T-SB-001-13

@TOYOTA
Rev1
T-SB-0001-13
Technical Service Bulletin
January 2, 2013
Maintenance for EV & Auxiliary Batteries
Service
Category
Section
General
Toyota Supports ~
Pre-De livery Service
Market
ASE Certification .
USA
Applicability
YEAR(S)
MODEL(S)
2013-2014
RAV4 EV
ADDITIONAL INFORMATION
REVISION NOTICE
September 6, 2013 Rev1:
• Applicability has been updated to include 2014 model year RAV4 EV vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
The RAV4 EV is equipped with 2 types of batteries:
•
Electric Vehicle (EV) Traction Battery
•
12-volt Auxiliary Battery
If the RAV4 EV is put into storage, the state of charge (SOC) of the EV battery and auxiliary battery
will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage,
proper maintenance is necessary.
Please perform the following maintenance service for the EV battery and 12-volt auxiliary battery.
NOTE
• Before disconnecting the auxiliary battery, confirm the shift lever is in the "P" position and
apply the parking brake completely. The shift lever CANNOT be shifted from the "P" position
with the 12-volt auxiliary battery disconnected.
• When the negative(-) terminal of the auxiliary battery is reconnected, the EV system may not
operate if the vehicle is already in "Ready On" state. If this occurs, push the Start/Stop switch
to re-initiate the "Ready On" mode. The "Ready" light should illuminate on the Instrument
Panel. If the EV system will not "Ready On" refer to the Repair Manual for diagnosis.
Warranty Information
OP CODE
DESCRIPTION
N/A
Not Applicable to Warranty
© 2013 Toyota Motor Sales , USA
TIME
OFP
T1
T2
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@TOYOTA
T-SB-0001-13
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January 2, 2013
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Maintenance for EV & Auxiliary Batteries
Maintenance Items
CONDITION"
MAINTENANCE OPERATION
Before Delivery
Fully charge 12-volt auxiliary battery (deliver the vehicle
to the customer after it is fully charged 12 .6 V or more).
To Store for 30 Days or More
Disconnect the negative(-) terminal of the 12-volt
auxiliary battery under the hood to prevent the
SOC of the auxiliary battery from decreasing during
storage due to parasitic current.
Just After Unloading & Every 2 Months
Fully charge EV battery using vehicle charging station .
· The condition also corresponds with the section titles within this bulletin.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QlY
GR8 Battery Diagnostic Station **
00002-MCGRB
1
•• Essential SST.
NOlE
The GR8 Battery Diagnostic Station (PIN 00002-MCGRS) supersedes the Automatic Trickle Charger
(P/N 00002-YA122-01) and Fast Battery Chargers (Associated PIN ASE6003 and Christie P/N
CAPPDQ). P/N 00002-YA122-01, ASE6003, and CAPPDQ are now obsolete.
Before Delivery
Fully charge the 12-volt auxiliary battery:
1. Before charging the auxiliary battery, turn OFF vehicle, lights, and accessories.
2. Open the hood.
© 2013 Toyota Motor Sales , USA
@TOYOTA
T-SB-0001-13
Rev1
January 2, 2013
Page 3 of 9
Maintenance for EV &, Auxiliary Batteries
Before Delivery -Fully charge the 12-volt auxiliary battery: (Continued)
3. Remove the positive(+) terminal cover.
Figure 1.
1
Positive Battery Terminal
2
Negative Battery Terminal.
3
Hold Down Clamp
4. Check the battery SOC.
•
If the batteryvoltage is LESS THAN 12.6 V, then continue to step 5.
•
If the battery voltage is 12.6 V or MORE, replace the positive(+) terminal cover and close
the hood.
NOTE
If measuring the voltage with the negative(-) terminal connected, turn vehicle OFF and turn
ON the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.
© 2013 Toyota Motor Sales, USA
@TOYOTA
T-SB-0001-13
Rev1
January 2, 2013
Maintenance for EV & Auxiliary Batteries
Before Delivery -Fully charge the 12-volt auxiliary battery: (Continued)
5. Test/charge the 12-volt auxiliary battery using the
GR8 Battery Diagnostic Station.
Figure 2.
A. Connect the red charger clamp to the
positive(+) battery terminal and the black
charger clamp to the negative (-) battery
terminal.
B. Plug the charger into a grounded 110-volt
nominal outlet and flip the power switch to the
"ON" position .
C. Once the charger is properly turned ON,
perform a diagnostic charge.
The GR8 Battery Diagnostic Station will
indicate result when complete.
1
If the battery tests bad ("Replace Battery"),
then replace the auxiliary battery.
NOTE
If the auxiliary battery was stored at 32' F WC)
or below, charge the auxiliary battery in a room
above 32° F WC).
CAUTION
• Charge in a well-ventilated area.
• Do NOT allow sparks or fire near the
auxiliary battery.
If the GR8 Battery Diagnostic Station is NOT
available, you may charge the 12-volt battery by
cycling the vehicle on to "READY"
• Run time will vary depending on the state of
charge.
• If this method is used, you must confirm that
the battery is charged to 12.8 volts using a
DVOM.
© 2013 Toyota Motor Sales , USA
I
P/N 00002-MCGRS
Page 4 of 9
@TOYOTA
T-SB-0001-13
Rev1
January 2, 2013
Maintenance for EV & Auxiliary Batteries
Before Delivery -Fully charge the 12-volt auxiliary battery: (Continued)
6_ After charging the auxiliary battery, install the
positive (+}terminal cover.
Figure 3.
1
Positive Battery Terminal
2
Negative Battery Terminal
3
Hold Down Clamp
7. Close the hood.
To Store for 30 Days or More
Disconnect the negative(-) terminal:
1. Turn OFF vehicle, lights, and accessories.
2. Open the hood.
© 2013 Toyota Motor Sales, USA
Page 5 of 9
@TOYOTA
T-SB-0001-13
Rev1
January 2, 2013
Maintenance for EV & Auxiliary Batteries
To Store for 30 Days or More · Disconnect the negative (-) terminal: (Continued)
3. Disconnect the negative(-) terminal.
Figure 4.
1
Positive Battery Terminal
2
Negative Battery Terminal
3
Hold Down Clamp
4. Close the hood.
N01E
When it is necessary to move ihe vehicle, reconnect the negative (-)terminal.
© 2013 Toyota Motor Sales, USA
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®TOYOTA
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January 2, 2013
Maintenance for EV & Auxiliary Batteries
To Store for 30 Days or More (Continued)
When removing the vehicle from storage, connect the negative (-) terminal:
1. Open the hood .
2. Connect the negative (-) tenninal.
Figure 5.
Torque: 6.0 N*m (61 kgf*cm, 4.4 ft*lbf)
~~----...-., ~-_fil....c:::ILJZ::~::JY""
~~---~- ~~
1
Positive Battery Terminal
2
Negative Battery Terminal
3
Hold Down Clamp
3. Close the hood.
NOlE
When the negative (-)terminal of the auxiliary battery is reconnected, the EV system may not
operate if the vehicle is already in "Ready On" state. If this occurs, push the Start/Stop switch
to re-initiate the "Ready On" mode. The "Ready" light should illuminate on the Instrument
Panel. If the EV system will not "Ready On" refer to the Repair Manual for diagnosis.
© 2013 Toyota Motor Sales , USA
@TOYOTA
T-SB-0001-13
Rev1
January 2, 2013
Page 8 of 9
Maintenance for EV & Auxiliary Batteries
Every Two Months
NOTE
Be sure to reconnect the negative(-) terminal of the auxiliary battery BEFORE performing this
procedure.
1. Park the vehicle next to the EV Charging Station.
2. Apply the parking brake.
3. Turn OFF vehicle, lights, and accessories .
4. Check that the shift lever is in the "P" position.
5. Connect the charging station plug to the vehicle . Confirm that both lights above the charge
plug illuminate. Fully charge the EV battery.
Figure 6.
1
Charging Indicator
4
Charging Port
2
Charging Port Door
5
Charging Cable with CCID (in trunk)
3
Charging Port Cap
6
EV Charging station
© 2013 Toyota Motor Sales , USA
@TOYOTA
Rev1
T-SB-0001-13
January 2, 2013
Page 9 of 9
Maintenance for EV & Auxiliary Batteries
Every Two Months (Continued)
Figure 7.
A
I LightA
B
I
Light B
Check the status of the charging indicator. The charging indicator consists of 2 lights that display
charging status by illuminating , flashing, and turning off as follows .
CHARGING INDICATOR
CHARGING STATUS
LIGHT A
The charging cable is connected to
the vehicle and the charging and/or
pre-climate schedule is set
LIGHT B
Lights A and B flash On and Off alternatively fur 10 minutes .
(After 10 minutes both lights rema in Off until charging starts)
Charge level is less than 49%
Flashes
Off
Charge level is between 50%
and less than 99%
Illuminates
Flashes
Charging is complete
Both lights A and B illuminate for 10 minutes.
(After 10 minutes both lights turn Off)
Malfunction occurred during
charging
Both lights A and B quickly flash simultaneously fur 10 seconds.
(After 10 seconds both lights turn Off)
The indicator lights will not flash or turn on when the charging cable is not connected properly.
© 2013 To)":lta Motor Sales , USA