NHTSA ID Number: 10152247
Manufacturer Communication Number: T-SB-0119-15
TSB/Document Date: 2018-12-17
Summary
TSB: This bulletin includes basic procedures for performing a Rescue Charge on Ni-MH High Voltage (HV) Batteries. This bulletin should be used in conjunction with the Repair Manual while performing Rescue Charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota
Hybrid System (THS) Charger.
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TSB/Document ID: T-SB-0119-15
Replacement Service Bulletin Number:
MFR Communication Date: 2015-12-02
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
T-SB-0119-15
December 2, 2015
High Voltage (HV) Battery Rescue Charge (HEV
Workstation / GRX-5100)
Service
Category
Engine/Hybrid System
Section
Market USA
Applicability
YEAR(S)
MODEL(S)
2013 - 2016
Avalon HV
2007 - 2016
Camry HV
2006 - 2016
Highlander HV
2012 - 2016
Prius C
2012 - 2016
Prius V
2001 - 2015
Prius
ADDITIONAL INFORMATION
Introduction
This bulletin includes basic procedures for performing a Rescue Charge on Ni-MH High Voltage
(HV) Batteries. This bulletin should be used in conjunction with the Repair Manual while
performing Rescue Charge. The GRX-5100 should be used wherever the Repair Manual
references the Toyota Hybrid System (THS) Charger.
Required Tools & Equipment
SPECIAL SERVICETOOLS (SST)
PART NUMBER
High Voltage Battery Service Unit*
01413-00002
Interface ECU* - 64
01413-00017
High Voltage Cable* (A)
01413-00013
QTY
1
© 2015 Toyota Motor Sales, USA
Page 1 of 15
T-SB-0119-15
December 2, 2015
Page 2 of 15
High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)
Required Tools & Equipment (Continued)
SPECIAL SERVICETOOLS (SST)
PART NUMBER
High Voltage Cable* (B)
01413-00014
High Voltage Cable* (C )
01413-00015
High Voltage Cable* (D)
01413-00016
High Voltage Cable* (E )
01413-00009
High Voltage Cable* (G)
01413-00018
Interlock Connector*
01413-00003
Stack Balance Cable* (I)
01413-00024
Low Voltage Cable* (P)
01413-00022
Low Voltage Cable* (Q)
01413-00023
Low Voltage Cable* (R )
01413-00004
Cell Voltage Cable* (J)
01413-00019
Temperature Sensor Cable* (K)
01413-00020
Cell Voltage Cable* (L)
01413-00021
Universal High Voltage Cable* (V)
01413-00007
Universal Fuse Box*
01413-00010
AC Power Cord* (S)
01413-00005
D/C Adapter Kit* (T&U)
01413-00006
Banana Jack Extension Cable* (X)
01413-00031
AC Circuit Checker*
01413-00012
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2015 Toyota Motor Sales, USA
QTY
1
T-SB-0119-15
December 2, 2015
Page 3 of 15
High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)
Required Tools & Equipment (Continued)
REQUIRED EQUIPMENT
SUPPLIER
PART NUMBER
Techstream 2.0*
QTY
TS2UNIT
ADE
Techstream Lite
1
TSLITEPDLR01
* Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
Software version 10.30.029 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Rescue Charge Ni-MH
1. Preliminary Vehicle Inspection.
A. Inspect Auxiliary Battery Voltage.
B. Measure the voltage between the terminals of the auxiliary battery.
NOTE
Standard Voltage is approximately 11 V or more.
HINT
If the voltage is 11 V or less, either charge the auxiliary battery or replace it with an
auxiliary battery that is already charged.
2. Inspect HV Battery.
CAUTION
Always wear the appropriate Personal Protective Equipment (PPE) provided in the HEV
Workstation when working with High Voltage. (Insulated gloves, insulated apron, and arc
protective helmet w/ face shield).
Always use insulated tools when working with High Voltage.
Always use the Cones, Barriers and High Voltage car toppers provided in the HEV
Workstation to create a perimeter around the vehicle and work area.
HINT
Removing the service plug grip interrupts the High Voltage circuit.
High Voltage wiring connectors are orange.
© 2015 Toyota Motor Sales, USA
T-SB-0119-15
December 2, 2015
Page 4 of 15
High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)
Rescue Charge Ni-MH (Continued)
A. Check the charge level of the HV battery.
B. Check whether the HV battery warning message is shown in the vehicle’s multiinformation display.
C. Confirm if the engine starts. If the engine starts, let the vehicle idle in park (P) until the
engine stops (self-charge has completed). If the engine cannot start, follow the
procedures below to charge the HV Battery.
HINT
Always use Techstream to troubleshoot the Hybrid System before attempting HV
Battery Charge.
Charging time while using the GRX-5100 is 10 minutes per charge cycle when the
battery temperature is above 77°F (25°C), 10 minutes may be sufficient, if the
battery temperature is below 32°F (0°C), 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 GRX-5100 will automatically stop 10
minutes after charging starts.
3.
Connecting the GRX-5100 for Rescue Charge.
A. Disconnect the 12V auxiliary battery.
B. Connect the power input (cable S) to the GRX-5100 and connect the cable into a
grounded AC 100 to 240 V receptacle.
NOTICE
Always confirm the AC 100 to 240 V receptacle has a properly functioning ground
by using the AC Circuit Checker provided in the HEV Workstation 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 the plug (cable S) have been damaged or
removed.
C. Turn the GRX-5100 on.
© 2015 Toyota Motor Sales, USA
T-SB-0119-15
December 2, 2015
Page 5 of 15
High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)
Rescue Charge Ni-MH (Continued)
D. Select “RESCUE CHARGE” by using the
arrow key, then press “SELECT”.
Figure 1.
E. Confirm you are wearing the appropriate
PPE for High Voltage service.
Figure 2.
F. Press “YES”.
HINT
Always wear the appropriate
personal protective equipment (PPE)
when working with High Voltage:
Insulated gloves, insulated apron,
arc protective helmet w/face shield.
G. Press “NEXT”.
Figure 3.
HINT
Please refer to the Repair Manual for
vehicle specific instructions for
disassembly and connector locations.
© 2015 Toyota Motor Sales, USA
T-SB-0119-15
December 2, 2015
Page 6 of 15
High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)
Rescue Charge Ni-MH (Continued)
H. Remove the Service Plug Grip.
I.
Press “YES”.
Figure 4.
J. Remove the inverter terminal cover.
K. Check terminal voltage.
Figure 5.
NOTE
Standard Voltage: 0 volts.
© 2015 Toyota Motor Sales, USA
T-SB-0119-15
December 2, 2015
Page 7 of 15
High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)
Rescue Charge Ni-MH (Continued)
L. Disconnect the frame wire.
Figure 6.
M. Measure the resistance according to the
value(s) in the table below.
HINT
If the shielding of the frame wire is not
securely connected to body ground,
the GRX-5100 will NOT operate.
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