HV BATTERY CHARGING

PROCEDURE

INSPECT AUXILIARY BATTERY VOLTAGE
1. Measure the auxiliary battery voltage.
  
  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.

Standard Voltage
Approximately 11 V or more

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.

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Wear insulated gloves.

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. Check whether the HV battery warning message is shown on 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 to 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 HV battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the HV 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.)
Remove the service plug grip.

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Remove the connector cover assembly.

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Check terminal voltage.

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*A for LHD

Remove the bolt and disconnect the frame wire connector from the inverter with converter assembly. (for LHD)
Note
- Do not allow any foreign matter or water to enter the inverter with converter assembly.
- Do not touch the connector waterproofing rubber or terminals.
- Do not damage the connectors, connector housings or inverter with converter assembly during disconnection.
- Insulate the removed connectors with insulating tape.
- Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
*A for RHD

Disengage the clamp. (for RHD)
Remove the bolt and disconnect the frame wire connector from the inverter with converter assembly. (for RHD)
Note
- Do not allow any foreign matter or water to enter the inverter with converter assembly.
- Do not touch the connector waterproofing rubber or terminals.
- Do not damage the connector, connector housing or inverter with converter assembly during disconnection.
- Insulate the removed connector with insulating tape.
- Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

*A	for LHD
*B	for RHD

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

Standard Resistance

Tester Connection	Condition	Specified Condition
Frame wire connector housing - Body ground	Always	Below 1 Ω

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.

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

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*A for LHD

*B for RHD

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

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

*A	for LHD	-	-
*1	HV Battery	*2	Frame Wire
*3	Inverter with Converter Assembly	-	-
*a	EV Bonding Cable (Green Cable)	*b	Low Voltage Cable
*c	High Voltage Cable	*d	Power Input Plug
*e	Grounded AC 100 to 240 V Receptacle	*f	THS Charger
*g	Bolt (91553-80665)	-	-

*A	for RHD	-	-
*1	HV Battery	*2	Frame Wire
*3	Inverter with Converter Assembly	-	-
*a	EV Bonding Cable (Green Cable)	*b	Low Voltage Cable
*c	High Voltage Cable	*d	Power Input Plug
*e	Grounded AC 100 to 240 V Receptacle	*f	THS Charger
*g	Bolt (91553-80665)	-	-

Note

Make sure to connect the EV bonding cable first to prevent electrical shock.
Connect all the THS charger cables in the order shown in the illustration to prevent electrical shock.

*A for LHD

*B for RHD

Connect SST (EV bonding cable (green cable)) to the installation bolt of the motor cable bracket assembly.

SST

09882-10070

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Connect SST (EV bonding cable (green cable)) to SST (THS charger).

SST

09880-10021 ( 09881-10041 )

*A	for LHD
*B	for RHD
*1	Connector Cover Assembly Bolt

Connect SST (low voltage cable) to the position shown in the illustration, and then tighten the bolt.

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

Tighten the connector cover assembly bolt.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
*A for LHD

*B for RHD

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

SST

09882-10040

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.).
*a Low Voltage Cable

*b High Voltage Cable

Connect SST (low voltage cable) and SST (high voltage cable) to SST (THS charger) in the order shown in the illustration.
Install the service plug grip.

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Connect the negative (-) auxiliary battery terminal.
Connect SST (power input plug) of SST (THS charger) to a grounded AC 100 to 240 V receptacle.

SST

09881-10050

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

Connect the GTS to the DLC3.
Turn the power switch on (IG).

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

Powertrain > Hybrid Control > Active Test

Tester Display
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

OFF

OFF → ON

OFF

OFF → ON

Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is 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 in 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 SST (power inlet plug) of the charger from the grounded AC 100 to 240 V receptacle.
Disconnect the negative (-) terminal of the auxiliary battery.
Remove the service plug grip.

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*a Low Voltage Cable

*b High Voltage Cable

Disconnect SST (high voltage cable) and SST (low voltage cable) from SST (THS charger) in the order shown in the illustration.
*A for LHD

*B for RHD

Remove the bolt (91553-80665) and disconnect SST (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.

*A	for LHD
*B	for RHD
*1	Connector Cover Assembly Bolt

Remove the bolt and disconnect SST (low voltage cable).

Remove the bolt and connector cover assembly.
Disconnect SST (EV bonding cable (green cable)) from the THS charger.
*A for LHD

*B for RHD

Disconnect SST (EV bonding cable (green cable)) from the installation bolt of the motor cable bracket assembly.
Tighten the bolt.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Remove the connector cover assembly from the inverter with converter assembly.
Connect the frame wire connector to the inverter with converter assembly with the bolt. (for LHD)

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Note
- Do not allow any foreign matter or water to enter the inverter with converter assembly.
- Do not touch the connector waterproofing rubber or terminals.
- Do not damage the connectors, connector housings or inverter with converter assembly during connection.
- Make sure that the connectors are fully engaged.
- Do not use the bolt (91553-80665) used for connecting the high voltage cable of the charger.
Connect the frame wire connector to the inverter with converter assembly with the bolt. (for RHD)

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Note
- Do not allow any foreign matter or water to enter the inverter with converter assembly.
- Do not touch the connector waterproofing rubber or terminals.
- Do not damage the connector, connector housing or inverter with converter assembly during connection.
- Make sure that the connector is fully engaged.
- Do not use the bolt (91553-80665) used for connecting the high voltage cable of the charger.
Engage the clamp. (for RHD)
Install the connector cover assembly.

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Install the service plug grip.

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Check if the engine starts.

Tech Tips

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

CHECK HV BATTERY AFTER HV BATTERY CHARGE
1. Check for DTCs.
  
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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 procedures required after the cable is disconnected and reconnected to the negative (-) terminal of the auxiliary battery.