Name

Skill Module Number: 3.1

Subject: Dual Battery Module

Objective: The technician will

Identify and locate the components of the dual battery system
Increase their understanding of the operation of the auxiliary
battery sensing circuit
Be able to test the operation of the auxiliary battery relay

Vehicle and tools required:

W211 vehicle
Electrical test kit with a DVOM and Dekade box
SDS / DAS

Required material:

Presentation handout

Instructions:

1. Follow the instructions and answer the questions.

2. Ask your instructor for assistance if needed.
3. Stop at instructor check points

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1. Fill in the Blanks using your handout chapter as a reference.

Name Number Location

a. System Battery G1 __
b. Auxiliary Battery __

c. Battery Control Module ___________ _______________________

d. Auxiliary Battery Relay __

e. Cut off Relay __

f. Polyswitch Fuse __

g. The System battery is an type of battery with a Ah rating.

h. The Auxiliary battery is an type of battery with a Ah rating.

2. The polyswitch fuse (F30) is a positive temperature coefficient thermistor. This

means that as temperature increases, the resistance _.

Make sure that the ignition is off and the key is removed from the EIS.

Locate the polyswitch fuse and remove it.

3. Using a DVOM, what is the resistance of the polyswitch fuse? __

Using the appropriate leads from the electrical test kit, install a Dekade box in
place of the polyswitch fuse.

Set the resistance of the Dekade box to the approximate resistance that you
measured for the polyswitch fuse (round to the nearest whole number).

Connect SDS / DAS to the vehicle. Turn ignition on / engine off.

Navigate to Control Units / Body / Battery Control Module (BCM) / Maintenance

operations, control module adaptations or control module exchange / Fault
codes.

Erase all fault codes in the Battery Control Module.

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 Start the engine and navigate to the actual values screen for the Battery Control
Module.

4. Note the following actual values:

a. Terminal 30 __

b. Auxiliary battery voltage __

c. Number of auxiliary battery recharge operations __

5. Does anything appear to be wrong with either voltage value? Yes / No

6. Using a DVOM, what is the available voltage of G1/7? __

7. Does the voltage measured with the DVOM match the actual value for G1/7?

Yes / No

Note: Allow the engine to run long enough to have >13.5 volts at terminal 30 before
proceeding.

While leaving the resistance that you already have selected in the Dekade box,
select and add 6K ohms to the circuit by selecting the 4K ohms and 2K ohms
resistors respectively.

8. What happened to the actual value voltage for the auxiliary battery?

__

What is the voltage of G1/7 as measured with the DVOM? _________________

While leaving the original resistance in the Dekade box, deselect the 6K ohms
that you just added and select the 10K ohms switch.

9. What is the actual value for the auxiliary battery voltage now?

__

What is the voltage of G1/7 as measured with the DVOM? _________________

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 On the Dekade box, leave the 10K ohms on the circuit and add the previous 6K
ohms resistance to it by selecting the 4K ohms and 2K ohms resistors (original
resistance of the polyswitch fuse plus 16K ohms).

10. What is the actual value for the auxiliary battery voltage now?

__ __

What is the voltage of G1/7 as measured with the DVOM? ________________

11. Do the actual value voltages and the DVOM voltages agree in steps 8,9, &10?

Yes / No

12. The actual value voltage of G1/7 as seen by N82 is being monitored through
what component?
_________________________________________________

13. Did the number of auxiliary battery recharge operations increase at any time
while you were adding resistance to the circuit?
Yes / No

Note: This counter will be reset if the system battery is disconnected from N82

14. As you increased the resistance in the voltage monitoring circuit, was charging
voltage applied to the auxiliary battery?
Yes / No

On SDS back out to the initial mask of DAS.

Shut off the engine and return the decade box value to the original setting as
measured in step 3.

15. Start the engine. What does the DVOM measure at G1/7 ? ________________

Monitor the DVOM and add 16K of resistance at the decade box.

16. When the resistance was increased what did the DVOM measure at G1/7 ?

________________

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17. Wait approximately 60 seconds and record the voltage measured by the DVOM.

__________________

18. As you increased the resistance in the voltage monitoring circuit, was charging
voltage applied to the auxiliary battery?
Yes / No

19. Why were there different results in step 14 as compared to step 18?

_______________________________________________________________

Instructor check point ___________

20. If the proper conditions exist, how many auxiliary battery recharge operations
will the Battery Control Module attempt per circuit 15 key cycle?

__________ _ __

21. Is there a warning of a battery malfunction in the instrument cluster? Yes / No

What is the color of the display? _____________________________________

22. Use SDS to check for fault codes in N82.

What are the DTC,s listed? _________________________________________

_________________________________________
.
23. Do you have a fault code(s) associated with auxiliary battery relay (K57/2), the
polyswitch fuse (F30) and/or the auxliary battery (G1/7)?
Yes / No

Do not erase these codes at this time.

24. Why might you have fault codes associated with these components from the
actions that you just performed?

__

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 __

__

Note: Currently there is no known specified value for the polyswitch fuse. An
excessive resistance in the polyswitch fuse will cause the BCM to read a
faulty voltage for the auxiliary battery (G1/7).

Shut off the engine, remove the Dekade box (be sure to turn off all of resistor
switches that you selected) and reinstall the polyswitch fuse (F30).

Restart the engine with the polyswitch fuse installed.

25. Is the Battery warning message still displayed in the Cluster? Yes / No

Navigate to the actuations screen and select K57/2 (auxiliary battery relay)

26. What is the available voltage of the auxiliary battery (G1/7) as measured with
the DVOM?
_____ __

Momentarily activate the auxiliary battery relay (K57/2) while you are monitoring
the voltage of the auxiliary battery.

27. What happened to the voltage of the auxiliary battery while the relay was
activated?
_ __

28. Could this be used to determine if the relay and its contacts are OK? Yes / No

Navigate back to the fault codes screen.

Erase any fault codes in the Battery Control Module.

Note: All DTCs will be erased from N82 if the systems battery is disconnected
from N82.

Remove the key from the EIS.

Return all tools and equipment.

Instructor check point ___________

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