NHTSA ID Number: 10213900
Manufacturer Communication Number: T-SB-0110-20 Rev
TSB/Document Date: 2022-06-13
Summary
TSB: This bulletin includes basic procedures for performing a rescue charge at battery on high voltage (HV) Ni-MH and Li-ion batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing the battery rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota
Hybrid System (THS) charger
T-SB-0110-20
Rev1
November 2, 2020
High Voltage (HV) Battery Rescue Charge at Battery
(HEV Workstation/GRX-5100)
Service
Category
Engine/Hybrid System
Section
Hybrid/Battery Control System
Market USA
Applicability
YEAR(S)
MODEL(S)
2019 - 2022
Avalon HV, RAV4 HV
2018 - 2022
Camry HV
2020 - 2022
Corolla HV, Highlander HV
2016 - 2022
Prius
2021 - 2022
Sienna HV, Venza HV
2022
Tundra HV
ADDITIONAL INFORMATION
REVISION NOTICE
May 31, 2022 Rev1:
Applicability has been updated to include 2021 – 2022 model year Sienna Hybrid and Venza
Hybrid; and 2022 model year Avalon Hybrid, Camry Hybrid, Highlander Hybrid, RAV4 Hybrid,
Prius, and Tundra Hybrid vehicles.
The Required Tools & Equipment and Rescue Charge at Battery sections have been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
This bulletin includes basic procedures for performing a rescue charge at battery on high voltage
(HV) Ni-MH and Li-ion batteries. This bulletin should be used in conjunction with the applicable
model and model year Repair Manual while performing the battery rescue charge. The GRX-5100
should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
N/A
Not Applicable to Warranty
–
–
–
–
© 2022 Toyota Motor Sales, USA
Page 1 of 18
T-SB-0110-20
Rev1
November 2, 2020
Page 2 of 18
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
High Voltage Battery Service Unit*
01413-00002
1
High Voltage Cable* A619 A and B
01416-00119
1
Universal High Voltage Cable* (V)
01413-00007
1
Low Voltage Cable* (R)
01413-00004
1
Universal Fuse Box*
01413-00010
1
AC Power Cord* (S)
01413-00005
1
Banana Jack Extension Cable* (X)
01413-00031
1
AC Circuit Checker*
01413-00012
1
Battery Diagnostic Tool*
DCA-8000P T
1
*Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2022 Toyota Motor Sales, USA
T-SB-0110-20
Rev1
November 2, 2020
Page 3 of 18
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment (continued)
The table below is a cross reference matrix showing the TMC THS charger part numbers and the equivalent
TMNA GRX-5100 charger part numbers. This matrix can be used as a guide to ensure the correct cables are
selected when following the applicable model and model year Repair Manual and this Service Bulletin to
complete a rescue charge.
TMC PART NUMBERS*
MAIN
SUBCOMPONENTS
IMAGE
TMNA PART NUMBERS**
DESCRIPTION
MAIN
SUBCOMPONENTS
IMAGE
DESCRIPTION
09881-10041
THS
Charger
0141300002
GRX-5100T
GRX-5100
High
Voltage
Battery
Service Unit
09881-10081
THC
Charger
AC Cable
0141300005
A573
AC Power
Cord (S)
09882-10070
Low
Voltage
Cable
0141300004
A533
Low Voltage
Cable (R)
A619
High
Voltage
Cable A619
A and B
0141300031
A564
Banana
Jack
Extension
Cable (X)
0141300010
A296
Universal
Fuse Box
A571
Universal
High
Voltage
Cable (V)
0988010021
0141600119
09882-10090
High
Voltage
Cable
0141300007
* The TMC part numbers listed in the table are NOT available in North America.
**The TMNA part numbers listed in the table are available in North America and should be included in the HEV Workstation
(large orange toolbox).
© 2022 Toyota Motor Sales, USA
T-SB-0110-20
Rev1
November 2, 2020
Page 4 of 18
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment (continued)
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVI*
PART NUMBER
TSADVUNIT
Techstream 2.0
TS2UNIT
ADE
1
Techstream Lite
TSLITEPDLR01
Techstream Lite (Green Cable)
TSLP2DLR01
*Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
Software version 17.00.020 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Rescue Charge at Battery
1. Inspect the vehicle.
A. Inspect the auxiliary battery voltage.
B. Test the auxiliary battery using the DCA-8000 Battery Diagnostic Tool to ensure the
battery is fully charged.
2. Inspect the HV battery.
A. Check the charge level of the HV battery.
B. Check whether the HV battery warning message is shown in the vehicle’s
multi-information display.
C. Confirm whether the engine starts.
Does the engine start?
YES — Go to step 7.
NO — Continue to step 3.
QTY
© 2022 Toyota Motor Sales, USA
T-SB-0110-20
Rev1
November 2, 2020
Page 5 of 18
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
3. Prepare the vehicle for a rescue charge.
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 with 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.
NOTE
Do NOT proceed with the Toyota THS charger connection instructions in the Repair Manual. Follow
the proceeding steps in this bulletin to correctly use the GRX-5100 instead.
Refer to TIS, applicable model and model year Repair Manual:
2019 – 2020 Avalon HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
2021 Avalon HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2022 Avalon HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2018 – 2020 Camry HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
2021 – 2022 Camry HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
© 2022 Toyota Motor Sales, USA
T-SB-0110-20
Rev1
November 2, 2020
Page 6 of 18
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
2018 – 2020 Camry HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2021 – 2022 Camry HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2020 – 2022 Corolla HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
2021 – 2022 Corolla HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2020 – 2022 Highlander HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery: Charging”
2016 – 2017 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
2016 – 2017 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2018 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
2018 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2019 – 2020 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
2019 – 2020 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”
2021 – 2022 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”
© 2022 Toyota Motor Sales, USA
T-SB-0110-20
Rev1
November 2, 2020
Page 7 of 18
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium lead positive grid, maximizes conductivity and...
- Robust envelope separator with puncture resistant back...
- Vent cap design that resists acid leakage
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium Lead positive grid, maximizes conductivity and...
- Robust Envelope Separator with puncture-resistant back...
- Vent cap design that resists acid leakage
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TSB/Document ID: T-SB-0110-20 Rev
Replacement Service Bulletin Number:
MFR Communication Date: 2022-05-31
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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