T-SB-0194-12 Service Bulletin/Repair Instructions

@TOYOTA

Technical Service Bulletin
October 16, 2012
T-SB-0194-12
Maintenance for HV & Auxiliary Batteries

Service

Category
General
Section
Pre-Delivery Service
Toyota Supports ~

ASE Certification ~
USA
Market
Applicability

YEAR(S)
MODEL(S)
2013
Prius, Prius C, Prius

PHV, Prius V
ADDITIONAL INFORMATION
Introduction
Prius vehicles are equipped with 2 types of batteries:

• Hybrid Vehicle (HV) battery

• 12-volt auxiliary battery

If Prius vehicles are put into storage, the state of charge (SOC) of its HV battery and auxiliary

battery will gradually decrease. To prevent the auxiliary battery from becoming discharged during

storage, proper maintenance is necessary.

Please perform the following maintenance service for the HV battery and 12-volt auxiliary battery.

NOTE

• Before disconnecting the auxiliary battery, confirm the shift lever is in the "P" position and

apply the parking brake completely. The shift lever CANNOT be shifted from the "P" position

with the 12-volt auxiliary battery disconnected.

• If the negative (-) terminal of the auxiliary battery is reconnected, even if the power button is in

the "START" mode, the hybrid system may NOT start. In this case, push the "POWER" button

and select the "START" mode again to start the hybrid system (the " READY" light is ON). If the

hybrid system still does NOT start (the "READY" light is OFF), refer to the Repair Manual.
Warranty Information

OP CODE
DESCRIPTION
TIME
OFP
T1
T2
N/A
Not Applicable to Warranty
-
-
-
-
© 2012 Toyota Motor Sales, USA
Page 1 of 7
@TOYOTA
T-SB-0194-12
October 16, 2012
Page 2 of 7
Maintenance for HV & Auxiliary Batteries
Maintenance Items

CONDITION*
MAINTENANCE OPERATION
Before Delivery
Fully charge 12-volt auxiliary battery (deliver the vehicle to

the customer after it is fully charged 12.6 V or more).
To Store for 30 Days or More
Disconnect the negative (-)terminal of the 12-volt

auxiliary battery in the luggage compartment to prevent

the SOC of the auxiliary battery from decreasing during

storage due to parasitic current.
Just After Unloading & Every 2 Months
Keep the Hybrid System ON for 30 minutes with the

transm ission in the "P" position (in order to charge the

HV battery and the auxiliary battery).
* The condition also corresponds with the section titles within this TSB.
Required Tools & Equipment

SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
GR8 Battery Diagnostic Station*
00002-MCGR8
1
* Essential SST.
NOTE

The GR8 Battery Diagnostic Station (P/N 00002-MCGRB) supersedes the Automatic Trickle Charger

(P/N 00002-YA122-01) and Fast Battery Chargers (Associated P/N ASE6003 and Christie P/N

CAPPDQ). P/N 00002-YA122-01 , ASE6003, and CAPPDQ are now obsolete .
© 2012 Toyota Motor Sales, USA
@TOYOTA
T-SB-0194-12
October 16, 2012
Page 3 of 7
Maintenance for HV & Auxiliary Batteries
Before Delivery

Fully charge the 12-volt auxiliary battery:
1. Before charging the auxiliary battery, turn OFF all lights, accessories, and the hybrid system.

2. Open the back door and remove the battery cover.

3. Remove the positive(+) terminal cover.
Figure 1.
1
I
Positive Terminal
4. Check the battery SOC.

• If the battery voltage is LESS THAN 12.6 V, then continue to step 5.

• If the battery voltage is 12.6 V or MORE, replace the positive(+) terminal cover, install

battery cover and close the back door.

NOTE

• If measuring the voltage with the negative (-) terminal connected, turn OFF the power

switch and turn ON the headlights for 20 to 30 seconds. This will remove the surface

charge from the battery.

• If the engine has been running before measuring the voltage, wait 20 minutes or more after

the engine stops. This removes the surface charge.
© 2012 Toyota Motor Sales, USA
@TOYOTA
October 16, 2012
T-SB-0194-12
Maintenance for HV & Auxiliary Batteries
Before Delivery

Fully charge the 12-volt auxiliary battery: (Continued)
5. Test/charge the 12-volt auxiliary battery using the

GR8 Battery Diagnostic Station.
Figure 2.
A. Connect the red charger clamp to the positive

(+) battery terminal and the black charger

clamp to the negative(- ) battery terminal.

B. Plug the charger into a grounded 110-volt

nominal outlet and flip the power switch to the

"ON" position .

C. Once the charger is properly turned ON ,

perform a diagnostic charge.

The GR8 Battery Diagnostic Station will

indicate result when complete.

If the battery tests bad ("Replace Battery"),

then replace the auxiliary battery.
1
NOTE

If the auxiliary battery was stored at 32° F

(0°C) or below, charge the auxiliary battery

in a room above 32° F (0°C).
CAUTION

• Charge in a well-ventilated area.

• Do NOT allow sparks or fire near the

auxiliary battery.
If the GR8 Battery Diagnostic Station is NOT

available , you may charge the 12-volt battery

by cycling the vehicle on to "READY."

• Run time will vary depending on the state

of charge.

• If this method is used , you must confirm

that the battery is charged to 12.8 volts

using a DVOM .
© 2012 Toyota Motor Sales, USA
I
P/N 00002-MCGRB
Page 4 of 7
@TOYOTA
T-SB-0194-12
October 16, 2012
Maintenance for HV & Auxiliary Batteries
Before Delivery

Fully charge the 12-volt auxiliary battery: (Continued)
6. After charging the auxiliary battery, install the

positive(+) terminal cover.
Figure 3.
1
I
Positive Terminal
7. Install the battery cover and close the back door.

To Store for 30 Days or More

Disconnect the negative (-) terminal:
1. Turn OFF all lights, accessories, and the hybrid system.

2. Open back door and remove the battery cover

3. Disconnect the negative (-)terminal.
Figure 4.
1
© 2012 Toyota Motor Sales, USA
I
Negative Terminal
Page 5 of 7
@TOYOTA
October 16, 2012
T-SB-0194-12
Page
6 of 7
Maintenance for HV & Auxiliary Batteries
To Store for 30 Days or More

Disconnect the negative(-) terminal: (Continued)
4. Install the battery cover and close the back door.

NOTE

When it is necessary to move the vehicle, reconnect the negative (-) terminal.

When removing the vehicle from storage, connect the negative (-) terminal:
1. Open the back door and remove the battery cover.

2. Connect the negative (-)terminal.
Figure 5.
Torque: 6.0 N*m (61 kgf*cm, 4.4 ft*lbf)
1
I
Negative Terminal
3. Install the battery cover and close the back door.

NOTE

After recharging the auxiliary battery, the hybrid system may NOT start. Follow the procedure

below to initialize the system.

• Put the shift lever in the "P" position.

• Open and close any of the doors.

• Restart the hybrid system.
© 2012 Toyota Motor Sales, USA
•

@TOYOTA
T-SB-0194-12
October 16, 2012
Page 7 of 7
Maintenance for HV & Auxiliary Batteries
Every Two Months

Cycle vehicle to "READY" ON :

NOTE

• When the remaining capacity of the HV battery is low, the gasoline engine automatically starts

and the HV battery is charged by the generator. The 12-volt auxiliary battery is also charged by

the HV battery regardless of the gasoline engine operation.

• Be sure to reconnect the negative (-) terminal of the auxiliary battery BEFORE performing

this procedure.
1. Park the vehicle in open air or connect the exhaust extraction hose to the exhaust pipe.

2. Apply the parking brake.

3. With the brake pedal depressed, push the

"POWER" button and select the "START' mode

and check that the "READY" light in the meter

illuminates when the hybrid system starts (the

"READY" light is ON).
Figure 6.
"\.\!J.1~
/,.,,,,,
-(READY)-
~

4. Turn OFF all lights and accessories.

5. Check that the shift lever is in the "P" position.

6. Keep the "READY" light on and charge the HV battery for 30 minutes.

NOTE

• If the amount of charging energy is small, the display may NOT indicate the energy flow.

• Ensure there is a sufficient amount of fuel for the vehicle to run for 30 minutes.
© 2012 Toyota Motor Sales, USA
...........
------------~

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