SERVICE BULLETIN

TOPIC:
IDENT NO:
SUPERSEDES:
DATE:
SUBJECT:

Electronic Controls
17-2964
New
September 15, 2006

Battery Maintenance

MODELS AFFECTED:

All Engines

Always keep the engine batteries in good operating

condition and at full charge. Failure to do so may effect
the performance of the ESM and other electronic controls.
Sulfation of batteries starts when specific gravity falls
below 1.225 or voltage measures less than 12.4 (see
Table 1). Sulfation hardens the battery plates reducing
and eventually destroying the ability of the battery to
generate power or to dampen voltage ripples (noise)
caused by battery charging or loads with switching
power supplies. Failure of the battery to adequately
dampen voltage ripples may lead to malfunction of
battery powered devices.

WARNING
Comply with the battery manufacturer's
recommendations for procedures concerning
proper battery use and maintenance. Improper
maintenance or misuse can cause severe personal
injury or death.

WARNING
Batteries contain sulfuric acid and generate
explosive mixtures of hydrogen and oxygen
gases. Keep any device that may cause sparks or
flames away from the battery to prevent explosion.
Batteries can explode causing severe personal
injury or death.

WARNING
Always wear protective glasses or goggles and
protective clothing when working with batteries.
You must follow the battery manufacturers
i n s t r u c t i o n s o n s a f e t y, m a i n t e n a n c e a n d
installation procedures. Failure to follow the
battery manufacturers instructions can cause
severe personal injury or death.

WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999

BATTERY INDICATED STATE OF CHARGE

NOTE: 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 may read misleadingly high. The
surface charge must be removed before testing. To
remove surface charge, the battery must experience a
load of 20 amps for three or more minutes.
1. Use a temperature compensated hydrometer to
measure the electrolyte specific gravity readings in
each cell. Record the readings.
2. Measure the open circuit voltage across the
terminals. Record the reading.
3. Using the recorded values determine the state of
charge (see Table 1).
4. See Table 3 troubleshooting chart.
NOTE: The state of charge listed is approximate. The
relationship between state of charge and voltage
varies by CCA rating and size. Voltage below 11.90 V
may mean that the battery has a shorted cell or that
the plates are sulfated and can not accept a charge.
Table 1. Determining State of Charge
STATE OF
CHARGE

SPECIFIC
GRAVITY

12.70 & Above

100 %

.280

12.50

75 %

.240

12.30

50 %

.200

12.10

25 %

.170

Discharged

.140

VOLTAGE

11.90 & Below

Table 2. Cranking Amps - Commercial Batteries

CCA @ 0F (-18 C)
CA @ 32F (0 C)
RC minutes @ 25 A

4D

8D

1000A

1300A

1200A

1560A

320 min.

435 min.

CCA = Cold Cranking Amps

CA = Cranking Amps
RC = Reserve Capacity

Page 1 of 2

Service Bulletin No. 17-2964

Table 3. Battery Troubleshooting
IF
Has cracks or holes in the container or
cover.
Battery
Appearance

Has black deposits on underside of vent

plugs.

Is low.
Is adjusted frequently.
Is 75% or greater.
Is between 25% and 75%.
State Of Charge

Battery has been overcharged (see NOTE 4)

Verify battery charger is operating correctly and settings are correct.
Fill electrolyte to correct level using distilled or deionized water.
Battery is receiving too much charging current.
Verify battery charger is operating correctly and settings are correct.
Verify battery is good with a high rate load test (see NOTE 3).
Recharge battery (see NOTE 2).

Is less than 25%.

Measured open circuit voltage is lower
than value given in the Table 2.

Specific Gravity
Of Cells

Replace battery.

Has corroded terminals posts.

Has black tide-marks on inside walls

about one inch below the cover.
Electrolyte Level

THEN

Differential between cells exceeds .05.

Is uniformly low.

Replace battery.
Replace battery (internally short-circuited).
Verify battery charger is operating correctly and settings
are correct, recharge battery (see NOTE 1).

NOTE 1:Batteries which have low but uniform specific gravities in each cell and which clearly require an extended
recharge 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 with
any further tests. Observe that the battery does accept a charging current, even though it may be small in
amperes, 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 may
read misleadingly high. The surface charge must be removed before testing. To remove surface charge, the
battery must experience a load of 20 amps for 3 plus minutes.
NOTE 3:High-Rate Load TestIf the state-of-charge is 75% or higher, the battery should be given a high-rate load
test. Typically, the high-rate load tester will discharge a battery through an adjustable carbon-pile resistance
and indicate the terminal voltage as the discharge proceeds. After 15 seconds the battery voltage will not
drop below a specified value (typically 9.6 V) if the battery is in good condition and if the current is set at
about 50% of the Cold Cranking Amps (CCA) (see Table 2). The minimum acceptable voltage reading will
vary as battery temperature decreases. Read and follow the manufacturers instructions for the tester.
NOTE 4:OverchargingBatteries which have suffered as a result of considerable overcharging may show extremely
low electrolyte levels, black deposits on the underside of the vent plugs or black tide-marks on the inside
walls of the container from about one inch below the cover. If these signs are present, the battery charger
setting must be checked and reset according to the manufacturer's instructions before a battery is returned
to service, batteries in which electrolyte levels have to be adjusted frequently are clearly receiving too much
charging current.

Page 2 of 2

WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999