DRIVE BATTERY EXTERNAL CONNECTION SYSTEM

Inspection Procedure 2: Drive battery external connection system

note

When measuring the insulation resistance, set the range of the special tool electric insulation tester (MB992355) to 1,000 V.
Do not restore removed parts unless instructed to do so, and perform the inspection while disassembling the drive battery.
There may be multiple parts with lowered insulation resistance. Record the faulty parts and keep inspecting until the inspection procedures are completed.

TROUBLESHOOTING HINTS

DIAGNOSIS

Required Special Tools:

1.Bus bar covering check

(1) Remove the drive battery from the vehicle (Refer to DRIVE BATTERY REMOVAL AND INSTALLATION

(2) Remove the following parts from the drive battery (Refer to SERVICE PROCEDURE

(3) Remove the bus bar between the drive battery high voltage connector (rear) and junction box No. 2.

(4) Check that there is no damage on the bus bar covering.

Is the check result normal?

Record the bus bar as a faulty part. Then,

2.Bus bar covering check

(1) Remove the bus bar between the drive battery high voltage connector (front) and junction box No. 2.

(2) Check that there is no damage on the bus bar covering.

Is the check result normal?

Record the bus bar as a faulty part. Then,

3.Insulation resistance check of drive battery high voltage connector (front)

(1) Measure the insulation resistance between the P/N terminal of the drive battery high voltage connector (front) and a ground point.

+ terminal	– terminal	Normal condition
P terminal of the drive battery high voltage connector (front)	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more
N terminal of the drive battery high voltage connector (front)	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more

Is the check result normal?

Record the drive battery high voltage connector (front) as a faulty part. Then,

4.Insulation resistance check of drive battery high voltage connector (rear)

(1) Measure the insulation resistance between the P/N terminal of the drive battery high voltage connector (rear) and a ground point.

+ terminal	– terminal	Normal condition
P terminal of the drive battery high voltage connector (rear)	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more
N terminal of the drive battery high voltage connector (rear)	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more

Is the check result normal?

Record the drive battery high voltage connector (rear) as a faulty part. Then,

5.Insulation resistance check of junction box No. 2

(1) Measure the insulation resistance between the P/N terminal of the junction box No. 2 and a ground point.

+ terminal	– terminal	Normal condition
P terminal of the junction box No. 2	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more
N terminal of the junction box No. 2	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more

Is the check result normal?

Record the junction box No. 2 as a faulty part. Then,

6.Inspection result confirmation

(1) Confirm the faulty parts recorded in the previous procedures.

Is there any faulty part?

Replace all the recorded parts, then

7.Insulation resistance check of external connection system of drive battery

(1) Assemble the drive battery just before the battery tray cover installation (Refer to SERVICE PROCEDURE

(2) Measure the insulation resistance at the drive battery cable connecting part.

+ terminal	– terminal	Normal condition
Drive battery P terminal	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more
Drive battery N terminal	Ground point (ground bolt of the drive battery tray etc.)	50 MΩ or more

Is the check result normal?

The procedure is complete.