Activation of 101-4000 Batteries, 115-2421 Batteries, and 9X-9730 Batteries That Are Shipped Without Electrolyte {1401} Caterpillar

Off-Highway Truck/Tractor

769D (S/N: 5SS1-UP)

773D (S/N: 7CS1-UP)

776D (S/N: 5ER1-UP)

777D (S/N: 3PR1-UP)

784C (S/N: 2PZ1-UP)

785C (S/N: 1HW1-UP; 5AZ1-UP)

789C (S/N: 2BW1-UP)

793C (S/N: 4GZ1-UP)

Quarry Truck

771D (S/N: 6YS1-UP)

775D (S/N: 8AS1-UP)

Wheel Loader

994F (S/N: 4421-UP)

Introduction

This Special Instruction contains the required procedures and information needed to activate batteries that are shipped without electrolyte. Batteries that are shipped without electrolyte will have improved service life. Make sure that the recommended tools and reference materials are available before you activate the battery.

Do not perform any procedures until you read the entire Special Instruction. Do not perform any procedures until you understand the entire Special Instruction.

Refer to the publications that follow:

• Service Manual, SEBD0625, "Battery Service Manual"

• Special Instruction, SEHS7633, "Battery Test Procedure"

Safety Precautions

Read the safety information that follows before activating the batteries.

Handling Batteries and Battery Acid

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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.

Take precautions when you handle batteries and electrolyte.

Eyes

If electrolyte splashes into your eye, flood the eye with water for fifteen minutes. Seek medical attention immediately.

Internal

If you drink electrolyte, drink large quantities of water or drink large quantities of milk. After you drink the water or milk, drink some milk of magnesia, some egg, or some vegetable oil. Seek medical attention immediately.

External

If electrolyte contacts your skin, use water to wash the electrolyte off your skin. Seek medical attention immediately.

Batteries Can Explode

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Batteries give off flammable fumes that can explode. Prevent sparks near the batteries. They could cause vapors to explode. Do not allow jump cable ends to contact each other or the machine. Do not smoke when checking battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear eye protection when starting a machine with jump start cables. Improper jump procedures can cause an explosion resulting in personal injury. Always connect battery positive (+) to battery positive (+) and battery negative (−) to battery negative (−). Jump start only with a battery source and with the same voltage as the stalled machine. Turn off all lights and accessories on the stalled machine. Otherwise, they operate when the jump source is connected.

During normal operation, batteries produce hydrogen and oxygen gases. As the gases escape through the vent caps, an explosive atmosphere may develop around the battery. Poor ventilation can contribute to the development of the explosive atmosphere.

After the battery is charged, an explosive atmosphere may be present for many hours.

A connection that generates sparks can cause a battery to explode. Sparks can be generated when you connect or you disconnect a battery.

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Do not, under any circumstances, remove the vent caps from a Caterpillar battery while charging. Removal of the vent caps can allow flammable fumes to accumulate which can cause an explosion that may result in personal injury or death. The vent caps should only be removed, during maintenance, to add water to serviceable batteries. The vent caps of maintenance-free batteries should not be removed.

After you activate a maintenance free battery, the electrolyte level does not need to be checked. Therefore, the vent caps of a maintenance free battery do not require removal.

Charging A Battery

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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.

Before you charge a battery, read Special Instruction, SEHS7633, "Battery Test Procedure".

Charge the battery in a well ventilated area. Proper safety devices should be available.

Required Tools And Supplies

Use battery grade sulfuric acid for electrolyte. The sulfuric acid should have a specific gravity of 1.265.

Add Electrolyte

1. Remove the filler plugs from the battery.

   Note: Save the plugs from maintenance free batteries. The plugs will be used again after the electrolyte is added.

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   Illustration 1	g00605450
   Add electrolyte.

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   Illustration 2	g00605465
   (A) Vent ring.

2. Use electrolyte in order to fill the battery cells to the bottom of the vent rings (A). Refer to Table 1 in order to find the amount of electrolyte that is required.

   Note: When you fill the battery with electrolyte, the battery and the electrolyte should be at a temperature between 16 °C (60.8 °F) and 38 °C (100.4 °F) in order to obtain optimum performance.

3. Install the vent assemblies on conventional batteries. Install the filler plugs on maintenance free batteries. Tighten the filler plugs to a torque of 3.4 ± 1.1 N·m (30.1 ± 9.7 lb in).

   Note: Do not remove the vent plugs from a maintenance free battery in order to inspect the level of the electrolyte.

Test The Battery

Testing The Battery In Warm Climates

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Illustration 3	g00605525
Battery Charging

1. If the battery and the electrolyte are at a temperature between 16 °C (60.8 °F) and 38 °C (100.4 °F), apply a load to the battery. The load should equal one half of the cold cranking amperage rating. Apply the load for fifteen seconds.

2. When the load is applied to the battery, check the available voltage at the battery after fifteen seconds. If the voltage is above 9.0 Volts, the battery is ready for use. If the voltage is below 9 Volts, charge 115-2421 Batteries for 20 minutes at a setting of 40 amperes. Charge 9X-9730 Batteries and 101-4000 Batteries for 20 minutes at a setting of 60 amperes.

3. Again, apply the load to the battery. The load should equal one half of the cold cranking amperage rating. Apply the load for fifteen seconds.

4. When the load is applied to the battery, check the available voltage at the battery after fifteen seconds. If the voltage is above 9.0 Volts, the battery is ready for use. If the voltage is below 9 Volts, the battery is not usable. Return the battery in order to be recycled.

Testing The Battery In Cold Climates

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Illustration 4	g00607614
Battery Charging

1. Charge the battery for 20 minutes at a setting of 40 amperes if any of the indicated conditions are present.

   • The ambient temperature is below 16 °C (60.8°F).

   • The temperature of the battery is below 16 °C (60.8°F).

   • The temperature of the electrolyte is below 16 °C (60.8°F).

2. After the battery is charged, apply a load to the battery. The load should equal one half of the cold cranking amperage rating. Apply the load for fifteen seconds.

3. When the load is applied to the battery, check the available voltage at the battery after fifteen seconds. If the voltage is above 9.0 Volts, the battery is ready for use.

4. If the voltage is below 9.0 Volts, measure the temperature of the electrolyte in one of the center cells. If the electrolyte is between 16 °C (60.8 °F) and 38 °C (100.4 °F), the battery is not usable. Return the battery in order to be recycled.

5. If the electrolyte is below 16 °C (60.8 °F), the battery should be moved to a warmer location. Allow the battery and the electrolyte to reach a temperature between 16 °C (60.8 °F) and 38 °C (100.4 °F).

6. Again, apply the load to the battery. The load should equal one half of the cold cranking amperage rating. Apply the load for fifteen seconds.

7. When the load is applied to the battery, check the available voltage at the battery after fifteen seconds. If the voltage is above 9.0 Volts, the battery is ready for use.

8. If the voltage is below 9.0 Volts, the battery is not usable. Return the battery in order to be recycled.