Toyota Prius Hybrid Engine System, Running Hybrid Engine Experiment Manual / HY-EPS-2

TOYOTA PRIUS (HYBRID)

2.2. TECHNICAL SPECIFICATION
Toyota PRIUS Hybrid Engine System, Running Hybrid Engine Trainer has been produced
according to your requirements and specifications. It contains a particular engine brand and
model which meet your needs. The instrumentation has been provided according to the
specifications.
Table 2.1 Toyota PRIUS Hybrid Engine Technical Specification

NO. TECHNICAL SPECIFICATION

1 Manufacturer TOYOTA
2 Model PRIUS GEN III
HYBRID SYNERGY DRIVE
3 Type Series/Parallel, full Hybrid
4 System Output 134Bhp (100 kW)
ENGINE
5 Engine Type 2ZR-FXE (Atkinson Cycle)
6 Layout Four Cylinder, in-line
7 Fuel Type Gasoline (petrol)
8 Valve Arrangement DOHC, 16 Valves with VVT-i
9 Displacement 1.8L, 1,798 cm³ (109.72 cu in)
10 Cylinder Bore 80.5 mm (3.17 in)
11 Cylinder Stroke 88.3 mm (3.47 in)
12 Compression Ratio 13.04:1
13 Power Output 98 BHP / 73 kW at 5200 Rpm
14 Torque Output 142 Nm at 3600 Rpm
15 Total Hybrid System Output 120 BHP / 90 kW at 5200 Rpm
16 Firing Order 1–3–4–2
17 Fuel System Electronic Fuel Injection (EFI)
18 Octane No. 95 or greater
19 Emission Level Euro 5
TRANSMISSION
20 Transmission Type Electric Continuously Variable Transmission (ECVT)
21 Gear Ratios
Forward 2.68
Reverse 2.68
22 Differential Gear Ratio 3.27
ELECTRIC MOTOR
23 Motor Type Permanent Magnet, Synchronous
24 Max. Voltage 650 VDC

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25 Max. Power 80 BHP / 60kW

26 Max. Torque 207 Nm
HIGH – VOLTAGE BATTERY
27 Battery Type and Capacity Nickel-metal Hydride (Ni-MH)
28 Nominal Voltage 201.6 V (168 x 1.2V cells)
29 No. of battery modules 28
30 Battery Capacity 6.5 Ah (1.3kWh)
31 System Voltage 650V

2.3. SETTING UP THE TRAINER

Follow procedure below before setting up the trainer:
1. Unpack the trainer unit from its package.
2. Please do an inventory for all trainer parts.
3. Check the trainer to ensure there is no damage during delivery.
4. Place the trainer in a sufficient area.

SPECIAL NOTE
• Due to Airfreight regulations, Engine Oil, Automatic Transmission Fluid (ATF),
radiator coolant, PCU/Inverter Coolant, and Brake Fluid have been flushed.
• Ensure to do the correct procedures to fill all the above liquid before running the
engine. For more detail please see Chapter 4. “Pre-Operation Procedures”.
• Ensure all the above liquid level are sufficient.

2.4. USING THE TRAINER

1. Prepare the trainer in a sufficient area.
2. Ensure the caster wheels are fully locked.
3. Before operating the Hybrid Engine Toyota Prius (HY-EPS-2) Trainer, make sure
that you understand the function of each component of the trainer and read the
operational manual thoroughly.
4. Ensure to lubricate the engine and check the level of engine oil. Check engine oil level
by pulling the oil dipstick. Also check Power control unit (PCU)/inverter-converter
coolant. Add water coolant if necessary.
5. Ensure all switches on the Instrument and Control Panel are OFF.

2.5. PART IDENTIFICATION

This Labtech Hybrid Engine Toyota Prius (HY-EPS-2) Trainer consists of several main parts
as follows:

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1. Hybrid Vehicle (HV) Battery

2. Auxiliary 12VDC Battery
3. Internal Combustion Engine (ICE)
4. Power Control Unit (PCU) Inverter-Converter
5. Hybrid Transaxle Unit
6. Instrument and Control Panel with Electrical Fault System
Observe figure below carefully to familiarize yourself with the components of the trainer.

Figure 2.1. Overview of Labtech Toyota PRIUS Hybrid Engine System Trainer;
(1) High Voltage (HV) Battery, (2) Power Control Unit (PCU) Inverter-Converter, (3) Internal Combustion
Engine (ICE) Toyota 2ZR-FXE, (4) Hybrid Transaxle and (5) Instrument and Control Panel with Electrical
Fault System.

2.5.1. Hybrid Vehicle Battery

Battery pack. Nominal Voltage of the Nickel-metal Hydride (Ni-MH) battery pack remains at
201.6 VDC. Cooling air velocity and volume have been increased for increasing cooling
efficiency and improving battery efficiency and fuel economy.

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Figure 2.2. The parts of High Voltage (HV) Battery

No. Parts Name

1 High Voltage (HV) Battery
2 Service Plug
3 Battery Cooling Blower

Figure 2.3. 12VDC Auxiliary Battery

2.5.2. Internal Combustion Engine (ICE)

The internal combustion engine (ICE) is a Petrol Engine TOYOTA Model 2ZR-FXE, four
stroke engine, 4 cylinder inline, with water cooling system, Double Over Head Cam (DOHC),
16 valves with Variable Valve Timing Intelligent (VVT-i), Electronic Fuel Injection (EFI)
system.

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Figure 2.4. The Engine Parts (side view)

No. Parts Name No. Parts Name

1 Front Right Disc Brake / Wheel 9 Output/Drive Shaft
2 Engine Control Module 10 Exhaust Manifold
3 Fuse Box 11 Brake Fluid Reservoir
4 Ignition Coil 12 EGR Valve Assembly
5 Engine Cylinder Head 13 Power management Control
6 Engine Coolant Reservoir 14 Transmission Control
7 Exhaust Muffler 15 Fuse and Relay Box
8 Front Left Disc Brake/Wheel

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Figure 2.5. The Engine Parts (top view)

No. Parts Name No. Parts Name

16 Engine Coolant Reservoir 22 Air Filter
17 Engine Oil Dipstick 23 12VDC Auxiliary Battery
18 Fuel Rail 24 Fuel Tank
19 Engine Oil Cap Filler 25 Intake Manifold
20 Engine Head Cover 26 Radiator Assembly
21 Fuel Injector 27 Mass Air Flow (MAF) Sensor

Fuel Tank
The fuel tank is made of stainless steel and it is equipped with refueling cap and drain valve.
The inside of the fuel tank consists of electric fuel pump, fuel strainer and fuel level sender
mechanism from Toyota Prius. It is removable for cleaning and refueling purposes. The
capacity of fuel tank is ± 10 Liters. The fuel tank has hoses, which connect the fuel pump to

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the fuel system. One hose is used to supply and circulate fuel from electric fuel pump to fuel
system (fuel pump-fuel filter-fuel rail/injector and pressure regulator), and the other hose is
used to return fuel from pressure regulator back to the fuel tank.

Figure 2.6. Labtech Toyota Prius running engine system fuel tank

Radiator Assembly
Radiator can be disassembled from the engine frame by simply disconnecting its hoses and
loosen all of the bolts and nuts. These can protect the radiator if the engine is being
dismantled. Radiator is equipped with a radiator fan and reservoir radiator.

Figure 2.7. Radiator Assembly

2.5.3. Power Control Unit (PCU) Inverter-Converter

Power Control Unit (PCU) Inverter-converter adjusts power source voltage to the appropriate
level by converting between direct (DC) and alternating current (AC). System operating
voltage is now boosted from battery voltage to as high as 650 VDC by the vehicle’s boost
converter before being converted into three-phase alternating current by the inverter, which in
Toyota it refers to as Power Control Unit (PCU). All Hybrid Synergy Drive vehicles released

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subsequent to that vehicle have employed a boost converter capable of up to 650 VDC output
to the inverter.

Figure 2.8. The Parts of Power Control Unit (PCU) Inverter-Converter

No. Parts Name

1 Power Control Unit (PCU)
2 Three-phase AC Cable for MG2
3 Three-phase AC Cable for MG1
4 Input HV Battery Cable to Power Control Unit
5 Cooling Water Inlet

Figure 2.9. Diagram of Power Control Unit (PCU) Inverter-Converter cooling system
(Toyota PRIUS Gen 2)

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Figure 2.10. Power Control Unit (PCU) Inverter-Converter Cooling Radiator

Figure 2.11. The parts of Power Control Unit (PCU) Inverter-Converter

No. Parts Name

1 Input HV Battery Cable
2 Power Control Unit Coolant Reservoir
3 Output HV Cable (MG2)
4 Power Control Unit (PCU) Inverter-Converter Unit
5 Power Control Unit Cooling Water Pump

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2.5.4. Transaxle Unit

Figure 2.12. Transaxle Parts

No. Parts Name

1 Toyota Prius Hybrid Transaxle Unit
2 CV Joint
3 Input HV Cable From Motor Generator (MG2)
4 Current Sensor
5 Input HV Cable From Motor Generator (MG1)

2.5.5. Labtech Toyota Prius Hybrid Engine System Instrument and Control Panel

Figure 2.13. Labtech Toyota Prius Hybrid Engine System Instrument and Control Panel

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No. Parts Name

1 Hybrid System Power and Transmission Control Panel
2 Hybrid System Instrument Indicator Panel
3 Toyota Prius Engine Electrical Diagram
4 Title Name
5 Hybrid System Block Diagram

Hybrid System Power and Transmission Control Panel

Figure 2.14. Hybrid System Power and Transmission Control Panel

No. Parts Name Function

1 Power Switch Button
2 Display Mode Button
3 Immobilizer Key/Smart Key It is the main key of the trainer
4 OBD Port II
5 Hazard Button
6 Hybrid Operating Modes
7 Transmission Shifter
8 Parking Button
To start and stop the trainer
To change the display from Energy monitor display to
hybrid system display. For more detail, please refer to
Sub Chapter 5.6. POWER MODE, ECO MODE AND
EV MODE ACTIVATION
To connect the scanner to the engine
To activate the hazard lamp
To change the hybrid system to power modes, EV
Modes, and/or ECO Modes
To change the transmission position
To change the transmission to Parking position

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Engine Main Frame

The engine is mounted on the rubber mounts in a mounting frame which can absorb engine
vibration. The mounting frame is made of tubular steel to make it strong and rigid. The engine
frame has four casters with 4-inch diameter for each caster.

Figure 2.15. Engine Main Frame

Test Points and Fault Simulator (Toyota Prius Engine Electrical Diagram and Hybrid
System Block Diagram)

Figure 2.16. Engine (2ZR-FXE) Electrical Diagram Test Points and Fault Simulators
Remark :
a. Engine Electrical Wiring Diagram and Test Points
b. Engine Fault Simulator Push Button

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Figure 2.17. Hybrid System Block Diagram Test Points and Fault Simulators

Remark :
a. Hybrid System Block Diagram Wiring Diagram and Test Points
b. Hybrid Fault Simulator Push Button

Engine Electrical and Block Wiring Diagram and Test Points (HY-EPS-2)
Engine Wiring Diagram and Test Points (HY-EPS-2) enables the students to measure the
engine electrical system. The test points are placed on the electrical wiring lines of each
component.
There are 20 Faults systems available on this Trainer. 10 Faults for Engine system and 10
Faults for Hybrid system.

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2.6. HOW TO USE ELECTRICAL FAULT SYSTEM AND TEST POINTS

(HY-EPS-2)

Labtech features its unique interactive electronic troubleshooting fault insertion system on
many of its Toyota Prius Hybrid Engine System, Running Hybrid Engine Trainer. This system
was developed for the real hands in which the area of troubleshooting electrical circuits and
systems for engine sensors or engine control system is difficult to be taught. It will strengthen
the understanding of logical troubleshooting procedures, enable you to observe and test the
system under a variety of faults. The faults are easily activated and the system can instantly be
reset back to normal operating conditions (Reset Button). In addition, the faults can be hidden
for testing purposes (LED Control). The system is fun to use as you will enjoy seeing what
happens to the system when the various combinations of faults are introduced.

2.6.1. System Description

Labtech Prius Hybrid Engine System, Running Hybrid Engine Trainer has a unique fault
simulation system that makes troubleshooting more interesting and understandable to the
student. The troubleshooting system consists of fault selector switches, which are
electronically selected using the micro switches. The faults can be made visible with the LED
on the fault display board or they can be hidden to test the student’s troubleshooting skills.
The fault simulator is used to simulate engine electrical malfunction. When a fault is activated
(ON), a corresponding LED will light as shown in Figure 2.18. (b) and you will see the fault
effect on the engine system. To disable the LED, press LED Control, see Figure 2.18 (a) and
to normalize the system press RESET switch, see Figure 2.19. Use fault simulator list table
on the Appendix as a reference for faulty circuits.

Figure 2.18. (a) LED control is activated to hide the fault indicator (b) LED Fault Indicator lights up
when the fault is activated

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Figure 2.19. Depressing Fault Reset Push Button.

2.6.2. Major Features of the Interactive Troubleshooting Fault System

a. Electrical Circuit Diagram Display
Electrical Circuit Block Diagram is silk screened onto a display panel which is centrally
located on the front of the engine instrument and control panel. The highly visible
electrical circuit diagram strengthens your understanding about the systems circuitry and is
essential to develop the troubleshooting skills.

b. Test Points
Test points are used to diagnose and troubleshoot the fault circuits of fault simulation
system.

c. LED Fault Display

Each fault has an LED display light to inform you when the fault is activated. This helps
you to visualize the relationships between the faults and their corresponding symptoms.

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Figure 2.20. LED Fault Indicator is glowing when the fault is activated

d. Easy Fault Activation

A micro switch is used to activate the faults. Faults may be introduced one a time or in
groups of various combinations. There is no limit to the number of faults that can be
activated at any one time; you can even activate them all as desired.
Caution
The fault system cannot be turned on while the engine is still running because it will cause
electrical spike that can damage the electrical parts.

To activate the fault simulation please follow the procedure below:

1. Press the power switch twice.

Figure 2.21. Pressing Power Switch

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2. Observe the instrument panel indicator, make sure the light is on.

Figure 2.22. Instrument panel indicator. ON position

3. The fault simulation is ready to be used by pressing the fault switches.
4. To see the effect of fault system, turn On the hybrid engine by pressing the brake pedal
and pressing the power button once more.
5. Observe the instrument panel indicator and make sure the “READY” indicator lights
up.

Figure 2.23. Instrument panel indicator. “READY” position

e. Troubleshooting Instruction
Many of Labtech trainers include troubleshooting diagrams as part of the courseware.
These diagrams will assist you how to approach fault diagnosis in a logical, quick and
efficient manner. You will also gain experience with troubleshooting ladder logic and how
to logically approach a problem from a systematic and symptomatic point of view. So, it
helps you to develop professional troubleshooting skills quickly.

f. Testing Mode
The LED fault indicator display can be deactivated, so that faults can be active but the
display is switched off. In this mode, you (as instructor) can introduce a series of faults
and someone else will not know which faults are in used. You will then be able to ask
him/her to use the test points to identify where the faults are.

Figure 2.24. Hiding the Active Fault to Test the Student Capability

g. Fault Reminder
It is helpful for the instructor in case he/she forgot which fault was activated. Just press the
LED Control Button while system is under hidden fault, it shows the last fault activated.
When the button is released, the fault mode will be back to the hidden.

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2.7. SAFETY PRECAUTIONS

Follow these instructions to ensure the student safety during the experiments/observation and
to avoid the trainer from damage. The Labtech Toyota Prius trainer, running Hybrid engine
contains many mechanism and fluids that may move suddenly, become hot, or electrically
energized. To avoid serious injury, please observe the following safety precautions.

When Working on the Engine

➢ Keep hands, clothing, and tools away from the moving fan.
➢ Be careful not to touch the engine, power control unit (PCU), radiator, exhaust
manifold, etc., right after the engine running as they may become hot. Oil and other
fluids may also be hot.
➢ Do not put anything that may burn easily, such as paper or rags, in the engine area.
➢ Do not smoke, do not cause sparks or expose an open flame to the fuel. Fuel fumes are
flammable.
➢ Never touch, disassemble, remove or replace the high voltage parts, cables and their
connectors. It can cause severe burns or electric shock.
➢ When the hybrid system is operating with the “READY” indicator on, the engine may
suddenly start in some cases. When you inspect the engine, make sure to turn Off the
hybrid system (go to Maintenance mode is necessary).
➢ Running with the air cleaner filter removed may cause excessive engine wear due to dirt
in the air.

When Working Near the Electric Cooling Fan or Radiator Safety

➢ Be sure the “POWER” switch Off. With the POWER switch in ON mode, the electric
cooling fan may automatically start to run if the coolant temperature is high.

Safety Glasses
➢ Wear suitable eye protection to prevent eye injuries

2.7.1. High Voltage Safety

The HV battery pack powers the high voltage electrical system with DC electricity. Positive
and negative orange colored high voltage power cables are routed from the battery pack, back
of instrument and control panel box, to the power control unit (PCU) inverter/converter.
The inverter/converter contains a circuit that boosts the HV battery voltage from 200 Volts to
600 Volts DC. The inverter/converter creates 3-phase AC to power the motor. Power cables
are routed from the inverter/converter to each high voltage motors (electric motor and electric
generator/MG).

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High Voltage Safety System:

• A high voltage fuse (1) provides short circuit protection in the HV Battery pack.
• Positive and negative high voltage power cables (2) connected to the HV Battery pack
are controlled by 12V normally open relay (3). When the trainer is shut off, the relays
stop electricity from leaving the HV Battery.
• A Ground fault monitor (4) continuously monitor for high voltage leakage to the metal
chassis/frame while the trainer is running. If malfunction is detected, the hybrid
vehicle computer control (4) will illuminate the master warning light in the
instrument cluster and a message indicating that the hybrid system is malfunctioning
will be displayed on the multi-information display.

Figure 2.25. High voltage safety system (a) Trainer Shut Off (READT-OFF), (b) Trainer On and
operational (READY-ON)

Necessary Items:
• An electrical tester that is capable of measuring DC 750Volt or more.
• Wear protective clothing, including insulated gloves (electrically insulated), rubber
gloves, safety goggles, and safety shoes.
• Before wearing insulated gloves, make sure that they are not cranked, ruptured torn, or
damaged in any way. Do not wear wet insulated gloves.

2.7.2. High Voltage Precautions

The Hybrid engine comes with high voltage DC and AC systems. It is very dangerous and can
cause severe burns and electric shock that may result in death or serious injury.
1. Never touch, disassemble, remove or replace the high voltage parts, cables and their
connectors.
2. The hybrid system will become hot after starting because the system uses high
voltage. Be careful of both the high voltage and the high temperature, and always obey
the caution labels attached on the vehicle.
3. Never disconnect the service plug when the engine is running. The service plug is used
only when the vehicle is serviced and is subject to high voltage.
4. Do not subject the service plug to strong impacts. Also, avoid splashing large amount
of water onto the HV Battery.

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2.7.3. Hybrid Battery Air Vent

1. Do not put foreign objects over the air vent. The hybrid battery (traction battery) may
overheat and be damaged.
2. Clean the air vent regularly to prevent the hybrid battery (traction battery) from
overheating.
3. Do not wet the air vent. It may cause short circuit and damage the hybrid battery
(traction battery).
4. Do not load a large amount of water into the trainer. If water spills over the hybrid
battery (traction battery), the battery may damage.

2.7.4. Intelligent/Smart Key

1. Do not allow the intelligent Key, which contains electrical components, come in
contact with water or salt water. It could affect the function of its system.
2. Do not drop the Intelligent Key.
3. Do not throw the Intelligent Key against another object.
4. Do not change or modify the Intelligent Key.
5. Do not attach the Intelligent Key with a key holder that contains a magnet.
6. Do not place the Intelligent Key near equipment that produces magnetic field, such as
TV, Audio equipment, personal computer or cellular phone.

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2.8. MAINTENANCE

1. Make sure the engine uses proper amount of good multigrade oil. Oil should be changed
according to the usage of the engine or at least twice a year if it is used in a stationary
condition.
2. Make sure the engine uses clean fuel and clean air whenever it is running. If the unit is not
used for long periods, the fuel tank should be drained and cleaned.
3. If the engine will be stored for long period, the battery cable should be disconnected and
the radiator water should be emptied.
4. Do not allow the engine to run at idle speed for long period.
5. It is recommended to run the hybrid engine at least once a week periodically.
6. Do not splash or spill liquid in the trainer, such as in the hybrid/HV battery (traction
battery), battery blower air vent. Doing so may cause the hybrid/HV battery, electrical
components, etc., to malfunction or catch fire.
7. Turn off the hybrid system and ensure that there is adequate ventilation before performing
maintenance checks.

If you perform maintenance, be sure to follow the correct procedure below:

No. Items Part and Tools

1 12volt battery condition
2 Engine/Power Control unit
coolant level
3 Brake fluid level
4 Fuses
• Grease
• Conventional wrench (for terminal clamp
bolts)
• Use Toyota Super Long Life Coolant or
similar high quality ethylene glycol based
non-silicate, non amine, non-nitrite and
non-borate coolant with long life hybrid
organic acid technology.
• Funnel (used only for adding coolant)
• Toyota Genuine Motor Oil or equivalent
• Rag or paper towel
• Funnel (used only for adding engine oil)
• Fuse with same ampere rating as original

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