HYBRID CONTROL SYSTEM Rear Motor High-voltage Circuit

DESCRIPTION

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

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

Related Parts Check
Area Inspection Step
Rear motor cable connection check Check for open circuit in the connection condition of the cable from the inverter to the rear motor. 1, 3
Rear motor, rear motor cable, extension wire Check the rear motor (including cable) internal resistance and the insulation resistance with body ground to check for an open or short circuit. 2
Rear motor cable Check for open or short in rear motor cable. 4
Extension wire Check for open or short circuit in extension wire. 5

WIRING DIAGRAM

B002K8IE01
*a Extension Wire Assembly
*b Rear Traction Motor with Transaxle Assembly (Rear Motor (MGR))
*c Inverter with Converter Assembly
*d High Voltage Line

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:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • 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.

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    Tech Tips

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

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.

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PROCEDURE


  1. CHECK INVERTER WITH CONVERTER ASSEMBLY (NO. 2 FRAME WIRE (REAR MOTOR 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. B002JUO

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

    3. B002IZUC01
      *1 No. 2 Frame Wire (Rear Motor Cable)

      Check that the bolts for the No. 2 frame wire (rear motor cable) are tightened to the specified torque, the No. 2 frame wire (rear motor cable) is connected securely, and there are no contact problems.

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

      Note

      Make sure that the tightening torque of the bolt is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. Disconnect the No. 2 frame wire (rear motor 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 No. 2 frame wire (rear motor cable) to the inverter with converter assembly.

    7. Install the inverter cover UPR.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  2. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (REAR MOTOR (MGR))

    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. B002JUO

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

    3. B002IZUC01
      *1 No. 2 Frame Wire (Rear Motor Cable)

      Disconnect the No. 2 frame wire (rear motor cable) from the inverter with converter assembly.

    4. B002JCBC30
      *1 Shield Ground
      *a

      No. 2 Frame Wire (rear motor cable)

      (Inverter with Converter Assembly Side)

      Check the rear motor (MGR) for an interphase short using a milliohmmeter.


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

        Tech Tips

        If the rear motor (MGR) 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
        t1-1 (R-W) - t1-3 (R-U) Power switch off 163 to 176 mΩ
        t1-2 (R-V) - t1-1 (R-W) Power switch off 163 to 176 mΩ
        t1-3 (R-U) - t1-2 (R-V) Power switch off 163 to 176 mΩ

        Tech Tips

        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 (°F).)

    5. When checking for a short circuit between rear motor phases without using a milliohmmeter.

      Note

      The rear motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the rear motor cable terminals with tape (non-residue type) or equivalent.

      Tech Tips

      A short circuit between the rear motor phases can be checked simply without using a milliohmmeter.


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

      2. Turn the power switch on (IG).

        Note

        Turning the power switch on (IG) with the service plug grip removed causes other DTCs to be stored. Clear the DTCs after performing this inspection.

      3. Move the shift lever to N.

      4. Lift up the vehicle.

      5. Rotate the rear wheels in the same direction simultaneously by hand.

        Standard
        Left and right wheels rotate smoothly (No short circuit between phases)

        Tech Tips

        If a short circuit exists between the rear motor phases, the rear wheels do not rotate smoothly (some resistance is felt).

      6. Lower the vehicle.

      7. Move the shift lever to P.

      8. Turn the power switch off.

      9. Disconnect the cable from the negative (-) auxiliary battery terminal.

    6. 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
      Tester Connection Condition Specified Condition
      t1-1 (R-W) - Body ground and shield ground Power switch off 100 MΩ or higher
      t1-2 (R-V) - Body ground and shield ground Power switch off 100 MΩ or higher
      t1-3 (R-U) - Body ground and shield ground Power switch off 100 MΩ or higher

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

      Tech Tips

      Perform this procedure only when checking for a short circuit between rear motor phases without using a milliohmmeter.

      Standard Resistance
      Tester Connection Condition Specified Condition
      t1-1 (R-W) - t1-2 (R-V) Power switch off Below 1 Ω
      t1-2 (R-V) - t1-3 (R-U) Power switch off Below 1 Ω

    8. Reconnect the No. 2 frame wire (rear motor cable).

    9. Install the inverter cover UPR.

      Result
      Proceed to
      OK
      NG

    OK

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

    NG

  3. CHECK REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (NO. 2 FRAME WIRE (REAR MOTOR 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. B002KPI

      Check that the bolts for the No. 2 frame wire (rear motor cable) are tightened to the specified torque, the No. 2 frame wire (rear motor cable) is connected securely, and there are no contact problems.

      Specified Condition
      T = 15 N*m (153 kgf*cm, 11 ft.*lbf)

      Note

      Make sure that the tightening torque of the bolt is between 12 and 18 N*m (122 and 184 kgf*cm, 9 and 13 ft.*lbf).

    3. Disconnect the No. 2 frame wire (rear motor cable) from the rear traction motor with transaxle assembly

    4. Check for arc marks at the bolts for the No. 2 frame wire (rear 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

    5. Connect the No. 2 frame wire (rear motor cable).


    B

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    C

    CONNECT SECURELY

    A

  4. CHECK NO. 2 FRAME WIRE (REAR MOTOR 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. B002JUO

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

    3. B002IZUC01
      *1 No. 2 Frame Wire (Rear Motor Cable)

      Disconnect the No. 2 frame wire (rear motor cable) from the inverter with converter assembly.

    4. B002KPI

      Disconnect the No. 2 frame wire (rear motor cable) from the rear traction motor with transaxle assembly.

    5. B002JCBC30
      *1 Shield Ground
      *a

      No. 2 Frame Wire (rear motor cable)

      (Inverter with Converter Assembly Side)

      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
      Tester Connection Condition Specified Condition
      t1-1 (R-W) - Body ground and shield ground Power switch off 10 MΩ or higher
      t1-2 (R-V) - Body ground and shield ground Power switch off 10 MΩ or higher
      t1-3 (R-U) - Body ground and shield ground Power switch off 10 MΩ or higher

      Note

      Wrap the terminals of three-phase AC cable with insulating tape to avoid them coming into contact with body ground.

    6. B002KCZC02
      *1 Shield Ground
      *a

      No. 2 Frame Wire (rear motor cable)

      (Inverter with Converter Assembly Side)
      *b

      No. 2 Frame Wire (rear motor cable)

      (Rear Traction Motor with Transaxle Assembly Side)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      t1-1 (R-W) - t3-1 (R-W) Power switch off Below 1 Ω
      t1-2 (R-V) - t3-2 (R-V) Power switch off Below 1 Ω
      t1-3 (R-U) - t3-3 (R-U) Power switch off Below 1 Ω
      t1-1 (R-W) - t3-3 (R-U) Power switch off 10 kΩ or higher
      t1-2 (R-V) - t3-1 (R-W) Power switch off 10 kΩ or higher
      t1-3 (R-U) - t3-2 (R-V) Power switch off 10 kΩ or higher

    7. Connect the No. 2 frame wire (rear motor cable) to the rear traction motor with transaxle assembly.

    8. Connect the No. 2 frame wire (rear motor cable) to the inverter with converter assembly.

    9. Install the inverter cover UPR.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 2 FRAME WIRE Click here

    OK

  5. CHECK EXTENSION WIRE ASSEMBLY

    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 extension wire assembly from the rear traction motor with transaxle assembly.

      Click here

    3. B002KNYC01
      *1 Extension Wire Assembly
      *2 Shield Shell

      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
      Tester Connection Condition Specified Condition
      R-U - Shield shell Power switch off 100 MΩ or higher
      R-V - Shield shell Power switch off 100 MΩ or higher
      R-W - Shield shell Power switch off 100 MΩ or higher

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      R-U - R-U Power switch off Below 1 Ω
      R-V - R-V Power switch off Below 1 Ω
      R-W - R-W Power switch off Below 1 Ω
      R-U - R-V Power switch off 100 kΩ or higher
      R-V - R-W Power switch off 100 kΩ or higher
      R-W - R-U Power switch off 100 kΩ or higher

    5. Install the extension wire.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY Click here

    NG

    REPLACE EXTENSION WIRE ASSEMBLY Click here