Toyota RAV4 EV Manual
Electric vehicle
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Table of Contents
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Table of Contents
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Summary of Contents for Toyota RAV4 EV
- Page 1 RAV4 EV Electric Vehicle ELECTRIC VEHICLE DISMANTLING MANUAL QEA38 Series...
- Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota RAV4 EV electric vehicles. RAV4 EV dismantling procedures are similar to other non-electric Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota RAV4 EV electric vehicle, as they may not be familiar to dismantlers.
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Page 3: Table Of Contents
Table of Contents About the RAV4 EV .............................1 RAV4 EV Identification ..........................2 Exterior .................................3 Interior................................4 Motor Compartment ............................5 Electric Vehicle Component Locations & Descriptions................6 Specifications ..............................7 Electric Vehicle Operation ...........................8 Vehicle Operation............................8 Electric Vehicle (EV) Battery Assembly and Auxiliary Battery ...............9 EV Battery Assembly ............................9... -
Page 4: About The Rav4 Ev
Electricity stored in a high voltage Electric Vehicle (EV) battery assembly for the electric motor. The following illustration demonstrates how the RAV4 EV operates in various driving modes. Utilizing the charge cable assembly connected to a 120/240 Volt outlet, the vehicle’s EV battery assembly can be fully charged within 40 hours (when charging on 120 Volt / 15 Amp) or 6 hours (when charging on 240 Volt / 40 Amp) from a fully discharged state. -
Page 5: Rav4 Ev Identification
RAV4 EV Identification In appearance, the 2012 model year RAV4 EV is nearly identical to the conventional, non-electric Toyota RAV4. The RAV4 EV is a 5-door SUV. Exterior, interior, and motor compartment illustrations are provided to assist in identification. The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl and on the left side B pillar. -
Page 6: Exterior
RAV4 EV Identification (Continued) Exterior logos on the back door. logo on the driver and front passenger door. logo on the front upper grille. Charge inlet door located on the left side rear quarter panel. Exterior Left Side View Exterior Front View and Rear View... -
Page 7: Interior
RAV4 EV Identification (Continued) Interior The instrument cluster (power meter, driving range & battery gauge, READY indicator, plug-in indicator and warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-electric RAV4. -
Page 8: Motor Compartment
RAV4 EV Identification (Continued) Motor Compartment Logo on the plastic cover. Orange colored high voltage power cables. Motor Compartment View Power Cables... -
Page 9: Electric Vehicle Component Locations & Descriptions
Electric Vehicle Component Locations & Descriptions Component Location Description 12 Volt Auxiliary Motor A lead-acid battery that supplies power to the low voltage Battery Compartment devices. Electric Vehicle (EV) Undercarriage 386 Volt Lithium-ion (Li-ion) battery assembly consisting Battery Assembly of 3.6 Volt cells connected in a series-parallel circuit. Power Cables Undercarriage, Orange colored power cables carry high voltage Alternating... -
Page 10: Specifications
Electric Vehicle Component Locations & Descriptions (Continued) Specifications Electric Motor: 154 hp (115 kW), AC Inductive Motor Transaxle: Automatic Only EV Battery Assembly: 386 Volt Sealed Li-ion Battery Curb Weight: 4,032 lbs/1,829 kg Frame Material: Steel Unibody Body Material: Steel Panels Seating Capacity: 5 passengers... -
Page 11: Electric Vehicle Operation
Vehicle Operation • With the RAV4 EV, the system is operational while the READY indicator is on. • Never assume that the vehicle is shut off just because the motor compartment is silent. Always look for the READY indicator status. The vehicle is shut off when the READY indicator is off. -
Page 12: Electric Vehicle (Ev) Battery Assembly And Auxiliary Battery
Electric Vehicle (EV) Battery Assembly and Auxiliary Battery The RAV4 EV features a high voltage Electric Vehicle (EV) battery assembly that contains sealed Lithium-ion (Li-ion) battery cells. EV Battery Assembly • The EV battery assembly is enclosed in a metal case and is rigidly mounted to the undercarriage. -
Page 13: Ev Battery Assembly Recovery
Auxiliary Battery • The RAV4 EV contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle. As with other conventional vehicles, the negative terminal of the auxiliary battery is grounded to the metal chassis of the vehicle. -
Page 14: High Voltage Safety
High Voltage Safety The EV battery assembly powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the EV battery assembly, under the vehicle floor pan, to the drive unit (inverter and motor) and DC/DC converter. The inverter contains a circuit that boosts and inverts the 386 Volts DC from the EV battery assembly to 450 Volts AC to power the motor. -
Page 15: Service Plug Grip
High Voltage Safety (Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 15). Volt DC Volt DC Main Battery Drive Unit Contactor Inverter (Relay) Volt DC AC 3-Phase Contactor Motor (Relay) Volt DC Volt DC Battery... -
Page 16: Precaution To Be Observed When Dismantling The Vehicle
Precaution to be observed when dismantling the vehicle WARNING: • The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component. -
Page 17: Spills
Spills The RAV4 EV contains some of the same common automotive fluids used in other non-electric Toyota vehicles, with the exception of the Li-ion electrolyte used in the EV battery assembly. The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the battery cell separators, even if the battery cells are crushed or cracked, it is unlikely that liquid electrolyte will leak. -
Page 18: Dismantling The Vehicle
Dismantling the vehicle The following 5 pages contain general instructions for use when working on a RAV4 EV. Read these instructions before proceeding to the EV battery removal instructions on page 20. WARNING: • The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. - Page 19 (1) Using insulating gloves, press the part with the black claw and pull the handle up slightly to release the lock. Press Pull (2) Press the black-colored tab and lift the handle Upright upright, then remove the service plug grip by taking the handle and pulling it directly upward.
- Page 20 6. If the service plug grip cannot be removed due to damage to the vehicle, remove the IG2 fuse (15 A blue colored). Caution: This operation shuts off the EV system. Be sure to wear insulated gloves because high voltage is not shut off inside the EV battery. When it is possible to remove the service plug grip, remove it and continue the procedure.
- Page 21 10. With the exception of the EV battery assembly, remove parts by following procedures which are similar to conventional Toyota vehicles. For the removal of the EV battery assembly, refer to the following pages.
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Page 23: Removal Of Ev Battery Assembly
Removal of EV Battery Assembly WARNING: • Be sure to wear insulated gloves when handling high-voltage parts. • Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work. •... - Page 24 4. REMOVE SERVICE PLUG GRIP Caution: • Wear insulating gloves and protective goggles. • Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair. • After removing the service plug grip, attach a note to it to prevent other technicians from mistakenly reconnecting it while you are servicing the vehicle.
- Page 25 5. REMOVE NO.1 MOTOR UNDER COVER ASSEMBLY (1) Remove the 8 screws, 11 clips and No.1 motor under cover assembly. 6. REMOVE UPPER NO. 1 FLOOR BOARD (1) Remove the 4 screws, 11 clips and upper No. 1 floor board. 7.
- Page 26 8. DRAIN COOLANT (for EV Battery) (1) Remove the battery reservoir tank cap (for EV battery). Caution: To avoid the danger of being burned, do not remove the battery reservoir tank cap while the coolant for the radiator is still hot. (2) Connect an air blow gun with a SST (air regulator) to either disconnected EV battery Air Blow Gun...
- Page 27 10. CHECK TERMINAL VOLTAGE Caution: Wear insulated gloves and protective goggles. (1) for Motor cable side: Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors shown in the illustration. Standard voltage: 0 V Hint: Use a measuring range of DC 750 V or more on the voltmeter. (2) for Charge cable side: Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors shown in...
- Page 28 (5) for Fuse side: Using a voltmeter, measure the voltage between each terminal and body ground as shown in the illustration.. Standard voltage: 0 V Hint: Use a measuring range of DC 750 V or more on the voltmeter. 11. DISCONNECT MOTOR CABLE Caution: Wear insulated gloves and protective goggles.
- Page 29 13. REMOVE HIGH VOLTAGE FUSE Caution: Wear insulated gloves and protective goggles. Hint: Perform this procedure only when replacement of the high voltage fuse is necessary. (1) Remove the 2 bolts and high voltage fuse. 14. REMOVE ELECTRIC VEHICLE BATTERY ASSEMBLY Caution: Wear insulated gloves and protective goggles.
- Page 30 (3) Set an engine lifter. Check that the lifter is set securely. Notice: Align the center of the battery shown in the illustration with the center of the engine lifter. Install a palette on the lifter cradle to make sure not to apply too much force to the underside of the battery.
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Page 31: Hv Battery Caution Label
HV Battery Caution Label...