Safety prevention

Cautions for electrical technicians using medical electrics

Forbidden operation

Warning：

● There is strong magnetic components on this vehicle

● If technician use medical electrics,e.g electronic pacemakers, which couldn’t be operated in the vehicle ,otherwise,the function of electrics may be effected by strong magnetic components.

Cautions for normal charge

Warning:

● If technician use the medical electrics like pacemakers, cardiovascular, in addition to the top, the machine only could be used after the function of machine checked and confirmed before normally operation.

● In the normal charging operation, Medical electrics may be affected by electromagnetic wave. When Technicians use the medical electrics like pacemakers, cardiovascular, in addition to the top etc, it is not allowed to enter into crew capsule (including luggage).

Cautions for communication equipment

● If technicians use the medical electrics like pacemakers, cardiovascular, in addition to the top etc, please keep enough distance with the communication equipment.

● Remote intelligent terminal of electromagnetic waves may affect the function of the medical electrics like pacemakers, cardiovascular, in addition to the top etc.

● If technicians use the medical electrics like pacemakers, cardiovascular, in addition to the top etc, remote intelligent terminal of electromagnetic waves may affect the function of the medical electrics. It is needed to let the manufacturer of the medial electrics confirm that the possible affection to medical electric equipment when using remote intelligent terminal .

Keypoint checking before maintenance

High pressure system can be run automatically, it is need to confirm that remote air conditioning and recharged regularly are not set before maintenance.

Cautions：

● If set remote air-conditioner or charged regularly, even though the switch is closed, high pressure system can be run automatically.

Cautions for "safety airbag"and"safety belt preloaded"of auxiliary constraint system

The combination use of "safety airbag"and"safety belt preloaded"of auxiliary constraint system and front seat belt could decrease the damage to driver and passengers when collision. The auxiliary constraint system include seat belt, airbag for driver, airbag for co-driver. The detailed information for auxiliary constraint system could refers to the sections of “airbag system” and “seat belt”

Warning:

To avoid unexpected accident, we need to obey the following:

● To avoid the auxiliary constraint system invalid, all the maintenance only could be operated by JAC authorized distributors because the risk of injury to people will be increased after invalid.

● Non-standard auxiliary constraint system of maintenance including non-standard disassembly and installation, may result in auxiliary constraint system accident triggered, causing personal injury accidents. About remove the airbag module method, please see "airbag system" section.

● In addition to the maintenance instructions in the manual operation, do not use electrical test equipment to test any circuit of auxiliary constraint system. Auxiliary constraint system of connectors and wiring harness use yellow or orange color.

Cautions when use electrical tools (pneumatic or electric)and hammer

● when electric switch in the "ON" block, near the airbag diagnostic sensors or other sensor, do not use power tools or hammer to operate sensor parts area. Severe vibration may activate the sensor, some airbags, causing serious damage.

● When using power tools or hammer, put the keys in the "LOCK" block, unplug the 12 v lead-acid battery cathode, waiting at least 1 minute, then for checking and maintenance.

Cautions for removing 12V battery

Turn the key to “on”,then to “lock” before remove 12v battery

Tip:

● Even if the key in the "LOCK" and the 12 v battery charging function may start automatically.

● After turn the key to "ON" --> "LOCK", 12 v battery automatic charging will not start.

Cautions for steering control system

● When turn steering wheel quickly,could hear the noise around steering wheel, which is the voice of the steering control system to work normally. If turn the steering wheel slowly , appear harsh noise, which is regarded as the abnormal phenomena. If yes, please repair.

Preparation work

Special tools

The actual tool shape may be different from illustration shown.

Tool	Diagram	Instruction
Diagnostic instrument X-431		ABS system fault diagnosis

System description

Component layout

1 Steering wheel assembly	2 Steering column	3 EPS motor
4 EPS controller	5 steering shaft with universal joint assembly	6 Steering assembly

System principle

System principal diagram

Description

EPS controller receives the speed signal, the electrical signal, steering torque signal, control EPS motor and provide the best power steering torque .

Electric booster steering system fault warning light

Turn the key to "START" from the "LOCK", ,the vehicle at “READY” status, steering control system self-check. If it is normal, the system enter the working state; If not, electric booster steering system fault warning lights lit, the system has no power.

When steering control system is failure, electrical booster steering system fault warning light lit, start safety-invalid mode.

Condition	electrical booster steering system fault warning light
After “READY”	Light off
Start vehicle	Light off
Steering control system fault	Light on

Safety- invalid

System fault, electric booster steering system fault warning lights lit, entering into no power or small power steering mode (steering wheel steering force will be heavier).

There is only speed signal fault, entering into small power mode, the steering force becomes obviously heavy.

Protective function

Overload using steering function (such as continuous turning in the same place), temperature of EPS controller and EPS motor rise fast, when the temperature reached set value, EPS controller control of EPS motor, reduce the working current, (overload protection).At this time, the steering force becomes obviously heavy,which is normal. Once temperature is reduced to set data, power function will recover.

Electrical principle

Stitch definition

Stitch no	Definition	Measuring status	Reference	Remark
1	Power signal（-）,ground		0V
2	Power signal（+）		9-16V
3	Motor output（-）	No moving for steering wheel	5-7V
4	Motor output（+）	No moving for steering wheel	5-7V
5	Sensor main angle signal（PWM-P）	Key is in “ON”,steering wheel is in the middle	2.5±0.05V
6	Sensor vice angle signal（PWM-S）	Key is in “ON”,steering wheel is in the middle	2.5±0.05V
7	Sensor torque pulse width signal1（PWM-T1）	Key is in “ON”,steering wheel is in the middle	2.5±0.05V
8	Sensor torque pulse width signal 2（PWM-T2）	Key is in “ON”,steering wheel is in the middle	2.5±0.05V
9	Power 1 （VCC1）	Key is in “ON”	5V
10	Grounding 1（GND1）	Key is in “ON”	0V
11	Power 2（VCC2）	Key is in “ON”	5V
12	Grounding 2（GND2）	Key is in “ON”	0V
17	Electrical signal	Key is in “ON”	12V
19	CAN-L
20	CAN-H

Fault code reading

Steering control system fault, fault is stored within the EPS controller, which could read through diagnosis instrument or "flash code" .

Serial No	Fault code	Description
1	C1611	Main signal of torque sensor is out of range
2	C1612	Vice signal of torque sensor is out of range
3	C1613	Main signal and vice signal of torque sensor is out of range
4	C1614	Torque sample with too long time.
5	C1615	Angle abnormal fault
6	C1317	Angle zero unlearning
7	C1621	Battery voltage too high
8	C1622	Battery voltage too low
9	C1632	EEPROM data consistency fault
10	C1641	Speed invalid fault
11	C1643	Electrical signal loss
12	C1651	Motor short circuit fault
13	C1661	Relay open
14	C1662	Current sensor-calibration fault of current middle
15	C1663	Current sensor-over current
16	C1664	+5VA voltage fault
17	C1665	EPS controller- inner fault
18	C1667	Temperature sensor-MOSFET overheat
19	U1000	CAN-BUSOFF fault or report sending overtime
20	U1001	Vehicle READY signal report overtime
21	U1002	Speed signal report accepting overtime

Basic check

Diagnostic and maintenance process

Fault diagnostic process details

1 Collect customer information

Before check, carefully ask customer concerns or driving vehicles together with the customer which is very important for solving the problem.

2 Check symptom

According to the information collected through interviewing with the customer ,reappear information of customer specified symptoms. Check whether the symptoms caused by the failure mode.

Caution:

When symptoms are caused by normal operation, please fully inspect each related parts and let customers understand the symptoms are normal.

3 Check electrical booster steering system fault warning light. Please see “electrical booster steering system fault warning light check”

4 EPS fault diagnosis and maintenance

Diagnose whether there is fault code with diagnostic instrument ;

Yes>>record and delete fault code, turn to “fault code, electrical line fault diagnosis”

No>> turn to “Normal symptom and analysis”

Diagnosis working list

In general, customers have their own judgment standard to a problem. Therefore, careful enough to ask to understand customer's concern is very important. Preparing interview list make diagnostic information systematic. Some times, many conditions occur at the same time resulting in failure.

Interview list sample

Interview list
Customer name	Gender	Plate No	Original registered date
		Model	VIN
Production date		Motor power	Mileage	km
Symptom		□Steering wheel is not in the middle
		□Electrical booster steering system fault warning light on
		□noise □vibration
		□others（）
Firstly appear		□recently □other（）
Appearing frequency		□always □regular □sometimes（ times/day）
Climate condition		□no relation
	weather	□sunny □cloudy □rainy □snow □others（）
	temperature	□hot □warm □Cool □Cold □temperature (about ℃）
	comparative humid	□high高 □normal □low
Road conditions		□city road □suburb □highway □Mountain road □non-paving road
Operation conditions etc		□no relation □Drive motor startup □Unload □Driving □Speedup □ drive with same speed □decrease speed □turning □steering wheel turning
Other conditions
Remark

Fault code、circuit fault diagnosis

Torque sensor of C1611 、C1612、C1613、C1614、C1317

Fault	Item	Instruction	Possible reason
C1611	Torque sensor	Main signal of torque sensor is out of range	Harness or connectors Torque sensor EPS controller
C1612	Torque sensor	Vice signal of torque sensor is out of range
C1613	Torque sensor	Main signal and vice signal of torque sensor is out of range
C1614	Torque sensor	Torque sample with too long time.
C1615	Torque sensor	Angle abnormal fault
C1664	Torque sensor	+5V power fault

1 Preparation work

If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.

2 Check whether EPS controller pins and wiring harness connector damage or loose.

Yes>> repair or replace. Next step.

No>> Next step

3 Perform self-diagnosis

① Delete fault code

② Put the key on "LOCK" block, waiting for more than 10 s.

③ Put the key on "ON" block,

④ Check whether fault code exists.

Yes>> next step

No >> finish diagnosis

4 Replace EPS controller, check whether fault code exists.

Yes>> torque sensor fault. Please replace steering column.

No >> finish diagnosis

Speed signal C1641、U1002

Fault

Item

Instruction

Possible reason

C1641

Speed signa

Speed signl invalid fault

Harness or connectors

ABS

EPS controller

U1002

Speed signa

Speed signal accepting overtime

1 Preparation work

If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.

2 Check whether EPS controller pins and wiring harness connector damage or loose.

Yes>> repair or replace. Next step.

No>> Next step

3 Perform self-diagnosis

① Delete fault code

② Put the key on "LOCK" block, waiting for more than 10 s.

③ Put the key on "ON" block,

④ Check whether fault code exists.

Yes>> next step

No >> finish diagnosis

4 Check ABS and ground eletrical line of electric control unit

Carry out ABS diagnosis. Please see “Brake control system-fault diagnosis”to check whether there is fault.

Yes>> repair or replace.

No >> next step, finish diagnosis

5 Replace EPS controller, check whether fault code exists.

Yes>> repair or replace.

No >> finish diagnosis

EPS motor C1651

Fault

Item

Instruction

Possible reason

C1141

EPS motor

Motor short circuit

Harness or connectors

EPS motor

EPS controller

1 Preparation work

If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.

2 Check whether EPS controller pins and wiring harness connector damage or loose.

Yes>> repair or replace. Next step.

No>> Next step

3 Perform self-diagnosis

① Delete fault code

② Put the key on "LOCK" block, waiting for more than 10 s.

③ Put the key on "ON" block,

④ Check whether fault code exists.

Yes>> next step

No >> finish diagnosis

4 Replace EPS controller, check whether fault code exists.

Yes>> EPS motor fault, replace steering column.

No >> finish diagnosis

EPS controller C1632、C1661、C1662、C1665、C1667

Fault	Item	Instruction	Possible reason
C1632	EPS controller	EEPROM data consistency of failure	EPS controller
C1661	EPS controller	Relay open
C1662	EPS controller	calibration error Of current middle point
C1663	EPS controller	Current sensor overflow
C1665	EPS controller	The control unit internal fault
C1667	EPS controller	MOSFET overheating fault

1 Preparation work

If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.

2 Check whether EPS controller pins and wiring harness connector damage or loose.

Yes>> repair or replace. Next step.

No>> Next step

3 Perform self-diagnosis

① Delete fault code

② Put the key on "LOCK" block, waiting for more than 10 s.

③ Put the key on "ON" block,

④ Check whether fault code exists.

Yes>> next step

No >> finish diagnosis

4 Replace EPS controller

Battery voltage fault C1621、C1622

Fault

Item

Instruction

Possible reason

C1621

Battery voltage

Battery voltage too high ＞17.5V

Harness or connectors

EPS controller

fuse

Power supply circuit

12V battery

C1622

Battery voltage

Battery voltage fault

1 Preparation work

If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.

2 Check whether EPS controller pins and wiring harness connector damage or loose.

Yes>> repair or replace. Next step.

No>> Next step

3 Perform self-diagnosis

① Delete fault code

② Put the key on "LOCK" block, waiting for more than 10 s.

③ Put the key on "ON" block,

④ Check whether fault code exists.

Yes>> next step

No >> finish diagnosis

4 Check EPS controller grounding circuit.

① Put the key on “LOCK”block.

② Remove the EPS controller power port connector, check whether the wire end pin correspondence with the power port 1 is through with ground.

Yes >> Next step

No > > grounding circuit open circuit or short circuit. Repair or replacement, the implementation of the self-diagnosis

5 Check EPS controller power supply circuit

① Connect connectors of EPS controller at power terminal, put the key on "ON" block.

② Respectively check whether voltage between wiring harness and ground of corresponding EPS controller power port 2 and vehicle signal port 17 is normal.

Yes >> Next step

No > > harness open circuit or short circuit. Repair or replacement, the implementation of the self-diagnosis

6 Replace EPS controller.

CAN communication U1000

Fault

Item

Instruction

Possible reason

U1000

CAN communication

BUS-OFF fault or CAN report sending overtime

CAN communication

EPS controller

1 Preparation work

If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.

2 Check whether EPS controller pins and wiring harness connector damage or loose.

Yes>> repair or replace. Next step.

No>> Next step

3 Perform self-diagnosis

① Delete fault code

② Put the key on "LOCK" block, waiting for more than 10 s.

③ Put the key on "ON" block,

④ Check whether fault code exists.

Yes>> next step

No >> finish diagnosis

4 Check CAN communication system, please see “Electric tumble sub-manual - CAN communication system ", detect if there is a fault .

Yes>> repair or replace.

No>> Next step

5 Replace EPS controller,check whether fault code exists.

Yes>> repair or replace.

No>> Finish diagnosis

Common symptom and analysis

Steering heavily or too light

1 Carry out self-diagnosis, check whether self-diagnosis result has fault code.

Yes >>EPS fault diagnosis and maintenance.Next step.

No>> Turn to 3

2 Check symptom

Check whether there is abnormal symptom such as “heavier”or “too light”

Yes>> Next step

No >> diagnosis finish

3 Check torque sensor

Check whether the voltage between terminal 7 and 10 of torque sensor is normal.

Yes>> check and adjust steering wheel steering force. Please see”steering system- basic check”.

No>> Replace steering column.

Different steering force for left and right

1 Carry out self-diagnosis, check whether self-diagnosis result has fault code.

Yes >>EPS fault diagnosis and maintenance.Next step.

No>> Turn to 3

2 Check symptom

Check whether it is different for the steering force for left and right.

Yes>> Next step

No >> diagnosis finish

3 Front wheel alignment check

Check whether it is normal for wheel alignment. Please see “ front suspension-wheel alignment”.

Yes>> check and adjust steering wheel steering force. Please see “ check steering wheel steering force”.

No>> wheel alignment. Turn to 2.

Vibration of steering force

1 Carry out self-diagnosis, check whether self-diagnosis result has fault code.

Yes >>EPS fault diagnosis and maintenance.Next step.

No>> Turn to 3

2 Check symptom

Check whether steering force vibrate.

Yes>> Next step

No >> diagnosis finish

3 Check the connection of steering shaft with universal joint is normal.

Yes>> check and adjust steering wheel steering force. Please see “ check steering wheel steering force”.

No>> Maintenance or replace. Turn to 2.