2001 TOYOTA PRIUS relay

A13558
Power Cable
to System Main Relay,
InverterBattery ECU
Service Plug Assembly
High Voltage Fuse
Service Plug
Power CableBattery Block No. 10L±W
L
76
to System Main Relay,
Inverter
DI±328
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U)
DTC P3005 High Voltage Fuse Snapped
CIRCUIT DESCRIPTION
A fuse is set in the service plug to protect high±voltage system parts.
DTC No.DTC Detecting ConditionTrouble Area
P3005Although interlock switch is connected, voltage of battery block
No. 10 is less than specified.
High voltage fuse

Power cable
WIRING DIAGRAM
DI827±01

DI±332
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U) 4/27/01
DTC P3009 Leak Detected
CIRCUIT DESCRIPTION
Electric leak from the high±voltage system, which may seriously harm the human body, is detected by this
code.
DTC No.DTC Detecting ConditionTrouble Area
P3009Electric leak from high±voltage system
(Insulating resistance of power cable is 100 kW or less.)

Power cable

HV transaxle

Converter & inverter assembly

Battery cover

System main relay

Battery temperature sensor

Battery ECU

Battery carrier catch bracket

Main battery cable

Service plug assembly

HV battery assembly
INSPECTION PROCEDURE
1 Is DTC P3125 of HV ECU being output?
YES Go to relevant DTC chart.
NO
2 Are there any other codes (Desides DTC P3009) being output?
YES Go to relevant DTC chart.
NO
DI82A±01

± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±337
2001 PRIUS (RM778U)
9 Check insulating resistance of main battery cable.
PREPARATION:
(a) Under step 7 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxilia-
ry battery.
(b) Remove the service plug.
(c) Remove the main battery cables. (Disconnect 4 terminals of a long and a short cables connected be-
tween the system main relay and the HV battery.)
CHECK:
Using a megger (500V), measure the insulating resistance between the main battery cable and body ground.
OK:
Insulating resistance: 10MW or more
NG Replace the main battery cable.
OK
10 Check insulating resistance of system main relay.
CHECK:
Using a megger (500V), measure the insulating resistance between each of 2 connected parts of the system
main relay to the power cables and body ground, and between each of 2 connected parts of the system main
relay to the main battery cables and body ground.
OK:
Insulating resistance: 10MW or more
NG Replace the system main relay.
OK

A14079
Battery ECU
B19
Battery Fan Relay
B15
Battery
Blower
Motor
B16
Battery Blower
Motor Controller
Fusible Link Block No. 1
Fusible Link Block No. 2BATT FAN Engine Room J/B
Battery
BI BJ32
J/C L ± R L ± B LG ± R
L ± B L ± R
L ± R
MAINW ± B
W ± B B ± G
BJ J33 BJ32 C
1
F181
F131
F122
1B 8
1J7
IH13 1
5 2
L1
2
L3
1 429
B182
B188
B18
W ± B
W ± B B
13
J/CFCTL1
VM
SI
VM SI
+B E
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±351
2001 PRIUS (RM778U)
DTC P3077 Battery Cooling Fan Motor Circuit Malfunc-
tion
CIRCUIT DESCRIPTION
To control rise in battery temperature during driving and charging, the battery fan operation is controlled in
3 levels depending on battery temperature.
DTC No.DTC Detecting ConditionTrouble Area
P3077
Electric error in battery cooling fan motor circuit continues for
10 sec.
(2 trip detection logic)
Battery blower motor

Battery fan relay

Battery blower motor controller

Wire harness
WIRING DIAGRAM
DI82G±01

A14084
Engine Room J/B
FAN Fuse
DI±352
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U)
INSPECTION PROCEDURE
1 Check FAN fuse of engine room J/B.
PREPARATION:
Remove the FAN fuse from the engine room J/B.
CHECK:
Check the continuity of the FAN fuse.
OK:
Continuity
NG Check for short in all harness and components
connected to FAN fuse. Check that the motor is
not locked. If locked, replace the motor.
OK
2 Check blower fan relay (See page HV±35).
NG Replace the blower fan relay.
OK
3 Check blower motor operation.
PREPARATION:
Remove the blower motor (See page HV±32).
CHECK:
Apply battery voltage to the power supply terminal of the motor, and check the fan rotation.
OK:
The fan rotates normally.
NG Replace the blower motor.
OK
Replace battery blower motor controller.

A14075
S8
SMRBattery ECU
6
7
2Y±B Y Y±R3
B18
4
B18
10
B18 V±IB V+
V±IB V+
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±353
2001 PRIUS (RM778U)
DTC P3115 HV Battery Current Sensor Malfunction
CIRCUIT DESCRIPTION
The battery ECU inputs signals from a current sensor in the system main relay and controls the output cur-
rent.
DTC No.DTC Detecting ConditionTrouble Area
P3115Failure or open circuit in battery current sensor.
(2 trip detection logic)
System main relay (Battery current sensor)

Wire harness
WIRING DIAGRAM
DI82H±01

DI±354
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U)
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P3115) being output?
YES Go to relevant DTC chart.
NO
2 Check for open and short in wire harness between HV ECU terminals (V+, IB V±)
and system main relay terminals (6, 7, 2).
PREPARATION:
(a) Disconnect the connector from the battery ECU.
(b) Disconnect the connector from the system main relay.
CHECK:
Check that the wire harness between the battery ECU and the system main relay is short and open.
OK:
No short and open
NG Repair or replace the wire harness.
OK

A15566
72
65431
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±355
2001 PRIUS (RM778U)
3 Check resistance of HV battery current sensor (In system main relay).
CHECK:
Using an ohmmeter, measure the resistance between terminals.
OK:
Standard resistance:
Terminal No. (Tester+)Terminal No. (Tester±)Resistance
6730 ± 50 kW
62More than 10 MW
7630 ± 50 kW
72More than 10 MW
26300 ± 400 kW
273 ± 5 MW
NG Replace the system main relay.
OK
Check fitting of connector S8 of system main
relay and correct if necessary.