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Battery Test Procedure{1401}

SMCS - 1401-081

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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 under warranty consideration

The procedures and the tests refer to batteries of the following types:

Caterpillar General Service Battery

Caterpillar Premium High Output 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.

Recommended Tools And Special Instructions

The procedures and the tests in this publication were developed with Caterpillar Service Tools. The following Caterpillar Service Tools
and information publications are recommended:

8T-0900 AC/DC Clamp-On Ammeter

155-5175 AC Current Probe

155-5176 AC/DC Current Probe

127-8078 Battery Analyzer

177-2330 Battery Analyzer

4C-4911 Battery Load Tester

6V-7070 Heavy-Duty Digital Multimeter

146-4080 Regular-Duty Digital Multimeter

Special Instruction, SEHS7734, "Use Of The 6V-7070 And 6V-7800 Multimeter"

Special Instruction, SEHS8420, "Using The 8T-0900 AC/DC Clamp On Ammeter"

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

3. Seek immediate medical attention.

External - If electrolyte burns the skin, proceed with the following steps:

1. Immediately flush the burned area with water.

2. Seek immediate medical attention.

Batteries Can Explode

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 when you disconnect a battery from an external circuit such as a battery charger
or the battery cables.

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.

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.

Battery Case Cleaning And Battery Terminal Post Cleaning

Battery Case Cleaning

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.

Battery Terminal Post Cleaning

The battery terminal post(s) 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 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.

Recommended Battery Charger Specifications

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 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.

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 Special Instructions" " in this publication.

Visual Inspection For Damage

The battery is under 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 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.

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's 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 capable of some additional service after the battery is filled and/or after the battery is charged.

Use distilled water or use any clean water that is safe to drink.

Fill the cells to the bottom of the filler neck.

Refer to ""Conductance Test (Using The 127-8078 Battery Analyzer)" ".

Procedure For Using The 127-8078 Battery Analyzer

NOTICE
A battery must be clean and free from corrosion, before the following procedures are
used. Failure to do so can cause a false visual inspection and/or false test results.

Refer to ""Battery Case Cleaning And Battery Terminal Post Cleaning" " in this publication.

Conductance Test (Using The 127-8078 Battery Analyzer)

Do NOT charge the battery prior to testing, if the battery is not installed.

If the battery is installed, the connections between the batteries do NOT need to be removed in order to test the following systems:

12 volt system with one battery

24 volt system with two batteries

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:

12 volt system with more than one battery

24 volt system with more than two batteries

1. Visually inspect the battery.

2. Check the electrolyte level.

3. Connect the tester's "RED" positive lead to the battery positive post. Connect the tester's "BLACK" Negative lead to the battery
 negative post.

Rock the tester's leads back and forth in order to ensure a good connection. A bad connection on one side of either clamp will
cause an incorrect reading.

Test "A - Cell Test"

Turn the "Tester Functions" dial to "A - Cell Test".

If the "RED Bad Cell" indicator does NOT illuminate, the cells are good. Proceed to Test "B - Battery Condition".

If the "RED Bad Cell" indicator illuminates, the cells are not good.

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.

Test "B - Battery Condition"

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".

If meter (B) indicates in the GREEN area, the battery is in good condition. Continue to Test "C-Volts".

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.

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.

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).

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.

Test "C - Volts"

Turn the "Tester Functions" dial to the "C - Volts" position.

If the battery has been recently charged, then the surface charge must be removed. Refer to ""Removing The Surface Charge" "
in this publication.

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.

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".

Test "D - Cranking Power"

Turn the "Tester Functions" dial to "D - Cranking Power".

Read the "Cranking Power" on meter (D).

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).

Procedure For Using The 177-2330 Battery Analyzer

Illustration 1 g00658592

The 177-2330 Battery Analyzer will test any 6 volt battery or 12 volt battery with any of the following capacities:

50 to 4,000 Cold Cranking Amp (CCA)

65 to 5,000 Cranking Amp (CA)

 6 to 500 Amp Hour (A-Hr)

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.

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 g00644085
Battery Test Start Screen

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 g00644100
Low Voltage Display Screen

c. Select the "Cold Battery Test", if necessary.

Illustration 4 g00644104
Cold Battery Test Display Screen

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:

Cold Cranking Amp (CCA)

Cranking Amp (CA)

Ampere Hour (A-Hr)

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 g00644154
Cold Cranking Ampere Rating (CCA) Display screen

Illustration 6 g00644162
Cranking Ampere Rating (CA) Display Screen

Illustration 7 g00644165
Battery Amp Hour Rating (A-HR) Display Screen

5. Press the "GO" key. The analyzer will display one of the following conditions of the battery:

Good

Low Charge

Charge/Retest
 Bad

The state of the battery charge will also be displayed.

Illustration 8 g00644281
Battery Pass

Note: The battery is capable of holding a charge.

Illustration 9 g00644301
Battery Pass / Low Charge

Note: The battery is good, but the battery should be recharged.

 Illustration 10 g00644304
Charge / Retest

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.

Illustration 11 g00644426
Bad battery

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.

Battery Charging Procedures

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. This 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.

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 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:

The battery becomes very 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'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.

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.

Battery Case Leaking

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 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
Output Batteries warped. This is caused by an excessive temperature.

The battery may not pass a load test.

Caterpillar Maintenance Free The battery may not accept a charging current.
Batteries
The battery may not pass a load test.

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 on the battery causing 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. This can shorten
the life of the battery.
Illustration 12 g00657874
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

The battery has a shorted cell. This 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 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 full capacity depends on the duration of the sulfated condition.

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 6V-7070 Digital Multimeter .

1. Set the multimeter to 20 volts 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 volt battery - The battery voltage is below 11.5 volts and the battery will NOT accept a charging current within 15 minutes
of starting the test.

8 volt battery - The battery voltage is below 7.67 volts and the battery will NOT accept a charging current within 15 minutes of
starting the test.

6 volt battery - The battery voltage is below 5.75 volts 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 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 Volt 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's rating (CCA). Use the battery
load tester for 15 seconds. Wait for five minutes and then measure the open circuit voltage. Refer to ""Open Circuit Voltage" ".

To find the battery's 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 volts indicates that the battery needs to be charged.

To determine the charging time, refer to table 3 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 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

15-34 35-49 50-69 70-99 100-129 130-164 165-199 200-249

Battery rating (ampere hour) (1)

Setting for the battery charger

5.0 7.5 10 15 20 25 30 35
(ampere) (2)
(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".
(2) 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 Volt battery 12.4 or more 12.39-12.20 12.19-12.00 less than 12.00

8 Volt battery 8.27 or more 8.26-8.13 8.12-8.00 less than 8.00

6 Volt battery 6.20 or more 6.19-6.10 6.09-6.00 less than 6.00

Load test
Charging time in hours 2.0 3.0 4.0
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)

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

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

Use a digital voltmeter to measure the open circuit voltage.

Select a charging rate. Select the charging time. Refer to Table 2 and 3.

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.

Additional Information

Refer to Service Manual, SEBD0625, "Battery Service Manual" for additional information.

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 1.75 volts 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 - This is a procedure to check the ability of a battery. This procedure determines if the battery can carry a charge,
and if the battery can sustain a charge.

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.

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:

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) - 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:

Ignition

Low beam headlights

Windshield wipers

Defroster at low speed

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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