12 5
ECB (Electronically Controlled Brake)
General
– The total brake force provided by both hydraulic and regenerative brakes matches the braking power
required
Regenerative Brake Hydraulic Brake
12 6
ECB (Electronically Controlled Brake)
ECB Operation
– Hydraulic brake pressure is generated electrically (brake by wire)
Conventional Vehicle ECB Vehicle
Sensor Skid Control
ECU
Control
Brake Force Generation
Brake Force Generation
12 7
Indicator and Warning
12 8
Indicator and Warning
Combination Meter
– READY light indicates that the vehicle is ready to drive
Ready Light
12 9
Indicator and Warning
Multi Display
– Energy monitor shows the energy flow
13 0
Indicator and Warning
Multi Display
– Warning display
• Warning marks
Automatic Headlight Leveling System
Warning Oil
Pressure Warning
High Engine Coolant Temperature
Warning
Hybrid System Abnormal
HV Battery Warning Discharge
Warning
EPS Warning
13 1
Indicator and Warning
Multi Display
– Warning message
13 2
Other Systems
13 3
Other Systems
General
– Engine is operated intermittently, so power steering and A/C compressor uses electric power
EPS (Electric Power Steering) Electric Inverter Compressor
13 4
Other Systems
EPS (Electric Power Steering)
– Column assist type EPS is used
Column Assist Type EPS
Reduction Mechanism
EPS ECU DC Motor
(12V)
Torque Sensor
13 5
Other Systems
Air Conditioning – Service Point
• Don’t use the compressor oil other than ND11
ND -OIL11
ND-OIL8
13 6
Service Point
13 7
Service Point
Inspection Mode
– In the inspection mode, engine is continuously operated (P range) and motor TRC is turned of
Note: Other hybrid vehicle has several types of inspection mode.
For derails, please refer to the repair manual.
Mode Vehicle Condition Purpose Transferring Procedure
Inspection Mode- 2WD Inspection (Inspection Mod1)
•Keeps engine running (P range)
•Motor TRC is OFF
•Exhaust gas test
•Engine adjusting
•Speedometer test
•Manual procedure
•Intelligent tester (Active Test)
Inspection Mode- 2WD Chassis- Dynamo
(Inspection Mod2)
Motor TRC is OFF Speedometer test (chassis
dynamometer)
Intelligent tester (Active Test)
13 8
Service Point
Inspection Mode
– Manual procedure
OFF
IG-ON
Depress
twice Depress
twice Depress
twice
Accelerator Pedal
IG-ON
READY with brake
Change the power mode to OFF inspection mode is canceled
within 60 seconds
Click Movie
13 9
Service Point
High-voltage Wire Harness
– All high-voltage wire harness and connectors are colored orange
High-voltage Wire Harness
High-voltage Wire Harness Click Movie
14 0
Service Point
High-voltage Wire Harness
– Use a megohmmeter to measure the insulation resistance (Standard: 2 10 M)
Notice: If you use the 1000V range, it
causes the breakdown of the parts
Basically use the 500V range
It cannot check the insulation resistance correctly by the TOYOTA
Electrical Tester It cannot check the insulation resistance correctly by the TOYOTA
Electrical Tester Megohmmeter
14 1
Service Point
High-voltage Wire Harness – Risk of electric shock
Case Condition Risk of Electric Shock
Touch the high-voltage + side No risk
Touch the body (high-voltage - side)
when there is a electrical leakage No risk
Touch the high-voltage + side when
there is a electrical leakage Possibility of electric shock
Touch the high-voltage + and - side Electric shock !
14 2
Service Point
Safety Precautions
– Before servicing the high voltage area
• Make sure to perform the followings;
1. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign
2. Turn the power mode to off
3. Remove the key from key slot and carry the key 4. Disconnect auxiliary battery negative terminal 5. Check the insulated gloves
6. Remove the service plug 7. Wait 5 min. or more
8. Measure the inverter terminal voltage (0V check)
14 3
Service Point
Safety Precautions
5. Before servicing the high voltage area
Wait 10 minutes or more to discharge high-voltage condenser in the inverter
5 min.
High-voltage Condenser
Discharge Discharge
Service plug disconnection
Elect- ricity
0V
Inverter Assembly
14 4
Service Point
Safety Precautions
– Before servicing the high voltage area
1.Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers
14 5
Service Point
Safety Precautions
– Before servicing the high voltage area 5.Check the insulated gloves
Not cracked, ruptured, torn, or damaged
Not wet
14 6
Service Point
Safety Precautions
– Before servicing the high voltage area 6.Remove the service plug
Remove before servicing
Service Plug
Carry in your pocket
14 7
Service Point
Safety Precautions
– Before servicing the high voltage area
8.Measure the inverter terminal voltage (0V check)
Inverter Assembly
0 V
Between 3 phases
0 V
3 phases and body ground
14 8
Service Point
Safety Precautions
– During servicing the high voltage area
• Insulate the tools by vinyl tape
Insulated Vinyl Tape
14 9
Service Point
Safety Precautions
– During servicing the high voltage area
• Insulate the disconnected high-voltage connector with insulated vinyl tape
Insulated Vinyl Tape
15 0
Service Point
Safety Precautions
– During servicing the high voltage area
• Non-reusable nut is used to the installation of high voltage line
Example of use
Non- reusable
Wire x SMR
Junction Block x Module
New
Used
15 1
Service Point
Safety Precautions
– After servicing the high voltage area
• Before reinstalling the service plug, check again the following
You have not left a part or tool inside
The high-voltage terminal nuts and screws are properly tightened
The connectors are correctly connected
15 2
Service Point
Safety Precautions
– After servicing the high voltage area
• Be sure to install the service plug before starting the hybrid system
READY ON
After servicin
g
Installation
Vehicle damages
15 3
HV Battery Warning Light illuminates
Can not READY ON
DTC P3000-389 (HV Battery Malfunction) is detected
Service Point
Response When The HV Battery (201.6V) Runs Out – Vehicle conditions when HV battery low voltage
15 4
THS Charger
Service Point
Response When The HV Battery (201.6V) Runs Out – Charge the HV Battery using THS Charger
Note: THS charger is the recommended tool
THS Charger
15 5
Service Point
Battery Pack Removal / Installation
– If the HV battery electrolyte leaks, don’t touch it
Don’t touch the battery electrolyte !
Boric Acid Solution Neutralize
battery electrolyte
Boric Acid (800 g)
Water (20 liters)