TOYOTA

T-SB-0001-13 January 2, 2013 Technical Service Bulletin

Maintenance for EV & Auxiliary Batteries

Service
Category General

Toyota Supports
ASE Certification te

Section Pre-Delivery Service Market USA %
Applicability

YEAR(S) MODEL(S} ADDITIONAL INFORMATION

2013 RAV4 EV
introduction

The RAV4 EV is equipped with 2 types of batteries:
+ Electric Vehicle (EV) Traction Battery
* 12-volt Auxiliary Battery

If the RAV4 EV is put into storage, the state of charge (SOC) of the EV battery and auxiliary battery
will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage,

proper maintenance is necéssary.

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

NOTE

with the 12-volt auxiliary battery disconnected.

* 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

+ When the negative (-) terminal of the auxiliary battery is reconnected, the EV system may not
operate if the vehicle is already in “Ready On” state. If this occurs, push the StartStop switch
to re-initiate the “Ready On” mode. The “Ready” light should illuminate on the Instrument
Panel. If the EV system will not “Ready On” refer to the Repair Manual for diagnosis.

Warranty Information

OP CODE DESCRIPTION TIME OFP m1 «| OT2
NIA Not Applicable to Warranty S SS a a
© 2013 Toyota Motor Sales, USA Page 1 of 9

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Maintenance for EV & Auxiliary Batteries

Maintenance Items

CONDITION* MAINTENANCE OPERATION

Fully charge 12-volt auxiliary battery (deliver the vehicle

Before Delivery to the customer after it is fully charged 12.6 V or more).

Disconnect the negative (-) terminal of the 12-volt
auxiliary battery under the hood to prevent the
SOC of the auxiliary battery from decreasing during
storage due to parasitic current,

To Store for 30 Days or More

Just After Unloading & Every 2 Months Fully charge EV battery using vehicle charging station.

“The condition also corresponds with the section titles within this bulletin.

Required Tools & Equipment

SPECIAL SERVICE TOOLS (SST) PART NUMBER aty
GRB8 Battery Diagnostic Station*” 00002-MCGR8 1
** Essential SST.

NOTE

The GR8 Battery Diagnostic Station (P/N 00002-MCGR8) supersedes the Automatic Trickle Charger
(PIN 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.

© 2013 Toyota Motor Sales, USA

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Maintenance for EV & Auxiliary Batteries

Before Delivery
Fully charge the 12-volt auxiliary battery:
1. Before charging the auxiliary battery, turn OFF vehicle, lights, and accessories.

2. Open the hood. Figure 1.

1 | Positive Battery Terminal
2 | Negative Battery Terminal
2 | Hold Down Clamp

3. Remove the positive (+) terminal cover.
4, Check the battery SOC.
° Ifthe 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 and close
the hood.

NOTE

(f measuring the voltage with the negative (-) terminal connected, turn vehicle OFF and turn
ON the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

© 2013 Toyola Motor Sales, USA

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Maintenance for EV & Auxiliary Batteries

Before Delivery
Fully charge the 12-volt auxiliary battery: (Continued)

5. Test/charge the 12-volt auxiliary battery using the — Figure 2.
GR8 Battery Diagnostic Station.

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

If the battery tests bad ("Replace Battery"),
then replace the auxiliary battery.

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
auxillary 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.

+ {f this method is used, you must confirm that
the battery is charged to 12.8 volts using a
DBVOM.

© 2013 Toyota Motor Sales, USA

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Maintenance for EV & Auxiliary Batteries

Before Delivery
Fully charge the 12-volt auxiliary battery: (Continued)

6. After charging the auxiliary battery, install the Figure 3.
positive (+) terminal cover.

1 | Positive Battery Terminal

2. | Negative Battery Terminal
3. | Hold Down Clamp

7. Close the hood.

© 2013 Toyota Motor Sales, USA

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Maintenance for EV & Auxiliary Batteries

To Store for 30 Days or More
Disconnect the negative (~) terminal:
1. Turn OFF vehicle, lights, and accessories.
2. Open the hood.

3. Disconnect the negative (--) terminal. Figure 4.

1 Positive Battery Terminal

2 | Negative Battary Terminal
3. | Hold Down Clamp

4. Close the hood.

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

© 2013 Toyota Mator Sales, USA

TOYOTA T-SB-0001-13 January 2, 2043 Page 7 of 9

Maintenance for EV & Auxiliary Batteries

To Store for 30 Days or More (Continued)
When removing the vehicle from storage, connect the negative (--) terminal:
1. Open the hood.

2. Connect the negative (-) terminal. Figure 5.
Torque: 6.0 N*m (61 kgf*cm, 4.4 ft*lbf)

1 | Positive Battery Terminal
2 | Negative Battery Terminal
3} Hold Down Clamp

3. Close the hood.

NOTE

When the negative (-) terminal of the auxiliary battery is reconnected, the EV system may not
operate if the vehicle is already in “Ready On” state. If this occurs, push the Start/Stop switch
to re-initiate the “Ready On” mode. The “Ready” light should illuminate on the Instrument
Panel. If the EV system will not “Ready On” refer to the Repair Manual for diagnosis.

© 2013 Toyota Motor Sales, USA

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Maintenance for EV & Auxiliary Batteries

Every Two Months

NOTE
Be sure to reconnect the negative (-) terminal of the auxiliary battery BEFORE performing this
procedure.

. Park the vehicle next to the EV Charging Station.
. Apply the parking brake.
. Turn OFF vehicle, lights, and accessories.

. Check that the shift lever is in the “P” position.

a fon =

. Connect the charging station plug to the vehicle. Confirm that both lights above the charge
plug iliuminate. Fully charge the EV battery.

Figure 6.

1 | Charging Indicator 4 | Charging Port
2 | Charging Port Door 5. | Charging Cable with CCID (in trunk)
3a | Charging Port Cap 6 | Ev Charging Station

© 2013 Toyota Motor Sales, USA

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Maintenance for EV & Auxiliary Batteries

Every Two Months (Continued)

Figure 7.

[Fa Tight a ] [8 [etn s |

Check the status of the charging indicator. The charging indicator consists of 2 lights that display
charging status by illuminating, flashing, and turning off as follows.

CHARGING INDICATOR
LIGHT A LIGHT B

The charging cable is connected to Lights A and B flash On and Off alternatively for 10 minutes.
the vehicle and the charging and/or (After 10 minutes both lights remain Off until charging starts)
pre-climate schedule is set

CHARGING STATUS

Charge level is less than 49% Flashes Off
ong loss than 58% ituminates Flashes

Both lights A and B illuminate for 10 minutes.
(After 10 minutes both tights turn Off)

Malfunction occurred during Both lights A and B quickly flash simultaneously for 10 seconds.
charging (After 10 seconds both lights turn Off)

Charging is complete

The indicator lights will not flash or turn on when the charging cable is not connected properly.

© 2013 Toyota Motor Sales, USA