CHRYSLER LLC Document Number: PS-7454

Process Standard Date Published: 2008-09-17

Category Code: M-6 Change Level: M
EASL Requirement: Yes
RESTRICTED: No

BATTERY – TESTING, HANDLING, AND RECHARGE PROCEDURE (FOR FINAL LINE BATTERY
INSTALLATION APPLICATIONS FOR ALL CHRYSLER ASSEMBLY PLANTS)

1.0 GENERAL

1.1 Purpose

This standard describes the requirements for proper battery handling and recharging.

1.2 Coverage of this Standard ***

To ensure that batteries (perishable component) will not be drained during the assembly process below a
certain voltage level measured at the powertrain control module (PCM). Level to be established and
published by Vehicle Electrical Engineering (VEE) on an annual basis (Reference Table 3).

2.0 PROCESS

2.1 Receiving ***

Batteries must be received at the Chrysler Assembly plant with an open circuit voltage (OCV) of 12.65 volts
minimum, this is for flooded and AGM batteries.

2.1.1 Shipping Containers ***

All batteries must be shipped to Chrysler in containers approved by Chrysler Packaging Engineering

Each container must have two pallet cards, on any two adjacent sides, with a "Use Before" date that is 15
days after the shipping date from the battery manufacturer. Date cards must stay with the pallets and
should not be attached to the top cover or the banding straps.

Returnable dunnage must be cleaned prior to re-shipment to Chrysler facility.

The number of battery layers per pallet must adhere to the following:

TABLE 1: SHIPPING CRITERIA

BATTERY GROUP SIZE MAXIMUM NUMBER OF LAYERS PER PALLET
26R 4
27 2
31 2
34 3
65 3
75 4
86 4
H7 3
H8 3

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2.1.2 Case Surfaces

Battery case surface must be free of contaminates (grease, dirt, excessive dust, oil, etc.).

2.1.3 Posts ***

When received by Chrysler the posts must be clean and free of oxides, sulfates, or other contaminants.
Batteries with white lead carbonate are not to be used and must be either cleaned or rejected by the
operator. The posts may have an approved anti-corrosion agents present if approved by Engineering.
A visual aid showing unacceptable white carbonate is to be displayed at the battery installation station in
all plants.

2.2 Storage

2.2.1 Stock Rotation

Batteries must be rotated First-In First-Out (FIFO).

Batteries shall not be ordered prior to a scheduled shutdown period.

Battery stock shall be kept at a minimum level during the shutdown.

2.2.2 Protection

A. Batteries are not to be stored exposed to outside elements (heat, cold or moisture).

B. Batteries must be stored either inside Chrysler Plants or in ambient room temperature conditions.

C. Do not double stack pallets. The pallet labels shall specify "do not double stack" on any two adjacent
sides of the pallet.

2.3 Production Line ***

Locate the battery installation as near to the end of the assembly line as possible to minimize in-process
drains.

A. Each battery shall be used before the “Use Before” date on the pallet card. Pallet cards must be kept
with the pallet until all the batteries on that pallet are used. Batteries between one and fifteen days past
the “Use Before” date are to be recharged or can be used if the battery has an OCV above the limits in
section 2.3.B below. Batteries greater than fifteen days but less than 30 days must be recharged.
(Reference Section 2.9 - Recharging of this standard.) All batteries greater then 30 days old must be
scrapped.

B. Any battery found below 12.65 volts on the pallet prior to vehicle installation, must have the pallet card
information (i.e. pallet number) included in on the NC ticket for the ticket to be valid.

C. Operators should install batteries with an ergo arm. If possible the arms should be equipped so that
the open circuit voltage can be measured and recorded into the PFS system.

2.3.1 Ignition Off Draw (IOD) Fuse / Connector (if applicable)

A. Refer to operation description sheets (ODS) or Standard Work Instructions (SWI) for proper handling of
IOD fuse or connector throughout the assembly process.

B. The IOD Fuse must be pulled or disconnected before releasing the vehicle from the plant.

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C. The Ignition switch will be in the “Off” position when installing or removing the IOD fuse. Inserting or
removing the IOD fuse, or any fuse, with the key in the run position has the potential to cause inadvertent
faults in the various electronic modules.

2.4 Vehicle Shipping/Certification

2.4.1 Vehicle Prep for Battery Test ***

A. All vehicles will have the battery voltage measured through the diagnostic connector (16-way OBD II
connector) inside of the vehicle. Acceptable battery values for each vehicle line are listed in Table 3 of this
specification.

B. All diesel vehicles will have the ignition key in the “on” mode for 25-30 seconds before checking for battery
voltage. No external load, i.e., turning on headlights, is required to remove the surface charge on diesel
vehicles..

C. All gasoline vehicles will have the ignition key in the “on” mode for 90-120 seconds before checking for
battery voltage. Vehicles which have the ignition on for less will be required to remove the surface charge
from the battery. To remove the surface charge a current draw of 25-30 amps will be placed on the battery for
8 seconds (test for complete bulb check) or a current draw of 10-15 amps will be placed on the battery for 15
seconds (low or high beam headlights). Battery voltage should not be recorded until at least 5-10 seconds
after the surface charge is removed.

D. An “RPM” check must be performed on all vehicles to verify that the vehicle is not running before
recording the battery voltage into PFS. Otherwise a maximum of 13.35 volts will be used for the upper
test limit of the battery test.

E. Vehicle accessories and lights are to be turned off when measuring for battery voltage. External
current draws such as automatic temperature fan controls can make the vehicle fail the battery test.

F. Any vehicle which fails the battery test must have its battery recharged or replaced. Recharging the
battery at the assembly plant must be done with a GR-1 charger from Midtronics. See section 2.9.4 of this
specification for details. If the battery fails the end of line test after being recharged the battery must be
replaced.

G. All vehicles which fail the battery test must be retested through the diagnostic connector and pass the
voltage value listed in Table 3.

H. Vehicles which enter into repair after the battery voltage test has been conducted, must be retested to
the ship line software verifing a good battery is being shipped.

2.5 Electrical Drains ***

Manufacturing shall determine the proper procedures to ensure there are no electrical drains on the
battery during any manufacturing process. (e.g., under hood lights, interior lights, radio, ignition in the
“On” or “ACC” position, etc.). All vehicles which are held “in repair status” (waiting for parts) and cannot
be repaired immediately must have their IOD fuses pulled, before being stored outside.

2.6 Vehicle Converter Requirements (Conversion Vans, etc.)

Batteries in vehicles ready to be released must meet requirements as stated above. Additionally, all
converted vehicles must be subjected to IOD Test.

2.7 Repairs

Manufacturing shall determine the proper procedures to ensure there are minimum electrical drains on the
battery during the repair process. To avoid electrical drains an external power source should be used in
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all electrical repair areas. Also any other repair area in which the ignition switch is left in the “ON” or
“ACC” mode should be using an external power source. The recommended power source is the PSC 550
Power Supply Charger. If an alternative device is used, it must meet the following specifications:

- INPUT VOLTS (Vac): 108-132

- FREQUENCY (Hz): 40-70
- MAX AMP DRAW (AC): 15
- MAX WATT DRAW (VA): 1053 (1620) )
- OUTPUT AMPS (VA): 55
- OUTPUT VOLTS (DC): 13.4 @ FULL LOAD
- Output Voltage Tolerance (no load) + or - .7%
- Output Voltage (full load) approx. 13.4 v (DC)
- Ripple and noise <50 mV rms
- Typical Efficiency >100%
- Line Regulation 100 mV rms
- Load regulation <1%
- Fan control
- Thermal protection
- Working temperature range 0-40C
- Storage temperature -20 to 80C
- Charger Engine Design : Switch Mode

Vehicle accessories and lights are to remain off and not to be used to signal the vehicle for repair or repair
processes.

Vehicle electrical repairs must conclude with a Battery Voltage Test. (Reference Section 2.4.1 – Vehicle
Prep for Battery Test of this Standard.)

Vehicles must meet all shipping requirements as stated in Section 2.4 – Vehicle Shipping/Certification of
this Standard.

2.7.1 Breaks, Lunches, Shift Changes, and Down Times ***

There shall be no electrical drains on the batteries during lunch or shift changes. Electrical drains would
include Huntsville testers, under hood lights, interior lights, radios, or the ignition being left in the “ON
mode or ACC mode.”

2.8 Yard Holds ***

Vehicle accessories and lights are to remain off and not to be used to signal the vehicle for yard hold or
any yard hold processes.

There shall be no electrical drains (e.g. under hood lights, interior lights, radio, ignition in the “On” or
“ACC” position, etc.) on the battery during the yard hold.

Batteries from vehicles that were part of a yard hold must meet all shipping requirements as stated in
Section 2.4 - Vehicle Shipping/Certification of this Standard.

2.9 Recharging

2.9.1 Criteria for Recharging ***

Prior to installation any battery below 12.65 volts must be recharged. (Reference Section 2.1 – Receiving
of this Standard.)

Batteries exceeding the “Use Before” date located on the pallet must be recharged.

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Batteries failing Vehicle Shipping/Certification must be recharged. (Reference Section 2.4 – Vehicle
Shipping/Certification of this Standard.)

Batteries which have previously been recharged and have a white daub of paint by the negative post will
not be recharged. These batteries will be scrapped. Scrap these batteries in accordance of the Stationary
Energy Environmental Guideline WCFM500.

Any battery which is 30 days past the use before date must be scapped.

2.9.2 Shipping to Recharger

Batteries must be sorted as to "need recharge", damaged, or defective. Damaged or defective batteries
must be labeled with a daub of red paint on the negative post and retained for supplier inspection.

Batteries are to be well packed and banded, records must be maintained including lot size, dates shipped
and returned.

Batteries must be shipped to Recharger within 10 days following removal from vehicle/line.

2.9.3 Charging Methods

WARNING:
- Do not charge a battery if test indicator is clear (when present).
- Do not attempt to open the battery venting system.
- Do not recharge damaged batteries.
- Do not connect or disconnect a battery while the power source is "on".
- Do not allow battery temperature to exceed 100 degrees F (38 degrees C) during charging.
- Any battery that spews electrolyte must be removed from the charger and scrapped.
- Any battery that has been frozen must be scrapped.

2.9.3.1 Sorting

Batteries shall be checked and sorted prior to recharge as follows:

A. CCA – All batteries in circuit must be of the same rating.

B. OCV – All batteries in circuit must be grouped by initial OCV.

OCV is greater than or equal to 12.20 volts or OCV is less than 12.20 volts.

2.9.3.2 Parallel Charging - Preferred Method

- Charging current must be limited to 10 amperes maximum per battery.

- The power source shall be limited to a maximum of 16.15 +/- .15 volts.
- If initial OCV is less than or equals to 12.20 volts then charge battery for 24 hours.
- If initial OCV is greater than 12.20 volts charge battery for 16 hours.

2.9.3.3 Series Charging

- Charging current must be limited to 10 amperes.

- Charging current must be reduced in steps to prevent battery post voltage from exceeding 16.2 volts.
- Voltages must be monitored hourly.

2.9.3.4 Labeling ***

Batteries that have been recharged must be marked with a daub of white paint within a 2-inch radius of the

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negative post, NOT on the top or on the side of the negative post. Paint daub must not be applied on
label. The recharge date must be included on all batteries which have been recharged.

2.9.3.5 Shipping Back to Assembly Plant

- Batteries are to be clean and dry, and free of all oxide build-ups.
- Batteries are to be returned to the submitting plant palletized by CCA rating.
- Batteries must be well packed and banded.
- Each container must have two pallet cards, on any two adjacent sides, with "Use Before" date that is 15
days after Recharger shipment.
- Batteries must be processed and returned from Recharger to submitting plant within 10 days.

2.9.3.6 Assembly Plant Receiving Inspection ***

All batteries returned from recharge facility must be 100% inspected per procedures 2.1 & 2.1.3 specified
in this document prior to shipping to assembly plant.

Recharged batteries should be included in FIFO.

2.9.4 Using GR1-921 FAC Midtronics Charger (Recommended)

Turn GR1 on and place cables to correct battery posts.

Make sure that Diagnostic/Charger is selected and press enter.

Select Flooded or AGM for the battery you are to charge and press enter.

Set the proper CCA value listed in Table 3 by pressing the up or down arrows and press enter.

Allow machine to analyze battery.

Machine will automatically go into a charging mode if the battery is determined to be good and just needs
a recharged. If the battery is failed, replace the battery and NC the failed battery.

Once the battery is done charging, it will display “Top Off Mode”. Press the stop button and remove
cables from the battery.

If another charger is used, it must meet the following specifications:

Automatic Charging Voltage: 12V.

Manual Charging Voltage: 12V

Charging Amps (max.) for Automatic and Manual modes: Fast Charge - 60 Amps, Medium Charge - 30 -
Amps, Slow Charge - 10 Amps.

Peak Amps: 80 Amps.

Boost/Jump Start charge mode: 250 Amps.

SLI Battery Types: Flooded and AGM

Charge cycles: Diagnostic Fast Charge (with Top-Off mode - when applicable), Manual-timed (max. 120
minutes), Manual-continuous.

Conductance Test: 0-1500 CCA

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Load Test: 150-170 Amp load for additional test(s) and surface charge removal.

2.9.5 Vehicle Storage***

Vehicles being held shall not have any electrical drains on the battery. These vehicles must also have
there IOD fuse pulled.

Vehicles being held after passing the Validation Line for battery voltage certification must be retested with
the ship line software before reshipping.

Vehicles in storage outside of the manufacturing facility if held for more than 40 days must have an OCV
test performed. A hand held Midtronics tester, Micro820XL or equivalent will be used. Batteries below
12.55 voltages must be replaced before the vehicle can be shipped.

Vehicle held for PRI holds which require any drain on the battery, i.e., module reflashing, etc, must have
their battery voltage measured before shipping. If the vehicles are less then 40 days old, they must have
an OCV of 12.65 volts or higher.

3.0 QUALITY

Refer to CS-9801 for general quality requirements.

4.0 PLANT PROCESS ASSESMENT ***

The plant quality control department will perform the plant assessment found in attachment 1. This
assessment must be conducted at least every six months. The assessment must be kept on file for the
model year. Process changes and work assignments will influence this assessment and could have an
impact on battery life. Engineering will perform spot checks to verify that changes in the plant process
does not reduce the battery integrity.

5.0 DEFINITIONS/ABBREVIATIONS/ACRONYMS

Ignition Off Draw (IOD): The quiescent current draw including vehicle system memories that continue
even though the ignition is shut off.

Open Circuit Voltage (OCV): The voltage potential across the battery posts with the battery disconnected
from any load; battery must not have received any amount of charging or discharging for twenty (24) hours
prior to taking a reading.

State Of Charge (SOC): The battery charge condition as a percentage of the original, fully charged
condition.

Cold Cranking Amperage (CCA): The number of amperes a battery can deliver for 30 seconds at 0
degree F (-17.8 degrees C) and maintain a minimum voltage of 7.2 volts.

Series Charging Circuit: A circuit that has only one path for the current to flow. Batteries arranged in
series are connected with negative of the first to positive of the second, etc.

Parallel Charging Circuit: A circuit that provides more than one path for current flow. A parallel
arrangement of batteries would have all positive posts connected to a conductor and all negative posts
connected to another conductor.

Surface Charge: A temporary open circuit voltage, which is higher than stabilized battery open circuit
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voltage, resulting in an optimistically high OCV.

6.0 GENERAL INFORMATION

Three asterisks “***” after the section/paragraph header denotes single or multiple technical changes to
the section/paragraph.

Certain important information relative to this standard has been included in separate standards. To assure
the processes submitted meet all of Chrysler requirements, it is mandatory that the requirements in the
following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability

Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by

<S> and <E> which correspond to Safety and Emission Shields respectively. The Chrysler-mandated
requirements are designated by <D> and correspond to the Diamond symbol respectively.

For specific information on this document, please refer to the contact person shown in the "Publication
Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@chrysler.com.

7.0 REFERENCES

CS-9003
CS-9800
CS-9801

8.0 ENGINEERING APPROVED SOURCE LIST

TABLE 2: ENGINEERING APPROVED SOURCE LIST

Materials covered by this standard shall only be purchased from those source(s) listed in this table.
Supplier Supplier Code Additional Information
Exide Technologies, NA 11478
Exide Technologies, Europe 41931
Johnson Controls 44949
Banner GmbH 95723
Global Energy Systems, S.A. de C. V. 37925

9.0 PUBLICATION INFORMATION

Contact/Phone Number: Robert Horn, (313) 493-3672

Alternate Contact/Phone Number: Chris Saari, (313) 653-5402
Department Name & Department Number./Tech Club/Organization: Battery Center of Competency / 6940
Date Standard Originally Issued: 1982-08-06
Date Published: 2008-09-17
Change Notice:

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Description of Change:
- Table #3 Revised
- Sections Revised/Updated were: 2.2.2.A, 2.3.A, 2.4.1.D, 2.4.1.E and 8.0

Criteria for Battery Recharge (Reference PS-7454

Sections 2.9 through 2.9.4)

Has the Battery's "Use Yes Battery must be

Before" Date expired? scrapped.

Is there a white paint Yes

daub next to the
Negative post?
No

No
No

Will the battery be

Is the Battery's OCV Yes shipped to the
Label Battery as
less that 12.75V prior to Recharger within 10
"Need Recharge"
vehicle installation? days of line or vehicle
removal?

No Yes

Ship Battery to the

Recharger.

Is the Battery Yes Label Battery as

damaged? "Damaged"

No

Yes Mark Negative

Is the Battery Label Batteryas
post with Red
defective? "Defective"
Paint.

No

Contact Supplier
and retain Battery
for Supplier
inspection.
Install Battery.

Yes

Does the battery Charge Battery

No Does GR1-921 FAC Yes Does GR!-921 No
pass Vehicle using GR1-921
Midtronics say it is a say "Good
Shipping/ FAC Midtronic's
good Battery? Battery"?
Certification? Charger.

Yes No

Ship Vehicle

FIGURE 1: CRITERIA FOR BATTERY RECHARGE

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 TABLE 3: BATTERY VOLTAGE CRITERIA ***
Battery Criteria for Vehicle Shipping
Reference Section 1.2

Vehicle Engine PCM/GPEC LOCATION

Assy Plant Line Battery CCA type Battery voltage voltage Comments
WTAP DS 730 GAS 12.55 12.33 CERT Line
WTAP ND 600 & 750 GAS 12.55 12.33 CERT Line
SLNAP DS 730 GAS 12.55 12.33 CERT 06
SLNAP DH 600 & 750 Diesel 12.55 12.38 CERT 06
SALTILLO DR/DH 600 & 750 GAS 12.55 12.40 Yard Area
SALTILLO DH 600 & 750 Diesel 12.55 12.40 Yard Area
NEWARK HB 600 & 750 GAS 12.55 12.20 CERT Line
NEWARK HB 600 & 750 GAS 12.55 12.10 power lift gate
NEWARK HB-HEV Hybrid 12.55 12.20 CERT Line
TNAP KK 600 GAS 12.55 12.28 SHIP Line
TNAP KK 800 Diesel 12.55 12.10 SHIP Line
TNAP KA 600 GAS 12.55 12.28 SHIP Line
TNAP KA 800 Diesel 12.55 12.10 SHIP Line
TSAP JK 600 GAS 12.55 12.28 SHIP Line
TSAP JK 825 Diesel 12.50 12.10 SHIP Line
JNAP WK 625 GAS 12.55 12.24 SHIP Line
JNAP WK 800 Diesel 12.55 12.30 SHIP Line
JNAP XK 625 GAS 12.55 12.20 SHIP Line
BRAMPTON LX/LC 625 & 800 GAS 12.55 12.30 CERT Line
SHAP JS 525 GAS 12.55 12.28 CERT K
SHAP JS 700 Diesel 12.50 12.20 CERT K
BELVIDERE PM/MK 525 GAS 12.55 12.15 Headlight aim
BELVIDERE PM/MK 700 Diesel 12.50 12.00 Headlight aim
WINDSOR RT 600 GAS 12.55 12.25 Battery 07
STSAP RT 600 GAS 12.55 12.25 ZONE 04
STSAP RT 825 Diesel 12.50 12.10 ZONE 04
TOLUCA JC 525 GAS 12.55 12.28 JD Power Line
TOLUCA JC 700 Diesel 12.50 12.20 JD Power Line
TOLUCA PT 510 GAS 12.55 12.33 JD Power Line
TOLUCA PT 700 Diesel 12.50 12.20 JD Power Line
GRAZ RS 700 Diesel 12.50 12.20 SHIP Line
GRAZ WK/XK 730 GAS 12.55 12.34 SHIP Line
GRAZ WK/XK 800 Diesel 12.55 12.40 SHIP Line
GRAZ LX 730 GAS 12.55 12.40 SHIP Line
GRAZ LX 800 Diesel 12.55 12.40 SHIP Line

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 ATTACHMENT 1***
Plant Process Assessment
Plant: Date: Assessors:
Needs
Good
Area Process question improvement Comments
Shipping/Receiving
1 Is there designated storage area for batteries ? (Not in trailers, or direct sunlight.)
2 Is Material Handling verifying stock rotation ( First in first out ) FIFO?
3 Is there a proper staging area for batteries, and does it follow FIFO?
4 Is Material Handling verifying "Use by date" card?
5 Are batteries that are past the "Use by date" being quarantined?
6 Is there a designated quarantine area, and is it marked properly with RED tags?
7 Are batteries that are less then 15 days past "Use by date" being recharged?
8 Is there a written Process for Recharge?
9 Are batteries that are 15 day greater then the "Use by date" being scrap?
10 What is the process for proper disposal?
Battery Installation
11 Is operator verifying Battery post for oxidation? Create JES (Visual Aid sheet)
Does Ergo Assist Arm check minimum voltage ( 12.75Vstandard batteries or 12.6 for AGM)? Is it functioning? Is it
12
tied to PFS?
13 If battery is dropped or damaged during installation is it being scrapped?
Terminals not torqued
14 Are the terminals that are not torqued prior to end of shift removed from battery post?
15 Is ignition key in the "OFF" Position and vehicle in "Park" except when doing the Hunstville tests?
Terminals torqued
16 Is ignition key in the "OFF" Position and vehicle in "Park" except when doing the required Electrical tests.
17 Is Keys turned off after each Electrical test?
Are all external loads turned off except when being tested? ( Radio, Dome Lights, Head Lights, Cluster, Back light,
18
Hood Deck lid )
19 Is the Heated backlight turned off after 1 minute? ( Does not apply if engine is running)
20 Is Remote start verification conducted before Ship line? ( Suggest Final Electrical )
Is the IOD fuse pulled at the end of shift for all cars in Neutral on Dual Conveyor Lines? (Applies to Brampton and
21
SHAP Convertible Line ONLY )
22 Are Dome Lights switch in the OFF position?
Huntsville testers
23 Is the key placed in the OFF position after the Huntsville Test?
Does the Hunstville software require the ignition to be turned off before end of test?
During Breaks/ Lunch. Is the ignition key turned to the "Off" position for vehicles that did not complete Final Huntsville
24
test? ( Engineering will verify that Huntsville will not false fail)
Repair Areas
25 While vehicle is in for non electrical repair. Is the IOD pulled, and all unneeded electrical turned off?
26 While vehicle is in for Electrical repair. Is Power drops / Chargers being used?
27 Does repair stalls use the same Huntsville software test as the shipping line tester?
Shipping/Validation Line
27 Is battery voltage checked for Go / No GO? Is the pass/ fail criteria meet PS-7454?
29 Is IOD fuse pulled after the last electrical test? Or prior to shipping?
30 If vehicle fails Battery Voltage test. Is battery being recharged using GR-1 tester?
Vascor/Transportation
31 Are they verifying for the IOD fuse being pulled? If not are they pulling fuse?

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