Battery System - Service Information: Other RAM Pickup 2500

CLEANING

The following information details the recommended cleaning procedures for the battery and related components. In addition to the maintenance schedules, , it is recommended that these procedures be performed any time the battery or related components must be removed for vehicle service. Refer to Maintenance Schedules , Description .

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1. Clean the battery cable terminal clamps (2) of all corrosion. Remove any corrosion using a wire brush or a post and terminal cleaning tool (1), and a sodium bicarbonate (baking soda) and warm water cleaning solution.
2. Clean the battery tray and battery hold down hardware of all corrosion. Remove any corrosion using a wire brush and a sodium bicarbonate (baking soda) and warm water cleaning solution. Paint any exposed bare metal.
3. If the removed battery is to be reinstalled, clean the outside of the battery case (3) and the top cover with a sodium bicarbonate (baking soda) and warm water cleaning solution (2) using a stiff bristle parts cleaning brush (1) to remove any acid film. Rinse the battery with clean water. Ensure that the cleaning solution does not enter the battery cells through the vent holes. If the battery is being replaced, for the factory-installed battery specifications. Refer to «Specifications»(ref-457788-S27498667042012030200000) . Confirm that the replacement battery is the correct size and has the correct ratings for the vehicle.
4. Clean the battery thermal guard with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film.
5. Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner (1), and a sodium bicarbonate (baking soda) and warm water cleaning solution.

Midtronics GR8 BATTERY TESTER

The Midtronics GR8 battery tester is designed to help diagnose the cause of an inoperative battery. for instructions on the use of the Midtronics GR8 battery tester. Refer to BATTERY , Standard Procedure .

A battery that will not accept a charge is inoperative, and must be replaced. Further testing is not required. A fully-charged battery must be load tested to determine its cranking capacity. A battery that is fully-charged, but does not pass the load test, is inoperative and must be replaced.

Note. Completely discharged batteries may take several hours to accept a charge. Refer to Standard Procedures for the proper battery charging procedures.

BATTERY CHARGING

Battery charging is the means by which the battery can be restored to its full voltage potential. A battery is fully-charged when

1. Midtronics (special tool #GR8-1220KIT-CHRY, AGM Battery Tester/Charger Station) tester indicates battery is OK.
2. All of the battery cells are gassing freely during battery charging.
3. Open-circuit voltage of the battery is 12.65 volts or above.

After the battery has been charged to 12.65 volts or greater, perform a load test to determine the battery cranking capacity, for the proper battery load test procedures. Refer to BATTERY , Standard Procedure . If the battery will endure a load test, return the battery to service. If the battery will not endure a load test, it is inoperative and must be replaced.

Clean and inspect the battery hold down, tray, terminals, posts, and top before completing battery service. Refer to Cleaning . for the proper battery system cleaning and inspection procedures. Refer to Inspection .

CHARGING A COMPLETELY DISCHARGED BATTERY

The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced.

1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. If the reading is below ten volts, the battery charging current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on the ammeters built into many battery chargers.
2. Disconnect and isolate the battery negative cable. Connect the Midtronics (special tool #GR8-1220KIT-CHRY, AGM Battery Tester/Charger Station). NOTE: Some battery chargers are equipped with polarity-sensing circuitry. This circuitry protects the battery charger and the battery from being damaged if they are improperly connected. 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.
3. Battery chargers vary in the amount of voltage and current they provide. The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table. If the charging current is still not measurable at the end of the charging time, the battery is inoperative and must be replaced. If the charging current is measurable during the charging time, the battery may be good and the charging should be completed in the normal manner.

CHARGING TIME REQUIRED

The time required to charge a battery will vary, depending upon the following factors

1. Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time of a small capacity battery.
2. Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first. As the battery warms, it will accept a higher charging current rate (amperage).
3. Charger Capacity - A battery charger that supplies only five amperes will require a longer charging time. A battery charger that supplies twenty amperes or more will require a shorter charging time.
4. State-Of-Charge - A completely discharged battery requires more charging time than a partially discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the charging current (amperage) will be low. As the battery charges, the specific gravity of the electrolyte will gradually rise.

The Battery Charging Time Table gives an indication of the time required to charge a typical battery at room temperature based upon the battery state-of-charge and the charger capacity.

GR8 BATTERY TESTER / CHARGER

Always use the Midtronics GR8 Instruction Manual that was supplied with the tester as a reference. If the Instruction Manual is not available the following procedure can be used

Quick Reference Guide

Inspect the battery for damages and check the electrolyte level. Always use the necessary safety precautions when working with batteries to prevent severe injury or death. Follow all manufacturers instructions and BCI (Battery Council International) safety recommendations, which include the following precautions

Main Menu

The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons lead directly to the function they represent, while others are menu icons that lead to two or more options.

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Automatically tests, charges, and provides battery decision using the information you select in a series of screens. Start here to generate warranty codes.

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Tests the starting and charging systems.

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Maintains battery voltage at 13.5 volts to provide uninterrupted reprogramming of ECUs and retain vehicle system settings.

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Includes a utility to view and print a test counter, a data transfer utility, the software version and date, the Midtronics GR8 serial number for the control module, and current wireless channel.

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The Setup Menu lets you customize options in the Midtronics GR8 to suit your needs.

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Provides a list of topics and definitions. Also includes Midtronics Customer Service phone numbers.

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Automatically tests and charges battery, starting, and charging system. Generates a warranty code for Replace and Bad Cell decisions.

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Pre Delivery Inspection (PDI): For testing delivered vehicles and lot maintenance. Uses the same inputs as a diagnostic charge.

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Dual Battery Charge mode allows the charger to be used with dual battery systems.

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Makes high output current available to boost charge an in-vehicle battery and assist in starting the engine.

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Provides a timed charge that ranges from 5 to 120 minutes or a continuous charge that ends when you press the STOP key.

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In this mode the charger can provide a trickle charge for long term, low amp battery charging.

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Generates 15-digit warranty codes for physically defective batteries or customer good will.

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1. Control module: Backlit graphical display and keypad for data entry.
2. ON/OFF switch: ON/OFF switch Turns power on and off to the GR8.
3. STATUS light: Lights in conjunction with beeping alarm to indicate transitions and warnings.
4. Data card slot: For future upgrades via a data card. The slot contains a plastic filler card for protection.

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1. Battery Decisions
2. Select Rating
3. Measured capacity
4. Measured voltage
5. Good Range NOTE: The warranty code screen will only be displayed for REPLACE BATTERY and BAD CELL-REPLACE decisions.
6. Enter this number into wiTech
7. Replace range
8. Replaced AMP Hours
9. Charging Time

NEGATIVE

1. Position the battery negative cable (5) in the vehicle.
2. One at a time, install the battery cable retaining pushpins (3), fasteners and routing clips until the cable is secure in the vehicle.
3. Install the bolt (6) securing the negative cable (1) to the left frame rail.
4. Install the bolt (4) securing the negative cable (5) to the engine.
5. Install the bolt (4) securing the negative cable (3) to the left front fender.
6. Connect the battery negative cable terminal clamp (3).
7. Check the vehicle for normal operation.

POSITIVE

1. Position the battery positive cable (1) in the vehicle.
2. Install the nut (3) securing the cable (1) to the alternator (2).
3. Secure the terminal cap (4) to the alternator stud.
4. Install the cable (1) pushpin into the bracket to the left of the alternator.
5. Raise the vehicle on a hoist. Refer to «Hoisting , Standard Procedure»(ref-457775-S03796115192012030200000) .
6. Install the nut (5) securing the cable to the starter solenoid (6).
7. Connect the battery cable retaining pushpins (1) securing the cable to the left frame rail.
8. Lower the vehicle.
9. Install the battery cable retaining pushpin (8) securing the cable to the battery tray.
10. Install the wire harness connector (7) pushpin into the Totally Integrated Power Module (TIPM) (5) housing.
11. Connect the wire harness connector (6) at the TIPM.
12. Install the nut (9) securing the cable to the TIPM.
13. Connect the battery positive cable terminal clamp (1).
14. Connect the battery negative cable terminal clamp (3).
15. Check the vehicle for normal operation.

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1. Remove the battery (3) from the battery tray. Refer to «BATTERY , Removal»(ref-457788-S28723389202012030200000) .
2. Remove the Totally Integrated Power Module (TIPM) (5). Refer to «MODULE, Totally Integrated Power (TIPM) , Removal»(ref-457819-S27313914492012030200000) .
3. Disconnect the wire harness retainers from the battery tray assembly.
4. Disconnect the purge solenoid (6) from its mounting bracket.
5. Remove the anti-lock brake controller (if equipped) retaining bolts and support the brake controller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit.
6. Remove the left front wheelhouse splash shield. Refer to «SHIELD, Splash, Front Wheelhouse , Removal»(ref-457777-S20081177382012030200000) and «SHIELD, Splash, Rear Wheelhouse , Removal»(ref-457777-S39858187832012030200000) .
7. Mark the location of the cruise servo (3) (if equipped) and remove the retaining screws. Position the servo out of the way.
8. Disconnect the left front fender ground wire.
9. Remove the remaining battery tray retaining bolts (2).
10. Remove the battery tray from the vehicle.