13my rav4 ev cert app final

TOYOTA

Application For Certification - Part 1

2013 Model Year

Durability Group : DTYXEEENNZZZ

Evap/refueling Families : N/A

Test Group : DTYXV00.0DA9

Test Group Description : Battery Electric Vehicle (BEV)

LDV

Applicable Standards : Tier 2 - Bin 1 (Federal)

LEV II - ZEV (California)

Carlines Covered : RAV4 EV

Vehicles Tested:

Vehicle I.D. Configuration Test Test Number

12-QA1E 00 FTP CTYX10022452

12-QA1E 00 HWFET CTYX10022451

12-QA1E 01 FTP CTYX10021707

12-QA1E 01 HWFET CTYX10022450

EPA Response Requested By: January 4, 2013 For Questions, Contact: Tony D’Ambrosi 734-995-2586

Table of Contents

Section 1 Correspondence and Communications

Section 2 Durability Group Description

Section 3 Evaporative / Refueling Family Description

Section 4 Durability Procedure Description

Section 5 Test Group Description

Section 6 Test Vehicle Description

Section 7 Test Results

Section 8 Emission Testing Waiver Statements

Section 9 OBD System Description

Section 10 Description of Alternative-fueled Vehicles

Section 11 AECD Descriptions

Section 12 Description of Vehicles Covered by Certificate and Test Parameters

Section 13 Projected Sales

Section 14 Request for Certificate

Section 15 Other Information

Section 16 Confidential Information

Section 17 California ARB Information

Page: 0-DTYXV00.0DA9-1

Issued: 12/04/2012

1. Correspondence and Communications

1.1 Mailing information

Corporate name and address to appear on Certificates of Conformity/Executive Orders

Toyota Motor Corporation

1, Toyota-cho, Toyota,

Aichi, 47l-8572

Japan

Person and address to whom the Certificates of Conformity should be mailed

Toshio Yoshidome

Vice President

Toyota Motor Engineering & Manufacturing North America, Inc.

Toyota Technical Center

1588 Woodridge Avenue, RR#7

Ann Arbor, Michigan 48105

U.S.A.

Person and address to whom the Executive Orders should be mailed

Hiroshi Shimo

Manager

Vehicle Regulation and Certification Engineering



1630 West 186th Street

Gardena, California 90248

U.S.A.


Issued: 12/04/2012

1.2 Responsible official

Names and title of persons authorized to communicate with EPA and CARB



Toshio Yoshidome --- Vice President, Powertrain Design & Tuning/Chassis Design/Regulation &

Certification

Kevin Webber --- General Manager, Vehicle Certification and Regulation Engineering

Fumito Chiba --- General Manager, Powertrain Certification & Test Engineering

Vehicle Regulation & Certification Engineering (Ann Arbor Office)

Main Phone No. (734) 995 - 2600

Fax No. (734) 995 - 9049

Name Title Phone No. E-mail Address

Matt Kevnick Senior Principal

Engineer

(734) 995-3755 [email protected]

Masahiro Konno Group Coordinator (734) 995-3753 [email protected]

Thomas Beierschmitt Senior Principal

Engineer

(734) 995-3743 [email protected]

Tony D’Ambrosi * Principal Engineer (734) 995-2586 [email protected]

Vehicle Regulation & Certification Engineering (Los Angeles Office)

Main Phone No. (310) 787 - 5500

Fax No. (310) 787 - 5655


Hiroshi Shimo Manager (310) 787-5867 [email protected]

Michael Lord Senior Principal Engineer (310) 787-5644 [email protected]

Mort Smith * Principal Engineer (310) 787-5647 [email protected]

Naomi Kruse Certification Assistant (310) 787-5510 [email protected]

Powertrain Certification & Test Engineering

Main Phone No. (734) 995 - 2600

Fax No. (734) 995 – 5971


Fumito Chiba General Manager (734) 995-3745 [email protected]

Will Meschievitz * Specialist (734) 995-6831 [email protected]

Julie Worster Associate (734) 995-3715 [email protected]

(*: Primary contact)


Issued: 12/04/2012

2. Durability Group Description

2.1 Durability Group Name: DTYXEEENNZZZ


Issued: 12/04/2012

3. Evaporative / Refueling Family Description

Not Applicable (N/A) for EV


Issued: 12/04/2012

4. Durability Group Description

Durability procedures and deterioration factors are N/A for EV.


Issued: 12/04/2012

5. Test Group Description

5.1 Test group name : DTYXV00.0DA9

5.2 Engine displacements covered : N/A

5.3 Fuel Type : Electricity

5.4 Vehicle class covered : LDV (Federal)

5.5 Federal emission standards class : Tier 2 - Bin 1

5.6 California emission standards class : LEV II - ZEV

5.7 Applicable emission standards : Please reference Certification

Summary Information Report in Section 7


Issued: 12/04/2012

6. Test Vehicle Description

Vehicle I.D. * Configuration Vehicle Type Test Performed

12-QA1E 00 (ext. range charge) Certification FEDV FTP & HwFET All-Electric Range Test

12-QA1E 01 (standard charge) Certification FEDV FTP & HwFET All-Electric Range Test

* For detailed information regarding test vehicles, please reference the Vehicle Information sheet in Verify.


Issued: 12/04/2012

7. Test Results


Issued: 12/04/2012


Issued: 12/04/2012

8. Emission testing waiver statements

N/A for Electric Vehicle.


Issued: 12/04/2012

9 OBD System Description

N/A for Electric Vehicle.


Issued: 12/04/2012

10 Description of Alternative-fueled Vehicles

Please refer to the FOI common file.


Issued: 12/04/2012

11 AECD Descriptions

Please refer to the CBI common file.


Issued: 12/04/2012

12 Description of Vehicles Covered by Certificate and Test Parameters

12.1 Vehicle Parameters / Specifications

Durability Group : DTYXEEENNZZZ


Carline Model name Model code ETW Trans. Tire Axle

ratio

Sales

Area

RAV4 EV RAV4 EV QEA38L-CNDGSA 4250 Auto 225/65R17 AS 9.73 50S

Note: Vehicle break-in period of 1000 miles conducted on mileage accumulation dynamometer

Component Specs Remarks/Requirements

Drive Unit

Reduction Ratio 9.73 ± 0.03

Torque 415Nm max

FMVSS 114, FMVSS 305 Max Power 115kW @ 3900Nm

Max Operating Speed 14,500rpm

DC/DC

Input voltage (constant) 180V ~ 450V

FMVSS 305 Max rated output current 200A

Output Voltage (constant) 13.5V ~ 15V

Output Voltage (range) 9V ~ 16V

Battery

Category Li-ion FMVSS 305

Pack Max Voltage 386V 420V possible under charge

Pack Min Voltage 276V 230V possible under load;

192V under load when “cold”

Continuous Output ≥ 62kW

Max Output ≥ 129kW with WOT (30 sec.)

Charger Max Output 8.8kW Input = 240V / 40A (9.6kW)

SAE J1772


Issued: 12/04/2012

12.1.1 Preparation for Toyota EV/HV tests on the 2WD/4WD dynamometer with customer's vehicle.

Model

nameDrive System start by

Indication

when system

ready

(see *1)

How to set

"Spesial

Mode"

Indication

on instrumental

panel

(see *2)

How to set

"Special

Mode"

Indication

on instrumental

panel

(see *1)

How to set

"Spesial

Mode"

Indication

on instrumental

panel

(see *2)

How to set

"Special

Mode"

Indication

on instrumental

panel

RAV4 EV FF Power Button READY Type a Type A Type a Type A

for

driving

for

road load investigation and

setting

4WD dynamo2WD dynamofor

road load investigation and

setting

for

driving

Manufacturer: TOYOTA Exh Test Group: DTYXV00.0DA9 Evap Fam: N/A

All Eng Codes in Eng Fam: CA 49S 50S x AB965 , ORVR: N/A

Exh Std: CA Tier1 US EPA Tier1

LEVI: TLEV LEV ULEV Interim Non-Tier2

LEVII: LEV ULEV SULEV ATPZEV ZEV x Tier2 Bin1 x

Evap Std: N/A

Veh Class(es): PC x LDT1 LDT2 MDV1 MDV2 MDV3 MDV4 MDV5

Single Cert Std for Multi-Class Eng Fam: N/A (specify: N/A, LDT1, MDV1, MDV2, MDV3, MDV4)

Fuel Type(s): Dedicated Flex-Fuel Dual-Fuel Bi-Fuel Gasoline Diesel

CNG LNG LPG M85 Other (specify) Electricity

Exh Emiss Test Fuel(s): Indo CBG CNG LPG M85 Other (specify) Electricity

Diesel: 13 CCR 2282 40 CFR 86.113-90 40 CFR 86.113-94

Evaporative Emission Test Procedure: N/A

Service Accum: Std AMA Mod AMA Mfr ADP x Other (specify)

NMOG Test Procedure: N/A R/L Test Proc: N/A

Engine Configuration:N/A Displacement: N/A

Valves per Cylinder: N/A Rated HP1: N/A RPM

Engine: N/A Drive: FWD x RWD 4WD-FT 4WD-PT

Exhaust ECS (e.g., MFI, EGR, TC, CAC): N/A


Issued: 12/04/2012

12.2 General Technical Descriptions

� Description of battery � Lithium-ion battery

The Lithium-ion battery has a limited service life. The Lithium-ion (Li-ion) battery capacity

(the ability to hold a charge) reduces with time and use in the same way as other rechargeable

batteries. The extent at which capacity reduce changes drastically depending on the environment

(ambient temperature, etc.) and usage conditions, such as how the vehicle is driven and how the

traction battery is charged. This is a natural characteristic of lithium-ion batteries, and is not a

malfunction.

� Description of Motor - AC Induction type motor with maximum output of 300 kW.

� Description of Transmission

Shifting the shift lever (see Figure to the right)

o Operate the shift lever gently and ensure correct

shifting operation.

o When shifting to D or R positions, move the shift

lever along the shift gate.

o To shift to N position, slide the shift lever to the left

and hold it. The shift position will change to N.

o Shifting to B is only possible when shift position D

is selected.

o The shift lever always return to this original

position after a shifting operation.

o When shifting from P to N, D or R, from D to R, or from R to D, ensure that the brake

pedal is being depressed and the vehicle is stationary.

o Shift positions explained below:

Shift Position Function

P Parking the vehicle/starting the EV system

R Reversing

N Neutral

D Normal Driving *

B Applying regenerative braking when driving down

hills or on steep slopes

* For good power economy and noise reduction, the D position should be usually used.

� Description of regenerative braking system

When braking (regenerative braking), the electric motor charges the Li-ion battery.

The driving range can be extended by actively using this regenerative braking to store electricity

in the traction battery. In the following situations, kinetic energy is converted to electric

energy and deceleration force can be obtained in conjunction with the charging of the Li-ion

battery.

o The accelerator pedal is released while driving with the shift position in D or B.

o The brake pedal is depressed while driving with the shift position in D or B.


Issued: 12/04/2012

12.2 General Technical Descriptions (Cont.)

� Vehicle Starting Procedures

Performing the following operations when carrying the electronic key on your person starts

the EV system:

1. Check that the charging cable is disconnected.

2. Check that the parking brake is set.

3. Sit in the driver’s seat and firmly depress the brake pedal. The “POWER” switch indicator

turns green (Note: When the shift position is in N, the EV system cannot start).

4. Push the P position switch when starting the EV system. After a few seconds, the

“READY” indicator comes on with a beep sound.

� Vehicle Charging Procedures *1

1. Turn EV System Off and select charging method.

2. Prepare the charging cable *2

3. Insert the charging cable’s plug into the electrical receptacle of the external power source.

4. Press the test button on the CCID (Charging Circuit Interrupting Device) to check that the

electrical leakage detection function operates properly.

5. Pull up the charging port door lever.

6. Unlock the charging port cap by moving the lock. Open the charging port cap.

7. Remove the charging connector cap (affix to the charging cable).

8. Confirm the charging cable connector’s direction and insert it into the charging port.

9. Check the status of the charging indicator lights.

*1 This vehicle has two user-selectable charging modes:

Standard and Extended Range (This mode extends the driving range to its maximum in a single charge).

o Charging mode can be selected by the customer via simple NAVI operation.

o If a specific charging mode is not selected, the previously selected charging mode is utilized when plugged in.

*2

Charging cable:

o Toyota strongly recommends using the SAE J1772 compliant specialized charging cable for this vehicle when

charging.

o Charging cables are designed to be used with a specific connected power source (AC 120 V or AC 240 V). If

using a charging cable other than the one that is supplied with the vehicle at the time of purchase, always contact

your Toyota dealer.


Issued: 12/04/2012

13 Projected Sales and Compliance Plans



Issued: 12/04/2012

14 Request for Certificate


Evap/refueling family : N/A

Carline : RAV4 EV

TOYOTA MOTOR CORPORATION requests that EPA issue a 2013 model year certificate of

conformity for the above specified test group more fully described in this application.

This combination complies with the following emission standards:

Federal: Tier 2 - Bin 1

California: LEV II - ZEV

This combination meets all applicable regulations contained within 40 CFR Part 86. The application is current

as of this date. The Toyota RAV4 EV is not equipped with a fuel fired heater and does not emit

exhaust/evaporative emissions.

Toshio Yoshidome

Vice President

Toyota Technical Center U.S.A. Inc.


Issued: 12/04/2012

15 Other Information

15.1 Certification Fee Filing Form


Issued: 12/04/2012

15.2 VECI Label (Sample):

TOYOTATOYOTATOYOTATOYOTA VEHICLE EMISSION CONTROL INFORMATION TOYOTA MOTOR CORPORATION Conforms to regulations 2013MY TEST GROUP : DTYXV00.0DA9 EVAP FAMILY : N/A U.S.EPA : T2B1 LDV OBD:N/A Fuel: Electricity California : ZEV PC OBD:N/A Fuel: Electricity No adjustments needed NONE OF THE PERFORMANCE WARRANTY TESTS OF 40 CFR PART 85, SUBPART W, IS TO BE PERFORMED.


Issued: 12/04/2012

16 Confidential Information



Issued: 12/04/2012

17 California ARB Information

Please refer to the FOI common file for the following information.

o Service literature

o Emission Control Information Labels

o Service Information Availability


Issued: 12/04/2012

17.11 Supplemental Data Sheet

2013 MODEL-YEAR AIR RESOURCES BOARD SUPPLEMENTAL DATA SHEET

PASSENGER CARS, LIGHT-DUTY TRUCKS AND MEDIUM-DUTY VEHICLES

Engine Vehicle Models Code Trans. ETW

or

Test

Wt

DPA or

RLHP Code (Model)

(50S)

01 QEA38L-CNDGSA

(RAV4 EV)

Auto 4250 13.5






Evap Std: N/A










Engine Configuration: N/A Displacement: N/A





Issued: 12/04/2012

17.11.00 Certification Review Sheet

2013 MODEL-YEAR AIR RESOURCES BOARD CERTIFICATION REVIEW SHEET

PASSENGER CARS, LIGHT-DUTY TRUCKS AND MEDIUM-DUTY VEHICLES

Section # Section #

1 Authorized Representative 1.2 22 Gen std, increase in Emiss,

2 Fuel Specifications - Safety, Meets all Reqm FOI-8

3 Test Equipment - 23 Driveability Statement FOI-17.1

4 Test Procedure - 24 Adjustable Parameters -

5 Mileage Accumulation Route CBI-4 25 Tamper Resistance Method(s) -

6 Emission Warranty Statement Part2 FOI-6.00.01 26 Fill Pipe Specifications N/A

7 Maint: Cert/Req’d/Recm’d - 27 High Altitude Compliance N/A

8 Emiss Label/Vac Hose Diag - 28 OBD Sys incl Marked Revisions N/A

9 Evap Control System N/A 29 I & M Test Procedure & Data -

10 Engine Parameters 5 30 50 Degree F Compliance -

11 Fuel System - 31 Manufacturer’s RAF -

12 Ignition System - 32 Phase-In Plans: ORVR Cert Std -

13 Exhaust Control System N/A Full Range Misfire Monitoring N/A

14 Proj Sales(LDT/MDV Split) CBI-17.1 LEV CAT Monitoring-1.5 x std N/A

15 Vehicle Description 12.1 0.020” Orifice-Based Leak Chk N/A

16 Evap Bench Test Procedure - MDV VEC Calculation -

17 R/L Temp & Press Profiles N/A 33 NMOG Fleet Average Calcuration N/A

18 EDV Selection - 34 AB965 Credits/Withdrawals -

19 Prod Veh same as Test Veh FOI-17.1 35 EPA Certificate to follow

20 Emission Label Durability - 36 Equiv NMOG Proc-ARB Approval N/A

Durability Fuel Econ. (Range) Emission Emission 21 Test Vehicle Information Data Vehicle Data Vehicle Data Vehicle Data Vehicle

C/O or C/A MY ID N/A C/O 12-QA1E N/A N/A

Vehicle Log Page(s) -

Zero Mile Book Page(s) -

Maint Logs & Engr Eval - - -






Evap Std: N/A










Engine Configuration: N/A Displacement: N/A





Issued: 12/04/2012

*2

17.11.00 Certification Review Sheet

2013 MODEL-YEAR AIR RESOURCES BOARD CERTIFICATION REVIEW SHEET

PASSENGER CARS, LIGHT-DUTY TRUCKS AND MEDIUM-DUTY VEHICLES Manufacturer:

Toyota

Exhaust Test Group:

DTYXV00.0DA9

Evaporative Family:

N/A

P R O J E C T E D E M I S S I O N S *1

(grams/mile, except, grams/test for D+HS, and grams/gallon for ORVR)

Emission

Data

Vehicle ID

E/G

Code

Test

Loc Trans ETW RLHP

MPGe

City/

Hwy

Range

Miles

City/

Hwy NMOG CO NOx

20oF

CO

Hwy

NOx

City

CO2

Hwy

CO2

E V A P O R A T I V E *1

Whole

Vehicle

3-day

D+HS*1 R/L

Whole

Vehicle

2-day

D+HS*1 ORVR

Fuel

-only

3-day

D+HS

12-QA1E 01 EPA AV 4250 13.5 117/ 172/ 50k N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

(00) *3 106 157 120k N/A N/A N/A N/A N/A N/A N/A N/A - N/A

150k N/A N/A N/A N/A N/A - - - N/A N/A

12-QA1E 01 EPA/ AV 4250 13.5 108/ 134/ 50k N/A N/A N/A - N/A - - N/A N/A N/A N/A N/A

(01) *4 MFR 105 126 120k N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

150k - - - N/A - N/A N/A N/A N/A N/A

(1) The EDV(s) above comply with standards of (@50k): N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

(@120k): N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A


Deterioration Factors(DFs) of (@50k) : N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A



50oF emissions (w/o DFs): - - -

50oF standards: N/A N/A N/A

Remarks: *1 Exh. / Evap. Emissions all N/A for electric vehicle.

*2 MPGe and Range values are based off of unadjusted data

*3 Extended Range Charge Mode

*4 Standard Charge Mode


Issued: 12/04/2012

13my rav4 ev cert app final

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