RM36D0EC _51 Engine / Hybrid System _083048 HYBRID / BATTERY CONTROL _0709511 HYBRID CONTROL SYSTEM J

HYBRID / BATTERY CONTROL  HYBRID CONTROL SYSTEM  Generator High-voltage Circuit  


DESCRIPTION

The cause of this malfunction may be the generator high-voltage circuit.

Check the generator internal resistance and the connection condition of the high-voltage line between the inverter and generator to check whether there is an open or short circuit.

Related Parts Check
Area Inspection
Motor cable (for MG1) connection check Check for the connection condition of the cable from the inverter to the generator.
Generator or motor cable (for MG1) Check the generator (including cable) internal resistance and the insulation resistance with body ground to check for an open or short circuit.

WIRING DIAGRAM

C304949E92
1.156,2.427 2.99,2.667 1.833,0.24 10 false : High Voltage Line 2.438,0.438 2.594,0.635 0.156,0.198 10 false W 2.448,0.792 2.604,0.99 0.156,0.198 10 false U 2.448,1.146 2.604,1.344 0.156,0.198 10 false V 2.677,0.385 2.833,0.583 0.156,0.198 10 false 4 2.677,0.74 2.833,0.938 0.156,0.198 10 false 5 2.667,1.125 2.823,1.323 0.156,0.198 10 false 6 1.073,1.594 2.125,1.76 1.052,0.167 10 false d1 1.063,1.729 3.281,2.417 2.219,0.688 10 false Hybrid Vehicle Transaxle Assembly (Generator (MG1)) 4.906,0.427 5.063,0.625 0.156,0.198 10 false 4 4.917,0.771 5.073,0.969 0.156,0.198 10 false 5 4.917,1.135 5.073,1.333 0.156,0.198 10 false 6 5.063,1.594 5.427,1.792 0.365,0.198 10 false d2 5.052,1.729 7.063,2.302 2.01,0.573 10 false Inverter with Converter Assembly 5.115,0.552 5.271,0.75 0.156,0.198 10 false W 5.115,0.906 5.271,1.104 0.156,0.198 10 false U 5.125,1.25 5.281,1.448 0.156,0.198 10 false V

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


PROCEDURE

1.CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Remove the inverter cover from the inverter with converter assembly.


c.
C412490

Check that the bolts for the motor cable are tightened to the specified torque, the generator cable is connected securely, and there are no contact problems.

Specified Condition:

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



d.

Disconnect the motor cable from the inverter with converter assembly.


e.

Check for arc marks at the terminals for the motor cable.

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



f.

Reconnect the motor cable.


g.

Reinstall the inverter cover.



A

2.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR (MG1))

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

2.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (GENERATOR (MG1))
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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Remove the inverter cover from the inverter with converter assembly.


c.

Disconnect the motor cable from the inverter with converter assembly.


d.
A407601C49
1.438,0.146 1.771,0.365 0.333,0.219 1.781,1.74 1.927,1 true 2.229,1.76 2.208,1 true 2.604,1.771 2.542,1.021 true 2.948,1.802 2.917,1.656 true 1.542,0.188 1.854,0.385 0.313,0.198 10 false d2 0.104,0.125 0.417,0.323 0.313,0.198 10 false *a 1.708,1.823 2.021,2.021 0.313,0.198 10 false W 2.188,1.813 2.5,2.01 0.313,0.198 10 false U 2.552,1.823 2.865,2.021 0.313,0.198 10 false V 2.896,1.844 3.208,2.042 0.313,0.198 10 false *1
*1 Shield Ground
*a Motor Cable (for MG1)
(Inverter with Converter Assembly Side)


Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

HINT:

If the generator (MG1) temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.


Standard Resistance:
Tester Connection Condition Specified Condition
d2-4 (W) - d2-5 (U) Power switch off 49.3 to 54.4 mΩ
d2-5 (U) - d2-6 (V) Power switch off 49.3 to 54.4 mΩ
d2-6 (V) - d2-4 (W) Power switch off 49.3 to 54.4 mΩ


NOTICE:
·

Use a direct current(DC) resistance tester with a 0.1 mΩ resolution capable of measuring the standard values above when performing this check.

The correct measurement cannot be taken if an alternating current(AC) resistance tester is used for this check.

·

Select the appropriate measurement range capable of measuring the standard values above when performing a measurement.

Do not select the inapproprate measurement range as the corrent resistance cannot be measured.



HINT:

To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).

R20 = Rt / {1 + 0.00393 X (T - 20)}

The calculation is based on the following:

R20: Resistance at 20°C (68°F) (mΩ)

Rt: Measured resistance (mΩ)

T: Temperature when the resistance is measured (°C)



e.

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

NOTICE:
·

Use a direct current(DC) resistance tester capable of measuring resistances of 100 MΩ or higher at DC 500 V when performing this check.

Do not use an alternating current(AC) resistance tester for this check as the correct measurement cannot be taken.

·

After DC 500 V is applied and insulation resistance value has stabilized, read the measured value.

Time is needed for the insulation resistance value to stabilize. If a measurement value is read before it has stabilized, the correct measurement cannot be taken.



Standard Resistance:
Tester Connection Condition Specified Condition
d2-4 (W) - Body ground and shield ground Power switch off 10 MΩ or higher
d2-5 (U) - Body ground and shield ground Power switch off 10 MΩ or higher
d2-6 (V) - Body ground and shield ground Power switch off 10 MΩ or higher



f.

Reconnect the motor cable.


g.

Reinstall the inverter cover.


Result:
Proceed to
OK
NG



OK

GENERATOR HIGH-VOLTAGE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

NG

3.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)
3.CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE 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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Remove the inverter with converter assembly.


c.
C412491

Check that the bolts for the motor cable are tightened to the specified torque, the motor cable is connected securely, and there are no contact problems.

Specified Condition:

T=10 N*m (102 kgf*cm, 7 ft.*lbf)



d.

Disconnect the motor cable from the hybrid vehicle transaxle assembly.


e.

Check for arc marks at the terminals for the generator cable.

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



f.

Reconnect the motor cable.


g.

Reinstall the inverter with converter assembly.



A

4.CHECK MOTOR CABLE (FOR MG1)

B

REPLACE MALFUNCTIONING PARTS

C

CONNECT SECURELY

4.CHECK MOTOR CABLE (FOR MG1)
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 power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.



b.

Remove the inverter with converter assembly.


c.

Remove the motor cable.


d.

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

A407602C21
1.75,0.615 2.042,0.865 0.292,0.25 5.135,0.615 5.427,0.865 0.292,0.25 2.979,1.979 3.094,2.219 true 2.115,1.458 1.938,2.188 true 2.375,1.458 2.323,2.177 true 2.646,1.458 2.76,2.156 true 5.938,1.24 6.104,2.135 true 5.698,1.24 5.719,2.115 true 5.427,1.24 5.229,2.115 true 6.542,1.521 6.656,1.76 true 0.177,0.156 0.49,0.354 0.313,0.198 10 false *a 1.823,0.677 2.135,0.875 0.313,0.198 10 false d2 5.208,0.677 5.521,0.875 0.313,0.198 10 false d1 3.167,2.167 3.479,2.365 0.313,0.198 10 false *1 1.875,2.229 2.188,2.427 0.313,0.198 10 false W 5.177,2.167 5.49,2.365 0.313,0.198 10 false W 2.292,2.229 2.604,2.427 0.313,0.198 10 false U 5.688,2.156 6,2.354 0.313,0.198 10 false U 2.729,2.229 3.042,2.427 0.313,0.198 10 false V 6.073,2.167 6.385,2.365 0.313,0.198 10 false V 6.74,1.719 7.052,1.917 0.313,0.198 10 false *1
*1 Shield Ground - -
*a Motor Cable - -


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
d2-4 (W) or d1-4 (W) - Shield ground Power switch off 10 MΩ or higher
d2-5 (U) or d1-5 (U) - Shield ground Power switch off 10 MΩ or higher
d2-6 (V) or d1-6 (V) - Shield ground Power switch off 10 MΩ or higher


NOTICE:

Wrap the terminals of the motor cable with insulating tape to prevent them from coming into contact with body ground.



e.

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

Standard Resistance:
Tester Connection Condition Specified Condition
d2-4 (W) - d1-4 (W) Power switch off Below 1 Ω
d2-5 (U) - d1-5 (U) Power switch off Below 1 Ω
d2-6 (V) - d1-6 (V) Power switch off Below 1 Ω
d2-4 (W) - d1-5 (U) Power switch off 10 MΩ or higher
d2-5 (U) - d1-6 (V) Power switch off 10 MΩ or higher
d2-6 (V) - d1-4 (W) Power switch off 10 MΩ or higher



f.

Reinstall the motor cable.


g.

Reinstall the inverter with converter assembly.


Result:
Proceed to
OK
NG



OK

REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

Click hereDrivetrain>P710 (HYBRID TRANSMISSION / TRANSAXLE)>HYBRID VEHICLE TRANSAXLE>REMOVAL


NG

REPLACE MOTOR CABLE

Click hereDrivetrain>P710 (HYBRID TRANSMISSION / TRANSAXLE)>MOTOR CABLE>REMOVAL