By Barry O’Leary
Caterpillar Forest Products
Excess vibration is the leading cause of premature battery failure in off-road equipment. Vibration from loose mounts, missing battery hold-downs, etc., can loosen plate material and cause the battery to short out. Other factors that reduce life include extreme heat, freezing temperatures, overcharging, undercharging and an undersized battery.
Under normal use and charging conditions, premium high output or heavy-duty batteries in colder climates can last 48 to 54 months. In hotter conditions it may be only 18 to 23 months. The ideal operating temperature range for most batteries is 68˚ to 77˚F. With every 15˚ increase above that, the life of lead-acid batteries is cut in half.
Buy Smart
You need a tough battery for your machine’s applications and working conditions. Don’t be fooled by low-priced alternatives. Invest in a rugged, reliable battery—one that delivers maximum cold cranking amps, exceeds the industry standard for vibration resistance and deep discharge and withstands the punishing environment and climate where you operate your equipment. Look for batteries with the following features:
- 4D and 8D batteries with non-accessible flush covers that never need water and reduce maintenance costs.
- Positive and negative plates anchored to the container bottom and locked at the top of the cell element for maximum resistance to vibration.
- Thicker internal terminal posts that lower electrical resistance for higher output during starts.
- Forged terminal post bushings that provide maximum strength and resistance to acid seepage that causes corrosion.
- Manifold vented cover with built-in flame arrester to direct corrosive gases away from battery, venting outside the battery compartment.
- Thick, robust container that withstands the rugged treatment typical of heavy-duty commercial use.
Proper Voltage
Operate batteries within the proper charge and discharge voltages. The symptoms of overcharging are excessive water use, black lead material on underside of vent caps or high readings on ammeter. An undercharged battery causes plates to harden (sulfate) and then the battery will no longer accept a charge. Use a charge controller circuit to prevent battery overcharge and a low voltage disconnect (LVD) circuit to reduce excessive battery discharge.
A battery emits gases when the charge rate is higher than the battery can accommodate. Chargers typically reduce the charge rate as the battery nears a full charge, eliminating most of the gassing. Additional charging creates heat and water loss, producing hydrogen and oxygen gases. The excess heat damages plates and separators, and water loss lowers electrolyte levels. While no battery should be charged beyond the time required, it is especially important not to charge sealed batteries for long periods because the water cannot be replaced.
The voltage regulator controls voltage output to maintain a proper state of charge in the battery. A voltage regulator setting that is too high causes overcharging and reduces life, while a low setting undercharges and reduces performance. Check regulators every 2,000 hours. Batteries should not be installed and forgotten.
Maintenance, Storage
Add these battery checks to your maintenance routine:
Check battery terminals, box and wiring for damage or corrosion.
Check battery tray for corrosion, which could indicate a cracked battery.
Confirm that terminal connections and hold-downs are torqued properly to prevent excessive vibration.
Remove any debris under the battery, which can cause premature wear of the case and possibly loss of electrolyte.
Be sure vent caps are in place. Missing caps can compromise safety and allow contamination.
Tighten alternator belts and check the alternator output voltage with a voltmeter. If your machine will sit idle for an extended period, disconnect the battery or remove and store it in a cool, dry place.