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:


    • 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.

    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. A005F2EE01
        Text in Illustration
        *1 P Position Request Indicator Light (Blinking)
        *2 HV battery SOC indicator light (Blinking)

        Check if both the HV battery SOC indicator light on the combination meter and the P position request indicator light are blinking.

        Tech Tips

        If both lights are blinking, this indicates that the HV battery SOC is very low and charging is required.

      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.

        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. Disconnect the negative terminal of the auxiliary battery.

    3. Remove the service plug grip Click here.

    4. Remove the inverter cover Click here.

    5. Check terminal voltage Click here.

    6. A005AI7

      Remove the 4 bolts and disconnect the frame wire.

      Note


      • Insulate the disconnected 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. A005CI7

      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
    8. A005AB4

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

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

      A005DJKE02
      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 - -
      SST
      09880-10021   ( 09881-10041, 09881-10061 )
      09882-10080   ( 91553-80616 )
      09883-00010
      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.

    10. A005BCC

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    11. A005AYB

      Connect the EV bonding cable to the THS charger.

    12. A005E2Q

      Install the inverter cover to the inverter with converter assembly.

      Note


      • Make sure that the interlock are fully engaged.

      • Do not allow any foreign matter 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.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    14. A005ESEE05
      Text in Illustration
      *1 Interlock

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

      Note

      Make sure that the interlock is fully engaged.

    15. A0059YPE02
      Text in Illustration
      *a Protector A
      *b Protector B

      Remove frame wire protector A from protector B as shown in the illustration (for RHD).

      Note


      • Take care not to apply vertical force on protector B.

      • Take care not to damage protector B.

      • Make sure that protector A is not installed when connecting the frame wire to the inverter with converter assembly.

    16. A005A38E01
      Text in Illustration
      *a Protector B

      Check that protector B is not damaged (for RHD).

      Note

      If protector B is damaged, replace the frame wire.

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

      A005DG8E02
      Text in Illustration
      *1 Interlock - -
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    18. Slide the cover as shown in the illustration and install bolt A.

      Note


      • Make sure that the interlock is fully engaged.

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

    19. A005DCNE01
      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 by the circled numbers in the illustration.

    20. Install the service plug grip Click here.

    21. Connect the negative auxiliary battery terminal.

    22. 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 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 has been turned clockwise and released).

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

    6. A005AVQ

      Turn the THS charger MAIN switch on.

      Tech Tips

      The MAIN indicator will illuminate green.

    7. Press the START switch.

      A005AKW

      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 receptacle.

      2. Disconnect the negative terminal of the auxiliary battery.

      3. Remove the service plug grip Click here.

      4. A005EK9E01
        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 by the circled numbers in the illustration.

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

        A005DAH
      6. Remove the 3 bolts and disconnect the high voltage cable from the frame wire.

      7. A005E2Q

        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.

      8. A005DC6

        Remove the interlock cover from the inverter with converter assembly.

      9. A005AYB

        Disconnect the EV bonding cable from the THS charger.

      10. A005BCC

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

      11. A005DDPE11
        Text in Illustration
        *1 Interlock
        *2 High voltage cables of the hybrid battery
        *a Front view of frame wire connector

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

      12. Fully tighten the 4 bolts.

        Torque:
        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 is fully engaged.

      13. Install the inverter cover Click here.

      14. Install the service plug grip Click here.

      15. Connect the negative terminal of the auxiliary battery.

    11. Check if the engine starts.

      Tech Tips

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

    12. Return the vehicle to its original condition.

  4. 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.

        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.