PLUG-IN CHARGE CONTROL SYSTEM AC Line Insulation Malfunction

DESCRIPTION

The CCID (Charging Circuit Interrupting Device) built into the electric vehicle charger cable assembly detects insulation malfunctions in the AC line between the CCID and electric vehicle charger assembly.

A003ZX3E01

WIRING DIAGRAM

Refer to the wiring diagram for DTC P0D5C-847 Click here.

INSPECTION PROCEDURE

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly or electric vehicle charger assembly, turn the power switch off. Also, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, 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 plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or 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 Click here.

    Tech Tips

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly and electric vehicle charger 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 Click here.

PROCEDURE


  1. SIMULATION TEST

    CAUTION:

    Be sure to wear insulated gloves.


    1. Perform plug-in charging using the electric vehicle charger cable assembly and vehicle that the customer used.

    2. Check the condition of the power and error warning indicators on the electric vehicle charger cable assembly.

      Result
      Power Indicator Error Warning Indicator Plug-in Charge Status Proceed to

      Flashes

      (3 times)

      		 Illuminated Not charging A
      Illuminated Off Charging B
      Other - C

      Tech Tips


      • For details on the status of the power and error warning indicators, refer to Charge Cable On-vehicle Inspection Click here.

      • If the Test button is pressed, the power indicator will flash 3 times and the error warning indicator will illuminate. Plug-in charging will not start until the Reset button is pressed.


    B

    COMPLETED (EXPLAIN TO CUSTOMER THAT OPERATION IS NORMAL)

    C

    CHECK CHARGE CABLE Click here

    A

  2. CHECK ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Perform plug-in charging using a known good electric vehicle charger cable assembly and the vehicle that the customer used.

    2. Check the condition of the power and error warning indicators on the electric vehicle charger cable assembly.

      Result
      Power Indicator Error Warning Indicator Plug-in Charge Status Proceed to

      Flashes

      (3 times)

      		 Illuminated Not charging A
      Illuminated Off Charging B

    B

    REPLACE ELECTRIC VEHICLE CHARGER CABLE ASSEMBLY

    A

  3. CHECK EV CHARGER WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the electric vehicle charger cable assembly is not installed.

    2. Check that the service plug grip is not installed.

      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.

    3. A0042SYE01

      Disconnect the a1 electric vehicle charger assembly connector Click here.

    4. A0043LQE01
      Text in Illustration
      *a

      Electric Vehicle Charger Wire

      (Electric Vehicle Charger Assembly Side)

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      a1-1 (ACIH) - Body ground Power switch off 10 MΩ or higher
      a1-2 (ACIC) - Body ground Power switch off 10 MΩ or higher

    5. Reconnect the a1 electric vehicle charger assembly connector.


    NG

    CHECK ELECTRIC VEHICLE CHARGER CABLE (VEHICLE) Click here

    OK

    REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

  4. CHECK ELECTRIC VEHICLE CHARGER CABLE (VEHICLE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      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. A00407IE01

      Disconnect the at1 electric vehicle charger wire connector Click here.

    3. A0043WJE01
      Text in Illustration
      *a

      Electric Vehicle Charger Cable

      (Electric Vehicle Charger Wire Side)

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      at1-2 (ACIH) - Body ground Power switch off 10 MΩ or higher
      at1-1 (ACIC) - Body ground Power switch off 10 MΩ or higher

    4. Reconnect the at1 electric vehicle charger wire connector.


    NG

    REPLACE ELECTRIC VEHICLE CHARGER CABLE Click here

    OK

    REPLACE EV CHARGER WIRE Click here