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HV BATTERY CHARGING

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  1. Click here

    INSPECT AUXILIARY BATTERY VOLTAGE


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

      Standard voltage
      Approximately 11 V or more
      Tip:

      • 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. Check the charge level of the HV battery.


      1. A003X5I

        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 park (P) selected until the engine stops (self charge has completed).

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

        Tip:

        • Before performing external charging, always use the intelligent tester 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. Click here

    PREPARATION FOR HV BATTERY CHARGING

    CAUTION:

    • Wear insulated gloves when working on the high voltage system.

    • After removing the service plug grip, do not turn the power switch on (READY) as this may cause a malfunction.

    • After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

    • After removing the service plug grip, wait 10 minutes before touching any of the high voltage connectors or terminals.

    Tip:

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

    • High voltage wiring connectors are orange.


    1. Disconnect the negative terminal of the auxiliary battery.

    2. Remove the service plug grip (Click here).

    3. Remove the inverter cover assembly LH (w/cover) (Click here).

    4. Remove the inverter cover (Click here).

    5. Check terminal voltage (Click here).

    6. A003V6E

      Remove the 4 bolts and disconnect the frame wire.

      Note:

      • Insulate the removed terminals with insulating tape.

      • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

    7. A003VWV

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

      Tip:

      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
    8. A003WQ7

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

    9. A003ZTSE01

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

      Table 1. 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 - -
      09880-10021 09881-10041
      09881-10050
      09881-10090
      09881-10100
      09881-10110
      09881-10120
      09881-10130
      09882-10080 91553-80616
      09883-00010
      09882-10070
      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.

    10. A003VMD

      Connect the EV bonding cable to the inverter with converter assembly.

      8.0 N*m 82 kgf*cm 71 in.*lbf
    11. A003VV4

      Connect the EV bonding cable to the THS charger.

    12. A003WYX

      Install the inverter cover to the inverter with converter assembly.

      Note:

      • Make sure that the interlock are fully engaged.

      • Do not allow any foreign objects or water to enter the inverter with converter assembly.

    13. Connect the low voltage cables to the positions shown in the illustration, and then tighten the 9 bolts.

      11 N*m 112 kgf*cm 8 ft.*lbf
    14. A003XKZE02

      Connect the disconnected frame wire to the high voltage cable with 3 bolts as shown in the illustration.

      Table 2. Text in Illustration
      *1 Interlock - -
      8.0 N*m 82 kgf*cm 71 in.*lbf

    15. Slide the cover as shown in the illustration and install bolt A.

      Note:

      • Make sure that the interlock are fully engaged.

      • Tighten bolt A by hand (do not use any tools).

    16. A003VRIE02

      Install the interlock cover over the location where the frame wire is connected.

      Table 3. Text in Illustration
      *1 Interlock
      Note:

      Make sure that the interlock are fully engaged.

    17. A003WZXE01

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

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

    18. Install the service plug grip (Click here).

    19. Connect the negative auxiliary battery terminal.

    20. 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. Click here

    HV BATTERY CHARGING


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

    2. Connect the intelligent tester to the DLC3.

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

      Tip:

      • 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 intelligent tester and the power switch off and then perform the Charge Battery 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. A003ZPS

      Turn the THS charger MAIN switch on.

      Tip:

      The MAIN indicator will illuminate green.

    7. A003YR8

      Press the START switch.

      Tip:

      • 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.

      Tip:

      • 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 receptacle.

      2. Disconnect the negative terminal of the auxiliary battery.

      3. Remove the service plug grip (Click here).

      4. A003Z72E01

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

        Table 5. Text in Illustration
        *1 Low Voltage Cable
        *2 High Voltage Cable
      5. A003WGH

        Remove the interlock cover from the inverter with converter assembly.

      6. A003X3Z

        Remove the bolt and slide the cover as shown in the illustration.

      7. Remove the 3 bolts and disconnect the high voltage cable from the frame wire.

      8. A003WYX

        Remove the 9 bolts, low voltage cable and inverter cover.

        Note:

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

      9. A003VV4

        Disconnect the EV bonding cable from the THS charger.

      10. A003VMD

        Remove the bolt and disconnect the EV bonding cable from the inverter with converter assembly.

      11. A003WPGE04

        Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.

        Table 6. Text in Illustration
        *1 Interlock
        *2 High voltage cables of the hybrid battery
        *a Front view of frame wire connector

      12. Fully tighten the 4 bolts.

        Bolt A
        8.0 N*m 82 kgf*cm 71 in.*lbf
        Bolt B
        9.2 N*m 94 kgf*cm 81 in.*lbf
        Note:

        • Be sure to use a torque wrench to tighten the bolts.

        • Make sure that the interlock are fully engaged.

      13. Install the inverter cover (Click here).

      14. Install the inverter cover assembly LH (w/cover) (Click here).

      15. Install the service plug grip (Click here).

      16. Connect the negative terminal of the auxiliary battery.

    11. Check if the engine starts.

      Tip:

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

    12. Return the vehicle to its original condition.

  4. Click here

    CHECK HV BATTERY AFTER HV BATTERY CHARGE


    1. Check for DTCs.

    2. Perform the self-charging operation.


      1. Start the engine and leave park (P) selected until the engine stops idling.

        Tip:

        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.