Electrical Vehicle Traction Motor System

Precaution

Precaution for Technicians Using Medical Electric

Operation Prohibition

Normal Charge Precaution

Remote Communication System Operation Precaution

Point to Be Checked Before Starting Maintenance Work

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

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

Precaution for Removing 12V Battery

High Voltage Precaution

Regulations on Workers with Medical Electronics

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

General Precaution

Precaution for Removing 12V Battery

General Precautions

Preparation

General Service Tools

System Description

Description

Traction Motor Specifications

Component Parts

Component Parts Location

Traction Motor Controller (PCU)

Traction Motor

High Voltage Warning Label

Structure and Operation

Structure Drawing

Operation Description

System

Traction Motor Controller System Description

Principle Schematic

Fail-Safe Mode

Protection Control

Traction Motor Power Control

System Description

Operating Principle

Traction Motor Generation Control

System Description

Operating Principle

Diagnosis System (Traction Motor Controller)

Diagnosis Description

Traction Motor Controller Diagnosis Information

Traction Motor Controller

Reference Value

Fault Protection

Protection Control

DTC Inspection Priority Chart

DTC Index

Basic Inspection

Diagnosis and Repair Work Flow

Work Flow

Traction Motor Fault and Circuit Diagnosis

A2 Traction Motor Overspeed Fault

DTC Logic

Diagnosis Step

A3 Traction Motor Overcurrent Fault

DTC Logic

Diagnosis Step

A4 High Voltage Overvoltage Fault

DTC Logic

Diagnosis Step

A5 High Voltage Undervoltage Fault

DTC Logic

Diagnosis Step

A6 Traction Motor Overtemperature Fault

DTC Logic

Diagnosis Step

A7 Traction Motor controller Overtemperature Fault

DTC Logic

Diagnosis Step

A8 Low Voltage Power Supply Undervoltage

DTC Logic

Diagnosis Step

A9 IGBT Fault                                                                                                                                         

DTC Logic

Diagnosis Step

AA Traction Motor Rotary Transformer Fault

DTC Logic                                                                                                                                        

Diagnosis Step

B2 CAN Communication Fault                                                                                                             

DTC Logic

Diagnosis Step

B3 IGBT Overtemperature Fault

DTC Logic

Diagnosis Step

E8 W-phase Current Sensor Circuit Fault

DTC Logic

Diagnosis Step

E9 V-phase Current Sensor Circuit Fault

DTC Logic

Diagnosis Step

EA U-phase Current Sensor Circuit Fault

DTC Logic

Diagnosis Step

EB W-phase Current Sensor Self-check Fault

DTC Logic

Diagnosis Step

EC V-phase current sensor self-check fault

DTC Logic

Diagnosis Step

ED U-phase Current Sensor Self-check Fault

DTC Logic

Diagnosis Step

F3 Traction Motor Low Voltage Power Supply Fault

DTC Logic

Diagnosis Step

F4 Traction Motor Input Sissing Phase

DTC Logic

Diagnosis Step

51 Traction Motor Overspeed Warning

DTC Logic

Diagnosis Step

52 Traction Motor Overcurrent Warning

DTC Logic

Diagnosis Step

53 High Voltage Overvoltage Warning

DTC Logic

Diagnosis Step

54 High Voltage Undervoltage Warning

DTC Logic

Diagnosis Step

55 Traction Motor Overtemperature Warning

DTC Logic

Diagnosis Step

56 Traction Motor Controller Overtemperature Warning

DTC Logic

Diagnosis Step

59 IGBT Overtemperature Warning

DTC Logic

Diagnosis Step

2F Locked Rotor State

DTC Logic

Diagnosis Step

30 Voltage Detected Circuit Fault

DTC Logic

Diagnosis Step

31 Data Storage Abnormal

DTC Logic

Diagnosis Step

32 IGBT Temperature Detected Circuit Fault

DTC Logic

Diagnosis Step

AB Traction Motor Temperature Sensor Self-check Fault

DTC Logic

Diagnosis Step

EE Traction Motor Temperature Sensor Self-check Fault

DTC Logic

Diagnosis Step                                                                                                                                

DC/DC Fault

Fault Logic

Diagnosis Step

Traction Motor Insulation Resistance Value Inspection

Component Description

Traction Motor Controller Insulation Resistance Value Inspection

Component Description

Symptom Diagnosis

Electromagnetic Noise

Description

Removal and Installation

Traction Motor Controller

Exploded View

Removal and Installation

Inspection after Installation

Traction Motor

Exploded View

Removal and Installation

Inspection after Installation

Precaution

Precaution for Technicians Using Medical Electric

Operation Prohibition

Warning:

    Parts with strong magnet are used in this vehicle.

    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.

Remote Communication System Operation Precaution

Warning:

    Electromagnetic wave of TBOX (Remote Intelligent Terminal) might affect the function of the implantable medical electric device.

    If a technician uses other medical electric device than implantable cardiac pacemaker or implantable cardioverter defibrillator, the electromagnetic wave of TBOX might affect the function of the device. The possible effects on the device must be checked with the device manufacturer before TBOX 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.

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”.

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.

Note:

    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.

    After taking down high voltage harness, immediately insulate disconnected high voltage connectors terminals with insulating tape.

Regulations on Workers with Medical Electronics

Warning:

    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.

General Precaution

1)    It’s forbidden to remove VCU or DC/DC box.

2)    When connecting or disconnecting VCU and wiring harness, pay attention not to damage terminal pin (bended or broken off). When connecting wiring harness connector, check whether terminal pin is bended or broken off.

Precaution for Removing 12V Battery

When removing the 12V battery, turn key to “ON”, and then to “LOCK”.

Note:

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

    The automatic 12V battery charge control does not start within approximately one hour when the power switch is turned “ON”-->“LOCK”.

General Precautions

    Take care when handling the traction motor inverter so that dust, dirt, and other substances do not enter into the inside from the opening.

Preparation

General Service Tools

System Description

Description

The traction motor contains a compact, lightweight, high output, high efficiency “Permanent Magnet Synchronous Motor” (PMSM).

The traction motor inverter is a device which converts DC power from the power battery to AC power, and drives the traction motor. At the same time, it can converts kinetic energy that wheel rotates into electric energy (AC converts into DC) to charge power battery.

DC/DC is intergrated in traction motor controller, its function is to convert high voltage of battery to low voltage to supply power for vehicle low voltage system.

Traction Motor Specifications

Component Parts

Component Parts Location

Component Description

Traction Motor Controller (PCU)

    Traction motor controller is installed in engine compartment, using CAN communication control, and drives traction motor by receiving torque instruct sent by VCU and collected traction motor position signal.

    Traction motor controller controls energy transmission between power battery and traction motor, and its hardware system mainly consists of auxiliary power supply circuit, control circuit, drive circuit, protection circuit, IGBT module. Software control is the core of traction motor controller, mainly controls PWM wave signal output by vector control algorithm, realizes torque limit output according to traction motor external characteristic curve graph, realizes positive and negative rotation of traction motor and torque control according to sampling of current and rotor position signal and filtering.

Traction Motor

    The traction motor contains an “Interior Permanent Magnet Synchronous Motor (IPMSM)”. A permanent magnet is embedded inside the rotor core, and the rotating magnetic field generated by the stator coil is used to generate rotational torque.     The traction motor is able to generate torque even when the vehicle is stopped, and outputs maximum drive torque when the vehicle starts moving in order to provide good initial acceleration. Torque and speed characteristics is shown as right picture

High Voltage Warning Label

    High voltage warning label is stuck on each component parts below.     When replacing component parts make sure to stick it on original position. Traction Motor Controller     The high voltage warning label (1) is stuck on the top of traction motor controller
Traction motor     The high voltage warning label (2) is stuck on the top of traction motor

Structure and Operation

Structure Drawing

Traction Motor Mechanism

1. Front end cover	2. Housing	3. Three-phase wire	4. Junction box
5. Rear end cover	6. Rotary transformer end cover	7. Rotary transformer	8. Rotor
9. Bearing	10. Shaft	11. Stator

Operation Description

Operation Principle

When three-phase AC current is applied to the stator coil, a rotating magnetic field is generated. This rotating magnetic field pulls on the permanent magnet inside the rotor core, generating rotational torque that is synchronized with the rotating magnetic field.

In order to generate optimal rotor rotation, judgments regarding the position (angle) of the permanent magnet within the rotor core and the timing of current application to the coil are necessary. For this purpose, the traction motor resolver and current sensor are used in order to continually detect the rotating position of the rotor and control the timing of current application to the coil.

System

Traction Motor Controller System Description

    The traction motor controller controls the traction motor based on the target motor torque signal transmitted by EV system CAN from the VCU.

    Traction motor controller converts DC power from battery to AC power, and drives traction motor accurately based on resolver detection signal and current sensor detection signal.

    At deceleration, traction motor is used as generator. It converts kinetic energy generated by rotary motion of tires (AC power) to electric energy (DC power) and charges battery.

    If malfunction is detected, the system enters fail-safe mode.

System Diagram

 

Principle Schematic

Fail-Safe Mode

Protection Control

When temperature of traction motor inverter or traction motor components rises, the traction motor inverter temporarily enters a protective control state in order to protect the system. It automatically returns to the normal status if the safety is secured.

 

Traction Motor Power Control

System Description

The traction motor controller applies AC power to the traction motor according to the target motor torque signal calculated by VCU in order to generate drive force.

Operating Principle

Energy Flow

When the traction motor controller receives the target motor torque signal from the VCU via EV system CAN.

 

Traction Motor Generation Control

System Description

During deceleration, the traction motor controller drives the traction motor to function as a generator based on the regenerative torque command signal sent via EV system CAN from the VCU, converting the kinetic torque generated by rotation of the tires into electrical energy. The converted electrical energy charges the battery.

The regenerative torque that is generated when the traction motor is driven as a generator can be used as braking force, reducing the burden on the service brakes.

Operating Principle

Energy Flow

When the traction motor controller receives the regenerative torque command signal from the VCU via EV system CAN

Diagnosis System (Traction Motor Controller)

Diagnosis Description

JAC EV diagnosis service system is an on-board trouble diagnosis system which can read related information about components. The square frame shown below is related information about EV system.

DTC of traction mtoro controller is displayed in vehicle state 2 in diagnosis service system. The square frame shown below is traction motor controller DTC.

History faults of traction motor controller are displayed in PCU diagnosis service panel in diagnosis service system. Shown below is related information of traction motor controller fault. Specific operation is first click “Read fault code”, thus history fault type can be read from DTC list; and then click “Read freeze frame”, thus related information of fault can be displayed out. Clicking “Clear fault code” can clear history fault.

The followings are the representated explanation meaning when history fault is detected and displayed.

DTC

Note: Operate the power switch from OFF to ON.

    Traction motor controller memorizes DTC.

    The procedure to erase DTC from traction motor controller memory is described in “Disgnosis description: System description”.

Connect vehicle diagnosis connector, power on controller, and read monitoring data to ensure fault reason.

For traction motor system, corresponding DTCs are showns in below list. Note: 1^st class is serious fault, come down to personal safety, must disconnect high voltage; 2^nd class is normal fault, must do corresponding protection, but vehicle can drive; 3^rd class is general fault, record fault, don’t do any strategic treatment.

Traction Motor Controller Diagnosis Information

Traction Motor Controller

Reference Value

 

Terminal Layout

23 PIN

 

14 PIN

 

Fault Protection

 

Protection Control

When temperature of traction motor inverter or traction motor components rises, the traction motor inverter temporarily enters a protective control state in order to protect the system. It automatically returns to the normal status if the safety is secured.

 

DTC Inspection Priorit Chart

If some DTCs are displayed at the same time, perform inspections one by one based on the priority as per thefollowing list.

 

DTC Index

 

Basic Inspection

Diagnosis and Repair Work Flow

Work Flow

Flow Chart

 

Detail Procedure

Use "Diagnostic Worksheet" for more information related symptoms (accident/failure occurs when the state and the environment) to customer inquiries. (Please refer to “Diagnostic Worksheet” below).

>>Go to step 2

1.    Check DTC

2.    If display DTC, excute the following steps

Record DTC

Research on the Relationship between failure reason and customer description. (Symptom table is useful. See "Symptom Chart")

3.    Check the associated maintenance records to get more information.

Whether customers have described the symptoms and has been detected DTC?

It describes the symptoms, and showed DTC. >> Go to 3.

It describes the symptoms but no DTC. >> Go 4.

No description and no DTC. >> Go to 5.

Try to confirm the symptoms with the description from the customer.

Check the normal operation and fault protection associated symptoms. See "Fail-Safe."

"Diagnostic Worksheet" is very helpful to verify the fault.

Relationship status to detect symptoms between symptoms and verified.

>>Go to step 5

Try to confirm the symptoms with the description from the customer.

Check the normal operation and fault protection associated to the symptoms. See "Fail-Safe."

"Diagnostic Worksheet" is helpful to verify the failure.

Relationship status to detect symptoms between symptoms and verified.

>>Go to step 6

"DTC Confirmation Procedure" and confirm DTC is detected again.

If there are two or more DTC detected, please refer to "DTC Check priority list" on page TBD and decide the order of fault diagnosis.

DTC detected?

Yes >> Go to step 7

No >> Refer to "Troubleshooting about intermittent issues" to check.

Refer to "Symptoms Checklist," based on the confirmed failure symptoms in step 4 and possible causes, confirm the final troubleshooting methods.

Is there symptoms description?

Yes >> Go to step 7

No >> Use diagnostic tools to monitor the input information and services related to sensor or check the voltage of VCU pins. Please refer to “Reference value” above.

Check the fault system according to diagnosis steps

Is there fault part?

Yes >> Go to step 8

No >> Use diagnostic tools to monitor the input information and services related to sensor or check the voltage-dependent VCU pins. Please refer to “Safe-Fail” mode above.

1.    Repair or replace defective parts.

2.    After finish repairing or replacement, reconnect the components or connectors.

3.    Check the DTC. If DTC is displayed, clear it.

>> Go to step 9

When detected DTC in step 2, perform "DTC Confirmation Procedure" or "Overall Function Check" again and confirm the fault has been properly repaired. If the symptoms described by the customer, referring to steps 3 and 4 in the diagnosis of symptoms, confirmed that the symptoms described by the user is not detected.

Normal or abnormal?

Abnormal (detect DTC) >> Go to step 7

Abnormal (still failure) >> Go to step 4

Normal >> Before returned vehicle to user, clear the DTC.

Diagnosis Worksheet

Instruction

EV control system could failure caused by a lot of drive situation. Fully aware of these situation can make troubleshooting more quickly and accurately. Generally, each customer has different feeling to the same fail. Therefore, to fully understand the customer’s description of symptoms is very important. To solve problem efficiently, diagnosis worksheet is recommended to use.

Diagnosis Worksheet

 

 

 

Traction Motor Fault and Circuit Diagnosis

A2 Traction Motor Overspeed Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector, check resistance value of rotary transforming wire

Whether check result is normal?

Normal >>Turn to step 2

Abnormal >>Replace traction motor

1.    Replace traction motor controller

2.    Connect maintenance switch

3.    Turn key to “ON”

4.    Check diagnosis result

Whether detected DTC?

Yes >>Replace traction motor

No >>Check finish

A3 Traction Motor Overcurrent Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector, check resistance value of rotary transforming wire

Whether check result is normal?

Normal >>Turn to step 2

Abnormal >>Replace traction motor

1.    Replace traction motor controller

2.    Connect maintenance switch

3.    Turn key to “ON”

4.    Check diagnosis result

Whether detected DTC?

Yes >>Replace traction motor

No >>Check finish

 

A4 High Voltage Overvoltage Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Check input voltage of high voltage.

Whether is overvoltage?

Yes >>Turn to step 2

No >>Replace traction motor controller

Check output voltage of power battery.

Whether is overvoltage?

Yes >>Check power battery

No >>Replace traction motor controller

A5 High Voltage Undervoltage Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Check input voltage of high voltage.

Whether is undervoltage?

Yes >>Turn to step 2

No >>Replace traction motor controller

Check output voltage of power battery.

Whether is undervoltage?

Yes >>Check power battery

No >>Replace traction motor controller

A6 Traction Motor Overtemperature Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether work normally?

Yes >>Turn to step 2

No >>Replace water pump

Whether is enough?

Yes >>Turn to step 3

No >>Fill full coolant

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector,Check traction motor temperature sensor signal线的Resistance value。

Whether check result is normal?

Normal >>Replace traction motor

Abnormal >>Turn to step 4

Disconnect low voltage connector of traction motor, and check resistance value of traction motor temperature sensor signal wire.

Whether check result is normal?

Normal >>Replace connecting wiring harness of traction motor and traction motor controller

Abnormal >>Replace traction motor

A7 Traction Motor controller Overtemperature Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether work normally?

Yes >>Turn to step 2

No >>Replace water pump

Whether is enough?

Yes >>Replace traction motor controller

No >>Fill full coolant

A8 Low Voltage Power Supply Undervoltage

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

A9 IGBT Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

AA Traction Motor Rotary Transformer Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector, check resistance value of rotary transforming wire

Whether check result is normal?

Normal >>Turn to step 2

Abnormal >>Replace traction motor

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 4

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 5

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

B2 CAN Communication Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is normal?

Yes >>Turn to step 2

No >>Replace VCU

Whether connection is normal?

Yes >>Replace traction motor controller

No >>Replace low voltage connecting wiring harness

B3 IGBT Overtemperature Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether work normally?

Yes >>Turn to step 2

No >>Replace water pump

Whether is enough?

Yes >>Replace traction motor controller

No >>Fill full coolant

E8 W-phase Current Sensor Circuit Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

E9 V-phase Current Sensor Circuit Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

EA U-phase Current Sensor Circuit Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

EB W-phase Current Sensor Self-check Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

EC V-phase current sensor self-check fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

ED U-phase Current Sensor Self-check Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

F3 Traction Motor Low Voltage Power Supply Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

F4 Traction Motor Input Sissing Phase

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Turn to step 3

3.    Check history fault

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Remove high voltage three-phase wire, check resistance value between phases

Whether check result is normal?

Normal >>Turn to step 2

Abnormal >>Replace traction motor

Check whether connection of each wire is conductive

Yes >>Replace traction motor controller

No >>Replace high voltage three-phase wire

51 Traction Motor Overspeed Warning

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector, check resistance value of rotary transforming wire

Whether check result is normal?

Normal >>Turn to step 2

Abnormal >>Replace traction motor

1.Replace traction motor controller

2.    Connect maintenance switch

3.    Turn key to “ON”

4.    Check diagnosis result

Whether detected DTC?

Yes >>Replace traction motor

No >>Check finish

52 Traction Motor Overcurrent Warning

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector, check resistance value of rotary transforming wire

Whether check result is normal?

Normal >>Turn to step 2

Abnormal >>Replace traction motor

1.Replace traction motor controller

2.    Connect maintenance switch

3.    Turn key to “ON”

4.    Check diagnosis result

Whether detected DTC?

Yes >>Replace traction motor

No >>Check finish

53 High Voltage Overvoltage Warning

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Check input voltage of high voltage.

Whether is overvoltage?

Yes >>Turn to step 2

No >>Replace traction motor controller

Check output voltage of power battery.

Whether is overvoltage?

Yes >>Check power battery

No >>Replace traction motor controller

 

54 High Voltage Undervoltage Warning

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Check input voltage of high voltage.

Whether is undervoltage?

Yes >>Turn to step 2

No >>Replace traction motor controller

Check output voltage of power battery.

Whether is undervoltage?

Yes >>Check power battery

No >>Replace traction motor controller

 

55 Traction Motor Overtemperature Warning

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether work normally?

Yes >>Turn to step 2

No >>Replace water pump

Whether is enough?

Yes >>Turn to step 3

No >>Fill full coolant

1.    Turn key to “OFF”

2.    Disconnect maintenance switch

3.    Disconnect low voltage 14-pin connector, and check resistance value of traction motor temperature sensor signal wire

Whether check result is normal?

Normal >>Replace traction motor

Abnormal >>Turn to step 4

Disconnect low voltage connector of traction motor, and check resistance value of traction motor temperature sensor signal wire.

Whether check result is normal?

Normal >>Replace low voltage connecting wiring harness of traction motor and traction motor controller

Abnormal >>Replace traction motor

 

56 Traction Motor Controller Overtemperature Warning

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether work normally?

Yes >>Turn to step 2

No >>Replace water pump

Whether is enough?

Yes >>Replace traction motor controller

No >>Fill full coolant

59 IGBT Overtemperature Warning

DTC Logic

DTC Diagnosis Logic

DTC NO.	Fault name	DTC Diagnosis Condition	Possible reason
59	IGBT overtemperature warning	IGBT temperature exceed 95℃	         Water pump          Cooling pipeline is blocked          Coolant is not enough          Traction motor controller

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether work normally?

Yes >>Turn to step 2

No >>Replace water pump

Whether is enough?

Yes >>Replace traction motor controller

No >>Fill full coolant

 

2F Locked Rotor State

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

30 Voltage Detected Circuit Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

31 Data Storage Abnormal

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

32 IGBT Temperature Detected Circuit Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

AB Traction Motor Temperature Sensor Self-check Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

EE Traction Motor Temperature Sensor Self-check Fault

DTC Logic

DTC Diagnosis Logic

DTCConfirmation Procedure

1.    Turn key to “ON”

2.    Check diagnosis result

Whether detected DTC?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is lower than 9V

Yes >>Turn to step 2

No >>Replace traction motor controller

Whether is lower than 9V

Yes >>Turn to step 3

No >>Replace low voltage connecting wiring harness

Refer to “DCDC Electrical equipment inspection”

Whether works normally?

Yes >>Turn to step 4

No >>Replace DCDC

Whether connection is normal?

Yes >>Replace battery

No >>Replace connecting wiring harness

DC/DC Fault

Fault Logic

DC/DC Fault Diagnosis Logic

Fault Confirmation Procedure

1.    Turn key to “ON”

After 2.6s, check whether DC/DC output voltage is 13-15V.

Whether DC/DC output voltage is lower than 13V?

Yes >>Refer to “Diagnosis step”

No >>Check finish

Diagnosis Step

Whether is 1

Yes >>Turn to step 2

No >>Check whether VCU is normal?

Whether is higher than 200V

Yes >>Replace DC/DC

No >>Check whether battery system is normal, and check whether high voltage relay is actuated

Traction Motor Insulation Resistance Value Inspection

Component Description

Warning:

    Because electric vehicles contain 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 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.

    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.

    Be sure to wear insulating protective equipment consisting of glove, shoes and glasses/face shield before beginning work on the high voltage system.

    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.

1.    Ready

Warning: First cut off high voltage part, and check high voltage return circuit.     Separate high voltage component and power battery, refer to “Removal and installation”.     Check voltage of traction motor controller positive and negative electrode wire, standard is ≤5V. 2.    Check traction motor insulation resistance value     Remove traction motor, refer to “Removal and installation”.

    Regulate gear position of high voltage insulation inspection device to 1000V, and check insulation resistance value of traction motor three-phase to housing.

Check requirement

Measure each phase insulation resistance of traction motor three-phase (U-phase, V-phase, W-phase). Require insulation resistance value all to be more than or equal to 20MΩ.

Traction Motor Controller Insulation Resistance Value Inspection

Component Description

Warning:

    Because electric vehicles contain 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 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.

    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.

    Be sure to wear insulating protective equipment consisting of glove, shoes and glasses/face shield before beginning work on the high voltage system.

    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.

1.    Ready

Warning: First cut off high voltage part, and check high voltage return circuit.     Separate high voltage component and power battery, refer to “Removal and installation”.     Check voltage of traction motor controller positive and negative electrode wire, standard is ≤5V.
2.    Check traction motor controller insulation resistance value     Remove traction motor controller, refer to "Removal and installation".     Regulate gear position of high voltage insulation inspection device to 1000V, and check insulation resistance value of generatrix wire to housing and three-phase to housing.

 

Check requirement

 

Symptom Diagnosis

Electromagnetic Noise

Description

The electromagnetic noise of the traction motor may become more noticeable when accelerating on a steep slope (large output torque). This occurs when the IGBT switching frequency is lowered by the traction motor inverter due to high temperature of the IGBT inside the traction motor inverter. This does not indicate a problem with the traction motor inverter characteristics or control.

Removal and Installation

Traction Motor Controller

Exploded View

: vehicle right ahead side

Removal and Installation

Warning:

    Because electric vehicles contain 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 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.

    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.

    Be sure to wear insulating protective equipment consisting of glove, shoes and glasses/face shield before beginning work on the high voltage system.

    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.

CAUTION:

There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

Removal:

Steps for replacing controller

1.    Cut off vehicle high voltage, disconnect battery maintenance switch, as shown picture below

2.    Open front compartment cover, and check traction motor system

3.    Disconnect positive and negative electrode generatrix connector

1.    Positive and negative generatrix

4.    Disconnect three-phase wire connector

1.    Three-phase wire

5.    Disconnect low voltage connector

1.    14-pin low voltage connector 2. 23-pin low voltage connector 3. DCDC output terminal

6.    Remove DCDC grounding

1.    DCDC grounding

7.    Remove inlet/outlet water pipe

1.    Inlet water pipe 2. Outlet water pipe

8.    Remove controller fixed bolts, and complete replacement of traction motor controller

Installation: Install according to the contrary sequence of removal.

Inspection after Installation

    Check all bolts are connected well, whether there is missing bolt or bolt not being tightened according to the requirement.

    After installing traction motor controller, measure resistance between traction motor controller and vehicle body, and check equipotential. Requirement: Traction motor controller –Ground Resistance≤0.1Ω

If result deviates from standard values, check that no paint, oil, dirt, or other substance is adhering to bolts or conductive mounting parts. If any such substance is adhering, clean the surrounding area and remove the substance.

Traction Motor

Exploded View

Removal and Installation

Warning:

    Because hybrid vehicles and electric vehicles contain 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.

    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.

    Due to traction motor has high voltage and strong magnetic, don’t use things with magnetic (such as bank card etc.) when check and maintenance, it may be damaged if carry these things when maintenance.

    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. 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.

    Be sure to wear insulating protective equipment consisting of glove, shoes and glasses/face shield before beginning work on the high voltage system.

    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.

Caution:

There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do
so in the Service Manual.

Removal

Warning:

         Discharge decelerator gear oil before removing power assembly. Refer to “Decelerator”.

Follow the steps below to remove, and install according to the contrary steps.

Installation

Warning:

    Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it with a new clip before installing.

    Before installing traction motor and decelerator assembly, should use lubricant to lubricate traction motor shaft spline, and at the same time fill lubricant (min 8.5g (0.3oz), max 20g (0.7oz)) to decelerator input shaft (inner spline).

    When installing traction motor and decelerator assembly, don’t damage or miss installing O-type sealing ring. Besides, sealing ring is quick-wear part, need to replace new sealing ring.

    If traction motor was replaced, apply high voltage warning label, refer to “High voltage warning label”.

1.    Inspection Before Installation

1)    Traction motor should be connected to three-phase wire, signal wire, and equipped with connector, and wiring harness and connector should be no damage; traction motor three-phase wire and low voltage wiring harness insulation satisfy with that insulation resistance value ≥20MΩ when DC1000V.

2)    There is no sundries in traction motor housing, and there is no abvious processing defect.

2.    Installation of traction motor and decelerator assembly

1)    Install sealing ring to sealing ring groove of traction motor, decelerator locating pin aligning to locating pin on traction motor, and aligning to install, and decelerator assembly connects to traction motor by spline.

 

1. Locating pin hole

2. Sealing ring

2)    Align 6 holes between traction motor and decelerator, connect to decelerator by tightening with 2 bolts assembly 1 (Bolt Q15010130, spring washer Q40310, flat washer Q40110 assembly), bolt (Q1841050) and 2 nuts (Q33010) and 2 bolts (Q1841050), tighten torque: 45~50Nm, as shown below

1.    Bolt Q15010130, spring washer Q40310, flat washer Q40110

2.    Bolt Q1841050, nut Q33010

 

1.    Bolt Q1841050, nut Q33010

3.    Installation of traction motor and decelerator assembly with cross beam

1)    Align 5 holes on cross beam to 5 double-screw bolts of traction motor and decelerator assembly and install, and install 5 hexgon flange tightening nut (Q33012) and tighten, tighten torque: 85~90Nm.

1. Nut Q33012

4.    Connect rotary transformer connector side.

1.    Rotary transformer connector

5.    Controller junction box connects to high voltage three-phase wire.

1.    High voltage three-phase wire

6.    Add and fill lubricant to decelerator after traction motor assembly is installed on vehicle, lubricant requirement refer to “Decelerator”.

Inspection after Installation

    Check all bolts are connected well, whether there is missing bolt or bolt not being tightened according to the requirement.

    After installing traction motor controller, measure resistance between traction motor controller and vehicle body, and check equipotential. Requirement: Traction motor controller –Ground Resistance≤0.1Ω

If result deviates from standard values, check that no paint, oil, dirt, or other substance is adhering to bolts or conductive mounting parts. If any such substance is adhering, clean the surrounding area and remove the substance.

 

 

Motor controller insulation resistance detection

Components Description

Warning:

WARNING: Because of hybrids and electric vehicles are equipped with high-voltage power batteries, there is a high risk of high-voltage electric shock, leakage, and similar accidents if the high-pressure system is handled improperly. Ensure that the correct work flow is followed during inspection and maintenance.

Before inspecting and servicing the high pressure system and its protection, make sure that the service switch has been disassembled to cut off the high voltage power supply.

Ensure that the maintenance switch is removed in your bag or carried on the body, so as not to repair the work of other people inadvertently put the maintenance switch plug.

Insulation protection equipment, including insulated gloves, insulated shoes and face shields, should be worn before maintenance work on high pressure systems.

During the high-pressure system overhaul, personnel responsibility must be specified in order to ensure that other people will not contact the car. When the repair work is suspended, please cover the high-pressure portion with insulating material to prevent other people from contacting.

1 ready

WARNING: First cut off the high voltage section and then detect the high voltage circuit.

Separate the high voltage components from the power battery, see "Removal and Installation".

Detection of motor controller positive and negative bus voltage, the standard ≤ 5V.

2 Motor controller insulation resistance detection

Remove the motor controller, see "Removal and Installation".

The stall of the high-voltage insulation detector stalls should be switched to 1000V when detecting the insulation resistance of the bus to the shell and the three-phase line the shell.

Testing requirements

Motor controller		Ground point	Insulation resistance standard
Name	Terminal
High voltage female line	Female line positive	Motor controller shell	≥20MΩ
	Female line negative
High pressure three phase interface	U phase
	V phase
	W phase

 

Symptom diagnosis

Electromagnetic noise

Description

    The electromagnetic noise of the drive motor becomes more pronounced when the high torque is output at very low speed. When this case occurs, the motor controller will reduce the frequency of IGBT conversion, then the situation will appear. This does not mean that there is a problem with the characteristics or control of the motor controller.

Disassembly and installment

Motor controller

Explosive view

 

Beam 2.bracket of the drive controller 3.Three-phase line cover plate 4.Three-phase line

: The front of the vehicle

disassembly and installment

Warning:

Since hybrids and electric vehicles usually contain high-voltage batteries, if high-voltage components and vehicles are handled incorrectly, there is a risk of electric shock, leakage, or similar incidents. Be sure to follow the correct working procedures when performing inspections and maintenance.

Be sure to place the maintenance switch in your own pocket to avoid the mis-operation of other staff during the maintenance process leading to the conduction of the high voltage circuit.

Insulation protection equipment, including insulated gloves, insulated shoes and face shields, should be worn before maintenance work on high pressure systems.

Overhaul personnel has responsibilities to ensure that other people will not contact the car. When the repair work is suspended, please cover the high-pressure portion with insulating material to prevent other people from contacting.

Note：

When the maintenance switch is removed, switching the vehicle to the READY state may cause malfunction. So do not change the vehicle to READY state unless instructed to do so in the service manual.

Demolition

Steps of replacing the controller

1. Cut off the vehicle high voltage, the battery maintenance switch off, as shown below, the maintenance switch will be unplugged.

2. Open the front hatch and check the electric drive system

 

3. Remove the positive and negative bus connections

                                              1. Positive and negative female line    

 

4. Remove the positive and negative bus connections

                                                    1. Three-phase line

 

5. Unplug the low voltage connector

1. 14Pin low voltage connector 2. 23Pin low voltage connector 3. DCDC output connecting rod

(6) Remove DCDC ground

(1)DCDC ground

 

7) remove the water inlet and outlet pipe

1. Water inlet pipe  2. Water outlet pipe

8. Remove the controller fixing bolts and complete the motor controller replacement.

 

Installation

The installation is carried out in the opposite way of disassembly.

Detection after installation

Check whether the bolts are connected reliably, whether they are missing bolts or bolts are not tightened as required.

After installing the motor controller, measure the resistance between the motor controller and the body, check whether the potential.

Requirements: Motor controller to ground resistance ≤ 0.1Ω

   If the results deviate from the standard values, check for paint, oil, dust, or other substances attached to bolts or conductive parts. If any of these substances are attached, clean the surrounding area and remove impurities.

Motor

Explosive view

    1. Power train joist 2. Three-phase line 3. Rotary transformer wire 4 Drive motor

   

Disassembly and Assembly

Warning:

Since hybrids and electric vehicles usually contain high-voltage batteries, if high-voltage components and vehicles are handled incorrectly, there is a risk of electric shock, leakage, or similar incidents. Be sure to follow the correct working procedures when performing inspections and maintenance.

A person using a medical device such as a pacemaker may not operate the vehicle because the drive motor carries high pressure and strong magnetic, which may affect the function of the medical device.

As the drive motor carries high pressure and strong magnetic, check and repair do not use magnetic things (such as bank cards, etc.), these items carried in the body to do maintenance may also be damaged.

Be sure to remove the high pressure service switch before performing high voltage system harness and component inspection or repair. Ensure that the maintenance switch is removed in your bag or carried on the body, so as not to repair the work of other people inadvertently put the maintenance switch plug.

Before starting to operate the high pressure system, wear insulation protection equipment, including insulated gloves, insulated shoes and face shields.

Overhaul personnel has responsibilities to ensure that other people will not contact the car. When the repair work is suspended, please cover the high-pressure portion with insulating material to prevent other people from contacting.

Attention:

    When the maintenance switch is removed, switching the vehicle to the READY state may cause malfunction. So do not change the vehicle to READY state unless instructed to do so in the service manual.

Demolition

Warning

It is necessary to release the reducer gear oil before removing the power train. Refer to the reducer assembly.

Disassembly mode Refer to the following mounting section to install the reverse step to disassemble.

 

Installation

Warning

It is necessary to install the high pressure wire bundle belt normally. If the bundle belt is damaged, replacement before installing new.

Before installing the drive motor and reducer assembly, apply grease lubrication to drive the motor shaft spline while injecting grease (minimum 8.5 g (0.3 ounce), up to 20 g (0.7 ounce) to the reducer input shaft Spline).

Do not damage and drop O-ring when installing drive motor and gear unit assembly. In addition, the seal is a consumable part, each need to be replaced from the new assembly before the new ring.

If the drive motor is replaced, a high voltage warning mark is affixed at the A position, refer to the "High Voltage Warning Mark".

  

 

1. Verify the following before assembling

1) The drive motor should be connected with three-phase line, rotary transformer wire, and equipped with connectors, and wiring harness and connectors are not damaged; drive motor three-phase line and rotary transformer insulation to meet the DC1000V insulation resistance ≥ 20MΩ.

2) drive the motor housing face clean no debris, no obvious processing defects.

 

2. Assemble the drive motor and gear unit assembly

Install the sealing ring into the sealing ring of the drive motor, the reducer locating pin is aligned with the locating pin hole on the driving motor, the alignment position assembly and the reducer assembly are connected with the driving motor through spline.

  1. Locate pin hole 2. Seal ring                               

(Bolt Q15010105, spring pad Q40110, flat pad Q40110 combination) 1, bolt assembly 2 (bolt Q15010105, spring pad Q40310, flat pad Q40110 combination), the bolt assembly 1, bolts (Q1841050) plus nut (Q33010) combination of two and bolts (Q1841050) 2 will drive motor and reducer connection fastening, tightening torque ■ 45 ~ 50Nm, as shown below

                          2. Bolt Q15010105, spring pad Q40310, flat pad Q40110

                                                 

                                1. Bolt Q1841050, nut Q33010

 

3. Assemble the drive motor and gear unit assembly

1) Assemble the 5 holes on the power assembly joists to the 5 stud alignment positions of the drive motor and gear unit assembly, and install the five hexagonal flange lock nuts (Q33012) and tighten and tighten Torque ■ 85 ~ 90Nm.

   1.Nut Q33012                   

 

The controller is plugged into the rotary transformer connector.

                             1. Rotary transformer wire connector

 

The controller terminal box connects the three-phase line.

                           1. Detection of high voltage three-phase line

 

6. Power train installed on the vehicle after the need to add fuel to the reducer, refueling requirements see reducer assembly.

Detection after installation

Check whether the bolts are connected reliably, whether they are missing bolts or bolts are not tightened as required.

After installing the drive motor, measure the resistance between the drive motor and the body, check whether it is equipotential.

Requirements: Motor housing resistance to ground ≤ 0.1Ω

If the results deviate from the standard values, check for paint, oil, dust, or other substances attached to bolts or conductive parts. If any of these substances are attached, clean the surrounding area and remove impurities.