PROCEDURE
INSPECT AUXILIARY BATTERY VOLTAGE
Measure the voltage between the terminals of the auxiliary battery.
Standard voltage |
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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.
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.
Check the charge level of the HV battery.
*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.
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.)
Disconnect the negative terminal of the auxiliary battery.
Remove the service plug grip Click here.
Remove the inverter cover Click here.
Check terminal voltage Click here.
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.
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 | ||||||
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If the result is not as specified, inspect the connection shown in the illustration for proper installation Click here.
Connect the THS charger in the order shown by the circled numbers in the 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 | - | - |
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.
Connect the EV bonding cable to the inverter with converter assembly.
Connect the EV bonding cable to the THS charger.
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.
Connect the low voltage cables to the positions shown in the illustration, and then tighten the 9 bolts.
*1 | Interlock |
Install the interlock cover over the location where the frame wire is connected.
Note
Make sure that the interlock is fully engaged.
*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.
*a | Protector B |
Check that protector B is not damaged (for RHD).
Note
If protector B is damaged, replace the frame wire.
Connect the disconnected frame wire to the high voltage cable with the 3 bolts as shown in the illustration.
*1 | Interlock | - | - |
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).
*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.
Install the service plug grip Click here.
Connect the negative auxiliary battery terminal.
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.
HV BATTERY CHARGING
Turn the power switch of the vehicle on (IG).
Connect the GTS to the DLC3.
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 | ||||||||||||||||||||
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Make sure that the EMERGENCY STOP switch is in the reset condition (the switch has been turned clockwise and released).
Make sure that the BREAKER is in the ON position.
Turn the THS charger MAIN switch on.
Tech Tips
The MAIN indicator will illuminate green.
Press the START switch.
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.
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%.
Turn the power switch off.
Remove the THS charger and install the frame wire.
Note
Make sure to disconnect the EV bonding cable last.
Disconnect the power inlet plug of the charger from the receptacle.
Disconnect the negative terminal of the auxiliary battery.
Remove the service plug grip Click here.
*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.
Remove the bolt and slide the cover as shown in the illustration.
Remove the 3 bolts and disconnect the high voltage cable from the frame wire.
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.
Remove the interlock cover from the inverter with converter assembly.
Disconnect the EV bonding cable from the THS charger.
Remove the bolt and disconnect the EV bonding cable from the inverter with converter assembly.
*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.
Fully tighten the 4 bolts.
Note
Be sure to use a torque wrench to tighten the bolts.
Make sure that the interlock is fully engaged.
Install the inverter cover Click here.
Install the service plug grip Click here.
Connect the negative terminal of the auxiliary battery.
Check if the engine starts.
Tech Tips
If the engine does not start, perform the HV battery charging operation again.
Return the vehicle to its original condition.
CHECK HV BATTERY AFTER HV BATTERY CHARGE
Check for DTCs.
Perform the self-charging operation.
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.