FC BOOST CONTROL SYSTEM, Diagnostic DTC:P1D06-450, P1D07-450, P1D08-450, P1D09-450

DTC Code DTC Name
P1D06-450 U Phase IPM Overcurrent
P1D07-450 V Phase IPM Overcurrent
P1D08-450 W Phase IPM Overcurrent
P1D09-450 X Phase IPM Overcurrent

DESCRIPTION

Refer to high voltage system diagram for the System Description.

Click here

If an overcurrent occurs in the FC converter assembly, the FC boost control ECU detects a malfunction.

DTC No. Detection Item DTC Detection Condition Trouble Area Warning Indicate
P1D06-450 U Phase IPM Overcurrent

U phase fail signal is detected. (Overcurrent)

(1 trip detection logic)

  • FC converter assembly

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • FCV transaxle with motor assembly

  • Inverter cooling system

  • Cooling fan system

  • Wire harness or connector

 Master Warning Light: Comes on
P1D07-450 V Phase IPM Overcurrent

V phase fail signal is detected. (Overcurrent)

(1 trip detection logic)

  • FC converter assembly

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • FCV transaxle with motor assembly

  • Inverter cooling system

  • Cooling fan system

  • Wire harness or connector

 Master Warning Light: Comes on
P1D08-450 W Phase IPM Overcurrent

W phase fail signal is detected. (Overcurrent)

(1 trip detection logic)

  • FC converter assembly

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • FCV transaxle with motor assembly

  • Inverter cooling system

  • Cooling fan system

  • Wire harness or connector

 Master Warning Light: Comes on
P1D09-450 X Phase IPM Overcurrent

X phase fail signal is detected. (Overcurrent)

(1 trip detection logic)

  • FC converter assembly

  • Inverter with converter assembly

  • FC air compressor with motor assembly

  • FCV transaxle with motor assembly

  • Inverter cooling system

  • Cooling fan system

  • Wire harness or connector

 Master Warning Light: Comes on

Tech Tips

If the inverter is malfunctioning, DTCs related to the inverter are also output to the EV control ECU.

Related Data List
DTC No. Data List
P1D06-450

  • U Phase IPM Fail Signal

  • U Phase Reactor Current
P1D07-450

  • V Phase IPM Fail Signal

  • V Phase Reactor Current
P1D08-450

  • W Phase IPM Fail Signal

  • W Phase Reactor Current
P1D09-450

  • X Phase IPM Fail Signal

  • X Phase Reactor Current

WIRING DIAGRAM

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

Click here

Refer to the wiring diagram for the high-voltage circuit.

Click here

Refer to the wiring diagram for the inverter low-voltage circuit.

Click here

Refer to the wiring diagram for the FC boost converter low-voltage circuit.

Click here

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

Tech Tips

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).

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

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


    • FC system is activated: Data List shows that "FC Mode" is "FC Working" and "FC Intermittent Operation" is "OFF".

  4. Wait at least 15 seconds with the FC system activated.

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

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

PROCEDURE


  1. CHECK DTC OUTPUT (FCDC)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / FCDC / Trouble Codes.


      Powertrain > FCDC > Trouble Codes

    5. Check for DTCs.

      Result
      Result Proceed to
      "DTC P1D06-450, P1D07-450, P1D08-450 or P1D09-450 only is output" or "DTCs except the ones in the table below are output" A
      Any of the following DTCs are output B
      Malfunction Content Relevant DTC
      Microcomputer malfunction P060B-450 Internal Control Module A/D Processing Performance
      P2511-450 FCDC CPU Circuit Intermittent No Continuity
      Sensor and actuator circuit malfunction P1D1E-450 FC Converter Output Voltage Sensor Circuit Low
      P1D1F-450 FC Converter Output Voltage Sensor Circuit High
      P1D23-450 FC Converter Input Voltage Sensor Circuit High
      System malfunction P1D0E-450 FVH (FC Converter Output Voltage)/VH Voltage Correlation
      P1D0F-450 FVC (Cell Monitor Voltage)/FVL (FC Converter Input Voltage) Correlation

      Tech Tips


      • DTC P1D06-450, P1D07-450, P1D08-450 or P1D09-450 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    6. Turn the power switch off.


    B

    GO TO DTC CHART (FC BOOST CONTROL SYSTEM) Click here

    A

  2. CHECK DTC OUTPUT (EV)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Turn the GTS on.

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


      Powertrain > EV > Trouble Codes

    5. Check for DTCs.

      Result
      Result Proceed to
      "EV related DTCs are not output" or "DTCs other than those shown below are output" A
      Any of the following DTCs are also output B
      Malfunction Content Relevant DTC
      Microcomputer malfunction P0A1D (all INF codes)*1 EV Control Module
      System malfunction P0AA6-526 EV Battery Voltage System Isolation Fault
      P0C76-523 EV Battery System Discharge Time Too Long

      Tech Tips


      • *1: If any INF codes are output for this DTC, refer to the corresponding diagnostic procedure.

      • DTC P1D06-450, P1D07-450, P1D08-450 or P1D09-450 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    6. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  3. CHECK CONNECTOR CONNECTION CONDITION (FC 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. A01MFR3

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

      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

  4. 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.

      Click here

      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

  5. CHECK COOLING SYSTEM

    Click here

    Tech Tips

    If the "Cooling System" inspection results are normal, perform the next step.

    Result
    Proceed to
    NEXT

    NEXT

  6. CHECK FC AIR COMPRESSOR RESOLVER CIRCUIT

    Click here

    Tech Tips

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

    Result
    Proceed to
    NEXT

    NEXT

  7. CHECK MOTOR RESOLVER CIRCUIT

    Click here

    Tech Tips

    If the "Motor Resolver Circuit" inspection results are normal, perform the next step.

    Result
    Proceed to
    NEXT

    NEXT

  8. CHECK FC AIR COMPRESSOR HIGH-VOLTAGE CIRCUIT

    Click here

    Tech Tips

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

    Result
    Proceed to
    NEXT

    NEXT

  9. CHECK MOTOR HIGH-VOLTAGE CIRCUIT

    Click here

    Tech Tips

    If the "Motor High-voltage Circuit" inspection results are normal, perform the next step.

    Result
    Proceed to
    NEXT

    NEXT

  10. REPLACE FC CONVERTER ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

  11. CLEAR DTC


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / FCDC / Trouble Codes.


      Powertrain > FCDC > Clear DTCs

    5. Clear the DTCs.

      Result
      Proceed to
      NEXT

    6. Turn the power switch off and wait for 3 minutes or more.


    NEXT

  12. CHECK DTC OUTPUT (FCDC)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Turn the GTS on.

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


      Powertrain > FC > Data List
      Tester Display
      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 activated. (Waiting for at least 2 minutes is required after turning the power switch on)

      Tech Tips

      FC system is activated: Data List shows that "FC Mode" is "FC Working" and "FC Intermittent Operation" is "OFF"

    6. Wait at least 15 seconds with the FC system activated.

    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.

    9. Enter the following menus: Powertrain / FCDC / Trouble Codes.


      Powertrain > FCDC > Trouble Codes

    10. Check for DTCs.

      Result
      Result Proceed to
      DTCs are not output A
      DTCs are output B

    11. Turn the power switch off.


    A

    END

    B

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here