Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L...

Página 1 de 7

Shutdown SIS

Previous Screen

Product: NO EQUIPMENT SELECTED

Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED

Tool Operating Manual

Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries{0785,
1401}
Media Number -SEHS9249-00 Publication Date -01/09/1990 Date Updated -11/10/2001

Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt Lead

Acid Batteries{0785, 1401}
SMCS - 0785; 1401

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022
Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L... Página 2 de 7

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

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022
Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L... Página 3 de 7

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022
Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L... Página 4 de 7

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

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022
Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L... Página 5 de 7

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

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022
Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L... Página 6 de 7

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022
Media Search - SEHS9249 - Use of 4C4911 Battery Load Tester for 6, 8 and 12 Volt L... Página 7 de 7

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:

Caterpillar Service Technology Group

330 S. W. Adams LD180
Peoria IL. 61602

Attn: Repair Center

Copyright 1993 - 2022 Caterpillar Inc. Mon Mar 14 10:32:31 UTC-0400 2022
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 14-03-2022