Transcript PRIUS (Chassis) - Selamat Datang di SMK Negeri 3 Buduran

Model Outline
for Technician
Contents
Hybrid System
Click a Section Tab
1
Engine
Chassis
Body Electrical
Model Outline
2
for Technician
Hybrid System
Engine
Chassis
Body Electrical
P410 Hybrid Transaxle
Electric Shift Lever System
Suspension
Brake
Brake Control System
Steering
Model Outline
for Technician
Hybrid System
P410 Hybrid Transaxle
Engine
Chassis
Body Electrical
Overall
– P410 hybrid transaxle mainly consists of the following
components
Compound Gear Unit
MG2
Oil Pump
(Mechanical Type)
• Power Split Planetary
Gear (Right Side)
• Motor Speed Reduction
Planetary Gear
(Left Side)
Transaxle
Damper
MG1
Final Drive
Gear
Counter
Driven Gear
3
Final Driven
Gear
Differential
Gear Unit
Model Outline
for Technician
Hybrid System
P410 Hybrid Transaxle
Engine
Chassis
Body Electrical
Specification
Transaxle Type
P410
(New PRIUS)
P310
(RX400h)
Shift Pattern
P–R–N–D–B

Total Speed Reduction Ratio
3.267
3.542
No. of Ring Gear Teeth
78

No. of Pinion Gear Teeth
23

No. of Sun Gear Teeth
30

No. of Ring Gear Teeth
58

No. of Pinion Gear Teeth
18

No. of Sun Gear Teeth
22

No. of Drive Gear Teeth
54

No. of Driven Gear Teeth
55

No. of Drive Gear Teeth
24
25
No. of Driven Gear Teeth
77
77
Type
ATF WS

Capacity [L (US qts, Imp. qts)]
3.3 (3.5, 2.9)
4.2 (4.4, 3.7)
92 (203)
117 (258)
Compound
Gear Unit
Power Split
Planetary Unit
Motor Speed
Reduction
Planetary
Gear
Counter Gear
Final Gear
Fluid
Weight (Reference)*1 [kg (lb)]
4
*1: The figure shown is the weight with the oil fully filled.
Model Outline
for Technician
Hybrid System
P410 Hybrid Transaxle
Engine
Chassis
Body Electrical
Gear Train
Power Split
Planetary Gear
Motor Speed
Reduction
Planetary Gear
Engine
Compound
Gear Unit
Oil Pump
Transaxle
Damper
MG2
MG1
Counter Driven Gear
Differential
Gear Unit
5
Final Drive Gear
Model Outline
for Technician
Hybrid System
P410 Hybrid Transaxle
Engine
Chassis
Body Electrical
Gear Train
Power Split Device
• Sun Gear: MG1
• Planetary Carrier: Engine
• Ring Gear: Compound Gear
(to Wheels)
Engine
MG1
Motor Speed Reduction Device
• Sun Gear: MG2
• Planetary Carrier: Fixed
• Rear Gear: Compound Gear (to Wheels)
MG2
To Front Wheel
6
Model Outline
for Technician
Hybrid System
Engine
P410 Hybrid Transaxle
Chassis
Body Electrical
Compound Gear Unit
– Each planetary ring gear is integrated with the
compound gear unit.
– Furthermore, this compound gear unit is integrated
with a counter drive gear and parking gear.
Counter
Drive Gear
Parking Lock Gear
Ring Gear
(Motor Speed Reduction
Planetary Gear)
Ring Gear
(Power Split Planetary Gear)
Motor Speed
Reduction Planetary
Gear Unit
Power Split
Planetary Gear Unit
Counter Drive Gear
(Compound Gear)
[Compound Gear Unit]
7
Model Outline
for Technician
Hybrid System
P410 Hybrid Transaxle
Engine
Chassis
Body Electrical
Transaxle Damper
– Two types of damping characteristics are adopted
• Low torsion-type coil spring damper
• Dry single-plate friction material prevents the
damage to the transaxle by the excessive engine
torque by slipping
Transaxle Damper
8
Model Outline
for Technician
Hybrid System
P410 Hybrid Transaxle
Engine
Chassis
Body Electrical
Lubrication System
– Final gear with an oil sling type lubrication mechanism
– Oil catch tank is used in order to supply oil to each
gear train from there in a stable manner.
Oil Hole
Oil Catch
Tank
Oil Catch
Tank
MG
Motor Cooling
9
Final Gear
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(P410 Hybrid Transaxle)
Lubrication System
– Drain plug and filler plug for hybrid transaxle fluid
Filler Plug for Hybrid
Transaxle Fluid
(10 mm Hexagon)
Front
Drain Plug for Hybrid
Transaxle Fluid
(10 mm Hexagon)
10
Drain Plug for Hybrid
System Coolant
(10 mm Hexagon)
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(P410 Hybrid Transaxle)
Lubrication System
– Add hybrid transaxle fluid
• Filling method is the same as the conventional
manual transaxle
0 to 10 mm
(0.394 in.)
Filler Plug for Hybrid Transaxle Fluid
11
New PRIUS
Previous Model
Coolant Type
TOYOTA Genuine ATF WS

Capacity
3.3 liters
(3.5 US qts, 2.9 Imp. qts)
—
Same as previous model
—
Maintenance Interval
Inspect / Replace
Model Outline
for Technician
Hybrid System
Engine
P410 Hybrid Transaxle
Chassis
Body Electrical
Cooling System
– Cooling system that is independent from the engine
cooling system is provided to cool the inverter with
converter assembly, MG1 and MG2
HV Radiator
(for Inverter)
Inverter with
Converter Assembly
HV Radiator
Reserve Tank
Inverter with
Converter Assembly
HV Radiator
Reserve Tank
HV Water Pump
with Motor
HV Transaxle
12
HV Radiator
HV Water Pump
with Motor
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Feature
– This system changes the shift range using a shift-bywire technology
– Compact shift lever is used. It’s a momentary shift
type that returns to the home position when the
[Shift Position Indicator]
driver’s hand is released
P Position Switch
Operation
signal
Only
connected
electrically
Shift Lever
Parking Lock Actuator
13
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
System Diagram
Shift Lever Assembly
Parking Lock Actuator Relay
P Position Switch
P Position
Indicator Light
Rotation
Angle Sensor
Transmission
Control ECU
Parking
Lock Motor
Parking Lock Actuator
V Bus No.1
DLC3
Certification ECU
LIN
Immobiliser Code ECU
Shift Lever Position
Sensor
Shift Sensor
Select Sensor
Power
Management
Control ECU
(HV CPU)
Combination Meter
Shift Position Indicator
Master Warning Light
Buzzer
Multi-information Display
14
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Parts Location
Master
Warning Light
Engine
Chassis
Body Electrical
Multi-information Display
Shift Position
Indicator
Select
Sensor
Power Management
Control ECU (HV CPU)
Transmission
Control ECU
Shift
Sensor
Certification
ECU
Selector Lever Assembly
Immobiliser
Code ECU
15
• P Position Switch
• P Position Indicator Light
Parking Lock Actuator
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Shift Lever and Shift Position Indicator
– Shift lever is designed to always return to its home
position. Therefore, shift position that is current
selected can be checked on the shift position indicator
Current Shift
Position Indication
P Position
R Position
Operated by driver
N Position
Returns automatically
D Position
16
B Position
NOTE: When the shift lever is in a position other
than D or B, the B position indicator will turn off.
Shift Position Indicator
Model Outline
for Technician
Hybrid System
Engine
Electric Shift Lever System
Chassis
Body Electrical
Shift Control
– Table below shows how the shift lever / P position
switch operation are controlled at each shift position
Shift Position
Power Source Status
Operation
IG-OFF
-
Unable to change the shift position
Shift Lever
Unable to change the shift position
ACC
IG-ON
READY
P
R
N
D
B
P Position Switch
Shift Lever
P Position Switch
Shift Lever
P Position Switch
READY >>> IG-OFF
17
-
: Current Position
: Positions to which shift position can be changed
: with brake pedal depressing
: with stopped vehicle
: Available always
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Reject Function
– To ensure safety, this system might not change the
shift position even if the driver operates the shift lever
of P position switch in the following cases
Shift operation which causes reject function to
operate
The driver changes the shift position out of P
without depressing the brake pedal
The driver changes the shift position to
P with the P position switch operation
While
driving The driver changes the shift position
from D to R, from B to R or from R to D
The driver changed the shift
lever position to B
18
Shift position after rejection
Held in P position
Changed to N position
Changed to N position
from P
Held in P position
from R
Changed to N position
from N
Held in N position
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Shift Lever
– Shift lever has built-in shift lever position sensor to
detect the shift position (R, N, D and B)
• Shift lever position sensor consists of a select sensor
and shift sensor, and uses Hall ICs for position
detection
Select Sensor
Shift Sensor
19
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Shift Lever
– Select sensor
• Detects the lateral movement of the shift lever
• Sensor hall IC contains 2 circuits, one for main
signal, one the sub signal (differing characteristics)
Hall ICs
Output Characteristics
5
Magnet Slider
(Connected to shift lever)
Output
Voltage
[V]
0
Center, B
20
R, N, D
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Shift Lever
– Shift sensor
• Detects the longitudinal movement of the shift lever
• Sensor hall IC contains 2 circuits, one for main
signal, one the sub signal
Output Characteristics
Hall ICs
5
Output
Voltage
[V]
Magnets
Cross-section
21
0
LHD Model
D, B Side
R Side
RHD Model
R Side
D, B Side
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
P Position Switch
– P position indicator light shows the conditions of the
electric shift lever system as follows
P Position Indicator Light
Lights up
OFF
Blink (First) [Approx. 4 Hz]
Blink (Slow) [Approx. 0.5 Hz]
Contents
Shift position is in P
(Parking lock is in P position)
Shift position is not in P
(Parking lock is in non-P position)
Parking lock actuator takes long to switch
between P position and non-P position
System malfunction
Parking
switch
22
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Parking Lock Control
– Upon receiving an actuation signal from the P position
switch via transmission control ECU, the motor rotates
to engage or disengage the parking lock mechanism
Compound Gear
• Parking Lock Gear
Parking Lock Mechanism
Parking Lock Actuator
23
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Parking Lock Control
– Parking lock actuator (SR motor)
• Parking lock actuator mainly consists of a switched
reluctance motor and a cycloid reduction mechanism
• Rotation angle sensor consists of 2 Hall ICs
Shift Control
Motor
Reduction
Mechanism
W Phase
Magnet
Coil
V Phase
U Phase
Rotation Angle
Sensor (Hall IC)
Output
Shaft
Stator
Rotor
[Switched Reluctance Motor]
24
Model Outline
for Technician
Reference
Hybrid System
Engine
Chassis
Body Electrical
(Electric Shift Lever System)
Parking Lock Control
– Parking lock actuator (SR motor)
• Electric current is passed through the stator coil.
The coil becomes electromagnet, and attracts the
rotor (rotor rotates)
Electromagnet
W
U
Magnetism
V
W
W
V
U
U
W
V
V
25
: Electric current flows
U
W
U
V
W
W
V
U
U
W
V
V
U
W
U
V
W
V
U
U
W
V
V
U
W
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Parking Lock Control
– Parking lock actuator (Cycloid reduction mechanism)
• Cycloid reduction mechanism ensures complete
releasing operation for parking lock when vehicle is
parked on slope road in which requires a high torque
Shift Control
Motor
Magnet
Reduction
Mechanism
Inside Gear
(61 teeth)
Eccentric Plate
Center
Outside Gear
(60 teeth)
Motor Input
Shaft Center
Rotation Angle
Sensor (Hall IC)
Eccentric
Plate
Output
Shaft
Output Shaft
[Image of Cycloid Reduction Mechanism]
26
* Operation same as VGRS reduction gear
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Parking Lock Control
– Parking lock mechanism
• The engagement of the parking lock pawl with the
parking gear that is integrated with the compound
gear locks the movement of the vehicle
[Unlock Condition]
1. Parking lock actuator rotes
2. Parking lock lever is rotated and
the parking lock rod is pushed
3. Parking lock pawl is pushed up
4. Parking lock pawl engages with
the parking gear
[Lock Condition]
27
Parking Gear
Engage
Portion
Parking Lock
Lever
Parking
Lock
Pawl
Parking Lock Rod
Parking Lock
Actuator
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
DTC
– When the malfunction occurs in this system, the
transmission control ECU stores the DTCs in its
memory
DTC No.
28
Detection Item
P Position Indicator
C2300*
Actuator System Malfunction
Blink (Slow)
C2301*
Shift Changing Time Malfunction
Blink (Slow)
C2303*
Short in Power Source Relay Circuit
C2304*
Open or Short Circuit in “U” Phase
Blink (Slow)
C2305*
Open or Short Circuit in "V" Phase
Blink (Slow)
C2306*
Open or Short Circuit in "W" Phase
Blink (Slow)
C2307*
Over Current Malfunction
Blink (Slow)
C2308
EEPROM Malfunction
???
C2309
Open in B+ Circuit
???
C2310
Open or Short Circuit in Battery Circuit
C2311
Communication Error from HV ECU
C2315
HV System
U0146
Lost Communication with Body ECU
Normal Operation
Normal Operation
Blink (Slow)
Normal Operation
*: Remove the “P COM MAIN” fuse (Fuse Box 7.5 A) to erase the these DTCs because the
they cannot be erased with the tester
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
DTC
– Location of “P COM MAIN” fuse
– Remove the “P COM MAIN” fuse for approx. 60 sec. to
erase the some DTCs
“P COM MAIN” Fuse (7.5 A)
29
Model Outline
for Technician
Hybrid System
Electric Shift Lever System
Engine
Chassis
Body Electrical
Case of Emergency
– To stop the hybrid system
• If it cannot shift position into P, the power source
mode can be turned off by applying the parking
brake
If malfunction in parking
lock actuator, it cannot
shift position into P
Parking Brake
is applied
Power Source
Mode OFF is
impossible
Vehicle
Stopped
READY Power Source Mode OFF is possible
30
Model Outline
for Technician
Suspension
Hybrid System
Engine
Chassis
Body Electrical
Front Suspension
– MacPherson strut type independent suspension
Shock Absorber
• Multi-leaf Type Liner
Control Valve
Stabilizer Bar
[Front Wheel Alignment (Unloaded vehicle)]
31
Tire Size
195/65R15
Tread
1525 mm (60.0 in.)
Caster
5°53’ (5.88°)
Camber
-0°13’ (-0.22°)
Toe-in
2.0 mm (0.08 in.)
King Pin Inclination
12°16’ (12.27°)
Model Outline
for Technician
Suspension
Hybrid System
Engine
Chassis
Body Electrical
Rear Suspension
– Torsion-beam type suspension
Shock Absorber
• Multi-leaf Type Liner
Control Valve
Axle Beam
[Rear Wheel Alignment (Unloaded vehicle)]
32
Tire Size
195/65R15
Tread
1520 mm (59.8 in.)
Caster
-1°29’ (-1.48°)
Toe-in
2.9 mm (0.11 in.)
Trailing Arm
Model Outline
Brake
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Specification
Master Cylinder
Type
Diameter
22.2 mm (0.87 in.)
Brake Booster
Hydraulic
Brake Type
Caliper Type
Front Brake
Wheel Cylinder Diameter
Rotor Size (D x T)
Pad
Brake Type
Caliper Type
Rear Brake
Wheel Cylinder Diameter
Rotor Size (D x T)
Pad
Brake Control System
33
Single (Center Valve)
Ventilated Disc
PEAL57
57.22 mm (2.25 in.)
255 mm x 25 mm (10.0 in. x 0.98 in.)
T4146
Solid Disc
CLA11H
38.18 mm (1.50 in.)
259 mm x 9 mm (10.2 in. x 0.35 in.)
NS254
ABS with EBD, BA, TRAC (TRC), VSC,
Hill-start Assist Control and
Cooperative Control with EPS
Model Outline
Brake
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Rear Brake
– Build-in type disc brake that has a build-in parking
brake mechanism is provided
Rear Brake Caliper
Check Ball
Input Shaft
PKB OFF
PKB ON
Disc
Pad
Crank Lever
Push Rod
Nut Sleeve
Parking Brake Cable
34
Disc Rotor
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake)
Rear Brake
– Parking brake lever travel adjustment
Check and adjust the parking brake lever travel
Confirm the clearance between operation lever and stopper
(at the parking brake released)
Stopper
0.5 mm or less
Operation Lever
35
Model Outline
Brake
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Emergency Brake Signal
– Feature
• This function blinks the stop light at sudden braking
to reduce the risk of rear-end collision
Blinks
automatically
36
Model Outline
Brake
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Emergency Brake Signal
– System Diagram
V Bus No.1
Yaw Rate and
Acceleration Sensor
Skid Control
ECU
Stop Light
Control Relay
Speed Sensors
Stop Light Switch
Hazard Warning
Light Switch
37
Hazard Warning
Light
Stop Light
Model Outline
Brake
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Emergency Brake Signal
– Operation Condition
Operation Start Conditions
•SPD is more than 55 km/h (34 mph)
•Driver depresses the brake pedal
•Vehicle deceleration exceeded specified
value
38
Operation Cancel Conditions
• Driver release the brake pedal
• Vehicle deceleration became
less than specified value
• Driver pushes the hazard
warning light switch
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
ECB (Electronically Controlled Brake) System
– A new ECB system changed the following items from
the current ECB system to realize a compact and
lightweight
• The master cylinder, skid control ECU, sensors,
solenoid valves and stroke simulator are integrated
• The hydraulic brake booster is used as a mechanism
back-up if the brake system fails
Master Cylinder
Stoke Simulator
Solenoid Valves
Sensors
ECU
Solenoid Valves
Sensors
Stroke Simulator
Hydraulic Brake
Booster
Power Supply Unit
Power Supply Unit
ECU
39
Capacitor
Capacitor
Current Model
New Model
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
System Diagram
Brake Booster Pump
Accumulator
Pump Motor
ABS
Motor
Relay
Front Door Courtesy
Light Switch (Driver)
Skid Control Buzzer
Stop Light Switch
Stop Light
Control Relay
40
V Bus
No.1
Stroke
Simulator
Speed Sensors
Brake Fluid Level
Warning Switch
Brake Booster with Master Cylinder
Brake Pedal Stroke Sensor
ABS
Main
Relay
Skid
Control
ECU
Solenoid
Valves
Regulator Pressure
Sensor
Wheel Cylinder
Pressure Sensor
Accumulator
Pressure Sensor
Power
Management
Control ECU
Main Body
ECU
Power
Steering ECU
Yaw Rate &
Acceleration
Sensor
Steering
Angle Sensor
Combination
Meter
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Layout of Main Component
Chassis
Body Electrical
Slip Indicator
ABS Warning Light
Skid Control Buzzer
Brake Warning Light
Brake Pedal Stroke Sensor
Parking Brake Switch
Stop Light Control Relay
Brake Master
Cylinder Reservoir
Power
Management
Control ECU
Steering
Angle Sensor
Stop Light Switch
Main Body ECU
41
Brake Booster
Pump Assembly
Brake Booster with
Master Cylinder
- Brake Actuator
Engine Room No.1 Relay Block
Yaw Rate and
Acceleration Sensor
Model Outline
for Technician
Hybrid System
Engine
Brake Control System
Chassis
Body Electrical
Regenerative Brake Cooperative Control
– The apportioning of the brake force between the
hydraulic brake and the regenerative brake
Driver’s Demand
Braking
Force
Hydraulic
Braking Force
Regenerative
Braking Force
Time
Changes in Braking Force Apportionment
42
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Hydraulic Circuit
Brake Master
Cylinder
Reservoir
Accumulator
Pump Motor
Brake Fluid
Level Warning
Switch
Hydraulic Brake Booster
: Accumulator
Pressure Sensor
Stroke
Simulator
: Regulator Pressure Sensor
Brake Actuator
: Wheel Pressure Sensor
: Linear Solenoid Valve
: Switching Solenoid Valve
: Pressure Holding
Solenoid Valve
: Pressure Reduction
Solenoid Valve
FR LH
43
FR RH
RR LH
RR RH
Model Outline
for Technician
Hybrid System
Engine
Brake Control System
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Brake Actuator
• Brake actuator that consists of actuator portion and
skid control ECU changes the brake fluid path during
the operation of brake control
Brake Booster with
Master Cylinder
Brake Actuator
Brake Actuator
44
•
•
•
•
•
•
•
Skid Control ECU
2 Linear Solenoid Valves
4 Switching Solenoid Valves
8 Control Solenoid Valves
Regulator Pressure sensor
Wheel Cylinder Pressure Sensor
Accumulator Pressure Sensor
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Brake Actuator
• Solenoid Valve Operation
Solenoid Valves
Linear Solenoid Valve
Switching Solenoid Valve
Control Solenoid Valve
Controls the wheel cylinder pressure to generate a
braking force responsive to a braking force requirement
when the brake pedal is depressed normally
Switches the brake hydraulic path when the brake
control system is activated
Control the wheel cylinder pressure when the brake
system is activated
Regulator Pressure sensor
This sensor converts into the electric signal the fluid
pressure generated by the hydraulic brake booster, and
transmits them to the skid control ECU
Wheel Cylinder Pressure Sensor
This sensor detects the fluid pressure of the respective
wheel cylinders and transmits them to the skid control
ECU
Accumulator Pressure Sensor
45
Function
This sensor constantly detects the fluid pressure in the
accumulator and transmits them to the skid control ECU
Model Outline
for Technician
Hybrid System
Engine
Brake Control System
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Brake Actuator
• Solenoid Valve Operation
Solenoid Valves
SSC
SRC
SMC
FLH
FLR
FRH
FRR
Linear
Solenoid Valve
SLA
SLR
SCC
RLH
RLR
Switching
Solenoid Valve
RRH
RRR
Control
Solenoid Valve
46
OFF
SLA
Close
SLR
Close
SSC
Close
SCC
Close
SMC
Open
SRC
Open
FLH
Open
FRH
Open
RLH
Open
RRH
Open
FLR
Close
FRR
Close
RLR
Close
RRR
Close
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Brake Actuator
• Solenoid Valve Operation
Solenoid Valves
Linear
Solenoid Valve
Switching
Solenoid Valve
Control
Solenoid Valve
47
Normal Braking Operation
System Fails
Increase
Holding
Reduction
SLA
ON (Half-open)
OFF (Close)
OFF (Close)
OFF (Close)
SLR
OFF (Close)
OFF (Close)
ON (Half-open)
OFF (Close)
SSC
ON (Open)
ON (Open)
ON (Open)
OFF (Close)
SCC
ON (Open)
ON (Open)
ON (Open)
OFF (Close)
SMC
ON (Close)
ON (Close)
ON (Close)
OFF (Open)
SRC
ON (Close)
ON (Close)
ON (Close)
OFF (Open)
FLH
OFF (Open)
OFF (Open)
OFF (Open)
OFF (Open)
FRH
OFF (Open)
OFF (Open)
OFF (Open)
OFF (Open)
RLH
OFF (Open)
OFF (Open)
OFF (Open)
OFF (Open)
RRH
OFF (Open)
OFF (Open)
OFF (Open)
OFF (Open)
FLR
OFF (Close)
OFF (Close)
OFF (Close)
OFF (Close)
FRR
OFF (Close)
OFF (Close)
OFF (Close)
OFF (Close)
RLR
OFF (Close)
OFF (Close)
OFF (Close)
OFF (Close)
RRR
OFF (Close)
OFF (Close)
OFF (Close)
OFF (Close)
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Hydraulic Brake Booster
• Hydraulic brake booster generates the hydraulic
pressure in accordance with the amount of effort
applied to the brake pedal by the driver
[Hydraulic Brake Booster Cross Section]
Hydraulic
Brake Booster
48
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Hydraulic Brake Booster
• Structure
Reservoir
Tank Accumulator
Brake
Actuator
Spool Valve
49
Reservoir
Tank
Regulator Piston
Front
Wheel Cylinder
Rear
Wheel Cylinder
Power Piston
Operating Rod
Booster
Chamber
Master Cylinder
Piston
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Hydraulic Brake Booster
• Normal Operation
From
Reservoir
Tank Accumulator
Reservoir
Tank
Brake pedal is
depressed
To Brake
Actuator
50
Booster
Chamber
To Front
Wheel Cylinder
To Rear
Wheel Cylinder
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Brake Booster with Master Cylinder
– Stroke Simulator
• Stroke simulator generates the brake pedal stroke in
accordance with the driver pedal effort during
braking
[Stroke Simulator Cross Section]
Piston
Rubber
Stroke Simulator
51
Brake Master
Cylinder Reservoir
Hydraulic
Brake Booster
Model Outline
for Technician
Hybrid System
Engine
Brake Control System
Chassis
Body Electrical
Brake Booster Pump Assembly
– The power supply portion which consists of the pump,
pump motor, accumulator, relief valve and accumulator
pressure sensor generates and stores hydraulic
pressure
Pump Motor
Accumulator
[Accumulator Cross Section]
Pump
Motor
Accumulator
Nitrogen
Gas
Camshaft
Bellows
Pump
Brake Fluid
52
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Disposal of brake boost pump assembly
– When discarding the accumulator, make a hole in the
accumulator housing in order to discharge the inside
gas using a drill
[Disposal Procedure]
Gas
1. Secure the accumulator in a vise
2. Using a drill, make a hole in the A of accumulator
Vise
Point
Area
A
25 mm (0.98 in.)
B
60 mm (2.36 in.)
B
CAUTION: Be careful when drilling because shards of metal may fly about,
so always use proper safety equipment
53
A
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Hill-start Assist Control
– When starting uphill, this control maintains the
hydraulic pressure to four wheels in order to prevent
the vehicle from descending backward
Operating Conditions
Cancel Conditions
When the following conditions are met, this control starts.
If the control is started, the buzzer sounds once.
- Shift position is in other than P
- The accelerator pedal is not depressed
- The vehicle is at standstill
- The parking brake is not applied
- The brake pedal is further depressed
When the one of following condition is met, this control is canceled.
If the control is canceled, the buzzer sounds twice.
- Shift position is changed to P
- The parking brake is applied
- The brake pedal is depressed again
- The brake pedal is released for several seconds
- The brake pedal is depressed and kept continually for 3 minutes
If the control is canceled, the buzzer does not sound.
- The accelerator pedal is depressed
54
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Hill-start Assist Control
– System Operation
Brake pedal is
further depressed
Fluid Pressure
Sound Once
Brake Pedal
Depressing Force
Sound Twice
Brake pedal
is depressed
Control-start
Fluid Pressure
Vehicle-stop
Fluid Pressure
Vehicle
Stops
Control
Starts
Accelerator
Pedal ON
Hill-start Assist
Control Operation
55
When the
accelerator
pedal is not
depressed
Cancellation
conditions are met
Model Outline
for Technician
Hybrid System
Engine
Brake Control System
Chassis
Body Electrical
Spiral Cable with Steering Angle Sensor
– Absolute angle type steering angle sensor is used
Model
PRIUS
Conventional Models
Sensor Type
Absolute Angle Type
Relative Angle Type
Rotation Angle Sensor
MREs

Neutral Position
Position constantly
memorized
Position when battery
terminal is connected
—
No need initialization
Required initialization*
Remove
steering
wheel, etc.
No need initialization /
Required initialization*
Required initialization*
With Spiral Cable
Steering angle
sensor only
After battery
terminal is
reconnected
Supply Part
*: When the gap more than specified value arises between memorized steering position
and the steering position after the battery reconnected
56
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Spiral Cable with Steering Angle Sensor
– Notice for steering angle sensor
• Do not remove steering sensor from spiral cable
Combination
Switch Assembly
Spiral Cable with
Steering Angle Sensor
Notice:
• Do not replace the spiral cable with the battery
connected and the engine switch ON
• Do not rotate the spiral cable with the battery
connected and the engine switch ON
• Ensure that the steering wheel is installed and
aligned straight when inspecting the steering sensor
• Do not remove the steering sensor from the spiral
cable
• If disassembly, replace a new one
NOTE: Steering sensor is supplied with spiral cable
57
Steering
Angle Sensor
Spiral Cable
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Combination Meter
– When the following conditions are met, the warning
light illuminates to warn the driver
Slip
Indicator
Brake
Warning
Light /
Red
Brake
Warning
Light /
Yellow
ABS
Warning
Light
Illuminate
-
-
-
-
-
-
Illuminate
Malfunction occurs in TRAC (TRC) or VSC
Blink
-
-
-
Malfunction occurs in the apportioning of
brake
-
Illuminate
-
-
Parking brake is on or
brake fluid level is low
-
Illuminate
-
-
Minor malfunction occurs in the brake
system which does not affect brake force
-
-
Illuminate
-
Warning Light*
Conditions
TRAC (TRC), VSC or Hill-start assist control
operate
Malfunction occurs in ABS, EBD or BA
*: The indicator is a design for –A model
58
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Preparation for replacement
– When the parts related to the brake system are
replaced, stop the pump motor and decompress the
accumulator and brake actuator
[Disable Brake Control]
1. Wait at least 2 minutes after the power switch OFF
NOTICE: Do not depress the brake pedal or open/close the doors
until the reservoir level switch connector is disconnected
2. Disconnect the reservoir level switch connector
3. Connect the Intelligent Tester and turn the power switch to IG-ON
4. Turn the Intelligent Tester ON
enter the following menu: Chassis / ABS/VSC/TRC / Active Test
5. Select “ECB Invalid”
6. Depress the brake pedal more than 40 times,
and then check the brake pedal is no longer depressed
7. Finish “ECB Invalid”
59
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Air Bleeding
– When the following items are replaced or installed, be
sure to perform the air bleeding using the tester
Work Procedure
Replaced/Installed
Item
Bleed Brake Line
• Flexible hose (front / rear)
• Disc brake cylinder
(front / rear)
Bleed Brake Master Cylinder
• Brake booster pump assembly
• Brake booster with master cylinder
• Brake master cylinder reservoir
Procedure
1.Wait at least 2 minutes after the power switch OFF
2.Remove the brake master cylinder reservoir filler cap
3.Add brake fluid into reservoir between MAX and MIN level
4.Connect the tester to DLC3
5.Turn the power switch to IG-ON
6.Perform “Chassis / ABS/VSC/TRAC / Air Bleeding”
Bleed
Brake Line
60
7.Select “Usual air bleeding” and replace brake fluid according to the tester
8.After replacing brake fluid, tighten each bleeder plug
- Front bleeder plug / Rear bleeder plug
9.Clear DTCs
7.Select “ABS actuator has been replaced” and replace brake fluid according
Bleed Brake
to the tester
Master
8.After replacing brake fluid, tighten each bleeder plug
Cylinder
- Front bleeder plug / Rear bleeder plug / Stroke simulator bleeder plug
9.Clear DTCs
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Initialization and Calibration
– After replacing the following parts, perform the
initialization and calibration
Replacement
•Brake Pedal
•Brake Pedal
Stroke Sensor
Initialization
1.Clearing the stored linear
solenoid valve calibration data
2.Initialization and calibration of
the linear solenoid valve
•Brake Booster with
Master Cylinder
•Yaw Rate and
Acceleration Sensor
•Front Wheel Alignment
Adjustment
61
Calibration
1.Clearing zero point
calibration data
2.Yaw rate and acceleration
sensor zero point calibration
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Initialization and Calibration
– Linear solenoid valve initialization
Procedure
Vehicle Condition
Clearing the stored
linear solenoid valve
calibration data
Initialization and
calibration of the
linear solenoid valve
• Power mode is OFF
• Shift lever is in P
• Steering wheel is centered
1.Connect the tester to DLC3
2.Turn the power switch to IG-ON
3.Perform “Chassis / ABS/VSC/TRAC / Utility / Reset Memory”
4.Perform yaw rate and acceleration sensor zero point calibration
1.Turn the power switch OFF
2.Release the parking brake
3.Turn the power switch to IG-ON
4.Perform “Chassis / ABS/VSC/TRAC / Utility / ECB Utility / Linear
Valve Offset”
5.Keep the vehicle stationary without depressing the brake pedal
for 1 or 2 minutes
6.Check that interval between blinks of the brake warning light /
yellow
0.125 sec.
0.125 sec.
ON
OFF
7.Check that DTC C1345 is not output
62
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
Initialization and Calibration
– Yaw rate and acceleration sensor zero point calibration
Procedure
Vehicle Condition
Clearing zero point
calibration data
Yaw rate and
acceleration sensor
zero point calibration
• Power mode is OFF
• Shift lever is in P
• Steering wheel is centered
1.Connect the tester to DLC3
2.Turn the power switch to IG-ON
3.Perform “Chassis / ABS/VSC/TRAC / Utility / Reset Memory”
4.Turn the power switch OFF
1.Turn the power switch to IG-ON
2.Perform “Chassis / ABS/VSC/TRAC / Utility / Test Mode”
3.Keep the vehicle stationary for 2 sec. or more
4.Check that the ABS warning light, brake warning light / yellow
and slip indicator lights on for several seconds and then blinks
0.125 sec.
ON
OFF
63
0.125 sec.
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
ECB (Electronically Controlled Brake) Invalid Mode
– This mode allows the brake fluid to be replaced
without using the Intelligent Tester
Blinking
OFF >>>IG-ON
within 60 seconds
64
Shift Position
N
P
Brake Pedal
Operation
Depress
8 times or
more within
5 sec.
Depress
8 times or
more within
5 sec.
N
Depress
8 times or
more within
5 sec.
P
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Brake Control System)
ECB (Electronically Controlled Brake) Invalid Mode
– When either of the following condition is met, ECB
Invalid Mode is canceled (Not resuming)
• The shift lever is moved from P to either position
• Turn the power switch to READY
• Turn the power switch OFF
• The parking brake is released
• The vehicle speed is not 0 km/h (0 mph)
Illuminates
65
Model Outline
for Technician
Hybrid System
Brake Control System
Engine
Chassis
Body Electrical
Fail-safe
– When the malfunction occurs in the brake system, the
hydraulic brake booster supplies fluid pressure directly
to the wheel cylinders
Malfunction Portion
Brake actuator stops
• The fluid pressure generated in the hydraulic brake booster
by the driver’s brake pedal operation is directly supplied to
wheel cylinders
Accumulator pressure
is not supplied
• The fluid pressure generated in the master cylinder of
hydraulic brake booster is supplied only to front wheel
cylinders
Front brake system
malfunction
66
Operation
• The fluid pressure generated in the hydraulic brake booster
is directly supplied to rear wheel cylinders
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
(Brake Control System)
DTC for ECB (Electrically Controlled Brake)
DTC No.
67
Detection Item
C1202
Master Reservoir Level Malfunction
C1203
ECM Communication Circuit Malfunction
C1211
SLA Linear Solenoid
C1212
SLR Linear Solenoid
C1214
Hydraulic Control System Malfunction
C1225
SA1 Solenoid Circuit
C1226
SA2 Solenoid Circuit
C1227
SA3 Solenoid Circuit
C1228
STR Solenoid Circuit
C1242
Open in IG1 / IG2 Power Source Circuit
C1246
Master Cylinder Pressure Sensor Malfunction
C1247
Stroke Sensor Malfunction
C1249
Open in Stop Light Switch Circuit
C1252
Brake Booster Pump Motor on Time Abnormally Long
C1253
Pump Motor Relay Malfunction
C1256
Accumulator Low Pressure
C1257
Power Supply Drive Circuit
C1259
HV System Regenerative Malfunction
Body Electrical
Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
(Brake Control System)
DTC for ECB (Electrically Controlled Brake)
DTC No.
68
Detection Item
C1300
Skid Control ECU Malfunction
C1311
Open in Main Relay 1 Circuit
C1312
Short in Main Relay 1 Circuit
C1345
Linear Solenoid Valve Offset Learning Undone
C1352
Front Increasing Pressure Solenoid RH Malfunction
C1353
Front Increasing Pressure Solenoid LH Malfunction
C1356
Front Decreasing Pressure Solenoid RH Malfunction
C1357
Front Decreasing Pressure Solenoid LH Malfunction
C1364
Wheel Cylinder Pressure Sensor Malfunction
C1365
Accumulator Pressure Sensor Malfunction
C1368
Linear Solenoid Valve Offset Malfunction
C1391
Accumulator Leak Malfunction
C1392
Stroke Sensor Zero Point Calibration Undone
C1451
Motor Drive Permission Malfunction
U0073
Control Module Communication Bus OFF
U0293
Communication Error from HV ECU
Body Electrical
Model Outline
Steering
for Technician
Hybrid System
Engine
Chassis
Body Electrical
EPS (Electrical Power Steering) System
– Column assist type EPS system is used
[Models with brushless type
power steering motor]
[Specification]
Type
Vehicle Speed
Sensing Type
Gear Ratio (Overall)
18.5
No. of Turns Lock to Lock
2.81
Rack Stroke [mm (in.)]
69
Steering Column Assembly
- Torque Sensor
- Rotation Angle Sensor
- Power Steering Motor
70.1 (2.76)
Power Steering
ECU
Model Outline
Steering
for Technician
Hybrid System
Engine
Chassis
Body Electrical
System Diagram
Steering Column Assembly
Power
Steering ECU
Torque Sensor
Rotation Angle Sensor*
Boost
Converter*
Power Steering Motor
V Bus No.1
DLC3
70
Steering
Angle
Sensor
Combination
Meter
*: Models with brushless type power steering motor
Skid Control
ECU
•Vehicle
Speed Signal
Power
Management
Control ECU
Model Outline
Steering
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Major Difference from previous PRIUS
Item
Assist Type
Power Steering ECU
Motor
Rotation Angle Sensor
Torque Sensor
Reduction Mechanism
71
New Model
Previous Model
Column Assist Type

N.A.
With Temperature Sensor
With Boost Converter
N.A.
DC Motor

3-phase Brushless Motor
N.A.
Resolver Type
N.A.
Hall IC Type
Inductance Type
Worm and Wheel Gear

Model Outline
Steering
for Technician
Hybrid System
Engine
Chassis
Body Electrical
Major Difference from previous PRIUS
Item
Multi Display
New Model
Previous Model
N.A.
PS Warning
Warning Light
Initialization and Calibration
72
P/S Warning Light
Master Warning Light
Necessary

Model Outline
for Technician
Service Point
Hybrid System
Engine
Chassis
Body Electrical
(Steering)
Initialization and Calibration
– Perform the initialization and calibration of EPS system
in the following cases
• Power steering ECU is replaced
• Steering column assembly is
replaced
• Steering effort differs between
left and right
73
Brushless
type
motor
Rotation angle
sensor
initialization
Torque sensor
zero point
calibration
Assist Map
Writing
O
O
O