automotive hybrid-automotive hybrids.ppt

about hybrid technology car.

1. Instructor

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
What is the Hybrid Vehicle?
Why is the hybrid vehicle necessary?
–Increase automobile market

5. 5
What is the Hybrid Vehicle?
Why is the hybrid vehicle necessary?
–Expanding energy consumption
2006
Energy
Consumption
1970

6. 6
What is the Hybrid Vehicle?
Why is the hybrid vehicle necessary?
–Global warming caused by CO2
C
O
2

C
o
n
c
e
n
t
r
a
t
i
o
n

500
300
260
600
400
(ppmv)
12001400160018002000
2100
CO2

7. 7
What is the Hybrid Vehicle?
Why is the hybrid vehicle necessary?
Low fuel consumption and low CO2 emission
vehicle is required

8. 8
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

9. 9
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

10. 10
What is the Hybrid Vehicle?
Kind of Hybrid System
–Parallel Hybrid System
•The wheels are driven by both the engine and the
motor

11. 11
What is the Hybrid Vehicle?
Kind of Hybrid System
–THS (TOYOTA Hybrid System)
•Strong points of both series/parallel systems
realized in one system

12. 12
What is the Hybrid Vehicle?
Kind of Hybrid System
–Hybrid system comparison
System
Fuel Economy Improvement Driving Performance
Idling
Stop
Energy
Recovery
High-efficiency
Operation Control
Total
Efficiency
Acceleration
Continuous
High Output
Series     
Parallel    
THS
(Series /
Parallel)
    
: Excellent: Superior: Somewhat Unfavorable

13. 13
What is the Hybrid Vehicle?
Other Hybrid Vehicle
–Fuel cell hybrid vehicle
PRIUS
(THS)
FCHV
(Fuel Cell Hybrid Vehicle)
Engine
Battery
Motor
Power
Control
Unit
Fuel Cell
Battery
Motor
Power
Control
Unit

14. 14
What is the Hybrid Vehicle?
Well-to-wheel efficiency
Fuel
Efficiency
(Well-to-Tank)
[%]
Vehicle
Efficiency
(Tank-to-Wheel)
[%]
Overall Efficiency
(Well-to-Wheel)
[%]
Recent
Gasoline Model
88 16
PRIUS
(NHW11)
88
32
PRIUS
(NHW20)
37
TOYOTA FCHV 58* 50
FCHV (Target) 70 60
*: Hydrogen from CNG
0 10 20 30 40
14
28
32
29
42

15. 15
What is the Hybrid Vehicle?
THS II (TOYOTA Hybrid System)
–Concept
Higher
Power
Low Fuel
Consumption

16. 16
What is the Hybrid Vehicle?
THS II (TOYOTA Hybrid System)
–Hybrid vehicle realizes low fuel consumption and
higher power
PRIUS
(NHW20)
J
a
p
a
n
e
s
e

1
0

–

1
5

M
o
d
e

F
u
e
l

E
f
f
i
c
i
e
n
c
y
(
k
m
/
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

17. 17
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

18. 18
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

19. 19
What is the Hybrid Vehicle?
Hybrid Vehicle Line-up
*: Only for Japanese market
PRIUS
(NHW11)
PRIUS
(NHW20)
ESTIMA*
CROWN*
ALPHARD*
RX400h
HIGHLANDER
GS450h
CAMRY
LS600h
1997 2001 2003 2004 2006 2007
1997 2001 2003 2004 2006 2007

20. 20
What is the Hybrid Vehicle?
Number of Hybrid Vehicles for Sale
C
u
m
u
l
a
t
i
v
e

S
a
l
e
s

1997 2001 2003 2004 2006 2007
1997 2001 2003 2004 2006 2007
100,000
200,000
300,000
400,000
500,000
600,000

21. 21
THS II
(TOYOTA Hybrid System)
PRIUS [NHW20]

22. 22
THS II (TOYOTA Hybrid System)
THS II Components
Generator (MG1)
HV Battery
Engine
Motor (MG2)
Inverter
Power-
dividing
Device

23. 23
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
DLC3DLC3
HV
ECU

24. 24
THS II (TOYOTA Hybrid System)
Location
HV Battery
Engine
Inverter
Hybrid Transaxle
•Generator (MG1)
•Motor (MG2)
•Power-dividing Mechanism

25. 25
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
Battery12V 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

26. 26
THS II (TOYOTA Hybrid System)
Outline
–System operation
Start-off
Normal
Driving
AccelerationDeceleration Stop
Electric
motor only
Motor and
Engine
Motor and Engine
(additional power
drawn from battery)
Battery
charging
Engine
automatically
shuts off

27. 27
THS II (TOYOTA Hybrid System)
Outline
–System operation
Vehicle Stopped Start-off,
Low Load Driving,
Reverse
Normal Driving
High Load Driving Deceleration Vehicle Stopped
(Charging)

28. 28
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

29. 29
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

30. 30
THS II (TOYOTA Hybrid System)
HV Battery
–Full sealed nickel metal hydride (Ni-MH) battery
–DC 201.6V
–Located behind the rear seat

31. 31
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

32. 32
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

33. 33
THS II (TOYOTA Hybrid System)
Steering System
–EPS (Electric Power Steering) is used
EPS ECU
EPS Motor

34. 34
THS II (TOYOTA Hybrid System)
Air Conditioning System
–Compact, high-performance scroll compressor driven
by motor
Electric Inverter Compressor

35. 35
THS II (TOYOTA Hybrid System)
Multi Display
–Energy Monitor

36. 36
THS II (TOYOTA Hybrid System)
Multi Display
–Fuel consumption indicator

37. 37
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

38. 38
THS II (TOYOTA Hybrid System)
Power Cable
–Orange-colored wire harness / connector
High-voltage circuit
High-voltage Wire Harness
High-voltage Wire Harness

39. 39
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

40. 40
Engine

41. 41
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)

42. 42
Engine
Atkinson Cycle
Compression Stroke < Expansion Stroke
High thermal efficiency
Compression Expansion

43. 43
Engine
Atkinson Cycle
–Depending on the driving condition, the cylinder
volume is varied by VVT-i
Valve Timing (Intake Valve) Cylinder Volume
105°
72°
VVT-i
Operation
BDC
TDC

44. 44
Engine
Atkinson Cycle
–Intake valve close timing is late
Valve Timing (Intake Valve) Cylinder Volume
105°
C
o
m
p
r
e
s
s
i
o
n

S
t
r
o
k
e
E
x
p
a
n
s
i
o
n

S
t
r
o
k
e
BDC
TDC

45. 45
Engine
Atkinson Cycle
–Intake valve close timing is middle
Valve Timing (Intake Valve) Cylinder Volume
BDC
TDC
90°
E
x
p
a
n
s
i
o
n

S
t
r
o
k
e
C
o
m
p
r
e
s
s
i
o
n

S
t
r
o
k
e

46. 46
Engine
Atkinson Cycle
–Intake valve close timing is early
Valve Timing (Intake Valve) Cylinder Volume
72°
E
x
p
a
n
s
i
o
n

S
t
r
o
k
e
C
o
m
p
r
e
s
s
i
o
n

S
t
r
o
k
e
BDC
TDC

47. 47
Engine
Drive Belt System
–A/C compressor pulley is not existing
–Simply belt layout
Crank Pulley
A/C compressor
pulley is not existing
Water Pump Pulley
Idler Pulley
Adjust Bolt

48. 48
Hybrid Transaxle

49. 49
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

50. 50
Hybrid Transaxle
Overview
–P112 type
MG2 MG1
Planetary Gears
Chain-drive
Sprocket

51. 51
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

52. 52
Hybrid Transaxle
MG1 / MG2
–Compact and lightweight, highly efficient AC500V
motor generator
MG2MG1

53. 53
Hybrid Transaxle
MG1
–Main operations  Generator
–When engine starting  Starter
MG1
Stator Coil
Rotor
Speed Sensor

54. 54
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

55. 55
Hybrid Transaxle
Speed Sensor (Resolver)
–Detects position, speed and direction of MG1 / MG2
rotors
Speed Sensor
(for MG1)
Speed Sensor
(for MG2)

56. 56
Hybrid Transaxle
Transaxle Damper
–Installed at location of conventional clutch
Reduces shock which occurs when kinetic energy is
transmitted

57. 57
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

58. 58
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

59. 59
Inverter Assembly

60. 60
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

61. 61
Inverter Assembly
Components
HV Battery
Inverter Assembly
A/C
Inverter
Variable-
voltage
System
MG1
MG2
Inverter
DC - DC
Converter

62. 62
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)

63. 63
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

64. 64
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

65. 65
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

66. 66
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

67. 67
HV Battery Assembly

68. 68
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)

69. 69
HV Battery Assembly
Components
Current
Sensor
SMR3
SMR2
Resister
Module
Battery ECU
SMR1
Service
Plug
Connector

70. 70
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)

71. 71
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

72. 72
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

73. 73
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
DriveCharge
Voltage
(SOC)
SOC
Charge
Request
Power
Request
Charging
Control
HV ECU
Engine
ECU
MG1

74. 74
HV Battery Assembly
SMR (System Main Relay)
–Turns ON / OFF the high-voltage circuit
SMR1
SMR2
SMR3

75. 75
HV Battery Assembly
SMR
–Shutdown control
READY OFF At Collision
Interlock Switch OFF
(Service plug grip disconnection, Inverter cover open)

76. 76
HV Battery Assembly
Service Plug
–Shut off the high voltage circuit manually
Service Plug

77. 77
HV Battery Assembly
Auxiliary Battery
–Auxiliary battery supplies power to headlights, audio,
and all ECUs
Auxiliary
Battery

78. 78
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

79. 79
HV Battery Assembly
Auxiliary Battery
–Jump Start Terminal
•”+” terminal of auxiliary battery for jump start is
used
Jump Start
Terminal

80. 80
THS II Operation

81. 81
THS II Operation
Components
Generator (MG1)
HV Battery
Engine
Motor (MG2)
Inverter
Power-dividing
Device
Differential
Mechanism

82. 82
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

83. 83
THS II Operation
THS-II Control
–Motive Force Suppression Control
•When wheel slipping is detected, the HV ECU
controls the MG2 motive force and applies the
hydraulic brake force
MG2
Traction
Control
Brake
Force
Inverter
Speed
Sensor
High SpeedSkid
Control
ECU
HV ECU
Each
wheel
Speed
Sensors
Slipping

84. 84
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
DriveAccelerator 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

85. 85
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

86. 86
THS II Operation
THS-II Control
–Motor Drive Mode Control (except U.S.A. model)
•Operation conditions
EV ModeNormal
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

87. 87
ECB
(Electronically Controlled Brake)

88. 88
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

89. 89
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

90. 90
Indicator and Warning

91. 91
Indicator and Warning
Combination Meter
–READY light indicates that the vehicle is ready to drive
Ready Light

92. 92
Indicator and Warning
Multi Display
–Energy monitor shows the energy flow

93. 93
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

94. 94
Indicator and Warning
Multi Display
–Warning message

95. 95
Other Systems

96. 96
Other Systems
General
–Engine is operated intermittently, so power steering
and A/C compressor uses electric power
EPS (Electric Power Steering) Electric Inverter Compressor

97. 97
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

98. 98
Other Systems
Air Conditioning
–Service Point
•Don’t use the compressor oil other than ND11
N
D
-
O
I
L
1
1
ND-OIL8

99. 99
Service Point

100. 100
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)

101. 101
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

102. 102
Service Point
High-voltage Wire Harness
–All high-voltage wire harness and connectors are
colored orange
High-voltage Wire Harness
High-voltage Wire Harness

103. 103
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

104. 104
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 !

105. 105
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)

106. 106
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

107. 107
Service Point
Safety Precautions
–Before servicing the high voltage area
5.Check the insulated gloves
Not cracked, ruptured, torn,
or damaged
Not wet

108. 108
Service Point
Safety Precautions
–Before servicing the high voltage area
6.Remove the service plug
Remove before servicing
Service Plug
Carry in your pocket

109. 109
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

110. 110
Service Point
Safety Precautions
–During servicing the high voltage area
•Insulate the tools by vinyl tape
Insulated Vinyl Tape

111. 111
Service Point
Safety Precautions
–During servicing the high voltage area
•Insulate the disconnected high-voltage connector
with insulated vinyl tape
Insulated Vinyl Tape

112. 112
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

113. 113
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

114. 114
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

115. 115
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

116. 116
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

117. 117
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)

118. 118
Service Point
Towing
Notice: If there is a electrical leakage, motor regenerates
the electricity by wheel rotation