HYBRID CONTROL SYSTEM Motor Resolver Circuit

DESCRIPTION

The cause of this malfunction may be the drive motor resolver.

Check the drive motor resolver internal resistance and the connection condition from the inverter to the resolver.

Related Parts Check
Area Inspection Step
Wire harness and connector between the inverter and drive motor resolver Check for short circuit between wire harness and +B side. 1
Resolver, wire harness, connector Check the internal resistance of resolver (including wire harness), body ground resistance, and connector connection condition. 2, 3
Wire harness Check for open or short circuit in wire harness. 4

SYSTEM DESCRIPTION

A resolver is a sensor that is used to detect the position of the magnetic poles of the rotor of a drive motor. Knowing the position of the poles is indispensable for ensuring precise control of the drive motor.

Each resolver contains a stator that has an excitation coil and 2 detection coils (S, C). The gap between the stator and rotor changes as the rotor turns because the rotor is oval shaped. An alternating current with a predetermined frequency flows through the excitation coil, and detection coils S and C output alternating currents in accordance with the sensor rotor position.

The MG ECU, which is built into the inverter with converter assembly, detects the absolute position of the rotor according to the phases of detection coils S and C and the heights of their waveforms. Furthermore, the CPU calculates the amount of change in the position within a predetermined length of time, in order to use the resolver as a revolution speed sensor.

The MG ECU monitors signals output from the drive motor resolver and detects malfunctions.

B000ZMME19

WIRING DIAGRAM

B000ZHCE21

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:


  • B006JFB
    B006JM4

    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 grips from both FC stack assembly and EV battery.


    • Inspecting the high-voltage system

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

    • Disconnecting the low voltage connector of the EV battery

    • Disconnecting the low voltage connector of the FC stack assembly

    • Disconnecting the low voltage connector of the FC converter assembly

      Tech Tips

      No removal order is specified for the service plug grips of the FC stack assembly and EV battery.

  • B006JBZ

    After removing the service plug grip from the EV battery, 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 grip from the FC stack assembly, store it in a safe location and use the "HIGH-VOLTAGE, DO NOT TOUCH" sign to notify other technicians that you are working on the high-voltage system.

  • B000ZMTC04
    *a Without waiting for 10 minutes

    After removal of the service plug grips of both FC stack assembly and EV battery, wait for at least 10 minutes before touching the high-voltage connectors and 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

    Tech Tips

    At least 10 minutes are necessary to discharge the high-voltage capacitors inside the inverter with converter assembly and FC stack 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.

    Click here

  • When reinstalling the service plug grip to the FC stack assembly or the EV battery, slide the lever of the service plug until the letters "UNLOCK" are completely hidden, and insert it firmly.

    Click here

  • When the vehicle is parked with the power switch off, if the FC control ECU judges that the FC stack temperature will go below 0°C (32°F), it activates the FC air compressor, hydrogen pump and FC cooling water pump for a maximum of 180 seconds and drains water from the FC stack assembly. When performing inspection or repairs with the power switch off (not on (IG) or on (READY)), disconnect the cable from the negative (-) auxiliary battery terminal before performing work (If the auxiliary battery voltage is needed to conduct inspection, warm up the FC system beforehand).

Tech Tips


  • If the problem symptom cannot be reproduced, performing a road test on a road on which the vehicle tends to vibrate will make it easier to reproduce the symptom.

  • If the resolver is malfunctioning, the vehicle may not drive smoothly.

PROCEDURE


  1. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DRIVE MOTOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed to FC stack assembly and EV battery.

      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. Disconnect the inverter with converter assembly connector.

      Click here

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

    4. Turn the power switch on (IG).

    5. B000ZHQC51
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      D1-4 (MRF) - Body ground Power switch on (IG) Below 1 V
      D1-11 (MRFG) - Body ground Power switch on (IG) Below 1 V
      D1-5 (MSN) - Body ground Power switch on (IG) Below 1 V
      D1-12 (MSNG) - Body ground Power switch on (IG) Below 1 V
      D1-6 (MCS) - Body ground Power switch on (IG) Below 1 V
      D1-13 (MCSG) - Body ground Power switch on (IG) Below 1 V

      Note

      Turning the power switch on (IG) with the inverter with converter assembly disconnected causes other DTCs to be stored. Clear the DTCs after performing this inspection.

    6. Turn the power switch off.

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

    8. Reconnect the inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  2. CHECK DRIVE MOTOR RESOLVER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed to FC stack assembly and EV battery.

      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. Disconnect the inverter with converter assembly connector.

    3. B000ZHQC52
      *a

      Front view of wire harness connector

      (to Inverter with Converter Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      D1-4 (MRF) - D1-11 (MRFG) Power switch off 5.8 to 11.8 Ω
      D1-5 (MSN) - D1-12 (MSNG) Power switch off 11.7 to 17.7 Ω
      D1-6 (MCS) - D1-13 (MCSG) Power switch off 11.7 to 17.7 Ω
      D1-4 (MRF) or D1-11 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-5 (MSN) or D1-12 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-6 (MCS) or D1-13 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

    4. Reconnect the inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    OK

    MOTOR RESOLVER CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

    NG

  3. CHECK CONNECTOR CONNECTION CONDITION (DRIVE MOTOR RESOLVER CONNECTOR)


    1. A01MH08

      Check the connection condition of the drive motor resolver connector and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

      Click here

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  4. CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY - DRIVE MOTOR RESOLVER)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed to FC stack assembly and EV battery.

      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. Disconnect the inverter with converter assembly connector.

    3. Disconnect the drive motor resolver connector.

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

      B000ZIVC13
      *a

      Front view of wire harness connector

      (to Motor Resolver)

      		 *b

      Front view of wire harness connector

      (to Inverter with Converter Assembly)
      Standard Resistance
      Tester Connection Condition Specified Condition
      D1-4 (MRF) - D6-1 (MRF) Power switch off Below 1 Ω
      D1-11 (MRFG) - D6-4 (MRFG) Power switch off Below 1 Ω
      D1-5 (MSN) - D6-2 (MSN) Power switch off Below 1 Ω
      D1-12 (MSNG) - D6-5 (MSNG) Power switch off Below 1 Ω
      D1-6 (MCS) - D6-3 (MCS) Power switch off Below 1 Ω
      D1-13 (MCSG) - D6-6 (MCSG) Power switch off Below 1 Ω
      D1-4 (MRF) or D6-1 (MRF) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-11 (MRFG) or D6-4 (MRFG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-5 (MSN) or D6-2 (MSN) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-12 (MSNG) or D6-5 (MSNG) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-6 (MCS) or D6-3 (MCS) - Body ground and other terminals Power switch off 1 MΩ or higher
      D1-13 (MCSG) or D6-6 (MCSG) - Body ground and other terminals Power switch off 1 MΩ or higher

      Tech Tips

      The motor resolver is not available as a supply part. If it requires replacement, replace the FCV transaxle with motor assembly.

    5. Reconnect the drive motor resolver connector.

    6. Reconnect the inverter with converter assembly connector.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE FCV TRANSAXLE WITH MOTOR ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR