Contents Click a Section Tab New Model PRIUS 2009

Contents Click a Section Tab New Model PRIUS 2009
Instructor & Technical Staff

Overall System Diagram Components MG (Motor Generator) Inverter with Converter Assembly HV Battery HV Control System Special Notes on Service

Overall Main Components [Electric Power Path] : AC : DC
New Model PRIUS 2009 Overall Main Components [Electric Power Path] : AC : DC Hybrid Vehicle Transaxle Assembly Engine Power Split Planetary Gear Unit MG1 HV Battery MG2 Motor Speed Reduction Planetary Gear Unit Inverter with Converter Assembly Reference Instructor & Technical Staff

Overall Gear Train 2 planetary gear units MG2 MG1 Engine Counter Gear
New Model PRIUS 2009 Overall Gear Train 2 planetary gear units MG1 MG2 Engine To Front Wheel Counter Gear Engine: Planetary Carrier (Power Split Planetary Gear Unit) MG1: Sun Gear (Power Split Planetary Gear Unit) MG2: Sun Gear (Motor Speed Reduction Planetary Gear Unit) Instructor & Technical Staff

Overall Nomographic Chart
New Model PRIUS 2009 Overall Nomographic Chart Sun Gear (MG1) Carrier (Engine) Ring Gear (Wheel) (Fixed) (MG2) + - Torque rpm Power Split Planetary Gear Unit Motor Speed Reduction Planetary Gear Unit Vertical lines show rpm and direction of rotation Spaces between vertical lines show gear ratios Arrows show torque direction Vertical lines show rpm and direction of rotation Spaces between vertical lines show gear ratios Arrows show torque direction (Red: Discharge / Blue: Charge) - MG1, MG2 Condition - Rotation Direction of MG + - Torque Discharge Charge Instructor & Technical Staff

Overall Major Difference from previous model MG1 / MG2 Inverter
New Model PRIUS 2009 Overall Major Difference from previous model Item Contents MG1 / MG2 Weight reduction Max. output is increased Max. system voltage is increased Inverter Volume reduction Boost voltage is increased (Max. 650 V) Maintenance interval of SLLC is changed A/C inverter is separated HV Control Various driving mode is adopted - EV drive mode - ECO drive mode - PWR mode Instructor & Technical Staff

   Click an illustration to open a master sheet   
New Model PRIUS 2009 System Diagram System Diagram (Overall)    Click an illustration to open a master sheet    Instructor & Technical Staff

Components Layout of Main Components HV Battery Unit
New Model PRIUS 2009 Components Layout of Main Components HV Battery Unit Battery Module (DC V) Junction Block Battery Smart Unit Auxiliary Battery (Sealed Type) 2ZR-FXE Engine Cooler Compressor with Motor Assembly Power Cable Insulation and Isolation of High-voltage Both positive and negative terminals of every high-voltage circuit are insulated from body ground. An orange colored cover is used for all high-voltage cables so that customers and technicians can easily distinguish high-voltage cables. A case or cover is provided for each of the high-voltage units (HV battery, Inverter with Converter Assembly, Hybrid Transaxle, etc.) and high-voltage cables. Power Management Control ECU (HV CPU) ECM Inverter with Converter Assembly Boost Converter • Inverter MG ECU DC/DC Converter for Auxiliary Battery P410 Hybrid Transaxle MG1 • MG2 Instructor & Technical Staff

MG (Motor Generator) MG1 and MG2 Features
New Model PRIUS 2009 MG (Motor Generator) MG1 and MG2 Features Total weight is reduced (Approx. 33%) and Max. motor output (MG2) is increased (from 50 kW to 60 kW) MG1 MG2 Previous Model New PRIUS More compact, more light weight design achieved through centralized winding of the coils. Motor rotational speed was significantly increased, improving power performance Instructor & Technical Staff

Permanent Magnet Motor
New Model PRIUS 2009 MG (Motor Generator) MG1 and MG2 Specifications New PRIUS Previous Model MG1 Type Permanent Magnet Motor  Max. System Voltage AC 650 V AC 500 V MG2 Max. Output 60 kW (80 HP) 50 kW (67 HP) Max. Torque 207 Nm (153 ftlbf) 400 Nm (295 ftlbf) * 546 Nm (403 ftlbf) Cooling System Water-cooled Air-cooled MG (Motor Generator) *: Torque is boosted 2.64 times by the motor speed reduction planetary gear unit. Instructor & Technical Staff

Inverter with Converter Assembly
New Model PRIUS 2009 Inverter with Converter Assembly Feature Light weight and compact design Inverter with Converter Assembly New PRIUS Previous Model Components Inverter, Boost Converter, MG ECU and DC/DC Converter Inverter, Boost Converter, DC/DC Converter and A/C Inverter Cooling System Overall SLLC (Separate with engine cooling system)  Structure Direct Cooling Indirect Cooling Size (Reference) Weight [kg (lb)] Approx (29.8) Approx. ??? Volume [L] Approx. 13 Approx. 26 Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly Feature Light weight and compact design High-voltage Cable for MG1 High-voltage Cable for MG2 High-voltage Cable for HV Battery High-voltage Cable for Electric A/C Compressor Inverter with Converter Assembly Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly Main Components and Functions Inverter assembly has a multi-layer structure which mainly consists of the capacitor, intelligent power modules, reactor, MG ECU, and DC/DC converter achieving a lightweight and compact design Inverter Terminal Cover Intelligent Power Modules (IPMs) Interlock Switch (for Inverter Terminal Cover) MG (Motor Generator) Capacitor Reactor Inverter Current Sensor DC/DC Converter Portion MG ECU Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly System Diagram HV Battery Unit (DC V) Inverter with Converter Assembly Transaxle Battery Modules Boost Converter (DC V  DC 650 V [max.]) Inverter (DC  AC) MG2 MG1 for MG2 SMR DC/DC Converter [Auxiliary Battery] (DC V  DC 14 V) for MG1 DC 201.6 V Cooler Compressor with Motor Assembly Auxiliary Battery Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly System Diagram Boost converter + Inverter Inverter with Converter Assembly IGBT Boost Converter (DC) Inverter (AC) IPM IPM IGBT Reactor MG1 MG2 IPM: Intelligent Power Module IGBT: Insulated Gate Bipolar Transistor Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly Atmospheric Pressure Sensor Provided on the MG ECU board. The sensor detects atmospheric pressure and transmits a signal to the MG ECU to allow corrections that correspond to the usage environment Breakdown Voltage (kV) [Breakdown Voltage vs. Pressure x Gap] Pressure x Gap (Fixed: 1 cm) Figure is Paschen curve (Paschen’s Law). The law essentially states that the breakdown voltage of parallel plates in a gas as a function of pressure and gap distance, usually written as V= f( pd ), where p is the pressure, d is the gap distance and f is the proportional. Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly Atmospheric Pressure Sensor Relation DTCs of atmospheric pressure sensor DTC NO. Detection Item DTC Detection Condition P Manifold Absolute Pressure – Barometric Pressure Correction Difference between the atmospheric pressure value of the atmospheric presser sensor in the inverter with converter assembly and the manifold absolute pressure sensor (for EGR control) exceeds a specified value. The same condition recurs within 3 hours when driving in EV mode P Barometric Pressure Sensor “A” Circuit Low Short to GND in the atmospheric pressure sensor P Barometric Pressure Sensor “A” Circuit High Open or short to +B in the atmospheric pressure sensor Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly Cooling System Inverter assembly is cooled by the dedicated radiator of a cooling system that is separate from that of the engine cooling system Inverter with Converter Assembly HV Radiator Reserve Tank HV Radiator (for Inverter) Inverter with Converter Assembly HV Radiator Reserve Tank This cooling system (HV water pump with motor) always activates when the power mode is selected to READY-ON state. Radiator for inverter is located above A/C condenser HV Water Pump with Motor HV Radiator HV Transaxle HV Water Pump with Motor Instructor & Technical Staff

New Model PRIUS 2009 Inverter with Converter Assembly Cooling System Maintenance interval of coolant is slightly changed New PRIUS Previous Model Coolant Type TOYOTA Genuine Super Long Life Coolant (SLLC) or Equivalent  Capacity 3.4 liters — Maintenance Interval Inspect Same as previous model Differ among the destination Replace First Time km km Subsequent Km Instructor & Technical Staff

Service Point (Inverter with Converter Assembly)
New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Hybrid Coolant Replacement Draining method Drain plug for hybrid system coolant Filler Plug for Hybrid Transaxle Fluid (10 mm Hexagon) Front Measure the volume of the drained coolant, and replace it with a volume that is greater than the drained coolant (as a guide for bleeding air). Drain Plug for Hybrid Transaxle Fluid (10 mm Hexagon) Drain Plug for Hybrid System Coolant (10 mm Hexagon) Instructor & Technical Staff

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Hybrid Coolant Replacement Refilling method for Engine for HV System Refill the inverter reserve tank with coolant up to the FULL level Operate the water pump by using Active Test While adding coolant so that the coolant level is kept around the FULL level in the reserve tank, operate the water pump for approx. 10 min. and stop it for approx. 1 min. Repeat the above operation “3” until air bleeding is completed Standard: When the operation sound of the water pump becomes small or when no air bubbles can be seen in the inverter reserve tank, bleeding of the coolant system is complete Active Test: "Powertrain" >>> “Hybrid Control" >>> “Active Test" >>> “Active the Water Pump“ Point: Air bleeding is completed if the operating sound of the water pump decreases and the flow of the coolant in the reserve tank improves. Also, air bleeding is completed if there is no change in the coolant level in the reserve tank when the water pump is stopped. NOTICE: Do not reuse the drained coolant because it may contain foreign objects. Instructor & Technical Staff

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Hybrid Coolant Replacement Refilling method (continued) If the vehicle is driven with air in the coolant system, the following DTCs may appear DTC No. INF Code DTC Item P0A01 725 Motor Electronics Coolant Temperature Sensor Circuit Range / Performance 726 P0A78 284 Drive Motor “A” Inverter Performance P0A7A 322 Generator Inverter Performance P0A93 346 Inverter Cooling System Performance P0A94 553 DC / DC Converter Performance P0AEE 276 Motor Inverter Temperature Sensor “A” Circuit Range / Performance 277 P3221 314 Generator Inverter Temperature Sensor Circuit Range / Performance 315 P3226 562 DC / DC Boost Converter Temperature Sensor 563 Instructor & Technical Staff

Safety Precautions Before inspecting or servicing the high-voltage system, be sure to follow all safety measures CAUTION Turn the power switch OFF and remove the key from interior detection area for entry and start system Disconnect the cable from auxiliary battery negative terminal Check the insulated gloves Remove the service plug grip Wait for 10 minutes or more to discharge the high-voltage capacitor inside the inverter assembly Measure the inverter terminal voltage (0V Check) Insulate the disconnected high-voltage connector with insulated vinyl tape

Safety Precautions 2. Disconnect the cable from auxiliary battery negative terminal Sealed type battery is used and located in the luggage room Location of Auxiliary Battery Auxiliary Battery (Sealed-type) Hydrogen Drain Port Battery Temp. Sensor Luggage Room

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Safety Precautions 3. Check the insulated gloves Before using insulated glove, be sure to check them for cracks, tears and other types of damage [Recommended Procedure]     Place the glove on its side. Roll the opening up 2 or 3 times. Fold the opening in half to close it. Confirm that there are no air leaks. Tears = tercarik-carik/sobek [Previous Procedure] Instructor & Technical Staff

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Safety Precautions 4. Remove the service plug grip and keep the removed service plug grip in your pocket Insulated Glove   NOTICE: Keep the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage components.   Keep in your pocket Service Plug Grip Instructor & Technical Staff

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Safety Precautions 5. After removing the service plug, wait 10 minutes or more to discharge high-voltage capacitor High-voltage Capacitor Discharge 0V Elect-ricity NOTICE: After removing the service plug, wait 10 minutes or more to discharge high-voltage capacitor. Service plug removal 10 min. Instructor & Technical Staff

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Safety Precautions 6. Make sure the high-voltage capacitor terminal voltage is 0V (Tester range: 750 V or more) 0 V Plus Terminal Minus Terminal High Voltage Fuse [High-voltage Capacitor Terminal] Instructor & Technical Staff

Safety Precautions 7. Insulate the disconnected high-voltage connector with insulated vinyl tape Insulated Vinyl Tape

New Model PRIUS 2009 Service Point (Inverter with Converter Assembly) Precautions for Removal Removal After removing the service plug, wait 10 minutes or more to discharge high-voltage capacitor Remove the 9 bolts and inverter terminal cover. Make sure the high-voltage capacitor terminal voltage is 0V (Tester range: 750 V or more) NOTICE: When the lifting the cover, do not tilt it, because the cover has a connector for the interlock device. Cover the opening with non-residue tape to prevent entry of foreign matter of liquid after removing the connector cover. Connector Inverter Terminal Cover Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter. Instructor & Technical Staff

New Model PRIUS 2009 HV Battery Features As with the previous model, HV battery locates in the luggage compartment behind the rear seat Air Intake (Right side of rear seat) HV Battery Intake Air Duct Air intake located at the right side of the rear seat HV Battery Cooling Blower Service Plug Grip CAUTION: The HV battery is the high-voltage component. Use extreme caution during service. Instructor & Technical Staff

HV Battery Main Components
New Model PRIUS 2009 HV Battery Main Components The HV battery mainly consists of the following components. HV Battery Temperature Sensors (for battery modules) HV Battery (Battery Modules) Battery Smart Unit HV Battery Cooling Blower (Brushless) HV Junction Block Assembly HV Battery Temperature Sensor (for intake air) Service Plug Connector CAUTION: The HV battery is the high-voltage component. Use extreme caution during service. Instructor & Technical Staff

HV Battery HV Battery Specifications
New Model PRIUS 2009 HV Battery HV Battery Specifications Basic construction is the same as the previous model Major difference from previous model New PRIUS Previous Model Battery Module Type Sealed Nickel Metal Hydride Battery  Cell Quantity 168 cells (6 cells X 28 modules) Nominal Voltage 201.6 V (1.2 V X 168 cells) Service Plug Grip Main Fuse 125 A Interlock Switch with NA HV Battery Cooling Blower Motor Type Brushless Motor Brush Motor Fan Type Sirocco Fan HV Battery Temp. Sensor for Intake Air x 1 for Battery Module x 3 HV Junction Block Assembly SMRs (SMRB / SMRP / SMRG), HV Battery Current Sensor, Precharge Resistor Instructor & Technical Staff

HV Battery Cooling Blower
New Model PRIUS 2009 HV Battery HV Battery Cooling System To ensure the proper performance of the HV battery while it generates heat during the repetitive charge and discharge cycles, a dedicated cooling system is used for the HV battery. Intake Air Duct HV Battery Cooling Blower Exhaust Air Duct A high output brushless type motor is used for the blower motor, and the inner shape of the blower case has been optimized. As a result, blower noise is reduced. Repetitive = Berulang-ulang Cooling Air Flow HV Battery [HV Battery Temperature Sensor] : for Battery Module : for Intake Air Instructor & Technical Staff

HV Battery HV Junction Block Assembly
New Model PRIUS 2009 HV Battery HV Junction Block Assembly Three SMRs are relays that connect and disconnect the power source of the high-voltage circuit upon receiving a signal from the power management control ECU (HV CPU) Power Management Control ECU (HV CPU) Battery Smart Unit SMRG SMRB HV Battery Current Sensor SMRB SMRP Service Plug Battery Modules HV junction block assembly consists of the System Main Relays (SMRs [SMRB (positive side) / SMRG (negative side) / SMRP (negative side)]), precharge resistor and HV battery current sensor. Operation of High-voltage Circuit - When the driver attempts to put the vehicle in the READY-ON state, the SMRs operate in the following order: >>> SMRB turns ON, SMRP turns ON, SMRG turns ON, and then SMRP turns OFF - When the driver turns the “READY” mode off, SMRG turns OFF and then SMRB turns OFF Resistor SMRG HV Battery Current Sensor Precharge Resistor SMRP NOTE: Do NOT remove SMRs on the HV junction block assembly. Instructor & Technical Staff

Service Point (HV Battery)
New Model PRIUS 2009 Service Point (HV Battery) Precautions before Removing the HV Battery Make sure the system has not output the DTC P0AA6 (Hybrid Battery Voltage System Isolation Fault) before handling the HV battery unit. If the DTC is output, troubleshoot the system before proceeding. DTC Detailed Information Code Display INF Code Information (Trouble Area) P0AA6 Hybrid Battery Voltage System Isolation Fault 526 All Area insulation abnormality of the entire high-voltage circuit 611 Electric Compressor and A/C Inverter 612 HV Battery, Battery Smart Unit, HV Relay Assembly 613 Hybrid Transmission, Inverter with Converter Assembly 614 DC High-voltage Area When we must serve with DTC P0AA6 for some causes… Due to the risk of short circuits and electric shocks caused by the reduced insulation resistance, make sure to wear insulated gloves and use insulated tools. Instructor & Technical Staff

Service Point (HV Battery)
New Model PRIUS 2009 Service Point (HV Battery) Precautions for Removal and Installation HV battery has a battery cover lock striker. And it can be released only with the tip of the service plug grip Service Plug Grip PUSH The battery cover lock striker prevents the technician from inadvertently failing to remove the service plug grip. The HV battery cannot be removed unless the lock of battery cover lock striker is unlocked. Lock Release [Battery Cover Lock Striker] Instructor & Technical Staff

HV Control System Various Driving Mode
New Model PRIUS 2009 HV Control System Various Driving Mode New PRIUS has a various driving mode. EV Drive Mode Indicator Light Driving with only the electric motor ECO MODE Indicator Light (New Item) Moderates the response of the accelerator pedal operation to support ECO driving EV Drive Mode Indicator Light (Basic operation is the same as the previous model (except –A model). - EV drive mode indicator light informs the driver that the EV drive mode is entered. - In the EV drive mode, the vehicle runs like an electric vehicle which is driven with only the electric motor. ECO MODE Indicator Light (New Items) - ECO MODE indicator light informs the driver that the ECO drive mode is entered. - This mode moderates the response of the accelerator pedal operation to support ECO driving. PWR MODE Indicator Light - PWR MODE indicator light informs the driver that the power mode is entered. - This system optimizes acceleration performance by increasing the motive force in the acceleration pedal opening middle range more than normal. Eco Driving Indicator Light (Basic operation is the conventional vehicle) - Eco driving indicator light informs the driver of whether the accelerator pedal is being operated in an environmental friendly manner by illumination. PWR MODE Indicator Light Optimizes acceleration performance by increasing the motive force in the acceleration pedal opening Instructor & Technical Staff

HV Control System EV Drive Mode ( )
New Model PRIUS 2009 HV Control System EV Drive Mode ( ) In the EV drive mode, the vehicle runs like an electric vehicle which is driven with only the electric motor When all conditions in the table below are satisfied, the EV drive mode can be used Operating Condition The hybrid system temperature is not high (The hybrid system temperature will be high when the outside air temperature is high or after the vehicle has traveled up a hill or at high speeds). The hybrid system temperature is not low (The hybrid system temperature will be low after the vehicle has been left for a long time when the outside air temperature is low). Engine coolant temperature is the specified value or more -A: Approx. 20 deg C (68 deg F) / Except –A: 0 deg C (32 deg F) The SOC is approx. 50 % or more (Level 4 or more). The vehicle speed is approx. 40 km/h (25 mph) or less. The accelerator pedal depression amount is a certain level or below. The defroster is off. The cruise control system is not operating. EV drive mode will achieve a low level of noise as well as reduction of the emission gas by residential areas in the midnight or in the covered parking lot. Hybrid vehicle is designed to have the best fuel economy during normal driving (driving using a combination of gasoline engine and electric motor power). Frequent use of the EV drive mode may worsen fuel economy. Reference: Available driving range differs depending on factors such as the HV battery charging level or air conditioning condition, the driving range is from about several hundred meters to 1 km (about 0.6 miles). Instructor & Technical Staff

Accelerator Pedal Opening Angle
New Model PRIUS 2009 HV Control System ECO Drive Mode ( ) Optimizes fuel economy and driving performance by gently generating the motive force against the accelerator pedal operation At the same time, it supports Eco driving by optimizing the air conditioning performance Accelerator Pedal Opening Angle PWR Mode Normal ECO Mode Motive Force Output ECO Drive Mode is newly adopted ECO drive mode control balances driving performance, air conditioning performance and fuel economy performance using control that prioritizes fuel economy performance Under the control of the ECO Drive Mode, the air conditioning amplifier assembly restricts the air conditioning system performance under specified conditions, thus improving fuel economy. Instructor & Technical Staff

Accelerator Pedal Opening Angle
New Model PRIUS 2009 HV Control System PWR Mode ( ) Optimizes acceleration performance by increasing the motive force in the acceleration pedal opening middle range more than normal Accelerator Pedal Opening Angle PWR Mode Normal ECO Mode Motive Force Output Instructor & Technical Staff

HV Control System Cutoff of High-voltage Circuits
New Model PRIUS 2009 HV Control System Cutoff of High-voltage Circuits High-voltage circuits can be cut off either automatically or manually to prevent electrocution. System Main Relays for Automatic Cutoff SMRs Service Plug for Manual Cutoff Cutoff with the power switch Power Switch Airbag Sensor Assembly Cutoff in the event of a collision Interlock Switch (Service Plug Grip) Power Management Control ECU (HV CPU) Service Plug Airbag sensor assembly sends the airbag deployment signal to power management Control ECU (HV CPU) via the direct line. Interlock Switch (Inverter with Converter Assy Cover) Cutoff when the interlock device is activated Interlock Switch (High-voltage cable of Inverter with Converter Assy) Instructor & Technical Staff

High-voltage Cable for HV Battery
New Model PRIUS 2009 HV Control System Cutoff of High-voltage Circuits Interlock switch (connector) Inverter with converter assembly portion HV battery portion High-voltage Cable for HV Battery Connector Connector Connector Service Plug Instructor & Technical Staff

HV Control System Cutoff of High-voltage Circuits
High-voltage circuits can be cut off either automatically or manually to prevent electrocution. Automatic Cutoff [System Main Relays] (SMRs) Cutoff interlocked with the power mode SMRs are turned OFF when the driver turns the power mode OFF. Cutoff in the event of a collision The power management control ECU (HV CPU) receives a signal of the occurrence of a collision via the airbag sensor assembly, and turns OFF the SMRs. Cutoff when the interlock device is activated The interlock device detects whether the service plug is installed. If the technician forgets to remove the service plug, and they perform a high-voltage operation, removing the inverter with converter assembly cover will turn OFF the SMRs due to the interlock circuit. Manual Cutoff with Service Plug The service plug located in the middle of the HV battery makes it possible to cut off all high-voltage circuits. Remove the service plug when inspecting or maintaining high-voltage circuits. (Wait for 10 min. after removing the service plug)

Special Notes on Service
If a Battery is Discharged When the battery is discharged, the following conditions occur: Auxiliary battery (Rechargeable) No combination meter display even with the power mode ON. Unable to enter the READY-ON state. Headlights are dim and the horn sound is weak. HV battery (Replace HV battery) The hybrid system detects abnormality and displays a warning message on the multi-information display. DTC P ,389 (HV battery malfunction) is stored in the power management control ECU (HV CPU).

New Model PRIUS 2009 Special Notes on Service Auxiliary Battery Sealed type battery is used. Therefore, do NOT perform a quick charge. Charging Charge at 5.0 A or less within 12 hours Replacement Replace dedicated battery for PRIUS (S46B24R) Location of Auxiliary Battery Auxiliary Battery (Sealed-type) Hydrogen Drain Port Battery Temp. Sensor Luggage Room Instructor & Technical Staff

New Model PRIUS 2009 Special Notes on Service Auxiliary Battery Connecting location of booster cable Negative Booster Terminal Positive Booster Terminal Reference Instructor & Technical Staff

New Model PRIUS 2009 Special Notes on Service Reference Inspection Mode (not using tester) Inspection Mode procedure Procedure is the same as the previous model Accelerator Pedal Operation within 60 seconds OFF >>>IG-ON Depress Twice Shift Position IG-ON >>> READY READY The inspection mode has 2 methods to activate, one is a method using the tester, and other one is a method not using the tester. Activating Inspection Mode (using tester) - Select from the tester menus: Powertrain >>> Hybrid Control >>> Active Test >>> Inspection Mode – 2WD Inspection - Check that the “Maintenance Mode” is displayed on the multi-information display. Then turn the power switch to READY-ON state while depressing the brake pedal. During Inspection Mode READY indicator light and slip indicator light in the combination meter will illuminate. NOTICE: When operating Inspection Mode, apply the parking brake securely to prevent the vehicle moves Instructor & Technical Staff

Service Point Safety Precautions
New Model PRIUS 2009 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) When 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). Instructor & Technical Staff

New Model PRIUS 2009 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 Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high-voltage system is being inspected and/or repaired. Instructor & Technical Staff

Not cracked, ruptured, torn, or damaged
New Model PRIUS 2009 Service Point Safety Precautions Before servicing the high voltage area 5.Check the insulated gloves Not cracked, ruptured, torn, or damaged Insulated glove - not cracked, ruptured, torn, or damaged - not wet Not wet Instructor & Technical Staff

Remove before servicing
New Model PRIUS 2009 Service Point Safety Precautions Before servicing the high voltage area 6.Remove the service plug Carry in your pocket Service Plug Before inspecting or servicing the high-voltage system, remove service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while you are servicing the vehicle. Remove before servicing Instructor & Technical Staff

High-voltage Condenser
New Model PRIUS 2009 Service Point Safety Precautions Before servicing the high voltage area 7.Wait 5 minutes or more to discharge high-voltage condenser in the inverter 5 min. High-voltage Condenser Discharge Service plug disconnection Elect-ricity 0V Inverter Assembly After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals. Note: 5 minutes are required to discharge the high-voltage condenser inside the inverter assembly. Instructor & Technical Staff

New Model PRIUS 2009 Service Point Safety Precautions Before servicing the high voltage area 8.Measure the inverter terminal voltage (0V check) 0 V Between 3 phases 3 phases and body ground 0 V Using a voltmeter, measure the voltage between terminals of 3 phases (U-V, V-W, U-W) and between each terminal and body ground to verify that they are approx. 0V. Caution: Wear the insulated gloves. Reference Inverter Assembly Instructor & Technical Staff

New Model PRIUS 2009 Service Point Safety Precautions During servicing the high voltage area Insulate the tools by vinyl tape Insulated Vinyl Tape Reference Instructor & Technical Staff

New Model PRIUS 2009 Service Point Safety Precautions During servicing the high voltage area Insulate the disconnected high-voltage connector with insulated vinyl tape Insulated Vinyl Tape After disconnecting a high-voltage connector or terminal, insulate it with insulated vinyl tape. Instructor & Technical Staff

Junction Block x Module
New Model PRIUS 2009 Service Point Safety Precautions During servicing the high voltage area Non-reusable nut is used to the installation of high voltage line New Example of use Wire x SMR Used Non-reusable nut is used to the installation of high voltage line. Non-reusable Junction Block x Module Instructor & Technical Staff

Service Point Safety Precautions After servicing the high voltage area
New Model PRIUS 2009 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 Before reinstalling the service plug, check again that - you have not left a part or tool inside. - the high-voltage terminal screws are properly tightened. - the connectors are correctly connected. Instructor & Technical Staff

Service Point Short-circuit of MG1, MG2
New Model PRIUS 2009 Service Point Short-circuit of MG1, MG2 Use a milliohm meter to judge the short-circuit in the motor coil Short-circuit It cannot check the motor coil resistance correctly by the TOYOTA Electrical Tester Use a milliohm meter to judge the short-circuit in the motor coil. Note: It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester. Because the resistance is very low. Measurement: Measure the resistance between 3 phases. Standard (at 20°C): MG1 >>> Approx. 109 m / MG2 >>> Approx. 135 m / Difference between 3 phases >>> 2m or less Note: If the MG1 / MG2 temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Milliohm Meter Instructor & Technical Staff

Service Point After servicing Safety Precautions
New Model PRIUS 2009 Service Point Safety Precautions After servicing the high voltage area Be sure to install the service plug before starting the hybrid system Vehicle damages After servicing Be sure to install the service plug before starting the hybrid system. Starting the hybrid system with the service plug removed may damage the vehicle. Installation READY ON Instructor & Technical Staff

Service Point Response When The Auxiliary Battery (12V) Runs Out
New Model PRIUS 2009 Service Point Response When The Auxiliary Battery (12V) Runs Out Vehicle conditions when auxiliary battery low voltage 9.5 V 0 V Shift position indicator doesn’t light up Multi display goes out Shift position indicator blinks Normal Black Out Shift position indicator doesn’t light up >>> by the command from HV ECU Shift position indicator blinks >>> by the operation of Combination Meter READY ON Instructor & Technical Staff

Service Point Response When The HV Battery (201.6V) Runs Out
New Model PRIUS 2009 Service Point Response When The HV Battery (201.6V) Runs Out Vehicle conditions when HV battery low voltage HV Battery Warning Light illuminates Can not READY ON DTC P (HV Battery Malfunction) is detected Instructor & Technical Staff

Note: THS charger is the recommended tool
New Model PRIUS 2009 Service Point Response When The HV Battery (201.6V) Runs Out Charge the HV Battery using THS Charger When the HV battery runs out, charge it by THS Charger. Charging time for engine start: Approx. 10 minute (at 25°C) Caution: Wear the insulated gloves when connect / disconnect the THS charger. Never disconnect the THS charger connecter during charging. THS Charger THS Charger Note: THS charger is the recommended tool Instructor & Technical Staff

Neutralize battery electrolyte
New Model PRIUS 2009 Service Point Battery Pack Removal / Installation If the HV battery electrolyte leaks, don’t touch it Neutralize battery electrolyte Don’t touch the battery electrolyte ! Boric Acid Solution [Caution at battery pack removal] - The HV battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. - To neutralize battery electrolyte, use a boric acid solution or vinegar. Boric Acid (800 g) Water (20 liters) Instructor & Technical Staff

New Model PRIUS 2009 Service Point Towing Notice: If there is a electrical leakage, motor regenerates the electricity by wheel rotation Instructor & Technical Staff

Contents Click a Section Tab New Model PRIUS 2009

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