1 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 charge 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 disconnects, it is forbidden that the key is at “ON” position or switched to “START” position.

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.

1）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:

1 The coolant R-12 and R-134a should not be mixed used, otherwise the electrical compressor may operate abnormally. In order to make sure the 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.

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

Attention:

3 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.

4 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.

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

6 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.

7 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

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

2 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 refrigeran

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 tool
Spring card plier		Spring card plier
Refrigerant recycling, regeneration and refilling system		Passive test lamp
Heating gun		Insulated gloves
Insulated shoes		Aspirator bump
Safety helmet	Safety glass

System introduction

Introduction

 The vehicle adopts environmental dual steaming electrical air conditioning system.

 The vehicle adopts air conditioning system with the core of compressor controller and air conditioner controller.

Components

Air conditioner controlling system layout

A Environment temperature sensor B Evaporator C Internal temperature sensor
D Left side of air conditioner host E Rear side of air conditioner host F Right side of air conditioner host

Component introduction

Serial number	Component name
1	Environment temperature sensor
2	Evaporator surface temperature sensor
3	Internal temperature sensor
4	Module motor
5	Temperature motor
6	Speed regulating module
7	New air return motor

Module motor

Introduction

 Module motor is installed on the left side of electrical heater shell.

 When module button is changed, it feedbacks module signal to air conditioner controller which takes control of module motor and regulates damper position.

 When module motor is started, it feedbacks voltage difference to air conditioner controller which takes action against signal. When module damper reaches required position, module motor stops working.

Operating principle

Wiring diagram

Temperature motor

Introduction

 Temperature motor is installed on lower side of electrical heater shell.

 When temperature button is changed, it feedbacks module signal to air conditioner controller which takes control of module motor and regulates damper position.

 When temperature motor is started, it feedbacks voltage difference to air conditioner controller which takes action against signal. When mixed damper reaches required position, temperature motor stops working.

Operating principle

Wiring diagram

New air return motor

Introduction

 New air return motor is installed on inside and outside air inlet duct of evaporator blower.

 When new air return button is changed, it feedbacks new air return request signal to air conditioner controller which takes control of new air return motor and regulates new air return damper position.

 When new air return motor is started, it feedbacks voltage difference to air conditioner controller which takes action against signal. When new air return damper reaches required position, new air return motor stops working.

Operating principle

Wiring diagram

Blower motor

Introduction

The motor drives fan rotation to provide required airflow volume.

Specification

Rotating direction	Clockwise direction
Fan size	Φ147mm×76.2mm
Motor diameter	Φ68mm
Motor rating	234W

Detection

The anode terminal can be added any voltage. The cathode requires inspection after grounded. Normally, the blower rotational speed increases with high voltage.

Expanding valve

Introduction

 Expanding valve is installed on inlet of evaporator.

 High pressure refrigerant outflowing from reservoir dryer ejects through expanding valve holes. It changes from liquid state to low pressure mist sate after sharp expansion.

 Except throttling and depressurization, the expanding valve can also regulate refrigerant flow according to refrigerant overheat size of evaporator outlet.

Specification

Type	H type
Volume	1.5RT
Opening	1.6mm

Attention:

When expanding valve cover is off, electrical driving compartment transfers heat to heating package. That causes the expanding valve pressure to rise and a large amount of refrigerant to flow into evaporator. If the refrigerant cannot be vaporized thoroughly, liquid refrigerant will flow into compressor and damage it.

Electrical heater assembly

Introduction

 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.

 There are two levels of heating in electrical heater. The first level wattage is 1kw. The second level is with wattage of 1.5KW and working voltage of 331VDC.

Operating principle

Evaporator

Introduction

 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.

 Evaporator contains many refrigerant channel made by aluminum board welding. Each channel between two groups contains wave tropical.

Operating principle

Evaporator surface temperature sensor

Introduction

 It senses surface temperature of evaporator to avoid icing.

 The feature of sensor is increasing resistance with lower temperature and reducing resistance with higher temperature.

Specification

Temperature（℃）	Resistance（kΩ）	Voltage（V）
30.00	1.98	0.99
25.00	2.45	1.17
20.00	3.06	1.38
15.00	3.85	1.62
10.00	4.88	1.89
5.00	6.22	2.19
4.00	6.54	2.25
3.00	6.87	2.31
2.00	7.23	2.37
1.00	7.60	2.44
0.00	8.00	2.50
-1.00	8.42	2.56
-2.00	8.87	2.63
-3.00	9.34	2.69
-4.00	9.48	2.71
-5.00	10.37	2.82

Air conditioner filter

Introduction

 The vehicle adopts pellet type air conditioner filter to remove foreign stuff and peculiar smell so as to keep a comfortable internal environment.

 The replacement period of air conditioner filter is 5000-12000km. It is required to check and replace air conditioner filter regularly in areas with serous atmosphere pollution and poor road condition.

One-piece electrical compressor

Introduction

 The type of compressor is electrical vortex.

 The compressor controller regulates electrical compressor rotating speed through IPM module inverter. It also owns function of over-current, low voltage, over voltage, over-temperature, phase loss and other protective function.

Condenser and dryer bottle

Introduction

 The function of condenser is cooling high temperature high voltage refrigerant steam from compressor.

 The condenser is parallel flow condenser which contains super-cooling area and integrated with dryer bottle. Super-cooling can improve cooling performance.

 During maintenance, remove the sealing cover on lower side of dryer bottle to replace silicon gel.

Triple unit pressure switch

Introduction

 According to air conditioning system refrigerant pressure value, it turns on or off the pressure switch and sends signal to air conditioner controller.

 The cooling fan changes into high rotating speed state when air conditioning system voltage reaches 1.4KW so as to prevent cooling performance decreasing by rising pressure.

Wiring diagram

Specification

Distinction	ON	OFF
High voltage	26.0（kg/㎠）	32.0（kg/㎠）
Low voltage	2.3（kg/㎠）	2.0（kg/㎠）
Medium voltage	18.0（kg/㎠）	14.0（kg/㎠）

Condenser fan assembly

Introduction

 Condenser fan is fixed on cooling system radiator and installed on front of electrical driving compartment.

 Condenser fan is axial-flow type.

 Condenser fan rotating speed is controlled by VCU and with multiple gear speed.

Refrigerant pipeline

Introduction

 It connects various parts of cooling circuit together into a closed system.

 Each pipe joint adopts O-ring axial sealing.

 The vehicle is composed of four refrigerant pipelines.

High voltage pipe：Connect condenser and evaporator and install triple unit pressure switch.

High voltage exhaust pipe：Connect electrical compressor and condenser.

Low voltage aspirating pipe：Connect electrical compressor and evaporator.

Liquid pipe distribution line：Connect to battery compartment evaporator.

The heating unit,a water-heating type, makes use of the cooling water from engine which flows into compartment heater core body through two water heating pipes. The blower gets the air inside or outside the compartment flowing across the heater core surface and gets the temperature raised, reaching the heating purpose. The heater core structure is the same as the condenser's, adopting Parallel Flow Design. Refer to table 5 for parameters. In addition, the heater unit is integrated with the temperature, mode wind door and execution mechanism, adjusting the wind door by the motor of automatic controlling system to meet the set temperature and mode requirements. Specific control principle is stated in the next section.

Table 5

Core body dimension (WXHXD)		165X206X29
Fin clearance /fin number		1.83/2 /112
Duct/number		2.04X25.4/18
Front area		0.03399m²
Heating amount (kcal/h)/ Wind pressure difference (mmAq)	200m³/h	3093/7.6
	300m³/h	4380/13.1
	350m³/h		4925/16.0
	400m³/h		5411/19.3

Air conditioning controller

Instruction

● A/C controller collects temperature signal inside or outside vehicle and evaporator, controls A/C system actuator working.

● A/C controller and VCU、electric compressor controller interact information with CAN communication.

Controller logical function

Serial No.	Button	function	System action and display	Function relieving keying
1	Air volume rotary knob	Regulating air volume	1） Using continuously speed regulation,rotary knob is used to regulate blower air volume. 2） MP5 synchronous display 0-7 files.	Rotating to left ending,air volume decreases to 0 state,that means closing the blower.
2	Defrost keying	Regulating to defrosting mode	Key is on “ON” state,press defrosting mode keying. 1） If the blower fan speed is 0, the front defrost indicator and front panel defrost icon will be on, and the A/C indicator and snowflake icon will not be lit. 2） If the blower fan speed is greater than 0, the A/C indicator and the snowflake icon are lit, and the compressor operates. 3） Working on defrosting function, initial setting is new air. 4） Press defrosting keying repeatedly,the state keeps on	Working on defrosting function: 1)Press the A/C button, the A/C indicator and the snowflake icon are extinguished, and the compressor does not work; 2) Reduce the wind speed of the blower to 0, exit the defrost mode, the A/C indicator and the snowflake icon are extinguished, the compressor does not work; increase the wind speed of the blower to >0, restore the defrost status, and the defrost indicator is always on. 3)Press other modes,enter in other modes,then could relieving defrosting lamp lighting state.
3	A/C button	Controls compressor on and off	1）Press the A/C key repeatedly to turn the compressor on or off, and the A/C indicator and snowflake icon change synchronously. 2）When the blower wind speed is 0, the A/C button does not respond. 3) When the defrost function is performed, the A/C is turned on by default. 4)initialization,A/C always is off 5)Under modes except defrosting,temperature rotary knob stays heating area,A/C is forbidden to start.	1)The A/C button is pressed, its indicator light goes out, and the compressor is off. 2) The blower fan speed is adjusted to 0, the A/C button indicator and the snowflake icon are extinguished, and the compressor is turned off. 3)Under modes except defrosting,temperature rotary knob stays heating area,A/C stops working.
4	return air key	Controls new and return air switch	Press return air key repeatedly,air damper doing homologous switch;indicator lamp lighting means return air state;indicator lamp extinguishing means new air state.	1） Working on defrosting or blowing feet and defrosting function, initial setting is new air. 2） 2)After the air conditioner is turned on, the return air state is the state before the air conditioner was turned off last time.
5	Rear defrosting key	Controls rear defrosting on and off	Press the rear defrost button repeatedly to turn the defrost on oroff.； In the rear defrost operation, the indicator and the rear defrost icon on the touch panel light up	nothing to do with air conditioning function
6	Temperature rotary knob	Regulating mode	1)Operating temperature rotary knob to regulate temperature air damper for temperature regulation. 2)The setting temperature increases in 1℃/every time,maximum temperature 32℃,minimum temperature 16℃. 3)The key is in the "ON" position, blower >0 position, the temperature knob is turned to the heating area, PTC is turned on, the air conditioner starts heating 4) If the blower fan speed is 0, the front defrost indicator and the front panel defrost icon will be lit, and the A/C indicator and the snowflake icon will not be lit. If the blower fan speed is adjusted to >0 in this case, the A/C lamp and the snowflake icon will light up again and the compressor will operate.	1) The temperature button can be freely set in the power-on state. 2) The blower fan speed is adjusted to 0, and the air conditioner heating is turned off.
7	Blowing face keying	Regulating to blowing face mode	Press the keying,switch mode air damper to blowing face position;blowing feet indicator lamp lights,A/C、in-out air state remain the same	3)Press other modes,enter in other modes,then could relieving present state.
8	Blowing face/feet Button	Regulating to blowing face/feet mode	Press the keying,switch mode air damper to blowing face position;blowing feet indicator lamp lights,A/C、in-out air state remain the same	3)Press other modes,enter in other modes,then could relieving present state.
9	Blowing feet keying	Regulating to blowing feet mode	Press the keying,switch mode air damper to blowing face position;blowing feet indicator lamp lights,A/C、in-out air state remain the same	3)Press other modes,enter in other modes,then could relieving present state.
10	Blowing feet/defrosting Button	Regulating to blowing feet/defrosting	Press the keying,switch mode air damper to blowing feet/defrosting position;blowing feet/defrosting indicator lamp lights,A/C、in-out air state remain the same	3)Press other modes,enter in other modes,then could relieving present state.

System principle

System framework

Binary pressure switch

Compressor controlling

Controlling principle

 Air conditioner controller receives compressor opening request signal from touch panel.

 Air conditioner controller checks whether the blower is open. If the blower is open, it regulates compressor rotating speed according to setting temperature and environment temperature.

 When difference value between set temperature and environment temperature is more than 2℃ , compressor will operate at full speed. When difference value between set temperature and environment temperature is less or equal difference value between set temperature and environment temperature is more than 2℃, compressor enters frequency conversion.

 During compressor operating process, compressor controller monitors operating state in real time. When operating state is abnormal, compressor can handle and response promptly.

Electrical heater controlling

Controlling principle

 There are two levels of heating in electrical heater. The first level wattage is 1KW. The second level wattage is 1.5KW.

 There is temperature sensor on electrical heater surface. When temperatures sensors collects temperature above 95℃, air conditioner controller will automatically disconnect electrical heater power supply input.

 There is temperature switch on electrical heater surface. When temperatures switch collects temperature above 95℃, air conditioner controller will automatically disconnect electrical heater power supply input.

 When internal temperature of vehicle is above 25℃, electrical heater will not operate. When internal temperature of vehicle is between 5℃ with 25℃, electrical heater will operate at first heating level. When internal temperature of vehicle is under 5℃ , electrical heater will operate at maximum heating level.

Diagnosis

Instruction

When A/C control system breaks down.the symptoms of the A/C system should be judged first,adopt homologous methods to eliminate and maintain.

Symptom list

Compressor symptom list

Serial No.	Faults name	Faults code
1	Compressor cavity temperature is too high	1
2	Compressor cavity temperature reaches the setting value	2
3	Compressor over current	3
4	Compressor over load	4
5	input DC under voltage	5
6	input DC over voltage	6
7	Compressor cannot receive CAN signal	7

A/C controller symptom list

Serial No.	Faults name	Faults code
1	Evaporator temperature sensor feed back short out to earth	3
2	Evaporator temperature sensor feed back shut off to earth	4
3	Indoor temperature sensor feed back short out to earth	5
4	Indoor temperature sensor feed back shut off to earth	6
5	Outdoor temperature sensor feedback ground short circuit	7
6	Outdoor temperature sensor feedback ground breaking	8
7	Mode servo motor feed back short out or shut off to earth	9
8	Mode servo motor stalled	10
9	Temperature servo motor feed back short out or shut off to earth	11
10	Temperature servo motor stalled	12
11	PTC Temperature Sensor short out	13
12	PTC Temperature Sensor shut off	14

Compressor cavity temperature is too high

Description

Serial No.	Type	Conditions	Troubleshooting
1	Compressor cavity temperature is too high	IPM temperature is no less than 80 ℃	Compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 1 or not;

3 If checking out code 1,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 Replace compressor

2 Restart compressor,verify whether the function is normal or not;

3 If it still has some problem,please check high voltage power input circuit

Compressor cavity temperature reaches the setting value

Description

Serial No.	Name	Conditions	Troubleshooting
2	Compressor cavity temperature reaches the setting value	IPM temperature is no less than 70 ℃	Compressor runs in limited power

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 2 or not;

3 If checking out code 2,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 check whether compressor works normally or not;

2 check condenser fan works normally or not;

1 Restart compressor,verify whether the function is normal or not;

4 If it still has some problem,please check high voltage power input circuit

Compressor over current

Description

Serial No.	Name	Conditions	Troubleshooting
3	Compressor over current	Input current is more than 7A	Compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 3 or not;

3 If checking out code 3,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 Replace compressor

2 Restart compressor,verify whether the function is normal or not;

3 If it still has some problem,please check high voltage power input circuit

Compressor over load

Description

Serial No.

Name

Conditions

Troubleshooting

Compressor over load

Output power greater than 2000W

1.Compressor power is between 2000W to 2200W,compressor decrease power to work

2.Compressor power is over 2200W,compressor stops working.

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 4 or not;

3 If checking out code 4,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 Replace compressor

2 Restart compressor,verify whether the function is normal or not;

3 If it still has some problem,please check high voltage power input circuit

Input under voltage

Description

Serial No.	Type	Conditions	Troubleshooting
5	DC input under-voltage <280V	Power battery input voltage is too low	Compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 5 or not;

3 If checking out code 5,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 check vehicle power on voltage

2 check whether vehicle high voltage circuit is normal or not

3 Restart compressor,verify whether the function is normal or not;

4 If it still has some problem,please check whether compressor function meet requirements

Input over voltage

Description

Serial No.	Type	Conditions	Troubleshooting
6	Input DC over-voltage ≥378V	Power battery input voltage is too high	Compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 6 or not;

3 If checking out code 6,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 1 check vehicle power on voltage

2 Restart compressor,verify whether the function is normal or not;

3 4 If it still has some problem,please check whether compressor function meet requirements

Compressor cannot receive CAN signal

Description

Serial No.	Type	Conditions	Troubleshooting
7	Compressor cannot receive CAN signal	Compressor controller couldn’t receive communication signal in 5s or longer time.	Communication breaks down 5s,compressor stops working.

Faults diagnosis flow

1 Connect the CAN signal of compressor controller to computer system;

2 Start compressor and observe whether computer system could detect malfunction code 7 or not;

3 If checking out code 7,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 Replace compressor

2 Restart compressor,verify whether the function is normal or not;

3 If it still has some problem,please check high voltage power input circuit

Evaporator temperature sensor feed back short out to earth

Description

Serial No.

Type

Conditions

Troubleshooting

Evaporator temperature sensor short circuit to ground

Evaporation temperature sensor short circuit to ground, feedback is 0V.

Initial temperature is 10℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 3 or not;

3 If checking out code 3,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace evaporator temperature sensor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Evaporator temperature sensor feed back shut off to earth

Description

Serial No.	Type	Conditions	Troubleshooting
2	Evaporator temperature sensor feed back shut off to earth	Evaporation temperature sensor feedback voltage is 5.0V	Initial temperature is 10℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 4 or not;

3 If a fault code 4 is detected, "Process flow" is performed; if fault code 3 is not detected, the diagnosis is completed.

treatment flow

1 replace evaporator temperature sensor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Indoor temperature sensor feed back short out to earth

Description

Serial No.	Type	Conditions	Troubleshooting
3	Indoor temperature sensor feed back short out to earth	Indoor temperature sensor feedback voltage is 0V	Initial temperature is 20℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 5 or not;

3 If checking out code 5,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace indoor temperature sensor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Indoor temperature sensor feed back shut off to earth

Description

Serial No.	Type	Conditions	Troubleshooting
4	Indoor temperature sensor feed back shut off to earth	Indoor temperature sensor feedback voltage is 5.0V	Initial temperature is 20℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 6 or not;

3 If checking out code 6,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace indoor temperature sensor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Outdoor temperature sensor feedback ground short circuit

Description

Serial No.	Type	Conditions	Troubleshooting
5	Outdoor temperature sensor feedback ground short circuit	Outdoor temperature sensor feedback voltage is 0V	Initial temperature is 25℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 7 or not;

3 If checking out code 7,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 Replace outdoor temperature sensor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Outdoor temperature sensor feedback ground breaking

Description

Serial No.	Type	Conditions	Troubleshooting
6	Outdoor temperature sensor feedback ground breaking	Outdoor temperature sensor feedback voltage is 5.0V	Initial temperature is 25℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 8 or not;

3 If checking out code 8,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 Replace outdoor temperature sensor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Mode servo motor feed back short out or shut off to earth

Description

Serial No.	Type	Conditions	Troubleshooting
7	Mode servo motor feed back short out or shut off to earth	Mode motor feedback voltage is 0V	Mode motor compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 9 or not;

3 If checking out code 9,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace mode motor

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Mode servo motor stalled

Description

Serial No.	Type	Conditions	Troubleshooting
8	Mode servo motor stalled	Motor does not move	Mode motor compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 10 or not;

3 If checking out code 10,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace mode motor

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Temperature servo motor feed back short out or shut off to earth

Description

Serial No.	Type	Conditions	Troubleshooting
9	Temperature servo motor feed back short out or shut off to earth	Temperature motor feedback voltage is 0V	Temperature motor compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 11 or not;

3 If checking out code 11,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace mode motor

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Temperature servo motor stalled

Description

Serial No.	Type	Conditions	Troubleshooting
10	Mode servo motor stalled	Motor does not move	Temperature motor compressor stops working

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 12 or not;

3 If checking out code 12,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace temperature motor;

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

PTC temperature sensor feedback ground short circuit

Description

Serial No.	Type	Conditions	Troubleshooting
11	PTC temperature sensor feedback ground short circuit	PTC temperature sensor feedback voltage is 5V	Initial temperature is 105℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 13 or not;

3 If checking out code 13,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace PTC

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

PTC temperature sensor feed back shut off to earth

Description

Serial No.	Type	Conditions	Troubleshooting
12	Indoor temperature sensor feed back shut off to earth	Indoor temperature sensor feedback voltage is 0V	Initial temperature is 105℃.

Faults diagnosis flow

1 Connect the CAN signal of A/C controller to computer system;

2 Start A/C and observe whether computer system could detect malfunction code 14 or not;

3 If checking out code 14,do “treatment flow”;otherwise finish the diagnosis.

treatment flow

1 replace PTC

2 Restart A/C,verify whether the function is normal or not;

3 If it still has some problem,please check whether A/C function meet requirements

Wire harness framework

framework

Connector information

Air conditioning controller

Connector number	M13
Connector name	Air conditioning controller
Connector model	AMP1376113-1

Terminal number	Wire color	Signal name
1	R	IGN2
2	null	null
3	BrB	Background light positive pole
4	L	Background light negative pole
5	RB	PTC opening first way
6	RW	PTC opening second way
7	RW	CAN high
8	RY	CAN low
9	null	null
10	B	vehicle power ground wire
11	null	null
12	BW	ventilation fan -
13	Gr	temperature motor+
14	BrO	temperature motor-
15	L	mode motor +
16	R	mode motor -
17	LW	New Return Air Motor+
18	BrR	New Return Air Motor-
19	GR	Evaporator temperature sensor +
20	Rr	sensor and motor reference ground wire
21	L	BATT+
22	null	null
23	null	null
24	null	null
25	BrV	rear defrost request
26	WB	rear defrost feedback
27	GB	PTC temperature switch+
28	GR	PTC temperature switch-
29	G	PTC Temperature Sensor +
30	YR	PTC Temperature Sensor -
31	GrR	outdoor temperature sensor+
32	Br	blank
33	G	5V reference voltage
34	P	temperature motor position
35	Y	mode motor position
36		GND
37	null	null
38	Y	outdoor temperature sensor+
39	L	Blower on signal
40	G	wind speed adjustment (continuous speed regulation)

Mode motor

Connector number	M06
Connector name	Mode motor
Connector model	KUM PH842-07011

Terminal number	Wire color	Signal name
1	R	Mode motor power supply positive
2	YB	Mode motor power supply negative
3	YR	Mode Motor Position Signal Power Positive
4	G	Mode motor feedback voltage
5	B	Ground

temperature motor

Connector number	M08
Connector name	temperature motor
Connector model	KUM PH842-07011

Terminal number	Wire color	Signal name
1	R	Temperature motor power supply positive
2	YB	Temperature motor power is negative
3	YR	Temperature motor position signal power supply is positive
4	G	Temperature motor feedback voltage
5	B	Ground

New Return Air Motor

Connector number	M09
Connector name	New Return Air Motor
Connector model	KUM PH842-07011

Terminal number	Wire color	Signal name
1	BrR	New return air motor power supply
2	LW	New return air power is negative

Blower motor

Connector number	M11
Connector name	Blower motor
Connector model	KET MG620042

Terminal number	Wire color	Signal name
1	Lg	Blower motor power is negative
2	LV	Blower motor power is positive

Speed control module

Connector number	M12
Connector name	Speed control module
Connector model	DJ 7042-6.3-21

Terminal number	Wire color	Signal name
1	L	Speed control module voltage control end
2	Lg	Speed regulator power supply negative
3	B	Speed control module power supply

Evaporator face temperature sensor

Connector number	M13
Connector name	Evaporator temperature sensor
Connector model	AMP 368545-1

Terminal No.	Wire color	Signal name
1	Br	Temperature sensor +
2	GR	Temperature sensor -

Outdoor temperature sensor

Connector number	B13
Connector name	Outdoor temperature sensor
Connector model	YAZAKI 7283-7028-30

Terminal number	Wire color	Signal name
1	Br	Temperature sensor +
2	GR	Temperature sensor -

Indoor temperature sensor

Connector number	M16
Connector name	Indoor temperature sensor
Connector model	AMP 174929-1

Terminal No.	Wire color	Signal name
1	Br	Indoor temperature sensor fan power supply
2	Y	Indoor temperature sensor fan power negative
3	B	Temperature sensor +
4	Y	Temperature sensor -

Electric compressor assembly

Connector number	M18
Connector name	Electric compressor assembly
Connector model	DY3F1002SNF
Connector model	MOLEX 194290044

Terminal No.	Wire color	Signal name
1	R	Compressor high voltage power+
2	B	Compressor high voltage power-

Terminal No.	Wire color	Signal name
1	W	solenoid valve 1 +
2	B	Ground
3	RW	CAN_H
4	RY	CAN_L
5	R	IGN2
6	Y	solenoid valve 2 +

Basic inspection

DIAGNOSIS AND REPAIR WORK FLOW

Work process

Malfunction phenomenon	Possible cause for malfunction	Excluding method
No refrigerant in air conditioning system	Refrigerant leakage	Visual method: 1）Observe each connecting part if there is any oil which indicates possible leakage. Put soap water on suspicious part and observe if there is air bubbles. 2）Observe core surface of condenser and evaporator whether there is scratch, crush and damage.
		Vacuumize Vacuumize the refrigerating system and listen if there is sizzle sound which indicates leakage.
		Device inspection: 1）Use electronic leakage detector which is of high sensitivity to detect. 2）Use dye tracer to detect.
System compressor lubricant is inadequate	Replace system components and add or lesson lubricant according to regulations.	Please confirm compressor lubricant specification first. It cannot be mixed. Compressor lubricant is POE.
		After recycling refrigerant, add about 30ml compressor lubricant.
		Replace compressor and pour out all lubricant in compressor and then add 120ml compressor lubricant.
		Replace pipeline: add about 30ml compressor lubricant.
		Replace condenser: add about 60ml compressor lubricant.
		Replace evaporator: add about 50ml compressor lubricant.
		Replace silicon gel: add about 10ml compressor lubricant.
Air volume is abnormal	No air from air conditioner	Wiring malfunction: 1）Check blower motor wiring and confirm whether connectors are loosen. 2）Replace fuse if it is fell off or damaged. 3）Replace relay if it is damaged.
	No air from air conditioner	Mechanical failure: 1）Replace blower if it is damaged. 2）Replace temperature damper mechanism if it is damaged and cannot be regulated to refrigerating state. 3）Replace air conditioner controller if it is damaged. 4）Replace speed regulating module if it is damaged.
	Air conditioner volume is small.	Check battery voltage whether there is short voltage.
		Check whether duct is congested and grilling is fully opened.
		Replace speed regulating module if it is damaged.
		Check whether air conditioner filter wind resistance is huge and whether it is congested by dirt and foreign stuff.
		Check whether blower motor operates in reverse direction and adjust anode and cathode of connectors.
Refrigerating failure of air conditioner	No refrigerant for system	Use test table to test, please refer to “Refrigerant leakage” for inspection.
	No air blow	Please refer to “Abnormal air volume” for inspection.
	Compressor does not work	Signal is blocked: Pressure switch is damaged and no pressure signal. Detect short connected signal ad replace air conditioner pipeline if it is damaged.
	Compressor does not work	Replace compressor if it is damaged inside.
Bad air conditioner refrigerating	Refrigerant is insufficient.	Check whether pressure is in normal range. Add refrigerant if it insufficient.
	Refrigerant is insufficient.	Check whether there is leakage in air conditioning system. Detect leaking point if needed.
	Compressor lubricant is excessive.	Pour out excessive compressor lubricant and add moderate compressor lubricant.
	Compressor does not work normally	Replace compressor if it does not reach normal operating rotating speed.
	Air volume is small	Please refer to “Abnormal air volume” for inspection.
No heating for air conditioner system	PTC does not work PTC	The core of PTC is damaged. Replace heater assembly.
	PTC does not work PTC	PTC connector is poor connected. Replace heater assembly.
	No air blow of air conditioner	Please refer to “Abnormal air volume” for inspection.
	Controlling failure	Replace air conditioner controller if temperature regulating is damaged or damper cannot be regulated to maximum heating.
Abnormal sound in air conditioner system	Abnormal sound from pipe expanding valve	After air conditioner is turned on, check whether there is flowing chirps at expanding valve. Adjust or replace expanding valve.
	Abnormal sound from damper mechanism	Check whether there is resistance and tick or chuckle when adjusting damper mechanism. If there is, cost lubricant on damper mechanism or replace mechanism components.
	Abnormal sound from blower	Abnormal sound from blower shell 1）If there is booming sound, check whether blower motor is rotating in reverse direction. Replace harness or adjust connector terminal. 2）If there is chuckle or sizzle, replace blower motor. 3）If there is bang, check whether there is foreign stuff in volute. Remove it and check and handle.
	Abnormal sound from blower	If blower is not installed firmly, there is vibration sound.
Peculiar smell in air conditioner system	Filter is with mildew	Remove filter to check whether the surface is seriously polluted and replace it timely.
Peculiar smell in air conditioner system	Frozen water cannot be exhausted smoothly.	Frozen water cannot be exhausted thoroughly. There is water in shell which causes mildew. Replace draining pipe position.

Removal and installation

Environment temperature sensor

Removal

1 Pull out environment temperature sensor ① from mounting bracket waist shape hole.

2 Disconnect connectors connected to environment temperature sensor.

Installation

Install it in reverse order of removal.

Vehicle interior temperature sensor

Removal

1 Disconnect low voltage connectors o f vehicle internal temperature sensor.

2 Remove two fixing screws ① of vehicle internal temperature sensor.

Installation

Install it in reverse order of removal.

Evaporator surface temperature sensor

Removal

1 Pull out evaporator surface temperature sensor from evaporator surface.

Reminder:

When pulling it out, please take care to not squeeze or scratch flat tube and fin.

2 Disconnect low voltage connectors of evaporator surface temperature sensor.

Installation

Install it in reverse order of removal.

Reminder:

Please put the evaporator sensor at same position as the original.

Speed regulating module

Removal

1 Disconnect low voltage connectors of speed regulating module.

2 Remove two fixing screws① of speed regulating module.

Installation

Install it in reverse order of removal.

Maintenance data and specification

One-piece electrical compressor

Motor type	Permanent-magnet synchronous motor
Discharging capacity	32ml/r
Operating voltage	220-312-400V
Rated/ highest rotating speed	3420/5000rpm
Rated wattage	1.5kw
Rated current	4.5A
Maximum working current	7A
Over voltage protection	400V
Short voltage protection	220V

Electrical heater

Rated voltage	331VDC
Rated wattage	2.5KW
Wattage deviation	-5%～10%
Insulating resistance	≥100MΩ
Leaked current	＜0.5mA
Striking current	≤19A

Air conditioner controller

Operating temperature	-30℃～80℃
Operating voltage	9～16VDC
Operating current	≤2A
Controlled precision	±0.5℃
Damper controlling	Stepping motor control
Communication mode	CAN 2.0B