CAT BATTERY CARE & MAINTENANCE GUIDE ®

Important: Always Wear Eye Protection

SAFETY PRECAUTIONS LOAD TESTING JUMP STARTING CHARGING TIPS
FOLLOW SAFETY PRECAUTIONS – WEAR PROPER EYE PROTECTION.
SHIELD EYES AND FACE AT ALL TIMES... NEVER LEAN DIRECTLY OVER BATTERY
Batteries should be boost charged if the
FOLLOW SAFETY PRECAUTIONS– SET AT 1/2 COLD CRANKING WHEN TESTING, JUMP STARTING OR PERFORMING OTHER MAINTENANCE. BATTERY CHARGING
AMPERE (CCA) RATING*. open circuit voltage (voltmeter) reading is
WEAR PROPER EYE PROTECTION. Be sure any vent caps are tight and level, 3. Connect one end of negative (-) booster
RATE/TIME TABLES
below 12.4 volts. See chart at right. Amp Hour Rating Charging Rate
First perform an open circuit voltage test 4. Set the tester for one-half the battery’s then place a damp rag over the vent caps of cable to negative (-) terminal of assisting • Prior to charging, read the manufacturer’s 15-34 5 Amps
using the Caterpillar® Digital Voltmeter, 0°F cold crank rating and apply the load both batteries. Be sure machines/vehicles battery, wired to ground. instructions for proper charger hook-up and use. 35-49 7.5 Amps
4C6600, for a fast, accurate test. for 15 seconds. Battery ambient tempera- do not touch each other. • Turn charger OFF and disconnect battery prior 50-69 10 Amps
4. Complete hook-up by connecting other
ture must be 10°C (50°F) or greater. to hook-up to avoid dangerous sparks. 70-99 15 Amps
Then perform an adjustable load test. 1. Connect one end of positive (+) booster end of negative (-) booster cable TO 100-129 20 Amps
A load test is the best way to determine if cable to positive (+) terminal of discharged ENGINE BLOCK OF STALLED MACHINE • Use charts below for normal charge of a battery 130-164 25 Amps
the battery is delivering adequate electrical 9.5 VOLTS OK FOR 12V BATTERY! battery, wired to starter or solenoid. OR VEHICLE-AS FAR AWAY FROM based on the ambient temperature at time of 165-199 30 Amps
performance. Make sure your variable load 4.7 VOLTS OK FOR 6V BATTERY! BATTERY AS POSSIBLE... AWAY FROM charge. Note – there is a potential of battery 200-249 35 Amps
tester is working properly. 2. Connect other end of positive (+) booster MOVING FAN AND FUEL LINES. explosion when batteries are overcharged.
Important: Always Wear Eye Protection Perform all work in a well ventilated area. 5. With the load still on the battery, check cable to positive (+) terminal of assisting OPEN CIRCUIT VOLTAGE
• A battery that has NOT begun to accept the
Never lean directly over a battery while the tester reading. A steady reading of battery. 5. Start both machines or vehicles and 12 Volt 8 Volt 6 Volt Charging
ALWAYS WEAR SAFETY GLASSES AND A MINIMUM (1/2 of recommended) charging
boosting, testing or charging it. IF DISCHARGED–RECHARGE! 9.5 volts for 12V battery or 4.7 volts for 6V remove cables in reverse order of Battery Battery Battery Time
current WITHIN 15 minutes at the highest
FACE SHIELD WHEN WORKING ON OR battery while under load indicates a good connection. Discard the rag. Load Test
1. You can’t load test a discharged battery. charger setting (or voltage) should be replaced.
NEAR BATTERIES. PROTECT YOUR EYES! 12.40 & 8.27 & 6.20 & No
Always attempt to charge it before load battery. • If violent gassing or spewing of electrolyte above above above Charging
All batteries generate explosive hydrogen Batteries contain corrosive sulfuric acid
testing if below 12.4 volts. If above 12.0 volts, PROTECT YOUR EYES! occurs or the battery case feels hot to the touch, Required
gas. Keep sparks, flames and cigarettes that can destroy clothing and burn the 1 4 2
remove surface charge before charging. LESS THAN 9.5 VOLTS OR 4.7 VOLTS 3 temporarily reduce or halt charging. 12.39- 8.26- 6.19- 2.0
away from batteries at all times. Do not skin. Neutralize acid spills with a paste 12.20 8.13 6.10 Hours
connect or disconnect “live” circuits. To Refer to the charging instructions below for RECHARGE OR REPLACE. + IMPORTANT: connect to ground, away • NEVER attempt to charge a frozen battery.
made of baking soda and water. + Booster 12.19- 8.12- 6.09- 3.0
important information. from battery... AWAY FROM MOVING Allow it to warm up to room temperature
avoid creating sparks, always turn charging 6. If the reading is below 9.5 or 4.7 volts Battery! 12.00 8.00 6.00 Hours
BE CAREFUL! FAN AND FUEL LINES. before placing on charge.
and testing equipment OFF before attach- under load, boost charge the battery and Below Below Below 4.0
ing or removing clamps. NEVER USE COMPRESSED AIR FOR TURN TESTER OFF! IMPORTANT: BOTH BATTERIES OR SETS OF BATTERIES MUST BE THE SAME VOLTAGE! PROTECT YOUR EYES! 12.00 8.00 6.00 Hours
test it again. If the second reading is still
ALWAYS DISCONNECT GROUNDED CABLE CLEANING NEAR A BATTERY. 2. To avoid sparking, be sure load tester low, replace the battery. DO NOT MIX VOLTAGES! Optimum charging volts for 12-volt battery vs. temperature for lead acid batteries, utilizing an alternator.
FIRST AND CONNECT IT LAST TO PREVENT Rapid air movement from compressed air is OFF and battery is disconnected before TEMP C TEMP F *MF CA/CA *LOW ANTIMONY *HYBRID AGM GEL
DANGEROUS SPARKS. combined with dust, dirt, etc. will create hook-up. Use computer memory saver to Opt Voltage Opt Voltage Opt Voltage Opt Voltage Opt Voltage
static electricity, which may lead to an retain the machine’s electronic memory (If the CCA rating is unknown, use 200 DRY CHARGE ACTIVATION > 52 > 126 12.94 12.64 12.64 12.64 12.64
explosion. while the battery is disconnected. * for auto batteries, 350 for commercial
IMPORTANT... WEAR PROPER EYE PROTECTION!
41-52
26-40
105-126
78-104
13.32
13.80
13.02
13.50
13.02
13.50
12.90
13.02
12.80
13.02
batteries and 100 for small-engine 20-25 68-77 14.10 14.10 14.10 13.50 13.50
RED TO POSITIVE & batteries.) IMPORTANT 0-19 32-67 14.46 14.16 14.16 14.16 14.16
PROPER INSTALLATION BLACK TO NEGATIVE. Each vent opening is sealed with a remov- 4. If a boost charge is required, the battery <0 < 32 15.90 15.60 15.60 15.60 15.60
3. Connect the positive (+) tester clamp to able plastic plug. Do not remove this plug is to be charged for 20 minutes at the Optimum charging volts for 12-volt battery vs. temperature for lead acid batteries, utilizing a charger.
the positive (+) battery terminal. Then FOR COMPLETE LOAD TEST PROCEDURE until you are ready to fill the battery with following rates: TEMP TEMP *MF *MF *LOW *LOW
FOLLOW SAFETY PRECAUTIONS – 4. Put corrosion protection washers on
connect the negative (-) tester clamp to INFORMATION REFER TO THE electrolyte. Only when you are ready to fill,
• 15 amp for 12 Volt batteries under 600 CCA C F CA/CA CA/CA ANTIMONY ANTIMONY *HYBRID *HYBRID AGM AGM GEL GEL
WEAR PROPER EYE PROTECTION. battery terminals, install new battery in the negative (-) battery terminal. Always CATERPILLAR BATTERY LOAD TESTER remove and discard the seal plugs. Use Float Equalize Float Equalize Float Equalize Float Equalize Float Equalize
1. Before removing old battery, mark the • 40 amp for 12 Volt batteries 600-1200 CCA Volts Volts Volts Volts Volts Volts Volts Volts Volts Volts
same position as old one, and tighten protect your eyes. SEHS9249. large vent caps to close openings when
positive (+) and negative (-) cables for battery is filled and placed in service. • 60 amp for all 8 Volt batteries and 80 176 12.90 14.70 12.60 13.20 12.60 13.80 12.90 13.50 12.80 12.90
hold-down. Be sure terminals will clear 12 Volt batteries over 1200 CCA 60 140 12.94 14.74 12.64 13.24 12.64 13.84 12.90 13.54 12.80 12.94
proper connection to the new battery. hood, fender, box lid, etc. ACTIVATION • 40 amp for all 6 Volt batteries 40 104 13.32 15.12 13.02 13.62 13.02 14.22 13.02 13.92 13.02 13.32
2. Always disconnect the ground cable first 5. Connect positive (+) cable first, 20 68 13.80 15.60 13.50 14.10 13.50 14.70 13.50 14.40 13.50 13.80
1. Fill each cell to proper level with battery-
[usually negative (-)] to avoid any sparking 5. After boost charging, the battery is to be 0 32 14.46 16.26 14.16 14.76 14.16 15.36 14.16 15.06 14.16 14.46
around battery. Then disconnect the then connect ground cable last. Use a
special side terminal torque tool to tighten
ROTATE BATTERY STOCK grade sulfuric acid of 1.265 specific gravity.
Battery and acid must be at a temperature
load tested again at 1/2 the CCA rating for
10 seconds. The battery may be put into
-30 -22 15.90 17.70 15.60 16.20 15.60 16.80 15.60 16.50 15.60
*Use Caterpillar Data Sheet, PEHJ0073 to identify chemical construction of Caterpillar Batteries to determine recommended charging
15.90
positive (+) cable and carefully remove of 16°C to 38°C (60°F to 100°F) at time of voltages in previous tables.
side terminal cables without damage. service if 10 second voltages are as listed
the old battery. USE OLDEST BATTERIES FIRST. filling.
Never over tighten or hammer cables in step 3.
3. Clean and inspect the battery tray. When 2. Apply a load of 1/2 the CCA rating for
necessary, replace the tray and hold-down onto terminals.
assembly. Also replace the battery cables if 6. Coat terminals and cable connection
Batteries require periodic stock rotation
and routine charging. Always rotate stock
MONTH 10 seconds.
6. Recycle all scrap batteries. Your Cat
Dealer accepts spent batteries for recycling. CHOOSE PLENTY OF POWER
needed. Cable ends MUST be clean and with a corrosion protection spray. A- January G - July 3. The battery is ready for use or must
using the FIFO (First In, First Out) method... Starting Power Starting Power
corrosion free. be given a “booster” charge with 10
instead of FISH (First In, Still Here). B- February H - August CHOOSE COLD CRANKING AMPS... Available from Battery Required By Engine
seconds test voltage reading as follows:
C- March J - September NOT MONTHS OF WARRANTY!
Batteries used at Caterpillar manufacturing Size Ready Boost 105% 110%
facilities or shipped from the battery D- April K - October Always use a battery that has enough cranking
IN-MACHINE/VEHICLE SERVICE manufacturer for the replacement market
have a label affixed to the battery (or
E- May L - November
12V
8V
6V
9V or more
6V or more
4.5V or more
below 9V
below 6V
below 4.5V
power, reserve capacity and vibration resistance
to get the job done. Consider the machine or
stamped on battery carton if provided) F- June M- December vehicle manufacturer’s recommended capacity to
FOLLOW SAFETY PRECAUTIONS – Scrape or brush off the residue and wash 100% 100%
with the following shipping date codes: be a minimum-capacity guideline. A machine or
WEAR PROPER EYE PROTECTION.
Prior to any testing, visually inspect the
the area with clean water. Following your
visual inspection, check the battery’s state YEAR
BATTERY STORAGE TIPS vehicle that has a lot of electrical accessories
such as on-board computers, air conditioning,
battery. Look for: of charge with a voltmeter. two-way radios, etc., will need a more powerful
PROTECT YOUR EYES! 8 - 1998 3 - 2003
• Cracked or broken case or cover Example: A3 = Battery shipped Storage temperature is critical for batteries. • Do not stack batteries more than 2 high battery for optimum performance. 65% 155%
• Leaking case-to-cover seal NEVER USE COMPRESSED AIR FOR January 2003 9 - 1999 4 - 2004 Batteries should be stored in a cool, dry (3 high if automotive). Batteries must be Along with electrical accessories, temperature
• Damaged or leaking terminals CLEANING NEAR A BATTERY. 0 - 2000
area in an upright position. Keep them as in cartons or have protected corrugated also has an effect on battery performance.
5 - 2005 cool as possible, but above freezing for packaging placed between each stacked 40% 210%
• Loose cable connections Rapid air movement from compressed air
maximum life. layer. Machines or vehicles that are operated
• Corrosion combined with dust, dirt, etc. will create
REMEMBER... IF BATTERIES ARE STORED 1 - 2001 6 - 2006
static electricity, which may lead to an • Test non-maintenance free wet batteries in extremely hot or cold climates may need a
WET OR DRY, YOU MUST ALWAYS ROTATE 2 - 2002 battery with a higher CCA rating. 18% 268%
Neutralize any corrosion with a baking explosion. 7 - 2007 • Never stack batteries directly on top of each every 4-6 months, Maintenance Free every
soda/water paste or battery cleaner spray. YOUR STOCK! other unless they are in cartons or on ship- 12 months, and recharge if necessary. REMEMBER... YOU CAN’T BUY A
ping pallets protected by corrugated • Dry batteries that are not activated have Temperature has a dramatic effect on a battery’s ability to crank an
Note: The Cat Digital Battery Analyzer (Part # 177-2330) enables you to determine whether a battery is bad or in need of a
BATTERY WITH TOO MUCH POWER! engine. Not only do cold temperatures rob batteries of power, they also
recharge in just 20 seconds, without having to remove the battery from the machine or vehicle. It quickly and accurately tests the packaging. unlimited shelf life. thicken motor oil, making engines harder to start. And heat can damage
condition of 12-volt and 6-volt batteries, even discharged to as low as one volt.
batteries by causing internal components to wear out quickly while also
ALWAYS TEST BATTERY BEFORE making engines difficult to start.
For Sales and Service Call: INSTALLATION, AND CHARGE IF NECESSARY. © 2007 Caterpillar
PEWP4050-03
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