hybrid technology

1. 1
TOYOTA Hybrid Technology

2. 2
Contents
What is the Hybrid Vehicle?
THS II (TOYOTA Hybrid System)
Engine
Hybrid Transaxle
Inverter Assembly
HV Battery
THS II Operation
ECB (Electronically Controlled Brake)
Indicator and Warning
Other System
Service Point
Other Hybrid Vehicles

3. 3
What is the Hybrid Vehicle?

4. 4
CO2
Concentration
500
300
260
600
400
(ppmv)
1200 1400 1600 1800 2000
2100
What is the Hybrid Vehicle?
Why is the hybrid vehicle necessary?
Low fuel consumption and low CO2 emission
vehicle is required
Increase Automobile
market
Expanding Energy
Consumption
2006
1970

5. 5
What is the Hybrid Vehicle?
Why is the hybrid vehicle necessary?
– Hybrid technology is the core for eco-car development
•Low fuel consumption
•Low CO2 emission
THS II
FCHV
THS
Ultimate eco-car
CNG DPR
DPNR
Common-rail VVT-i
Lean Burn
D-4
EV
Diesel
Engine
Alternative
Energy
Gasoline
Engine
Electric
Vehicle

6. 6
What is the Hybrid Vehicle?
Kind of Hybrid System
– Series Hybrid System
• In this system, the engine is used to supply
electrical power to the motor, which then turns the
wheels

7. 7
What is the Hybrid Vehicle?
Kind of Hybrid System
– Parallel Hybrid System
• The wheels are driven by both the engine and the
motor

8. 8
What is the Hybrid Vehicle?
Kind of Hybrid System
– THS (TOYOTA Hybrid System)
• Strong points of both series/parallel systems
realized in one system

9. 9
What is the Hybrid Vehicle?
THS II (TOYOTA Hybrid System)
– Concept
Higher
Power
Low Fuel
Consumption

10. 10
What is the Hybrid Vehicle?
THS II (TOYOTA Hybrid System)
– Hybrid vehicle realizes low fuel consumption and
higher power
PRIUS
(NHW20)
Japanese
10
–
15
Mode
Fuel
Efficiency
(km/L)
0 – 100 km/h Acceleration (sec.)
Good Acceleration
Good Fuel
Economy
PRIUS
(NHW11)
Corolla
(1.3L) Corolla
(1.5L)
CAMRY
(2.4L)
Tradeoff between performance
and fuel economy in
conventional vehicle

11. 11
What is the Hybrid Vehicle?
Driving Method
– The vehicle can run on gasoline only, and does not
need to be recharge
– If the battery charge drops, the engine drives the
generator, which recharges the battery

12. 12
What is the Hybrid Vehicle?
Driving Method
– The vehicle may be driven while the “READY” light is
ON
– The engine will stop while the vehicle is stopped, in
order to improve fuel economy
– The engine starts up automatically after the vehicle
starts off

13. 13
THS II
(TOYOTA Hybrid System)
PRIUS [NHW20]

14. 14
THS II (TOYOTA Hybrid System)
Main Component Location
HV Battery
Engine
Inverter
Hybrid Transaxle
•Generator (MG1)
•Motor (MG2)
•Power-dividing Mechanism Click Movie

15. 15
MOVIE
Shift Lever
Parking Switch
Shift Lever
Main Component Location
THS II (TOYOTA Hybrid System)

16. 16
THS II (TOYOTA Hybrid System)
System Diagram
HV
Battery
Brake
Actuator
Auxiliary
Battery
Electric A/C
Compressor
A/C
Inverter
DC – DC
Converter
SMR1, 2 and 3
Boost
Converter
MG1 MG2
Hybrid Transaxle
Inverter
Engine
Shift Position
Sensor
(Shift, Select)
Accelerator
Pedal Position
Sensor
EV Mode
Switch
Speed
Sensors
CAN
Engine
ECU
Skid Control
ECU
Battery
ECU
DLC3
HV
ECU
Click here to see
operation of
shift lever

17. 17
THS II (TOYOTA Hybrid System)
Outline
– Compression from conventional vehicle
Item
Conventional
Vehicle
THS II Note for THS II
Power
Source
Engine
•Engine
•Motor
•Generator
•Motor drive is possible
(Engine OFF)
•Engine motive force is
divided for drive and
electric generation
Trans-
mission
•A/T
•M/T
Power Splitting
Device
•Divide the engine, motor
and generator power
•Function as CVT
Brake Hydraulic Brake
•Hydraulic Brake
•Regenerative Brake
Cooperative control
between hydraulic and
regenerative brake
Battery 12V Battery
•12V Battery
•201.6V Battery
High-voltage supply for
motor drive
Power
Train
Control
Engine ECU
•HV ECU
•Engine ECU
•Inverter
Controls the engine,
motor and generator

18. 18
THS II (TOYOTA Hybrid System)
Outline
– System operation
Start-off
Normal
Driving Acceleration Deceleration Stop
Electric
motor only
Motor and
Engine
Motor and Engine
(additional power
drawn from battery)
Battery
charging
Engine
automatically
shuts off

19. 19
THS II (TOYOTA Hybrid System)
1NZ-FXE Engine
– 1.5 liter, In-line 4-cylinder, 16-valve DOHC, gasoline
engine
1NZ-FXE
X = Atkinson Cycle

20. 20
THS II (TOYOTA Hybrid System)
Hybrid Transaxle
– Includes AC 500V motor, generator and power-
dividing mechanism
– Uses a continuously variable transmission mechanism
to achieve smooth and quiet operations
MG1
MG2
Power-dividing
Mechanism

21. 21
THS II (TOYOTA Hybrid System)
HV Battery
– Full sealed nickel metal hydride (Ni-MH) battery
– DC 201.6V
– Located behind the rear seat

22. 22
THS II (TOYOTA Hybrid System)
Inverter Assembly
– Inverter
• DC  AC high voltage
– Variable-voltage System
• DC 200V stepped up to
Max. DC 500V
– DC-DC Converter
• DC 200V stepped down
to DC 12V
– A/C Inverter
• DC  AC to drive the
A/C compressor

23. 23
THS II (TOYOTA Hybrid System)
Brake System
– ECB (Electrically Controlled Brake)
– Hydraulic brake pressure is controlled by electrical
signal and cooperate regenerative brake
Skid
Control
ECU
Vehicle Condition
Driver’s Demand
HV ECU
Regenerative
Brake Control
Hydraulic
Brake Control

24. 24
THS II (TOYOTA Hybrid System)
Steering System
– EPS (Electric Power Steering) is used
EPS ECU
EPS Motor

25. 25
THS II (TOYOTA Hybrid System)
Air Conditioning System
– Compact, high-performance scroll compressor driven
by motor
Electric Inverter Compressor

26. 26
THS II (TOYOTA Hybrid System)
Multi Display
– Energy Monitor

27. 27
THS II (TOYOTA Hybrid System)
Multi Display
– Fuel consumption indicator

28. 28
THS II (TOYOTA Hybrid System)
Auxiliary Battery (12V)
– Auxiliary battery supplies power to headlights, audio,
and all ECUs
– Sealed-type battery is used
Auxiliary
Battery

29. 29
THS II (TOYOTA Hybrid System)
Power Cable
– Orange-colored wire harness / connector
High-voltage circuit
High-voltage Wire Harness
High-voltage Wire Harness

30. 30
THS II (TOYOTA Hybrid System)
Service Plug
– Shut off the high-voltage circuit
Caution: Wear insulated gloves when disconnecting / connecting the
service plug to prevent against electrical shock
Service Plug

31. 31
Engine

32. 32
Engine
Atkinson Cycle
– The “X” of the 1NZ-FXE indicates the use of the
Atkinson cycle, the principle applied for this vehicle’s
engine
Atkinson cycle
High thermal efficiency
1NZ-FXE (PRIUS)

33. 33
Engine
Overview
– Atkinson cycle
Compression Stroke < Expansion Stroke
High thermal efficiency
Compression Expansion

34. 34
Engine
Overview
– Atkinson cycle
• Depending on the driving condition, the cylinder
volume is varied by VVT-i
Valve Timing (Intake Valve)
TDC
BDC
72º
105º
VVT-i
Operation
Cylinder Volume
105º
72º
90º

35. 38
Engine
Overview
– Specifications
Item 1NZ-FXE (’04 PRIUS) 1NZ-FE (Corolla)
No. of Cylinders & Arrangement 4-Cylinder, in-line 
Valve Mechanism
16-Valve DOHC,
Chain Drive, VVT-I

Displacement cm3 (cu. in.) 1497 (91.3) 
Bore x Stroke mm (in.) 75.0 x 84.7 (2.95 x 3.33) 
Compression Ratio 13.0 10.5
Max. Output EEC (-W, -Q) 57 kW @ 5000 rpm 78 kW @ 6000 rpm
Max. Torque EEC (-W, -Q) 115 N·m@ 4200 rpm 145 N·m@ 4200 rpm
Valve
Timing
Intake
Open 18 - -15 BTDC 42 - -2 BTDC
Close 72 - 105 ABDC 10 - 50 ABDC
Exhaust
Open 34 BBDC 42 BBDC
Close 2 ATDC 
Emission Regulation STEP IV STEP III

36. 39
Engine
Overview
– Engine compartment
Radiators (for engine and
inverter) are one piece
Drive belt simply layout
TOYOTA Genuine
Super LLC

37. 40
Engine
Overview
– Interior
32-bit engine ECU with
CAN communication
Non-contact type accelerator
pedal position sensor

38. 41
Engine
Overview
– Under floor
Plastic Type Fuel
Tank (-W, -Q)

39. 42
Shape is changed
to weight reduction
223g (Corolla)

194g (Prius)
Piston skirt portion is
reduced to friction reduction
New resin coat to
friction reduction
Engine
Engine Proper
– Piston
• Lightweight and low friction
Corolla
Prius

40. 43
Engine
Piston
Ring
Cross section Tension Thickness Others
Top
Ring
Inner Bevel Type
4.2 N

3 N
1.2 mm (0.047 in.)

0.8 mm (0.031 in.)
PVD coat is used to
improve wear
resistance
Second
Ring
Taper Type
3.3 N

3 N
1.2 mm (0.047 in.)

1.0 mm (0.039 in.)
Steel material is
used to improve
wear resistance
Oil Ring
2 Piece Type
17 N

8 N
2.0 mm (0.079 in.)

1.5 mm (0.059 in.)
-
Corolla

Prius
 Engine Proper
• Piston Ring
– Lower tension and thinner piston ring is used for
friction reduction

41. 44
Engine
Throttle Body (ETCS-i)
Throttle valve is controlled by the HV ECU.
ETCS-i also controls the cruise control system.

42. 45
Engine
Radiator
(for engine)
Radiator
(for Inverter)
Front
Drain Plug
(for engine)
 Cooling System
Radiators (for engine and inverter) are one piece

43. 46
Engine
Coolant Heat Storage System
– General
• This system reduces the amount of adhesion of fuel
on the intake port wall after engine starting
Hot coolant in
the tank
Before engine start
Hot coolant to
cylinder head Heated
Amount of
adhesion of
fuel is
reduced after
engine start

44. 47
Engine
Coolant Heat Storage System
– Components
Coolant Heat Storage
Tank Outlet Temp. Sensor
Engine Coolant
Temp. Sensor
Coolant Heat
Storage
Water Pump
Water
Valve
Water Pump
(for Heater)
Coolant Heat
Storage Tank
to / from
heater core
Reverse Side

45. 48
Engine
Coolant Heat Storage System
– Operation
• Engine running (w/o storage operation)
Cylinder
Block
Water
Pump
Water
Pump
Heater
Core
Cylinder Head
OF
F
Water
Valve

46. 49
Engine
Coolant Heat Storage System
– Operation
• Storage operation (during engine running)
Cylinder
Block
Water
Pump
Water
Pump
Heater
Core
Cylinder Head
OF
F
Hot coolant
is stored
Water
Valve

47. 50
Engine
Coolant Heat Storage System
– Operation
• Storage operation (during engine running)
 Operation chart
Warm-up
Others
Storage operation (during engine running)
[Max.: 4 times]
Meets start
conditions
Meets stop
conditions
Engine
Starting
Tank coolant temp. is
90 °C (194 °F) or
more
Storage is
Completed
Confidential

48. 51
Engine
Coolant Heat Storage System
– Diagnosis
• DTCs for Coolant Heat Storage System
DTC
No.
Detection Item
DTC
No.
Detection Item
P1115
Coolant temp. sensor circuit for
coolant heat storage system
P1122
Water valve position sensor circuit
low
P1116
Coolant temp. sensor circuit stuck
for coolant heat storage system
P1123
Water valve position sensor circuit
high
P1117
Coolant temp. sensor circuit low for
coolant heat storage system
P1150
Coolant Path Clog Up for Coolant
Heat Storage System
P1118
Coolant temp. sensor circuit high
for coolant heat storage system
P1151 Coolant Heat Storage Tank
P1120 Water valve position sensor circuit P2601
Coolant pump control circuit range /
performance
P1121
Water valve position sensor circuit
stuck
P2610
ECM / PCM internal engine off timer
performance

49. 52
Engine
Coolant Heat Storage System
– Service Point
• Coolant Replacement
 Drain engine coolant
1. Disconnect the coolant heat storage water pump connector
2. Remove the radiator cap
3. Connect a vinyl hose to drain cocks (engine, radiator, coolant
heat storage tank)
4. Loosen the drain cock plugs (engine, radiator, coolant heat
storage tank), and drain coolant
5. Drain the coolant in the radiator reservoir tank
Caution: The coolant in coolant heat storage tank is
hot even if engine and radiator are cold

50. 53
Engine
Coolant Heat Storage System
– Service Point
• Coolant Replacement
 Fill engine coolant
1. Tighten the drain cock plugs and disconnect a vinyl hose (engine,
radiator, coolant heat storage tank)
2. Connect a vinyl hose to the bleeder plug of radiator and insert the
another side of hose to reservoir tank
3. Using 6 mm socket hexagon wrench, loosen the radiator bleeder plug
from service hole
4. Fill the coolant into the radiator
5. Tighten the radiator bleeder plug and install the radiator cap
6. Fill the radiator reservoir tank with coolant to the full level
7. Connect the coolant heat storage water pump connector
8. Connect the Intelligent Tester II to DLC3 and turn to IG/ON

51. 54
Engine
Coolant Heat Storage System
– Service Point
• Coolant Replacement
 Fill engine coolant
9. Perform the ACTIVE TEST of water pump (coolant heat storage water
pump operates for 30 sec.)
10. Loosen the radiator bleeder plug and fill the coolant into the radiator
11. Tighten the radiator bleeder plug
12. Repeat the steps 9 to 11 until coolant cannot be added
13. Disconnect the vinyl hose
14. Warm-up engine until the thermostat is opened (inspection mode)
15. Stop the engine, and wait until the coolant gets cold
16. Fill the coolant into the radiator
17. Repeat the step 14 to 16 until coolant level stops going down
18. Check DTC and clear the DTC which relates to the water pump

52. 55
Engine
Fuel System
(Vapor reducing fuel tank)
Reduce the amount of
fuel vapors released
when vehicle is
parked.

53. 56
Engine
Fuel System
(Vapor reducing fuel tank)
It is composed of two parts:
a metal outer tank,
and a plastic
membrane inside the
fuel tank.
NOTE:
Normal tank capacity
is 45 liters; tank
capacity decreases by
5 liters at –10°C.
Click!
zoom

54. 58
Engine
Fuel System
(Vapor reducing fuel tank)
Fuel Sender Gauge
Sub-tank is installed
inside the fuel tank,
inside which a fuel
pump and sender
gauge are attached.
Sub-tank
Fuel Sender Gauge

55. 59
Engine
Fuel System
(Vapor reducing fuel tank)
Fuel Sender Gauge
The fuel pump and
sender gauge can not
be removed from the
fuel tank.
If the pump or gauge
malfunctions
Replace the tank
assembly

56. 60
Engine
Drive Belt System
– A/C compressor pulley is not existing
– Simply belt layout
A/C compressor
pulley is not existing
Water Pump Pulley
Crank Pulley
Idler Pulley
Adjust Bolt

57. 61
Hybrid Transaxle

58. 62
Hybrid Transaxle
Overview
– P112 type
– Components:
• MG (Motor Generator) 1
• MG (Motor Generator) 2
• Power-dividing Mechanism (Planetary Gears)
• Reduction Mechanism
• Differential Mechanism
– Fluid type: ATF WS
– Capacity: 3.8 liters

59. 63
Hybrid Transaxle
Overview
– P112 type
MG2 MG1
Planetary Gears
Chain-drive
Sprocket

60. 64
Hybrid Transaxle
Overview
– P112 type
Counter
Drive Gear
Final Drive
Pinion Gear
Counter-
driven Gear
Final Ring
Gear
Chain-driven
Sprocket
Reduction
Mechanism
Differential
Mechanism

61. 65
Hybrid Transaxle
MG1 / MG2
– Compact and lightweight, highly efficient AC500V
motor generator
MG2
MG1

62. 66
Hybrid Transaxle
MG1
– Main operations  Generator
– When engine starting  Starter
MG1
Stator Coil
Rotor
Speed Sensor

63. 67
Hybrid Transaxle
MG2
– When driving  Main power to engine power (Starting
off) or provides supplementary
– When braking  Converts kinetic energy to
electrical energy
MG2
Stator Coil Rotor
Speed Sensor

64. 68
Hybrid Transaxle
Speed Sensor (Resolver)
– Detects position, speed and direction of MG1 / MG2
rotors
Speed Sensor
(for MG1)
Speed Sensor
(for MG2)

65. 69
Hybrid Transaxle
Transaxle Damper
– Installed at location of conventional clutch
Reduces shock which occurs when kinetic energy is
transmitted

66. 70
Hybrid Transaxle
Cooling System
– Cooling circuit is used for both MG1 / MG2
– Separate cooling system from engine
Reservoir
Pump
MG1 / 2
Radiator
Inverter
Reservoir Tank
Radiator
Electric
Water Pump

67. 71
Hybrid Transaxle
Oil Pump
– Forced lubrication system via trochoid pump used to
lubricate main shaft bearings
– Oil pump functions when engine is being driven
Oil Pump

68. 72
Hybrid Transaxle
Mayor Different with Prius Generation III

69. 73
Inverter Assembly

70. 74
Inverter Assembly
Components
– Inverter
• DC  AC high voltage
– Variable-voltage System
• DC201.6V stepped up to
max. DC500V
– DC-DC Converter
• DC201.6V stepped down
to DC 12V
– A/C Inverter
• DC  AC to drives the
A/C compressor

71. 75
Inverter Assembly
Components
HV Battery
Inverter Assembly
A/C
Inverter
Variable-
voltage
System
MG1
MG2
Inverter
DC - DC
Converter

72. 76
Inverter Assembly
Variable-voltage System
– DC 201.6V  Max. DC 500V conversion
HV Battery
DC 201.6V DC500V
Variable-
voltage System
•IPM (IGBT)
•Reactor
Max. DC 500V
 
DC 201.6V
Inverter Assembly
AC500V
MG2
: Discharge : Charge
MG1
Inverter
(IPM)

73. 77
Inverter Assembly
Inverter Operation
– Motor control
Motor Torque is controlled
by the current value
Motor Speed is controlled by
the frequency
Low
Torque
High
Torque
Low
Speed
High
Speed

74. 78
Inverter Assembly
DC – DC Converter
– DC201V  DC 12V
DC 201.6V
DC – DC Converter
Inverter Assembly
Auxiliary
Battery
DC 12V
DC

AC
AC 201.6V

AC 12V
AC

DC
MG1
MG2
HV Battery
Inverter
Variable-
voltage
System

75. 79
Inverter Assembly
A/C inverter
– DC201.6V  AC201.6V conversion
Electric
Inverter
Compressor
HV ECU
HV Battery
A/C ECU
Target
Compressor
Speed
DC 201.6V
AC 201.6V
A/C Inverter
DC 201.6V

AC 201.6V
Inverter Assembly

76. 80
Inverter Assembly
Cooling System
– Cooling circuit is used for inverter assembly
– Separate cooling system from engine
Reservoir
Pump
MG1 / 2
Radiator
Inverter
Reservoir Tank
Radiator
Electric
Water Pump

77. 81
HV Battery Assembly

78. 82
HV Battery Assembly
Power Supply
– The HV battery supplies power to MG1 / MG2
– The auxiliary battery supplies power to HV ECU and
Engine ECU (all ECU)
– When both are functioning properly, the vehicle will
start
HV Battery
(DC 201.6V)
Auxiliary Battery
(DC 12V)

79. 83
HV Battery Assembly
Components
Current
Sensor
SMR3
SMR2
Resister
Module
Battery ECU
SMR1
Service
Plug
Connector

80. 84
HV Battery Assembly
Battery Module
– Nickel metal hydride (Ni-MH) battery
(1.2V x 6 cells) x 28 modules = 168 cells = DC 201.6 V
28 Module
Module
(1.2V x 6 cells)

81. 85
HV Battery Assembly
Battery ECU
– Maintains control of HV battery SOC (State of charge)
– Ensures battery capability
Service
Plug
Temp. Sensors
(Thermistor)
Battery
Cooling Fan
Motor
HV Battery
Current
Sensor
Voltage x 14
+
-
Temp. x 4
Battery ECU
SOC
Control
Cooling Fan
Control
Electrical Leakage Detection
for High-voltage System
Diagnosis Function
for HV Battery
HV Battery
Condition Detection
•HV ECU
•Engine ECU
•A/C ECU
CAN
Battery
Cooling Fan
Relay
Battery
Cooling Fan
Controller

82. 86
HV Battery Assembly
Battery ECU
– Controls SOC to match THS characteristics
– The SOC is maintained at approx, 60%. A margin is
given for further recharging via regenerative braking
– Sends requests to HV ECU to obtain desired SOC

83. 87
HV Battery Assembly
SOC Control
– When the SOC is dropped, battery ECU sends the
“Charge Request” signal to HV ECU
Battery ECU
HV Battery Engine
Drive
Charge
Voltage
(SOC)
SOC
Charge
Request
Power
Request
Charging
Control
HV ECU
Engine
ECU
MG1

84. 88
HV Battery Assembly
SMR (System Main Relay)
– Turns ON / OFF the high-voltage circuit
SMR1
SMR2
SMR3

85. 89
HV Battery Assembly
SMR
– Shutdown control
READY OFF At Collision
Interlock Switch OFF
(Service plug grip disconnection, Inverter cover open)

86. 90
HV Battery Assembly
Service Plug
– Shut off the high voltage circuit manually
Service Plug

87. 91
HV Battery Assembly
Auxiliary Battery
– Auxiliary battery supplies power to headlights, audio,
and all ECUs
Auxiliary
Battery

88. 92
HV Battery Assembly
Auxiliary Battery
– Sealed-type battery is used
Notice:
Refrain from quick charging
Because the battery fluid
cannot be replenished
Never use an ordinary battery

89. 93
HV Battery Assembly
Auxiliary Battery
– Jump Start Terminal
• ”+” terminal of auxiliary battery for jump start is
used
Jump Start
Terminal

90. 94
Auxiliary Battery
– Jump Start Procedure Auxiliary Battery
Special Notes on Service
Positive Terminal
Negative Terminal
Click Movie

91. 95
THS II Operation

92. 96
THS II Operation
Components
Generator (MG1)
HV Battery
Engine
Motor (MG2)
Inverter
Power-dividing
Device
Differential
Mechanism

93. 97
THS II Operation
Power-dividing Mechanism (Planetary Gears)
– Sun gear: MG1
– Planetary Carrier: Engine
– Ring Gear: MG2 (Front Wheel)
MG1
MG2
Engine
To Front Wheel
Chain
Power-dividing
Mechanism

94. 98
Unit Planetary gear
Unit Planetary gear Ring Gear Planetary Carrier
Sun Gear
Perangkat Pembagi Power

95. 99
Bagan Nomographic
Arah Rotasi
+ -
Mome
n
+ Discharge (Motor) Charge (Generator)
- Charge (Generator) Discharge (Motor)
Kondisi MG1, MG2

96. 100
Bagan Nomographic
Prinsip Kerja-1
Sun gear: fixed (tertahan)
Ring gear: berputar (input)
Planetary carrier: ?
 Referensi ke bagan
Klik di atas untuk melihat film (movie)

97. 101
Bagan Nomographic
Prinsip Kerja-2
Planetary carrier: fixed
(tertahan)
Ring gear: berputar (input)
Sun gear: ?
 Referensi ke bagan
Klik di atas untuk melihat film (movie)

98. 102
THS II Operation
Engine Starting and Idling
Click!
Movie
Vehicle
Speed
Click!
animasi

99. 103
Menghidupkan Mesin
Menghidupkan Mesin
MG1 bekerja sebagai motor starter
 Referensi ke bagan

100. 104
Menghidupkan Mesin
Starting Mesin dan Idling
Mesin menggerakkan MG1 untuk mengisi baterai HV.
 Referensi ke bagan

101. 105
THS II Operation
Vehicle Starting Off
Vehicle
Speed
Click!
Movie
Click!
animasi

102. 106
Kendaraan Mulai Berjalan
 Referensi ke bagan
Starting Off-1
Hanya MG2 yang digunakan dalam beban ringan/
akselerasi ringan.

103. 107
Kendaraan Mulai Berjalan
 Referensi ke bagan
Starting Off-2
MG1 bekerja untuk menghidupkan mesin saat
dibutuhkan tambahan power.

104. 108
Kendaraan Mulai Berjalan
 Referensi ke bagan
Starting Off-3
Mesin menggerakkan MG1 untuk membangkitkan listrik
untuk MG2

105. 109
Vehicle
Speed
THS II Operation
Accelerating Under Low Load (Light Throttle)
– Request more power, MG1 starts engine
Click!
Movie
Click!
animasi

106. 110
Selama Merayap (Cruising):
Selama Merayap (Cruising):
MG2 membangkitkan listrik untuk MG1.
Unit planetary gear bertindak sebagai CVT.
 Referensi ke bagan

107. 111
Selama Merayap (Cruising):
Akselerasi Ringan
MG1 membangkitkan listrik untuk MG2.
MG2 menyediakan power penggerak tambahan.
 Referensi ke bagan

108. 112
THS II Operation
Accelerating Under Heavy Load (Full Throttle)
Vehicle
Speed
Click!
Movie
Click!
animasi

109. 113
Akselerasi Full Throttle
 Referensi ke bagan
Akselerasi Full Throttle

110. 114
THS II Operation
Decelerating
Vehicle
Speed
Click!
Movie
Click!
animasi

111. 115
Deselerasi
 Referensi ke bagan
D range
MG2 berperan sebagai generator untuk mengisi baterai
HV.

112. 116
Deselerasi
B range
MG1 menggerakkan mesin untuk pengereman oleh
mesin.
 Referensi ke bagan

113. 117
THS II Operation
Driving in Reverse
Vehicle
Speed
Click!
Movie
Click!
animasi

114. 118
Pengendaraan Mundur
Pengendaraan Mundur
Hanya MG2 yang digunakan untuk mundur.
 Referensi ke bagan

115. 119
Kontrol
Motor Traction Control
Mengontrol MG2 dan rem hidrolik.
MG2
Traction
Control
Gaya
Pengereman Inverter
Sensor
Kecepatan
Kecepatan Tinggi
ECU Skid
Control ECU
HV
Sensor
Kecepatan
Setiap
Roda
Slipping

116. 120
Kontrol
Kontrol Bantuan Menanjak
Mengontrol rem hidrolik belakang.
ECU HV
Traction Control
Gaya
Pengereman
ECU Skid
Control
Sinyal Sensor Kecepatan MG2 dll.
Mencegah kendaraan dari
terguling ke belakang

117. 121
THS II Operation
THS-II Control
– Motor Drive Mode Control (except U.S.A. model)
• In this mode, the vehicle is driven by only MG2 by
operating the EV Mode Switch
Drive
Accelerator Pedal
Position Sensor
Battery ECU
•SOC Condition
•Battery Temp.
EV
Mode
Switch
Skid Control
ECU
Speed
Sensors
Combination
Meter
Gateway
ECU
EV Mode
Indicator
Light
HV ECU
Inverter
HV
Battery
Engine ECU

118. 122
THS II Operation
THS-II Control
– Motor Drive Mode Control (except U.S.A. model)
• EV Mode Switch is momentary type
LHD Model
EV Mode
Switch

119. 123
THS II Operation
THS-II Control
– Motor Drive Mode Control (except U.S.A. model)
• Operation conditions
EV Mode
Normal
Push
EV mode canceling conditions
•EV mode switch is pushed
•HV battery SOC drops
•HV battery temp. is low or high
•Engine is warming up
•Vehicle speed exceeds the
specified speed
•The accelerator pedal position
angle exceeds the specified value
or

120. 124
ECB
(Electronically Controlled Brake)

121. 125
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

122. 126
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

123. 127
Indicator and Warning

124. 128
Indicator and Warning
Combination Meter
– READY light indicates that the vehicle is ready to drive
Ready Light

125. 129
Indicator and Warning
Multi Display
– Energy monitor shows the energy flow

126. 130
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

127. 131
Indicator and Warning
Multi Display
– Warning message

128. 132
Other Systems

129. 133
Other Systems
General
– Engine is operated intermittently, so power steering
and A/C compressor uses electric power
EPS (Electric Power Steering) Electric Inverter Compressor

130. 134
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

131. 135
Other Systems
Air Conditioning
– Service Point
• Don’t use the compressor oil other than ND11

132. 136
Service Point

133. 137
Service Point
Inspection Mode
– In the inspection mode, engine is continuously
operated (P range) and motor TRC is turned off
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)

134. 138
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

135. 139
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

136. 140
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
Megohmmeter

137. 141
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 !

138. 142
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)

139. 143
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
Service plug
disconnection
Elect-
ricity
0V
Inverter
Assembly

140. 144
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

141. 145
Service Point
Safety Precautions
– Before servicing the high voltage area
5.Check the insulated gloves
Not cracked, ruptured, torn,
or damaged
Not wet

142. 146
Service Point
Safety Precautions
– Before servicing the high voltage area
6.Remove the service plug
Remove before servicing
Service Plug

143. 147
Service Point
Safety Precautions
– Before servicing the high voltage area
8.Measure the inverter terminal voltage (0V check)
Inverter Assembly
Between
3 phases
3 phases and
body ground

144. 148
Service Point
Safety Precautions
– During servicing the high voltage area
• Insulate the tools by vinyl tape
Insulated Vinyl Tape

145. 149
Service Point
Safety Precautions
– During servicing the high voltage area
• Insulate the disconnected high-voltage connector
with insulated vinyl tape
Insulated Vinyl Tape

146. 150
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

147. 151
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

148. 152
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
servicing
Installation
Vehicle
damages

149. 153
 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

150. 154
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

151. 155
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)

152. 156
Service Point
Towing
Notice: If there is a electrical leakage, motor regenerates
the electricity by wheel rotation