Battery Charging Non-HP2
Tools Required
J 42000 Battery Tester
| • | For best results, use an automatic taper-rate battery charger with a voltage capability of 16 volts. |
| • | 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 using the J 42000 before charging. |
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
Notice: 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 ECM/PCM or other electronic components.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
When charging side-terminal batteries with the battery cables connected, connect the charger to the positive cable bolt and to a ground located away from the battery. When charging side-terminal batteries with the battery cables disconnected, install the battery side terminal adapters and connect the charger to the adapters.
Tighten
Tighten the battery side terminal adapters to 15 N·m (11 lb ft).
Use the following procedure to charge the battery:
- Turn OFF the charger.
- Ensure that all of the battery terminal connections are clean and tight.
- Connect the charger positive lead to the battery positive terminal on the Battery or Fuse Block - Underhood.
- Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment that is connected directly to the battery negative terminal, but away from the battery. If the negative battery cable is disconnected and a terminal adapter is being used, connect directly to the adapter.
- Turn ON the charger and set to the highest setting for normal charging.
- Inspect the battery every half hour after starting the battery charger.
- After charging, test the battery. Refer to Battery Inspection/Test .
Notice: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger may damage such equipment.
| • | Charge the battery until the taper-rate charger indicates that the battery is fully charged. |
| • | 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. |
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 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.
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 . The new replacement battery will be delivered at approximately 80 percent SOC and must be charged fully using the J 42634 battery module charger before installation.
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 from the energy storage box (ESB). Refer to Hybrid Battery Service Disconnect/Connect . 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. 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 and EL-42000-30 Panasonic Battery Test Terminals (HP2) 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 EL-42000-30 Panasonic Battery Test Terminals (HP2) 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 15.0 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 . |
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
Notice: 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.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Important:
• Remove the ESB trim cover and ESB intermediate cover. Refer to
Battery Cover Replacement - Rear Seat
and
Battery Cover Replacement
. • Isolate the battery to be tested or charged. • Install the test adapters on the terminals, refer to
EL-42000-30 Panasonic Battery Test Terminals (HP2)
and hand tighten only.
Automatic Battery Charger
Use the following procedure to charge the battery:
- Turn OFF the charger.
- Ensure that all of the battery terminal connections are clean and tight.
- Connect the charger positive lead to the battery positive terminal and the negative charger lead to the negative battery terminal.
- Turn ON the charger and set to the automatic setting.
- Inspect the battery every half hour after starting the battery charger.
- Charge the battery until the until the taper-rate charger indicates that the battery is fully charged.
- 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.
- After charging, test the battery. Refer to Battery Inspection/Test .
Manual Battery Charger
| • | If charging with a manual battery charger use the following procedure to ensure proper results. |
| • | Use of any boost charging method will cause damage to the Panasonic Battery. |
| • | Monitor battery charging every 30 minutes. |
Step | Current Limit | Max. Voltage | Charging Time |
|---|---|---|---|
1 | 12 amps | 15.0 V | 0.5 hrs |
2 | 6 amps | 15.0 V | 0.5 hrs |
3 | 3 amps | 15.0 V | 0.5 hrs |
4 | 1.5 amps | 15.0 V | 1.0 hrs |
Total | -- | -- | 2.5 hrs |
After charging, test the battery. Refer to Battery Inspection/Test .
Battery Charging Optima
Tools Required
J 42000 Battery Tester
| • | Only use a voltage regulated charger |
| • | 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 using the J 42000 before charging. |
Recommended Charging Rates
Use the following values when charging the battery.
Battery Charger: 14.8 volts, 13.75 amps maximum, and 24 hours maximum. Until charging amperage is below 0.5 amp.Constant Voltage: 14.7 to 15.0 volts, temperature 122° F (50° C), no current limits, continue until current falls below 1 amp, then finish with 2 amp constant current for 1 hour.
Float Charge: 13.2 to 13.8 volts, 1 amp maximum current, time indefinite.
Charging Procedure
Notice: 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.
- Disconnect the battery cables. Refer to Battery Cable Disconnect and Connection .
- Ensure that all of the battery terminals are clean.
- Connect the battery charger per manufacturer's operating recommendations.
- Turn ON the charger and set the charging voltage. Refer to Recommended Charging Rates.
- Inspect the battery every half hour after starting the battery. Estimate the battery temperature by feeling the side of the battery.
- After charging, test the battery. Refer to Battery Inspection/Test .
Tip
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.
