Battery Test Procedure SEHS7633 PDF

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Special Instruction
Battery Test Procedure{1401}
Media Number -SEHS7633-09 Publication Date -22/11/2010 Date Updated -22/11/2010
i04134796
Battery Test Procedure{1401}

SMCS - 1401-081
Caterpillar Products: All
Introduction
This instruction provides the necessary information in order to test the following battery types:
• A new battery
• A battery that is in service
• A battery that is being considered for warranty
The procedures and the tests refer to batteries of the following types:
• Caterpillar General Service Battery
• Caterpillar Premium Battery
• Maintenance Free Battery
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.
Safety Precautions
Handling Batteries And Battery Acid
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 29/12/2012
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 working with acid or when adding electrolyte to a battery, wear a face shield and
protective clothing 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
External - If electrolyte burns the skin, proceed with the following steps:
1. Immediately flush the burned area with water.
Explosive Gases
Batteries generate explosive gases.
Always disconnect the circuit away from the battery; never towards the
battery.
Always keep sparks, flames or any other ignition sources away from the
battery.
Always wear a protective face shield and protective clothing when

working on or near batteries.
Batteries produce hydrogen and oxygen gases during normal operation. Gases escape through the
vent caps. An explosive atmosphere may collect around the battery, especially if ventilation is
poor. The explosive atmosphere may still be present for several hours after the battery is charged.
Batteries can release explosive gasses when charging.
DO NOT under any circumstances remove the vent caps from a battery
while the battery is charging.
Charging the battery with the vent caps removed could result in an
explosion and personal injury.
Caterpillar General Service Batteries and Caterpillar Premium High Output Batteries have vent
caps. The vent caps have a built-in flame arrestor. The vent caps reduce the possibility of external
sparks that could ignite gases that are inside of the battery. Caution is still required.
Internal sparks that are generated by an open connection may cause a battery to explode.
Sparks can also be generated when you connect and/or disconnect a battery from an external
circuit such as a battery charger or the battery cables.
Charging
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.
Always let the ice melt before attempting to charge.
Do not attempt to charge a battery until you are familiar with the procedures for using the battery
charger.
Starting From An External Source
Improper jumper cable connections can cause an explosion resulting in

personal injury.
For the correct procedures, refer to the Operation and Maintenance Manual for the product.
Battery charging equipment must always be located in an area that provides proper safety and
proper ventilation.
Recommended Operating Temperatures

The maximum temperatures of operation for Caterpillar batteries is 52 °C (125 °F). The ideal
operating temperature range for Caterpillar batteries is 20° to 25°C (68 ° to 77 °F). Battery life is
cut in half for every 9.4 °C (48.9 °F) of ambient temperature that is above 25 °C (77 °F). This
equation is valid for any of the following types of batteries that are lead acid: sealed, accessible,
gelled and industrial. The temperature of the battery should not exceed 52 °C (125 °F) during
normal operation. When the battery is exposed to extreme heat, electrolyte is converted into
hydrogen and oxygen gases. The result is a loss in performance, shorter service life, and the
potential for an explosion.
Batteries that are used in cool or moderate conditions can last between two and three times longer
than batteries used in hot climates. In colder climates, the duration of battery life is between 48
and 54 months. In warmer locations, the duration of standard battery life is 18 to 23 months. This
data is based on normal usage. Normal usage includes a good charge and a good condition of
discharge.
Recommended Tools And References

The procedures and the tests in this publication were developed with Caterpillar Service Tools.
The following Caterpillar Service Tools and information publications are recommended:
• 225-8266 Ammeter Tool Gp
• 349-4199 AC/DC Current Probe
• 177-2330 Battery Analyzer
• 4C-4911 Battery Load Tester
• 237-5130 Digital Multimeter Gp
• 146-4080 Digital Multimeter Gp
• Refer to the user manual for more information about using the 225-8266 Ammeter Tool
Gp .
• Refer to Operating Manual, NEHS0764, "Using the 177-2330 Battery Analyzer " for
detailed instruction on the use and the testing procedure of the 177-2330 Battery Analyzer
• Refer to Special Instruction, SEHS9249, "Use Of The 4C-4911 Battery Load Tester For 6, 8
V and 12 V Lead Acid Batteries."
• Refer to the manual that is provided by the supplier for more information on the use of the
237-5130 Digital Multimeter Gp .
• Refer to Operation Manual, NEHS0678 for complete information for the use of the 146-
4080 Digital Multimeter Gp
Recommended Cleaning
Cleaning the Battery
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 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 maneuver 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.
NOTICE
Rapid air movement from compressed air combined with dust, dirt, or
other forms of debris can create static electricity. Static electricity may
lead to an explosion when in the vicinity of a battery, resulting in
personal injury or death. Never use compressed air for cleaning in the
vicinity of a battery.
Remove the cleaning solution from the battery and neutralize the battery by rinsing the battery
with clean water.
Cleaning the Battery Terminal Post

The battery terminal posts may be corroded.
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 posts 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.
Recommended Specifications for the Battery Charger

The following specifications and/or features can be used as guidelines when you charge a battery:
• Use a battery charger with a rugged design.
• Use a battery charger that is rated for heavy-duty commercial use.
• The REQUIRED AC power source must match the AVAILABLE AC power source.
• For 12 V batteries, use a charger that is rated at 70 A. For 6 V batteries, use a charger that is
rated at 110 A.
• Continuous shorting (touching) of the charger output lead wiring should not damage the
battery charger.
• Use a charger that has a relay for polarity protection. The polarity protection 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 V rate can be used on an 8 V 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.
Battery Test And Warranty Procedures

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 References" " in this publication.
Visual Inspection For Damage

The battery is under a warranty and the battery will be replaced by Caterpillar, if the following
conditions occur:
• The battery develops a leak within 30 days of delivering the battery.
• There is no external visible damage in the area of the leak.
If there is external visible damage in the area of the leak, then replace the battery at the expense
customer .
If the battery is eroded in areas that were in contact with the hold-downs, then replace the battery
at the expense of the customer.
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.
Refer to ""Causes Of Battery Failure" " in this publication.
Electrolyte Level Above Plates In All Cells

Note: If the battery is sealed, then this test cannot be done.
The electrolyte level must be above the plates in each cell before continuing. The electrolyte level
does not need to be up to the bottom of the filler neck. The electrolyte level only needs to be
above the plates. The battery may still be serviceable after the battery is filled and after the battery
is properly charged. The battery service life and cranking performance will be reduced if the
electrolyte level is below the top of the plates.
Note: The warranty is voided if the electrolyte level is below the top of the plates. Remove the
warranty sticker from the battery. The battery may still be functional after the battery is filled
and/or after the battery is charged.
• Use distilled water or clean water that is safe for drinking.
• Fill the cells to the bottom of the filler neck.
• Test the battery. Refer to .Operating Manual, NEHS0764, "Using the 177-2330 Battery
Analyzer "
Procedure For Using The 177-2330 Battery Analyzer
Illustration 1 g00658592
Refer to Operating Manual, NEHS0764, "Using the 177-2330 Battery Analyzer " for detailed
instruction on the use and the testing procedure of the 177-2330 Battery Analyzer
Procedures for Battery Charging

Preparing The Battery
Clean the battery case and the battery terminal posts.
Refer to the "Battery Case Cleaning And Battery Terminal Post Cleaning" section in this service
publication.
Preparing The Battery Charger
Note: Some battery chargers are equipped with a polarity protection relay. The relay protects the
battery charger from damage if the charger is connected in a series circuit to the battery.
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.
DO NOT attempt to charge more than one battery at a time.
Before you connect the charger to the battery, the following tasks must be performed:
• Ensure that the charger is in the OFF position.
• The voltage of the battery charger and the rated voltage of the battery should be equal.
Battery Charging and the Effects of Temperature
Refer to Table 1.0 in the Caterpillar Data Sheet, "Battery Charging Parameters" if the battery type
is changed from the factory specified battery type to ensure optimum battery life.
The voltage of the charge should be compensated for the temperature of the battery in high
ambient temperatures or extreme ambient temperatures. The following items are reasons for the
compensation of temperature:
• Prevent the thermal runaway of the batteries when the batteries are used in high temperature
conditions.
• Prevent excessive loss of water and shortenings of the battery life.
Thermal runaway - When heat of the battery is created faster than the dissipation of battery heat.
If this condition continues, permanent battery damage will occur.
A battery will emit hydrogen and oxygen gases when the battery is being charged. The gases are
emitted due to the decomposition of water. A battery emits gases because the battery is being
charged at a rate that is higher than the acceptable rate for the battery. Generally, a battery will
emit gas when the battery reaches a full state of charge. A charger automatically reduces the
charge rate as the battery reaches the fully charged state in order to eliminate most of the gases
from being emitted. It is important not to charge Caterpillar maintenance free batteries for
extended periods of time at rates that will cause the batteries to emit gases. Also, the gases can
cause the pressure in the battery to increase. No battery should be charged for a long period of
time.
When a battery has reached a full state of charge any additional charging will result in heat that is
wasted and the loss of water. The excess heat is damaging to the plates and the separators. The
loss of water lowers the electrolyte level. The loss of water increases the specific gravity of the
electrolyte. The factors that are previously mentioned decrease the service life of the battery. The
previous factors also increase the potential for an explosion. Temperature compensation of the
charging voltage can prolong the life of the battery.
• 5 percent compensation at 86 °C (186 °F)
Machine Charging System Recommendations
In order to limit the alternator voltage to a safe value, a voltage regulator is included in the
charging circuit. The primary function of the voltage regulator is to control of the output voltage
in order to maintain the battery at a proper state of charge.
Many voltage regulators are compensated for temperature. The system voltage is decreased as the
temperature increases. Normal settings are adjusted for 25 °C (77 °F). The voltage adjustment is
used in order to compensate for the acceptance of the charge by the battery.
The setting of the voltage regulator can influence the service life and performance of the battery.
Settings that are too high result in overcharging and reducing the life of the battery. Settings that
are too low result in the following conditions: undercharging, reduced performance and a
discharged battery.
The voltage regulator must be checked in 16093 km (10000 mi) intervals. Also, the voltage
regulator can be checked in 2000 hour intervals or during normal oil change intervals. The voltage
regulator should be checked immediately if the battery is hot to the touch or if the electrolyte is
frothing from the vents.
Table 1
Optimum charging voltage for a 12 V battery versus temperature that is using an
alternator
MF CA/CA Low Antimony Hybrid AGM
Temperature GEL
12.94 12.64 12.64 12.64 12.64

52 °C (126 °F)
12.90 12.80
41° to 52°C (106° to 126°F) 13.32 13.02 13.02
13.02 13.02
26° to 40°C (79° to 104°F) 13.80 13.50 13.50
13.50 13.50
14.10 14.10 14.10
20° to 25°C (68° to 77°F)
14.16 14.16
0° ± 19°C (32° ± 66°F) 14.46 14.16 14.16
15.60 15.60
15.90 15.60 15.60
0 °C (32 °F)
Refer to the Caterpillar Data Sheet, PEHJ-0073 in order to identify the chemical construction of
Caterpillar batteries in order to determine the recommended charging voltages.
Table 2
Optimum Charging Voltage for 12 V Batteries versus Temperature that are using a Charger
Temp Low Antimony
MF CA/CA Hybrid AGM GEL
Float Float Float Float Float

volts Equalize volts Equalize volts Equalize volts Equalize volts Equalize
volts volts volts volts volts
80 °C 12.90 14.70 12.60 13.20 12.60 13.80 12.90 13.50 12.80 12.90
(176 °
F)
60 °C 12.94 12.64 12.64 12.90 12.80

14.74 13.24 13.84 13.54 12.94
(140 °
F)
40 °C 13.32 13.02 13.02 13.02 13.02

15.12 13.62 14.22 13.92 13.32
(104 °
F)
20 °C 13.80 13.50 13.50 13.50 13.50

15.60 14.10 14.70 14.40 13.80
(68 °
F)
0 °C 14.46 14.16 14.16 14.16 14.16

16.26 14.76 15.36 15.06 14.46
(32 °
F)
-30 °
15.90 15.60 15.60 15.60 15.60
C (- 17.70 16.20 16.80 16.50 15.90
22 °
F)
Battery Composition and Battery Charging
Several Caterpillar battery compositions are currently on the market.
Maintenance Free - The battery uses lead calcium grids for the positive plates and the negative
plates. The battery has a lower acceptance of charge than the other batteries. The battery tolerates
overcharging better than the other batteries.
Low Antimony - The battery uses grids of lead antimony for the positive plates and the negative
plates. The battery has a higher acceptance of charge. The battery is prone to overcharging.
Hybrid - The battery uses a lead antimony for the positive grid. The battery uses lead calcium for
the negative grid. The capacity of the charge is between the maintenance free battery and the low
antimony battery. The battery is prone to overcharging.
Lead antimony and some of the hybrid batteries require the addition of water. Lead calcium
batteries do not require the addition of water. Battery types should never be mixed on a machine.
If the battery types are mixed, some batteries may be overcharged and some batteries may not be
charged completely. If one battery needs to be replaced, all of the batteries should be replaced.
Charging The Battery
Follow these guidelines for charging the battery:
• DO NOT charge in the RED zone.
• DO NOT touch the charger leads or disconnect the charger leads while the charger is turned
ON.
Note: For a 12 V battery, do not exceed a terminal voltage of 16 V. However, the terminal voltage
may exceed 16 V ONLY for the first 15 minutes while the battery is beginning in order to accept a
charge.
Overcharging may occur even if the charging voltage is under 16 V. Overcharging is indicated by
the following symptoms:
• The battery becomes warm.
• A smell of acid is present.
• The battery emits smoke or the battery emits a dense vapor.
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 RED positive (+) lead to the battery's positive (+) terminal post and
connect the charger 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 V for a 12
V battery.
Causes Of Battery Failure
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.
No Apparent Failure Mode

The battery does not show any signs of failure. Inspect the battery for the following conditions:
• Poor connections and/or an open circuit
• Corroded, loose and damaged connections in the cranking circuit
• Corroded battery terminal posts
Note: Refer to ""Battery Case Cleaning And Battery Terminal Post Cleaning" " if these conditions
are present.
Leaking Battery Case

A cracked case or a broken case can be caused by the following occurrences:
• A defect in the quality or in the manufacturing
• Foreign material that is trapped under the battery at the time of installation
• Abuse
• Allowing a discharged cell or a dead cell to freeze
• The battery hold-downs are too tight.
• 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.
Table 3
Effects Of Overcharging Batteries
Type Of Battery Effect
Caterpillar General All of the battery cells have a low level of electrolyte.
Service Batteries
Caterpillar Premium When the plates of the battery are inspected through the filler holes,
High Output Batteries the plates may appear to be warped. Excessive temperature can
cause plate warpage.
The battery may not pass a load test.
Caterpillar Maintenance The battery may not accept a charging current.
Free Batteries
The battery may not pass a load test.
Accessible Batteries
Accessible batteries are batteries with caps that can be removed in order to allow access to check
the electrolyte levels. Use deionized water or mineral free water to change the level in the battery
cells.
Accessible batteries are recommended in all generator set applications. Generator set applications
commonly use a constant charge such as a float charge during operation and the use of this type of
constant charge shortens the life of the battery if the battery is not maintained properly. Using
accessible batteries allows proper maintenance and service to the batteries. Proper maintenance
and service will maximize the life of the batteries.
If an accessible design is not available, a design that is not accessible can be used. A battery that is
not accessible must be replaced after 3 years of service. For warmer regions of the world, replace
the battery that is not accessible within 2 years.
The table below lists the recommended accessible batteries and the batteries that are not
accessible.
Table 4
Group Size Accessible Batteries that are not accessible
8D 101-4000 153-5720
4D 9X-9730 153-5710
4D 9X-9720 153-5700
31 115-2422, 115-2421 9X-3404
Maintaining Accessible Batteries
Accessible batteries require periodic checks for proper electrolyte level. The electrolyte level
should be covering the grids 13 mm (0.50 inch) within the battery in order to maximize the
transfer of the full charge. If the liquid level is below the grids, only add deionized water or
mineral free water. Never add battery acid to top off the volume, as the addition of extra acid will
destroy the grids.
Check the level of the electrolyte in accessible batteries every 1000 service hours. In warmer
climates, check more frequently, such as every 500 hours in order to make sure that the electrolyte
level is 13 mm (0.50 inch) above the top of the separators.
Undercharging
The following examples are causes of undercharging:
• An alternator that is not matched to the load demands
• A faulty alternator
• Loose alternator drive belts
• Broken alternator drive belts
• Insufficient time between engine start and engine stop
• 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
• A machine that is parked or stored with an accessory left ON
• The alternator voltage regulator is set too low.
• Moisture and/or debris can cause the battery to self-discharge.
Undercharging on a battery can be caused by connecting a Caterpillar General Service Battery or a

Caterpillar Premium High Output Battery in a series circuit with a Maintenance Free Battery.
Contaminated Electrolyte
Contaminated electrolyte can be caused by adding contaminated water to a battery during the
service life of the battery. Adding contaminated water to a battery can shorten the life of the
battery.
Illustration 2
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:
• Short circuiting within the battery cell
• Dark electrolyte
• Plate material that appears to be peeling, corroding, separating, or splitting
All Other Battery Types
The following situations are effects of vibration:
• An exploded battery due to an open circuit inside one cell
• A shorted cell in the battery may be due to the following conditions: an increase in the
charging current, overheating and excessive gassing.
• A cracked battery case
• Loose battery terminal posts
• Poor cranking speed
Sulfation
Micro-crystalline particles on the surface of the battery plates can be caused by the following
situations:
• Using a battery with the electrolyte level below the top of the plates
• A discharged battery that is being stored for more than 1 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 some sulfation occurs. The ability to store electricity and the ability to deliver
electricity at the full capacity depends on the duration of the sulfated condition.
The sulfation has the following effects on a battery:
• The battery cannot pass a load test.
• The battery cannot accept a normal charging current.
Procedure For Using The 4C-4911 Battery Load Tester

Visually inspect the battery for damage. Refer to ""Visual Inspection For Damage" ". Check the
electrolyte levels in the battery cells. Refer to ""Electrolyte Level Above Plates In All Cells" ".
Open Circuit Voltage

Use a 237-5130 Digital Multimeter Gp .
1. Set the multimeter to 20 V on the "DC" scale.
2. Touch the meter probes to the battery terminals (RED probe to POSITIVE terminal and
BLACK probe to NEGATIVE terminal).
If the battery voltage is low, refer to ""Charging" " in this publication.
Replace the battery if any of the following conditions occur:
12 V battery - The battery voltage is below 11.5 V and the battery will NOT accept a
charging current within 15 minutes of starting the test.
Removing The Surface Charge

Note: This procedure is necessary to ensure an accurate voltage reading.
If a battery has recently been charged, a false charge or a surface charge may exist. This surface
charge MUST be removed.
Note: The surface charge can be removed with the battery in the machine or with the battery out
of the machine.
Remove The Surface Charge From A 12 V Battery When The Battery Is Not Installed
Use a battery load tester in order to test the battery. Set the battery load tester at one half of the
battery rating (CCA). Use the battery load tester for 15 seconds. Wait for 5 minutes and then
measure the open circuit voltage. Refer to ""Open Circuit Voltage" ".
To find the battery rating (CCA), see the label on the battery. If the battery has no label, refer to
Specification, PEHP2001, "Specifications For Caterpillar Batteries" or Special Publication,
PEKP9100, "Caterpillar Parts Sales Kit".
A rating below 12.40 V indicates that the battery needs to be charged.
To determine the charging time, refer to table 7 in this publication.
Remove The Surface Charge From a Battery While The Battery Is Installed
Note: The fuel shutoff valve (if equipped) and/or the governor control (if equipped) MUST be in
the OFF position before starting the engine.
• Crank the engine for approximately 5 seconds.
• Stabilize the battery for 5 minutes.
• Remove the battery terminal cables and the battery terminal wires from the battery.
• Refer to ""Open Circuit Voltage" " in order to measure the voltage.
• For a 12 V battery, a rating (CCA) that is BELOW 12.40 V indicates that the battery needs
to be charged.
• For an 8 V battery, a rating (CCA) that is BELOW 8.27 V indicates that the battery needs to
be charged.
• For a 6 V battery, a rating (CCA) that is BELOW 6.20 V 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 5
Battery Charging Ampere Rate
Battery rating (ampere 15- 35- 50- 70- 100- 130- 165- 200-
hour) (1) 34 49 69 99 129 164 199 249
Setting for the battery
5.0 7.5 10 15 20 25 30 35
charger (ampere)
(1)
.
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"
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 6
Optimum Charging Voltage for 12 V Batteries versus Temperature that are using a Charger
Temp Low Antimony
MF CA/CA Hybrid AGM GEL
Float Float Float Float Float

Equalize Equalize Equalize Equalize Equalize
80 °C 12.90 12.60 12.60 12.90 12.80

14.70 13.20 13.80 13.50 12.90
(176 °
F)
60 °C 12.94 12.64 12.64 12.90 12.80

14.74 13.24 13.84 13.54 12.94
(140 °
F)
40 °C 13.32 13.02 13.02 13.02 13.02

15.12 13.62 14.22 13.92 13.32
(104 °
F)
20 °C 13.80 13.50 13.50 13.50 13.50

15.60 14.10 14.70 14.40 13.80
(68 °
F)
0 °C 14.46 14.16 14.16 14.16 14.16

16.26 14.76 15.36 15.06 14.46
(32 °
F)
-30 °
15.90 15.60 15.60 15.60 15.60
C (- 17.70 16.20 16.80 16.50 15.90
22 °
F)
Refer to the Caterpillar Data Sheet, PEHJ-0073 in order to identify the chemical construction of
Caterpillar batteries in order to determine the recommended charging voltages.
Table 7
Open Circuit Voltage
12.39-12.20 12.19-12.00 less than 12.00
12 V battery 12.4 or more
less than 8.00

8 V battery 8.27 or more 8.26-8.13 8.12-8.00
6 V battery 6.20 or more 6.19-6.10 6.09-6.00 less than 6.00
Load test
Charging time in
Charging is not 2.0 3.0 4.0
hours 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 in order to 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 V.
1. To reach 70 percent of the full charge, charge the battery at 20 A for 4 hours.
Alternatively, charge the battery at 10 A for 8 hours.
2. To reach a charge of 100 percent, charge the battery at 10 A for an additional four hours.
Alternatively, charge the battery at 5 A 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.
Ampere Hour Capacity (A-Hr) and Cold Cranking Amp (CCA)
Do not attempt to charge a battery with the vent caps missing.
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
The battery should be charged according to the voltage. Refer to Tables 2 and 5.
Charging Voltage
Charge the battery according to the specified voltage. Refer to Tables 5 and 6.
Using the Tables for the Battery Charging Rate
• Use a digital voltmeter to measure the open circuit voltage.
• Select a rate of amperage and a rate of charge of voltage. Select the charging time. Refer to
Table 5, 6 and 7.
Note: Refer to Specification, PEHP2001, "Specifications For Caterpillar Batteries" or Special

Publication, PEKP9100, "Caterpillar Parts Sales Kit" if the Ampere Hour (A-Hr) is unknown.
Terms And Definitions

Ampere (Amp) (A) - The amount of current flow through a circuit.
Amp Hour Rating - The Amp hour rating is determined by testing a fully charged battery at a
temperature of 26.7 °C (80 °F). A constant low drain for 20 hours is required.
At the end of that time, the voltage of each battery cell must be 1.75V or more.
Battery - A device for generating an electric current by chemical reaction
Battery Cell - A battery cell is used for converting chemical energy into electric energy.
Battery Charger - A device for replacing electricity in a battery that was removed during the
discharge cycle
Battery Load Test - A procedure to check the ability of a battery. The procedure determines if the
battery can carry a charge, and if the battery can sustain a charge.
Battery Load Tester - Equipment used to perform a battery load test. The battery load tester will
measure the battery terminal voltage at the end of a specified time while the battery is under a
specified load current.
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 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
V.
Corrosion - An accumulation of solid sulfates of iron, copper, or other metals. Corrosion usually
accumulates around the battery terminals. The 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) - 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 with out electrolyte has been dry charged. The
battery is activated by adding the correct amount of electrolyte.
Electrolyte (Acid) - The liquid that is in a battery. The 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 - An electrically conductive framework that is made from a lead alloy. The grid supports the
active material of a battery plate.
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 - A unit of measure that is used for measuring electrical resistance.
Open Circuit Voltage (OCV) - 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 V.
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:
• Each battery has the same system voltage.
• 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) - 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:
• Ignition
• Low beam headlights
• Windshield wipers
• Defroster at low speed
Reserve Capacity Rating - The amount of time that is required for a battery to deliver 25 A 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 - 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 V batteries are connected in series the circuit voltage will be equal to the sum (total)
of the two battery voltages (24 V).
Short Circuit - 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 - 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 - 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) - 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.
Copyright 1993 - 2012 Caterpillar Inc. Sat Dec 29 08:49:42 EST 2012
All Rights Reserved.
Private Network For SIS Licensees.

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Battery Test Procedure{1401}

Caterpillar Products: All

• A battery that is in service

• A battery that is being considered for warranty

• Caterpillar General Service Battery

• Caterpillar Premium Battery

• Maintenance Free Battery

If an accident occurs use the following antidotes:

2. Seek immediate medical attention.

Internal - If electrolyte is consumed, proceed with the following steps:

1. Immediately drink large quantities of water or milk.

3. Seek immediate medical attention.

1. Immediately flush the burned area with water.

2. Seek immediate medical attention.

Batteries generate explosive gases.

Always wear a protective face shield and protective clothing when

Batteries can release explosive gasses when charging.

Charging a battery in this condition can cause an explosion that may

Always let the ice melt before attempting to charge.

Starting From An External Source

Improper jumper cable connections can cause an explosion resulting in

Recommended Operating Temperatures

Recommended Tools And References

• 225-8266 Ammeter Tool Gp

• 349-4199 AC/DC Current Probe

• 177-2330 Battery Analyzer

• 4C-4911 Battery Load Tester

• 237-5130 Digital Multimeter Gp

• 146-4080 Digital Multimeter Gp

Batteries can be cleaned with one of the following solutions:

Cleaning the Battery Terminal Post

DO NOT remove any more material than necessary, or the cable

Recommended Specifications for the Battery Charger

• Use a battery charger with a rugged design.

• Use a battery charger that is rated for heavy-duty commercial use.

Battery Test And Warranty Procedures

Refer to ""Recommended Tools And References" " in this publication.

Visual Inspection For Damage

• The battery develops a leak within 30 days of delivering the battery.

• There is no external visible damage in the area of the leak.

Refer to ""Causes Of Battery Failure" " in this publication.

Electrolyte Level Above Plates In All Cells

• Use distilled water or clean water that is safe for drinking.

• Fill the cells to the bottom of the filler neck.

Procedure For Using The 177-2330 Battery Analyzer

Procedures for Battery Charging

Preparing The Battery Charger

Connect a charged battery in parallel, positive to positive, and negative

DO NOT attempt to charge more than one battery at a time.

• Ensure that the charger is in the OFF position.

Battery Charging and the Effects of Temperature

• Prevent excessive loss of water and shortenings of the battery life.

• 5 percent compensation at 86 °C (186 °F)

• 10 percent compensation at 95 °C (203 °F)

• 15 percent compensation at 104 °C (219 °F)

Machine Charging System Recommendations

12.94 12.64 12.64 12.64 12.64

Float Float Float Float Float

60 °C 12.94 12.64 12.64 12.90 12.80

40 °C 13.32 13.02 13.02 13.02 13.02

20 °C 13.80 13.50 13.50 13.50 13.50