Hybrid Battery System: Precaution

1. Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as 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.
   NOTE: 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.
2. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals
   Fig 1: Removing Service Plug Grip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT.

   Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

3. 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 2 bolts and connector cover. (For the removal and installation procedures related to the connector cover, (See INVERTER WITH CONVERTER ))
      NOTE: Cover the opening with non-residue tape to prevent entry of foreign matter or liquid after removing the connector cover.
      Fig 2: Locating Connector Cover Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Measure the voltage according to the value(s) in the table below.

      Standard voltage 

      VOLTAGE SPECIFICATION
      
      

      Tester Connection	Condition	Specified Condition
      Inspection point	10 minutes passed after removing the service plug	0 V

      HINT.

      Set the tester to DC750 V or more to measure the voltage.

4. When turning the power switch on (IG) during inspections, do not press the power switch with the brake pedal depressed
   Fig 3: Measuring Voltage Between Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.
5. Turn the power switch off, wear insulated gloves, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.
6. Turn the power switch off before performing any resistance checks
7. Turn the power switch off before disconnecting or reconnecting any connectors
8. When high-voltage connectors are removed, wrap the connectors with insulation tape to prevent them from contacting foreign objects.

1. When the warning light is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the power switch on (READY) may not start the system (the system may not enter the READY-on state) on the first attempt If so, turn the power switch off and reattempt to start the hybrid system.

HINT.

The AMD terminal is connected to the positive terminal of the auxiliary battery.

1. Be sure to disconnect the negative terminal from the auxiliary battery before disconnecting the AMD terminal from the hybrid vehicle converter.
2. After disconnecting the AMD terminal, wrap the terminal with insulation tape.
3. Be sure to reconnect the AMD terminal to the hybrid vehicle converter before reconnecting the negative terminal to the auxiliary battery
   NOTE: A short circuit to ground may occur if the AMD terminal is disconnected before the negative terminal of the auxiliary battery is disconnected. If a short circuit to ground occurs, it can result in an open circuit in a fusible link or fuse.