Safety precaution

Precautions for normal charging

Warning：

If an engineer uses medical electronic devices including heart pacemaker, cardioverter, defibrillator, the device can be only be used after its function being checked and confirmed before charging.

During normal charging operation,an engineer who uses medical electronic devices including heart pacemaker, cardioverter, defibrillator cannot enter passenger compartment (including trunk).

High-voltage preventive measure

Warning ：

The electric vehicle has a high-voltage battery. If the operation on the vehicle and high-voltage parts is incorrect, there are risks of leakage of electricity, electric shock, or similar accidents. Thus, it is mandatory to follow correct procedures to check and maintain.

Before disconnecting repair switch, please put the key on “LOCK” position or unplug the key.

Disconnect repair switch before checking or maintaining high-voltage system. It is forbidden to close repair switch during the process of checking and maintenance. Before starting the operation on high-voltage system, be sure to wear insulated protection equipment, including gloves, shoes, and glasses.

When a technician is operating high-voltage system, please ensure no one touching the vehicle. When there is no maintenance operation, please take insulated protection on the high-voltage sections to prevent anyone touching.

When repair switch is disconnected, it is forbidden to put the key at “ON” position or turn to “START” gear.

High-voltage cable and safety sign

The color of high-voltage cable is orange and there are safety signs on the power battery assembly and other high-voltage parts. Do not touch these cables and parts.

Handling of high voltage terminals

When the connector of high-voltage cable is plugged out, please use insulated adhesive tape to bind up immediately.

Regulation for a person wearing medical electronic device

The vehicle has strong magnetic parts. If an engineer uses medical electronic device, such as electronic pacemaker, its function may be affected by strong magnetic parts. Thus, these people cannot carry out repair work.

Forbidden accompanying article during work

The vehicle has strong magnetic parts. Thus, during work it is forbidden to take metal articles which may cause short circuit or magnetic articles such us various bank cards which may be damaged.

Place “Repairing High-voltage Parts, No Touch!” warning sign

Before repairing high-voltage parts, please place “Repairing High-voltage Parts, No Touch” warning sign on the prominent position of the repaired vehicle to remind other people.

Precaution for removing 12V battery

Before removing 12V battery, turn the key to “ON” position, and then turn to “LOCK” position

Reminder ：

Though the key is at “LOCK” position, auto-recharge function of 12V battery may activate.

After the key turns from “ON” to “LOCK”, auto-recharge function of 12V battery will not activate.

Precaution for supplemental restraint system "airbag" and "safety belt pretension"

Supplemental restraint system “airbag” and “safety belt pretension” is used together with front seat safety belts, which can reduce the damage to the driver and front passenger during collision. Supplemental restraint system consists of safety belt, driver airbag, and front passenger airbag. The detailed information of supplemental restraint system is included in the chapters of airbag system and seat safety belt.

Warning :

In order to avoid accidents, please abide by the following content:

To avoid the failure of supplemental restraint system and considering that the risk of physical injuries will increase during collision if the system fails, all the service must be executed by JAC authorized dealer.

Non-normative maintenance of supplemental restraint system including non-normative removal and installation may result in accidental trigger of the system and cause physical injuries. Regarding the method of removing airbag module, please refer to Airbag System chapter.

Except for the operations in the service manual, please do not use electrical test device to test any circuit of supplemental restraint system. The color of harness and connector of supplemental restraint system is yellow or orange.

Precaution for using power tool (pneumatic or electric) and hammer

When power switch is at “ON” position and approach airbag diagnosis sensor or other sensors of airbag system, please do not use power tools or hammer on the sensor part area. Violent vibration may trigger these sensors and airbag to cause serious injuries.

When using power tools or hammer, put the key at “LOCK” position, unplug the negative pole of 12V lead-acid battery, wait at least one minute, and then start maintenance.

Cautions for R-134a

Warning：

The coolant R-12 and R-134a should not be mixed used, otherwise the electrical compressor may operate abnormally. In order to make sure coolant R-134a being pure and recyclable, use a filling device to refill or reclaim the coolant according to the process specified on the coolant label.

The R-134a air conditioner system requires specialized compressor lubricant. If non-specialized lubricant is used, it may cause the electrical compressor to work abnormally.

It is prohibited to put the R-134a exposed in the air.

Attention：

When dismantling the refrigerating circuit parts of the air conditioner, seal the refrigerating circuit connectors of each parts immediately in order to avoid the moisture in the air entering the refrigerating circuit.

The sealing lid can only be removed when installing the refrigerating circuit parts of the air conditioner system and all components should be installed as soon as possible in order to avoid the moisture in the air entering the refrigerating circuit.

The compressor lubricant should be sealed securely otherwise it will be useless when moisture absorbed.

Do not inhale coolant or vaporous compressor lubricant otherwise it will cause discomfort to eyes, nose and throat. Use special tool to reclaim refrigerant. If there is leakage of the conditioner system, the repairing place should be in open air. Any other question about the safety and health of refrigerant, please refer to the manufacturer of the coolant and compressor lubricant.

The compressor lubricant is forbidden to get in touch with polystyrene which may make it ineffective.

Contamination of refrigerant

If the refrigerant is not pure, please take below measures:

Explain to consumer that it is forbidden to release refrigerant which will contaminate the atmosphere.

Recycling polluted refrigerant may damage the recycling equipment and contaminate the coolant in the device.

Use special refrigerant filling device to reclaim and refill the refrigerant and do not reclaim polluted refrigerant. The handling of refrigerant must abide by local rules and regulations. As for replacing the parts of cooling system, please refer to related chapter in maintenance manual.

Normal precautions for refrigerant

Warning：

It is forbidden to release refrigerant in the air. Please use special recycling equipment to release refrigerant.

It is required to wear eyes and hand protective equipment during operation relating to refrigerant and air conditioner system.

Do not keep refrigerant stored in more than 52℃ temperature.

Do not use open flame to burn refrigerant tank. Put the refrigerant tank in warm water if heating is needed.

Do not throw or press the refrigerant tank.

Do keep the refrigerant away from open flame because it will release poisonous gas.

Make sure the working place is with good ventilation otherwise the refrigerant will inhale oxygen in the air and cause personnel to suffocate.

Do not make pressure or leakage test for repairing equipment of R-134a and air conditioner system filled with compressed air. The mixture of R-134a and air is combustible and it will cause personal injury or property loss in the event of burning. Please consult the refrigerant manufacturer for more safety information.

Precautions for dye leakage inspection

The air conditioner system does not contain fluorescent leakage detection dye.

Do not use fluorescent leakage detection dye in the air conditioner system.

Precautions for compressor lubricant

It is required to use specialized compressor lubricant RL168H for the air conditioner system otherwise it will cause malfunction of the air conditioner system.

Do not use recycling and filling device of normal lubricant refrigerant.

The recycling and filling device of conventional lubricant refrigerant can only be used for the vehicle after thoroughly and clean rinse.

Precautions for electrical compressor maintenance

The intake and exhaust vent of the compressor should be installed sealing-plug to avoid any entrance of air or impurities.

After the compressor is removed, please place it in same state as it is installed on the vehicle.

The compressor needs to operate for more than two minutes after installation.

Preparation work

Lubricant and refrigerant

Name	Function	Remark
Refrigerant R-134a	Used for refrigeration cycle
Compressor lubricant RL68H	Compressor lubricant

Special tool

Name	Picture	Name	Picture
Digital multimeter		High strength invisible lamp
Remover Plier		Triple table
Halogen leakage detector		Tracer color syringe
Tracer color R134a		Microthermometer
Positive current brake valve		Sealing protective equipment
Refillable recycling tank of fifty pounds		Pressure test adapter
Lip shape sealing removal tool for air conditioning system		O-ring sealing removal tool
Valve core removal and installation tool		O-ring sealing installation
Spring card plier		Spring card plier
Refrigerant recycling, regeneration and refilling system		Passive test lamp
Heating gun		Insulated gloves
Insulated shoes		Aspirator bump

System introduction

Introduction

The refrigerating system adopts environmental dual steaming electrical air conditioning system and attach no destruction to ozone.

The air conditioning system is composed of blower unit, refrigerating unit and heating unit.

The air conditioning system adopts one-piece electrical vortex compressor.

The heating system adopts electrical heater.

Specification

One-piece electrical compressor

Serial number	Technique index		Unit	Parameter value
1	Compressor	Motor model	/	Permanent magnet synchronous motor
2		Operating voltage range	V	220-312-400
3		Rated /Highest rotating speed	rpm	3420/5000
4		Rated wattage	kW	1.5
5		Peak power	kW	2.5
6		Rated current	A	4.5
7		Maximum operating current	A	7
8		Insulation resistance	/	1000Vdc，50MΩ，25℃（without refrigerant ） 1000Vdc，≥20MΩ，25℃（Fill 400g refrigerant ）
9		Operating environment temperature	℃	-20～85
10		Refrigerating capacity	kW	3.0
11		Energy efficiency ratio COP		2.2
12		Designed lifetime	km	10/15
13		Noise	dB	≤68
14		Over-current protection setting	A	7
15		Over-voltage protection setting	V	400
16		Low-voltage protection setting	V	220
17		Over-warm protection setting of controller	℃	82
18		Direct current busbar voltage range	V	220～400
19		Insulating resistance to vehicle	MΩ	≥100
20		Preventive requirement	/	IP67
21		Operating environment temperature	℃	-20～85
22		Cooling method	/	Use refrigerant to cool

Condenser

Effective core size W×H×D（mm）	619×361×16
Fin spacing （mm）	1.7
Fin quantity	37
Front part area （㎡）	0.223

Evaporator

Effective core size W×H×D（mm）	218×211×80
Fin spacing （mm）	1.7
Tube place number	17
Front part area （㎡）	0.0459

Refrigerant

Name	HFC-134a
Usage amount (g)	400

Electrical heater

Battery voltage （v）	331
Output wattage （kW）	2.5
Volume （cm³）	350

Components

Air conditioning system layout

Serial number	Component name	Function
1	Condenser	Tool cool high temperature high voltage gas refrigerant discharged by compressor into high voltage low temperature liquid refrigerant
2	One-piece compressor	The vortex disc is driven by motor to provide power to refrigeration cycle
3	Air conditioner controller	The air conditioner controller receives request signal from touch panel and signal of interior and exterior temperature to control the operation of air conditioning system actuator.
4	Blower assembly	The blower is composed of motor and fan. It provides motor to air conditioning system air circulation
5	Evaporator	Refrigerant is transferred from frost to gas and absorb heat inside the vehicle.
6	Expanding valve	It makes liquid refrigerant in high voltage to frost liquid in low voltage so as to save energy, lower temperature and decrease voltage.
7	Solenoid valve in crew compartment	It controls connection and disconnection of the air conditioner refrigeration circulation.
8	Solenoid valve in battery	It controls connection and disconnection of battery refrigeration circulation.
9	Triple pressure switch	It opens or closes pressure switch according to pressure value of air conditioner refrigeration circulation to protect air conditioning pressure.
10	Temperature sensor	It detects temperature signal and send to air conditioning sensor.
11	Electrical heater	PTC core is heated after connected to electricity and the blower sends hot wind to crew compartment.

Air conditioner mainframe

Blower

The blower is composed of motor and fan. It provides motor to air conditioning system air circulation. Air conditioner inside and outside air is controlled by interior and exterior gas button. In interior cycle, it inhales air from side inlet of air conditioner host. In exterior, it inhales air from vehicle front end shied lid.

Evaporator

Liquid refrigerant with throttling and depressurization is heated and boiled in evaporator. The refrigerant absorbs heat in the air while the blower consistently sends cooled air to crew compartment to lower the temperature.

Expanding valve

High pressure refrigerant discharged from reservoir dryer outflows through holes of expanding valve. It changes from liquid state into low pressure mist state after sharp expansion. Except throttling and depressurization, the expanding valve can also regulate refrigerant flow according to refrigerant overheat size of evaporator outlet.

Electrical heater

Electrical heater is composed of positive temperature coefficient thermal ceramic resistance. When the temperature exceeds a certain value, electrical resistance value increases with temperature rise in a jumping step. The temperature of the electrical heater surface is stable in a constant range.

Reminder ：

Electrical heater is composed of two groups of corrugated aluminum semiconductor material which can be opened separately or simultaneously so as to achieve economical or comfortable heating.

One-piece electrical compressor

The type of compressor is electrical vortex. Compressor controller and compressor are integrated. The controller regulates electrical compressor rotating speed through IPM module inverter. It also owns function of over-current and low voltage auto-detection and protection.

Reminder：

IPM module is composed of IGBT and intelligent power unit which drives and protect s circuit encapsulation.

IGBT (Insulated Gate Bipolar Transistor) is a semiconductor device in which a small voltage drives high voltage and large current.

The compressor drives the vortex in translational rotation through the rotation of motor itself so as to achieve suction and discharge of refrigerant.

Condenser

The condenser is composed of parallel flow condenser and reservoir dryer. The reservoir and condenser are integrated. The parallel condenser is a heating exchange device in which a flat tube and fin are integrated. The function of condenser is cooling high temperature high voltage refrigerant steam discharged by the compressor and condenses it into liquid. The heat released by refrigerant steam is blown away by the surrounding air into atmosphere.

Refrigerant and compressor lubricant

Refrigerant：The used refrigerant is HFC-134a which does not contain chlorine to damage atmospheric ozone layer.

Compressor lubricant：The used compressor lubricant is RL168H which is a kind of ester with high insulation performance.

Reminder：

HFC：Hydro Fluoro Carbon

RL：Refrigeration Lubricant

Warning signs for high voltage

It is required to stick high voltage warning signs on the electrical air conditioner compressor shell.

Make sure the warning sign is stuck on the original position after replacing electrical air conditioner compressor.

System

Refrigeration system

Refrigeration principle

The air conditioning system is composed of electrical compressor, condenser, front evaporator, triple unit pressure switch, rear evaporator, magnetic valve, air conditioner controller, pipes and other components. It consists of two refrigeration circuit. Each refrigeration circuit is controlled by magnetic valve.

Refrigeration system protection

Triple unit pressure switch

When the refrigeration pressure is abnormal, the triple unit pressure switch feedback pressure signal so as to close refrigeration system and protect the system.

When the pressure of the high voltage terminal is more than 3.2MPa, the triple unit pressure switch feedback pressure signal to close refrigeration system.

When the pressure of the high voltage terminal is lower than 0.2MPa, the triple unit pressure switch feedback pressure signal to close refrigeration system.

Reminder ：

The pressure value is read directly from pressure gauge.

The triple unit pressure switch is installed on pipe of the condenser discharging terminal.

Heating system

Heating system principle

Heating system is composed of blower and PTC electrical heater core. Under the action of the blower, the outside air heats the core through electrical heater and exchanges heat with air to raise the air temperature and reaches the purpose of heating.

Basic inspection

Diagnosis and maintenance procedure

Malfunction diagnosis procedure

System leakage inspection

The air conditioning system is usually detected by vacuum detection method.

Vacuum detection method：

Connect the intermediate refrigeration pipe to vacuum pump and open the vacuum and high and low voltage switch of the table set.

The system vacuum time lasts more than thirty minutes.

When the system is finished vacuum, hold it for fifteen minutes.

Observe if there is any rebound of the high and low voltage pointer. No rebound indicates no leakage in the system. If there is backing up, it is required to detect if any connector is leaked.

After leakage detection is finished, close the switches of the table set first and then close vacuum pump. Remove intermediate refrigeration pipe.

1 Closing valve

2 Refrigerant refilling port

3 Triple unit

table

Pressure state analysis

Phenomenon and state	Analysis of cause	Countermeasures
High voltage is high Low voltage is high	Refrigeration loop is mixed with air	Re-vacuumize and refill refrigerant
	Refrigerant refilling is redundant	Discharge spare refrigerant
	Lubricant is redundant	Discharge spare lubricant
	Condenser heat dissipation is poor.	Clean dirt on condenser surface or replace condenser.
	Cooling fan works abnormally.	Repair or replace cooling fan
High voltage is low Low voltage is low	Refrigerant refilling is insufficient	Add refrigerant.
	Refrigerant is leaked	Repair or replace leaked components
	O-ring is damaged.	Replace O-ring
High voltage is normal Low voltage is high	Expanding valve is over-opened or damaged	Adjust expanding valve opening or replace expanding valve.
	Refrigerant refilling is redundant	Discharge spare refrigerant
	Compressor is failed.	Replace compressor.
High voltage is normal Low voltage is low	Refrigerant refilling is insufficient.	Add refrigerant.
	Expanding valve is icy blocked.	Replace reservoir dryer bottle.
	Evaporator is dirty or internally blocked.	Clean or replace evaporator.
High voltage is low Low voltage is high	Compressor efficiency is reduced.	Repair or replace compressor.
High voltage is low Low voltage is high	Expanding valve is over-opened.	Adjust expanding valve opening or replace expanding valve.
High voltage is low Low voltage is negative pressure	After engine stops, low pressure increases significantly, and system is blocked by ice.	Replace reservoir dryer bottle.
High voltage is low Low voltage is negative pressure	After downtime, low voltage rises slowly and system is blocked.	Detect blocked parts and replace components.

Diagnosis

Refrigeration system malfunction

Heating system malfunction

Periodic maintenance

Refrigeration system

Inspect air conditioning system periodically and confirm if any leakage in the refrigeration loop and refill refrigerant timely.

Condition

Reference pressure

Outside temperature 30℃～35℃

Wind speed at seven gear and internal circulation

Low voltage ：0.1MPa～0.3MPa

High voltage ：1.0MPa～1.8MPa

Reminder ：

Use pressure triple table to detect refrigeration system loop.

When temperature is high, liquid pipe pressure is possibly more than 1.8MPa.

If any malfunction occurs, please refer to basic inspection.

1 Low voltage meter（blue）	2 High voltage meter (red)
3 Low voltage manual valve (L0)	4 High voltage side manual valve (HI)
5 Triple meter hose

Attention ：

Pressure table should be maintained carefully and kept clean. It is required to prevent the tube from water and dirt when it is not used. Exhaust the inside air when it is used.

It is required to tighten the connector between the pressure table and hose manually. It is prohibited to tighten it by tools.

Refrigerant refilling

Warning ：

It is prohibited to use high pressure mouth to refill separately.

It is prohibited to press refrigerant refilling valve core manually.

Reminder：

The high pressure mouth is on the thinner pipe connected to the condenser. The low pressure mouth is on the thicker pipe connected to the evaporator.

Make sure that the refrigerant refilling machine is with certain amount of R-134a.

Normal refrigerant refilling method

Use special refrigerant refilling machine.

Twist off high and low pressure refilling mouth sealing lid of the pipe.

Loosen the switching valve of the refrigerant high and low pressure refilling mouth.

Connect refrigerant refilling machine with high and low pressure refilling mouth of the air conditioning pipe.

Turn on refrigerant refilling machine and turn the high and low pressure refilling switch at “OPEN” gear.

Operate it according to refrigerant refilling procedure.

Reminder：

Vacumminze for more than fifteen minutes and keep the pressure for leakage detection.

When connecting the hose, check whether the sealing ring is damaged. Replace it if it is damaged.

When connecting the joints, tighten it with moderate force. Heavy power will damage the sealing ring and cause refrigerant leakage.

7 After refilling is finished, remove the refrigerant refilling machine and tighten the sealing lid of the high and low pressure refilling month.

1 Closing valve

2 Refrigerant refilling mouth

3 Refrigerant refilling machine

Simple refilling method

1 Switch off sealing lid of the high and low pressure refilling month.

2 Loosen switching valve of the triple table high and low pressure refilling mouth.

3 Connect triple table high and low pressure pipe with air conditioning pipe high and low pressure refilling mouth.

4 Connect triple table liquid pipe and vacuum pump suction part. Open triple table high and low pressure valve.

5 Vacuumize for more than fifteen minutes and keep pressure for leakage detection.

6 Close triple table high and low pressure valve and remove vacuum pump from triple table liquid pipe.

7 Connect triple table liquid pipe and refrigerant reservoir.

8 Switch on refrigerant reservoir and refill refrigerant from triple table high and low pressure valve.

9 After refilling is finished, remove the refrigerant refilling machine and tighten the sealing lid of the high and low pressure refilling month.

1 Closing valve

2 Refrigerant refilling mouth

3 Triple meter

4 Vacuum pump

Reminder：

During refilling process, turning on the compressor can shorten the refilling time.

When using simple refilling method, please pay attention to refill a certain amount.

Removal and installation

1 Condenser	2 Exhaust pipe assembly
3 Integrated compressor assembly	4 Pipe and expanding valve assembly
5 Blower evaporator assembly	6 Battery evaporator
7 Heating equipment	8 Crew compartment magnetic valve
9 Battery magnetic valve

Air conditioner host assembly

1 Dashboard frame

2 Air conditioner host

3 Front dash plate

Removal

Use refrigerant in recycling system of refrigerant specialized recycling equipment.

Pull out air conditioner host related connectors.

Remove dashboard assembly, please refer to chapter of “Dashboard”.

Remove fixing nut between air conditioner host and dashboard frame.

Open front compartment and remove fixing bolt of expanding valve.

Remove connecting bolt between air conditioner host and vehicle.

Remove air conditioner host.

Installation

Install it in reverse order of removal.

Condenser

Removal

Use refrigerant in recycling system of refrigerant specialized recycling equipment.

Remove pipe bolt connected to condenser.

Remove fixing bolt of condenser.

Remove fixing gasket between condenser and lower suspension.

Remove condenser.

Installation

Install it in reverse order of removal.

Air conditioner pipeline

1 Condenser

2 Compressor

3 Air conditioner host

4 Expanding valve

Removal

Use refrigerant in recycling system of refrigerant specialized recycling equipment.

Pull out connectors between triple pressure switch and magnetic valve.

Remove connecting bolt of pipeline connector.

Remove fixing nut of magnetic valve.

Remove air conditioner pipeline.

Installation

Install it in reverse order of removal.

Electrical compressor

Removal

Use refrigerant in recycling system of refrigerant specialized recycling equipment.

Pull out high and low voltage connectors of electrical compressor.

Remove connecting bolt related to compressor.

Remove fixing but of compressor bracket.

Remove compressor assembly.

Installation

Install it in reverse order of removal.

Air conditioner controller

Removal

1 Unclench air conditioner controller assembly.

2 Disconnect air conditioner controller harness connector.

3 Take down air conditioner controller.

Disassembling and assembling

Air conditioner host

Air conditioner host is composed of blower, temperature damper motor, module damper motor, internal and external air damper motor, speed regulating module, electrical heater and other parts.

Blower

Disassembling

Remove fixing bolt of blower.