Section 4004 BATTERY SERVICING AND TESTING 4004 © 2000 6: CASE UNITED KINGDOM LIMITED Don 7.7321 February 1988 (Rev4004-2 TABLE OF CONTENTS. SPECIFICATIONS SPECIAL TOOLS .... SAFETY PROCEDURES MAINTENANCE Electrolyte Level Inspecting and Cleaning the Battery, Cables and Terminals, BATTERY TESTING Method One - Five Step Battery Test... Method Two - Using Heavy Duty Battery Tester.. CHARGING THE BATTERY ... PREPARING A DRY CHARGED BATTERY FOR USE BOOSTER BATTERY CONNECTIONS Don7-73211 Issued 6-98‘Type of System... SPECIFICATIONS 4004-3 12 Volt, Negative Ground Batteries ‘One 12 Volt, Low Maintenance Hybrid Battery or “Two 12 Vol, Low Maintenance Hybrid Batteries Connected in Parallel DIN Type 60527, Top Stud Terminals BATTERY | SAE (COLD CRANKING ss a AMPERE | RESERVE TYPE CAPACITY) HOURS | CAPACITY 629 1000 Amps: ‘670 Amps 600 Amps 170 320 mins | 644 660 Amps: 440 Amps ‘400 Amps. "95 180 mins | 664 770 Amps. sis Amps | 465Amps | 105 210 mins 665 ‘810 Amps. 545 Amps | 490 Amps 120 220 mins SPECIAL TOOLS Don 7-73211 (CAS10990 HEAVY DUTY BATTERY TESTER, (CASI0991 RECHARGEABLE BATTERY PACK (€AS10932 OPTICAL ENGINE COOLANT AND BATTERY ELECTROLYTE TESTER Issued 6-004004-4 SAFETY PROCEDURES WARNING: THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS AR SYB01, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALEAT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. ure WARNING: BATTERY ACID CAUSES WARNING: Do not charge a frozen battery, SEVERE BURNS. Batteries contains ican explode, causing serious injury. 529 sulphuric acid. Avoid contact with skin, eyes r clothing. Antidote: EXTERNAL - flush with water. INTERINAL - drink large quantities of WARNING: — Battery explosion and/or water or milk. Follow with milk of magnesia, damage to electrical components can result beaten egg or vegetable oll. Call a physician from improper connection of booster A immediately. EYES - flush with water for 15 batteries or charger. Connect positive to minutes and get prompt medical attention positive and negative to negative. Externally, BATTERIES PRODUCE EXPLOSIVE battery acid can cause bums and blindness, GASES. Keep sparks, flame and cigarettes and taken intemaliy is poison. see away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. naan, WARNING: Always connect the ground cable last and disconnect the ground cable first 80 you do not cause a spark at the battery. A spark can cause a battery WARNING: When working around storage explosion and cause injury. sao A batteries, remember that all of the exposed metal parts are ‘live’. Never lay a metal object across the terminals because a spark or short circuit will result nasa MAINTENANCE Electrolyte Level Check the electrolyte level in each cell every 300 hours of operation. The machine is equipped with either one (1) or two (2) Low Maintenance batteries. If electrolyte level is low add distilled water to just cover the top of the separators. DO NOT OVER FILL. Do not Use water which contains minerals. The level should be 3 to 6 mm (0.12 to 0.24 inch) below vent well. When distilled water is added at ambient temperatures below 0°C (32°F) the batteries must be charged immediately to mix the water and electrolyte or the water will freeze, because the water will stay on top of the electrolyte. Inspecting and Cleaning the Battery, Cables and Terminals Inspect the battery at regular intervals for dirt, corrosion and damage. Electrolyte and dirt on the top of the battery can cause the baltery to discharge by providing a passage for the current to tlow. Make sure the vents are installed firmly in position and the battery top is clean and dry. The battery terminals must be kept clean and tight. Remove all corrosion with a wire brush, then wash with a weak solution of baking soda or ammonia Apply petroleum jelly to the terminals to prevent more corrosion. DO NOT apply grease. Don 7-79211 Issued 6-004004-5 BATTERY TESTING Method One - Five Step Battery Test Follow STEP 1 to STEP § to correctly determine the condition of the battery if Automatic Battery Tester (AS10930 is not available. NOTE: Batteries may be overcharged or undercharged due to a fault in the tractors electrical system Always make sure the electrical system is working correctly. NOTE: /f the Voltmeter Reading in STEP 2 shows a reading of below 10 volts, it may not be possible to successtully recharge the battery and its further service life is often greatly reduced. NOTE: Where discoloured electrolyte is observed, this is always due to a service related condition. STEP 1. VISUAL CHECK + Make sure cable connections are clean and tight. Clean foreign material from the battery top. + Inspect the battery case, battery posts and cables for damage. * Check the electrolyte level, refer to "Electrolyte Level” on page 4 + Ifyou added distiled water to the battery, the battery must be charged for 15 minutes at 15 to 20 amperes to mix the water with the electrolyte STEP 2. VOLTMETER | STEP3.HIGH RATE | STEP 4,HYDROMETER READING | STEP 5. BATTERY ADING DISCHARGE TEST (see NOTE 1) CONDITION 10 to 11.5 volts Below 9 volts REPLACE | (voltage often rises) | creen asove 260 $6) BATTERY | | wre (1225 1260 80) RED (BELOW 1225 50) 10 to 11.5 volts Below 9 volts B [EL | REPLACE (voltage often rises) | Green asove 1260 so) x} BATTERY WuTe (1225 to 126080) RED (BELOW 1225 5G) Oto 12.6 volts Below 3 volts REPLACE | (voltage normally GREEN (ABOVE 126080) BATTERY zero) WHITE (1225 to 1260 50) RED (BELOW 1225 56) a 6t0 12.4 volts Below 9 volts ] REPLACE (voltage steadily falls) | Green asove 1260 50) r BATTERY | wore (1225 0 128086) rep se.ow 122580) |} Below 10 volts | Below 3 votts RECHARGE (voltage can be zero) | Green asove 1260 $0) BATTERY Watre (1225 to 1260 56) (see NOTE 2) RED (BELOW 1225 5G) Above 11.5 volts 310 9 volts: iI RECHARGE (votage remains sta- | aacen asove 1240 s6) BATTERY ble) WHITE (1228 to 1280 56) | | RED (BELOW 1225 SG) | NOTE 1: Recori readings from each battery cell. The cell nearest the positive terminal is cell number 1. Using the hydrometer as a pump check the two end ceils for discoloured electrolyte. NOTE 2: The battery is over discharged and may not recover alter recharging. Don 7-73211 Issued 6-004004-6 Method Two - Using Heavy Duty Battery Tester Sees RE-TESTAFTER (= crancna | © 1. CONTROL KNOB (SAE CRANK AMPS) 2. TEMPERATURE SWITCH 3. TEST BUTTON 4. CHARGE LEVEL INDICATOR 5. BATTERY CONDITION INDICATOR 6. TEST IN PROGRESS INDICATOR LAMP 7, TEST COMPLETE INDICATOR LAMP 8. RE-TEST AFTER CHARGING INDICATOR LAMP ‘STEP 1 Connect CAS10990 heavy duty battery tester onto the battery. Set the AMPS SAE control knob (1) to the correct SAE (cold cranking capacity) for the battery installed, refer to “SPECIFICATIONS” on page 3 STEP 2 Make sure the TEMPERATURE switch (2) is in the >0°C (normal) position NOTE: In temperatures below 0°C (32°F) move the TEMPERATURE switch (2) to the <0°C (cold) position, STEP 3 Connect the positive (+ RED) cable clamp of the automatic battery tester to the positive (+ RED) cable terminal on the machine battery. Connect the negative (- BLACK) cable clamp of the automatic battery tester to the positive (- BLACK) cable terminal on the machine battery. NOTE: It is not necessary to disconnect and remove the battery from the tractor. If the automatic battery tester is incorrectly connected it will not work. If the bleeper sounds the battery must be recharged before the test can continue, refer to “CHARGING THE BATTERY” on page 8. STEP 4 Press the TEST button (3) and the test will begin automatically. The test will be completed in 40 seconds or less, to determine the condition of the battery refer to “Test Results” on page 7. on 7.79211 Issued 6-004004-7 STEP 5 If the battery charge level is below 20% it is not possible to complete the test without a booster battery, the re- test after charging indicator lamp (8) will flash and a bleeper will sound. To re-test the battery, using the cables supplied connect CAS10930 heavy duty battery tester to a booster battery and repeat STEP 4. Alternatively connect CAS10931 Rechargeable Battery Pack to CAS 10930 heavy duty battery tester and repeat STEP 4. Test Results BATTERY CHARGE LEVEL | CHARGE LEVEL INDICATOR DISPLAY READING RESULT Flashing Display Result being calculated Solid Display Result confirmed 5 Bars lluminated 100% (fully charged) 4 Bars illuminated 80% 3 Bars Illuminated 60% — 2 Bars tluminated 40% 17 Bar luminated 20% 1 Bar Flashing BATTERY FLAT, reler to “CHARGING THE BATTERY” on page 8 | BATTERY CONDITION l CONDITION INDICATOR DISPLAY READING RESULT | Flashing Display Result being calculated ‘Solid Display | Result confirmed and bleeper sounds 3 Green Bars lluminated ‘Good battery - return to service 2 Green Bars Illuminated Good battery - return to service | | 7 Green Bar liuminated | Battery performance adequate | (but may need replacing in near future) | 7 Red Bariiuninaiod | Replace baton - ureerceabla | | 2 Red Bars tluminated Replace battery - unserviceable | E NOTE: Red bars continue to flash at end of test. Don 7-73211 Issues 6-004004-8 CHARGING THE BATTERY IMPORTANT: /f the battery has been in storage WARNING: Do not charge a frozen battery, check the voltmeter reading, if the reading is itcan explode, causing serious injury. Ws23 above 12.5 volts the battery does not need charging. If the voltmeter reading is below 12.5 IMPORTANT: Before charging the battery check volts follow the charging procedure to recharge the electrolyte level, refer to “Electrolyte Level” the battery. on page 4 STEP 1 Install the battery onto a suitable variable battery charger. Select the correct battery type installed on your tractor, refer to “SPECIFICATIONS” on page 3. Set the charging rate at § to 7 amps for batteries above 90 ‘Ampere Hours (set charging rate of 3 to 4 amps for batteries below 90 Ampere Hours). Charge the battery for 12 hours, NOTE: If an automatic battery charger is used, battery charging is complete when the GREEN indicator light is illuminated. STEP 2 Atter charging allow the battery to stand for 24 hours before measuring battery voltage, the voltage reading should be above 12.7 volts It the battery is immediately required measure the cells with a hydrometer, the hydrometer reading for each cell should be a minimum of 1.270 Sg NOTE: /f the voltage reading or hydrometer readings are not correct repeat STEP 2 and recharge the battery. If after a second charge the battery fails to achieve the correct readings, refer to “BATTERY TESTING’ on page 5 PREPARING A DRY CHARGED BATTERY FOR USE STEP 1 Remove the battery vents and fill each cell with electrolyte to just cover the top of the separators. DO NOT OVER FILL. The level should be 3 to 6 mm (0.12 to 0.24 inch) below vent well. Install the battery vents. STEP 2 Follow the procedure above for CHARGING THE BATTERY. Don 7-79211 ‘ssued 6-004004-9 BOOSTER BATTERY CONNECTIONS WARNING: — Battery explosion and/or damage to electrical components can result from improper connection of booster batteries or charger. Connect positive to WARNING: Always connect the ground cable last and disconnect the ground cable AA tte so yor 00 et casse'a Spa at tho battery. A spark can cause a battery positive and negative to negative. Externally, explosion and cause injury. 530 battery acid can cause burns and blindness, and taken internally is poison. nasa IMPORTANT: When connecting a booster battery to the machine battery make sure the booster battery and the discharged battery have the same voltage (i.e. 12 VOLTS). Make sure you connect positive to positive and negative to a good ground on the machine chassis frame. DO NOT connect booster battery cables across the terminals of the starter. Always follow the procedure in your Operators Manual for Starting the Engine. STEP 1 Position the machine with the booster battery next to the machine with the discharged battery so the booster cables can be easily connected. MAKE SURE the machines do not touch, STEP 2 ‘Check the electrolyte levels and inspect the batteries, refer to “MAINTENANCE” on page 4. STEP 3 ‘On both machines turn OFF all electrical loads. Connect the positive (+) cable clamp of the booster battery to the positive (+ RED) cable terminal on the discharged battery. Connect the negative (-) cable clamp of the booster battery to a good ground on the chassis frame of the machine with the discharged battery. STEP 4 Start the engine of the machine with the booster battery and run for approximately two minutes. STEP 5 Follow the procedure in your Operators Manual and start the engine of the machine with the discharged battery. If the engine will not start after 30 seconds STOP THE PROCEDURE. Wait three minutes to allow the starter motor to cool. STEP 6 After starting allow the machine to idle, remove the negative (-) cable clamp from the chassis frame, then remove the negative (-) cable clamp from the booster battery. Remove the positive (+) cable clamp from the discharged battery, then remove the positive (+) cable clamp from the booster battery. BOOSTER BATTERY DISCHARGED BATTERY To GROUND yet —_— CHASSIS GROUND Don 7.79211 Issued 6-00