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Midtronics GRX-5100 Quick Training Manual
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Midtronics GRX-5100 Quick Training Manual

Battery service unit
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NiMH Battery Rescue Charging with the GRX-5100
This Quick Training Guide provides an overview of the components and operation of the High Voltage
Battery Service Unit (GRX-5100) and the HEV Workstation for performing rescue charging of NiMH
batteries in Toyota hybrid vehicles. Prepared only for technicians that are Toyota Hybrid System certified.
CAUTIONS:
• Always wear the appropriate Personal Protective Equipment (PPE) provided in the HEV Workstation
when working with High Voltage.
• Always use the safing procedures detailed in the repair information for the specific hybrid model you
are working with.
Quick Training Guide – QT015A
Click the ENTER button to view the Quick Training Guide.
ENTER
©Toyota Motor Sales, U.S.A., Inc., December 16, 2015

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Summary of Contents for Midtronics GRX-5100

  • Page 1 This Quick Training Guide provides an overview of the components and operation of the High Voltage Battery Service Unit (GRX-5100) and the HEV Workstation for performing rescue charging of NiMH batteries in Toyota hybrid vehicles. Prepared only for technicians that are Toyota Hybrid System certified.

  • Page 2: Before Servicing

    Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Click the tabs at the top and side to view each section Before Servicing 1. Turn the vehicle power switch OFF, and remove the 4.
  • Page 3 Monitor battery voltage until charging is complete • Turn the vehicle power switch OFF and turn off the GRX-5100 • Disconnect the GRX-5100 power cord and remove the negative battery terminal of the auxiliary battery • Remove the service plug grip •...
  • Page 4 Click the tabs at the top and side to view each section Screens, Part 1 These are the screens on the GRX-5100 control panel that you will see when performing a rescue charge. 1. Main Menu – Use the left 5.
  • Page 5 Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Click the tabs at the top and side to view each section 2001 – 2009 Pruis Step 6 of the charging process for the 2001-2003 Pruis and the 2004-2009 Pruis differs slightly from other Toyota hybrid models.
  • Page 6 Click the tabs at the top and side to view each section Screens, Part 2 These are the screens on the GRX-5100 control panel that you will see when performing a rescue charge. 8. Self-Test – Wait while the Charge – Connect the...

  • Page 7: Cabling Overview

    Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Click the tabs at the top and side to view each section Cabling Overview This is an overview of the cable connections for rescue charging.
  • Page 8 Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Click the tabs at the top and side to view each section Verify Frame Wire Ground After disconnecting the frame wire and...

  • Page 9: Low Voltage Cable

    (EV) bonding cable AND a low voltage cable, the instructions on Low voltage cable “R” is used the GRX-5100 control panel refer to connecting the green HV (EV) for most Toyota hybrid models. bonding cable first, then connecting the low voltage cable next.

  • Page 10: High Voltage Cables

    Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Click the tabs at the top and side to view each section High Voltage Cables High Voltage Cable Use for: Prius (‘01-‘03)
  • Page 11 Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Click the tabs at the top and side to view each section Interlock Cover On some vehicle models, there is an interlock located on the frame wire that opens the high voltage circuit if the frame wire is disconnected.
  • Page 12 Toyota NiMH Battery Rescue Charging with the GRX-5100 Quick Training Guide QT015A Battery Charge HEV Workstation GRX-5100 Charging Process Cable Connections Active Test Battery Charge Active Test Click the tabs at the top to view each section When starting the Active Test, observe the Data List The Battery Charge Active Test turns on SMRB and to verify that SMRB and SMRG are ON.