HV Battery

HYBRID / BATTERY CONTROL: HV BATTERY: CHARGING

1. INSPECT AUXILIARY BATTERY VOLTAGE

(a) Measure the voltage between the terminals of the auxiliary battery.

Standard voltage:

Approximately 11 V or more

HINT
* 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.

(b) Check the charge level of the HV battery.

(1) Check whether the HV battery warning message is shown in the multi-information display.





(2) Confirm if the engine starts. If the engine starts, leave it idling with park (P) selected until the engine stops (self charge has completed).

If the engine cannot start, follow the procedure and charge the HV battery.

HINT
* Before performing external charging, always use the Techstream 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 battery temperature is 77°F (25°C), 10 minutes may be sufficient, if the battery temperature is 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 THS charger will automatically stop 10 minutes after charging starts.)

2. PREPARATION FOR HV BATTERY CHARGING

CAUTION:
* Wear insulated gloves when working on the high voltage system.
* After removing the service plug grip, do not turn the power switch on (READY) as this may cause a malfunction.
* After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
* After removing the service plug grip, wait 10 minutes before touching any of the high voltage connectors or terminals.
HINT
* Removing the service plug grip interrupts the high voltage circuit.
* High voltage wiring connectors are orange.

(a) Disconnect the negative terminal of the auxiliary battery.

(b) Remove the service plug grip Removal.

(c) Remove the inverter cover assembly LH (w/cover) Removal.

(d) Remove the inverter cover Removal.

(e) Check terminal voltage Removal.

(f) Remove the 4 bolts and disconnect the frame wire.





NOTICE:
* Insulate the disconnected terminals with insulating tape.
* Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

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





HINT
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.

Standard Resistance:





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





(i) Connect the THS charger in the order shown by the circled numbers in the illustration.





Text in Illustration





SST : 09880-10021

09881-10041

09881-10061

SST : 09881-10050

SST : 09881-10081

SST : 09881-10090

SST : 09882-10080

91553-80616

SST : 09883-00010

SST : 09882-10070

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

(j) Connect the EV bonding cable to the inverter with converter assembly.





Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(k) Connect the EV bonding cable to the THS charger.





(l) Install the inverter cover to the inverter with converter assembly.





NOTICE:
* Make sure that the interlock are fully engaged.
* Do not allow any foreign objects or water to enter the inverter with converter assembly.

(m) Connect the low voltage cables to the positions shown in the illustration, and then tighten the 9 bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

(n) Connect the disconnected frame wire to the high voltage cable with 3 bolts as shown in the illustration.





Text in Illustration





Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(o) Slide the cover as shown in the illustration and install bolt A.

NOTICE:
* Make sure that the interlock is fully engaged.
* Tighten bolt A by hand (do not use any tools).

(p) Install the interlock cover over the location where the frame wire is connected.





Text in Illustration





NOTICE:
Make sure that the interlock is fully engaged.

(q) Connect the low voltage cable and high voltage cable to the THS charger in the order shown by the circled numbers in the illustration.





Text in Illustration





(r) Install the service plug grip Installation.

(s) Connect the negative auxiliary battery terminal.

(t) Connect the power input plug of the charger to a grounded AC 100 to 240 V receptacle.

NOTICE:
* 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.

3. HV BATTERY CHARGING

(a) Turn the power switch of the vehicle on (IG).

(b) Connect the Techstream to the DLC3.

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

HINT
* 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 Techstream and the power switch off and then perform the Charge Battery procedure again.

"SMRB" and "SMRG" in Data List during "Battery Charge" Active Test:





(d) Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is turned clockwise and released).

(e) Make sure that the BREAKER is in the ON position.

(f) Turn the THS charger MAIN switch on.





HINT
The MAIN indicator will illuminate green.

(g) Press the START switch.





HINT
* 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.

(h) Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off.

HINT
* 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 77°F (25°C), 10 minutes may be sufficient, if the battery temperature is 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 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%.

(i) Turn the power switch off.

(j) Remove the THS charger and install the frame wire.

NOTICE:
Make sure to disconnect the EV bonding cable last.

(1) Disconnect the power inlet plug of the charger from the receptacle.

(2) Disconnect the negative terminal of the auxiliary battery.

(3) Remove the service plug grip Removal.

(4) Disconnect the high voltage cable and low voltage cable from the THS charger in the order shown by the circled numbers in the illustration.





Text in Illustration





(5) Remove the interlock cover from the inverter with converter assembly.





(6) Remove the bolt and slide the cover as shown in the illustration.





(7) Remove the 3 bolts and disconnect the high voltage cable from the frame wire.

(8) Remove the 9 bolts, low voltage cable and inverter cover.





NOTICE:
Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

Disconnect the EV bonding cable from the THS charger.





Remove the bolt and disconnect the EV bonding cable from the inverter with converter assembly.





(11) Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.





Text in Illustration





(12) Fully tighten the 4 bolts.

Bolt A - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

Bolt B - Torque : 9.2 Nm (94 kgf-cm, 81 in-lbf)

NOTICE:
* Be sure to use a torque wrench to tighten the bolts.
* Make sure that the interlock is fully engaged.

(13) Install the inverter cover Installation.

(14) Install the inverter cover assembly LH (w/ Cover) Installation.

(15) Install the service plug grip Installation.

(16) Connect the negative terminal of the auxiliary battery.

(k) Check if the engine starts.

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

(l) Return the vehicle to its original condition.

4. CHECK HV BATTERY AFTER HV BATTERY CHARGE

(a) Check for DTCs.

(b) Perform the self-charging operation.

(1) Start the engine and leave park (P) selected until the engine stops idling.

HINT
When the engine stops idling, this indicates that self-charging is complete. Perform any initialization required after the negative terminal of the auxiliary battery is disconnected and reconnected.