Use Of The 9S1990 And 1P7400 Battery Charger Testers{0785} Caterpillar


Use Of The 9S1990 And 1P7400 Battery Charger Testers{0785}

Usage:

Use the procedure shown in Special Instruction Form SMHS7633, "BATTERY TEST PROCEDURE", for the testing and charging of 6 volt, 8 volt and 12 volt batteries. When testing a Caterpillar battery for warranty purposes, make a record of all test information on the "CATERPILLAR BATTERY WARRANTY TEST SHEET", Form SEHS7629.

Specifications

General Information

COLOR CODING OF LEADS
Positive leads have red insulators and negative leads have black insulators.
METER ZERO CORRECTORS
Meter pointers must be set on zero before starting tests. This is done by adjusting the external meter zero correctors with power OFF.
VOLTMETER
The desired scale of the multi-scale voltmeter is selected by using the Voltmeter Selector Switch. The 16 volt scale is used for 12 volt battery tests. The 8 volt scale is used for 6 volt battery tests.
AMMETER
The ammeter has two scales. When the Test Selector Knob is turned clockwise, the amperage is read on the upper or 600 ampere scale. When the knob is turned counterclockwise to its stop, the charger will operate and the charge rate will be indicated on the 75 ampere scale (90 amps full scale).
TIME SELECTOR
The Time Selector is used to control the duration of the charge period when fast charging the battery. When the preset time for fast charging runs out, the charge rate is automatically switched to slow charge, where it remains until the charger tester is turned off.
CHARGE RATE SELECTOR
The Charge Rate Selector is a rotary switch used to select the desired charge rate for fast charging and slow charging the battery. It provides seven steps of control, at either 6 or 12 volt levels and high or slow charge rates.
VOLTAGE SELECTOR
The Voltage Selector is a three position toggle switch for establishing proper tester circuitry for 6 volt, 8 volt or 12 volt battery testing. The center position of the switch is OFF.
TEST SELECTOR
The Test Selector establishes proper circuitry for performing the Load Test and has a spring loaded lock to keep it in the OFF position. For Load Testing, the amount of load applied depends on how much the control is rotated in a clockwise direction. For battery charging, the control must be rotated counterclockwise to its stop.
AC POWER SOURCE
The tester must be connected to an AC power source as indicated on the nameplate.
PROTECTIVE DEVICE
An automatic resetting circuit breaker is used in the charging circuit to protect the rectifiers if an improper connection is made to the battery.

------ WARNING! ------

When charging batteries and during the Load Test, the battery vent caps must be installed to prevent the electrolyte from being sprayed (released) out of the battery. Make sure the holes in the vent caps are open and free of dirt. Because battery gases are explosive, always keep all fire and sparks away from the battery at all times.

-------WARNING!-------

Load Test

(1) Put the selectors for VOLTMETER (1), CHARGE RATE (2), VOLTAGE (3) and TEST (4) in the OFF position. Connect battery leads (5) and (6) to the battery posts (red to positive and black to negative).

(2) Set VOLTMETER SELECTOR (1) on the 8 volt position for 6 and 8 volt batteries, and the 16 volt position for 12 volt batteries. Put voltage selector (3) on 6 for 6 volt batteries or on 12 for 8 volt and 12 volt batteries.

(3) Rotate TEST SELECTOR (4) clockwise to the specified test load reading as indicated on the 600 ampere scale on meter (7). For the correct test load, refer to Special Instruction Form SMHS7633, "BATTERY TEST PROCEDURE".

(4) Maintain the specified test load for fifteen seconds. After application of the load for fifteen seconds, look at the reading on the voltmeter with the battery still under load. Remove the load and make a record of this reading.

Battery Charging

------ WARNING! ------

Battery gases are an explosive mixture of hydrogen and oxygen. Keep all sparks and flames away from batteries. Charge batteries only in areas with good air movement. Before charging a discharged battery in cold weather, make sure there is no ice in the cells. Charging a battery in this condition can result in an explosion. Always let the ice melt in the cells before charging.

-------WARNING!-------

(1) Remove all dirt and corrosion from the battery posts and the top of the battery. Make sure the holes in the vent caps are open and free of dirt because these caps must be installed while the battery is being charged.

(2) Check the level of the electrolyte before charging the battery. The electrolyte must be above the plates.

(3) If the battery is to be charged in the machine, disconnect the cables from the battery. Remove the cover for the battery and open the battery compartment of the machine.

IMPORTANT: The 9S1990 and 1P7400 Battery Charger Testers have a relay for the protection of the charger if the connection to the battery is not correct (a correct connection is the positive lead on the charger to the positive post on the battery, and the negative lead on the charger to the negative post on the battery). If the battery cannot be charged, check the connection of the charger to the battery. Also, if a battery has been discharged too much, there will not be enough voltage in the battery to close the relay in the charger. Connect another battery in parallel with the discharged battery for just enough time to close the relay.

(4) Put all switches in the OFF position. Connect BATTERY leads (1) and (2) to the battery posts, red to positive (+) and black to negative (-).

(5) Put VOLTAGE SELECTOR switch (3) in the 6 volt position for 6 and 8 volt batteries or in the 12 volt position for 12 volt batteries. Rotate TEST SELECTOR knob (4) counterclockwise to the stop.

(6) For fast charging only, set time selector (5) for the desired period of fast charging. Set CHARGE RATE SELECTOR (6) to the rate shown in Special Instruction Form SMHS7633, "BATTERY TEST PROCEDURE". During charging, the battery voltage must not be more than 7.75 volts for a 6 volt battery, 10.4 volts for an 8 volt battery, or 15.5 volts for a 12 volt battery. If battery voltage is more than this in the first three minutes of charging, use the slow charge procedure to charge the battery.

(7) For slow charging only, turn TIME SELECTOR (5) to the "O" position. Set the CHARGE RATE SELECTOR (6) to the rate shown in Special Instruction Form SMHS7633, "BATTERY TEST PROCEDURE".

Troubleshooting The Battery Charger Tester

(A) Equipment Needed

Volt-Ohm Meter (VOM) Continuity Tester 12 Volt Battery

------ WARNING! ------

Always disconnect the power source and the battery before making continuity checks.

-------WARNING!-------

(B) Circuit Function

When the BATTERY leads of the battery charger tester are connected to a 6, 8, or 12 volt source, relay RY2 is energized and closes its contacts thereby completing the AC power connection. When the VOLTAGE SELECTOR switch SW1 is moved to the 12 VOLTS position, relay RY1 is energized, closes its contacts and turns on the cooling fan. When the VOLTAGE SELECTOR switch SW1 is moved to the 6 VOLTS position, a 33 ohm resistor is taken out of series with relay RY1 which provides sufficient current to actuate RY1, closing its contacts and turning on the cooling fan. In the 6 VOLTS position, SW1 also energizes relay K1 which shunts resistor R6 into the load circuit, reducing the resistance for 6 volt operation.

The CHARGE RATE SELECTOR switch SW2 selects the proper transformer tap to provide the input power for the specified charge rate.

The VOLTMETER SELECTOR switch SW3 selects the proper series resistor to provide the correct voltage for voltmeter operation.

The TEST SELECTOR switch, when rotated counterclockwise to the battery charging position, disconnects the carbon pile from the circuit, allows the charger to operate and connects the ammeter through the 90 amp shunt. Rotating the TEST SELECTOR switch clockwise to the TEST position connects the carbon pile to the circuit, provides increasing load to the battery by compressing the carbon pile, and connects the ammeter into the circuit through the 600 amp shunt.

The TIME SELECTOR switch T connects the timing reactor L1 into the circuit. This switch allows a length of time to be selected for fast charging. At the end of this time, the charger returns to slow charge until turned off.

The AC input voltage is passed through transformer T1 to step it down, and then through rectifier CR1 to convert it to DC for the charging circuitry.

(C) Checking The Voltmeter

If during any test the voltmeter readings are suspected of being inaccurate, use a VOM to check the voltage being measured. If the two readings do not agree, use the following procedure to determine the cause.

(1) Check the voltmeter zero position, and adjust it if necessary.

(2) Check for inaccuracies on the other voltmeter scales by measuring a known voltage.

(3) If the voltmeter is inaccurate on one scale only, check the condition of the resistor connected in series with that voltmeter scale position.

(4) If the voltmeter is inaccurate on all scales, install a new voltmeter.

(D) Checking The Charging Circuit

(1) If the battery charger tester will not charge, check for correct polarity connections to the battery.

(2) If the battery being charged is badly discharged, it will not close relay RY2. Attempt to close this relay by temporarily connecting a charged battery in parallel with the one being charged.

(3) If RY2 still fails to close, check for voltage at the relay across test points 1. If this voltage exists, install a new relay. If there is no voltage at the relay, check continuity in the BATTERY test leads.

(4) If RY2 has closed properly, check for 115 ± 10 VAC (9S1990) or 220 ± 20 VAC (1P7400) across test points 2. If this voltage does not exist, check the source voltage and continuity through the TIME SELECTOR switch. If this voltage does exist, check continuity through SW1 and SW2.

NOTE: For steps 5 and 6, put the CHARGE RATE SELECTOR switch in the proper position for the battery being used.

(5) Check for voltage across test points 3. This voltage should be 18 ± 2 VAC for a 12 volt battery and 14 ± 2 VAC for a 6 volt battery. If this voltage is not correct, install a new transformer.

(6) If the voltage in the above step is correct, check the voltage across test points 4. This voltage should be 12 ± 1 VDC for a 12 volt battery and 6 ± 1 VDC for a 6 volt battery. If this voltage is not correct, install a new rectifier CR1.

(7) If the voltage in the above step is correct, check for continuity through circuit breaker CB1 and the BATTERY leads. For a 6 volt battery, make sure that relay K1 has closed shunting R6 into the circuit.

(8) If the TIME SELECTOR switch does not time correctly, check the switch and reactor L1. Install a replacement for faulty component.

(9) If the ammeter readings are incorrect, check for a failure in shunt R2 or in the meter. Install a replacement for faulty component.

(10) If the tester fails to operate in the load test mode, check the contact of the brass plates in the carbon pile. If this contact exists and the tester will not load consistently, install a new carbon pile assembly.

(E) Wiring Diagram And Test Points

(F) Component Location And Parts List

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