Energy Storage Box (ESB) Battery Replacement

ENERGY STORAGE BOX (ESB) BATTERY REPLACEMENT

TOOLS REQUIRED
J 43679 Battery Removal Handles

CAUTION:
- To reduce the risk of severe shock and burns, disable the 42 volt (42V) system anytime you perform service work on or around the energy storage box (ESB). The 42V system will still be active after you have disabled the ESB.
- To reduce the risk of severe shock and burns, always disconnect the 42 volt (42V) energy storage box (ESB) before doing any work to the ESB system. To disconnect the ESB, turn the engine off and turn OFF the service disconnect switch, which is located on the passenger side of the ESB.

REMOVAL PROCEDURE

IMPORTANT:
- If one battery fails testing, replacement of that specific battery is required. If two of the three batteries fail testing, replacement of all three batteries is required.
- If replacement of all three batteries is required, the technician MUST perform the (Reset Battery Total A hrs.) procedure with the scan tool via BECM Output Controls.




1. Perform the battery pack service charge procedure. Refer to Battery Pack Service Charge - HP2.
2. Remove the energy storage box (ESB) intermediate cover.
3. If necessary, remove the battery cut-off switch.
4. Disconnect the battery resistor electrical connectors (1) from the appropriate battery.
5. Disconnect the battery thermistor electrical connectors from the appropriate battery.




6. If necessary, remove the power cable nuts (1) from battery 1 and battery 2.
7. Remove the power cable (3) from battery 1 and battery 2.
8. Remove the battery resistor from the battery 1 positive terminal.




9. If necessary, cut the tie straps (1) securing the power cables to the ESB.
10. Remove the power cable nuts (3) from battery 2 and battery 3.
11. Remove the power cable (2) from battery 2 and battery 3.
12. Remove the battery resistor from the battery 3 negative terminal.




13. If necessary, remove the power cable nut (1) from battery 3.
14. Remove the power cable (3) from battery 3.
15. Remove the battery resistor from the battery 3 positive terminal.




16. Disconnect the battery vent hose(s) from the appropriate battery.
17. If necessary, disengage the retainers securing the battery vent hose.




18. Remove the battery vent cap (2) from the appropriate battery.




19. Remove the appropriate battery hold down bracket nut.
20. Remove the appropriate battery hold down bracket.




21. Install J 43679, to the lifting points on the appropriate battery.




22. Remove the appropriate battery.

INSTALLATION PROCEDURE

IMPORTANT: The NEW replacement battery will be delivered at approximately 80 percent state of charge (SOC) and must be charged alone to 100 percent SOC prior to installation.




1. Charge the NEW replacement battery. Refer to Battery Charging.
2. Install J 43679, to the lifting points on the NEW battery.




3. Install the appropriate battery.




4. Remove J 43679, from the battery.




5. Ensure that the batteries (1, 2 and 3) have the positive and negative terminals properly oriented.




6. Install the appropriate battery hold down bracket.
7. Install the appropriate battery hold down bracket nut.

Tighten the nut to 10 N.m (89 lb in).

NOTE: Refer to Fastener Notice in Service Precautions.




8. Install the battery vent cap (2) to the appropriate battery.




9. Connect the battery vent hose(s) to the appropriate battery.
10. If necessary, engage the retainers securing the battery vent hose.




11. If necessary, install the battery resistor to the battery 3 positive terminal.
12. Install the power cable (3) to battery 3.
13. Install the power cable nut (1) to battery 3.

Tighten the nut to 10 N.m (89 lb in).




14. If necessary, install the battery resistor to the battery 3 negative terminal.
15. Install the power cable (2) to battery 2 and battery 3.
16. Install the power cable nuts (3) to battery 2 and battery 3.

Tighten the nuts to 10 N.m (89 lb in).

17. Install NEW tie straps (1) securing the power cable to the ESB.




18. If necessary, install the battery resistor to the battery 1 positive terminal.
19. Install the power cable (3) to battery 1 and battery 2.
20. Install the power cable nuts (1) to battery 1 and battery 2.

Tighten the nuts to 10 N.m (89 lb in).




21. Connect the battery thermistor electrical connectors to the appropriate battery.
22. Connect the battery resistor electrical connectors (1) to the appropriate battery.
23. If necessary, install the battery cut-off switch.
24. Install the ESB intermediate cover.