Battery - Handling Guidelines and Testing Procedures
NUMBER: 08-050-05GROUP: Electrical
DATE: September 12, 2005
SUBJECT:
Battery Handling Guidelines And Testing Procedures
MODELS:
2002 - 2006 (VA) Sprinter
DISCUSSION:
Vehicle Storage Guidelines
To avoid deeply discharged or sulfated batteries before delivery, most Chrysler Group vehicles have an Ignition-Off-Draw (IOD) fuse that is used to limit voltage draw during storage periods. Sprinter is NOT equipped with an IOD fuse, thus it is important to check the battery charge level at least monthly if the vehicle is not in operation. Failure to maintain adequate battery charge levels may result in a sulfated battery which will lead to battery failure.
Proper New Vehicle Inspection and Storage procedures as outlined in Section NV30-5 of the Global Warranty Administration Manual state that Dealers must "Check each vehicle's battery for an adequate state of charge at least once a month. It's the dealership's responsibility to charge discharged batteries." A battery that is only discharged is not eligible for warranty coverage. A battery may only be warranted for a defect in manufacturing or workmanship.
The battery must be recharged if the charge level drops below 75%, which is equivalent to an open circuit voltage of 12.4 volts. Disconnecting the battery helps avoid ignition off draw during extended storage (more than 30 days). Please see below for proper testing and charging procedures.
Charging A Battery
A completely discharged battery does not accept normal charging current at the beginning.
Such low current may not be detectable on the ammeters built into many battery chargers.
The amount of time required for a battery to accept measurable charging current may vary between 1 and 2 hours depending on the charging voltage.
Some battery chargers are equipped with polarity-sensing circuitry. If the battery state-of-charge is too low for the polarity-sensing circuitry to detect, the battery charger will not operate. This makes it appear that the battery will not accept charging current. See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity-sensing circuitry.
DIAGNOSIS:
The battery, starting, and charging Systems in the vehicle operate with one another and must be tested as a complete system. In order for the engine to start and the battery to maintain its charge properly, all of the components that are used in these systems must perform within specifications. It is important that the battery, starting, and charging system be thoroughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal battery discharge, overcharging or early battery failure must be diagnosed by using the following diagnostic procedures and corrected before a battery is replaced.
Any of the following conditions can result in abnormal battery discharging:
^ A faulty or incorrect battery. See Diagnostic Procedure A
^ A faulty or incorrect charging system component. See Diagnostic Procedure B.
^ A faulty circuit or component causing excessive ignition-off draw.
^ Electrical loads that exceed the output of the charging system. This can be due to equipment installed after manufacture, or repeated short trip use.
^ A faulty or incorrect starting system component
^ Corroded or loose battery posts and/or terminal clamps.
^ Slow driving speeds (heavy traffic conditions) or prolonged idling, with high-amperage draw systems in use.
SPECIAL TOOLS/EQUIPMENT REQUIRED:
DIAGNOSTIC PROCEDURE A / Testing the battery using Midtronics Micro420:
1. Before testing the battery make sure that it is fully charged. Charging a battery generates a surface charge, which influences the test results. This surface charge must be removed, by loading the battery. Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery voltage to stabilize.
2. Connect the tester directly to the battery terminals, the red clamp to positive (+) and the black clamp to negative (-). Then follow the selections as described below:
a. SELECT TEST - 1. IN THE VEHICLE TEST: Make certain all of the vehicle accessory loads are OFF including the ignition, do not use this test if multiple batteries are connected. 2. OUT OF THE VEHICLE TEST
b. TESTING AT (location the tester is connected) - 1. BATTERY POST - This is the preferred position and must be selected if connected accordingly. 2. JUMP START POST
c. SELECT INPUT (according to what is stated on the battery) - 1. Cold Cranking Amps (CCA) is the standard for specifying batteries in the United States. Batteries installed in Sprinter Cargo Vans and Cab-Chassis have such a specification. 2. European Norm (EN) is the specification for the original batteries in Sprinter Passenger Vans.
d. SET RATING - Select the appropriate rating that is stated on the battery.
3. The tester will then run its self programmed test of the battery and display the results.
4. If "REPLACE BATTERY" is the result of the test, this may mean a poor connection between the vehicle's cables and battery exists. After disconnecting the vehicle's battery cables from the battery, retest the battery using the "OUT OF VEHICLE" test before replacing.
5. If the tester displays "SYSTEM NOISE CHECK LOADS" even though all accessories including the ignition are shut off, disconnect the battery and retest it using the "OUT OF VEHICLE" test.
6. While viewing the battery test result, press the "CODE" button in order to obtain the "SERVICE CODE", which is required on every warranty claim submitted for battery replacement
NOTE:
Disconnecting the battery from the vehicle will reset the radio and the timer of the auxiliary heater. Make sure to reprogram both if necessary.
DIAGNOSTIC PROCEDURE B / Testing the alternator using a load tester:
1. Connect the tester directly to the battery terminals, the red clamp to positive (+) and the black clamp to negative (-). If testing mode selection is required, set the load tester on "charging", without following the manufacturer's instructions for a charging test. Then hook up the ammeter clamp around the cable coming from the alternator and going to fuse # 1 in the fuse box at the positive terminal of the battery (do NOT hook it up around the negative battery cable). A vehicle equipped with additional electrical devices may have a parallel power cable coming from the alternator. To ensure proper test results, this parallel cable must be disconnected. Make sure that the ammeter reads zero while the engine is not running. Then start the engine and increase its speed up to 3000 rpm.
2. Check the voltage reading of the load tester. If it is over 14.5 volts, the regulator is not working properly and needs to be replaced.
3. Use the load regulator to increase the alternator's amperage up to the specified value (printed in big letters on the rear plastic cover of the alternator). Check the voltage reading of the load tester. If it drops under 13 volts the alternator is not working properly and needs to be replaced.
POLICY:
Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.