INSTALLATION
(1) In st all the battery hold down brackets.
(2) In st all t he two n uts tha t secure the ba tter y
hold down br ackets to the battery tray. Tighten t o 70
in. lb s .
BAT T ERY CABLES
DESCRIPTION
The batt ery cables are lar ge gauge, str anded cop-
per wires sheathed within a h eavy plastic or syn-
thet ic rubber insulating jacket. The wire used in th e
batt ery cables combines excellent flexibility an d reli-
abilit y wit h high elect rical curr ent car rying capacity.
The ba tter y cables can not be repaired and, if da m-
aged or fau lty they m ust be replaced. Bot h th e bat-
tery positive and negat ive cables are ava ila ble for
service replacem ent only as a unit wit h the battery
positive cable wire h arness or the bat tery negat ive
cable wire har ness, which may include por tions of
the wiring circuits for the generator and other com-
pon ents on some models.
The battery cables featu re a st amped brass clamp-
ing t ype female battery t erminal crim ped onto one
end of the battery ca ble wire an d th en solder-dipped.
A squa re hea ded pinch-bolt and hex nut are installed
at th e open end of the female ba ttery term ina l clam p.
The battery posit ive cable also in cludes a r ed molded
rubber protect ive cover for the fema le batt ery ter mi-
nal clamp. La rge eyelet t ype term inals a re crim ped
onto the opposite en d of th e bat tery cable wire and
then solder-dipped. The ba tter y positive cable wires
have a red insulating jacket to provide visual identi-
ficat ion and featu re a larger female batt ery ter minal
clam p to allow con nection to the la rger batt ery posi-
tive term inal post. Th e ba tter y negat ive cable wir es
have a black insu lating jacket and a smaller female
batt ery term inal cla mp.
OPERATION
The ba tter y ca bles connect th e battery t erminal
posts to th e vehicle electrical syst em. These cables
also provide a return pat h for electr ical curr ent gen -
erat ed by th e charging system for restoring the volt -
age potent ial of the battery. The fem ale bat tery
term inal clamps on t he ends of th e ba ttery cable
wires provide a strong and reliable connection of the
batt ery cable t o the batt ery ter mina l posts. The ter-
minal pinch bolts allow the fem ale termina l clamps
to be tightened ar ound the male terminal posts on
the t op of th e battery. The eyelet termina ls secured
to the ends of t he bat tery cable wires opposite th e
female battery ter min al cla mps provide secur e and
reliable con nection of the ba ttery to the veh icle elec-
trical system.
DIAGNOSIS AND TESTING - BATTERY CABLES
A volta ge drop t est will det ermine if there is exces-
sive r esistance in the ba ttery cable ter minal conn ec-
tions or th e battery cables. If excessive resistan ce is
found in the batt ery cable connect ions, the con nec-
tion point sh ould be disassembled, clean ed of all cor-
rosion or foreign materia l, th en reassembled.
Following rea ssembly, check the voltage dr op for the
batt ery cable connect ion and th e ba ttery cable aga in
to confirm repair.
When perform ing the volt age drop test , it is impor-
tant to remem ber tha t t he voltage drop is givin g an
indication of the resistance bet ween the two points at
which the voltmet er probes ar e a ttached. EXAM-
PLE: When testing the resista nce of th e ba tter y pos-
itive ca ble, touch the voltmeter leads to the batter y
positive cable ter minal cla mp and to the ba ttery pos-
itive cable eyelet term inal at the sta rter solenoid
B(+) ter minal stud. If you pr obe t he bat tery positive
term inal post and t he battery positive cable eyelet
term inal at t he starter solen oid B(+) terminal st ud,
you are r eadin g th e combin ed volta ge drop in th e
batt ery positive cable terminal clamp-to-terminal
post connection and the bat tery positive ca ble.
VOL TAGE 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.
8F - 14 BAT T ER Y S Y S T EM VA
To Next Page