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GRX-5100

Cable Connections

Click the tabs at the top and side to view each section

Charging Process

HEV Workstation

1.  Main Menu

 – Use the left 

and right arrow keys on 
the control panel to scroll 
through the menu choices 
until “Rescue Charge” is 
highlighted, then press the button  
under “Select.”

2.  Warning

 – Confirm you are 

wearing appropriate personal 
protective equipment by 
pressing the button under 
“Yes.” Always refer to the 
repair information for the specific Toyota 
hybrid model you are working with.

3.  Warning

 – Confirm you are 

following appropriate repair 
procedures by pressing the 
button under “Next.”

4.  Warning

 – Confirm that you 

have removed the service 
plug grip by pressing the 
button under “Yes.”

5.  Instructions

 – Connect the 

green HV (EV) bonding cable  
to the vehicle per the repair 
instructions, and then press 
the button under “Next.”

6.  Instructions

 – The only 

wire in the low voltage 
cable (Cable “R”) is the 
green bonding wire that was 
connected  to the vehicle in 

Screens,

 

Part 1

These are the screens on the GRX-5100 control panel that you will see when performing a rescue charge.

Battery

Condition

Befor

e

Servicing

Pr

ocess

Overview

Scr
eens:

Part 1

7.  Instructions

 – Connect the  

vehicle-specific high voltage 
cable between the vehicle 
and the high voltage fuse 
box. Then connect the 
universal cable between the fuse box and the 
GRX-5100. When the high voltage cables are 
connected, press the button under “Next.”

the previous step. Therefore, it is only necessary 
to now connect the low voltage cable to the GRX-
5100, and then press the button under “Next.” 

(See “2001-2009 Pruis” tab for exceptions.)

Battery Charge 

Active Test

Toyota NiMH Battery Rescue Charging with the GRX-5100

Quick Training Guide QT015A

Scr
eens:

Part 2

2001-2009

Prius

13 of 21

©Toyota Motor Sales, U.S.A., Inc., December 16, 2015

Summary of Contents for GRX-5100 L

Page 1: ...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 P...

Page 2: ...hicle you re servicing for the specific location and procedure for removing the service plug grip Before Servicing 1 Turn the vehicle power switch OFF and remove the key from the interior detection ar...

Page 3: ...power switch OFF and turn off the GRX 5100 Disconnect GRX 5100 Disconnect the GRX 5100 power cord and remove the negative battery terminal of the auxiliary battery Remove the service plug grip Disconn...

Page 4: ...tions and then press the button under Next 6 Instructions The only wire in the low voltage cable Cable R is the green bonding wire that was connected to the vehicle in Screens Part 1 These are the scr...

Page 5: ...reen appears connect the low voltage cable as instructed in the Repair Manual then connect the other end to the GRX 5100 GRX 5100 Cable Connections Click the tabs at the top and side to view each sect...

Page 6: ...s the button under Next Charge Wait while the GRX 5100 performs an HV bonding test Charge Connect the Techstream to DLC3 and navigate to the Battery Charge Active Test Turn the Active Test ON and then...

Page 7: ...ions for rescue charging Note that the high voltage cable that connects to the vehicle is model specific Cabling Overview Verify Frame Wire Ground Low Voltage Cable High Voltage Cables Interlock Cover...

Page 8: ...ield line of the frame wire is not securely connected to body ground the error message Battery not detected or HV bonding test failed may appear and the GRX 5100 will not operate If the resistance is...

Page 9: ...low voltage cable and the green HV EV bonding cable are one and the same cable R Because 2001 2009 Prius models continue to use an green HV EV bonding cable AND a low voltage cable the instructions on...

Page 10: ...cable Cable V to the high voltage fuse box 4 Connect Cable V to the GRX 5100 High Voltage Cables Verify Frame Wire Ground Low Voltage Cable High Voltage Cables Cabling Overview High Voltage Cable Use...

Page 11: ...if the frame wire is disconnected It is not possible to charge the battery with this interlock open so an interlock cover is provided in drawer 2 of the HEV Workstation When installed the interlock co...

Page 12: ...procedure again As charging is taking place monitor the battery voltage If battery is insufficiently charged not above minimum voltage after first 10 minute cycle repeat the charge cycle Battery Char...

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