Voltage Converter: Testing and Inspection

P112 HYBRID VEHICLE CONTROL: INVERTER WITH CONVERTER: ON-VEHICLE INSPECTION

ON-VEHICLE INSPECTION

1. INSPECT INVERTER
CAUTION: Wear insulating gloves.
HINT: Check DTCs before performing the inspections on the converter and inverter, and perform the appropriate troubleshooting.

(a) Turn the power switch OFF.
(b) Remove the service plug grip Removal.





(c) Remove the inverter cover.
(1) Using a T30 "torx" socket, remove the screw.
(2) Remove the 12 bolts and inverter cover.





(d) Disconnect connectors A and B shown in the illustration.
(e) Turn the power switch ON (IG).
If turning the power switch ON (IG) with the service plug grip removed, the DTC of the interlock switch system will be output.
(f) Using a voltmeter, measure the voltage. Also, using an ohmmeter, measure the resistance.
NOTE: The inspection should be performed on the wire harness side, not on the terminal side.





Standard condition:









If the standards are not met, replace the inverter with converter assembly.
2. INSPECT CONVERTER




CAUTION: Wear insulating gloves.
HINT: If the HV system warning, master warning light and charge warning come on at the same time, check the DTCs and perform the appropriate troubleshooting.





(a) Check the operation.
(1) Using a voltmeter, measure the voltage of the auxiliary battery terminal when the "READY" light is OFF and ON.
Standard voltage:





HINT: When the "READY" light is ON, the converter outputs the voltage. When it is OFF, the auxiliary battery outputs the voltage.

(b) Inspect the output current.




(1) Remove the 5 bolts, and disconnect the MG1 power cables from the inverter.
CAUTION:
- Wear insulating gloves.
- Insulate the connector parts with insulating tape.




(2) Remove the 5 bolts, and disconnect the MG2 power cable.
CAUTION:
- Wear insulating gloves.
- Insulate the connector parts with insulating tape.




(3) Install a voltmeter and the AC/DC 400 A probe to the locations shown in the illustration.
(4) Connect the MG1 power cable to the MG1 power cable terminal with the 5 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulating gloves.
(5) Connect the MG2 power cable to the MG2 power cable terminal with the 3 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulating gloves.
(6) With the "READY" light ON, operate the 12 V electrical devices one by one, and then measure the output current.
Standard ampere:
Approximately 80 A or less
HINT: If the output current is 0 A or greater than 80 A, check the input/output signal.

(c) Check the input/output signal.




(1) Disconnect the connectors shown in the illustration.
(2) Using a voltmeter, measure the voltage between the body ground and the terminal of the vehicle side wire harness connector.
Standard condition:
Equal to the auxiliary battery terminal voltage




(3) Disconnect the connectors shown in the illustration.




(4) Turn the power switch ON (IG). Using a voltmeter and ohmmeter, measure the voltage and resistance between the connector terminals on the vehicle harness side.
Standard condition:






If the standards are not met, replace the inverter with converter assembly.