HYBRID CONTROL SYSTEM Generator High-voltage Circuit

DESCRIPTION

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

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

Related Parts Check
Area Inspection Step
Generator cable connection check Check for the connection condition of the cable from the inverter to the generator. 1, 3
Generator or generator cable Check the generator (including cable) internal resistance and the insulation resistance with body ground to check for an open or short circuit. 2
Generator cable Check the generator cable internal resistance and the insulation resistance with body ground to check for an open or short circuit. 4

WIRING DIAGRAM

B004E37E29

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 (GENERATOR 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. B004EFUC01
      *A for LHD
      *B for RHD

      Remove the inverter cover from the inverter with converter assembly.

    3. B004F15C01
      *A for LHD
      *B for RHD
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)

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

    7. Install the inverter cover.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  2. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (MG1)

    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. B004EFUC01
      *A for LHD
      *B for RHD

      Remove the inverter cover from the inverter with converter assembly.

    3. B004GCNC01
      *A for LHD
      *B for RHD
      *1

      Motor Cable

      (Inverter with Converter Assembly Side)
      *2

      Generator Cable

      (Inverter with Converter Assembly Side)

      Disconnect the generator cable and motor cable from the inverter with converter assembly.

    4. B004F9RC03
      *A for LHD
      *B for RHD
      *1 Shield Ground
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      Check generator (MG1) 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 generator (MG1) 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
        for LHD
        Tester Connection Condition Specified Condition
        r1-3 (W) -r1-1 (U) Power switch off 59.2 to 65.2 mΩ
        r1-2 (V) - r1-3 (W) Power switch off 62.2 to 68.2 mΩ
        r1-1 (U) - r1-2 (V) Power switch off 59.2 to 65.2 mΩ
        for RHD
        Tester Connection Condition Specified Condition
        r1-1 (W) -r1-3 (U) Power switch off 59.0 to 65.0 mΩ
        r1-2 (V) - r1-1 (W) Power switch off 61.9 to 67.9 mΩ
        r1-3 (U) - r1-2 (V) Power switch off 59.0 to 65.0 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)

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

      Note

      The motor generates current when wheels are rotated by hand. Before performing the inspection, wrap the motor cable terminals with insulation tape.

      Tech Tips

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

      6. Move the shift lever to P.

      7. Lower the vehicle.

      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
      for LHD
      Tester Connection Condition Specified Condition
      r1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      r1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-3 (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 motor phases without using a milliohmmeter.

      Standard Resistance
      for LHD
      Tester Connection Condition Specified Condition
      r1-3(W) - r1-2(V) Power switch off Below 1 Ω
      r1-2(V) - r1-1(U) Power switch off Below 1 Ω
      for RHD
      Tester Connection Condition Specified Condition
      r1-1(W) - r1-2(V) Power switch off Below 1 Ω
      r1-2(V) - r1-3(U) Power switch off Below 1 Ω

    8. Connect the generator cable and motor cable.

    9. Install the inverter cover.

      Result
      Proceed to
      OK
      NG

    OK

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

    NG

  3. CHECK HYBRID VEHICLE TRANSMISSION ASSEMBLY (GENERATOR 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. Remove the hybrid vehicle transmission assembly.

      Click here

    3. B004E1M

      Check that the bolts for the generator cable are tightened to the specified torque, the generator 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 generator cable from the hybrid vehicle transmission 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 generator cable to the hybrid vehicle transmission assembly.

    7. Install the hybrid vehicle transmission assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  4. CHECK GENERATOR 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. Remove the generator cable.

      Click here

    3. 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
      for LHD
      Tester Connection Condition Specified Condition
      r1-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-1 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      r1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-2 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      r1-3 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      B004FNWC03
      *A for LHD *B for RHD
      *1 Shield ground - -
      *a

      Generator Cable

      (Inverter with Converter Assembly Side)

      		 *b

      Generator Cable

      (Hybrid Vehicle Transmission Assembly Side)

      Note

      Wrap the terminal of the generator cable with insulating tape to prevent them from coming into contact with body ground.

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

      Standard Resistance
      for LHD
      Tester Connection Condition Specified Condition
      r1-3 (W) - r2-1 (U) Power switch off 100 MΩ or higher
      r1-2 (V) - r2-3 (W) Power switch off 100 MΩ or higher
      r1-1 (U) - r2-2 (V) Power switch off 100 MΩ or higher
      r1-3 (W) - r2-3 (W) Power switch off Below 1 Ω
      r1-2 (V) - r2-2 (V) Power switch off Below 1 Ω
      r1-1 (U) - r2-1 (U) Power switch off Below 1 Ω
      for RHD
      Tester Connection Condition Specified Condition
      r1-1 (W) - r2-1 (U) Power switch off 100 MΩ or higher
      r1-2 (V) - r2-3 (W) Power switch off 100 MΩ or higher
      r1-3 (U) - r2-2 (V) Power switch off 100 MΩ or higher
      r1-1 (W) - r2-3 (W) Power switch off Below 1 Ω
      r1-2 (V) - r2-2 (V) Power switch off Below 1 Ω
      r1-3 (U) - r2-1 (U) Power switch off Below 1 Ω

    5. Install the generator cable.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HYBRID VEHICLE TRANSMISSION ASSEMBLY Click here

    NG

    REPLACE GENERATOR CABLE Click here