M0090131 Battery Analyzer 480-4181 (484-4859 Group) {0374, 0599, 0709, 1401, 7468} Caterpillar

Caterpillar Products

All Machines

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.

Introduction

Hand Held Accuracy with a Pulsed 120 Amp Load

The 480-4131 Battery Analyzer is the ultimate hand-held battery tester. It is the answer to portability in a professionally accurate load battery tester.

What to Expect from the 480-4181 Battery Analyzer

Immediately recognize a bad battery.The 480-4131 Battery Analyzer is a portable full-featured menu-driven battery tester that provides quick, professional load results using Digital Pulse Load. The 480-4131 Battery Analyzer is user-friendly. Detailed test results are displayed after each test or can be reviewed and/or printed.

Caution:The 480-4131 Battery Analyzer grill may get hot after repeated use. Be sure to hold the unit from the side grips only. Keep hands away from the grill.

Note: The 480-4131 Battery Analyzer checks and load tests 6 volt and 12 volt batteries. The following examples illustrated are for a 12 volt system. The 480-4131 Battery Analyzer automatically identifies the appropriate voltage and displays the menu selection and instructions needed for that system.

Additional Safety

• Carefully read all operating instructions before using the 480-4131 Battery Analyzer

• Wear eye protection when working around batteries.

• Be sure that each test is completed before removing load clamps to prevent arcing and potential explosion from battery gases. Never remove load clamps while testing. Keep sparks flames, or cigarettes away from batteries.

• Keep hair, hands, and clothing as well as tester leads and cords away from moving blades and belts.

• Provide adequate ventilation to remove vehicle exhaust.

• In extremely cold temperatures, check for frozen electrolytic fluid before applying load. Do not attempt to Load Test or charge a battery under 20 degrees Fahrenheit. Allow the battery to warm to room temperature before testing or charging.

Warning!Never attach the 480-4131 Battery Analyzer to a battery that is connected to any other tester or charging unit. Damage may result.

Cause of Battery Failure

• Incorrect Application:Wrong size battery may have inadequate cold cranking rating for original vehicle specifications.

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

• Improper Maintenance:Low electrolytic fluid and corrosion on battery connections can greatly reduce battery life and affect battery performance.

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

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

• Undercharging:Undercharging caused by a faulty charging system or low voltage regulation can cause lead sulfate to gradually build up and crystallize on the plates greatly reducing the battery capacity and ability to be recharged.

Inspection

Valid automotive electrical system testing depends on all the components being in good operating condition. In addition, the battery MUST have sufficient charge for testing. Carefully perform the following steps before attempting any electrical diagnosis.

Visual Check

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

2. 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.

3. Inspect starting system. Check starter, solenoid, and regulator for loose connections, loose mounts, and frayed or cracked wires.

Controls and Functions

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LCD - Displays menus and test results

KEYS - When each key is pressed, a beep sounds to assure contact has been made.

On/Off Key - This is the manual on/off key.

Y Enter Key - This key selects the next menu, the cursor line item, and answers "yes" to a test progression.

N Esc Key - This key cancels a test or progression. It also returns to the previous menu.

+Up Key - This key moves up the cursor to select a menu line item and increments certain displayed values.

-Down Arrow Key - This key moves the cursor down to select a menu line and decrements certain displayed values.

Print Key - Point the analyzer infrared print light towards the IR Print Receiver and press the print key. Continue to point the print light towards the IR Print Receiver until printing is completed. Test results will be printed.

USB Ports

USB Type A - For data download to flash memory.

USB Type Mini B - Future expansion factory use.

Infrared Print Light - When the print button is pressed, infrared data will be transmitted to the printer IR receiver if pointed in the appropriate direction (up to 15 ft).

Maintenance

Clamps

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Both jaws of each clamp must firmly engage the battery terminal. The copper jaw contains the smaller gauge wire that reads the voltage and the silver jaw 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.

Battery Clamp/Lead Replacement

Over time, the battery clamps will need to be replaced if any of the following are indicated:

• CCA values seem to be way off

• If there is continuity between the copper jaws.

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

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1. Remove protective rubber boot from tester.

2. Remove battery cover on the back of the tester by removing the 4 Phillips head screws using a #1 Phillips screw driver.
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3. Remove both volt lead Phillips head screws, lock washers, and flat washers using a #1 Phillips screw driver.
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4. Remove the 8 mm hex head bolt, lock washer, and flat washer from the positive side current lead using an 8mm socket.
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5. Remove the 10 mm hex head bolt, lock washer, and flat washer from the negative side current lead using a 10 mm drive socket.
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6. Unthread both cable strain reliefs from the tester, and pull both cables out of the tester.
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7. Remove rubber insert from both threaded fittings on tester.
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8. Cut off small plastic fingers from both threaded fittings using a wire cutter.
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9. Insert cables through threaded fittings. Fittings have a slot on the inside to clear the terminal. Align the terminal with the slot when inserting the cable through threaded fitting. Replacement cables 480-4132 Red, 480-4134 Black.
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10. Continue installing replacement cable and clamp assemblies in reverse order of removal. Note hardware assembly order. (Fastener, lock washer, then flat washer.)
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11. Tighten hardware. Recommended torque:

    1. 8 mm and 10 mm hex head screws: 22 IN. LBS.

    2. Phillips head volt lead screws: 6 IN. LBS

Battery Replacement

When the LCD indicates a low internal battery, the analyzer will shut down and not operate until the 9 volt battery is replaced. Remove rubber insulator boot, then remove the back cover and replace the battery. Replacement 9V Battery is IU-9534.

Hook Up

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1. Press the On/Off button. Connect the clamps as instructed on the LCD.

   Note: If the clamps are disconnected, you will be prompted again to begin a new battery test.

2. Use post adapters on threaded steel posts and side terminal batteries. Make sure that post adapters are screwed firmly against the lead pad.

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Connection Errors

1. If the clamps are reversed, the Reversed Connection warning will be displayed on the LCD with an audible beeping.

2. If one or both of the clamps are not in complete contact (both of the copper and silver jaw) CHECK CONNECTIONS! will flash on the LCD.

Battery Test

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If battery test is selected, and the clamps are not connected to the battery, the following screen will appear.

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Other screens that may appear depending on the battery temperature or voltage:

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After the Digital Pulse Load Test is completed, results similar to one of the following sample screens will appear.

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Other Menu Items

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Hints to Avoid File Errors

1. The unit will detect if the USB memory device is full and report the error.

2. If data file already exists, the unit will append the new data to the file.

3. The smart port uses 8.3 filename convention. Memory devices that have long file names will cause errors.

4. The smart port uses FAT File System. Memory devices with other file systems will cause errors.

5. For best results, use USB memory devices that have the FAT File System, plenty of free disk space, and only have file names in the 8.3 file naming format.

6. Wait until prompted to insert the USB memory device into the smart port.

Printing Test Results

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Point the 480-4131 Battery Analyzer in the direction of the Infrared Printer (within 15 ft.). Press print. Wait for the screen to clear before moving the analyzer. It takes a moment to send all the test data.

1. Make sure that the Infrared Printer is properly set up.

2. After a test is made, make sure that the results are displayed on the LCD.

3. Point the analyzer in the direction of the Infrared Printer (within 15 ft).

4. Press the PRINT key and the test results will be printed.

5. Depending on the test made, the printer will sometimes yield more information than the LCD.

6. Wait until the printer stops printing before you press the print key again.

   Note: Contact Supplier to purchase the optional printer.

Volt Meter

Scroll down to Volt Meter, then select VOLT METER by pressing Y.

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Setup

Scroll down to Setup. Select Setup by pressing Y.

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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 a period of 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's 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. In no event shall the manufacturer 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 voids this warranty. The manufacturer disclaims any liability or consequential damages due to breach of any written or implied warranty on its test equipment.

Warranty and Service Information

Warranty claims to the manufacturer's 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 Test 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 Test Equipment). Protect the product by shipping in original carton or add plenty of over-pack cushioning such as crumpled up newspaper.

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