On-Vehicle Inspection [12/2023 - ]: Procedure

HINT: 

• 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.

         HINT: 

         Refer to HOW TO PROCEED WITH TROUBLESHOOTING [12/2023 - ]

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.

         HINT: 

         Refer to PROBLEM SYMPTOMS TABLE [12/2023 - ]

      2. If the malfunction is reproduced, perform [#2].
3. If the malfunction is reproduced [#2]:
   1. 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.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Power Indicator
      *b	Charging Indicator
      *c	Error Warning Indicator

      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	-	Plug in the electric vehicle charger cable assembly to a socket. Check if voltage is present at the socket.
      			CCID internal malfunction.	The CCID internal electronic does not turn on.	◦	-	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. Electric leak on the vehicle side Electric leak on the electric vehicle charger cable assembly side Incorrect detection due to power source malfunction	◦	-	Check the operation at several different electrical outlets. If the malfunction can be reproduced only at a specific electrical outlet, the electrical outlet may be malfunctioning and should be checked by a qualified tradesperson. If the malfunction is reproduced at several electrical outlets. HINT:  Refer to AC Line Insulation Malfunction [12/2023 - ] Make sure to use an outlet other than one used by the customer.
      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.	◦	◦	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.	◦	◦	Check the operation at several different electrical outlets. If the malfunction can be reproduced only at a specific electrical outlet, the electrical outlet may be abnormal voltage and should be checked by a qualified tradesperson. If the malfunction is reproduced at several electrical outlets, replace the electric vehicle charger cable assembly. HINT:  Make sure to use an outlet other than one used by the customer.
      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 Connecting part of electrical outlet is extremely hot Power source plug internal malfunction	◦	-	Check the operation at several different electrical outlets. HINT:  Make sure that the plug is fully inserted into the outlet. If the malfunction can be reproduced only at a specific electrical outlet, the electrical outlet may have internal deterioration and should be checked by a qualified tradesperson. If defects reemerge with the multiple electrical outlets, exchange only the power plug redo the reemergence confirmation.If it reemerges, replace the charging cable. HINT:  Make sure to use an outlet other than one used by the customer.
      Flashes (interval of 0.25 seconds)	-	Flashes (interval of 0.25 seconds)	Power source plug temperature detection malfunction	The electric vehicle charger assembly is not connected correctly. Charging plug temperature cannot be detected.	◦	-	Check that the electric vehicle charger assembly is locked correctly. If the electric vehicle charger assembly is not locked, reconnect and lock it correctly. If the electric vehicle charger cable assembly is locked correctly, check for an open in the circuit.
      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

      HINT: 

      • In the case of an electricity leakage error:

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        *a	Flashing 3 times
        *b	Illuminated
        *c	Off
        *d	0.5 seconds
        *e	2.5 seconds

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

      • Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        *a	Flashing at interval of 0.25 seconds
        *b	Illuminated
        *c	Off
        *d	0.25 seconds

        In the case of a power source plug temperature detection malfunction:

        The power indicator and error indicator flash in the pattern shown in the illustration.

      • If a certain number of charging cycles is reached, CCID relay operation will be suspended.
      • The end of service life advance notice and end of service life reached warnings are displayed when charging has completed and a corresponding number of charging cycles has been performed.