● Technicians using a medical electric device such as pacemaker must never perform operation on the vehicle, as magnetic field can affect the device function by approaching to such parts.

Normal Charge Precaution

Warning:

● If a technician uses a medical electric device such as an implantable cardiac pacemaker or an implantable cardioverter defibrillator, the possible effects on the devices must be checked with the device manufacturer before starting the charge operation.

● As radiated electromagnetic wave generated by on board charger at normal charge operation may effect medical electric devices, a technicians using a medical electric device such as implantable cardiac pacemaker or an implantable cardioverter defibrillator must not enter the vehicle compartment (including luggage room) during normal charge operation.

Precaution at Telematics System Operation

1 If a technician uses implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), please keep enough distance from communication device.

2 The electromagnetic wave of TCU might affect the function of the implantable cardiac pacemaker or the implantable cardioverter defibrillator (ICD), when using the service, etc.

3 If a technician uses other medical electric devices than implantable cardiac pacemaker or implantable cardioverter defibrillator (ICD), the electromagnetic wave of TCU might affect the function of the device. The possible effects on the devices must be checked with the device manufacturer before TCU use.

Point to Be Checked Before Starting Maintenance Work

High voltage system may start automatically. It is required to check that the timer air conditioner and timer charge are not set before starting maintenance work.

Note:

If the timer air conditioner or timer charge is set, the high voltage system starts automatically even when the power switch is in OFF state.

Precaution for Supplement Restraint System (SRS) “Air Bag” and “Seat Belt Pre-tensioner”

The Supplemental Restraint System such as “Air Bag” and “Seat Belt Pre-tensioner”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt and driver’s air bag, front passenger’s air bag. Information necessary to service the system safety is included in the “Air Bag System” and “Seat Belt” of this Service Manual.

Warning:

Always observe the following items for preventing accidental activation:

● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized JAC MOTORS dealer.

● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Air Bag Module, see “Air Bag System”.

● Never use electrical test equipment on any circuit related to SRS unless instructed to in this Workshop Manual. SRS wiring harnesses can be identified by yellow or orange harnesses or harness connectors.

Precaution When Using Power Tools (Air or Electric) and Hammers

● When working near the Air Bag Diagnosis Sensor or other Air Bag System sensors with the power switch “ON”, never use air or electric power tools or strike near the sensors with a hammer. Heavy vibration could activate the sensors and deploy the air bag, possibly causing serious injury.

● When using air or electric power tools or hammers, always switch the power switch to “OFF”, disconnect the 12V battery negative electrode, and wait at least 1 minute before performing any service.

High Voltage Precaution

Warning:

● Because electrical vehicle contains a high voltage battery, there is the 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.

● Be sure to turn ignition switch to “LOCK” or pull it off before disconnecting maintenance switch.

● Disconnect maintenance switch before checking or maintaining high voltage system, and forbid anybody close maintenance switch during check and maintenance. Be sure to ware insulating protective equipment including glove, shoes and face shield before beginning work on the high voltage system.

● Ensure that other persons do not touch the vehicle when maintenance personnel operating high voltage system. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.

Forbid turning ignition switch to “ON” or “START” after maintenance switch being disconnected.

High Voltage Harness and Equipment Identification

The color of high voltage harness is orange, there is safety identification on power battery assembly and other high voltage devices. Don’t carelessly touch these harnesses and parts.

Handling of High Voltage Harness and Terminals

Immediately insulate disconnected high voltage connectors terminals with insulating tape.

Regulations on Workers with Medical Electronics

The vehicle contains parts that contain powerful magnets. If a person who is wearing a pacemaker or other medical device is close to these parts, the medical device may be affected by the magnets. Such person must not perform work on the vehicle.

Prohibited Items to Carry During Work

Because this vehicle uses components that contain high voltage and powerful magnetism, due not carry any metal products which may cause short circuits, or any magnetic media (cash cards, prepaid cards, etc.) which may be damaged on your person when working.

Posting a sign of “Danger! High voltage area. Keep out”

To call the attention of other workers, indicate “High voltage work in process. Do not touch!” on vehicles where work is being performed on the high voltage systems.

Precaution for Removing 12V Battery

Before removing 12V battery, turn power switch to “ON”, and then to “LOCK”.

Note:

The automatic 12V battery charge control may start even when the power switch is in “OFF” state.

● The automatic 12V battery charge control does not start when the power switch is turned “ON” --> “LOCK”.

General Precaution

● Pay attention not to let dust or other small items get into the controller from opening when removing controller.

Preparation

General Service Tools

Tool name		Description
Insulated gloves ( Guaranteed insulation performance for 1000V/300A)		Removing and installing high voltage components
Leather gloves (Use leather gloves that can fasten the wrist tight)		1. Removing and installing high voltage components 2. Protect insulated gloves
Insulated safety shoes		Removing and installing high voltage components
Safety glasses (ANSI Z87.1)		1. Removing and installing high voltage components 2. To protect eye from the spatter on the work to electric line
Insulated helmet		Removing and installing high voltage components
Insulation resistance tester (Multitester)		Measuring voltage and insulation resistance

System Description

Function and Structure

Function Instruction

Decelerator locates between drive motor and drive axle, mainly transmits driving force from drive motor to drive axle, and it can also reduce the speed and let left and right drive wheel rotate in different speed, thus vehicle can turn and drive on uneven roads.

Structure Instruction

Decelerator is single ratio decelerator with mid-axle, mainly constructed by input gear, middle gear, output gear and left/right housing cover. Other components are oil filling plug, oil draining plug and vent plugs. Drive motor power output shaft directly connects with decelerator input shaft by spline.

Sectional View

1. Left housing	2. Right housing	3. Differential oil seal	4. Differential bearing
5. Differential	6. Middle shaft driven gear	7. Middle shaft gear	8. Middle shaft
9. Middle shaft bearing	10. Input shaft gear	11. Input shaft bearing

Removal and Installation

Warning:

● The electric vehicle contains power battery assembly, if handling the high voltage components and vehicle improperly, there is risk for electric shock, leakage or other accidents. When performing inspections and maintenance, follow the correct procedures.

● Ensure to disconnect maintenance switch before performing component inspections and maintenance.

● Before operating high voltage system, be sure to wear insulated protective equipment including gloves, shoes and face shield.

● Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.

Warning:

● There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the maintenance switch is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Workshop Manual.

● Because the vehicle uses components that contain powerful magnetism, person using a medical electric device such as pacemaker must never operate the vehicle, as magnetic field can affect the device function by approaching to such parts.

Removal

Warning:

● Disconnect high voltage, and cut off high voltage circuit.

To prevent shock hazards, be sure to put on insulating protective device before beginning work on high voltage system.

① Disconnect spinning wire connector and spinning fixed binding tape being connected to controller.

② Disconnect three-phase wire being connected to motor;

③ Discharge decelerator gear oil;

④ Remove 5 nuts on crossbeam, and remove drive motor and decelerator assembly from crossbeam;

⑤ Remove drive motor from the assembly;

Installation

Warning:

● Vehicle in minimum temperature≥-40℃, decelerator lubricant uses 75W/90 GL-4 gear oil, and it’s forbidden to mixed use other type lubricant;

● Failure that caused by not according to requirement to fill proper decelerator gear oil is not in the range of warranty;

● When filling oil, vehicle should be placed in flat road;

● Before installing decelerator and drive motor, use lubricant to lubricate surrounding shaft spline, and fill lubricant at the same time (minimum 8.5g, maximum 20g to decelerator input shaft (inner spline)). When installing, be careful not damage sealing ring.

Check the following items before installation

● Fitting end surface of decelerator and motor is clean and there is no sundries, and there is no obvious processing defects;

● There should be decompression valve on decelerator and there is no damage;

● Decelerator oil seal should be well, if damaged, replace new;

● Decelerator housing should be no damage, there is no oil leaking in all parts; if leaking, replace decelerator assembly.

Installation of accelerator and drive motor

① Install O-type ring to end surface groove of drive motor, evenly spread lubricant to drive motor spline to avoid spline rusted, and place decelerator flat, align output shaft of drive motor to decelerator input spline and insert, slowly rotate and drop to fit. Adjust position, and rotate to right position (locating by locating pin);

② Use bolt assembly 2 (Bolt Q15010130, spring washer Q40310, flat gasket Q40110 assembly), 2 connect and tighten decelerator assembly and driving motor, tighten torque 45～50Nm. Pay attention that bolt should cross through the direction from decelerator to motor when installing;

③ Use 2 bolts (Q1841050) cross through the direction from motor to decelerator, and connect and tighten decelerator assembly and drive motor, tighten torque 45～50Nm;

④ Use 2 bolts (Q1841050) cross through the direction from motor to decelerator, and use 2 nuts (Q33010) connect and tighten decelerator assembly and drive motor, tighten torque 45～50Nm;

Connection of motor and decelerator assembly and crossbeam

① After pre-installing motor and decelerator assembly, cross 5 bolts through 5 vent holes on power assembly crossbeam, and use 5 nuts (Q33012) to connecting tighten, tighten torque is 85～90Nm.

Check the following items after installation

① There should be oil in decelerator;

② Whether decelerator oil filling plug screw M16×1.5 (Tighten torque 30～40Nm), oil discharging plug screw M18×1.5 (Tighten torque 35～45Nm) is tightened well, if not, please tighten.

Gear Oil

Detection of Oil Level

① Remove oil filling plug screw, check whether oil is full by oil filling plug screw installation hole;

② Should spread screw thread sealant before installing oil filling plug screw, and tighten bolt according to required tighten torque (Tighten torque is 30～40Nm).

Fill Oil

① Remove oil filling plug screw, fill new gear oil until oil level close to oil inlet port getting to specified height, about L.

Discharge Oil

① Remove oil filling plug screw;

② Remove oil discharging plug screw, and discharge gear oil;

③ Should spread screw thread sealant before installing oil filling plug screw and oil discharging plug screw, tighten according to specified tighten torque (Oil filling plug screw tighten torque 30～40Nm, oil discharging plug screw tighten torque 35～45Nm).