HYBRID CONTROL SYSTEM Motor High-voltage Circuit

DESCRIPTION

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

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

For high voltage wiring diagrams, refer to the system description.

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Related Parts Check
Area Inspection Step
Drive motor cable connection check Check for open or short circuit in the connection condition of the cable from the inverter to the drive motor. 1
Drive motor and drive motor cable Check the drive motor (including cable) internal resistance and insulation resistance with body ground to check for an open or short circuit. 2

WIRING DIAGRAM

B000ZM6E17
*a FCV Transaxle with Motor Assembly
*b Inverter with Converter Assembly
*c 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:


  • 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.

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    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.

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  • 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.

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  • 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).

PROCEDURE


  1. CHECK INVERTER WITH CONVERTER ASSEMBLY (MOTOR CABLE CONNECTION CONDITION)

    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. B000ZNG

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

      Tech Tips

      Make sure that no foreign matter, coolant or water has entered the inverter assembly with converter. Confirm that the inverter coolant volume has not increased.

    3. B000ZFNC02
      *1 Drive motor Cable

      Check that the bolts for the drive motor cable are tightened to the specified torque, the drive 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 drive motor cable from the inverter with converter assembly.

    5. Check for arc marks at the terminals for the drive 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

    6. Connect the drive motor cable to the inverter with converter assembly.

    7. Install the inverter terminal cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  2. CHECK FCV TRANSAXLE WITH MOTOR ASSEMBLY

    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. B000ZNG

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

      Tech Tips

      Make sure that no foreign matter, coolant or water has entered the inverter assembly with converter. Confirm that the inverter coolant volume has not increased.

    3. B000ZFNC03
      *1 Drive motor Cable

      Disconnect the drive motor cable from the inverter with converter assembly.

    4. B000ZSGC02
      *1 Shield Ground
      *a

      Drive motor Cable

      (Inverter with Converter Assembly Side)

      Check the drive motor 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 drive motor 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
        i2-1 (W) - i2-3 (U) Power switch off 52.4 to 58.4 mΩ
        i2-2 (V) - i2-1 (W) Power switch off 50.5 to 56.5 mΩ
        i2-3 (U) - i2-2 (V) Power switch off 50.5 to 56.5 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 drive motor phases without using a milliohmmeter.

      Note

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

      Tech Tips

      A short circuit between the drive 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 front 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 drive motor phases, the front 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
      i2-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      i2-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      i2-3 (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 drive motor phases without using a milliohmmeter.

      Standard Resistance
      Tester Connection Condition Specified Condition
      i2-1 (W) - i2-2 (V) Power switch off Below 1 Ω
      i2-2 (V) - i2-3 (U) Power switch off Below 1 Ω

    8. Reconnect the drive motor cable.

    9. Install the inverter terminal cover.

      Result
      Proceed to
      OK
      NG

    OK

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

    NG

    REPLACE FCV TRANSAXLE WITH MOTOR ASSEMBLY Click here