SECTION 414-01: Battery, Mounting and Cables
2005 E-Series Workshop Manual
REMOVAL AND INSTALLATION
Procedure revision date: 07/01/2004
Battery - Auxiliary Printable View (264 KB)
Removal
WARNING: Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal Have Ford E350 Cutaway Diesel. - ani_caut.gifbr />
WARNING: Keep body from under the auxiliary or secondary battery when disconnecting or reconnecting the auxiliary battery safety straps since the battery weighs 50 pounds and bodily injury can result. Failure to follow these instructions may result inHave Ford E350 Cutaway Diesel. - ani_caut.gifjury.
NOTE: The preferred method of service requires the use of a floor hoist to lift the vehicle overhead, and a transmission jack to support and lower the auxiliary battery case.
NOTE: The auxiliary battery can be charged while the auxiliary battery safety straps are connected to the vehicle. Follow the procedures up to and including disconnection of the auxiliary battery cables.
Disable the vehicle electrical supply. For additional information, refer to Dual Battery Disconnect in this section.
Remove the auxiliary battery case from the frame.
Remove the auxiliary battery cables.
Support the battery and case with a transmission jack. Disengage the safety straps and roll the auxiliary battery and case on the transmission jack away from the vehicle.
Disconnect - Vehicles with 6.0L engineSimplified Battery Configuration - 6.0L
Item Part Number Description 1 10655 Primary Battery 2 10655 Secondary Battery 3 - Frame Rail Ground 4 - Starter Motor Relay Junction
CAUTION: If equipped with the CD6 audio unit, precautions must be taken when the battery has been disconnected. When reconnecting the battery, make sure no interruption of power occurs for 30 seconds. If power is interrupted during the first 30 seconds, permanent damage to the CD6 audio unit will result.
CAUTION: Make sure to cover the ground cable terminal end with electrical tape or with a suitable insulating device.
Disconnect the secondary battery ground cable.
Connect - Vehicles with 6.0L engineReconnect the secondary battery ground cable.
dual generator system Visual Inspection Chart
Functionality
The PCM provides voltage on the generator I circuits 1183 (WH/YE)/904 (LG/RD) to initiate charging. This voltage turns on the regulator, allowing current to flow from the battery sense A circuit to the generator field coil and to ground through the regulator field control. With the key in the ON position (dual generator system), voltage is supplied by the powertrain control module (PCM)-controlled I circuit 1183 (WH/YE) to I circuit 904 (LG/RD) to the upper generator and through the I circuit 1185 (YE) from the PCM to the I circuit 1183 (WH/YE) at the lower generator. The PCM will not turn on the lower generator during glow plug cycling (the glow plugs continue to cycle after engine start, during the first minutes of engine warm-up). If the glow plug system is cycling, the PCM supplies voltage to the lower generator momentarily to check the I circuit (verifies there is a volt drop), then shuts off the I circuit voltage on the lower generator. Once the glow plug system stops cycling, the PCM supplies voltage on the lower generator I circuit 1185 (YE)/1183 (WH/YE), which activates the generator/regulator.
Once the generator begins generating current, a voltage signal is taken from the generator stator and fed back to the regulator internally. This voltage feedback signal (typically one-half of the battery voltage) is used by the PCM to turn off the charging system warning indicator.
With the system functioning normally, the generator output current is determined by the voltage of the A circuit 35 (OG/LB). The A circuit 35 (OG/LB) voltage is compared to a set voltage internal to the regulator, and the regulator controls the generator field current to maintain the correct generator output.
The set voltage varies with temperature and is typically higher in cold temperatures and lower in warm temperatures. This allows for more efficient battery recharge in the winter and reduces the chance of overcharging in the summer.
Battery Positive Output (B+) Circuit 1119 (RD) (Upper Generator), 2037 (RD) (Lower Generator)
The generator output is supplied through the battery positive output (B+) terminal on the rear of the generator to the battery and the electrical system.
I Circuit - Dual Generator
The I (ignition) circuit is used to turn on the voltage regulator(s). This circuit is powered up when the key is in the ON position. When the PCM detects the key is in the ON position, the PCM provides voltage to the upper generator I circuit 1183 (WH/YE)/904 (LG/RD) and to the lower generator I circuit 1185 (YE)/1183 (WH/YE). The voltage to the lower generator is only momentary unless the glow plug system is not cycling. Once the glow plugs stop cycling, the PCM provides constant voltage on the lower generator I circuit 1185 (YE)/1183 (WH/YE).
A Circuit
The A circuit or battery sense circuit is used to sense battery voltage. This voltage is used by the regulator to determine the generator output.
Inspection and Verification
WARNING: Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Also, shield your eyes when working near batteries to protect against possible splashing of the acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury.
WARNING: Batteries normally produce explosive gases which may cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When charging or working near a battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury.
WARNING: When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury, damage to the vehicle or to the battery. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury.
NOTICE: Do not make jumper connections except as directed. Incorrect connections may damage the voltage regulator test terminals, fuses, or fusible links.
NOTICE: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes.
NOTE: While carrying out any pinpoint test, disregard any DTCs set while following any specific pinpoint test. After the completion of any test, be sure to clear all codes in the PCM.
NOTE: All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.Verify the customer concern.
Visually inspect for obvious signs of mechanical or electrical damage.
Mechanical Electrical Battery case, posts, hold-down clamp, cables, and connections for damage
Generator drive (serpentine) belt for condition and tension to make sure there is no slip between the belt and the pulley. Refer to Section 303-05.
Battery condition
Generator pulley
Battery junction box (BJB) fuse 23 (10A)
Charging system warning indicator
Circuitry
Cables
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