SERVICE BULLETIN

Page 1 of 2WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999

Always keep the engine batteries in good operatingcondition and at full charge. Failure to do so may effectthe performance of the ESM and other electronic con-trols.

Sulfation of batteries starts when specific gravity fallsbelow 1.225 or voltage measures less than 12.4 (seeTable 1). Sulfation hardens the battery plates reducingand eventually destroying the ability of the battery togenerate power or to dampen voltage ripples (noise)caused by battery charging or loads with switchingpower supplies. Failure of the battery to adequatelydampen voltage ripples may lead to malfunction ofbattery powered devices.

WARNINGComply w i th the bat ter y manufacturer 'srecommendations for procedures concerningproper battery use and maintenance. Impropermaintenance or misuse can cause severe personalinjury or death.

WARNINGBatteries contain sulfuric acid and generateexplosive mixtures of hydrogen and oxygengases. Keep any device that may cause sparks orflames away from the battery to prevent explosion.Batteries can explode causing severe personalinjury or death.

WARNINGAlways wear protective glasses or goggles andprotective clothing when working with batteries.You must follow the battery manufacturer’sinst ruct ions on sa fe ty, main tenance andinstallation procedures. Failure to follow thebattery manufacturer’s instructions can causesevere personal injury or death.

BATTERY INDICATED STATE OF CHARGE

NOTE: The battery must be fully charged for severalhours before testing. If batteries have been receiving acharge current within the previous few hours, theopen-circuit voltage may read misleadingly high. Thesurface charge must be removed before testing. Toremove surface charge, the battery must experience aload of 20 amps for three or more minutes.

1. Use a temperature compensated hydrometer tomeasure the electrolyte specific gravity readings ineach cell. Record the readings.

2. Measure the open circuit voltage across theterminals. Record the reading.

3. Using the recorded values determine the state ofcharge (see Table 1).

4. See Table 3 troubleshooting chart.

NOTE: The state of charge listed is approximate. Therelationship between state of charge and voltagevaries by CCA rating and size. Voltage below 11.90 Vmay mean that the battery has a shorted cell or thatthe plates are sulfated and can not accept a charge.

Table 1. Determining State of Charge

Table 2. Cranking Amps - Commercial Batteries

TOPIC: Electronic ControlsIDENT NO: 17-2964

SUPERSEDES: NewDATE: September 15, 2006

SUBJECT: Battery Maintenance

MODELS AFFECTED: All Engines

VOLTAGE STATE OF CHARGE

SPECIFIC GRAVITY

12.70 & Above 100 % .280

12.50 75 % .240

12.30 50 % .200

12.10 25 % .170

11.90 & Below Discharged .140

4D 8DCCA @ 0°F (-18 °C) 1000A 1300A

CA @ 32°F (0 °C) 1200A 1560A

RC minutes @ 25 A 320 min. 435 min.

CCA = Cold Cranking AmpsCA = Cranking AmpsRC = Reserve Capacity

Service Bulletin No. 17-2964

Page 2 of 2 WAUKESHA ENGINEDRESSER, INC.WAUKESHA, WI 53188-4999

Table 3. Battery Troubleshooting

NOTE 1:Batteries which have low but uniform specific gravities in each cell and which clearly require an extendedrecharge may have become deeply discharged. This may be nothing more than a battery charger problem,but the system should be checked out before the battery is returned to service.

NOTE 2:Recharging Batteries which are at less than 75% state of charge need recharging before proceeding withany further tests. Observe that the battery does accept a charging current, even though it may be small inamperes, when the charger is switched on. The battery must be fully charged for several hours before testing.If batteries have been receiving a charge current within the previous few hours, the open-circuit voltage mayread misleadingly high. The surface charge must be removed before testing. To remove surface charge, thebattery must experience a load of 20 amps for 3 plus minutes.

NOTE 3:High-Rate Load Test—If the state-of-charge is 75% or higher, the battery should be given a high-rate loadtest. Typically, the high-rate load tester will discharge a battery through an adjustable carbon-pile resistanceand indicate the terminal voltage as the discharge proceeds. After 15 seconds the battery voltage will notdrop below a specified value (typically 9.6 V) if the battery is in good condition and if the current is set atabout 50% of the Cold Cranking Amps (CCA) (see Table 2). The minimum acceptable voltage reading willvary as battery temperature decreases. Read and follow the manufacturers instructions for the tester.

NOTE 4:Overcharging—Batteries which have suffered as a result of considerable overcharging may show extremelylow electrolyte levels, black deposits on the underside of the vent plugs or black “tide-marks” on the insidewalls of the container from about one inch below the cover. If these signs are present, the battery chargersetting must be checked and reset according to the manufacturer's instructions before a battery is returnedto service, batteries in which electrolyte levels have to be adjusted frequently are clearly receiving too muchcharging current.

IF THEN

Battery Appearance

Has cracks or holes in the container or cover. Replace battery.Has corroded terminals posts.

Has black deposits on underside of vent plugs. Battery has been overcharged (see NOTE 4)

Verify battery charger is operating correctly and settings are correct.Has black “tide-marks” on inside walls about one inch below the cover.

Electrolyte LevelIs low. Fill electrolyte to correct level using distilled or deionized water.

Is adjusted frequently. Battery is receiving too much charging current.Verify battery charger is operating correctly and settings are correct.

State Of Charge

Is 75% or greater. Verify battery is good with a high rate load test (see NOTE 3).

Is between 25% and 75%. Recharge battery (see NOTE 2).

Is less than 25%.Replace battery.Measured open circuit voltage is lower

than value given in the Table 2.

Specific GravityOf Cells

Differential between cells exceeds .05. Replace battery (internally short-circuited).

Is uniformly low. Verify battery charger is operating correctly and settings are correct, recharge battery (see NOTE 1).