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SI M61 01 19
Engine Electrical Systems
May 2019
Technical Service
STANDARD OCCASIONAL USE CABLE CHARGING
COMPLAINT TROUBLESHOOTING
MODEL
F60 PHEV (MINI Cooper S E Countryman ALL4)
SITUATION
The customer may complain about any of the following scenarios-
• The vehicle cannot be charged with the standard “Occasional Use Cable” (OUC) charging cable
• An indicator light on the OUC control panel lights up or flashes
• The charging procedure does not start, or aborts
• A “Fault” indicator light on the vehicle High Voltage (HV) charging socket lights up red
• The charging time with the OUC is too long
• The charging time is too long even though the “maximum” setting was selected in the vehicle
One or several of the following Check Control (CC) messages may be displayed to the customer:
Note: The customer only sees the CC text in the vehicle displays. The ID code can be identified by
the Key Reader.
CC message ID code
Check charging cable ID 802 or ID 808
Grid power too low ID 803
Charging not possible ID 804
Additionally, the following fault codes may be stored in the EME (electrical machine electronics) fault
memory:
Fault code Text
222833 Charge management: CC message 803, grid power too low
222834 Charge management: CC message 804, charging not possible
222842 Charge management function: Fault during the charging procedure
222846 Charge management function: Fault during the charging procedure
CAUSE
TIS Service Bulletin Page 1 of 3
https://www.minitis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/507… 6/3/2019
A fault when charging the vehicle can be due to various causes:
• The charging cable was not correctly plugged into the vehicle charging plug
• The charging cable did not lock completely into position
• The internal fuse (ground fault circuit-breaker) in the charging cable has detected a residual current
and switches off
• Voltage supply problems related to the charging infrastructure (public grid or customer home grid)
Note: When an under-voltage (below 90V AC) is detected in electrical power grid, the cable stops
charging. The cable will try to restart after 5 minutes if grid voltage rises to at least 90V. During this undervoltage
condition, the red “FAULT” LED will be displayed on the OUC control panel. This may result in “Grid
Faults” to be stored in the vehicle.
Note: To address this customer concern, the OUC software (as of suffix 03 in the AI number,
on the back label) has been upgraded with enhanced charging strategy.
PROCEDURE
In the event of a customer complaint, refer to “B611918 Attachment 1 High Voltage Charging Cable
troubleshooting guide.pdf”
.
Important warning for working on the high-voltage systems:
Only properly trained personnel, who have passed all applicable technical training courses, should
perform any maintenance or repairs on any Hybrid or Electric Vehicle. Work performed by unqualified
persons may result in severe injury or damage to the vehicle. Additional information is found in
Repair Instruction 61 00… Observe safety instructions when handling electric vehicles.
Note: For more information, the OUC manufacturer’s Safety Guidelines recommendations (pages
4-9) in Second Gen. Occasional Use Cable Charger Manual (Attachment 2).
PARTS INFORMATION
Part Number Description Quantity
61 44 6 818
634
Standard cable/ Mode 2 charge cable/ Standard charging cable with
temperature sensor 1
WARRANTY INFORMATION
Not applicable.
ATTACHMENTS
View PDF attachment M610119 Attachment 1 High Voltage Charging Cable troubleshooting guide.
TIS Service Bulletin Page 2 of 3
https://www.minitis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/507… 6/3/2019
View PDF attachment M610119 Attachment 2 2nd Gen. Occasional Use Cable Manual.
[ Copyright ©2019 BMW of North America, Inc. ]
TIS Service Bulletin Page 3 of 3
https://www.minitis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/507… 6/3/2019
Attachment 1 to SI M610119 May 2019
High Voltage (HV) charging cable troubleshooting guide
Important warning for working on the high-voltage systems:
Only properly trained personnel, who have passed all applicable technical training courses,
should perform any maintenance or repairs on any Hybrid or Electric Vehicle. Work performed
by unqualified persons may result in severe injury or damage to the vehicle. Additional
information is found in Repair Instruction 61 00… Observe safety instructions when handling
electric vehicles.
In the event of a customer complaint, proceed as follows:
1. Perform a visually inspection of the Occasional Use
Charging cable (OUC) for external damage.
Replace the OUC if damage is found.
Note: All standard OUC chargers perform an
automatic reset (self-test) when the power input plug
is unplugged from the A/C grid wall outlet, and
immediately plugged back in.
Note: The Second Generation OUC charger is
easily identified by its bright yellow electrical cord. The
updated OUC has a lower output current (10A)
compared to its predecessor which may result in longer
charging times.
See the attached link to the manual for more
specifications.
2. Perform the following diagnostic procedure for the OUC:
1. Disconnect the charging plug from vehicle.
2. Disconnect the OUC plug from the A/C wall outlet.
3. Wait 5 seconds.
4. Re-connect the OUC plug to the A/C wall outlet.
5. Wait until the Power LED shines green steadily.
a. if not, go to step 8
6. Connect the OUC to the vehicle charge socket again.
7. Charging should start automatically.
8. If there is still an indicator light (displayed or flashing) on the OUC control panel:
a. Perform fault diagnosis according to the instructions displayed on the rear surface of the
control panel or according to the operating instructions of the OUC.
Refer to section 5 of the charging cable manual (Attachment 2 to this SIB):
SecondGenOccasionalUseCableManual.pdf
3. If the Power LED indicator shines green
steadily on the OUC control panel after the
charger self-test:
 Connect the OUC to the vehicle charging
socket, and push it in until it latches
securely.
Note: Make certain that the charging
cable connector fits correctly in the charging
socket and latches properly.
3a. If the charging procedure does not start, proceed as follows:
 Check whether the charging procedure starts with a “Known Good” standard OUC
 If the charging procedure starts with the “Known Good” OUC; replace the defective OUC
 Submit a TSARA case titled “OUC Replacement”
3b. If the charging procedure does not start with a “Known Good” OUC:
 Run diagnosis with the latest ISTA version and follow the recommended test plans
3c. If the charging procedure starts without problems:
 Perform the charging test plan diagnosis with ISTA to verify the charger is functioning properly,
and charging according to specifications
 If no faults could be identified either on the OUC or vehicle; the problem may be caused by the
charging infrastructure such as the public electric grid or the customer home grid
If so, and if the issue continues:
 Ask the customer to use a different (dedicated) electrical outlet for charging the vehicle
 Also (if possible) verify that the home grid connection corresponds to charging
recommendations
Charging cable voltage supply recommendations
When charging with the standard OUC charger only use:
 A properly grounded, dedicated wall outlet (only used for charging),
 capable of supplying a minimum of 15A,
 and if necessary, qualified and tested by a licensed electrician.
Do Not use the standard OUC charger in combination with:
 Electrical extension cords
 Multi-outlet power strips
 Voltage surge protectors
Note:
For more information refer to the OUC manufacturer’s Safety Guidelines recommendations
(pages 4-9) in Attachment link:
SecondGenOccasionalUseCableManual.pdf
Attachment 2 to M610110 May 2019
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