MEEY High-voltage System Service Manual

MEEY High-voltage System Service

Manual

Prepared by: Date:

Section chief: Date:

Battery Application Section: Date:

Power Application Section: Date:

High Voltage Control Section: Date:

High Voltage Safety Research Section: Date:

Project manager: Date:

Department manager： Date:

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Revision History
Version Date of Drafted Reviewed
Summary of Revised Content Approve
No. Implementation by by
001 First issue

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 MEEY High-voltage System Service Manual

Contents

Contents .............................................................................................................................................. 3
1 Scope of application and high voltage safety operation specification......................................... 5
1.1 Scope of Application ..................................................................................................... 5
1.2 High voltage safety operation specification .................................................................. 5
2 Terms and abbreviations ............................................................................................................. 6
3 Overview of MEEY high-voltage system ..................................................................................... 7
3.1 Components of MEEY high-voltage system ................................................................. 7
4 Traction battery pack assembly ................................................................................................... 8
4.1 Battery pack position ..................................................................................................... 8
4.2 Battery pack appearance .............................................................................................. 8
4.3 Structure of battery pack ............................................................................................... 9
4.4 Judgment of problems in fault mode ............................................................................. 9
4.1.1 Battery pack over-temperature .............................................................................. 9
4.1.2 Battery pack SOC jump ....................................................................................... 10
4.1.3 Battery pack leakage ........................................................................................... 10
4.1.4 Capacity calibration error ..................................................................................... 10
4.1.5 Battery pack protection structure or collision ....................................................... 10
4.1.6 Water in battery pack ........................................................................................... 11
4.1.7 Other faults of battery pack.................................................................................. 11
4.5 Disassembly of battery pack ....................................................................................... 11
4.5.1 Personal Protective Equipment ........................................................................... 11
4.5.2 Operation tools ..................................................................................................... 12
4.5.3 Precautions for Assembly & Disassembly of Power Battery ............................... 12
4.5.4 Removal process ................................................................................................. 13
4.6 Installation of power battery ........................................................................................ 13
4.7 Battery management system ...................................................................................... 14
4.7.1 System overview .................................................................................................. 14
4.7.2 Component position ............................................................................................. 14
4.7.3 Connector pin definition ....................................................................................... 14
4.7.4 Terminal diagnosis ............................................................................................... 17
4.7.5 Diagnosis Process ............................................................................................... 18
4.7.6 DTC ...................................................................................................................... 18
4.7.8 Replacement process of battery management controller.................................... 26
5 Vehicle control unit .................................................................................................................... 27
5.1 Position of Complete Bus Controller ........................................................................... 27
5.2 Electrical schematic diagram ...................................................................................... 27
5.3 Diagnosis Process ...................................................................................................... 27
5.4 DTC and troubleshooting process .............................................................................. 29
5.5 Pin definition ................................................................................................................ 31
5.6 Fault classification ....................................................................................................... 35
5.7 Fault judgment............................................................................................................. 35
5.8 Removal and Vs. repair............................................................................................... 35
5.9 Calibration (IMMO matching + horizontal inclination calibration) ............................... 35
6 PDU............................................................................................................................................ 38
6.1 Location ....................................................................................................................... 38
6.2 Definition of LV Pins .................................................................................................... 38
6.3 Structure description ................................................................................................... 39
6.4 Fault diagnosis ............................................................................................................ 41
6.5 List of DTCs................................................................................................................. 42
6.6 Perform comprehensive diagnosis.............................................................................. 42

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6.6.1 DC step-down fault .............................................................................................. 42

6.6.2 Voltage detection fault ......................................................................................... 43
6.7 Replacement of charging and distribution assembly .................................................. 44
6.8 Assembly Instructions ................................................................................................. 47
7 Charging port & European-standard DC communication converter ......................................... 47
7.1 Location ....................................................................................................................... 47
7.2 Definition of LV Pins .................................................................................................... 48
7.3 Fault diagnosis ............................................................................................................ 49
7.4 Replacement of European-standard AC/DC integrated charging port ....................... 50
8 OBC assembly ........................................................................................................................... 51
8.1 Location ....................................................................................................................... 51
8.2 Definition of LV Pins .................................................................................................... 52
8.3 Structure description ................................................................................................... 52
8.4 Fault diagnosis ............................................................................................................ 53
8.5 List of DTCs................................................................................................................. 54
8.6 Perform comprehensive diagnosis.............................................................................. 55
8.7 Replace on-board charger assembly .......................................................................... 56
9 Front drive electric powertrain ................................................................................................... 57
9.1 Overview ..................................................................................................................... 57
9.2 Technical parameters .................................................................................................. 57
9.3 Maintenance pretreatment and descriptions............................................................... 58
9.4 Overall structure diagram of electric powertrain ......................................................... 58
9.5 Outline drawing of electric powertrain ......................................................................... 59
9.6 Disassembly and repair of front drive powertrain assembly ....................................... 59
9.6.1 Disassembly and repair of front drive electric powertrain ................................... 59
9.6.2 Removal and maintenance of transmission......................................................... 61
9.6.3 Removal and maintenance of the drive motor..................................................... 63
9.6.4 Disassembly and repair of drive motor control unit ............................................. 68
9.7 Definitions of Drive Motor Controller Pins ................................................................... 69
9.8 Diagnosis Trouble Codes of Drive Motor Controller ................................................... 70
10 Vehicle electric leakage troubleshooting ............................................................................ 71
10.1 Testing tools ................................................................................................................ 71
10.2 Testing requirements .................................................................................................. 71
10.3 Testing method............................................................................................................ 71
11 Problem feedback and message data collection ............................................................... 72
11.1 Vehicle problem feedback ........................................................................................... 72
11.2 Message data collection.............................................................................................. 72

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1 Scope of application and high voltage safety operation specification

1.1 Scope of Application
This manual sets forth the troubleshooting of the high-voltage system of MEEY model, mainly covering
the inspection and repair based on DTCs and the guidance for disassembly of high-voltage parts.
1.2 High voltage safety operation specification
1.2.1 Personnel qualification requirements
For repair of the high-voltage system of electric vehicles, operators need to be qualified as a mechanic
complying with the applicable national regulations or hold the electrician certificate.
1.2.2 Work site requirements
The work site must be dry and free of water damage, iron scraps, wire and other metal objects, and must
be insulated level ground or bench. If necessary, a layer of insulating rubber mat needs to be laid at the
work site. At the work site, warning signs should be laid and high-voltage work area should be isolated,
to prohibit the entry or approach of unrelated personnel. The work site should be equipped with
emergency rescue and disaster handling facilities, such as dry powder fire extinguishers, fire hydrants,
first aid kits, etc. The work site should be inside a building or a place not exposed to rain.
1.2.3 Guarding system
In case that there is a possibility of touching the high-voltage live part, the guarding system should be
implemented. One operator should be accompanied by one guardian. It is forbidden for two or more
people to work at the same time, and other people is prohibited to touch the operator. The guardian
should manage the work site effectively and guide the operator through operation; the operator should
work according to the guardian's instructions. The operator is prohibited to work without the permission
of the guardian.
1.2.4. High Voltage Safety Precautions
1) The operator must wear insulating rubber shoes and insulating gloves with voltage class greater than
the highest voltage of the object to be operated, and wear an arc-protection mask if necessary. Check
whether it is intact, dry and free of foreign objects to ensure the safety before the use. Operators are not
allowed to wear metal decorations.
Table 1 Common PPE
Insulated gloves Arc-protection mask Insulated rubber shoes

2) Operators are not allowed to operate high voltage live parts in principle, unless required for
measurement during the insulation resistance test of battery pack. High voltage measurement shall be
done with one hand. For example, the measuring instrument shall have at least one probe equipped with
insulated crocodile clip. During the measurement, set the clip to the positive or negative terminal of the
circuit, and then connect another probe to the other terminal of the circuit. During the measurement, hold
the probe with one hand only, and keep the other hand off the vehicle.
3) Before the operation, the high-voltage system should be powered off. Set the vehicle power switch to
“OFF” position, wait for 5 minutes, and then disconnect the negative terminal of the low-voltage battery,
and unplug the high-voltage buses from the battery pack, ensuring that the voltage between the
unplugged high-voltage buses is in the safety voltage range (less than 60V DC).
4) During the operation, operators should properly store the removed high and low voltage system wires,
and wrap the wires with special insulating rubber sleeves to prevent electric shock or other accidents
due to bare wire terminals.

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5) After overhaul of the high-voltage system, the guardian needs to carefully check whether the circuit is
satisfactory, and whether the vehicle can be powered on.
6) In a fire accident of the vehicle, the operator should cut off the high-voltage circuit provided that his or
her own safety is guaranteed. If the fire is not on the battery pack and small, it may be put out with dry
powder fire extinguishers and yellow sand provided that the high-voltage circuit has been cut off. If the
fire is large or on the battery pack, it may be put out with the high-pressure fire nozzle in a place far from
the vehicle; after the naked fire is extinguished, continue to spray water for half an hour. After the fire
extinguishment, the temperature of the battery pack should be continuously monitored to prevent
secondary fire.
7) The vehicle shall never be charged during the repair; after replacing the high-voltage parts, measure
whether the parts are well grounded; all the removed bolts need to be tightened according to the
corresponding standard torque.
8) When measuring the male end of the high-voltage harness on the vehicle, be sure not to short-circuit
the wire and the shielding with the probe; it is recommended to use special test tools.
9) After disassembling the traction battery pack, use insulated items (such as wooden support) to
separate the battery pack from the earth, and seal the coolant outlet and high-voltage connector with
special rubber or plastic sleeves. Removed battery pack should be put at a dry, shady and ventilated
place.
10) For the high-voltage parts to be uncased, measures should be taken to prevent foreign objects from
falling into the parts.
11) High-voltage circuit devices (such as fuse) must be replaced in accordance with the vehicle design
specifications and parameters.
12) Never allow operators to work with fatigue so as to prevent safety accidents.

2 Terms and abbreviations

Table 2.1 Common Terms and Abbreviations
Term/abbreviation Definition Description
PDU + three-in-one Scheme of PDU + three-in-one electric drive assembly
MEEY electric drive + 40kw + 40kw OBC
OBC .
Power distribution Integrated DC and high-voltage distribution box,
PDU
unit mainly realizing charging and distribution functions
Integrated motor control unit, transmission and motor
Three-in-one electric Three-in-one electric
assembly, mainly realizing vehicle drive and energy
drive drive assembly
recovery
On-board equipment that converts AC power into
OBC On-board charger
high-voltage DC power to charge the traction battery
Voltage detection DC charging anode and cathode contactor sintering
VDM
module detection and charging port voltage detection
Electric drive
EDCM Buck DC charging using motor boost control method
charging module
MCU Drive motor controller Controlling motor speed, torque, etc.
Control module for controlling body electrical system,
BCM Body control module including power windows, PEPS system, headlamps,
turn signal lamps, etc.
Achieving air heating or traction battery pack heating
PTC Heater
function

DC DC\DC converter: Converting the high-voltage DC power of the battery

pack into low-voltage DC power of about 14V to
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provide low-voltage power for the vehicle and charge

the 12V battery
High voltage Detecting the vehicle insulation resistance and
HVSU
switching unit monitoring the vehicle leakage state
A module that collects voltage, temperature and other
BIC Battery collector
information of cell and performs cell equalization
The control module that mainly manages the charging
BMC Battery manager
and discharging of the battery
Battery
Converting and processing data to enable
BCC communication
communication between BIC and BMC
conversion module
Battery Management Battery management system composed of BMC, BCC
BMS
System and BIC
Complete vehicle Working with the electric drive powertrain to perform
VCU
controller drive control of the complete vehicle, etc.
SRS Airbag Protecting vehicle occupants in the event of a collision
SCU Gear control Controlling vehicle transmission gears (P/N/D/R)
The electro-hydraulic braking system that provides
IPB IHB
assistance to the vehicle on demand
The equipment that achieves DTC diagnosis, data
Vehicle diagnostic
VDS stream reading, programming, parameter calibration
system
and other functions
Vehicle CAN communication high line,
CAN-H CAN high harnesses/terminal/signal for communication between
vehicle components/modules
Vehicle CAN communication low line,
CAH-L CAN low harness/terminal/signal for communication between
vehicle components/modules

3 Overview of MEEY high-voltage system

MEEY applies the scheme of PDU + three-in-one electric drive assembly + 40kw OBC, where the battery
is a lithium iron phosphate battery pack (BMC is integrated in the battery pack).
3.1 Components of MEEY high-voltage system
High voltage is provided with the following functions: store the electric energy from the power grid, and
reasonably distribute and manage the stored electric energy, where the stored electric energy is
converted for the powertrain to provide energy source, provide low voltage power for low voltage system,
and manage the on/off functions of whole high voltage system. MEEY high-voltage system consists of
three-in-one electric drive assembly, PDU, traction battery, BMC (integrated inside the battery pack),
VCU, integrated AC/DC charging port, 40kw OBC, etc. The layout of components of the high-voltage
system is detailed in Fig. 3-1.

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European
High-voltage standard AC/DC
charging port
harness

Power
distribution unit

40kW onboard
charger

Complete Traction battery pack (lithium

Front drive vehicle controller iron phosphate battery)
motor assembly

Figure 3-1 Layout of Components of MEEY High-voltage System

Motor compartment: Three-in-one electric drive assembly (platform B high voltage version), PDU (DC
60kw)
Passenger compartment: Traction battery pack (166 cells, rated capacity of 135AH, rated voltage of
531.2V), VCU
Trunk: Integrated AC/DC charging port, 40kw OBC (supporting 40kw, 6.6kw, 3.3kw and three to seven
charging)

4 Traction battery pack assembly

4.1 Battery pack position
The battery pack is located at the underbody, as shown in Figure 4-1:

Power battery pack

Figure 4-1 Battery Pack Position

4.2 Battery pack appearance
Battery pack appearance is as shown in Figure 4-2:

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Figure 4-2 Battery pack appearance

4.3 Structure of battery pack
The structure of battery pack is as shown in Figure 4-3:

Figure 4-3 Battery Structure

No. Components Quantity Remark
1 Refitting base 14
2 Water outlet 1
3 Water inlet 1
4 Grounding block 2
5 HV connector 1
6 Low voltage connector 1

4.4 Judgment of problems in fault mode

4.1.1 Battery pack over-temperature
There are two conditions of battery pack over-temperature: a. The signal collection is distorted due to the
sensor fault; b. The internal resistance of battery pack is too large, which results in excessive heat during
charging or discharging.
In case of the over-temperature of battery pack, the meter will report the battery pack over-temperature

fault.

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In case of the over-temperature of battery pack, please park the vehicle immediately by the roadside and
contact the maintenance staff.
Troubleshooting: Remove the battery pack and send it to BYD for professional maintenance.
4.1.2 Battery pack SOC jump
Battery pack SOC jump: The voltage of a single cell is decreased due to the fault of one or several cells
inside the battery pack. Vehicle SOC will correct it according to the voltage. In this case, the SOC will
jump and the vehicle will correct the cruising range automatically to that under the current SOC value.
In case of the battery pack jump, please park the vehicle immediately by the roadside and contact the
maintenance staff.
Troubleshooting: Remove the battery pack and send it to BYD for professional maintenance.
4.1.3 Battery pack leakage
Two kinds of battery pack leakage: 1. common leakage; 2. critical leakage.
In case of battery pack leakage, "EV function limited” message will appear on the instrument panel, and
in case of serious leakage, the vehicle output power will be limited.
In case of the battery pack leakage, please park the vehicle immediately by the roadside and contact the
maintenance staff.
Read the data (leakage fault) with ED400 (or VDS1000, VDS2000).
Troubleshooting: Remove the battery pack and send it to BYD for professional maintenance.
4.1.4 Capacity calibration error
Capacity calibration error: the errors of battery pack capacity caused by the external human factors or
the calibrating failure of current SOC; capacity calibration error will cause the cruising range to not match
the current SOC value. In critical cases, the cruising range jump will occur or the driver’s misjudgment of
mileage will cause the vehicle to break down.
In case of battery capacity calibration error, please contact the BYD maintenance staff.
Troubleshooting:
1. If conditions permit, discharge the vehicle through the charging cabinet until the vehicle automatically
cuts off the power, and then charge the vehicle until the SOC is 100%. When the SOC is about 90%,
connect the upper computer through the CAN port of the front cabin power network , switch on the
monitoring system of battery management system, collect the current charging capacity when the
vehicle is charged to 100% SOC, and re-label this charging capacity corresponding to SOC 100% in the
battery management system to power on the vehicle. The vehicle returns to normal.
2. If the vehicle cannot be discharged through the charging cabinet, park the vehicle on the charging
position if the SOC is as small as possible, turn on the PTC heating to discharge the vehicle's electricity
until the power is cut off automatically, and then charge the vehicle until the SOC is charged to 100%.
When the SOC is charged to about 90%, connect the upper computer through the CAN port of fore cabin
power network, open the battery management controller monitoring system, and collect the current
charging capacity when the vehicle SOC is charged to 100%, re-label this charging capacity for SOC
100% into the battery management controller, restore the power to vehicle, and the vehicle will be
recovered.
3. The vehicle battery management controller is provided with the repair function. If the above two
conditions cannot be realized, the vehicle capacity will be corrected to close to the actual capacity after
multiple charging and discharging. However, this method may cause the driver to misjudge the driving
range, causing the vehicle to break down.
4.1.5 Battery pack protection structure or collision
Battery pack protection structure or collision: MEEY is equipped with battery pack guard plate as a
protection measure. External human or environmental factors may caused the battery pack protection
structure to be hit during the driving process, and the core of battery pack may be damaged in critical
situations.

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In case of the battery pack jump, please park the vehicle immediately by the roadside and contact the
maintenance staff.
Troubleshooting: Read the battery management controller data with the Ed400,(or DS1000,VDS2000)
check whether the voltage and current are normal, and check the battery pack for fault warning. Check
the protection structure of the battery pack or the collision degree of the battery pack:
1. If the anti-collision steel pipe is damaged, replace the new accessories.
2. If the scratch resistant guard board is damaged, replace the new accessories.
3. If the battery pack tray is seriously deformed, remove the battery pack and deliver it to BYD for
professional maintenance.
4.1.6 Water in battery pack
Water inside the battery pack: the damage to the sealing structure of battery pack or prolonged soaking
or flooding of the vehicle may lead to the risk of water inside the battery pack.
If the vehicle is soaked or flooded for a long time, please contact BYD staff immediately for on-site
treatment.
Handling method: If there is water in the battery pack, deliver the battery pack to BYD for professional
maintenance.
4.1.7 Other faults of battery pack
In case of other faults of battery pack, please contact BYD staff immediately for on-site treatment.
4.5 Disassembly of battery pack
4.5.1 Personal Protective Equipment
Image Name Required Usage

For removing the screws, etc. and

Gloves Canvas gloves the hand protection during the
handling

Withstand voltage above Foot protection when removing or

Insulated shoe
1000V releasing the high-voltage parts

Protection at power battery outlet,

Ordinary electrical
Insulating tape service switch, signal cable
insulating tape
interface

Withstand voltage of Hand and arm protection for

Insulated gloves
1000V or above operating the high-voltage parts

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Resistance to corrosion Face protection for removing the

Protective mask
of acid and alkali solution leaking power battery

4.5.2 Operation tools

Image Name Required Usage

High-voltage Withstand voltage above

Remove the screw, etc
insulation tools 1000V

Lift Lift for vehicle repairing Raise the vehicle

The height is 1.2-1.4 m, and

Simple bracket
the bearing capacity is Hold the power battery
trolley
1,000 kg

Common vehicle repairing

Sleeve wrench Remove the vehicle parts
tools

The dimension of platform

is 1800mmx800mm, the
Lift table lifting height is not less Hold the power battery
than 1.4 m, and the load
capacity is 1000kg

Bearing over 300kg, and

Power forklift Move the power battery
lifting height over 1.5m

4.5.3 Precautions for Assembly & Disassembly of Power Battery

The MEEY power battery is a dangerous high voltage product. The maintenance personnel shall pay
attention to the following precautions during removal and installation:
1.The connection points indicated with yellow line or parts with high-voltage signs may only be
dismantled by the service personnel authorized by BYD;
2. The output outlet socket of power battery must be covered for insulation protection to avoid electric
shock caused by falling of foreign matters;
3. Pay attention to that the sampling wires shall not be pulled hard and bent excessively to prevent the
signal line from being damaged during removal;
4. The screws must be tightened with special tools in accordance with the design torque requirements
during installation;
5. The dust and dirt shall be removed before assembling the connection piece of the power copper bar
and module;
6. Pay attention to the part identification during removal of power battery to avoid omission or wrong
installation;
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7. The fastener must be marked with a torque mark after installation;

During the removal and installation, the power battery shall be prevented from the violent removal,
dropping, collision, module tilting, heavy pressure on module, excessive pulling of sampling wire,
artificial short circuit and other abnormal operations; it can only be removed by the workers;
Power battery is a high-voltage device, and improper operation may easily cause the personal injury or
death. Please refer to this disassembly & assembly specification for all procedures and precautions.
4.5.4 Removal process
Preparation
↓ Warning
Lift the vehicle
↓ ● To avoid the personal injury, only the professionals
Remove the guard plate and may remove the power battery.
ground at one time ● Do not touch or operate the power battery without
↓ appropriate protective equipment.
Unplug the high voltage connector ●Turn OFF the power supply of the vehicle before
and low voltage connector operation.
↓ ● Remove the battery according to the process.
Remove the inlet and outlet hoses
● During the removal, pay attention to the high-voltage
of battery pack, and collect the
warning signs on the power battery and the vehicle.
coolant
↓ ● During the removal, do not damage the parts with
Remove the fixing bolts *14 of locking function.
battery pack ● During the removal, properly protect the power
↓ battery.
Drop the battery pack
↓
End
4.6 Installation of power battery
Installation process:
Connect the inlet
Lift the battery
and outlet hoses, Install
pack to the Install
High voltage the Lower
mounting base the Fill the
Preparation → → connector and → → lower → the → → End
to fit the body ground coolant
low voltage guard vehicle
and secure wire
connector in board
with bolts
sequence
Install the traction battery as follows:

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(1) Place the traction battery pack assembly on the lifting platform or simple installation platform, and
push it into the installation station (the traction battery pack assembly is heavy, so please pay attention to
safety).

(2) Align the assembly with the mounting holes, lift the battery pack to make the battery pack assembly fit
the body mounting holes, and then tighten 14 fixing bolts (M12 bolts*10, tightened to torque of 135 N ▪ M,
M8 bolts*4, tightened to torque of 22 N ▪ M).
4.7 Battery management system
4.7.1 System overview
For this vehicle, the battery management system is composed of battery management controller (BMC),
HVSU, BIC, battery sampling wire, and is placed inside the battery pack. The battery management
controller is mainly designed for charge/discharge management, contactor control, power control,
battery abnormal state alarm and protection, SOC/SOH calculation, self-test and communication; the
HVSU is mainly designed for current sampling, total voltage/ sintering detection, and leakage detection;
the BIC is mainly designed for battery voltage sampling, cell equalization, etc.; the traction battery
sampling wire is mainly designed for connecting the battery management controller, HVSU and BIC to
realize the communication and information exchange between them.
4.7.2 Component position
The battery management controller and HVSU are located inside the PDU in the battery pack, as shown
below:

Water inlet

Collector 1 Collector m Low voltage

connector

blade battery blade battery Cathode

1 n contactor

Power battery systems

HV
Main fuse Main contactor connector

Pre-Charging Pre-charging
Contactor resistor

Water outlet
Blue line: coolant line
Green line: communication cable/low-voltage power supply cable Red line: high-voltage electrical connection cable

Figure 1 MEEY Battery Management Controller, HVSU in the PDU of Battery Pack
4.7.3 Connector pin definition
Projection drawing of low-voltage connectors of traction battery pack:

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Projection drawing of vehicle harness connectors to low-voltage connectors of traction battery pack:

Pin definition
Steady-state
Pin No. Port name Port definition Harness connection Signal Type operating
current/ A
1 NC NC
2 NC NC
3 NC NC
12V Constant 12V constant power Connecting vehicle
4 Voltage 2A
power input low voltage harness
Connecting vehicle
5 IG3 electric IG3 electric Voltage 2A
low voltage harness
To front passenger’s
Power battery Power battery subnet
6 diagnose interface CAN ≤1A
subnet CANH CANH
32PIN-29
To front passenger’s
Power battery Power battery subnet
7 diagnose interface CAN ≤1A
subnet CANL CANL
32PIN-30
To the DC charging
DC charging port
8 DC charging CANL CAN ≤1A
CANL
12 PIN-4
9 NC NC
To low-voltage wire
Power net
10 Power net CANL harness power net of CAN ≤1A
CANL
vehicle
11 NC NC
DC charging DC charging positive To DC charging and
12 positive and and negative contactor distributing assembly Voltage ≤1A
negative power supply（IG3） 3PIN-8
contactor power

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supply（IG3）
High voltage
DC interlocking
13 interlocking PWM input 1 PWM ≤1A
connector 2PIN-2
input 1
DC charging To the DC charging
DC charging port port
14 port Simulation ≤1A
temperature 1+
temperature 1+ 12 PIN-7
To the DC charging
DC charging port
15 DC charging CANH CAN ≤1A
CANH
12 PIN-5
Low-voltage wire
16 IG3 power GND IG3 power GND GND 4A
harness of vehicle
Low-voltage wire
Power net
17 Power net CANH harness power net of CAN ≤1A
CANH
vehicle
High voltage To DC charging
18 interlocking PWM output 1 distributing assembly PWM ≤1A
output 1 3PIN-13
Reserved
(VTOV)
19 / / / /
contactor
control
DC charging To the DC charging
DC charging port port
20 port Simulation ≤1A
temperature 2+
temperature 2+ 12 PIN-9
DC charging To the DC charging
port DC charging port port
21 GND ≤1A
temperature temperature 1-/2-
1-/2- 12PIN-8/10

Collision hardwire
22 Collision signal ECU PWM ≤1A
signal input
12V battery 12V battery voltage Connecting vehicle
23 GND 4A
voltage GND GND low voltage harness
DC charging DC charging anode
To DC charging and
positive contactor control signal Electrical
24 distributing assembly ≤1A
contactor output, lowering the level
3PIN-9
control conduction
AC charging
Connect AC charging Electrical
25 CC signal connection ≤1A
port 12 PIN -2 level
confirmation CC signal
European-standard
communication
DC charging
DC charging auxiliary module 20PIN-4 (this Electrical
26 auxiliary power ≤1A
power wake-up A+ pin is not connected level
wake-up A+
when OBC is
available)
27 NC NC
28 NC NC
29 IG3 electric IG3 electric Connecting vehicle Voltage 2A

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low voltage harness

30
DC charging DC charging cathode
To DC charging
negative contactor control signal Electrical
31 distributing assembly ≤1A
contactor output, lowering the level
3PIN-10
control conduction
DC charging To the DC charging
connection port Electrical
32 CC2 signal ≤1A
confirmation CC2 level
signal 12 PIN-3

33 NC NC
4.7.4 Terminal diagnosis
1. Connect the low-voltage harness connectors of the battery pack
2. Measure each terminal value
Normal values are as follows:
Pin No. Port name Measurement condition Normal value
1 NC
2 NC
3 NC
4 12V Constant power Any position 9～16V
5 IG3 power supply ON mode 9～16V
6 NC
7 NC
8 DC charging CANL DC charging 1.5～2.5V
9 NC
10 Power net CANL ON mode 1.5～2.5V
Power network CAN shielded
11
ground Always Less than 1 V
DC charging positive and negative
12
contactor power supply（IG3） ON mode 9～16V
13 High voltage interlocking input 1 ON mode PWM pulse signal
14 DC charging port temperature 1+ ON mode 0.5-200KΩ
15 DC charging CANH DC charging 2.5～3.5V
16 IG3 power GND Always Less than 1 V
17 Power net CANH ON mode 2.5～3.5V
18 High voltage interlocking output 1 ON mode PWM pulse signal
Open state: 9-16V
19 (VTOV) contactor control DC VTOV discharge
Close state: less than 1V
20 DC charging port temperature 2+ ON mode 0.5-200KΩ
21 DC charging port temperature 1-/2- For test of pins 14, 20
22 Collision signal ON mode PWM pulse signal

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23 12V battery voltage GND Always Less than 1 V

DC charging positive contactor Open state: 9-16V
24 DC charging
control Close state: less than 1V
Alternating current
25 CC signal Less than 2.9V
charging
DC charging auxiliary power
26 DC charging 9～16V
wake-up A+
27 NC
28 NC
29 IG3 power supply ON mode 9～16V
30 NC
DC charging negative contactor Open state: 9-16V
31 DC charging
control Close state: less than 1V
32 CC2 signal DC charging 2.1-3.0V
33 NC
4.7.5 Diagnosis Process
1 Drive the vehicle into the maintenance workshop.

2 Check whether the LV (low voltage) battery voltage and the power supply of the vehicle low
voltage harness are normal
Standard voltage range:
12~14V
If the voltage value is lower than 12V, please charge
or replace the LV (low voltage) battery of the
harness of the vehicle before NEXT step.
3 Properly butt joint the connector and switch the complete vehicle to ON power to enter into the
fault codes diagnosis of battery manager.

5 Adjust, repair or replace for the faults

6 Perform the pinpoint test

7 End
4.7.6 DTC
Fault code
S/N Fault Definition Components to Be Checked
(ISO 15031-6)
1 P1A0000 Serious leakage fault Check the power battery, three-in-one,
electric assembly, heater, A/C compressor
and PTC

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2 P1A0100 Common leakage fault Check the power battery, three-in-one,

electric assembly, heater, A/C compressor
and PTC
3 P1A0200 BIC1 abnormal Power battery pack
4 P1A0300 BIC2 abnormal Power battery pack
5 P1A0400 BIC3 abnormal Power battery pack
6 P1A0500 BIC4 abnormal Power battery pack
7 P1A0600 BIC5 abnormal Power battery pack
8 P1A0700 Abnormal BIC6 working fault Power battery pack
9 P1A0800 Abnormal BIC7 working fault Power battery pack
10 P1A0900 Abnormal BIC8 working fault Power battery pack
11 P1A0A00 Abnormal BIC9 working fault Power battery pack
12 P1A0B00 Abnormal BIC10 working fault Power battery pack
13 P1A0C00 BIC1 abnormal voltage Power battery pack
sampling
14 P1A0D00 BIC2 abnormal voltage Power battery pack
sampling
15 P1A0E00 BIC3 abnormal voltage Power battery pack
sampling
16 P1A0F00 BIC4 abnormal voltage Power battery pack
sampling
17 P1A1000 BIC5 abnormal voltage Power battery pack
sampling
18 P1A1100 Abnormal BIC6 voltage Power battery pack
sampling fault
19 P1A1200 Abnormal BIC7 voltage Power battery pack
sampling fault
20 P1A1300 Abnormal BIC8 voltage Power battery pack
sampling fault
21 P1A1400 Abnormal BIC9 voltage Power battery pack
sampling fault
22 P1A1500 Abnormal BIC10 voltage Power battery pack
sampling fault
23 P1A2000 BIC1 abnormal temperature Power battery pack
sampling
24 P1A2100 BIC2 abnormal temperature Power battery pack
sampling
25 P1A2200 BIC3 abnormal temperature Power battery pack
sampling
26 P1A2300 BIC4 abnormal temperature Power battery pack
sampling
27 P1A2400 BIC5 abnormal temperature Power battery pack
sampling
28 P1A2500 Abnormal BIC6 temperature Power battery pack
sampling fault
29 P1A2600 Abnormal BIC7 temperature Power battery pack
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sampling fault
30 P1A2700 Abnormal BIC8 temperature Power battery pack
sampling fault
31 P1A2800 Abnormal BIC9 temperature Power battery pack
sampling fault
32 P1A2900 Abnormal BIC10 temperature Power battery pack
sampling fault
33 P1A3400 Pre-charging failure Check the power battery, HV distribution
box/HVDB, motor control unit and DC
assembly, A/C compressor and PTC, as well
as high voltage harness
34 P1A3522 Power battery's single-cell Power battery pack
voltage seriously high
35 P1A3622 Power battery's single-cell Power battery pack
voltage high
36 P1A3721 Power battery's single-cell Power battery pack
voltage seriously low
37 P1A3821 Power battery's single-cell Power battery pack
voltage low
38 P1A3922 Power battery's single-cell Power battery pack
temperature seriously high
39 P1A3A22 Power battery's single-cell Power battery pack
temperature high
40 P1A3B21 Power battery's single-cell Power battery pack
temperature seriously low
41 P1A3C00 Power battery's single-cell Power battery pack
temperature low
42 P1A3D00 Negative contactor inspection Negative contactor, harness and BMC
failure
43 P1A3E00 Main contactor loop check fault Master contactor, harness and BMC
44 P1A3F00 Pre-charging contactor loop Pre-charging contactor, harness and BMC
check fault
45 P1A4000 Charging contactor loop check Charging contactor, harness and BMC
fault
46 P1A4100 Main contactor sintering Master contactor, harness, BMC and
leakage module
47 P1A4200 Cathode contactor sintering Negative contactor, harness, BMC and
leakage module
48 P1A4800 Main contactor disconnected Motor controller
by motor controller
49 P1A5100 Collision hardwire signal PWM Collision hard wire
abnormality warning
50 P1A5200 Collision system fault Collision signal
51 U011000 Communication fault with Motor controller, BMC and harness
motor controller
52 U110387 Communication fault with Airbag ECU, BMC and harness
airbag ECU

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53 P1A6000 High-voltage interlock 1 fault Battery management controller, high voltage

electronic control assembly and low voltage
harness
54 U029787 Communication fault with On-board, BMC and harness
on-board charger
55 U012200 Communication fault with LBMC, BMC, harness
low-voltage BMC
56 P1AC000 Airbag ECU collision alarm Airbag ECU
57 P1AC200 High-voltage interlock 2 fault BMC, harness
58 P1A9800 Abnormal BIC11 working fault Power battery pack
59 P1A9900 Abnormal BIC12 working fault Power battery pack
60 P1A9A00 Abnormal BIC13 working fault Power battery pack
61 P1A9B00 Abnormal BIC14 working fault Power battery pack
62 P1A9C00 Abnormal BIC15 working fault Power battery pack
63 P1A9D00 Abnormal BIC16 working fault Power battery pack
64 P1A9E00 Abnormal BIC17 working fault Power battery pack
65 P1A9F00 Abnormal BIC18 working fault Power battery pack
66 P1AA000 Abnormal BIC19 working fault Power battery pack
67 P1AA100 Abnormal BIC20 working fault Power battery pack
68 P1AA200 Abnormal BIC11 voltage Power battery pack
sampling fault
69 P1AA300 Abnormal BIC12 voltage Power battery pack
sampling fault
70 P1AA400 Abnormal BIC13 voltage Power battery pack
sampling fault
71 P1AA500 Abnormal BIC14 voltage Power battery pack
sampling fault
72 P1AA600 Abnormal BIC15 voltage Power battery pack
sampling fault
73 P1AA700 Abnormal BIC16 voltage Power battery pack
sampling fault
74 P1AA800 Abnormal BIC17 voltage Power battery pack
sampling fault
75 P1AA900 Abnormal BIC18 voltage Power battery pack
sampling fault
76 P1AAA00 Abnormal BIC19 voltage Power battery pack
sampling fault
77 P1AAB00 Abnormal BIC20 voltage Power battery pack
sampling fault
78 P1AAC00 Abnormal BIC11 temperature Power battery pack
sampling fault
79 P1AAD00 Abnormal BIC12 temperature Power battery pack
sampling fault
80 P1AAE00 Abnormal BIC13 temperature Power battery pack
sampling fault

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81 P1AAF00 Abnormal BIC14 temperature Power battery pack

sampling fault
82 P1AB000 Abnormal BIC15 temperature Power battery pack
sampling fault
83 P1AB100 Abnormal BIC16 temperature Power battery pack
sampling fault
84 P1AB200 Abnormal BIC17 temperature Power battery pack
sampling fault
85 P1AB300 Abnormal BIC18 temperature Power battery pack
sampling fault
86 P1AB400 Abnormal BIC19 temperature Power battery pack
sampling fault
87 P1AB500 Abnormal BIC20 temperature Power battery pack
sampling fault
88 P1AC800 Anode contactor loop check BMC, harness and contactor
fault
89 P1AC900 DC charging induction signal DC charging induction line
interrupt
90 U029C00 Communication fault of battery BMC, VTOG and harness
manager system with VTOG
91 U029800 Communication fault of battery BMC, DC, harness
manager system with DC
92 U02A200 Communication fault with Active leakage module, BMC and harness
active bleed module
93 U016400 Communication fault with air A/C, BMC and harness
conditioner
94 U023487 Communication fault with Heater, BMC and harness
battery heater
95 P1ADE00 Battery cooling failure due to A/C
the fault of air conditioner
96 P1ADF00 Inner battery cycle failure due A/C
to the fault of air conditioner
97 P1AE000 Battery heating failure due to A/C
the fault of air conditioner
98 P1AE100 Battery heating failure due to Heater
the fault of heater
99 P1AD44B Slightly high charging port Charging port temperature
temperature 1
100 P1AD54B Slightly high charging port Charging port temperature
temperature 2
101 P1AD698 Slightly high charging port Charging port temperature
temperature 3
102 P1AD900 Abnormal temperature Charging port temperature
sampling point at charging port
103 P1A5B00 Contactor disconnected due to Double-circuit power supply
dual-circuit power supply fault
104 P1A5500 Battery management system Battery
12V power supply input too
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high
105 P1A5600 Battery management system Battery
12V power supply input too low
106 P1ACB07 DC charging anode contactor Charging positive contactor, BMC, harness
sintering and leakage module
107 P1ACC07 DC charging cathode contactor Charging negative contactor, BMC, harness
sintering and leakage module
108 P1AE500 Disconnection of low voltage LV (low voltage) battery
output line
109 P1AE617 Low-voltage battery voltage too LV (low voltage) battery
low
110 P1AE616 Low-voltage battery voltage too LV (low voltage) battery
high
111 P1AE800 DC charging positive contactor Charging positive contactor, harness and
loop check fault BMC
112 P1AE900 DC charging negative Charging negative contactor, harness and
contactor loop check fault BMC
113 U014087 Communication fault to BCM BCM, BMC and harness
114 U012187 Communication fault to ABS ABS, BMC and harness
115 U110287 Communication fault to RCM RCM, BMC and harness
116 U015587 Communication fault with Instrument, BMC and harness
combination instrument
117 U029487 Communication fault with Mode switch, BMC and harness
mode switch
118 P1AEA00 PTC short circuit fault PTC
119 P1AEB00 Buck-boost module fault Buck-boost module
120 U014B87 Communication fault with DC DC charging cabinet and BMC
charging cabinet
121 P1AEC00 DC charging cabinet fault DC charging cabinet
122 P1AF200 Abnormal DC charger voltage DC charging cabinet
output
123 P1AF300 Active stopping of charging for DC charging cabinet
DC charging cabinet
124 P1AF400 Insufficient capacity of DC DC charging cabinet
charging cabinet
125 P1AFC00 On-board charger high voltage On-board
interlocking fault
126 P1AFD00 DC-DC high voltage DC
interlocking fault
127 P1AFE00 Pre-electronic control high Pre-electronic control
voltage interlocking fault
128 P1ADC00 Pre-electronic control high Pre-electronic control
voltage interlocking fault
129 P1AFF00 Post-electronic control high Post-electronic control
voltage interlocking fault
130 P1AFA00 Battery heater high voltage Heater

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interlocking fault
131 P1AFB00 A/C system high voltage A/C
interlocking fault
132 P1A9700 Abnormal BCM disconnection IG3
IG3 relay fault
133 P1AF800 Non-update fault of battery BMC
data
134 P2B7000 General fault of voltage Battery pack
sampling wire break
135 P2B7100 Serious fault of voltage Battery pack
sampling wire break
136 P2B7200 General fault of temperature Battery pack
sampling wire break
137 P2B7300 Serious fault of temperature Battery pack
sampling wire break
138 P2B7400 Traction battery overcharge Battery pack
139 P2B7517 Traction battery pack Battery pack
overvoltage
140 P2B7516 Traction battery pack Battery pack
undervoltage
141 P2B7700 Serious traction battery Battery pack
connector overtemperature
142 P2B7800 General traction battery Battery pack
connector overtemperature
143 P2B7900 Battery pack charging Battery pack
overcurrent
144 P2B7A00 Inconsistent AC charging gun OBC, BMC, harness
connection signal
145 P2B7B00 General shunt Battery pack/ HVSU
overtemperature
146 P2B7C00 Serious shunt overtemperature Battery pack/ HVSU
147 P2B7D00 Shunt temperature sampling Battery pack/ HVSU
failure
148 P2B7E00 Great shunt current sampling Battery pack/ HVSU
error
149 P2B7F00 Shunt sampling current Battery pack/ HVSU
identification failure
150 P2B8000 HVSU_PACK+ voltage Battery pack/ HVSU
sampling failure
151 P2B8100 HVSU_LINK+ voltage Battery pack/ HVSU
sampling failure
152 P2B8200 HVSU_LINK- voltage sampling Battery pack/ HVSU
failure
153 U027D87 HVSU communication failure HVSU
154 P2B8400 Abnormal HVSU chip HVSU
155 P2B8500 Abnormal HVSU power supply BMC/HVSU

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156 P2B8700 BIC chip temperature error BMC

157 P2B8812 BIC equalization short circuit BMC
158 P2B8813 BIC equalization open circuit BMC
159 P2B8A00 BIC configuration inconsistent BMC
with module state
160 P2B8E00 Serious high-side drive error BMC
161 P2B8F12 High-side drive short circuit to BMC
power supply
162 P2B9000 General high-side drive error BMC
163 P1A4E00 Battery pack overcurrent Battery pack
164 P1AC400 Serious cell imbalance Battery pack
165 P1AE400 High voltage process ended DC
due to abnormal low voltage
supply
166 P1AF600 Traction battery pack thermal Battery pack
runaway
167 P2B9100 Abnormal DC charging port PDU DC contactor and vehicle high voltage
voltage module leakage
168 P2B9219 High-side drive overcurrent Battery pack/ BMC/HVSU
(HVSU channel)
169 P2B9298 High-side drive BMC
overtemperature
170 P2B9211 High-side short circuit to Low-voltage control harness related to
ground SC (contactor channel) contactor in battery pack/ contactor in
battery pack/ BMC
171 P2B9311 High-side short circuit to BMC/HVSU
ground SC (HVSU channel)
172 P2B9212 High-side short circuit to power Low-voltage control harness related to
OS (contactor channel) contactor in battery pack/ contactor in
battery pack/ BMC
173 P2B9213 High-side drive open circuit Low-voltage control harness related to
contactor in battery pack/ contactor in
battery pack/ BMC
174 U018087 Lost communication with BMC
high-side drive
175 U007301 Power CAN Bus Off Communication quality of vehicle power
network
176 U007302 DC charging CAN Bus Off Communication quality of vehicle charging
network
177 U017D87 Communication timeout with VDM
VDM
178 U017E87 Communication timeout with DC boost module
DC boost module
179 P2B9200 Abnormal battery temperature Battery pack
difference
180 U027E01 BIC1 cascade communication Battery pack
failure

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181 U027E02 BIC2 cascade communication Battery pack

failure
182 U027E03 BIC3 cascade communication Battery pack
failure
183 U027E04 BIC4 cascade communication Battery pack
failure
184 U027E05 BIC5 cascade communication Battery pack
failure
185 U027E06 BIC6 cascade communication Battery pack
failure
186 U027E07 BIC7 cascade communication Battery pack
failure
187 U027E08 BIC8 cascade communication Battery pack
failure
188 U027E09 BIC9 cascade communication Battery pack
failure
189 U027E0A BIC10 cascade communication Battery pack
failure
190 U027E0B BIC11 cascade communication Battery pack
failure
191 U027E0C BIC12 cascade communication Battery pack
failure
192 U027E0D BIC13 cascade communication Battery pack
failure
193 U027E0E BIC14 cascade communication Battery pack
failure
194 U027E0F BIC15 cascade communication Battery pack
failure
195 U027E10 BIC16 cascade communication Battery pack
failure
196 U027E11 BIC17 cascade communication Battery pack
failure
197 U027E12 BIC18 cascade communication Battery pack
failure
198 U027E13 BIC19 cascade communication Battery pack
failure
199 U027E14 BIC20 cascade communication Battery pack
failure
200 P2B9400 Traction battery overdischarge Battery pack
201 P2B9700 Traction battery thermal Battery pack
management system leakage
202 P2B9800 Vehicle configuration Report BMC software code and version to
inconsistent with BMC function the engineering institute for verification
state
203 P1AF601 Abnormal traction battery pack Battery pack
temperature limit
4.7.8 Replacement process of battery management controller

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The battery management controller should be removed by the battery pack supplier if it is verified that
the controller is faulty, resulting in failure of the vehicle to run;

5 Vehicle control unit

5.1 Position of Complete Bus Controller

Front passenger
area
Driver area

Complete vehicle
controller

Schematic Diagram of the Location of Vehicle Controller 1

5.2 Electrical schematic diagram

F1/36
VCU
10A

Power Power Brake lamp switch Stepless fan

Net Net

12V 12V Collision Power Net Power Net Brake switch signal Stepless fan signal
Power Power signal control output PWM
VCU ECU
Throttle Throttle Throttle Throttle
Power Power Shield depth power depth power Throttle Throttle depth power depth power Feedback Water pump Water pump
supply supply GND supply 1 supply 2 depth 1 depth 2 GND 1 GND 2 button control signal detection signal

F1/38
electronic
coolant pump
10A

Motor cooling
water pump
Multi-media control panel

Accelerator pedal

*Luxury version

Electrical Schematic Diagram of Vehicle Controller

5.3 Diagnosis Process
11 Bring the vehicle into the maintenance shop

Next step

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22 Check the voltage of low-voltage battery

Standard voltage range:
10~16V
If the voltage is lower than 10V, please charge or
replace the batteries before next step.

Next step

33 Insert the diagnostic equipment and perform the terminal diagnosis, read and record all fault
codes of the module

Next step

44 Clear all fault codes of the module and return to Off position

Next step

55 Set the power in ON position 3 minutes later, read and record all fault codes of the module.

Next step

66 Refer to the Fault Diagnosis List.

Results Perform
The phenomenon is not specified in A
the Fault Diagnosis List.
The phenomenon is specified in the B
Fault Diagnosis List.

B Go to Step 8

7 Check the fuse and low-voltage connector

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(a) Check whether the low-voltage connector of the vehicle control unit is connected well, and whether
the terminal is normal. Repair the relevant part if necessary.
(b) Check the continuity of the fuse and replace the fuse if necessary.
(c) Proceed to the next step if the above is OK.

OK

88 Repair or replace the vehicle control unit according to the troubleshooting process based on DTC

Next step

99 Test confirmation

Next step

110 End

5.4 DTC and troubleshooting process

S/N Fault code Fault Definition
（ISO15031-6）
1 P1D7902 Collision signal fault of vehicle controller
2 P1D6144 EEPROM error of vehicle controller
3 P1D6200 Cruise switch signal fault of vehicle controller
4 P1D6300 Water pump drive fault of vehicle controller
5 P1D7B00 Throttle signal failure-1 signal failure
6 P1D7C00 Throttle signal failure-2 signal failure
7 P1D6600 Accelerator signal failure -check fault
8 P1D6700 Brake signal fault - 1 signal fault
9 P1D6800 Brake signal fault - 2 signal fault
10 P1D6900 Brake signal fault - check fault
11 U011187 Communication fault with the battery management system (BMS)
12 U024E87 Communication fault to ESC
13 U012887 Communication fault to EPB
14 U029187 Communication fault with gear controller
15 U016487 Communication fault with air conditioner
16 U014087 Communication fault to BCM
17 U029887 Communication fault to DC
18 U012187 Communication fault to ABS
19 U01A500 Communication fault with front drive motor controller (FMCU)
20 U01A600 Communication fault with rear drive motor controller (RMCU)

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S/N Fault code Fault Definition

（ISO15031-6）
21 U024C87 Communication fault with I-KEY
22 P1D6D00 DSP reset fault of vehicle controller
23 P1D9017 Power battery's single-cell voltage high
24 P1D9016 Power battery's single-cell voltage low
25 P1D9100 Power battery's total voltage high
26 P1D9117 Power battery's total voltage seriously high
27 P1D9200 Power battery's total voltage low
28 P1D9216 Power battery's total voltage seriously low
29 P1D9308 Abnormality in power battery's lifespan
30 P1D8500 Vacuum pump system failure 1
31 P1D9E00 Vacuum pump system failure 2
32 P1D9F00 Vacuum pump system failure 3
33 P1D6B00 Vacuum pump system failure 4
34 P1D8600 Critical leakage of vacuum pump
35 P1D8700 Common leakage of vacuum pump
36 P1D8800 Vacuum pump reaching the life limit.
37 P1D8900 Fault of vacuum pump relay 1
38 P1D8A00 Fault of vacuum pump relay 2
39 P1D8B00 Fault of vacuum pump relays 1 and 2
40 P1D8400 Water temperature error (OBC)
41 P1D9400 Disconnection of low voltage output line
42 P1D9516 Low-voltage supply voltage too low
43 P1D9517 Low-voltage supply voltage too high
44 P1D9600 Abnormality in power battery's lifespan - counter out of order
45 P1D9700 Abnormality in power battery's lifespan - abnormal check value
46 P1D9800 Abnormal temperature sampling
47 P1D8300 Limited power of vehicle
48 P1D9A00 Fault of vacuum pressure sensor
49 P1D9900 Fault of barometric pressure senso (reserved)
50 B17A300 SRS CAN signal abnormality
51 B17A400 SRS hardwire signal abnormality
52 P1D8D00 Stepless fan motor stalling, short circuit, etc.
53 P1D8E00 Stepless fan over-temperature protection, electronic error, etc
54 P1D8F00 Stepless fan power supply overvoltage/ undervoltage
55 U029400 Communication fault with mode switch
56 P1D9B00 Water temperature sensor fault
57 P1D9C00 Water over-temperature

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S/N Fault code Fault Definition

（ISO15031-6）
58 P1B1F00 Anti-theft verification failure
59 U014F87 Communication fault with the charging and distributing assembly
60 B116212 Short circuit of water temperature sensor
61 B116214 Open circuit of water temperature sensor
62 U012A00 Communication fault to EPS
63 P1BA000 Cruise configuration not written
64 U011987 Communication fault between VCU and boosting DC
65 U014D87 Communication fault with intelligent drive module
66 U014E87 Communication fault with security gateway module
67 P1D7A00 Dry operation of cooling water pump
68 P1D7E00 Coolant pump stall or shutdown due to overcurrent
69 P1D7F00 Cooling water pump over-temperature shutdown fault
70 P1D8000 Low speed of cooling water pump
71 U029F87 Communication fault to OBC
72 U025B87 Master cylinder pressure test timeout or data error
73 U019780 Communication failure with IPB
74 P2B5100 IPB pedal travel error
75 U022887 Communication failure with EDCM

5.5 Pin definition

64-pin connector on the device

64-pin connector on the harness

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Inrush current, Power

inrush time, stall supply Remarks
Steady-state
Pin Port Harness current, stall time nature (possibility
Port name Signal Type working of sharing
No. definition connection (waveform (e.g.
Current/A the fuse,
required for constant
etc.)
motor)/A power)
External
1 +12V0 IG3 Power supply 0.23A 15A 2ms IG3
input power
2 / /
External
3 +12V0 IG3 Power supply 0.23A 15A 2ms IG3
input power
4 / /
External
5 GND input power Body GND GND 0.23A 15A 2ms
GND
6 / /
External
7 GND input power Body GND GND 0.23A 15A 2ms
GND
8 / /
Braking Braking
9 +5V depth power depth sensor 5mA Reserved
supply 2 pin D/ pin 7
Braking Braking
10 +5V depth power depth sensor 5mA Reserved
supply 1 pin G / pin 2
Vacuum Vacuum
pressure pressure
11 +5V sensor sensor 12.5mA Reserved
Power supply Pin 1
12 / /
13 / /
Water pump
PUMP-TE
14 detection Pump pin 2 PWM
ST-IN
signal
High level
IN-FEET-B Brake switch Brake switch
15 Active 0.6mA
RAKE signal pin 3
≥9V
Only snow
Snow mode mode
Snow mode/ switch pin 5 / Low level switch is
16 feedback feedback 0.6mA connected
switching selector Active
for MEEY
switch pin 1
.
Junction
Vacuum between
pump replay vacuum
V-PUMP-T detection High level
17 pump relays 0.6mA Reserved
EST-IN signal Active
1,2 and
(0 or 12V) vacuum
pump pin 1
Economic /
ECO/SPO-
18 sport mode Switch group 0.6mA Reserved
IN
input

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 MEEY High-voltage System Service Manual

Stepless fan
L-FAN-OU Stepless fan
19 signal control PWM
T pin 3
/ loop check
Power
network CAN
20 GND signal GND Shield GND GND
Shield GND
Power net
21 CANH Power Net
CANH
Power net
22 CANL Power Net
CANL
Throttle
Throttle position
23 +5V depth power sensor 10mA
supply 1
Pin 3
Throttle
Throttle position
24 +5V depth power sensor 10mA
supply 2
Pin 2
25 / /
26 / /
27 / /
28 / /
29 / /
PUMP-OU Water pump
30 Pump pin 3 PWM
T control signal
Economy/sp
ECO/SPO-
31 orts mode Switch group 0.6mA Reserved
OUT
output
32 / /
Collision SRS module
33 CRASH-IN PWM 0.6mA
signal pin 46
34 / /
35 / /
36 / /
Throttle
Throttle position
37 GND depth power sensor
GND 1
Pin 5
Throttle
Throttle position
38 GND depth power sensor
GND 2
Pin 6
39 / /
40 / /
The control Low level
Vacuum
V-PUMP1- pin of
41 pump relay 1 Active 10mA Reserved
OUT vacuum
control signal ＜1V
pump relay 1
42 / /
43 / /
44 / /
45 / /

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Vacuum Vacuum
0~5V
pressure pressure
46 VP-Sensor sensor sensor Simulation 0.2mA Reserved
signal
Signal Pin 3
Throttle
depth
47 GND Shield GND GND
shielding
GND
Throttle
Accelerator position Analog
48 DC-GAIN2 depth Signal sensor 0.2mA
quantity
2
Pin 1
Braking Braking
DC-BRAK Analog
49 depth signal depth sensor 0.2mA Reserved
E2 quantity
2 Pin C/ pin 8
Braking Braking
DC-BRAK Analog
50 depth signal depth sensor 0.2mA Reserved
E1 quantity
1 Pin F/ pin 1
Brake depth Braking
51 GND power depth sensor Reserved
ground 2 Pin B/ pin 9
Brake depth Braking
52 GND power depth sensor Reserved
ground 1 Pin A/ pin 10
Vacuum
Vacuum pressure
53 EARTH pressure sensor Reserved
sensor GND
Pin 2
54 / /
The control
Vacuum
V-PUMP2- pin of
55 pump relay 2 0.2A Reserved
OUT vacuum
control signal
pump relay 2
56 / /
57 / /
Water
Water
temperature
58 EARTH temperature Reserved
sensor signal
sensor pin A
GND
MT-Watert Water Water
Resistance
59 emp-Sens temperature temperature 15.2mA Reserved
type
or sensor signal sensor pin C
CURISE_I Cruise Analog
60 Cruise switch 13.8mA Reserved
N control signal quantity
Cruise
61 EARTH control signal Cruise switch Reserved
ground
Throttle
Accelerator position Analog
62 DC-GAIN1 depth Signal sensor 0.2mA
quantity
1
Pin 4
Brake depth
63 GND shielding Shield GND GND Reserved
GND
64 / /

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5.6 Fault classification

1. No signal or abnormal signal of vehicle controller
2. Fault of vehicle controller
5.7 Fault judgment
1. Read the vehicle controller module with the diagnostic instrument / VDS and get the corresponding
fault code. Water in the connector, looseness of connector and damage of harness may cause the
abnormal signals.
2. The faulty module shall be replaced, and the vehicle controller may be replaced to determine whether
the vehicle controller is faulty.
5.8 Removal and Vs. repair
1. Personal protective equipment
Protective gloves, used for the hand protection when removing the screws and interior components and
handling the parts
2. Operation tools
Slotted screwdriver, cross screwdriver, flat nose pliers, ratchet and sleeve
3. Precautions for disassembly and assembly of VCU
Remove the interior trims slowly with the flat nose pliers near the clip to avoid damage.
4. Removal process
At the front two installation points, the fixing nuts need to be removed after removal of the console left
and right knee guard plates, and at the rear two installation points, the fixing nuts need to be removed
after removal of the console body and the left and right floor air ducts.
5. Installation Process
Install in the reverse order of removal.
5.9 Calibration (IMMO matching + horizontal inclination calibration)
Before and after replacement of the VCU, the following operations need to be carried out (taking SCEB
model as an example):
Select the IMMO matching module and click for entry:

Burglary prevention Tire pressure monitor

matching module matching

1. Click "MCU programming"

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Ⅸ Controller Steering shaft lock Key programming Motor controller

programming programming programming

Motor controller
password clearing

2. Click "Read" in the figure below

Motor controller programming

Replace motor
controller

Read

3. Click the start button at the lower part of the screen and put the key close to the start button for IMMO
matching. Successful IMMO programming screen is as shown below;

Motor controller programming

VDC initialization…

Entering motor controller programming status. Please wait…

Determining the old and new versions of IKEY controller and motor controller…

Please insert the valid old key of the vehicle…

Motor controller self-learning please wait...

The motor controller was programmed successfully

Inclination calibrated:
Before the inclination calibration, be sure to park the vehicle on a level ground;
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1. Click "Calibration" option;

Vacuum pump working Tilt down line

time resetting calibration

2. Select "Inclination EOL calibration” module;

Tilt down line calibration

Calibration condition requirements

(1) The OK mode on the vehicle is ;

Read

3. Click "Read"; and click the start button;

Tilt down line calibration

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4. Successful calibration screen is as shown below

Tilt down line calibration

Extended diagnostic mode：

Extended diagnostic mode switched
Start tilt calibration:
Tilt calibration: start calibration
Request routine result (check calibration result):
Calibration result: Calibrate successfully

6 PDU
6.1 Location
The charging and distribution assembly is arranged on the upper part of the front compartment of the
vehicle, as shown in the following Fig.:
Integrated AC/DC
charging port
DC charging connection
Charging and harness sub-assembly
distribution
assembly AC charging connection
harness sub-assembly

High voltage
distribution harness
sub-assembly

6.2 Definition of LV Pins

Projection drawing of low-voltage connector is as follows:

Pin definition

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Pin No. Port name Port definition Harness connection

1 Power input External 12V power supply Connect to IG3 power
2 Power input External 12V power supply Connect to IG3 power
3 GND Constant power supply GND 1 Connect power GND
4 / /
5 / /
6 / /
7 / /
DC charging anode / DC charging
8 SOURSE-JCQ To battery 33PIN-12
cathode contactor power supply
DC charging anode contactor control
9 CONTROL-JCQ+ To battery 33PIN-24
signal
DC charging cathode contactor control
10 CONTROL-JCQ- To battery 33PIN-31
signal
11 / /
To DC interlocking
12 DCHS-IN DC high voltage interlocking input
connector 2pin-1
13 DCHS-OUT DC high voltage interlocking output To battery 33PIN-18
14 / /
15 / /
16 CAN-H Power network CAN-H
17 CAN-L Power network CAN-L
18 / /
19 GND Constant power supply GND 2
20 / /
Voltage detection
21 External 12V power supply Connect to IG3 power
board power input
/ /
23 GND External 12V power GND Power supply GND
24 / /
25 CAN-H Power net CAN line
26 CAN-L Power net CAN line
27 CAN shielding CAN shielding ground
28 / /
29 / /
30 / /
31 / /
32 / /
33 / /

6.3 Structure description

Port S/N Definition Diagram

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AC charging
6
(plug)
AC
5 discharge
(plug)
DC charging
4
input
Air
conditioner
12 compressor
power
distribution
Air
conditioner
10
PTC power
distribution
Electrical 13 Plug
interface Low-voltage
11
anode output
Low-voltage
3
signal
HV DC
7
input// output
Motor
controller
8
power
distribution
N wire
29
interface
Power
distribution
28 for 40KW
OBC
assembly
Main
19 positioning
(φ8.5)
Auxiliary
9 positioning
Mechanical (φ9*10.5)
interface Auxiliary
14
positioning
15 (φ10)

17 Auxiliary
positioning
18 (φ10)

Water 16 Water inlet

pipeline 2 Water outlet
interface 1 Exhaust port

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Bonding
20
point
Bonding
22
point
Bonding
23
point
Bonding
24
point
Water pipe
21
fixing point
Other Water pipe
interfaces 25
fixing point
Water pipe
26
fixing point
Exhaust
27
valve

14 Auxiliary
positioning
15 (φ10)

17 Auxiliary
positioning
18 (φ10)

6.4 Fault diagnosis

1 Drive the vehicle into the maintenance workshop.

Next
step

2 Check the voltage of the LV (low voltage) battery

Standard voltage range:
11~14V
If the voltage is lower than 11V, please charge or replace the batteries before next step.

Next
step

3 Refer to the Fault Diagnosis List.

Results Perform
The phenomenon is not specified A
in the Fault Diagnosis List.
The phenomenon is specified in B

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the Fault Diagnosis List.

B Go to Step 5

4 Comprehensive diagnosis

Next
step

5 Adjust, repair and replace

Next
step

6 Perform the pinpoint test

Next
step

7 End

6.5 List of DTCs

S/N Fault code Fault description
DCDC fault code
1 P1EC000 Voltage at high-voltage side too high at reduction
2 P1EC100 Voltage at high-voltage side too low at reduction
3 P1EC600 Current at high-voltage side too high at reduction
4 P1EC200 Voltage at low-voltage side too high at reduction
5 P1EC300 Voltage at low-voltage side too low at reduction
6 P1EC400 Current at low-voltage side too high at reduction
7 P1EC700 Hardware fault at reduction
8 P1EE000 Radiator over-temperature
9 U014000 Communication fault to BCM
10 P1ED317 Low-voltage supply voltage too low
11 P1ED316 Low-voltage supply voltage too high

6.6 Perform comprehensive diagnosis.

6.6.1 DC step-down fault
When the low-voltage power supply system of the vehicle fails, preliminarily determine the fault cause
according to the following procedure.
1 Check the voltage of power battery.
a) The vehicle is at “OK” position
b) Check if the DC bus voltage is normal with VDS2000

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DC Normal value
Bus voltage About 332-630.8V

NG
Check the battery pack and
high-voltage line

OK

3 Check whether the low-voltage power supply of PDU is at 9-16V

NG Check the low-voltage circuit

OK

4 Check whether the DC output voltage of PDU is 9-16V

NG Check the low-voltage circuit

OK

5 Replace the charging and distributing assembly

6.6.2 Voltage detection fault
When the DC charging of the vehicle fails, preliminarily determine the fault cause according to the
following procedure
1 Can it be charged by another charging pile?

Ok Charging pile fault

NG

2 Check whether there is a message in VDM

NG

2.1 Check whether the low-voltage connector pin of PDU is powered on

NG The vehicle low-voltage

system is faulty

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OK

2.2 Use VDS2000 to check VDM message, check for sintering, and do self-test of fault.
Yes: Replace the PDU;
No: Observe the DC charging port and capacitor voltage; if there is no voltage on the DC charging
port side and the capacitor voltage is normal, check whether BMC and electronic control fault
exists

6.7 Replacement of charging and distribution assembly

1. Disconnect the low voltage connector
1. Power off the vehicle (set to “OFF” position);
2. Disconnect the low voltage negative terminal of the battery
3. Disconnect the connector of the charging and distribution assembly to the power battery as follows:

Power battery
connector

2. Removal of Load Connector

1) Remove the water inlet pipe, water outlet pipe and exhaust pipe with the water pipe pliers;

Inlet
pipe

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Exhaust
pipe

Outlet pipe

2) Manually remove the A/C PTC connector, A/C compressor connector, power distribution connector
of 40KW OBC, and low-voltage harness connector; (note that the connectors are provided with
secondary locking mechanism)

Air conditioner
compressor
connector
Air conditioner
PTC connector

Power
distribution
connector of
40KW OBC
assembly

Low-voltage
harness
connector

3) Remove the LV positive wire and 2 grounding wires using the No.13 socket.

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4) Undo 4 bolts (purple bolts shown below) with #7 socket wrench.

3. Removal of Wiring Nose

After disconnecting the vehicle low-voltage system and the traction battery connector of PDU, undo the
large cover bolts of PDU (purple bolts shown below) with the #7 socket wrench, and undo the
tamper-proof bolts of PDU (green bolts shown below) with the inner pentagonal torx tool.

Undo 10 M6 bolts with #10 socket wrench. The following purple parts are wiring nose connection
mechanism.

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4. Removal of fixing point of charging and distribution assembly

Remove four M8 bolts on the mounting support of charging and distributing assembly with No. 13 sleeve
tool.

6.8 Assembly Instructions

Take out the faulty charging and distributing assembly and replace it with a new one. Assemble the
charging and distributing assembly with the same tool following the reverse order.
Including all the fastening bolts of the upper cover, M5 bolts should be tightened to the torque of 2.8±0.3
N.m; including all the fastening bolts of the wiring nose, M6 bolts should be tightened to the torque of 9±1
N.m; including the four mounting foot bolts of the PDU, M8 bolts should be tightened to the torque of
20±2 Nm.

7 Charging port & European-standard DC communication converter

7.1 Location
MEEY applies integrated charging port, which is located at the right quarter panel of the vehicle.
The European-standard DC communication converter is located at the left side of the vehicle trunk.

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European-standard AC/DC
integrated charging port

AC charging connection
harness sub-assembly

DC charging connection
High voltage distribution harness sub-assembly
harness sub-assembly
Power distribution
unit

7.2 Definition of LV Pins

Projection drawing of low-voltage connector is as follows:

LV connector of DC charging port European-standard communication module

Table 7-1 Pin Definition of European-standard Communication Module

Pin No. Port name Port definition Harness connection

1 CP Charging communication signal Connect pin -1 of charging port
2
3
4
5
6
7
DC charging subnetwork
8 CAN low To battery pack 33PIN-8
communication CAN-low
9
10 Power 12V 12V power positive To B22
11 PE Ground wire To vehicle body GND
12
13
14
15
16
17
DC charging subnetwork
18 CAN high To battery pack 33PIN-15
communication CAN-high
19
20 GND 12V power negative To vehicle body GND

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Table 7-2 Pin Definition of DC Charging Port

Pin No. Port name Port definition Harness connection

To European-standard DC charging
1 CP Charging communication signal communication module -1
To 40kW OBC14-5
To 40kW OBC14-4
2 PP DC charging sensor signal
To battery 33PIN-25
3 Locking power supply To all-in-one F08
4 Unlocking power To all-in-one F07
5 Locking status check To all-in-one E09
6 T1-CDK+ Temperature sensor high To 40kW OBC14-11
7 DC charging port temperature 1 To battery 33PIN-14
DC charging port temperature
detection ground 1, DC
8 To battery 33PIN-21
charging port temperature
detection ground 2
9 DC charging port temperature 2 To battery 33PIN-20
10 T2-CDK+ Temperature sensor high 40kWOBC14-12
11 T3-CDK+ Temperature sensor high 40kWOBC14-13
T1-CDK-, T2-CDK-,
12 Temperature sensor low Body GND
T3-CDK-

Table 7-3 DC Interlocking Connector

Pin No. Port name Port definition Harness connection

DC charging socket adapter To charging and distributing
1 Interlocking input
interlocking assembly 33PIN-12
DC charging socket adapter
2 Interlocking output To battery 33PIN-13
interlocking

7.3 Fault diagnosis

As a conduction charging medium, the charging port must have wear and aging problems, and it should
be covered by the maintenance scope. See the following table for the specific maintenance items and
criterions:
1) Turn off the vehicle (to the “OFF” position), unlock the vehicle, and open the charging port cover
and cap;
2) Visually check the plastic insulation shell of charging port for the hot melting deformation, and
replace the shell of which the deformation affects the normal operation;
3) Visually check the charging port and terminal for the foreign matters, discharge the foreign matters
with high-pressure air gun and replace the charging port and terminal of which the foreign matters affect
the normal operation.
4) Visually check whether the leaf spring and the bottom of charging port are blackened, and replace
the blackened ones;
5) Visually check whether the leaf spring and bottom of charging port become yellow. If so, open the
back door and rear left side wall access to check whether the cable at the rear of charging port is burnt
and deformed (with the auxiliary lighting). Replace the leaf spring which turns yellow and the outer layer
of cable turns black;

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6) Visually check the leaf spring of terminal for breakage and replace the broken one;
7) Replace any charging port beyond the quality warranty period at your own expense (if it is not
replaced, inform the user of potential safety hazards and associated loss to the charging plug).
7.4 Replacement of European-standard AC/DC integrated charging port
Power off the vehicle (set to “OFF” position) and disconnect the connector of the PDU to the traction
battery.
The vehicle applies AC and DC integrated charging port. In the aftermarket replacement, only the AC
charging port is replaced separately, and the purchased AC charging port materials are as follows:
1. Disconnect the connector of the AC charging port to the 40KW OBC.

Connector

Push

2. Remove the straps in the blue circles shown below, taking care not to damage the straps as much as
possible.
Then take off the straps in the red circles shown below, and remove the nuts for the ground terminal and
the mounting bracket with the #10 socket wrench.
Afterwards, remove the emergency blind nut from the stud, and remove the low-voltage connector.

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Earth
terminal
Low voltage
connector

Emergency
rivet nut

Cable ties
Fixing
Bracket

Cable ties

3. Remove the DC charging port from the body mounting plate with the #10 socket wrench. During the
removal, take off the cover.

Mounting
nuts

Assemble the integrated charging port in the reverse order to the disassembly.

8 OBC assembly
8.1 Location
The on-board charger assembly is located in the luggage compartment of the vehicle, the AC charging
port assembly is located at the right quarter panel, and the high-voltage distribution harness is located at
the underbody and connected to the PDU and the on-board charger assembly.
As shown in the following figure:

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Integrated AC/DC
charging port

Charging and
distribution assembly

8.2 Definition of LV Pins

Projection drawing of low-voltage connector is as follows:

Definitions of pins are as follows:

Pin No. Port name Port definition Harness connection

1 Constant power 12V Constant power
2 CAN-H CAN_H
3 CAN-L CAN_L
CC (European
4 Confirmation of charging connection AC charging port 12- 2
standard PP)
5 CP CP AC charging port 12- 1
6
7 Power supply GND
8 Power supply GND
9
10
11 L1 wire temperature sensor signal AC charging port 12- 7
12 L2 wire temperature sensor signal AC charging port 12- 9
13 L3 wire temperature sensor signal AC charging port 12- 11
14

8.3 Structure description

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Internal high
voltage

S/N Definition Docking instructions

1 Mounting support Installed on the luggage compartment bracket
2 Mounting support Installed on the luggage compartment bracket
3 AC input interface 1 To AC charging port
4 AC input interface 2 To AC charging port
5 Water outlet Connect the water outlet pipe
6 High-voltage DC output To PDU
interface
7 Water inlet Connect the water inlet pipe
8 Low voltage signal interface To low-voltage wire harnesses
9 Mounting support Installed on the luggage compartment bracket
10 Mounting support Installed on the luggage compartment bracket

8.4 Fault diagnosis

1 Drive the vehicle into the maintenance workshop.

Next
step

2 Check the voltage of the LV (low voltage) battery

Standard voltage range:
11~14V
If the voltage is lower than 11V, please charge or
replace the batteries before next step.
Next
step

3 Refer to the Fault Diagnosis List.

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Results Perform
The phenomenon is not specified A
in the Fault Diagnosis List.
The phenomenon is specified in B
the Fault Diagnosis List.

B Go to Step 5

4 Comprehensive diagnosis

Next
step

5 Adjust, repair and replace

Next
step

6 Perform the pinpoint test

Next
step

7 End

8.5 List of DTCs

S/N Fault code Fault description
OBC fault code
1 P157016 Low voltage at AC side
2 P157017 High voltage at AC side
3 P157219 Over-current at DC side
4 P157216 Low voltage at DC side
5 P157217 High voltage at DC side
6 P157400 Supply device fault
7 P157616 Low-voltage supply voltage too low
8 P157617 Low-voltage supply voltage too high
9 P157897 Abnormal CC signal
10 P15794B Temperature sampling 1 high
11 P157A37 Charging net frequency high
12 P157A36 Charging net frequency low
13 P157B00 Over-current at AC side
14 P157C00 Hardware protection
15 P157E11 Charging connection signal externally short to ground
16 P157E12 Charging connection signal externally short to power

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17 P157F11 Short circuit at AC output end

18 P15834B Temperature sampling 2 high
19 P158798 Charging port temperature seriously too high
20 P158900 Abnormal temperature sampling at charging port
21 P158A00 Abnormal electronic lock
22 P151100 AC high-voltage interlock fault
23 U011100 BMC communication timeout
24 U015500 Combination instrument communication timeout
25 U024500 Multimedia communication timeout
26 P151500 Water temperature sensor fault
27 P15FD00 Cooling water temperature too high
28 U014087 BCM communication timeout
29 U011181 Abnormal BMC message data
30 U015587 Abnormal combination instrument message data
31 U024587 Abnormal multimedia message data
32 U014081 Abnormal BCM message data
33 U011182 Abnormal BMC cycle counter
34 P15FE00 Communication fault of main controller with sub-module
35 P15FF00 Failure of the internal temperature sensor

8.6 Perform comprehensive diagnosis.

Diagnosis Process of AC Charging Fault
In case of the charging failure, initially identify the possible causes according to the procedures below.
1 Check whether the external interface of the on-board charger assembly and distributing assembly
is well connected, and whether the low-voltage connector of AC charging socket is well
connected

NG Joint the connector

OK

2 Check if the vehicle is able to drive at “OK” position

NG Check the battery management

system and motor controller

OK

3 Check if the charging can be conducted at “OK” position

NG Check the low-voltage

distribution and gateway

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OK

4 Replace on-board charger assembly

8.7 Replace on-board charger assembly

1 Vehicle Returning to “OFF” Position
Vehicle flameout (return to OFF mode); Disconnect the negative pole of the battery；
2 . Removal of External Interface
1) Remove the water inlet water outlet pipe with the water pipe pliers;

Inlet pipe Outlet

pipe

2) Manually remove the high-voltage DC output connector, AC charging input connector and
low-voltage harness connector;

High voltage AC input

DC output connector
connector

Low
voltage
connector

3. Removing the mounting feet of OBC assembly

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Remove four M8 nuts on the mounting support of charging and distributing assembly with No. 13 sleeve
tool.

Mounting
support

Internal high
voltage

4 . Assembly Instructions
Take out on-board charger and distributing assembly and replace it with a new one. Assemble on-board
charger and distributing assembly with the same tool following the reverse order.
Tightening torque of M8 bolts: 22±1 N.m.

9 Front drive electric powertrain

9.1 Overview
MEEY front drive electric powertrain consists of drive motor, drive motor control unit and transmission,
which are integrated in the motor compartment of the vehicle. The drive motor is mainly designed to
convert the electric energy provided by the drive motor control unit into mechanical energy and output it
to the transmission, and convert the mechanical energy input from the transmission into electric energy
and output it to the drive motor control unit; the drive motor control unit is mainly designed to control the
energy transmission between the traction battery and the drive motor; the transmission is mainly
designed for deceleration and torque increase of the powertrain motor.

Front drive motor

assembly

Layout of front drive electric powertrain in motor compartment

9.2 Technical parameters

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Item Technical Parameters

Maximum output torque of the motor: 180N.m/(0~3714rpm)/30s
Rated torque of motor 70N.m/(0~4775rpm)/continuous
70/3714-12100/30s
Maximum input power of motor
100kW/(5305-6000)/5s
Rated motor power (kW) 35kW/(4775~12000rpm)/continuous
Maximum output speed of motor 12100rpm
Weight of electric powertrain 64kg
Transmission fluid capacity (0.65±0.05)L
Type of transmission fluid SHELL S3-ATF-MD3

9.3 Maintenance pretreatment and descriptions

(1) Electric powertrain
1) The automatic transmission applies oil bath lubrication. Recommended brand of transmission fluid:
SHELL, or the proven equivalent.
2) After disassembling and repairing the powertrain assembly, reassemble it onto the vehicle, and make
sure the oil seal is normal after the drive shaft is inserted into the splined snap ring of the transmission
differential port and locked. Add (0.65±0.05) L of SHELL S3-ATF-MD3 oil. Make sure that threads of the
filler plug and drain plug are normal. Tightening torque of the oil filling plug is 35-39N.m and that the
drain plug is 47 -53N.m paint mark is required after tightening
3) When assembling the motor and transmission, pay attention to protecting the O-ring and oil seal of the
transmission input shaft.
4) When assembling the motor and drive motor control unit, always ensure that the three-phase wire
terminal of front transmission motor is aligned with the interface of the drive motor control unit, and pay
attention to protecting the seal ring of the three-phase wire terminal of the front transmission motor.
(2) Bolts and nuts
Loosen and tighten the bolts or nuts motor assembly and gearbox shell, the drive and shell diagonally.
Replace the bolts which are cracked or damaged.
(3) Bearings
1) When replacing the bearing, apply grease onto the cylindrical mating surface between the inner &
outer races, the shaft and the housing seat hole.
2) The bearings detached from the shaft assembly can not be reused, but must be renewed.
3) When bearing replacement is required for the input shaft, output shaft and differential, please check
whether the gaskets need to be replaced.
9.4 Overall structure diagram of electric powertrain

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Fig.2 Front Drive Motor Assembly Parts

Main parts of front drive powertrain assembly
S/N Name of Part
1 Drive motor assembly
2 Drive motor controller assembly
3 Front transmission assembly

9.5 Outline drawing of electric powertrain

With overall dimensions of A×B×C=551mm×424.5mm×376mm, the outline of MEEY front drive electric
powertrain is as shown in Figure 3.

Figure 3 Outline of MEEY Front Drive Electric Powertrain

9.6 Disassembly and repair of front drive powertrain assembly
9.6.1 Disassembly and repair of front drive electric powertrain
When disassembling the front drive electric powertrain removed from the vehicle, please pay attention to
protecting all parts and storing them well to prevent the parts from being damaged accidentally.
1. Drain the gear oil:
Before disassembling the (in Fig. 4) powertrain, open the drain plug assembly to drain the oil inside the
transmission, and then tighten the drain plug to prevent foreign objects from falling into the transmission
assembly cavity during disassembly.

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Oil drain plug

Figure 4 Draining Gear Oil

2. Drain the coolant:
Drain the water in the cooling water channel from the water outlet with the air gun from the water inlet

Electric control
water inlet

Motor water
outlet

Fig.5 Location of water Inlet and Outlet of Motor Assembly Location

3. Bolts and Nuts
Loosen and tighten the bolts or nuts on the drive motor end cap and gearbox shell, the drive motor
controller and shell diagonally. Replace the bolts which are cracked or damaged.
When installing the drive motor control unit, pay attention to the positions of its four bolt holes. When
connecting the three-phase cable to the drive motor, be careful not to scratch the drive motor and its
control unit.
4. Airtightness test
Conduct airtightness test on the assembly and the water pipeline after replacing the motor or electronic
control system.
5. Precautions
Considerations for the re-installation of front drive motor assembly after disassembling and repairing

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a) Use the differential oil seal protective sleeve (see Figure 6) to protect the oil seal before the drive shaft
is inserted into the differential port of the transmission. Then insert the drive shaft into the differential port
splined snap ring and lock it (see Figure 7), ensuring that the differential oil seal is normal and intact;
b) Add 0.65±0.05L oil (recommended oil S3-ATF-MD3). Make sure that threads of the filler plug and
drain plug are normal. Tightening torque of the oil filling plug is 37 ± 2N.m and that the drain plug is 50 ±
3N.m, and paint mark is required after tightening

Differential oil
seal

Oil seal
sheath

Figure 6 Oil Seal Protective Sleeve Fig. 7 Fitting Between Oil Seal and Drive Shaft
c) When installing the drive motor control unit, pay attention to the positions of its bolt holes. When
connecting the three-phase cable to the drive motor, be careful not to scratch the drive motor and its
control unit.
d) After the assembly is installed in the vehicle, it needs to be charged with AC (or DC) for 10 min;
observe the change of coolant level in the tank, make sure the level is above (or parallel to) MAX scale,
and add coolant if required.
9.6.2 Removal and maintenance of transmission
1. Common Faults and Troubleshooting of Transmission Assembly
Common related
Fault Confirmation Troubleshooting
faults
Renew the differential oil seal (1. Remove the leaky
Visually check or touch oil seal as follows: screw a pointed bolt into the oil
the oil seals of 2 seal, and then pull out the oil seal with pliers; 2. Install
Leakage of differentials (as shown in the new oil seal as follows: set the oil seal onto the oil
differential oil seal Fig.12). In case of oil seal tooling, then align the tooling with the oil seal
leakage, there will be hole, put it at the right position, and gently tap it with a
obvious traces hammer to the right position, ensuring the oil seal and
lip are smooth and even).
Visually check or touch Replace the magnetic hexagon socket plug (drain
the oil drain plug (as plug) gasket or hexagon socket plug (loosen the drain
Leakage of oil drain
shown in Fig. 13). In plug with H10 torque wrench, check whether the
plug
case of oil leakage, there problem lies in the gasket or plug, and then replace
will be obvious traces the gasket or plug).
Preliminarily determine where the noise is emitted,
make a recording, send the recording data to the
Obvious unusual noise is after-sales service person in charge of quality, and
emitted during running of provide it to the technical department for synchronous
Driving noise
the vehicle or after the verification, and then conduct repair according to the
window is closed actual situation. If it is determined that the noise is
from the front drive electric powertrain, return it to the
factory for repair.

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Provide fault data to the quality department and

technical department for synchronous
Other problems Confirm the fault
troubleshooting, and then arrange repair or return to
the factory for repair according to the result.

Differential oil seal location

Figure 12 Location of Oil Seal of Front Transmission Assembly

2. Disassembly and repair of front transmission assembly
Before disassembling the front transmission assembly, remove the front drive electric powertrain from
the vehicle, then carry out disassembly and repair of the transmission assembly: open the drain plug
assembly, discharge the oil inside the transmission assembly, and then install the drain plug assembly to
prevent foreign objects from falling into the transmission cavity during the disassembly process. In the
process of disassembly, please pay attention to the protection and storage of all parts to prevent
accidental damage to parts.
The front transmission assembly needs to be returned to the factory for disassembly and repair. First,
disassemble the drive motor control unit (as detailed above). The transmission needs to be returned to
the factory for disassembly and repair by the manufacturer. After repair, the transmission will be cleaned
and assembled by the manufacturer. After the sealant is completely solidified, add cooling oil to the
transmission from the oil filler until the oil level is flush with the bottom surface of the oil filler, and fix the
breather pipe assembly and filler plug assembly on the transmission. Put the transmission casing still to
check cooling oil for leakage, and if any, remove the corresponding position for re-sealing.
3. Oil change of front transmission assembly
The front transmission assembly applies oil bath lubrication. SHELL S3-ATF-MD3 gear oil is
recommended.

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Oil fill plug

Oil drain bolt
assembly

Figure 13 Oil Change of Front Transmission

Please conduct maintenance on the transmission of MEEY front drive electric powertrain in the following
steps:
1. Open the drain and filler plug assemblies respectively and drain the oil from the transmission.
Meanwhile, check whether the drain plug assembly and O-ring are intact and replace them when
necessary;
2. After the oil is drained, tighten the drain plug assembly to the torque of 47-53N.m.
3. Add (0.65±0.05)L SHELL S3-ATF-MD3 gear oil through the oil filler, and observe whether leakage
exists; In case of leakage, disassemble the corresponding part and re-seal it; screw up the filler plug
assembly and tighten it to the torque of 35-39N.m.
9.6.3 Removal and maintenance of the drive motor
Pay attention to well protect and store all the parts in the disassembly process to avoid the accidental
damages to the parts.
1. Disassembly and repair of motor N wire
Pay attention to well protect and store all the parts in the disassembly process to avoid the accidental
damages to the parts.
2. Disassembly of motor N wire
a) Undo 4 M5 bolts and 2 M8 bolts of the small cover, and remove the residual sealant at the cover
seal;
b) Undo M8 bolts of wiring nose of the motor N wire;
c) Undo 4 M5 bolts from the flange mounting surface of the motor N wire;
d) Pull out the motor N wire perpendicular to the flange surface, paying attention to the state of the N
wire seal ring;

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Sealant
Motor N wire application
Mounting bolts of path
flange of motor N wire
Flange of motor
N wire

Rear
cover

Figure 15 Small Cover

Wiring nose of
Terminal motor N wire
block fixing
bolt
M8 fixing bolt

Terminal Wiring nose of motor

block stator end

Figure 14 Structure of Connection Box of Motor N Wire

S/N Name of Part Pieces (PCS) Remark
1 Small cover 1
2 Small cover fixing bolt M5 4 M5, tightening torque: 6Nm
3 Small cover fixing bolt M8 2 M8, tightening torque: 25Nm
4 Motor N wire flange mounting bolt M5 4 M5, tightening torque: 5Nm
5 M8 fixing bolt 1 M8, tightening torque: 25Nm
3. Assembly of motor N wire
a) Insert the wiring nose of N wire into the rear cover, paying attention to the mistake-proofing tab of
flange to ensure that the seal ring is in the flange sealing groove;
b) Fix the wiring nose of N wire onto the N wire terminal block with M8 bolts (tightening torque: 25±2
Nm), paying attention to the position of the two wiring noses on the terminal block (the wiring nose of the
motor stator end should be outside);
c) Tighten the 4 M5 bolts of the flange of N wire;
d) Apply sealant onto the small cover of motor, and tighten 4 M5 bolts and 2 M8 bolts diagonally;

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M8 fixing bolt

Small cover plate

2*8M bolts

Small
Small cover plate cover
4*M5 bolts

Figure 16 Exploded View of Motor N Wire

4. Precautions
During assembly, note that the O-ring of N wire needs to be in the flange sealing groove, to avoid
damage to the seal during assembly, resulting in sealing failure;
When assembling the wiring nose, the wiring nose of N wire should be under the wiring nose of stator
end, as shown in Figure 14.
5 Removal and maintenance of the drive motor
Pay attention to well protect and store all the parts in the disassembly process to avoid the accidental
damages to the parts.
5.1 Before removal：
Before disassembling the powertrain, open the drain plug assembly to drain the oil inside the
transmission, and then tighten the drain plug assembly to prevent foreign objects from falling into the
transmission assembly cavity during disassembly.
5.2 Removal
Removing the drive motor
a) Remove the motor N wire according to step 3.1.1, as shown in Figure 16;
b) Undo the 2×M5 fixing bolts of the terminal block and remove the terminal block. Undo the 10 M5
bolts of the rear cover and remove the rear cover, as shown in Figure 17;

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Rear
cover

Terminal
block

2×M5 bolts

10×M5 bolts

Figure 17 Exploded View of Rear Cover

c) Loosen the 3 M6 bolts for fixing the three-phase wire and remove the resolver and temperature
sensor connector; (phase sequence of three-phase wire from left to right: U, V, W), as shown in Figure
18.

Three-phase line Connector of rotary transformer

fastening bolt and temperature sensor
4×M10 bolts

Figure 18 Motor Three-phase Wire and Resolver Figure 19 Exploded View of Electronic Control System
d) Remove the motor control unit: Undo the 4 M10 bolts for fixing the drive motor control unit, remove the
drive motor control unit and protect the water inlet against collision with the drive motor. Then blow dry
the residual water at water inlet and outlet with an air gun, as shown in Figure 19.
5.3 Removal of resolver and temperature sensor connector
Press the clip and pull out the resolver and temperature sensor connector. The pin definition of the
connector is shown below.

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Connector pin definition (external view)

Rotary transformer connector pin
definition (external view)
Pin S/N Definition
Temperature sensor 1
Temperature sensor
2(reserved)

Temperature sensor 1
Temperature sensor
2(reserved)

Fig. 20 Resolver Connector Fig. 21 Pin Definition of Resolver Connector

5.4 Sealant application of motor end cover
After the troubleshooting, sealant should be applied onto the end cover in the following steps before
installing the small end cover of the motor:
a) Clear the residual sealant on the mating surface of the end cover and the rear end cover;
b) Apply sealant onto the end cover, in the path as shown in Figure 22;

Figure 22 Sealant Application Path of Motor End Cover

c) Set the end cover onto the rear end cover of the motor after alignment with the bolt holes;
d) Assemble the bolts in order, then tighten the bolts alternately and make paint marks.
5.5 Common Faults and Troubleshooting of Drive Motor:
Common related
Fault Confirmation Troubleshooting
faults
Test the sine, cosine and excitation impedance of
If the resistance value is
the resolver through the patch cord with the
Rotary normal, check the controller, if
frequency set to 10kHz. The corresponding
transformer fault the resistance value is
impedance requirements are as follows: sine: 205
of vehicle abnormal, replace the rotary
Ω ± 42 Ω, cosine: 205 Ω ± 42 Ω, excitation: 120 Ω ±
transformer;
24 Ω.
Remove the small end cap of motor, and remove If the test results are normal,
Vehicle current the fixing bolts of stator outgoing line, and test the check and inspect the
leakage insulation and voltage resistance of the stator controller. If the insulation and
against the motor shell. voltage resistance are poor,
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Insulation resistance: DC1000V, 10S, ﹥ 50MΩ remove the motor and return it
Voltage resistance: AC2000V, 60S, <20mA to the factory for inspection and
maintenance.
Send the recording data to the
person in charge of after-sales,
Abnormal noise Confirm the working conditions of abnormal noise
and provide it to the technical
of vehicle and record it
department for synchronous
confirmation and processing
Disassembly and return to the
Other problems Confirm the fault
factory
9.6.4 Disassembly and repair of drive motor control unit
Before the disassembly, the high-voltage harness needs to be disconnected for 5 min. Pay attention to
well protect and store all the parts in the disassembly process to avoid the accidental damages to the
parts.
1 Removal of drive motor controller
a) Use the air gun to drain the coolant in the coolant pipeline from the water outlet at the water inlet,
and detach the pipe clip and pipe;
b) Remove the motor N wire according to step 3.1.1, as shown in Figure 16;
c) Undo the 2×M5 fixing bolts of the terminal block and remove the terminal block. Undo the 10 M5
bolts of the rear cover and remove the rear cover, as shown in Figure 17;
d) Loosen the 3 M6 bolts for fixing the three-phase wire and remove the resolver and temperature
sensor connector; (phase sequence of three-phase wire from left to right: U, V, W), as shown in Figure
18;
d) Undo the 4 M10 bolts for fixing the drive motor control unit, remove the drive motor control unit and
protect the water inlet against collision with the drive motor. Then blow dry the residual water at water
inlet and outlet with an air gun, as shown in Figure 19.
Finally, separate the drive motor control unit from the motor and transmission, and protect the water inlet
and outlet of each part from being knocked.
2. Repair
If it is determined that the transmission assembly or drive motor needs to be returned to the factory for
repair, the transmission assembly together with the drive motor should be returned to the factory for
disassembly and repair after the drive motor control unit is removed.
3. Assembly of the drive motor controller
3.1 Before Installation

Figure 23 Before Assembly of Drive Motor Control Unit

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3.2 After Installation

Figure 24 After Assembly of Drive Motor Control Unit

9.7 Definitions of Drive Motor Controller Pins

Fig.25. Definitions of Drive Motor Controller Pins

Definitions of Drive Motor Controller Pins Table：

Power
supply
Steady-state Impulse
Connector Port Harness Signal nature
Port name working current and Remark
pins definition connection Type (e.g.
current stall current
constant
power)
12 V power
To vehicle
1 supply DND-IN 2 30A/100ms
body GND
GND
2 / /
Reserved CAN Reserved
3 CANH 2 0.5
CAN signal CAN-High
Reserved CAN Reserved
4 CANL 2 0.5
CAN signal CAN-Low
To SRS
Collision PWM
5 CRASH_IN ECU pin PWM
signal signal
#10
12 V power
To vehicle
6 supply DND-IN 2 30A/100ms
body GND
GND

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7 / /
Collision
To vehicle
8 signal EARTH-1 0.5
body GND
GND
CAN Power net
9 CAN high CANH 0.5
signal CAN-H
12V power
10 +12V To B22 2 30A/100ms IG3
positive
12V power
11 +12V To B22 2 30A/100ms IG3
positive
12 / 0.5
Shielding
CAN GND Shielded
13 shielding EARTH /
Shielded wire
ground
wire
CAN Power net
14 CAN low CANL 0.5
signal CAN-L

9.8 Diagnosis Trouble Codes of Drive Motor Controller

See the following table: DTC

DTC Description
P2B0017 DC charging input is overvoltage
P2B0019 Direct current charging input is overcurrent
P2B001C The instantaneous voltage on the DC charging input side is high
P2B001D The instantaneous current on the DC charging input side is high
P2B0016 Direct current charging input is undervoltage
P2B0200 DC charging step-down failure
P2B0317 DC rechargeable battery side is overvoltage
P2B031C The instantaneous voltage on the DC rechargeable battery side is
high
P2B0316 DC rechargeable battery side is undervoltage
U016887 Communication failure between DC charging and BMS
P2B0500 IPM protection for DC charging
P2B0F00 Abnormal heat dissipation fault
P2B0D00 DC charging fault recovery timeout
P2B0E00 DC charging restart too many times
P2B1000 Abnormality in power battery's lifespan
P2B111B Power battery's total voltage high
P2B121B Power battery's single-cell voltage high
P260300 EDCM A-phase IGBT overtemperature
P260400 EDCM B-phase IGBT overtemperature
P260500 EDCM C-phase IGBT overtemperature
P260600 EDCM motor winding overtemperature

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DTC Description
P260700 EDCM rotor position protection failure
P260B00 EDCM current Hall sensor A fault
P260C00 EDCM current Hall sensor B fault
P260D00 EDCM current Hall sensor C fault
P260E00 EDCM IGBT three-phase temperature calibration fault alarm
P260F19 EDCM CPLD overcurrent
P260F17 EDCM CPLD overvoltage
P261000 EDCM DSP1 crash
P261100 EDCM CPLD operation fault
P261200 EDCM CPLD detection IGBT upper bridge error
P261300 EDCM CPLD detection IGBT lower bridge error
U029F87 EDCM and OBC communication failure
P261416 Power battery's total voltage low
P261500 EDCM IPM overtemperature
P261600 EDCM current unbalance
P2B0B2B DC charging inductor over-temperature

10 Vehicle electric leakage troubleshooting

10.1 Testing tools
a) Multimeter (internal resistance: above 10MΩ), VDS;
b) Adjustable resistance meter (range: 10KΩ~1MΩ);
c) Insulating gloves, insulating shoes (withstand voltage: above 1KV);
d) Insulation resistance tester (with DC 500V and DC 1000V positions, for example: HIOKI 3455-20
high-voltage insulation resistance meter);
10.2 Testing requirements
a) Operators need to be qualified as a mechanic complying with the applicable national regulations or
hold the electrician certificate;
b) Operators must wear the necessary PPE, such as insulating gloves, insulating shoes, etc.; check
that the PPE is intact, dry and free of foreign objects to ensure safety before use;
c) Never allow operators to work with fatigue so as to prevent safety accidents;
d) The work site should be isolated by isolation belt and provided with high voltage warning signs. And
one operator should be accompanied by one guardian;
e) Operators are not allowed to wear metal decorations, such as watches, rings, etc.;
f) The vehicle must be parked on an insulated ground. For example, special repair stations should be
set for new energy vehicles.
10.3 Testing method
Wear insulating gloves and insulating shoes, and provided that safety is guaranteed:
1. Unplug the battery pack bus with the vehicle powered off.
2. Use insulation resistance tester to measure the insulation resistance to ground of positive and
negative copper busbars inside the PDU respectively (to connect the copper busbar of battery pack or
front electronic control system for test).

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3. If the resistance is greater than 1MΩ, it indicates that there is no problem with the load; the battery
pack has leakage problem.
4. If the measured insulation resistance is abnormal, it indicates load leakage. In that case, remove
the loads separately for insulation test to locate the problem.

Battery package Front electric

busbar copper control busbar
plate copper plate

11 Problem feedback and message data collection

11.1 Vehicle problem feedback
When some problems are too complicated to be solved, fill out the Vehicle Problem Feedback Form to
report the problems to the Automotive Engineering Institute.
11.2 Message data collection
If necessary, collect the message data when the fault is reproduced. Please refer to other related
documents for the collection method of message data.

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