HYBRID CONTROL SYSTEM HV Battery High-voltage Line Circuit

DESCRIPTION

The cause of the malfunction may be the HV battery high-voltage line circuit.

Check the continuity in the high-voltage line from the HV battery to the inverter.

Check the connection condition and for an open circuit in the frame wire from the service plug grip and HV battery to the inverter and perform a function check of the system main relay.

Related Parts Check
Area Inspection Step
High-voltage circuit from HV battery to inverter Check connection condition and for open circuit. 1, 4, 5, 6, 7
Service plug grip Check connection condition and for open circuit. 2, 3
System Main Relay Check operation condition as relay. 8, 9

SYSTEM DESCRIPTION

The HV battery high voltage is supplied to the inverter via the system main relay operation.

WIRING DIAGRAM

B004EQLE11

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.

    Click here

    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 (FRAME WIRE 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. B004E6OC01
      *A for LHD
      *B for RHD

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

    3. B004FBBC01
      *A for LHD
      *B for RHD

      Check that the bolt for the frame wire is tightened to the specified torque, the frame wire 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 frame wire from the inverter with converter assembly.

    5. Check for arc marks on the terminals of the frame wire.

      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. Reconnect the frame wire to the inverter with converter assembly.

    7. Install the connector cover assembly to the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  2. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK
      Dirt or foreign matter has not entered the connectors, and there is no evidence of contamination.

    2. Install the service plug grip.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  3. INSPECT SERVICE PLUG GRIP


    1. Remove the service plug grip.

      Click here

    2. B004FRCC02
      *1 Service Plug Grip

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    3. Install the service plug grip.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  4. CHECK HYBRID BATTERY TERMINAL BLOCK (FRAME WIRE 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 No. 4 hybrid battery shield panel.

      Click here

    3. B004GF3

      Check the connector connection condition between the frame wire and the hybrid battery terminal block.

    4. Disconnect the frame wire from the hybrid battery terminal block.

    5. Check for arc marks on the terminals of the frame wire.

      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. Reconnect the frame wire to the hybrid battery terminal block.

    7. Install the No. 4 hybrid battery shield panel.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  5. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HYBRID BATTERY TERMINAL BLOCK 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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004EVK

      Check that the hybrid battery terminal block nuts are tightened to the specified torque and the hybrid battery terminal block is not loose or has poor contact.

      Specified Condition
      T=9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Remove the hybrid battery terminal block.

      Click here

    5. Check for arc marks on the terminals of the HV battery high voltage terminals.

      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. Install the upper No. 1 hybrid battery cover sub-assembly.

    7. Install the hybrid battery terminal block.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  6. CHECK FRAME WIRE

    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 No. 4 hybrid battery shield panel.

      Click here

    3. B004GF3

      Disconnect the frame wire from the hybrid battery terminal block.

    4. B004E6OC01
      *A for LHD
      *B for RHD

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

    5. B004FBBC01
      *A for LHD
      *B for RHD

      Disconnect the frame wire from the inverter with converter assembly.

    6. B004GSOC10
      *1 Shield Ground
      *a

      Frame Wire

      (Inverter with Converter Assembly Side)
      *b

      Frame Wire

      (Hybrid Battery Terminal Block Side)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      V2-1 (CBI) - V5-1 (CBI) Power switch off Below 1 Ω
      V2-2 (CEI) - V4-1 (CEI) Power switch off Below 1 Ω

    7. 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
      V2-1 (CBI) or V5-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      V2-2 (CEI) or V4-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      V2-1 (CBI) - V2-2 (CEI) or V5-1 (CBI) - V4-1 (CEI) Power switch off 10 MΩ or higher

    8. Reconnect the frame wire to the inverter with converter assembly.

    9. Reconnect the frame wire to the hybrid battery terminal block.

    10. Install the connector cover assembly.

    11. Install the No. 4 hybrid battery shield panel.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE FRAME WIRE Click here

    OK

  7. CHECK HYBRID BATTERY TERMINAL BLOCK

    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004EA6C11
      *a

      Component without harness connected

      (Hybrid Battery Terminal Block)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A-1 (CBI) - V5-1 (CBI) Power switch off Below 1 Ω
      B-1 (CEI) - V4-1 (CEI) Power switch off Below 1 Ω

    4. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    OK

  8. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    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 HV battery junction block assembly.

      Click here

    3. B004E4MC08
      *a

      Component without harness connected

      (HV Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      o1-1 (+) - A-1 (CBI) Auxiliary battery voltage not applied between terminals p2-4 (SMRB) and p2-2 (GND) 10 kΩ or higher
      o1-1 (+) - A-1 (CBI) Auxiliary battery voltage applied between terminals p2-4 (SMRB) and p2-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      p2-4 (SMRB) - p2-2 (GND) -40 to 80°C (-40 to 176°F) 18.4 to 36.3 Ω

    5. Install the HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  9. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    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 HV battery junction block assembly.

      Click here

    3. B004E4MC09
      *a

      Component without harness connected

      (HV Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      n2-1 (-) - B-1 (CEI) Auxiliary battery voltage not applied between terminals p2-1 (SMRG) and p2-2 (GND) 10 kΩ or higher
      n2-1 (-) - B-1 (CEI) Auxiliary battery voltage applied between terminals p2-1 (SMRG) and p2-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      p2-1 (SMRG) - p2-2 (GND) -40 to 80°C (-40 to 176°F) 18.4 to 36.3 Ω

    5. Install the HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    OK

    HV BATTERY HIGH-VOLTAGE LINE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here