FILM 1677281 - Caterpillar

condition of charge in the battery at each regular inspection will show if the charging system operates correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed. A large amount of water would be more than one ounce of water per cell per week or per every 100 service hours.When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring and components that are a permanent part of the system. Off-engine testing or bench testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, perform a test to prove that the units have been repaired to the original condition of operation.See Special Instruction, REHS0354, "Charging System Troubleshooting" for the correct procedures to use to test the charging system. This publication also contains the specifications to use when you test the charging system.To check for correct output of the alternator, see the Specifications module.Before the start of on-engine testing, the charging system and the battery must be checked according to the following steps.
The battery must be at least 75 percent (1.225 Sp Gr) of the full charge. The battery must be held tightly in place. The battery holder must not put too much stress on the battery.
Cables between the battery, the starter, and the engine ground must be the correct size. Wires and cables must be free of corrosion. Wires and cables must have cable support clamps to prevent stress on battery connections (terminals).
Leads, junctions, switches, and panel instruments that have direct relation to the charging circuit must give correct circuit control.
Inspect the drive components for the charging unit to be sure that the components are free of grease and oil. Be sure that the drive components have the ability to operate the charging unit.