RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604245 INVERTER WITH CONVERTER A

HYBRID / BATTERY CONTROL INVERTER WITH CONVERTER REASSEMBLY

CAUTION / NOTICE / HINT

0.583,3.771 1.25,3.938 0.667,0.167 0.552,4.563 1.219,4.729 0.667,0.167 0.656,5.24 1.406,5.406 0.75,0.167 6.229,5.094 6.979,5.26 0.75,0.167 6.167,2.917 6.917,3.083 0.75,0.167 4.729,0.885 5.396,1.052 0.667,0.167 6.354,4.417 7.021,4.583 0.667,0.167 6.177,5.406 6.844,5.573 0.667,0.167 4.969,2.375 5.969,2.542 1,0.167 5.844,0.708 6.594,0.875 0.75,0.167 0.49,1.01 1.469,1.177 0.979,0.167 6.188,5.052 7.021,5.302 0.833,0.25 0.313,1.531 0.979,1.698 0.667,0.167 0.458,0.969 1.51,1.219 1.052,0.25 5.75,3.479 5.969,3.479 false 5.01,1.531 4.844,1.531 4.844,1.531 4.74,1.74 false 1.698,1.583 2.125,1.583 false 5.792,1.573 5.958,1.573 false 2.677,5.469 2.885,5.469 false 4.854,5.115 4.979,5.115 false 1.729,3.948 1.635,4.167 1.635,4.167 1.51,4.167 false 6.073,3.927 5.906,3.927 5.906,3.927 5.74,4 false 1.479,3.74 1.385,3.854 1.385,3.854 1.26,3.854 false 4.719,0.969 4.583,0.969 4.583,0.969 4.458,1.344 false 5.833,0.792 5.698,0.792 5.698,0.792 5.573,1.167 false 1.927,4.375 1.823,4.74 1.823,4.74 1.698,4.74 false 6.104,4.281 6.188,4.5 6.188,4.5 6.354,4.5 false 5.938,5.271 6.073,5.49 6.073,5.49 6.167,5.49 false 5.99,4.958 6.125,5.177 6.125,5.177 6.229,5.177 false 1.448,4.542 1.354,4.656 1.354,4.656 1.229,4.656 false 5.979,2.458 6.073,2.458 6.073,2.458 6.156,2.625 false 6.156,3 6.021,3 6.021,3 5.906,3.052 false 1.406,5.323 1.625,5.323 false 1.104,1.458 1.063,1.625 1.063,1.625 0.979,1.625 false 1.688,1.021 1.604,1.104 1.604,1.104 1.479,1.104 false 5.51,2.823 5.677,2.823 false 6.198,4.219 6.656,4.417 0.458,0.198 10 false x2 3.104,5.354 3.385,5.708 0.281,0.354 18 false 6 6.25,3.344 6.531,3.698 0.281,0.354 18 false 5 6.042,1.417 6.323,1.771 0.281,0.354 18 false 2 4.698,4.917 4.979,5.271 0.281,0.354 18 false 4 2.427,1.469 2.708,1.823 0.281,0.354 18 false 3 6.146,3.823 6.427,4.177 0.281,0.354 18 false 1 1.542,4.594 1.823,4.948 0.281,0.354 18 false 1 4.563,1.333 5.021,1.531 0.458,0.198 10 false x3 5.958,3.063 6.417,3.26 0.458,0.198 10 false x2 1.719,5.365 2.177,5.563 0.458,0.198 10 false x2 1.854,0.906 2.313,1.104 0.458,0.198 10 false x2 1.698,3.667 2.156,3.865 0.458,0.198 10 false x2 1.333,4 1.615,4.354 0.281,0.354 18 false 1 5.083,1.365 5.365,1.719 0.281,0.354 18 false 1 5.313,2.688 5.594,3.042 0.281,0.354 18 false 1 0.667,3.781 1.438,4.042 0.771,0.26 8 false 10 (102, 7) 0.615,4.563 1.385,4.823 0.771,0.26 8 false 10 (102, 7) 4.802,0.896 5.573,1.156 0.771,0.26 8 false 10 (102, 7) 6.427,4.417 7.094,4.688 0.667,0.271 8 false 10 (102, 7) 5.917,0.729 6.583,1 0.667,0.271 8 false 13 (133, 10) 6.219,2.927 6.885,3.198 0.667,0.271 8 false 15 (153, 11) 5.031,2.375 6.073,2.635 1.042,0.26 8 false 8.0 (82, 71 in.*lbf) 0.719,5.24 1.385,5.51 0.667,0.271 8 false 15 (153, 11) 0.531,1.01 1.646,1.281 1.115,0.271 8 false 8.0 (82, 71 in.*lbf) 0.385,1.531 1.156,1.792 0.771,0.26 8 false 10 (102, 7) 6.24,5.406 6.906,5.677 0.667,0.271 8 false 10 (102, 7) 6.302,5.094 6.969,5.365 0.667,0.271 8 false 16 (163, 12)

Procedure		Part Name Code
1	WIRE HARNESS CLAMP BRACKET	-	-	-	-
2	BRACKET	23211K	-	-	-
3	HIGH VOLTAGE AIR CONDITIONING WIRE	821H2A	(202307,999999,_51,_144957,_0604245,RM100000002BTRH_01_0004,)	-	-
4	NO. 3 ENGINE WIRE	82123	(202307,999999,_51,_144957,_0604245,RM100000002BTRH_01_0003,)	-	-
5	NO. 2 INVERTER BRACKET	G9215	(202307,999999,_51,_144957,_0604245,RM100000002BTRH_01_0002,)	-	-
6	NO. 1 INVERTER BRACKET	G9214	(202307,999999,_51,_144957,_0604245,RM100000002BTRH_01_0001,)	-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

PROCEDURE

Hide Display 1.INSTALL WIRE HARNESS CLAMP BRACKET

3.063,0.542 3.219,0.74 0.156,0.198 10 false A 1.229,1.49 1.385,1.688 0.156,0.198 10 true A 2.677,1.146 2.833,1.344 0.156,0.198 10 true A 2.365,3.083 2.521,3.281 0.156,0.198 10 true A 2.729,2.583 2.885,2.781 0.156,0.198 10 true A 6.073,1.052 6.229,1.25 0.156,0.198 10 true A 6.542,0.823 6.698,1.021 0.156,0.198 10 true A 0.635,2.188 0.792,2.385 0.156,0.198 10 false A 4.302,1.573 4.458,1.771 0.156,0.198 10 false B

Torque:: Bolt A : 10 N*m (102 kgf*cm, 7 ft.*lbf); Bolt B : 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Hide Display 23211K 2.INSTALL BRACKET

Torque:: 13 N*m (133 kgf*cm, 10 ft.*lbf)

Hide Display 821H2A 3.INSTALL HIGH VOLTAGE AIR CONDITIONING WIRE

CAUTION:: Be sure to wear insulated gloves.

NOTICE:: ·

Do not allow any foreign matter or water to enter the inverter with converter assembly.

·

Do not touch the waterproof seal or terminals of the connector.

·

Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.

2.052,0.781 1.76,0.448 true 1.552,0.313 1.865,0.51 0.313,0.198 10 false *a 5.073,0.26 5.26,0.469 0.188,0.208 10 true A 4.292,1.438 4.479,1.646 0.188,0.208 10 true A 6.188,0.677 6.375,0.885 0.188,0.208 10 true B

Waterproof Seal

Torque:: Bolt A : 8.0 N*m (82 kgf*cm, 71 in.*lbf); Bolt B : 10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide Display 82123 4.INSTALL NO. 3 ENGINE WIRE

CAUTION:: Be sure to wear insulated gloves.

NOTICE:: ·

Do not allow any foreign matter or water to enter the inverter with converter assembly.

·

Perform this procedure when it is necessary to replace the inverter with converter assembly and the No. 3 engine wire.

0.396,0.094 0.594,0.365 0.198,0.271 18 false i 3.656,0.219 3.938,0.573 0.281,0.354 18 false ii

Engage the clamp and connect the engine wire to the inverter with converter assembly with bolt and nut.

Torque:: Bolt : 10 N*m (102 kgf*cm, 7 ft.*lbf); Nut : 16 N*m (163 kgf*cm, 12 ft.*lbf)

NOTICE:: ·

Move the tool in the downward direction to tighten the nut as shown in the illustration.

·

To avoid damaging the threads, be sure to perform the procedure by hand.

ii.

Engage the 2 claws.

Hide Display G9215 5.INSTALL NO. 2 INVERTER BRACKET

NOTICE:: 1.865,0.677 2.323,0.229 true 0.094,0.063 0.406,0.26 0.313,0.198 10 false *a 0,0 0.313,0.198 0.313,0.198 10 false *b 2.375,0.094 2.688,0.292 0.313,0.198 10 false *b; Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.; *a: Bottom of Inverter with Converter Assembly

*b: Support

0.083,0.083 0.333,0.417 0.25,0.333 6.01,1.198 6.167,1.302 true 5.375,1.333 5.542,1.427 true 0.146,0.115 0.427,0.469 0.281,0.354 18 false ! 0.417,0.115 0.865,0.365 0.448,0.25 18 false i, ii 6.208,1.292 6.365,1.49 0.156,0.198 10 false A 5.604,1.385 5.76,1.583 0.156,0.198 10 false A 2.427,0.74 2.583,0.938 0.156,0.198 10 false 1 3.01,0.833 3.167,1.031 0.156,0.198 10 true 2

Set the inverter with converter assembly on wooden blocks.

ii.

Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.

NOTICE:: Do not touch portion (A) of the No. 2 inverter bracket.

iii.

Fully tighten the 2 bolts in the order shown in the illustration.

Torque:: 15 N*m (153 kgf*cm, 11 ft.*lbf)

Hide Display G9214 6.INSTALL NO. 1 INVERTER BRACKET

0.083,0.083 0.333,0.417 0.25,0.333 5.833,0.823 6.177,1.052 true 5.292,1.25 5.583,1.406 true 0.146,0.115 0.427,0.469 0.281,0.354 18 false ! 0.417,0.115 0.865,0.365 0.448,0.25 18 false i 5.688,0.688 5.844,0.885 0.156,0.198 10 false A 5.625,1.354 5.781,1.552 0.156,0.198 10 false A 2.417,0.698 2.573,0.896 0.156,0.198 10 false 1 2.938,0.823 3.094,1.021 0.156,0.198 10 true 2

Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.

NOTICE:: Do not touch portion (A) of the No. 1 inverter bracket.

ii.

Fully tighten the 2 bolts in the order shown in the illustration.

Torque:: 15 N*m (153 kgf*cm, 11 ft.*lbf)