Service Point

1. Service Point

2. 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.

3. Service Point • Inspection Mode • Manual procedure within 60 seconds with brake Accelerator Pedal OFF  IG-ON IG-ON  READY Depress twice Depress twice Depress twice Change the power mode to OFF  inspection mode is canceled

4. Service Point • Diagnosis • Each DTC has information code [INF Code] • It contains detailed information Detailed Information Freeze Frame Data DTC INF Codes

5. Service Point • Diagnosis • In the hybrid system, DTCs and INF code are provided to narrow down the trouble areas Detection Item Detection Condition

6. Click! Service Point • Diagnosis • Data list for hybrid vehicle Data List

7. Click! Service Point • Diagnosis • Active test for hybrid vehicle Active Test

8. Service Point • High-voltage Wire Harness • All high-voltage wire harness and connectors are colored orange High-voltage Wire Harness High-voltage Wire Harness

9. Service Point • High-voltage Wire Harness • Insulation resistance between the high-voltage circuit and the body is always monitored Meter a HV ECU High-voltage Circuit Load Battery ECU Electrical Leakage Detection Circuit Insulation Resistance Body

10. MG1 MG2 Reference (Service Point) • High-voltage Wire Harness • Electrical leakage detection area INF. Code: 612 (HV Battery Area) INF. Code: 614 (High Voltage Direct Current Area) INF. Code: 613 (Transaxle Area) Resister SMR1 SMR1 Inverter Inverter SMR2 SMR2 Boost Converter Power Cable A/C Inverter A/C Inverter INF. Code: 611 (A/C Area) SMR3 SMR3 DC – DC Converter Battery ECU Electrical Leakage Detection Circuit

11. It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester Service Point • High-voltage Wire Harness • Use a megohmmeter to measure the insulation resistance (Standard: 2  10 M) Megohmmeter Basically use the 500V range Notice: If you use the 1000V range, it causes the breakdown of the parts

12. Service Point • High-voltage Wire Harness • Risk of electric shock

13. 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. 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

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

16. Service Point • Safety Precautions • Before servicing the high voltage area 6.Remove the service plug Carry in your pocket Service Plug Remove before servicing

17. High-voltage Condenser Discharge 0V Elect-ricity Service plug disconnection 5 min. Service Point • Safety Precautions • Before servicing the high voltage area 7.Wait 5 minutes or more to discharge high-voltage condenser in the inverter Inverter Assembly

18. 0 V 0 V Service Point • Safety Precautions • Before servicing the high voltage area 8.Measure the inverter terminal voltage (0V check) Between 3 phases 3 phases and body ground Inverter Assembly

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

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

21. 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 New Wire x SMR Used Non-reusable Junction Block x Module

22. 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

23. 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 Installation READY ON

24. 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 Shift position indicator blinks Multi display goes out Black Out Normal READY ON

25. Service Point • Response When The Auxiliary Battery (12V) Runs Out • Charge the auxiliary battery by jump starting or battery charger Slow Charge Jump Starting Battery Charger

26. 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 P3000-389 (HV Battery Malfunction) is detected

27. Service Point • Response When The HV Battery (201.6V) Runs Out • Charge the HV Battery using THS Charger THS Charger THS Charger Note: THS charger is the recommended tool

28. Don’t touch the battery electrolyte ! Service Point • Battery Pack Removal / Installation • If the HV battery electrolyte leaks, don’t touch it Neutralize battery electrolyte Boric Acid Solution Boric Acid (800 g) Water (20 liters)

29. Short-circuit It cannot check the motor coil resistance correctly by the TOYOTA Electrical Tester Service Point • Short-circuit of MG1, MG2 • Use a milliohm meter to judge the short-circuit in the motor coil Milliohm Meter

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