RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604232 HYBRID CONTROL SYSTEM J

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  Inverter Low-voltage Circuit  


DESCRIPTION

The cause of the malfunction may be the low-voltage circuit.

Check whether there is an open circuit in the inverter +B low-voltage power source system or a problem in the communication between the hybrid vehicle control ECU and inverter.

Related Parts Check
Area Inspection
Inverter +B low-voltage power source system check Check for inverter overcurrent malfunction.
Communication malfunction between hybrid vehicle control ECU and MG-ECU inside inverter with converter assembly Check for inverter overcurrent malfunction due to communication malfunction.
Check for short to ground in inverter +B low-voltage power source system -

WIRING DIAGRAM

A368540E73
6.115,1.5 7.135,1.906 1.021,0.406 10 false from IGCT-MAIN NO. 1 Relay 6.24,0.938 7,1.156 0.76,0.219 10 false PCU NO. 1 5.469,2.271 5.958,2.573 0.49,0.302 10 false GND2 5.49,1.844 5.979,2.146 0.49,0.302 10 false GND1 5.552,0.792 5.948,1.01 0.396,0.219 10 false IGC1 5.573,1.229 6,1.448 0.427,0.219 10 false IGC2 4.198,0.844 4.688,1.146 0.49,0.302 10 false HMCL 2.177,0.865 2.667,1.167 0.49,0.302 10 false HMCL 2.167,1.333 2.656,1.635 0.49,0.302 10 false HMCH 4.188,1.333 4.677,1.635 0.49,0.302 10 false HMCH 4.042,2.906 6.104,3.531 2.063,0.625 10 false Inverter with Converter Assembly 5.938,2.146 6.427,2.448 0.49,0.302 10 false 12 2.646,0.938 3.135,1.24 0.49,0.302 10 false A197 5.938,1.115 6.427,1.417 0.49,0.302 10 false 9 5.927,1.708 6.417,2.01 0.49,0.302 10 false 4 5.948,0.667 6.438,0.969 0.49,0.302 10 false 1 6.667,0.656 6.979,0.948 0.313,0.292 10 false 1 6.396,0.656 6.708,0.948 0.313,0.292 10 false 2 3.927,0.854 4.417,1.156 0.49,0.302 10 false 30 3.917,1.323 4.406,1.625 0.49,0.302 10 false 29 4.063,2.74 4.552,3.042 0.49,0.302 10 false A192 0.552,1.781 1.042,2.083 0.49,0.302 10 false I278 2.771,0.75 3.26,1.052 0.49,0.302 10 false 1 2.729,1.25 3.219,1.552 0.49,0.302 10 false 2 2.708,1.906 3.198,2.208 0.49,0.302 10 false 13 3.927,2.01 4.417,2.313 0.49,0.302 10 false 20 4.198,2.125 4.958,2.427 0.76,0.302 10 false DRN1 2.208,2.125 2.969,2.427 0.76,0.302 10 false DRN5 0.917,2.74 3.927,3.167 3.01,0.427 10 false Hybrid Vehicle Control ECU 0.938,1.802 1.427,2.104 0.49,0.302 10 false E1 0.948,2.323 1.438,2.625 0.49,0.302 10 false E12 0.583,2.104 0.885,2.375 0.302,0.271 10 false 24 0.615,1.604 0.917,1.875 0.302,0.271 10 false 1 4.958,1.25 5.219,1.521 0.26,0.271 10 false * 1.802,1.24 2.063,1.51 0.26,0.271 10 false * 0.333,3.427 2.104,3.75 1.771,0.323 10 false *: Approximately 120 Ω 2.646,1.427 3.135,1.729 0.49,0.302 10 false A197 2.625,2.104 3.115,2.406 0.49,0.302 10 false A197 0.51,2.292 1,2.594 0.49,0.302 10 false A197

CAUTION / NOTICE / HINT

This diagnostic procedure is referenced to in the diagnostic procedure of several DTCs.

If the result of this diagnostic procedure is normal, proceed as directed in the procedure for the DTC.

CAUTION:

Refer to the precautions before inspecting high voltage circuit.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION


NOTICE:
·

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY

·

When disconnecting and reconnecting the auxiliary battery

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART




PROCEDURE

1.CHECK FUSE (PCU NO. 1)
a.

Remove the PCU NO. 1 fuse from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
PCU NO. 1 fuse Always Below 1 Ω



c.

Install the PCU NO. 1 fuse.


Result:
Proceed to
OK
NG



OK

2.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)

NG

5.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)
2.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY POWER SOURCE CIRCUIT)
CAUTION:

Be sure to wear insulated gloves.


a.

Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the inverter with converter assembly connector.


c.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
A192-4 (GND1) - Body ground Ignition switch off Below 1 Ω
A192-12 (GND2) - Body ground Ignition switch off Below 1 Ω



d.

Connect the cable to the negative (-) auxiliary battery terminal.


e.

Turn the ignition switch to ON.


f.

Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
A192-1 (IGC1) - Body ground Ignition switch ON Same as auxiliary battery voltage
A192-9 (IGC2) - Body ground Ignition switch ON Same as auxiliary battery voltage


NOTICE:

Turning the ignition switch to ON with the inverter with converter assembly connector disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.



g.

Turn the ignition switch off.


h.

Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.


i.

Reconnect the inverter with converter assembly connector.


Result:
Proceed to
OK
NG



OK

3.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY)

NG

REPAIR OR REPLACE POWER SOURCE CIRCUIT

3.CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER WITH CONVERTER ASSEMBLY)
CAUTION:

Be sure to wear insulated gloves.


a.

Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the inverter with converter assembly connector.


c.

Disconnect the hybrid vehicle control ECU connector.


d.

Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):
Tester Connection Condition Specified Condition
A192-29 (HMCH) - A197-2 (HMCH) Ignition switch off Below 1 Ω
A192-30 (HMCL) - A197-1 (HMCL) Ignition switch off Below 1 Ω


Standard Resistance (Check for Short):
Tester Connection Condition Specified Condition
A192-29 (HMCH) or A197-2 (HMCH) - Body ground and other terminals Ignition switch off 10 kΩ or higher
A192-30 (HMCL) or A197-1 (HMCL) - Body ground and other terminals Ignition switch off 10 kΩ or higher



e.

Connect the cable to the negative (-) auxiliary battery terminal.


f.

Turn the ignition switch to ON.


g.

Measure the voltage according to the value(s) in the table below.

Standard Voltage:
Tester Connection Condition Specified Condition
A192-29 (HMCH) or A197-2 (HMCH) - Body ground and other terminals Ignition switch ON Below 1 V
A192-30 (HMCL) or A197-1 (HMCL) - Body ground and other terminals Ignition switch ON Below 1 V


NOTICE:

Turning the ignition switch to ON with the hybrid vehicle control ECU and inverter with converter assembly connectors disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.



h.

Turn the ignition switch off.


i.

Disconnect the cable from the negative (-) auxiliary battery terminal and wait for 2 minutes or more.


j.

Reconnect the hybrid vehicle control ECU connector.


k.

Reconnect the inverter with converter assembly connector.


Result:
Proceed to
OK
NG



OK

4.CHECK HYBRID VEHICLE CONTROL ECU

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

4.CHECK HYBRID VEHICLE CONTROL ECU
a.

Disconnect the hybrid vehicle control ECU connector.


b.

Measure the resistance according to the value(s) in the table below.

A460286C38
2.51,0.24 2.917,0.479 0.406,0.24 3.063,2.333 3.344,1.281 true 3.885,2.323 3.531,1.292 true 0.313,0.24 0.625,0.396 0.313,0.156 10 false *a 2.854,2.365 3.49,2.615 0.635,0.25 10 false HMCH 3.74,2.354 4.375,2.604 0.635,0.25 10 false HMCL 2.552,0.26 2.979,0.448 0.427,0.188 10 false A197
*a Component without harness connected
(Hybrid Vehicle Control ECU) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
A197-1 (HMCL) - A197-2 (HMCH) Ignition switch off 80 to 170 Ω



c.

Reconnect the hybrid vehicle control ECU connector.


Result:
Proceed to
OK
NG



OK

INVERTER LOW-VOLTAGE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

REPLACE HYBRID VEHICLE CONTROL ECU

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID VEHICLE CONTROL ECU>REMOVAL


5.CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - PCU FUSE)
CAUTION:

Be sure to wear insulated gloves.


a.

Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Disconnect the inverter with converter assembly connector.


c.

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
Tester Connection Condition Specified Condition
A192-1 (IGC1) - Body ground Ignition switch off 10 kΩ or higher
A192-9 (IGC2) - Body ground Ignition switch off 10 kΩ or higher



d.

Reconnect the inverter with converter assembly connector.


Result:
Proceed to
OK
NG



OK

6.REPLACE INVERTER WITH CONVERTER ASSEMBLY

NG

7.REPAIR OR REPLACE HARNESS OR CONNECTOR
6.REPLACE INVERTER WITH CONVERTER ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>INVERTER WITH CONVERTER>REMOVAL

Result:
Proceed to
NEXT



NEXT

REPLACE FUSE (PCU NO. 1)

7.REPAIR OR REPLACE HARNESS OR CONNECTOR
Result:
Proceed to
NEXT



NEXT

REPLACE FUSE (PCU NO. 1)