T-SB-0119-15 Rev1 December 2, 2015

High Voltage (HV) Battery Rescue Charge (HEV

Workstation / GRX-5100)
Service
Category Engine/Hybrid System

Section Hybrid/Battery Control System Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2013 - 2018 Avalon HV

2007 - 2017 Camry HV

2006 - 2019 Highlander HV

2012 - 2019 Prius C

2012 - 2017 Prius V

2001 - 2015 Prius

2016 - 2018 RAV4 HV

REVISION NOTICE
May 01, 2020 Rev1:
• Applicability has been updated to include 2017 – 2018 model year Avalon Hybrid, 2017 model
year Camry Hybrid, 2017 – 2019 model year Highlander Hybrid, 2017 – 2019 model year Prius C,
2017 model year Prius V, and 2016 – 2018 model year RAV4 vehicles.
• The entire bulletin has been updated.
Any previous printed versions of this bulletin should be discarded.

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 applicable model and model
year Repair Manual while performing a 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 – – – –

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Required Tools & Equipment

SPECIAL SERVICETOOLS (SST) PART NUMBER QTY

High Voltage Battery Service Unit* 01413-00002 1

Interface ECU* – 64 01413-00017 1
High Voltage Cable* (A) 01413-00013 1
High Voltage Cable* (B) 01413-00014 1
High Voltage Cable* (C) 01413-00015 1
High Voltage Cable* (D) 01413-00016 1
High Voltage Cable* (E) 01413-00009 1
High Voltage Cable* (G) 01413-00018 1
Universal High Voltage Cable* (V) 01413-00007 1
Interlock Connector* 01413-00003 1
Stack Balance Cable* (I) 01413-00024 1
Low Voltage Cable* (P) 01413-00022 1
Low Voltage Cable* (Q) 01413-00023 1
Low Voltage Cable* (R) 01413-00004 1
Cell Voltage Cable* (J) 01413-00019 1
Cell Voltage Cable* (L) 01413-00021 1
Temperature Sensor Cable* (K) 01413-00020 1
Universal Fuse Box* 01413-00010 1
AC Power Cord* (S) 01413-00005 1
D/C Adapter Kit* (T&U) 01413-00006 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.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Required Tools & Equipment (continued)

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY

Techstream ADVi* 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 15.00.028 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. Inspect the vehicle.

A. Inspect the auxiliary battery voltage.

B. Measure the voltage between the terminals of the auxiliary battery.

NOTE
• Standard Voltage is approximately 11V or more.
• If the voltage is less than 11V, charge the auxiliary battery or replace it with an auxiliary
battery that is already charged.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

2. Inspect the 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.

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 6.
• NO — Continue to step 3.

3. Connect the GRX-5100 for a rescue charge.

NOTE
• ALWAYS use Techstream to troubleshoot the hybrid system before attempting an
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).
• 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.

A. Disconnect the 12V auxiliary battery.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

B. Use the table below to select the high voltage and low voltage cables for a specific model.
Some vehicles may also require a high voltage accessory.
Table 1.
PART NUMBER/MODEL APPLICATION
HV LOW VOLTAGE CABLE/
HIGH VOLTAGE CABLES
ACCESSORY HV BONDING CABLE

MODEL MODEL 01413-00010

MODEL 01413- 01413- 01413- 01413- 01413- 01413- 01413- 01413- 01413-
NAME YEAR UNIVERSAL
CODE 00007 00013 00014 00015 00016 00009 01413-00003 00022 00023 00004
FUSE BOX
HV* HV* HV* HV* HV* HV* INTERLOCK LV** LV** LV**
CABLE CABLE CABLE CABLE CABLE CABLE CONNECTOR CABLE CABLE CABLE
V A B C D E P Q R

Avalon HV 2013 – 2018 AVX40 X X – – – X – – – – X

2007 – 2011 AHV40 X X – – – X – – – – X

Camry HV
2012 – 2017 AVV50 X X – – – X – – – – X

MHU23 X X – – X – – – – – X
2006 – 2007
MHU28 X X – – X – – – – – X
Highlander
2008 – 2010 MHU48 X X – – – X – – – – X
HV
2011 – 2013 GVU48 X X – – – – X X – – X

2014 – 2019 GVU58 X X – – – – X X – – X

2001 – 2003 NHW11 X X X – – – – – X – –

Prius 2004 – 2009 NHW20 X X – X – – – – – X –

2010 – 2015 ZVW30 X X – – – – X X – – X

Prius C 2012 – 2019 NHP10 X X – – – – X X – – X

Prius V 2012 – 2017 ZVW41 X X – – – – X X – – X

RAV4 HV 2016 – 2018 AVA44 X X – – – X – – – – X

*HV = High Voltage

**LV = Low Voltage

C. Connect the power input (Cable S) to the GRX-5100 and connect the cable into a grounded
AC 100 to 240V receptacle.

NOTICE
ALWAYS confirm the AC 100 to 240V 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.

D. Turn the GRX-5100 ON.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

E. Select RESCUE CHARGE by using the Figure 1.

arrow key, then press SELECT.

F. Confirm you are wearing the appropriate PPE for high voltage service.

CAUTION
ALWAYS wear the appropriate PPE when working with high voltage: Insulated gloves,
insulated apron, and arc protective helmet w/face shield.

G. Press YES. Figure 2.

H. Press NEXT. Figure 3.

NOTE
Refer to the applicable model and model
year Repair Manual for vehicle specific
instructions for disassembly and
connector locations.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

I. Remove the service plug grip.

NOTE
Refer to the applicable model and model year Repair Manual at TIS – Engine Hybrid System –
Hybrid/Battery Control System – HV Battery Charging for the appropriate wait time AFTER the
high voltage service plug grip is pulled.

J. Press YES. Figure 4.

K. Remove the inverter terminal cover.

L. Check the terminal voltage. Figure 5.

HINT
Standard voltage is 0V.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

M. Disconnect the frame wire. Figure 6.

N. Measure the resistance according to the

value(s) in the table below.

NOTE
If the shielding of the frame wire is NOT
securely connected to body ground, the
GRX-5100 will NOT operate.

TESTER CONNECTION CONDITION SPECIFIED CONDITION

Frame Wire Connector Housing –
Always Below 1 Ω
Body Ground

O. If the results are NOT as specified, inspect the connection according to the applicable
model and model year Repair Manual at TIS – Engine Hybrid System – Hybrid/Battery
Control System – HV Battery Charging for proper installation.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

P. Connect the corresponding high voltage cable to the fuse box.

Q. Connect High Voltage Cable V to the fuse box.

R. Connect High Voltage Cable V to the GRX-5100.

S. Connect the corresponding low voltage cable to the GRX-5100.

T. Install the inverter terminal cover to the inverter assembly.

NOTICE
• Do NOT allow any foreign material or water to enter the inverter assembly.
• Make sure ALL connectors are securely connected.

CAUTION
• ALWAYS wear insulated gloves and the appropriate PPE provided in the HEV
Workstation when working with high voltage.
• ALWAYS use insulated tools provided in the HEV Workstation when working with
high voltage.

U. Connect the green high voltage bonding Figure 7.

cable to a suitable chassis ground.

V. Press NEXT.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

W. Connect the low voltage cable to inverter terminal cover.

X. Press NEXT. Figure 8.

NOTE
NOT ALL vehicles require a separate
low voltage cable circuit.

Y. Connect the high voltage cable to the vehicle’s frame wire.

Z. Press NEXT. Figure 9.

NOTE
• Certain high voltage cables require a
grounding bolt to complete the high
voltage bonding test.
• High voltage cables requiring a
grounding bolt have been labeled using
a black sticker indicating bolt location,
size, and torque.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

AA. Install the interlock connector in Figure 10.

the inverter.

NOTE
The battery charge active test will fail
and a DTC will set if the interlock
connector is NOT installed.

1
z

1 Interlock

BB. Inspect the connection according to the Figure 11.

applicable model and model year Repair 1 2
z z
Manual at TIS – Engine Hybrid System –
Hybrid / Battery Control System – HV
Battery Charging for proper installation.

NOTE
An overall view of connectors and their
connections for the GRX-5100 during a
high voltage battery rescue charge is
shown in Figure 11.

3
z
6
z

5 4
z z
1 Grounding Bolt

2 Interlock Connector

3 Fuse Box

4 Cable V

5 Cable R

6 Cable E

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

CC. Wait for the internal test to complete. Figure 12.

DD. Install the service plug grip.

EE. Press NEXT. Figure 13.

NOTICE
Make sure the service plug grip’s
interlock is fully engaged.

FF. Connect the negative (–) terminal of the auxiliary battery.

NOTE
Using the power supply mode, connect the Battery Diagnostic Tool to the auxiliary battery.

GG. Wait for the high voltage bonding test Figure 14.
to complete.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

4. HV battery rescue charging.

A. Turn the vehicle power switch to the IG-ON position.
B. Connect Techstream to DLC3.
C. Refer to the following menus: Powertrain – Hybrid Control – Active Test – Battery Charge.

HINT
During the battery charge active test, check the System Main Relay Status – SMRB and the
System Main Relay Status – SMRG on the data list.

D. Open the battery charge active test and Figure 15.

click the ON button on Techstream.
Then press NEXT on the GRX-5100 to
start HV battery charging within
30 seconds.

NOTE
• AFTER the battery charge active test has been turned ON, press the NEXT button on the
GRX-5100 within 30 seconds. If the NEXT button is NOT pressed within the 30 seconds, the
SMR will open and the GRX-5100 will NOT be able to charge the HV battery.
• If the shielding of the frame wire is NOT securely connected to body ground, the GRX-5100 will
NOT operate.
• The GRX-5100 charging condition status will be displayed on the screen of the GRX-5100 while
charging the HV battery.
• During the HV battery charge cycle, the voltage and charge current will be recorded on the
flash drive.
• The GRX-5100 will automatically stop 10 minutes AFTER charging starts. SMRs will automatically
open as soon as the GRX-5100 stops charging.
• If the data list values are NOT as specified in the table below, restart Techstream and cycle the
vehicle’s power switch to the IG-ON/OFF positions, and then perform the HV battery rescue
charging procedure again.

ACTIVE TEST GRX-5100 START DATA LIST SYSTEM MAIN DATA LIST SYSTEM MAIN
STEP
BATTERY CHARGE SWITCH RELAY STATUS – SMRB RELAY STATUS – SMRG
1 OFF OFF OFF OFF
2 OFF → ON OFF OFF → ON OFF → ON
3 ON OFF → ON ON ON

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

E. Wait for the HV battery rescue charge Figure 16.

to start.

F. Repeat the charge cycle up to three Figure 17.

times if required.

NOTE
• Charging time while using the GRX-5100 is 10 minutes per charge cycle when the battery
temperature is above 77°F (25°C).
• 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.
• 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 were 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 GRX-5100 restores the SOC
approximately 2%.

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High Voltage (HV) Battery Rescue Charge (HEV Workstation / GRX-5100)

Rescue Charge Ni-MH (continued)

5. Reassemble the vehicle.

CAUTION
• ALWAYS wear insulated gloves and the appropriate PPE provided in the HEV Workstation
when working with high voltage.
• ALWAYS use insulated tools provided in the HEV Workstation when working with
high voltage.

A. Turn the GRX-5100 power switch OFF.

B. Turn the vehicle power switch OFF.
C. Disconnect 12V auxiliary battery.
D. Remove the service plug grip.
E. Remove the GRX-5100 cables and interlock connector.
F. Reassemble the vehicle following the applicable model and model year Repair Manual at
TIS – Engine Hybrid System – Hybrid/Battery Control System – HV Battery Charging.
G. Install the service plug grip.

H. Connect the 12V auxiliary battery.

I. Check for ANY DTCs.

J. Confirm whether the engine cranks.

Does the engine crank?
• YES — Continue to sub step K.
• NO — Repeat steps 3 – 5.
K. Confirm whether the engine starts.
Does the engine start?
• YES — Continue to step 6.
• NO — Continue diagnosis using the applicable Repair Manual.
6. Allow the vehicle to idle in park “P” until the engine stops. Once the engine stops, self-charge
has been completed.

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