Battery Inspection/Test Non-HP2
Diagnostic Aids
Caution: Refer to Battery Disconnect Caution in the Preface section.
Important:
• The battery test using the
J 42000
Battery Tester requires correct connections to the battery terminals. A failure to obtain the correct connections during the test may result in a failed test
on a good battery. • Use the Out of Vehicle test for each battery when testing a vehicle with dual batteries.
Follow these instructions in order to avoid an incorrect diagnosis because of connections:
| • | If testing the vehicle with the battery cables still connected, wiggle the J 42000 clips on the terminal bolt. This may cut through any coating or through any oxidation that may be present on the bolt. |
| Even new bolts contain a protective coating that may insulate or cause a resistance in the test circuit. |
| • | If correct connections to the battery terminal bolts in the vehicle are in doubt, perform the following steps: |
| 1. | Disconnect the negative battery cable. |
| 2. | Disconnect the positive battery cable. |
| 3. | Install the test adapters on the terminals. |
| 4. | Follow the instructions for testing a removed battery. |
| • | If the tester displays a REPLACE BATTERY or BAD CELL-REPLACE result for a battery tested in the vehicle with the battery cables connected, perform the following steps: |
| 1. | Disconnect the negative battery cable. |
| 2. | Disconnect the positive battery cable. |
| 3. | Install the tester adapters. |
| Important: Always write the test code displayed by the tester on the repair order for any warranty purposes. The number is a unique code that describes the test data for a particular battery at a particular time. The test code may occasionally repeat when you retest the same battery. More often, each test will result in a different code. Use the test code from the second, or Out of Vehicle test. |
| 4. | Follow the instructions for testing a removed battery. |
| 5. | Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL-REPLACE result. |
Use the test code from the second test for any warranty purposes.
| • | Use the correct terminal adapters. |
| Do not use any common bolts or a combination of bolts, of nuts, and of washers as adapters when testing the battery. |
| Use the test adapters that are provided with the J 42000 or GM P/N 12303040 terminal adapters. If the adapters that are provided with the J 42000 require replacement, use GM P/N 12303040. Any other adapter may not contact the correct areas of the battery terminal, causing a resistance that may result in an invalid battery test result. |
Step | Action | Value(s) | Yes | No | ||||||
|---|---|---|---|---|---|---|---|---|---|---|
|
Caution: Refer to Battery Disconnect Caution in the Preface section. | ||||||||||
1 | Inspect the battery for a cracked, broken, or damaged case, which may be indicated by battery acid leakage. Is the battery OK? | -- | Go to Step 2 | Go to Step 19 | ||||||
2 | Compare the cold cranking amperage (CCA) and reserve capacity (RC) of the battery to the original battery or original equipment (OE) specification. Refer to Battery Usage . Does the battery meet or exceed the specifications? | -- | Go to Step 3 | Go to Step 19 | ||||||
3 | Does the hydrometer display a yellow dot? | -- | Go to Step 4 | Go to Step 5 | ||||||
4 | Tap the hydrometer lightly on top with the handle of a small screwdriver in order to dislodge any air bubbles inside the battery. Does the hydrometer still display a yellow dot? | -- | Go to Step 19 | Go to Step 5 | ||||||
5 |
Does the negative connector rotate? | -- | Go to Step 6 | Go to Step 7 | ||||||
6 | Use a torque wrench in order to verify the torque to loosen the negative battery terminal bolt. Is the torque above the specified value? | 10 N·m (88 lb in) | Go to Step 8 | Go to Step 7 | ||||||
7 | Disconnect the negative battery cable. Is the cable disconnected? | -- | Go to Step 9 | -- | ||||||
8 |
Is the repair complete? | -- | Go to Step 9 | -- | ||||||
9 | Rotate the positive battery cable connector clockwise with light finger pressure. Does the positive connector rotate? | -- | Go to Step 10 | Go to Step 11 | ||||||
10 | Use a torque wrench in order to verify the torque to loosen the positive battery terminal bolt. Is the torque above the specified value? | 10 N·m (88 lb in) | Go to Step 12 | Go to Step 11 | ||||||
11 | Disconnect the positive battery cable. Is the cable disconnected? | -- | Go to Step 13 | -- | ||||||
12 |
Is the repair complete? | -- | Go to Step 13 | -- | ||||||
13 |
Are the metal connecting parts clean and in good condition? | -- | Go to Step 14 | -- | ||||||
14 |
Is the cable bolt properly tightened? | 15 N·m (11 lb ft) | Go to Step 15 | -- | ||||||
15 |
Is the cable bolt properly tightened? | 15 N·m (11 lb ft) | Go to Step 16 | -- | ||||||
16 |
Important: Ensure that all of the electrical loads are turned OFF.
Did the tester pass the battery? | -- | Go to Step 17 | Go to Step 18 | ||||||
17 |
Did you complete this action? | -- | Battery OK | -- | ||||||
18 |
Did you complete the replacement? | -- | Battery OK | -- | ||||||
19 | Replace the battery. Refer to Battery Replacement . Did you complete the replacement? | -- | Battery OK | -- | ||||||
Battery Inspection/Test HP2
Diagnostic Aids
Caution: Refer to Battery Disconnect Caution in the Preface section.
Caution: To help avoid personal injury, always disconnect the 36V generator battery carrier before doing any work to the generator battery carrier system. To disconnect the generator battery carrier, turn the engine off and turn OFF the service disconnect switch, which is located on the passenger side of the generator battery carrier.
Caution: To help avoid personal injury, disable the 36V system anytime you perform service work on or around the generator battery carrier. The 36V system will still be active after you have disabled the generator battery carrier.
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 Ahrs.) procedure with the scan
tool via BECM Output Controls.
Important: All Panasonic batteries must be isolated or disconnected before testing or charging begins. Refer to Battery to Battery Positive to Negative Cable Replacement - Battery 1 to Battery 2 or Battery to Battery Positive to Negative Cable Replacement - Battery 2 to Battery 3 for proper battery isolation.
The service disconnect switch must be turned to the OFF position. Refer to Hybrid Battery Service Disconnect/Connect . The 42-volt harness MUST also be disconnected at the energy storage box (ESB). Remove the red connector position assurance (CPA) retainer and disconnect the 42-volt positive/negative cable electrical connector. Refer to Generator Battery Positive and Negative Cable Replacement . 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 Battery Tester and EL-42000-30 Panasonic Battery Test Terminals (HP2) Terminal Adapters must be used to gain proper results. The battery test using the J 42000 tester requires correct connections to the battery terminals. Testing requires the use of the EL-42000-30 Panasonic Battery Test Terminals (HP2) battery test terminal to ensure a lead to lead contact between the battery and the test terminals and to be hand tighten only, overtightening may 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.
- Remove the ESB trim cover and the ESB intermediate cover. Refer to Battery Cover Replacement and Battery Cover Replacement - Rear Seat .
- Isolate the battery to be tested or charged.
- Install the test adapters on the battery to be tested, refer to EL-42000-30 Panasonic Battery Test Terminals (HP2) and hand tighten only.
- Connect the Midtronics Micro tester to the battery.
- Follow the instructions supplied with the J 42000 .
Important: If testing with the Midtronics Micro 410 tester, enter a CCA rating of 1050.
If testing with the Midtronics Micro 411A tester, enter a CCA rating of 825. The tester model number is located on the lower front label. Always write the test code displayed by the tester on the repair order for any warranty purposes. The number is a unique code that describes the test data for a particular battery at a particular time. The test code may occasionally repeat when you retest the same battery. More often, each test will result in a different code. Use the test code from the second, battery test.| • | If the battery tester displays CHARGE BATTERY AND RETEST, refer to Battery Charging for a vehicle with Panasonic batteries. |
| • | Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL-REPLACE result. |
| • | Use the test code from the second test for any warranty purposes. |
Battery Inspection/Test Optima
Diagnostic Aids
Caution: Refer to Battery Disconnect Caution in the Preface section.
Important:
• Verify that all battery connections are clean and torqued to fastener specification. • Use the Out of Vehicle test for each battery in the system.
Follow these instructions in order to avoid an incorrect diagnosis:
- Disconnect the negative battery cables. Refer to the Battery Cable Disconnect and Connection .
- Install the test adapters on the terminals.
- Follow the instructions for testing a removed battery.
- Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL-REPLACE result.
Important: Use the correct terminal adapters. Do not use any common bolts or a combination of bolts, of nuts, and of washers as adapters when testing the battery. Use the test adapters that are provided with the J 42000 or GM P/N 12303040 terminal adapters. If the adapters that are provided with the J 42000 require replacement, use GM P/N 12303040. Any other adapter may not contact the correct areas of the battery terminal, causing a resistance that may result in an invalid battery test result.
