B2830
Description
The quick charge voltage sensor is installed in the DC/DC junction box. The sensor detects the voltage between the high voltage circuit (+) side and (-) side on the upstream side of the quick charge relay (side where the quick charge port is located). The on-board charger uses this signal to monitor the status of the quick charge relay.
DTC Logic
DTC DETECTION LOGIC
DTC CONFIRMATION PROCEDURE
1. PERFORM DTC CONFIRMATION PROCEDURE
With CONSULT
1.Perform quick charging at least 30 seconds.
2.Turn power switch ON.
3.Check "SELF-DIAG RESULTS" of "CHARGER".
Is DTC detected?
YES- Proceed to "Diagnosis Procedure" .
NO- INSPECTION END
Diagnosis Procedure
WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- Refer to "High Voltage Precautions" High Voltage Precautions.
CAUTION:
- There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.
- Erase DTC after the work is completed.
1. CHECK SELF-DIAGNOSTIC RESULT IN VCM
With CONSULT
1.Turn power switch ON.
2.Check "SELF-DIAG RESULTS" of "EV/HEV".
Is any DTC is detected?
YES- Check the DTC.
NO- GO TO 2.
2. CHECK QUICK CHARGE PORT CONDITION
Check for any adhering foreign substances, cracking, or damage on the quick charge port. Refer to "Inspection" Testing and Inspection.
Is the inspection result normal?
YES- GO TO 3.
NO- Clean or replace the quick charge port. Refer to "Removal and Installation" Removal and Installation.
3. CHECK QUICK CHARGE RELAY OPERATION
With CONSULT
1.Turn power switch ON.
2.On the CONSULT screen, select "CHARGER" - "ACTIVE TEST" - "Q/CHG RELAY +".
3.Switch the quick charge relay between ON and OFF to check operating noise.
NOTE:
If operating noise is hard to hear, use a sound scope to check noise.
4.Check "Q/CHG RELAY -" in the same manner.
Is operating sound heard?
YES- GO TO 12.
NO- GO TO 4.
4. CHECK F/S CHG RELAY OPERATION
With CONSULT
1.On the CONSULT screen, select "EV/HEV" - "ACTIVE TEST" - "F/S CHG RELAY".
2.Switch the F/S CHG relay between ON and OFF to check operating noise of the F/S CHG relay.
Is operating sound heard?
YES- GO TO 5.
NO- Check F/S CHG relay system. Refer to "Diagnosis Procedure" F/S CHG Relay.
5. CHECK QUICK CHARGE RELAY DRIVE CIRCUIT-I
With CONSULT
1.Turn power switch OFF.
2.Disconnect on-board charger harness connector.
3.Turn power switch ON.
4.On the CONSULT screen, select "EV/HEV" - "ACTIVE TEST" - "F/S CHG RELAY".
5.Turn ON the F/S CHG relay.
6.Check the voltage between on-board charger harness connector and ground.
Is the inspection result normal?
YES- GO TO 10.
NO- GO TO 6.
6. CHECK QUICK CHARGE RELAY POWER SUPPLY
With CONSULT
1.Turn power switch OFF.
2.Disconnect DC/DC junction box harness connector.
3.Turn power switch ON.
4.On the CONSULT screen, select "EV/HEV" - "ACTIVE TEST" - "F/S CHG RELAY".
5.Turn ON the F/S CHG relay.
6.Check the voltage between DC/DC junction box harness connector and ground.
Is the inspection result normal?
YES- GO TO 8.
NO- GO TO 7.
7. CHECK QUICK CHARGE RELAY POWER SUPPLY CIRCUIT
1.Turn power switch OFF.
2.Remove F/S CHG relay.
3.Check the continuity between F/S CHG relay harness connector and DC/DC junction box harness connector.
4.Also check harness for short to ground.
Is the inspection result normal?
YES- Check F/S CHG relay system. Refer to "Diagnosis Procedure" F/S CHG Relay.
NO- Repair or replace error-detected parts.
8. CHECK QUICK CHARGE RELAY
1.Turn power switch OFF.
2.Check the resistance between DC/DC junction box harness connector terminals.
Is the inspection result normal?
YES- GO TO 9.
NO- Replace DC/DC junction box. Refer to "Removal and Installation" Removal And Installation.
9. CHECK QUICK CHARGE RELAY DRIVE CIRCUIT-II
Check the continuity between DC/DC junction box harness connector and on-board charger harness connector.
Is the inspection result normal?
YES- Check intermittent incident. Refer to "Intermittent Incident" Intermittent Incident.
NO- Repair or replace error-detected parts.
10. CHECK ON-BOARD CHARGER GROUND CIRCUIT
Check the continuity between on-board charger harness connector and ground.
Is the inspection result normal?
YES- GO TO 11.
NO- Repair or replace error-detected parts.
11. CHECK INTERMITTENT INCIDENT
Check intermittent incident. Refer to "Intermittent Incident" Intermittent Incident.
Is the inspection result normal?
YES- Replace DC/DC junction box. Refer to "Removal and Installation" Removal And Installation.
NO- Repair or replace error-detected parts.
12. CHECK QUICK CHARGE VOLTAGE SENSOR SIGNAL CIRCUIT
1.Turn power switch OFF.
2.Disconnect DC/DC junction box harness connector and on-board charger connector.
3.Check the continuity between DC/DC junction box harness connector and on-board charger harness connector.
4.Also check harness for short to ground and short to power.
Is the inspection result normal?
YES- GO TO 13.
NO- Repair or replace error-detected parts.
13. CHECK QUICK CHARGE VOLTAGE SENSOR
Perform component inspection. Refer to "Component Inspection (Quick Charge Voltage Sensor)" .
Is the inspection result normal?
YES- GO TO 14.
NO- Replace DC/DC junction box. Refer to "Removal and Installation" Removal And Installation.
14. PRECONDITIONING
WARNING:
Disconnect high voltage. Refer to "How to Disconnect High Voltage" Service and Repair.
Check voltage in high voltage circuit. (Check that condenser are discharged.)
1.Lift up the vehicle and remove the Li-ion battery under covers. Refer to "Removal and Installation" Service and Repair (without Li-ion battery heater models), "Removal and Installation" Service and Repair (with Li-ion battery heater models).
2.Disconnect high voltage harness connector from front side of Li-ion battery. Refer to "Removal and Installation" Service and Repair (without Li-ion battery heater models), "Removal and Installation" Service and Repair (with Li-ion battery heater models).
3.Measure voltage between high voltage harness connector terminals.
DANGER:
Touching high voltage components without using the appropriate protective equipment will cause electrocution.
Standard: 5 V or less
CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
- GO TO 15.
15. CHECK HIGH VOLTAGE HARNESS
1.Disconnect the high voltage harness connector from the quick charge port and DC/DC junction box.
2.Check the continuity between DC/DC junction box harness connector and quick charge port harness connector.
Is the inspection result normal?
YES- GO TO 16.
NO- Replace the high voltage harness.
16. CHECK INTERMITTENT INCIDENT
Check intermittent incident. Refer to "Intermittent Incident" Intermittent Incident.
Is the inspection result normal?
YES- Replace DC/DC junction box (high voltage circuit malfunction). Refer to "Removal and Installation" Removal And Installation.
NO- Repair or replace error-detected parts.
Component Inspection (Quick Charge Voltage Sensor)
1. CHECK QUICK CHARGE VOLTAGE SENSOR
1.Reconnect all harness connectors disconnected.
2.Turn power switch ON.
3.Check the voltage between on-board charger harness connector terminals.
Is the inspection result normal?
YES- INSPECTION END
NO- Replace DC/DC junction box. Refer to "Removal and Installation" Removal And Installation.