Batteries and Electrical Parts - Dozer Motors

3

Batteries and

Electrical Parts

Premium High Output Batteries . . . . . . . . . . . . . . . . 4

General Service Batteries . . . . . . . . . . . . . . . . . . . . . 5

Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . 9

BCI Group Size Interchange Guide . . . . . . . . . . . . . 11

BCI Assembly Numbers, Cell Layouts and Terminals 17

Battery Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Emergency Start Systems . . . . . . . . . . . . . . . . . . . . . 19

Composite Halogen Lights . . . . . . . . . . . . . . . . . . . . . 20

Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Electrical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2 153-5690 1000 10.2 259 6.9 176 9.3 239 45 20 33 14 4.8 5.0

4D 9X-9720 1000 20.8 527 8.6 218 9.8 250 101 46 59 27 15.9 15.0

4D 153-5700 — 20.8 527 8.8 222 9.8 248 101 46 — — — —

4D 9X-9730 1000 20.8 527 8.6 218 9.8 250 119 54 81 37 14.8 14.0

8D 101-4000 1000 20.8 527 11.1 280 9.8 250 132 60 86 39 18.0 17.0

8D 153-5720 — 20.8 527 11.1 280 9.8 250 132 60 — — — —

24 153-5656 — 10.2 258 6.8 174 8.9 226 39 17 — — — —

31 3T-5760 — 13.0 333 6.8 174 9.4 240 55 25 — — — —

31 9X-3404 — 13.0 333 6.8 174 9.4 240 58 25 — — — —

31 115-2421 — 13.0 333 6.8 174 9.4 240 60 27 44 44 6.6 6.0

31 115-2422 — 13.0 333 6.8 174 9.4 240 60 27 — — — —

74 153-5660 — 10.2 258 6.8 174 8.2 207 39 17 — — — —

All batteries have taper post design and are shipped dry except as noted. * For 30 seconds at 0° F ** 25 Amp output at 80° F

Premium High Output Batteries

● Provide three or more times the life of the best known batterybrands.

● Deliver reliable starts due to high cold cranking amps (CCA) andreserve capacities (RC).

● Exceed the industry’s most abusive vibration tests.

● Successfully recharge even after a radio or disconnect switch is lefton for over 72 hours.

4

Batteries and Electrical Parts

BCI COLD RESERVE AMP HR.GROUP PART CRANKING CAPACITY CAPACITY

SIZE NUMBER VOLTS AMPS* MINUTES** @ 20 HRS. CONSTRUCTION

BCI ADD WATER BCI OVERALL DIMENSIONS NOMINAL WEIGHT ACIDGROUP PART MAINTENANCE LENGTH WIDTH HEIGHT WET DRY TO FILL

SIZE NUMBER CHECK/HRS. (in) (mm) (in) (mm) (in) (mm) (lbs) (kg) (lbs) (kg) (qt) (liter)

2 153-5690 6 765 210 90 Polypropylene Case, Low Antimony Design

4D 9X-9720 12 1000 275 140 Polypropylene Case, Low Antimony Calcium Design

4D 153-5700 12 1100 305 145 Polypropylene Case, Calcium Design (Wet only)

4D 9X-9730 12 1300 400 190 Polypropylene Case, Low Antimony Calcium Design

8D 101-4000 12 1400 400 190 Polypropylene Case, Low Antimony Calcium Design

8D 153-5720 12 1465 465 200 Polypropylene Case, Calcium Design (Wet only)

24 153-5656 12 650 110 52 Polypropylene Case, Calcium Design (Wet only)

31 3T-5760 12 750 165 100 Polypropylene Case, Calcium Design (Wet only)

31 9X-3404 12 900 165 100 Polypropylene Case, Calcium Design (Wet only)

31 115-2421 12 950 170 90 Polypropylene Case, Calcium Design

31 115-2422 12 950 170 90 Polypropylene Case, Calcium Design (Wet only)

74 153-5660 12 650 110 52 Polypropylene Case, Calcium Design, Side Terminals (Wet only)


5

General Service Batteries (Dry)B

CI

CO

LD

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RV

EA

MP

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OU

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AN

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HH

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TO F

ILL

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UM

BE

RV

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MP

S*

MIN

UT

ES

**@

20 H

RS

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ON

ST

RU

CT

ION

(in

)(m

m)

(in

)(m

m)

(in

)(m

m)

(lb

s)(k

g)

(lb

s)(k

g)

(qt)

(lit

er)

All

batte

ries

have

tap

er p

ost

desi

gn a

nd a

re s

hipp

ed d

ry e

xcep

t as

not

ed*

For

30

seco

nds

at 0

°F

** 2

5 A

mp

outp

ut a

t 80

°F

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ricu

ltu

ral /

Ind

ust

rial

/ Tr

uck

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635

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6


General Service Batteries (Wet — Available only for U.S. and U.S. export)

BC

IC

OL

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ES

ER

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AM

PH

R.

BC

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n)

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)(l

bs)

(kg

)(l

bs)

(kg

)(q

t)(l

iter

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All

batte

ries

have

tap

er p

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gn a

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re s

hipp

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ry e

xcep

t as

not

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For

30

seco

nds

at 0

°F

** 2

5 A

mp

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Ag

ricu

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ral /

Ind

ust

rial

/ Tr

uck

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635

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Mai

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——

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——

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7

General Service Batteries (Wet — Available only for U.S. and U.S. export)B

CI

CO

LD

RE

SE

RV

EA

MP

HR

.B

CI O

VE

RA

LL

DIM

EN

SIO

NS

NO

MIN

AL

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IGH

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GR

OU

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RT

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AN

KIN

GC

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CIT

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CIT

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EN

GT

HW

IDT

HH

EIG

HT

WE

TD

RY

TO F

ILL

SIZ

EN

UM

BE

RV

OLT

SA

MP

S*

MIN

UT

ES

**@

20 H

RS

.C

ON

ST

RU

CT

ION

(in

)(m

m)

(in

)(m

m)

(in

)(m

m)

(lb

s)(k

g)

(lb

s)(k

g)

(qt)

(lit

er)

All

batte

ries

have

tap

er p

ost

desi

gn a

nd a

re s

hipp

ed d

ry e

xcep

t as

not

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seco

nds

at 0

°F

** 2

5 A

mp

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ut a

t 80

°F

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oti

ve /

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ht

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ck

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8


General Service Batteries (Wet — Available only for U.S. and U.S. export)

BC

IC

OL

DR

ES

ER

VE

AM

PH

R.

BC

I OV

ER

AL

LD

IME

NS

ION

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OM

INA

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UP

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RA

NK

ING

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ITY

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PAC

ITY

LE

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TH

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IZE

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MB

ER

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AM

PS

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TE

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@20

HR

S.

CO

NS

TR

UC

TIO

N(i

n)

(mm

)(i

n)

(mm

)(i

n)

(mm

)(l

bs)

(kg

)(l

bs)

(kg

)(q

t)(l

iter

)

All

batte

ries

have

tap

er p

ost

desi

gn a

nd a

re s

hipp

ed d

ry e

xcep

t as

not

ed*

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30

seco

nds

at 0

°F

** 2

5 A

mp

outp

ut a

t 80

°F

Mar

ine

/ Rec

reat

ion

al

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16

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——

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185

188

——

——

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aint

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251

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——

——

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cium

Grid

s (S

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——

——

(Stu

d te

rmin

als)

Selling Batteries in Applications Other than Caterpillar Equipment

Caterpillar batteries fit a wide variety of applications including many competitive earthmoving machines,industrial equipment, farm implements, on-highway trucks and passenger cars. The Caterpillar BatteryCross Reference Guide, PEGP7801, lists the proper size for many applications.

Sometimes the proper BCI Group size may not be known. In this case, always consider the following beforerecommending a battery:

● Voltage

● Cold Cranking Power

● Overall Dimensions

● Terminal Type and Position

When helping customers compare Caterpillar batteries to other brands of batteries, stress these areas:

● Performance Specifications (Particularly Cold Cranking Power)● Battery Construction Features● Warranty

Identifying Battery Sales Opportunities

A quick visual inspection of a customer's battery can often identify replacement sales opportunities. Look for the following signs which indicate a potentially weak battery:

● Missing vent caps

Replacement Vent Caps

REPLACEMENT BATTERYVENT PARTCAP NUMBER

7N-0060 9S-4700, 5S-7219, 9S-7120, 9S-7130, 7N-7200, 4S-9261,4S-9219, 9G-3837, 4N-9500, 8N-0500, 9G-4231, 9G-4232, 9G-4233,

9G-4234, 9G-4250, 8C-3620, 8C-3621, 8C-3622, 8C-3623,8C-3624, 8C-3630, 8C-3631, 8C-3632, 8C-3635, 8C-3640.

6N-9826 4N-4495, 9S-4701

7N-7238 9S-7170

● Warranty markings indicating a battery over 3 years old

● Excessive corrosion on terminals

● Signs of acid leaks (especially near the terminals)

● Unusually low acid levels

Warranty InformationConsult your Cat Warranty Guide for details of the Caterpillar Battery Warranty.

9


Industry Battery Ratings

The battery industry has established two methods of rating batteries. The ratings are designed to reflect theincreased cranking and electrical requirements of today's vehicles.

Cold Cranking Power at 0°F (-17.8°C)* This rating:

● Recognizes that the most important function of the battery is to provide power for cranking and startingthe engine.

● Takes into consideration the effects of engine displacement, compression ratio, temperature, time, enginecondition and a minimum practical terminal voltage.

● Indicates the discharge rate in amperes that a fully-charged battery will maintain for 30 seconds at 0°F(-17.8°C) without the terminal voltage falling below the lowest practical voltage for cranking and ignition.* Note: Many retail outlets are advertising battery Cranking Amps (CA) rather than Cold Cranking Amps (CCA). Cranking Amps are measured

at 32˚F (0˚C), which artificially elevates the starting power of a battery

Reserve Capacity Rating at 80°F (26.7°C)

This rating indicates:

● The number of minutes that a fully-charged battery at 80°F (26.7°C) will supply power for ignition,lights and accessories if the charging system fails.

Battery Maintenance Tips

Proper battery maintenance is essential to ensure quick, dependable starting and reliable operation of theelectrical system. Make it a habit to regularly check the condition of your Cat Battery.

1. Check the electrolyte level in each cell to make sure it is above the plates.

2. Keep the battery terminals free from corrosion.

3. Vent caps should be in place and secure. Make sure the vent holes are not plugged.

4. Check the battery holddown clamps to make sure they are fastened securely.

NOTE: If battery failure is a recurring problem, it may be due to a malfunction in the charging system, suchas a defective alternator or voltage regulator. (See Special Instruction Form SEHS7633 for details on eachstep of battery testing.)

See the Caterpillar Battery Cross Reference Guide (PEGP7801) for special machine applications.

10


BCI Group Size Interchange Guide

BCI YEARS THE AUTOMOBILE MANUFACTURERSGROUP ALTERNATE USED BELOW USE THE FIRST

SIZE REPLACEMENT REPLACEMENT FOOTNOTE AS O.E. COLUMN AS O.E. BATTERIES

21 24 a 1970-1991 Chrysler, Subaru, Mazda

26, 86 b34 a, b

21R 24F a 1981-1991 GM, Isuzu, Mazda26R b

22F 21R 24F a 1970-1990 Ford, AMC, Renault, Saab, Opel, Jaguar, Toyota, 26R b Chevrolet GEO

22NF 45 f 1970-1977 Renault, MG, Triumph, Austin

23 24F, 22F, 21R 26R b 1977-1980 Ford, Peugeot

24 21 27 a 1970-1998 AMC, Chrysler, Toyota, Nissan, Hyundai, Lexus,26, 34, 86 b Alpha Romeo, Mazda and other imports

24F 22F, 21R 27F a 1970-1998 Ford, Toyota, Nissan, Saab, Acura, Hyundai, Lexus,26R, 85 b Alpha Romeo, Honda

25 21, 24 26, 34, 86 b 1979-1990 Chrysler, Mazda, Nissan, Hyundai, Isuzu, Eagle

26 34, 86 a 1978-1991 Chrysler, Honda, GM, Suzuki, Chevrolet GEO

24 a, c21 c

26R 22F, 21R 24F, 27F a, c Not an Original Equipment Group Size

27 24, 21 26, 34, 86 b 1970-1998 Chrysler, Toyota, Nissan, Mitsubishi, Ford, Isuzu, Infiniti

27F 24F, 22F, 21R 26R, 85 b 1970-1991 Ford, Toyota, Nissan

33 1984-1987 Ford

34 26, 86 21, 24 c 1985-1991 Chrysler, Ford

34R Not an Original Equipment Group Size 1989-1991 Sterling

35 24F a 1982-1998 Ford, GM, Mazda, Nissan, Subaru, Hyundai, Chevrolet GEO, Lexus, Toyota, Honda

41 42 1975-1998 Volkswagen, Porsche, Audi

42 41 a 1970-1990 Volkswagen, Porsche, Audi, Renault, Yugo, BMW

43 48 1970-1975 Mercedes-Benz

44 49 1970-1975 Mercedes-Benz

45 22NF f 1970-1991 Honda, Mitsubishi, Acura, GEO Tracker, Dodge Imports

46 24 e 1970-1986 Volvo

47 42 e 1970-1991 Mercedes-Benz, BMW, Volvo, Merkur, Sterling, Saab

48 48, 41 e 1976-1991 Mercedes-Benz, BMW, Peugeot, Volvo

49 41 e 1974-1998 Mercedes-Benz, Volvo, Porsche, Peugeot

54 56 1978-1986 Ford, AMC, Jeep

55 56 1978-1990 Ford, AMC, Jeep

56 1978-1990 Ford, AMC, Jeep

57 58 1981-1986 Ford

58 1981-1998 Ford, Jeep, Renault

59 65 1996-1998 Ford


11

a Check battery tray for adequate length.

b I-bar height adapter may be required in top holddown applications require modification.

c Batteries are 1” taller, check clearance under hood. Top hold-down may require modification or replacement.

d Top holddown may require Group 56 height-width adapter.

f Bottom holddown may require modification if located on narrow end of battery.

NOTE: This guide is intended as a supplement, not a primary source.

BCI Group Size Interchange Guide (cont.)

BCI YEARS THE AUTOMOBILE MANUFACTURERSGROUP ALTERNATE USED BELOW USE THE FIRST

SIZE REPLACEMENT REPLACEMENT FOOTNOTE AS O.E. COLUMN AS O.E. BATTERIES

61 62, 63 56 d 1980-1986 Ford

64 a

62 63 56 d 1980-1988 Ford

64 a

63 62 56 d 1980-1988 Ford

64 a

64 62, 63 56 d 1980-1991 Ford

65 1984-1998 Ford, Mazda, Lincoln

70 75, 78 a 1981-1991 GM

74 a, c71 c

72 71 74 a 1970-1977 GM

70, 75 b78 a, b

73 71 74 a 1976-1982 GM

70, 75 b78 a, b

74 71 70, 75, 78 b 1970-1985 GM, Jaguar

75 70 74 a, c 1982-1998 GM

71 c78 a

76 1982-1985 GM

77 71, 74 70, 75, 78 b 1971-1974 GM

78 70, 75 71, 74 c 1983-1998 GM

85 26R 1987-1991 LeMans

86 26 1989-1998 Eagle, Laser, Mitisubishi

91 1998 BMW

94R 1998 Audi

12


a Check battery tray for adequate length.

b I-bar height adapter may be required in top holddown applications require modification.

c Batteries are 1” taller, check clearance under hood. Top hold-down may require modification or replacement.

d Top holddown may require Group 56 height-width adapter.

f Bottom holddown may require modification if located on narrow end of battery.

NOTE: This guide is intended as a supplement, not a primary source.


BCIGROUP ALTERNATESIZE* VOLTS REPLACEMENT REMARKS

3ET 12 Volts 3EE The Group 3EE is 15/16 inch shorter than the Group 3ET.

6D 12 Volts 4D The Group 4D is 11/4 inch narrower than the Group 6D.

8D 12 Volts 4D The Group 4D is 23/8 inch narrower than the Group 8D.

30H 12 Volts 29H The Group 30H is 3/8 inch longer than the Group 29H.

30HR 12 Volts 29H The Group 30HR is 3/8 inch longer than the Group 29H and has the opposite polarity.

32N 12 Volts 29NF The Group 32N is 11/4 inch longer than the Group 29NF.

60 12 Volts 27 or 27F Depending upon cable length BCI Group Size 27F or 27 may be substituted for the Group 60.

2 6 Volts 1 The Group 2 is 11/4 inch longer than the Group 1.

2E 6 Volts 3EH The Group 3EH is 1/4 inch wider and 11/16 inch taller than the Group 2E.

3 6 Volts 2 The Group 3 is 13/8 inch longer than the Group 2.

4EH 6 Volts 3EH The Group 3EH is 5/8 inch narrower than the Group 4EH.

5D 6 Volts 4 The Group 5D is 5/8 inch longer than the Group 4.

7D 6 Volts 4 The Group 7D is 31/8 inch longer than the Group 4.

NOTE: Due to the wide variety of battery holddowns in use today, some holddown modifications may be required when making the abovesubstitutions.

This guide is intended as supplement, not a primary source.

13



PERFORMANCE RANGESBCI MAXIMUM OVERALL DIMENSIONS ASSEMBLY COLD CRANKING RESERVE CAPACITY

GROUP LENGTH WIDTH HEIGHT FIGURE PERFORMANCE AMPS MINUTES @ 80°FNUMBER (in) (mm) (in) (mm) (in) (mm) NO.◆ @ 0°F (–17.8°C) (26.7°C)

Passenger Car and Light Commercial Batteries 12-Volt (6 Cells)

21 83/16 208 613/16 173 83/4 222 10 310-400 50-70

21R 83/16 208 613/16 173 83/4 222 11 310-500 50-70

22F 91/2 241 67/8 175 85/16 211 11F 220-425 45-90

22HF 91/2 241 67/8 175 9 229 11F 400 69

22NF 97/16 240 51/2 140 815/16 227 11F 210-325 50-60

22R 9 229 67/8 175 85/16 211 11 290-350 45-90

24 101/4 260 613/16 173 87/8 225 10 165-625 50-95

24F 103/4 273 613/16 173 9 229 11F 250-585 50-95

24H 101/4 260 613/16 173 93/8 238 10 305-365 70-95

24R 101/4 260 613/16 173 9 229 11 440-475 70-95

24T 101/4 260 613/16 173 93/4 248 10 370-385 110

25 91/16 230 67/8 175 87/8 225 10 310-490 50-90

26 83/16 208 613/16 173 73/4 197 10 310-440 50-80

26R 83/16 208 613/16 173 73/4 197 11 405-525 60-80

27 121/16 306 613/16 173 87/8 225 10 270-700 102-140

27F 121/2 318 613/16 173 815/16 227 11F 360-660 95-140

27H 113/4 298 613/16 173 91/4 235 10 440 125

29NF 13 330 51/2 140 815/16 227 11F 330-350 95

33 135/16 338 613/16 173 93/8 238 11F 1050 165

34 101/4 260 613/16 173 77/8 200 10 375-650 100-110

34R 101/4 260 613/16 173 77/8 200 11 675 110

35 91/16 230 67/8 175 87/8 225 11 310-500 80-110

40 1015/16 277 67/8 174 67/8 175 15 600-650 110-120

41 119/16 293 67/8 175 67/8 175 15 235-650 65-95

42 99/16 243 613/16 173 613/16 173 15 260-495 65-95

43 131/8 334 67/8 175 81/16 205 15 375 115

45 97/16 240 51/2 140 815/16 227 10F 250-470 60-80

46 103/4 273 613/16 173 9 229 10F 350-450 75-95

47 911/16 246 67/8 175 71/2 190 24(A, F) 370-550 75-85

48 121/16 306 67/8 175 79/16 192 24(A, F) 450-695 85-95

49 15 381 67/8 175 79/16 192 24 600-810 140-150

50 131/2 343 5 127 10 254 10 400-600 85-100

51 93/8 238 51/16 129 813/16 223 10 405-435 70

51R 93/8 238 51/16 129 813/16 223 11 405-435 70

52 75/16 186 513/16 147 81/4 210 10 405 70

53 13 330 411/16 119 81/4 210 14 280 40

14


NOTES:◆ Letter in parenthesis indicates terminal type; see page 24 for “Terminals”.

* Rod End Types — Extend Top Ledge with holes for holddown bolts.

† Ratings for batteries recommended for Motor Coach and Bus service are for double insulation. When double insulation is used in other types, deduct 15% from the rating values for cold cranking performance.

➀ Not in application section but still manufactured.

➁ Special use battery not shown in application section.

➂ Capacity test in minutes @ 75 amperes to 5.25 volts at 80°F (26.7°C); cold cranking performance test not normally required for this battery.

BCI Group Size Interchange Guide (cont.)



Passenger Car and Light Commercial Batteries 12-Volt (6 Cells) (cont.)

54 75/16 186 61/16 154 83/8 212 19 305-330 60

55 85/8 218 61/16 154 83/8 212 19 370-450 75

56 10 254 61/16 154 83/8 212 19 450-505 90

57 81/16 205 73/16 183 615/16 177 22 310 60

58 101/16 255 73/16 183 615/16 177 25 380-540 75

58R 101/16 255 73/16 183 615/16 177 23 540 75

60 131/16 332 65/16 160 87/8 225 12 305-385 65-115

61 79/16 192 63/8 162 87/8 225 20 310 60

62 87/8 225 63/8 162 87/8 225 20 380 75

63 103/16 258 63/8 162 87/8 225 20 450 90

64 1111/16 296 63/8 162 87/8 225 20 475-535 105-120

65 121/16 306 71/2 190 79/16 192 21 650-850 130-165

70 83/16 208 71/16 179 711/16 196 17 260-525 60-80

71 83/16 208 71/16 179 81/2 216 17 275-430 75-90

72 91/16 230 71/16 179 81/4 210 17 275-350 60-90

73 91/16 230 71/16 179 81/2 216 17 430-475 80-115

74 101/4 260 71/4 184 83/4 222 17 350-550 75-140

75 91/16 230 71/16 179 711/16 196 17 430-690 90

76 131/8 334 71/16 179 81/2 216 17 750-1075 150-175

78 101/4 260 71/16 179 711/16 196 17 515-770 105-115

85 91/16 230 613/16 173 8 203 11 550-630 90

86 91/16 230 613/16 173 8 203 10 430-525 90

90 911/16 246 67/8 175 67/8 175 24 520 80

91 11 280 67/8 175 67/8 175 24 600 100

92 121/2 317 67/8 175 67/8 175 24 650 130

93 15 354 67/8 175 67/8 175 24 800 150

Passenger Car and Light Commercial Batteries 6-Volt (3 Cells)

1 91/8 232 71/8 181 93/8 238 2 400-545 105-165

2 103/8 264 71/8 181 93/8 238 2 475-650 135-230

2E 197/16 492 41/8 105 91/8 232 5 485 140

2N 10 254 59/16 141 815/16 227 1 450 135

17HF* 73/8 187 67/8 175 9 229 2B ➀ ➀

Heavy-Duty Commercial Batteries 12-Volt (6 Cells)

4D 203/4 527 83/4 222 97/8 250 8 490-950 225-325

6D 203/4 527 10 254 101/4 260 8 750 310

8D 203/4 527 111/8 283 97/8 250 8 850-1250 235-465

15








16

Batteries and Electrical PartsBCI Group Size Interchange Guide (cont.)



Heavy-Duty Commercial Batteries 12-Volt (6 Cells) (cont.)

28 105/16 216 613/16 173 97/16 240 18 400-535 80-135

29H 131/8 334 63/4 171 91/8 232 10 525-840 145

30H 131/2 343 613/16 173 91/4 235 10 380-685 120-150

31 13 330 613/16 173 97/16 240 18(A, T) 455-950 100-200

Heavy-Duty Commercial Batteries 6-Volt (3 Cells)

3 113/4 298 71/8 181 93/8 238 2 525-660 210-230

4 131/8 334 71/8 181 93/8 238 2 550-975 240-420

5D 133/4 349 71/8 181 93/8 238 2 720-820 310-380

7D 161/4 413 71/8 181 93/8 238 2 680-875 370-426

Heavy-Duty Motor Coach and Bus Batteries 12-Volt (6 Cells) †

4B 211/4 540 111/8 283 107/8 276 8(B) 430 250

Special Tractor Batteries 6-Volt (3 Cells)

3EH 195/16 491 43/8 111 913/16 249 5 740-850 220-340

4EH 195/16 491 5 127 913/16 249 5 850 340-420

Special Tractor Batteries 12-Volt (6 Cells)

3EE 195/16 491 43/8 111 87/8 225 9 260-360 80-105

3ET 195/16 491 43/8 111 913/16 249 9 355-425 130-135

4DLT 20 508 83/16 208 715/16 202 16L 650-820 200-290

12T 71/16 177 615/16 177 715/16 202 10 460 160

16TF 169/16 421 71/8 181 111/8 283 10F 600 240

17TF 171/16 433 615/16 177 715/16 202 11L 510 145

General Utility Batteries 12-Volt (6 Cells)

U1 73/4 197 53/16 132 75/16 186 10(X) 120-295 23-40

U1R 73/4 197 53/16 132 75/16 186 11(X) 220-235 25-37

U2 65/16 160 53/16 132 71/8 181 10(X) 120 17

Electric Vehicle Batteries 6-Volt (3 Cells)

GC2 103/8 264 73/16 183 105/8 270 2 ➂ ➂

GC2H➁ 103/8 264 73/16 183 115/8 295 2 ➂ ➂

16







ASSEMBLY FIGURE SUFFIXES

B Ledge for Rod-end Hold-down

C SAE Hold-down Design 1 or 1A

J SAE Hold-down Design 2

F SAE Hold-down Design 3

L Lifting Ledge

17


Designs and designations supplied for reference only. See your battery supplier for dimensional details.

FIG. 1 (Grp 2N)

FIG. 8 (Grp 4D, 6D, 8D, 4B)

FIG. 10 (Grp 45, 46, 16TF)

FIG. 11F (Grp 22F, 22HF, 22NF, 24F, 27F, 27HF, 29NF)

FIG 16L (Grp 4DLT)

FIG. 19 (Grp 54, 55, 56)

FIG. 23 (Grp 57) FIG. 24 (Grp 58R)

SAE TERMINAL DESIGNS OTHER TERMINAL DESIGNS

TYPE ZTYPE XTYPE V

TYPE U TYPE W TYPE Y

PLAN-85BUS

TYPE T

FIG. 25 (Grp 47, 48, 49)

FIG. 20 (Grp 61, 62, 63, 64) FIG. 21 (Grp 58, 65)

FIG. 17 (Grp 70, 71, 72, 73, 74, 75, 76, 77, 78) FIG. 18 (Grp. 28, 31)

FIG. 12 (Grp 60) FIG. 14 (Grp 53) FIG. 15 (Grp 41, 42, 43, 44)

FIG. 11 (Grp 21R, 22R, 22NL(Y), 24R, 29HR34R, 35, 85, 30HR, 32N, U1R(X) )

FIG. 11L (Grp 23, 33, 17TF)

FIG. 9 (Grp 3EE, 3ET)FIG. 10 (Grp 21, 24, 24H, 24T, 25, 26, 27, 27H, 34, 50,

51, 52, 86, 29H, 30H, 12T, 20H, U1(X), U2(X) )

FIG. 2 (Grp 1, 2, 3, 4, 5D, 7D) FIG. 2B (Grp 17HF) FIG. 5 (Grp 2E, 3EH, 4EH)

A

S

12-VOLT ASSEMBLIES – TERMINAL POSITIONS & CELL LAYOUTS

BCI Assembly Numbers, Cell Layouts, and Terminals

Battery Cable Terminals

CABLE PARTITEM SIZE NUMBER

Battery Cable Terminal (A Negative) 2/0 3S-6050

Battery Cable Terminal (A Negative) 3/0 9S-6333

Battery Cable Terminal (A Positive) 2/0 3S-6049

Battery Cable Terminal (A Positive) 3/0 3S-6051

Battery Cable Terminal (B Negative) 1/0 9S-5753

Battery Cable Terminal (B Negative) 2/0 9S-5755

Battery Cable Terminal (B Positive) 1/0 9S-5752

Battery Cable Terminal (B Positive) 2/0 9S-5754

Battery Cable Terminal (C 1/2” Hole) 1/0 1M-4986

Battery Cable Terminal (C 1/2” Hole) 2/0 1S-7251

Battery Cable Terminal (C 1/2” Hole) 3/0 5P-2600

Battery Cable Terminal (C 1/2” Hole) 4/0 3L-7634

Battery Cable Terminal (C 1/4” Hole) 1/0 030-1709



Battery Cable Terminal (C 3/8” Hole) 2/0 1S-7252






Battery Ground Straps

GROUND END BATTERY ENDLENGTH HOLE HOLE PART

ITEM (in) (mm) (in) (mm) (in) (mm) NUMBER

Battery Ground Strap 4.3 108 7/16 11 9/16 14 8M-4963

Battery Ground Strap 5.4 137 5/16 8 3/16 5 8L-8420

Battery Ground Strap 5.5 140 7/16 11 7/16 11 1S-2342

Battery Ground Strap 12.0 305 13/32 10 9/16 14 2L-6716

Battery Ground Strap 12.0 305 17/32 14 13/32 10 4M-7146

Battery Ground Strap 18.0 457 17/32 14 21/32 17 3R-2853

18


A BC

Battery Cable Repair Kit

● For use during cable fabrication and repair.

● For use with heavy 8 through 0000 gauge electrical cables.

● Kit includes box cable cutter, crimping tool, and assorted butt splices.

PARTITEM NUMBER

Cable Repair Kit 6V-3025

Booster Cables

● Ensure quick and efficient connections.

LENGTHPART

ITEM (ft) (m) NUMBER

Booster Cable 12.00 3.660 4C-4933

Booster Cable with “Safety Lite” 12.00 3.660 4C-4934

Booster Cable 15.00 4.570 4C-4935

Booster Cable 15.00 4.570 4C-4938

Booster Cable 20.00 6.000 4C-4936

Booster Cable 20.00 6.000 4C-4937

Emergency Start System

● Provides fast and easy starts to stalled direct electric start equipment.

● 10 ft. (2.45 m) plug assembly is used for starting stalled equipmentfrom an auxiliary battery pack.

● 15 ft. (3.81 m) plug assembly is used for starting stalled equipment byjumping from another piece of equipment.

PARTITEM NUMBER

Emergency Start System (10-foot Plug Assembly) 8S-2632

Emergency Start System (15-foot Plug Assembly) 9S-3664

19


Emergency Jump Start Receptacle Assemblies

● Mount on the machine to provide a direct electrical connection to thestarting motor.

● Available in several cable lengths to suit your particular application.

● For use with 8S-2632 or 9S-3664 Emergency Start Systems.

LENGTHPART

ITEM (ft) (m) NUMBER

Emergency Jump Start Receptacle Assembly 1.25 0.381 9S-9015

Emergency Jump Start Receptacle Assembly 1.42 0.457 2G-1830



Emergency Jump Start Receptacle Assembly 6.00 1.819 4N-6580

Emergency Jump Start Receptacle Assembly 7.00 2.134 1P-1250

Emergency Jump Start Receptacle Assembly 9.00 2.682 4N-6579


Emergency Jump Start Receptacle Assembly 12.00 3.658 9D-8647

Composite Halogen Lights

● Provide longer life and lower operating costs.

● Provide 30 to 35% more light output than conventional lights andmaintain full light output over their lifetime.

● Provide easy replacement for existing conventional lights or may beadded as additional lamp assemblies.

● Replacement bulbs fit all lamps of the same voltage.

● Standard on all new Cat production machines.

ELECTRICAL PART LENS BODY FACEITEM SIZE VOLTAGE CONNECTOR NUMBER ASSY. ASSY. SEAL BULB

Suspension Mount Flood Lamp 3” x 5” 12 2 Pin D.T. 105-8070 9X-4174 9X-3455 9X-4243 9W-0607

Suspension Mount Flood Lamp 3” x 5” 24 2 Pin D.T. 112-9378 9X-4174 9X-3455 9X-4243 9X-3463

Suspension Mount Flood Lamp 3” x 5” 24 Ring 117-3468 9X-4174 9X-3455 9X-4243 9X-3463

Vertical Mount Flood Lamp 3” x 5” 24 2 Pin D.T. 135-5549 9X-4174 9X-3455 9X-4243 9X-3463

Vertical Mount Flood Lamp 5” x 5” 12 Screw Terminal 9X-7779 9X-4174 9X-3455 9X-4243 9W-0607

Vertical Mount Flood Lamp 5” x 5” 24 Screw Terminal 9X-1439 9X-4174 9X-3455 9X-4243 9X-3463

Vertical Mount High-Beam Headlamp (Off-Road) 5” x 5” 12 Screw Terminal 9X-8180 9X-7797 9X-3455 9X-4243 9W-0607

Vertical Mount High-Beam Headlamp 5” x 5” 24 Screw Terminal 9X-7170 9X-7797 9X-3455 9X-4243 9X-3463

Vertical Mount Low-Beam Headlamp (Off-Road) 5” x 5” 12 Screw Terminal 9X-8179 9X-7798 9X-3455 9X-4243 9W-0607

Vertical Mount Low-Beam Headlamp 5” x 5” 24 Screw Terminal 9X-7169 9X-7798 9X-3455 9X-4243 9X-3463

20


Sealed Beam Electrical Lamps

ANSI PARTITEM VOLTAGE NUMBER WATTAGE NUMBER

Beam Lamp 12 — 50 6T-7157

Dual Head Lamp 24 4579 60 1M-5899

Flood Lamp 6 4219 30 1M-7361

Flood Lamp 12 4478 60 2M-4168

Flood Lamp 24 — 90 8T-9886

Flood Lamp 24 4578 60 1M-5898

Flood Lamp (Halogen) 24 H4578 60 9W-1281

Flood Lamp (Screw Terminal) 12 4410 35 2P-7469

Flood Lamp (Screw Terminal) 24 4752 60 6N-7987

Head Lamp 12 7780 60 2M-4169

Head Lamp 24 4880 60 1M-5928

Head Lamp (Halogen) 12 H4651 50 9W-0050

Head Lamp (Halogen) 24 H4880 60 9W-1280

Head Lamp (Screw Terminal) 24 4750 60 7N-7682

Hi/Lo Lamp 6 4031 45/35 1M-5897

Hi/Lo Lamp 12 4431 45/35 1H-7027

Hi/Lo Lamp (Halogen) 12 H4656 35/35 9W-0049

High Head Lamp 24 4814 90 5S-5149

High Head Lamp (Halogen) 24 H4815 90 8T-8753

Low Head Lamp 24 4813 90 5S-5150

Low Head Lamp (Halogen) 24 H4813 90 8T-8752

Spot Lamp 24 4505 50 7T-1371

Trapezoid Lamp 12 — 35 7T-2890

LED Lights

● Provides extended life and increased vibration resistance.

● Uses less amperage than incandescent lights.

● Retrofittable to any 24-volt application.

PARTITEM SHAPE COLOR NUMBER

Stop and Tail Light Rectangular Red 135-0426

Stop and Tail Light Round Red 143-2014

Front Turn and Park Rectangular Amber 135-0427

Front Turn and Park Round Amber 135-0428

21


Miniature Electrical Lamps

ANSI PARTITEM VOLTAGE NUMBER NUMBER

Miniature Electrical Lamp 6 63 9B-3117

Miniature Electrical Lamp 6 1154 8M-7119


Miniature Electrical Lamp 12 67 9W-2471

Miniature Electrical Lamp 12 93 1S-4168



Miniature Electrical Lamp 12 1157 7S-1800

Miniature Electrical Lamp 12 1816 8L-9801

Miniature Electrical Lamp 24 — 7N-9967

Miniature Electrical Lamp 24 265 7X-2058

Miniature Electrical Lamp 24 307 8J-4863

Miniature Electrical Lamp 24 356 5D-0019




Miniature Electrical Lamp 24 624 7N-1996

Miniature Electrical Lamp 24 1251 3H-2691

Miniature Electrical Lamp 24 1309 9K-9140

Miniature Electrical Lamp 24 1495 9W-2111

Miniature Electrical Lamp 24 1638 8T-9749

Miniature Electrical Lamp 24 1662 034-2535

Miniature Electrical Lamp 24 1683 7H-2976




Miniature Electrical Lamp 24 623R 9S-3335

22


Stop/Tail Lamps

BODYITEM VOLTAGE ASSY. BULB

Stop Lamp 6 8M-9319 —

Stop Lamp 12 8M-9319 —

Stop Lamp 12 7M-7147 5M-8034

Stop Lamp 24 7M-7147 7H-2976

Tail Lamp 6 8M-9319 8M-7119

Tail Lamp 12 8M-9319 7S-1800

Tail Lamp 12 7M-7147 7M-9957

Tail Lamp 24 7M-7147 2D-1959

Dash Lamps

● Allow operators to read gauges at night.

● For use with miniature electrical lamps.

WIRE LENGTHBODY

ITEM VOLTAGE (in) (mm) ASSY. BULB

Dash Lamp 6 6 - 24 152 - 610 6N-8355 9B-3117

Dash Lamp 12 6 - 24 152 - 610 6N-8355 7M-9957

Dash Lamp 24 6 - 24 152 - 610 6N-8355 3H-2691

23


3A 250V Time Delay Ferrule 9G-3782

4A 250V Time Delay Ferrule 9K-1896

5A 500V Time Delay Ferrule 5N-0095

30A 32V Time Delay Ferrule 6N-9353

10A 32V Plug Fuse 9W-1442



30A 32V Plug Fuse 8T-9636

12A 250V TRON Rectifier 7C-3882

15A 130V TRON Rectifier 3N-2050

15A 250V TRON Rectifier 3N-7807

25A 600V TRON Rectifier 7L-2760




400A 150V TRON Rectifier 039-6987

50A 30VDC Stud Mounted 3C-1064

60A 125V Stud Mounted 031-2436










60A 125V Low Voltage Limiter 090-7012



0.75A 250V Ferrule 7T-0037

1.25A 250V Ferrule 034-3128

1A 250V Ferrule 8K-4644

1A 600V Ferrule 3N-5612

2A 250V Ferrule 8D-8724

2A 250V Ferrule 039-8989

3A 32V Ferrule 8M-0454




5A 32V Ferrule 5A-3837

5A 250V Ferrule 2S-6024


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MAXIMUM FUSE PARTAMPERAGE VOLTAGE DESC. NUMBER GRAPHIC

Fuses


MAXIMUM FUSE PARTAMPERAGE VOLTAGE DESC. NUMBER GRAPHIC

25

5A 250V Ferrule 033-3672


6A 60V Ferrule 3T-5802



7.5A 250V Ferrule 3K-8781

7.5A 32V Ferrule 8M-0455


10A 250V Ferrule 9Y-6027

10A 250V Ferrule 3K-8782




25A 32V Ferrule 3T-4425


5A 250VAC General Purpose 5N-5532


12A 600V LIMITRON 9Y-8419


60A 300VAC SC Time-Lag 091-8556

10A 32V Mini 113-8490

15A 32V Mini 113-8491

20A 32V Mini 113-8492

25A 32V Mini 113-8493

Fuses

Fuse Holders and Puller

PARTITEM NUMBER

Dashmount Fuse Holder 4K-5122

In-Line Fuse Holder 051-4069

Fuse Block 5K-2849

Fuse Holder 7N-8292

Wire-to-Wire Fuse Holder 3K-8783

Wire-to-Wire Fuse Holder 8D-8719

Fuse Puller 116-7471

Pressure Switches

For use with engine oil pressure sensing or any application requiringsetting switches.

SWITCHING POINT CONTACTSAT PORT ELECTRICAL PART

ITEM (psi) (kPa) 0 kPa FITTING CONNECTOR NUMBER

Pressure Switch 5.5 ± 3 37.9 ± 21 Open 1/4 NPTF #8 Screws 3E-2026

Pressure Switch 10.0 ± 3 68.9 ± 21 Open 1/8 NPTF #8 Screws 107-0611

Pressure Switch 10.0 ± 3 68.9 ± 21 Closed 1/8 NPTF #8 Screws 107-0616

Pressure Switch 10.0 ± 3 68.9 ± 21 Open 1/4 NPTF #8 Screws 107-0612

Pressure Switch 10.0 ± 3 68.9 ± 21 Open 9/16 UNF Sure Seal 6T-4949

Pressure Switch 18.0 ± 3 124.0 ± 21 Open and Closed 9/16 UNF Sure Seal 6T-6652



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Bulk Electrical Cable and Wire

PACKAGE*LENGTH PART

ITEM GAUGE (ft) (m) NUMBER

Lighting Wire No. 6 50.00 15.000 5P-5675






Starter Cable Black 0 25.00 7.620 5P-0746

Starter Cable Black 00 25.00 7.620 5P-0747

Starter Cable Red 0 25.00 7.620 5P-0760




Ignition Wire 0.28” (7 mm) 25.00 7.620 5P-6036

Glow Plug Wire No. 12 25.00 7.620 5P-6020

Natural Gas Engine Ignition Wire No. 21 10.00 3.050 5P-1930

* Serviced in increments of their packaged length.

Electrical Terminals

SCREW WIRE PARTITEM SIZE SIZE NUMBER

Blade Terminal 16-14 5P-4571 (30)

Blade Terminal 16-14 4S-1988 (10)

Butt Splices 12-10 2S-1043 (15)

Butt Splices 16-14 8S-4626 (15)

Ring Terminal 1/4” 8 2L-8058 (10)

Ring Terminal 1/4” 12-10 2L-8067 (10)

Ring Terminal 1/4” 16-14 2L-8077 (15)

Ring Terminal 3/8” 12-10 2L-8069 (10)

Ring Terminal 3/8” 16-14 2L-8079 (15)

Ring Terminal 1/2” 12-10 2L-8071 (10)

Ring Terminal No. 10 16-14 2L-8076 (20)



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Electrical Terminal Kit

● Contains 12 different types and sizes of terminals.

● Contains a multi-purpose crimping tool that performs all the stepsrequired to install new tools.

● Eliminates the need for a soldering iron and insulating material.

PARTITEM NUMBER

Terminal Assortment 140-9944

Conduits

INSIDE PACKAGE*DIAMETER LENGTH PART

ITEM (in) (mm) (ft) (m) NUMBER

Flexible Steel Conduit 0.38 10 25.00 7.620 5P-3399



Non-Metallic Conduit (Loom / Auto) 0.25 6 100.00 30.480 5P-5984







Vinyl Covered, Flexible Steel Conduit 0.38 10 25.00 7.620 5P-0694





Wire Protector

OUTSIDE PACKAGE*DIAMETER LENGTH PART

ITEM (in) (mm) (ft) (m) NUMBER

Wire Protector 0.25 6 25.00 7.620 5P-6039


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Electrical Conduit Field Repair Fasteners

● Provide fast and easy electrical system repairs.

● Made of high-impact plastic and locked with a steel spring clip.

● Designed to separate for quick installation or removal.

PARTITEM NUMBER

Repair Fastener 9S-5324

Sure-Seal Electrical Connector Kit

● For use in replacing faulty conventional connectors or fabricatingnew wiring harnesses.

● Provides longer service life and superior corrosion resistance.

● Allows for fast, in-field installation.

● Each kit includes a box assembly (6V-3007), crimping and strippingtool (6V-3001), contact insertion tool (6V-3008), and an assortment ofSure-Seal connectors.

PARTITEM NUMBER

Sure-Seal Electrical Connector Kit 6V-3000

Deutsch (DT) Style Connector Service Kit

● Contains a wedge removal tool (9U-7247).

● For use with a 12-18 gauge crimping tool (1U-5804).

PARTITEM NUMBER

Deutsch (DT) Style Connector Service Kit 9U-7246

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Field Soldering Iron Group

● For use in soldering electrical connections in the field.

● Designed to be lightweight and easy to use.

● Designed with a temperature regulated tip that provides bettercontrol for outdoor usage.

● Designed with an in-line fuse to help prevent damage or overload.

● For use with a 12V vehicle cigarette lighter plug or with a 4C-9024Portable Battery Pack.

PARTITEM NUMBER

Field Soldering Iron Group 9U-7560

Solder 9U-7562

Crimping Tools

PARTITEM NUMBER

Standard Crimping Tool 9S-9150

Heavy-Duty Crimping Tool 8S-1075

12-18 Gauge Crimping Tool 1U-5804

Voltage Tester

● Checks for the presence of up to 36 volts within a circuit.

● Made of a high-impact plastic housing that resists damage fromgrease or chemicals.

PARTITEM NUMBER

Voltage Tester 5P-7277

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Circuit Tester

● Provides a fast check for continuity in non-energized circuits.

● Shines brightly when connected to zero ohms and progressively dimsup to about 10 ohms.

● Includes batteries and bulb.

PARTITEM NUMBER

Circuit Tester 8T-0500

24 to 12 Volt Converters

● Provide the necessary voltage conversion to run cab accessories —such as two-way radios and tape players.

AMP PARTITEM CAPACITY NUMBER

12 to 24 Volt Converter (Radio installation - 24 volt) 2/2 134-1346

12 to 24 Volt Converter (Non radio installation - 12 volt) 5 119-1733

24 to 12 Volt Converter 2 114-7143

24 to 12 Volt Converter 5 9G-6981

24 to 12 Volt Converter 15 3E-8646

Spark Plug Firing Indicator

● Provides a simple, effective way to check spark plug voltage.

● Shows voltage intensity, spark plug misfires, faulty coils, and faultywiring.

● Features a compact size and handy clip for pocket storage.

PARTITEM NUMBER

Firing Indicators 9U-6695

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Battery Analyzer

● Features a portable, durable, lightweight design for use on servicetrucks or parts counters.

● Tests batteries without disconnecting them from the machine orwithout charging or discharging.

● For use in testing 12 volt batteries.

PARTITEM NUMBER

Battery Analyzer 127-8078

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Batteries and Electrical Parts - Dozer Motors

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Transcript of Batteries and Electrical Parts - Dozer Motors