TIGOR EV_ZIPTRON_SERVICE MANUAL

HV ELECTRICAL SYSTEM CONTENTS 1. GENERAL INFORMATION .......................................................................................................1 A. TOOLS...................................................................................................................................1 B. HAND GLOVES .....................................................................................................................1 C. PPES FOR HV.......................................................................................................................2 D. MEASURING TOOLS............................................................................................................5 E. SAFETY INSTRUCTIONS .....................................................................................................6 F. DO’S AND DON’TS................................................................................................................7 G. SAFETY WHILE SERVICING .............................................................................................10 H. WASHING INSTRUCTIONS................................................................................................14 I. ELECTRICAL COMPONENT INFORMATION......................................................................15 J. MOTOR COMPARTMENT ...................................................................................................16 2. TYPES OF CHARGING...........................................................................................................17 A. NORMAL CHARGING .........................................................................................................18 B. FAST CHARGING ...............................................................................................................23 3. TIGHTENING TORQUES ........................................................................................................25 4. SPECIAL TOOLS ....................................................................................................................30 5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE ...............................32 6. HV CONNECTOR CONNECTION & LOCKING PROCESS ...................................................34 7. ON VEHICLE REMOVAL ........................................................................................................42 A. POWER DISTRIBUTION UNIT (PDU) REMOVAL ..............................................................42 B. VEHICLE CONTROL UNIT..................................................................................................44 C. DC – DC CONVERTOR REMOVAL....................................................................................45 D. ON BOARD CHARGER (OBC) REMOVAL .........................................................................47 E. VACCUM PUMP REMOVAL ...............................................................................................50 F. E - DRIVE REMOVAL ..........................................................................................................50 G. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS..............................54