RM3660EC _51 Engine / Hybrid System _080773 HYBRID / BATTERY CONTROL _0600291 PA10 HYBRID CONTROL SYSTEM(for LITHIUM-ION BATTERY) J

HYBRID / BATTERY CONTROL  PA10 HYBRID CONTROL SYSTEM(for LITHIUM-ION BATTERY)  HV Battery High-voltage Line Circuit  


DESCRIPTION

The cause of the malfunction may be the HV battery high-voltage line circuit.

Check the continuity in the high-voltage line from the HV battery to the inverter.

Check the connection condition and for an open circuit in the frame wire from the service plug grip, EV electric battery fuse and HV battery to the inverter and perform a function check of the system main relay.

Related Parts Check
Area Inspection
High-voltage circuit from HV battery to inverter Check connection condition and for open circuit.
Service plug grip Check connection condition and for open circuit.
EV electric battery fuse Check for open circuit.
System Main Relay Check operation condition as relay.

SYSTEM DESCRIPTION

The HV battery high voltage is supplied to the inverter via the system main relay operation.

WIRING DIAGRAM

A520720E19
0.052,3.208 0.844,3.75 0.792,0.542 10 false Service Plug Grip 1.438,0.969 1.719,1.188 0.281,0.219 10 false z22 1.51,0.792 1.667,0.99 0.156,0.198 10 false 1 1.427,2.219 1.583,2.417 0.156,0.198 10 false 1 1.427,1.5 1.583,1.698 0.156,0.198 10 false 1 1.156,2.229 1.615,2.427 0.458,0.198 10 false B 1.156,1.51 1.313,1.708 0.156,0.198 10 false A 0.198,1.875 1.177,2.271 0.979,0.396 10 false HV Battery 1.448,3.917 1.906,4.115 0.458,0.198 10 false z23 1.521,3.74 1.677,3.938 0.156,0.198 10 false 1 1.792,0.833 1.948,1.031 0.156,0.198 10 false + 1.802,3.771 1.958,3.969 0.156,0.198 10 false - 3.146,1.646 3.76,1.844 0.615,0.198 10 false SMRB 3.156,4.615 3.792,4.823 0.635,0.208 10 false SMRG 3.813,1.292 4.427,1.49 0.615,0.198 10 false SMRB 6.167,4.646 6.781,4.844 0.615,0.198 10 false SMRB 6.167,5.115 6.802,5.323 0.635,0.208 10 false SMRG 3.781,4.24 4.417,4.448 0.635,0.208 10 false SMRG 3.958,0.833 4.417,1.031 0.458,0.198 10 false CBI 3.948,3.771 4.406,3.969 0.458,0.198 10 false CEI 3.906,5.823 4.365,6.021 0.458,0.198 10 false GND 4.344,0.969 4.656,1.167 0.313,0.198 10 false W3 4.396,0.781 4.552,0.979 0.156,0.198 10 false 1 4.281,1.417 4.74,1.615 0.458,0.198 10 false O169 4.406,1.219 4.563,1.417 0.156,0.198 10 false 4 4.344,3.927 4.677,4.125 0.333,0.198 10 false W2 4.396,3.729 4.552,3.927 0.156,0.198 10 false 1 4.281,4.365 4.74,4.563 0.458,0.198 10 false O169 4.281,5.938 4.74,6.135 0.458,0.198 10 false O169 4.396,4.188 4.552,4.385 0.156,0.198 10 false 6 4.396,5.74 4.552,5.938 0.156,0.198 10 false 2 1.865,6.542 4.219,6.802 2.354,0.26 10 false HV Battery Junction Block Assembly 5.448,6.385 5.875,6.573 0.427,0.188 10 false I3 5.427,6.594 7.146,7.208 1.719,0.615 10 false Hybrid Vehicle Control ECU 5.958,4.729 6.271,4.927 0.313,0.198 10 false 3 5.906,5.208 6.219,5.406 0.313,0.198 10 false 27 5.75,2.323 6.063,2.521 0.313,0.198 10 false W4 5.75,2.531 7.104,3.104 1.354,0.573 10 false Inverter with Converter Assembly 6.26,0.969 6.719,1.167 0.458,0.198 10 false CBI 6.26,1.823 6.719,2.021 0.458,0.198 10 false CEI 6.042,0.844 6.198,1.042 0.156,0.198 10 false 1 6.052,1.688 6.208,1.885 0.156,0.198 10 false 2 6.833,4.76 6.99,4.958 0.156,0.198 10 false * 6.833,5.229 6.99,5.427 0.156,0.198 10 false * 1.24,7.406 2.896,7.625 1.656,0.219 10 false : HV Battery Voltage Line 3.292,7.406 6.813,7.604 3.521,0.198 10 false *: with Monitor Circuit 0.969,3.385 1.125,3.583 0.156,0.198 10 false 1 0.969,2.99 1.125,3.188 0.156,0.198 10 false 2

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>PA10 HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY)>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 INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)
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.
A520715

Check that the bolts for the HV floor under wire is tightened to the specified torque, the HV floor under wire is connected securely, and there are no contact problems.

Specified Condition:

T = 8.0 N*m (82 kgf*cm, 71 in.*lbf)



c.

Disconnect the HV floor under wire from the inverter with converter assembly.


d.

Check for arc marks on the terminals for the HV floor under wire and inverter with converter assembly.

Result:
Result Proceed to
The terminals are connected securely and there are no contact problems. There are no arc marks. A
The terminals are not connected securely and there is a contact problem. There are arc marks. B
The terminals are not connected securely and there is a contact problem. There are no arc marks. C
The terminals are connected securely and there are no contact problems. There are arc marks. B



e.

Reconnect the HV floor under wire.



A

2.CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

2.CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)
CAUTION:

Be sure to wear insulated gloves.


a.

Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

OK:

Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.



b.

Install the service plug grip.


Result:
Proceed to
OK
NG



OK

3.INSPECT SERVICE PLUG GRIP

NG

REPLACE SERVICE PLUG GRIP

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL


3.INSPECT SERVICE PLUG GRIP
CAUTION:

Be sure to wear insulated gloves.


a.

Remove the service plug grip.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL


b.
A365294C01
0.104,0.083 0.417,0.24 0.313,0.156 10 false *1
*1 Service Plug Grip


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

Standard Resistance:
Tester Connection Condition Specified Condition
Service plug grip terminals Always Below 1 Ω



c.

Install the service plug grip.


Result:
Proceed to
OK
NG



OK

4.CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)

NG

REPLACE SERVICE PLUG GRIP

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL


4.CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER WIRE CONNECTION CONDITION)
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.
A523828N09
1.552,0.313 1.917,0.542 0.365,0.229 2.25,0.75 2.604,1 0.354,0.25 2.292,0.781 2.573,0.958 0.281,0.177 10 true W2 1.583,0.344 1.854,0.521 0.271,0.177 10 true W3

Check that the HV floor under wire is connected securely, and there are no contact problems.


c.

Disconnect the HV floor under wire connectors from the HV battery junction block assembly.


d.

Check for arc marks on the terminals of the HV floor under wire and the HV battery junction block assembly.

Result:
Result Proceed to
The terminals are connected securely and there are no contact problems. There are no arc marks. A
The terminals are not connected securely and there is a contact problem. There are arc marks. B
The terminals are not connected securely and there is a contact problem. There are no arc marks. C
The terminals are connected securely and there are no contact problems. There are arc marks. B



e.

Reconnect the HV floor under wire.



A

5.CHECK FLOOR UNDER WIRE

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

5.CHECK FLOOR UNDER WIRE
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.
A523828N09
1.552,0.313 1.917,0.542 0.365,0.229 2.25,0.75 2.604,1 0.354,0.25 2.292,0.781 2.573,0.958 0.281,0.177 10 true W2 1.583,0.344 1.854,0.521 0.271,0.177 10 true W3

Disconnect the HV floor under wire connectors from the HV battery junction block assembly.


c.
A520715N01
1.531,0.125 1.885,0.375 0.354,0.25 1.563,0.146 1.875,0.344 0.313,0.198 10 true W4

Disconnect the HV floor under wire connector from the inverter with converter assembly.


d.

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

A515382C10
1.854,0.375 2.167,0.594 0.313,0.219 3.771,0.479 4.167,0.708 0.396,0.229 5.677,0.521 6.031,0.74 0.354,0.219 4.396,0.698 4.073,1.094 true 5.333,0.708 5.708,1.115 true 1.792,1.875 1.146,2.281 true 2.177,1.885 2.719,2.292 true 2.854,2.75 2.042,2.167 true 0.813,0.177 1.125,0.333 0.313,0.156 10 false *a 3.708,0.167 4.021,0.323 0.313,0.156 10 false *b 1.906,0.396 2.219,0.552 0.313,0.156 10 false W4 3.865,0.51 4.219,0.719 0.354,0.208 10 false W3 5.76,0.552 6.073,0.708 0.313,0.156 10 false W2 3.813,1.042 4.125,1.198 0.313,0.156 10 false CBI 5.76,1.073 6.073,1.229 0.313,0.156 10 false CEI 1.031,2.323 1.344,2.479 0.313,0.156 10 false CBI 2.667,2.323 2.979,2.479 0.313,0.156 10 false CEI 2.719,2.771 3.458,3.01 0.74,0.24 10 false SHDI
*a HV Floor Under Wire
(Inverter with Converter Assembly Side) 		*b HV Floor Under Wire
(HV Battery Junction Block Assembly Side)


Standard Resistance:
Tester Connection Condition Specified Condition
W4-1 (CBI) - W3-1 (CBI) Ignition switch off Below 1 Ω
W4-2 (CEI) - W2-1 (CEI) Ignition switch off Below 1 Ω


NOTICE:

Be sure not to damage or deform the terminal being inspected.



e.

Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.


Standard Resistance:
Tester Connection Condition Specified Condition
W4-1 (CBI) or W3-1 (CBI) - W4-3 (SHDI) and Body ground Ignition switch off 10 MΩ or higher
W4-2 (CEI) or W2-1 (CEI) - W4-3 (SHDI) and Body ground Ignition switch off 10 MΩ or higher
W4-1 (CBI) - W4-2 (CEI) Ignition switch off 10 MΩ or higher
W3-1 (CBI) - W2-1 (CEI) Ignition switch off 10 MΩ or higher



f.

Reconnect the HV floor under wire connector to the inverter with converter assembly.


g.

Reconnect the HV floor under wire connectors to the HV battery junction block assembly.


Result:
Proceed to
OK
NG



OK

6.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

NG

REPLACE FLOOR UNDER WIRE

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>8ZR-FXE FRAME WIRE>REMOVAL


6.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)
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.

Remove the HV battery junction block assembly.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY)>REMOVAL


c.

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

A515114C68
3.948,0.115 4.375,0.333 0.427,0.219 5.635,1.51 5.979,1.719 0.344,0.208 4.583,1.385 5.031,1.604 0.448,0.219 4.24,0.625 4.573,0.313 true 4.052,1.031 4.292,0.802 true 4.698,1.063 4.323,1.583 true 6.458,1.698 5.802,1.125 true 0.573,0.146 0.885,0.302 0.313,0.156 10 false *a 4,0.146 4.458,0.344 0.458,0.198 10 false O169 4.458,0.167 4.792,0.375 0.333,0.208 10 false GND 3.833,1.052 4.26,1.208 0.427,0.156 10 true SMRB 5.698,1.531 5.99,1.719 0.292,0.188 10 false z22 6.5,1.708 6.656,1.906 0.156,0.198 10 false + 4.688,1.406 5.063,1.594 0.375,0.188 10 false W3 4.188,1.635 4.438,1.833 0.25,0.198 10 false CBI
*a Component without harness connected
(HV Battery Junction Block Assembly) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
z22-1 (+) - W3-1 (CBI) Auxiliary battery voltage not applied between terminals O169-4 (SMRB) and O169-2 (GND) 10 kΩ or higher
z22-1 (+) - W3-1 (CBI) Auxiliary battery voltage applied between terminals O169-4 (SMRB) and O169-2 (GND) Below 1 Ω



d.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O169-4 (SMRB) - O169-2 (GND) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω



e.

Install the HV battery junction block assembly.


Result:
Proceed to
OK
NG



OK

7.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

NG

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY)>REMOVAL


7.INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)
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.

Remove the HV battery junction block assembly.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY)>REMOVAL


c.

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

A515114C69
3.969,0.115 4.396,0.323 0.427,0.208 1.885,0.479 2.25,0.656 0.365,0.177 2.969,0.448 3.271,0.667 0.302,0.219 3.802,1.146 4.115,0.792 true 4.615,0.302 4.24,0.688 true 2.74,1.344 3.073,0.958 true 1.542,1.135 2.052,0.938 true 0.573,0.146 0.885,0.302 0.313,0.156 10 false *a 4.021,0.135 4.479,0.333 0.458,0.198 10 false O169 4.521,0.156 4.854,0.302 0.333,0.146 10 true GND 3.625,1.177 4.073,1.375 0.448,0.198 10 true SMRG 3.01,0.479 3.333,0.656 0.323,0.177 10 false W2 1.958,0.479 2.292,0.635 0.333,0.156 10 false z23 2.615,1.375 2.99,1.583 0.375,0.208 10 false CEI 1.417,1.115 1.573,1.313 0.156,0.198 10 false -
*a Component without harness connected
(HV Battery Junction Block Assembly) 		- -


Standard Resistance:
Tester Connection Condition Specified Condition
z23-1 (-) - W2-1 (CEI) Auxiliary battery voltage not applied between terminals O169-6 (SMRG) and O169-2 (GND) 10 kΩ or higher
z32-1 (-) - W2-1 (CEI) Auxiliary battery voltage applied between terminals O169-6 (SMRG) and O169-2 (GND) Below 1 Ω



d.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O169-6 (SMRG) - O169-2 (GND) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω



e.

Install the HV battery junction block assembly.


Result:
Proceed to
OK
NG



OK

HV BATTERY HIGH-VOLTAGE LINE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY)>REMOVAL