
{
The battery rating is usually found on the top of the battery. Press the up arrow or the down arrow
in order to select the proper battery capacity.
Illustration 5
Cold Cranking Ampere Rating (CCA) Display screen
g00644154
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Illustration 6
Cranking Ampere Rating (CA) Display Screen
g00644162
Illustration 7
Battery Amp Hour Rating (A-HR) Display Screen
g00644165
5. Press the "GO" key. The analyzer will display one of the following conditions of the battery:
{
Good
Low Charge
Charge/Retest
Bad
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Illustration 8
Battery Pass
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g00644281
Illustration 9
Battery Pass / Low Charge
g00644301
Illustration 10
Charge / Retest
g00644304
Note: The condition of the battery can be determined when the battery is fully charged. If this
message appears and the battery is fully charged, then this is not a good battery.
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Illustration 11
Bad battery
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g00644426
Note: The battery will not sustain a charge and the battery should be replaced.
6. Remove the clamps from the battery posts when the test is finished. Press the OFF key on the
battery analyzer.
NOTICE
A battery can be in a low state of charge and will NOT have sufficient
voltage to activate the relay.
Connect a charged battery in parallel, positive to positive and negative
to negative, to the discharged battery for JUST enough time to activate
the relay.
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The voltage of the battery charger and the rated voltage of the battery should be equal.
DO NOT touch the charger leads or disconnect the charger leads while the charger is turned ON.
Note: For a 12 volt battery, do not exceed a terminal voltage of 16 volts. However, the terminal voltage
may exceed 16 volts ONLY for the first 15 minutes while the battery is beginning to accept a charge.
Overcharging may occur even if the charging voltage is under 16 volts. Overcharging is indicated by the
following symptoms:
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If any of these symptoms occur, reduce the charging rate in order to eliminate the overcharging.
Complete the charging at the LOWER charging rate.
Use the charging voltage that is recommended. Refer to ""Charging" " in this publication. If the
recommended current is NOT exceeded, the initial charging voltage can be equal to the capacity of the
charger.
Use the following procedure to charge the battery:
1. Connect the charger's RED positive (+) lead to the battery's positive (+) terminal post and connect
the charger's BLACK negative (-) lead to the battery's negative (-) terminal post.
2. Adjust the battery charger to the correct voltage.
3. Turn the battery charger ON.
If the charger is set at the highest voltage and the battery does NOT begin to accept the recommended 50
percent MINIMUM charging current within the first 15 minutes, replace the battery.
The warranty should be accepted ONLY if the open circuit voltage is greater than 11.5 volts for a 12
Volt battery.
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NOTICE
Find the cause of the failure before you install a new battery or return
the original battery to service.
Failure to do so could result in a repeat failure.
Use the following topics as guidelines to determine the cause of the failure.
Note: Refer to ""Battery Case Cleaning And Battery Terminal Post Cleaning" " if these conditions are
present.
Foreign material that is trapped under the battery at the time of installation
Abuse
The battery hold-downs are too loose. Inspect the battery for eroded areas at the point of contact
with the battery hold-downs.
The battery case will appear to be leaking. The battery vent plug holes may be partially blocked.
Overcharging
Some of the causes and resulting effects of overcharging are dependent on the type of battery.
A faulty voltage regulator can cause an above normal charging rate to any battery type.
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Table 1
Effects Of Overcharging Batteries
Type Of Battery
Effect
Caterpillar General Service All of the battery cells have a low level of electrolyte.
Batteries
Caterpillar Premium High When the plates of the battery are inspected through the filler holes, the
plates may appear to be warped. This is caused by an excessive
Output Batteries
temperature.
The battery may not pass a load test.
Caterpillar Maintenance
Free Batteries
Undercharging
The following examples are causes of undercharging:
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A faulty alternator
A machine or an engine that is operated with the disconnect switch (if equipped) in the OFF
position
Extended storage of a machine or engine with the disconnect switch (if equipped) in the ON
position
Contaminated Electrolyte
Contaminated electrolyte can be caused by adding contaminated water to a battery during the service life
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Illustration 12
g0065
Vibration
Internal damage and external damage to any battery type can be caused by vibration. The effects of
vibration may vary according to the type of battery. A Maintenance Free Battery cannot be inspected
internally because of the sealed design.
Caterpillar General Service Battery And Caterpillar Premium High Output Battery
The following situations are effects of vibration:
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Dark electrolyte
Sulfation
Micro-crystalline particles on the surface of the battery plates can be caused by the following situations:
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Using a battery with the electrolyte level below the top of the plates
A discharged battery that is being stored for more than one month
While the machine is in storage, the disconnect switch is left in the ON position.
You cannot reverse the effects of sulfation that is produced over long periods of time.
The battery will permanently lose some of the ability to store electricity and the ability to deliver
electricity if sulfation occurs. The ability to store electricity and the ability to deliver electricity at the
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Remove the battery terminal cables and the battery terminal wires from the battery.
For a 12 volt battery, a rating (CCA) that is BELOW 12.40 volts indicates that the battery needs to
be charged.
For an 8 volt battery, a rating (CCA) that is BELOW 8.27 volts indicates that the battery needs to
be charged.
For a 6 volt battery, a rating (CCA) that is BELOW 6.20 volts indicates that the battery needs to
be charged.
CHARGING
Charging the battery with the recommendations from the tables will NOT obtain a full charge. Charge
the battery to the required charge level. Use the following tables:
Table 2
Battery Charging Rate
Battery rating (ampere
hour) (1)
Setting for the battery
charger (ampere) (2)
(1)
100129
130164
165199
200249
5.0
20
25
30
35
7.5
10
15
To determine the rating, A-Hr and the Cold Cranking Amp CCA refer to one of the following publications:
Specification, PEHP2001, "Specifications For Caterpillar Batteries" and Special Publication, PEKP9100, "Caterpillar
Parts Sales Kit".
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(2)
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A setting of one-half of the amperes may be used. However, the time for charging must be DOUBLED. A battery that is
being tested for a warranty MUST accept the MINIMUM charge within 15 minutes. The minimum charge is 50 percent
of the amperes.
Table 3
Open Circuit Voltage
12.39-12.20
12.19-12.00
8.27 or more
8.26-8.13
8.12-8.00
6.20 or more
6.19-6.10
6.09-6.00
2.0
3.0
4.0
12 Volt battery
12.4 or more
8 Volt battery
6 Volt battery
Charging time in hours
Load test
Charging is not required.
The above charging rates and charging times will bring a battery to approximately 70 percent of a full
charge. If a 100 percent state of charge is required to return the battery to service, use the following
procedure:
1. Charge the battery at the rate from the table. This will bring the battery to approximately 70
percent of a full charge.
2. Charge the battery at half of the same rate. Use the same amount of time that was used to bring the
battery to approximately 70 percent of a full charge.
For example, charging is needed for a battery with a rating of 100 ampere hours. The battery has a
voltage that is less than 12 volts.
1. To reach 70 percent of the full charge, charge the battery at 20 amperes for 4 hours.
Alternatively, charge the battery at 10 amperes for 8 hours.
2. To reach a charge of 100 percent, charge the battery at 10 amperes for an additional 4 hours.
Alternatively, charge the battery at 5 amperes for an additional 8 hours.
Note: Since the amperes that are needed for charging will usually change with time, periodically check
the amperage. Adjust the amperage, if necessary. Stay near the recommended rate. If the battery
becomes warm or a smell of acid becomes noticeable, reduce the charging rate.
Amp Hour Capacity (A-Hr) and Cold Cranking Amps (CCA)
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These vent caps have built-in (internal) flame arrestors that reduce the
possibility of external sparks igniting inside of the battery.
Caution is still required.
Note: Caterpillar General Service and Caterpillar Premium High Output batteries have vent caps.
Charging Time
Charge the battery for the specified time. Refer to Table 2. The amperes may fall below the specified
value near the end of charging.
Charging Voltage
Only during the first 15 minutes of charging, a 12 volt battery can exceed 16 volts.
Using the Battery Charging Rate Tables
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Select a charging rate. Select the charging time. Refer to Table 2 and 3.
Additional Information
Refer to Service Manual, SEBD0625, "Battery Service Manual" for additional information.
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Battery Load Tester - This equipment is used to perform a battery load test. This will measure the
battery's terminal voltage at the end of a specified time while the battery is under a specified load
current.
Caterpillar General Service Battery Caterpillar Premium High Output Battery Charging - The process of replacing electricity in a battery that was removed during the discharge
cycle.
Circuit - A closed path followed by an electrical current. Described as a complete path for a closed
circuit and a disconnected path for an open circuit
Cold Cranking Amp (CCA) - A measure of the battery's ability to deliver a current under cold
conditions
The rating (CCA) is the minimum amperage which must be maintained by the battery at 17.8 C (0 F)
for 30 seconds. At the end of the 30 seconds, each battery cell must have a minimum of 1.2 volts.
Corrosion - This is an accumulation of solid sulfates of iron, copper, or other metals. Corrosion usually
accumulates around the battery terminals. This accumulation can cause poor electrical contact between
the battery cables and the battery terminals. Poor contact between the battery cables and the terminals
can reduce the flow of voltage to the starter. Poor electrical contact can also STOP the flow of voltage to
the starter.
Cycle - The discharge and corresponding recharge of a battery (lead-acid).
Direct Current (DC) - This is an electrical current that flows in one direction only.
A fully charged battery (lead-acid) has a direct current (DC). When the battery is discharged, direct
current must be used to recharge the battery.
Discharge - When the electrical power is drained from a battery, the battery has been discharged.
Dry Charged - A battery that is shipped and stored without electrolyte (acid) has been dry charged. The
battery is activated by adding the correct amount of electrolyte.
Electrolyte (Acid) - This is the liquid that is in a battery. This liquid is a mixture of sulfuric acid and
water.
In a battery, electrolyte is used as a conductor of electricity during the charge and discharge cycle of a
battery.
The battery will store electricity when electrolyte is added to the battery and the electrolyte touches the
active material on the plates.
Grid - This is an electrically conductive framework that is made from a lead alloy. The grid supports the
active material of a battery plate.
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Hybrid (Dual-Alloy) Battery - This is a battery that uses low levels of antimony in the positive grid
and calcium in the negative grid.
Low Antimony Battery - The grids in this battery are made up of a lead alloy. This lead alloy contains
no less than 1.5 percent antimony and no more than 3 percent antimony.
Maintenance Free Battery - This battery does not require a periodic check. A maintenance free battery
is normally sealed in order to prevent access to the electrolyte. However, some Maintenance Free
Batteries are accessible.
Maintenance Possible Battery - This battery is maintenance free and accessible. Calcium is used on
both the negative grids and the positive grids. The removable caps allow you to check the water levels
and the specific gravity.
Negative - This negative magnetic field has a polarity which is opposite to the polarity of the positive
magnetic field.
OHM - This is a unit of measure that is used for measuring electrical resistance.
Open Circuit Voltage (OCV) - This is the voltage of a battery when a battery is not delivering
electricity or receiving electricity. The voltage of a fully charged battery cell is 2.11 volts.
Parallel Circuit - A circuit which provides more than one path for current flow
A parallel arrangement of batteries is a configuration of two or more two-terminal components
connected between two points. The parallel circuit has one negative terminal and one positive terminal
connected to the two points.
When two or more batteries are connected in a parallel circuit, the following situations may occur:
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The sum of each battery's capacity is the CCA and the RC of the system.
Positive - This positive magnetic field has a polarity which is opposite to the polarity of the negative
magnetic field.
Reserve Capacity (RC) - This is the ability of a battery to sustain a minimum electrical load during a
charging system failure.
This minimum load in severe conditions requires current for the following accessories:
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Ignition
Windshield wipers
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Reserve Capacity Rating - This is the amount of time that is required for a battery to deliver 25
amperes at a temperature of 26.7 C (80 F). This rating is important in case the alternator or the
generator fails. The Reserve Capacity Rating is the duration of battery power for essential accessories.
Resistance - This is the opposition to the free flow of current in a circuit. The resistance is measured in
Ohms.
Series Circuit - A circuit which has only one path for current flow
Batteries that are arranged in series are connected with the NEG post of the first battery to the POS post
of the second battery.
When two 12 volt batteries are connected in series the circuit voltage will be equal to the sum (total) of
the two battery voltages (24 volt).
Short Circuit - This is an unwanted path for electricity. An internal short circuit causes a reduction of
voltage in the cell and specific gravity in the shorted cell.
Specific Gravity - The strength or percentage of sulfuric acid in the electrolyte
Specific Gravity is determined by using a hydrometer to compare the weight of the electrolyte to an
equal amount of pure water, which has a specific gravity value of 1.0.
A specific gravity value of 1.265 0.005 is used to activate a Caterpillar battery in a normal
environment. In humid areas, a specific gravity value of 1.225 0.005 is used.
State of Charge - This is the amount of electrical energy that is stored in a battery. The state of charge
is expressed as a percentage of the energy in comparison to a fully charged battery.
The stabilized open circuit voltage determines the state of charge. The stabilized open circuit voltage is
measured after the surface charge has been removed.
Surface Charge - This is a false voltage reading on the battery plates. The surface charge on a battery
happens during the charging cycle.
The surface charge must be removed before the open circuit voltage (state of charge) can be determined.
Volt (V) - This is the unit of measure for electrical potential.
Wet Charged Battery - This type of battery is already filled with electrolyte and fully charged. Wet
charged batteries are ready to use.
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