Battery Test Procedure {1401} Caterpillar

Battery Test Procedure {1401}

Usage:

D3400 01T

Engine: All Gas Engines
Engine Commercial: All Diesel
Generator Set: All
Power Module: All Power Modules

Introduction

This instruction provides the necessary information 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 High Output Battery
Maintenance Free Battery and Maintenance Free Accessible Battery
Low Maintenance Battery
Maintenance 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

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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.

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:

Force the eyes open. Flood the eyes with cool, clean water for at least 15 minutes.
Seek immediate medical attention.

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

Immediately drink large quantities of water or milk.
After you drink the milk or the water, drink one of the following liquids:
- Milk of magnesia
- Beaten eggs
- Vegetable oil
Seek immediate medical attention.

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

Immediately flush the burned area with water.
Seek immediate medical attention.

Explosive Gases

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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.

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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 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

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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.

Do not attempt to charge a battery until you are familiar with the procedures for using the battery charger.

Starting From An External Source

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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.

Lead Acid Battery Composition

Caterpillar offers several battery compositions. These compositions consist of flooded lead acid batteries and valve regulated lead acid batteries.

Flooded Lead Acid Batteries (Wet or Dry)

Batteries (when active) containing "free flowing" liquid electrolyte (water and sulfuric acid solution).

Maintenance Free (lead calcium) - The battery contains a calcium alloy in the positive and negative grids. The battery has a lower acceptance of charge than the other batteries, meaning the battery accepts charge more slowly, but the battery tolerates overcharging better than the other batteries. A maintenance free battery is normally sealed to prevent access to the electrolyte.
Maintenance Free Accessible (lead calcium) - The battery contains a calcium alloy in the positive and negative grids. The battery has a lower acceptance of charge than the other batteries. The battery tolerates overcharging better than the other batteries. The removable caps allow you to check the water levels and the specific gravity.
Maintenance or Low Antimony (lead antimony) - The battery contains a lead antimony alloy in the positive and negative grids. The battery has a higher charge acceptance than lead calcium batteries but is prone to overcharging.
Low Maintenance or Hybrid - The battery contains a lead antimony alloy in the positive grid, and a lead calcium alloy in the negative grid. The capacity of the charge is between the maintenance free battery and the low antimony battery, but is stillsomewhat prone to overcharging.

Maintenance/low antimony batteries, low maintenance/hybrid batteries, and maintenance free accessible batteries require the addition of water. Inspect fluid levels every 1000 hours. In warmer climates, check more frequently, such as every 500 hours.

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 the batteries should be replaced.

Valve Regulated Lead Acid Batteries (VRLA)

These batteries have no "free flowing" liquid electrolyte and in the cell operate on the oxygen recombination cycle, which is designated to minimize water loss. VRLA batteries feature vents that are one-way bump-valves. These low pressures valves prohibit air ingress to the cell while permitting gases to vent from the cell if necessary. There are two primary types of VRLA batteries:

Absorbed Glass Mat (AGM) - The electrolyte is absorbed in glass microfiber separator material leaving no free electrolyte in the cell to split
GEL - The electrolyte has been immobilized by the addition of a chemical agent, normally fine silica, to prevent spillage.

Wet Charged Batteries vs Dry Charged Batteries

Wet Charged Batteries

Wet charged batteries are already filled with electrolyte and fully charged when the batteries leave the supplier. Wet charged batteries are ready to use. Advantages of wet-charged batteries include:

Higher cold cranking amps (CCA) ratings which result in greater engine cranking performance
Higher reserve capacity ratings which means greater/longer energy capability
Elimination of the cost of adding electrolyte for activation
Cost — cheaper to manufacture

Dry Charged Batteries

Dry charged batteries contain no electrolyte or acid when the battery leaves the supplier. The battery is activated by adding the correct amount of electrolyte. Dry charged batteries must be filled with electrolyte (1.265 specific gravity) or "activated" and then (if needed) boost charged before being placed in service.

The main advantage of dry charged batteries is that the batteries can be stored for long periods of time without permanent damage (still important to use FIFO process). The batteries do not experience appreciable deterioration such as sulfation or corrosion while in storage. This is not true for a "wet" battery.

Accessible Batteries

Accessible batteries are batteries with caps that can be removed to allow 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 high temperature and 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.

Battery Processing and Handling

Receiving Inspection for Batteries already in Machine/Genset and Individual Batteries

Upon receipt, batteries must have a minimum of 12.45 OCV (Open Circuit Voltage). When new should measure 12.65 V or greater. If below 12.45 a boost charge is required.
Verify that all safety warning, warranty, and date code labels are on batteries. The date code label (ship date) is located near positive post. The letter indicates the month, and the number indicates the year. For example, B7 indicates February 2017 ship date.
The disconnect switch and key switch must be turned off and cab door closed when the vehicle is not in use. Not utilizing the switch and leaving the door open or any part of the electrical system on may discharge the battery.

Individual Battery Storage

Keep battery inventory at a minimum and always rotate stock using the FIFO (First In, First Out) method. As batteries age, they become discharged. Utilizing FIFO will prevent battery decay from poor stock rotation. Twelve V batteries, when new, will measure 12.65 V or more. With long periods of storage, this charge voltage drops (quicker in hot weather, slower in cold). If stock rotation is poor, every 90 days, measure battery OCV. If below 12.45 V provide boost charge. ALWAYS TEST BATTERIES BEFORE INSTALLATION, AND CHARGE IF NECESSARY.If batteries are stored until they are older than 18 months or until the voltage drops below 12.0 V, they should not be sold as a new battery since performance and service life will be reduced. The above voltage requirements should be halved for 6 V batteries. To observe these guidelines, you must know when the batteries were received — which is when the shelf life begins. Refer to "Identification of Battery Manufacturing, Shipping, and Final Charge Dates" for additional information.
Never stack batteries directly on top of each other unless the batteries are in cartons or on shipping pallets protected by corrugated packaging. Do not stack batteries more than two high (three high if automotive type batteries). Batteries must be in either cartons or have protected corrugated packaging placed between each stacked layer.
If stock rotation is poor, every 90 days, measure battery OCV. If below 12.45 V provide a boost charge. Batteries older than 18 months or below 12.00 OCV are not to be recharged, to be sold, or for use in prime product. Performance and service life are severely reduced.
Storage temperature is critical for batteries to maximize battery life. Batteries should be stored in a cool, dry area in an upright position. Batteries should be stored in the coolest, but not freezing, location possible. In hot climates, battery voltage will drop at a quicker rate. Batteries stored in a high-rise must never be stored above the second rack or exposed to sunlight. Heat will discharge batteries quickly and batteries must be kept away from ceiling heat. Here is an example of battery discharge rate, base on heat:

Discharge Rate:

Three percent per month at 21° C (70° F)
Six percent per month at 32° C (90° F)
Add 3 percent for every 11° C or 20° F

Machine Storage

If machine storage is extended to longer than 30 days (extended storage). Every 90 days, measure battery OCV. If below12.45 V, provide a boost charge.
The disconnect switch and key switch must be turned off and cab door closed when the vehicle is not in use. Not utilizing the switch and leaving the door open or any part of the electrical system on may discharge the battery. Batteries older than 18 months or below 12.00 OCV are not to be recharged and used in prime product. Performance and service life are severely reduced.

Prior to Machine or Individual Battery Sale

Battery OCV should be measured prior to individual sale or installation in a machine. Battery OCV must be 12.45 V or greater prior to installation. If between 12.45 V and 12.00 V, provide boost charge. Batteries older than 18 months or with an OCV below 12.00 V are not to be recharged, to be sold, or for use in prime product.
The disconnect switch and key switch must be turned off and cab door closed when the vehicle is not in use. Leaving the door open or any part of the electrical system on may discharge the battery.
Observe proper torque when installing battery hold-downs and terminals. There have been warranty claims for cracked posts and cases due to over-tightening.
Keep the top of battery clean. Part numbers, safety warning, warranty, and date code labels must remain legible.

Identification of Battery Manufacturing, Shipping, and Final Charge Dates

All battery manufacturers have some type of markings on the battery case that help to determine when the battery was manufactured, and in the case of wet batteries, when the battery was charged or shipped by the battery manufacturer.

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Table 1
Universal Date Codes for Shipping and Final Charge Dates
Month	Code
JAN	A0⁽¹⁾
FEB	B1⁽¹⁾
MAR	C2⁽¹⁾
APR	D3⁽¹⁾
MAY	E⁽¹⁾
JUN	F⁽¹⁾
JUL	G⁽¹⁾
AUG	H⁽¹⁾
SEP	J⁽¹⁾
OCT	K⁽¹⁾
NOV	L⁽¹⁾
DEC	M⁽¹⁾

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⁽¹⁾	Last digit of the year (i.e. 0 = 2010, 1 = 2011, 2 = 2012, 3 = 2013, and so forth)

Note: The letter "I" is not used to designate a month. Too easy to confuse with the number 1.

Batteries Produced by East Penn Manufacturing

Both wet and dry batteries produced by East Penn Manufacturing will have a number etched into the side ledge of the top cover of the battery. This is a long number that is unique to their system requirements but the first four numbersdesignate theyear and dayof manufacture of the battery.All the other numbers relate to production lines/plants. Also, wet batteries shipped from our supplier East Penn Manufacturing will have a small date code sticker affixed to the top of the cover (near the positive terminal), which denotes the month and year of shipment/final charge. This sticker is not used on dry batteries since they are not activated.

Date code labels are normally affixed starting the mid point of the month. For Example: Batteries shipped 1 January 2014to 15 January 2014get A4 label. 16 January 2014to 15 February 2014get B4 label and so on. This is done to factor in a delivery time cushion from time of shipment till received at dealer or distribution point (i.e. freight forwarder).

Generally, Cat PHO batteries are built to order and are rarely kept in stock at the manufacturer longer than 60 days to 120 days. If kept longer, Cat specifications call for the manufacturer to get approval from the Cat Engineering for recharge of wet batteries.

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Illustration 1	g06002951
(1) Battery Shipped (2) Manufactured Date Code

Battery Shipped

F1 = June 2011

Manufactured Date Code: 3009123456

3 = produced in year 2013
009 = the ninth day of the year (January 9th)

Manufactured Date Code: 41061234567

4 = produced in year 2014
106 = the 106th day of the year (April 15th)

Batteries Produced by Johnson Controls Inc. (JCI) Europe

These wet batteries shipped from JCI Europe will have a date of manufacturer code stamped into the case cover near the terminal. The wet batteries should also have a sticker affixed to the top of the battery (or stamped on the battery carton if one is provided), which denotes the month and year of shipment. The stamped code and the sticker will follow the same universal designation for month/year as shown in Table 1.

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Illustration 2	g06002983
(2) Manufactured Date Code

Manufactured Date Code: 22 3 MF

22 = Day of Month
3 = Year (2013)
M = December (per universal label)
F = Battery Plant (in this case France)

Batteries Produced by Johnson Controls Inc. (JCI) Brazil

These wet batteries shipped from JCI Brazil will have a date of manufacturer code stamped into the case cover near the warning label. The wet batteries should also have a sticker affixed to the top of the battery which denotes the month and year of shipment/final charge. The sticker will follow the same universal designation for month/year as shown in Table 1.

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Illustration 3	g06002996
(1) Battery Shipped (2) Manufactured Date Code

Battery Shipped

L9 = November 2009

Manufactured Date Code: 18/06/13 40001

18 = produced on day 18
06 = produced in month June
13 = produced in year 2013
4 = Line of production
0001 = Sequential code (0000 up to 9999)

For example: 18/06/13 40001 means that "This battery is the first manufactured on production line 4 on 18 June 2013".

Batteries Produced by Camel Battery

These wet batteries shipped from Camel Battery will have a date of manufacturer code stamped into the case cover. The wet batteries will also have a sticker affixed to the top of the battery, which denotes the month and year of shipment/final charge. The sticker will follow the same universal designation for month/year as shown in Table 1.

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Illustration 4	g06003229

Battery Shipped

D3 = April 2013

Manufactured Date Code: 3 A 02 A1 X X 0001

3 = produced in year 2013
A = produced in month January (A - January, B - February, and so on)
02 = day of month (01 - 1^st day of month, 02 - 2^nd day on month, and so on)
A1 = Shift Number (A1 - 1^st, B1 - 2^nd, A2 - 27^th, B2 - 28^th, and so on)
X = Special Number
X = Origin Number
0001 = Serial Number (0001 - 1^st sample, 0002 - 2^nd, and so on)

For example: 2J31A10A0001 means that "This battery is the 1^st sample manufactured on 1^st shift on 31 October 2012".

Battery Maintenance

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.

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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 near a battery, resulting in personal injury or death. Never use compressed air for cleaning near 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 the battery 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.

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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.

Checking Cable Tightness

Terminal connections must be tightened according to the drawing specifications of the terminal.

Checking Hold-Down Tightness

Batteries should be solidly mounted to a carrier that is attached in a robust manner to the machine. The design of the hold-down device shall be sufficiently strong to retain the battery weight as well as any vibration or dynamic forces generated by the off-road machine. Hold-down devices shall distribute the retention force uniformly over the perimeter of the battery and avoid stress concentrations in the battery case, hold-down device, or battery carrier. Hold-down hardware should fit properly and must be torqued.

Torque hardware ... 6.8 ± 1.4 N·m (60 ± 12 lb in)

Checking Electrolyte Levels

Maintain fluid levels to prevent battery dry out and maximize battery useful/service life.

Inspect fluid levels every 1000 hours. In warmer climates, check more frequently, such as every 500 hours.
Fluid level should be maintained at 5 mm (0.20 inch) to 7 mm (0.28 inch) below the bottom of the cell inspection hole.
Plates/grids are not to be exposed.
Add de-ionized water or mineral free water when needed.

Open Circuit Voltage (OCV) Measurement

Using the 237-5130 Digital Multimeter Gp, measure battery OCV. If OCV is less than 12.45 V provide boost charge. Batteries should not be allowed to discharge below 12.00 V. Performance and service life are severely reduced.

Note: The disconnect switch and key switch must be turned off and cab door closed when the vehicle is not in use. Not utilizing the switch and leaving the door open or any part of the electrical system on may discharge the battery.

Recommended Operating Temperatures

The normal or ideal operating temperature range for Caterpillar batteries is 20° to 25°C (68 ° to 77 °F). The maximum temperature of operation forCaterpillar batteries is 52 °C (125 °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 months to 23 months. This data is based on normal usage. Normal usage includes a good charge and a good condition of discharge.

Note: This data is based on no water additions and usage of flat voltage regulator on charging voltage. Water additions and usage of temperature compensation of the charging voltage will prolong life of batteries.

Causes Of Battery Failure

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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 "Valve Regulated Lead Acid Batteries (VRLA)" 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

Caused from inadequate charge voltage settings, high operating temperatures, and poor maintenance practices.

A faulty voltage regulator can cause an above normal charging rate to any battery type.

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.

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.

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.

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:

4C-4911 Battery Load Tester - Refer to Special Instruction, SEHS9249, "Use Of The 4C-4911 Battery Load Tester For 6, 8 V and 12 V Lead Acid Batteries."
237-5130 Digital Multimeter Gp - Refer to the manual that is provided by the supplier for more information on the use of the 237-5130 Digital Multimeter Gp.

Battery Test And Warranty Procedures

Record the results of the test on the Special Instruction, SEHS9326, Battery Test Sheet Report.

Use the recommended tools or the equivalent tools when you are testing a battery for warranty consideration.

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Illustration 5	g00657874

Visual Inspection
1. 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.
2. 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.
3. If the battery terminal is damaged, then replace the battery at the expense of the customer.
  
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  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.
4. 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.
Open Circuit Voltage (OCV) Measurement
Use the 237-5130 Digital Multimeter Gp to measure the battery OCV. If the OCV is greater than or equal to the voltage in Table , proceed to Step 6. If the OCV is less than the voltage in Table 2, proceed to Step 7.
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Table 2
Battery Minimum Voltage

12 V 12.40 V

8 V 8.27 V

6 V 6.20 V

Table 2
Battery	Minimum Voltage
12 V	12.40 V
8 V	8.27 V
6 V	6.20 V

Procedures for Battery Charging

Preparing The Battery
Clean the battery case and the battery terminal posts.

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.

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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, ensure that the charger is in the OFF position.
Charging The Battery
Follow these guidelines for charging the battery:
- 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 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 to eliminate the overcharging. Complete the charging at the LOWER charging rate.
Use the charging voltage that is recommended. 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.

Charging Procedure

Use the instructions and tables below to determine the proper charge rate and duration.

Select a charge rate (in Amperes) by determining battery Amp Hour capacity. To determine the Ah rating, refer to battery warning label or in the PEHJ0073, Cat Batteries Datasheet. A setting of one-half of the amperes may be used. However, the time for charging must be DOUBLED.

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Table 3
Battery Charging Ampere Rate Determined by Battery Ah Capacity
Battery rating (ampere hour)		15-34	35-49	50-69	70-99	100-129	130-164	165-199	200-249
Charge Rate (ampere)		5.0	7.5	10	15	20	25	30	35

Use a digital voltmeter to measure the battery OCV.
Based off the battery OCV, determine the battery charge duration.

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Table 4
Charge Time Determined by Battery OCV
12 V Battery	More than 12.40 V	12.39 V to 12.20 V	12.19 V to 12.00 V	Less than 12.00 V
8 V Battery	More than 8.27 V	8.26 V to 8.13 V	8.12 V to 8.00 V	Less than 8.00 V
6 V Battery	More than 6.20 V	6.19 V to 6.10 V	6.09 V to 6.00 V	Less than 6.00 V
Charging Time (in hours)	Load Test Charging is not required.	2.0 hrs	3.0 hrs	4.0 hrs

The charging rates and charging times in Table 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:

Charge the battery at the rate from the table to bring the battery to approximately 70 percent of a full charge.
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.

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.
To reach a charge of 100 percent, charge the battery at 10 A for an extra 4 hours. Alternatively, charge the battery at 5 A for an extra 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.

Minimum Charge Rate
A battery that is being tested for a warranty MUST accept the MINIMUM charge within 30 minutes. The minimum charge is 50 percent of the charge rate, in amperes. If battery accepts minimum charge within 30 minutes, complete charging as per specification in Step 1, then proceed to Step 5. If battery DOES NOT accept minimum charge within 30 minutes, then proceed to Step 5.
Open Circuit Voltage (OCV) Measurement
Use the 237-5130 Digital Multimeter Gp to measure the battery OCV. If the OCV is greater than or equal to the minimum voltage in Table 1, proceed to Step 6. If the OCV is less than or equal to the minimum voltage in Table 1, and the OCV in Step 2 is less than 12.00 V replace the battery at the expense of the customer.
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Table 5
Battery Minimum Voltage

12 V 11.50 V

8 V 7.67 V

6 V 5.75 V
Load Test
Refer to Special Instruction, SEHS9249, Use Of The 4C-4911 Battery Load Tester For 6, 8 V and 12 V Lead Acid Batteries for additional information.
- Visually inspect the battery fro obvious damage. Do not test battery if posts are loose, case is cracked or fluid level in cells is below the top of the plates. Do not test a frozen battery.
- Be sure that the load adjustment knob is turned fully counterclockwise to be sure that the load is off.
- Connect red clamp to the positive battery post and black clamp to negative battery post. Rock clamps to be sure of good electrical connections.
- Adjust load to one half CCA rating of battery for 15 seconds (for CCA ratings see PEHJ0073, Cat Batteries Datasheet).
- With load on read and record the voltage.
- Turn load adjustment knob fully counterclockwise and remove battery clips.
- Battery passed load test, if OCV is less than or equal to the minimum Voltage in Table , REJECT CLAIM
- Failed load test, if the OCV is less than the minimum Voltage in Table, ACCEPT CLAIM
- Failed load test, if the OCV is less than the minimum Voltage in Table and if the OCV in Step 2 is less than 12.00 V, REJECT CLAIM
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Table 6
Battery Minimum Voltage

12 V 9.50 V

8 V 6.30 V

6 V 4.70 V
Conclusion
- Reject claim, if the battery warranty claim was rejected in any of the Steps 1 through 6.
- Accept claim, if the battery warranty claim was accepted in any of the Steps 1 through 6.

Table 5
Battery	Minimum Voltage
12 V	11.50 V
8 V	7.67 V
6 V	5.75 V

Table 6
Battery	Minimum Voltage
12 V	9.50 V
8 V	6.30 V
6 V	4.70 V

Terms And Definitions

Absorbed Glass Mat - A type of non-woven separator material comprised almost entirely of glass microfibers that absorb and retains the electrolyte leaving no free electrolyte in the cell to spill. Valve Regulated Lead Acid (VRLA) batteries made with this material are often referred to as AGM batteries.

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 V 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 without 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 battery 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 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.

VRLA - Valve Regulated Lead Acid Battery - AGM and Gel are the two types of VRLA batteries. These batteries have no free liquid electrolyte and in the cell operate on the oxygen recombination cycle, which is designed to minimize water loss. VRLA batteries feature vents that are one-way burp-valves. These low-pressure burp-valves prohibit air ingress to the cell while permitting gases to vent from the cell if necessary. The pressure maintained in the battery, though onlyvery slight (less than 3psi) is required to facilitate the oxygen recombination reaction, which converts the oxygen generated at the positive plates back into water.

Wet Charged Battery - This type of battery is already filled with electrolyte and fully charged. Wet charged batteries are ready to use.