Hybrid Battery Control: Hv Battery: Charging; 2010 My Ls600h [11:2009 - ]

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11/4/14, 4:YBRID BATTERY CONTROL: HV BATTERY: CHARGING; 2010 MY LS600H [11/2009 - ]

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Last Modified: 3-17-2014 6.6 N Doc ID: RM000004GKI022X

Model Year: 2010 Model: LS600H Prod Date Range: [11/2009 - ]

Title: HYBRID BATTERY CONTROL: HV BATTERY: CHARGING; 2010 MY LS600H [11/2009 - ]

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.

2. PREPARATION FOR HV BATTERY CHARGING

CAUTION:

The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result

if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure .

Wear insulated gloves.

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.

(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 the shift lever in P until the enginestops (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 25C (77F), 10 minutes may be
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sufficient, if the battery temperature is 0C (32F), 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.)

(b) Remove the service plug grip .

(c) Remove the V-bank cover sub-assembly .

(d) Remove the engine room side cover RH .

(e) Remove the cowl top ventilator louver RH .

(f) Remove the motor cable cover RH .

(g) Remove the inverter cover assembly RH .

(h) Remove the 2 bolts and connector cover assembly.

(i) Check terminal voltage .

(j) Remove the inverter terminal cover.

NOTICE:

Lift the inverter terminal cover, keeping it horizontal so that it will not tilt. Failure to do so may break the

inverter cover guide pins.

(1) Remove the 2 bolts.

(2) Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near

bolt hole A to raise the terminal cover by approximately 2 mm (0.08in.). (*1)
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NOTICE:

Tape the screwdriver tip before use.

(3) Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near

bolt hole B to raise the terminal cover by approximately 2 mm (0.08in.). (*2)

NOTICE:


HINT:

Repeat the preceding steps (*1) and (*2) until the inverter cover can be easily removed by hand.

(k) Remove the inverter terminal cover by hand.

NOTICE:

Do not allow any objects to get on the rubber waterproofing seals of the inverter terminal cover.

Do not touch the rubber waterproofing seals.

When removing the inverter terminal cover, do not end the connector terminals for the interlock part.

Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry

of foreign matter.

HINT:

The interlock terminals connect to the inverter terminal cover and are located inside the inverter, close to

the guide pin that is beside the three bolts that secure the motor cable terminals.

(l) Remove the 3 bolts and separate the motor cable brackets.

(m) Remove the 5 bolts and pull out the motor cable from the

inverter with converter assembly.

NOTICE:

Cover the hole where the cable was connected with tape or

equivalent (non-residue type) to prevent entry of foreign matter.

When removing the bolts that secure the cable, do not damageanything inside the inverter with converter assembly.

(n) Remove the 5 bolts and pull out the generator cable from the


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(r) 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:

TESTER CONNECTION CONDITION SPECIFIED

CONDITION

Frame wire connector housing - Body

groundAlways Below 1 !

(s) If the result is not as specified, inspect the connection shown in

the illustration for proper installation.

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


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SST: 09880-10021

09881-10041

SST: 09882-10040

SST: 09882-10070

SST: 09881-10081

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.


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(u) Connect the EV bonding cable to the installation bolt of the No.

1 motor cooling pipe.

Torque:

13 Nm {133 kgfcm, 10ftlbf}

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

(w) Install the connector cover assembly to the inverter with

converter assembly.

(x) Connect the low voltage cable to the installation bolt of the connector cover.

Torque:

8.0 Nm {82 kgfcm, 71inlbf}

(y) Connect the high voltage cable to the frame wire with the bolt.

Torque:



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(z) Connect the low voltage cable and high voltage cable to the THS

charger in the order shown in the illustration.

(aa) Install the service plug grip .

(ab) Connect the negative (-) auxiliary battery terminal.

(ac) 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 HV battery charging procedure again.

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

STEP ACTIVE TEST

BATTERY

CHARGE

THS CHARGER

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

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

released).
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(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 25C (77F), 10 minutes may be

sufficient, if the battery temperature is 0C (32F), 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.


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(1) Disconnect the power inlet plug of the charger from the grounded AC 100 to 240 V receptacle.

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

(3) Remove the service plug grip .

(4) Disconnect the high voltage cable and low voltage cable from

the THS charger in the order shown in the illustration.

(5) Remove the bolt and disconnect the high voltage cable from

the frame wire.

(6) Disconnect the low voltage cable from the installation bolt of

the connector cover.

(7) Remove the connector cover assembly from the inverter with converter assembly.
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(8) Disconnect the EV bonding cable from the THS charger.

(9) Disconnect the EV bonding cable from the installation bolt of

the No. 1 motor cooling pipe.

(10) Install the cooling pipe with the bolt.

Torque:

13 Nm {133 kgfcm, 10ftlbf}

(11) Install the frame wire to the inverter with converter

assembly with the bolt.

Torque:

8.0. Nm {82 kgfcm, 71inlbf}

(12) Remove the inverter terminal cover.

NOTICE:

Lift the inverter terminal cover, keeping it horizontal so that it will not tilt. Failure to do so may break the

inverter cover guide pins.


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1. Remove the 2 bolts.

2. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter

case near bolt hole A to raise the terminal cover by approximately 2 mm (0.08in.). (*1)

NOTICE:


3. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter

case near bolt hole B to raise the terminal cover by approximately 2 mm (0.08in.). (*2)

NOTICE:


HINT:

Repeat the preceding steps (*1) and (*2) until the inverter cover can be easily

removed by hand.

4. Remove the inverter terminal cover by hand.

NOTICE:

Do not allow any objects to get on the rubber waterproofing seals of the inverter

terminal cover.

Do not touch the rubber waterproofing seals.

When removing the inverter terminal cover, do not bend the connector terminals for

the interlock part.

(13) Connect the generator cable to the inverter with converter

assembly.

(14) Secure the generator cable to the inverter with converter assembly with the 5 bolts.


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Torque:


NOTICE:

When installing the bolts that secure the cable, do not damage anything inside the inverter with converter

assembly.

Make sure that no foreign matter is present on the terminal block.

Make sure to tighten each bolt to the specified torque. Failure to do so may result in damage to the bolt,

cable or inverter with converter assembly.

(15) Connect the motor cable to the inverter with converter

assembly.

(16) Secure the motor cable to the inverter with converter assembly with the 5 bolts.

Torque:


NOTICE:

When installing the bolts that secure the cable, do not damage anything inside the inverter with converter

assembly.

Make sure that no foreign matter is present on the terminal block.

Make sure to tighten each bolt to the specified torque. Failure to do so may result in damage to the bolt,

cable or inverter with converter assembly.

(17) Install the motor cable brackets with the 3 bolts.

Torque:


(18) Install the inverter terminal cover.

1. Set the inverter terminal cover to the inverter with converter assembly.


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NOTICE:

Check that the sealing rubber is securely installed to the inverter terminal cover before

installing the cover.

Make sure that there are no foreign objects on the rubber waterproofing seals beforeinstalling the inverter terminal cover.

Install the inverter terminal cover while inserting the guide pins on the both sides of

the cover into guide pin holes of the inverter case.

When installing the inverter terminal cover, do not bend the connector terminals for

the interlock part.

2. Push in both ends of the inverter terminal cover by hand, keeping it horizontal.

NOTICE:

Insert the inverter terminal cover, keeping it horizontal, preventing it from tilting.

Make sure that both the inverter terminal bolt holes are aligned and in contact with the

holes in the inverter case.

3. Secure the inverter terminal cover to the inverter with converter assembly with the 2 bolts.

Torque:


(19) Install the connector cover with the 2 bolts.

Torque:


(20) Install the service plug grip .

(21) Connect the negative (-) auxiliary battery terminal.

(22) Check if the engine starts.
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HINT:

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

(23) 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 it idling with the shift lever in P until the engine stops.

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.

Hybrid Battery Control: Hv Battery: Charging; 2010 My Ls600h [11:2009 - ]

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