Battery Safety
Contents
1. DD Detroit Diesel Combustion Output Eng 5 Pay close attention to any footnoted information IHC International TPU ENYE DES Direct a Electric Start Harvester Co SOHC Te lf you are specifying a battery to a customer who drives DIN Deutsche ind industrial or Taa r in extreme weather conditions and or has a vehicle Industrie JD John Deere mea with many electrical options suggest a battery with E Gack ae ae Venturi more cold cranking amps than the minimum that is Head Cam PetroleumGas W with listed Batteries with more cold cranking amps will EFI Electronic MFI Multi Port was wanont not harm the vehicle or equipment however batteries i Fuel Injection Wisc Wisconsin r equip 7 NOV ETR Electronic _ MT Manual 2WD 2Wheel Drive with fewer cold cranking amps may fail prematurely Tuning Radio Transimiseioia AWD 4 Wheel Drive BEST FIT ESTIMATE FIT ESTIMATE Some equipment manufacturers do not provide complete replacement battery information In some cases replacement battery size must be estimated using the best information available to guide the battery replacement data guide user However the user is cautioned that the size stated is only an estimate Size and terminal post arrangements may vary from the original equipment manufacturer Therefore the user should obtain specific battery replacement size information from the owner s manual or from the dealer or equipment manufacturer Caution should always be exercised to assure proper ca2. January G July 8 1998 4 2004 B February H August 9 1999 5 2005 C March J September 0 2000 6 2006 D April K October 1 2001 7 2007 E May L November 2 2002 F June M December 3 2003 Always use oldest batteries first Example A3 Battery shipped January 2003 Remember wet or dry batteries always rotate your stock BATTERY SAFETY CAT BATTERY GARE amp MAINTENANCE GUIDE IMPORTANT ALWAYS WEAR EYE PROTECTION JUMP STARTING Shield eyes and face at all times Never lean directly over battery when testing jump starting or performing other maintenance Be sure any vent caps are tight and level then place a damp rag over the vent caps of both batteries Be sure machines do not touch each other 1 Connect one end of positive booster cable to positive terminal of discharged battery wired to starter or solenoid 2 Connect other end of positive booster cable to positive terminal of assisting battery 3 Connect one end of negative booster cable to negative terminal of assisting battery wired to ground 4 Complete hook up by connecting other end of negative booster cable TO ENGINE BLOCK OF STALLED MACHINE AS FAR AWAY FROM BATTERY AS POSSIBLE 5 Start both machines and remove cables in reverse order of connection Discard the rag Protect your Eyes Booster Battery Connect to ground
3. amp away from battery IMPORTANT Both batteries or sets of batteries must be the same voltage Do not mix voltages VIMY Ne 4 9 te Xe Causes Severe Burns Contains sulfuric acid Avoid contact with skin eyes or clothing External Flush with water Internal Drink large quantities of water or milk Follow with Antidote milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the state of California to cause cancer and birth defects or other reproductive harm Wash hands after handling CALIFORNIA Proposition 65 Warning Ia Pd lt or DRY CHARGE ACTIVATION A N Important Each vent opening is sealed with a removable plastic plug Do not remove this plug until you are ready to fill the battery with electrolyte Only when you are ready to fill remove and discard the seal plugs Use large vent caps to close openings when battery is filled and placed in service Activation 1 Fill each cell to proper level with battery grade sulfuric acid of 1 265 specific gravity Battery and acid must be at a tem perature of 16 C to 38 C 60 F to 100 F at time of filling Apply a load of 1 2 the Cold Cranking Ampere CCA rating for 10 seconds Sie Ready Boost NO Go Note t
4. 0 cis Important Never overcharge batteries Excessive charging will shorten battery life For complete battery charging and test procedures refer to Cat Special Instruction SEHS7633 Proper Charging of Threaded Post Terminal Batteries Group 31 Charging Posts should be used to ensure the testing and charging results for threaded stud terminal batteries Due to their 3 8 thread stud the charging posts will provide a flush lead to lead contact Tighten the charging post until it is snug and secure Group 31 Charging Posts DO NOT USE Stainless Steel Nuts or the Threaded Stud for testing or charging batteries They do not provide the necessary lead to lead contact and can reduce your Cold Cranking Amperage CCA and state of charge readings 5 Battery Nuts FULLY TIGHTEN FOR COMPLETE T LEAD TO LEAD CONTACT ooo Threaded Stud IMPORTANT NEVER overcharge batteries Excessive charging WILL shorten battery life For complete battery charging and test procedures refer to the Battery Test Procedure SEHS7633 ALAAVS AYALLVE CAT BATTERY GARE amp MAINTENANCE GUIDE IMPORTANT ALWAYS WEAR EYE PROTECTION BATTERY SAFETY CHOOSE PLENTY OF POWER Choose cranking amps Not months of warranty Always use a battery that has enough cranking power reserve capacity and vibration resistance to get the job done Consider the machine or vehicle manufacturer s recommended capaci
5. 2004 Battery Cross Reference Guide HOW TO USE THIS APPLICATION GUIDE This guide is intended to help select the proper battery es gt j j m lt N Ja TI m om lt ABBREVIATIONS USED IN THIS GUIDE or an alternate recommendation The application a ee elec electric i sorta section lists the minimum cold crankingamps O Fand Ae Ange ey annie eam the recommended and optional replacement battery AT Aortic Fad Fader OHC Over Head Cam part numbers The manufacturers are listed alphabet Transmission Fig Figure OHV oe ically For Passenger Cars Light Trucks and Vans BCI Battery Council Fi Fuel Injection se Gane the applications are listed by year and engine size Calif California Fla Florida pkg package a i FWD Front Wheel The remaining vehicles and equipment are listed by carb carburetor Drive PS Power Steering model and or engine numbers To assure the proper CAT ee GM General Motors ae peas Off replacement battery arr GSE Gas Starting ae Engine ne 1 Find the correct manufacturer eee Amos OF BES este oe eee ight rear 2 Determine the year and or model CFI conia Fire window S C Supercharged nection eiros SEO Special 3 Select the correct model or engine comp compression H D Heavy Duty Electrical Cont Continental H O High Output Option 4 Read across to the part number and Conv Convertible HP Horsepower SGB Sound Guard if applicable an optional part number cyl cylinder HSC High Swirl aus ae feds
6. ables without damage Never overtighten or ham mer cables onto terminals 6 Coat terminals and cable connection with a corrosion protection spray IN MACHINE VEHICLE SERVICE Follow safety precautions wear proper eye protection Prior to any testing visually inspect the battery Look for e Cracked or broken case or cover e Leaking case to cover seal Damaged or leaking terminals e Loose cable connections Corrosion Neutralize any corrosion with a baking soda water paste or battery cleaner spray Scrape or brush off the residue and wash the area with clean water Following your visual inspection check the battery s state of charge with a voltmeter NOTE The Cat Digital Battery Analyzer Part 177 2330 enables you to determine whether a battery is bad or in need of a recharge in just 20 seconds without having to remove the bat tery from the machine or vehicle It quickly and accurately tests condition of 12 volt and 6 volt batteries even discharged to as low as one volt Protect your eyes CAT BATTERY GARE amp MAINTENANCE GUIDE IMPORTANT ALWAYS WEAR EYE PROTECTION a LOAD TESTING Follow safety precautions wear proper eye protection First perform an open circuit voltage test using the Caterpillar Digital Voltmeter 4C6600 for a fast accurate test Then per form an adjustable load test A load test is the best way to deter mine if the battery is delivering adequate electrical perfor
7. are not activated have unlimited shelf life ALWAYS test and charge if necessary before installation ES CHARGING TIPS Fo j llow safety precautions wear proper eye protection Batteries should be boost charged if the open circuit voltage voltmeter reading is below 12 4 volts See chart below e Prior to charging read the manufacturer s instructions for proper charger hook up and use e Turn charger off and disconnect battery prior to hook up to avoid dangerous sparks Protect your eyes e A battery that has not begun to accept the minimum 1 2 of Recommended charging current within 15 minutes at the highest charger setting or voltage Should be replaced e f violent gassing or spewing of electrolyte occurs or the battery case feels hot to the touch temporarily reduce or halt charging e Never attempt to charge a frozen battery Allow it to warm up to room temperature before placing on charge OPEN CIRCUIT VOLTAGE 12 Volt 8 Volt 6 Volt Charging Battery Battery Battery Time Load Test 12 40 amp 8 27 amp 6 20 amp No above above above Charging Required BATTERY CHARGING RATE TIME TABLES Amp Hour Charging Rating Rate 15 34 5 0 Amps 35 49 7 9 Amps 50 69 10 Amps 10 99 15 Amps 100 129 20 Amps 130 164 25 Amps 165 199 30 Amps 200 249 35 Amps 12 39 8 205 ee 2 0 12 20 8 13 Hours 12 4941 O 12 5 09 3 0 12 00 8 00 6 00 Hours Below Below Below 12 00 8 00 6 0
8. ble hook up and sufficient post clearance before closing the hood or battery cover Otherwise electrical system damage and or personal injury could result BATTERY RATINGS RATINGS COLD CRANKING AMPS 0 F The primary function of the battery is to provide power to crank the engine during starting This process requires a large discharge of amperes over a short period of time Therefore the cold cranking performance rating is defined as the discharge load in amperes which a new fully charged battery at 0 F can deliver for 30 seconds and maintain a minimum voltage of 7 2 volts for a 12 volt battery 3 6 volts for a 6 volt battery The cold cranking performance ratings listed in the application section of the guide are the minimum recommendation for each application There is no warranty level or battery life expectancy expressed or implied by these ratings CRANKING AMPS 32 F The cranking performance rating is defined as the discharge load in amperes which a new fully charged battery at a temperature of 32 F can deliver for 30 seconds and maintain a minimum voltage of 7 2 volts for a 12 volt battery or 3 6 volts for a 6 volt battery RESERVE CAPACITY Another function of the battery is to provide emergency power for ignition lights etc in the event of failure of the vehicle s battery recharging system The reserve capacity rating is defined as the number of minutes a new fully charged battery at 80 F can be discharged at 25 amperes and main
9. he voltage reading after 10 seconds Use this chart to determine if the battery is ready for use or must be boost charged A lf a boost charge is required the battery is to be charged for 20 minutes at the following rates 15 amp for 12 Volt batteries under 600 CCA 40 amp for 12 Volt batteries 600 1200 CCA 60 amp for all 8 Volt batteries and 12 Volt batteries over 1200 CCA 40 amp for all 6 Volt batteries Sz After boost charging the battery is to be load tested again at 1 2 the CCA rating for 10 seconds The battery may be put into service if 10 second voltages are as listed in step 3 OD Recycle all scrap batteries Your Cat Dealer accepts spent batteries for recycling CAT BATTERY CARE amp MAINTENANGE GUIDE IMPORTANT ALWAYS WEAR EYE PROTECTION i BATTERY STORAGE TIPS storage temperature is critical for batteries Batteries should be stored in a cool dry area in an upright position Keep them as cool as possible but above freezing for maximum temperature life e Never stack batteries directly on top of each other unless they re in cartons or on shipping pallets protected by corrugated packaging e Do not stack more than 2 high 3 high if automotive Batteries must be in cartons or protected with corrugated packaging between layers e Test non maintenance free wet batteries every 4 6 months Maintenance Free every 12 months and recharge if necessary e Dry batteries that
10. mance Make sure your variable load tester is working properly Early Diagnosis Your Cat dealer can determine your battery s pre charge con dition with the Cat Digital Battery Analyzer 177 2330 This ana lyzer provides you with a quick and accurate procedure to know the condition of your battery before you spend time charging it up or before replacing it with another battery This analyzer quickly tests 6 or 12 volt batteries and tells you in 20 seconds if your battery is bad or in need of recharge It can be used to test the full line of Caterpillar Batteries and any others that are within 50 to 2000 cold cranking amps 65 to 2500 cranking amps or 6 to 249 amp hours capacity The analyzer even works on batteries discharged down as far as one volt In addition a battery can even be tested without removing it from its vehicle lf Discharged Recharge 1 You can t load test a discharged battery with most testers Always attempt to charge it before load testing if below 12 4 volts Refer to the charging chart for important information Turn Tester Off 2 To avoid sparking be sure load tester is off and battery is dis connected before hook up Use computer memory saver to retain the machine s electronic memory while the battery is disconnected Red to Positive amp Black to Negative 3 Connect the positive tester clamp to the positive bat tery terminal Then connect the negative tester clamp to the nega
11. mation in this guide any liability for damages as a consequence of using the information in this guide is expressly denied Users should also attempt to obtain replacement battery data from the original equipment manufacturer s user manual or service department for their specific application
12. tain a minimum voltage of 10 5 volts for a 12 volt battery or 5 25 volts for a 6 volt battery HEAT SHIELDS L Protective heat shields are being used around batteries with increasing frequency to protect them from premature failure due to high underhood temperatures Failure to replace the heat shield after installation of a replacement battery may reduce its electrical performance and life gt i Lil LL lt N gt ce Lit lt i CAT BATTERY GARE amp MAINTENANCE GUIDE IMPORTANT ALWAYS WEAR EYE PROTECTION SAFETY PRECAUTIONS Always wear safety glasses and a face Shield when working on or near batteries DANGER POISON WAS SHIELD EYES EXPLOSIVE GASES WS CAN CAUSE BLINDNESS OR INJURY NO SPARKS FLAMES OR SMOKING _ SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS FLUSH EYES IMMEDIATELY WITH DO NOT OPEN Q 2 lt ROKA A eo RECYCLE KEEP OUT OF REACH OF CHILDREN CONTAINS SULFURIC ACID FOR MEDICAL EMERGENCY IN USA OR CANADA CONTACT 800 458 5924 OTHER COUNTRIES CONTACT 303 893 1322 DO NOT TIP WATER GET MEDICAL HELP FAST PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the state of California to cause cancer and reproductive harm Wash hands after handling All batteries generate explosive hydrogen gas Keep sparks flames and cigarettes a
13. tive battery terminal Always protect your eyes Set at 12 Cold Cranking Ampere rating 4 Set the tester for one half the battery s 0 F cold crank rating and apply the load for 15 seconds Battery ambient tempera ture must be 10 C 50 F or greater 9 5 Volts OK for 12V battery 4 7 Volts OK for 6V battery 5 With the load still on the battery check the tester reading A steady reading of 9 5 volts for 12V battery or 4 7 volts for 6V battery while under load indicates a good battery Less than 9 5 Volts or 4 7 Volts Recharge or Replace 6 If the reading is below 9 5 or 4 7 volts under load boost charge the battery and test it again If the second reading is still below replace the battery If the CCA rating is unknown use 200 for auto batteries 350 for commercial batteries and 100 for small engine batteries For complete load test procedure information refer to Caterpillar publication number SEHS9249 oo j j 5 lt N Ja TI m ome lt ROTATE BATTERY STOCK Use oldest batteries first Batteries require periodic stock rotation and routine charg ing Always rotate stock using the FIFO First In First Out method Instead of FISH First In Still Here Batteries pack aged in cartons have the shipping date stamped on the carton Keep the battery in the carton until it is put to use Batteries used in Caterpillar manufacturing facilities use the following shipping date codes Month Year A
14. ty to be a minimum capacity guideline A machine or vehicle that has a lot of electrical accessories such as on board computers air conditioning two way radios etc will need a more powerful battery for optimum performance Along with electrical accessories temperature also has an effect on battery performance Machines or vehicles that are operated in extremely cold climates may need a battery with a higher CCA rating Remember you can t buy a battery with too much power Starting Power Starting Power Available from Battery Required By Engine 110 100 Temperature has a dramatic effect on a battery s ability to crank an engine Not only does cold rob batteries of power it also stiffens motor oil making engines harder to start And heat can damage batteries by causing internal components to wear out quickly while also making engines difficult to start DISCLAIMER The battery replacement data published in this guide has been obtained from Battery Council International The information contained in this guide was the most current information available at the time of publication The information is subject to change upon notice from equipment manufacturers or field experi ence Users should consult the most current edition of this application guide The marketer and manufacturer expressly deny any responsibility for the accu racy provided While every effort has been made to accurately catalog the replacement battery infor
15. way from batteries at all times Do not connect or disconnect live circuits To avoid creating sparks always turn charging and testing equipment off before attach ing or removing clamps Always disconnect grounded cable first and connect it last to prevent dangerous sparks Perform all work in a well ventilated area Never lean directly over a battery while boosting testing or charging it Protect your eyes Batteries contain corrosive sulfuric acid that can destroy clothing and burn the skin Neutralize acid spills with a paste made of baking soda and water Be careful PROPER INSTALLATION Follow safety precautions wear proper eye protection 1 Before removing old battery mark the positive and negative cables for proper connection to the new battery 2 Always disconnect the ground cable first usually negative to avoid any sparking around battery Then disconnect the positive cable and carefully remove the old battery 3 Clean and inspect the battery tray If necessary replace the tray hold down and or battery cables Cable ends must be clean and corrosion free 4 Put corrosion protection washers on battery terminals and then install new battery in same position as old one and tight en hold down Be sure terminals will clear hood fender box lid etc 5 Connect positive cable first then connect ground cable last Use a special side terminal torque tool to tighten side terminal c
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