Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries{0785, 1401} Caterpillar

Introduction

The 4C4911 Battery Load Tester can be used to load test 6, 8 and 12 Volt heavy equipment and automotive batteries. It has two heavy duty load cables which can be easily fastened to the battery terminals. A load adjustment knob on the top permits the current being drawn from the battery to be adjusted to a maximum of 1000 amperes. The tester is cooled by an internal fan that is automatically activated when a load is applied.

The Battery Load Tester is a portable unit in a metal case and will work well in field conditions.

The tester has a built in LCD digital voltmeter and amperage meter. The digital voltmeter accurately measures the battery voltage at the battery through tracer wires buried inside the load cables. The digital amperage meter accurately display the current being drawn from the battery under test.

Safety Information

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Batteries give off flammable fumes which can explode. To avoid the risk of an explosion, use in a well ventilated room. Do not strike a match, cause a spark, or smoke in the vicinity of a battery during the test procedure. Follow the instructions below.

1. Connect and disconnect the tester clamps only when the load knob is adjusted fully counterclockwise (left).

2. Position the tester at least 457 mm (18") off the floor.

Theory of Operation (Refer to Schematic)

Three stacks of carbon piles are used to create a variable load. These stacks of carbon piles distribute heat generated by battery loading over a larger area. This allows the carbon piles to be cooled more effectively.

An internal fan automatically blows air across the carbon piles when a load is applied. The internal fan is powered by the battery being tested.

At the completion of a load test, an internal switch disconnects the ammeter from the shunt. The switch also ties the ammeters input leads together. This prevents the ammeter from reading a small thermocouple voltage at the shunt.

Both LCD meters are powered by an internal 9 volt alkaline battery. Battery life can be prolonged by turning the meters off when they are not in use.

Battery Load Tester Schematic (All resistors 1/4 watt).
(A) Positive (+) Battery Clamp. (B) Carbon Pile Assembly. (C) Shunt. (D) Negative (-) Battery Clamp. (E) Fan. (F) Amps Calibrate. (G) Volts Calibrate. (H) Power.

4C4911 Battery Load Tester

1. Load Control Knob: Adjusts the current being drawn from the battery being tested to a maximum of 1000 amperes.

2. Digital Volt Meter: Measures the voltage of the battery being tested.

3. Digital Amperage Meter: Displays the current (in amperes) being drawn from the battery being tested.

4. Test Leads: Battery Clips on ends of cables connect the load tester to the battery being tested

5. Power Switch: Applies power to digital meters.

Specifications

* Load test: 6, 8 and 12 volt batteries.

* Load current range: 0 to 1000 amperes.

* Duty Cycle: Continuous, limited only by cable and clamp heating.

* Operating temperature range: 0°C to 50°C (32°F to 122°F)

* Voltmeter temperature stability: 0.0006 volts / °C

* Voltmeter accuracy: 0.1% of full scale ± 1 digit.

* Ammeter accuracy: ± 3% of reading ± 1 digit.

* 9 volt battery life: 1800 hours continuous operation.

* Size: 330.2 x 330.2 x 304.8 mm (13 x 13 x 12").

* Weight: 12.4 kg (27.3 lb).

Operating Instructions

1. Visually inspect battery for obvious damage. Do not test battery if post are loose, case is cracked or fluid level in cells is below the top of the plates. DO NOT test a frozen battery.

2. Be sure the load adjustment knob is turned fully counterclockwise to be sure the load is off.

3. Connect red clamp to the positive (Pos, +, P) battery post and black clamp to the negative (Neg, -, N) battery post. Rock clamps to be sure of good electrical connection.

4. Determine state of charge.

* Refer to Special Instruction SEHS7633 entitled Battery Test Procedure for information on how to determine the state of charge from the open circuit voltage.

5. Load Test.

* Adjust load to one-half CCA rating of battery for 15 seconds (for CCA ratings see PEDP0030, United States only).

* With load on read and record the voltage.

* Turn load adjustment knob fully counterclockwise and remove battery clips.

Maintenance

A 9 volt alkaline battery provides power to the LCD digital meters through power switch (5). The battery will power the meters continuously for 1800 hours.

To increase battery life, turn the meters off when the tester is not in use. A "Lo Batt" indication in the "Amps" display window indicates that the instrument battery is low.

To replace the instrument battery turn the power switch (5) to the "off" position. Remove the two screws on the battery cover (6) and remove old battery. Replace the old battery with a fresh alkaline battery and replace battery cover (6).

Calibration

The following equipment is needed to calibrate the 4C4911 Battery Load Tester:

* 6V7070 or 6V7800 Digital Multimeter (See Special Instruction SEHS7734).

* 8T0900 Clamp-on Ammeter (See Special Instruction SEHS8420).

Voltmeter Calibration

1. Connect the test leads from the 4C4911 Battery Load Tester to a good, fully charged 12 volt battery. Connect the red clamp to the positive (pos, +, p) battery post and the black clamp to the negative (neg, -, n) battery post.

2. Connect the test leads from the 6V7070 or 6V7800 Digital Voltmeter to the same battery as in Step 1. Connect the red lead to the positive (pos, +, p) battery post and the black lead to the negative (neg, -, n) battery post. The function range switch on the digital voltmeter should be set for 20 VDC.

3. Adjust the voltmeter calibration (7) on the battery load tester so the "Volts" display reads the same as the digital voltmeter.

4. Apply a small amount of fingernail polish on the voltmeter calibration adjustment (7). This will prevent the adjustment from changing due to shock and vibration.

5. Voltmeter calibration is complete.

Ammeter Calibration

NOTE: For best results use a battery with a CCA rating of 800 Amps or greater.

1. Connect the test leads from the 4C4911 Battery Load Tester to a good, fully charged 12 volt battery. Connect the red clamp to the positive (pos, +, p) battery post and the black clamp to the negative (neg, -, n) battery post.

2. Connect the 8T0900 Clamp-on Ammeter to the positive (red, +,) cable on the battery load tester. Lock on the 8T0900 Clamp-on Ammeter power trigger and adjust the DC zero adjust to read 000 Amps.

3. Adjust the load control knob (2) so the 8T0900 Clamp-on Ammeter reads 1/2 the CCA rating of the battery.

4. Adjust the ammeter calibration (8) on the battery load tester so the "Amps" display reads the same as the 8T0900 Clamp-on Ammeter.

5. Adjust the load control knob (2) for 000 Amps (no load).

6. Apply a small amount of fingernail polish on the ammeter calibration adjustment (8). This will prevent the adjustment from changing due to shock and vibration.

7. Ammeter calibration is complete.

Repair

If the battery load tester seems to be operating incorrectly, calibrate the unit as shown in the calibration section of this instruction. If this does not correct the problem, the tester should be returned for repair. A letter should accompany the returned unit indicating the problem and the date of purchase from Caterpillar.

* Battery load testers less than one year old will be repaired under warranty except for abuse.

* Out of warranty repairs will be charged to the owner.

The repair center for the battery load tester is:

Attn: Repair Center