M0077220 (NEHS1231) 115V & 230V Battery Chargers {1401, 751B} Caterpillar

Caterpillar Products

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Introduction

European Union Compliant, CE Marked (230V version)

Important Safety Information

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Think Safety

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Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as “DANGER”,“WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section

General Hazard

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Information

Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Obey all local regulations for the disposal of liquids.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to the Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

Crushing Prevention and Cutting Prevention

Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

Stay clear of all rotating and moving parts.

Safety Icon Nomenclature

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Personal Protection/Important Information

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Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

General Information Section

Contact Information

For product support questions concerning this tool, contact the Dealer Service Tools Hotline at

USA 800-542-8665, Option 1

International 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

Safety

Safety Instructions

1. This manual contains important safety and operating instructions for battery charger Models 485-9464/485-9465.

2. Do not expose charger to rain or snow.

3. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons.

4. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when disconnecting charger.

5. An extension cord should not be used unless necessary. Use of improper extension cord could result in a risk of fire and electric shock. If an extension cord must be used.

   1. Make sure that pins on plug of extension cord are the same number, size, and shape as those of the plug on charger.

   2. Make sure that extension cord is properly wired and in good electrical condition.

   3. Make sure that wire size is large enough for AC ampere rating of charger as specified in Table 1.

6. Do not operate charger with damaged cord or plug – replace the cord or plug immediately.

7. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. Take it to a qualified serviceman.

8. Do not disassemble charger. Take charger to a qualified serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

9. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

10. WARNING - RISK OF EXPLOSIVE GASSES.

    1. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASSES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER.

    2. To reduce risk of battery explosion, follow these instructions and the instructions published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of battery. Review cautionary marking on these products and on engine.

11. PERSONAL PRECAUTIONS

    1. Consider having someone available nearby to come to your aid if needed when you work near a lead-acid battery.

    2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

    3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.

    4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately.

    5. NEVER smoke or allow a spark or flame in vicinity of battery or engine.

    6. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion.

    7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.

    8. Use charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low voltage electrical system other than in a starter- motor application. Do not use battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage property.

    9. NEVER charge a frozen battery.

12. PREPARE TO CHARGE

    1. If necessary to remove battery from vehicle to charge, always remove grounded terminal from battery first. Make sure that all accessories in the vehicle are off, so as not to cause an arc.

    2. Be sure that area around battery is ventilated while battery is being charged.

    3. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.

    4. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve regulated lead acid batteries, carefully follow manufacturer recharging instructions.

    5. Study all battery manufacturer-specific precautions while charging and recommended rates of charge.

    6. Determine voltage of battery by referring to car owners manual and make sure that output voltage selector switch is set at correct voltage. If charger has adjustable charge rate, charge battery initially at lowest rate.

13. CHARGER LOCATION

    1. Locate charger as far away from battery as dc cables permit.

    2. Never place charger directly above battery being charged. Gasses from battery will corrode and damage charger.

    3. Never allow battery acid to drip on charger when reading electrolyte-specific gravity or filling battery.

    4. Do not operate charger in a closed-in area or restrict ventilation in any way.

    5. Do not set a battery on top of charger.

14. DC CONNECTION PRECAUTIONS

    1. Connect and disconnect dc output clips only after setting any charger switches to off position and removing AC cord from electric outlet. Never allow clips to touch each other.

    2. Attach clips to battery and chassis as indicated in 15(e), 15(f), and 16(b) through 16(d).

15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE. A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION TO REDUCE RISK OF A SPARK NEAR BATTERY.

    1. Position AC and DC cords to reduce risk of damage by hood, door, or moving engine part.

    2. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.

    3. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has larger diameter than NEGATIVE (NEG, N,–) post.

    4. Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to chassis (as in most vehicles), see (e). If positive post is grounded to the chassis, see (f).

    5. For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet- metal body parts. Connect to a heavy gage metal part of the frame or engine block.

    6. For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the frame or engine block.

    7. When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle chassis, and then remove clip from battery terminal.

    8. See operating instructions for length of charge information.

16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE TO REDUCE RISK OF A SPARK NEAR A BATTERY. A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION.

    1. Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post.

    2. Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, –) battery post.

    3. Connect POSITIVE (RED) charger clip o POSITIVE (POS, P, +) post of battery.

    4. Position yourself, and the free end of cable as far away from battery as possible – then connect NEGATIVE (BLACK) charger clip to free end of cable.

    5. Do not face battery when making final connection.

    6. When disconnecting charger, always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical.

    7. A marine (boat) battery must be removed and charged on shore. To charge battery on board requires equipment specially designed for marine use.

AC Input Rating/Size Table

PERSONAL SAFETY PRECAUTIONS

1. Wear protective goggles or a full face shield.

2. Wear protective clothing. Leave no exposed skin.

3. Have plenty of fresh water and hand soap available for use if acid should contact your eyes, skin, or clothing.

4. Remove all metal objects (pens, tools, jewelry and so on) from your body. These items can create a direct short between the battery terminals and can cause serious burns.

5. DO NOT carry tools or metal objects near a battery. These items can fall on the battery terminals creating a high current short. This could result in a fire, burns, explosion, and so on.

6. DO NOT touch your face, eyes, or other body parts without first washing your hands. Battery acid can burn and irritate eye and skin tissue.

7. Use the one hand rule! Keep one hand in your pocket whenever you make an electrical connection. This reduces the risk of electric shock to the user.

8. DO NOT attempt to open or modify the unit.

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CAUSE OF BATTERY FAILURE

• Incorrect ApplicationWrong size battery may have inadequate cold cranking Amp rating for original vehicle specifications.

• Incorrect InstallationLoose battery hold-downs cause excessive vibration, which can result in damage to the plates.

• Improper MaintenanceLow electrolytic fluid and corrosion on battery connections, can greatly reduce battery life and affect battery performance.

• Age of BatteryIf the date code on the battery indicates it is fairly old, the failure may be due to natural causes.

• OverchargingOvercharging caused by a high-voltage regulator setting or incorrect battery charging can cause excessive gassing, heat, and water loss.

• UnderchargingUndercharging caused by a faulty charging system or low voltage regulator setting can cause lead sulfate to gradually build up and crystallize on the plates greatly reducing the battery capacity and ability to be recharge.

INSPECTION

Carefully perform the following before attempting any electrical diagnosis.

VISUAL CHECK

• Inspect Belts for cracks, glazed surface, and fraying. Tighten loose belts.

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• Inspect Battery for terminal corrosion, loose or broken posts, cracks in the case, loose hold-downs, low electrolyte level, moisture, and dirt around the terminals.

• Inspect Starting System Check starter, solenoid, and regulator for loose connections, loose mounts, and frayed or cracked wires.

• Inspect Starting System Check starter, solenoid, and regulator for loose connections, loose mounts, and frayed or cracked wires.

• Important Note A damaged battery must be replaced before proceeding.

During the charge sequence the charger will indicate the estimated time remaining to complete the charge. Actual charge time may vary depending on ability of the battery to accept a charge. The charge time may be extended if the charger senses the battery temperature is becoming to warm by reducing the charge current to protect the battery. The LCD screen makes it possible to view the chargers charging status.

The LCD provides easy menu instructions and charge results for close-up operation.

The charger will automatically charge a 6V, 12V, or 24V battery in a Fast Charge mode or Full Charge mode.

Fast Charge Mode Quickly charges the battery up to a level that it can be put back into service, and the remaining charge will be put back into the battery by the vehicles charging system.

Full Charge Mode Provides a full charge to the battery.

Nomenclature

Control and Functions

1. AC On/Off Switch LCD turns on when AC switch is on.

2. LCD Displays menus and charge results.
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3. KEYS When each key is pressed a beep sounds to assure contact has been made. Y EnterKey - This key selects the main or next menu. It also selects the cursor line item and answers yes to a charge progression. +UpKey - This key moves up the cursor to select a menu line item. It also increments a value. -DownKey - This key moves the cursor down to select a menu line. It also decrements a value. N EscKey - This key cancels a charge or progression. It also returns to the previous menu.

4. Battery Charge Sequence Indicating change in progress, charge complete, or see display for additional information.

USB Port on the left side.

USB - B Connection - Future expansion/factory use.

Hook Up

1. Turn on the AC switch. The LCD will come on if the unit is properly plugged into an AC outlet. For your safety, make sure that the AC receptacle is properly grounded.

   Note: The charger is equipped with a 8ft power cord. Never use an extension cord smaller than 12 gauge or longer than 50ft. Make sure that the extension cord and receptacle are properly grounded.

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   Note: Due to gasses and usual corrosion around the positive terminal it is important to connect the positive (+) red clamp first. Make sure that the connection is certain. Then connect the negative (-) black clamp.

2. Connect the supplied temperature probe to the temperature probe port on the left side of the charger with the power switch in the off position. Install the temperature probe in the supplied bracket as shown below and place the temperature probe so that it points at side center approximately 2 to 4 inches from the battery. The temperature probe will monitor the battery temperature during the charge. If the battery temperature starts to rise quickly, the charger will automatically decrease the charge current to protect the battery.
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3. If the charger displays one of the following messages check your connections.

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Red = (+) Positive and Black = (-) Negative

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Make sure that the terminals are clean and the connection is secure. If the "Check Battery Connections" remains the connections are not secure. If you are sure of a solid connection, replace the battery.

Charge Sequence

From the menu select CHARGE using the +/- keys.

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Then press 'Y' Enter to continue.

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The unit will ask if you are charging a battery bank. if you are, press 'Y'. If you are charging a single battery press 'N'.

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Choose how many batteries are in the bank. 2, 3, or 4. Use the + (Up) or - (Down) keys to change the number. Press 'Y' to select the number.

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Does the battery or batteries have a Caterpillar part number? Press 'Y' if it does, press 'N' if it does not.

If no temperature probe is connected use the +(Up) and - (Down) keys to enter the current battery temp. The (Up) & (Down) keys increment & decrement in units of 10. Press 'Y' to begin.If a temperature probe is connected the battery temperature will be measured automatically.

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The unit will go back to main menu.

If the battery temperature is above 120°F the following message will appear.

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The unit will go back to main menu.

If the battery temp is below 20°F, the following message will appear.

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Summary Screen

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Select the first part of the Cat part number. Use the + (Up) or - (Down) keys to scroll through the possible numbers. Press 'Y' to continue.

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Select the last part of the Cat part number. Use the + (Up) or - (Down) keys to scroll through the possible numbers. Press 'Y' to continue.

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If a Caterpillar part number was selected, this summary screen will be displayed. To confirm that the inputs are correct, press 'Y'. Press 'N' if changes are needed. The unit will go back and let you Re-Enter the battery information.

If there is not a Caterpillar part number, the following 3 screens will be displayed.

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The battery rating displayed will be either the default rating, or the last entered rating will be displayed. (This setting can be changed at setup.) Adjust the rating using the +/- keys. Press 'Y' to continue.

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Press the (+Up) or (-Down) keys to cycle through the battery types. Press 'Y' when it matches the type of battery you are charging.

BATTERY TYPE

STARTING STANDRD OPTIONS STARTING AGM

DEEP CYCLE AGM

DEEP CYCLE STD

GELL CELL

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Press the (+ Up) or (- Down) key to choose FAST CHARGE or FULL CHARGE.

Press 'Y' to continue.

If there is no Caterpillar part number this summary screen will be displayed.

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Confirm that the inputs are correct. Press 'Y' if they are correct. The charge will start. Press 'N' to re-enter temp, battery rating, battery type, or charge type.

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If the charger determines a low voltage, it will ask you to select the rated battery voltage 6V, 12V, or 24V. Use + (Up) or - (Down) key to select rated battery voltage. Press 'Y' to continue.

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After a short time, the display will indicate the maximum time to complete the charge. You can press 'N' at any time to stop the charge.

Automated Conditions

If the battery temperature goes over 140°F, charging will stop. The LED indicators will show the status during a fully automated charge sequence. This makes it possible to view the status and final results at a distance.

• Red "CHARGING" in progress light, indicates that battery is being charged.

• Green "CHARGING COMPLETE" light, indicates that battery has been charged.

• Amber "SEE DISPLAY" light, indicates that additional information is displayed on the screen.

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Normal Charge. Press 'Y' to go back to menu.

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Failed to Charge - The battery failed to accept a charge. Test battery with a battery tester. If battery tests bad, replace the battery. If battery tests good, try charging the battery again.

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Battery Overheated - The battery got too hot to safely charge. Let the battery cool and then recharge.

Battery may not be accepting a normal charge. Test battery with a battery tester. If battery tests bad, replace the battery. If battery tests good try charging the battery again.

SETUP

The charger factory default settings are English, F (Temp), CCA, 600 CCA. To change the settings, use the following setup menus.

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Scroll Down to Setup. Select Setup by pressing 'Y'.

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Choose between Spanish or English Language.

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Select the temp in Fahrenheit or Centigrade.

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Select the rating from CCA, MCA, CA, AH, EN.

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You can also select the default rating to be the last entered CCA value, or a particular amount such as 600 CCA.

REVIEW

From the menu select REVIEW using the +/- keys.

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Press 'N' to return to the main menu.

ABOUT THE 485–9464/485–9465

Select ABOUT from the main menu. The following is displayed.

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Press 'N' to return to the main menu.

• Keep leads free of oil. Clean with warm, soapy water.

• Never insert an object into the fan vents. This can cause electrical and/or mechanical damage. Never cover the fan vents.

• Never attempt to open up or repair the tester. Repairs should only be done by an authorized repair center.

Note: Doing so could void the warranty.

• Always be sure that the tester is off and the smart clamps are removed from the battery before cleaning.

IMPORTANT - Both jaws of each clamp must firmly engage all terminals. The copper jaw contains the smaller gauge wire that reads the voltage and the silver jar contains the larger conducting wire that draws the load in each test. Jaw insulation is necessary for accurate readings. Damaged clamps or loose wires will affect the readings. Keep clamps clean and in good repair. DO NOT ATTEMPT TO REPLACE CLAMPS WITH ANYTHING OTHER THAN AUTO METER CLAMPS.

Over time the battery clamps will need to be replaced if the following are indicated.

• If there is continuity between the silver and copper jaw.

• If there is excessive damage or corrosion to the cables or clamps.

• Disconnect the back cover.

• Remove the battery to prevent shorting.

• Disconnect the two small wires from the PC board.

• Remove the large cables from the copper busses.

• Carefully pull each wire through the grommets.

• Reverse the procedure in replacing new clamps.

LIMITED WARRANTY

12 MONTHS FROM DATE OF PURCHASE The manufacturer warrants to the consumer that this product will be free from defects in material or workmanship for twelve (12) months from the date of original purchase. Products that fail within this 12-month warranty period will be repaired or replaced at the manufacturer option to the consumer, when determined by the manufacturer that the product failed due to defects in material or workmanship.

This warranty is limited to the repair or replacement of parts and the necessary labor by the manufacturer to effect the repair or replacement of the product. The manufacturer will not be responsible for special, incidental, or consequential damages or costs incurred due to the failure of this product.

Improper use, accident, water damage, abuse, unauthorized repairs, or alterations void this warranty.

The manufacturer disclaims any liability or consequential damages due to breach of any written or implied warranty on the test equipment.

WARRANTY AND SERVICE INFORMATION

Warranty claims to the manufacturer service department must be transportation prepaid and accompanied with dated proof of purchase.

This warranty applies only to the original purchaser and is non-transferable.

Shipper damage incurred during return shipments is not covered under this warranty. It is the responsibility of the shipper (the customer returning the equipment) to package the tester properly to prevent any damage during return shipment. Repair costs for such damages will be charged back to shipper (customer returning the equipment). Protect the product by shipping in the original carton or adding plenty of over-pack cushioning such as crumpled up newspaper.