CHARGE CABLE ON-VEHICLE INSPECTION

PROCEDURE


  1. INSPECT ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY

    Tech Tips


    • When inspecting the electric vehicle charger cable assembly provided with the vehicle, use a known good AC power source and electric vehicle charger cable assembly.

    • If a malfunction is detected, the CCID relay will turn off immediately to stop the supply of power to the vehicle.

    • Before checking the plug-in charging function, make sure that the SOC of the HV battery is less than 70%.

    • If the SOC of the HV battery is 70% or more and the electric vehicle charger cable assembly is connected to the inlet AC charger cable to perform plug-in charging, the charging indicator of the electric charger cable assembly will not illuminate and the charging indicator (EV charger lid indicator assembly) will illuminate for several seconds and then turn off.

    • While performing plug-in charging, if the electric vehicle charger cable assembly (charging connector) is shaken, charging will be suspended for safety.

    • The electric vehicle charger cable assembly is unrelated to the display of the EV driving distance.


    1. Check the plug-in charging function:


      1. Connect the electric vehicle charger cable assembly and perform plug-in charging.

        Note


        • Make sure to use a known good AC power source.

        • Make sure to use a known good electric vehicle charger cable assembly.


        1. If the malfunction cannot be reproduced, perform [#1].

        2. If the malfunction can be reproduced, inspect the vehicle.

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    2. If the malfunction cannot be reproduced [#1]:


      1. Connect the electric vehicle charger cable assembly and perform plug-in charging.

        Note


        • Make sure to use a known good AC power source.

        • Make sure to use the electric vehicle charger cable assembly that the customer used when the malfunction occurred.


        1. If the malfunction cannot be reproduced, check the condition of the AC power source and charging conditions when the malfunction occurred based on the interview with the customer.

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        2. If the malfunction is reproduced, perform [#2].

    3. If the malfunction is reproduced [#2]:


      1. B006HRRC02
        *a Power Indicator
        *b Charging Indicator
        *c Error Warning Indicator

        Compare the state of the power indicator, charging indicator and error indicator of the electric vehicle charger cable assembly while performing plug-in charging with the following table.

        Power Indicator Charging Indicator Error Warning Indicator Content Detection Condition Socket Connection Charging Inlet Connection Procedure
        Illuminated - Off Voltage is applied to the plug. - ○ - -
        Off - Off Voltage is not applied to the plug. - x -

        1. Plug in the electric vehicle charger cable assembly to a socket.

        2. Check if voltage is present at the socket.

        1. CCID internal power source malfunction

        2. CCID power indicator malfunction

        1. The CCID internal power source does not turn on.

        2. The power indicator illumination circuit is open.

        		 ○ - Replace the electric vehicle charger cable assembly.
        Illuminated Off

        Flashes

        (once)

        		 CCID relay stuck closed error The conditions to close the CCID relay are not met but the relay is closed. ○ - Replace the electric vehicle charger cable assembly.
        Illuminated Off

        Flashes

        (twice)

        		 CCID relay stuck open error The conditions to close the CCID relay are met but the relay is open. ○ ○ Replace the electric vehicle charger cable assembly.
        Illuminated Off

        Flashes

        (3 times)

        		 Electricity leakage detected

        The electricity leakage detection function is operating.


        1. Electric leak on the vehicle side

        2. Electric leak on the electric vehicle charger cable assembly side

        		 ○ - Replace the electric vehicle charger cable assembly.
        Illuminated Off

        Flashes

        (4 times)

        		 CPLT (duty) error The duty ratio is less than 5% or 40% or more. ○ ○ Replace the electric vehicle charger cable assembly.
        Illuminated Off

        Flashes

        (5 times)

        		 CPLT (-12V) error

        -12 V cannot be detected while the duty waveform is output.


        1. Internal malfunction of the electric vehicle charger assembly

        2. Internal malfunction of the electric vehicle charger cable assembly

        		 ○ ○ Replace the electric vehicle charger cable assembly.
        Illuminated Off

        Flashes

        (6 times)

        		 Electricity leakage self diagnosis error The electricity leakage self diagnosis function is abnormal. ○ ○ Replace the electric vehicle charger cable assembly.

        Flashes

        (interval of 0.25 seconds)

        		 - Off Abnormally high power source plug (electrical outlet) temperature detected

        Abnormally high power source plug (electrical outlet) temperature detected


        1. Connecting part of electrical outlet is extremely hot

        2. Power source plug internal malfunction

        		 ○ -

        Check the operation at several different electrical outlets.


        1. If the malfunction is reproduced at a specific electrical outlet, check the terminals of the electrical outlet.

        2. If the malfunction is reproduced at several electrical outlets, replace the electric vehicle charger cable assembly.

        Flashes

        (interval of 0.25 seconds)

        		 -

        Flashes

        (interval of 0.25 seconds)

        		 Power source plug temperature detection malfunction Charging plug temperature cannot be detected. ○ - Check for an open in the electric vehicle charger cable assembly.
        Illuminated -

        Flashes

        (interval of 0.25 seconds)

        		 Advance notice of end of service life The number of charging cycles has reached a specific number. ○ - -
        Illuminated - Illuminated End of service life reached The maximum number of charging cycles has been reached. ○ - Replace the electric vehicle charger cable assembly.

        • ○: Correct

        • x: Incorrect