iEV7S lithium battery pack module
replacement and maintenance process
iEV7S 三元锂电池包模组更换维修流程
版本号：
2020.10
Preparation work
准备工作
Use the software（PACK MONITOR）of SINOEV to judge and record the number of
the problem battery and its module and fully charged before unpacking on the vehicle.
在整车上用华霆上位机软件，判断、记录问题电池的编号和所在的模组，并拆包
前充满电
See the maintenance manual for details of high voltage precautions and special tools
preparation
高压预防措施和专用工具准备详情见维修手册。
Module replacement process
模组更换流程
（一）
Take out the power battery pack
（一）取出动力电池包
1. Put the key in the off position, disconnect the negative pole of the battery, pull out
the maintenance switch, and power down the whole vehicle
1. 钥匙置于 OFF 挡，断蓄电池负极，拔下维修开关，让整车下电。
2. After standing for 10 minutes, lift the vehicle,dismantle battery anticollision
beam,power battery assembly under guard I and II
2. 静止 10 分钟后，将车辆举升，拆除电池防撞梁、动力电池总成下护板Ⅰ和下
护板Ⅱ。
3. Prepare a bucket, disassemble the connecting pipe between the battery inlet and
outlet aluminum base and the battery inlet and outlet pipe,the water bucket
catches the outflow coolant
3. 准备一个水桶，先拆卸电池进出水铝基座与整车电池进出水管连接管，水桶
接住整车冷却回路中流出的冷却液。
4. After the cooling circuit is drained, first pull out the low-voltage connector and
high-voltage connector, and remove the battery pack fixing bolt，place the battery
pack on the tray and remove the battery pack
4. 冷却回路排液完毕后，先拔出低压接插件，高压接插件，拆除电池包固定螺
栓，将电池包置于托盘上,取下电池包。
5. The cooling liquid inside the battery pack is discharged with an air gun, install the
MSD and then test the air tightness of the whole package.(Add 1.6-1.8kpa into
the battery pack for air tightness test, lasting for about 1 min, and the air pressure
reduction is less than 0.2kpa, which is normal)
5. 用气枪排出电池包内部的冷却液，安装维修开关，随后进行整包气密性检测。
（向电池包内部加入 1.6-1.8Kpa 进行气密性检测，持续约 1 分钟，气压减少量小
于 0.2Kpa，即为正常）
6. Then check the air tightness of the cooling pipeline. After the test is normal,
prepare to unpack（Add 250kPa air pressure into the cooling pipeline for tightness
test, lasting for about 300 seconds, and the leakage is less than 0.5kpa, which is
normal）
6. 接着对冷却管路进行气密性检查，检测正常后，准备进行拆包。（向冷却管
路内加入 250Kpa 气压进行气密性检测，持续约 300 秒，泄漏量小于 0.5Kpa，即
为正常）
Note:
注意事项：
1 Do air tightness test, in order to ensure that the air tightness of battery
pack is normal before unpacking.If the air tightness fails to pass the test, please
check the leakage point first and feed back to JAC （The cause of air tightness
failure is likely to be caused by the leakage of external connecting pipe, so it is
necessary to confirm whether the air tightness detection tooling is normal before
using）
Air tightness problem detection method: inject air into the whole package,
keep the air pressure at 1.6-1.8kpa, spray soap water on the outer surface of
battery pack, observe the bubble situation, and determine the specific air leakage
point.It is a very serious problem that the air tightness of the whole package fails
to pass, which means that the waterproof level of the battery pack cannot reach
IP67. The air tightness test of the whole package before unpacking will help us to
determine the responsibility for the more serious fault problems inside the
battery pack.
1 做气密性检测，为了确保电池包拆包前气密性是正常的。如检测时气
密性未通过，请先排查泄漏点，并反馈给 JAC。（注意，气密不通过原因极可
能为外接管泄漏导致，故使用气密检测工装前，务必确认气密检测工装是否正
常）
气密问题排查方法：整包注入空气，保持在 1.6-1.8kpa 的气压，通过给电池
包外表面喷洒肥皂水，观察气泡情况，判定具体漏气点。如存在螺栓固定处漏
气，请拆包前先确认各螺栓的扭矩，并反馈给 JAC。整包气密性不通过是非常
严重的一个问题，这代表着电池包的防水等级无法达到 IP67，拆包前的整包气
密检测将有助于我们对电池包内部更严重的故障问题进行责任判定。
2 Before air tightness test, high voltage port and low voltage port should
be plugged with special plug tool
2 气密性检测前，需用专用堵头工具将高压端口和低压端口堵上。
（二）
Disassemble the battery pack and replace the module
（二）拆解电池包，更换模组
7. Remove the fixing bolts and remove the upper shell of battery pack
7. 拆除固定螺栓，拆卸电池包上壳体
8. Pull out LBC low-voltage harness in sequence, then remove BDU, disconnect
main positive, main negative soft connection, pay attention to wrap high-voltage
connection with insulating tape
8. 按顺序拔出 LBC 低压线束，随后拆除 BDU，断开主正，主负软连接，注意用
绝缘胶布包裹高压连接。
9. Pull out the low voltage harness and temperature acquisition harness of the
module, and remove the soft connection between the modules
9. 拔下模组的低压线束，温度采集线束，拆除模组之间的软连接。
10. Pull out the cooling line and remove the MSD bracket
10.拔出冷却管路，移除维修开关支架。
11. Remove the fixing bolts of the module, find the location of the fault single
module, and take out the module with tooling
11.拆除模组固定螺栓，找到故障的单个模组所在位置，用工装取出相应模组
12. Disassemble the module and find the single module with fault
12.对模组进行拆卸，找到故障的单个模组。
13. The voltage value should be measured before the replacement of the new module.
The voltage value should be consistent with the voltage value of the adjacent
module. The voltage value should be adjusted by the charging and discharging
equipment，Differential pressure is ±10mv
13.在换上新模组之前，要测量新模组电压，电压值要与相邻模组电压值一致，
电压值使用充放电设备调整，压差在±10mv。
14. After replacing the module, remember to apply conductive paste between
adjacent modules, reassemble the module, and lift the module back into the
battery pack with tooling
14.更换完模组后，记得涂抹相邻模组间的导电膏，将模组重新组装好，并用工
装将模组抬回电池包内。
Note：
注意事项：
1 When pulling out LBC low-voltage harness, pull it out from high-end to
low-end
1 拔出 LBC 低压线束时，从高端到低端拔出
2 The cooling pipe belongs to the loss part, and its service life is inserted
and unplugged three times. After three times, it is recommended to replace the
cooling pipe with a new one after unpacking
2 冷却管路属于损耗件，使用寿命插拔 3 次，后续拆包建议更换新的冷
却管路。
3 After removing the cooling pipe, use adhesive tape or other tools to
block the cooling pipe interface of the module to prevent foreign matter from
entering
3 在拆下冷却管路后，要用胶布或者其他工具封堵模组的冷却管路接口，
防止异物进入
4 When lifting the module back into the battery pack, be careful not to
damage the cooling pipe under the metal bracket
4 将模组抬回电池包内时，注意金属支架不要损坏下方的冷却管路
5 Disconnect the high-voltage soft connection, must be insulated
protection
5 断开高压软连接时，一定要进行绝缘保护
6 During the process of unpacking, do not place bolts and metal objects
on the top of the battery pack module
6 拆包过程中，严禁螺栓及金属物放在电池包模组上方
（三）
Install the power battery pack
（三）安装动力电池包
15. Install the cooling line first, and check the air tightness of the cooling line after
installation（Add 250kPa air pressure into the cooling pipeline for tightness test,
lasting for about 300 seconds, and the leakage is less than 0.5kpa, which is
normal）
15.先安装冷却管路，安装完成后对冷却管路进行气密性检测（向冷却管路内加
入 250Kpa 气压进行气密性检测，持续约 300 秒，泄漏量小于 0.5Kpa，即为正常）
16. Plug in the LBC low-voltage wire harness, install the BDU, plug in the module
low-voltage data cable, temperature acquisition cable, and connect the soft
connection
16.插上 LBC 低压线束，安装 BDU，插上模组低压数据线，温度采集线，接上软
连接
17. After the installation connect the tooling and test the battery pack's voltage,
temperature and other information with the SINOEV software （ PACK
MONITOR）
17.安装完成后，连接工装，用华霆上位机软件检测电池包的电压，温度等信息。
18. After everything is normal, install the cover of the battery pack. Note that there is
a fixing bolt in the middle of the front and rear end of the battery pack in the
opposite direction from other bolts.
18.一切正常后，安装电池包上壳盖，注意电池包前端后端中间有一个固定螺栓
与其他螺栓方向相反。
19. Install the MSD,check the air tightness of the battery pack(Add 1.6-1.8kpa into
the battery pack for air tightness test, lasting for about 1 min, and the air pressure
reduction is less than 0.2kpa, which is normal)
19.安装维修开关，对电池包进行整包气密性检测。（向电池包内部加入 1.6-1.8Kpa
进行气密性检测，持续约 1 分钟，气压减少量小于 0.2Kpa，即为正常）
20. After everything is normal, disassemble MSD ,pack the battery back into the
car ,connect the cooling pipe, connect the high-voltage connector and the
low-voltage connector, install the guard board and MSD connect the negative
pole of 12V battery.
20.一切正常后，拆卸维修开关，将电池包装回车内，连接冷却水管，连接高压
接插件，低压接插件，安装护板，安装维修开关，将 12V 蓄电池负极连接上。
21. Turn the key to on gear, slowly fill the expansion kettle with coolant to the "F"
mark, connect the vehicle with the can card, open the computer software, and
make the water pump run for 5-10 minutes. Finally, add the coolant in the
expansion kettle to the "F" mark.
21. 钥匙打到 ON 档，向膨胀水壶中缓慢加注冷却液至“F”刻度线，车辆连接 CAN
卡，打开江淮上位机软件，进行强制水泵工作，让水泵运行 5-10 分钟，最后再
补充膨胀水壶中的冷却液到“F”刻度线。
22. After the coolant has been replenished, charge the vehicle fully. When the vehicle
is fully charged, the SOC will be automatically corrected. After standing still for
2 hours under full power, use the diagnostic software of JAC to detect the voltage
of the replaced module. The voltage difference is ± 10MV
22. 冷却液补充完毕后，对车辆进行充电，要充满电，满电状态 SOC 会自动修正，
满电状态下静止 2 小时后，使用华霆上位机检测更换模组的电压，电压压差:±
10mv。
23. After the maintenance, the vehicle will be delivered to the customer, and the
customer's usage will be continuously followed up.
23. 维修完成后，车辆交付给客户，后续持续跟踪客户使用情况。
Note:
注意事项：
1 The cooling pipe is a secondary locking device, pay attention to locking
1 冷却管路是二次锁紧装置，注意锁紧
2 The air tightness test must be carried out after the installation. If the
whole package is not tested to ensure the normal air tightness, water may enter
the battery pack in rainy weather or when passing through the wading road
surface, causing damage to the battery pack
2 安装完成后一定要进行气密性检测，如果不做整包气密性检测，确保
气密性正常，在雨水天气，或者通过涉水路面时，水可能会进入电池包，造成
电池包损坏；
3 If the air tightness of the cooling pipeline is not tested to ensure normal
air tightness, it may cause coolant leakage, short circuit of the internal wiring
harness and ablation. In serious cases, it will ignite the battery pack and cause
vehicle spontaneous combustion
3 如果不做冷却管路气密性检测，确保气密性正常，可能会造成冷却液
泄露，使内部线束短路，烧蚀，严重的会点燃电池包，造成车辆自燃。
4 Check if there is any metal left inside the battery pack before sealing,
and take it out if there is any.
4 封包前检查有没有金属物遗落在电池包内部，有的话一定要取出。
5 Fill in the JAC specified coolant
5 加注 JAC 指定冷却液
Special case: when the vehicle cannot be charged and full charge maintenance
cannot be carried out.
特殊情况：当车辆无法充电，无法进行满电维修时。
1
．
Firstly, according to the above steps, disassemble the battery pack, find the
fault module, remove it, and replace the new module. The voltage difference
between the new module and the adjacent module of the original battery pack is
± 10mV. After the installation, put the battery pack back into the vehicle for
charging. The upper computer is used to detect and observe the current state.
Then charge and discharge 3-5 times to see if the voltage difference is stable
within the allowable range. If in range, deliver to customer normally
1. 首先安照上述步骤，拆卸电池包，找到故障模组，拆除下来，将新模组更换
上去，新模组电压与原电池包相邻模组电压差值±10mv，安装完成后，将电池
包放回车内，进行充电。用上位机检测，观察当前状态。随后进行 3-5 次充放
电，看压差是否稳定在允许范围。如果在范围，正常交付给客户。
2
．
If it's out of range, let's say the differential voltage is too large.In the state of
full power, remove the battery pack, open the battery pack, disconnect the
positive and negative soft connection of the fault module, and use the electric
supplement instrument to charge, adopting the mode of constant voltage
2. 如果不在范围，假设压差过大。在满电状态下，将电池包拆下，打开电池包，
断开故障模组正负的软连接，用补电仪进行补电，采用恒压补电的方式。
ANHUI JIANGHUAI AUTOMOBILE GROUP CORP., LTD
Compiling 编制 Leo.Yang(杨泽华）
Audit 审核 Youwang.Zhang(张有旺）
Approve 批准 Alex.He(何心诚）