SERVICE MANUAL MOTORS EV EV
Developed by: Technical Literature Cell. Release Date : June 2020/ First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2020 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA NEXON EV. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. For ease of use, this workshop manual is divided into 3 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS ▪ HV ELECTRICAL SYSTEM ▪ HV ELECTRICAL SYSTEM ▪ DRIVESHAFT ▪ SUSPENSION ▪ WHEELS & TYRES ▪ STEERING ▪ BRAKE ▪ FATC ▪ BODY ▪ SRS THE BOOK– 2 CONTAINS ▪ Diagnostic Trouble Shooting Codes (DTC) List of All ECU’s HV & LV THE BOOK– 3 CONTAINS ▪ Service Schematics HV & LV
INDEX SR. NO GROUP 1 HV ELECTRICAL SYSTEM 2 LV ELECTRICAL SYSTEM 3 DRIVESHAFT 4 SUSPENSION 5 WHEELS & TYRES 6 STEERING 7 BRAKE 8 FATC 9 BODY 10 SRS
HV ELECTRICAL SYSTEM HV ELECTRICAL SYSTEM
HV ELECTRICAL SYSTEM CONTENTS 1. GENERAL INFORMATION..................................................................................................... 1 1.1. TOOLS ............................................................................................................................. 1 1.2. HAND GLOVES................................................................................................................ 1 1.3. PPES FOR HV ................................................................................................................. 2 1.4. MEASURING TOOLS....................................................................................................... 5 1.5. SAFETY INSTRUCTIONS................................................................................................ 6 1.6. DO’S AND DON’TS .......................................................................................................... 7 1.7. SAFETY WHILE SERVICING......................................................................................... 10 1.8. WASHING INSTRUCTIONS........................................................................................... 14 1.9. ELECTRICAL COMPONENT INFORMATION................................................................ 15 1.10. MOTOR COMPARTMENT ........................................................................................... 17 2. TYPES OF CHARGING ........................................................................................................ 18 A. NORMAL CHARGING....................................................................................................... 19 B. FAST CHARGING............................................................................................................. 24 3. TIGHTENING TORQUES...................................................................................................... 26 4. SPECIAL TOOLS ................................................................................................................. 32 5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE .............................. 34 6. HV COMPONENTS UNDER BONNET COMPARTMENT..................................................... 35 A. POWER DISTRIBUTION UNIT (PDU) REMOVAL ............................................................ 36 B. VEHICLE CONTROL UNIT ............................................................................................... 38 C. DC – DC CONVERTOR & ON BOARD CHARGER REMOVAL........................................ 39 D. VACCUM PUMP REMOVAL............................................................................................. 41 E. E - DRIVE REMOVAL ....................................................................................................... 42 F. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS ....................................... 45
HV ELECTRICAL SYSTEM 7. TRACTION COOLING SYSTEM (TCS) ................................................................................ 46 A. SYSTEM LAYOUT ............................................................................................................ 46 B. CIRCUIT SCHEMATICS ................................................................................................... 46 C. TCS COOLANT DRAINING PROCEDURE....................................................................... 47 D. TCS COOLANT FILLING PROCEDURE........................................................................... 47 E. RADIATOR / RADIATOR FAN REMOVAL ........................................................................ 48 F. CONDENSOR REMOVAL................................................................................................. 49 G. AUX TANK RESERVIOR REMOVAL................................................................................ 50 8. HV BATTERY ....................................................................................................................... 52 A. SYSTEM LAYOUT ............................................................................................................ 52 B. HV BATTERY REMOVAL ................................................................................................. 52 9. BATTERY COOLING SYSTEM (BCS).................................................................................. 55 A. SYSTEM LAYOUT ............................................................................................................ 55 B. CIRCUIT SCHEMATICS ................................................................................................... 55 C. BCS COOLANT DRAINING PROCEDURE ...................................................................... 56 D. BCS COOLANT FILLING PROCEDURE .......................................................................... 56 E. COMPRESSOR ................................................................................................................ 57 F. BATTERY COOLING PUMP REMOVAL ........................................................................... 58 G. AUX TANK RESERVIOR REMOVAL................................................................................ 59 H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL ........................................................... 60 I. HV / LV CHARGER PORT & CABLE REMOVAL ............................................................... 61 J. CCS2 INLET ACTUATOR REPLACEMENT PROCEDURE............................................... 63 10. CRADLE ............................................................................................................................... 65 A. CRADLE EXPLODED VIEW ............................................................................................. 65 B. CRADLE REMOVAL ......................................................................................................... 66 C. CRADLE FITMENT ........................................................................................................... 67
HV ELECTRICAL SYSTEM 1 1. GENERAL INFORMATION 1.1 TOOLS These tools are to be use while working on High voltage system and components: PDU, OBC, DCDC, E Drive, Battery Pack, PTC Heater, Compressor and HV Harnesses. a) General Tools - Can be sued on mechanical components and maintain specified torque. b) Insulated tools- Must & should use insulated tools while working on High voltage system components and maintain recommended torques. And Proper range of measuring tools should be used. 1.2 HAND GLOVES: a) Nitrile - Must and should use nitrile gloves while working on High voltage system components. b) ESD - must and should use while removing and assembling of any component of LV System. c) Cotton - must use while working on mechanical components (brakes, suspension etc).
HV ELECTRICAL SYSTEM 2 1.3 PPEs FOR HV Electrical safety shoes: Electric safety shoes are nonconductive shoes, which does not complete electrical circuit through your body to ground. These are lightweight as compared to mechanical safety shoes. While working on High voltage system one should use electrical safety shoes. Safety goggles and Helmet: To be use as indicated in the designated area. Insulating gloves with leather protectors: While working on High voltage system one should use insulating gloves in accordance with EN 60903:2003 (AC 1000V) Before using insulating gloves, check them for any cuts or holes by visual inspection. Also perform inflation test Each operator should have their own insulation gloves to avoid misuse and proper handling Over insulation gloves, operators should use leather protectors, to avoid holes in insulating gloves by sharp objects. Insulating tools: While working on high voltage system use insulating VDE tools in accordance with IEC 60900:2004(AC 1000V). This is to avoid persons contact with metal part of tool. Handle these tools carefully to avoid.
HV ELECTRICAL SYSTEM 3 Insulating mats: Insulating mats are used to isolate person working on vehicle from ground. Insulated rescue hook: Insulated rescue hook should be placed near working area and should easily accessible Incase of any person gets shock, other person should not touch with hands and pull the person who got shock. Instated other person should pull the person who got shock with insulated rescue hook shown below. Lock out and tag out: In the workplace always have lock-outs on items with a potential safety concern. Lock-out/de-energize high voltage equipment before debugging, working, or installing new equipment. Ensure that only qualified people are working on the vehicle. Minimizes the chance of injury for curious “passers-by” when nobody is around. LOTO (Lockout, Tag-out) examples: Power source for equipment (line power, power supply, etc). Authorized personnel: Only authorized personnel who are aware of the high voltage dangers should work on HV equipment.
HV ELECTRICAL SYSTEM 4 Buddy system: Do not work alone on high voltage system. Make sure somebody is there to monitor and help you.
HV ELECTRICAL SYSTEM 5 1.4 MEASURING TOOLS: While working on high voltage system we use many tools to identify presence of high voltage system, monitor different parameters and check health of system Below are the components which we generally use: MULTIMETER Multimeter can be used to measure current, voltage, continuity of circuit. For measurement using multimeter we need terminals to be accessible Cat III type Multimeters should be used. ISOLATION MEASUREMENT TOOL (MEGGER) Isolation measurement tool is used to measure resistance connected between its terminals. It can be done at different voltages. Based on the resistance value we can predict if high voltage is in contact with low voltage or not.
HV ELECTRICAL SYSTEM 6 1.5 SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM
HV ELECTRICAL SYSTEM 7 1.6 DO’S AND DON’TS DO’S DON’TS Always wear appropriate PPEs before working on high voltage system For working on HV system, undergo training. Before start working on HV, system contact vehicle owner and confirm it is safe to work. Do not have fear that it is not safe to work on High voltage system. Do not work on HV system if you have not undergone training. Do not touch any HV component (marked as danger and orange color) inside vehicle if you do not knowledge about system. Do not assume anything and start working. Follow one hand principle: Use only one hand while working on HV components. Do not use both hands together while working on electrical vehicle components. During vehicle build, keep the 12V LV battery negative disconnected. Do not connect the 12V LV battery negative during vehicle build.
HV ELECTRICAL SYSTEM 8 DO’S DON’TS Each EV components enclosures shall be connected to chassis with cable. Do not keep the earthing point in loose condition; apply the torque as per the drawing. HV battery pack power connector and service disconnect shall be connected at the lasr, when all safety checks are done. Never work on high voltage system when it is in active state Use the insulated tools for the assembly. Do not use the non-insulated tools for the assembly.
HV ELECTRICAL SYSTEM 9 DO’S DON’TS Use the insulated gloves & shoes for HV System. Don not touch the HV components having the symbol (shown in the image) without insulated gloves. Remove watches, rings or any metal ornaments while working on high voltage system. Do not wear watches, rings or any metal ornaments while working on high voltage system. Only trained person aware of HV safety shall be allowed to work on vehicle. Do not start working on High voltage system immediately after disconnecting high voltage battery, wait for 5minutes (Ask supervisor for exact timing, as it may vary from system to Earthing points where enclosures are connected to chassis shall be free from the point. Do not carry out any welding work when high voltage battery is active. After removing service, disconnect LOTO practice to be followed.
HV ELECTRICAL SYSTEM 10 1.7 SAFETY WHILE SERVICING Example: Changing HV fuse inside PDU
HV ELECTRICAL SYSTEM 11
HV ELECTRICAL SYSTEM 12
HV ELECTRICAL SYSTEM 13
HV ELECTRICAL SYSTEM 14 1.8 WASHING INSTRUCTIONS HIGH-PRESSURE WASHING INSRTUCTION WARNING Do not direct high-pressure washer fluid/ water jets (Pressure above 0.5 bar) at electrical devices and connecter during washing. This is to pre-vent malfunction / failure of electrical system due to water ingress. High-pressure washing is not allowed in the motor bay and on the battery connectors. When using high-pressure washers, make sure to maintain sufficient distance from the vehicle. Insufficient clearance or excessive pressure can lead to component damage or water penetration. Do not spray the camera, sensors or its surrounding area directly with a high-pressure washer. Shock from high-pressure water may cause the device to not operate normally. Do not bring the nozzle tip close to boots (rubber or plastic covers) or connectors, as they may be damage if they are exposed to high-pressure water. Pressure washing is not recommended at under hood area (Bonnet), under body & near rear LH.wheel arch. WASHING PROCEDURE Following these tips while washing your vehicle. 1. Always wash your vehicle in shade and the surface is at room tempera-ture. 2. Wash with mild vehicle wash soap like ‘Car Shampoo’ and use a soft bristle brush, sponge or soft cloth and rinse it frequently while washing to avoid scratches. 3. To avoid scratches, please wear soft gloves. Remove finger rings, nails, wristwatch while washing. 4. To remove stubborn stains and contaminant like tar, use turpentine or cleaners like ‘Stain remover’, which are safe for, paint surfaces. 5. Avoid substances like petrol, diesel, kerosene, benzene, thinner, acids or other solvents that cause damage to paint. 6. Dry your vehicle thoroughly to pre-vent any damp spots. 7. Rinse all surfaces thoroughly to pre-vent any traces of soap and other cleaners as this may lead to the formation of stains on the painted sur-face later.
HV ELECTRICAL SYSTEM 15 1.9 ELECTRICAL COMPONENT INFORMATION SR. NO. DESCRIPTION 1 HIGH VOLTAGE BATTERY 2 DC-DC CONVERTER 3 PDU ASSEMBLY 4 MCU 5 ON BOARD CHARGER 6 HIGH VOLTAGE CABLES 7 CHARGING PORTS 8 CABLE HV AC CHARGING GUN 9 COOLANT PUMP 10 TRACTION MOTOR COMPONENT DETAILS A. High Voltage Battery (lithium - ion) An on board high voltage electrical energy storage device.
HV ELECTRICAL SYSTEM 16 B. DC – DC Converter A device that converts HV DC power from the HV battery to LV DC power which is required to maintain LV battery charge, which in turn powers the LV systems like lights, wipers, infotainment, etc. in the vehicle. C. Power Distribution Unit Distributes power from the high voltage battery to the HV components like inverter, DC-DC converter, Ecompressor etc. D. Motor Control Unit A device to control traction motor. E. On-Board Charger (OBC) A device that charges the high voltage battery by converting AC power from a domestic supply into DC power and supplying it to the battery. F. High Voltage Cable Use for high voltage electrical energy. G. Charging Port Provided for charging purpose. H. Cable HV AC Charging Gun Provided for charging purpose. I. Traction Motor. A device that converts electrical energy into rotational mechanical energy, which is then transfer as rotational torque to the wheels through the gearbox.
HV ELECTRICAL SYSTEM 17 1.10. MOTOR COMPARTMENT SR. NO. DESCRIPTION 1 HIGH VOLTAGE COMPONENTS & POWER ELECTRONICS 2 COOLANT TANK (TCS & BCS) 3 12-V BATTERY 4 MOTOR COMPARTMENT FUSE BOX 5 BRAKE FLUID CONTAINER 6 WINDSHIELD WASHER CONTAINER
HV ELECTRICAL SYSTEM 18 2. TYPES OF CHARGING Normal charging (AC charging) It takes about 8.5 hours at room temperature and normal operating conditions for the EV to charge from 10% to 90% with Normal Charging. The charging gun will be locked after switching on the AC supply. Fast charging (DC charging) Nexon EV can be fast charged using any fast charging station or equipment compliant to Combined Charging System standard having Type 2 connector (CCS Type 2). It takes 60 minutes for the high voltage battery to charge from 0% to 80% using any CCS Type 2 fast charging station. The charging gun will be locked after switching on the DC supply. NOTE: Battery performance and durability can deteriorate if the fast charger is used constantly. Use of Fast Charging should be minimized in order to help prolong high voltage battery life. After a maximum of four fast charging cycles of battery pack, it is recommended to use Normal Charging to achieve 100% State of Charge for optimum performance of high voltage battery pack. TYPRS OF CHARGING CHARGING SPECIFICATIONS CHARGE PORT CHARGE GUN POWER SOURCE Normal / AC Charging Nominal voltage: 230 V ac RMS Single phase, 50Hz supply. Voltage range : Minimum voltage = 190V ac RMS Maximum voltage = 250V ac RMS Power rating = 3.3 kW ac RMS Rated current 16A ac RMS. 3 pin wall socket Fast / DC Charging Nominal voltage: 320V DC. Charging station (CCS Type 2) voltage capability should be greater than or equal to 370V DC.
HV ELECTRICAL SYSTEM 19 A. NORMAL/AC CHARGING Precautions for Normal Charging 1. Proper maintenance of earthling pit is must. Add water & add salts at regular intervals into the earth pits in order to maintain the value of earth resistance. Check annually the condition of the electrodes so as to add or replace electrodes. 2. The electrical socket used for EV charging and its associated wiring should be able to supply 15A dedicated load continuously. 3. Check the charging inlet for accumulation of dust or any foreign objects. 4. Don’t try to pull off the charging gun during charging. 5. Don’t pull out the charging gun if it is in locked condition as excess force can break or damage the locking mechanism. Charging instructions 1. Vehicle must be parked with park brake in engaged state before connecting the charging gun. 2. Vehicle charging port must be free of dust, water or snow while connecting the charging gun; if not proper cleaning method must be used to remove dust, water and ice. Refer ‘Section 6. Cleaning of Vehicle Inlet’. 3. If the charging gun is removed, reinsertion should be done after at least 10 seconds of removal of the charging gun. Gun unlocking feature on EV The charging gun will automatically un- lock once you switch off AC power sup- ply, in Normal Charging. In case of Fast Charging it will take around 15 seconds for the charging gun to unlock. Normal Charging procedure: 1. Engage the park brake. (Charging will not start without engaging the park brake). 2. Connect the plug to the AC power socket. 3. DO NOT plug into a power strip. 4. Open the protective cap on Charging Gun. 5. Pull the ‘Charging-inlet Flap Open Lever’ to open the charging inlet flap. 6. Open the protective cap on Charging Inlet. 7. Before connecting the charging gun to vehicle charging socket, make sure the gun lock is released. CAUTION: If the Gun Lock is not released please don’t insert the Charging Gun forcefully into the socket. It may damage the Charging Socket. 8. If the actuator is engaged and the gun is not getting inserted properly, contact TML service center.
HV ELECTRICAL SYSTEM 20 9. Remove any dust on the Charging Gun and Charging Inlet. Connect the charging gun to vehicle AC Charging Inlet. 10. Switch on the AC supply. 11. Charging Gun will be locked after switching on the AC supply. You will hear a “click” sound, when the gun is connected correctly. NOTE When vehicle is in Charging Mode, it will not go in Drive (D), Sport (S) or Reverse(R). 12. Normally the car starts automatically charging. If not, please refer ‘Troubleshooting Guide for Normal Charging’ table. 13. Open the driver door and see instrument cluster to know SoC, time to charge and gun connection status. 14. In case the park brake is not engaged or partially engaged the charging won’t start and ‘Engage Park Brake to start charging’ message will be displayed on instrument cluster. NOTE Infotainment and cabin cooling can be used during charging of the vehicle by putting the vehicle in Ignition. 15. To stop the charging, switch off the AC power supply. 16. The charging gun will be unlocked after switching off the AC supply. 17. Pull out the plug. 18. Put on the protective caps on both Charging Gun and Vehicle Inlet. NOTE Once Normal/Fast charging is completed, 90 seconds of time gap is required before the vehicle can be started. After turning off the vehicle, wait for four seconds if you want to start the vehicle again. In emergency charging shutdown conditions, Gun won’t be unlocked. Contact authorised TATA Service Centre. In unforeseeable circumstances if the charging gun is stuck to the socket after charging is done, user has to contact the service personnel. No mechanical override to remove the charging gun is available for user.
HV ELECTRICAL SYSTEM 21 MAINTENANCE OF NORMAL CHARGING GUN The Portable Charger for Normal charging requires no maintenance other than occasional cleaning. WARNING: To reduce the risk of electrical shock or equipment damage, be cautious while cleaning the connectors and case. Clean the charging gun using a soft cloth lightly moistened with mild detergent solution. Never use any type of abrasive pad, scouring powder, or flammable solvents such as alcohol or benzene. 1. The electrical socket used for EV charging and its associated wiring should be able to supply 15A dedicated load continuously. 2. Do not use charging gun if it is wet in interface area. Allow it to dry before use. CAUTION: Changes or modifications to this product by other than an authorized service facility may void SAEJ1772 compliance. State of charge (SoC) gauge for high voltage battery Provided in the instrument cluster as a tell-tale. It shows the charging status of the high voltage battery. Low charge or minimum position on the indicator indicates that there is not enough energy in the high voltage battery. Full charge or max position indicates that the HV battery is fully charged. When driving on highways, make sure to check in advance if the HV battery is charged enough. When the bar turns red on the high voltage charge indicator, the low charge warning lamp turns ON to alert you of the battery level. When the charge percentage is less than 25% in the high voltage battery, the vehicle speed is limited and then eventually the vehicle will be turned OFF. Charge the vehicle immediately.
HV ELECTRICAL SYSTEM 22 NORMAL CHARGING CONTROL BOX INDICATIONS: 1. Home 2. Control Box 3. Vehicle 4. Fault Normal Charging Control Box Normal Charging control box indications Working state Home Control box Vehicle Fault Example Description Selfinspection state Blink Blink Blink Blink Self-inspection for system Standby state On Off Off Off No fault Blink Plug temperature is high Charging state On On Blink Off No fault Blink Plug temperature is high Charging stopped On On On Off No fault Blink Plug temperature is high
HV ELECTRICAL SYSTEM 23 TROUBLESHOOTING GUIDE FOR NORMAL CHARGING Refer the below table if charging is not starting or if it stops abruptly. The below symbols of ‘House’, ‘Control Box’, ‘Vehicle’ and ‘Fault’ can be seen on the control box beside the respective LEDs. Fault category Indication Home Control box Vehicle Fault Recommended action Interface fault in home Blink Blink Blink Blink Improper earth connection. Check the earth pit. Short circuit between PE and phase. Error in domestic supply side. Stop changing. AC voltage is either less than 190V or more than 250V. Error in domestic supply side. Stop changing. Blink Off Off Blink Proper connection of plug and socket should be ensured. Also, check socket rating and use 20 A socket. Control box fault Off Blink Off On Contact TATA Motors service engineer. Off Blink Off Blink Vehicle fault Off Off Blink On Go to nearest TATA Motors Service Centre. Off Off Blink Blink Legend
HV ELECTRICAL SYSTEM 24 B. FAST CHARGING 1. Engage the parking brake. (Charging won’t start without engaging the parking brake). 2. Pull out the Charging Gun from DC/Fast Charging Station. 3. Open the protective cap on Charging Gun. 4. Pull the ‘Charging-inlet Flap Open Lever’ to open the charging door. 5. Open the charger-inlet flap. 6. If the actuator is engaged and the gun is not getting inserted properly, contact TML service center. CAUTION: If the Gun Lock is not released please don’t insert the Charging Gun forcefully into the socket. It may damage the Charging Socket. 7. Remove any dust on the Charging Gun and Charging Inlet. 8. Connect the charging gun to vehicle AC and DC Charging Inlet. 9. You hear a “click”, when the Gun is connected correctly. 10. Switch on the DC charging station supply. 11. Charging Gun will be locked after switching on the DC charging station. 12. Normally the car starts automatically charging. If not, please refer Charging Gun’s Fault Indication & Indi-cation Priority. NOTE: When vehicle is in Charging Mode, it will not go in Drive(D), Sport (S) or Reverse(R). 13. Open the driver door and see instrument cluster to know SoC, time to charge and gun connection status. 14. In case the park brake is not engaged or partially engaged the charging won’t start and ‘Engage Park Brake to start charging’ message will be displayed on instrument cluster.
HV ELECTRICAL SYSTEM 25 NOTE: Infotainment and cabin cooling can be used during charging of the vehicle by putting the vehicle in Ignition. 15. To stop the charging, switch off DC charging station. 16. The charging gun will be unlocked 15seconds after switching off the sup-ply from DC charging station. 17. Put on the protective caps on both Charging Gun and Vehicle Inlet. NOTE: If you remove the charging gun from the vehicle and if you wish to reinsert the gun to recharge the vehicle, please wait for at least 10 seconds before charging gun is plugged again. In emergency charging shutdown conditions, Gun won’t be unlocked. Contact authorised TATA Service Centre. Action to be taken when charging stops abruptly Check the reason for interruption of charging. (Refer ‘Troubleshooting guide for Normal Charging’ table). Switch off the AC supply. Remove the charging gun from the charging inlet. Wait for 5 minutes. Restart the charging. (Refer charging procedure). Cleaning of Charging Inlet: Covering the charging gun and charging in-let by dust cap will ensure protection from water and dust. Precautions to be taken while cleaning the charging inlet: Keep the vehicle lid always closed. When the lid is open ensure that dust caps are in closed position. During normal charging, make sure that DC charging cap is closed. In case of dust/mud accumulation in charging port, it can be cleaned by spraying clean water. In case of snow accumulation in charging port, it can be cleaned with spraying clean lukewarm water. Allow the water to drain completely through drain holes. Allow the charging port to dry completely. NOTE: Water entering into the charging port will always be drained through the drain system. If water is stagnant in charging port area call Tata Motors Authorised service centre to rectify the issue.
HV ELECTRICAL SYSTEM 26 3. TIGHTENING TORQUES: SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 1 BRACKET LH (MOTOR MOUNTING SUPPORT M8 X 40 2.5 2 BRACKET TOP (MOTOR MTG) M8 X 25 2.5 3 BRACKET ASSY RH SIDE MOTOR MOUNT M10X1.25X45 4.9 4 BRACKET TOP RH SIDE MOTOR MOUNT M10 X 45 4.9
HV ELECTRICAL SYSTEM 27 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 5 BRACKET DC-DC CONVERTER M6 X 14 1 6 BRACKET CHARGER + MTG M6 X 18 1 7 BRACKET ASSY CHARGER + CONVERTER MTG M8 X 20 1
HV ELECTRICAL SYSTEM 28 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 8 BRACKET ASSY CHARGER + CONVERTER MTG M6 X 12 1 9 BRACKET CHARGER + CONVERTER MTG M6 X 12 1 10 PDU MOUNTING SCREW M8 X 20 2.5 11 BRACKET CHARGER + CONVERTER MTG M8 X 20 1
HV ELECTRICAL SYSTEM 29 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 12 ASSEMBLE PLATE, SUPPORT BRACKET WITH CRADLE ASSEMBLY M8 X 20 1 13 HIGH VOLTAGE BATTERY ASSY MTG M10X1.25X40 4.6 14 HIGH VOLTAGE BATTERY ASSY MTG M10X1.25X55 4.6 15 C-MOUNT ASSY, E drive M12 X 1.25 X 105 10.5 - 11
HV ELECTRICAL SYSTEM 30 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 16 BRACKET,CMOUNT M10 X 80 6 - 6.5 17 BRACKET,CMOUNT M10 X 1.25 X 50 5.5 - 6 18 A-MOUNT ASSY M10 X 1.25 X 40 6 - 6.5 19 A-MOUNT ASSY M12 X 45 12.5 - 13
HV ELECTRICAL SYSTEM 31 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 20 A-MOUNT ASSY M10 X 1.25 X 40 6 - 6.5 21 B-MOUNT ASSY M10 X 1.25 X 30 6 – 6.5 22 B-MOUNT ASSY M12 X 65 10.5 - 11
HV ELECTRICAL SYSTEM 32 4. SPECIAL TOOLS LIST: SR.NO. DISCRIPTION PART NO TOOL IMAGE 1 Battery pack lifting hanger / E Drive lifting Hanger Tackle unit 512358902407 2 E Drive Support Stand 512358902411 3 Battery Pack Fixture 512358902405 4 E Drive Fixture 512358902408
HV ELECTRICAL SYSTEM 33 SR.NO. DISCRIPTION PART NO TOOL IMAGE 5 E Drive Fixture Attachment Kit (Upgrade) 512358902409 6 Transmission Jack 8855WORK0083 7 Hydraulic Trolley/Scissor lift 512358902404 8 TS20 TROX BIT WITH DRIVER 885551235801
HV ELECTRICAL SYSTEM 34 5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE: 1. Turn off the vehicle Ignition. 2. Open the bonnet of the vehicle. 3. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 4. Lift vehicle on two post and apply parking brake. 5. Loosen and remove the mounting screw and take out battery connection cover. 6. Remove high voltage battery MSD. NOTE Clean the MSD and lever mechanism in case of dirt deposition/accumulation with a wet cloth, then access the lever. Otherwise the jammed lever mechanism can break during unlocking. 7. Wait for 10 Min after removing MSD from vehicle for working on vehicle. Removal of HV Battery MSD and Lockout tagout of vehicle is recommended The removal of HV Battery pack MSD (Manual Service Disconnect) and Lockout-tagout procedure must be followed in/during the below mentioned conditions, Visible damage is observed in the high voltage system and components due to accidents, abuse etc. Service and maintenance of high voltage system and components. High voltage system and components: PDU, OBC, DCDC, E Drive, Battery Pack, PTC Heater, Compressor and HV Harnesses.
HV ELECTRICAL SYSTEM 35 6. HV COMPONENT IN UNDER BONNET COMPARTMENT LAYOUT OF HV COMPONENT
HV ELECTRICAL SYSTEM 36 A. POWER DISTRIBUTION UNIT (PDU) REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Loosen and Remove the mounting screw and take out the motor cover. 3. Remove the LV wiring harness cable and connector connected to PDU. 4. Remove the connector and cable of HV junction box to AC compressor connected to PDU. 5. Remove the connector and cable of charger connected to PDU. 6. Remove the connector and cable of HV DCDC convertor to HV junction box connected to PDU. 7. Remove the connector and cable of AC unit assembly connected to PDU.
HV ELECTRICAL SYSTEM 37 8. Loosen and Remove the ground terminal cable screw to PDU. 9. Remove the connector and cable of HV charger to vehicle inlet connection connected to PDU. 10. Remove the connector and cable of battery connected to PDU. 11. Remove the connector and cable of motor controller connected to PDU. 12. Remove the four screws mounted on the bracket and safely remove the PDU. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 38 B. VEHICLE CONTROL UNIT REMOVAL 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 1. Loosen and Remove the mounting screw and take out the motor cover. 2. Disconnect the connectors and wiring harness connected to the controller. 3. Loosen and Remove the screws of supporting bracket. 4. Loosen and Remove the screws mounted on the bracket and safely take out the controller. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 39 C. DC - DC CONVERTOR & ON - BOARD CHARGER REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Loosen and Remove the mounting screw and take out the motor cover. 3. Remove the connector hose and Drain the coolant.(Refer Coolant draining procedure). 4. Disconnect the connectors and LV wiring harness connected to the DC - DC Convertor and Charger. 5. Disconnect the connectors and wiring harness connected to the DC - DC Convertor to PDU. 6. Remove Ground connection of OBC. 7. Disconnect the connectors and wiring harness connected to the charger to PDU. 8. Disconnect the cable connectors connected to the charger to vehicle inlet connection.
HV ELECTRICAL SYSTEM 40 9. Remove the +ve terminal of “DCDC converter to Aux. battery harness” on DCDC converter. 10. Remove the DCDC converter ground cable on DCDC converter. 11. Remove battery and battery tray. (Refer “Removal & refitment of from battery Section). 12. Remove Vehicle Control Unit. (Refer “Removal & refitment of from Vehicle Controller Unit Section.) 13. Loosen and remove the mounting screw on bracket take out. 14. Take out the bracket along with DC – DC converter and OBC. 15. Loosen and remove the mounting screw of charger and take out. 16. Loosen and remove the mounting screw of DC - DC converter and take out. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 41 D. VACUUM PUMP REMOVAL 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Loosen and Remove the mounting screw and take out the motor cover. 4. Disconnect the electrical connection of vacuum pump. 5. Remove the mounting hose of vacuum pump & drain the oil (Refer maintenance section.) 6. Loosen and Remove the mounting screw and take out the vacuum pump. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 42 E. E-DRIVE REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Loosen and Remove the mounting screws & nut of splashguard. 3. Loosen and Remove the mounting screws & nut of splashguard. 4. Loosen and remove the mounting nut of tyre & take out (LH / RH side ) 5. Loosen and remove the boll joint bolt of lower arm to axle both LH & RH side. 6. Apply brake and remove drive shaft lock nut on both LH and RH side. 7. Drain the coolant and Remove the pump (Refer coolant pump section for removal process).
HV ELECTRICAL SYSTEM 43 8. Remove drive shaft by pulling disk brake and Take out drive shaft LH / RH from gearbox. (Drain oil before carrying out this process). 9. Loosen and Remove the mounting screw and take out the motor cover. 10. Remove the connector and cable of motor controller connected to PDU. 11. Disconnection the wiring harness of motor. 12. Remove of ground cables of E-drive. 13. Remove the Hose Pipe Charger out to Motor Inlet and drain coolant.
HV ELECTRICAL SYSTEM 44 14. Loosen and remove the mounting bolts of motor bracket support. 15. Loosen and remove the mounting bolts of motor bracket support. 16. Loosen and remove the mounting bolts of upper side motor bracket support. 17. Loosen and remove the mounting bolt of sub frame bottom shell. 18. Loosen and remove the mounting bolt nuts of Bracket C-Mount. 19. Use special tool to keep E drive safely down take it out. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 45 F. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS A. Oil level check 1. Before checking the oil level, stop the motor and lift the vehicle horizontally. 2. With the vehicle raised check for oil leakage if there is oil leakage, it should be repaired. 3. Remove the oil level plug, check whether the oil reaches the bottom of the oil level plug, and check whether the oil is polluted. Relationship between oil level and oil level plug 4. If the oil level is in is insufficient, replenish the lubricating oil to the oil level line shown in the figure. if the lubricating oil is polluted, replace the lubricating oil. B. Discharge and filling of lubricating oil 1. Before checking the oil level, stop the motor and lift the vehicle horizontally. 2. With the vehicle-raised check for oil leakage if there is oil leakage, it should be repaired. 3. Remove the drain plug and drain the waste oil, the position of the drain plug. The position of Drain oil plug and oil level plug 4. Apply a small amount of sealant(LT5910) to the drain plug and tighten it according to the specified torque (15±3Nm) 5. Remove the oil level plug, The position of the oil level plug. The position of Drain oil plug and oil level plug 6. According to the specified model (BOT 350M3) and oil quantity (0.6L-0.8L) add new lubricating oil to the oil level plug. 7. Apply a small amount of ssealant (LT5910) to the oil level plug and tighten it according to the specified torque (15±3Nm).
HV ELECTRICAL SYSTEM 46 7. TRACTION COOLING SYSTEM (TCS) A. SYSTEM LAYOUT B. CIRCUIT SCHEMATIC
HV ELECTRICAL SYSTEM 47 C. TCS COOLANT DRAINING PROCEDURE COOLANT QUANTITY: 2.9 Lit COOLANT SPECIFICATIONS: Ratio 40:60 - Ethylene Glycol (1.160Lit) + Water (1.740 Lit) DRAINING PROCEDURE NOTE: ‘While draining the coolant TCS Aux. tank Cap must be in open condition’. 1. Ensure Traction coolant temperature is normal / ambient temperature. 2. Remove Aux Tank cap. 3. Place the container to collect coolant. 4. Remove the Hose spring band clamp before pump inlet. 5. Remove the Motor outlet Hose spring band clamp. 6. Collect the Coolant in the container & wait till coolant get drain from Traction cooling system. D. TCS COOLANT FILLING PROCEDURE 1. Open the Aux Tank and fill coolant up to Max mark on Aux Tank. 2. Ensure that all hoses are connected and clamps are fitted properly before filling coolant from auxiliary tank. 3. Fill coolant up to the Max level in auxiliary tank. 4. Start the vehicle and after 5 minutes check the coolant level, If it drops then top up till MAX level. NOTE After filling the coolant, the coolant pump can be run through the service tool for the deaeration of coolant circuit. Or the vehicle can be cranked to run the pump, because in vehicle cranked state the pump operation starts in default speed which will in turn deaerate the circuit.
HV ELECTRICAL SYSTEM 48 E. RADIATOR / RADIATOR FAN REMOVAL 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Loosen and Remove the mounting screws & nut of splashguard. 4. Loosen and Remove the mounting screws & nut of splashguard. 5. Discharge the refrigerant using standard recovering equipment. (Refer maintenance section.) 6. Remove front bumper assembly (For procedure (refer front bumper removal procedure in body section) 7. Remove electrical connection of Radiator fan assy. 8. Loosen and remove the mounting nut of radiator fan assy both side safety take it out. 9. Loosen and remove the mounting nut of fan and take it out. Fitment. Follow reverse procedure for assembly. COOLING FAN ON/OFF CONDITIONS Pd (bar) CRFM 2.5<Pd<20 Slow speed Pd>20 Fast speed (continue in fast speed till Pd reaches 14 bar)
HV ELECTRICAL SYSTEM 49 F. CONDENSER REMOVAL NOTE: Drain the coolant (Refer TCS Coolant Draining procedure). ‘While draining the coolant TCS Aux. tank Cap must be in open condition’. 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove the Radiator to E-drive hose. (Refer removal procedure in E drive section). 4. Remove the hose Condenser to coolant pump. 5. Remove the mounting nut of Liquid Line Condenser to Chiller Unit. 6. Remove the mounting nut of Liquid Line Condenser to Compressor. 7. Remove the mounting hose of Air Vent Hose, Radiator to Aux Water Tank.
HV ELECTRICAL SYSTEM 50 8. Remove the mounting screw of radiator. 9. Remove the mounting Sealing Rivet of Radiator Sealing both sides. 10. Remove the mounting screw of Condenser Unit Assy take it out. Fitment. Follow reverse procedure for assembly. NOTE Ensure condenser front area is clean and side sealing are fitted properly. Clogging of condenser and absence of side sealing lead to higher operating pressures of AC system. G. AUX TANK RESERVIOR REMOVAL 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove the Drain the coolant and pump hose (Refer coolant pump section for removal process)
HV ELECTRICAL SYSTEM 51 4. Remove rubber hoses connected to aux. tank. 5. Loosen and remove the mounting bolt washer of bracket tank. 6. Loosen and remove the mounting screw of tank & take it out. Fitment. Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 52 8. HV BATTERY A. SYSTEM LAYOUT B. HV BATTERY REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Remove the spring band clamp and hose connected to HV battery assembly and Drain coolant (Refer Coolant draining procedure). NOTE: ‘BCS aux. tank cap must be in open condition while draining coolant’.
HV ELECTRICAL SYSTEM 53 3. Remove the connector and chassis ground cable connected to HV battery assembly. 4. Disconnect the connector cable of PDU to Battery. 5. Disconnect and Remove the connector and powertrain harness connected to HV battery assembly NOTE Use special tool to keep HV battery. 6. Loosen and Remove the mounting screws of HV battery assembly safely take out (use Special tool). Fitment Follow reverse procedure for HV battery assembly considering following points. Align Battery pack using Hydraulic Trolley/Scissor lift with vehicle from bottom side. Rear brackets are removed to prevent fouling with RTB before lifting the battery pack. Lift the Battery pack to match the vehicle underbody cavity and mounting holes of pack are coincided to the BIW bush holes. Once the pack is aligned, rear brackets are first re-attached at points 6 and 7 in the same fashion. All hardware’s are assembled and recommended Torque value of 45 Nm on all 8
HV ELECTRICAL SYSTEM 54 bolts (4 per bracket) in diagonal fashion per bracket. Fasteners are to be pre-assembled in the sequence of : a. M10 bolt - 40 mm, 55 mm b. Spring Washer B10 c. 3D plain washer A10 4 Fastener assemblies with M10 x 40 mm bolts shall be assembled on mounting points 6, 7, 13 and 14. 10 Fastener assemblies with M10 x 55 mm bolts shall be assembled on rest of the mounting points. Once all the bolts are hand tightened and fitment is ensured, pack is ready to be mechanically torqued. Whilst torqueing, the bolts must be torqued in the following order to ensure correct fit of the battery pack – Tightening Torque 4.6 Kgf m (45 N m). - 06 & 13 - 14 & 7 - 05 & 12 - 08 & 1 - 02 & 9 - 11 & 4 - 03 & 10
HV ELECTRICAL SYSTEM 55 9. BATTERY COOLING SYSTEM (BCS) A. SYSTEM LAYOUT B. CIRCUIT SCHEMATIC
HV ELECTRICAL SYSTEM 56 C. BCS COOLANT DRAINING PROCEDURE COOLANT QUANTITY: 3.6 Lit COOLANT SPECIFICATIONS: Ratio 40:60 - Ethylene Glycol + Water DRAINING PROCEDURE NOTE: ‘While draining the coolant BCS Aux. tank Cap must be in open condition’. Ensure MSD (Manual service disconnect) is remove before coolant draining. 1. Ensure that BCS is coolant temperature is normal (equal to ambient temperature) before draining. 2. Remove coolant hose connection from battery Inlet and Outlet. 3. Remove cap of auxiliary coolant tank. 4. Wait till coolant gets drain from battery Inlet and Outlet ports and mating hoses. 5. Pass pressurized air from battery inlet port to and coolant will come out from battery outlet port. It is to flush out coolant battery side. 6. Close auxiliary tank cap and pass pressurized air from mating hose of battery outlet port and coolant will come out from battery inlet hose. It is to flush out coolant from chiller unit, BCS pump and BCS hoses. D. BCS COOLANT FILLING PROCEDURE 1. Open the Aux Tank and fill coolant up to Max mark on Aux Tank. 2. Ensure that all hoses are connected and clamps are fitted properly before filling coolant from auxiliary tank 3. Initially fill coolant till neck of auxiliary tank 4. Turn ON ignition and BCS pump will start working 5. After starting BCS pump, coolant will start circulating in the system and coolant level will drop in the auxiliary tank 6. Fill the coolant up to the MAX level in the auxiliary tank and after filling keep system running for 10 minutes. If coolant level drops then top up till MAX level. 7. After completion of work drive vehicle for 1.5 - 2 kilometres and check coolant level. If it drops then top up till MAX level. NOTE As soon as ignition is turn ON, coolant pump start operating. If coolant doesn’t reach up to pump then pump gets OFF (detects dry run) to avoid dry run of pump. It starts again after fix time interval. This type of ON / OFF attempts of pump happens 20 times. Once coolant reaches to pump, it keeps running continuously.
HV ELECTRICAL SYSTEM 57 E. COMPRESSOR Type Scroll Capacity 27cc Oil quantity 120ml REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Discharge the refrigerant using standard recovering equipment. (Refer maintenance section.) 3. Remove Electrical Connection to compressor. 4. Loosen and Remove the ground terminal cable screw to compressor. 5. Remove the mounting nut and disconnect the Suction pipe of compressor to Heat Exchanger. 6. Remove the mounting nut and disconnect the Discharge pipe of compressor to front end module assy. 7. Loosen and remove the mounting cap screw of compressor and take it out. Fitment. Follow reverse procedure for assembly. Tighten the following fasteners to the recommended torque. i) Compressor mounting. ii) Refrigerant lines on compressor.
HV ELECTRICAL SYSTEM 58 NOTE • Always use compressor vibration dampers Do’s and Don'ts • Use only recommended refrigerant (R134a) and correct charge quantity (580 gms) in the AC system • Use only recommended lubricating oil for AC compressor (POE RL68H oil) • Ensure HV and LV connections of PTC heater are properly connected • Don’t remove connections of PTC heater when it is working • Always check coolant level in BCS tank • Avoid coolant leakage in BCS system • Do not change routing of coolant hoses. If hose get pinch then coolant flow will be restricted leading to battery over heat. F. BATTERY COOLING PUMP REMOVAL NOTE: Drain the coolant. (Refer BCS Coolant draining procedure). ‘While draining the coolant BCS Aux. tank Cap must be in open condition’. 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove the connected the hoses battery to cooling pump and Heat Exchanger. (refer “Removal & refitment of from HV battery Unit Section.) Fitment. Follow reverse procedure for assembly
HV ELECTRICAL SYSTEM 59 G. AUX TANK RESERVIOR REMOVAL 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove the Drain the coolant and pump hose (Refer coolant pump section for removal process) 4. Remove rubber hoses connected to aux. tank. 5. Loosen and remove the mounting screw of tank & take it out. Fitment. Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 60 H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL Type – Plate type chiller REMOVAL 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Discharge the refrigerant using standard recovering equipment. (Refer maintenance section.) 4. Remove Electrical connection of chiller unit. 5. Remove the mounting nut and disconnect the Suction line and the discharge line of Heat Exchanger. 6. Remove the hose and drain the coolant of heat exchanger to coolant pump. 7. Remove the hose and drain the coolant of heat exchanger to HV battery.
HV ELECTRICAL SYSTEM 61 8. Remove the mounting screw of heat exchanger of bracket. Fitment Follow reverse procedure for assembly. Tighten the following fasteners to the recommended torque. i) Compressor mounting. ii) Refrigerant lines on compressor. • Service and Maintenance Coolant drain and refill • Conduct activity when BCS pump is off • Remove cap of auxiliary tank • Remove one connection from battery inlet / outlet joint and drain the coolant. Refilling of coolant • Close all joints • Fill coolant from auxiliary tank • Follow de-aeration process. I. HV / LV CHARGER PORT & CABLE REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Remove the connector and cable of HV charger to vehicle inlet connection connected to PDU. 3. Disconnect the cable connectors connected to the charger to vehicle inlet connection. 4. Pull out the fuel cap outside.
HV ELECTRICAL SYSTEM 62 5. Disconnect the electrical wiring harness. 6. Remove LV connection on charging port. 7. Remove the mounting nuts of flue cap. 8. Open tail gate 9. Remove tail gate trim (refer removal from body section) 10. Loosen and Remove the ground terminal cable screw. 11. Remove HV Battery (refer HV Battery removal from section). 12. Remove electrical connection and take out the HV charger cable. Fitment Follow reverse procedure for assembly.
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