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Diagnostic Aids

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CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
CAUTION: 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.
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.
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 hrs.) 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 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. 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 energy storage box (ESB). Remove the red connector position assurance (CPA) retainer and disconnect the 42-volt positive/negative cable electrical connector. Refer to Positive and Negative Battery Cable (42V) Replacement (5.3L Engine w/RPO HP2) . 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 J 42000-30  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 J 42000-30  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.

  1. Remove the ESB trim cover and the ESB intermediate cover. Refer to Energy Storage Box (ESB) Intermediate Cover Replacement (5.3L Engine w/RPO HP2) and Energy Storage Box (ESB) Trim Cover Replacement (5.3L Engine w/RPO HP2) .
  2. Isolate the battery to be tested or charged.
  3. Install the test adapters on the battery to be tested, refer to J 42000-30  and hand tighten only.
  4. Connect the Midtronics Micro tester to the battery.
  5. 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 (Non-HP2)  or Battery Charging (HP2)  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.
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