System
System Instructions
Instruction
Vehicle charger
applies secondary conversion system, including PFC conversion (adjust circuit
for power factor) and AC/DC rectifier. It can improve charging efficiency,
accuracy and battery’s lifespan.
Note:
PFC is a circuit
for increasing power factor. It can improve the efficiency of transforming AC
into DC.
Description of
charging control
For more
information on charging control, please refer to “AC charging control” and “DC
charging control” sections.
Charging mode
This vehicle has
AC charging mode and DC charging mode. The AC charging includes charging pile
charging and household power charging, and each charging can be selected by
four modes: normal mode, long-range mode, long-life mode, and low-temperature
charging.
Note：
If the charging is
suspended before full charging, it can be restarted.
The charging time
depends on battery group’s remaining power, power supply, external temperature
and battery’s lifespan. The charging time in this manual is only a nominal
value, which may differ from actual time.
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Charging mode
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Energy level
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Charging time tips *2
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AC charging mode *1
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Normal charging
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100%
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8h（25℃）
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Long-life
charging
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80%
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7h（25℃）
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Timing charge
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—
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—
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Remote charging
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100%
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8h（25℃）
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Low temperature
charging mode
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100%
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16h
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DC charging pile
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80%
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1H (25℃)
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*1:
This charging mode is the AC pile charging. If you change it to household
charging, the time will increase by about 1/3.
*2: The
charging time starts when the indicator is on.
AC charging mode
(normal charging)
During AC charging
mode (normal charging) and fixed-time charging hasn’t been set, the charging
will start when charging socket is connected to charging socket.
AC charging mode
(low-life charging)
In the AC charging
mode (long-life charging), the power battery charge cut-off voltage will be
lower than the charge cut-off voltage in the normal charge mode to increase the
service life of the power battery.
AC charging mode
(fixed-time charging)
During AC charging
mode (fixed-time charging), the charging will start and stop according to your
set.
AC charging mode
(remote charging)
During AC charging
mode (remote charging), the charging will start after receiving remote control
signal.
AC charging mode
(low temperature charging)
During AC charging
mode (low-temperature charging), heating device will be activated to heat
battery.
DC charging pile
DC charging mode
will charge vehicle by DC charging pile. The maximum charging current differs
according to battery’s power and temperature. If the charging is unfinished,
yet the vehicle or charging pile’s setting time is up, the charging will stop.
Principles and operations
Vehicle Charger
1
Vehicle charger applies Inrush current-limit circuit and EMI
filter circuit to prevent DC network’s fluctuation and high-frequency’s
interference on facility.
2
Rectifying circuit will transform the AC into DC.
3
PFC is a circuit for increasing power factor. It can improve the
efficiency of transforming AC into DC. DC current will be transformed by full-bridge
insulated circuit and exported to battery.
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Quasi-resonant reverse
connection isolation conversion circuit
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Inrush current limiting
circuit
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Fire wire
Zero line
Ground line
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Load information
acquisition circuit
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Full-bridge conversion isolation
circuit
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High voltage +
High voltage -
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Sub-power module (low
voltage)
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Optical isolation circuit
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Temperature Feet 1 Feet
Temperature Feet 2 Feet
Electronic lock positive
Electronic lock negative
Electronic lock feedback
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Precautions for operation
Charging cable,Charging socket,Charging plugoperation
1
Do not touchthe metal pin of charging socket and
plug
2
Do not disassemble
or modifycharging cable, socket and plug
3
Do not pull charging
cable in brute force.
4
Do
not twine cable, socket and plug.
5
Do
not drag cable, socket and plug.
6
Do not put themnear heat source.
7
Fall-off
or shock is prohibited.
8
Do
not place heavy objects on charging cable.
Precautions
for charging
1
Please use specificplug for JAC iEV5 vehicle only;
2. Check
whether water, dust or other materials exist inside plug and socket。
Warning:
l Water, dust or foreign materials on
socket and plug may cause electric shock or leakage. Pleasedo not touch socket or plug unless
necessary.
l Charging plug is not allowed to use if water, dust or other
materials exist on socket or plug.
3. Please check
whether rust or other damage exists on charging socket and plug, and confirm
the connection is tight.
Warning:
l
Because leakage,
electric shock, short circuit or fire may occur, if any of the above problems are found, charging is
prohibited.
4. Charging is prohibited when the
charging socket or charging plug is submerged.
5. Do not charge
vehicle if charging cable is wrapped up.
6. Do not charge
vehicle under thunderstorm weather.
7. Stop
charging if abnormal smell or fog appears.
8. When
charging is complete, close the charging port cover to prevent water or dust.
9. Make sure
charging plug is pulled out if you need to turn the key on “READY”.
Note:
The key cannot be turned on “READY” when charging socket and plug
are connected
10 To prevent fire
accidents or electric shock caused by electric leakage, please use normal
charging plug that is water-proof.
11 Make sure the
rated current of household socket exceeds 16A
Warning:
l Using charging socket whose rated
current is below standard may cause overheat or fire accidents;
l Do not usegenerator or power supplywhich hasn’t been listed in this manualfor vehicle’s charging.
Note:
Failure may happen during charging if using generator or power
supply which hasn’t been listed in this manual.
12. While charging
in DC, please use charging pile that is matched with vehicle.
System diagnosis (CHR)
Diagnosis function
function
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Diagnostic test
mode
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Function
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VCU
identification
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Read error code
on vehicle charger
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Data monitoring
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Monitoring on
VCU input and output data
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CHR diagnosis information
Vehicle Charger
Ref. value
The value
displayed in the diagnostic tool
Ref. value
Note:
l All data listed below may differ from actual value, as these
figures are calculated by vehicle charger according to the signal uploaded from
relevant sensors.
l Vehicle cannot be charged while power-on.
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Monitoring
subject
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Condition
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value/status
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DC charging socket
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Power supply
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DC charging port connected
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connected
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DC charging port disconnected
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disconnected
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Charging signal of DC charging pile
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uncharged
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“Start charging” button on charging pile hasn't been pressed
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loose
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“Start charging” button on charging pile is pressed
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pressed
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DC charge wake-up signal
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l uncharged
l No
failure exists in charging system
l Charging
button is pressed
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0V converting to
12V
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Permission signal of DC charging
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l uncharged
l No
failure exists in charging system
l Charging
button is pressed
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Charging pile allows signal to be sent
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AC charging anode contactor
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AC charging
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close
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Non-DC
charging
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disconnected
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AC charging cathode contactor
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AC charging
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close
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Non-DC
charging
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disconnected
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DC charging anode contactor
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DC charging
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close
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Non-DC
charging
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disconnected
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DC charging cathode contactor
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DC charging
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close
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Non-DC
charging
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disconnected
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Vehicle
Charger 12V wake-up
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AC
charging process
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12V
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Non-AC
charging
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0V
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AC
charging CC signal
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charging
pile’s connection is OK, normal charging
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Household
charging connection is OK, normal charging
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No
connection
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0V
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Charger’s
temperature
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Charger’s
internal temperature
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-40℃~85℃
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Charger’s
output voltage
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AC
charging
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200V~
420V
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Connector layout
Connector of DC charging socket (low voltage)
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Connector for vehicle charger (low voltage)
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Connector of AC charging socket (low voltage)
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Physical value
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Connector name
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Terminal number
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Function description
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Condition
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Value
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Signal name
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Input/output
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Connector of AC charging socket (low voltage)
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1
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Thermal resistance 1
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Output
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2
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Thermal resistance 2
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Output
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3
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Connection confirm
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Output
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Vehicle has connected to socket, normal
charging process
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4
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Charging control confirm
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Output
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Vehicle has connected to socket, normal
charging process
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5
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NC
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6
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Signal feedback
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Output
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------------
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7
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12V-
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Input
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Vehicle door locked
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12V
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8
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12V+
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Input
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Vehicle door locked
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12V-
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Connector for
vehicle charger (low voltage)
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A
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CCOUT (connect the
original VCU to collect the CC resistance port)
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Output
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CC resistance detected
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1.5K/680Ω/220Ω
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B
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NC (empty foot)
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Input
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Constant power input
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12V
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C
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CP
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Input
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CP connection is normal
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------------
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D
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CC
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Input
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CP connection is normal
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1.5K/680Ω/220Ω
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E
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GND
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Output
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Charger is working
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12V-
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F
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12V output wake-up
signal
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Output
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Charger is working
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12V+
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G
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CANL
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Input/output
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Charger is working
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------------
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H
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CANH
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Input/output
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Charger is working
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------------
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J
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HVIL2+
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Output
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K
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HVIL2-
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Output
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L
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Thermistor 1 positive
terminal
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Input
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Charger is working
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Resistance
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M
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Thermistor 1 negative
terminal
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Input
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Charger is working
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Resistance
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N
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NC (empty foot)
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P
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NC (empty foot)
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R
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NC (empty foot)
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S
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Electronic lock
feedback 1 pin (connect the electronic lock PIN2)
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Input
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Charger is working
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Conducted
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T
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Electronic lock power
supply 2 pin (connect the electronic lock PIN3)
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Input
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Charger is working
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12V
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U
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Electronic lock power
supply 1 pin (connect the electronic lock PIN1)
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Input
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Charger is working
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12V
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V
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12V constant power
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Input
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Constant power input
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12V
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Connector of DC charging socket (low voltage)
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1
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S+
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Input/output
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DC charging
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------------
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2
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S-
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Input/output
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DC charging process
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------------
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3
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NC
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------------
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------------
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4
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CC2
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Input
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Charging connection test
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2.3V-2.7V
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5
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A+
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Output
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DC charging process
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12V+
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6
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A-
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Output
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DC charging process
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12V-
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Safety-failed list
Safety-failed list
If failure happens
in vehicle charger, please refer to “safety-failed list” for solution. The
solution methods are different with respect to different failures and failure
modes.
Failure mode
Mode A: charging
prohibited, failure can be cleared automatically
Mode B: charging
prohibited, failure can be cleared automatically after rebooting.
Mode C: charging
prohibited, failure cannot be cleared and vehicle charges needs replacement.
Mode D: vehicle
charger outputs power in rated power or below, with DTC uploaded.
Safety-failed list
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DTC
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Failed
list
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Reason for
failure
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mode
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A
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B
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C
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D
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P3301
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AC
over-voltage
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220V DC
under-voltage
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×
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P3302
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AC
under-voltage
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220V DC
over-voltage
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×
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P3303
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Battery
over-voltage
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Battery
over-voltage
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×
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P3304
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Battery
under-voltage
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Battery
under-voltage
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×
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P3305
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PFC
under-voltage
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Internal
PFC voltage is too low
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×
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P3306
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PFC
over-voltage
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Internal
PFC voltage is too high
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×
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P3307
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Over-temperature
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Charger
temperature is too high
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×
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P3308
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Output
over-current
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Charger’s
output current is too high
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×
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P3309
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Temperature
sensor failed
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Charger’s
temperature sensor is broken
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×
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P330a
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VCU cannot receive messages
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Abnormal communication
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×
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P330b
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Abnormal
current order
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Abnormal
VCU current order
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×
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P330c
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Abnormal
voltage order
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Abnormal
VCU voltage order
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×
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P330d
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Abnormal
CC loop
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CC loop
circuit cannot check resistance or resistance is abnormal
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×
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P330e
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Abnormal CP loop
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CP loop
circuit’s duty ratio is abnormal
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×
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P330f
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Electronic lock unlock failure
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Electronic
lock unlock error
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×
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P3310
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Electronic lock locking failure
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Electronic
lock locking error
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×
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P3311
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AC charging socket over
temperature
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Temperature
is too high
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×
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P3312
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AC charging socket temperature
abnormal
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Temperature
sensor failure
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×
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DTC index
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DTC
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Failure
Name
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Failure Light
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P3301
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AC over-voltage
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——
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P3302
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AC under-voltage
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——
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P3303
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Battery
over-voltage
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——
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P3304
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Battery
under-voltage
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——
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P3305
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PFC
under-voltage
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——
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P3306
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PFC over-voltage
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——
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P3307
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over-temperature
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——
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P3308
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Output
over-current
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——
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P3309
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Temperature
sensor failure
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——
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P330a
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VCU cannot receive messages
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——
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P330b
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Abnormal current
order
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——
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P330c
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Abnormal voltage
order
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——
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P330d
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Abnormal CC loop
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——
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P330e
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Abnormal CP loop
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——
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P330f
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Electronic lock
unlock failure
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——
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P3310
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Electronic lock
locking failure
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——
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P3311
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AC charging socket
over temperature
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——
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P3312
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AC charging
socket temperature abnormal
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——
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Instruction of indicators on control box
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Instruction of indicators on control box
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Status
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Power (red light)
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Connected (green light)
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Charging (blue light)
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Error (yellow light)
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1
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extinguished
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extinguished
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extinguished
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extinguished
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No power
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2
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Keep lighting
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extinguished
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extinguished
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extinguished
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Power hasn’t been connected
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3
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Keep lighting
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Keep lighting
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flicker
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extinguished
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charging
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4
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Keep lighting
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Keep lighting
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Keep lighting
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extinguished
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Half-connected (S2 disconnected for 10 seconds continuously)
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5
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Keep lighting
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Keep lighting
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extinguished
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Keep lighting
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Communication error
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6
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Keep lighting
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flicker
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flicker
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extinguished
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first-time over-current protection
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7
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Keep lighting
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Keep lighting
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flicker
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Keep lighting
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Second-time over-current protection
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8
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Keep lighting
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flicker
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flicker
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Keep lighting
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Electric leakage protection
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9
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Keep lighting
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extinguished
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extinguished
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flicker
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Over-voltage/under-voltage protection
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10
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Keep lighting
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Keep lighting
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Keep lighting
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Keep lighting
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Overheat protection
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11
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Keep lighting
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extinguished
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extinguished
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Keep lighting
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Leakage self-inspection protection
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Harness Diagram
Charging system
Diagram
Electronic lock power
supply 1 pin
Electronic lock power
supply 2 pin electronic lock feedback 1 pin
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12V+ constant current
input
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Temperature detection 1
pin
Temperature detection 2
pin
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DC charging plug DC
charging socket
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High voltage junction box
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AC charging plug AC
charging socket
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Charging system
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Connector number
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NC1
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Connector
name
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AC charging socket assembly high voltage plug
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Connector type
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RT06164SNHEC03
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Terminal
No.
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Wire
color
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Wire
diameter
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Signal name
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A
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6
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AC power
supply (L)
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B
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6
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Neutral
(N)
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C
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6
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Ground
line (PE)
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Connector number
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NC2
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Connector
name
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AC charging socket assembly low voltage plug
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Connector type
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PP0447701
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Terminal
No.
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Wire
color
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Wire
diameter
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Signal name
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1
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0.75
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Temperature
control 1 (WK1)
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2
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0.75
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Temperature
control 2 (WK2)
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3
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0.75
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Charging
connection confirm (CC)
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4
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0.75
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Charging
control confirm (CP)
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5
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6
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0.5
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12V-(electronic
lock power negative)
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7
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0.5
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Electronic
lock signal control harness
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8
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0.5
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12V+(Electronic
lock power positive)
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Connector number
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CH1
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Connector
name
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On-board charger high voltage input connector
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Connector type
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DY3F1203SNF
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Terminal
No.
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Wire
color
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Wire
diameter
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Signal name
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A
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Red
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2.5
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AC power
supply (L)
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B
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Yellow
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2.5
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Neutral
(N)
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C
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Black
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2.5
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Ground
line (PE)
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Connector number
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CH2
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Connector
name
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On-board charger high voltage output connector
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Connector type
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DY3F1002SNF
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Terminal
No.
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Wire
color
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Wire
diameter
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Signal name
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A
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Red
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2.5
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Positive
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B
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Black
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2.5
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Negative
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Connector number
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CH3
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Connector
name
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Connector for vehicle charger (low voltage)
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Connector type
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RT001619SN03
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Terminal
No.
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Wire
color
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Wire
diameter
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Signal name
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A
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0.5
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CCOUT
(connect the original VCU to collect the CC resistance port)
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B
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0.5
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NC (empty
pin)
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C
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0.5
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CP
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D
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0.5
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CC
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E
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0.5
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GND
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F
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0.5
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12V
output wake-up signal
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G
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0.5
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CANL
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H
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0.5
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CANH
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J
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0.5
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HVIL2
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K
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0.5
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HVIL2
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L
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0.5
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Thermistor
1 positive terminal
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M
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0.5
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Thermistor
1 negative terminal
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N
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0.5
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NC (empty
pin)
|
|
P
|
|
0.5
|
NC (empty
pin)
|
|
R
|
|
0.5
|
NC (empty
pin)
|
|
S
|
|
0.5
|
Electronic
lock feedback 1 pin (connect the electronic lock PIN2)
|
|
T
|
|
0.5
|
Electronic
lock power supply 2 pin (connect the electronic lock PIN3)
|
|
U
|
|
0.5
|
Electronic
lock power supply 1 pin (connect the electronic lock PIN1)
|
|
V
|
|
0.5
|
12V
constant power
|
|
Connector number
|
QC1
|
|
Connector
name
|
DC charging socket high voltage input connector
|
|
Connector type
|
GYHB-2-150E
|
|
Terminal
No.
|
Wire
color
|
Wire
diameter
|
Signal name
|
|
1
|
Red
|
6
|
DC +
|
|
2
|
Black
|
6
|
DC -
|
|
Connector number
|
QC1
|
|
Connector
name
|
Connector of DC charging socket (low voltage)
|
|
Connector type
|
AMP174262-2
|
|
Terminal
No.
|
Wire
color
|
Wire
diameter
|
Signal name
|
|
1
|
|
0.5
|
S+
|
|
2
|
|
0.5
|
S-
|
|
3
|
|
0.5
|
NC
|
|
4
|
|
0.5
|
CC2
|
|
5
|
|
0.5
|
A+
|
|
6
|
|
0.5
|
A-
|
Basic check
Diagnosis and preparation
Work Procedures
Procedures of diagnosis and repair
1.Obtain
symptom information
Use the Diagnostic Worksheet
to ask the customer for details about the symptoms (status and environment at
the time of the accident / failure). (Refer to the below. "Diagnostic
working list")
>> Go to step 2
2.Check
the DTC of on-board charger
1.Check
the DTC of on-board charger.
If DTC
is detected, please carry out operations below:
-Record
DTC and freeze the data
-
Check the relationship between the failure reason detected by the DTC and the
symptoms described by the customer.
3.
Review the relevant maintenance records for more information.
Has
the customer already described the symptoms and have already detected the DTC?
Fault described and DTC has been displayed. >> Go to step 3
Symptoms described, yet DTC hasn’t been displayed. >> Go to step 4
No
description or DTC displayed. >> Go to step 5
3.Confirm
symptoms
Try to diagnose the symptoms
described by the customer.
Also
check the normal operation and the relevant symptoms on "safety -
failure" mode list. Refer to “Safety-failure” mode list The
"Diagnostic Worksheet" is helpful in verifying the failure.
Verify
the relevance of symptoms and conditions that trigger the failure
>> Go to step 5
4.Confirm
symptoms
Try to
confirm the symptoms described by the customer.
Refer
to “safety-failure” list Please refer “safety-failure” list
Verify
the relevance of symptoms and conditions that trigger the failure
Yes >> Go to step 6
5.Execute
the DTC confirmation
step
Execute
"DTC confirmation procedure" for the displayed DTC, and then confirm
whether the DTC is detected again.
Note:
l If DTC
hasn’t been checked again, freezing data will be helpful to check failures.
l If no
relevant failure check procedure is listed in maintenance manual, please check
spare parts’ function.
If
spare parts’ function is abnormal,please refer to “DTC check procedure” for
details
Whether
DTC is detected ?
Yes>>
GO to step 7.
No
>> Check according to “failure simulation test”
6.Check
the system failure through the symptom
table
According
to the "symptom table", the fault diagnosis system is diagnosed based
on the symptoms confirmed in step 2, and the method of the fault diagnosis is
determined based on the possible causes and symptoms.
Has
the failure been described?
Yes>>
GO to step 7.
No>>
Using diagnostic tools to monitor the data of relevant sensors.
7.Check
the failed parts by means of the diagnostic
procedure
Check the defective parts by
means of the diagnostic procedure
Is
there a faulty part?
Yes>>
GO to step 8.
No>>
Using diagnostic tools to monitor the data of relevant sensors.
8.Replace or repair the faulty part
Replace
or repair the faulty part
After
repair or replacement of faulty part, please connect the spare part with
diagnostic system and check again.
Check
DTC and clear if the DTC is detected.
>> Go to step 9.
9.Final check
When
the DTC is detected in step 2, perform the "DTC confirmation step" or
"Full function check" again, and then confirm that the fault has been
properly repaired. If the symptoms are described by the customer, confirm the
symptoms identified by referring step 3 and step 4, and check that the symptoms
described by the user are not detected.
Whether
DTC is detected ?
Abnormal (DTC detected) >> Go to 7
Symptoms reappear >> Go to 4
No
detection >> Clear DTC before delivering vehicle to customer
Diagnostic working list
Instruction
Error
information of charging system can be acquired by understanding working
conditions correctly.
Generally,
customer has his own judging standard on the failure. Therefore, by consulting
user’s description on failure or problem, technicians can understand failure
better. All error information can be classified by applying diagnostic working
list.
Note:
l Some conditions may cause DTC detected
Diagnostic working list
|
Diagnostic
working list
|
|
Customer Name
|
|
License plate number
|
|
Registration date
|
|
|
Vehicle model
|
|
|
Acceptance date
|
|
VIN could be obtained from the
ECU.
|
|
Mileage
|
Kilo meter
(km)
|
|
problem
|
group
|
Feedback
|
|
Condition of vehicle failure
|
R / Q / N
/ O
|
Driving （R）
DC charging（Q） AC
charging（N） Other (O)
|
|
Symptom
|
R
|
“READY” lamp indicator off Bad
Driving Jitter Unable to travel Excessive noise Insufficient
braking force Powerless acceleration High consumption Switch failure
Warning light on Mode cannot be cut off Other
（
）
|
|
Detailed
syndrome
|
|
|
Instrument
indication information
|
|
|
Power
consumption
|
km/Kw.h
|
|
Remaining
power
|
|
|
Q,N
|
Can not
chargeCharge interrupted Slow charging Fixed-time charging unavailable
Remote charging unavailable
Can not
be charged immediately Other
|
|
Detailed
syndrome
|
|
|
DC
charging pile display information (if any)
|
|
|
O
|
A/C
unavailable Poor A/C performance Battery capacity loss Other
|
|
Detailed
syndrome
|
|
|
The road condition / state when
the fault occurred
|
R/O
|
Ordinary road highway mountain
road bumpy road flat road uphill downhill steering other
|
|
Q/N/O
|
Charging
initial charging process charging finished after setting charging time
(not charging yet)
Fixed-time charging process remote charging process Other
|
|
Driving conditions
|
R
|
When the system is on When the
"READY" lamp indicator on (when the vehicle is in parking) When the
vehicle is running When
the vehicle is accelerating
Vehicle running in constant speed
When the vehicle is taxing When the vehicle is braking Just before the
vehicle is stopped Just after the vehicle is stopped
The key is placed in the
"LOCK" or pulled out When AC is on When mode change Other
|
|
Vehicle
speed
|
Km
|
|
The
acceleration pedal position
|
|
|
DC charging pile
|
Q
|
DC
charging pile
|
In line with the national standard DC charging pile
(ver. 2015) Not in line with the national standard DC charging pile (ver.
2015)
|
|
Position
|
|
|
DC
charging pile set
|
|
|
Other
|
|
|
Household
power outlet
|
N
|
In line with the national standard socket (ver. 2015) Not in
line with the national standard socket (ver. 2015)
|
|
Position
|
|
|
Voltage
|
V
|
|
Fuse
current
|
A
|
|
Other
information
|
|
|
Remaining power
|
Q/N/O
|
With
remaining power Without remaining power
|
|
Gears / operations
|
R
|
D R N ECO operating method （
→ ）
|
|
Environmental conditions
|
R / Q / N
/ O
|
Weather
|
|
|
Temperature
|
℃
|
|
Occurrence frequency
|
Always
Once Sometimes （happened for times） Other
|
|
Fault recovery condition
|
After the key is in the
"OFF" or pulled outReplace the 12V battery or harness Gear
shift During the driving
READY
Other
|
|
【Memorandum】
|
Regular Maintenance
Charging socket assembly
Check
Checking
method
Eye-check on following items:
lWhether
crackle exists.
lWhether
dust/foreign material exists.
lWhether
damage exists.
lWhether sealing ring is normal.
Note:
lCompulsory check to ensure no breakage
exists on sealing ring.
lSealing ring must be placed inside
socket port.
Processing charging socket
assembly
l Clean charging socket.
l Replace socket if sealing ring is
broken.
l Replace socket if port cover is damaged.
l Replace socket if AC and DC charging
socket is damaged,
Test socket’s insulation
resistance
l Disconnect
the high-voltage circuit.
l Test
the insulation resistance between AC charging socket (A) L, N and PE. The
resistance should exceed 20MΩ
l Test the
insulation resistance between DC charging socket (B) L, N and PE. The
resistance should exceed 20MΩ
Warning:
l Please use
tramegger with range exceeding 500V to test the resistance.
On-board charger
Warning:
l As the
electric vehicle contains a high voltage battery, if the high pressure
components and vehicles are handled incorrectly, there is a risk of electric
shock, shock, leakage or similar accidents, so be sure to follow the correct
procedures to check and maintain.
l Before
the maintenance switch is disconnected, the key must be placed in the
"LOCK" or unplugged.
l Check
or maintain the high pressure system before disconnecting the service switch.
And no one is allowed to turn off the maintenance switch during the inspection
and maintenance process. Before starting the high voltage system operation, be
sure to wear insulation protection equipment, including gloves, shoes and
glasses.
l Make
sure other people will not touch the vehicle while service personnel is
operating high-pressure system. When maintenance work is suspended, the high-voltage
part should be under insulation protection to prevent other people from
touching.
Pre-operation
Warning:
l Cut off the high-voltage circuit and
test the voltage
l Disconnect the high-voltage of power
battery
Danger:
l Electric
shock may occur if touching high-voltage part without proper protection
Warning:
Ensure to wear protective equipments before disassembly so
as to prevent potential damage during disassembly.
Standard: 5V or under 5V
Test insulated resistance of
vehicle charger
l Disconnect
the high-voltage connection of vehicle charger
l Test the
insultated resistance between input/output port and charger’s shell. The
resistance should exceed 20MΩ.
Danger:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
DTC/Diagnostics on circuit
Charging connection and grounded circuit
Diagnostic Procedure
1
Check the fuse
Check
if the following fuses are blown.
|
Fuse
position
|
Fuse
type
|
|
High
voltage junction box
|
AC
charging fuse
|
|
DC
charging fuse
|
Check
if the fuses are blown.
Normal >>Change the
fuse.
No >>go to step 2
2
Check whether vehicle charger is grounded
1.
Place the key in the "LOCK".
2.
Disconnect the high-voltage connector of vehicle charger
3.
Check whether connection between charger’s connector and ground is fluent.
|
+
|
-
|
Conduction
|
|
Vehicle
Charger
|
|
Connector
|
Pin
|
|
CH1
|
C
|
Ground
|
Yes
|
Whether
it is conducted
Yes >>go to step 3
No >>repair or replace
the failed connector
3
Test insulated resistance of vehicle charger
1.
Test insulated resistance of vehicle charger
|
+
|
-
|
>20MΩ
(500V
test)
|
|
Vehicle
Charger
|
|
Connector
|
Pin
|
|
CH1
|
A
or B
|
Ground
|
Yes
|
|
CH2
|
1
or 2
|
Yes
|
Check
if the result is normal.
Yes >>go to step 4
No >>repair or replace
the failed vehicle charger
4
Check whether AC charging socket is conducted
1.
Check whether AC charging socket is conducted
|
+
|
Socket
port
|
Whether
conducted
|
|
AC
charging socket
|
|
Connector
|
Pin
|
|
NC1
|
L
|
L
|
Yes
|
|
N
|
N
|
|
PE
|
PE
|
|
NC2
|
CC
|
CC
|
|
CP
|
CP
|
Whether
it is conducted ?
Yes >>go to step 5
No >>repair or replace
the failed AC charging socket
5
Test the wake-up signal of vehicle charger
1.
Connect vehicle charger’s high-voltage connector and disconnect the low-voltage
connector
2.
Connect AC charging socket
3.
Test the voltage between wake-up signal pin and ground
|
+
|
-
|
Voltage
|
|
Car
Charger
|
|
Connector
|
Pin
|
|
CH3
|
F
|
Ground
|
12V
|
Check
if the result is normal.
Yes >>go to step 6
No >>repair or replace
the failed vehicle charger
6
Test CAN communication signal of vehicle charger
1.
Connect vehicle charger’s high-voltage connector and disconnect the low-voltage
connector
2.
Connect AC charging socket
3.
Test the voltage between CANH and CANL
|
+
|
-
|
Voltage
|
|
Car
Charger
|
Vehicle
Charger
|
|
Connector
|
Pin
|
Connector
|
Pin
|
|
CH3
|
G
|
CH3
|
H
|
Around
0.3V
|
Check
if the result is normal.
Yes >> Detection is
finished.
No >>repair or replace
the failed vehicle charger
P3301 220V AC input over-voltage
instruction
220V
AC power will supply energy for vehicle charger. Unstable AC power may affect
vehicle charger’s performance.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3301.
|
220V AC input over-voltage
|
Vehicle charger detects that
AC current exceeds 265Vac while charging.
|
l 220V
AC power fluctuation
l Hardware
failure on vehicle charger
|
DTC
Diagnostic Procedure
1.Perform
DTC confirmation
procedure
1.At
least 10S entering into the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No >> Check finished.
1.Check
whether 220V AC power is over-voltage
1.Check whether 220V AC power
is over-voltage
Yes >> Replace vehicle charger.
No >> No failure on
vehicle charger.
Confirm conditions
1. Confirm AC power is normal
2. Confirm vehicle can be
charged normally
Note:
During
charging, charger will cut off output if 220V AC power is over-voltage; the
charger will back to normal working when AC power is restored.
P3301 220V AC input under-voltage
instruction
220V
AC power will supply energy for vehicle charger. Unstable AC power may affect
vehicle charger’s performance.
DTC logic
DTC
check logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3302.
|
220V AC input under-voltage
|
Vehicle charger detects that
AC current is below 85±8Vac while charging.
|
l 220V
AC power fluctuation
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Check
whether 220V AC power is under-voltage
1.Check whether 220V AC power
is under-voltage.
Yes >> Replace vehicle
charger.
No >> No failure on
vehicle charger.
Confirm
conditions
1. Confirm AC power is normal
2. Confirm vehicle can be
charged normally
Note:
During
charging, charger will cut off output if 220V AC power is under-voltage; the
charger will back to normal working when AC power is restored.
P3303 The on-board charger output is over-voltage
Instruction
The
on-board charger has output capacity (200V~420V). If vehicle charger detects
the output port’s voltage exceeds its output capacity, the charger will shut
down output automatically and protect its hardware.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3303.
|
Vehicle charger’s output is
over-voltage
|
Vehicle charger detects that
output voltage exceeds 420V
|
l Power
battery is over-voltage
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm
whether power battery is
over-voltage
1.Confirm whether power
battery is over-voltage
Yes >> Replace vehicle
charger.
No >> No failure on
vehicle charger.
Confirm
conditions
1. Confirm power battery is
normal.
2. Confirm vehicle can be
charged normally.
P3304 The on-board charger output is
under-voltage
Instruction
The
on-board charger has output capacity (200V~420V). If vehicle charger detects
the output port’s voltage is lower than its output capacity, the charger will
shut down output automatically and protect its hardware.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3304.
|
Vehicle charger’s output is
under-voltage
|
Vehicle charger detects that
AC current is below 200Vdc while charging.
|
l Power
battery is under-voltage
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Check
whether power battery is
over-voltage
1.Check whether power battery
is under-voltage.
Yes
>> Replace vehicle charger.
No
>> No failure on vehicle charger.
Confirm
conditions
1. Confirm power battery is
normal.
2. Confirm vehicle can be
charged normally
P3305 vehicle charger PFC is
over-voltage
instruction
When
under normal charging, vehicle charger’s PFC output voltage has a certain range
(330V~410V). When vehicle charger detects PFC output voltage exceeds 410V,
vehicle charge will shut down output automatically and protect its hardware.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3305.
|
P3305 vehicle charger PFC is
over-voltage
|
Vehicle charger detects that
PFC output voltage exceeds 410Vdc
|
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No >> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P3305
1.Confirm whether the
on-board charger DTC is P3305.
Yes >> Replace vehicle
charger.
No >> Diagnosis
finished.
Confirm
conditions
1. Confirm vehicle can be
charged normally
P3306 The on-board charger PFC is
under-voltage
Instruction
When
under normal charging, the on-board charger PFC output voltage has a certain
range (330V~410V). When vehicle charger detects PFC output voltage is lower
than 330V, vehicle charge will shut down output automatically and protect its
hardware.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3306.
|
Vehicle charger PFC is
under-voltage
|
Vehicle charger detects that
PFC output voltage is lower than 350Vdc
|
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P3306
1.Confirm whether the
on-board charger DTC is P3306.
Yes >> Replace vehicle
charger.
No >> Diagnosis
finished.
Confirm
conditions
1. Confirm vehicle can be
charged normally
P3307
The on-board charger is over-temperature
Instruction
The
on-board charger normal working temperature ranges from -40℃~85℃. The charger
will shut down output if the actual temperature is out of range so as to
protect its hardware.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3307
|
Vehicle charger
over-temperature
|
Vehicle charger detects that
self-temperature exceeds 85℃.
|
l The
fuel pump does not work.
l Coolant
is used up.
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No >> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P3307
1.Confirm whether the
on-board charger DTC is P3307.
Yes >> Go to step 2.
No >> Diagnosis
finished.
2.Check
if the water pump works normally
1.Check if the water pump
works normally.
Yes >> Go to step 3.
No >> Replace the water
pump.
3.
Confirm whether the coolant is used up
1.Confirm whether the coolant
is used up
Yes >> Add the coolant.
No >> Replace vehicle
charger
Confirm
conditions
1. Confirm whether vehicle can
be charged normally
P3308 On-board charger output
over-current
Instruction
If
output current exceeds a certain extent, vehicle charger will shut down its
output so as to protect hardware.
DTC logic
DTC
check logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3308
|
Vehicle charger output over-current
|
The on-board charger detects
that average output current exceeds 24A within 100ms while charging
|
l Fluctuation
of power grid
l Hardware
failure on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P3308
1.Confirm whether the
on-board charger DTC is P3308.
Yes >> Go to step 2
No >> Diagnosis
finished.
2.Confirm
whether power grid is stable
2.Confirm whether power grid
is stable.
Yes >> Replace vehicle
charger.
No >> Replace power
supply.
Confirm
conditions
1. Confirm the vehicle can be
charged normally
P3309 The on-board charger temperature
sensor failure
Instruction
The
on-board charger will transfer the temperature information to charger’s
controller through temperature sensor. If temperature exceeds a certain range,
vehicle charger will limit power output or stop working. At the same time, the
on-board charger sends the temperature information to the VCU, and the VCU
controls the start and stop of the pump according to the temperature
information of the on-board charger, so that the on-board charger works in an
appropriate temperature range.
DTC Logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC diagnostic
conditions
|
The
possible causes for failure
|
|
P3309
|
Failure on charger
temperature sensor
|
Confirm vehicle charger’s
DTC is P3309 while charging
|
l Short
or open circuit exists on temperature sensor
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No >> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P3309
1.Confirm whether the
on-board charger DTC P3309
Yes >> Replace vehicle
charger.
No >> diagnosis
finished.
Confirm
conditions
1. Confirm whether vehicle can
be charged normally
P330a
cannot receive VCU message
instruction
Vehicle
charger cannot receive VCU message before charging. Charger has no output and
wake-up signal will not close, with uploading “VCU message cannot received”
DTC logic
DTC
check logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P330a
|
VCU cannot receive messages
|
Charger cannot receive VCU
message within 3min even when wake-up signal exists.
|
l Poor
connection on connector
|
DTC check method
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P330a
1.Confirm whether the
on-board charger DTC is P330a.
Yes >> Check whether
there is poor connection on connector.
No >> diagnosis
finished.
Confirm
conditions
1. Confirm whether vehicle can
be charged normally
P330b Abnormal VCU current order
Instruction
Vehicle
charger will adjust output current according to the order from VCU if working
normally. If the order from VCU has exceeded charger’s output capacity, the charger
will upload failure of abnormal VCU current order.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P330b.
|
Abnormal order from VCU
|
The order of VCU current has
exceeded 24A while charging
|
l VCU
failure
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm the on-board charger DTC P330b
1.Confirm whether the on-board
charger DTC is P330b
Yes >> Replace the
on-board charger.
No >> Diagnosis
finished.
Confirm
conditions
1. Confirm vehicle can be
charged normally
2. Confirm vehicle charger
will not upload P330b
P330c Abnormal VCU voltage order
Instruction
Vehicle
charger will adjust output voltage according to the order from VCU if working
normally. If the order from VCU has exceeded charger’s output capacity, the
charger will upload failure of abnormal VCU voltage order.
DTC logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P330c.
|
Abnormal current order from
VCU
|
The order of VCU voltage has
exceeded 420V while charging
|
l VCU
failure
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm vehicle charger DTC P330c
1.Confirm vehicle charger
DTC is P330c
Yes >> Check VCU
messages
No >> Diagnosis
finished.
Confirm
conditions
1. Confirm vehicle can be
charged normally
2. Confirm vehicle charger
will not upload P330c
P330d Abnormal resistance of CC circuit
Instruction
CC
resistance is abnormal or cannot be detected while vehicle charger is working.
Vehicle charger will upload failure of CC loop circuit abnormal.
DTC Logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P330d
|
Abnormal CC loop circuit
|
When the on-board charger is
powered on or during normal operation, no CC resistance or abnormal CC
resistance can be detected within 3 minutes
|
l Poor
connection on CC circuit
l Failure
on vehicle charger
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm the on-board vehicle charger DTC
P330d
1. Confirm whether vehicle
charger DTC is P330d
Yes >>go to step 2
No >> diagnosis
finished.
2.confirm
whether poor connection exists in CC circuit
1.confirm whether poor
connection exists in CC circuit
Yes>>replace AC charging
socket or plug
No >> Replace vehicle
charger
Confirm
conditions
1. Confirm vehicle can be
charged normally
2. Confirm vehicle charger
will not upload P330d
P330e CP loop circuit is abnormal
Instruction
When
the on-board charger is powered on or during normal operation, the duty cycle
of the CP circuit is abnormal, and the on-board charger reports an abnormal CP
circuit fault.
DTC Logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P330e.
|
Abnormal CP loop circuit
|
When the car charger is
powered on or during normal operation, no CP duty cycle or abnormal duty
cycle can be detected within 3 minutes
|
l Poor
connection on CC loop circuit
l Charging
pile failure
l Vehicle
charger failure
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into the
AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm
vehicle charger’s DTC is P330e
1. Confirm whether vehicle
charger’s DTC is P330e
Yes >>go to step 2
No >> diagnosis
finished.
2.Confirm
whether poor connection exists in CP loop
circuit
1.Confirm whether poor
connection exists in CP loop circuit
Yes>>replace AC charging
socket or plug
No >>go to step 3
3.Check
if the charging pile works normally
1.Check if the charging pile
works normally.
Yes >> Replace vehicle
charger.
No >> Replace charging
pile.
Confirm
conditions
1. Confirm vehicle can be
charged normally
2. Confirm vehicle charger
will not upload P330e
P330f Electronic lock unlock failure
Instruction
The
on-board charger unlocks the electronic lock according to the key unlock
request signal. If the electronic lock cannot be unlocked, the on-board charger
reports the electronic lock unlocking fault.
DTC Logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P330f
|
Electronic lock unlock
failure
|
Electronic lock unlock error
|
l Circuit
connection abnormal
l Electronic
lock locking failure
l Vehicle
charger fialure
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm vehicle charger DTC is P330f
1. Confirm whether vehicle
charger DTC is P330f
Yes >>go to step 2
No >> diagnosis
finished.
2.Confirm
whether the low-voltage line connection is abnormal.
1.Confirm whether the
low-voltage line connection is abnormal.
Yes >> Replace or repair
low-voltage line.
No >> Go to step 3.
3.Confirm
whether the electronic lock is
abnormal
1.Confirm whether the
electronic lock is abnormal.
Yes>> Replace the electronic
lock.
No >> Replace vehicle
charger.
Confirm
conditions
1. Confirm vehicle can be
charged normally
2. Confirm vehicle charger
will not upload P330f.
P33010 Electronic lock locking failure
Instruction
The
on-board charger is based on the key unlock request signal or the electronic
lock when the power is turned on. If the electronic lock cannot be locked, the
on-board charger reports the electronic lock locking fault.
DTC Logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3310
|
Electronic lock locking
failure
|
Electronic lock locking
error
|
l Circuit
connection abnormal
l Electronic
lock locking failure
l Vehicle
charger failure
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No
>> Check finished.
Faults
diagnosis
1.Confirm vehicle charger DTC P3310
1.Confirm whether the vehicle
charger DTC is P3310.
Yes >> Go to step 2.
No >> Diagnosis
finished.
2.Confirm
whether the low-voltage line connection is abnormal.
1.Confirm whether the
low-voltage line connection is abnormal.
Yes >> Replace or repair
low-voltage line.
No >>go to step 3
3.Confirm
whether the electronic lock is
abnormal
1.Confirm whether the
electronic lock is abnormal.
Yes>> Replace the
electronic lock.
No >> Replace vehicle
charger
Confirm
conditions
1. Confirm vehicle can be
charged normally
2. Confirm vehicle charger
will not upload P3310.
P3311 AC charging socket over temperature
Instruction
The
normal operating temperature of the AC charging socket is -40°C~100°C. The
outlet exceeds this temperature range. The on-board charger will shut down the
output and protect the charging socket.
DTC Logic
DTC
diagnosis logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3311
|
AC charging socket over
temperature
|
When charging, the on-board
charger detects that the temperature of the AC charging socket exceeds 100°C.
|
l Low
voltage circuit line abnormal
l Socket
abnormal
l Vehicle
charger failure
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No >> Check finished.
Faults
diagnosis
1.Confirm vehicle charger DTC P3311
1.Confirm whether the vehicle
charger DTC is P3311.
Yes >> Go to step 2
No >> Diagnosis
finished.
2.Confirm
whether the low-voltage line connection is abnormal.
1.Confirm whether the
low-voltage line connection is abnormal.
Yes >> Replace or repair
low-voltage line.
No >>go to step 3
3.Confirm
whether the socket is
abnormal
1.Confirm whether the socket
is abnormal.
Yes>> Replace the
socket.
No >> Replace the
vehicle on-board charger.
Confirm
conditions
1. Confirm whether vehicle can
be charged normally
2. Confirm vehicle charger
will not upload P3311.
P3312 AC charging socket temperature sensor
fault
Instruction
The
normal working temperature of the AC charging socket is -40°C~100°C. When the
socket temperature sensor is abnormal, the on-board charging device reduces the
power output.
DTC Logic
DTC
check logic
|
DTC
number
|
Failure
Name
|
DTC
diagnostic conditions
|
The
possible causes for failure
|
|
P3312
|
AC charging socket
temperature sensor failure
|
Vehicle charger DTC is P3312
while charging
|
l Short
or open circuit exists on temperature sensor
|
DTC Diagnostic Procedure
1.Perform
DTC confirmation procedure
1.At least 10S entering into
the AC charging mode.
2. Check the diagnostic
results.
Whether DTC is detected ?
Yes >> Refer to
"Diagnostic Procedure" below.
No >> Check finished.
Faults
diagnosis
1.Confirm vehicle charger DTC P3312
1.Confirm whether the on-board
charger DTC is P3312.
Yes>> Replace the AC
charging socket.
No >> Diagnosis
finished.
Confirm
conditions
1. Confirm whether vehicle can
be charged normally
System
diagnosis
Vehicle
Charger
Symptom
list
|
Symptom
|
The
check items as following:
|
Solutions
|
|
Charging instantly, cannot
be executed
|
No output exists in external
power supply
|
Confirm whether output
exists in external power If timing device is equipped on external power, the
output power will exist only within timing range.
|
|
Incorrect connection of
charging plug
|
Confirm whether charging plug
connects correctly
|
|
Connector hasn’t been
connected properly
|
Confirm charging connector
is connected properly
|
|
The vehicle is in charging
state
|
Confirm the key is on “LOCK”
before charging
|
|
AC charging and DC charging
are both connected
|
Either AC charging or DC
charging will be OK
Note: AC charging and DC
charging cannot proceed simultaneously
|
|
Timing switch has been set
|
Press down timing switch
|
|
Power battery is full
|
No Action
Note: if power battery is
full, the charging will not proceed If power battery is full, charging will
stop automatically
|
|
The battery temperature is
too high
|
Confirm battery temperature
is lower than 65℃
|
|
12V lead-acid battery needs
feed
|
Charging battery
|
|
Vehicle failure
|
Check VCU error code
|
|
Symptom
|
The
check items as following:
|
Solutions
|
|
Charging instantly, cannot
be executed
|
No output exists in external
power supply
|
Confirm whether output
exists in external power If timing device is equipped on external power, the
output power will exist only within timing range.
|
|
Incorrect connection of
charging plug
|
Confirm whether charging
plug connects correctly
|
|
Connector hasn’t been
connected properly
|
Confirm charging connector
is connected properly
|
|
The vehicle is in charging
state
|
Confirm the key is on “LOCK”
before charging
|
|
AC charging and DC charging
are both connected
|
Either AC charging or DC
charging will be OK
Note: AC charging and DC
charging cannot proceed simultaneously
|
|
Power battery is full
|
No Action
Note: if power battery is
full, the charging will not proceed If power battery is full, charging will
stop automatically
|
|
The battery temperature is
too high
|
Confirm battery temperature
is lower than 65℃
|
|
12V lead-acid battery needs
feed
|
Charging battery
|
|
Vehicle failure
|
Check VCU error code
|
|
The set start-charging time
is later than finish-charging time
|
Set correct time for start-charging and finish-charging
|
|
The set start-charging time
is earlier than current time
|
Set start-charging time
later than current time
|
|
The set finish-charging time
is earlier than current time
|
Set finish-charging time
later than current time
|
|
Error date and time on timer
|
Confirm the date and time on
timer are correct
|
|
Fixed-time charging hasn’t
been set
|
Set fixed-time charging
|
|
Symptom
|
The
check items as following:
|
Solutions
|
|
Remote charging cannot be
executed
|
No output exists in external
power supply
|
Confirm whether output
exists in external power If timing device is equipped on external power, the
output power will exist only within timing range.
|
|
Incorrect connection of
charging plug
|
Confirm whether charging
plug connects correctly
|
|
Connector hasn’t been
connected properly
|
Confirm charging connector
is connected properly
|
|
The vehicle is in charging
state
|
Confirm the key is on “LOCK”
before charging
|
|
Power battery is full
|
No Action
Note: if power battery is
full, the charging will not proceed If power battery is full, charging will
stop automatically
|
|
Power battery temperature
too high
|
Confirm battery temperature
is lower than 65℃
|
|
12V lead-acid battery needs
feed
|
Charging battery
|
|
Vehicle failure
|
Check VCU error code
|
|
Vehicle cannot receive
charging signal
|
Confirm phone signal exists
at your current position
Confirm phone signal exists
at vehicle’s position
|
|
Symptom
|
The
check items as following:
|
Solutions
|
|
Charging interrupted
|
No output from external
power
|
Confirm whether output
exists in external power Confirm the breaker is closed If timing device is
equipped on external power, the output power will exist only within timing
range.
|
|
Finish-charging time is up
|
Proceed normal charging
Note: when timing charging
is set, the charging will stop when finish time is up, even the battery
hasn’t been fully charged.
|
|
Power battery temperature
too high
|
Confirm battery temperature
is lower than 65℃
|
|
Vehicle failure
|
Check VCU error code
|
|
DC charging cannot be
executed
|
Connector hasn’t been
connected properly
|
Confirm charging connector
is connected properly
|
|
The vehicle is in charging
state
|
Confirm the key is on “LOCK”
before charging
|
|
Power battery temperature
too high
|
Confirm battery temperature
is lower than 65℃
|
|
Power battery is full
|
No Action
Note: if power battery is
full, the charging will not proceed If power battery is full, charging will
stop automatically
|
|
12V lead-acid battery needs
feed
|
Charging battery
|
|
Vehicle failure
|
Check VCU error code
|
|
Symptom
|
The
check items as following:
|
Solutions
|
|
DC charging interrupted
|
AC charging and DC charging
are both connected
|
Either AC charging or DC
charging will be OK
Note: AC charging and DC
charging cannot proceed simultaneously
|
|
Power battery temperature
too high
|
Confirm battery temperature
is lower than 65℃
|
|
Vehicle failure
|
Check VCU error code
|
Disassembly and installment
On-board charger
Exploded view
: The front of the vehicle
：N·m
1.Power
assembly joist 2.High-voltage terminal box 3.Vehicle charger4.AC charging socket assembly
Disassembly and assembly of
vehicle charger
Warning:
l Electric vehicles contain a high voltage battery, There is a risk
of electric shock, electric leakage, or similar accidents if the high voltage
component and vehicle are handled incorrectly. Be sure to follow the correct
work procedures when performing inspection and maintenance.
l Be sure to remove the service plug in order to shut off the high
voltage circuits before performing inspection or maintenance of high voltage
system harnesses and parts.
l Be sure to put the removed service plug in your pocket and carry
it with you so that another person does not accidentally connect it while work
is in progress. Before operations on high-voltage system, be sure to wear
insulation protection equipment, including gloves, shoes and glasses.
l Make sure other people will not touch the vehicle while service
personnel is operating high-pressure system. When maintenance work is
suspended, the high-voltage part should be under insulation protection to
prevent other people from touching.
l When the maintenance switch is disconnected, the key is forbidden
to turn to "ON" or "START".
Disassembly
Warning:
Before operating
high-voltage system Refer to "Overview - How to disconnect high
voltage".
: The front of the vehicle
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
Charger’s disassembly procedures are as follow:
1. Check the high voltage
circuit voltage.
①
Disconnect all high-voltage harness connectors around the high-voltage junction
box.
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
② test the voltage between
high-voltage connector’s pins
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
Standard: 5V or under 5V
Attention：
Please use multimeter with
measuring range exceeding 500V while testing voltage
2. For disassembly of
high-voltage junction box, please refer to “Disassembly and assembly of
high-voltage junction box”
3. Drain the coolant inside
the radiator. Refer to the "Cooling System" in chassis maintenance.
4. Remove the cooling water
pipe from the on-board charger. Refer to the "Cooling System" in
chassis.
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
5. Disconnect the high-voltage
cable input connector ① and output connector ② of the car charger. Rotate the
connector housing counterclockwise to release the plug and socket. Pull the
plug horizontally out of the socket.
: The front of the vehicle
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
After unplugging the
connector, wrap it with insulating tape to prevent the connector pins from
being exposed.
l
Unplug
high-voltage input connector by following procedures marked in picture below
l
Unplug
high-voltage output connector by following procedures marked in picture below
6. Disconnect low-voltage harness connector①,
press snap joint, loosen socket and plug, then pull out plug from socket.
: The front of the vehicle
l
Unplug
low-voltage harness connector by following procedures marked in picture below
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
7. Disassemble fixing bolt① of vehicle charger
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
8. Remove vehicle charger from power assembly
joist
Warning:
Ensure to wear protective equipments
before disassembly so as to prevent potential damage during disassembly.
assembly
Assembly procedure is opposite to disassembly procedures
Warning:
Ensure
to wear protective equipments before disassembly so as to prevent potential
damage during disassembly.
After replacing
charger, please check whether the mark (A) is on original position.
: The front of the vehicle
