T-SB-0110-20 Rev

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
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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.
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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).
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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
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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
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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
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)

2021 – 2022 Prius:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”

2019 (11/18 – 02/19) RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”

2019 (02/19 – 10/19) RAV4:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”

2020 (10/19 – 06/20) RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”

2020 (06/20 – 08/20) RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”

2020 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”

2021 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”

2021 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”

2022 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Nickel Metal Hydride Battery): Charging”

2022 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery (for Lithium-Ion Battery): Charging”

2021 – 2022 Sienna HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery: Charging”

2022 Tundra HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery: Charging”
© 2022 Toyota Motor Sales, USA
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November 2, 2020
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)

2021 – 2022 Venza HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control: HV
Battery: Charging”
4. 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. Remove necessary SST cables located in the HEV tool box drawers.
NOTE
The required cables are listed in the Required Tools & Equipment table shown on page 2.
B. 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.
C. Turn the GRX-5100 ON.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
D. Select Rescue Charge by using the arrow
key, then press Select.
Figure 1.
E. 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 with face shield.
F. Press Yes.
Figure 2.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
Figure 3.
G. Press Next.
NOTE
Refer to the applicable model and model
year Repair Manual for vehicle specific
instructions for disassembly and
connector locations.
H. Ensure the service plug grip is removed,
then press Yes.
Figure 4.
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.
I.
Connect the High Voltage Cable V to the fuse box.
J. Connect the Banana Jack Extension Cable X to the Universal Fuse Box.
K. Connect High Voltage Cable V to the GRX-5100.
L. Connect the Low Voltage Cable R to the GRX-5100.
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.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
M. Connect the green high voltage bonding
cable to a suitable chassis ground.
Figure 5.
N. Press Next.
Figure 6.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
O. Connect the low voltage cable as shown in
the Repair Manual.
Figure 7.
NOTE
The Repair Manual may call this cable
“EV bonding cable (green cable).”
P. Press Next.
Figure 8.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
Q. Plug Cable A619A and Cable A619B into
the HV battery location shown in the
Repair Manual.
Figure 9.
NOTE
Install the HV cables above in the same
location on the junction block as the “High
voltage cable” listed in the Repair Manual.
R. Connect the red (+) Banana Jack Extension
cable into A619A, and the black (-) banana
jack extension cable into A619B.
Figure 10.
S. 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.
NOTE
The Repair Manual will show THS charger usage; please use the GRX-5100 instead.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
T. Press Next.
Figure 11.
U. Wait for the internal test to complete.
Figure 12.
V. Install the service plug grip.
Figure 13.
W. Press Next.
NOTICE
Make sure the service plug grip’s
interlock is fully engaged.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
X. Connect the negative (–) terminal of the auxiliary battery.
NOTE
Using the power supply mode, connect the DCA-8000 to the auxiliary battery.
Y. Wait for the high voltage bonding test
to complete.
Figure 14.
5. 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.
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High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
D. Open the battery charge active test and
click the ON button on Techstream. Then
press Next on the GRX-5100 to start HV
battery charging within 30 seconds.
Figure 15.
NOTE

AFTER the battery charge active test has been turned ON, press Next on the GRX-5100
within 30 seconds. If Next is NOT pressed within 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.





STEP
ACTIVE TEST
BATTERY
CHARGE
GRX-5100 START
SWITCH
DATA LIST SYSTEM MAIN
RELAY STATUS – SMRB
DATA LIST SYSTEM MAIN
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 at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
E. Wait for the HV battery rescue charge
to start.
Figure 16.
F. Repeat the charge cycle up to three times
if required.
Figure 17.
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 at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
6. 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 the 12V auxiliary battery.
D. Remove the service plug grip.
E. Remove the GRX-5100 cables.
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 substep K.

NO — Repeat steps 3 – 6.
K. Confirm whether the engine starts.
Does the engine start?

YES — Continue to step 7.

NO — Continue diagnosis using the applicable Repair Manual.
7. Allow the vehicle to idle in park “P” until the engine stops. Once the engine stops, self-charge
has been completed.
© 2022 Toyota Motor Sales, USA