Plug-In Charge Control System
HYBRID / BATTERY CONTROL: PLUG-IN CHARGE CONTROL SYSTEM: PRECAUTION
1. PRECAUTIONS FOR INSPECTING PLUG-IN CHARGE CONTROL SYSTEM
(a) Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly or electric vehicle charger assembly, take safety precautions such as turning the power switch off, wearing insulated gloves and removing the service plug grip to prevent electrical shocks. 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.
NOTICE:
* After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.
* After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.
(b) After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.
HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly and electric vehicle charger assembly.
(c) Check the voltage at the terminals in the inspection point in the inverter with converter assembly.
CAUTION:
Be sure to wear insulated gloves.
(1) Remove the 9 bolts and inverter cover.
NOTICE:
Cover the opening with non-residue tape to prevent entry of foreign matter or liquid after removing the connector cover.
(2) Measure the voltage according to the value(s) in the table below.
Standard Voltage:
HINT
Set the tester to DC750 V or more to measure the voltage.
(d) When turning the power switch on (IG) during inspections, do not press the power switch with the brake pedal depressed.
CAUTION:
Pressing the power switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area.
(e) Turn the power switch off, wear insulated gloves, and disconnect the cable from the negative (-) terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.
(f) Turn the power switch off before performing any resistance checks.
(g) Turn the power switch off before disconnecting or reconnecting any connectors.
(h) When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or a insulated tool.
(i) When high-voltage connectors are removed, wrap the connectors with insulation tape to prevent them from contacting foreign objects.
(j) If plug-in charging is cancelled, delayed or interrupted due to a cause other than a vehicle malfunction (no DTC output), the cause is memorized in the "Charge Cancel History" Plug-In Charge Control System.
2. PRECAUTION WHEN INSTALLING SERVICE PLUG GRIP
(a) Connect the auxiliary battery on the same day of installing the service plug grip to allow the battery cell voltage equalization function of the battery smart unit to operate.
3. PRECAUTIONS FOR DISCONNECTING AMD TERMINAL
HINT
The AMD terminal is connected to the positive terminal of the auxiliary battery. To prevent damage when the AMD terminal is being disconnected, use the following procedure.
(a) Be sure to disconnect the cable from the negative (-) terminal of the auxiliary battery before disconnecting the AMD terminal from the engine room junction block assembly.
Text in Illustration
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.
(b) After disconnecting the AMD terminal, wrap the terminal with insulation tape.
(c) Be sure to reconnect the AMD terminal to the engine room junction block assembly before reconnecting the cable of the negative (-) terminal of the auxiliary battery.
NOTICE:
A short circuit to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) terminal of the auxiliary battery. If a short circuit to ground occurs, it can result in an open circuit in a fusible link or fuse.
4. PRECAUTION WHEN REPLACING HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY
(a) Make sure to perform the "Normal Battery Stack Average Voltage Calculation" before removing a hybrid vehicle supply stack sub-assembly Hybrid Control System.
5. PRECAUTION WHEN HANDLING HV BATTERY
(a) When handling the HV battery, disconnect the high voltage connector of the battery smart unit to prevent the hybrid battery cell voltage from dropping.
6. PRECAUTION WHEN DISPOSING OF HV BATTERY AND HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY
(a) When disposing of HV batteries and hybrid vehicle supply stack assemblies, make sure to return them through an authorized collection agent who is capable of handling them safely. If they are returned via the manufacturer specified route, they will be returned properly and in a safe manner by an authorized collection agent.
CAUTION:
* Before returning the HV battery or a hybrid vehicle supply stack sub-assembly, make sure to perform a recovery inspection Testing and Inspection.
* Accidents such as electric shock may result if the HV battery or a hybrid vehicle supply stack sub-assembly is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries or hybrid vehicle supply stack assemblies through an authorized collection agent.
* To reduce the risk of fire, the HV battery or hybrid vehicle supply stack sub-assembly must not be stored in an area where it will be exposed to fire or high temperatures.
7. PRECAUTION WHEN REPLACING POWER MANAGEMENT CONTROL ECU AND ECM
HV battery learning values are stored in the power management control ECU and ECM to display "HAVE TRACTION BATTERY INSPECTED" on the multi-information display. When either of these ECUs is replaced, the new ECU receives the HV battery learning value data from the other ECU and updates the information.
NOTICE:
* Do not replace the power management control ECU and ECM at the same time as it clears the HV battery learning values. However, if it is necessary to replace both ECUs at the same time, replace them by following the procedure below.
* Do not replace the power management control ECU or ECM with used ones from other vehicles.
(a) Procedure when replacing both power management control ECU and ECM:
(1) Disconnect the cable from the negative (-) auxiliary battery terminal.
(2) Replace either of the ECUs.
(3) Connect the cable to the negative (-) auxiliary battery terminal.
(4) Turn the power switch on (READY) and wait for 5 minutes or more.
(5) Turn the power switch off and disconnect the cable from the negative (-) auxiliary battery terminal.
(6) Replace the other ECU.
(7) Connect the cable to the negative (-) auxiliary battery terminal.
(8) Check that the power switch can be turned on (READY).
HINT
If the power management control ECU and ECM are replaced at the same time without following the above procedure, replace either of the ECUs with its original one and then replace it again by following the above procedure. If the correct procedure is not followed, perform the procedure again from the beginning.
8. DISCONNECTING AND RECONNECTING NEGATIVE AUXILIARY BATTERY CABLE
(a) Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or electrical components.
Text in Illustration
(b) Before disconnecting and reconnecting the auxiliary battery cable, turn the power switch off and the headlight switch off. Then loosen the terminal nut completely. Do not damage the cable or terminal.
(c) When the auxiliary battery cable is disconnected, the clock and radio settings and stored DTCs are cleared. Therefore, before disconnecting the auxiliary battery cable, make a note of them.
NOTICE:
* After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.
* When the cable is disconnected from the negative (-) auxiliary battery terminal, initialize the following system(s) after the cable is reconnected.
