4 New Energy Vehicle Components / 4.1 Integrated E-axle Device | PDF pages 75-188

4.1 Integrated E-axle Device

4.1.1 Quality Warranty Statement

4.1.1.1 Emission Quality Warranty Statement

– For emissions-related warranty (5 years or 100,000

miles) under “powertrain” list main components that need to

be covered – motor, inverter, HV battery charging system,

batteries and thermal management.

– The emission-related warranty covers all components

whose failure would increase a vehicle's emissions of air

conditioning refrigerants.

4.1.2 specifications

4.1.2.1 Fastener Specifications

Range Of Torque

Specifications

Fastener name

Metric System（ft-lb）

The grounding wire fixing bolt

connecting the integrated axle and the

(11 ft-lb +/- .5 ft-lb) ft-lb

frame assembly

4.1.2.2 Technical Parameters

Drive Motor

Item

General Parameters

Jiangsu Maxwell Industries Co., Ltd.

Manufacturer

Type

Permanent magnetic synchronous motor

Continuous power

170kW

Peak power

260kW

Continuous torque

184 lb·ft

Peak torque

405lb·ft

Speed range

0-11,000 r/min

Insulation grade

Cooling method

Water cooling

Protection rating

IP67

Weight

60 kg

System efficiency

97.4%

4.1.3 Decomposition Diagram

4.1.3.1 Decomposition Diagram

Axle Electric Drive Assy

4.1.4 Inspect

4.1.4.1 Inspection of Electric Drive System

Before starting the vehicle, check whether the relevant data

displayed on the instrument cluster is normal. If the data is

abnormal, do not drive the vehicle. Instead, record the system

fault type and related data, and report the information to the

Windrose authorized service station.

caution

If the high voltage battery or motor system fails, please

contact a Windrose authorized service station for repair

in time.

4.1.5 System Schematic Diagram

4.1.5.1 Electrical Schematic Diagram

4.1.6 Diagnostic Information and Steps

4.1.6.1 Diagnosis Description

Before diagnosing faults in the integrated axle device, it is important to understand and familiarize oneself with the working

principle of the integrated axle device, and then begin system diagnosis. This will help determine the correct fault diagnosis steps

when a fault occurs, and more importantly, it will help determine whether the situation described by the customer belongs to

normal operation. Any fault diagnosis of integrated axle devices should start with routine inspection, guiding maintenance

personnel to take the next logical step for fault diagnosis. Understanding and correctly using the diagnostic process can shorten

the diagnosis time and avoid misjudgment of faulty parts.

4.1.6.2 Routine Inspection

• Check for aftermarket installation devices that may affect the operation of the integrated axle device system, ensuring that

these devices do not affect the operation of the integrated axle device system.

• Inspect system components that are easily accessible or visible to make sure they are not visibly damaged or have conditions

that could cause failure.

4.1.6.3 DTC Confirmation

1.Connect the diagnostic instrument to the diagnostic interface, read and record the DTC, and then clear the DTC.

2. Restart the vehicle.

3. Read the fault code of the control system again to confirm whether the system has a fault code output.

– Yes:Diagnose based on the output fault code.

– No:Perform intermittent fault checks, refer to Inspection Of Intermittent Fault

4.1.6.4 Inspection Of Intermittent Faults

caution

•

Clear DTC.

•

Conduct mock tests.

•

Check and shake the wiring harness, connector box terminals.

When the fault cannot be confirmed by DTC inspection, the fault phenomenon only occasionally occurs in use. This should

confirm all circuits and components that may cause the failure. In many cases, the fault location can be quickly and efficiently

identified by performing the basic checks shown in the flowchart below. Especially for faults such as poor contact of wiring

harness connectors. Fault Definition: This fault is not currently occurring, but historical DTC records indicate that this fault has

occurred. Or the customer has reported the fault to be repaired, but because the fault is not related to the DTC, the fault

symptoms cannot be reproduced at this time.

Diagnostic Steps:

Step 1

Check the battery voltage.

Perform vehicle power-up operation.

Measure the voltage of the battery.

According to the measured values, the corresponding

diagnostic step is entered.

Result

To Step

22 V - 27.4 V

Yes

Less than 22 V

Check the main battery. Refer to

Inspection Of Main Battery

Yes

Visual physical inspection.

Step 2

Performing this step is an important means to preliminarily

determine the location of the fault:

• Check the wiring harness is damaged, whether there are

wear, broken skin and other faults.

• Check the wiring harness is improperly arranged. It is

strictly forbidden to close the wiring harness to high voltage

or high current devices.

• Check the positive and negative cables of the battery are

connected reliably and whether there are any phenomena

such as looseness, oxidation and corrosion.

Next Step

Step 3

Check the wiring harness, connectors.

Many intermittent failures are caused by wire harness

and connector movement caused by vibration, twisting,

uneven road or component operation.

If the circuit resistance is too high, the component may

not work properly. Use the diagnostic instrument to

force the actuator to drive. If it can't work normally,

Check the relevant circuit has line faults such as

excessive resistance.

Next Step

Step 4

Reproduce the fault and record the data of the control unit with the instrument.

Connect the vehicle fault diagnosis instrument, and use

the data recording function of the fault diagnosis

instrument to record the data when intermittent faults

occur on the road test vehicle. After pressing the button

of the vehicle data logger, the control module data can

be recorded in the event of intermittent failure, which

can be used to identify the failure location.

Another diagnostic method is to connect the digital

multimeter to the suspicious circuit while the vehicle is

running. The abnormal reading value of the digital

multimeter may indicate the fault location.

Next Step

Step 5

The fault LED illuminates intermittently, but the system has no fault code set.

The following conditions may cause the fault LED to

illuminate intermittently, but the system will not set a DTC:

• Electromagnetic interference caused by abnormally

working relays, solenoid valves or switches controlled by

the control module.

• Accessories that are not original or after-market, such as

car phones, alarms, lights or radios, are not installed

correctly.

• The fault indicator control circuit is intermittently shorted to

ground.

• The control module ground point is loose.

Next Step

Step 6

Other checks.

Check the charging system for the following conditions:

• Is the output voltage of the high and low voltage charging

system correct? If the DCDC1 output voltage is not around

27.5 V and the DCDC2 output voltage is not around 30.5 V,

repair the charging system.

Next Step

Step 7

Go to the fault symptom table.

4.1.6.5 List Of Diagnostic Trouble Codes (DTCs)

MCU1

Fault Description

Exclusion Method

Fault Code

Supply Voltage Too High

B111717

Refer to MCU1 Power Fault

Supply Voltage Too Low

B111716

VDC Signal checksum Fault

P226500

VDC Signal rollingcounter Fault

P226600

U012287

Lost Communication With VDC

Refer to MCU1 Communication Fault

U015687

Lost Communication With CDCU

U019887

Lost Communication With T-BOX

U008E88

CAN Bus Off

SiC Temperature Sensor "U" Circuit

P222200

short to ground

SiC Temperature Sensor "U" Circuit

P222300

short to battery or open

Refer to MCU1 Internal Fault

SiC Temperature Sensor "V" Circuit

P222400

short to ground

SiC Temperature Sensor "V" Circuit

P222500

short to battery or open

Fault Description

Exclusion Method

Fault Code

SiC Temperature Sensor "V" Circuit

P222600

short to ground

SiC Temperature Sensor "V" Circuit

P222700

short to battery or open

SiC Temperature Sensor ，Any Two

P222800

Phase electronic failure

Drive Motor "A" Temperature Sensor

P222B00

Circuit short to ground or open

Drive Motor "A" Temperature Sensor

P222C00

Circuit short to battery

Drive Motor "B" Temperature Sensor

P222D00

Circuit short to ground or open

Drive Motor "B" Temperature Sensor

P222E00

Circuit short to battery

Drive Motor "A" and "B" Temperature

P222F00

Sensor compare failure

Drive Motor "A" and "B" Temperature

P223000

Sensor Circuit electrical failure

Drive Motor Stalling Fault

P223100

Coolant Temperature Sensor Circuit

P223300

short to ground

Coolant Temperature Sensor Circuit

P223400

short to battery or open

Dreating Due to Drive Motor OverSpeed

P223500

Drive Motor OverSpeed Fault

P223600

Function Safety Speed Monitoring Faul

P223700

High Bridge Driver Fault

P223800

Low Bridge Driver Fault

P223900

CAN Link Chip Fault

P223A00

SBC Chip fault

P223B00

Current sensor Power supply voltage

P223C00

out of range

Power supply fault of driver board 5V out

P223D00

of range

SiC driver IC power supply voltage out

P223E00

of range

Function Safety internal Low

P223F00

PowerSupply Monitoring Fault

A/D Processing Performance fault

P224000

Fault Description

Exclusion Method

Fault Code

P224100

EEPROM Fault

MCU Unexpected Restart fault

P224200

P224300

MCU Self-Check fault

P224400

Shutdown Path Check fault

Inverter Performance Unexpected

P224500

operation

Torque difference between function

P224600

Safety layer and QM out of range fault

Torque difference between function

Safety layer and Requested out of

P224700

range fault

Enter ASC State Due to Back-EMF

P224800

voltage too high

P226700

Drive Motor Zero Position Not Learned

Resolver QM SIN/COS Signal out of

P226800

range Fault

Resolver QM EXC Signal amplitude out

P226900

of range Fault

Resolver FUSA EXC Signal amplitude

P227000

out of range Fault

Resolver FUSA SIN/COS Signal out of

P227100

range Fault

Current timestamp and Angle

P227200

timestampt Check Fault

L1 Electrical angle and Electrical angle

P227300

Check Fault

Resolver SIN and COS Sum of squares

P227400

Check Fault

High Bridge Driver INTA Fault

P227500

High Bridge Driver INTB Fault

P227600

Low Bridge Driver INTA Fault

P227700

Low Bridge Driver INTB Fault

P227800

Dreating Due to SiC Over temperature

P222000

SiC Overtemperature

P222100

Dreating due to Drive Motor Over

P222900

Refer to MCU1 Overheating Fault

temperature

Drive Motor Overtemperature

P222A00

Dreating Due to Coolant Over

P223200

temperature

Fault Description

Exclusion Method

Fault Code

Active Discharge time-out

P224900

Dreating Due to HVDC UnderVoltage

P224A00

HVDC UnderVoltage

P224B00

HVDC "A" Inverter Voltage Sensor

P224C00

Circuit voltage out of range

HVDC "B" Inverter Voltage Sensor

P224D00

Circuit voltage out of range

Function Safety HVDC Monitoring Fault

P224E00

Dreating Due to HVDC OverVoltag

P224F00

HVDC Voltage above SW threshold

P225000

HVDC Voltage above HW threshold

P225100

Drive Motor "U" Current value above

P225200

SW threshold

Drive Motor "V" Current value above

P225300

SW threshold

Drive Motor "W" Current value above

P225400

SW threshold

Drive Motor "U/V/W" Current value

P225500

above HW threshold

Refer to MCU1 High Voltage Circuit

Drive Motor "U"Phase Circuit open Fault

P225600

Fault

Drive Motor "V“Phase Circuit open Fault

P225700

Drive Motor "W"Phase Circuit open

P225800

Fault

Drive Motor "U/V/W" Phase Current

P225900

Sum Check above threshold Fault

Drive Motor "U" Phase Current Offset

P225A00

Exceeded Learning Limit

Drive Motor "V" Phase Current Offset

P225B00

Exceeded Learning Limit

Drive Motor "W" Phase Current Offset

P225C00

Exceeded Learning Limit

Drive Motor "U" Phase Current Sensor

P225D00

Circuit short to ground or open

Drive Motor "U" Phase Current Sensor

P225E00

Circuit short to battery

Drive Motor "V" Phase Current Sensor

P225F00

Circuit short to ground or open

Drive Motor "V" Phase Current Sensor

P226000

Circuit short to battery

Fault Description

Exclusion Method

Fault Code

Drive Motor "W" Phase Current Sensor

P226100

Circuit short to ground or open

Drive Motor "W" Phase Current Sensor

P226200

Circuit short to battery

Function Safety Current Monitoring

P226300

Fault

P226400

Collision fault

Refer to MCU1 Collision Fault

MCU2

Fault Description

Exclusion Method

Fault Code

Supply Voltage Too High

B111717

Refer to MCU2 Power Fault

Supply Voltage Too Low

B111716

VDC Signal checksum Fault

P236500

VDC Signal rollingcounter Fault

P236600

U012287

Lost Communication With VDC

Refer to MCU2 Communication Fault

U015687

Lost Communication With CDCU

U019887

Lost Communication With T-BOX

U008E88

CAN Bus Off

SiC Temperature Sensor "U" Circuit

P232200

short to ground

SiC Temperature Sensor "U" Circuit

P232300

short to battery or open

SiC Temperature Sensor "V" Circuit

P232400

short to ground

SiC Temperature Sensor "V" Circuit

P232500

short to battery or open

SiC Temperature Sensor "V" Circuit

P232600

short to ground

SiC Temperature Sensor "V" Circuit

Refer to MCU2 Internal Fault

P232700

short to battery or open

SiC Temperature Sensor ，Any Two

P232800

Phase electronic failure

Drive Motor "A" Temperature Sensor

P232B00

Circuit short to ground or open

Drive Motor "A" Temperature Sensor

P232C00

Circuit short to battery

Drive Motor "B" Temperature Sensor

P232D00

Circuit short to ground or open

Drive Motor "B" Temperature Sensor

P232E00

Circuit short to battery

Fault Description

Exclusion Method

Fault Code

Drive Motor "A" and "B" Temperature

P232F00

Sensor compare failure

Drive Motor "A" and "B" Temperature

P233000

Sensor Circuit electrical failure

Drive Motor Stalling Fault

P233100

Coolant Temperature Sensor Circuit

P233300

short to ground

Coolant Temperature Sensor Circuit

P233400

short to battery or open

Dreating Due to Drive Motor OverSpeed

P233500

Drive Motor OverSpeed Fault

P233600

Function Safety Speed Monitoring Faul

P233700

High Bridge Driver Fault

P233800

Low Bridge Driver Fault

P233900

CAN Link Chip Fault

P233A00

SBC Chip fault

P233B00

Current sensor Power supply voltage

P233C00

out of range

Power supply fault of driver board 5V out

P233D00

of range

SiC driver IC power supply voltage out

P233E00

of range

Function Safety internal Low

P233F00

PowerSupply Monitoring Fault

A/D Processing Performance fault

P234000

P234100

EEPROM Fault

MCU Unexpected Restart fault

P234200

P234300

MCU Self-Check fault

P234400

Shutdown Path Check fault

Inverter Performance Unexpected

P234500

operation

Torque difference between function

P234600

Safety layer and QM out of range fault

Torque difference between function

Safety layer and Requested out of

P234700

range fault

Enter ASC State Due to Back-EMF

P234800

voltage too high

P236700

Drive Motor Zero Position Not Learned

Fault Description

Exclusion Method

Fault Code

Resolver QM SIN/COS Signal out of

P236800

range Fault

Resolver QM EXC Signal amplitude out

P236900

of range Fault

Resolver FUSA EXC Signal amplitude

P237000

out of range Fault

Resolver FUSA SIN/COS Signal out of

P237100

range Fault

Current timestamp and Angle

P237200

timestampt Check Fault

L1 Electrical angle and Electrical angle

P237300

Check Fault

Resolver SIN and COS Sum of squares

P237400

Check Fault

High Bridge Driver INTA Fault

P237500

High Bridge Driver INTB Fault

P237600

Low Bridge Driver INTA Fault

P237700

Low Bridge Driver INTB Fault

P237800

Dreating Due to SiC Over temperature

P232000

SiC Overtemperature

P232100

Dreating due to Drive Motor Over

P232900

Refer to MCU2 Overheating Fault

temperature

Drive Motor Overtemperature

P232A00

Dreating Due to Coolant Over

P233200

temperature

Active Discharge time-out

P234900

Dreating Due to HVDC UnderVoltage

P234A00

HVDC UnderVoltage

P234B00

HVDC "A" Inverter Voltage Sensor

P234C00

Circuit voltage out of range

HVDC "B" Inverter Voltage Sensor

P234D00

Refer to MCU2 High Voltage Circuit

Circuit voltage out of range

Fault

Function Safety HVDC Monitoring Fault

P234E00

Dreating Due to HVDC OverVoltag

P234F00

HVDC Voltage above SW threshold

P235000

HVDC Voltage above HW threshold

P235100

Drive Motor "U" Current value above

P235200

SW threshold

Fault Description

Exclusion Method

Fault Code

Drive Motor "V" Current value above

P235300

SW threshold

Drive Motor "W" Current value above

P235400

SW threshold

Drive Motor "U/V/W" Current value

P235500

above HW threshold

Drive Motor "U"Phase Circuit open Fault

P235600

Drive Motor "V“Phase Circuit open Fault

P235700

Drive Motor "W"Phase Circuit open

P235800

Fault

Drive Motor "U/V/W" Phase Current

P235900

Sum Check above threshold Fault

Drive Motor "U" Phase Current Offset

P235A00

Exceeded Learning Limit

Drive Motor "V" Phase Current Offset

P235B00

Exceeded Learning Limit

Drive Motor "W" Phase Current Offset

P235C00

Exceeded Learning Limit

Drive Motor "U" Phase Current Sensor

P235D00

Circuit short to ground or open

Drive Motor "U" Phase Current Sensor

P235E00

Circuit short to battery

Drive Motor "V" Phase Current Sensor

P235F00

Circuit short to ground or open

Drive Motor "V" Phase Current Sensor

P236000

Circuit short to battery

Drive Motor "W" Phase Current Sensor

P236100

Circuit short to ground or open

Drive Motor "W" Phase Current Sensor

P236200

Circuit short to battery

Function Safety Current Monitoring

P236300

Fault

P236400

Collision fault

Refer to MCU2 Collision fault

MCU3

Fault Description

Exclusion Method

Fault Code

Supply Voltage Too High

B111717

Refer to MCU3 Power Fault

Supply Voltage Too Low

B111716

VDC Signal checksum Fault

P246500

Refer to MCU3 Communication Fault

VDC Signal rollingcounter Fault

P246600

Fault Description

Exclusion Method

Fault Code

U012287

Lost Communication With VDC

U015687

Lost Communication With CDCU

U019887

Lost Communication With T-BOX

U008E88

CAN Bus Off

SiC Temperature Sensor "U" Circuit

P242200

short to ground

SiC Temperature Sensor "U" Circuit

P242300

short to battery or open

SiC Temperature Sensor "V" Circuit

P242400

short to ground

SiC Temperature Sensor "V" Circuit

P242500

short to battery or open

SiC Temperature Sensor "V" Circuit

P242600

short to ground

SiC Temperature Sensor "V" Circuit

P242700

short to battery or open

SiC Temperature Sensor ，Any Two

P242800

Phase electronic failure

Drive Motor "A" Temperature Sensor

P242B00

Circuit short to ground or open

Drive Motor "A" Temperature Sensor

P242C00

Circuit short to battery

Refer to MCU3 Internal Fault

Drive Motor "B" Temperature Sensor

P242D00

Circuit short to ground or open

Drive Motor "B" Temperature Sensor

P242E00

Circuit short to battery

Drive Motor "A" and "B" Temperature

P242F00

Sensor compare failure

Drive Motor "A" and "B" Temperature

P243000

Sensor Circuit electrical failure

Drive Motor Stalling Fault

P243100

Coolant Temperature Sensor Circuit

P243300

short to ground

Coolant Temperature Sensor Circuit

P243400

short to battery or open

Dreating Due to Drive Motor OverSpeed

P243500

Drive Motor OverSpeed Fault

P243600

Function Safety Speed Monitoring Faul

P243700

High Bridge Driver Fault

P243800

Low Bridge Driver Fault

P243900

Fault Description

Exclusion Method

Fault Code

CAN Link Chip Fault

P243A00

SBC Chip fault

P243B00

Current sensor Power supply voltage

P243C00

out of range

Power supply fault of driver board 5V out

P243D00

of range

SiC driver IC power supply voltage out

P243E00

of range

Function Safety internal Low

P243F00

PowerSupply Monitoring Fault

A/D Processing Performance fault

P244000

P244100

EEPROM Fault

MCU Unexpected Restart fault

P244200

P244300

MCU Self-Check fault

P244400

Shutdown Path Check fault

Inverter Performance Unexpected

P244500

operation

Torque difference between function

P244600

Safety layer and QM out of range fault

Torque difference between function

Safety layer and Requested out of

P244700

range fault

Enter ASC State Due to Back-EMF

P244800

voltage too high

P246700

Drive Motor Zero Position Not Learned

Resolver QM SIN/COS Signal out of

P246800

range Fault

Resolver QM EXC Signal amplitude out

P246900

of range Fault

Resolver FUSA EXC Signal amplitude

P247000

out of range Fault

Resolver FUSA SIN/COS Signal out of

P247100

range Fault

Current timestamp and Angle

P247200

timestampt Check Fault

L1 Electrical angle and Electrical angle

P247300

Check Fault

Resolver SIN and COS Sum of squares

P247400

Check Fault

High Bridge Driver INTA Fault

P247500

Fault Description

Exclusion Method

Fault Code

High Bridge Driver INTB Fault

P247600

Low Bridge Driver INTA Fault

P247700

Low Bridge Driver INTB Fault

P247800

Dreating Due to SiC Over temperature

P242000

SiC Overtemperature

P242100

Dreating due to Drive Motor Over

P242900

Refer to MCU3 Overheating Fault

temperature

Drive Motor Overtemperature

P242A00

Dreating Due to Coolant Over

P243200

temperature

Active Discharge time-out

P244900

Dreating Due to HVDC UnderVoltage

P244A00

HVDC UnderVoltage

P244B00

HVDC "A" Inverter Voltage Sensor

P244C00

Circuit voltage out of range

HVDC "B" Inverter Voltage Sensor

P244D00

Circuit voltage out of range

Function Safety HVDC Monitoring Fault

P244E00

Dreating Due to HVDC OverVoltag

P244F00

HVDC Voltage above SW threshold

P245000

HVDC Voltage above HW threshold

P245100

Drive Motor "U" Current value above

P245200

SW threshold

Drive Motor "V" Current value above

Refer to MCU3 High Voltage Circuit

P245300

SW threshold

Fault

Drive Motor "W" Current value above

P245400

SW threshold

Drive Motor "U/V/W" Current value

P245500

above HW threshold

Drive Motor "U"Phase Circuit open Fault

P245600

Drive Motor "V“Phase Circuit open Fault

P245700

Drive Motor "W"Phase Circuit open

P245800

Fault

Drive Motor "U/V/W" Phase Current

P245900

Sum Check above threshold Fault

Drive Motor "U" Phase Current Offset

P245A00

Exceeded Learning Limit

Drive Motor "V" Phase Current Offset

P245B00

Exceeded Learning Limit

Fault Description

Exclusion Method

Fault Code

Drive Motor "W" Phase Current Offset

P245C00

Exceeded Learning Limit

Drive Motor "U" Phase Current Sensor

P245D00

Circuit short to ground or open

Drive Motor "U" Phase Current Sensor

P245E00

Circuit short to battery

Drive Motor "V" Phase Current Sensor

P245F00

Circuit short to ground or open

Drive Motor "V" Phase Current Sensor

P246000

Circuit short to battery

Drive Motor "W" Phase Current Sensor

P246100

Circuit short to ground or open

Drive Motor "W" Phase Current Sensor

P246200

Circuit short to battery

Function Safety Current Monitoring

P246300

Fault

P246400

Collision fault

Refer to MCU3 Collision Fault

MCU4

Fault Description

Exclusion Method

Fault Code

Supply Voltage Too High

B111717

Refer to MCU4 Power Fault

Supply Voltage Too Low

B111716

VDC Signal checksum Fault

P256500

VDC Signal rollingcounter Fault

P256600

U012287

Lost Communication With VDC

Refer to MCU4 Communication Fault

U015687

Lost Communication With CDCU

U019887

Lost Communication With T-BOX

U008E88

CAN Bus Off

SiC Temperature Sensor "U" Circuit

P252200

short to ground

SiC Temperature Sensor "U" Circuit

P252300

short to battery or open

SiC Temperature Sensor "V" Circuit

P252400

short to ground

Refer to MCU4 Internal Fault

SiC Temperature Sensor "V" Circuit

P252500

short to battery or open

SiC Temperature Sensor "V" Circuit

P252600

short to ground

SiC Temperature Sensor "V" Circuit

P252700

short to battery or open

Fault Description

Exclusion Method

Fault Code

SiC Temperature Sensor ，Any Two

P252800

Phase electronic failure

Drive Motor "A" Temperature Sensor

P252B00

Circuit short to ground or open

Drive Motor "A" Temperature Sensor

P252C00

Circuit short to battery

Drive Motor "B" Temperature Sensor

P252D00

Circuit short to ground or open

Drive Motor "B" Temperature Sensor

P252E00

Circuit short to battery

Drive Motor "A" and "B" Temperature

P252F00

Sensor compare failure

Drive Motor "A" and "B" Temperature

P253000

Sensor Circuit electrical failure

Drive Motor Stalling Fault

P253100

Coolant Temperature Sensor Circuit

P253300

short to ground

Coolant Temperature Sensor Circuit

P253400

short to battery or open

Dreating Due to Drive Motor OverSpeed

P253500

Drive Motor OverSpeed Fault

P253600

Function Safety Speed Monitoring Faul

P253700

High Bridge Driver Fault

P253800

Low Bridge Driver Fault

P253900

CAN Link Chip Fault

P253A00

SBC Chip fault

P253B00

Current sensor Power supply voltage

P253C00

out of range

Power supply fault of driver board 5V out

P253D00

of range

SiC driver IC power supply voltage out

P253E00

of range

Function Safety internal Low

P253F00

PowerSupply Monitoring Fault

A/D Processing Performance fault

P254000

P254100

EEPROM Fault

MCU Unexpected Restart fault

P254200

P254300

MCU Self-Check fault

P254400

Shutdown Path Check fault

Fault Description

Exclusion Method

Fault Code

Inverter Performance Unexpected

P254500

operation

Torque difference between function

P254600

Safety layer and QM out of range fault

Torque difference between function

Safety layer and Requested out of

P254700

range fault

Enter ASC State Due to Back-EMF

P254800

voltage too high

P256700

Drive Motor Zero Position Not Learned

Resolver QM SIN/COS Signal out of

P256800

range Fault

Resolver QM EXC Signal amplitude out

P256900

of range Fault

Resolver FUSA EXC Signal amplitude

P257000

out of range Fault

Resolver FUSA SIN/COS Signal out of

P257100

range Fault

Current timestamp and Angle

P257200

timestampt Check Fault

L1 Electrical angle and Electrical angle

P257300

Check Fault

Resolver SIN and COS Sum of squares

P257400

Check Fault

High Bridge Driver INTA Fault

P257500

High Bridge Driver INTB Fault

P257600

Low Bridge Driver INTA Fault

P257700

Low Bridge Driver INTB Fault

P257800

Dreating Due to SiC Over temperature

P252000

SiC Overtemperature

P252100

Dreating due to Drive Motor Over

P252900

Refer to MCU4 Overheating Fault

temperature

Drive Motor Overtemperature

P252A00

Dreating Due to Coolant Over

P253200

temperature

Active Discharge time-out

P254900

Refer to MCU4 High Voltage Circuit

Dreating Due to HVDC UnderVoltage

P254A00

Fault

HVDC UnderVoltage

P254B00

Fault Description

Exclusion Method

Fault Code

HVDC "A" Inverter Voltage Sensor

P254C00

Circuit voltage out of range

HVDC "B" Inverter Voltage Sensor

P254D00

Circuit voltage out of range

Function Safety HVDC Monitoring Fault

P254E00

Dreating Due to HVDC OverVoltag

P254F00

HVDC Voltage above SW threshold

P255000

HVDC Voltage above HW threshold

P255100

Drive Motor "U" Current value above

P255200

SW threshold

Drive Motor "V" Current value above

P255300

SW threshold

Drive Motor "W" Current value above

P255400

SW threshold

Drive Motor "U/V/W" Current value

P255500

above HW threshold

Drive Motor "U"Phase Circuit open Fault

P255600

Drive Motor "V“Phase Circuit open Fault

P255700

Drive Motor "W"Phase Circuit open

P255800

Fault

Drive Motor "U/V/W" Phase Current

P255900

Sum Check above threshold Fault

Drive Motor "U" Phase Current Offset

P255A00

Exceeded Learning Limit

Drive Motor "V" Phase Current Offset

P255B00

Exceeded Learning Limit

Drive Motor "W" Phase Current Offset

P255C00

Exceeded Learning Limit

Drive Motor "U" Phase Current Sensor

P255D00

Circuit short to ground or open

Drive Motor "U" Phase Current Sensor

P255E00

Circuit short to battery

Drive Motor "V" Phase Current Sensor

P255F00

Circuit short to ground or open

Drive Motor "V" Phase Current Sensor

P256000

Circuit short to battery

Drive Motor "W" Phase Current Sensor

P256100

Circuit short to ground or open

Drive Motor "W" Phase Current Sensor

P256200

Circuit short to battery

Fault Description

Exclusion Method

Fault Code

Function Safety Current Monitoring

P256300

Fault

P256400

Collision fault

Refer to MCU4 Collision Fault

TCU1

Fault Description

Exclusion Method

Fault Code

High battery voltage

B111717

Refer to TCU1 Power Fault

Low battery voltage

B111716

U012287

Communication with VCU was lost

Loss of communication with MCU (TCU

can receive life signals from MCU1-4 on

U012A87

the bus)

Loss of communication with MCU (TCU

can receive life signals from MCU1-4 on

U012B87

the bus)

Refer to TCU1 Communication Fault

Loss of communication with MCU (TCU

can receive life signals from MCU1-4 on

U012D87

the bus)

U008E88

PCAN4 BusOff

CDCUCommunication exception

U012E87

TDWCommunication exception

U012F87

First and second gear position sensor

P270300

open circuit failure

First and second gear position sensor to

P270301

power short circuit fault

First and second gear position sensor to

P270302

ground short-circuit fault

The first and second gear position

P270303

sensor signal exceeds the upper limit

The first and second gear position

P270304

sensor signal exceeds the lower limit

Refer to TCU1 Internal Fault

The output shaft speed sensor is open

P270305

faulty

The output shaft speed sensor short-

P270306

circuits the power supply

The output shaft speed sensor is short

P270307

circuit to the ground

The output shaft speed sensor signal

P270308

exceeds the upper limit

P27031E

Reverse second shift failed

Fault Description

Exclusion Method

Fault Code

Second shift in 1st gear failed

P27031F

Second gear failed

P270320

Shift power supply harness positive and

P270348

negative connection

P270349

Shift actuator stuck

The shift motor current sensor is faulty

P270350

The MCU1 motor has abnormal

P270351

overspeed in the drive gear

The MCU4 motor has abnormal

P270352

overspeed in the drive gear

Velocity ratio anomaly

P270353

P270354

Abnormal shift

Shift motor open circuit fault

P270355

The shift motor is short circuit to the

P270356

power supply

Shift motor to ground short circuit fault

P270357

The 5V power supply to the position

P270358

sensor is abnormal

The 8V power supply to the tachometer

P270359

is abnormal

The temperature of the control board is

P270360

too high

TCU2

Fault Description

Exclusion Method

Fault Code

TCU Power Supply Overvoltage

B111717

Refer to TCU2 Power Fault

TCU Power Supply Undervoltage

B111716

U012287

Communication lost with VCU

Loss of communication with MCU (TCU

can receive life signals from MCU1-4 on

U012A87

the bus)

Loss of communication with MCU (TCU

can receive life signals from MCU1-4 on

U012B87

the bus)

Refer to TCU2 Communication Fault

Loss of communication with MCU (TCU

can receive life signals from MCU1-4 on

U012D87

the bus)

U008E88

PCAN4 BusOff

CDCU communication anomaly

U012E87

TDW communication anomaly

U012F87

Fault Description

Exclusion Method

Fault Code

Open circuit fault in 1st/2nd gear

P670300

position sensor

Short circuit to power supply in 1st/2nd

P670301

gear position sensor

Short circuit to ground in 1st/2nd gear

P670302

position sensor

Signal from 1st/2nd gear position

P670303

sensor exceeds upper limit

Signal from 1st/2nd gear position

P670304

sensor falls below lower limit

Open circuit fault in output shaft speed

P670305

sensor

Output shaft speed sensor short circuit

P670306

to power supply

Output shaft speed sensor short circuit

P670307

to ground

Output shaft speed sensor signal

P670308

exceeds upper limit

Reverse gear secondary engagement

P67031E

failure

Refer to TCU2 Internal Fault

1st gear secondary engagement failure

P67031F

2nd gear secondary engagement failure

P670320

Reversed Polarity in Shift Power Supply

P670348

Harness

P670349

Stuck Shift Actuator

P670350

Shift Motor Current Sensor Failure

MCU1 motor exhibits abnormal

P670351

overspeed in drive mode

MCU4 motor exhibits abnormal

P670352

overspeed in drive mode

Abnormal gear ratio

P670353

Abnormal gear disengagement

P670354

Shift motor open-circuit fault

P670355

Shift motor short-circuit to power supply

P670356

Shift motor short-circuit to ground

P670357

Position sensor 5V power supply

P670358

anomaly

RPM sensor 8V power supply anomaly

P670359

Control board over-temperature fault

P670360

4.1.6.6 MCU1 Power Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Main battery

Supply Voltage Too

KL30＞36V

B111717

2. Low voltage

High

debounce 127count*10ms

charging system

3. Wiring harness

4. Low voltage

KL30＜15V

Supply Voltage Too

interface of

B111716

debounce 127count*10ms

Low

electric drive

medium axle

vehicle

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides MCU1?

Check the main battery. Refer to Inspection Of The Main Battery

– Yes:

Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault

Next step

– No:

Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.7 MCU1 Communication Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

VDC Signal checksum

VDC_MCU_Msg CheckSum error

P226500

Fault

deboumce 19count*10ms

VDC_MCU_Msg Counter alive error

（The Rolling Counter value changes less than 1 or

VDC Signal

P226600

The Rolling

rollingcounter Fault

Counter value changes more than 5 ）

1.Wiring harness

deboumce 19count*10ms

2. Electric drive

Lost Communication

VDC_MCUx_Torque_cmd timeout

mid-axle vehicle

U012287

With VDC

debounce 127count*40ms

low-voltage

interface

HighReTotalVehicleDistance timeout

Lost Communication

U015687

debounce 127count*40ms

With CDCU

Lost Communication

TGW_Hours timeout

U019887

With T-BOX

debounce 127count*40ms

"Bus-off" has been detected by AURIX

U008E88

CAN Bus Off

debounce 32count*10ms

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 6:Clear and confirm DTC.

4.1.6.8 MCU1 Internal Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P222200

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P222300

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P222400

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

1. SiC

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

Temperature

deboumce 127count*10ms

Sensor "V" Circuit

Sensor Circuit

P222500

if collect SiCTEMP short to Power/GND，The value of

short to battery or

and Related

this sensor is not used as a temperature strategy

open

Wiring

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P222600

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P222700

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC Temperature

more than one SiC Temperature Sensor Circuit General

Sensor ，Any Two

P222800

Electrical Failures

Phase electronic

deboumce 127count*10ms

failure

1. Motor

motor TEMPAD＜650

Drive Motor "A"

debounce 127count*10ms

Temperature

Temperature Sensor

Sensor Circuit

if collect motor TEMP short to GND or open circuit

P222B00

Circuit short to ground

and Related

within 5count*100ms，The value of this sensor is not

or open

Wiring

used as a temperature strategy

Description

DTC Trigger Conditions

Faulty Part

DTC Code

motor TEMPAD＞3600

Drive Motor "A"

debounce 127count*10ms

Temperature Sensor

P222C00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

motor TEMPAD＜650

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

if collect motor TEMP short to GND or open circuit

P222D00

Circuit short to ground

within 5count*100ms，The value of this sensor is not

or open

used as a temperature strategy

motor TEMPAD＞3600

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

P222E00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

Drive Motor "A" and

"B" Temperature

abs(STATOR_TEMP1- STATOR_TEMP2) > 30℃

P222F00

Sensor compare

debounce 127count*10ms

failure

Drive Motor "A" and

more than one Motor Temperature Sensor Circuit

"B" Temperature

P223000

General Electrical Failures

Sensor Circuit

debounce 127count*10m

electrical failure

1. Motor Body

abs Torque＞250NM and abs speed＜20rpm

Drive Motor Stalling

P223100

and Speed

debounce 2s+127count*10ms（3.27s）

Fault

Monitoring

Dreating Due to Drive

abs Speed>11200

P223500

Related Circuits

Motor OverSpeed

deboumce 43count*10ms

Drive Motor

abs Speed>12000

P223600

OverSpeed Fault

deboumce 22count*10ms

1. Water

Coolant Temperature

Coolant Temperature Sensor signal is below threshold

Temperature

Sensor Circuit short to

P223300

AD< 250

Sensor Circuit

ground

debounce 127count*10ms

and Related

Coolant Temperature

Coolant Temperature Sensor signal is above threshold

Wiring

Sensor Circuit short to

P223400

AD> 3780

battery or open

debounce 127count*10ms

1. Electric drive

abs （L2 spped-L1 speed）＞300rpm or abs Speed

Function Safety Speed

mid-axle vehicle

P223700

>12000

Monitoring Faul

low-voltage

deboumce 22count*10ms

interface

High Bridge Driver

The Gate driver IC Fault pin active

1. Gate driver

P223800

Fault

debounce 1count*PWM

chip and related

Low Bridge Driver

The Gate driver IC Fault pin active

circuitry

P223900

Fault

debounce 1count*PWM

Description

DTC Trigger Conditions

Faulty Part

DTC Code

High Bridge Driver

The Gate driver register value active

P227500

INTA Fault

debounce 1count*1ms

High Bridge Driver

The Gate driver register value active

P227600

INTB Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P227700

INTA Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P227800

INTB Fault

debounce 1count*1ms

1. CAN Chip and

Recive fault state from CAN IC

CAN Link Chip Fault

Communication

P223A00

deboumce 19count*10ms

Circuitry

1. Smart Power

Management

SBC fault detected

SBC Chip fault

P223B00

Chip (SBC) and

deboumce 19count*10ms

Related Circuitry

Current sensor Power

The DTC is stored if the control module detects that:

supply voltage out of

current sensro 5V supply< 4.5 V OR > 5.5 V

P223C00

1. Control Module

range

deboumce 19count*10ms

Power Supply

Circuit (Including

Power supply fault of

Drive board 5V supply:(< 4.5V) OR ( >5.5 V)

Current Sensor

driver board 5V out of

P223D00

deboumce 19count*10ms

Power Supply,

range

Driver Board

SepicVolt：＜18V or ＞22V

Power Supply,

Function Safety

or PCanVolt：＜4.5V or ＞5.5V

and Low-Voltage

internal Low

or P5vExtVolt：＜4.5V or ＞5.5V

P223F00

Monitoring

PowerSupply

or P5vAnVolt：＜4.5V or ＞5.5V

Circuit)

Monitoring Fault

or VoltCore：＜1.1V or ＞1.5V

deboumce 22count*10ms

1. SiC Gate Drive

SiC driver IC power

Entering OVP > 22 V

Voltage Circuit

supply voltage out of

P223E00

Entering UVP < 18V

and Protection

range

deboumce 19count*10ms

Circuit

1. Aurix

microcontrollers

A/D Processing

Internal Aurix ADC fault

P224000

feature built-in

deboumce 19count*10ms

Performance fault

analog-to-digital

converters.

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Electrically

Erasable

The DTC is stored if :

Programmable

1.Motor not been calibrated（current coef\positon offset

Read-Only

\voltage coeff)

P224100

EEPROM Fault

Memory

2.EEPROM read fault CRC ERR

(EEPROM) and

3.EEPROM write fault CRC ERR

Related Read/

deboumce 19count*10ms

Write Circuits

read SBC wake up reason when MCU wake up，if SBC

MCU Unexpected

report LPOFF -DEEP FS state trigger DTC

1. Microcontroller

P224200

deboumce 19count*10ms

Restart fault

Unit (MCU) and

Fault reason：SBC OK，MCU reset

Reset/Wake-up

Related Circuits

Startup test failed and enter safty state fault.

P224300

MCU Self-Check fault

deboumce 19count*10ms

Shutdown Path Check

Shutdown Path Check test failed.

1. Shutdown Path

P224400

deboumce 19count*10ms

Detection Circuit

fault

1. SiC Operating

Inverter Performance

Enter SiC mode！=Request mode.

Mode Control

P224500

Unexpected operation

deboumce 22count*10ms

and Monitoring

Circuit

Torque difference

abs(safety torque-Qm torque)>40Nm

between function

P224600

or torque direction err & abs acture torque >30NM

Safety layer and QM

debounce 19count*10ms

out of range fault

1. Torque Control

and Calibration

Torque difference

Related Circuits

between function

abs （safety torque-Requeste Torque）＞50NM

Safety layer and

P224700

debounce 19count*10ms

Requested out of

range fault

1. Motor Back

Enter ASC State Due

EMF Monitoring

abs Speed＞8000rpm and Back-EMF voltage＞Udc

to Back-EMF voltage

P224800

and ASC Status

debounce 19count*10ms

too high

Control Circuit

check the offset is default value

Drive Motor Zero

debounce 5count*10ms

P226700

Position Not Learned

(Use default value in SW）

1. Resolver

Resolver QM SIN/COS

QM_SIN＞1.2 or QM_SIN＜0.8

Sensor and

P226800

Signal out of range

or QM_COS＞1.2 or QM_COS＜0.8

Angle Sampling

Fault

debounce 19count*10ms

Related Circuitry

Resolver QM EXC

QM_EXC amplitude＞1.2

Signal amplitude out of

P226900

or QM_EXC amplitude＜0.8

range Fault

debounce 19count*10ms

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Resolver FUSA EXC

FUSA_EXC amplitude＞1.2

Signal amplitude out of

P227000

or FUSA_EXC amplitude＜0.8

range Fault

debounce 19count*10ms

Resolver FUSA SIN/

FUSA_SIN＞1.2 or FUSA_SIN＜0.8 or FUSA_COS＞

COS Signal out of

P227100

1.2 or FUSA_COS＜0.8

range Fault

debounce 19count*10ms

Current timestamp and

abs（Current timestamp - Angle timestamp）＞110us

P227200

Angle timestampt

debounce 19count*10ms

Check Fault

L1 Electrical angle and

abs(Qm_AngleAct - FUSA_AngleAct) > 30[deg]

P227300

Electrical angle Check

(Electrical angle）

Fault

debounce 19count*10ms

Resolver SIN and

SQRT(Sin²+Cos²) < 0.8 OR SQRT(Sin²+Cos²) > 1.2

P227400

COS Sum of squares

debounce 19count*10ms

Check Fault

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium

axle vehicle.

Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 5:Clear and confirm DTC.

4.1.6.9 MCU1 Overheating Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Dreating Due to SiC

SiC NTC temperature >95°C

P222000

Over temperature

debounce 43count*10ms

SiC NTC temperature >110°C

SiC Overtemperature

P222100

debounce 43count*10ms

1. Temperature

Dreating due to Drive

Monitoring and

Motor temp >140°C

Motor Over

P222900

Protection Circuit

debounce 127count*10ms

temperature

(SiC, Motor,

Drive Motor

Motor temp >150°C

Cooling Water)

P222A00

Overtemperature

debounce 127count*10ms

Dreating Due to

Coolant Temperature > 70 degC

Coolant Over

P223200

debounce 127count*10ms

temperature

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Move the vehicle to a normal temperature environment and let it sit for a while.

Step 4:Check the vehicle has any fault codes related to the thermal management system?

Prioritize troubleshooting related to thermal management systems.

– Yes:

Next step

– No:

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.10 MCU1 High Voltage Circuit Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. High-Voltage

Active Discharge

Active Discharge time-

HVDC>60V after 1s when discharge activated

Circuit and

P224900

out

debounce 43count*10ms

Related Control

Circuit

Dreating Due to HVDC

1.UHVDC phys <520V

P224A00

UnderVoltage

debounce 22count*10ms

1.UHVDC phys <490V

HVDC UnderVoltage

P224B00

debounce 22count*10ms

HVDC "A" Inverter

UHVDC_1 phys ＞1200V

Voltage Sensor Circuit

debounce 22count*10ms

P224C00

voltage out of range

Note：UHVDC_1 phys fault，use UHVDC_2 phys

HVDC "B" Inverter

UHVDC_2 phys ＞1200V

Voltage Sensor Circuit

P224D00

1. DC Bus

debounce 22count*10ms

voltage out of range

Voltage

abs（UHVDC_1 phys-UDC_BAT）＞60V

Monitoring and

debounce 19count*10ms

Protection Circuit

Function Safety HVDC

Note：If abs（UHVDC_1 phys-UDC_BAT）＞60V and

P224E00

Monitoring Fault

abs （UHVDC_2 phys-UDC_BAT）＜40V，

WhlMotSysUdc use UHVDC_2 phys；and Post-fault

processing use UHVDC_2 phys

Dreating Due to HVDC

DC Link voltage beyond 930V

P224F00

OverVoltag

deboumce 22count*10ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

P225000

Link voltage beyond 960V

SW threshold

deboumce 127count*1ms

Description

DTC Trigger Conditions

Faulty Part

DTC Code

The DTC is stored if the control module detects that: DC

HVDC Voltage above

Link voltage beyond 971V

P225100

HW threshold

deboumce 1count*pwm

The DTC is stored if the control module detects that:

Drive Motor "U"

abs( Current value) > 700A)

P225200

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "V"

abs( Current value) > 700A)

P225300

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "W"

abs( Current value) > 700A)

P225400

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "U/V/W"

abs(U/V/W Current value) > 780A)

P225500

Current value above

debounce 2*count*pwm

HW threshold

Drive Motor "U"Phase

When In Tq mode, No phase current feedback

P225600

Circuit open Fault

debounce 19*count*10ms

Drive Motor "V“Phase

When In Tq mode, No phase current feedback

P225700

1. Inverter Phase

Circuit open Fault

debounce 19*count*10ms

Current

Drive Motor "W"Phase

When In Tq mode, No phase current feedback

P225800

Monitoring and

Circuit open Fault

debounce 19*count*10ms

Control Circuit

Drive Motor "U/V/W"

abs(INV_IAC_SUM)>120A

Phase Current Sum

P225900

debounce 19*count*10ms

Check above threshold

Fault

Drive Motor "U" Phase

Current Offset

abs(offset in the AC phase U)>50AD（raw）

P225A00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "V" Phase

Current Offset

abs(offset in the AC phase V)>50AD（raw）

P225B00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "W" Phase

Current Offset

abs(offset in the AC phase W)>50AD（raw）

P225C00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "U" Phase

1. Current

Current Sensor Circuit

current Raw value below 200

P225D00

Sensors and

short to ground or

debounce 19*10ms

Related Circuits

open

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Drive Motor "U" Phase

current Raw value beyond 4000

Current Sensor Circuit

P225E00

debounce 19*10ms

short to battery

Drive Motor "V" Phase

Current Sensor Circuit

current Raw value below 200

P225F00

short to ground or

debounce 19*10ms

open

Drive Motor "V" Phase

current Raw value beyond 4000

Current Sensor Circuit

P226000

debounce 19*10ms

short to battery

Drive Motor "W" Phase

Current Sensor Circuit

current Raw value below 200

P226100

short to ground or

debounce 19*10ms

open

Drive Motor "W" Phase

current Raw value beyond 4000

Current Sensor Circuit

P226200

debounce 19*10ms

short to battery

abs(INV_IAC_SUM)>120A

or abs current value：＞1400A

Function Safety

P226300

or abs U/V/W（Qm current - Fusa Current）＞80A

Current Monitoring

or abs U/V/W currentOffset＞50AD（raw）

Fault

debounce 19*10ms

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive mid axle vehicle.

Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive medium axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.11 MCU1 Collision Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1.Collision Signal

Collision occurred

Reception and

P226400

Collision fault

Collision signal received

Related Interface

Anti-shake: 1 count*10ms

Circuitry

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3.Diagnostic Steps

Step 1:DTC Confirmation. Refer toDTC Confirmation

Step 2:Routine Inspection. Refer toRoutine Inspection

Step 3:Inspect the vehicle for collision damage？

Please inspect the vehicle based on the actual collision damage.

– Yes:

Next step

– No:

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 6:Clear and confirm DTC.

4.1.6.12 MCU2 Power Fault

1.DTC Monitoring Logic

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

1. Main battery

Supply Voltage Too

KL30＞36V

B111717

2. Low voltage

High

debounce 127count*10ms

charging system

3. Wiring harness

4. Low voltage

KL30＜15V

Supply Voltage Too

interface of

B111716

debounce 127count*10ms

Low

electric drive

medium axle

vehicle

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides MCU2?

Check the main battery. Refer to Inspection Of The Main Battery

– Yes:

Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault

Next step

– No:

Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.13 MCU2 Communication Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

VDC Signal checksum

P236500

deboumce 19count*10ms

Fault

VDC_MCU_Msg Counter alive error

VDC Signal

（The Rolling Counter value changes less than 1 or

P236600

rollingcounter Fault

The Rolling Counter value changes more than 5 ）

1.Wiring harness

deboumce 19count*10ms

2. Electric drive

Lost Communication

VDC_MCUx_Torque_cmd timeout

U012287

mid-axle vehicle

With VDC

debounce 127count*40ms

low-voltage

HighReTotalVehicleDistance timeout

Lost Communication

interface

U015687

debounce 127count*40ms

With CDCU

Lost Communication

TGW_Hours timeout

U019887

With T-BOX

debounce 127count*40ms

"Bus-off" has been detected by AURIX

U008E88

CAN Bus Off

debounce 32count*10ms

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 6:Clear and confirm DTC.

4.1.6.14 MCU2 Internal Fault

1.DTC Monitoring Logic

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P232200

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P232300

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P232400

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

1.SiC

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

Temperature

deboumce 127count*10ms

Sensor "V" Circuit

Sensor Circuit

P232500

if collect SiCTEMP short to Power/GND，The value of

short to battery or

and Related

this sensor is not used as a temperature strategy

open

Wiring

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P232600

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P232700

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC Temperature

more than one SiC Temperature Sensor Circuit General

Sensor ，Any Two

P232800

Electrical Failures

Phase electronic

deboumce 127count*10ms

failure

1.Motor

motor TEMPAD＜650

Drive Motor "A"

debounce 127count*10ms

Temperature

Temperature Sensor

Sensor Circuit

if collect motor TEMP short to GND or open circuit

P232B00

Circuit short to ground

and Related

within 5count*100ms，The value of this sensor is not

or open

Wiring

used as a temperature strategy

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

motor TEMPAD＞3600

Drive Motor "A"

debounce 127count*10ms

Temperature Sensor

P232C00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

motor TEMPAD＜650

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

if collect motor TEMP short to GND or open circuit

P232D00

Circuit short to ground

within 5count*100ms，The value of this sensor is not

or open

used as a temperature strategy

motor TEMPAD＞3600

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

P232E00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

Drive Motor "A" and

"B" Temperature

abs(STATOR_TEMP1- STATOR_TEMP2) > 30℃

P232F00

Sensor compare

debounce 127count*10ms

failure

Drive Motor "A" and

more than one Motor Temperature Sensor Circuit

"B" Temperature

P233000

General Electrical Failures

Sensor Circuit

debounce 127count*10m

electrical failure

abs Torque＞250NM and abs speed＜20rpm

Drive Motor Stalling

P233100

debounce 2s+127count*10ms（3.27s）

Fault

Dreating Due to Drive

abs Speed>11200

P233500

Motor OverSpeed

deboumce 43count*10ms

1.Motor Body and

Speed Monitoring

Drive Motor

abs Speed>12000

P233600

Related Circuits

OverSpeed Fault

deboumce 22count*10ms

abs （L2 spped-L1 speed）＞300rpm or abs Speed

Function Safety Speed

P233700

>12000

Monitoring Faul

deboumce 22count*10ms

Coolant Temperature

Coolant Temperature Sensor signal is below threshold

1.Water

Sensor Circuit short to

P233300

AD< 250

Temperature

ground

debounce 127count*10ms

Sensor Circuit

Coolant Temperature

Coolant Temperature Sensor signal is above threshold

and Related

Sensor Circuit short to

P233400

AD> 3780

Wiring

battery or open

debounce 127count*10ms

High Bridge Driver

The Gate driver IC Fault pin active

P233800

Fault

debounce 1count*PWM

1.Gate driver chip

Low Bridge Driver

The Gate driver IC Fault pin active

and related

P233900

Fault

debounce 1count*PWM

circuitry

High Bridge Driver

The Gate driver register value active

P237500

INTA Fault

debounce 1count*1ms

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

High Bridge Driver

The Gate driver register value active

P237600

INTB Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P237700

INTA Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P237800

INTB Fault

debounce 1count*1ms

1.CAN Chip and

Recive fault state from CAN IC

Communication

CAN Link Chip Fault

P233A00

deboumce 19count*10ms

Circuitry

1.Smart Power

Management

SBC fault detected

SBC Chip fault

P233B00

Chip (SBC) and

deboumce 19count*10ms

Related Circuitry

Current sensor Power

The DTC is stored if the control module detects that:

supply voltage out of

P233C00

current sensro 5V supply< 4.5 V OR > 5.5 V

1.Control Module

range

deboumce 19count*10ms

Power Supply

Circuit (Including

Power supply fault of

Drive board 5V supply: (< 4.5V) OR ( >5.5 V)

Current Sensor

driver board 5V out of

P233D00

deboumce 19count*10ms

Power Supply,

range

Driver Board

SepicVolt：＜18V or ＞22V

Power Supply,

Function Safety

or PCanVolt：＜4.5V or ＞5.5V

and Low-Voltage

internal Low

or P5vExtVolt：＜4.5V or ＞5.5V

P233F00

Monitoring

PowerSupply

or P5vAnVolt：＜4.5V or ＞5.5V

Circuit)

Monitoring Fault

or VoltCore：＜1.1V or ＞1.5V

deboumce 22count*10ms

1.SiC Gate Drive

SiC driver IC power

Entering OVP > 22 V

Voltage Circuit

supply voltage out of

P233E00

Entering UVP < 18V

and Protection

range

deboumce 19count*10ms

Circuit

1.Aurix

microcontrollers

Internal Aurix ADC fault

A/D Processing

P234000

feature built-in

deboumce 19count*10ms

Performance fault

analog-to-digital

converters

1.Electrically

Erasable

The DTC is stored if :

Programmable

1.Motor not been calibrated（current coef\positon offset

Read-Only

\voltage coeff)

P234100

EEPROM Fault

Memory

2.EEPROM read fault CRC ERR

(EEPROM) and

3.EEPROM write fault CRC ERR

Related Read/

deboumce 19count*10ms

Write Circuits

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

read SBC wake up reason when MCU wake up，if SBC

MCU Unexpected

report LPOFF -DEEP FS state trigger DTC

1.Microcontroller

P234200

Restart fault

deboumce 19count*10ms

Unit (MCU) and

Fault reason：SBC OK，MCU reset

Reset/Wake-up

Related Circuits

Startup test failed and enter safty state fault.

P234300

MCU Self-Check fault

deboumce 19count*10ms

Shutdown Path Check

Shutdown Path Check test failed.

1.Shutdown Path

P234400

fault

deboumce 19count*10ms

Detection Circuit

1.SiC Operating

Inverter Performance

Enter SiC mode！=Request mode.

Mode Control

P234500

Unexpected operation

deboumce 22count*10ms

and Monitoring

Circuit

Torque difference

abs(safety torque-Qm torque)>40Nm or torque

between function

P234600

direction err & abs acture torque >30NM

Safety layer and QM

debounce 19count*10ms

out of range fault

1.Torque Control

and Calibration

Torque difference

Related Circuits

between function

abs （safety torque-Requeste Torque）＞50NM

Safety layer and

P234700

debounce 19count*10ms

Requested out of

range fault

1.Motor Back

Enter ASC State Due

EMF Monitoring

abs Speed＞8000rpm and Back-EMF voltage＞Udc

to Back-EMF voltage

P234800

and ASC Status

debounce 19count*10ms

too high

Control Circuit

check the offset is default value

Drive Motor Zero

debounce 5count*10ms

P236700

Position Not Learned

(Use default value in SW）

Resolver QM SIN/COS

QM_SIN＞1.2 or QM_SIN＜0.8

P236800

or QM_COS＞1.2 or QM_COS＜0.8

Signal out of range

Fault

debounce 19count*10ms

1.Resolver

Resolver QM EXC

QM_EXC amplitude＞1.2 or QM_EXC amplitude＜0.8

Sensor and

Signal amplitude out of

P236900

debounce 19count*10ms

Angle Sampling

range Fault

Related Circuitry

Resolver FUSA EXC

FUSA_EXC amplitude＞1.2 or FUSA_EXC amplitude＜

Signal amplitude out of

P237000

0.8

range Fault

debounce 19count*10ms

Resolver FUSA SIN/

FUSA_SIN＞1.2 or FUSA_SIN＜0.8

COS Signal out of

P237100

or FUSA_COS＞1.2 or FUSA_COS＜0.8

range Fault

debounce 19count*10ms

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

Current timestamp and

abs（Current timestamp - Angle timestamp）＞110us

P237200

Angle timestampt

debounce 19count*10ms

Check Fault

L1 Electrical angle and

abs(Qm_AngleAct - FUSA_AngleAct) > 30[deg]

P237300

Electrical angle Check

(Electrical angle）

Fault

debounce 19count*10ms

Resolver SIN and

SQRT(Sin²+Cos²) < 0.8 OR SQRT(Sin²+Cos²) > 1.2

P237400

COS Sum of squares

debounce 19count*10ms

Check Fault

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium

axle vehicle.

Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 5:Clear and confirm DTC.

4.1.6.15 MCU2 Overheating Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Dreating Due to SiC

SiC NTC temperature >95°C

P232000

Over temperature

debounce 43count*10ms

SiC NTC temperature >110°C

SiC Overtemperature

P232100

debounce 43count*10ms

1. Temperature

Dreating due to Drive

Monitoring and

Motor temp >140°C

Motor Over

P232900

Protection Circuit

debounce 127count*10ms

temperature

(SiC, Motor,

Drive Motor

Motor temp >150°C

Cooling Water)

P232A00

Overtemperature

debounce 127count*10ms

Dreating Due to

Coolant Temperature > 70 degC

Coolant Over

P233200

debounce 127count*10ms

temperature

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Move the vehicle to a normal temperature environment and let it sit for a while.

Step 4:Check the vehicle has any fault codes related to the thermal management system?

Prioritize troubleshooting related to thermal management systems.

– Yes:

Next step

– No:

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.16 MCU2 High Voltage Circuit Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. High-Voltage

Active Discharge

Active Discharge time-

HVDC>60V after 1s when discharge activated

Circuit and

P234900

out

debounce 43count*10ms

Related Control

Circuit

Dreating Due to HVDC

1.UHVDC phys <520V

P234A00

UnderVoltage

debounce 22count*10ms

1.UHVDC phys <490V

HVDC UnderVoltage

P234B00

debounce 22count*10ms

HVDC "A" Inverter

UHVDC_1 phys ＞1200V

Voltage Sensor Circuit

debounce 22count*10ms

P234C00

voltage out of range

Note：UHVDC_1 phys fault，use UHVDC_2 phys

HVDC "B" Inverter

UHVDC_2 phys ＞1200V

Voltage Sensor Circuit

P234D00

debounce 22count*10ms

voltage out of range

1. DC Bus

abs（UHVDC_1 phys-UDC_BAT）＞60V

Voltage

debounce 19count*10ms

Monitoring and

Note：If abs（UHVDC_1 phys-UDC_BAT）＞60V and

Function Safety HVDC

P234E00

Protection Circuit

Monitoring Fault

abs （UHVDC_2 phys-UDC_BAT）＜40V，

WhlMotSysUdc use UHVDC_2 phys；and Post-fault

processing use UHVDC_2 phys

Dreating Due to HVDC

DC Link voltage beyond 930V

P234F00

OverVoltag

deboumce 22count*10ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

P235000

Link voltage beyond 960V

SW threshold

deboumce 127count*1ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

Link voltage beyond 971V

P235100

HW threshold

deboumce 1count*pwm

1. Inverter Phase

The DTC is stored if the control module detects that:

Drive Motor "U"

Current

abs( Current value) > 700A)

P235200

Current value above

Monitoring and

debounce 10*count*pwm

SW threshold

Control Circuit

Description

DTC Trigger Conditions

Faulty Part

DTC Code

The DTC is stored if the control module detects that:

Drive Motor "V"

abs( Current value) > 700A)

P235300

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "W"

abs( Current value) > 700A)

P235400

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "U/V/W"

abs(U/V/W Current value) > 780A)

P235500

Current value above

debounce 2*count*pwm

HW threshold

Drive Motor "U"Phase

When In Tq mode, No phase current feedback

P235600

Circuit open Fault

debounce 19*count*10ms

Drive Motor "V“Phase

When In Tq mode, No phase current feedback

P235700

Circuit open Fault

debounce 19*count*10ms

Drive Motor "W"Phase

When In Tq mode, No phase current feedback

P235800

Circuit open Fault

debounce 19*count*10ms

Drive Motor "U/V/W"

abs(INV_IAC_SUM)>120A

Phase Current Sum

P235900

debounce 19*count*10ms

Check above threshold

Fault

Drive Motor "U" Phase

Current Offset

abs(offset in the AC phase U)>50AD（raw）

P235A00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "V" Phase

Current Offset

abs(offset in the AC phase V)>50AD（raw）

P235B00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "W" Phase

Current Offset

abs(offset in the AC phase W)>50AD（raw）

P235C00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "U" Phase

Current Sensor Circuit

current Raw value below 200

P235D00

short to ground or

debounce 19*10ms

1. Current

open

Sensors and

Related Circuits

Drive Motor "U" Phase

current Raw value beyond 4000

Current Sensor Circuit

P235E00

debounce 19*10ms

short to battery

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Drive Motor "V" Phase

Current Sensor Circuit

current Raw value below 200

P235F00

short to ground or

debounce 19*10ms

open

Drive Motor "V" Phase

current Raw value beyond 4000

Current Sensor Circuit

P236000

debounce 19*10ms

short to battery

Drive Motor "W" Phase

Current Sensor Circuit

current Raw value below 200

P236100

short to ground or

debounce 19*10ms

open

Drive Motor "W" Phase

current Raw value beyond 4000

Current Sensor Circuit

P236200

debounce 19*10ms

short to battery

abs(INV_IAC_SUM)>120A

or abs current value：＞1400A

Function Safety

P236300

Current Monitoring

or abs U/V/W（Qm current - Fusa Current）＞80A

Fault

or abs U/V/W currentOffset＞50AD（raw）

debounce 19*10ms

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive mid axle vehicle.

Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive medium axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.17 MCU2 Collision fault

1.DTC Monitoring Logic

Description

DTC Ttrigger Conditions

Faulty Part

DTC Code

1.Collision Signal

Collision occurred

Reception and

P236400

Collision fault

Collision signal received

Related Interface

Anti-shake: 1 count*10ms

Circuitry

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3.Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Inspect the vehicle for collision damage？

Please inspect the vehicle based on the actual collision damage.

– Yes:

Next step

–– No:

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 6:Clear and confirm DTC.

4.1.6.18 MCU3 Power Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Main battery

Supply Voltage Too

KL30＞36V

B111717

2. Low voltage

High

debounce 127count*10ms

charging system

3. Wiring harness

4. Low voltage

KL30＜15V

Supply Voltage Too

B111716

interface of

debounce 127count*10ms

Low

electric drive rear

axle vehicle

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

B12-1

C4-21

Total body power

Middle and rear axle MCU-KL30 O421

supply B+ L22

VDC-1

BDCU-4

B48-26

C93-97

status feedback H01

Smart Junction

Differential lock

Box - Body

B01-1

MCU4-CAN

drive wake up the power supply E146

The PDU, TCU, middrive, and rear

B07-2

B07-16

switch/parking

power supply

Switch class

KL30 shift

switch P116

I7_B_C

KL15 Power

supply P102

I7_C_B

switch - Shift

Combination

-KL30 P116b

Differential lock feedback signal

MCU power supply KL30 O421b

I1_B_IP

H01b

MCU4-CAN-H PH04e

MCU4-CANL PL04e

I1_IP_B

switch - Shift

KL15 Power

Combination

-KL30 P116b

supply P102

KL15 Power

Power KL30

supply P102a

C25-17

C25-1

C25-13

C25-5

C25-6

P116b

E-axle rear axle vehicle low voltage port

IP18-3

IP18-9

C25-20

C25-3

C25-4

MCU3-CAN-H PH04h

MCU3-CAN-L PL04h

MCU3-CAN-H PH04f

MCU3-CANL PL04f

MCU Power Supply - Z66

Shift switch

120Ω

IP18-8

IP18-2

IP18-1

PCAN4-H PH04d

PCAN4-L PL04d

Ground Z12d

C114-2

C114-1

CAN resistance -120Ω

MCU3-CAN

G02

G14

PCAN4

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides MCU3?

Check the main battery. Refer to Inspection Of The Main Battery

– Yes:

Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault

Next step

– No:

Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive rear axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 7:Clear and confirm DTC.

4.1.6.19 MCU3 Communication Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

VDC Signal checksum

P246500

deboumce 19count*10ms

Fault

VDC_MCU_Msg Counter alive error

VDC Signal

（The Rolling Counter value changes less than 1 or

P246600

rollingcounter Fault

The Rolling Counter value changes more than 5 ）

1.Wiring harness

deboumce 19count*10ms

2. Electric drive

Lost Communication

VDC_MCUx_Torque_cmd timeout

U012287

rear axle vehicle

With VDC

debounce 127count*40ms

low-voltage

HighReTotalVehicleDistance timeout

Lost Communication

interface

U015687

debounce 127count*40ms

With CDCU

Lost Communication

TGW_Hours timeout

U019887

With T-BOX

debounce 127count*40ms

"Bus-off" has been detected by AURIX

U008E88

CAN Bus Off

debounce 32count*10ms

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

B12-1

C4-21

Total body power

Middle and rear axle MCU-KL30 O421

supply B+ L22

VDC-1

BDCU-4

B48-26

C93-97

status feedback H01

Smart Junction

Differential lock

Box - Body

B01-1

MCU4-CAN

drive wake up the power supply E146

The PDU, TCU, middrive, and rear

B07-2

B07-16

switch/parking

power supply

Switch class

KL30 shift

switch P116

I7_B_C

KL15 Power

supply P102

I7_C_B

switch - Shift

Combination

-KL30 P116b

Differential lock feedback signal

MCU power supply KL30 O421b

I1_B_IP

H01b

MCU4-CAN-H PH04e

MCU4-CANL PL04e

I1_IP_B

switch - Shift

KL15 Power

Combination

-KL30 P116b

supply P102

KL15 Power

Power KL30

supply P102a

C25-17

C25-1

C25-13

C25-5

C25-6

P116b

E-axle rear axle vehicle low voltage port

IP18-3

IP18-9

C25-20

C25-3

C25-4

MCU3-CAN-H PH04h

MCU3-CAN-L PL04h

MCU3-CAN-H PH04f

MCU3-CANL PL04f

MCU Power Supply - Z66

Shift switch

120Ω

IP18-8

IP18-2

IP18-1

PCAN4-H PH04d

PCAN4-L PL04d

Ground Z12d

C114-2

C114-1

CAN resistance -120Ω

MCU3-CAN

G02

G14

PCAN4

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 6:Clear and confirm DTC.

4.1.6.20 MCU3 Internal Fault

1.DTC Monitoring Logic

Description

DTC Trigger conditions

Faulty Part

DTC Code

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P242200

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P242300

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P242400

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

1. SiC

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

Temperature

deboumce 127count*10ms

Sensor "V" Circuit

Sensor Circuit

P242500

if collect SiCTEMP short to Power/GND，The value of

short to battery or

and Related

this sensor is not used as a temperature strategy

open

Wiring

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P242600

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P242700

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC Temperature

more than one SiC Temperature Sensor Circuit General

Sensor ，Any Two

P242800

Electrical Failures

Phase electronic

deboumce 127count*10ms

failure

1. Motor

motor TEMPAD＜650

Drive Motor "A"

debounce 127count*10ms

Temperature

Temperature Sensor

Sensor Circuit

if collect motor TEMP short to GND or open circuit

P242B00

Circuit short to ground

and Related

within 5count*100ms，The value of this sensor is not

or open

Wiring

used as a temperature strategy

Description

DTC Trigger conditions

Faulty Part

DTC Code

motor TEMPAD＞3600

Drive Motor "A"

debounce 127count*10ms

Temperature Sensor

P242C00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

motor TEMPAD＜650

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

if collect motor TEMP short to GND or open circuit

P242D00

Circuit short to ground

within 5count*100ms，The value of this sensor is not

or open

used as a temperature strategy

motor TEMPAD＞3600

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

P242E00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

Drive Motor "A" and

"B" Temperature

abs(STATOR_TEMP1- STATOR_TEMP2) > 30℃

P242F00

Sensor compare

debounce 127count*10ms

failure

Drive Motor "A" and

more than one Motor Temperature Sensor Circuit

"B" Temperature

P243000

General Electrical Failures

Sensor Circuit

debounce 127count*10m

electrical failure

abs Torque＞250NM and abs speed＜20rpm

Drive Motor Stalling

P243100

debounce 2s+127count*10ms（3.27s）

Fault

Dreating Due to Drive

abs Speed>11200

P243500

1. Motor Body

Motor OverSpeed

deboumce 43count*10ms

and Speed

Drive Motor

abs Speed>12000

Monitoring

P243600

OverSpeed Fault

deboumce 22count*10ms

Related Circuitry

abs （L2 spped-L1 speed）＞300rpm or abs Speed

Function Safety Speed

P243700

>12000

Monitoring Faul

deboumce 22count*10ms

Coolant Temperature

Coolant Temperature Sensor signal is below threshold

1. Water

Sensor Circuit short to

P243300

AD< 250

Temperature

ground

debounce 127count*10ms

Sensor Circuit

Coolant Temperature

Coolant Temperature Sensor signal is above threshold

and Related

Sensor Circuit short to

P243400

AD> 3780

Wiring

battery or open

debounce 127count*10ms

High Bridge Driver

The Gate driver IC Fault pin active

P243800

Fault

debounce 1count*PWM

1.Gate driver chip

Low Bridge Driver

The Gate driver IC Fault pin active

and related

P243900

Fault

debounce 1count*PWM

circuitry

High Bridge Driver

The Gate driver register value active

P247500

INTA Fault

debounce 1count*1ms

Description

DTC Trigger conditions

Faulty Part

DTC Code

High Bridge Driver

The Gate driver register value active

P247600

INTB Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P247700

INTA Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P247800

INTB Fault

debounce 1count*1ms

1. CAN Chip and

Recive fault state from CAN IC

Communication

CAN Link Chip Fault

P243A00

deboumce 19count*10ms

Circuitry

1.Smart Power

Management

SBC fault detected

SBC Chip fault

P243B00

Chip (SBC) and

deboumce 19count*10ms

Related Circuitry

Current sensor Power

The DTC is stored if the control module detects that:

supply voltage out of

P243C00

current sensro 5V supply< 4.5 V OR > 5.5 V

1. Control Module

range

deboumce 19count*10ms

Power Supply

Circuit (Including

Power supply fault of

Drive board 5V supply: (< 4.5V) OR ( >5.5 V)

Current Sensor

driver board 5V out of

P243D00

deboumce 19count*10ms

Power Supply,

range

Driver Board

SepicVolt：＜18V or ＞22V

Power Supply,

Function Safety

or PCanVolt：＜4.5V or ＞5.5V

and Low-Voltage

internal Low

or P5vExtVolt：＜4.5V or ＞5.5V

P243F00

Monitoring

PowerSupply

or P5vAnVolt：＜4.5V or ＞5.5V

Circuit)

Monitoring Fault

or VoltCore：＜1.1V or ＞1.5V

deboumce 22count*10ms

1. SiC Gate Drive

SiC driver IC power

Entering OVP > 22 V

Voltage Circuit

supply voltage out of

P243E00

Entering UVP < 18V

and Protection

range

deboumce 19count*10ms

Circuit

1. Aurix

microcontrollers

Internal Aurix ADC fault

A/D Processing

P244000

feature built-in

deboumce 19count*10ms

Performance fault

analog-to-digital

converters

1.Electrically

Erasable

The DTC is stored if :

Programmable

1.Motor not been calibrated（current coef\positon offset

Read-Only

\voltage coeff)

P244100

EEPROM Fault

Memory

2.EEPROM read fault CRC ERR

(EEPROM) and

3.EEPROM write fault CRC ERR

Related Read/

deboumce 19count*10ms

Write Circuits

Description

DTC Trigger conditions

Faulty Part

DTC Code

read SBC wake up reason when MCU wake up，if SBC

MCU Unexpected

report LPOFF -DEEP FS state trigger DTC

1. Microcontroller

P244200

Restart fault

deboumce 19count*10ms

Unit (MCU) and

Fault reason：SBC OK，MCU reset

Reset/Wake-up

Related Circuits

Startup test failed and enter safty state fault.

P244300

MCU Self-Check fault

deboumce 19count*10ms

Shutdown Path Check

Shutdown Path Check test failed.

1. Shutdown Path

P244400

fault

deboumce 19count*10ms

Detection Circuit

1. SiC Operating

Inverter Performance

Enter SiC mode！=Request mode.

Mode Control

P244500

Unexpected operation

deboumce 22count*10ms

and Monitoring

Circuit

Torque difference

abs(safety torque-Qm torque)>40Nm

between function

P244600

or torque direction err & abs acture torque >30NM

Safety layer and QM

debounce 19count*10ms

out of range fault

1. Torque Control

and Calibration

Torque difference

Related Circuits

between function

abs （safety torque-Requeste Torque）＞50NM

Safety layer and

P244700

debounce 19count*10ms

Requested out of

range fault

1. Motor Back

Enter ASC State Due

EMF Monitoring

abs Speed＞8000rpm and Back-EMF voltage＞Udc

to Back-EMF voltage

P244800

and ASC Status

debounce 19count*10ms

too high

Control Circuit

check the offset is default value

Drive Motor Zero

debounce 5count*10ms

P246700

Position Not Learned

(Use default value in SW）

Resolver QM SIN/COS

QM_SIN＞1.2 or QM_SIN＜0.8

P246800

or QM_COS＞1.2 or QM_COS＜0.8

Signal out of range

Fault

debounce 19count*10ms

1. Resolver

Resolver QM EXC

QM_EXC amplitude＞1.2 or QM_EXC amplitude＜0.8

Sensor and

Signal amplitude out of

P246900

debounce 19count*10ms

Angle Sampling

range Fault

Related Circuitry

Resolver FUSA EXC

FUSA_EXC amplitude＞1.2 or FUSA_EXC amplitude＜

Signal amplitude out of

P247000

0.8

range Fault

debounce 19count*10ms

Resolver FUSA SIN/

FUSA_SIN＞1.2 or FUSA_SIN＜0.8 or FUSA_COS＞

COS Signal out of

P247100

1.2 or FUSA_COS＜0.8

range Fault

debounce 19count*10ms

Description

DTC Trigger conditions

Faulty Part

DTC Code

Current timestamp and

abs（Current timestamp - Angle timestamp）＞110us

P247200

Angle timestampt

debounce 19count*10ms

Check Fault

L1 Electrical angle and

abs(Qm_AngleAct - FUSA_AngleAct) > 30[deg]

P247300

Electrical angle Check

(Electrical angle）

Fault

debounce 19count*10ms

Resolver SIN and

SQRT(Sin²+Cos²) < 0.8 OR SQRT(Sin²+Cos²) > 1.2

P247400

COS Sum of squares

debounce 19count*10ms

Check Fault

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 4:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 5:Clear and confirm DTC.

4.1.6.21 MCU3 Overheating Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Dreating Due to SiC

SiC NTC temperature >95°C

P242000

Over temperature

debounce 43count*10ms

SiC NTC temperature >110°C

SiC Overtemperature

P242100

debounce 43count*10ms

1. Temperature

Dreating due to Drive

Monitoring and

Motor temp >140°C

Motor Over

P242900

Protection Circuit

debounce 127count*10ms

temperature

(SiC, Motor,

Drive Motor

Motor temp >150°C

Cooling Water)

P242A00

Overtemperature

debounce 127count*10ms

Dreating Due to

Coolant Temperature > 70 degC

Coolant Over

P243200

debounce 127count*10ms

temperature

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Move the vehicle to a normal temperature environment and let it sit for a while.

Step 4:Check the vehicle has any fault codes related to the thermal management system?

Prioritize troubleshooting related to thermal management systems.

– Yes:

Next step

– No:

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 7:Clear and confirm DTC.

4.1.6.22 MCU3 High Voltage Circuit Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

High-Voltage

Active Discharge

Active Discharge time-

HVDC>60V after 1s when discharge activated

Circuit and

P244900

out

debounce 43count*10ms

Related Control

Circuit

Dreating Due to HVDC

1.UHVDC phys <520V

P244A00

UnderVoltage

debounce 22count*10ms

1.UHVDC phys <490V

HVDC UnderVoltage

P244B00

debounce 22count*10ms

HVDC "A" Inverter

UHVDC_1 phys ＞1200V

Voltage Sensor Circuit

debounce 22count*10ms

P244C00

voltage out of range

Note：UHVDC_1 phys fault，use UHVDC_2 phys

HVDC "B" Inverter

UHVDC_2 phys ＞1200V

Voltage Sensor Circuit

P244D00

debounce 22count*10ms

voltage out of range

1. DC Bus

abs（UHVDC_1 phys-UDC_BAT）＞60V

Voltage

debounce 19count*10ms

Monitoring and

Note：If abs（UHVDC_1 phys-UDC_BAT）＞60V and

Function Safety HVDC

P244E00

Protection Circuit

Monitoring Fault

abs （UHVDC_2 phys-UDC_BAT）＜40V，

WhlMotSysUdc use UHVDC_2 phys；and Post-fault

processing use UHVDC_2 phys

Dreating Due to HVDC

DC Link voltage beyond 930V

P244F00

OverVoltag

deboumce 22count*10ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

P245000

Link voltage beyond 960V

SW threshold

deboumce 127count*1ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

Link voltage beyond 971V

P245100

HW threshold

deboumce 1count*pwm

1. Inverter Phase

The DTC is stored if the control module detects that:

Drive Motor "U"

Current

abs( Current value) > 700A)

P245200

Current value above

Monitoring and

debounce 10*count*pwm

SW threshold

Control Circuit

Description

DTC Trigger Conditions

Faulty Part

DTC Code

The DTC is stored if the control module detects that:

Drive Motor "V"

abs( Current value) > 700A)

P245300

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "W"

abs( Current value) > 700A)

P245400

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "U/V/W"

abs(U/V/W Current value) > 780A)

P245500

Current value above

debounce 2*count*pwm

HW threshold

Drive Motor "U"Phase

When In Tq mode, No phase current feedback

P245600

Circuit open Fault

debounce 19*count*10ms

Drive Motor "V“Phase

When In Tq mode, No phase current feedback

P245700

Circuit open Fault

debounce 19*count*10ms

Drive Motor "W"Phase

When In Tq mode, No phase current feedback

P245800

Circuit open Fault

debounce 19*count*10ms

Drive Motor "U/V/W"

abs(INV_IAC_SUM)>120A

Phase Current Sum

P245900

debounce 19*count*10ms

Check above threshold

Fault

Drive Motor "U" Phase

Current Offset

abs(offset in the AC phase U)>50AD（raw）

P245A00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "V" Phase

Current Offset

abs(offset in the AC phase V)>50AD（raw）

P245B00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "W" Phase

Current Offset

abs(offset in the AC phase W)>50AD（raw）

P245C00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "U" Phase

Current Sensor Circuit

current Raw value below 200

P245D00

short to ground or

debounce 19*10ms

1. Current

open

Sensors and

Related Circuits

Drive Motor "U" Phase

current Raw value beyond 4000

Current Sensor Circuit

P245E00

debounce 19*10ms

short to battery

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Drive Motor "V" Phase

Current Sensor Circuit

current Raw value below 200

P245F00

short to ground or

debounce 19*10ms

open

Drive Motor "V" Phase

current Raw value beyond 4000

Current Sensor Circuit

P246000

debounce 19*10ms

short to battery

Drive Motor "W" Phase

Current Sensor Circuit

current Raw value below 200

P246100

short to ground or

debounce 19*10ms

open

Drive Motor "W" Phase

current Raw value beyond 4000

Current Sensor Circuit

P246200

debounce 19*10ms

short to battery

abs(INV_IAC_SUM)>120A

or abs current value：＞1400A

Function Safety

P246300

Current Monitoring

or abs U/V/W（Qm current - Fusa Current）＞80A

Fault

or abs U/V/W currentOffset＞50AD（raw）

debounce 19*10ms

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive rear axle vehicle.

Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive rear axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 7:Clear and confirm DTC.

4.1.6.23 MCU3 Collision Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Collision

Collision occurred

Signal Reception

P246400

Collision fault

Collision signal received

and Related

Anti-shake: 1 count*10ms

Interface Circuitry

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

B12-1

C4-21

Total body power

Middle and rear axle MCU-KL30 O421

supply B+ L22

VDC-1

BDCU-4

B48-26

C93-97

status feedback H01

Smart Junction

Differential lock

Box - Body

B01-1

MCU4-CAN

drive wake up the power supply E146

The PDU, TCU, middrive, and rear

B07-2

B07-16

switch/parking

power supply

Switch class

KL30 shift

switch P116

I7_B_C

KL15 Power

supply P102

I7_C_B

switch - Shift

Combination

-KL30 P116b

Differential lock feedback signal

MCU power supply KL30 O421b

I1_B_IP

H01b

MCU4-CAN-H PH04e

MCU4-CANL PL04e

I1_IP_B

switch - Shift

KL15 Power

Combination

-KL30 P116b

supply P102

KL15 Power

Power KL30

supply P102a

C25-17

C25-1

C25-13

C25-5

C25-6

P116b

E-axle rear axle vehicle low voltage port

IP18-3

IP18-9

C25-20

C25-3

C25-4

MCU3-CAN-H PH04h

MCU3-CAN-L PL04h

MCU3-CAN-H PH04f

MCU3-CANL PL04f

MCU Power Supply - Z66

Shift switch

120Ω

IP18-8

IP18-2

IP18-1

PCAN4-H PH04d

PCAN4-L PL04d

Ground Z12d

C114-2

C114-1

CAN resistance -120Ω

MCU3-CAN

G02

G14

PCAN4

3.Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Inspect the vehicle for collision damage？

Please inspect the vehicle based on the actual collision damage.

– Yes:

Next step

– No:

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 6:Clear and confirm DTC.

4.1.6.24 MCU4 Power Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Main battery

Supply Voltage Too

KL30＞36V

B111717

2. Low voltage

High

debounce 127count*10ms

charging system

3. Wiring harness

4. Low voltage

KL30＜15V

Supply Voltage Too

B111716

interface of

debounce 127count*10ms

Low

electric drive rear

axle vehicle

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

B12-1

C4-21

Total body power

Middle and rear axle MCU-KL30 O421

supply B+ L22

VDC-1

BDCU-4

B48-26

C93-97

status feedback H01

Smart Junction

Differential lock

Box - Body

B01-1

MCU4-CAN

drive wake up the power supply E146

The PDU, TCU, middrive, and rear

B07-2

B07-16

switch/parking

power supply

Switch class

KL30 shift

switch P116

I7_B_C

KL15 Power

supply P102

I7_C_B

switch - Shift

Combination

-KL30 P116b

Differential lock feedback signal

MCU power supply KL30 O421b

I1_B_IP

H01b

MCU4-CAN-H PH04e

MCU4-CANL PL04e

I1_IP_B

switch - Shift

KL15 Power

Combination

-KL30 P116b

supply P102

KL15 Power

Power KL30

supply P102a

C25-17

C25-1

C25-13

C25-5

C25-6

P116b

E-axle rear axle vehicle low voltage port

IP18-3

IP18-9

C25-20

C25-3

C25-4

MCU3-CAN-H PH04h

MCU3-CAN-L PL04h

MCU3-CAN-H PH04f

MCU3-CANL PL04f

MCU Power Supply - Z66

Shift switch

120Ω

IP18-8

IP18-2

IP18-1

PCAN4-H PH04d

PCAN4-L PL04d

Ground Z12d

C114-2

C114-1

CAN resistance -120Ω

MCU3-CAN

G02

G14

PCAN4

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides MCU3?

Check the main battery. Refer to Inspection Of The Main Battery

– Yes:

Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault

Next step

– No:

Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive rear axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 7:Clear and confirm DTC.

4.1.6.25 MCU4 Communication Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

VDC Signal checksum

P256500

deboumce 19count*10ms

Fault

VDC_MCU_Msg Counter alive error

VDC Signal

（The Rolling Counter value changes less than 1 or

P256600

rollingcounter Fault

The Rolling Counter value changes more than 5 ）

1.Wiring harness

deboumce 19count*10ms

2. Electric drive

Lost Communication

VDC_MCUx_Torque_cmd timeout

U012287

rear axle vehicle

With VDC

debounce 127count*40ms

low-voltage

HighReTotalVehicleDistance timeout

Lost Communication

interface

U015687

debounce 127count*40ms

With CDCU

Lost Communication

TGW_Hours timeout

U019887

With T-BOX

debounce 127count*40ms

"Bus-off" has been detected by AURIX

U008E88

CAN Bus Off

debounce 32count*10ms

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

B12-1

C4-21

Total body power

Middle and rear axle MCU-KL30 O421

supply B+ L22

VDC-1

BDCU-4

B48-26

C93-97

status feedback H01

Smart Junction

Differential lock

Box - Body

B01-1

MCU4-CAN

drive wake up the power supply E146

The PDU, TCU, middrive, and rear

B07-2

B07-16

switch/parking

power supply

Switch class

KL30 shift

switch P116

I7_B_C

KL15 Power

supply P102

I7_C_B

switch - Shift

Combination

-KL30 P116b

Differential lock feedback signal

MCU power supply KL30 O421b

I1_B_IP

H01b

MCU4-CAN-H PH04e

MCU4-CANL PL04e

I1_IP_B

switch - Shift

KL15 Power

Combination

-KL30 P116b

supply P102

KL15 Power

Power KL30

supply P102a

C25-17

C25-1

C25-13

C25-5

C25-6

P116b

E-axle rear axle vehicle low voltage port

IP18-3

IP18-9

C25-20

C25-3

C25-4

MCU3-CAN-H PH04h

MCU3-CAN-L PL04h

MCU3-CAN-H PH04f

MCU3-CANL PL04f

MCU Power Supply - Z66

Shift switch

120Ω

IP18-8

IP18-2

IP18-1

PCAN4-H PH04d

PCAN4-L PL04d

Ground Z12d

C114-2

C114-1

CAN resistance -120Ω

MCU3-CAN

G02

G14

PCAN4

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 6:Clear and confirm DTC.

4.1.6.26 MCU4 Internal Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P252200

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "U" Circuit

P252300

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P252400

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

1. SiC

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

Temperature

deboumce 127count*10ms

Sensor "V" Circuit

Sensor Circuit

P252500

if collect SiCTEMP short to Power/GND，The value of

short to battery or

and Related

this sensor is not used as a temperature strategy

open

Wiring

SiC_TEMP_W Duty Value≤17%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P252600

if collect SiCTEMP short to Power/GND，The value of

short to ground

this sensor is not used as a temperature strategy

SiC_TEMP_W Duty Value≥89.4%

SiC Temperature

deboumce 127count*10ms

Sensor "V" Circuit

P252700

if collect SiCTEMP short to Power/GND，The value of

short to battery or

this sensor is not used as a temperature strategy

open

SiC Temperature

more than one SiC Temperature Sensor Circuit General

Sensor ，Any Two

P252800

Electrical Failures

Phase electronic

deboumce 127count*10ms

failure

1. Motor

motor TEMPAD＜650

Drive Motor "A"

debounce 127count*10ms

Temperature

Temperature Sensor

Sensor Circuit

if collect motor TEMP short to GND or open circuit

P252B00

Circuit short to ground

and Related

within 5count*100ms，The value of this sensor is not

or open

Wiring

used as a temperature strategy

Description

DTC Trigger Conditions

Faulty Part

DTC Code

motor TEMPAD＞3600

Drive Motor "A"

debounce 127count*10ms

Temperature Sensor

P252C00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

motor TEMPAD＜650

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

if collect motor TEMP short to GND or open circuit

P252D00

Circuit short to ground

withinv5count*100ms，The value of this sensor is not

or open

used as avtemperature strategy

motor TEMPAD＞3600

Drive Motor "B"

debounce 127count*10ms

Temperature Sensor

P252E00

if collect motor TEMP short to battery ，The value of

Circuit short to battery

this sensor is not used as a temperature strategy

Drive Motor "A" and

"B" Temperature

abs(STATOR_TEMP1- STATOR_TEMP2) > 30℃

P252F00

Sensor compare

debounce 127count*10ms

failure

Drive Motor "A" and

more than one Motor Temperature Sensor Circuit

"B" Temperature

P253000

General Electrical Failures

Sensor Circuit

debounce 127count*10m

electrical failure

abs Torque＞250NM and abs speed＜20rpm

Drive Motor Stalling

P253100

debounce 2s+127count*10ms（3.27s）

Fault

Dreating Due to Drive

abs Speed>11200

P253500

Motor OverSpeed

deboumce 43count*10ms

1.Motor Body and

Speed Monitoring

Drive Motor

abs Speed>12000

P253600

Related Circuits

OverSpeed Fault

deboumce 22count*10ms

abs （L2 spped-L1 speed）＞300rpm or abs Speed

Function Safety Speed

P253700

>12000

Monitoring Faul

deboumce 22count*10ms

Coolant Temperature

Coolant Temperature Sensor signal is below threshold

1. Water

Sensor Circuit short to

P253300

AD< 250

Temperature

ground

debounce 127count*10ms

Sensor Circuit

Coolant Temperature

Coolant Temperature Sensor signal is above threshold

and Related

Sensor Circuit short to

P253400

AD> 3780

Wiring

battery or open

debounce 127count*10ms

High Bridge Driver

The Gate driver IC Fault pin active

P253800

Fault

debounce 1count*PWM

1. Gate driver

Low Bridge Driver

The Gate driver IC Fault pin active

chip and related

P253900

Fault

debounce 1count*PWM

circuitry

High Bridge Driver

The Gate driver register value active

P257500

INTA Fault

debounce 1count*1ms

Description

DTC Trigger Conditions

Faulty Part

DTC Code

High Bridge Driver

The Gate driver register value active

P257600

INTB Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P257700

INTA Fault

debounce 1count*1ms

Low Bridge Driver

The Gate driver register value active

P257800

INTB Fault

debounce 1count*1ms

1. CAN Chip and

Recive fault state from CAN IC

Communication

CAN Link Chip Fault

P253A00

deboumce 19count*10ms

Circuitry

1. Smart Power

Management

SBC fault detected

SBC Chip fault

P253B00

Chip (SBC) and

deboumce 19count*10ms

Related Circuitry

Current sensor Power

The DTC is stored if the control module detects that:

supply voltage out of

P253C00

current sensro 5V supply< 4.5 V OR > 5.5 V

1. Control Module

range

deboumce 19count*10ms

Power Supply

Circuit (Including

Power supply fault of

Drive board 5V supply: (< 4.5V) OR ( >5.5 V)

Current Sensor

driver board 5V out of

P253D00

deboumce 19count*10ms

Power Supply,

range

Driver Board

SepicVolt：＜18V or ＞22V

Power Supply,

Function Safety

or PCanVolt：＜4.5V or ＞5.5V

and Low-Voltage

internal Low

or P5vExtVolt：＜4.5V or ＞5.5V

P253F00

Monitoring

PowerSupply

or P5vAnVolt：＜4.5V or ＞5.5V

Circuit)

Monitoring Fault

or VoltCore：＜1.1V or ＞1.5V

deboumce 22count*10ms

1. SiC Gate Drive

SiC driver IC power

Entering OVP > 22 V

Voltage Circuit

supply voltage out of

P253E00

Entering UVP < 18V

and Protection

range

deboumce 19count*10ms

Circuit

1. Aurix

microcontrollers

Internal Aurix ADC faul

A/D Processing

P254000

feature built-in

deboumce 19count*10ms

Performance fault

analog-to-digital

converters.

1. Electrically

Erasable

The DTC is stored if :

Programmable

1.Motor not been calibrated（current coef\positon offset

Read-Only

\voltage coeff

P254100

EEPROM Fault

Memory

2.EEPROM read fault CRC ERR

(EEPROM) and

3.EEPROM write fault CRC ERR

Related Read/

deboumce 19count*10ms

Write Circuits

Description

DTC Trigger Conditions

Faulty Part

DTC Code

read SBC wake up reason when MCU wake up，if SBC

MCU Unexpected

report LPOFF -DEEP FS state trigger DTC

1. Microcontroller

P254200

Restart fault

deboumce 19count*10ms

Unit (MCU) and

Fault reason：SBC OK，MCU reset

Reset/Wake-up

Related Circuits

Startup test failed and enter safty state fault.

P254300

MCU Self-Check fault

deboumce 19count*10ms

Shutdown Path Check

Shutdown Path Check test failed.

1. Shutdown Path

P254400

fault

deboumce 19count*10ms

Detection Circuit

1. SiC Operating

Inverter Performance

Enter SiC mode！=Request mode.

Mode Control

P254500

Unexpected operation

deboumce 22count*10ms

and Monitoring

Circuit

Torque difference

abs(safety torque-Qm torque)>40Nm or torque

between function

P254600

direction err & abs acture torque >30NM

Safety layer and QM

debounce 19count*10ms

out of range fault

1. Torque Control

and Calibration

Torque difference

Related Circuits

between function

abs （safety torque-Requeste Torque）＞50NM

Safety layer and

P254700

debounce 19count*10ms

Requested out of

range fault

1. Motor Back

Enter ASC State Due

EMF Monitoring

abs Speed＞8000rpm and Back-EMF voltage＞Udc

to Back-EMF voltage

P254800

and ASC Status

debounce 19count*10ms

too high

Control Circuit

check the offset is default value

Drive Motor Zero

debounce 5count*10ms

P256700

Position Not Learned

(Use default value in SW）

Resolver QM SIN/COS

QM_SIN＞1.2 or QM_SIN＜0.8 or QM_COS＞1.2 or

P256800

QM_COS＜0.8

Signal out of range

Fault

debounce 19count*10ms

1. Resolver

Resolver QM EXC

QM_EXC amplitude＞1.2 or QM_EXC amplitude＜0.8

Sensor and

Signal amplitude out of

P256900

debounce 19count*10ms

Angle Sampling

range Fault

Related Circuitry

Resolver FUSA EXC

FUSA_EXC amplitude＞1.2 or FUSA_EXC amplitude＜

Signal amplitude out of

P257000

0.8

range Fault

debounce 19count*10ms

Resolver FUSA SIN/

FUSA_SIN＞1.2 or FUSA_SIN＜0.8 or FUSA_COS＞

COS Signal out of

P257100

1.2 or FUSA_COS＜0.8

range Fault

debounce 19count*10ms

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Current timestamp and

abs（Current timestamp - Angle timestamp）＞110us

P257200

Angle timestampt

debounce 19count*10ms

Check Fault

L1 Electrical angle and

abs(Qm_AngleAct - FUSA_AngleAct) > 30[deg]

P257300

Electrical angle Check

(Electrical angle）

Fault

debounce 19count*10ms

Resolver SIN and

SQRT(Sin²+Cos²) < 0.8

P257400

COS Sum of squares

OR SQRT(Sin²+Cos²) > 1.2

Check Fault

debounce 19count*10ms

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 4:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 5:Clear and confirm DTC.

4.1.6.27 MCU4 Overheating Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Dreating Due to SiC

SiC NTC temperature >95°C

P252000

Over temperature

debounce 43count*10ms

SiC NTC temperature >110°C

SiC Overtemperature

P252100

debounce 43count*10ms

1. Temperature

Dreating due to Drive

Monitoring and

Motor temp >140°C

Motor Over

P252900

Protection Circuit

debounce 127count*10ms

temperature

(SiC, Motor,

Drive Motor

Motor temp >150°C

Cooling Water)

P252A00

Overtemperature

debounce 127count*10ms

Dreating Due to

Coolant Temperature > 70 degC

Coolant Over

P253200

debounce 127count*10ms

temperature

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Move the vehicle to a normal temperature environment and let it sit for a while.

Step 4:Check the vehicle has any fault codes related to the thermal management system?

Prioritize troubleshooting related to thermal management systems.

– Yes:

Next step

– No:

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 7:Clear and confirm DTC.

4.1.6.28 MCU4 High Voltage Circuit Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. High-Voltage

Active Discharge

Active Discharge time-

HVDC>60V after 1s when discharge activated

Circuit and

P254900

out

debounce 43count*10ms

Related Control

Circuit

Dreating Due to HVDC

1.UHVDC phys <520V

P254A00

UnderVoltage

debounce 22count*10ms

1.UHVDC phys <490V

HVDC UnderVoltage

P254B00

debounce 22count*10ms

HVDC "A" Inverter

UHVDC_1 phys ＞1200V

Voltage Sensor Circuit

debounce 22count*10ms

P254C00

voltage out of range

Note：UHVDC_1 phys fault，use UHVDC_2 phys

HVDC "B" Inverter

UHVDC_2 phys ＞1200V

Voltage Sensor Circuit

P254D00

debounce 22count*10ms

voltage out of range

1. DC Bus

abs（UHVDC_1 phys-UDC_BAT）＞60V

Voltage

debounce 19count*10ms

Monitoring and

Note：If abs（UHVDC_1 phys-UDC_BAT）＞60V and

Function Safety HVDC

P254E00

Protection Circuit

Monitoring Fault

abs （UHVDC_2 phys-UDC_BAT）＜40V，

WhlMotSysUdc use UHVDC_2 phys；and Post-fault

processing use UHVDC_2 phys

Dreating Due to HVDC

DC Link voltage beyond 930V

P254F00

OverVoltag

deboumce 22count*10ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

P255000

Link voltage beyond 960V

SW threshold

deboumce 127count*1ms

The DTC is stored if the control module detects that: DC

HVDC Voltage above

Link voltage beyond 971V

P255100

HW threshold

deboumce 1count*pwm

1. Inverter Phase

The DTC is stored if the control module detects that:

Drive Motor "U"

Current

abs( Current value) > 700A)

P255200

Current value above

Monitoring and

debounce 10*count*pwm

SW threshold

Control Circuit

Description

DTC Trigger Conditions

Faulty Part

DTC Code

The DTC is stored if the control module detects that:

Drive Motor "V"

abs( Current value) > 700A)

P255300

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "W"

abs( Current value) > 700A)

P255400

Current value above

debounce 10*count*pwm

SW threshold

The DTC is stored if the control module detects that:

Drive Motor "U/V/W"

abs(U/V/W Current value) > 780A)

P255500

Current value above

debounce 2*count*pwm

HW threshold

Drive Motor "U"Phase

When In Tq mode, No phase current feedback

P255600

Circuit open Fault

debounce 19*count*10ms

Drive Motor "V“Phase

When In Tq mode, No phase current feedback

P255700

Circuit open Fault

debounce 19*count*10ms

Drive Motor "W"Phase

When In Tq mode, No phase current feedback

P255800

Circuit open Fault

debounce 19*count*10ms

Drive Motor "U/V/W"

abs(INV_IAC_SUM)>120A

Phase Current Sum

P255900

debounce 19*count*10ms

Check above threshold

Fault

Drive Motor "U" Phase

Current Offset

abs(offset in the AC phase U)>50AD（raw）

P255A00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "V" Phase

Current Offset

abs(offset in the AC phase V)>50AD（raw）

P255B00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "W" Phase

Current Offset

abs(offset in the AC phase W)>50AD（raw）

P255C00

Exceeded Learning

debounce 19*10ms

Limit

Drive Motor "U" Phase

Current Sensor Circuit

current Raw value below 200

P255D00

short to ground or

debounce 19*10ms

1. Current

open

Sensors and

Related Circuits

Drive Motor "U" Phase

current Raw value beyond 4000

Current Sensor Circuit

P255E00

debounce 19*10ms

short to battery

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Drive Motor "V" Phase

Current Sensor Circuit

current Raw value below 200

P255F00

short to ground or

debounce 19*10ms

open

Drive Motor "V" Phase

current Raw value beyond 4000

Current Sensor Circuit

P256000

debounce 19*10ms

short to battery

Drive Motor "W" Phase

Current Sensor Circuit

current Raw value below 200

P256100

short to ground or

debounce 19*10ms

open

Drive Motor "W" Phase

current Raw value beyond 4000

Current Sensor Circuit

P256200

debounce 19*10ms

short to battery

abs(INV_IAC_SUM)>120A

or abs current value：＞1400A

Function Safety

P256300

Current Monitoring

or abs U/V/W（Qm current - Fusa Current）＞80A

Fault

or abs U/V/W currentOffset＞50AD（raw）

debounce 19*10ms

2. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the high-voltage wiring harness of the low-voltage interface of the electric drive rear axle vehicle.

Step 4:Check the internal insulation detection circuit of the low-voltage interface of the electric drive rear axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive rear axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 7:Clear and confirm DTC.

4.1.6.29 MCU4 Collision Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Collision

Collision occurred

Signal Reception

P256400

Collision fault

Collision signal received

and Related

Anti-shake: 1 count*10ms

Interface Circuitry

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

B12-1

C4-21

Total body power

Middle and rear axle MCU-KL30 O421

supply B+ L22

VDC-1

BDCU-4

B48-26

C93-97

status feedback H01

Smart Junction

Differential lock

Box - Body

B01-1

MCU4-CAN

drive wake up the power supply E146

The PDU, TCU, middrive, and rear

B07-2

B07-16

switch/parking

power supply

Switch class

KL30 shift

switch P116

I7_B_C

KL15 Power

supply P102

I7_C_B

switch - Shift

Combination

-KL30 P116b

Differential lock feedback signal

MCU power supply KL30 O421b

I1_B_IP

H01b

MCU4-CAN-H PH04e

MCU4-CANL PL04e

I1_IP_B

switch - Shift

KL15 Power

Combination

-KL30 P116b

supply P102

KL15 Power

Power KL30

supply P102a

C25-17

C25-1

C25-13

C25-5

C25-6

P116b

E-axle rear axle vehicle low voltage port

IP18-3

IP18-9

C25-20

C25-3

C25-4

MCU3-CAN-H PH04h

MCU3-CAN-L PL04h

MCU3-CAN-H PH04f

MCU3-CANL PL04f

MCU Power Supply - Z66

Shift switch

120Ω

IP18-8

IP18-2

IP18-1

PCAN4-H PH04d

PCAN4-L PL04d

Ground Z12d

C114-2

C114-1

CAN resistance -120Ω

MCU3-CAN

G02

G14

PCAN4

3.Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Inspect the vehicle for collision damage？

Please inspect the vehicle based on the actual collision damage.

– Yes:

Next step

– No:

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive rear axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle - Rear

axle

Step 6:Clear and confirm DTC.

4.1.6.30 TCU1 Power Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Main battery

The TCU power supply

TCU supply voltage higher than 32V for a period of time

B111717

2. Low voltage

overvoltage

(about 200ms)

charging system

3. Wiring harness

4. Low voltage

The TCU supply

TCU supply voltage below 18V for a period of time

interface of

B111716

undervoltage

(about 200ms)

electric drive

medium axle

vehicle

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides TCU?

Check the main battery. Refer to Inspection Of The Main Battery

– Yes:

Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault

Next step

– No:

Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.31 TCU1 Communication Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

VDC Counter signal lost or unchanged for 500ms

Communication with

U012287

(detection message ID:0x18010327)

VCU was lost

Loss of communication

with MCU (TCU can

VDC Counter signal lost or unchanged for 500ms

receive life signals

U012A87

(detection message ID:0x18012774)

from MCU1-4 on the

bus)

Loss of communication

with MCU (TCU can

VDC Counter signal lost or unchanged for 500ms

receive life signals

U012B87

1.Wiring harness

(detection message ID:0x18012775)

from MCU1-4 on the

2. Electric drive

bus)

mid-axle vehicle

Loss of communication

low-voltage

with MCU (TCU can

interface

VDC Counter signal lost or unchanged for 500ms

receive life signals

U012D87

(detection message ID:0x18012777))

from MCU1-4 on the

bus)

The DTC was recorded after eight busoffs

U008E88

PCAN4 BusOff

The CDCU

CDCU communication remains unchanged for 500ms

U012E87

communication is

(Detection message ID:0x18FEC1EE)

abnormal

GSW does not change for 500ms(Check packet

TDW communication

U012F87

ID:0x18FEE6EE)

is abnormal

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 6:Clear and confirm DTC.

4.1.6.32 TCU1 Internal Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1, the sensor 5V power supply is normal;

First and second gear

2, position voltage <0.1V;

P270300

position sensor open

3, last 200ms

circuit failure

First and second gear

1, the sensor 5V power supply is normal;

position sensor to

2, position voltage >4.9;

P270301

power short circuit

3, last 200ms

fault

1. First and

First and second gear

1, the sensor 5V power supply is normal;

Second Gear

position sensor to

2, position voltage <0.1V;

P270302

Position Sensor

ground short-circuit

3, last 200ms

Circuit and

fault

Related Wiring

The first and second

1, the sensor power supply is normal;

gear position sensor

2, sensor voltage >4500mv;

P270303

signal exceeds the

3, last 1000ms;

upper limit

The first and second

1, the sensor power supply is normal;

gear position sensor

2, sensor voltage <500mv;

P270304

signal exceeds the

3, last 1000ms;

lower limit

1, the sensor 8V power supply is normal;

The output shaft speed

2, sensor AD signal voltage <2.5V;

P270305

sensor is open faulty

3, output shaft speed value =0rpm;

4, last 200ms;

1, the sensor 8V power supply is normal;

The output shaft speed

2, sensor AD signal voltage＞3.3V;

sensor short-circuits

P270306

1. Output Shaft

3, output shaft speed value =0rpm;

the power supply

Speed Sensor

4, last 200ms;

Circuit and

1, the sensor 8V power supply is normal;

Related Wiring

The output shaft speed

2, sensor AD signal voltage <0.25V;

sensor is short circuit

P270307

3, output shaft speed value =0rpm;

to the ground

4, last 200ms;

The output shaft speed

1, the sensor 8V power supply is normal;

sensor signal exceeds

2, speed value greater than 120km*1.2;

P270308

the upper limit

3, last 200ms;

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Reverse second shift

In a single shift cycle, the number of shift failures >=5

P27031E

failed

Second shift in 1st

In a single shift cycle, the number of shift failures >=5

P27031F

gear failed

1. Shift Actuator

Second gear failed

In a single shift cycle, the number of shift failures >=5

P270320

and Associated

1. When shifting, the actual motion direction of the

Control Circuitry

Shift power supply

shifting motor is opposite to the theoretical position

harness positive and

P270348

(request 1 gear but actually hang 2 gear direction);

negative connection

2, last 200ms

P270349

Shift actuator stuck

1. Take off the block card for 5s

1, displacement sensor change rate >1V

The shift motor current

2, shifting motor current <1.5A;

P270350

sensor is faulty

3, duty cycle ≥30; 4, last 1000ms

1, the shift motor power supply is normal;

Shift motor open circuit

2, duty cycle > 10, current less than 200mA;

P270355

fault

1. Shift Motor and

3, last 1000ms;

Current Sensor

The shift motor is short

Circuit

circuit to the power

P270356

supply

1, the shift motor power supply is normal;

Shift motor to ground

2, duty cycle > 10, current less than 200mA;

P270357

short circuit fault

3, last 1000ms;

The MCU1 motor has

1, the actual motor speed >11000rpm for 200ms

abnormal overspeed in

P270351

1. Motor Speed

2. Driving in gear

the drive gear

Monitoring and

Overspeed

The MCU4 motor has

1, the actual motor speed >11000rpm for 200ms

Protection Circuit

abnormal overspeed in

P270352

2. Driving in gear

the drive gear

In gear, | actual output shaft speed - theoretical output

Velocity ratio anomaly

P270353

shaft speed |>50rpm for 1000ms

1. Gear Position

Monitoring and

During a power-on process, if the internal gear of TCU

Gear Ratio

is inconsistent with the current requested gear of the

P270354

Abnormal shift

Control Circuitry

VDC for more than 5 times during driving, it is judged to

be abnormal gear removal

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1, 5V voltage sampling greater than 5.5V or less than

The 5V power supply

4.5V;

P270358

to the position sensor

1. Sensor Power

2, continuous 100ms;

is abnormal

Supply Circuit

1, 8V voltage sampling is greater than 9V or less than

The 8V power supply

(5V, 8V)

P270359

to the tachometer is

2, continuous 100ms;

abnormal

1. TCU Control

The temperature of the

Board

control board is too

The sampled temperature is greater than 75 ° C

P270360

Temperature

high

Monitoring and

Protection Circuit

2. Diagnostic Steps

Step 1:DTC confirmation. Refer to DTC Confirmation

Step 2:Routine inspection. Refer to Routine Inspection

Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium

axle vehicle.

Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 5:Clear and confirm DTC.

4.1.6.33 TCU2 Power Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. Main battery

TCU Power Supply

The TCU supply voltage remains above 32V for a

B111717

2. Low voltage

Overvoltage

sustained period (approximately 200ms).

charging system

3. Wiring harness

4. Low voltage

TCU Power Supply

The TCU supply voltage remains below 18V for a

interface of

B111716

Undervoltage

sustained period (approximately 200ms).

electric drive

medium axle

vehicle

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check if there are any other module power fault codes besides TCU?

Check the main battery. Refer to Inspection Of The Main Battery

– Yes:

Check the low-voltage charging system. Refer to DCDC1 Low-voltage Charging System Fault

Next step

– No:

Step 4:Check the power supply and grounding harness of the low-voltage interface of the electric drive medium axle vehicle.

Step 5:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 6:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 7:Clear and confirm DTC.

4.1.6.34 TCU2 Communication Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

VDC Counter signal loss or unchanged for 500ms

Communication lost

U012287

(Detection message ID: 0x18010327)

with VCU

Loss of communication

with MCU (TCU can

MCU1 counter signal loss or unchanged for 500ms

receive life signals

U012A87

(Detection message ID: 0x18012774)

from MCU1-4 on the

bus)

Loss of communication

with MCU (TCU can

MCU2 counter signal loss or unchanged for 500ms

1.Wiring harness

receive life signals

U012B87

(Detection message ID: 0x18012775)

2. Electric drive

from MCU1-4 on the

mid-axle vehicle

bus)

low-voltage

Loss of communication

interface

with MCU (TCU can

MCU4 counter signal loss or unchanged for 500ms

receive life signals

U012D87

(Detection message ID: 0x18012777)

from MCU1-4 on the

bus)

U008E88

PCAN4 BusOff

Record DTC after 8 BUSOFF events

CDCU communication remains unchanged for 500 ms

CDCU communication

U012E87

(detection message ID: 0x18FEC1EE)

anomaly

TDW communication

GSW remains unchanged for 500 ms (detection

U012F87

anomaly

message ID: 0x18FEE6EE)

2.Circuit Diagram

Smart Junction Box - Chassis

Battery

VDC-1

BDCU-4

B48-26

C4-21

C2-G

C93-97

MCU2-CAN

status feedback H01

Differential lock

Middle and rear axle MCU-KL30 O421

I7_B_C

I7_C_B

MCU2-CAN-H PH04d

feedback signal H01a

Wake-up call E146a

MCU2-CANL PL04d

Differential lock

TCU-KL30 G2G

C27-17

C27-19

C27-1

C27-13

C27-5

C27-6

E-axle mid axle vehicle low voltage port

C27-20

C27-22

C27-14

C27-15

C27-3

C27-4

MCU Power Supply - Z66

TCU Power supply - Z65

MCU1-CAN-H PH04c

MCU1-CANL PL04c

TCU-CAN-H PH04b

TCU-CANL PL04b

MCU1-CAN

TCU-CAN

G02

3. Diagnostic Steps

Step 1:DTC Confirmation. Refer to DTC Confirmation

Step 2:Routine Inspection. Refer to Routine Inspection

Step 3:Check the PCAN4 bus communication harness. Refer to Inspection Of PCAN4 Bus Network Integrity

Step 4:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive mid-axle

vehicle.

Step 5:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 6:Clear and confirm DTC.

4.1.6.35 TCU2 Internal Fault

1.DTC Monitoring Logic

Description

DTC Trigger Conditions

Faulty Part

DTC Code

Open circuit fault in

1. Sensor 5V power supply is normal;

P670300

1st/2nd gear position

2. Position voltage < 0.1V;

3. Persists for 200ms.

sensor

Short circuit to power

1. Sensor 5V power supply is normal;

supply in 1st/2nd gear

P670301

2. Position voltage > 4.9V;

position sensor

3. Sustained for 200ms.

1. First and

Short circuit to ground

Second Gear

1. Sensor 5V power supply is normal;

in 1st/2nd gear

Position Sensor

P670302

2. Position voltage < 0.1V;

position sensor

Circuit and

3. Persists for 200ms.

Related Wiring

Signal from 1st/2nd

1. Sensor power supply is normal;

gear position sensor

2. Sensor voltage > 4500 mV;

P670303

exceeds upper limit

3. Persists for 1000 ms;

1. Sensor power supply is normal;

Signal from 1st/2nd

2. Sensor voltage < 500 mV;

P670304

gear position sensor

3. Persists for 1000 ms;

falls below lower limit

1. Sensor 8V power supply is normal;

Open circuit fault in

2. Sensor AD signal voltage < 2.5V;

P670305

output shaft speed

3. Output shaft speed value = 0 rpm;

sensor

4. Persists for 200ms;

1. Sensor 8V power supply is normal;

Output shaft speed

2. Sensor AD signal voltage > 3.3V;

sensor short circuit to

P670306

1. Output Shaft

3. Output shaft speed value = 0 rpm;

power supply

Speed Sensor

4. Duration: 200ms;

Circuit and

1. Sensor 8V power supply is normal;

Related Wiring

Output shaft speed

2. Sensor AD signal voltage < 0.25V;

sensor short circuit to

P670307

3. Output shaft speed value = 0 rpm;

ground

4. Persists for 200ms;

Output shaft speed

1. Sensor 8V power supply is normal;

sensor signal exceeds

2. RPM value exceeds 120 km/h multiplied by 1.2;

P670308

upper limit

3. Persists for 200 milliseconds;

Reverse gear

1. Shift Actuator

During a single shift cycle, the number of shift failures is

secondary

and Associated

P67031E

≥5

engagement failure

Control Circuitry

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1st gear secondary

During a single shift cycle, the number of shift failures is

P67031F

engagement failure

≥5

2nd gear secondary

During a single shift cycle, the number of shift failures is

P670320

engagement failure

≥5

1. During gear shifting, the actual movement direction of

Reversed Polarity in

the shift motor is opposite to the theoretical position

P670348

Shift Power Supply

(requesting 1st gear but shifting toward 2nd gear);

Harness

2. Persists for 200ms;

1. Gear disengagement stuck for 5 seconds;

P670349

Stuck Shift Actuator

1. Displacement sensor change rate > 1V

2. Shift motor current < 1.5A

Shift Motor Current

P670350

3. Duty cycle ≥30%

Sensor Failure

4. Sustained for 1000ms

1. Gear shift motor power supply is normal;

Shift motor open-

1. Shift Motor and

2. Duty cycle > 10%, current < 200mA;

P670355

circuit fault

Current Sensor

3. Duration: 1000ms;

Circuit

Shift motor short-

P670356

circuit to power supply

1. Gear shift motor power supply is normal;

Shift motor short-

2. Duty cycle > 10%, current < 200mA;

P670357

circuit to ground

3. Duration: 1000ms;

1. Actual motor speed > 11,000 rpm sustained for 200

MCU1 motor exhibits

P670351

abnormal overspeed in

1. Motor Speed

2. Driving in gear

drive mode

Monitoring and

Overspeed

1. Actual motor speed > 11,000 rpm sustained for 200

MCU4 motor exhibits

Protection Circuit

P670352

abnormal overspeed in

2. Driving in gear

drive mode

In gear state, |Actual output shaft speed - Theoretical

Abnormal gear ratio

P670353

output shaft speed| > 50 rpm for 1000 ms;

1. Gear Position

During a power-up sequence, if the internal gear

Monitoring and

position within the TCU differs from the current gear

Gear Ratio

Abnormal gear

position requested by VDC more than five times while

P670354

Control Circuitry

disengagement

driving in gear, it is determined to be an abnormal gear

disengagement.

Description

DTC Trigger Conditions

Faulty Part

DTC Code

1. 5V voltage sampling exceeds 5.5V or falls below

Position sensor 5V

4.5V;

P670358

1.Sensor Power

power supply anomaly

2. Persists for 100ms;

Supply Circuit

(5V, 8V)

RPM sensor 8V power

1. 8V voltage sampling exceeds 9V or falls below 7V

P670359

supply anomaly

2. Persists for 100ms;

1. TCU Control

Board

Control board over-

Temperature sampling value > 75°C

P670360

Temperature

temperature fault

Monitoring and

Protection Circuit

2. Diagnostic Steps

Step 1:DTC confirmation. Refer to DTC Confirmation

Step 2:Routine inspection. Refer to Routine Inspection

Step 3:Rewrite the configuration code, reload the software, and upgrade the low-voltage interface of the electric drive medium

axle vehicle.

Step 4:Replace the low-voltage interface of the electric drive mid axle vehicle. Refer to Replacement Of Integrated axle -

Medium axle

Step 5:Clear and confirm DTC.

4.1.7 Dismantling and Installation

4.1.7.1 Replacement of E-Axle Device - Intermediate Axle

Intermediate Axle

Removal Procedures

Release air pressure from the brake system.

Open the door.

Open the front flip cover plate.

Disconnect the battery negative cable.

Perform power-off of high voltage system.

Jack the rear end of the vehicle.

Drain coolant from the power system.

Removal the fifth wheel assembly.

Remove the corrugated plate.

Remove the drive wheel (front left).

Removal the rear wheel housing left front assembly.

Remove the rear air spring assembly - 260 (left front).

Remove the shock absorber assembly (rear).

Remove the rear air spring assembly - 280 (left front).

Remove the longitudinal thrust rod assembly.

Remove the rear spring U-bolt.

Remove the balance beam (left).

Remove the drive wheel (right front)

Remove the rear wheel housing right front assembly.

Remove the rear air spring assembly - 260 (right front).

Remove the rear air spring assembly - 280 (right front).

Remove the balance beam (right).

Remove the X-shaped control arm assembly (front).

Disconnect the 2 harness connectors of the E-Axle Device

- intermediate axle.

Remove the 6 straps.

Disconnect the 2 harness connectors of the E-Axle Device

- intermediate axle.

Disconnect the 3 air pipes of the E-Axle Device -

intermediate axle.

Remove the 6 straps.

Disconnect the 2 harness connectors of the E-Axle Device

- intermediate axle.

Disconnect the 2 air pipes of the E-Axle Device -

intermediate axle.

Disconnect the 2 water pipes of the E-Axle Device -

intermediate axle.

caution

Use a clean container to receive the discharged

coolant.

Remove 1 fixing bolt of the high-voltage wire harness

clamp on the E-Axle Device-intermediate axle.

Remove 3 fixing bolts on the E-Axle Device-intermediate

axle.

Disconnect the 1 harness connector of the E-Axle Device

- intermediate axle.

Remove 4 fixing bolts of the fixed clamp for the high-

voltage wire harness of the E-Axle Device-intermediate

axle.

Using a lifting platform or other tools to remove the E-Axle

Device - intermediate axle.

Installation Procedures

Use a lifting platform or other tools to move the E-Axle

Device - intermediate axle to the installation position.

Install 2 fixing bolts of the fixed clamp for the high-voltage

wire harness on the E-Axle Device-intermediate axle.

Torque: (12 ft-lb +/- .36) ft-lb

Connect 1 wire harness connector of the E-Axle Device-

intermediate axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install 3 fixing bolts of the E-Axle Device-intermediate

axle.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

Install 1 fixing bolt of the high-voltage wire harness clamp

on the E-Axle Device-intermediate axle.

Torque:(9 ft-lb +/- .5 ft-lb) ft-lb

Connect the 2 water pipes of the E-Axle Device -

intermediate axle.

Connect the 2 air pipes of the E-Axle Device -

intermediate axle.

Connect 1 harness connector of the E-Axle Device -

intermediate axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install the 6 straps.

Connect the 3 air pipes of the E-Axle Device -

intermediate axle.

Connect 1 harness connector of the E-Axle Device -

intermediate axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install the 6 straps.

Connect 2 harness connector of the E-Axle Device -

intermediate axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install the X-shaped control arm assembly (front).

Install the balance beam (right).

Install the rear air spring assembly - 280 (right front).

Install the rear air spring assembly - 260 (right front).

Install the rear wheel housing right front assembly.

Install the drive wheel (right front).

Install the balance beam (left).

Install the rear spring U-bolt.

Install the longitudinal thrust rod assembly.

Install the rear air spring assembly - 280 (left front).

Install the shock absorber assembly (rear).

Install the rear air spring assembly - 260 (left front).

Install the rear wheel housing left front assembly.

Install the drive wheel (left front).

Install the corrugated plate.

Install the fifth wheel assembly.

Fill coolant in the power system.

Lower the rear end of the vehicle.

Perform power-on of the high voltage system.

Connect the battery negative cable.

Close the front flip cover plate.

Close the door.

4.1.7.2 Replacement of E-Axle Device - Rear Axle

Axle

Removal Procedures

Release air pressure from the brake system.

Open the door.

Open the front flip cover plate.

Disconnect the battery negative cable.

Perform power-off of high voltage system.

Jack the rear end of the vehicle.

Drain coolant from the power system.

Remove the rear wheel housing upper body.

Remove the drive wheel (rear left).

Remove the height adjustment device assembly (left).

Remove the rear left wheel housing middle body

assembly.

Remove the rear left wheel housing rear body assembly.

Remove the rear air spring assembly - 260 (rear left).

Remove the shock absorber assembly (rear).

Remove the rear air spring assembly - 280 (rear left).

Remove the longitudinal thrust rod assembly.

Remove the rear spring U-bolt.

Remove the rear spring U-bolt 2.

Remove the balance beam (left).

Remove the drive wheel (rear right).

Remove the height adjustment device assembly (right).

Remove the rear right wheel housing middle body

assembly.

Remove the rear right wheel housing rear body assembly.

Remove the rear air spring assembly - 260 (rear right).

Remove the rear air spring assembly - 280 (rear right).

Remove the balance beam (right).

Remove the dual channel module assembly.

Remove the X-shaped control arm assembly (rear).

Disconnect the 2 harness connectors of the E-Axle Device

- rear axle.

Remove the 4 straps.

Disconnect the 2 harness connectors of the E-Axle Device

- rear axle.

Disconnect the 2 harness connectors of the E-Axle Device

- rear axle.

Disconnect the 2 water pipes of the E-Axle Device - rear

axle.

caution

Use a clean container to receive the discharged

coolant.

Remove the 2 fixing bolts of the E-Axle Device - rear axle.

Remove the 2 fixing bolts of the high-voltage wire harness

clamp on the E-Axle Device - the rear axle.

Disconnect the 1 harness connectors of the E-Axle Device

- rear axle.

Remove the 4 fixing bolts of the E-Axle Device - rear axle.

Disconnect the 2 air pipes of the E-Axle Device - rear axle.

Remove the 2 straps of the E-Axle Device - rear axle.

Disconnect the 3 air pipes of the E-Axle Device - rear axle.

Remove the 2 straps of the E-Axle Device - rear axle.

Use a lifting platform or other tools to remove the E-Axle

Device - rear axle.

Installation Procedures

Use a lifting platform or other tools to move the E-Axle

Device - rear axle to the installation position.

Install the 2 straps of the E-Axle Device - rear axle.

Connect the 3 air pipes of the E-Axle Device - rear axle.

Install the 2 straps of the E-Axle Device - rear axle.

Connect the 2 air pipes of the E-Axle Device - rear axle.

Install the 4 fixing bolts of the high-voltage wire harness

clamp on the E-Axle Device - the rear axle.

Torque: (12 ft-lb +/- .36) ft-lb

Connect the 1 harness connectors of the E-Axle Device -

rear axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install the 2 fixing bolts of the high-voltage wire harness

clamp on the E-Axle Device - the rear axle.

Torque:(9 ft-lb +/- .5 ft-lb) ft-lb

Install the 2 fixing bolts of the E-Axle Device - rear axle.

Torque: (18 ft-lb +/- 2 ft-lb) ft-lb

Connect the 2 water pipes of the E-Axle Device - rear

axle.

Connect the 2 harness connectors of the E-Axle Device -

rear axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Connect the 2 harness connectors of the E-Axle Device -

rear axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install the 4 straps of the E-Axle Device - rear axle.

Connect the 2 harness connectors of the E-Axle Device -

rear axle.

caution

The harness is firmly connected following the

principal of "insert until a click is heard for

confirmation".

Install the X-shaped control arm assembly (rear).

Install the dual channel module assembly.

Install the balance beam (right).

Install the rear air spring assembly - 280 (rear right).

Install the rear air spring assembly - 260 (rear right).

Install the rear right wheel housing rear body assembly.

Install the rear right wheel housing middle body assembly.

Install the height adjustment device assembly (right).

Install the drive wheel (rear right).

Install the balance beam (left).

Install the rear spring U-bolt 2.

Install the rear spring U-bolt.

Install the longitudinal thrust rod assembly.

Install the rear air spring assembly - 280 (rear left).

Install the shock absorber assembly (rear).

Install the rear air spring assembly - 260 (rear left).

Install the rear left wheel housing rear body assembly.

Install the rear left wheel housing middle body assembly.

Install the height adjustment device assembly (left).

Install the drive wheel (rear left).

Install the rear wheel housing upper body.

Fill coolant in the power system.

Lower the rear end of the vehicle.

Perform power-on of the high voltage system.

Connect the battery negative cable.

Close the front flip cover plate.

Close the door.

caution

After replacing the parts, it is necessary to

recalibrate the height.

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