Code No. 04: Control Power Supply Voltage Abnormal












TROUBLE JUDGMENT


Check Condition
  • When the charging cable is connected.
or

  • While the electric motor switch is turned ON with the M.U.T.-III connected.
Judgement Criterion
  • For more than 10 seconds, the on board charger control power supply voltage is less than 7.2 V.
or

  • For more than 10 seconds, the on board charger control power supply voltage is more than 17.6 V.

FAIL-SAFE AND BACKUP FUNCTION



  • The charge is stopped.

PROBABLE CAUSES



  • The auxiliary battery is failed.
  • When starting at more than 17.6 V from the outside of the vehicle
  • The installation of the auxiliary battery terminal is failed.
  • The DC-DC converter is failed.
  • Open circuits of on board charger power supply, short circuits to earth or damage; poor contact of connector
  • The on board charger is failed.

DIAGNOSIS PROCEDURE


STEP 1. Auxiliary battery condition check


Q. Does the auxiliary battery start at the voltage more than 17.6 V from the outside of the vehicle recently?

Erase the diagnosis code, check end.
Go to Step 2 .

STEP 2. Auxiliary battery condition check


Q. Is the installation status of the auxiliary battery terminal abnormal?

Repair.
Go to Step 3 .

STEP 3. M.U.T.-III other system diagnosis code.


Q. Is diagnosis code of EV-ECU system set?

Check EV-ECU system (Refer to ).
Go to Step 4 .

STEP 4. Check the auxiliary battery charge warning lamp.



  • Electric motor switch: READY

Q. Is the auxiliary battery charge warning lamp lit?

Check DC-DC converter circuit (Refer to Inspection Procedure 2 ).
Go to Step 5 .

STEP 5. Check auxiliary battery



  • Check auxiliary battery (Refer to GROUP 54A - Auxiliary Battery - On-vehicle Service - Battery Test ).

Q. Is the check result normal?

Go to Step 6 .
Replace the auxiliary battery.

STEP 6. Connector check: E-03 on board charger/DC-DC converter connector


Q. Is the check result normal?

Go to Step 7 .
Repair.

STEP 7. Perform voltage measurement at E-03 on board charger/DC-DC converter



  • Disconnect connector, and measure at harness side.
  • Electric motor switch: ON
  • Voltage between terminal No. 2 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 11 .
Go to Step 8 .

STEP 8. Connector check: A-06X on board charger relay connector


Q. Is the check result normal?

Go to Step 9 .
Repair.

STEP 9. Check on board charger relay itself.



  • Check on board charger relay itself (Refer to ).

Q. Is the check result normal?

Go to Step 10 .
Replace the on board charger relay.

STEP 10. Perform voltage measurement at A-06X on board charger relay



  • Remove the relay, and measure at relay box side.
  • Voltage between terminal No. 4 and earth.
OK: System voltage

Q. Is the check result normal?


    Check intermediate connector A-107, and repair if necessary. If intermediate connector is normal, check and repair harness between A-06X (terminal No. 1) on board charger relay connector and E-03 (terminal No. 2) on board charger/DC-DC converter connector.

    • Check output line for open circuit, short circuit to earth.

    Check and repair harness between auxiliary battery and A-06X (terminal No. 4) on board charger relay connector.

    • Check power supply line for open circuit, short circuit to earth.

STEP 11. Connector check: A-06X on board charger relay connector


Q. Is the check result normal?

Go to Step 12 .
Repair.

STEP 12. Check on board charger relay itself.



  • Check on board charger relay itself (Refer to ).

Q. Is the check result normal?

Go to Step 13 .
Replace the on board charger relay

STEP 13. Check harness between auxiliary battery and A-06X (terminal No. 4) on board charger relay connector



  • Check power supply line for damage.

Q. Is the check result normal?

Go to Step 14 .
Repair.

STEP 14. Check harness between A-06X (terminal No. 1) on board charger relay connector and E-03 (terminal No. 2) on board charger/DC-DC converter connector


note Before checking harness, check intermediate connector A-107, and repair if necessary.

  • Check output line for damage.

Q. Is the check result normal?

Go to Step 15 .
Repair.

STEP 15. M.U.T.-III diagnosis code


Q. Is the diagnosis code set?

Replace the on board charger/DC-DC converter.
Intermittent malfunction (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points - How to Cope with Intermittent Malfunctions ).




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