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Inspection Procedure 10: Electric shock during normal charging.
 
 
 
 
COMMENTS ON TROUBLE SYMPTOM
If the electric shock occurs during normal charging, the malfunction of the EV home & quick charger cable, normal charging cable, On Board Charger (OBC)/DC-DC converter or domestic power supply is suspected.
 
 
TROUBLESHOOTING HINTS
  • Malfunction of the EV home & quick charger cable
  • Malfunction of the normal charging cable
  • Damaged wiring harness and connectors
  • Malfunction of the On Board Charger (OBC)/DC-DC converter
noteThe trouble may occur due to the following external factor.
• Malfunction of the external power supply.
 
 
DIAGNOSIS
Required Special Tools:
  • MB991223: Wiring harness set
  • MB992006: Extra fine probe
1.Check indicator on control box of normal charging cable.
Check the indicator on the control box of the normal charging cable (Refer to TROUBLE SYMPTOM CHART).
Is the check result normal?
Perform the corrective action according to the control box indicator.
 
2.Check usage condition of AC power supply
Is the outlet with the gorund used?
Use the outlet with the ground.
 
3.Check of the normal charging cable.
Check the normal charging cable (Refer to CHARGING CABLE CHECK).
Is the check result normal?
Replace the normal charging cable.
 
4.Check of open circuit between On Board Charger (OBC)/DC-DC converter and normal charge port connector (GND line).
Check the following wiring harness for open circuit.
  • Open circuit between the On Board Charger (OBC)/DC-DC converter connector (GND terminal) and normal charge port
  • Open circuit between the On Board Charger (OBC)/DC-DC converter connector (GND terminal) and body ground
Is the check result normal?
Repair the connector(s) or wiring harness, or replace the EV home & quick charger cable EV HOME & QUICK CHARGER CABLE REMOVAL AND INSTALLATION) .
 
5.Check of the normal charge port connector for the insulation resistance.
danger
cautionBefore measuring the insulation resistance, set the range of the electric insulation tester (Special tool: MB992355) to 500 V.If a range exceeding 500 V is used for the measurement, the part may be damaged.
(1) Disconnect the On Board Charger (OBC)/DC-DC converter connector (H9), and measure the insulation resistance at the wiring harness side.
(2) Measure the following harness for resistance
  • Resistance between On Board Charger (OBC)/DC-DC converter connector (HOT terminal), and body ground
  • Resistance between On Board Charger (OBC)/DC-DC converter connector (COLD terminal), and body ground
OK: 10 MΩ or more
Is the check result normal?
Replace the EV home & quick charger cable (Refer to EV HOME & QUICK CHARGER CABLE REMOVAL AND INSTALLATION).
 
6.Check of the On Board Charger (OBC)/DC-DC converter for the insulation resistance.
danger
cautionBefore measuring the insulation resistance, set the range of the electric insulation tester (Special tool: MB992355) to 500 V.If a range exceeding 500 V is used for the measurement, the part may be damaged.
Perform the insulation resistance check of the On Board Charger (OBC)/DC-DC converter (Refer to CHECK ON INSULATION RESISTANCE OF ON BOARD CHARGER (OBC) /DC-DC CONVERTER) .
Is the check result normal?
Repalce the On Board Charger (OBC)/DC-DC converter (Refer to ON BOARD CHARGER (OBC) &DC-DC CONVERTER REMOVAL AND INSTALLATION).
 
7.Retest the system.
Perform normal charging by using the Electric Vehicle Supply Equipment (EVSE) other then the defective one.
Does the trouble symptom persist?
Repalce the On Board Charger (OBC)/DC-DC converter (Refer to ON BOARD CHARGER (OBC) &DC-DC CONVERTER REMOVAL AND INSTALLATION).
Ask the user to inspect the external power supply