INVERTER WITH CONVERTER INSTALLATION

CAUTION / NOTICE / HINT

Note

If the inverter with converter assembly has been replaced with a new one, make sure to lock the No. 1 inverter cooling hose retainer.

A00080PE04
Text in Illustration
*1 Retainer

PROCEDURE


  1. INSTALL NO. 3 ENGINE ROOM WIRE


    1. A0003JP

      Temporarily install the No. 3 engine room wire to the inverter with converter assembly with the nut.

    2. Tighten the nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    3. Close the cover.

  2. INSTALL NO. 1 INVERTER COOLING HOSE


    1. A000931E04
      Text in Illustration
      *1 Retainer

      Connect the No. 1 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

      • To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

  3. INSTALL NO. 2 MOTOR CABLE BRACKET


    1. Install the No. 2 motor cable bracket to the inverter with converter assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL NO. 1 MOTOR CABLE BRACKET


    1. Install the No. 1 motor cable bracket to the inverter with converter assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL NO. 3 INVERTER BRACKET


    1. Temporarily install the No. 3 inverter bracket to the inverter with converter assembly with the 2 bolts.

    2. A0008WWE04

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  6. INSTALL NO. 2 INVERTER BRACKET


    1. Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.

    2. A0005YVE04

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  7. INSTALL NO. 1 INVERTER BRACKET


    1. Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.

    2. A0005Q9E04

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  8. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket to the inverter with converter assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  9. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket to the inverter with converter assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  10. INSTALL HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tech Tips

    Perform this procedure only when replacement of the high voltage fuse is necessary.


    1. Remove the bolt and connector cover assembly from the inverter with converter assembly.

      Note


      • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.

      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

    2. Install the high voltage fuse to the inverter with converter assembly with 2 new nuts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the nuts.

    3. Temporarily install the connector cover assembly with the bolt to prevent any foreign matter or water from entering the inverter with converter assembly.

  11. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. Temporarily install the inverter with converter assembly with the 2 bolts and nut.

      Note


      • Since the inverter with converter assembly is very heavy, 2 people are needed to install the inverter with converter assembly. When installing the inverter with converter assembly, do not damage the parts around it.

      • To prevent damage, do not hold the inverter with converter assembly by the connectors.

      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

    2. A0005IHE04

      Fully tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  12. CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY


    1. A0007QOE03
      Text in Illustration
      *1 Retainer

      Connect the No. 1 inverter cooling hose assembly to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

      • To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

  13. CONNECT NO. 4 INVERTER COOLING HOSE


    1. A00047EE03
      Text in Illustration
      *1 Retainer

      Connect the No. 4 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

      • To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses until installation.

  14. CONNECT NO. 3 ENGINE ROOM WIRE


    1. Connect the clamp to the engine room relay block and junction block assembly.

    2. Install the No. 3 engine room wire to the engine room relay block and junction block assembly with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Install the relay block cover to the engine room relay block and junction block assembly.

  15. CONNECT LOW VOLTAGE CONNECTOR

    CAUTION:

    Wear insulated gloves.


    1. A0008G1

      Connect the 3 low voltage connectors and lock the connector with the lock lever.

      Note


      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

      • Make sure that the connectors are fully engaged.

  16. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  17. CONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Do not damage the terminals, connector housings or inverter with converter assembly during connection.

    • Do not touch the connector waterproofing rubber or terminals.

    • Make sure that the connector is fully engaged.

    • Do not allow any foreign matter or water to enter the inverter with converter assembly.

    • Make sure that the connector does not come out when its body is pulled.


    1. Connect the frame wire and wire harness clamp to the inverter with converter assembly.

    2. Secure the frame wire to the inverter with converter assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  18. CONNECT NO. 4 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Do not damage the terminals, connector housings or inverter with converter assembly during connection.

    • Do not touch the connector waterproofing rubber or terminals.

    • Make sure that the connector is fully engaged.

    • Do not allow any foreign matter or water to enter the inverter with converter assembly.

    • Make sure that the connector does not come out when its body is pulled.


    1. Connect the No. 4 engine wire to the inverter with converter assembly.

    2. Connect the wire harness clamp to the No. 2 motor cable bracket.

  19. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. Install the connector cover assembly to the inverter with converter assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • Make sure that the interlock is fully engaged.

      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

  20. INSTALL NO. 3 MOTOR CABLE BRACKET


    1. Install the No. 3 motor cable bracket to the inverter with converter assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the hose clamp to the No. 3 motor cable bracket.

  21. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Do not damage the terminals, connector housings or inverter with converter assembly during connection.

    • Do not touch the connector waterproofing rubber or terminals.

    • Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. Connect the motor cable to the inverter with converter assembly.

    2. Connect the 3 wire harness clamps.

    3. Using an insulated tool, secure the motor cable to the inverter with converter assembly with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • The terminals should be connected securely.

      • The bolts should be tightened securely.

  22. INSTALL UPPER INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. Install the upper inverter cover (motor cable side) to the inverter with converter assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • Do not touch the upper inverter cover waterproofing rubber.

      • Visually confirm that the upper inverter cover waterproofing rubber is securely installed before installing the upper inverter cover.

      • Make sure that the interlock is fully engaged.

  23. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Do not damage the terminals, connector housings or inverter with converter assembly during connection.

    • Do not touch the connector waterproofing rubber or terminals.

    • Do not allow any foreign matter or water to enter the inverter with converter assembly.


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

    2. Connect the 2 wire harness clamps.

    3. Using an insulated tool, secure the generator cable to the inverter with converter assembly with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • The terminals should be connected securely.

      • The bolts should be tightend securely.

  24. INSTALL UPPER INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. Install the upper inverter cover (generator cable side) to the inverter with converter assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • Do not touch the upper inverter cover waterproofing rubber.

      • Visually confirm that the upper inverter cover waterproofing rubber is securely installed before installing the upper inverter cover.

      • Make sure that the interlock is fully engaged.

  25. INSTALL NO. 4 INVERTER BRACKET


    1. Temporarily install the No. 4 inverter bracket with the 3 bolts.

    2. A000487E02

      Tighten the 3 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  26. INSTALL NO. 5 INVERTER BRACKET


    1. Temporarily install the No. 5 inverter bracket with the 2 bolts.

    2. A00095QE04

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  27. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  28. INSTALL AIR CLEANER FILTER ELEMENT

    Click here

  29. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  30. INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

  31. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  32. INSTALL SERVICE PLUG GRIP

    Click here

  33. ADD COOLANT (for Inverter)

    Click here

  34. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here