CHARGE CABLE ON-VEHICLE INSPECTION


  1. INSPECT ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY

    Tech Tips


    • If the electric vehicle charger cable assembly that is normally used to plug-in charge the vehicle is available, perform the following inspections using it and a known good socket, and determine if the vehicle and electric vehicle charger cable assembly are functioning properly.

    • When an abnormality is detected, the CCID relay circuit will turn off immediately to stop the power supplied to the vehicle.

    • Even if the test button is pressed, plug-in charging will not start until the reset button is pressed.

    • If the electric vehicle charger cable assembly (charging connector side) is connected to the electric vehicle charger cable (charging inlet side) to start plug-in charging the vehicle when the HV battery is fully charged, the indicator on the vehicle will illuminate for a few seconds and then turn off.

    • If vibration is applied to the electric vehicle charger cable assembly (charging connector side) while plug-in charging, charging may stop to ensure safety.


    1. A0040Z6E01
      Text in Illustration
      *1 Power Indicator
      *2 Error Warning Indicator
      A0040DTE01
      Text in Illustration
      *a Example: When the power indicator flashes 3 times
      *b Illuminated
      *c Off

      While plug-in charging, check the status of the power and error warning indicators on the electric vehicle charger cable assembly in accordance with the following table.

      Tech Tips

      The power indicator flashes in the pattern shown in the illustration.

      Power 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 -

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


      • Check if voltage is present at the socket.

      • CCID internal power source malfunction


      • CCID power indicator malfunction

      • The CCID internal power source does not turn on.


      • The power indicator illumination circuit is open.

      		 ○ - Replace the electric vehicle charger cable assembly.

      Flashes

      (once)

      		 Illuminated 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.

      Flashes

      (twice)

      		 Illuminated 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.

      Flashes

      (3 times)

      		 Illuminated Electricity leakage detected

      The electricity leakage detection function is operating.


      • Electric leak on the vehicle side


      • Electric leak on the electric vehicle charger cable assembly side

      		 ○ -

      Inspect the AC line insulation Click here.
      A manual electricity leakage test is performed (Test button is pressed). ○ -

      Check manual electricity leakage test operation Click here

      Flashes

      (4 times)

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

      Flashes

      (5 times)

      		 Illuminated CPLT (-12 V) error

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


      • Internal malfunction of the plugin charge control ECU assembly


      • Internal malfunction of the electric vehicle charger cable assembly

      		 ○ ○

      Perform the following procedure:


      • Check for an electric leak using a known good electric vehicle charger cable assembly.


      • Inspect the plugin charge control ECU assembly (control pilot signal circuit) Click here.

      Flashes

      (6 times)

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

      Flashes

      (7 times)

      		 Illuminated Relay abnormal high temperature error An abnormally high CCID relay temperature is detected. ○ ○ Replace the electric vehicle charger cable assembly.
      Illuminated

      Flashes

      (continuously)

      		 Advance notice of end of service life The number of charging cycles has reached a specified number of times. ○ - -
      Illuminated Illuminated End of service life reached The accumulated number of charging cycles has reached a specified number for the service life of the unit. ○ - Replace the electric vehicle charger cable assembly.

      Flashes

      (continuously)

      		 Off Counter malfunction Malfunction of the charging counter ○ - Replace the electric vehicle charger cable assembly.

      ○: Correct

      X: Incorrect

      -: N/A

      Tech Tips


      • The CCID relay will no longer energize when the number of charging cycles reaches a specified number of times.

      • The end of service life notice or its advance notice will be indicated at the time when the number of charging cycles completed has reached a specified number of times.