HV BATTERY CHARGING

PROCEDURE


  1. INSPECT AUXILIARY BATTERY VOLTAGE


    1. Measure the voltage between the terminals of the auxiliary battery.

      Standard voltage
      Approximately 11 V or more

      Tech Tips


      • The horn should sound clearly.

      • If the voltage is 10 V or less, either charge the auxiliary battery (charging usually takes about 1 hour), or replace it with an auxiliary battery that is already charged.

  2. PREPARATION FOR HV BATTERY CHARGING

    CAUTION:


    • The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure Click here.

    • Wear insulated gloves.

    Tech Tips


    • Removing the service plug grip interrupts the high voltage circuit.

    • High voltage wiring connectors are orange.


    1. Check the charge level of the HV battery.


      1. A00042Z

        Check whether the HV battery warning message is shown in the multi-information display.

      2. Confirm if the engine starts. If the engine starts, leave it idling with the shift lever in P until the engine stops (self charge has completed).

        If the engine cannot start, follow the procedure and charge the HV battery.

        Tech Tips


        • Before performing external charging, always use the GTS to perform troubleshooting.

        • Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)

    2. Remove the service plug grip Click here.

    3. Remove the cool air intake duct seal Click here.

    4. Remove the inlet air cleaner assembly Click here.

    5. Remove the air cleaner cap sub-assembly Click here.

    6. Remove the air cleaner filter element Click here.

    7. Remove the air cleaner case sub-assembly Click here.

    8. A0008X5

      Remove the 2 bolts and connector cover assembly from the inverter with converter assembly.

      Note

      Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.

    9. Check terminal voltage Click here.

    10. A0006NU

      Remove the bolt from the inverter with converter assembly.

    11. A0005UK

      Disconnect the wire harness clamp and frame wire.

    12. A0006EX

      Measure the resistance according to the value(s) in the table below.

      Tech Tips

      If the shield line of the frame wire is not securely connected to body ground, the THS charger will not operate. The "FAULT" and "CABLE CONNECTION" warning lights will illuminate on the THS charger.

      Standard Resistance
      Tester Connection Condition Specified Condition
      Frame wire connector housing - Body ground Always Below 1 Ω
    13. A0009MM

      If the result is not as specified, inspect the connection shown in the illustration for proper installation Click here.

    14. A0008X5

      Temporarily install the connector cover assembly with the 2 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

    15. Connect the THS charger in the order shown by the circled numbers in the illustration.

      A0006FLE02
      Text in Illustration
      *1 EV Bonding Cable (Green Cable) *2 Low Voltage Cable
      *3 High Voltage Cable *4 HV Battery
      *5 Frame Wire *6 Inverter with Converter Assembly
      *7 EV Bonding Cable *8 Grounded AC 100 to 240 V Receptacle
      *9 THS Charger *10 Bolt (91553-80665)
      SST
      09880-10021   ( 09881-10041 )
      09882-10040
      09882-10070
      09881-10050
      09881-10090
      09881-10100
      09881-10110
      09881-10120
      09881-10130

      Note


      • Make sure to connect the EV bonding cable first to prevent electrical shock.

      • Connect all THS charger cables in the order shown in the illustration to prevent electrical shock.

    16. A0008FT

      Connect the EV bonding cable (green cable) to the installation bolt of the No. 5 inverter bracket.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    17. A0005WZ

      Connect the EV bonding cable to the THS charger.

    18. A0008XX

      Connect the low voltage cable to the positions shown in the illustration, and then tighten the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    19. A00080L

      Connect the frame wire to the high voltage cable with the bolt (91553-80665).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • The installation bolt that comes with the vehicle is too short to securely connect the frame wire to the high voltage cable of the charger.

      • Do not use the bolt (91553-80665) used for connecting the high voltage cable when reconnecting the frame wire to the vehicle.

      Tech Tips

      When connecting the high voltage cable, use a bolt with a nominal diameter of 6.0 mm (0.236 in.), a shaft length of 69.0 mm (2.72 in.) and a pitch of 1.0 mm (0.0394 in.).

    20. A0006FPE03
      Text in Illustration
      *1 Low Voltage Cable
      *2 High Voltage Cable

      Connect the low voltage cable and high voltage cable to the THS charger in the order shown in the illustration.

    21. Install the service plug grip Click here.

    22. Connect the negative (-) auxiliary battery terminal.

    23. Connect the power input plug of the charger to a grounded AC 100 to 240 V receptacle.

      Note

      Always use an AC 100 to 240 V receptacle with a properly functioning ground. The ground is designed to reduce the chance of electric shock if a malfunction occurs. Do not use the charger if any of the pins on its plug have been damaged or removed.

  3. HV BATTERY CHARGING


    1. Turn the power switch of the vehicle on (IG).

    2. Connect the GTS to the DLC3.

    3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Battery Charge

      Tech Tips


      • During the "Battery Charge" Active Test, check "System Main Relay Status - SMRB" and "System Main Relay Status - SMRG" in the Data List.

      • If the Data List values are not as specified in the table below, turn the GTS and the power switch off and then perform the HV battery charging procedure again.

      "SMRB" and "SMRG" in Data List during "Battery Charge" Active Test
      Step

      Active Test

      Battery Charge

      THS charger START

      switch

      Data List

      System Main Relay Status - SMRB

      Data List

      System Main Relay Status - SMRG

      1 OFF OFF OFF OFF
      2 OFF → ON OFF OFF → ON OFF → ON
      3 ON OFF → ON ON ON
    4. Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is turned clockwise and released).

    5. Make sure that the BREAKER is in the ON position.

    6. A0003UG

      Turn the THS charger MAIN switch on.

      Tech Tips

      The MAIN indicator will illuminate green.

    7. Press the START switch.

      A000413

      Tech Tips


      • When the START switch is turned on, the INITIAL CHECK indicator illuminates and an initial check starts. When the initial check completes successfully, the INITIAL CHECK indicator turns off, the CHARGING indicator illuminates and charging will start at the same time.

      • While the INITIAL CHECK indicator is illuminated, the insulation, 400 V output, emergency stop switch, connector connections and ground connection are inspected.

    8. Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off.

      Tech Tips


      • Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)

      • There is very little chance of overcharging the HV battery during the second or third charging cycle. The SOC will not likely increase beyond the upper limit because it was low enough to prevent the engine from starting. Even if the SOC was to increase enough to exceed the limit, the hybrid vehicle control ECU will stop the active test to prevent overcharging.

      • Cranking the engine once causes the SOC to drop approximately 1%.

      • Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%.

    9. Turn the power switch off.

    10. Remove the THS charger and install the frame wire.

      Note

      Make sure to disconnect the EV bonding cable last.


      1. Disconnect the power inlet plug of the charger from the grounded AC 100 to 240 V receptacle.

      2. Disconnect the negative (-) terminal of the auxiliary battery.

      3. Remove the service plug grip Click here.

      4. A00086DE04
        Text in Illustration
        *1 Low Voltage Cable
        *2 High Voltage Cable

        Disconnect the high voltage cable and low voltage cable from the THS charger in the order shown in the illustration.

      5. A00080L

        Remove the bolt (91553-80665) and disconnect the high voltage cable from the frame wire.

        Note

        Do not use the bolt (91553-80665) used for connecting the high voltage cable when reconnecting the frame wire to the vehicle.

      6. A0008XX

        Remove the 2 bolts and disconnect the low voltage cable.

      7. A0005WZ

        Disconnect the EV bonding cable from the THS charger.

      8. A0008FT

        Disconnect the EV bonding cable (green cable) from the installation bolt of the No. 5 inverter bracket.

      9. Tighten the bolt.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      10. Remove the connector cover assembly from the inverter with converter assembly.

      11. A0005UK

        Connect the wire harness clamp and frame wire.

      12. A0006NU

        Secure the frame wire to the inverter with converter assembly with the bolt.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

        Note

        Do not use the bolt (91553-80665) used for connecting the high voltage cable of the charger.

      13. Install the connector cover assembly to the inverter with converter assembly with the 2 bolts.

        Note

        Make sure that the interlock is fully engaged.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      14. Install the air cleaner case sub-assembly Click here.

      15. Install the air cleaner filter element Click here.

      16. Install the air cleaner cap sub-assembly Click here.

      17. Install the inlet air cleaner assembly Click here.

      18. Install the cool air intake duct seal Click here.

      19. Install the service plug grip Click here.

    11. Check if the engine starts.

      Tech Tips

      If the engine does not start, perform the HV battery charging operation again.

  4. CHECK HV BATTERY AFTER HV BATTERY CHARGE


    1. Check for DTCs.

    2. Perform the self-charging operation.


      1. Start the engine and leave it idling with the shift lever in P until the engine stops.

        Tech Tips

        When the engine stops idling, this indicates that self-charging is complete. Perform any initialization required after the negative terminal of the auxiliary battery is disconnected and reconnected.