Battery Charging (HP2)
BATTERY CHARGING (HP2)TOOLS REQUIRED
- J 42000 Battery Tester
- J 42634 Battery Module Charger or equivalent
DIAGNOSTIC AIDS
CAUTION:
- Refer to Battery Disconnect Caution in Service Precautions.
- To reduce the risk of severe shock and burns, always disconnect the 42 volt (42V) energy storage box (ESB) before doing any work under hood. To disconnect the ESB, turn the engine off and turn the service disconnect switch, located on the passenger side of the ESB, to OFF.
IMPORTANT: The Panasonic HV1255 Valve Regulated Lead Acid (VRLA) batteries used in the PHT operate at a normal range of approximately 50 percent state of charge (SOC). If one or more of the batteries are diagnosed with a low charge or a battery fault and BEFORE battery replacement, the battery pack service charge procedure must be performed. Refer to Battery Pack Service Charge - HP2 . This will ensure the vehicle battery pack will be equally balanced and charged. The new replacement battery will be delivered at approximately 80 percent SOC and must be charged alone to 100 percent SOC using the J 42634 battery module charger before installation. Battery Pack Service Charge - HP2
All Panasonic batteries must be isolated or disconnected before testing or charging begins. Refer to Energy Storage Box (ESB) Power Cable Replacement - Battery 1 to Battery 2 (5.3L Engine w/RPO HP2) or Energy Storage Box (ESB) Power Cable Replacement - Battery 2 to Battery 3 (5.3L Engine w/RPO HP2) for proper battery isolation.
The Service Disconnect Switch must be turned to the OFF position from the energy storage box (ESB). Refer to Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2).
The 42-volt harness MUST also be disconnected at the ESB. Remove the red connector position assurance (CPA) retainer and disconnect the 42-volt positive/negative cable electrical connector. This will ensure no power is present at the ESB, and no fuses or modules are affected during testing.
The Panasonic batteries in the Parallel Hybrid Truck (PHT) require both specific testing and charging procedures. Also the special service tools J 42000 and J 42000-30 must be used to gain proper results.
The battery test using the J 42000 requires correct connections to the battery terminals. Testing requires the use of the J 42000-30 to ensure a lead to lead contact between the battery and the test terminals and to be hand tighten only, overtightening will cause damage to the battery or test terminals.
A failure to obtain the correct connections during the test may result in a failed test on a good battery.
- For best results, use the J 42634 or equivalent automatic taper-rate battery charger with a voltage capability of 14.4 volts @ 12 amps max-set on automatic selection.
- The charging area should be well ventilated.
- Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test it before charging. Refer to Battery Inspection/Test (Non-HP2)Battery Inspection/Test (HP2). Battery Inspection/Test Battery Inspection/Test
CHARGING TIME REQUIRED
The time required to charge a battery will vary depending upon the following factors:
- The battery charger capacity.The higher the charger's amperage, the less time it will take to charge the battery.
- The state-of-charge of the battery.A completely discharged battery requires more than twice as much charging time as a half charged battery. In a discharged battery with a voltage below 11 volts, the battery has a very high internal resistance and may only accept a very low current at first-Later, as the charging current causes the acid content to increase in the electrolyte, the charging current will increase. Extremely discharged batteries may not activate the reversed voltage protection in some chargers. Refer to the manufacturers instructions for operating this circuitry.
- The temperature of the battery.The colder the battery is, the more time it takes to recharge the battery. The charging current accepted by a cold battery is very low at first. As the battery warms, the charging current will increase.
CHARGING PROCEDURE INDIVIDUAL PANASONIC BATTERIES
NOTE:
- Turn OFF the ignition when connecting or disconnecting the battery cables, the battery charger or the jumper cables. Failure to do so may damage the PCM or other electronic components.
- Refer to Fastener Notice in Service Precautions.
IMPORTANT:
- Remove the ESB trim cover and ESB intermediate cover.
- Isolate the battery to be tested or charged.
- Install the test adapters on the terminals, refer to J 42000-30 and hand tighten only.
Use the following procedure to charge the battery:
1. Turn OFF the charger.
2. Ensure that all of the battery terminal connections are clean and tight.
3. Connect the charger positive lead to the battery positive terminal and the negative charger lead to the negative battery terminal.
4. Turn ON the charger and set to the automatic setting.
5. Inspect the battery every half hour after starting the battery charger.
6. Charge the battery until the until the taper-rate charger indicates that the battery is fully charged.
7. Estimate the battery temperature by feeling the side of the battery-If it feels hot to the touch or its temperature is over 45°C (125°F), discontinue charging and allow the battery to cool before resuming charging.
8. After charging, test the battery. Refer to Battery Inspection/Test (Non-HP2)Battery Inspection/Test (HP2).
IMPORTANT:
- If charging with a manual battery charger use the procedure to ensure proper results.
- Use of any boost charging method will cause damage to the Panasonic Battery.