 If an engineer uses medical electronic devices including heart pacemaker, cardioverter, defibrillator, the device can be only be used after its function being checked and confirmed before starting normal operations.

 During normal charge operation, an engineer who uses medical electronic devices including heart pacemaker, cardioverter, defibrillator cannot enter passenger compartment (including trunk).

Precaution for high voltage

Warning:

 The electric vehicle has a high-voltage battery. If the operation on the vehicle and high-voltage parts is incorrect, there are risks of leakage of electricity, electric shock, or similar accidents. Thus, it is mandatory to follow correct procedures to check and maintain.

 Before disconnect repair switch, please put the key on “LOCK” position or unplug the key.

 Disconnect repair switch before checking or maintaining high-voltage system. It is forbidden to close repair switch during the process of checking and maintenance. Before starting the operation on high-voltage system, be sure to wear insulated protection equipment, including gloves, shoes, and glasses.

 When a technician is operating high-voltage system, please ensure no one touching the vehicle. When there is no maintenance operation, please take insulated protection on the high-voltage sections to prevent anyone touching.

 When repair switch disconnects, it is forbidden that the key is at “ON” position or switched to “START” position.

High-voltage cable and safety sign

The color of high-voltage cable is orange and there are safety signs on the power battery assembly and other high-voltage parts. Do not touch these cables and parts.

Handling of high-voltage cable terminal

When the connector of high-voltage cable is plugged out, please use insulated adhesive tape to bind up immediately.

Regulation for a person wearing medical electronic device

The vehicle has strong magnetic parts. If an engineer uses medical electronic device, such as electronic pacemaker, its function may be affected by strong magnetic parts. Thus, these people cannot carry out repair work.

Forbidden accompanying article during work

The vehicle has strong magnetic parts. Thus, during work it is forbidden to take metal articles which may cause short circuit or magnetic articles such us various bank cards which may be damaged.

Place “Repairing High-voltage Parts, No Touch!” warning sign

Before repairing high-voltage parts, please place “Repairing High-voltage Parts, No Touch” warning sign on the prominent position of the repaired vehicle to remind other people.

Precaution for supplemental restraint system "airbag" and "safety belt pretension

Supplemental restraint system “airbag” and “safety belt pretension” is used together with front seat safety belts, which can reduce the damage to the driver and front passenger during collision. Supplemental restraint system consists of safety belt, driver airbag, and front passenger airbag. The detailed information of supplemental restraint system is included in the chapters of airbag system and seat safety belt.

Warning:

In order to avoid accidents, please abide by the following content:

 To avoid the failure of supplemental restraint system and considering that the risk of physical injuries will increase during collision if the system fails, all the service must be executed by JAC authorized dealer.

 Non-normative maintenance of supplemental restraint system including non-normative removal and installation may result in accidental trigger of the system and cause physical injuries. Regarding the method of removing airbag module, please refer to Airbag System chapter.

 Except for the operations in the service manual, please do not use electrical test device to test any circuit of supplemental restraint system. The color of harness and connector of supplemental restraint system is yellow or orange.

Precaution for using power tool (pneumatic or electric) and hammer

When power switch is at “ON” position and approach airbag diagnosis sensor or other sensors of airbag system, please do not use power tools or hammer on the sensor part area. Violent vibration may trigger these sensors and airbag to cause serious injuries.

 When using power tools or hammer, put the key at “LOCK” position, unplug the negative pole of 12V lead-acid battery, wait at least one minute, and then start maintenance.

Preparation work

Special tool

Tool name	Tool picture	Tool name	Tool picture
Tramegger		Insulated gloves
Digital multimeter		Insulated shoes

System instruction

Instruction

High voltage distribution system main contains parts:high voltage connecting box、main cable and distribution cable。

Components

High voltage distribution system

高压图1

Serial No.	Component name	function
1	High voltage junction box	The electric energy of power battery assembly is distributed to the motor controller, one-piece air conditioning compressor and electric heater. Receive the electric energy of the on-board charger or the quick charging pile,deliver it to the power battery assembly
2	High voltage main cable	Deliver electric energy of power battery assembly to high voltage junction box
3	High voltage distribution cable	The power of the power battery assembly is delivered to the electric heater and the integrated air conditioner compressor.

High voltage junction box

● High-voltage junction box functions include power battery assembly power distribution, electric heater and fast charge on/off control, air conditioning system, fast charge, slow charge, motor control and other circuit overload protection.

● High voltage junction box has 6 high voltage cable connectors,fixing on on-board charger motor by 4 fixing points

Serial No.	Parts	function
1	Air conditioning system connector	Connect to high voltage distribution cable to deliver power to air conditioning system
2	Main cable connector	Connect to High voltage main cable
3	Motor Controller Connector (+)	Connect to positive pole of motor controller
4	Motor Controller Connector (-)	Connect to negative pole of motor controller
5	Car charger connector 1	connect to on-board charger
6	Low voltage connector	Realize high voltage interlocking and internal relay of high voltage junction box control
7	rapid charging connector	Connect to DC charging socket assembly

note:

● If connector terminal is damaged,please change high voltage junction box

● The high voltage warning label is affixed to position A.

High voltage main cable

high voltage main cable delivers electric energy of power battery assembly to high voltage junction box,and it has key position fail-safe and high voltage interlock functions

Serial number	Spare parts	Function
1	Power battery assembly connector	Connecting to power battery assembly
2	Main cable connector	Connecting to high voltage junction box
3	Lathedog	Fixing high voltage main cable

High voltage distribution cable

High voltage distribution cable transfers electricity of power battery assembly to electrical heater and one-piece air conditioner compressor. The connector ① is connected to one-piece air conditioning compressor. The connector ② is connected to high voltage junction box. The connector ③is connected to electrical heater.

Serial number	Spare parts	Function
1	Air conditioning system connector	Connecting to high voltage junction box to provide electricity to air conditioning system
2	One-piece air conditioner compressor connector	Connecting to one-piece air conditioner compressor
3	Electrical heater connector	Connecting to electrical heater
4	Vehicle body via hole sheath	Harness via hole protection and sealing
5	Buckle	Fixing high voltage distribution cable

System framework

framework

Connector information

Air conditioning system connector

Connector name	Air conditioning system connector
Connector type	XC158/27F12K1P13

Terminal No.	Definition
1	null
2	null
3	null
4	One-piece a/c compressor+
5	Electric heater1+
6	Electric heater2+
7	null
8	One-piece a/c compressor-
9	Electric heater1-
10	Electric heater2-
11	null
12	null

Power battery assembly connector

Connector name	Power battery assembly connector
Connector type	GYHD-2-150T G001

Terminal No.	Definition
1	Always positive
2	Always negative
3	High voltage interlock+
4	High voltage interlock-

Motor Controller Connector (+)

Connector name	Motor Controller Connector (+)
Connector type	CT34E-1ZJ(RE)-01E

Terminal number	Definition
1	Motor controller positive pole

Motor Controller Connector (-)

Connector name	Motor Controller Connector (-)
Connector type	CT34E-1ZJ(BK)-01E

Terminal number	Definition
1	Motor controller nagetive pole

On-board charger

Connector name	On-board charger
Connector type	DY3T1002PNF-05

Terminal number	Definition
A	Car charger DC +
B	Car Charger DC -

Low pressure connector (socket)

Connector name	Low pressure connector (socket)
Connector type	776267-1

Terminal number	Definition
1	electric heater relay 12V
2	Electric heater relay 1 control signal
3	Electric heater relay 2 control signal
4	Fast charge ground
5	Fast charge control signal
6	High voltage interlock 12V
7	High voltage interlock signal
8	null
9	null
10	null
11	null
12	null

rapid charging connector

Connector name	rapid charging connector
Connector type	GYHD-2-150T G001

Terminal No.	Definition
1	Fast charge positive
2	Fast charge negative
3	null
4	null

Electric heater connector

Connector name	Electric heater connector
Connector type	Y50DP-1204TJ2-11.1

Terminal No.	Definition
1	Electric heater1+
2	Electric heater1-
3	Electric heater2+
4	Electric heater2-

One-piece electric compressor connector

Connector name	One-piece electric compressor connector
Connector type	DY3T1002PNF-05

Terminal number	Definition
A	One-piece a/c compressor+
B	One-piece a/c compressor-

Diagnosis

Symptom list

Symptom	Checking list	Possible failed part
Insulation malfunction	Insulating resistance of vehicle high voltage system parts Battery controller	Overall high voltage parts Battery controller
Loop not conducting	High voltage loop fuse High voltage connector	High voltage junction box High voltage main cable High voltage distribution
Loop and short circuit	Vehicle high voltage system parts	Overall high voltage parts

Insulating malfunction diagnosis

Danger:

If touching high voltage components without wearing appropriate protective device, it will cause danger of shock.

Warning:

Before inspecting or maintaining high voltage system, please follow the “High voltage disconnection”procedure in overview.

Operation procedure

Reminder:

 Only when insulation malfunction is diagnosed in vehicle malfunction diagnosis, an engineer can detect insulation according to above procedure.

 If insulation of whole vehicle high voltage parts is qualified after inspection according to the procedure, please check whether the battery controller is normal.

Circuit conduction inspection

Air conditioning loop continuity check

prompt:

Digital Multimeter Usage Method Reference "Overview - Circuit Inspection"

1 Check whether the high-voltage connector has a back needle, pin twist, and breakage phenomenon

YES,>>change high voltage distribution cable

NO,>>Step 2.

2 Use a digital multimeter to measure continuity between the high-voltage junction box air-conditioning system connector pins 4/5/6 and the high-voltage main cable connector (socket) pin 1

Yes,>> Finish.

No,>> circuit out of conduction(according to this chapter to change safety fuse)

Motor Controller circuit conduction inspection

Check procedure reference air conditioning circuit continuity check

On-board charger circuit continuity check

Check procedure reference air conditioning circuit continuity check

Circuit short out inspection

One-piece compressor circuit short out inspection

1 Check whether the connector of the high-voltage system has needle retreat, pin twist, and breakage

YES,>>change cable

NO,>>Step 2.

2 Disconnect the high voltage main cable connector and use a digital multimeter to measure the continuity between the positive and negative terminals of the high voltage main cable connector.

YES,>>change high voltage main cable

NO,>>Step 3.

3 Disconnect the integrated electric compressor connector and use a digital multimeter to measure the continuity between the positive and negative electrodes of the integrated electric compressor connector of the high voltage distribution cable.

Normal >>Step 4

NO,>>Step 5.

4 Disconnect the high-voltage connector of the air-conditioning system, and use a digital multimeter to measure the continuity between the positive and negative electrodes of the integrated electric compressor connector of the high-voltage distribution cable.

YES,>>high voltage distribution cable is short out,change high voltage distribution cable

NO,>>Step 5.

5 Using a digital multimeter to measure the short circuit between the positive and negative terminals of the integrated motor compressor connector

YES,>>one-piece motor compressor breaks down,change one-piece motor compressor

NO,>>finish.

Other circuit short-circuiting check Refer to Integrated compressor circuit short circuit check.

Dismantling and installation

High voltage junction box

1 Direct current charging cable 2 high voltage junction box 3 High voltage distribution cable
4 High voltage main cable 5 PCU+ 6 PCU- 7 Vehicle charger motor

Removal

Danger:

If touching high voltage components without wearing appropriate protective device, it will cause danger of shock.

Warning:

Before checking or maintaining high voltage system, please follow procedure of “High voltage disconnection” in overview.

1 Exit the connector card lock, press the lock card and pull out the connector to main cable along horizontal direction.

2 Rotate the high voltage system connector hood in counterclockwise direction and pull out the air conditioning system connector.

3 Pull out motor controller connector.

4 Rotate the direct current charging connector in counterclockwise direction, pull out alternating current charging connector.( The method is same as conditioning system connector).

5 Pull out alternating current charging connector.(The method is same as pulling out main cable connector).

6 Rotate the one-piece air conditioner compressor connector hood in counterclockwise direction, pull out one-piece air conditioner system connector( The method is same as air conditioning system connector).

7 Remove four fixing bolts f high voltage junction box(Q1840825）.

8 Remove high voltage junction box

Installation

Install it according to reverse order of removal.

High voltage distribution cable

Removal

1 Removal auxiliary dashboard please refer to “Vehicle body system interior fascicle- dashboard”

2 Pull out electrical heater connector( The method is same as air conditioning system connector)

3 Remove four fixing cable tie of high voltage cable electrical heater branch.

1 Cable tie① 2 Cable tie②

4 Remove two fixing bolt on via sheath and cable tie as well as buckle on one-piece air conditioner compressor branch of high voltage distribution cable.

1 Fixing bolt 2 Buckle 3 Carbon tie

5 Remove high voltage distribution cable

Installation

Install it according to reverse order of removal.

High voltage main cable

Removal

1 Lifting the vehicle, please refer to chapter of “Vehicle lifting”.

2 Pull out power battery assembly connector.( The method is same as pulling out main cable connection)

3 Remove three nut on fixing clamp of main cable.

4 Remove main cable

Installation

Install it according to reverse order of removal.

Dismantling and installation

High voltage junction box

Removal

Warning:

The high voltage box can only be disassembled after removal.

Reminder:

 The high voltage junction box is divided into two layer, the upper layer is fuse, the lower layer is relay.

 If replacement of fuse is needed, open the upper lid of high voltage box and operate. If replacement of relay is needed, it is required to remove the fuse insulating board.

1 Remove sixteen bolt of high voltage box upper lid and then take the high voltage upper lid down.

捕获12

2 Remove fixing bolt and nut of air conditioner fuse.

1 Bolt 2 Nut

3 Remove PCU fuse, air conditioner fuse, direct current charging fuse, alternating fuse, please refer to the method of step two.

1 Air conditioner fuse 2 Direct current charging fuse 3 PCU fuse 4 Alternating charging fuse

4 Remove the upper insulating board.

5 Remove direct current charging relay and electrical heater relay.

1 PTC1relay 2 PTC2 relay 3 Direct current charging relay

Installation

Install it according to reverse order of removal.

Maintenance data and specification

Fuse

Serial number	Loop name	Specification of fuse
1	Motor controller loop	150A 450V
2	Air conditioner loop	30A 450V
3	Alternating current charging loop	30A 450V
4	Direct current charging loop	80A 450V

Relay

Serial number	Loop name	Specification of loop
1	Electrical heater loop	40A 450V
2	Direct current charging loop	100A 450V