Inspection Procedure 8: FAULT indicator (red lamp) blinks.








COMMENTS ON TROUBLE SYMPTOM


When detecting pilot signal abnormalities or earth leakages of regular charging high voltage circuits, the charging circuit interrupting device should blink the FAULT indicator (red lamp).

PROBABLE CAUSE



DIAGNOSIS PROCEDURE
danger When high voltage system components are served, be sure to pull service plugs to shut down high voltage (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).

STEP 1. Check charging cable itself

  • Check Charging Cable (Refer to ).

Q. Is the check result normal?
Go to Step 2 .
Replace the charging cable.

STEP 2. Connector check: G-03 regular charging connector and E-03 on board charger/DC-DC converter connector

Q. Are the check results normal?
Go to Step 3 .
Repair or replace the connector.

STEP 3. Check harness between G-03 (terminal No. 3) regular charging connector and E-03 (terminal No. 9) on board charger/DC-DC converter.
note Before checking harness, check intermediate connector G-12, and repair if necessary.

  • Check signal line for short circuits to earth.

Q. Is the check result normal?
Go to Step 4 .
Repair the damaged harness wire.

STEP 4. Connector check: G-11 on board charger/DC-DC converter connector
danger High voltage system components are served, be sure to pull service plugs to shut down high voltage (Refer to ).
danger When pulling service plugs, wear the specified protective equipment (Refer to ).

Q. Is the check result normal?
Go to Step 5 .
Repair or replace the connector.

STEP 5. Check the G-03 regular charging connector for the insulation resistance.
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.

  • Disconnect connector, and measure at harness side.
  • Disconnect G-11 on board charger/DC-DC converter connector.
  • Use special tool electric insulation tester (MB992355), to set the range to 500 V.
  • Insulation resistance between terminal No. 1 and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?
Go to Step 6 .
Replace harness between G-03 (terminal No. 1) regular charging connector and G-11 (terminal No. 1) on board charger/DC-DC converter connector.

STEP 6. Check the G-03 regular charging connector for the insulation resistance.
caution When the insulation resistance is measured, set the range of the special tool electric insulation tester (MB992355) to 500 V. When the insulation resistance is measured at the range more than 500 V, the component may be damaged.

  • Disconnect connector, and measure at harness side.
  • Disconnect G-11 on board charger/DC-DC converter connector.
  • Use special tool electric insulation tester (MB992355), to set the range to 500 V.
  • Insulation resistance between terminal No. 2 and body earth.
OK: 10 MΩ or more

Q. Is the check result normal?
Replace the on board charger/DC-DC converter.
Replace harness between G-03 (terminal No. 2) regular charging connector and G-11 (terminal No. 2) on board charger/DC-DC converter connector.




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