Click here

HYBRID CONTROL SYSTEM Generator High-voltage Circuit

Click here
Click here
DTC Code DTC Name
  Generator High-voltage Circuit
Click here

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.

Table 1. Related Parts Check
Area Inspection
Generator cable connection check Check for the connection condition of the cable from the inverter to the generator.
Generator or generator cable Check the generator (including cable) internal resistance and the insulation resistance with body ground to check for an open or short circuit.
Click here

WIRING DIAGRAM

Click here

CAUTION / NOTICE / HINT

This step is referenced from the procedures for each DTC.

If the inspection results below are normal, perform the next procedure for the referenced DTC.

CAUTION:

  • B004STG

    Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.


    • Inspecting the high-voltage system

    • Disconnecting the low voltage connector of the inverter with converter assembly

    • Disconnecting the low voltage connector of the HV battery

  • B004Y5N

    To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

  • B004SX1

    After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • B004W3JC06
    *a Without waiting for 10 minutes

    After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work.

    Click here

    Tip:

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

Note:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

Click here

PROCEDURE


  1. Click here

    CHECK INVERTER WITH CONVERTER ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note:

      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.

    2. Remove the inverter cover from the inverter with converter assembly.

    3. B004TNOC03
      *A for LHD
      *B for RHD

      Check that the bolts for the generator 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)

    4. Disconnect the generator cable from the inverter with converter assembly.

    5. 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

    6. Connect the generator cable to the inverter with converter assembly.

    7. Install the inverter cover.


    • AClick here
    • B

      REPLACE MALFUNCTIONING PARTS

    • C

      CONNECT SECURELY

  2. Click here

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note:

      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.

    2. Remove the inverter cover from the inverter with converter assembly.

    3. Disconnect the generator cable from the inverter with converter assembly.

    4. B004SLDC05
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

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

      Tip:

      If the generator 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
      Table 2. for LHD:
      Tester Connection Condition Specified Condition
      g3-3 (W) - g3-1 (U) Power switch off 32.2 to 36.5 mΩ
      g3-1 (U) - g3-2 (V) Power switch off 31.0 to 35.3 mΩ
      g3-2 (V) - g3-3 (W) Power switch off 31.1 to 35.4 mΩ
      Table 3. for RHD:
      Tester Connection Condition Specified Condition
      g1-1 (W) - g1-3 (U) Power switch off 32.2 to 36.5 mΩ
      g1-3 (U) - g1-2 (V) Power switch off 31.0 to 35.3 mΩ
      g1-2 (V) - g1-1 (W) Power switch off 31.1 to 35.4 mΩ
      Tip:

      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)

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

      Note:

      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
      Table 4. for LHD:
      Tester Connection Condition Specified Condition
      g3-3 (W) - Body ground and shield ground Power switch off 10 MΩ or higher
      g3-1 (U) - Body ground and shield ground Power switch off 10 MΩ or higher
      g3-2 (V) - Body ground and shield ground Power switch off 10 MΩ or higher
      Table 5. for RHD:
      Tester Connection Condition Specified Condition
      g1-1 (W) - Body ground and shield ground Power switch off 10 MΩ or higher
      g1-3 (U) - Body ground and shield ground Power switch off 10 MΩ or higher
      g1-2 (V) - Body ground and shield ground Power switch off 10 MΩ or higher

    6. Reconnect the generator cable.

    7. Install the inverter cover.

      Result
      Proceed to
      OK
      NG

    • OK

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

    • NGClick here
  3. Click here

    CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR CABLE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note:

      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.

    2. Remove the inverter with converter assembly.

    3. B004U29

      Check that the bolts for the generator 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)

    4. Disconnect the generator cable from the hybrid vehicle transmission assembly.

    5. 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

    6. Connect the generator cable to the hybrid vehicle transmission assembly.

    7. Install the inverter with converter assembly.


    • AClick here
    • B

      REPLACE MALFUNCTIONING PARTS

    • C

      CONNECT SECURELY

  4. Click here

    CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note:

      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.

    2. Remove the generator cable.

    3. B004S47C02
      *A for LHD *B for RHD
      *1 Shielded Ground *a Generator Cable

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

      Note:

      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
      Table 6. for LHD:
      Tester Connection Condition Specified Condition
      g3-3 (W) or g2-3 (W) - Body ground and shield ground Power switch off 10 MΩ or higher
      g3-1 (U) or g2-1 (U) - Body ground and shield ground Power switch off 10 MΩ or higher
      g3-2 (V) or g2-2 (V) - Body ground and shield ground Power switch off 10 MΩ or higher
      Table 7. for RHD:
      Tester Connection Condition Specified Condition
      g1-1 (W) or g2-3 (W) - Body ground and shield ground Power switch off 10 MΩ or higher
      g1-3 (U) or g2-1 (U) - Body ground and shield ground Power switch off 10 MΩ or higher
      g1-2 (V) or g2-2 (V) - Body ground and shield ground Power switch off 10 MΩ or higher
      Note:

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

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

      Standard Resistance
      Table 8. for LHD:
      Tester Connection Condition Specified Condition
      g3-3 (W) - g2-3 (W) Power switch off Below 1 Ω
      g3-1 (U) - g2-1 (U) Power switch off Below 1 Ω
      g3-2 (V) - g2-2 (V) Power switch off Below 1 Ω
      g3-3 (W) - g2-1 (U) Power switch off 10 MΩ or higher
      g3-1 (U) - g2-2 (V) Power switch off 10 MΩ or higher
      g3-2 (V) - g2-3 (W) Power switch off 10 MΩ or higher
      Table 9. for RHD:
      Tester Connection Condition Specified Condition
      g1-1 (W) - g2-3 (W) Power switch off Below 1 Ω
      g1-3 (U) - g2-1 (U) Power switch off Below 1 Ω
      g1-2 (V) - g2-2 (V) Power switch off Below 1 Ω
      g1-1 (W) - g2-1 (U) Power switch off 10 MΩ or higher
      g1-3 (U) - g2-2 (V) Power switch off 10 MΩ or higher
      g1-2 (V) - g2-3 (W) Power switch off 10 MΩ or higher

    5. Install the generator cable.

      Result
      Result
      OK
      NG

    • OK

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY for 2WD:

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY for AWD:

      REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLYClick here

    • NG

      REPLACE GENERATOR CABLE for 2WD:

      REPLACE GENERATOR CABLEClick here

      REPLACE GENERATOR CABLE for AWD:

      REPLACE GENERATOR CABLEClick here