add

2 Before the high-voltage parts for inspection and maintenance, disconnect the service switch can ensure

2
the high voltage disconnected.

Warning:

When operating the service switch must wear insulated protective equipment.

High risk identification

1 "Warning" label is stuck on the locations shown in Figure;

2 After replacement parts to ensure "Warning" label is stuck in the original location.

Power Battery assembly

“Warning” label is attached to the rear of the battery assembly.

: vehicle’s front end

System

System Instructions

System framework

Control

BDU

VCU wakeup

Monitor heat out-of-control status

Current detection

Total voltage

Insulation detection

Battery module temperature

Battery cell

Battery system

Charger

VCU

Input and output signal list

Input signal list

Transmission unit	Signal name
Vehicle controller	Vehicle CAN	Malfunction Diagnosis signal
		Malfunction clear signal

Output signallist

Transmission unit	Signal name
Vehicle controller	Vehicle CAN	Highest cell voltage signal
		Minimum cell voltage signal
		Highest cell voltage position signal
		Lowest cell voltage position signal
		The maximum temperature signal
		The lowest temperature signal
		The maximum temperature position signal
		The lowest temperature position signal
		Insulation resistance signal
		Signal of heat out-of-control status
		Battery assembly current signal
		Service switch voltage interlock signal

Instruction

Battery controller functions mainly includes the following:

1 Monitor battery assembly status and report to VCU, prevent over voltage, over discharge, over current and other fault.

2 In the charge-discharge process, if fault such as over voltage, over discharge, over current happen, to

2
detect faults timely and requires VCU to disconnect the mains contactor.

3 Balancing the battery voltage consistency in its best condition, to avoid affecting the voltage is too large for the charge and discharge capacity.

4 Te s ti ng and service switch interlock circuit state determines whether the connection is normal, and report

4
to the VCU, when the high voltage interlock loop fails, the vehicle can not be powered on properly.

5 Detect battery assembly insulation status, and report to VCU, when the insulating state can not meet the

5
requirements, the vehicle will not power up.

Battery protection

The battery needs to be charge or discharged in a reasonable voltage range, once beyond the range, either too low or too high will damage the battery. To avoid damage , battery controller detects the voltage of each single cell information and send it to VCU, VCU ensure them work within a reasonable voltage range.

Items	Control Strategy	Operating conditions
The voltage over-current protection	Control the charging current	When the cell voltages reach to the maximum charging voltage, the charging current progressive control
The voltage over-current protection	Turn off the main contactor	Current, the cell voltage exceeds the upper limit, and the time exceeds the predetermined time
Over-discharge Protection	Control the discharge current	Cell voltages reach to the discharge lower limit, the progressive control of the discharge current
Over-discharge Protection	Turn off the main contactor	Cell voltage is below the lower limit of the discharge cut-off voltage, and more than a predetermined time
Over-temperature Protection	Control the discharge current	When the temperature is reach to the limit, and gradually control the charge and discharge currents
Over-temperature Protection	Turn off the main contactor	When the temperature exceeds the limit, and more than a predetermined time

Balancing function

The balancer can adjust the battery cell to target value, the controller detects the battery cell voltage

information, and turn on the balancing switch , forms a discharge circuit, reducing the high-voltage battery cell

charging current until its voltage down to the same level with other battery cells.

System circuit diagram

Maintenance Switch

LBC

Gray

Black

Function instruction

Function instruction

Terminal number

Terminal number

Function instruction

Terminal number

Terminal number

Function instruction

Terminal number

Function instruction

Function instruction

Terminal number

Constant power

Wakeup signal

Blocking

Terminal number

Function instruction

Function instruction

Terminal number

Function instruction

Function instruction

Terminal number

Terminal number

Function instruction

Terminal number

Terminal number

Function instruction

Terminal number

Function instruction

Function instruction

Terminal number

Function instruction

Function instruction

Terminal number

Terminal number

Terminal number

Terminal number

Function instruction

Function instruction

Terminal number

Function instruction

Function instruction

Function instruction

Function instruction

Function instruction

Terminal number

Terminal number

Terminal number

Terminal number

Function instruction

Function instruction

Terminal number

Terminal number

Terminal number

Terminal number

Function instruction

Function instruction

Function instruction

Function instruction

Function instruction

Function instruction

Function instruction

Function instruction

Terminal number

Terminal number

Terminal number

Terminal number

Function instruction

Terminal number

Terminal number

Terminal number

Terminal number

Terminal number

Function instruction

Function instruction

Function instruction

Function instruction

Wiring harness arrangement

Operation Precautions

Power battery assembly

1 To extend battery life, avoid large rate charging;

2 Use the slow charge mode charging;

3 Avoid emergency deceleration or rush acceleration;

4 Avoid direct sunlight and stay away from heat.

Storage battery assembly

l Horizontal;

l Avoid double-stacked;

l Do not place battery assembly on the ground by direct contact, placed on the rubber mat;

l Away from water;

l Prevent debris falling on the battery assembly;

l Do not place the battery assembly outdoors, avoid direct sunlight.

System diagnosis

IEV diagnostic tool functions

"IEV diagnostic tool -LBC" to be completed by the following functions.

The main function

Items	function
Cell voltage inquiry	Quick and accurate query cell number and the corresponding voltage
Monomer temperature inquiry	Quick and accurate query temperature number and its corresponding temperature
System self-test	Quick Query system self-test results and fault conditions
Data Detection	Displays the current battery assembly input and output data
Faults diagnosis	Display fault code (DTC)

Accessibility Features

Items	Method	Triggering conditions
Fault data record	Save time and read the fault battery power system parameter information	Battery system fails

LBC diagnostic information

Power Battery System

Test value based on the diagnostic tool

Caution：

Cell voltage of Battery cell number 02-96 and 01 are the same when SOC is 5% and 95%. Temperature range of battery 2/3/4/5/6/7 can be regarded as the same with battery 1.

Inspection item	Condition		Reference value / status
Current	READY	The vehicle is stationary	Within ±5A
12V low voltage system	READY		11V-15mV
Insulated low-voltage pulse	READY		0.2MΩ-10MΩ
Service switch interlock	READY	Connection with service switch	With High voltage
Service switch interlock	READY	Disconnect the service switch	No high voltage
Cell voltage 01	READY	SOC5%	3000mV-3400mV
Cell voltage 01	READY	SOC95%	4010mV-4100mV
Power Battery total voltage	READY	SOC5%	288V-326V
Power Battery total voltage	READY	SOC95%	385V-393V
Power battery temperature 1	READY (vehicle stationary)	Ambient temperature 25 ℃	20-40℃ (Power battery temperature)
Temperature 8	READY (vehicle stationary)	Ambient temperature 25 ℃	20-40℃ (water inlet’s temperature)
Temperature 9	READY (vehicle stationary)	Ambient temperature 25 ℃	20-40℃ (water outlet’s temperature)
Temperature 10	READY (vehicle stationary)	Ambient temperature 25 ℃	20-40℃ (heater temperature)

Security – Failure

When VCU detect fault in battery assembly, VCU will protect the battery assembly by controlling the power

input and output, for different fault types and failure mode, the process is different.

Safety-failure mode

Mode A: forbid DC charging

Mode B: forbid AC charging

Mode C: forbid driving

Model D: cut off the high voltage

Safety-failure list

DTC	Failed list	Processing type				Other processing methods
DTC	Failed list	A	B	C	D	Other processing methods
P31E4- P31C9	LBC hardware failure					Battery fault indicator
P31BD	EEPROM Malfunction					Battery fault indicator
P31B2	Critical insulation malfunction			×	×	Battery fault indicator
P31AE	Power battery single cell voltage is too high	×	×			Battery fault indicator
P31AD	Power battery single cell voltage is too high			×
P31AB	Battery cell temperature is excessively low
P31AA	The battery temperature is too high					Limp
P31A9	Battery discharge current is too large					Battery fault indicator
P31A8	Malfunction of Battery Charging Over-current					Battery fault indicator
P31A7	Malfunction of total voltage severe under-voltage
P31A6	Malfunction of excessively high total voltage	×	×			Battery fault indicator
P31A3	Power battery single cell voltage is too low	×	×		×	Battery fault indicator
P317D	Single body spray explosion	×				Battery fault indicator
P317C	Still single-body self-discharge check_100Ω
P317B	Still single-body self-discharge check_50Ω
P316E	The high voltage interlock failure					Battery fault indicator
P315D	Insulation malfunction
P312F	No PWM signal change during insulation check					Battery fault indicator
P312E	Insulation check system short-circuit GND					Battery fault indicator
P312D	Insulation check system short-circuit VCC					Battery fault indicator
P312C	SHORT CIRCUIT ERROR OF TEMPERATURE SENSOR AND GND					Battery fault indicator
P312B	SHORT CIRCUIT ERROR OF TEMPERATURE SENSOR AND VCC					Battery fault indicator
P312A	TWO-PATH INCONSISTENCE ERROR OF CURRENT SENSOR					Battery fault indicator
P311F	Alert of battery cell’s dynamic voltage difference
P3179	Fire	×	×			Battery fault indicator
P3177	12V power supply is excessively high
P3176	12V power supply is excessively low					Limp
P3160	Battery temperature imbalance
P3147	Static voltage difference of cell is too large
P3146	Battery cell dynamic voltage difference is excessively high	×
P3139	Mis-closing of balance
P3138	Mis-opening of balance					Battery fault indicator
P3137	MISMATCHING ERROR OF CELL VOLTAGE AND TOTAL VOLTAGE
P3134	Loosening of cell voltage acquisition cable					Battery fault indicator
P3133	BATTERY CELL VOLTAGE INSPECTION ERROR- AD TRANSFER ERROR					Battery fault indicator
P3129	SHORT CIRCUIT ERROR OF CURRENT SENSOR AND GND					Battery fault indicator
P3128	SHORT CIRCUIT ERROR OF CURRENT SENSOR AND VCC					Battery fault indicator

DTCindex

DTC		Failure Name
228	P31E4	LBC hardware failure
227	P31E3
226	P31E2
225	P31E1
224	P31E0
223	P31DF
222	P31DE
221	P31DD
220	P31DC
219	P31DB
218	P31DA
217	P31D9
216	P31D8
215	P31D7
214	P31D6
213	P31D5
212	P31D4
211	P31D3
210	P31D2
209	P31D1
208	P31D0
207	P31CF
206	P31CE
205	P31CD
204	P31CC
203	P31CB
202	P31CA
201	P31C9
189	P31BD	EEPROM Malfunction
178	P31B2	Critical insulation malfunction
174	P31AE	Power battery single cell voltage is too high
173	P31AD	Power battery single cell voltage is too high
171	P31AB	Battery cell temperature is excessively low
170	P31AA	The battery temperature is too high
169	P31A9	Battery discharge current is too large
168	P31A8	Malfunction of Battery Charging Overcurrent
167	P31A7	Malfunction of total voltage severe under-voltage
166	P31A6	Malfunction of excessively high total voltage
163	P31A3	Power battery single cell voltage is too low
125	P317D	Single body spray explosion
124	P317C	Still single-body self-discharge check_100Ω
123	P317B	Still single-body self-discharge check_50Ω
121	P3179	Fire
119	P3177	12V power supply is excessively high
118	P3176	12V power supply is excessively low
110	P316E	The high voltage interlock failure
96	P3160	Battery temperature imbalance
93	P315D	Insulation malfunction
71	P3147	Static voltage difference of cell is too large
70	P3146	Battery cell dynamic voltage difference is excessively high
57	P3139	Mis-closing of balance
56	P3138	Mis-opening of balance
55	P3137	MISMATCHING ERROR OF CELL VOLTAGE AND TOTAL VOLTAGE
52	P3134	Loosening of cell voltage acquisition cable
51	P3133	BATTERY CELL VOLTAGE INSPECTION ERROR- AD TRANSFER ERROR
47	P312F	No PWM signal change during insulation check
46	P312E.	Insulation check system short-circuit GND
45	P312D.	Insulation check system short-circuit VCC
44	P312C.	SHORT CIRCUIT ERROR OF TEMPERATURE SENSOR AND GND
41	P3129.	SHORT CIRCUIT ERROR OF CURRENT SENSOR AND GND
40	P3128.	SHORT CIRCUIT ERROR OF CURRENT SENSOR AND VCC
31	P311F.	Alert of battery cell’s dynamic voltage difference

Harness Diagram

VCU

Harness Diagram

LBC

Terminal No.	Wire color	Wire diameter	Signal name	Terminal No.	Wire color	Wire diameter	Signal name
83	PW	0.5	VC83 Self-holding SSO control signal	A	Y	0.5	CANHk CAN-H signal interacting
85	L	0.5	VC85 Brake pedal sensor 2 ground	B	G	0.5	CANHk CAN-H signal interacting
86	Y	0.5	VC86 charging indicator 1 (Yellow light)	C	B	0.5	CANGED CAN shielded ground
91	R	0.5	VC91 Fast charge relay control signal	D	R	0.85	BM04 High level availability
92	PW	0.5	VC92 DCDC enable	E	R	1.25	VC107 B+ relay control
96	R	0.5	VC96 Brake pedal sensor 1 power-supply	F	W	0.5	VC99 B+ relay control
98	Y	0.5	VC96 Brake pedal sensor 2 power-supply	G	R	0.5	VC100 pre-charge relay control
99	W	0.5	VC99 Total Negative Relay Control (12V)	H	B	0.5	BM17 Fan power ground
100	R	0.5	VC100 pre-charge relay control (12V)	J	B	0.5	BM09 LBC power ground
101	LR	0.5	VC101 AC relay control (0V)	M	Y	0.5	CANHa Inner CAN high
104	R	0.5	VC104 Accelerator pedal sensor 2 power-supply	N	G	0.5	CANLa Inner CAN low
106	G	0.5	VC106 charging indicator 2 (green light)	R	G	0.5	BX08 high-voltage inter-lock signal 1.
107	R	0.5	VC107 Main positive Relay Control (12V)	S	WB	0.5	VC39 high-voltage inter-lock signal 2
109	B	0.5	VC109 Cooling water pump control signal	U	R	1.25	BM11 LBC fan power supply
112	RY	0.5	VC112 Accelerator pedal sensor 1 power-supply	V	WY	0.85	BM04a LBC power
115	Y	0.5	CANH-2
116	G	0.5	CANL-2
120	Y	0.5	CAN（H）
121	G	0.5	CAN（L）

Basic check

Diagnostic and maintenance workflow

Work process

Detailed flow

1.Obtain symptom information

Use the Diagnostic Worksheet to ask the customer for details about the symptoms (status and environment at the time of the accident / failure). (Please refer to the following. "Diagnostic working list")

>> Go to step 2

2.Detect DTC

1. Check DTC

2. If DTC display, perform the following steps.

- Record DTC.

- Study the relationship between the cause of the fault detected by the DTC and the symptoms described by the customer. (Symptom table is useful. Please refer to "Symptom comparison table")

3. 3. Review the relevant maintenance records for more information.

Has the customer already described the symptoms and have already detected the DTC?

Symptoms described and DTC has been displayed >> Go to step 3

Symptoms described, yet DTC hasn’t been displayed. >> Go to step 4

No description or DTC displayed. >> Go to step 5

3.Confirm symptoms

Try to diagnose the symptoms described by the customer.

Also check the normal operation and the relevant symptoms on "safety - failure" mode list. Refer to “Safety-failure” mode list The "Diagnostic Worksheet" is helpful in verifying the failure.

Verify the relevance of symptoms and conditions that trigger the failure

>> Go to step 5

4.Confirm symptoms

Try to diagnose the symptoms described by the customer.

Also check the normal operation and the "safety - failure" mode sheet related symptoms relevant to “safety-failure” mode list. Refer to “Safety-failure” mode list

“Diagnostic worksheet”is helpful to confirm the malfunction.

Verify the relevance of symptoms and conditions that trigger the failure

>> Go to step 6

5.Execute the DTC confirmation step

Execute "DTC confirmation procedure" for the displayed DTC, and then confirm that the DTC is detected again.

Caution：

l If DTC hasn’t been checked again, freezing data will be helpful to check failures.

l If no relevant failure check procedure is listed in maintenance manual, please check spare parts’ function.

If spare parts’ function is abnormal,please refer to “DTC check procedure” for details

Whether DTC is detected ?

Yes >> Go to step 7.

No >> Check according to “failure simulation test”

6.Check the system failure through the symptom table

According to the "symptom table", the fault diagnosis system is diagnosed based on the symptoms confirmed in step 4, and the method of the fault diagnosis is determined based on the possible causes and symptoms.

Is there symptomatic description?

Yes >> Go to step 7.

No>> Using diagnostic tools to monitor the data of relevant sensors.

7.Check the defective parts by means of the diagnostic procedure

Check the defective parts by means of the diagnostic procedure

Is there a faulty part?

Yes >> Go to step 8.

No>> Using diagnostic tools to monitor the data of relevant sensors.

8.repair or replace faulty parts

1. 8.repair or replace faulty parts

2. 2. After completing the repair and replacement work, reconnect the parts or connectors that were disconnected during the troubleshooting process.

3. Check DTC If DTC is displayed, erase it.

>> Go to step 9

9.Final check

When the DTC is detected in step 3, perform the "DTC confirmation step" or "Full function check" again, and then confirm that the fault has been properly repaired. If the symptoms are described by the customer, confirm the symptoms identified by referring step 4 and step 5, and check that the symptoms described by the user are not detected.

Whether DTC is detected ?

Abnormal (DTC detected) >> Go to 7

Symptoms reappear >> Go to 4

No detection >> Clear DTC before delivering vehicle to customer

Diagnostic working list

Instruction

Error information of charging system can be acquired by understanding working conditions correctly.

Generally, customer has his own judging standard on the failure. Therefore, by consulting user’s description on failure or problem, technicians can understand failure better. All error information can be classified by applying diagnostic working list.

Diagnostic working list

Diagnostic working list
Owner Name		Fault Date	VIN
		Useful life	Maintenance Date
		Mileage
Faults		□Cannot turn "ready" “ready” □Warning light on □Power limitation light on
		□Wading * □Noise * □Vibration * □Impact * □Gear noise *
		□Unable to travel * □Slow Acceleration * □Torque is small * □Radio noise *
		□Charge disabled □Other **:Detailed description
		Detailed breakdown:
Frequency		□Always □one-time □Sometimes (times / day) □Other
Charging state		□Full power □Half power □Low Power
Weather Condition		□No effect
	Weather	□Clear □Partly cloudy □rainy □Snow □Others ()
	Temperature	□Hot □Warm □Cool □Cold □Temperature (℃)
	Humidity	□High □Medium □Low □Humidity ( %)
Road Conditions		□No effect □City □Highway □Suburbs
		□Flat road □Collision □When turning (left / right)
		□Other
Gear Mode		□No effect
		□N Gear □R Gear □D Gear
Travel Mode		□No effect
		□Switch ON → OFF ON→OFF □Switch OFF → ON OFF→ON □READY
		□Driving □Slow down □Before parking □After parking □D shift(after stopping)
		□Charging □Other
		□Vehicle speed (km / h)
When the fault disappears		□Disappear when driving □Disappear When parking □Disappear When selecting drive mode
		□Disappear after KEY OFF □Disappear when charging is stopped □Always exist
		□Other
Other

Replace the battery assembly follow-up work

Description

When the battery assembly is replaced, VCU battery status information must be updated.
Battery cell charge equalization

Instruction

When a battery cell is not normal, we need to replace the battery pack. After the replacement, we need to

charge the new cell to balance it, and make it equal with other battery cells.

Work Steps

1.Check the target voltage value

Use diagnostic tool to read the battery cell voltage.

1. KEY ON

2. Read data.

3. Check the highest cell voltage and the corresponding position number.

Target voltage value: the highest cell voltage.

2.Check the cell voltage

Caution：

l This work needs to be performed at 0-40 ° C ambient temperature.

Cell voltage is lower than the target voltage value, go to step 4.

The cell voltage is higher than the target voltage value, go to step 3.

3.Cell voltage discharge

Caution：

l This work needs to be performed at 0-40 ° C ambient temperature.

Use balancer to discharge the cell voltage to 3.0V.

Go to Step 4.

4.Cell voltage regulating

l This work needs to be performed at 0-40 ° C ambient temperature.

Charge the battery cell to target value in voltage balancer.

After finish, go to step 5.

5.Check the module voltage

Removed the module from the balancer.

Use a multimeter to check the voltage and verify.

Target voltage ± 10mV.

Go to Step 6.

6.Check the cell voltage

After the battery assembly is installed, check the replaced cell voltage value.

Voltage differential to target value: ± 40mV.

Inspection End.

DTC / Circuit Diagnosis

P31E4 to P31C9 LBC hardware failure

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P31E4 to P31C9	LBC hardware failure	Failure happens on LBC hardware controller	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 2 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1. Replace the LBC, refer to the "Dismantling and assembling of battery assembly-LBC"

P31BD EEPROM Fault

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P31BD	EEPROM Malfunction	Failure occurs when recording or reading EEPROM	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 2 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

DiagnosticSteps

1.Replace LBC

1. Replace the LBC, refer to the "Dismantling and assembling of battery assembly-LBC"

P3146 Battery cell dynamic voltage difference is excessively high

DTC logic

DTC diagnostic logic

DTC number

Failure Name

DTC diagnostic conditions

The possible reasons for failure

P3146

Battery cell dynamic voltage difference is excessively high

LBC detected dynamic battery cell voltage is too large

l LBC

l High voltage connecting the copper bar

l Battery cell

l Voltage sample harness

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 2 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Use the "IEV diagnostic tool" inquiry LBC diagnostic service information

1.Turn the key to ON.

2. Check the diagnostic results.

Whether detected other DTC?

Detected P3147 >> Go to "P3147- diagnostic process."

Detected P3134 >> Go to "P3134- diagnostic process."

NO >> Go to step 2, refer to the "Dismantling and assembling of power battery assembly-LBC".

2.Use the "IEV diagnostic tool 'Check the battery cell information

1. Check the abnormal battery cell voltage and corresponding number.

3.Removal of Power Battery Assembly

1. Turn the key to "LOCK" or pull out.

2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".

4.Check whether the high voltage connecting copper barfixing bolt is loosed near the abnormal cell

1. Check whether the high voltage connecting copper bar fixing bolt is loosed near the abnormal cell

Test results normal?

YES >> Repair or replace the corresponding high-voltage connector copper bar.

NO >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".

P3139 Mis-closing of balance

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P3139	Mis-closing of balance	Balanced Control Circuit Failure	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 10 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

P3138 Mis-opening of balance

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P3138	Mis-opening of balance	Balanced Control Circuit Failure	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 10 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

2.Use the "IEV diagnostic tool 'Check the battery cell information

1. Check the highest cell voltage and the corresponding number.

2.Inquire whether abnormal cell exists or not

Check if the result is normal.

Yes >> Detection is finished.

No >> Go to step 3

3.Remove the battery assembly to replace the abnormal battery cell

1. Turn the key to "LOCK" or pull out.

2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".

3.Search for the cell position in the battery module according to the battery cell number, refer to "Removal and

installation of Battery assembly-Module layout ", refer to the "battery assembly dismantling and assembling -modular layout."

4. Dismantling the module assembly, identify abnormal monomer and replacement, refer to the "dismantling

and assembling the battery cell."

P3137 MISMATCHING ERROR OF CELL VOLTAGE AND TOTAL VOLTAGE

DTC logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P3137	Mismatching error of cell voltage and total voltage	LBC detected there is obvious deviation between cell voltage and total voltage	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 10 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

P3134 LOSSENING ERROR OF CELL VOLTAGE ACQUISITION CABLE

DTC Logic

DTC diagnostic logic

DTC number

Failure Name

DTC diagnostic conditions

The possible reasons for failure

P3134

Loosening error of cell voltage acquisition cable

Poor contact of LBC cell acquisition cable

l LBC

l Voltage acquisition cable

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 2 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

Warning:

l As the electric vehicle contains a high voltage battery, if the high pressure components and vehicles are handled incorrectly, there is a risk of electric shock, shock, leakage or similar accidents, so be sure to follow the correct procedures to check and maintain.

l Before the maintenance switch is disconnected, the key must be placed in the "LOCK" or unplugged.

l Check or maintain the high pressure system before disconnecting the service switch. And no one is allowed to turn off the maintenance switch during the inspection and maintenance process. Before starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.

l Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.

l When the maintenance switch is disconnected, the key is forbidden to "ON" or "START".

1.Use the "IEV diagnostic tool" inquiry LBC diagnostic service information

1.Turn the power switch ON and wait for 10s or more.

2.Read LBC temperature information.

3.Check the voltage and series number of abnormal cell.

2.Removal of Power Battery Assembly

1. Turn the key to "LOCK" or pull out.

2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".

3.Check the voltage acquisition harness

1.Find corresponding voltage acquisition connector according to the cell series number, and refer to “System description-system-system diagrams”.

2.Check if the connectors between module (M) and main harness (CT), LBC (J) and main harness.

Is it normal?

Yes>> repair or replace relative voltage acquisition harness.

NO >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".

P3133 CELL VOLTAGE INSPECTION ERROR- AD TRANSFER ERROR

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P3133	Voltage inspection error-AD transfer error	LBC cell voltage detected there is error during AD transferring	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 10 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

P312F Insulation Detection Circuit

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P312F	Malfunction of Insulation inspection	The amplitude of LBC collector’s insulation inspection voltage value remains unchanged	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 10 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

P312E Insulation Detection Fault

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P312E	Malfunction of Insulation inspection	LBC collector’s insulation inspection voltage value is near 0V	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the power switch ON and wait for 5min or more.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

P312D Insulation Detection Fault

DTC Logic

DTC diagnostic logic

DTC number	Failure Name	DTC diagnostic conditions	The possible reasons for failure
P312D	Malfunction of Insulation inspection	LBC collector’s insulation inspection voltage value is near 5V power voltage.	l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the power switch ON and wait for 5min or more.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

1.Replace LBC

1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”.

P312C temperature sensor fault

DTC Logic

DTC diagnostic logic

DTC number

Failure Name

DTC diagnostic conditions

The possible reasons for failure

P312C

Temperature sensor failure

LBC check the voltage value of battery temperature sensor is near 0V

l Wire harness or connector

l Temperature sensor

l LBC

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 10 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

Warning:

l Before the maintenance switch is disconnected, the key must be placed in the "LOCK" or unplugged.

l When the maintenance switch is disconnected, the key is forbidden to "ON" or "START".

1.Use the "IEV diagnostic tool" inquiry LBC diagnostic service information

1.Turn the power switch ON and wait for 10s or more.

2.Read LBC temperature information.

Is there a displayed value of temperature sensor quite large?

Yes >> confirm the series number of abnormal sensor, and GO TO 2.

NO >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".

2.Removal of Power Battery Assembly

1. Turn the key to "LOCK" or pull out.

2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".

3.Detect harness

1.Check the state of corresponding harness or connector of abnormal temperature sensor series number.

Check if the result is normal.

Yes >> Go to step 4

No>> back to normal connection.

4.Check the temperature sensor

Refer to “Components inspection”.

Check if the result is normal.

Yes>> GO TO 5.

No >> replace the abnormal temperature sensor.

Components inspection

1.Check the temperature sensor

1.Remove the temperature sensor.

2.Use multimeter to measure the resistance value in two ends of abnormal temperature sensor.

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	96	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	97	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	98	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	99	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	100	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	101	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	102	CT7	104	Refer to temperature table

Multimeter positive lead		Multimeter negative lead		Resistance value (Ω)
Connector	Terminal number	Connector	Terminal number	Refer to temperature table
CT7	103	CT7	104	Refer to temperature table

Temperature	Resistance value (Ω)
-20℃	75K
0℃	28K
25℃	10K
45℃	4.9K

Check if the result is normal.

Yes>> inspection end.

No >> replace the abnormal temperature sensor.

P311F CELL STATIC DIFFIRENTIAL PRESSURE TOO LARGE

DTC logic

DTC diagnostic logic

DTC number

Failure Name

DTC diagnostic conditions

The possible reasons for failure

P311F.

Alert of battery cell’s dynamic voltage difference

LBC detected the static voltage of cell is too large

l LBC

l High voltage connecting the copper bar

l Battery cell

l Voltage sample harness

DTC diagnostic procedures

1.Perform DTC confirmation procedure

1.Turn the key to "ON" , wait for more than 2 seconds.

2. Check the diagnostic results.

Whether DTC is detected ?

Yes >> Check out the "Diagnostic Procedure" below.

No >> Check finished.

Diagnostic steps

Warning:

l Before the maintenance switch is disconnected, the key must be placed in the "LOCK" or unplugged.

l When the maintenance switch is disconnected, the key is forbidden to "ON" or "START".

1.Use the "IEV diagnostic tool" inquiry LBC diagnostic service information

1.Turn the key to ON.

2. Check the diagnostic results.

Whether detected other DTC?

Detected P3134 >> Go to "P3134- diagnostic process."

P31AD is detected >> GO TO “P31AD-diagnosis flow”.

P31AB is detected >> GO TO “P31AB-diagnosis flow”.

No >> Go to step 2.

2.Use the "IEV diagnostic tool" inquiry LBC diagnostic service information

1.Check the serial number and voltage of abnormal battery cell.

3.Removal of Power Battery Assembly

1. Turn the key to "LOCK" or pull out.

2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".

1.Plug out the sampling harness of abnormal battery cell voltage, use multimeter to measure the corresponding sampling terminal of harness terminal, refer to “System Instruction-System-System Circuit Diagram”.

Multimeter positive lead	Multimeter negative lead	Whether it is consistent with the measured value of LBC.
Corresponding terminal of cell number.	The corresponding terminal of prior cell number.	Consistent（±10mV）

Check if the result is normal.

YES >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".

NO >> Replace battery cell, refer to the "dismantling and assembling the battery cell."

Powerbattery Assembly’sDisassembly and assembly

Power battery assembly

Exploded view

1. Power cell assy 2.iso-electrical connection bonding 3. Cell anti-collision beam 4. Power cell assy’s lower guard plate I

5. Plastic split cotter pin 6. Power cell assy's lower guard plate II 7. Power cell assy’s mounting bracket I

8. Power cell assy’s mounting bracket II

：N·m (kg-m,ft-lb)

Power cell assy’s disassemblyand assembly

Warning:

l 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

l
maintenance.

l Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

l Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress. Before operations on high-voltage system, be sure to wear insulation protection equipment, including gloves, shoes and glasses.

l When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START".

Refer to:

Power battery assembly “High Voltage Precautions”.

Removal of Power battery assembly

Warning:

Before operating high-voltage system Refer to "Overview - How to disconnect high voltage".

1 After lifting the vehicle, remove the anti-collision beam, lower guard plateⅠand Ⅱ.

2 Prepare a bucket, remove the water inlet and outlet aluminum base of the battery and the connecting pipe of the vehicle battery inlet and outlet pipe, keep the hose in the aluminum base of the battery inlet and outlet, and use the water bucket to catch the outflow coolant, which can be recycled. Do not pull out the high pressure and low pressure at this time, so as to prevent the coolant from polluting the connector and causing short circuit.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

To prevent shock hazard, be sure to wrap high voltage socket with insulated tape immediately after disassemble the battery pack.

3 Pull out the high voltage cable connector according to the following steps

4 Rotate metal sleeve anticlockwise to pull out low-voltage harness connector.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

5 Remove the mounting bolts of battery pack as the picture showed.And remove the A Bolt first.

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Warning:

DO NOT remove four C Bolts in the above picture.

6 Put the tray on the surface of lifting device.

7 Lift up the tray to the lower surface of battery and make them slightly contacted with each other.

Caution：

·Use transporting fixing bolts to fix the tray and battery pack.

8 Remove the mounting bolts of battery pack as the picture showed. And remove the B Bolt first.

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Warning:

DO NOT remove four C Bolts in the above picture.

9 Remove the fixing C Bolts of battery pack.。

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

10 Lower down the tray and remove the battery pack ① from the vehicle.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Installation of Power battery assembly

1 When replace a new battery pack, please refer to the following steps.

①Write down the replacing date on the sealed package of new battery pack.

②Divide the sealing strip with tracking date into two pieces, and stick on the battery pack and “Battery

②
Replace Record Sheet” respectively.

③Fill in the “Battery Replace Record Sheet”.

2 Mount two alignment pins ① in the position as shown in the picture.

: The front of the vehicle

3 Mount the battery in the vehicle body.

Aligning the battery pack ① with alignment pins ②.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

4 Mount fixing C bolts and remove the tray.

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

5 Remove the alignment pins from the vehicle body.

If the alignment pin ① is too tight to remove, please use a wrench to dismount.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

6 Mount fixing B Bolt of battery pack.

: The front of the vehicle

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

7 Mount fixing A Bolt of battery pack.

: The front of the vehicle

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

8 Rotate metal sleeve clockwise and insert the sleeve into low-voltage harness connector. Stop the insertion when the clicking sound appears.

9 Assemble the clamp ① between water-pipe assy’s flange and external pipelines.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

10 Mount the high voltage cable connector.

Connect the high voltage cable connector according to the following steps.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

11 Mount the lower protecting base Ⅰand Ⅱ of battery.

12 Install cell’s anti-collision beam.

13 Lower down the vehicle and fill the coolants according to the “maintenance routine” for air conditioner system.

14 Install the service switch Refer to "Overview - How to disconnect high voltage".

Inspection

Equipotential test

After mounting the battery pack, use multimeter to measure the resistance between battery housing and

vehicle body.

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Standard : ≤0.1Ω.

Removal and Installation of Power Battery Assembly

Power battery assembly

Explosive view

Power battery assembly

1. Service switch plug 2. Service switch socket 3. Upper housing assy

4. Sealer pad 5.LBC 6. LBC bracket

7. Right-front module assy 8.BDU upper housing 9. BDU pedestal

10. High-voltage harness connector 11. Sealer pad of high-voltage connector 12.sealer pad of low-voltage connector

13. High-voltage pedestal 14.low-voltage harness connector 15.sealer pad of high-voltage connector

16. Water pipe flange 17.left-front module assy 18.lower housing

19. Low-voltage harness assy 20. Rear module assy 21.flexible connection between modules

22. Fixing bracket of service switch 23. flexible connection between modules 24.sealer pad of fixing bracket of service switch 25. Quick-plug pipeline assy 26.stiffening plate of service switch

：Need to be replaced in every service time

：N·m (kg-m,ft-lb)

Left-front module assy

Right-26-series high-voltage guard cover I 2.copper bar of flexible connection between modules 3.Right-26-series high-voltage guard cover Ⅱ 4.right fixing parts of right-26-series 5.monitoring plate of thermal run-away 6.module’s pressing plate 7.pull rod of right-26-series 8. 5-Series cell module 9.left fixing parts of right-26-series 10.3-series cell module

：N·m (kg-m,ft-lb)

Module Layout

Rear module assy

Right-front module assy

Left-front module assy

Rear module assy

1. 44-Series outer cover plate I 2. 44-Series right fixing parts 3. 44-Series high-voltage guard cover I 4. 44-Series high-voltage guard plate II 5.copper bar of flexible connection betwenn modules 6. 4-Series cell module 7. 44-Series outer cover board II 8. 44-Series pull rod 9. 44-Series end plate 10. Epoxy plate 11. Monitor board of thermal runaway 12. 44-Series left fixing parts 13. 44-Series high-voltage guard cover III

：N·m (kg-m,ft-lb)
Module Layout

Rear module assy

Left-front module assy

Right-front module assy

BDU

BDUDisassembly and assembly

Warning:

l
maintenance.

l Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

l When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START".

Work Environment for Disassembly and Assembly of Power Battery Assembly

1 Must be an indoor environment

The work environment must be able to be isolated from the outside by shutters or other means to prevent

the intrusion of rain, snow, sand, and other substances.

The environment must be ventilated and prevent

the entry of sweat during work, and also prevent condensation from occurring as a result of high

temperature and humidity.

2 No entry of foreign materials

In addition to being indoors, the environment must not permit the entry during disassembly work of metal

powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.

If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take

other necessary steps.

3 The floor must be dry

The floor must not become wet as a result of causes such as vehicles entering when it is raining or

snowing.

4 Work Space

The size of work space should be about the size of a vehicle to assure the enough disassembly space.

An indicating sign or other measures must be taken during the disassembly so that persons other than the

workers do not enter the work space.

BDU Removal

1 Clean the dust and pollution on the surface of battery pack.

2 Remove the fixing reinforcing plate ① of service switch.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

3 Remove the fixing bolts A and nuts B according to the sequence, then remove the upper housing of power battery pack.

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

4 Plug out the BDU low voltage harness connector and remove the upper housing of BDU ①.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

5 Remove high voltage connecting nut of BDU front end, and then cut off the flexible connection ① of high voltage output.

Danger:

To prevent shock hazards during, please be sure to wear insulative protection gear.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

6 Remove high voltage connecting nut of BDU rear end, and then cut off the flexible connection ① of high

6
voltage input.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

7 Remove the BDU fixing bolts ①, and remove the BDU foundation support.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

Assembly of BDU

1.Mount the BDU foundation support and fix it on lower housing with bolts.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

2 Mount the high voltage connecting nut of BDU rear end.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

3 Mount the high voltage connecting nut of BDU front end.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

4 Tighten the fixing bolts and nuts according to the sequence in the following picture, then mount the upper housing of power battery pack.

: The front of the vehicle

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

5. Install the maintenance switch

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

BDU: check

Gas Tightness Inspection

1.Remove the vent valve, connect the air pump and the barometer at the same time

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

2.connect the air pump and the barometer

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

Carefully operate the gas-pressure meter to prevent the falling down.

3. Install the maintenance switch.Before testing, the high-pressure port and low-pressure port should be plugged with a special plug tool

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

4.Add 1.6-1.8kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.If the pressure drop is less than or equal to 0.2kPa, that is normal.

Caution：

Slowly operate the inflator during the inflating.

Do not let the air pressure exceed 1.8kPa.

5.If the pressure exceeds the limit, please use soapsuds to locate the leakage.

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

DO NOT let the soapsuds contact the service plug.

Equipotential test

After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）.

Standard : ≤0.1 Ω

Danger:

To prevent hazards during inspection, please be sure to wear protective gear.

Confirm Power Battery System State

1 Install power battery assembly

2 Connect the high voltage and low voltage connections between power battery assembly and the vehicle.

3 Turn off the service switch;

4 Connect the 12V battery negative cable.

5 Turn the key to “START” gear and confirm that the vehicle works normal.

LBC

LBCDisassembly and assembly

Warning:

l
maintenance.

l Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

l When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START".

Work Environment for Internal Disassembly and Assembly of Power Battery Assembly

1 Must be an indoor environment

The work environment must be able to be isolated from the outside by shutters or other means to prevent

the intrusion of rain, snow, sand, and other substances.

The environment must be ventilated and prevent

the entry of sweat during work, and also prevent condensation from occurring as a result of high

temperature and humidity.

2 No entry of foreign materials

In addition to being indoors, the environment must not permit the entry during disassembly work of metal

powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.

If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take

other necessary steps.

3 The floor must be dry

The floor must not become wet as a result of causes such as vehicles entering when it is raining or

snowing.

4 Work Space

The size of work space should be about the size of a vehicle to assure the enough disassembly space.

An indicating sign or other measures must be taken during the disassembly so that persons other than the

workers do not enter the work space.

Disassembly of LBC

1.Remove the battery pack, and please refer to “Disassembly and Assembly” of power battery assembly.

2.Remove the fixing reinforcing plate ①

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

3. Remove the fixing bolts A and nuts B according to the sequence, then remove the upper housing of power battery pack.

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

4. Disconnect the LBC low-voltage harness connector ①.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

5. Removal of LBC Set Bolt①.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

6 LBC Removal

LBC Assembly

The working flow of LBC assembly is opposite to the flow of disassembly.

1 Mount the LBC fixing bolts.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

2 Mount the LBC low voltage harness connector.

3 Tighten the fixing bolts and nuts according to the sequence in the following picture, then mount the upper housing of power battery pack.

: The front of the vehicle

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

5. Install the maintenance switch

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

Gas Tightness Inspection

1.Remove the vent valve, connect the air pump and the barometer at the same time

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

2.connect the air pump and the barometer

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

Carefully operate the gas-pressure meter to prevent the falling down.

3. Install the maintenance switch.Before testing, the high-pressure port and low-pressure port should be plugged with a special plug tool

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

4.Add 1.6-1.8kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.If the pressure drop is less than or equal to 0.2kPa, that is normal.

Caution：

Slowly operate the inflator during the inflating.

Do not let the air pressure exceed 1.8kPa.

5.If the pressure exceeds the limit, please use soapsuds to locate the leakage.

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

DO NOT let the soapsuds contact the service plug.

Equipotential test

After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）.

Standard : ≤0.1 Ω

Danger:

To prevent hazards during inspection, please be sure to wear protective gear.

Confirm Power Battery System State

1 Install power battery assembly

2 Connect the high voltage and low voltage connections between power battery assembly and the vehicle.

3 Turn off the service switch;

4 Connect the 12V battery negative cable.

5 Turn the key to “START” gear and confirm that the vehicle works normal.

Quick-plug pipeline assy

Disassembly and assembly of quick-plug pipeilne

Warning:

l
maintenance.

l Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

l When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START".

Work Environment for Internal Disassembly and Assembly of Power Battery Assembly

1 Must be an indoor environment

The work environment must be able to be isolated from the outside by shutters or other means to prevent

the intrusion of rain, snow, sand, and other substances.

The environment must be ventilated and prevent

the entry of sweat during work, and also prevent condensation from occurring as a result of high

temperature and humidity.

2 No entry of foreign materials

In addition to being indoors, the environment must not permit the entry during disassembly work of metal

powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.

If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take

other necessary steps.

3 The floor must be dry

The floor must not become wet as a result of causes such as vehicles entering when it is raining or

snowing.

prevent the coolant from dripping on floor during disassembly process, as the dripping will make the floor slippery.

4 Work Space

The size of work space should be about the size of a vehicle to assure the enough disassembly space.

An indicating sign or other measures must be taken during the disassembly so that persons other than the

workers do not enter the work space.
Disassembly of quick-plug pipeline assy

1 Clean the dust and pollutants on the surface of power battery.

2.Remove the fixing reinforcing plate ① of service switch.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Remove the fixing bolts A and nuts B according to the sequence, then remove the upper housing of power battery pack.

: The front of the vehicle

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

4 Plug out the BDU low-voltage harness connector and remove the upper housing of BDU ①.

5 Remove high-voltage connecting nut on BDU’s front end, and then cut off the flexible connection ① of high-voltage output.

Danger:

To prevent shock hazards during, please be sure to wear insulative protection gear.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

6 Remove the guard cover ① of high-voltage’s flexible connection on BDU’s rear-end.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

7 Remove the 4 fixing bolts ① of high-voltage connection on BDU rear end, then disconnect the flexible connections ②③ of high-voltage input.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

8 Remove the BDU fixing bolts ①, and dismantle the BDU pedestal support.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

9 disconnect all second locking device of quick-plug connector, then dismantle the branch pipe ① of water-outlet quick-plug pipeline on module’s front end.

10 disconnect main pipe ① and branch pipe ② of water-outlet quick-plug pipeline.

11 disconnect the connector and dismantle the main pipe ① of water-outlet quick-plug pipeline

12 disconnect all second locking device of quick-plug connector, then dismantle the branch pipe ② of water-outlet quick-plug pipeline.

13 Remove the high-voltage guard cover ①.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

14 dismantle the mounting bolt ① and ② of service switch’s bracket.

15 disassemble the mounting bolt ① of service switch, and dismantle the mounting bracket ② of service switch

16 disassemble the mounting bolt ① of service switch’s flexible connection, and dismantle the service switch assy.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

17 dismantle the high-voltage connecting guard plate ① and high-voltage guard cover ②.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

18 dismantle the mounting bracket ① of module high-voltage flexible connection, then disassemble the flexible connection ②.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

19 dismantle the high-voltage connecting guard plate ①.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

20 dismantle the mounting bracket ① of module high-voltage flexible connection, then disassemble the flexible connection ②.

Danger:

Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.

Warning:

To prevent hazards during disassembly, please be sure to wear insulating protective gear and

use insulating tools.

21 dismantle the quick-plug connector ① of water-inlet quick-plug pipeline, then disconnect branch pipe ② and the main pipe ③ of water-inlet quick-plug pipeline.

22 disconnect the connector and dismantle the main pipe ① of water-inlet quick-plug pipeline.

Assembly of quick-plug pipeline assy

1 Pre-insert branch pipe ① into module's liquid-cooling flat tube.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

2 Assemble rubber part ① on the main pipe of water-outlet quick-plug pipeline, then mount the pipeline assy on the pipe clamp.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

3 assemble the quick-plug connector ① on the aluminum pedestal.

Note：

During each disassembly/assembly process, ensure the assembling is firm and tight (the clip should be clamped into snap neck).

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

4 assemble the branch pipe ① of water-outlet quick-plug pipeline assy, then lock the locking device.

5 assemble the branch pipe ① of water-outlet quick-plug pipeline assy, then pre-insert module liquid-cooling flat tube.

6 connect the branch pipe ①, and main pipe ② of water-outlet quick-plug pipeline assy. Then assemble the branch pipe ① and lock the locking device.

7 assemble the branch pipe ① of front module’s water-inlet quick-plug pipeline.

8 assemble the rubber part ① on the main pipe of water-inlet quick-plug pipeline.

9 assemble the branch pipe ① of rear module's water-inlet quick-plug pipeline assy

10 assemble the branch pipe ① and main pipe ② of rear module’s water-inlet quick-plug pipeline assy.

Air tightness check of pipeline assy

1 assemble barometer (A).

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

Carefully operate the gas-pressure meter to prevent the falling down.

2. Inflate quick-plug pipeline assy with air until the air pressure reaches to 250KPa. Maintain the pressure for 300 seconds, and the air-leak amount should be 5KPa.

Caution：

· during inflating process, please operate gas-leak detecting device slowly.

· do not make pressure exceed 250KPa.

Maintenance limit:245KPa

6 if the pressure exceeds limit value, please replace quick-plug pipeline assy.

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Gas Tightness Inspection

1.Remove the vent valve, connect the air pump and the barometer at the same time

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

2.connect the air pump and the barometer

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

Carefully operate the gas-pressure meter to prevent the falling down.

3. Install the maintenance switch.Before testing, the high-pressure port and low-pressure port should be plugged with a special plug tool

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

4.Add 1.6-1.8kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.If the pressure drop is less than or equal to 0.2kPa, that is normal.

Caution：

Slowly operate the inflator during the inflating.

Do not let the air pressure exceed 1.8kPa.

5.If the pressure exceeds the limit, please use soapsuds to locate the leakage.

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

DO NOT let the soapsuds contact the service plug.

Equipotential test

After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）.

Standard : ≤0.1 Ω

Danger:

To prevent hazards during inspection, please be sure to wear protective gear.

Confirm Power Battery System State

1 Install power battery assembly

2 Connect the high voltage and low voltage connections between power battery assembly and the vehicle.

3 Turn off the service switch;

4 Connect the 12V battery negative cable.

5 Turn the key to “START” gear and confirm that the vehicle works normal.

Left-front module assy

Left-front module assy’s disassemble andassembly

Warning:

l
maintenance.

l Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

l When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START".

Work Environment for Internal Disassembly and Assembly of Power Battery Assembly

1 Must be an indoor environment

The work environment must be able to be isolated from the outside by shutters or other means to prevent

the intrusion of rain, snow, sand, and other substances.

The environment must be ventilated and prevent

the entry of sweat during work, and also prevent condensation from occurring as a result of high

temperature and humidity.

2 No entry of foreign materials

In addition to being indoors, the environment must not permit the entry during disassembly work of metal

powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.

If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take

other necessary steps.

3 The floor must be dry

The floor must not become wet as a result of causes such as vehicles entering when it is raining or

snowing.

4 Work Space

The size of work space should be about the size of a vehicle to assure the enough disassembly space.

An indicating sign or other measures must be taken during the disassembly so that persons other than the

workers do not enter the work space.

Disassembly of left-front module assy

1 Clean the dust and pollutants on the surface of power battery.

2 Remove the fixing reinforcing plate ① of service switch.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

3 Please dismantle the bolt ① and nut ② by following instructions on the picture below, then dismantle the upper housing of power battery assy.

: vehicle’s front-end

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

4 Disassemble BDU. Please refer to “disassembly and assembly of BDU” for details.

Danger:

There still will be risk of shock even you touch the high voltage components with protective

gear.

5 Disassemble the copper bar ① connecting left-front module and BDU, and high-voltage guard cover ②.

Danger:

There still will be risk of shock even you touch the high voltage components with protective

gear.

Warning:

To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly.

6 Disassemble the flexible connection ① between left-front module assy and rear module assy.

Danger:

There still will be risk of shock even you touch the high voltage components with protective

gear.

Warning:

To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly.

7 Disassemble the upper cover ① and flexible connection ② between left-front module assy and right module assy.

Danger:

There still will be risk of shock even you touch the high voltage components with protective

gear.

Warning:

To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly.

8 Plug out the connector A of LBC low-voltage harness.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

9 Disassemble the upper cover ① of harness fixing plate, then remove lower cover ② and low-voltage harness ③.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

10 Disassemble the upper cover ① of harness fixing plate, then remove low-voltage harness connector ② on module's front-end and low-voltage harness ③.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

11 Disassemble fixing bolt ① of service switch bracket, and remove the bracket ② of service switch’s flexible connection.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

12 Disassemble left-front module’s quick-plug pipeline ① on front end, and ② on rear end. Please refer to “quick-plug pipeline” for details.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

13 Disassemble fixing bolt ① of left-front module’s metal plate.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

14 Disassemble the fixing nut ① of left-front module assy.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

15 Remove left-front module assy, and put the module assy on workbench.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Make sure that a piece of insulation paper has been placed on the working table.

16 Disassemble the high-voltage connection of left-front module assy by following the steps below.

①　Disassemble the guard cover ① of left-front module assy.

Danger:

There still will be risk of shock even you touch the high voltage components with protective

gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

②　Disassemble the copper bar ① of module’s flexible connection.

Danger:

There still will be risk of shock even you touch the high voltage components with protective

gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

17 Disassemble the fixing nut ① of left-front module assy, then remove the fixing part ② on left and right side.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

18 Disassemble the fixing nut ① of left-front module’s pull rod, then remove the pull rod and the metal plate of left-front module assy.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Installation of left-front module assy

Hint The assembling procedures of left-front module assy is opposite to the disassembling procedures.

1. Assemble left-front battery module assy according to position shown in picture, then tighten the long pull-rod on module’s front and rear end.

Danger:

To prevent shock hazards during, please be sure to wear insulative protection gear.

Warning:

To prevent shock hazards, be sure to wrap the connection terminal with insulated tape, so as to prevent electric shock during assembling process.

2. Assemble side metal plate ① of left-front battery module.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

3. Assemble the fixing parts on left-front module’s two sides1.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

4. Assemble hexagon flange locking nut ① of non-metallic inserts on left-front module assy.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

5. Assemble high-voltage guard cover and flexible connection ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

6. Assemble left-front module’s quick-plug pipeline ① on front end, and ② on rear end.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Gas Tightness Inspection

1.Remove the vent valve, connect the air pump and the barometer at the same time

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

2.connect the air pump and the barometer

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

Carefully operate the gas-pressure meter to prevent the falling down.

3. Install the maintenance switch.Before testing, the high-pressure port and low-pressure port should be plugged with a special plug tool

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

4.Add 1.6-1.8kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.If the pressure drop is less than or equal to 0.2kPa, that is normal.

Caution：

Slowly operate the inflator during the inflating.

Do not let the air pressure exceed 1.8kPa.

5.If the pressure exceeds the limit, please use soapsuds to locate the leakage.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Caution：

DO NOT let the soapsuds contact the service plug.

Equipotential test

After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）.

Standard : ≤0.1 Ω

Danger:

To prevent hazards during inspection, please be sure to wear protective gear.

Confirm Power Battery System State

1 Install power battery assembly

2 Connect the high voltage and low voltage connections between power battery assembly and the vehicle.

3 Turn off the service switch;

4 Connect the 12V battery negative cable.

5 Turn the key to “START” gear and confirm that the vehicle works normal.

Rear module assy

Rear module assy’s disassemblyand assembly

Warning:

l
maintenance.

l Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.

l When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START".

Work Environment for Internal Disassembly and Assembly of Power Battery Assembly

1 Must be an indoor environment

The work environment must be able to be isolated from the outside by shutters or other means to prevent

the intrusion of rain, snow, sand, and other substances.

The environment must be ventilated and prevent

the entry of sweat during work, and also prevent condensation from occurring as a result of high

temperature and humidity.

2 No entry of foreign materials

In addition to being indoors, the environment must not permit the entry during disassembly work of metal

powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.

If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take

other necessary steps.

3 The floor must be dry

The floor must not become wet as a result of causes such as vehicles entering when it is raining or

snowing.

4 Work Space

The size of work space should be about the size of a vehicle to assure the enough disassembly space.

An indicating sign or other measures must be taken during the disassembly so that persons other than the

workers do not enter the work space.

Disassembly of rear module assy

1 Clean the dust and pollutants on the surface of power battery.

2 Remove the fixing reinforcing plate ① of service switch.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

3 Please dismantle the fixing bolt ① and nut ② by following instructions on the picture below, then dismantle the upper housing of power battery assy.

: vehicle’s front-end

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

4 Pull out the low-voltage harness connector ① of rear battery module assy.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

5 Remove the fixing snap joint ① of low-voltage main harness on rear module assy, then remove the low-voltage main harness ②.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

6 Disassemble the high-voltage guard cover ① and flexible connection ② between left-front&right-front module assy and rear module assy.

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

Warning:

To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly.

7 Disassemble fixing bolt ① of service switch bracket, and remove the bracket ② of service switch’s flexible connection.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear

8 Disassemble the high-voltage guard cover A of flexible connection between rear module assy and service switch. Then remove flexible connection B and C.

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

Warning:

To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly.

9 Disassemble the rear module’s quick-plug pipeline ① on upper-end, and ② on lower-end. Please refer to “quick-plug pipeline” for details.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear

10 Dismantle rear module assy’s fixing part and lower housing assy’s fixing bolt A and B.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear

11 Remove rear module assy ①, then place the assy on workbench.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Make sure that a piece of insulation paper has been placed on the working table.

12 Please disassemble the flexible connection of rear module assy by following steps below:

① Disassemble the copper bar ① of flexible connection by dismantling the fixing bolt.

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

② Disassemble the high-voltage guard cover ① and its fixing bolt on the rear module assy, then remove the flexible connection’s copper bar.

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

13 Disassemble the fixing nut ① of left fixing parts on rear module assy.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear

14 Disassemble the fixing nut ① of right fixing parts on rear module assy.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

15 Disassemble the fixing nut of rear module assy’s pull rod, then remove the pull-rod ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear

16 16 remove the module ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear

Assembly of rear module assy

Caution：

When replacing module assy, please perform equalizing charge to the module. Please refer to “module’s equalizing charge” for details.

1 When the module is replaced, please perform the following steps:

①Write down the replacing date on the sealed package of new battery pack.

②Divide the sealing strip with tracking date into two pieces, and stick on the battery pack and “Battery

②
Replace Record Sheet” respectively.

③Fill in the “Battery Replace Record Sheet”.

2 Assemble the rear module assy by following steps below.

①Assemble the rear module assy by following the arrangements of module’s anode&cathode shown in picture. Then tighten the long pull-rod on module’s two sides.

A. Rear module assy

: The front of the vehicle

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

②Check the assembling condition for battery module. Make sure the assembling process is carried out with correct installation method.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

3 Fix the left fixing parts ①.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

4 Fix the right fixing parts ①.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

5 Install the flexible connection of rear module assy according to the following steps:

①Assemble the copper bar ① of front/rear flexible connection.

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

② High-voltage guard cover ① of rear flexible connection.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

Caution：

Make sure that there is no error of mounting positions.

Make sure that the connection place is not loosening up after assembly.

6 Assemble the bolt A and nut B of rear module assy

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

7 Assemble the rear module’s quick-plug pipeline ① on upper-end, and ② on lower-end.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

8 Assemble the bracket ① of service switch’s flexible connection.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

9 Assemble the connecting strip B, C and the high-voltage guard cover A on service switch

截图07

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Caution：

Make sure that there is no error of mounting positions.

Make sure that the connection place is not loosening up after assembly.

10 Assemble the flexible connection ② and high-voltage guard cover ① of rear module assy.

Danger:

The risk of electric shock still exists even when you touch high-voltage parts with protective gear.

Perform the operation alone. Operations by multiple people may cause electric shock.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Caution：

Make sure that there is no error of mounting positions.

Make sure that the connection place is not loosening up after assembly.

11 Assemble the low-voltage main harness ② of rear battery module assy.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

12 Tighten the fixing bolts and nuts according to the sequence in the following picture, then mount the upper housing of power battery pack.

: The front of the vehicle

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

13 Install the maintenance switch’s reinforcing plate1.

Warning:

To prevent hazards during assembly, please be sure to wear protective gear.

Gas Tightness Inspection

1.Remove the vent valve, connect the air pump and the barometer at the same time

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

2.connect the air pump and the barometer

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

Caution：

Carefully operate the gas-pressure meter to prevent the falling down.

3. Install the maintenance switch.Before testing, the high-pressure port and low-pressure port should be plugged with a special plug tool

Warning:

To prevent hazards during inspection, please be sure to wear protective gear.

4.Add 1.6-1.8kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.If the pressure drop is less than or equal to 0.2kPa, that is normal.

Caution：

Slowly operate the inflator during the inflating.

Do not let the air pressure exceed 1.8kPa.

5.If the pressure exceeds the limit, please use soapsuds to locate the leakage.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Caution：

DO NOT let the soapsuds contact the service plug.

Equipotential test

After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）.

Standard : ≤0.1 Ω

Danger:

To prevent hazards during inspection, please be sure to wear protective gear.

Confirm Power Battery System State

1.Mount the battery pack.

2.Connect the high-voltage and low-voltage connections between battery and the vehicle.

3.Turn off the service switch.

4.Connect the negative terminal of 12V battery.

5.Turn the key to “START” gear and confirm that the vehicle works normal.
Disassembly and assembly of battery cell

Disassembly and assembly of battery cell

Warning:

l Before the maintenance switch is disconnected, the key must be placed in the "LOCK" or unplugged.

Work Environment for Internal Disassembly and Assembly of Power Battery Assembly

1 Must be an indoor environment

The work environment must be able to be isolated from the outside by shutters or other means to prevent

the intrusion of rain, snow, sand, and other substances.

The environment must be ventilated and prevent

the entry of sweat during work, and also prevent condensation from occurring as a result of high

temperature and humidity.

2 No entry of foreign materials

In addition to being indoors, the environment must not permit the entry during disassembly work of metal

powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.

If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take

other necessary steps.

3 The floor must be dry

The floor must not become wet as a result of causes such as vehicles entering when it is raining or

snowing.

4 Work Space

The size of work space should be about the size of a vehicle to assure the enough disassembly space.

An indicating sign or other measures must be taken during the disassembly so that persons other than the

workers do not enter the work space.

Disassembly and assembly of battery cell

1 To disassemble module assy, please refer to “disassembly and assembly of left-front module assy” and “disassembly and assembly of rear module assy” for details.

2 Prepare auxiliary line-drawing fixture for the disassembly of battery cell.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

3 Place the fixture on the upper side of cell cathode’s aluminum plate hole.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

4 Use the auxiliary line-drawing device to draw up a round line ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

5 Prepare small sander ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

6 Polish the surface of the aluminum plate, ABS plate and cell under the round line ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

7 Use plastic stick ① and rubber hammer to pound out the battery cell from cell’s anode to cathode.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

8 Apply fixing glue on the battery cell’s surface, then clean the redundant glue.

9 Use plastic stick to place electrode on the collector plate ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

10 Use laser-weld to weld up the aluminum terminal on battery cell’s anode ①.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

11 Use laser-weld to weld up the aluminum terminal on battery cell’s cathode.

12 clean the module's upper surface.

Warning:

To prevent hazards during disassembly, please be sure to wear protective gear.

Maintenance data and instructions

Maintenance data and instructions

Power Batteryassembly

Items	Instruction
Type	Ternary li-ion battery
Structure	42 parallel 96 series (4032 cells)
Voltage platform (V)	About 345.6
Weight (kg)	About 318

Profile Size	a（mm）	1176
	b（mm）	1039
	c（mm）	315
	d（mm）	1301

Tool name		Use description
Voltage Balancing Equipment		Voltage balance
Battery’s lifting table		Battery Lifter
Grinding machine		Polished battery cell

Tool name		Use description
Insulated gloves (To ensure the protection of an electricity of 1000V / 300A)		Disassembly and assembly of the high voltage parts
Leather gloves (Using leather gloves that can tighten the wrist)		1. Disassembly and assembly of high voltage parts 2. Protect insulated gloves
Insulated shoes		Disassembly and assembly of the high voltage parts
Protection glasses		Disassembly and assembly of the high voltage parts Prevent flares and protect eyes while repairing circuits
Insulated caps		Disassembly and assembly of the high voltage parts
Insulation Tester (Megohm meter)		Measuring voltage and insulation resistance
Energy-saving wrench		Module assembly
Electric wrench		Disassembly of spare parts

Sequence	Component	Function
1	Power battery assembly	Refer to “Power battery assembly”section
2	Service switch;	Refer to “Service Switch”Section
3	Left-front module assy	Refer to “left-front module assy” section
4	Temperature sensor 7	Refer to “Temperature Sensor”Section
5	Temperature sensor 1	Refer to “Temperature Sensor”Section
6	Temperature sensor 5	Refer to “Temperature Sensor”Section
7	Temperature sensor 4	Refer to “Temperature Sensor”Section
8	Temperature sensor 3	Refer to “Temperature Sensor”Section
9	Rear module assy	Refer to “rear module assy” section
10	Temperature sensor 8	Refer to “Temperature Sensor”Section
11	Quick-plug pipeline assy	Refer to “quick-plug pipeline assy”section
12	Temperature sensor 2	Refer to “Temperature Sensor”Section
13	Right-front module assy	Refer to “right-front module assy” section
14	Battery cut off unit	Refer to “Battery Cut Off Unit”Section
15	Temperature sensor 6	Refer to “Temperature Sensor”Section
16	Temperature sensor 9	Refer to “Temperature Sensor”Section
17	Battery controller	Refer to “Battery controller”Section

Multimeter positive lead	Multimeter negative lead	Whether conducted
One end of service plug	The other end of service plug	Conducted

Multimeter positive lead	Multimeter negative lead	Whether conducted
One end of service plug	The other end of service plug	Conducted

Multimeter positive lead	Multimeter negative lead	Voltage value
12V Lead-Acid battery positive	12V Lead-Acid battery negative	Approximate 12V

Multimeter positive lead		Multimeter negative lead		Connectivity
BDU(Current Sensor)		LBC
Connector	Terminal number	Connector	Terminal number
15326815	A	1318756-1（J5）	12	Conduction
	B		11
	C		3
	D		4

Safety Precaution

Battery Distribute Unit (BDU)

DiagnosticSteps

P31B2, P315D critical insulation failure, insulation failure

DiagnosticSteps

DiagnosticSteps

P31A9 serious battery discharge over-currentfault

P316E HIGH VOLTAGE INTERLOCKING ERROR

P3128 current sensorfault

Powerbattery Assembly’sDisassembly and assembly

LBCDisassembly and assembly