FC BOOST CONTROL SYSTEM ECU Power Source Circuit

DESCRIPTION

If the power switch is turned on (IG), electric current flows from terminal IG1D of the smart key ECU assembly to IG2-MAIN relay. Therefore, the IG2-MAIN relay contact will close and the IG2 signal will be input to terminal IG2 of the FC boost control ECU. The EV control ECU also outputs current to terminal MREL and turn on the IGCT NO.1 relay to supply power to terminals +B1 and +B2 of the FC boost control ECU.

WIRING DIAGRAM

B000ZFDE01

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.

    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


  • 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.

    Click here

  • 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).

  • 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.

    Click here

  • Inspect the fuses for circuits related to this system before performing the following procedure.

PROCEDURE


  1. CHECK TERMINAL VOLTAGE (IG2)

    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. A01MHEJ

      Disconnect the Ao1 FC converter assembly connector.

    3. Connect the cable to the negative (-) auxiliary battery terminal.

    4. Turn the power switch on (IG).

    5. B000ZLWC01
      *a

      Front view of wire harness connector

      (to FC Converter Assembly)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      Ao1-8 (IG2) - Body ground Power switch on (IG) 11 to 14 V

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Connect the FC converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK NO. 1INTEGRATION RELAY (POWER SOURCE VOLTAGE) Click here

    OK

  2. CHECK TERMINAL VOLTAGE (+B1, +B2)

    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. A01MHMW

      Disconnect the Ao2 FC converter assembly connector.

    3. Connect the cable to the negative (-) auxiliary battery terminal.

    4. Turn the power switch on (IG).

    5. B000ZF5C01
      *a

      Front view of wire harness connector

      (to FC Converter Assembly)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      Ao2-6 (+B1) - Body ground Power switch on (IG) 11 to 14 V
      Ao2-13 (+B2) - Body ground Power switch on (IG) 11 to 14 V

    6. Turn the power switch off.

    7. Disconnect the cable from the negative (-) auxiliary battery terminal.

    8. Connect the FC converter assembly connector.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK HARNESS AND CONNECTOR (IGCT NO. 1 RELAY - FC CONVERTER ASSEMBLY) Click here

    OK

  3. CHECK HARNESS AND CONNECTOR (FC CONVERTER ASSEMBLY - BODY GROUND)

    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. A01MHMW

      Disconnect the Ao2 FC converter assembly connector.

    3. B000ZF5C02
      *a

      Front view of wire harness connector

      (to FC Converter Assembly)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Ao2-5 (E1) - Body ground Power switch off Below 1 Ω
      Ao2-12 (E2) - Body ground Power switch off Below 1 Ω

    4. Connect the FC converter assembly connector.

      Result
      Proceed to
      OK
      NG

    OK

    CHECK FOR INTERMITTENT PROBLEMS Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  4. CHECK HARNESS AND CONNECTOR (IGCT NO. 1 RELAY - FC CONVERTER ASSEMBLY)

    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. Remove the IGCT NO. 1 relay from the motor compartment relay block.

    3. A01MHMW

      Disconnect the Ao2 FC converter assembly connector.

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

      B000ZRZC01
      *1 Motor compartment relay block *2 IGCT NO. 1 Relay
      *a

      Front view of wire harness connector

      (to FC Converter Assembly)

      		 - -
      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      5 (IGCT NO. 1 relay holder) - Ao2-6 (+B1) Power switch off Below 1 Ω
      5 (IGCT NO. 1 relay holder) - Ao2-13 (+B2) Power switch off Below 1 Ω
      Ao2-13 (+B2), Ao2-6 (+B1) or 5 (IGCT NO. 1 relay holder) - Body ground Power switch off 10 kΩ or higher

    5. Connect the FC converter assembly connector.

    6. Install the IGCT NO. 1 relay.

      Result
      Proceed to
      OK
      NG

    OK

    CHECK ECU POWER SOURCE CIRCUIT (HYBRID CONTROL SYSTEM) Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  5. CHECK NO. 1INTEGRATION RELAY (POWER SOURCE VOLTAGE)


    1. Remove the No. 1 integration relay from the motor compartment relay block.

    2. B000ZUZC01
      *1 No. 1 Integration Relay
      *a

      Front view of wire harness connector

      (to No. 1 Integration Relay)

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

      Standard Voltage
      Tester Connection Switch Condition Specified Condition
      1C-1 - Body ground Power switch off 11 to 14 V

    3. Install the No. 1 integration relay.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR (NO. 1 INTEGRATION RELAY - AUXILIARY BATTERY)

    OK

  6. INSPECT NO. 1 INTEGRATION RELAY (IG2-MAIN RELAY)


    1. Remove the No. 1 integration relay from the motor compartment relay block.

    2. Inspect the No. 1 integration relay.

      Click here

    3. Install the No. 1 integration relay.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 1 INTEGRATION RELAY Click here

    OK

  7. CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - BODY GROUND)


    1. Remove the No. 1 integration relay from the motor compartment relay block.

    2. B000ZILC01
      *1 No. 1 Integration Relay
      *a

      Front view of wire harness connector

      (to No. 1 Integration Relay)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      1B-3 - Body ground Power switch off Below 1 Ω

    3. Install the No. 1 integration relay.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  8. CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - FC CONVERTER ASSEMBLY)

    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. Remove the No. 1 integration relay from the motor compartment relay block.

    3. A01MHEJ

      Disconnect the Ao1 FC converter assembly connector.

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

      B000ZH4C01
      *1 No. 1 Integration Relay - -
      *a

      Front view of wire harness connector

      (to No. 1 Integration Relay)

      		 *b

      Front view of wire harness connector

      (to FC Converter Assembly)
      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      1B-4 - Ao1-8 (IG2) Power switch off Below 1 Ω
      1B-4 or Ao1-8 (IG2) - Body ground and other terminals Power switch off 10 kΩ or higher

    5. Connect the FC converter assembly connector.

    6. Install the No. 1 integration relay.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  9. CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - CERTIFICATION ECU (SMART KEY ECU ASSEMBLY))


    1. Remove the No. 1 integration relay from the motor compartment relay block.

    2. Disconnect the certification ECU (smart key ECU assembly) connector.

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

      B000ZTMC01
      *1 No. 1 Integration Relay - -
      *a

      Front view of wire harness connector

      (to No. 1 Integration Relay)

      		 *b

      Front view of wire harness connector

      (to Certification ECU (Smart Key ECU Assembly))
      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      1B-2 - G40-3 (IG1D) Power switch off Below 1 Ω
      1B-2 or G40-3 (IG1D) - Body ground and other terminals Power switch off 10 kΩ or higher

    4. Reconnect the certification ECU (smart key ECU assembly) connector.

    5. Install the No. 1 integration relay.

      Result
      Proceed to
      OK
      NG

    OK

    CHECK ENTRY AND START SYSTEM Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR