Dodge Sprinter 2006 Manual page 874

8F - 14 BA TTERY SYSTEM
INSTALLA TION
(1) In st a ll t h e ba t t er y h old down br a cket s.
(2) In st a ll t h e t wo n u t s t h a t secu r e t h e ba t t er y
h old down br a cket s t o t h e ba t t er y t r a y. Tigh t en t o 70
in . lbs.
BAT T ERY CABLES
DESCRIPTION
Th e ba t t er y ca bles a r e la r ge ga u ge, st r a n ded cop-
per wir es sh ea t h ed wit h in a h ea vy pla st ic or syn -
t h et ic r u bber in su la t in g ja cket . Th e wir e u sed in t h e
ba t t er y ca bles com bin es excellen t flexibilit y a n d r eli-
a bilit y wit h h igh elect r ica l cu r r en t ca r r yin g ca pa cit y.
Th e ba t t er y ca bles ca n n ot be r epa ir ed a n d, if da m -
a ged or fa u lt y t h ey m u st be r epla ced. Bot h t h e ba t -
t er y posit ive a n d n ega t ive ca bles a r e a va ila ble for
ser vice r epla cem en t on ly a s a u n it wit h t h e ba t t er y
posit ive ca ble wir e h a r n ess or t h e ba t t er y n ega t ive
ca ble wir e h a r n ess, wh ich m a y in clu de por t ion s of
t h e wir in g cir cu it s for t h e gen er a t or a n d ot h er com -
pon en t s on som e m odels.
Th e ba t t er y ca bles fea t u r e a st a m ped br a ss cla m p-
in g t ype fem a le ba t t er y t er m in a l cr im ped on t o on e
en d of t h e ba t t er y ca ble wir e a n d t h en solder-dipped.
A squ a r e h ea ded pin ch -bolt a n d h ex n u t a r e in st a lled
a t t h e open en d of t h e fem a le ba t t er y t er m in a l cla m p.
Th e ba t t er y posit ive ca ble a lso in clu des a r ed m olded
r u bber pr ot ect ive cover for t h e fem a le ba t t er y t er m i-
n a l cla m p. La r ge eyelet t ype t er m in a ls a r e cr im ped
on t o t h e opposit e en d of t h e ba t t er y ca ble wir e a n d
t h en solder-dipped. Th e ba t t er y posit ive ca ble wir es
h a ve a r ed in su la t in g ja cket t o pr ovide visu a l iden t i-
fica t ion a n d fea t u r e a la r ger fem a le ba t t er y t er m in a l
cla m p t o a llow con n ect ion t o t h e la r ger ba t t er y posi-
t ive t er m in a l post . Th e ba t t er y n ega t ive ca ble wir es
h a ve a bla ck in su la t in g ja cket a n d a sm a ller fem a le
ba t t er y t er m in a l cla m p.
OPERA TION
Th e ba t t er y ca bles con n ect t h e ba t t er y t er m in a l
post s t o t h e veh icle elect r ica l syst em . Th ese ca bles
a lso pr ovide a r et u r n pa t h for elect r ica l cu r r en t gen -
er a t ed by t h e ch a r gin g syst em for r est or in g t h e volt -
a ge pot en t ia l of t h e ba t t er y. Th e fem a le ba t t er y
t er m in a l cla m ps on t h e en ds of t h e ba t t er y ca ble
wir es pr ovide a st r on g a n d r elia ble con n ect ion of t h e
ba t t er y ca ble t o t h e ba t t er y t er m in a l post s. Th e t er-
m in a l pin ch bolt s a llow t h e fem a le t er m in a l cla m ps
t o be t igh t en ed a r ou n d t h e m a le t er m in a l post s on
t h e t op of t h e ba t t er y. Th e eyelet t er m in a ls secu r ed
t o t h e en ds of t h e ba t t er y ca ble wir es opposit e t h e
fem a le ba t t er y t er m in a l cla m ps pr ovide secu r e a n d
r elia ble con n ect ion of t h e ba t t er y t o t h e veh icle elec-
t r ica l syst em .
DIAGNOSIS AND TESTING - BA TTERY CABLES
A volt a ge dr op t est will det er m in e if t h er e is exces-
sive r esist a n ce in t h e ba t t er y ca ble t er m in a l con n ec-
t ion s or t h e ba t t er y ca bles. If excessive r esist a n ce is
fou n d in t h e ba t t er y ca ble con n ect ion s, t h e con n ec-
t ion poin t sh ou ld be disa ssem bled, clea n ed of a ll cor-
r osion or for eign
F ollowin g r ea ssem bly, ch eck t h e volt a ge dr op for t h e
ba t t er y ca ble con n ect ion a n d t h e ba t t er y ca ble a ga in
t o con fir m r epa ir.
Wh en per for m in g t h e volt a ge dr op t est , it is im por-
t a n t t o r em em ber t h a t t h e volt a ge dr op is givin g a n
in dica t ion of t h e r esist a n ce bet ween t h e t wo poin t s a t
wh ich t h e volt m et er pr obes a r e a t t a ch ed. EXAM-
P LE: Wh en t est in g t h e r esist a n ce of t h e ba t t er y pos-
it ive ca ble, t ou ch t h e volt m et er lea ds t o t h e ba t t er y
posit ive ca ble t er m in a l cla m p a n d t o t h e ba t t er y pos-
it ive ca ble eyelet t er m in a l a t t h e st a r t er solen oid
B(+) t er m in a l st u d. If you pr obe t h e ba t t er y posit ive
t er m in a l post a n d t h e ba t t er y posit ive ca ble eyelet
t er m in a l a t t h e st a r t er solen oid B(+) t er m in a l st u d,
you a r e r ea din g t h e com bin ed volt a ge dr op in t h e
ba t t er y posit ive ca ble t er m in a l cla m p-t o-t er m in a l
post con n ect ion a n d t h e ba t t er y posit ive ca ble.
VOLTAGE DROP TEST
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, OR LOW
ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-
BOOST, OR CHARGE. THE BATTERY MAY ARC
INTERNALLY AND EXPLODE. PERSONAL INJURY
AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
m a t er ia l, t h en r ea ssem bled.
VA