Removal [11/2018 - 02/2019]: Procedure

Refer to REMOVAL [11/2018 - 02/2019] 

See step  22

See step  23

See step  24

1. Remove the protective tape from the HV floor under wire opening.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Tape

2. Using a voltmeter, measure the voltage between the high voltage cable connector terminals.

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   *a	Voltage Measurement Position

   Standard voltage

   0 V

   HINT: 

   • Use measuring range of DC 750 V or more on the voltmeter.
   • If it is confirmed that high-voltage is not being applied to the inverter with converter assembly, the following procedures can be performed without using insulated tools or gloves.
3. Apply protective tape to the area that was exposed.
   NOTE:

   Use non-residue type tape.

1. Using a piece of cloth, clean the outside of the inverter with converter assembly and around the bolts.
   NOTE:

   To prevent foreign matter from entering the inverter with converter assembly, make sure that the protective tape is not partially removed.

• SST: 09890-47010 

1. Wear an antistatic wrist strap.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Connect the ground clip of the antistatic mat securely to a ground point provided in the workshop or on a workbench (anchor bolt).

   HINT: 

   If the ground clip cable is too short, use an extension cable.

3. Connect the ground clip of the antistatic wrist strap securely to the specified point of the antistatic mat.
4. When handling internal components of the inverter with converter assembly, use only antistatic gloves or bare hands to prevent damage from static electricity or the entry of foreign matter.

1. Place the inverter with converter assembly on a stand as shown in the illustration.
   NOTE:

   • Make sure to use the stand, otherwise the low voltage connectors or inverter upper cover may be damaged.
   • Make sure to place the inverter with converter assembly on the stand so that the coolant pipes are positioned downward.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Connect the ground clip of the antistatic wrist strap securely to the inverter with converter assembly.
3. Remove the 2 caps from the coolant pipes and drain the coolant (for inverter).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Blow compressed air into the inverter with converter assembly until most all of the coolant (for inverter) is blown out.

   NOTE:

   • Do not damage the coolant pipes.
   • Apply compressed air to the silver colored coolant pipe.

   HINT: 

   • Use a piece of cloth as shown in the illustration to prevent the coolant (for inverter) from spraying.
   • Cover the air inlet port with a piece of cloth to minimize air leakage.
   1. Install the 2 caps to the coolant pipes.

1. Remove the 8 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Using a screwdriver with its tip wrapped with protective tape, remove the converter cover from the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Protective Tape

   -

   -

   NOTE:

   • Do not damage the sealing surfaces of the inverter with converter assembly.
   • Do not touch or allow grease or oil to contact the sealing surfaces of the inverter with converter assembly.
   • Be careful not to damage the sealing surfaces of the inverter with converter assembly.
   • To prevent internal components of the inverter with converter assembly from being damaged, do not insert the screwdriver excessively.

1. Using a finger, remove any seal packing that has seeped into the inverter with converter assembly.

   HINT: 

   Make sure to remove any seal packing which has seeped toward the inside of inverter with converter assembly before installing the seal packing removal cover, otherwise the seal packing may be pushed into the inverter with converter assembly.

2. Break off the seal packing removal cover and scraper at each break off line.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Set the seal packing removal cover on the inverter with converter assembly and secure it with tape.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Tape

   NOTE:

   Make sure that the seal packing removal cover is in secure contact with the inside surface of the inverter with converter assembly without any gaps.

4. Place the inverter with converter assembly on its side on an antistatic mat as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	MG Connector Opening

   NOTE:

   • Make sure that the MG connector opening in the inverter with converter assembly is facing upward.
   • Make sure that the inverter with converter assembly is oriented correctly, otherwise seal packing may enter the inverter with converter assembly.
5. Using a scraper, remove any remaining seal packing from the inverter with converter assembly.
   NOTE:

   • It is not necessary to remove small amounts of seal packing which are not easily scraped off.

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

     *a	Correct	*b	Incorrect
     *c	Width of Sealing Surface	*d	Difficult to Remove Seal Packing
     *e	Peeled Off Seal Packing	*f	Seal Packing Remaining on Full Width of Sealing Surface

   • Make sure to use the scraper supplied with the seal packing removal cover.

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Use the small end of the scraper to remove seal packing from small areas such as bolt holes.

6. Remove the tape used to secure the seal packing removal cover and then remove any seal packing which was under the tape.
7. Using a clean piece of cloth, clean the sealing surfaces of the inverter with converter assembly.
   NOTE:

   • Do not use compressed air or a vacuum cleaner to clean the sealing surfaces of the inverter with converter assembly.
   • Do not use non-residue solvent to clean the sealing surfaces of the inverter with converter assembly.
8. Remove the seal packing removal cover.
   NOTE:

   Make sure that the inverter with converter assembly is oriented correctly, otherwise seal packing may enter the inverter with converter assembly when removing the seal packing removal cover.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

9. Make sure that the inverter with converter assembly is free of foreign matter.

1. Place the inverter with converter assembly on a stand as shown in the illustration.
   NOTE:

   Make sure that the inverter with converter assembly is oriented correctly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the 3 bolts (A) in the order shown in the illustration.
   Fig 1: Inverter With Converter Assembly Bolt Loosening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt (A)
   	Bolt (B)

3. Remove the 8 bolts (B).
4. Disconnect the HV converter kit connector and set it as shown in the illustration.
   NOTE:

   Make sure that the wire harness of the connector is engaged to the filter condenser.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5. Install 2 HV converter kit installation bolts at the positions shown in the illustration and tighten them in several steps to separate the HV converter kit from the inverter with converter assembly.
   NOTE:

   • Tighten the 2 bolts in several steps.
   • Do not forcibly separate the HV converter kit.
   • In order to prevent any foreign matter from entering the inverter with converter assembly, do not remove the bolts.
   Fig 2: Tightening HV Converter Kit Bolts In Several Steps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Hold the corners of the HV converter kit and remove it as shown in the illustration.

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   *a	Do Not Allow Coolant (for Inverter) to Enter	*b	Hold Here
   	Remove in this Direction	-	-

   WARNING:

   • As there is a coolant passage underneath the HV converter kit, be careful not to spill any coolant (for inverter) into the filter condenser or the holes around the edge of the inverter with converter assembly.
   • If any coolant (for inverter) spills into the filter condenser or the holes around the edge of the inverter with converter assembly, do not reuse the inverter with converter assembly.
   • If any coolant (for inverter) spills onto any area other than the specified areas, remove it with a clean piece of cloth.
7. Remove any metal shavings from the areas around the bolt holes and 2 positions where bolts were installed to separate the HV converter kit, using tape or equivalent.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Bolt Contacting Surface
   *b	Bolt Hole

8. Using a clean scraper, lift the O-ring at the position shown in the illustration and then remove it.
   WARNING:

   • When removing the O-ring, be careful not to spill any coolant (for inverter) into the filter condenser or the holes around the edge of the inverter with converter assembly.
   • If any coolant (for inverter) spills into the filter condenser or the holes around the edge of the inverter with converter assembly, do not reuse the inverter with converter assembly.
   • If any coolant (for inverter) spills onto any area other than the filter condenser or the holes around the edge of the inverter with converter assembly, remove it with a clean piece of cloth.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

9. Clean the O-ring groove of the inverter with converter assembly.
   NOTE:

   Make sure that the O-ring groove and coolant passage of the inverter with converter assembly are free of foreign matter.