HYBRID CONTROL SYSTEM, Diagnostic DTC:P1D75-450, P1D76-450, P1D77-450

DTC Code DTC Name
P1D75-450 FC Air Compressor Motor "A" Position Sensor Circuit
P1D76-450 FC Air Compressor Motor "A" Position Sensor Circuit Range/Performance
P1D77-450 FC Air Compressor Motor "A" Position Sensor Circuit Low

DTC SUMMARY


  1. MALFUNCTION DESCRIPTION

    These DTCs indicate the resolver output signal is abnormal. The cause of this malfunction may be one of the following:

    Area Main Malfunction Description Step
    Inverter low-voltage circuit The connectors are not connected properly 2
    FC air compressor motor resolver

    • Open or short circuit in the resolver for FC air compressor motor control

    • Internal FC air compressor motor malfunction (entry of foreign matter, etc.)

    		 3
    Wire harness system between the resolver and inverter with converter assembly

    • Open or short circuit in the wire harness

    • The connectors are not connected properly

    		 3
    Inside of inverter Inverter with converter assembly internal circuit malfunction 3

DESCRIPTION

Refer to the system description for the FC air compressor motor resolver circuit.

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DTC No. Detection Item DTC Detection Condition Trouble Area Warning Indicate
P1D75-450 FC Air Compressor Motor "A" Position Sensor Circuit

Interphase short in the FC air compressor motor resolver circuit:

A short circuit between signal lines of FC air compressor motor resolver phases is electrically detected.

(1 trip detection logic)

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • Wire harness or connector

Master Warning Light:

Comes on
P1D76-450 FC Air Compressor Motor "A" Position Sensor Circuit Range/Performance

FC air compressor motor resolver signal is out of the normal range (amplitude is too large or too small).

(1 trip detection logic)

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • Wire harness or connector

Master Warning Light:

Comes on
P1D77-450 FC Air Compressor Motor "A" Position Sensor Circuit Low

Open or short in the FC air compressor motor resolver circuit:

FC air compressor motor resolver signal is out of the normal range (amplitude is extremely small).

(1 trip detection logic)

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • Wire harness or connector

Master Warning Light:

Comes on

WIRING DIAGRAM

Refer to the wiring diagram for the FC air compressor motor resolver circuit.

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CAUTION / NOTICE / HINT

CAUTION:


  • B006JFB
    B006JM4

    Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grips from both FC stack assembly and EV battery.


    • Inspecting the high-voltage system

    • Disconnecting the low voltage connector of the inverter with converter assembly

    • Disconnecting the low voltage connector of the EV battery

    • Disconnecting the low voltage connector of the FC stack assembly

    • Disconnecting the low voltage connector of the FC converter assembly

      Tech Tips

      No removal order is specified for the service plug grips of the FC stack assembly and EV battery.

  • B006JBZ

    After removing the service plug grip from the EV battery, 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 grip from the FC stack assembly, store it in a safe location and use the "HIGH-VOLTAGE, DO NOT TOUCH" sign to notify other technicians that you are working on the high-voltage system.

  • B000ZMTC04
    *a Without waiting for 10 minutes

    After removal of the service plug grips of both FC stack assembly and EV battery, wait for at least 10 minutes before touching the high-voltage connectors and 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.

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    Tech Tips

    At least 10 minutes are necessary to discharge the high-voltage capacitors inside the inverter with converter assembly and FC stack 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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  • When reinstalling the service plug grip to the FC stack assembly or the EV battery, slide the lever of the service plug until the letters "UNLOCK" are completely hidden, and insert it firmly.

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  • When the vehicle is parked with the power switch off, if the FC control ECU judges that the FC stack temperature will go below 0°C (32°F), it activates the FC air compressor, hydrogen pump and FC cooling water pump for a maximum of 180 seconds and drains water from the FC stack assembly. When performing inspection or repairs with the power switch off (not on (IG) or on (READY)), disconnect the cable from the negative (-) auxiliary battery terminal before performing work (If the auxiliary battery voltage is needed to conduct inspection, warm up the FC system beforehand).

Tech Tips


  • If the problem symptom cannot be reproduced, performing a road test on a road on which the vehicle tends to vibrate will make it easier to reproduce the symptom.

  • If the resolver is malfunctioning, the vehicle may not drive smoothly.

  • After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


    1. Turn the power switch on (IG) and wait for 5 seconds or more.

    2. Connect the GTS to the DLC3.

    3. Turn the power switch on (IG).

    4. Enter the following menus: Powertrain / FC / Data List / FC Mode, FC Intermittent Operation.

    5. Move the shift lever to P, turn the power switch on (READY) and wait until the FC system is started. Waiting for at least 2 minutes is required after turning the power switch on (READY).


      • - FC system is started: "FC Working" is displayed for the Data List (FC) item "FC Mode" and "FC Intermittent Operation" is OFF.

    6. With the FC system operating, wait for 15 seconds or more.

    7. Drive the vehicle forward with the shift lever in D for 5 m (16 ft.) or more.

    8. Drive the vehicle backward with the shift lever in R for 5 m (16 ft.) or more.

PROCEDURE


  1. CHECK DTC OUTPUT (EV)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / EV / Trouble Codes.

    4. Check for DTCs.


      Powertrain > EV > Trouble Codes
      Result
      Result Proceed to
      Only P1D75-450, P1D76-450 or P1D77-450 is output, or DTCs other than P0A1B-163, 164, 511 or 512 are output simultaneously A
      P0A1B-163, 164, 511 or 512 is output simultaneously B

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. CHECK CONNECTOR CONNECTION CONDITION (INVERTER WITH CONVERTER ASSEMBLY CONNECTOR)

    Result
    Result Proceed to
    OK A
    NG (The connector is not connected securely.) B
    NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed to FC stack assembly and EV battery.

      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. A01MFWK

      Check the connection condition of the low voltage connector of the inverter with converter assembly and the contact pressure of each terminal. Check the terminals for deformation, and check the connector for water ingress and foreign matter.

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      Note

      Before disconnecting the connector, confirm that it is properly connected by checking that the locking claws are engaged and that the connector does not pull out.

      OK
      - The connector is connected securely.
      - The terminals are not deformed and are connected securely.
      - No water or foreign matter in the connector.
      Result
      Result Proceed to
      OK A
      NG (The connector is not connected securely.) B
      NG (The terminals are not making secure contact or are deformed, or water or foreign matter exists in the connector.) C

    B

    CONNECT SECURELY

    C

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    A

  3. CHECK FC AIR COMPRESSOR RESOLVER CIRCUIT

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    Tech Tips

    If the "FC Air Compressor Resolver Circuit" inspection results are normal, perform the next step.

    Result
    Proceed to
    NEXT

    NEXT

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here