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User Manual - ECROS Technology

1. Temperature of MG1 MG1 Temp C The temperature of MGI itself Page 37 Temperature of MG2 MG2 Temp C The temperature of MG2 itself I recall it was discovered that there are multiple temperature sensors buried in the stator windings of MG2 and this reading is probably some sort of average Requested Engine Power Req Power W The engine power requested by the Hybrid Vehicle ECU of the Engine ECU Or so it seems to me Target Engine Spin Rate Target eng spd The engine spin rate requested by the Hybrid Vehicle ECU of the Engine ECU Or so it seems to me The actual engine spin rate is usually close to this figure When engine power is cut off due to low demand but the car is moving at more than 42 m p h the value goes to 1000 r p m So the Engine ECU does not interpret this figure as a demand to run the engine at that speed using fuel Discharge Request SoC Dchg Rqsr SoC This seems to be stuck at zero If anyone sees anything else especially if it changes with some identifiable condition please let me know Accelerator Pedal Position Main Sensor Acc Sensr Main Accelerator pedal main position sensor output probably in volts The value typically ranges from 0 6 with no pedal displacement to 3 4 with the pedal pushed all the way to the floor Accelerator Pedal Position Sub Sensor Acc Sensor Sub Acceler
2. Guide has a list of all the parts that should be in the Mini Scanner package Please make sure that you have everything soon after receiving the package Contact ECROS Technology if there is anything missing or if there are signs of damage Tools and Supplies To install the Mini Scanner in your car you will need i E E ed Ma 1 iae CR e A small 1 Phillips screwdriver nd A flashlight to see up behind the dash Photo 2 Mark II Package Contents A twist tie to tie up the spare cable To complete the mounting bracket you may also need some stiff foam if you do not use the steering wheel in its fully up position see below for details Concealing the Adapter Cable The thing to do first also happens to be the trickiest The DLC adapter cable must be threaded behind the steering wheel assembly and down inside the dash so that it hangs into the driver s footwell The upper end is connected to the Mini Scanner and the lower end to the DLC adapter The cable is then concealed leading to a tidy appearance Experience with this step of the installation varies widely Some people have had no trouble at all and others have struggled for half an hour Leave yourself plenty of time for this and try to start out in a calm frame of mind Photo 3 Adapter Cable Page 3 Begin by releasing the steering wheel tilt mechanism Your car s User Manual contains instructions on how to do this The release lever is on
3. Note for Mark I owners skip this if you have a Mark II the Flash Loader in the Mark I indicates test mode with the message idle although it still functions as described above Modes are not changed automatically and you have to type p to go to program mode and v to got to verify mode There is no command to return to test mode other than restarting the Flash Loader If you send a file to the Flash Loader when it is in idle mode the basic syntax of the file is checked but nothing is programmed or verified The safest way to check an unknown file is to upload it in idle mode If you get nothing but dots the file is in Intel Hex16 format and should be safe to program into the Mini Scanner You can upload and program a new file to the Mini Scanner without erasing the existing program This will work if either the new program file is a strict superset of the existing one or if the two files are disjoint In the first case the Flash Loader will simply ignore all the bytes in the new file that have already been programmed in the same place by a previous upload In the second case all locations programmed by the second file are still in the unprogrammed state from a previous erasure This way of using the Flash Loader could be useful to add data to tables in the firmware in which space has been reserved for this purpose Summary of Button Functions The following table summarizes the functions of the Left and Right buttons
4. in Display mode the bottom two lines will show the items in Favorite slot 1 Also the Display slot is next after slot 7 By tapping Right and Left in Favorites mode you can effectively scroll down and up your list of favorite items two at a time Recall that in Favorites mode you cannot immediately tell by looking at the display that you are not in Display mode However the function of the Right and Left buttons is to scroll through the Favorite slots In Display mode these buttons have other functions as described elsewhere in this manual If you set the Mini Scanner to request more than four items only the first four are displayed but the additional items are retrieved from the car and logged via the serial port Favorite Slot 7 Recall that the Mini Scanner does not remember the items in the Display slot This is so that you can use this slot to browse data items that temporarily catch your interest If you climb a long steep hill for example you may want to know if the motor generators have heated up Using the Select Line modes you can find this out after pulling off the road by tapping Right and Left to find the relevant data items But you probably don t want to see the MG temperatures the next day in your garage So the data items in the Display slot are discarded when you turn off the car When the Mini Scanner is next turned on the Display slot data items are copied from Favorite slot 7 This is therefore where you sho
5. internal error internal error internal error internal error internal error internal error internal error internal error Motor Gate Shutdown Signal Line Connection Malfunction Motor Main CPU Malfunction Motor Main CPU Malfunction Motor Main CPU Malfunction Rotation Angle Check CPU Malfunction Rotation Angle Check CPU Malfunction Rotation Angle Check CPU Malfunction Rotation Angle Check CPU Malfunction Rotation Angle Check CPU Malfunction Rotation Angle Check CPU Malfunction Rotation Angle Check CPU Malfunction Important RAM Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator CPU Malfunction Generator R D Malfunction Generator R D Malfunction Generator R D Malfunction Generator R D Malfunction Generator R D Malfunction Generator R D Malfunction Generator Shutdown Signal Line Connection Malfunction Motor PWN Line Connection Malfunction Generator PWN Line Connection Malfunction Charge Inhibition Control Malfunction Motor CPU malfunction Motor CPU malfunction HV CPU Operation Malfunction Page 50 P3101 Engine System Malfunction 204 Input of abnormal signal from the ECM abnormal engine output 205 Input of abnormal signal from the ECM engine unable to start 238 Transaxle Malfunction When engine does not start even tho
6. 2 Oxygen B1 S2 mV Output in millivolts of oxygen sensor Bank 1 Sensor 2 Page 41 Appendix B Prius Diagnostic Trouble Codes This appendix lists the Diagnostic Trouble Codes DTCs for the 2001 2003 model year Prius NHW11 They may or may not be accurate for the 2004 Model Year and beyond NHW20 This information has been manually transcribed from the repair manual Many thanks go to the person who did this and sent the text to me in e mails There may be the occasional error in the transcription or I may have messed something up in converting the e mails to Web pages but most of the weird stuff you ll find here was in the manual So don t correct my grammar or ask me what a harf is It s Toyota s grammar and only they know what a harf is I have not tried to distinguish comments inserted by the transcriber from material actually in the manual for fear that I might make a mistake It should be fairly obvious because the grammar and spelling will be correct and there will be words like presumably which presumably don t appear in the original manual Anything I have inserted myself however is set off by an italic font Battery ECU Diagnostic Trouble Codes P1600 Backup power source circuit malfunction The battery ECU receives 12 volts from two sources P1600 signifies the absence of 12 volts at terminal AM which is normally kept live even with the steering wheel switch off P3001 Battery ECU malfunctio
7. MG2 This is how the car simulates moving to higher mechanical gears When the car is up to speed and power demand is low you will see MGI reverse direction Page 36 Now it is actually taking up power acting as a motor to increase the vehicle speed relative to the engine spin putting the car in what amounts to overdrive This power comes from MG2 which contrary to expectations now acts as a generator actually holding the car back Take a look at MG2 torque while you are cruising and you ll see a negative value MG1 Torque MG1 Torq N m MGI torque in newton metres This needs to be verified or at least checked I guessed the scaling of the data by observing a scaled figure of 8 when MGI was spinning at 4700 r p m and charging the battery at 13 amps with the car stationary Both mechanical and electrical powers work out to be a bit less than 4 kW Again I m starting to think that the current scaling is 2096 low Actual Regenerative Braking Torque Regen Act N m Actual regenerative braking torque in newton metres This needs to be verified Both this value and the requested regenerative braking torque below only move away from zero during braking However which is the request and which is actual is guesswork What I ve guessed to be actual has greater resolution than the request and tends to take a lower value than the request when they get over 100 The scaling to newton metres is I think correct
8. Throttle II s Throttle position sensor output in percent Note that the throttle we re talking about here is not the pedal under your right foot which is the accelerator pedal but the valve that restricts the flow of air into the engine inlet manifold The Toyota Repair Manual Volume 1 Diagnostics describes this item as Voltage Output of Throttle Position Sensor Calculated as a percentage It goes on to say that OV corresponds to 0 and SV to 100 When the throttle is fully closed we should see 0 5 and when the throttle is fully open 90 100 This makes me suspect that I am not scaling the data properly With my scaling the rest position of the throttle sensor seems to be at about 15 I obtained this scaling from Alex Peper s scan tool which I assume follows the standard for OBD II mandated items such as this one Calculated Engine Load Calc Load Calculated load in percent This is a standard OBD II data item The Toyota Repair Manual Volume 1 Diagnostics describes this as Calculator Load but explains that it is the Current intake air volume as a proportion of max intake air volume This makes a lot of sense if you substitute mass flow rate for volume The manual goes on to say that when idling you can expect a value of 5 4 19 2 and when Racing without load 2 250 rpm you should expect 6 9 16 2 Engine Coolant Temperature Engn Coolant C Engine coolan
9. a block has a nominal voltage of 12 x 1 2 14 4 volts In spite of this you are much more likely to see 15 to 16 volts when the battery is at rest no charge or discharge current Lowest Battery Block Number Min Bat Block 4 The reference number of the battery block that has the lowest voltage In a healthy battery this number is likely to move around between several blocks having the same voltage Highest Battery Block Voltage Max Bat Blk V The highest voltage of all battery blocks in volts In a healthy battery the difference between the highest and lowest block voltages will be around 0 1 volts Highest Battery Block Number Max Bat Block 4 The reference number of the battery block that has the highest voltage In a healthy battery this number is likely to move around between blocks having the same voltage Auxiliary Battery Voltage Aux Bat Volt V Auxiliary 12 V battery voltage With the car on but not started this will be around 12 volts but with it Ready it will be close to 13 8 volts as a result of the DC to DC converter supplying power from the main battery Oxygen Sensor Bank 1 Sensor 1 Oxygen B1 S1 mV Output in millivolts of oxygen sensor Bank 1 Sensor 1 Fuel Trim due to Oxygen Sensor O2 Fuel Trim Fuel trim due to the output of oxygen sensor Bank 1 Sensor 1 Oxygen Sensor Bank 1 Sensor
10. and cable correctly installed The pedal in the picture marked push on off is the emergency brake You will need to tie up the slack in the adapter cable so that it does not get in the way of the driver s feet The cable is 30 inches long which allows some extra length for ease of installation This results in a loop falling in front of the pedals Tie this up with a twist tie or in some other convenient way Don t tie it up so that the cable is tight just so that it doesn t hang down You will need a little slack to install the main unit It may be best to come back to this after completing the installation but don t forget it and get your foot tangled in the cable when you drive the car If at this point you re wondering whether the DLC adapter will get in the driver s way let me assure you that it has never got in my way In fact so that any problems in this area Page 5 are likely to happen to me first I have not tied up the slack in the cable but please do this yourself Not once have I kicked the adapter or the cable while driving or getting into or out of the car Note for Mark I owners skip this sidebar if you have a Mark II The Mark I Mini Scanner serial cable cannot be attached and detached from the main unit without opening the case If you want to log data to a computer in the car it may be a good idea to install the serial cable alongside the DLC adapter cable now It can be concealed behind the dash in th
11. as the actual regenerative braking torque tracks the negative torque at MG2 quite closely Of course this assumes that the scaling of MG2 torque is correct Requested Regenerative Braking Torque Regen Req N m Requested regenerative braking torque in newton metres This needs to be verified see actual regenerative braking torque above Main Battery Voltage Bat voltage V _ The main traction high voltage battery voltage Although we think of the battery as having 38 modules of six cells at 1 2 volts each for a total nominal voltage of 273 6 volts don t expect to see this voltage in practice With not much in the way of charge or discharge current you are more likely to see something around 300 volts This will drop when current is drawn from the battery and rise when it is charged It will also vary with the battery state of charge Temperature of MG1 Inverter Inv Temp MG1 C The temperature registered by the sensor in MGI s inverter The inverter is the electronic system that converts the main battery DC power into three phase AC power to drive the MG as a motor It also performs the reverse conversion when the MG acts as a generator Since it is not 10096 efficient lost energy appears as heat increasing the inverter s temperature The Prius inverters are water cooled Temperature of MG2 Inverter Inv Temp MG2 C The temperature registered by the sensor in MG2 s inverter
12. computer with the firmware file to the car If this is not convenient you can remove the Mini Scanner from the car take it to your computer and power it from a 9 volt smoke alarm battery Updating Firmware in the Car The easiest way to update the firmware is to use a portable device such as a notebook computer Make sure the new firmware file is stored on this computer that it has a serial COM port and a terminal emulator program is available on it It is best to run the computer from battery power If you power it from the car using an adapter make sure the output of the adapter is isolated from the car s electrical system The Mini Scanner is of necessity directly connected to the electrical ground of the car Using the 9 Volt Battery Hook Up Not everyone has a notebook computer or other portable computing device If you want to take the Mini Scanner to a computer to perform a firmware update special provision has been made for this Follow the uninstallation instructions to remove the main unit from the car You will need the 9 volt battery hookup that was included in your Mini Scanner package and a fairly fresh 9 volt alkaline smoke alarm battery or a well charged nickel metal hydride battery of the same size Page 23 As you have left the adapter cable in the car the header to which this cable connects will be open The battery connects to the left most two pins of this header The photograph at right shows the 9 volt
13. for setting up HyperTerminal correctly are included in Terminal Emulator Programs above TeraTerm Pro is supplied already properly configured I Just Don t Get Those Dots If you have a Mark II Mini Scanner or your terminal emulator is set up to pass line feeds that is when you hit the Enter key you get the mode announcement and prompt and you don t get dots in Step 6 the next thing to check is that the Mini Scanner is listening for Intel Hex records Go to verify mode and at the computer keyboard type the following remember the final Enter 0000000000 colon and ten zeros then Enter Page 29 00000001FF colon seven zeros a one two Fs then Enter After the first line you should get a dot After the second line you should be back at the idle prompt If this test does not work the Mini Scanner is probably at fault and may require repair If it does work the problem is with the file you re trying to load or the terminal emulator s file send function Make sure you re using the right firmware file that it has been un zipped the file extension should be hex and that the file contains lots of separate lines of numbers some lines quite long all starting with a colon character Get back the attention of the Flash Loader by starting again at step 4 or hitting Escape and Enter so that the prompt reappears Make sure your terminal emulator application is working properly If you turn on its local echo option you will
14. gives you access to is useful in three ways Youcan learn how to drive the car most efficiently With some technical inclination you can learn how the car works in various situations You can watch for any problems that might develop and if the check engine light comes on you can take steps to find out why Details of the second and third topics are contained in the body of this User Manual but the first deserves a little space here The Prius achieves its remarkable fuel economy in part by shutting down the engine in city driving and recovering energy during braking to charge the battery Both these functions are subject to technical limits If the engine has turned off a little too much pressure on the accelerator pedal will start it up again Too much pressure on the brake pedal will engage the friction brakes wasting energy instead of putting it back in the battery Using the battery current and state of charge displayed by the Mini Scanner you can see when you are approaching these limits and over time change the way you drive to avoid them and improve your fuel economy Vehicle Model Years The Prius Mini Scanner works with North American and European Prius from the 2001 to 2003 model years It does not work with first generation Prius nor has it been tested with second generation Prius sold in Japan In the third generation Prius starting with model year 2004 Toyota no longer use the OBD II bus for service diagnostics On
15. in the TeraTermPro folder of the CD ROM You can run the terminal emulator from the CD ROM by double clicking the file ttermpro exe It is probably better however to install it on your computer To do this just create a new folder somewhere of your choosing and copy to it all the files in the TeraTermPro folder on the CD ROM For example you might decide to install TeraTerm Pro in C Program Files TeraTermPro You can run the program by double clicking the file ttermpro exe in this new folder or you can create a shortcut in the Start menu or on the desktop Consult your operating system documentation for details There is a configuration change that you must make only if you are not using the COMI port of your computer Select Setup Serial port on the menu to bring up the TeraTerm Serial Port Setup dialog In the Port pick list select COM2 or COM3 etc according to which serial port you are using Click OK To save this change so that you don t have to make it every time select Setup Save setup on the menu to bring up the TeraTerm Save Setup dialog Browse to the directory into which you copied the TeraTerm Pro files and slick Save This will overwrite the original configuration and in future when you start TeraTerm Pro it will use the serial port you selected In step 6 of Firmware Update Procedure you will need to send the firmware file to the Mini Scanner Flash Loader To do this select File Send File on the menu to brin
16. is properly seated on the car s DLC If this all looks OK remove the Mini Scanner from the car Using the supplied 9 volt battery hook up power the Mini Scanner from a 9 volt smoke alarm battery as described in Using the 9 Volt Battery Hook Up below Press the On Reset button If nothing happens contact ECROS Technology to arrange for the return and replacement of the Mini Scanner If the Mini Scanner displays the banner and ISO9141 slow initialization message but then always reports no response and turns itself off make sure the car is turned on Start the car to be absolutely sure Again in this case check all connections but this is less likely to effect a cure Remember that the Mini Scanner only works with model year 2001 to 2003 North American and European Prius If your Mini Scanner powers up but cannot communicate with the car contact ECROS Technology to discuss the problem Of the 33 Mark I Mini Scanners shipped to six countries none failed to arrive in perfect condition nor failed to install properly in the car If you are unlucky enough to experience a problem ECROS Technology will work with you to get your Mini Scanner working or give you a full refund of the purchase price The Serial Port On the right hand side of the Mini Scanner case Mark II only there is a telephone type jack The proper name for this is an RJ11 so that s what I ll call it from now on This is the serial port which allows the Mini Scanner
17. new features added so you can make up your mind whether or not to update your Mini Scanner The actual firmware is posted on the Mini Scanner Web site and must be downloaded to a computer Downloading Firmware All released firmware for the Mini Scanner both Mark I and Mark II is posted on the Mini Scanner Web site As well as the most recent version many earlier versions are also available in case you want to go back to them Brief notes list the major changes at each version but you might want to save the version announcement e mails for detailed information if you think you will be bouncing between firmware versions The CD ROM that comes with your Mini Scanner contains the firmware installed on the Mini Scanner during manufacture and all earlier releases If you are familiar with downloading Zipped files from the Internet you can skip the rest of this section To download firmware begin by browsing to the firmware page from the Mini Scanner Web site at http miniscanner ecrostech com There are separate pages for Mark I and Mark II Mini Scanners Locate the version of the firmware you want to download Do not click its link but instead use your browser s facility to save the link target on your computer s disk In Internet Exploder right click on the link and select Save Target As from the pop up menu Browse to a suitable folder on your computer and save the file When the download is complete locate the file and unZip it t
18. practice and results in a small tidy main unit As compared to a front mounted membrane keypad the top mounted tactile switches can be found by touch and depress with a sharp click that can be felt by your fingers A passenger can easily operate the unit in a dark car If in spite of my recommendation to the contrary a driver decides to operate the unit he or she can find and press the buttons without taking his or her eyes off the road Page 11 The Left button often moves backwards through lists The Right button often moves forwards through lists A summary of the button actions appears in tabular form later in this User Manual Tap and Hold Each button can cause one of two actions depending on whether you tap or hold it To tap a button press it only briefly To hold a button press it and hold it down for one second or more then release it The action of a button always takes place when you release the button Modes The mini scanner has several modes of operation Display mode display the data items currently in the Display slot Favorites mode store items in Favorite slots or recall them to the Display slot Select Line modes choose the two data items to display in the Display slot Options mode set various options such as the rate at which data items are requested Trouble Codes mode retrieve and clear Diagnostic Trouble Codes from ECUs The scanner a
19. sensor V phase main sensor 293 Motor Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 294 Motor Inverter Current Sensor Malfunction Motor inverter current sensor V phase performance problem 295 Motor Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 296 Motor Inverter Current Sensor Malfunction Motor inverter current sensor malfunction W phase sub sensor 297 Motor Inverter Current Sensor Malfunction Open in motor inverter current sensor W phase sub sensor 298 Motor Inverter Current Sensor Malfunction Motor inverter current sensor malfunction W phase main sensor 299 Motor Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 300 Motor Inverter Current Sensor Malfunction Open in motor inverter current sensor W phase main sensor 301 Motor Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode Page 54 302 Motor Inverter Current Sensor Malfunction Motor inverter current sensor W phase performance problem 303 Motor Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 304 Motor Gate Shutdown Signal Line Conne
20. the buttons facing up Locate the header to which the adapter cable must be connected It is near the lower right corner just below the telephone type jack Like the header on the DLC adapter it consists of a group of ten gold pins in two rows of five with one pin snipped off Move the main unit into position behind the steering wheel where the adapter cable sticks out Place the connector on the end of the cable over the header and push it home Make sure that all pins go into holes in the connector With pin 1 snipped and its hole plugged you can t get the connector backwards but it is possible to to get the top row of pins in the bottom row of holes Take a look from the side to make sure you ve not done this Photo 9 shows a correctly fitted cable Note the gap between the connector and the telephone type jack Ifthis gap is absent remove the connector and try again The Pruis Mini Scanner Welcome CD ROM contains a larger photograph of Photo 9 Adapter Cable the correctly fitted adapter cable and two views of an Page 6 incorrectly fitted cable Even if you turn on the car with the cable incorrectly fitted you will not damage anything the Mini Scanner just won t work Note that the marked edge of the cable is to the right and the cable leads directly down and away from the main unit and does not fold over the top of the connector Note for Mark I owners skip this sidebar if you have a Mark II If you have a Mark I Mini Sca
21. the left side of the steering wheel behind the control stalk Push the lever down as far as it will go Now put the steering wheel to its lowest position by pulling it down The plastic housing around the back of the steering wheel assembly drops away from the dash and you will see a gap of half an inch or so Look into this gap It appears to be blocked at the back by a sort of flange that bends up from the steering assembly housing see Photo 4 The goal is to get the adapter cable into the gap over the top of this flange and then down behind the dash into the space around the driver s feet Obviously the cable is not going to drop down right in the middle of the steering wheel because that s where the steering mechanism is You need to work slightly to one side or the other With a Mark II Mini Scanner pass the cable to the right of the steering wheel This is the easier side to work on in a left hand drive car anyway and the adapter cable attaches to the main unit on this side For the Mark I Mini Scanner you can choose to pass the cable on either the left or the right side There are a number of minor reasons why you might chose the left side The cable attaches to the Mark I main unit slightly to the left of center The DLC3 into which the adapter plugs is on the left side of the driver area on left hand drive cars With the adapter cable on the left the Mark I serial cable can be passed behind the dash on the right But this is t
22. to 500 ms and 160 ms for Slow and Normal respectively Display Backlight This option is not effective in the Mark II Mini Scanner The backlight is controlled automatically by a light sensor Clear Trouble Codes This option controls whether or not you can clear Diagnostic Trouble Codes DTCs when in Trouble Codes mode The default is disabled You need to change it to enabled if you want to clear DTCs The selected choice for this option is saved at power down and will be effective at the next power up However you should be very sure about what you re doing when you clear DTCs and keeping this option disabled is a good idea Max Request Retries This option sets the number of times that the Mini Scanner will retry a message to the vehicle after getting no response Choices for the option are 0 to 5 in increments of 1 The default is 2 Page 17 The selected choice for this option is saved at power down and will be effective at the next power up PowerOff Delay sec This option sets the length of time that the Mini Scanner pauses after having decided to turn itself off before it actually powers off This pause gives the user a chance to see what is happening and read displayed messages Choices for the option are 2 to 7 seconds in 1 second increments The default is 5 seconds The selected choice for this option is saved at power down and will be effective at the next power up If the Mini Scanner needs to save new settings f
23. to be connected to a computer or other computing device such as a PDA Never connect the Mini Scanner to a telephone circuit as this will damage it A telephone cable and RJ11 to DB9 adapter are supplied with the Mini Scanner Using these you can connect the serial port to a personal computer COM port The type of connector used by the PC COM port is a DB9 You can also connect to any computing device that has this same type of connector for its serial port If your device has a different type of connector you will need a different adapter When you need to use the serial port plug one end of the telephone cable into the RJ11 on the Mini Scanner Plug the other end into the RJ11 side of the adapter Plug the DB9 side of the adapter into one of the COM ports of your computer You can use the serial port to record or log data from the Mini Scanner to a computer for later analysis update the firmware software that controls the operation of the Mini Scanner More information on using the serial port is given in the sections of the User Manual that deal with these functions Page 9 Mini Scanner Firmware When it arrives your Mini Scanner contains the firmware that was most up to date at the time of shipment From time to time new versions of the firmware may be released to add functionality and or correct problems You will hear about this by e mail To take advantage of new releases of Mini Scanner firmware obtain a new f
24. upload repeat step 6 before proceeding to step 7 The Mark II Flash Loader is automatically in verify mode after the upload but Mark I owners must type v If a firmware update is interrupted for example by accidentally resetting the Mini Scanner or a computer crash it should be sufficient to simply start again Try to be sure to get into the Flash Loader on your first reset attempt step 4 as otherwise you will run the part of the user program that was loaded There is a very very small chance that this could be harmful to the Mini Scanner or Flash Loader program Expert Use of the Flash Loader The Flash Loader has three modes of operation test program and verify This controls what happens to the data read from an input file A mode announcement message test prgm or vrfy appears each time the prompt is issued to tell you what mode you are in If you hit the enter key the prompt is repeated including the mode message Other input is not echoed so nothing will happen unless you hit a valid command key 6699 On activating the Flash Loader from system reset it is in test mode Typing p puts you in program mode typing v puts you in verify mode and typing t puts you in test mode You can switch between these modes at any time An erase operation puts the Flash Loader into program mode After reading in an Intel Hex16 file and detecting the end of file record the Flash Loader changes to verify mode
25. which we will discuss below You can tell that you are in this mode because the top display line is highlighted On the Mark I Mini Scanner a blinking cursor appears in the first character position On the Mark II Mini Scanner the entire line blinks In Select Line 1 mode tapping the Right and Left buttons scrolls forward and back through the list of items that are available for display When a new item is first selected no data is available for that item and the descriptive text appears with just placeholder characters where the value should be After a moment the Mini Scanner requests the data and the value returned by the ECU is shown There is no need to wait for this to happen you can keep tapping until the item you re looking for appears If you do wait in between taps you can read off the current value of each item in turn but please not while driving To select the data item for the second line of the display put the Mini Scanner in Select Line 2 mode From Display mode this takes three taps The second display line is highlighted so that you know you are in this mode As for the top line tapping Right and Left scrolls through the list of items that are available The same items are available for both display lines Now you know how to select the two items in the Display slot These will be shown when the Mini Scanner is in Display mode To get back to Display mode and stop the blinking you can tap Middle and go past Option
26. 325 Knock Sensor 1 Circuit Malfunction Bank 1 P0335 Crankshaft Position Sensor A Circuit Malfunction P0340 Camshaft Position Sensor Circuit Malfunction P0420 Catalyst System Efficiency Below Threshold Bank 1 Page 44 PO440 Evaporative Emission Control System Malfunction This and the following two DTCs can occur if you drive around for a while with a loose fuel filler cap I did this to test retrieving DTCs with the Prius Mini Scanner and it took more than a day for the problem to be detected P0441 Evaporative Emission Control System Incorrect Purge Flow P0446 Evaporative Emission Control System Vent Control Malfunction P0450 Evaporative Emission Control System Pressure Sensor Malfunction P0451 Evaporative Emission Control System Pressure Sensor Range Performance P0500 Vehicle Speed Sensor Malfunction P0505 Idle Control System Malfunction Engine ECU Manufacturer Controlled These items are taken from the table Engine Diagnostics manufacturer controlled on pages DI 17 and DI 18 in the Engine Diagnostics chapter of the Repair Manual Page 45 P1125 Throttle Control Motor Circuit Malfunction P1127 ETCS Actuator Power Source Circuit Malfunction P1128 Throttle Control Motor Lock Malfunction P1129 Electric Throttle Control System Malfunction P1300 Igniter Circuit Malfunction No 1 P1305 Igniter Circuit Malfunction No 2 P1310 Igniter Circuit Malfunction No 3 P1315 Igniter
27. CU ISO9141 slow initialization may fail and the Mini Scanner will then turn itself off This is probably a quirk of the vehicle and may not be present on all model years If it is important to you that this not happen go to the Hybrid Vehicle or Engine ECU before you leave trouble codes mode Clearing DTCs In Trouble Codes mode it is possible to clear DTCs as well as display them In general this is not a good idea as your service department may need this information to diagnose problems with your car Therefore to clear DTCs the Mini Scanner makes you jump through a few hoops First you must have Clearing Trouble Codes enabled in the Options mode Refer to the section on Options for how to do this Now select the ECU in which you want to clear DTCs by tapping the Right and Left buttons as before It doesn t matter if you are retrieving DTCs or not this will be started when you clear the DTCs Hold the Left button A message will appear asking you if you really want to clear the DTCs If Clearing Trouble Codes is not enabled in the Options mode you will be informed of this instead If you decide to continue and clear the DTCs hold the Left Page 21 button a second time The DTCs will be cleared and the Mini Scanner will retrieve the DTCs from that ECU which naturally will all be P0000 If you change your mind about clearing DTCs any button action other than holding the Left button will cancel the request Updating Mini Scanner Firmwa
28. CU and displayed So you can browse through the ECUs inspecting their DTCs in turn Interpreting DTCs The display shows three DTCs each consisting of a prefix letter and four digits The code P0000 means that there is no Trouble Code so when there are no DTCs in an ECU you will see P0000 P0000 P0000 If you have one DTC it will appear in the first position For example if you remove the Service Plug from the high voltage battery and turn the car on the Hybrid Vehicle ECU will show P3140 P0000 P0000 The code P3140 means Interlock Malfunction and can be looked up in the Diagnostic Repair Manual Much of the information from this manual is included in Appendix B Prius Diagnostic Trouble Codes below Leaving Trouble Codes Mode When you leave Trouble Codes mode by tapping or holding the Middle button if you started the retrieval of DTCs then the Mini Scanner has to get back to the mode of communication in which it can talk to all the ECUs and get data items To do this it will repeat the ISO9141 slow initialization that it did when you turned it on After a few seconds if you go back to Display mode the display and logging of data items will resume Changed settings have not been stored and the Display mode slots are as you left them The slow initialization is purely to get back in touch with all the ECUs Peculiar Quirk Experimentally I have found that if you return to Display mode while retrieving data from the Battery E
29. CU internal error RAM Braked 141 HV ECU internal error ROM Braked 142 ST Signal Circuit Malfunction When ST signal of HV ECU is ON with ignition Page 48 switch turned OFF 143 HV ECU 144 HV ECU 145 HV ECU 146 HV ECU 147 HV ECU 148 HV ECU 149 HV ECU 150 HV ECU 151 HV ECU 152 HV ECU 153 HV ECU 154 HV ECU 155 HV ECU 156 HV ECU 157 HV ECU 158 HV ECU 159 HV ECU 160 HV ECU 161 HV ECU 162 HV ECU 163 HV ECU 164 HV ECU 165 HV ECU 166 HV ECU 167 HV ECU 168 HV ECU 169 HV ECU 170 HV ECU 171 HV ECU 172 HV ECU 173 HV ECU 174 HV ECU 175 HV ECU internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error Immobilizer Malfunction Primary Check Malfunction Primary Check Malfunction Primary Check Malfunction Primary Check Malfunction HV CPU Malfunction HV CPU Malfunction Motor CPU Malfunction Motor CPU Malfunction Motor CPU Malfunction Motor CPU Malfunction Motor CPU Malfunction Motor CPU Malfunction Motor CPU Malfunction Motor CP
30. Chart in a Spreadsheet Creating a chart from data in this format imported into most spreadsheet programs is very easy Simply select the block of data you want to chart both rows and columns and instruct the program to make a chart from it Specify the type of chart as X Y or scatter so that the first column is used as X axis values You may also be able to specify that data points are joined by a line though some low end spreadsheets mishandle the blank cells By default both data columns will be plotted against the same Y axis so if they differ in scale for example engine r p m varying from 0 to 4000 and throttle varying from 15 to 60 you will have some more work to do to plot each column against its own Y axis Page 19 Control of Logging Logging can be controlled using the Right button when the Mini Scanner is in Display mode Holding the right button toggles logging off and on Logging is always on after powering up or resetting the Mini Scanner If you turn it off this selection will not be saved and it will be on again after a power cycle or reset The only reason you d turn it off would be if you have a computer connected and are capturing data and you want to reduce the file size by not logging during uninteresting driving periods So that you can find interesting events in a log file you can drop a mark into the file by tapping the Right button This happens even if logging is off so you can drop the mark and then turn log
31. Circuit Malfunction No 4 P1346 VVT Sensor Camshaft Position Sensor Circuit Range Performance Problem Bank 1 P1349 VVT System Malfunction Bank 1 P1430 Vacuum Sensor for Adsorber and Catalyst System Circuit Malfunction P1431 Vacuum Sensor for Adsorber and Catalyst System Circuit Range Performance Problem P1436 Variable Valve Malfunction P1437 Vacuum Line Malfunction P1455 Vapor Reducing Fuel Tank System Leak Detected Small Leak P1525 Resolver Circuit Malfunction P1600 ECM BATT Malfunction P1633 ECU Malfunction ETCS Circuit P1636 HV ECU Malfunction P1637 EGSTP Signal Malfunction P1656 OCV Circuit Malfunction for VVT i P3190 Poor Engine Power P3191 Engine does not start Hybrid Vehicle ECU Diagnostic Trouble Codes In addition to the letter plus four digit DTC the HV ECU generates information codes Page 46 consisting of three digits These give a more finely detailed definition of the problem They can be retrieved by the THHT Toyota Hand Held Tester but not by a normal OBD II scanner How the THHT retrieves information codes has not been determined therefore they cannot be retrieved by the Prius Mini Scanner From pages DI 199 through to DI 205 in the Hybrid Vehicle Control System chapter of the Repair Manual B2799 Immobilizer Malfunction 101 No input of signal from transponder key ECU C2692 Regenerative Brake Check 102 Regenerative Brake Check C2693 Regener
32. ECROS Technology www ecrostech com Prius Mini Scanner User Manual Manual Revision Preliminary H for Firmware Version 0 62 March 30 2004 This document is Copyright 2004 ECROS Technology All Rights Reserved Prius is a trademark of Toyota Corporation All other products and or service names mentioned in this user manual may be trademarks of the companies with which they are associated Table of Contents Introductio RATAR RI I ie IS SON VESTARI eden ee udo deu tu dus SR 1 Road gata a a a 1 Aboutthis Manual cipere eai SHIRE Fas aa AR sais D ES RA A Kaj IRE BARA 1 Outline of OP Sr at Ng DM 2 BANI Pc 2 NXehicle Model GAS ss an ta ear MH ea Qo Nequi qiie aa 2 Installing the Prius Mini Scannet aeterne eterno en tno ik akd b na aa vs 3 Unpacking the Mant SCannen oo e is aaa ete Rp LE ENT i o ERR Rott 3 Toolsand Supple Sien ie cie rao ta mota ene o D e D uam tes Coo odes 3 Concealing the Adapter Cable iue aeneae tuse rdc IR i dan ps Rope oc 3 Plugging in the DLC Adapletsoms ee tue a e pde get m me d ck 5 Installing the Main Unless itae es espe ted aus Ceo a pedes epo ea ban edenda qd 6 Adj sting th Display siete dace ote a deiude a dus pde if Securing the Main Unit im the Catus eene din toni retento oi Dee ie H1 eoe dd 8 Checking the Mini SC E ooo dos aO reset AR dU etd M e e deg 8 The Seriab Pott os pitels qas doeet uda a Dessin Gag MN con IN MINIS Eae RS IM d Ge 9 M ni Scanner Firm wat ey u
33. G2 torque in newton metres This needs to be verified or at least checked I guessed the scaling of the data by blocking the wheels of my car and watching this figure scaled climb to just over 200 before the car surged up onto the blocks Maybe someone could creep up a hill of known slope on battery power at constant speed In fact I m now starting to think that the scaling factor is wrong and the Mini Scanner reads torque low by 20 For example when it shows 100 N m the torque is really 125 N m Note that generally when a motor generator s spin and torque are in the same direction it is acting as a motor When they are in opposite directions i e one is positive and the other negative it is acting as a generator The only time that the foregoing is not true is during brief transition periods for example when the direction of spin is being changed by the application of power MG1 Spin Rate MG1 Spin rpm MGI spin rate in revolutions per minute This is an interesting figure to watch when you re interested in how the Prius manages without having gears to shift The faster MGI spins forwards the faster the engine can spin for a give vehicle speed and the more electrical power can be passed to MG2 to increase the total driving torque This is how the car simulates a lower mechanical gear By reducing MGI s spin rate the vehicle speed increases in relation to the engine spin rate but less electrical power is available to pass to
34. I Mini Scanner Item Request Rate This option sets the rate at which the Mini Scanner sends requests for data items to the vehicle Choices for the option are Slow Normal and Fast The default is Normal The selected choice for this option is saved at power down and will be effective at the next power up The request rate is controlled in the Mini Scanner by changing two parameters of the communication protocol The inter byte time P4 is the time that the Mini Scanner waits after completing the transmission of one octet of a request message before it begins the transmission of the next ISO9141 requires this time to be in the range 5 to 20 ms The inter message time P3 is the time that the Mini Scanner waits after receiving the last octet of a response message from the vehicle before it begins the transmission of the first octet of the next request message ISO9141 requires this time to be in the range 55 to 5000 ms The values of these parameters for the three request rates are shown in the following table Rate Slow Normal Fast P4 inter byte time 15 ms 10 ms 5 ms P3 inter message time 1000 ms 350 ms 55 ms The Prius seems to be perfectly happy with the Fast request rate all the time So the slower rates might end up not being very useful except to limit the length of log files taken over a long period of time I will probably scrunch the three choices up closer together at some time by decreasing P3
35. Safety devices operating with vehicle is stopped ILK signal ON 351 Open circuit in interlock signal circuit while vehicle is running P3145 Vehicle Speed Sensor Circuit Malfunction 352 No input of vehicle speed signal during cruise control driving Page 57
36. U Malfunction Motor CPU Malfunction Motor ECU Communication Circuit Malfunction Motor ECU Communication Circuit Malfunction Motor ECU Power Source Malfunction Motor ECU Power Source Malfunction Motor ECU Power Source Malfunction Motor ECU Power Source Malfunction Motor ECU Power Source Malfunction Motor R D Malfunction Motor R D Malfunction Motor R D Malfunction Motor R D Malfunction Motor R D Malfunction Motor REF Signal Malfunction Motor REF Signal Malfunction Motor REF Signal Malfunction Motor Inverter Current Sensor Malfunction Motor Inverter Current Sensor Malfunction Page 49 176 HV ECU 177 HV ECU 178 HV ECU 179 HV ECU 180 HV ECU 181 HV ECU 182 HV ECU 183 HV ECU 184 HV ECU 185 HV ECU 186 HV ECU 187 HV ECU 188 HV ECU 189 HV ECU 190 HV ECU 191 HV ECU 192 HV ECU 193 HV ECU 194 HV ECU 195 HV ECU 196 HV ECU 197 HV ECU 198 HV ECU 199 HV ECU 200 HV ECU 201 HV ECU 202 HV ECU 203 HV ECU 271 HV ECU 310 HV ECU 390 HV ECU 391 HV ECU 392 HV ECU 393 HV ECU internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error internal error
37. a history that the state of malfunction continued during inverter fail safe mode 257 Generator Temperature Sensor Malfunction GND short in generator temperature sensor 258 Generator Temperature Sensor Malfunction Generator temperature sensor malfunction 259 Generator Temperature Sensor Malfunction Open or B short in generator temperature sensor 260 Generator Temperature Sensor Malfunction Generator temperature sensor performance problem P3125 Converter amp Inverter Assembly Malfunction 263 DC DC Converter Malfunction B short in DCDC converter NODD wiring 264 DC DC Converter Malfunction DCDC converter malfunction 265 DC DC Converter Malfunction Open or GND short in DCDC converter NODD wiring 266 VM Malfunction Open or GND short in inverter voltage signal circuit 267 VM Malfunction B short in inverter voltage signal circuit 268 VM Malfunction Inverter voltage signal is inconsistent with battery voltage 269 VM Malfunction Inverter voltage sensor malfunction 270 VM Malfunction Abnormality of line connection of inverter voltage signal circuit When there is a history that the state of malfunction continued during inverter fail safe mode 272 Motor PWN Line Connection Malfunction Abnormality of the line connection of motor PWM When there is a history that the state of malfunction continued during inverter fail safe mode 273 Motor Inverter Gate Malfunction Motor inverter malfunction 274 Motor Inverter Temp
38. abnormal 1 5 sec after ignition is turned ON 219 When communication between brake ECU and HV ECU is abnormal 1 5 sec after ignition is turned ON 220 When communication between brake ECU and HV ECU is abnormal 1 5 sec after Page 51 ignition is turned ON 221 When communication between brake ECU and HV ECU is abnormal 1 5 sec after ignition is turned ON 222 When abnormal data is received from brake ECU P3110 IGCT Relay Malfunction 223 When IGCT relay is always closed P3115 System Main Relay Malfunction 224 SMR Cont 1 Malfunction Open or B short in system main relay No 1 circuit 225 SMR Cont 1 Malfunction Short in system main relay No 1 circuit 226 SMR Cont 2 Malfunction Open or B short in system main relay No 2 circuit 227 SMR Cont 2 Malfunction Short in system main relay No 2 circuit 228 SMR Cont 3 Malfunction Open or B short in system main relay No 3 circuit 229 SMR Cont 3 Malfunction Short in system main relay No 3 circuit 231 Deposit of SMR System main relay terminal deposited 232 Deposit of SMR System main relay terminal deposited 233 Deposit of SMR System main relay amp terminal deposited P3120 HV Transaxle Malfunction 234 Energy Balance Malfunction Small reduction of motor magnetism 235 Energy Balance Malfunction Large reduction of motor magnetism 236 Energy Balance Malfunction Small reduction of generator magnetism 237 Energy Balance Malfunction Large reduction of gener
39. ain text Do not use a file transfer protocol such as kermit or xmodem Firmware Update Procedure To perform a firmware update follow the numbered steps below In all cases of pressing or holding down a key it is a key on the computer keyboard to which I am referring When I say you will see I mean on the computer screen You are basically interacting with the computer and terminal emulator program from steps 3 to 7 and need not touch or look at the Mini Scanner except to press the On Reset button in step 4 1 Make sure the Mini Scanner has power If you are in the car and the DLC adapter and cable are connected normally this is already done There is no need to turn the car on If you have removed the Mini Scanner from the car use a 9 volt battery as described in Using the 9 Volt Battery Hook Up above 2 Connect the serial cable to the Mini Scanner and to a serial COM port on your computer see Connecting the Serial Cable above for details 3 Turn on the computer and run the terminal emulator application If you have not already done this set it to connect via the COM port to which you connected the Mini Scanner in step 2 and configure the serial port for 9600 bit s eight data bits no parity one stop bit and no flow control as described in Terminal Emulator Programs above 4 Hold down the escape Esc key see note below wait a second or two and while continuing to hold down the escape key press and release t
40. an drive the car in this state It is also safe to have the DLC adapter plugged in without the adapter cable attached The Mini Scanner has been designed not to present the risk of damage to your car When disconnecting the adapter cable always pull off the connector by grasping its body and pulling straight away from the header Never pull on the ribbon cable itself as it will become detached from the connector Replacement cables are available from ECROS Technology Removing the cable from the Mark II main unit is made rather difficult by the lack of space to get your fingers in I apologize for this design problem but I could find no solution Lift up the cable so that you can get a finger to the lower part of the connector If you have to use a small flat bladed screwdriver to pry up the connector from the pins do so gently Basic Operation In this chapter of the User Manual I will describe basic operation of the Mini Scanner including how to select data items to be retrieved from the car s ECUs and displayed Turning the Mini Scanner On and Off For the Mini Scanner to communicate with the car the car must be turned on although it need not actually be started To turn the Mini Scanner on press the On Reset button which is on the far left The Mini Scanner will begin sending messages to the car and displaying information sent back by the car s ECUs Page 10 If the Mini Scanner does not receive a response from the car it will disp
41. as a reference If you don t want to bother with this the preset contrast will probably be just find for you It is always possible to come back and adjust it later but you will have to remove the top of the case again unless you drill the hole Replace the front of the main unit case Tip the main unit towards you so that its face rests on the steering wheel housing Replace the four screws that hold the case together Tip the main unit back upright and you are ready to secure it in place Page 7 Securing the Main Unit in the Car You may have your own ideas about how to fix the Mini Scanner in place especially if you don t want to put it behind the steering wheel In this section I assume you do want it behind the steering wheel and also that you don t want to fix it directly to the car For other methods of fixing adhesive backed Velcro and or double sided foam tape will come in handy but are not included in the package The Mini Scanner comes with a simple mounting bracket The bottom of the bracket is intended to be trapped by the steering wheel assembly when you lift it back up into place The top of the bracket the larger part provides a surface to which you can fix the back of the main unit case It comes with a large piece of foam tape attached which will not let go once you ve pressed the Mini Scanner onto it If you want to have a second chance you could replace it with Velcro or perhaps only remove part of the backin
42. ative Brake Check 103 Regenerative Brake Check P1120 Accelerator Pedal Position Sensor Circuit Malfunction This DTC has been caught in the wild on an early 2001 model year Prius The accelerator pedal position sensor is know to cause problems on these cars and there is a TSB out on it 104 Open or short circuit in main accelerator sensor circuit 105 B short in main accelerator sensor circuit 106 Main sensor internal error 107 Open or short in sub accelerator sensor circuit 108 B short in sub accelerator sensor circuit 109 Sub sensor internal error 110 When difference between main sensor value and sub sensor value is large 111 When sub sensor value changes while main sensor value does not 112 When main sensor value changes while sub sensor value does not 113 When any of information code 104 112 continues to appear 114 Accelerator pedal not smoothly returning to original position P1520 Stop Light Switch Cruise Control System Malfunction 115 Open or short in stop light switch circuit P1566 Cruise Control System Malfunction 116 When STP signal of HV ECU is inconsistent with that of brake ECU with cruise control indicator ON P1600 BATT Malfunction 117 HV ECU back up power source circuit malfunction Page 47 P1780 Park Neutral Position Switch System Malfunction 118 When more than 2 main signals are ON 119 When main signal is not turned ON even though sub signal has been input 120 Open or short in sub sensor
43. ator magnetism 239 HV Transaxle Malfunction Shaft damaged 240 HV Transaxle Malfunction Generator locked 241 HV Transaxle Malfunction Torque limiter sliding 242 HV Transaxle Malfunction Planetary gear locked 243 Motor Resolver Malfunction Motor resolver inter phase short 244 Motor Resolver Malfunction Motor resolver inter phase short When there is a history that the state of malfunction continued during inverter fail safe mode 245 Motor Resolver Malfunction Open or short in motor resolver circuit 246 Motor Resolver Malfunction Open or short in motor resolver circuit When there is a history that the state of malfunction continued during inverter fail safe mode 247 Motor Temperature Sensor Malfunction GND short in motor temperature sensor 248 Motor Temperature Sensor Malfunction Motor temperature sensor malfunction 249 Motor Temperature Sensor Malfunction Open or B short in motor temperature Page 52 sensor 250 Motor Temperature Sensor Malfunction Motor temperature sensor performance problem 253 Generator Resolver Malfunction Generator resolver inter phase short 254 Generator Resolver Malfunction Generator resolver inter phase short When there is a history that the state of malfunction continued during inverter fail safe mode 255 Generator Resolver Malfunction Open or short in generator resolver circuit 256 Generator Resolver Malfunction Open or short in generator resolver circuit When there is
44. ator pedal subordinate position sensor output probably in volts The value typically ranges from 1 5 with no pedal displacement to 4 2 with the pedal pushed all the way to the floor Mode Selector Lever Position Sensor 2 Shift Sensor 2 Shift lever a k a Mode Selector Lever position sensor output probably in volts Typical values in P R N D and B respectively are 0 6 2 9 3 5 4 0 and 4 6 Mode Selector Lever Position Sensor 1 Shift Sensor 1 Shift lever a k a Mode Selector Lever position sensor output decoded into a one hot binary code The values in P R N D and B respectively are 1 2 4 8 and 16 When the lever is in between valid positions the value is zero Hybrid Powertrain Operating State Drive Condition The Toyota Repair Manual Volume 1 Diagnostics lists the values of this item thus 0 When engine is stopped 1 When stopping engine 2 When starting engine Page 38 When engine is stopped When cranking engine or engine is operating see below While generating power or load driving ON tn oe While racing engine in P position I see values of 0 1 2 and 4 most frequently and occasionally I see 3 I think 2 means that the engine is being spun up by the motors prior to applying fuel and spark and 1 means the engine is being forcibly spun down and its kinetic energy returned to th
45. avorites or option choices the power down delay will be increased by 50 to accommodate the additional message on the display Logging Data via the Serial Port This chapter of the Prius Mini Scanner User Manual describes the recording or logging of data using the serial port Data retrieved from the vehicle by the Mini Scanner can be sent to a computer via the serial port The data items sent are the same as those selected for display However only numerical data is sent the descriptive text and units that you see on the display are not sent You must remember what data was being displayed on each line when you examine the data This purely numerical data is very easy to import into a spreadsheet The format of the data is plain ASCII text In other words the number 62 5 will be sent as the four ASCII characters 6 2 and 5 The serial port operates at 9 600 bit s 8 data bits no parity and one stop bit These are the same setting used by the Flash Loader so if you have a terminal emulator set up for firmware updates you can use it to view the serial port data Just connect the computer up and start the terminal emulator as if you were going to update the firmware but don t hold down the escape key Using the terminal emulator s capture features you can save the data to a file for later analysis or charting in a spreadsheet program Timestamp Each data value is associated with a timestamp This indicates the appr
46. ays information on the operation of a Toyota Prius gasoline electric hybrid car You can use the informa tion to drive the car as economically as possi ble to understand how it works and to watch for any problems that might develop The Mini Scanner obtains information from the various computers or Electronic Control Units ECUs in the car It does this using the On Board Diagnostic OBD II data bus All Prius have this so no modifications are necessary and installation is fully reversible Photo 1 The Mark II Prius Mini Scanner You can position the Mini Scanner behind the steering wheel where most cars have their main instrument cluster The driver can then glance at the display without taking his or her eyes from the road for any longer than is usual It is also possible to locate the Mini Scanner for use by a passenger Over 50 data items can be retrieved from the car s ECUs and displayed Some represent vehicle operating data that would be present in any car such as engine r p m and coolant temperature Other items are specific to a gasoline electric hybrid vehicle such as the battery state of charge and current and the torque of the traction motor Finally many items give you diagnostic and trouble shooting information such as the temperature of the motors battery and inverter electronics The Mini Scanner can retrieve Diagnostic Trouble Codes DTCs from the main ECUs This is the information that Toyota s
47. battery hookup connected to a Mini Scanner and to a battery The red wire goes to the pin in the top row closer to the buttons but the connector will not fit the other way round so it should not be possible to get this wrong Additional photographs of higher resolution are included on the CD ROM If the display backlight is on the current drawn by the Mini Scanner is higher than is normal for a Photo 10 9 Volt Battery Connection battery of this type It is best therefore to work in a well lighted room so that the backlight remains off Connecting the Serial Cable The Mini Scanner serial cable consists of a telephone cord and an adapter Plug either end of the telephone cord into the adapter and plug the adapter into the COM port of your computer Plug the other end of the telephone cord into the jack on the right hand side of the Mini Scanner main unit Remember that although the Mini Scanner uses telephone type connectors and cords you should never connect it to a telephone circuit or it will be damaged Note for Mark I owners skip this sidebar if you have a Mark II The Mark I Mini Scanner does not have the externally accessible RJ11 jack for the serial cable Instead the case must be opened and the cable attached inside much like the adapter cable For details refer to the Mark I Web site If you are using an extension serial cable for extra reach you should make sure you have the right type of extension If
48. browse forwards and backwards through the complete list of data items by tapping the Right and Left buttons Therefore you will also use the Page 12 Display Slot to hold data items that you temporarily want to watch When the Mini Scanner turns off it forgets which data items were in the Display Slot The next time you turn it on the two items in Favorite Slot 7 see below will be copied to the Display Slot If you browse the data items in the Select Line modes and turn off the car the next time you use it the Mini Scanner will return to the state you deliberately set and will not be disturbed by your browsing Favorite Slots Data items in Favorite Slots are changed indirectly by copying the contents of the Display Slot However when the Mini Scanner turns off it remembers the data items in all seven Favorite Slots The next time you turn it on the contents of the Favorite Slots are exactly as you last set them Therefore the data items you put in Favorite Slots are typically the ones you re most interested in As Favorite Slot 7 is copied to the Display Slot when you turn on or reset the Mini Scanner this is where you should put the items you normally want to see on the top two lines of the display Selecting Display Items To select the data item to be shown in the top line of the display put the Mini Scanner in Select Line 1 mode To get to this mode from Display Mode tap Middle twice the first tap puts you in Favorites mode
49. ccur and how to solve them and advanced and expert use of the Flash Loader In most cases if you are not experiencing problems you can skip the remaining material Page 27 Problems and Errors This section attempts to identify some problems that might occur with firmware updates and tells you how to go about solving them The Flash Loader includes diagnostics to detect bad firmware files and hardware problems in the Mini Scanner and the errors it issues are listed and explained here If you are using a 9 volt battery and experience any problems make sure the battery is not the problem It does not have to be new but it should not be on the last half of its life Try a new battery if you have one Nothing Happens When I Reset the Mini Scanner If when you release the On Reset button in step 4 you see nothing at all in the terminal emulator window and the Mini Scanner starts normally check the following Make sure the COM port of your computer is working In many computers the COM ports can be disabled in the BIOS Check that you have configured the terminal emulator to use the COM port into which you have plugged the Mini Scanner serial cable Check all other configuration settings of the terminal emulator You should be using 9 600 bit s 8 data bits no parity and 1 stop bit Flow control should be disabled Make sure the plugs on the telephone cable are fully seated into the jacks in the Mini Scanner and serial port adapter The
50. circuit 121 When shift position detected by main signal is different from that detected by sub signal P3000 HV Battery Malfunction 123 Input of abnormal signal from battery ECU HV Battery System Malfunction 124 Input of abnormal signal from battery ECU high voltage fuse blown out 388 Discharge Inhibition Control Malfunction When charged battery is low due to leaving the vehicle in N position gas shortage or HV system malfunction 389 Drop of high voltage When main battery is dead or main battery is dead due to HV system malfunction P3001 HV Battery ECU Malfunction 129 Battery ECU malfunction P3004 Power Cable Malfunction 130 HV Battery Malfunction When HV battery voltage becomes lower than inverter voltage 131 Power Cable Malfunction When main fuse is blown out service plug is disconnected or limiter resistance is cut off 133 HV Battery Malfunction When inverter voltage sensor is malfunctioning or limiter resistance value increases P3100 HV ECU Malfunction 127 IB Circuit Malfunction B short in IB terminal circuit of HV ECU 128 IB Circuit Malfunction Open or short in IB terminal circuit of HV ECU 134 HV ECU Internal Error 135 HV ECU Internal Error 136 GO Signal Error Open or short in GO circuit 137 Engine Speed Sensor Malfunction 138 IB Circuit Malfunction When the difference between current of HV ECU and current of battery is large 139 HV ECU internal error IG Signal Circuit Malfunction 140 HV E
51. ction Malfunction B short in motor gate shutdown signal circuit 305 Motor Gate Shutdown Signal Line Connection Malfunction Open or GND short in motor gate shutdown signal circuit 306 Failure in Monitoring Motor Torque Performance 307 Abnormal Current Value of Motor 308 Detection of Collision Signal 309 Motor PWM Line Connection Malfunction Open or short in generator inverter switching wiring GUU GVU GWU 311 Generator Inverter Malfunction 312 Generator Inverter Temperature Sensor Malfunction Open or B short in generator inverter temperature sensor 313 Generator Inverter Temperature Sensor Malfunction GND short in generator inverter temperature sensor 314 Generator Inverter Temperature Sensor Malfunction Generator inverter temperature sensor malfunction 315 Generator Inverter Temperature Sensor Malfunction Generator inverter temperature sensor performance problem 316 Generator Inverter Sinv B short in generator inverter stop signal circuit 317 Generator Inverter Sinv Over voltage of inverter 318 Generator Inverter Sinv Open or GND short in generator inverter stop signal circuit 319 Generator Inverter Sinv Voltage drop of inverter power source 320 Generator Inverter Sinv Inverter circuit broken 321 Generator Inverter Finv B short in generator inverter fail signal circuit 322 Generator Inverter Finv Inverter overheating 323 Generator Inverter Finv Open or GND short in generator inverter fail signal cir
52. cuit 324 Generator Inverter Finv Inverter circuit broken 325 Generator Inverter Finv Inverter internal short 326 Generator Inverter Current Sensor Malfunction Generator inverter current sensor malfunction V phase sub sensor 327 Generator Inverter Current Sensor Malfunction Open in generator inverter current sensor V phase sub sensor 328 Generator Inverter Current Sensor Malfunction Generator inverter current sensor Page 55 malfunction V phase main sensor 329 Generator Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 330 Generator Inverter Current Sensor Malfunction Open in generator inverter current sensor V phase main sensor 331 Generator Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 332 Generator Inverter Current Sensor Malfunction Generator inverter current sensor V phase performance problem 333 Generator Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 334 Generator Inverter Current Sensor Malfunction Generator inverter current sensor malfunction W phase sub sensor 335 Generator Inverter Current Sensor Malfunction Open in generator inverter current sensor W phase sub sensor 336 Generator Inverter Current Sensor Malfunction Generator inverter cu
53. d the configuration mentioned in step 3 of Firmware Update Procedure below In future at step 3 just start HyperTerminal using your pre configured connection as described In step 6 of Firmware Update Procedure you will need to send the firmware file to the Mini Scanner Flash Loader To do this select Transfer Send Text File on the menu to bring up the Send Text File file browser dialog Using this browser locate the firmware file on your computer click on it to select it and then click the Open button The dialog will close and the file transfer will begin You should see dots begin to appear in the main HyperTerminal window as each record passes from the file to the Mini Scanner and Page 25 is acknowledged as correct Do not touch the keyboard until the file upload is complete and the Flash Loader presents you with a new prompt The upload will take several minutes Tera Term Pro The terminal emulator program TeraTerm Pro is included with the Mini Scanner on the Prius Mini Scanner Welcome CD ROM It is freeware which means that you can use it without registering or paying any money to anyone About the only thing you can t do with it is redistribute modified versions Unfortunately this is exactly what I ve done as I ve pre configured the program for the Mini Scanner I hope that the program s author does not consider changing the default settings to be modification TeraTerm Pro consists of a couple of dozen files which are
54. de Page 1 Outline of Operation Many of the ECUs in the Prius are connected to a data bus or network called the OBD II bus On Board Diagnostics version 2 The main purpose of this bus is to allow service personnel using special equipment to get information that helps them diagnose problems with the car The ECUs do not talk to each other on this bus Rather a tester device must be connected to the bus which sends messages to the ECUS requesting that they send back specific data The tester plugs into a Data Link Connector 3 DLC3 which is under the dash near the driver s left knee Toyota service centers use a Toyota Hand Held Tester or THHT to talk to the car s ECUs and monitor the vehicle s operation When you plug the Mini Scanner into the Prius DLC3 and turn it on it sends a signal on the OBD II bus to wake up the ECUs and then begins requesting data items Replies from the ECUs are decoded and the data is presented on the display Much of what you will find in this User Manual has to do with choosing the data items to be requested and controlling how and when they are displayed As well as displaying the data from the ECU replies the Mini Scanner sends them to a serial port which is like the COM port on a personal computer By connecting a PC or a PDA to this serial port you can store or log the data for analysis at some later time Using the Data The information that the Prius Mini Scanner
55. e update procedure 1 Mark I error 4 A mismatch was detected during a verify operation This error is issued for each record containing data that does not match the current Mini Scanner firmware The Mini Scanner does not contain the same firmware as the selected file 2 Mark I error 2 A record in the input file had a bad checksum The file is not in the correct format or is corrupt Obtain a new firmware file Note that an Intel Hex32 file is likely to cause this error The Flash Loader only reads Intel Hex16 files 3 Mark I error 3 A record in the input file had a bad value in the record type field The file is not an Intel Hex file is not in the correct format or is corrupt Obtain a new firmware file Note that an Intel Hex32 file is likely to cause this error The Flash Loader only reads Intel Hex16 files 4 Mark I error 1 A record in the input file contained a character that is not a hexadecimal digit The file is not an Intel Hex file is not in the correct format or is corrupt Obtain a new firmware file 5 Mark I error 7 Data from the firmware file cannot be programmed because it is at an address in the Mini Scanner memory that is not empty and does not already contain that data If you are performing a full update of the firmware start again and be sure to erase the old firmware first If this error recurs return the Mini Scanner for repair 6 Mark I error 5 The microcontroller was unable to unlock its
56. e battery A Mini Scanner owner who has paid more attention to this item than I have suggests that 3 means that the engine is running for a reason other than those covered by 4 That is engine power is not driving the car nor is it being used to generate electrical power This value is therefore seen during pre heat the first phase of engine warmup when the ignition timing is retarded low load driving at more than 42 m p h when the engine must spin to protect MG1 and when the engine runs to turn the air conditioning compressor Highest Battery Cell Temperature Cell Tmp Max C This might be the highest sensor temperature passed to the Hybrid Vehicle ECU by the Battery ECU Lowest Battery Cell Temperature Cell Tmp Min C This might be the lowest sensor temperature passed to the Hybrid Vehicle ECU by the Battery ECU Fuel Injector Opening Time Injector ms The Toyota Repair Manual Volume 1 Diagnostics describes this as Fuel injection time for cylinder No 1 and goes on to say that when idling it should be in the range 1 0 3 0 ms I would describe it as the time for which the fuel injectors are open each time they fire Itis interesting that the value tends to settle to around 7 ms above a certain power additional fuel being drawn only by an increase in engine spin rate not injector opening time Abnormal Revolution Variation Cyl 1 The Toyo
57. e data items in that slot So as well as watching the items in the Display slot you can with just a few quick taps watch any two items you have saved in a Favorite slot Suppose for example you are interested in the torque produced by the motor generators when you are going up a hill Normally you watch other items so these torques are not usually displayed Choose a Favorite slot say slot 3 and set the items in that slot to MGI torque and MG2 torque Now before you go up that hill you can quickly set the Mini Scanner to show you the torques by tapping Middle once and Right twice assuming you start in display mode At the top of the hill you can return to normal by holding Middle Although a slot only contains two items the Mark II Mini Scanner is able to display four lines of information As shipped it only displays two because only two data items are Page 14 requested from the car If you use the Options mode to increase the number of items requested see Items to Request Log the other two lines will start to fill up But what will they fill up with The answer is that they will display the items in the next slot beyond the one you ve selected If you ve set the Mini Scanner to Favorite slot 3 the items in that slot will appear on the top two lines If you ve chosen to request four data items the items in slot 4 will appear on the next two lines For the purposes of defining the next slot the Display slot is slot zero So
58. e main window Select File Save As on the menu to bring back the Connection Description dialog In the Name edit box type a suitable name that will allow you to remember what this connection is for For example you might type Mini Scanner Update If you wish you can choose an icon from those presented I rather like the one with the picture of an atom Click the OK button whereupon the dialog will disappear and be replaced with the Save As browser dialog HyperTerminal is offering to save a file describing the connection in a place of its choosing on your computer The filename is already filled in from what you entered in the previous dialog Accept this filename and location by clicking Save Again you are back at the main window Now exit HyperTerminal It sounds silly but do it You can use File Exit or click the Close button the one at top right with a cross in it Don t try to use HyperTerminal to communicate with the Mini Scanner at this point Go back to start HyperTerminal again but now as you reach the end of your exploration of the Start menu you will see two HyperTerminal s The new one is a folder which you can tell from the icon and the arrow pointing to another menu level Continue to this menu level and you should find the connection you just set up under the name you gave it Select this and HyperTerminal will start up with all the configuration already done At this point you have complete
59. e same way Threading the DB9 connector through the gap above the lowered steering wheel is made more difficult by its larger size but easier by its weight which makes it find its way down more readily I accomplished this on the right hand side of the steering wheel in just a few minutes You may have to get creative if you have trouble perhaps threading something else through and pulling the smaller ten pin connector on the other end in an upward direction Once the cable is threaded you can route it where you want for example over to the passenger side Be very careful to tie it up so it cannot snag on the driver s feet Instructions for connecting the Mark I serial cable to the Mini Scanner main unit are published separately Installing the Main Unit Now we move our attention back to the top end of the adapter cable We left this sticking out behind the steering wheel and we will now attach it to the main unit To open the main unit case take out the four screws in the back with a small 1 Phillips screwdriver Lift off the front of the case by gently pulling it straight away from the back and set it to one side The back part contains the Mini Scanner circuitry which will look like Photo 8 While the front is off be careful not to damage the exposed components inside Peel the protective plastic sheet from the Photo 8 The Main Unit with the Front Off front of the display Hold the main unit horizontally with
60. e toes n antt ce E NEU I ARE ERR I Greg URS 20 Browsing PC Saale nha dei ue o enne bu Due a ua n cia Stas 20 Interpreting sigurmar Rus Fee Re Ure E ra 21 Leaving Trouble Codes Mode eto ae iii Foot rest Guqenteayeh eA Tuer eto Skin as 21 Clearme DITS MER NR JONR SO 21 Updating Mini Scanner FIMWALE sa ce cea donee ee tat erre ks a 22 Downloading FA uei eiecit nto na dia cia eR AAA RD la 22 The Flash laera cq an R R SU E GR EEE Ria 23 Poser tothe Mini Scanner akra 23 Connecting the Serial Cable assa tennene een a a a E ecu ees 24 Terminal Emulator Prost I d hee sete ph suse RUBRI utet 24 Parmiware Update Procedures eost or ess tor tete reist seg Belesa d Der ka talna doge ia 21 Problems and Errors i c oce eee ded aE ee Sh ieee ods oho 28 Flash Loader ETO Spenter tanne i a a ie E la a na sa 30 Advanced Useor the F last EOS8der sas nn 31 Expert Use of the Flash Loadet cue eene cde MUR n anna A NR SR voeb ee n 31 Summary OF Button Funct Om cese avare la a SBA li a in 32 Appendix A Available Data eisa teme Ap eR crie aste sk 32 Listing of Data 88s epa tim eem a nl ciue ne aa 33 Appendix B Prius Diagnostic Trouble Codes eese 41 Battery ECU Diagnostic Trouble COSS oso oo orsi dei tege PR o aaa sn 41 Engine ECU Diagnostic Trouble Codes isi teri reed i rk ee ete a Asia 42 Hybrid Vehicle ECU Diagnostic Trouble Codes see 45 Introduction The Prius Mini Scanner displ
61. er in Trouble Codes mode tap the middle button until the display registers Diag Trouble Codes From Display mode this will be five taps Browsing ECUs When you enter Trouble Codes mode nothing much happens at first By tapping the Right and Left buttons you can browse forward and back in the list of ECUs with which the Mini Scanner can communicate These ECUs are the Engine ECU also known as the ECM Engine Control Module at address 1016 the Hybrid Vehicle ECU at address 1615 the Battery ECU at address D516 Data items are still being requested and logged In order to retrieve DTCs from an ECU select that ECU by tapping the Right and Left buttons and then hold the Right button The result will appear on the display after a short pause The requesting and logging of data items will stop This is because the Mini Scanner has to enter into a different mode of communication with the ECUs to retrieve the DTCs If you accidentally enter Trouble Page 20 Codes mode while logging you will not miss any information as long as you don t hold either the Right or Left buttons You can just leave this mode by tapping or holding the Middle button Once you have started the retrieval of DTCs by holding the Right button the information is refreshed at intervals of about one second So if a Trouble Code arises you will see it on the display If you tap the Right or Left buttons to select a different ECU DTCs will then be retrieved from that E
62. erature Open or B short in motor inverter temperature sensor 275 Motor Inverter Temperature GND short in motor inverter temperature sensor 2776 Sensor Malfunction Motor inverter temperature sensor malfunction 277 Sensor Malfunction Motor inverter temperature sensor performance problem Page 53 278 Motor Inverter Sinv B short in motor inverter stop signal circuit 279 Motor Inverter Sinv Over voltage of inverter 280 Motor Inverter Sinv Open or GND short in motor inverter stop signal circuit 281 Motor Inverter Sinv Voltage drop of inverter power source 282 Motor Inverter Sinv Inverter circuit broken 283 Motor Inverter Finv B short in motor inverter fail signal circuit 284 Motor Inverter Finv Inverter overheating 285 Motor Inverter Finv Open or GND short in motor inverter fail signal circuit 286 Motor Inverter Finv Inverter circuit broken 287 Motor Inverter Finv Inverter internal short 288 Motor Inverter Current Sensor Malfunction Motor inverter current sensor malfunction V phase sub sensor 289 Motor Inverter Current Sensor Malfunction Open in inverter current sensor V phase sub sensor 290 Motor Inverter Current Sensor Malfunction Motor inverter current sensor malfunction V phase main sensor 291 Motor Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 292 Motor Inverter Current Sensor Malfunction Open in motor inverter current
63. ervice centers use to locate problems with the vehicle Road Safety When installed and used properly the Prius Mini Scanner should be no more distracting to the driver than the speedometer or Multi Function Display Do not try to use the Mini Scanner when it is not properly secured or mount it in such a way that the driver must take his or her eyes off the road for more than a moment I strongly recommend that the driver not use the buttons while the car is moving To study the displayed information closely in this situation have someone else drive the car and operate the Mini Scanner from a passenger seat A long adapter cable is available as an accessory for this purpose However you choose to use the Mini Scanner I accept no responsibility for any failure to drive your car in a safe manner If you find the Mini Scanner distracting to the driver please return it for a refund of the purchase price About this Manual In this User Manual I will tell you how to install operate and look after your Prius Mini Scanner All the information you can get from your car is described In many cases its relevance to owning and driving your Prius is explained But before we plunge into the detailed stuff let s take a quick look at how the Mini Scanner works and think about what we might do with the data it will give us If you are desperate to plug the Mini Scanner in and start it up follow the procedure in the printed Read Me First Quick Start Gui
64. example 126 456 14 84 126 927 14 0 127 394 17 18 127 861 14 5 128 329 19 53 128 796 14 0 129 263 19 92 129 730 6 0 130 197 20 31 130 668 TaS I312135 719 92 131 606 4 0 132 074 19 92 132 540 8 5 Each line begins with a timestamp in the first column Data values are placed in columns after the timestamp separated from the timestamp by one or more tab characters The values of the data item selected for display in line one appear in the second column and are separated from the timestamp by a single tab The values of the data item selected for display in line two appear in the third column and are separated from the timestamp by two tabs When you capture the serial port data to a file and import the file into a spreadsheet program the timestamp line one data and line two data will appear in columns A B and C respectively As you pass 999 999 seconds a little more than sixteen minutes since the Mini Scanner was turned on or reset and the timestamp length steps up to eight digits the data columns will appear to jump one column to the right This has no effect when the data is imported into a spreadsheet If you select for display two data items that are retrieved from the same vehicle ECU using the same parameter ID PID then each vehicle response updates both display lines The effect on the serial port data is that twice as much data will appear and consecutive lines will have the same timestamp Creating a
65. g Temperature of Air Entering Engine Int Air Temp C Temperature of air flowing into the engine intake manifold in degrees Celsius The temperature sensor for this data item is built into the mass air flow sensor see below It is not the sensor behind the front bumper that measures ambient air temperature for display on the Multi Function Display Rate of Air Flow into Engine Air Flow gm s Rate of air flow into the engine intake manifold in grammes per second Since the emissions control system keeps the fuel to air ratio fairly constant at all times this air flow is a strong indicator of fuel flow as well Except that is when the engine is spinning without fuel or spark MG2 Spin Rate MG2 Spin rpm MG2 spin rate in revolutions per minute Since MG2 is connected to the front wheels of the vehicle via a fixed gear train there is a simple fixed relationship between the spin rate of MG2 and the vehicle speed Depending on the rolling radius of your tires you will see about 58 to 60 r p m at MG2 for each one m p h of vehicle speed Assuming standard US tires Potenzas and nominal inflation for an effective rolling radius of 11 1 inches the exact ratio from MG2 spin rate to vehicle speed is 6000 r p m to 163 27 km hr Although speed always has a positive value the spin rate of MG2 shows negative when the vehicle moves backwards MG2 Torque MG2 Torq N m M
66. g to expose a smaller area of adhesive The padding on the bottom of the bracket as supplied will work if you use the steering wheel in the fully up position If you use a lower position you will need to add some more padding A stiff foam is good for this or you could use some more double sided foam tape without removing the backing The foam tape supplied here is not very sticky unlike the tape on the top part and can be unwound for less padding Only remove the backing if you want some extra stick to hold it in place in the car or if you want to use it to secure extra padding With your left hand hold the padded end of the bracket in the gap between the steering wheel housing and the dash With your right hand raise the steering wheel into position so that it traps the bracket You can now release the bracket and use your left hand to lock the steering wheel into position You may have to release adjust and reinsert the bracket a number of times until the grip is firm at your preferred steering wheel height and the top of the bracket is at a good angle for mounting the Mini Scanner The bracket can be easily bent with your fingers Remove all or part of the backing from the large piece of foam tape Move the Mini Scanner main unit up towards the bracket guiding any spare adapter cable back behind the dash so that it is hidden When you are happy with the position of the bracket and the main unit allow them to touch Press the main un
67. g up the TeraTerm Send File file browser dialog Using this browser locate the firmware file on your computer click on it to select it and then click the Open button The browser dialog will close a different TeraTerm Send File dialog will open and the file transfer will begin You should see dots begin to appear in the main TeraTerm Pro window as each record passes from the file to the Mini Scanner and is acknowledged as correct It will probably be necessary to move the dialog out of the way to see this Do not touch the keyboard or click the dialog buttons until the file upload is complete and the Flash Loader presents you with a new prompt The upload will take a minute or so Other Terminal Emulators You can update the Mini Scanner firmware using any terminal emulator program that can send a file in plain text format Configure the serial port for 9 600 bit s 8 data bits 1 stop bit and no parity Disable flow control Make sure you select the COM port to which the Mini Scanner is connected Note for Mark I owners skip this sidebar if you have a Mark II The Mark I Mini Scanner has an earlier version of the Flash Loader than the Mark II and an additional configuration step is needed Set the terminal emulator so that line ends are transmitted as both a carriage return and a line feed Page 26 When you send the firmware file to the Mini Scanner Flash Loader in step 6 of Firmware Update Procedure make sure you send it as pl
68. ging on to keep the mark outside your data The format of the mark is Mk 7m where n is the mark number The mark number starts at zero for the first mark after power on or reset and increases by one for each mark you drop Should you use 255 marks the next number will go back to zero So that you know which mark number to look for in the file it is briefly shown on the display You can write it down together with a description of the interesting driving event but if you re driving you should of course have someone else write it down Marking the log file can be more useful than turning logging off and on because you can drop a mark after the interesting thing happened when it would be too late to turn logging on The above actions of the Right button are effective only in Display mode In all other modes you have no control over logging Trouble Codes Mode Trouble Codes mode allows you to see any Diagnostic Trouble Codes DTCs that the car s ECU have recorded These indicate problems with the vehicle ranging from the trivial the fuel filler cap is lose to the catastrophic the engine won t start If the check engine light or Malfunction Indicator Lamp MIL comes on it is very useful to find out why by retrieving DTCs Sometimes you can fix the problem yourself but at the very least you can tell your service center something about the problem You may be able to decide how urgent a trip to the shop might be To put the Mini Scann
69. hat is extract the contents of the Zip archive You can do this with WinZip many other utilities or features built Page 22 into recent versions of Microsoft Windows What pops out of the archive is the firmware file or files you will use below to update the Mini Scanner The Flash Loader The microcontroller in the Mini Scanner stores its program in a type of memory called Flash This is the same memory as is used in CompactFlash cards FlashDrives etc The name I think originally suggested that you could change the contents of this memory in a flash as compared to other technologies available when Flash was introduced A small utility called a Flash Loader is built into the Mini Scanner during manufacture This runs before the Mini Scanner program and normally does nothing but wait for a fraction of a second before continuing However if you hook up a computer to the serial port and hold down a key as described below the Flash Loader takes control and the main program does not run You can then use simple commands to remove the current firmware and install your new version The rest of this chapter describes in detail how to use the Flash Loader to update Mini Scanner firmware Power to the Mini Scanner To update firmware the Mini Scanner must have a source of power Normally it gets its power from the car via the DLC connector This is perfectly fine for updating firmware but it does mean that you have to take your
70. he On Reset button of the Mini Scanner This will get you into the Flash Loader and you will see a banner message and then a prompt gt 5 To erase the existing firmware in the Mini Scanner press Z You will see the message erasing and after a few seconds a new prompt Note for Mark I owners skip this if you have a Mark II as it happens automatically Put the Flash 19K TI Loader in program mode by pressing p You will see the message prgm and a new prompt 6 Using the terminal emulator application send the new firmware file to the Mini Scanner in plain ASCII text format As each record in the file is read you will see a dot appear It may take several minutes to complete the update Do not interrupt the update by resetting the Mini Scanner unplugging the cable or quitting the terminal emulator application When it is finished a new prompt will appear 6699 7 Press q to quit the Flash Loader the q will not be echoed The Mini Scanner will immediately run the new firmware Of course if you are not in a car or the car is not turned on the Mini Scanner will not get a vehicle response and so it will turn itself off Either now or later re install the Mini Scanner in the car or turn the car on and then press the On Reset button to start the new firmware 8 Disconnect the serial cable 1f desired That s all there is to it The rest of this chapter discusses problems that might o
71. he more difficult side on which to get your hand and arm up behind the dash You will have an easier time if you have small hands or can find someone who has to help you Failing this everything works fine with the adapter cable passing to the right of the steering mechanism Sitting in the driver s seat take hold of the adapter cable with the marked edge usually a red or black stripe to the right The 10 pin connector on the upper end of the cable will be facing away from you Pass this connector into the gap opened by lowering the steering wheel see Photo 4 Work a few inches to the right of the center of the steering wheel or to the left if that was your choice Angle the connector up so it clears the top of the flange Feed the cable forward until several inches of it have disappeared behind the dash Keep the marked edge of the cable to the right Photo 4 Threading the Adapter Cable Now you will have to hold or tape the rest of the cable in place while you fish for the end that has disappeared and pull it down I found it fairly easy to reach up behind the dash from below with one hand while holding the cable with the other I simply groped about in there while waving the cable to and fro and soon felt the cable moving and was able to get a hold on it This may work for you if you have a good sense of where your hand is even though you can t see it and you are physically and psychologically able to wriggle your hand u
72. hreshold could be anywhere in the range less than 33 to greater than or equal to 23 according to experimental results from multiple sources Main Battery Too High Batt Too High This may be the time for which the battery has risen above the maximum state of charge which is thought to be 80 Or it could be the number of times this has happened For me it always reads zero If anyone sees anything else especially if it changes with some identifiable condition please let me know Delta SoC Delta SoC This seems to be stuck at 2096 If anyone sees anything else especially if it changes with some identifiable condition please let me know This item sounds as if it s computed by the Mini Scanner from other data but it is not It comes directly from the ECU Ignition Off Time Ig Off Hour h The average time in hours for which the vehicle ignition is off This is not the time the ignition was off before you turned it back on The value is set to zero by clearing DTCs in the Battery ECU How the average is computed has not been determined A very large number here might suggest to service personnel that you are not driving the car often Number of Battery ECU Trouble Codes Battery DTCs Presumably the number of Diagnostic Trouble Codes stored in the Battery ECU This number seems to hover in the 20s These DTCs are not retrieved by the Mini Scanner in Trouble Codes mode s
73. iddle with it now Of course if you want the drill a small hole in the case you will be able to adjust the contrast from outside The contrast is set during manufacture and you may not need to change it Hold or prop up the Mini Scanner where you will fix it in place and make sure it points in the direction you desire directly towards you when you are in the normal driving position in most cases Don t lean the unit so far back that it catches reflections of the sky in the glass front of the display Turn it on by pressing the On Reset button which is on its own at the left With the car off the Mini Scanner will power up for about ten seconds which is long enough to evaluate the display You can turn the car on if you want to you don t need to start it Look for dark text and a clear background To try different contrast settings use your 1 Phillips screwdriver to adjust the small blue variable resistor on the left hand edge of the circuit board close to the bottom Stick the screwdriver in from the left and twist it very slightly One direction will darken both the text and background of the display and the other will lighten them Find the setting that is best for you when you are seated normally and the Mini Scanner is where you want it to be when you ve secured it in place I have found that the smallest degree of darkening of the background gives the best overall clarity Use the border of the display which stays clear for all settings
74. ile upload Note that if all is well then the q is not echoed The Mini Scanner just starts right up Note for Mark I owners skip this if you have a Mark II If there are only dots no errors during the 664 99 file upload a possible cause is that you did not type p to put the Flash Loader into program mode Lots of 5 or Error 7 Messages This error means that you are attempting to overwrite data that is already in the Mini Scanner A possible cause is that you missed out step 5 in the update procedure erasing the current firmware Flash Loader Errors This section explains error messages you might see from the Flash Loader if something goes wrong If you follow the update procedure carefully and use an unZipped firmware file obtained from ECROS Technology you are very very unlikely to ever see an error Page 30 Note for Mark I owners whereas the Mark II prints just a number such as 1 in place of the dot when an error occurs the Mark I prints something like error 4 The error numbers in the Mark I were in no particular order but for the Mark II were rearranged to give an indication of how severe the problem is In summary but format and number differ In the error descriptions the Mark I error message is shown in brackets e g Mark I error 4 after the Mark II error number e g 1 no user program The Mini Scanner does not contain a user program Repeat th
75. in the various modes in which the Mini Scanner operates Page 32 Left Button Right Button Hold Tap iue Tap Hold none none Display Mark Log Toggle Logging Copy to Display Previous Slot Favorites Next Slot Set from Display none Previous Item Select Line 1 Next Item none none Previous Item Select Line 2 Next Item none Make Choice Next Option Options Next Choice Default Choice Clear DTCs Previous ECU Trouble Codes Next ECU Get DTCs To move from one mode to the next tap the Middle button To return from any mode to Display mode hold the Middle button To turn off the Mini Scanner without turning off the car press the Left Middle and Right buttons at the same time On the Mark I Mini Scanner only to have the display backlight come on when you turn on or reset the unit hold the left button down until you have released the On Reset button Appendix A Available Data Items This appendix presents a listing of the data items that you can display with the Prius Mini Scanner For methods of selecting which items to display see above Any items that appear to be available for display but are not described here are unsupported which means I probably haven t figured out what they are yet The symbols are placeholders for the actual values You will see them when a data item is first selected to a display line but they will then be overwritten with the actual
76. inal Page 28 emulator window and the Mini Scanner starts up normally the serial port and terminal emulator are correctly set up However the Flash Loader is not detecting the escape character you are trying to send it It pauses only briefly during startup to look for this character The reason that step 4 tells you to hold down the escape key is to activate the auto repeat of your computer keyboard This sends many escape characters quite quickly so that one is noticed by the Flash Loader before it gives up and starts the Mini Scanner main program If sometimes you get to the Flash Loader banner prompt and sometimes you don t there is nothing wrong with trying repeatedly until you get in If you cannot activate the Flash Loader at all check the following Make sure that you still have the escape key held down when you release the On Reset button of the Mini Scanner Make sure that before you release the On Reset button you have held the escape key down long enough to start the auto repeat feature of your keyboard Check the repeat delay setting of the keyboard in the Windows Control Panel Check the keyboard repeat rate in the Windows Control Panel If it is set too low the Flash Loader might begin and end looking for an escape in between repeats Try increasing the repeat rate There may be a break between the computer s TXD transmit data pin and the Mini Scanner s RXD receive data pin Look for damage to the cables dirty
77. indows documentation for details OK realistically just look around until you find it I will now try to tell you how to use HyperTerminal although frankly I d rather you not use it because it is an appallingly badly designed piece of software Start HyperTerminal from the Start button depending on where it is on your version of WindowsTM The Connection Description dialog will appear Click Cancel to get rid of it Now you just have the HyperTerminal main window Select File Properties on the menu to bring up the New Connection Properties dialog On the Connect To tab of this dialog bring down the Connect using pick list and select COM1 or COM2 etc according to which serial port you are using on your computer Then click the Configure button to bring up the COMn Properties dialog Set the five pick lists as follows Bits per second to 9600 Data bits to 8 Parity to None Stop bits to 1 and Flow control to None Click the OK button to accept these new settings and get rid of this dialog Now go to the Settings tab of the New Connection Properties dialog which should still be on the screen Bring down the Emulation pick list and select TTY Click the ASCII Setup button and the ASCII Setup dialog appears Check the Send line ends with line feeds checkbox Click the OK button to finish this dialog Everything else can be left at its default value Click the OK button to finish up configuration You should once again be back to th
78. ion Choice Made In our example if we hold the Left button after tapping Right twice the number of items to be requested and logged will change from 2 to 4 Some option choices are saved at power down but others are lost when the Mini Scanner turns off See the description of the various Options for details Tapping the Left button moves forwards through the list of options The display will show the next option s name on the top line and its list of choices on the second line It is not possible to move backwards through the list of options If you change the selected choice for an option and move to the next option by tapping Left that change of selected choice is lost and if you return to that option the original and currently effective choice will be shown Example This example describes how to select the Fast request rate on a Mini Scanner that is currently set for the Normal request rate and has just been turned on Tap Middle until the Select Options announcement indicates that you have entered Options mode Tap Left until the top line of the display shows Item Request Rate i e the option you wish to change Tap Right once to change the selected choice from Norm to Fast The brackets will move to confirm the change in selection Hold Left Option Choice Made will appear on the bottom line of the display and the request rate will change to fast but perhaps not immediately see belo
79. irmware file and follow the procedure described in the chapter Updating Mini Scanner Firmware Uninstalling the Mini Scanner The Mini Scanner has been designed so that you can leave it installed in your car for however long you wish When it is off it takes no power from the car and will not contribute to battery drain There will be times however when you want to uninstall the Mini Scanner either completely or partially For example the DLC adapter must be unplugged in order for a diagnostic tester to be connected to the car Your dealer s service department may want to connect a tester and a technician performing emissions testing will certainly need to do this In these situations you can simply unplug the DLC adapter from the car but be sure not to leave it dangling in the way of the pedals You may not want to make it obvious to service technicians that you are using a scanner If you unplug the DLC adapter from the car and from the adapter cable and take it away there is nothing left to really suggest a connection to the DLC You could also disconnect and remove the main unit if you think a technician might guess what is going on You could also remove the adapter cable and leave no evidence at all depending on how easy or difficult you found the installation of the cable Should you decide to remove the main unit from the car for example for a firmware upload it is perfectly safe to leave the DLC adapter and cable plugged in You c
80. it back against the bracket By putting your fingers behind the main unit you can press them together more firmly or you can drop the steering wheel take the assembly out to do this and then put it back Make sure that cables falling below the dash are tied up out of the way of the driver s feet Your Mini Scanner is now installed Checking the Mini Scanner To check that your Mini Scanner is installed and working properly turn it on by pressing the On Reset button This is on the top at the far left hand side The display will show the firmware version for example Mini Scanner 0 61 and then below it the message 1SO9141 Slow Init If the car is not turned on after a few seconds the display will change to Slow Init no resp and soon after that the Mini Scanner will turn itself off If the car is turned on the display will begin showing data being retrieved from the ECUs Page 8 Detailed instructions on operating the Mini Scanner can be found below No harm can be done by pressing buttons at random but unless you read the rest of this User Manual you will probably fail to find some useful functionality Diagnosing Problems If when you press the On Reset button nothing happens the Mini Scanner is not getting power or has been severely damaged in shipping Check that the connectors at both ends of the adapter cable are properly seated on all header pins of the DLC adapter and the main unit Make sure the DLC adapter
81. item value retrieved from the vehicle For example Battery SoC will be replaced with something like Battery SoC 57 5 95 when the vehicle responds to a request for the value of the SoC Listing of Data Items The order in which items are listed here corresponds to the order in which they appear in the Mini Scanner s Select Line modes I have tried to keep the more interesting items early in the list and also at the very end since you can go backwards around the list Until the list stabilizes a new release may mess up your favorite selections so you might want to keep a written record of your favorites and check them after uploading new firmware Main Battery State of Charge SoC Battery SoC Main traction battery state of charge SoC in percent Experiments suggest that this percentage is referenced to the full rated capacity of the battery which is 6 5 ampere hours You can use the SoC value to estimate how willing the car will be to run on battery power only For example at 60 or higher you can draw up to about 30 amps from the battery before the engine starts up At lower SoC the current at which the engine starts is Page 33 reduced Correlating the indicated SoC with the battery icon on the Energy Monitor display results in some surprises The table below shows the SoC points at which the icon changes state in the charging and discharging directions These were determined by independe
82. lay a diagnostic message and turn itself off The most likely cause of this is that the car is not turned on Turn the car on and try again You can press the On Reset button to restart the Mini Scanner at any time It is not necessary to wait for it to turn itself off The Mini Scanner turns itself off soon after you turn off the car It does this by noticing that the car has stopped responding to requests for information A message to this effect will be displayed for a few seconds before the unit actually powers off If this message appears while the car is on a problem has developed Should you ever find that the Mini Scanner does not turn itself off when the car is turned off uninstall it at once and contact ECROS Technology to arrange for repair If you want to turn the unit off while the car is still turned on press all three of the Left Middle and Right buttons at the same time The Display Backlight Control of the Mark II Mini Scanner display backlight is automatic If it gets dark the backlight comes on and if it gets light it turns off In dawn and dusk conditions when there is some light but not enough to easily read the display the backlight is bright In deeper dark the intensity is reduced so as to maintain readability without glare The light sensor that makes this possible is behind the small dot on the front panel below the On Reset button If you cover this up backlight control will not work properly Whether user cont
83. lways powers up in Display mode and returns to this mode on a reset To cycle through the modes in the order listed above tap the Middle button To return to Display mode from any other mode hold the Middle button In some modes the Mini Scanner returns automatically to Display mode after a period of time in which no buttons are pressed Selecting Data Items to Display This chapter of the User Manual is concerned with how data items are selected for display from the more than 50 available see Appendix A Available Data Items Introducing Slots For reasons connected with the Mark I s two line display the Mini Scanner currently lets you select data items in pairs Each pair of data items makes up a slot There are eight slots available the Display Slot and seven Favorite slots numbered from 1 to 7 So you can set up the Mini Scanner with up to sixteen data items two in each of eight slots and quickly switch among them as described below The Display Slot The data items in the Display Slot appear in the top two lines of the display when the Mini Scanner is in Display Mode This is the mode in which you will normally have the Mini Scanner and the mode entered when you turn it on or reset it Therefore the data items you put in the Display Slot are typically the ones you re currently interested in The data items in the Display Slot are the easiest to change If you put the Mini Scanner in a Select Line mode you can
84. ly legally mandated information mostly related to emissions testing is available on that bus All the interesting data has been removed to the Controller Area Network CAN bus The Mini Scanner does not work with the 2004 model year Prius All the work of figuring out how to get the data from the car needs to be done again before a Mini Scanner like device can be made for that car Page 2 Installing the Prius Mini Scanner In this chapter of the User Manual I describe the installation of the Mini Scanner in your car I will assume that you want to fix the Mini Scanner behind the steering wheel If this isn t the case you ll need to adapt these instructions to your needs You should still read this section of the manual to find out how to correctly connect the cables The level of detail I give is intended to allow people with no experience of electronic equipment to complete the installation with ease I apologize if this makes tedious reading for some of you Installation as described here is completely reversible No holes are drilled wires cut or even spliced and nothing is stuck to the car If you take the Mini Scanner out of the car it is impossible to tell that it was ever there All instructions are written with reference to a left hand drive vehicle Owners of right hand drive vehicles should experience no particular problems adapting them hia XL NECS gt Unpacking the Mini Scanner The printed Read Me First Quick Start
85. mly together The edge of the cable marked with a red stripe will be to the right and the cable will lead directly away from the adapter rather than folding over the top of the connector as shown in Photo 6 Photo 6 Mark II DLC Adapter The Mark I DLC adapter is a little larger than the Mark II shown here but installation is otherwise the same Original Mark 1s not remanufactured do not have pin one snipped off to prevent the cable from being installed incorrectly so a little more care is needed Locate the Diagnostic Link Connector DLC or DLC3 To do this kneel on the ground outside the car next to the driver s side door Duck your head into the pedal area and look up underneath the lower edge ofthe dash You will find the DLC fixed in a recess in the plastic dash molding Once you know where the DLC is it will no longer be necessary to kneel down to find it you will be able to plug in the adapter by touch Plug the DLC adapter into the DLC It will only fit one lt lt lt new photo gt gt gt way Turn the adapter so that the red connector faces up Photo 7 Connecting to the DLC and is closer to you than the side to which cable is attached As you do this you will put a half twist in the cable and the marked side will now be on the left Tip the top of the adapter towards the front of the car and align the red plug with the DLC Press the adapter board firmly behind the red plug to seat it Photo 7 shows the DLC adapter
86. n P3002 HV ECU communication malfunction P3005 High voltage fuse snapped sic Presumably P3005 would also be recorded if an attempt was made to start up with the service plug removed as the high voltage fuse is physically located inside the plug P3006 Battery SOC are uneven P3006 not too sure about this but criterion appears to be maximum permitted difference between highest block voltage and lowest block voltage at any instant not including transients is 1 2 volts P3009 Leak detected P3009 Leak detected meaning a current leakage path the high voltage circuitry to the chassis has been detected Trigger level not known but the criterion for manual testing is insulation resistance not less than 10M ohms when tested at 500V DC P3010 Battery total resistance malfunction P3011 to P3029 Battery block malfunction The traction battery consists of 38 physical modules each containing 6 cells For the Page 42 purposes of monitoring by the battery ECU modules are paired into 19 blocks DTCs P3011 to P3029 appear to indicate the malfunction of a particular block although what malfunction means is not clear P3030 Battery voltage detective line snapped sic P3030 presumably means open circuit of one of the twenty voltage sense lines which are connected to the cell string at the ends and between each block P3060 Battery temperature sensor circuit malfunction P3076 Abnormal air flow by battery co
87. nner take account of the differences noted in this section when installing the main unit The Mark I case has loose end panels and you need to be careful not to lose them when you open the case and to guide them back into their slots when you reassemble it The header to which the adapter cable must be connected is in a completely different place It is slightly to the left of center on the lower edge of the circuit board and is labeled JP3 At the far right there is another very similar header labeled JP4 which is for the Mark I serial cable not the adapter cable If you connect the adapter cable to the wrong header you will not damage anything but the Mini Scanner will not work and the car will set the Check Engine Light The mounting bracket for the Mark I is fixed to the main unit by the bottom two screws that hold the case together Therefore replace the two screws closest to the buttons first and remember to put the bracket in place before inserting the remaining two screws The adapter cable passes underneath the bracket Make sure it is lying flat and is not folded Adjusting the Display The type of display used in the Mini Scanner is a Liquid Crystal Display LCD So that the text is clearly readable from the normal viewing position it may be necessary to make an adjustment to the contrast setting It is not particularly critical but since you cannot make the adjustment once the case is closed up you might want to f
88. nt experiments on US and UK Prius The EMPTY icon was not seen down to 22 SoC The maximum SoC achieved was 80 Charging Rising SoC Discharging Falling SoC SoC Battery Icon SoC Battery Icon 74 5 75 3 4 FULL 72 71 5 FULL 3 4 57 5 58 1 2 3 4 55 54 5 3 4 gt 1 2 44 5 45 1 4 1 2 42 41 5 1 2 gt 1 4 not known EMPTY gt 1 4 below 22 1 4 gt EMPTY Two things immediately stand out The range of SoC represented by each icon state is not uniform The 3 4 icon covers an SoC range of 17 but the 1 2 state covers only 13 The 1 4 icon appears to cover 20 or more and the FULL icon less than 10 if the maximum possible SoC is indeed 80 There is a hysteresis of 3 between icon state changes in the charging and discharging directions As a result the 3 4 icon can be displayed for SoCs in the range 55 to 74 5 If the car is not driven at low speed for many miles the SoC will not fall below 55 so it is no wonder that some people report that their battery icon never changes The battery icon should therefore be interpreted only as a very rough measure of battery SoC Main Battery Charge Current Current ICI A Main traction battery current in amperes The displayed value is positive for charge current into the battery and negative for discharge current out of the battery You can use this value in conjunc
89. o maybe they are in some sort of yet to be confirmed state If you clear DTCs in the Battery ECU the number does go to zero but soon increases again The relevance of this data item has not been determined Further investigation is needed Battery Air Temperature Sensor Batt Air Temp C The air temperature inside the main battery housing or something like that Maybe the exhaust air temperature that is the temperature of the air blown out by the fans Anyway this and the following four data items are going to give you an indication of how hot the battery is and perhaps explain a Mister Turtle lamp on the dash Battery Temperature Sensor 1 Battry Temp 1 C The temperature registered by battery temperature sensor number 1 Page 40 Battery Temperature Sensor 2 f Battry Temp 2 C The temperature registered by battery temperature sensor number 2 Battery Temperature Sensor 3 Battry Temp 3 C The temperature registered by battery temperature sensor number 3 Battery Temperature Sensor 4 Battry Temp 4 C The temperature registered by battery temperature sensor number 4 Lowest Battery Block Voltage Min Bat Blk V The lowest voltage of all battery blocks in volts A battery block is a pair of modules that are monitored as a unit by the battery ECU Each module consists of six cells so with twelve cells in total
90. oling fan P3077 Battery cooling fan motor circuit malfunction P3115 HV battery current sensor malfunction Engine ECU Diagnostic Trouble Codes Engine ECU SAE Controlled These items are taken from the table Engine Diagnostics SAE controlled on pages DI 14 to DI 16 in the Engine Diagnostics chapter of the Repair Manual Page 43 PO100 Mass Air Flow Circuit Malfunction P0101 Mass Air Flow Circuit Range Performance Problem P0110 Intake Air Temp Circuit Malfunction P0115 Engine Coolant Temp Circuit Malfunction P0116 Engine Coolant Temp Circuit Range Performance Problem P0120 Throttle Pedal Position Sensor Switch A Circuit Malfunction P0121 Throttle Pedal Position Sensor Switch A Circuit Range Performance Problem P0125 Insufficient Coolant Temp for Closed Loop Fuel Control P0128 Thermostat Malfunction P0130 Heated Oxygen Sensor Circuit Malfunction Bank 1 Sensor 1 Except Calif P0133 Oxygen Sensor Circuit Slow Response Bank 1 Sensor 1 P0135 Oxygen Sensor Circuit Malfunction Bank 1 Sensor 1 P0136 Oxygen Sensor Circuit Malfunction Bank 1 Sensor 2 P0141 Oxygen Sensor Heater Circuit Malfunction Bank 1 Sensor 2 P0171 System too Lean Fuel Trim P0172 System too Rich Fuel Trim P0300 Random Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected P0
91. or bent contacts etc I Don t Get Dots in Step 6 Very important note for Mark I owners skip this section if you have a Mark II About half of Mark I owners hit the problem described here They were people who knew how to set up HyperTerminal and therefore did not follow the instructions If you are reading this before performing a firmware update please set up HyperTerminal exactly as described or even better use TeraTerm Pro In the Mark II the Flash Loader has been improved so that the problem cannot occur If you get to the Flash Loader banner and everything seems to be working but when you send the firmware file to the Mini Scanner in step 7 you don t get dots as each record is processed your terminal emulator program may be suppressing line feed characters To test this start again You ll have to stop the file transfer or quit the terminal emulator program Once you have the terminal emulator going again try pressing the escape key to get back to the Flash Loader prompt If this does not work you will have to reset the Mini Scanner again Once at the prompt hit the Enter key several times If the mode announcement and prompt appear each time see I Still Don t Get Dots below If nothing happens the line feeds are not getting through Explore the settings of your terminal emulator looking for line end processing options Choose line feed or both carriage return and line feed Carriage return on its own will not work Instructions
92. oximate time at which the data item was sampled and had that value The timestamp is given in seconds Timestamps start at zero when you turn on or reset the Mini Scanner and do not represent real world or wall clock time The long term accuracy of the timestamps has not been measured but will be of the order of a second per hour The resolution of the timestamp is one millisecond but this is not its short term accuracy Do not assume that the logged data samples are as precisely placed in time as the timestamp resolution suggests When the data is actually sampled by an ECU in the vehicle is not known It could be sampled at some regular rate so that a request for the data returns the most recent sample whenever that was taken Or it is also possible that the sampling of data is triggered by the request on the OBD II bus But exactly when this happens in relation to the request message and response is not know The Mini Scanner records the timestamp from an internal clock when the first octet of the vehicle s response is received Page 18 Log Format The format in which timestamps and data are sent to the serial port is designed to be logged in a file and then imported into a spreadsheet The data can then be analyzed and visualized as a chart The timestamps and data values are separated by tab characters so when importing to a spreadsheet program specify the file type as a tab delimited text file The format is best explained by an
93. p into the innards of the car Another approach pioneered by someone close enough to drive to my house to pick up his Mini Scanner is to fish for the cable from below with a bent wire This requires you to lie on your back in the driver s foot well but with a flashlight you have the advantage of being able to see what you re doing When you get hold of the cable from below pull most of it down leaving just a couple of inches sticking out behind the steering wheel see Photo 5 This end of the cable can be Page 4 jiggled into the right place to connect to the lt lt lt new photo gt gt gt Mini Scanner main unit later Check that the Photo 5 A Couple of Inches marked edge of the cable is still to the right and that the 10 pin connector on the end of the cable faces away from you towards the front of the car Plugging in the DLC Adapter The DLC adapter should next be connected to the lower end of the adapter cable that is hanging into the driver s footwell Hold the adapter with the red plug at the top and facing towards you Locate the header a group of gold pins in the lower right hand corner The connector on the cable fits over these pins Put the connector over the header making sure all the pins sticking up from the DLC adapter line up with holes in the connector As pin one is snipped off and its hole in the connector is plugged up it should not be possible to get this wrong Squeeze the connector and adapter fir
94. programming hardware Return the Mini Scanner for repair 7 Mark I error 8 The microcontroller failed to write the new firmware into its memory Return the Mini Scanner for repair 8 Mark I error 6 or 9 The firmware file contains data to be written to an address reserved by the Flash Loader for its own use It has been constructed without proper regard for the rules that allow it to work with the Flash Loader Obtain a new firmware file The difference between errors 6 and 9 in the Mark I are subtle and not helpful to the user 9 Mark I error 0A You aborted a download by pressing the escape key Advanced Use of the Flash Loader In addition to updating firmware you can use the Flash Loader to verify that the firmware in the Mini Scanner corresponds to a particular file This is useful to make absolutely sure that an update worked and also to find out what firmware you are running if you lose track Follow the basic procedure but in step 5 don t erase the firmware and instead type v for verify You will see the message vrfy and a new prompt When you send the file using the terminal emulator dots should appear just as before If there is a difference between the file and what is in the Mini Scanner the message 1 or for the Mark I Page 31 error 4 will appear instead of a dot for each record of the file in which there is a mismatch To perform a verify operation immediately after a new
95. re The Prius Mini Scanner contains a very small highly integrated computer system called a microcontroller The software program running on the microcontroller defines what the Mini Scanner does It looks to see if you ve pressed a button communicates with the car and puts information on the display A computer has many different programs stored on disk one or more of which are loaded into memory on your command By contrast a microcontroller has just one program fixed directly into memory that always runs when the system is turned on For this reason what you probably think of as software is given the slightly different name of firmware It is firm rather than soft because it takes a little more effort to change Hardware of course is hard because you re stuck with it Nevertheless firmware can be changed with the right facilities and this chapter tells you how to go about just that From time to time ECROS Technology may release a new version of the Mini Scanner firmware Just as with Microsoft amp products the purpose of this is to introduce new bugs and obscure essential functionality with unnecessary features No of course what I hope to do is correct any problems that might arise and add more useful features I was just joking Bill please don t sue me Unless you ask to be removed from mailing lists you will be notified of new firmware versions by e mail This will include a description of what problems are fixed or
96. rols over the Mark II backlight are necessary will be decided according to feedback from owners Options to disable the automatic operation so that the backlight is always on or off and to adjust the average brightness can be added by a firmware update Note for Mark I owners skip this sidebar if you have a Mark II The Mark I Mini Scanner does not have automatic backlight control An option is available to turn the backlight on and off Also you can have the backlight come on when you turn on or reset the Mark I Mini Scanner by holding down the Left button Do not release the Left button until after you release the On Reset button Left Middle and Right Buttons The Mini Scanner is controlled by three buttons if we set aside the On Reset button These are called the Left Middle and Right buttons Button Functions The Left Middle and Right buttons have different actions at different times according to what the Mini Scanner is currently doing However each has certain common functions which help you remember how to operate the unit The Middle button is associated with mode changes 1 Getting at all the the functionality of the Mini Scanner with only three buttons may appear awkward and at first difficult to remember If more buttons were used operation might be simplified somewhat but the cost and size of the Mini Scanner would increase The three buttons give a control scheme that becomes fairly easy to use after some
97. rrent sensor malfunction W phase main sensor 337 Generator Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 338 Generator Inverter Current Sensor Malfunction Open in generator inverter current sensor W phase main sensor 339 Generator Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 340 Generator Inverter Current Sensor Malfunction Generator inverter current sensor W phase performance problem 341 Generator Inverter Current Sensor Malfunction when there is a history that the state of malfunction continued during inverter fail safe mode 342 Motor Gate Shutdown Signal Line Connection B short in generator gate shutdown signal 343 Motor Gate Shutdown Signal Line Connection Open or GND short in generator gate shutdown signal circuit 344 Failure in Monitoring Generator Torque Performance 345 Abnormal Current Value of Generator P3130 Inverter Cooling System Malfunction 346 Water pump system malfunction 347 Electric cooling fan system malfunction P3135 Circuit Breaker Sensor Malfunction 348 GND short in circuit breaker sensor Page 56 349 Open or B short in circuit breaker sensor P3140 Interlock Malfunction You can make this DTC happen quite easily and safely by removing the service plug from the main battery and turning the car on 350
98. s mode and Trouble Codes mode or you can just hold Middle which sends you from any mode straight to Display mode If you are selecting the item for the second line and you change your mind about what you want to see in the top line you need to get back to Select Line 1 mode You can t go backwards through the modes so the easiest thing to do is to hold Middle getting back to Display mode and then tap Middle twice Page 13 Setting and Saving Favorite Items As mentioned above Favorite slots are different from the Display slot in that they cannot be set directly but the Mini Scanner remembers the items in them when it is turned off So the next thing is to learn how to set the items in Favorite slots After you have used the Mini Scanner for a while it is best to come up with a plan of what items you will store If you don t yet have a plan pick any items just to get used to using Favorites Let s start by setting the items in Favorite Slot 1 Perhaps we want to store in this slot the engine r p m and coolant temperature First set these items into the Display slot as explained in the previous section Next we need to go to Favorites mode From Display mode this is one tap of the Middle button When you enter this mode the display will announce the current Favorite slot from 1 to 7 for a moment and then begin retrieving and displaying the data items in that slot There is no explicit indication that you are in Favorites mode so you have
99. s ovn tetatii n ds ab Po DOR Com ev Ra 10 Uninstalling the Minit Scanner ood roe te ep rer eese oed repete e peine eodem aa 10 Basic OperatIOB duod krassandi tipo t aeg va E ax nanna 10 Turning the Mini Scanner On and OTT ius ase ac e eye Cs mls op dk a qu eaa ck ER eee 10 Th Display Backlight i oe oer reor ar eoe etr a obice o ba Sx CHO e aD ROM RN UU 11 Left Middle and Right Butts a soo na fali a D an 11 B tton FUNCIONS encrena eo un Cua aae Taea aeae Gupta Na Ua Deu ctt cde 11 Tapcantf Hold 63 dee gne rib Io ples obe te omnc Cum rer dette ues 12 Aes T M naga 12 Selecting Data Items to Display oo der Ub etd aite ree betae aedes 12 Introducing Slots Laer a each debt gar p appa en Ga ay e eR aola e mta 12 Selecting Display MMS a i o ute erecti tote ann 13 Setting and Saving Favorite tems use oae apes co ir ede eris nc iue ex aep Dn 14 Using Favorite otiosus ou done gaga A a a Ga A DR CR ee 14 Choosing Opna a octo a coe es PU Deui ga pn 15 Prius Mint Scantier Options isan tri ie Cei ea vr sin deris ede reat 16 Logging Data via the Serial POL sco oerte diete veoh etse eno fuero sea ee cdeonshcacpedscntuees 18 TS A gece ants ae s f ea ana rede Dhu a a a quie i UR eue dec haee a 18 LOS Format artea a AI DR Cus A AR sg 19 Creating a Chart in a Spes raska Ba e ea ond ue ab eode ad 19 Got uentos n tdem aie inst iet aequ e uates aaa stie dein c pU E DU nd 20 Trouble C odes Mods ing icta ast
100. see the file being sent but this will obscure the responses of the Flash Loader somewhat The last line of data sent from the file should look something like this 00000001FF Windows NT and HyperTerminal have been reported to malfunction in the way we re now discussing The only known solution is to forget HyperTerminal and get a decent terminal emulator such as TeraTerm Pro I Get Some Dots Then They Stop Inspect the firmware file to make sure it s all there If somehow part of the file has been chopped off the firmware update will just stop in the middle Look at the last line of the file in a text editor such as Notepad It should be the end of file record which looks something like this 00000001FF The 01 in the eighth and ninth positions are the end of file record type and must be correct although other characters may be different If the file is corrupt you will need to get another one Another possibility is that the file send operation was terminated somehow If the terminal emulator program allows you to abort a transfer did you accidentally do this I don t want to beat this point to death but if you re using a 9 V battery you did make sure it s not on its last gasp didn t you It hasn t just died has it New Program Does Not Run If after successfully following the basic update procedure you get the message no user program when you type q the update did not take place Look for error messages during the f
101. t temperature in degrees Celsius With city driving in hot weather my engine temperature rises to 89 C which I presume is the point at which the thermostat opens The Toyota Repair Manual Volume 1 Diagnostics describes this as Engine coolant Temp Sensor Value and goes on to say that after warming up you should expect values in the range 80 95 C 176 203 F The blue cold engine light goes out when the engine coolant temperature reaches about 50 C The car will not stop the engine and run on battery power until the temperature reaches about 71 C However once this has happened the engine can cool to about 59 C before the car insists on running the engine again o Ignition Spark Advance Spark Advnce Cylinder one spark timing advance in degrees of crankshaft rotation It is very interesting to watch this during the first minute after you start the car It goes negative representing a timing retard The fuel air mixture is being ignited as the piston descends Very little energy is extracted which is why the car runs on battery power at this time watch the battery current also So the exhaust gas remains very hot and quickly heats up the oxygen sensors and catalytic converter to gain control over emissions The Toyota Repair Manual Volume 1 Diagnostics describes this as Ignition Timing of Cylinder No 1 and goes on to say that when idling you should expect to see values of BTDC 7 Page 35 15 de
102. ta Repair Manual Volume 1 Diagnostics Cyl 2 describes these items as Abnormal revolution variation for each cylinder It should normally be 0 Cy1 3 which is certainly the case for me A careful reading of the manual suggests that a non zero value for these EXT ETE PEE items would indicate that the cylinder is not contributing its fair share of drive power due for example to persistent mis fire abnormality in ignition or incorrect injection of fuel DC Inhibit Time DC Inhib Time This may be the time for which the DC to DC converter has been turned off to reduce the drain on the high voltage battery during periods of heavy use Or it could be the number of times this has happened For me it always reads zero If anyone sees anything else Page 39 especially if it changes with some identifiable condition please let me know Main Battery Too Low Batt Low Time This item is described in the repair manual Volume 1 as Cumulative number of times of battery dies For me it always reads zero It has been reported to increase to 1 after running the car out of fuel and continuing driving to a very low battery SoC No apparent harm came to the car as a result of this In particular the car started right up after fueling So dies in the Toyota description can probably be interpreted as falls to a lower SoC than is permitted in normal operation This battery dies t
103. tion with the battery state of charge to influence whether the car runs on battery power only or starts the engine In city driving especially with small hills you can obtain a noticeable improvement in fuel economy by extending periods of battery only driving and using the engine in a pulsed fashion to accelerate and climb hills You can also use this value to learn a braking strategy that avoids the use of the friction brakes and therefore maximizes the energy recovered by regenerative braking Vehicle Speed Speed II km hr Vehicle speed in kilometers per hour The Toyota Repair Manual Volume 1 Diagnostics says that when the vehicle is stopped the value should be 0 km hr How much does that manual cost again Vehicle Speed in Miles per Hour Speed ILL m p h Vehicle speed in miles per hour Since the ECUs respond to a request for vehicle speed in kilometers per hour this number is computed by dividing the result by 1 6 This should be accurate enough for Europeans to know by how much they re exceeding the speed limit in the United Kingdom However if you re recording speed via the serial port Page 34 to perform some off line calculations it is better to obtain the speed in kilometers per hour and compute the figure in miles per hour yourself if necessary Engine Spin Rate Tachometer Engine rpm Engine spin rate in revolutions per minute Throttle Position
104. to keep track of this You always enter Favorites mode in Favorite slot 1 The two data items you set into the Display slot are no longer visible but they are still there To copy them to the current Favorite slot hold the Right button Now you have set the items in this slot The Mini Scanner returns to Display mode ready for you to select new items and save them in another Favorite slot In Favorites mode tapping the Right and Left buttons moves forwards and backwards through the Favorite slots For example if when we entered Favorites mode above we had tapped Right twice before holding right we would have copied the items in the Display slot into Favorites slot 3 instead of 1 If you should want to copy the items from a Favorite slot into the Display slot go to that slot and hold the Left button instead of the Right which copies from the Display slot to the Favorite slot Using Favorite Slots Now that we have described how to set the data items in the Display slot and the Favorite slots it is time to explain what Favorite slots are for This will be easier to appreciate once you ve formed a plan of what items you re most interested in If possible make a tentative plan now and set up a few slots with data items you ll recognize If you go to Favorites mode one tap of Middle from Display mode and go to a Favorite slot tap Right and Left but don t hold any buttons to copy the slot the Mini Scanner just retrieves and displays th
105. ugh cranking it P3105 Battery ECU Communication Circuit Malfunction 206 When communication between battery ECU and HV ECU is abnormal 1 sec after ignition is turned ON 207 When communication between battery ECU and HV ECU is abnormal 1 sec after ignition is turned ON 208 When communication between battery ECU and HV ECU is abnormal 1 sec after ignition is turned ON P3106 ECM Communication Circuit Malfunction 209 When communication between ECM and HV ECU is abnormal 1 sec after ignition is turned ON 210 When communication between ECM and HV ECU is abnormal 1 sec after ignition is turned ON 211 When communication between ECM and HV ECU is abnormal 1 sec after ignition is turned ON 212 Input of abnormal signal from ECM 394 When ECM does not operate P3107 Airbag ECU Communication Circuit Malfunction 213 When communication between airbag ECU and HV ECU is abnormal 10 sec after ignition is turned ON 214 When communication between airbag ECU and HV ECU is abnormal 10 sec after ignition is turned ON 215 When communication between airbag ECU and HV ECU is abnormal 10 sec after ignition is turned ON P3108 A C Amplifier Communication Circuit Malfunction 216 When communication from A C amplifier to HV ECU is abnormal 217 When communication from A C amplifier to HV ECU is abnormal P3109 Brake ECU Communication Circuit Malfunction 218 When communication between brake ECU and HV ECU is
106. uld store the two items you want to see at the top of the display by default Choosing Options In Options mode the Mini Scanner allows you to set various options Details of the options themselves are given below First we describe here the general mechanism of choosing options To get to Options mode from Display mode tap Middle four times Upon entering this mode the mode announcement will display for a short time Then the first option will be presented The top line of the display shows the option name for example Items to Request Log The second line of the display shows the available choices for that option forexample 2 3 4 5 6 The currently selected choice is shown in brackets So the display described above means that the number of items to be requested and logged is 2 Use the right button to change the selected choice Tapping the Right button moves the selection forward thought the list of choices Holding the button sets the selection to the default choice It is not possible to go backwards through the list of choices Therefore options will be arranged to have a small number of choices In our example tapping Right twice will change the selected choice to 4 and the bottom line of the display will appear thus 2 3 4 5 6 Selecting an option choice does not put that choice into effect To do this hold the Left Page 15 button The choice is now effective and the bottom line of the display reads Opt
107. w for details Hold Middle to return to Display mode Prius Mini Scanner Options This section of the Prius Mini Scanner User Manual discusses the options that can be set in Options mode Items to Request Log This option sets the number of data items that will be requested from the vehicle The default is two so that the two data items selected into the current slot are requested and displayed In Display mode these are the items in the Display slot In Favorites mode these are the items in the current Favorite slot Other choices for the option are from 3 up to 6 The additional data items requested are defined by the next sequential slot s to the current slot For example in Display mode the third requested item is the first from Favorite slot 1 the fourth is the second in Favorite slot 1 etc Normally only the first two data items are displayed Four items would be displayed if the Display Method is set to Compress or if a 4 line display unit is installed However if logging via the serial port is active all requested items are logged After the first two items in columns two and three of the log file additional items appear in order in consecutive columns For example if the number of items is set to three the third item will appear in column four Page 16 The selected choice for this option is saved at power down and will be effective at the next power up Display Method This option is only for use in the Mark
108. y will click when they are all the way in If you have a Mini Scanner Mark I make sure the 10 pin connector is properly seated over all ten pins of the serial port header inside the main unit If you have a Mini Scanner with a debug port and have used it to replace the firmware you will have erased the Flash Loader You will need to put it back before you can use it again A ZiLOG ZDS II project to accomplish this was e mailed to you at about the time you received your Mini Scanner Check the items in the next section also I Get a Short Burst of Garbage If when you release the On Reset button in step 4 you get something in the terminal emulator window but it consists of punctuation and other garbage characters check the following Check the serial port configuration settings of the terminal emulator You should be using 9 600 bit s 8 data bits no parity and 1 stop bit If you are using a telephone cord other than the one supplied with the Mini Scanner Mark II make sure it is of the cross over kind If you hold up the little clear plastic plugs turn them the same way round and peer inside you should see the colored wires arranged in the opposite order at each end If you are using a serial cable extension make sure it is of the straight through kind and not a null modem cable Try without the extension I Get a Row of Dots If when you release the On Reset button in step 4 you get a row of dots in the term
109. you are planning to power your computer from the car look out for grounding problems lt lt To do expand and clarify gt gt Terminal Emulator Programs The computer or other device you use to update firmware must be able to run a kind of program called a terminal emulator This allows the computer to act as a terminal Whatever you type on the keyboard is transmitted to some other device that you have connected to and anything that device sends back is displayed on the screen Above we have connected to the Mini Scanner using the serial COM port but typically terminal emulators will also work with other connections such as the Internet The Microsoft WindowsTM operating system includes a terminal emulator program called HyperTerminal The Prius Mini Scanner Welcome CD ROM includes a freeware terminal emulator called TeraTerm Pro ECROS Technology recommends that you use TeraTerm Pro Not only is it easier to use but it completes the update in a quarter of the time as compared to HyperTerminal Other terminal emulators are available for the Windows Linux and Mac operating systems and will all work for firmware updates HyperTerminal Versions of Microsoft WindowsTM since about Windows 95 have included a Terminal Page 24 Emulator called HyperTerminal On Windows XP you can find it at Start Programs Accessories Communications HyperTerminal In other versions it may be in different places consult the W

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