HEV Battery Service Tool
INSTRUCTION MANUAL
GRX-5100
Hazardous voltage.
An improper connection can result in
serious injury or death.
To avoid electrical shock or burn, never alter the
GRX-5100’s original AC cord and plug. Disconnect plug from outlet when GRX-5100 is idle.
GRX-5100 HEV Battery Service Tool
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2
GRX-5100 HEV Battery Service Tool
Contents
General Safety Guidelines 5
Maintenance 5
Personal Precautions 6
Grounding & Power Cord Connections 6
GRX-5100 Location 7
Chapter 1: Introduction & Overview 8
Safety Precautions 8
Connecting To AC Power 8
Manual Conventions 8
Front View 9
Right End Panel 9
Connection Panel 9
Included Accessories 10
Optional Accessories 10
Display and Keypad 11
Data Entry Methods 12
Menu Icons 12
Option Buttons 12
Scrolling Lists 12
Alphanumeric Entry 12
Main Menu 12
Tool Info Menu 13
Utility Menu 13
Initial Startup 13
Changing User Preferences 13
Chapter 3: Stack/Pack Discharge 15
Stack/Pack Discharge Results 16
Chapter 4: Stack Balance 17
Stack Balance Results 17
Chapter 5: Tool Info 18
Totals 18
Life Time Totals 18
Version 18
Chapter 6: Utility Menu 19
Clock Adjust 19
Mode 19
Time 19
Format 19
Date 19
Display 19
Temperature 20
Capacity 20
Language 20
Dealer ID 20
Update 20
Performing An Update 20
Buzzer 21
Region 21
Chapter 2: Rescue Charge 14
Rescue Charge Results 14
Chapter 7: Error Messages 22
Error Codes 22
Hardware Error 23
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GRX-5100 HEV Battery Service Tool
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GRX-5100 HEV Battery Service Tool
General Safety Guidelines
General Safety Guidelines
IMPORTANT SAFETY INSTRUCTIONS - SAVE
THESE INSTRUCTIONS
IT IS OF UTMOST IMPORTANCE THAT BEFORE USING YOUR
GRX-5100, YOU READ THIS MANUAL AND FOLLOW THE
SAFETY AND OPERATING INSTRUCTIONS EXACTLY.
Hazardous voltage.
Can result in electric shock when the
protective covers are removed.
Circuit boards, test points, and output voltages also may be oating above (below)
chassis ground.
This GRX-5100 is designed for indoor use
only.
1. Maintenance
• Periodic inspection and care are highly recommended,
especially if the GRX-5100 is operating in a harsh environment.
• Inspect signs of overheating, rust paint deterioration,
and general condition of the unit. If corrective measures
should be taken, contact the Special Service Tools hotline
(1-800-933-8335) for service information.
• Removal of dust, dirt, and debris from the external enclo-
sure surfaces is encouraged and may be performed while
the unit is in operation.
IMPORTANT: There are no user-serviceable parts
inside the GRX-5100. At no time should personnel remove any cover.
• Ensure that the AC power line ground is connected prop-
erly to the GRX-5100 input connector or chassis. Similarly,
other power ground lines including those to application
and maintenance equipment must be grounded properly
for both personnel and equipment safety.
• In normal operation, the operator does not have access
to hazardous voltages within the chassis. However, depending on the user's application conguration, HIGH
VOLTAGES HAZARDOUS TO HUMAN SAFETY may be normally generated on the output terminals. The customer/
user must ensure that the output power lines are labeled
properly as to the safety hazards and that any inadvertent
contact with hazardous voltages is eliminated.
• This GRX-5100 is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have
been given supervision or instruction concerning use of the
GRX-5100 by a person responsible for their safety.
Risk of explosive gases
Batteries generate explosive gases during normal
operation, and when discharged or charged.
1.1 To reduce risk of battery explosion, follow these safety
instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery. Review cautionary
marking on these products and on the engine, and on the
vehicle or equipment containing the battery.
Charging a non-rechargeable battery may
cause the battery to burst.
To reduce the risk of injury, only charge rechargeable
type batteries.
If you are uncertain as to the type of battery you are attempting
to charge, or the correct procedure for checking the battery’s
state of charge, contact the seller or battery manufacturer.
1.2 Use of an attachment not recommended or sold by the
GRX-5100 manufacturer may result in a risk of re, electric
shock, or injury to persons.
1.3 To reduce risk of damage to the electric plug and cord,
pull by the plug rather than by the cord when disconnecting the GRX-5100.
1.4 Do not operate the GRX-5100 if it has received a sharp
blow, been dropped or otherwise damaged in any way;
contact the Special Service Tools hotline (1-800-933-
8335).
1.5
Do not disassemble the GRX-5100; when repair is required
contact
(see back cover of this manual for more information). Incorrect reassembly may result in a risk of electric shock or
re.
1.6 To reduce risk of electric shock, unplug the GRX-5100 from
the AC outlet or auxiliary 12VDC power cord before attempting any maintenance or cleaning. Turning o the
controls will not reduce this risk.
the Special Service Tools hotline (1-800-933-8335)
5
General Safety Guidelines
1.7
Connect and disconnect the battery leads only when di-
rected to do so by the GRX-5100.
1.8
Do not overcharge the battery (See Section 3).
1.9
Charge the battery in a dry, well-ventilated area.
1.10 Never place articles on or around the GRX-5100, or locate
the GRX-5100 in a way that will restrict the ow of cooling
air through the cabinet.
1.11
An extension cord should not be used unless absolutely
necessary. (See paragraph 3.3.)
1.12 Have a damaged cord or plug replaced immediately.
Do not expose the GRX-5100 to rain or
snow.
2. Personal Precautions
Only technicians certied to work on HEV
systems may use this equipment.
2.1
Always have someone within range of your voice, or close
enough to come to your aid, when working around batteries.
2.2 Have plenty of fresh water and soap nearby in case battery
electrolyte contacts skin, clothing or eyes.
2.3 Always wear all personal protective equipment (PPE)
when operating this equipment.
GRX-5100 HEV Battery Service Tool
3. Grounding & Power Cord Connections
3.1
The GRX-5100 must be grounded to reduce risk of electric
shock. The GRX-5100 is equipped with an electric cord having an equipment grounding conductor and a grounding
plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local
codes and ordinances.
Hazardous voltage.
An improper connection can result in
electric shock
To avoid electrical shock or burn, never alter
the GRX-5100’s original AC cord and plug. Disconnect plug from outlet when GRX-5100 is
idle.
IF THE PLUG DOES NOT FIT THE OUTLET, HAVE A PROPER
OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN.
3.2
This GRX-5100 is for use on a nominal 120 volts or 240 volts
circuit (240 volt power cord not included).
The 120V grounding plug looks like the plug illustrated
in Figure A. A temporary adapter, which looks like the
adapter illustrated in Figures B and C, may be used to
connect this plug to a two-pole receptacle as shown in
Figure B, if a properly grounded outlet is not available. The
temporary adapter should be used only until a properly
grounded outlet can be installed by a qualied electrician.
2.4 If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If electrolyte enters the
eye, immediately ush with cold running water for at least
10 minutes, and seek medical attention.
2.5 NEVER smoke or allow a spark or ame in vicinity of a battery or engine.
2.6 Be extra cautious to reduce risk of dropping a metal tool
onto the battery. It might spark or short circuit the battery
or other electrical part that may cause an explosion.
2.7 Before working with a battery, remove personal metal
items such as rings, bracelets, necklaces, watches, etc. A
battery can produce a short circuit current high enough
to weld such items causing a severe burn.
Non-rechargeable batteries may burst when
charging causing personal injury and damage.
To avoid electrical shock or burn, never alter the GRX-5100’s
original AC cord and plug. Disconnect plug from outlet
when GRX-5100 is idle.
The GRX-5100 is not intended to supply power to a lowvoltage electrical system other than applications using
rechargeable batteries.
Hazardous voltage.
An improper connection can result in
electric shock
Before using an adapter be certain the center
screw of the outlet plate is grounded. The rigid
ear or lug extending from the adapter must be
connected to a properly grounded outlet. Make
certain it is grounded. If necessary, replace the
original screw that secures the adapter ear or
lug to the cover plate and make the ground
connection to the grounded outlet.
USE OF AN ADAPTER IS NOT ALLOWED IN CANADA. IF A
GROUNDING-TYPE RECEPTACLE IS NOT AVAILABLE, DO
NOT USE THIS SERVICE TOOL UNTIL THE PROPER OUTLET
IS INSTALLED BY A QUALIFIED ELECTRICIAN.
2.8 NEVER charge a frozen battery; thaw it out rst.
6
GRX-5100 HEV Battery Service Tool
3.3 An extension cord should not be used unless absolutely
necessary. Use of an improper extension cord could result in a risk of re and electric shock. If an extension cord
must be used, make sure:
a. that the pins on plugs of the extension cord are the
same number, size, and shape as those of the plug
on the GRX-5100;
b. that the extension cord is properly wired and in
good electrical condition;
c. that the wire size is large enough for the AC ampere
rating of GRX-5100 as specied in the table.
Recommended minimum AWG* size for
extension cords for the GRX-5100
25ft.
(7.6m)
16 12 10 8
* American Wire Gauge
50ft.
(15.2m)
100ft.
(30.5m)
150ft.
(45.6m)
3.4 The plugs and receptacles have dedicated grounding
terminals and must be mated with plugs and receptacles
having matching grounding terminals.
General Safety Guidelines
4. GRX-5100 Location
IMPORTANT: The GRX-5100 is designed for indoor
use only!.
It is the responsibility of the operator to provide a controlled
environment for the equipment. Work tents are a common
method of protecting equipment in adverse conditions.
The GRX-5100 depends upon the surrounding air for cooling.
The free ow of air is important as is the air temperature. The
GRX-5100 must be mounted so that air can freely circulate all
around it.
4.1 Do not place combustible materials on or near the GRX5100 or mount the GRX-5100 closer than 3 inches from
any adjacent wall. The GRX-5100 must never be mounted
next to or above heat generating equipment.
4.2 Locate the GRX-5100 as far away from the battery as the
cables permit.
4.3 Never place the GRX-5100 directly above the battery being charged; gases from the battery will corrode and damage the GRX-5100.
4.4 Only operate the GRX-5100 in a well-ventilated area that is
free of dangerous vapors.
4.5 Store the GRX-5100 in safe, dry location
4.6 Do not operate the GRX-5100 in high relative humidity
conditions (95% non-condensing maximum)
7
Chapter 1: Introduction & Overview
GRX-5100 HEV Battery Service Tool
Chapter 1: Introduction & Overview
Safety Precautions
For safe, ecient, and accurate charging and discharging,
review the safety and operating instructions in this manual
before using the GRX-5100. In addition, follow all manufacturers’
instructions and SAE instructions.
Always use the necessary safety precautions when working with
batteries to prevent severe injury or death. Follow all Toyota/
Lexus/Scion instructions and SAE safety recommendations,
which include the following precautions:
Risk of explosive gases.
Never smoke or allow a spark or
ame in the vicinity of a battery.
Batteries can produce a highly explosive mix
of gases, even when the battery is not in operation. Always work in a well-ventilated area.
Wash hands after handling.
REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related accessories can contain lead and lead
compounds, chemicals known to the state of California
to cause cancer and birth defects or other reproductive
harm.
Battery electrolyte is highly corrosive. If electrolyte enters
your eyes, immediately ush them thoroughly with cold
running water for at least 10 minutes and seek medical
attention. If battery electrolyte gets on your skin or clothing, wash immediately with a mixture of water and baking
soda.
Always wear proper safety glasses and face shield when
working with or around batteries.
Keep hair, hands, and clothing as well as the GRX-5100
cords and cables away from moving engine parts.
Remove any jewelry or watches before you start servicing
the battery.
Use caution when working with metallic tools to prevent
sparks or short circuits.
Never lean over a battery when charging or discharging.
Never charge a frozen battery. Gases may form, cracking
the case, and spray out battery electrolyte.
Connecting To AC Power
Plug the GRX-5100 into a dedicated, grounded nominal 15amp or higher AC outlet. Press the power switch to the ON
position.
Manual Conventions
To help you learn how to use your GRX-5100, the manual uses
these symbols and typographical conventions:
Symbols And Typographical Conventions
Convention Description
The safety symbol indicates instructions
!
CAPITAL
LETTERS
NEXT The text for soft keys are in BOLD capital
for avoiding hazardous conditions and
personal injury.
The safety symbol with the words
CAUTION, WARNING, or DANGER
indicates instructions for avoiding
hazardous conditions and personal injury.
The wrench symbol indicates procedural
notes and helpful information.
The text for screen options are in regular
capital letters.
letters.
8
GRX-5100 HEV Battery Service Tool
Front View
Chapter 1: Introduction & Overview
Lifting Handles
Emergency STOP Button
Keyboard & Display
Right End Panel
Connection Panel
11A Midget Fuse
High Voltage Cable Connection
Connection Panel
External 12V Auxiliary Power
USB-A Port
For connecting an external USB-style jump drive.
GR-8
Not currently used.
RS-232
For future use.
11
USB-B
For future use.
12
Diagnostic Indicator LED Lights
13
Low Voltage Cable Connection
Used to connect to the low voltage battery electronic
control unit based on the application.
14
WiFi Antenna Connection
14
11
12
13
9
Chapter 1: Introduction & Overview
Included Accessories
GRX-5100 HEV Battery Service Tool
Midtronics
Part Number
A296 01413-00010 Universal Fuse Box -
A501 01413-00013 High Voltage Cable A A
A502 01413-00014 High Voltage Cable B B
A503 01413-00015 High Voltage Cable C C
A504 01413-00016 High Voltage Cable D D
A505 01413-00009 High Voltage Cable E E
A507 01413-00018 High Voltage Cable (+)
A521 01413-00024 Stack Balance Harness (+)
A531 01413-00022 Low Voltage Cable P P
A532 01413-00023 Low Voltage Cable Q Q
A533 01413-00004 Low Voltage Cable R R
A541 01413-00019 Cell Voltage Cable J J
A551 01413-00020 Temperature Sensor Cable K K
A552 01413-00021 Cell Voltage Cable L L
A564 01413-00031 Banana Jack Cable X X
A571 01413-00007 High Voltage Cable V V
A572 01413-00008 Low Voltage Cable W W
A573 01413-00005 AC Power Cord S
A574 / A575 01413-00006 DC Adapter Kit: 12VDC Cigarette Adapter Harness
A580 01413-00003 Interlock Connector -
A585 01413-00011 4GB USB Flash Drive -
A586 01413-00012 AC Circuit Checker -
BCU-64 01413-00017 BCU-64 Cell Interface Module -
GRX-5100 T 01413-00002 High Voltage Diagnostic Unit (GRX-5100) -
A587 01413-00031 WiFi Antenna -
A619 High Voltage Stack Harness #2-A
A620 BCU Harness A620
A621 BCU Temperature Harness A621
Toyota
Part Number
Description
High Voltage Cable (–)
Stack Balance Harness (–)
12VDC Cigarette to Clamp Adapter Harness
High Voltage Stack Harness #2-B
Designation
G (+)
G (–)
I (+)
I (–)
T
U
A-619-A
A-619-B
Letter
Optional Accessories
Midtronics
Part Number
A588 01413-00086 Harness, BCU-64 Jumper – Short Y
A589 01413-00087 Harness, BCU-64 Jumper – Long Z
A576 01413-00084 Fuse, Midget 11A 1000 VDC (Spares) -
A577 01413-00085 Fuse, Midget 20A 600 VDC (Spares) -
Toyota
Part Number
Description
10
Letter
Designation
GRX-5100 HEV Battery Service Tool
Chapter 1: Introduction & Overview
Display and Keypad
The display and keypad work together to help you quickly
nd and use the right tools at the right time. The display also
keeps you on track with onscreen navigation aids, directions
and messages. The illustration shows how the elements on the
screen relate to the keypad.
STOP Key
Press the STOP key to abort a battery servicing session.
Selection Area
The selection area below the Title Bar contains selectable
items or dialog boxes that display information or require
a response.
Menu Screen Arrows
When displayed in menu screens, the menu screen arrows
show you which ARROW key on the keypad to press to
display other icons or screens.
For example, the up and down arrows indicate when to
press or to display the screens above and below the
current screen.
you when to use or to select an icon.
When displayed under a list of options, the menu screen
arrows show you which keypad arrow to press to highlight
a character or item in a list.
Scroll Bar
Another navigational aid is the scroll bar on the right side
of the screen. The position of its scroll box shows you
whether the screen is the top (or only screen), middle, or
last in a series.
The left and right menu screen arrows tell
Title Bar
The title bar shows you the name of the current menu,
utility, or function.
Soft Keys
Press the two soft keys linked to the bottom of the screen
to perform the functions displayed above them. The
functions change depending on the menu or test process.
So it may be helpful to think of the words appearing above
them as part of the keys.
Some screens also indicate the page order with a notation
such as P1/3 (page 1 of 3).
Scroll
Box
Top or only
screen
Alphanumeric Keypad
In some cases, you can use the alphanumeric keypad to
enter numerical test parameters instead of scrolling to
them with the ARROW keys.
You can also use the alphanumeric keys to create and edit
customer coupons and your shop contact information on
printed test results, and manage User IDs.
To add a space, press . To erase a space and insert a
character, press .
Middle
screen
Last
screen
ARROW ( ) Keys
Press the ARROW keys to scroll to numerical values and
move to menus and icons.
11
Chapter 1: Introduction & Overview
GRX-5100 HEV Battery Service Tool
Refer to the following table for the characters associated
with each alphanumeric key.
Key Character
Alphanumeric Keys and Associated Characters
$ - ( ) 1
a b c 2
d e f 3
g h i 4
j k l 5
m n o 6
p q r s 7
t u v 8
w x y z 9
% , . # 0
Data Entry Methods
Typically, the soft key below the right half of the screen
conrms your choice, although the command above it may
vary. (Examples: SELECT, NEXT, and SAVE.) In a similar
fashion, the soft key below the left half of the screen cancels
your choice or returns you to the previous screen, although
the word above it may also vary. (Examples: BACK and CLEAR.)
When using the ARROW keys to select option buttons, press
NEXT to continue to the next step. When using the keypad,
no additional keypress is needed. Use
Main Menu at the start of the test and or the previous screen
during the test.
Menu Icons
A menu icon is a graphical
representation of a function you can
select, such as the Rescue Charge
Icon in the Main Menu. To select
an icon, use or to highlight it.
Highlighting changes the icon to a white picture on a black
background. To conrm your selection, press the appropriate
soft key.
Option Buttons
Some lists have option buttons before
each item. To select an item, use or
to move the dot to the button next
to the item. To conrm your selection,
press the appropriate soft key.
You can also use the alphanumeric keypad to enter the
number preceding the option button of your choice. No
additional keypress is needed to proceed.
BACK to return to the
Scrolling Lists
Scrolling lists contain items that
extend above and below the screen.
The rst number above the right soft
key indicates the position in the list
of the highlighted item. The second
number above the right soft key indicates the number of items
in the list.
To select an item, use or to highlight the item, and press
the appropriate soft key. To move the highlight bar up five
lines at a time, press . To
lines at a time,
press
move the highlight bar down ve
.
Alphanumeric Entry
Some selections require you to use
the alphanumeric keypad. These
“user-defined” selections have a
blinking horizontal line (cursor) to
the right of the last character.
Use or to highlight a line for editing. Display the character,
symbol, or number you want by rapidly pressing its key as
many times as needed. If you pause, the cursor moves to the
right. To backspace, press . Use to add a space. Use
or to highlight a line for editing. When nished, press the
appropriate soft key to save your settings.
Main Menu
The Main Menu is the starting point for all tools and utilities,
which are depicted as icons.
Icon Description
Perform a rescue charge on a discharged
battery pack.
STACK
Discharge a battery pack or individual battery
stack.
Charge or discharge a stack of the battery
pack to bring it into electrical balance.
View lifetime test totals and access software
version information.
Modify the tool clock, display, temp units, default
language, internal software, and warning tone.
RESCUE
CHARGE
DISCHARGE
BALANCE
TOOL INFO
UTILITY
12
GRX-5100 HEV Battery Service Tool
Chapter 1: Introduction & Overview
Tool Info Menu
The Tool Info menu allows you to select and view life-
time Totals and view Software Version information.
Icon Description
This report displays the total number of
charges and depowerings performed by the
TOTALS
VERSION
tool.
Lists the software version, version date, and
serial number.
Utility Menu
The Setup Menu lets you customize the GRX-5100 to suit
your needs. Before testing, check default values to see
what options you may want to change.
Icon Description
Settings to adjust the time.
CLOCK
Add a custom header to printed test results.
SHOP INFO
Adjust the screen contrast and backlight time.
DISPLAY
Select degrees in C or F for temperature
measurements.
TEMPERATURE
Select between Amp hours or Kilowatt hours
displayed.
CAPACITY
Set the default language for the tool display.
LANGUAGE
Enter the Dealer ID number.
DEALER ID
Updates the tool software using a USB-style
jump drive.
UPDATE
Turn the buzzer OFF. Default is ON.
BUZZER
Select the region of the globe in which the tool
is being used.
REGION
Following the logo screen, the LANGUAGE selection screen
appears on the display.
1. Select your LANGUAGE preference.
1 ENGLISH
2 SPANISH
3 FRENCH
2. Select date format.
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
3 YYYY/MM/DD (year/month/day)
3. Adjust the date and press NEXT to continue
Use
or
to select the month, day, and year. Use or
.
to adjust the digits.
10 / 5 / 2017
4. Select 24-hour or 12-hour (AM/PM) clock and press NEXT
to continue, or press the corresponding number key.
1 24 HOUR
2 AM/PM
5. Adjust the tester time setting and press NEXT to continue.
Use
or
to select the hour, minutes, or AM or PM. Use
or to adjust the digits.
9 : 07 AM
6. Use the keypad to enter your Dealer ID.
ENTER YOUR
DEALER ID
7. The Main Menu is now displayed on the screen.
Setting preferences are located in Chapter 6: Utility Menu.
Changing User Preferences
Initial Startup
When using the ARROW keys to select option buttons, press
SELECT or NEXT to continue to the next step. When using the
keypad, no additional keypress is usually needed. Use BACK
to return to the Main Menu at the start of the test and or the
previous screen during the test.
Before using your GRX-5100, you may want to change some of
the default settings.
13
Chapter 2: Rescue Charge
GRX-5100 HEV Battery Service Tool
Chapter 2: Rescue Charge
Use this function to perform a rescue charge on a bat-
tery pack to bring it up to a working voltage.
Hazardous voltage.
An improper connection can result in
electric shock
To avoid electrical shock or burn, never alter the
GRX-5100’s original AC cord and plug. Disconnect plug from outlet when GRX-5100 is idle.
IMPORTANT:
Make sure to properly prepare the battery pack by following all required Toyota/Lexus/
Scion guidelines. Refer to your Toyota/Lexus/Scion
documentation for complete information.
When using the ARROW keys to select option buttons, press
NEXT to continue to the next step. When using the keypad,
no additional keypress is needed. Use
BACK to return to the
Main Menu at the start of the test and or the previous screen
during the test.
NOTE: Maximum time for one Rescue Charge is 10
minutes. More than one Rescue Charge cycle may
be necessary to sucently charge the battery.
8. When prompted, re-install the High Voltage Service Plug.
The GRX-5100 performs an HV Bonding Test.
9. If the HV Bonding Test is successful, use Techstream to
turn on the High Voltage Battery Charge Active Test and
press NEXT within 30 seconds to begin the Rescue Charge
operation.
10. Press STOP to abort RESCUE CHARGE before the process
is complete.
Rescue Charge Results
When complete, the results are displayed on the screen. Press
EXIT to return to the Main Menu.
1. At the Main Menu, select the Rescue Charge icon.
2. Conrm that you are wearing the appropriate personal
protective equipment for high voltage service.
3. Conrm the appropriate repair procedures for this vehicle.
4. Ensure that the High Voltage Service Plug has been removed.
5. Connect the green HV Bonding Cable to a suitable chassis
ground.
6. Connect the Low Voltage cable to the vehicle as outlined
in the repair manual.
7. Connect the High Voltage cable to the vehicle as outlined
in the repair manual.
The GRX-5100 performs an internal self test.
Refer to Toyota/Lexus/Scion repair manual for procedures to
disconnect the GRX-5100 from the battery.
14
GRX-5100 HEV Battery Service Tool
Chapter 3: Stack/Pack Discharge
Chapter 3: Stack/Pack Discharge
Use this function to discharge a battery stack or bat-
tery pack down to a pre-determined voltage.
NOTE: The Stack/Pack Discharge procedure is the
same whether discharging a battery stack or an entire
battery pack. However the connection points to the
battery are dierent for each procedure. Consult the
appropriate Toyota/Lexus/Scion documentation for
the correct connections.
Hazardous voltage.
An improper connection can result in
serious injury or death.
To avoid electrical shock or burn, never alter
the GRX-5100’s original AC cord and plug. Disconnect plug from outlet when GRX-5100 is
idle.
IMPORTANT:
Make sure to properly prepare the battery pack by following all required Toyota/Lexus/
Scion guidelines. Refer to your Toyota/Lexus/Scion
documentation for complete information.
When using the ARROW keys to select option buttons, press
NEXT to continue to the next step. When using the keypad,
no additional keypress is needed. Use
BACK to return to the
Main Menu at the start of the test and or the previous screen
during the test.
5. Use the keypad to enter the last 6 digits of the VIN (if available). Press SKIP to move past this step.
PLEASE ENTER THE
LAST 6 DIGITS OF
VIN IF AVAILABLE
6. Select the high voltage fault status.
1 YES
2 NO
NOTE: Selecting YES will automatically limit all
discharge currents to 1.5 A.
7. Select the DISCHARGE MODE.
1 FOR SHIPMENT
2 FULL DISCHARGE
8. Select the discharge TARGET.
1 PACK
2 STACK #1
3 STACK #2
4 STACK #3 (Prius PHV Only)
NOTE: Depending on the condition of the battery
pack or section, this process may take several hours
to complete.
Before de-powering a battery pack or stack, make sure all of
the external components connected to the GRX-5100 are in
good working order.
1. At the Main Menu, select the Stack Balance icon.
2. Select the vehicle MAKE.
1 TOYOTA
3. Select the vehicle MODEL.
1 PRIUS PHV
2 PRIUS
4. Select the vehicle MODEL YEAR.
1 2012–2015
2 2016–CURRENT (Prius Only)
5 STACK #4 (Prius PHV Only)
9. Conrm that you are wearing the appropriate personal
protective equipment for high voltage service.
10. Conrm the appropriate repair procedures for this vehicle.
11. Conrm that the High Voltage Service Plug has been removed.
12. Connect the green HV Bonding Cable to a suitable mounting bracket.
13. Connect the Cell Voltage Interface cables from the BCU-64
to the Battery Pack.
14. Connect the Temperature Sensor Interface cables from
the BCU-64 to the Battery Pack.
15
Chapter 3: Stack/Pack Discharge
15. If PACK was selected in step 8, re-install the High Voltage
Service Plug and press NEXT.
If the connections between the GRX-5100 and the battery
pack are correct, a BATTERY DETECTED screen is displayed.
16. Press NEXT to begin the discharging process.
Following a GRX-5100 self test, the DISCHARGING screen
is displayed.
17. Use or to view the multiple cell voltage screens and
discharge graph during the discharging process.
Stack/Pack Discharge Results
Once the de-powering session is complete, the results are
displayed on the GRX-5100 using multiple screens.
Use or to the multiple cell voltage screens and discharge
graph screen. Press EXIT to return to the Main Menu.
GRX-5100 HEV Battery Service Tool
NOTE:
If the measured voltage is already at the Target
Voltage, no conditioning is required and the session is
aborted.
Refer to Toyota/Lexus/Scion repair manual for procedures to
disconnect the GRX-5100 from the battery stack/pack.
16
GRX-5100 HEV Battery Service Tool
Chapter 4: Stack Balance
Chapter 4: Stack Balance
Use this function to charge or discharge a stack of a
battery pack to bring it in balance with the other
stacks of the pack.
NOTE: Depending on the charge condition of the bat-
tery pack and the battery section being balanced, this
process can take several hours
Hazardous voltage.
An improper connection can result in
electric shock
To avoid electrical shock or burn, never alter the
GRX-5100’s original AC cord and plug. Disconnect plug from outlet when GRX-5100 is idle.
IMPORTANT:
Make sure to properly prepare the bat-
to complete.
tery pack by following all required Toyota/Lexus/
Scion guidelines. Refer to your Toyota/Lexus/Scion
documentation for complete information.
When using the ARROW keys to select option buttons, press
NEXT to continue to the next step. When using the keypad,
no additional keypress is needed. Use
BACK to return to the
Main Menu at the start of the test and or the previous screen
during the test.
1. At the Main Menu, select the Stack Balance icon.
2. Select the vehicle MAKE.
1 TOYOTA
6. Connect the Cell Voltage interface cables from the BCU-64
to the battery pack.
7. Connect the Temperature Sensors interface cables from
the BCU-64 to the battery pack.
If the battery stacks to be balanced are detected, the GRX5100 enters STACK BALANCE setup mode.
8. Press NEXT if one or more battery stacks requires balancing.
9. Connect the HV Bonding clamp to a suitable mounting
bracket.
10. Connect the High Voltage cables to the battery stack indicated on the following screen.
Once the HV Connection has been completed, the GRX5100 performs a self test and then enters into STACK
BALANCE mode.
11. Press STOP to abort STACK BALANCE before the process
is complete.
Stack Balance Results
When complete, the results are displayed on the screen. Press
EXIT to return to the Main Menu.
3. Select the vehicle MODEL.
1 PRIUS PHV
2 PRIUS
4. Select the vehicle MODEL YEAR.
1 2012–2015
2 2016–CURRENT (Prius Only)
5. Use the keypad to enter the last 6 digits of the VIN (if available). Press SKIP to move past this step.
PLEASE ENTER THE
LAST 6 DIGITS OF
VIN IF AVAILABLE
Refer to Toyota/Lexus/Scion repair manual for procedures to
disconnect the GRX-5100 from the battery pack.
17
Chapter 5: Tool Info
Chapter 5: Tool Info
The Tool Info Menu has two (2) utilities to help you
track the usage and history of your GRX-5100.
Totals
The TOTALS function counts the number of charges or
de-powerings and tracks the results.
1 LIFE TIME TOTALS
Select the Totals option you want to see and press NEXT to
continue.
Life Time Totals
LIFE TIME TOTALS show the total number of times the tool is
used to determine health and charge of battery packs and
battery sections.
GRX-5100 HEV Battery Service Tool
Version
The VERSION utility displays the important information
about GRX-5100 across multiple screens including
software version, EEPROM, version date, tool serial
number, and build number.
Use or to scroll between the screens of version
information.
18
GRX-5100 HEV Battery Service Tool
Chapter 6: Utility Menu
Chapter 6: Utility Menu
The Utility Menu has several functions that you can
use to customize the GRX-5100 user interface.
Clock Adjust
The CLOCK ADJUST utility has four settings. Use or
to highlight the setting you want to change.
Although the date and time have been set at the factory,
you may want to make adjustments based your time zone or
Daylight Saving Time.
MODE : AM/PM
TIME : 9:07 AM
FORMAT : /DD/MM/YYYY
DATE : 5/26/15
Mode
1. Select the MODE and press NEXT to continue.
2. Select 24-hour or 12-hour (AM/PM) clock and press NEXT
to continue, or press the corresponding number key.
1 24 HOUR
2 AM/PM
3. If you used the ARROW keys, press SAVE to save your set-
ting or BACK to return to the CLOCK ADJUST screen without saving the changes.
Date
1. S
elect the DATE
and press NEXT to continue,
and press
NEXT to continue.
2. Use
or
to highlight the month, day, and year. Use
or to adjust the digits.
9 / 26 / 2017
3. Press SAVE to save your setting or BACK to return to the
CLOCK ADJUST screen without saving the changes.
Shop
The SHOP INFO utility allows you to create a header
for your test results showing your business location
information. The utility’s three (3) information screens
contain 12 lines of text with a maximum of 17 characters per line.
Screen 1 Screen 2 Screen 3
1–YOUR SHOP NAME
2–1000 ANY STREET 6–YOUR PHONE NUMBER 10–
3–YOUR TOWN, STATE 7–WWW.WEBSITE.CO 11–
4–YOUR POSTAL CODE 8–SHOP ID NUMBER 12–
To create or overwrite a header:
1. Press or to highlight the line you want to change.
The cursor will be blinking to the right of the last character
in the line.
5–YOUR COUNTRY
—
9–
—
—
Time
1. Select the TIME and press NEXT to continue.
2. Select the hour, minutes, or AM or PM. Use or to
adjust the digits.
9 : 07 AM
3. Press SAVE to save your setting, or press BACK to return to
the CLOCK ADJUST screen.
Format
1. Select the FORMAT and press NEXT to continue.
2. Select date format.
1 MM/DD/YYYY (month/day/year)
2 DD/MM/YYYY (day/month/year)
3 YYYY/MM/DD (year/month/day)
3. If you used the ARROW keys, press SAVE to save your set-
ting or BACK to return to the CLOCK ADJUST screen without saving the changes.
2. Press to move the cursor backward to erase a character.
To move the cursor forward, press .
3. Insert a character by pressing the key associated with the
character as many times as needed.
4. You can center text by selecting blank spaces before and
after lines of text or insert spaces between words.
5. Press SAVE to save your setting or BACK to return to the
SHOP INFO screen without saving the changes.
Display
The DISPLAY utility allows you to adjust the contrast
of the text on the display and the backlight time.
The contrast level is 0 (lightest) to 10 (darkest). To change it:
1. Press or to adjust the LCD contrast, or use the corresponding number keys.
8 (1-10)
2. Press SAVE to save your setting or BACK to return to the
LCD OPTIONS screen without saving the changes.
19
Chapter 6: Utility Menu
GRX-5100 HEV Battery Service Tool
Temperature
The TEMPERATURE utility allows you to set the units
of measurement to either Fahrenheit or Celsius. To set
your preference:
1. Select the TEMPERATURE units.
1 CELSIUS
2 FAHRENHEIT
2. If you used the ARROW keys, press SAVE to save your set-
ting or BACK to return to the Admin Menu without saving
the changes.
Capacity
The CAPACITY function lets you select the units of battery capacity between Kilowatt hours and Amp hours.
1. Select the battery CAPACITY units.
1 AMP HOURS
2 KILOWATT HOURS
2. If you used the ARROW keys, press SAVE to save your set-
ting or BACK to return to the Utility Menu without saving
the changes.
Dealer ID
Use this function to enter the DEALER ID for your deal-
ership into the GRX-5100.
1. Use the keypad to type in the DEALER ID .
ENTER YOUR
DEALER ID
2. Press SAVE to save your setting or BACK to return to the
Utility Menu without saving the changes.
Update
The MUW (Midtronics Update Wizard) is a TIS-based
system to update the software in your GRX-5100 EV
Battery Service Tool.
When software updates become available, use this utility to
update the GRX-5100 using a USB-style jump drive inserted
into the USB-A port.
USB-A Port
Language
The LANGUAGE utility allows you to select a language
for the tool's display screen. You can override the selection when the GRX-5100 displays the language option
after you turn it on.
1. Select the LANGUAGE.
1 ENGLISH
2 SPANISH
3 FRENCH
2. If you used the ARROW keys, press SAVE to save your set-
ting or BACK to return to the Admin Menu without saving
the changes.
GRX-5100 Connection Panel
Performing An Update
NOTE: Updating the GRX-5100 software will take ap-
proximately 30 minutes.
1. On the GRX-5100, remove the USB jump drive inserted in
the USB-A port and Insert it in a USB port on an internetenabled, Windows-based computer.
2. The update utility executable le is available on the TIS
website at the following location:
20
GRX-5100 HEV Battery Service Tool
Chapter 6: Utility Menu
TIS>Diagnostics>Tools & Equipment> HEV Workstation>
Available Software Updates
3. Run the downloaded le to launch the update utility and
follow the on-screen instructions.
The utility will automatically download the GRX-5100
software update
and place it on the USB jump drive.
Buzzer
The BUZZER utility allows you to enable or disable the
warning tone that alerts you if the clamps are connected improperly and or there are other errors.
1. Select the BUZZER option.
1 OFF
2 ON
2. If you used the ARROW keys, press SAVE to save your set-
ting or BACK to return to the Utility Menu without saving
the changes.
Region
Use this function to select the time zone region in
which the GRX-5100 will operate.
1. Select the REGION.
1 NORTH AMERICA
2 ASIA PACIFIC
4. When nished, eject the jump drive from the computer
and re-insert it into the USB-A port on the GRX-5100.
5. At the Main Menu on the GRX-5100, navigate to the Update icon in the Utility Menu and press SELECT.
6. Select USB.
1 USB
The FLASH PROGRAM screen is displayed showing a
progress bar to indicate progress as the update progresses.
7. The Main Menu is displayed on the screen when the update is complete.
3 EUROPE
2. Press SAVE to save the selection.
The UTILITY menu is displayed.
21
Chapter 7: Error Messages
GRX-5100 HEV Battery Service Tool
Chapter 7: Error Messages
Error Codes
Error Description Type Recommended Action
10 Numeric entry is out of range User Selection Use the correct characters for the situation.
12 Internal memory is corrupt Hardware Power cycle unit. If error persists, contact
customer service to arrange service.
13 Clock not set correctly User Selection Enter correct date.
16 USB drive does not contain update les User Selection Verify update les are on the USB drive. Re-
download les to USB drive if necessary.
22-23 Internal LV temperature sensor broken Hardware Contact customer service to arrange service.
24-25 Internal LV temperature too low Hardware Allow the GRX-5100 to warm up. If error
persists, contact customer service to arrange
service.
26-27 Internal LV temperature too high Hardware Allow the GRX-5100 to cool down. If error
persists, contact customer service to arrange
service.
28-39 Self Test Failure Hardware Power cycle unit. If error persists, contact
customer service to arrange service.
40 Internal load temperature too high Hardware If discharge was conducted, let the unit cool
down. If error persists, contact customer service
to arrange service.
41-42 Internal HV temperature sensor broken Hardware Contact customer service to arrange service.
43-44 Internal HV temperature too low Hardware Allow the GRX-5100 to warm up. If error
persists, contact customer service to arrange
service.
45-46 Internal HV temperature too high Hardware Allow the GRX-5100 to cool down. If error
persists, contact customer service to arrange
service.
47 Internal Hardware Error Hardware Contact customer service to arrange service.
48 Internal EEProm Corrupt Hardware Contact customer service to arrange service.
49-55 Internal Communication Error Hardware Power cycle unit. If error persists, contact
customer service to arrange service.
56 Error communicating with BCU User Selection/Battery Check connections to pack. Verify correct
vehicle was selected.
57 User abort User Selection Re-start required operations.
58 Battery connected in reverse User Selection/Hardware Check connections to pack.
59 Battery not detected User Selection/Hardware Check connections to pack.
60 Battery under voltage detected User Selection/Hardware Check connections to pack.
61 Battery over voltage detected User Selection/Hardware Check connections to pack.
63 DC Current too high User Selection/Hardware Power cycle unit. If error persists, contact
customer service to arrange service.
64
Battery temperature too low ( ≤ –30°C)
65 Battery temperature too high ( ≥ 60°C) User Selection/Hardware Check connections to pack.
66 Cell delta voltage too high Battery Check connections to pack.
67 Cell under voltage detected Battery Check connections to pack.
68 Cell over voltage detected Battery Check connections to pack.
69
Battery temperature variation too high (50°C)
71 Battery already charged User Selection/Battery Check connections to pack.
72 Battery already discharged User Selection/Battery Check connections to pack.
73 12VDC Power Source; Charging disabled User Selection Connect to an AC source for charging.
74 Service Plug not detected User Selection/Battery
User Selection/Hardware Check connections to pack.
Battery Check connections to pack.
Make sure the vehicle service plug is fully inserted.
22
GRX-5100 HEV Battery Service Tool
Error Description Type Recommended Action
79 Emergency Stop Button Pressed User Selection After emergency situation has been addressed,
pull up on the Emergency Stop button on the top
of the GRX-5100 to reset tool.
80 High Voltage Fuse Blown User Selection/Hardware Check the fuses in the fuse box and replaced
fused as required.
82 12V Input Voltage too low (10V min.) User Selection/Hardware 12V power supplied to the GRX-5100 is too low.
Change battery source or plug into a wall.
84 Invalid BCU Cell Voltage Reading Battery Check connections to pack. Verify vehicle
selection and correct cables are used.
85 Invalid BCU Temp Sensor Reading Battery Check connections to pack. Verify vehicle
selection and correct cables are used.
91 Incorrect stack detected User Selection/Battery Verify vehicle selection and correct cables are
used.
92 Incompatible software versions detected User Selection/Hardware Perform a software update.
110 HV bonding test ground not detected User Selection/Hardware Verify a good chassis connection.
111 HV bonding test current too low User Selection/
Hardware/Battery
113 Low Voltage cable not connected User Selection Check connections to pack.
114 BCU-64 - Wrong Address User Selection Check the BCU address by conrmng the blue
115 BCU-64 - Communication Issue User Selection/Hardware Power cycle unit. If error persists, contact
116 Wrong number of BCU-64's connected User Selection Connect proper number for each pack.
117 Short Detection - Reverse Connection User Selection/Battery Check connections to pack.
118 Short Detection - Current too high User Selection/Battery Short on battery check connections to pack.
119 Short Detection - Voltage too low User Selection/Battery If on 12V aux, use AC if possible, check
120 12VDC power supply not working properly Hardware Check connections to pack. If error persists,
Verify a good chassis connection.
rotary knob of the BCU is set to zero (0).
customer service to arrange service.
connections to battery.
contact customer service to arrange service.
Chapter 7: Error Messages
If troubleshooting does not solve the problem, call the Special Service Tools hotline (1-800-933-8335).
Hardware Error
This error can be generated by damaged or improperly connected cables. To clear the error, turn o the GRX-5100, disconnect
the cable connections and reconnect. Then power the GRX-5100 back up.
23
Limited Warranty
The GRX5100, BCU-64 and Fuse Box are warranted to be free of defects in material and workmanship for
a period of ve (5) years and all other components for a period of two (2) years from the date of purchase.
The manufacturer will, at their option, repaired or replace the unit with a re-manufactured unit. This limited
warranty applies only to the manufacturer’s products, and does not cover any equipment, static damage, water
damage, overvoltage damage, dropping the unit or damage resulting from extraneous causes including owner
misuse. The manufacturer is not liable for any incidental or consequential damages from breach of warranty.
The warranty is void if the owner attempts to disassemble the GRX-5100, BCU-64, Fuse Box, cables or any other
components.
167-000863EN-A 5/18 ©2018 Midtronics, Inc. All rights reserved.
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