SERVICE MANUAL BOOK - 1 NEW NEXON EV
Developed by: Technical Literature Cell. Release Date : Oct 2023 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2023 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 ELECTRIC VEHICLES LTD. 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 NEW 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 GENERAL HIGH VOLTAGE (HV) ELECTRICAL SYSTEM (MR & LR) LOW VOLTAGE (LV) ELECTRICAL SYSTEM DRIVESHAFT SUSPENSION_MR SUSPENSION_LR WHEELS & TYRES STEERING (MANDO) BRAKE_MR BRAKE_LR ESP 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 SYSTEM THE BOOK– 4 CONTAINS INFO. FITMENT DRAWINGS THE BOOK– 5 CONTAINS BODY REPAIR MANUAL
TABLE OF CONTENT SR. NO GROUP 1 GENERAL 2 HV ELECTRICAL SYSTEM_MR & LR 3 LV ELECTRICAL SYSTEM 4 DRIVESHAFT 5 SUSPENSION_MR 6 SUSPENSION_LR 7 WHEELS & TYRES 8 STEERING 9 BRAKE_MR 10 BRAKE_LR 11 ESP 12 FATC 13 BODY 14 SRS
GENERAL GENERAL
GENERAL CONTENTS 1. TECHNICAL SPECIFICATION FOR MR................................................................................. 1 2. TECHNICAL SPECIFICATIONS FOR LR ............................................................................... 3 3. VEHICLE DIMENSIONS.......................................................................................................... 4 4. RECOMMENDED LUBRICANTS & COOLANTS.................................................................... 5 5. SERVICE AND MAINTENANCE ............................................................................................. 6 6. VEHICLE JACKING AND LIFTING POINTS........................................................................... 8 7 JACK AND TOOL BOX LOCATION IN VEHICL ...................................................................... 9 8. TOWING THE VEHICLE ...................................................................................................... 9 9. PUNCTURE REPAIR KIT (IF APPLICABLE)........................................................................ 10
GENERAL 1 1. TECHNICAL SPECIFICATIONS FOR MR: Powertrain Battery 30.2 kWh Li-ion Electric motor Permanent magnet synchronous motor Nominal voltage 320V Maximum power, kW 95kW Maximum torque, Nm 215Nm Transaxle Model and Type Electric Vehicle Transaxle No. Of gears Single speed, 1 Forward Drive + 1 Reverse Drive Steering Type Column Mounted Electric Power Assisted Steering System Brakes Brakes Front (Disc); Rear (Drum) Parking brake Manual Parking Brake Suspension Front Double acting telescopic type. Hydraulic; gas Filled. Rear Double acting telescopic type. Hydraulic; gas Filled. Wheels & Tyre Tyres (Front Wheel, Rear Wheel and Spare Wheel) 215/60 R16 95H (Radial / Tubeless / Normal) Wheel rims Option I: 6J x 16 steel wheel Option II: 6.5J x 16 steel wheel Cab / Body Type Steel Monocoque Body Electrical System System voltage 12 Volts Auxiliary battery 12V DIN 40 Ah
GENERAL 2 Main Chassis Dimension (in mm) Wheel base, mm 2498 Track front, mm 1540 Track rear, mm 1530 Overall length, mm 3995 Overall height, mm 1625 (unladen) Max. Width, mm 1802 Ground clearance, mm 169 Performance Max. Speed 120KMPH Max. Recommended grad ability 20% Minimum Turning Circle Dia. in meter as per IS:12222 10.6 Minimum Turning Clearance circle dia. in meters as per IS:12222 10.9 Weight Gross vehicle weight (Laden), kg 1850 Kerb weight (unladen), kg 1440 NOTE: For latest details, refer Owner’s Manual.
GENERAL 3 2. TECHNICAL SPECIFICATIONS FOR LR: Powertrain Battery 40.5 kWh Li-ion Electric motor Permanent magnet synchronous motor Nominal voltage 332.8 V Maximum power, kW 105 kW Maximum torque, Nm 215Nm Transaxle Model and Type Electric Vehicle Transaxle No. Of gears Single speed, 1 Forward Drive + 1 Reverse Drive Steering Type Column Mounted Electric Power Assisted Steering System Brakes Brakes Front (Disc); Rear (Disc) Parking brake Automatic Parking Brake Suspension Front Double acting telescopic type. Hydraulic; gas Filled. Rear Double acting telescopic type. Hydraulic; gas Filled. Wheels & Tyre Tyres (Front Wheel, Rear Wheel and Spare Wheel) 215/60 R16 95H (Radial / Tubeless / Normal) Wheel rims Option I: 6J x 16 steel wheel Option II: 6.5J x 16 steel wheel Cab / Body Type Steel Monocoque Body Electrical System System voltage 12 Volts Auxiliary battery 12V DIN 40 Ah
GENERAL 4 Main Chassis Dimension (in mm) Wheel base, mm 2498 Track front, mm 1540 Track rear, mm 1530 Overall length, mm 3995 Overall height, mm 1625 (unladen) Max. Width, mm 1802 Ground clearance, mm 159 Performance Max. Speed 150KMPH Max. Recommended grad ability 20% Minimum Turning Circle Dia. in meter as per IS:12222 10.6 Minimum Turning Clearance circle dia. in meters as per IS:12222 10.9 Weight Gross vehicle weight (Laden), kg 1941 Kerb weight (unladen), kg 1531 NOTE: For latest details, refer Owner’s Manual. 3. VEHICLE DIMENSIONS: NOTE: Dimensions are in mm, unladen condition.
GENERAL 5 4. RECOMMENDED LUBRICANTS & COOLANTS Item Specification Company Brand Qty. Coolant (Premixed) (Antifreeze agent+ Soft water 50:50 ratio) Class II/JIS K2234 TATA SS7700S1 SUNSTAR CCI Golden Cruiser LLC2200NP BCS 4.6 L TCS 3.5 L IOCL TATA MOTORS GENUINE COOLANT KOOL PLUS Transaxle Oil Synthetic SAE 75W90 BOT130M Castrol Castrol 1.3 L Brake Fluid SAE J1703 , DOT4 PETRONAS PETRONAS TATA MOTORS Genuine Brake Oil DOT 4S 0.9L Sunstar CCI Golden Cruiser Tata Genuine Brake Fluid (DOT4) Castrol Optional - CASTROL- Universal Brake Fluid DOT 4 AC Compressor oil FVC56EA/FVC68D Idemitsu Idemitsu 150 ml +/- 10 ml Refrigerant R-134a 580 gm +/- 20 gm Sunroof Grease MULTEMP 2C194 As required NOTE: For latest details, refer Owner’s Manual.
GENERAL 6 5. SERVICE AND MAINTENANCE
GENERAL 7 # Kms or months whichever occurs earlier, Note - Additionally, Tyre pressure to be checked every 15 days * More frequently for vehicle, operating in severe condition. Severe conditions as below- A: Repeatedly driving short distance of less than 7 km. B: Extensive low speed driving for long distances. C: Driving on rough, dusty, muddy, unpaved, graveled or salt-spread roads. D: Frequently driving in heavy traffic area & in stop & go condition E: Driving only on uphill, downhill, or mountain roads. F: Vehicle towing, driving for petrol car, taxi, or other commercial use G: Frequently driving under high speed & acceleration.
GENERAL 8 6. VEHICLE JACKING AND LIFTING POINTS: Make sure you follow the manufacturer’s instructions while lifting the car on two post lift. • Always ensure vehicle balance in service while applying two post lift to under body. • Care should be taken that the two post lift arm is not in contact with the bracket, brake or fuel pipes etc. • Before servicing, make sure to lock the lift after the vehicle is lifted up. • Following fig shows the front and the rear jacking points by two post lift JACKING POINTS Front and Rear jacking point USING THE FLOOR JACK: • Use the jacks at the locations as shown in the below. • Do not apply the jack against any part which may get deformed. • If front end or rear end of the vehicle is to be jacked ensure the wheels on ground and the parking brake is applied. Front jacking point Rear jacking point Images for Illustration Purpose Only
GENERAL 9 7. JACK AND TOOL BOX LOCATION IN VEHICLE: 8. TOWING THE VEHICLE: When towing a break down vehicle, certain precautions and procedures must be taken to prevent damage to the vehicle and/or components. Failure to follow standard towing procedures could result in an accident or injury due to the unsafe operating condition. To ensure proper towing and to prevent accidental damage to your vehicle, take help of a TATA MOTORS authorized EV dealer or a commercial tow-truck service. • Open the tailgate and remove tow hook from the tool kit. • Open the tow hook cover provided on the front bumper by pressing it at the bottom part and simultaneously pulling it at the top (as shown in fig). Screw in and tighten the tow hook in clockwise direction. • After towing, remove the towing hook •and press fit the cover properly. • Place the towing hook in the vehicle •tool kit. Tow Hook Location Correct Methods WARNING • Do not get under your vehicle after it has been lifted by a tow truck. • For towing a vehicle, the best way is to use a flat bed truck. Alternatively use a rigid tow bar. • Switch ‘ON’ the hazard warning indicators of both the vehicles to warn other road users. • Limit the speed to 20-30kmph. • In case of brake failure, use the parking brake to control the vehicle. • Fasten the tow rope or tow bar at the towing eyes. Otherwise, the vehicle could be damaged. • When towing, pull away slowly and smoothly. If the tractive power is too high, the vehicles could be damaged.
GENERAL 10 9. PUNCTURE REPAIR KIT (IF APPLICABLE): Introduction:- The Puncture repair Kit seals most tire punctures to restore temporarily mobility. Recommended use only for passenger car ground tires only and vehicle tire inflation pressure up to 300 kPa (3 bar, 43 psi). The system consists of a compressor and a sealant, and serves to effectively and conveniently seal punctures in car tires caused, for example, by nails or similar foreign objects with a diameter of up to ¼ “ (6 mm). Depending on the type and extent of tire damage, some tires can only be partially sealed or not sealed at all. Loss of tire pressure can affect vehicle handling, leading to loss of vehicle control. Observe the following rules when using the Puncture repair Kit: Drive with caution and avoid making sudden steering or driving maneuvers, especially if the vehicle is heavily loaded or you are towing a trailer. The system will provide you with an emergency temporary repair, enabling you to continue your journey to the next vehicle or tire dealer, or to drive a maximum distance of 200 km (120 miles). Do not exceed a maximum speed of 80 km/h (50 mph). Keep the Puncture repair Kit out of the reach of children. HIGHLIGHTS Maximum repairable diameter is 6mm. Ensuring an unaltered driving performance for another 200 km at a maximum 80 km/h. Suited for tires with maximum pressure requirement up to 43 psi. Cannot be used in case of sidewall puncture. WARNING Compliance with these instructions is vital to ensure vehicle safety. Non-compliance with these instructions means risking tire damage, which can affect vehicle handling and lead to loss. Do not use the Puncture repair Kit if the tire has already been damaged as a result of being driven underinflated. Do not try to seal damage other than that located within the visible tread of the tire. Do not try to seal damage to the tire's sidewall. INSTRUCTIONS ON HOW TO USE THE PUNCTURE REPAIR KIT SAFELY Use product with original vehicle ground tires only. Only use the Puncture repair Kit with tubeless tires. If used for other than its intended purpose, the Puncture repair Kit may cause severe accident or injury due to the fact that compressed air can act as an explosive or propellant. Park your vehicle at the roadside so that you do not obstruct the flow of traffic and you are able to use the Puncture repair Kit without being in danger. Engage the hand brake, even if you have parked on a level road, to ensure that the vehicle will not move. Do not attempt to remove foreign objects like nails or screws penetrating the tire. Leave them as they are.
GENERAL 11 Leave the engine running while the Puncture repair Kit is in use, but not if the vehicle is in an enclosed or poorly ventilated area. Never leave the Puncture repair Kit unattended while in use. Do not keep the compressor operating for more than 10 minutes other-wise there is a risk of it overheating. Replace the sealant bottle with a new one before the expiration date is reached (see bottle label). In case that the sealant is expired the functionality cannot be fully guaranteed. Only use original Puncture repair Kit bottles which are pressure resistant. How to proceed in the event of a tire puncture You can temporarily repair a tire puncture in two steps. First pump the tire sealant and air into the tire (see Step 1). Immediately there-after, drive a short distance (3-10 km / 2-6 miles) in order to distribute the sealant in the tire. After that, check the tire pressure and pump more air into the tire if necessary (see Step 2). Then you can proceed to drive with caution for a maxi-mum distance of 200 km (120 miles) and at a maximum speed of 80 km/h (50 mph). Inform all other users of the vehicle that the tire has been temporarily sealed with the Puncture repair Kit and make them aware of the special driving conditions to be observed. WARNING: - Need to drain fluid from tire before re-pair. STEP 1: PUMPING THE TIRE SEALANT AND AIR INTO THE TIRE 1. Peel off the decal denoting the maximum permissible speed (80 km/h | 50 mph) from the casing and attach it to the edge of the windscreen as shown on the picture. 2. Take the hose and power plug with cable out of the Puncture repair Kit casing. Unscrew the orange cap of the bottle connector. WARNING Leave the bottle seal intact. Screwing the bottle onto the bottle holder will pierce the seal of the bottle. Avoid skin contact with the sealant which contains natural rubber latex. Do not open pressure “air release” valve. Please use protective glove for safety purpose. 3. Unscrew the red cap of the sealant bottle. (Shake sealant bottle well before use). 4. Screw the bottle clockwise firmly against the slight resistance of the notches onto the sealing gasket of the bottle connector until it is screwed tight. 5. Remove the valve cap from the damaged tire. Pull the protective cap off the end of the hose and screw the hose firmly onto the valve of the damaged tire. Make sure that the compressor switch is switched to “0” and the pressure “air re-lease” valve is closed. 6. Insert power plug into the 12 volt power socket connection. 7. Start the motor (only if the vehicle is outdoors or in a well ventilated area). 8. Press compressor switch to “I”.
GENERAL 12 NOTE Check the sidewall of the tire prior to inflation. If there are any cracks, bumps or similar damage, do not attempt to inflate the tire. Do not stand directly beside the tire while the compressor is pumping. Watch the sidewall of the tire. If any cracks, bumps or similar damage appear, turn off the compressor and let the air out by means of the pressure “air release” valve. In this case, do not continue to use the tire When pumping in the sealant through the tire valve, the pressure may rise up to 500 kPa (5 bar, 73 psi) but will drop again after about 30 seconds. 9. Inflate the tire within about 10 minutes to an inflation pressure of minimum 180kPa, (1.8 bar, and 26 psi) and a maximum of 300kPa (3 bar, 43 psi). 10.Switch off the compressor briefly in order to read the actual tire pres-sure from the pressure gauge. WARNING If the tire inflation pressure does not reach 180kPa (1.8bar, 26 psi) within 10 minutes, the tire may have suffered excessive damage, making a tempo-rary repair impossible. In this case, do not continue to use the tire. 11. & 12. Once a tire inflation pressure of at least 180kPa (1.8 bar, 26 psi) has been reached. Switch the compressor to “0 Pull the power plug from the 12 volt power socket connection. Slowly unscrew the hose from the tire valve (sealant residues may escape from the hose) and put the protective cap back onto the hose. Leave the bottle in the holder. This avoids unexpected leakage of sealant residue. Make sure the Puncture repair Kit, the cap of the bottle and the orange cap are stored safely, but are still easily accessible, in the vehicle. 13. & 14. Immediately start and drive for about 3-10 km (2-6 miles) so that the sealant can seal the damaged area. Do not drive for more than 10 min and not any faster than 80 km/h (50 mph) (observe the decal indicating the permissible speed). WARNING If heavy vibrations, unsteady steering behaviour or noises should occur while driving, reduce your speed and drive with caution to a place where it is safe for you to stop the vehicle. Recheck the tire and its pressure. If the tire pressure is less than 130kPa (1.3bar, 19 psi) or if there are any visible cracks, bumps or similar damage on the side wall, do not continue to use the tire! STEP 2: CHECKING THE TIRE PRES-SURE 15.Stop the vehicle after driving about 3-10 km (2-6 miles).Check and, where necessary, adjust the pressure of the damaged tire. Remove the protective cap from the end of the hose. Screw the hose firmly onto the valve of the damaged tire. 16.Read the tire pressure from the pressure gauge. If the pressure of the sealant-filled tire is 130kPa (1.3 bar, 19 psi) or more, it must now be adjusted to the pressure specified for your vehicle (Refer sticker on vehicle). WARNING If the tire check shows that the pressure of the sealant-filled tire is less than 130kPa (1.3 bar, 19 psi) or if there are any visible cracks, bumps or similar tire damage on the side wall, you must not continue to use that tire. Make sure that the compressor switch is switched off to “0”. Insert the power plug into the 12volt power socket connection. Start the motor (only if the vehicle is outdoors or in a well ventilated area). 17. & 18. Switch the compressor on to “I” and pump the tire up to the specified tire pressure within max. 10 minutes.
GENERAL 13 NOTE Compressor unit we can use for filling the air & checking the pressure of the normal tire. Switch the compressor off and check the tire pressure again. If tire pressure is too high, deflate the tire to the specified pressure using the pressure “air release” valve. Rest of the remaining sealant in the hose might leak out when opening pressure “air release” valve or taking off the protective cap of the hose. Please use protective glove for safety purpose. Once you have inflated the tire to its correct tire pressure, switch off the compressor, pull the plug out of the socket, unscrew the hose, fasten the tire valve cap and put back on the protective cap of the hose. Leave the bottle in the holder and store the Puncture repair Kit away safely in the vehicle trunk. WARNING After using the sealant you may drive no faster than 80 km/h (50 mph), and the damaged tire must be replaced as quickly as possible (within a maximum driving distance of 200 km (120 miles). You must not continue to drive if heavy vibrations, unsteady steering behaviour or noises should occur while driving. 19.& 20. Drive to the nearest workshop to get the damaged tire repaired and if the tire repair is not possible, tire should be removed from the car. Before the tire is removed from the rim, inform your tire dealer that the tire contains seal-ant. Sealant deposits in a used hose may impair proper function of the Puncture repair Kit. Both the sealant bottle and the hose need to be replaced together after using the Puncture repair Kit. NOTE Remember that emergency road-side tire repair kits only provide temporary mobility. Regulation concerning tire repair after usage of Puncture Repair Kit may differ from country to country. You should consult a tire specialist for advice. WARNING Before driving, ensure tire is adjusted to recommended inflation pressure as indicated on vehicle placard. Monitor tire pressure until sealed tire is replaced. Proceed as described above from point 15 on-wards. New sealant and replacement parts can be purchased from your authorized repair shop or dealer. Sealant bottles can be disposed with household waste. LOCATION IN VEHICLE: NEXON EV – Near rear suspension tower, in vertical position, tightened with Velcro on carpet.
GENERAL 14 COMPRESSOR UNIT ASSY – Identification (5412 4010 01 73 – Micro 10 compressor #542) In AIS certificate, the model number #542 referred, which is reflected in all compressor barcodes as shown. All barcodes of the compressor model to TML will be with Barcode starting with #542 as below. Next nos is serial no for the respective compressor. TYRE PUNCTURE KIT ASSEMBLY SUPPLY CONDITION Assembly Level Description Part no 1 Puncture Kit Assembly 5412 4010 01 70 2 Compressor Unit Assembly 5412 4010 01 73 (Supplier ID:‐ Micro 10 compressor #542 2 Pouch‐Puncture kit 5412 4010 01 72 2 Sealant bottle 350 ml 5412 4010 98 01
HV ELECTRICAL SYSTEM_MR & LR HV ELECTRICAL SYSTEM
HV ELECTRICAL SYSTEM_MR & LR CONTENTS 1. GENERAL INFORMATION..................................................................................................... 1 A. GENERAL TOOLS FOR ELECTRIC VEHICLE ................................................................... 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................................................................................................. 17 2. TYPES OF CHARGING ........................................................................................................ 18 A. AC CHARGING (WALL MOUNT UNIT) ............................................................................. 19 B. NORMAL CHARGING ....................................................................................................... 21 C. FAST CHARGING............................................................................................................. 26 3. TIGHTENING TORQUES...................................................................................................... 28 4. SPECIAL TOOLS ................................................................................................................. 34 5. HV COMPONENTS DETAILS............................................................................................... 36 A. E-DRIVE EXPLODED VIEW ............................................................................................. 36 B. 3IN1 UNIT ASSY ............................................................................................................... 37 C. HV BATTRERY ASSY....................................................................................................... 38 D. HV SCHEMATICS (KANGER 3.0 LR/MR)......................................................................... 39 6. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE .............................. 40
HV ELECTRICAL SYSTEM_MR & LR 7. HV CONNECTOR CONNECTION & LOCKING PROCESS.................................................. 42 A. 3IN1 COMBO BOX TO E COMPRESSOR ........................................................................ 42 B. PDU TO OBC CONNECTOR ............................................................................................ 43 C. PDU TO CHARGING CABLE ............................................................................................ 44 D. PDU TO DC DC CABLE.................................................................................................... 45 E. PDU TO BATTERY CABLE ............................................................................................... 46 F. PDU TO E-DRIVE.............................................................................................................. 47 F. PROCEDURE TO FIT BADA CONNECTORS TO 3IN1 COMBO BOX.............................. 49 8. ISOLATION MEASUREMENT .............................................................................................. 52 9. HV COMPONENTS UNDER BONNET COMPARTMENT..................................................... 55 A. 3IN1 UNIT ASSY REMOVAL ............................................................................................ 55 B. SERVICIABLE ITEM 3IN1 UNIT ....................................................................................... 57 C. TOOLS FOR 3IN1 UNIT SERVICIABILTY ........................................................................ 59 D. 3IN1 UNIT SERVICIABILTY .............................................................................................. 60 E. VEHICLE CONTROL UNIT REMOVAL ............................................................................. 64 F. E - DRIVE REMOVAL ....................................................................................................... 65 E. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS............................. 68 10. TRACTION COOLING SYSTEM (TCS) ................................................................................ 70 A. SYSTEM LAYOUT ............................................................................................................ 70 B. CIRCUIT SCHEMATICS ................................................................................................... 70 C. TCS COOLANT DRAINING PROCEDURE....................................................................... 71 D. TCS COOLANT FILLING PROCEDURE........................................................................... 71 E. RADIATOR / RADIATOR FAN REMOVAL ........................................................................ 72 F. CONDENSOR REMOVAL................................................................................................. 73 G. TCS AUX TANK RESERVIOR REMOVAL........................................................................ 75
HV ELECTRICAL SYSTEM_MR & LR 11. HV BATTERY ....................................................................................................................... 76 A. SYSTEM LAYOUT ............................................................................................................ 76 B. HV BATTERY REMOVAL ................................................................................................. 76 12. BATTERY COOLING SYSTEM (BCS).................................................................................. 79 A. SYSTEM LAYOUT ............................................................................................................ 79 B. CIRCUIT SCHEMATICS ................................................................................................... 79 C. BCS COOLANT DRAINING PROCEDURE ...................................................................... 80 D. BCS COOLANT FILLING PROCEDURE .......................................................................... 80 E. BCS AUX TANK RESERVIOR REMOVAL........................................................................ 81 F. COMPRESSOR ................................................................................................................ 81 G. BATTERY COOLING PUMP REMOVAL .......................................................................... 83 H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL ........................................................... 83 13. HV / LV CHARGER CABLE.................................................................................................. 85 A. HV / LV CHARGER PORT & CABLE REMOVAL .............................................................. 85 B. CCS2 INLET ACTUATOR REPLACEMENT PROCEDURE .............................................. 86 14. CRADLE ............................................................................................................................... 89 A. CRADLE EXPLODED VIEW ............................................................................................. 89 B. CRADLE REMOVAL ......................................................................................................... 90 C. CRADLE FITMENT ........................................................................................................... 91 15. CRADLE MOUNTS ............................................................................................................... 95 ..............................................................................................................................................
HV ELECTRICAL SYSTEM_MR & LR 1 1. GENERAL INFORMATION A. GENERAL TOOLS FOR ELECTRIC VEHICLE These tools are to be use while working on High voltage system and components: (3in1 unit Assy, 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. B. HAND GLOVES: Nitrile - Must and should use nitrile gloves while working on High voltage system components. ESD - must and should use while removing and assembling of any component of LV System. Cotton - must use while working on mechanical components (brakes, suspension etc).
HV ELECTRICAL SYSTEM_MR & LR 2 C. 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.
HV ELECTRICAL SYSTEM_MR & LR 3 Insulating mats: Insulating mats are used to isolate person working on vehicle from ground. Image for Illustration only 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. Image for Illustration only 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).
HV ELECTRICAL SYSTEM_MR & LR 4 Authorized personnel: Only authorized personnel who are aware of the high voltage dangers should work on HV equipment. Image for Illustration only Buddy system: Do not work alone on high voltage system. Make sure somebody is there to monitor and help you. Image for Illustration only
HV ELECTRICAL SYSTEM_MR & LR 5 D. 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_MR & LR 6 E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM
HV ELECTRICAL SYSTEM_MR & LR 7 F. DO’S AND DON’TS (Images for Illustration only) 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_MR & LR 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 last, 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_MR & LR 9 DO’S DON’TS Use the insulated gloves & shoes for HV System. Do 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 system. 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_MR & LR 10 G. SAFETY WHILE SERVICING (Images for Illustration only) Example: Changing HV fuse inside PDU
HV ELECTRICAL SYSTEM_MR & LR 11 (Images for Illustration only)
HV ELECTRICAL SYSTEM_MR & LR 12 (Images for Illustration only)
HV ELECTRICAL SYSTEM_MR & LR 13 (Images for Illustration only)
HV ELECTRICAL SYSTEM_MR & LR 14 H. 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 prevent 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. (Images for Illustration only) WASHING PROCEDURE Following these tips while washing your vehicle. 1. Always wash your vehicle in shade and the surface is at room temperature. 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 prevent any damp spots. 7. Rinse all surfaces thoroughly to prevent any traces of soap and other cleaners as this may lead to the formation of stains on the painted surface later.
HV ELECTRICAL SYSTEM_MR & LR 15 I. ELECTRICAL COMPONENT INFORMATION SR. NO. DESCRIPTION 1 HIGH VOLTAGE BATTERY 2 3in1 UNIT ASSY 3 MCU 4 TRACTION MOTOR 5 HIGH VOLTAGE CABLES 6 CHARGING PORTS 7 CABLE HV AC CHARGING GUN 8 LOW VOLTAGE BATTERY
HV ELECTRICAL SYSTEM_MR & LR 16 COMPONENT DETAILS A. High Voltage Battery (lithium - ion) - 40.5 kWh Lithium Ion Battery Pack An on board high voltage electrical energy storage device. B. 3in1 Unit Assy i. 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. ii. Power Distribution Unit Distributes power from the high voltage battery to the HV components like inverter, DC-DC converter, Ecompressor etc. iii. On-Board Charger (OBC) - 6.6 kW 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. iv. Bi-D OBC C. Motor Control Unit A device to control traction motor. D. High Voltage Cable Use for high voltage electrical energy. E. Charging Port Provided for charging purpose. F. Cable HV AC Charging Gun Provided for charging purpose. G. Traction Motor - 105 kW (136PS) A device that converts electrical energy into rotational mechanical energy, which is then transfer as rotational torque to the wheels through the gearbox. NOTE: 3in1 Unit Assy includes OBC, DCDC converter and PDU in a single unit and the functionality of each unit is same as mentioned above.
HV ELECTRICAL SYSTEM_MR & LR 17 J. MOTOR COMPARTMENT SR. NO. DESCRIPTION 1 BRAKE FLUID CONTAINER 2 COOLANT TANK (TCS) 3 POWER TRAIN COVER 4 12-V BATTERY 5 MOTOR COMPARTMENT FUSE BOX 6 WINDSHIELD WASHER CONTAINER 7 COOLANT TANK (BCS)
HV ELECTRICAL SYSTEM_MR & LR 18 2. TYPES OF CHARGING Normal charging / AC charging Approximately 15 hours (time for a 0-100% charge, may increase basis factors such as ambient temperature, electrical load on meter, vehicle usage during and before charging, air conditioning usage during charging, aux loads etc.). AC Charging (WMU) Approximately 7 hours (time for a 0-100% charge, may increase basis factors such as ambient temperature, electrical load on meter, vehicle usage during and before charging, air conditioning usage during charging, aux loads etc.). Fast charging (DC charging) Approximately 1 hour (time for a 0-80% charge, may increase basis factors such as charger rating, ambient temperature, vehicle usage during and before charging, air conditioning usage during charging, aux loads etc.) 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 COMPONENT SPECIFICATIONS CHARGE PORT CHARGE GUN POWER SOURCE AC Charging (WMU) Nominal Voltage :230V AC RMS single 50Hz (L1,N ,PE,3 -Phase) Power Rating:7.5Kw AC RMS Rated Current 32A AC RMS Normal / AC Charging Nominal voltage: 230 V AC RMS Single phase, 50Hz supply. Power rating: 3.3 kW AC RMS Rated current 16A AC RMS. Fast / DC Charging Charging station voltage capability should be greater than or equal high voltage battery pack nominal voltage.
HV ELECTRICAL SYSTEM_MR & LR 19 A. AC CHARGING (WALL MOUNT UNIT) 1. EPB should be in engaged condition (Charging will not start without engaging EPB). 2. Pull the ‘Charging-inlet Flap Open Lever’ to open the charging inlet flap. 3. Open the protective cap on Charging Inlet (AC side). 4. Remove the charging gun from the WMU. (WMU will be separately installed at customer end). 5. Open the protective cap on WMU Charging Gun. 6. Before connecting the WMU charging gun to vehicle charging socket, make sure the gunlock is released. 7. If the actuator is engaged and the gun is not getting inserted properly, contact TATA Motors EV service center. 8. Remove any dust on the Charging Gun and Charging Inlet. Connect the WMU charging gun to vehicle AC Charging Inlet. 9. Scan the RFID provided, on the WMU to start charging. 10.Charging gun will be locked automatically. You will hear a “click” sound, when the gun is connected correctly. 11.Normally the car starts automatically charging. If not, please refer ‘Troubleshooting Guide in WMU’s owners' manual. 12.Open the door and see instrument cluster for State of Charge, Time to Charge and Gun connection status. 13.To stop the charging, scan the RFID on WMU. 14.The charging gun will be unlocked after pressing the fascia switch on the dashboard panel. Pull out the gun. 15.Put on the protective caps on both Charging Gun and Vehicle Inlet. Place the Charging gun back and close the charging inlet flap. NOTE: Separate manual for WMU will be provided along with the product. For more details on WMU, LED indications, troubleshooting guide etc. refer the same. WMU (WALL MOUNT UNIT) INPUT POWER REQUIREMENT AC Supply System 1-Phase, 3 Wire AC system (Ph + N + E) Nominal Input voltage 3Ø, 230VAC (Range: 90VAC to 265VAC) Input Frequency 50/60Hz Input Power 7.5kW (As per the System Capacity) SAFETY PRECAUTIONS i. Make sure that the equipment is well-grounded to avoid electric shock before opening the equipment ii. Do not modify, add, or alter any part of this product under any circumstances iii. Please make sure the input voltage, frequency, and other conditions have conformed to equipment requirements before power on iv. To ensure the service life of the equipment and stable operation, the equipment shall not be used in volatile gas or flammable environment DO’S AND DON’TS Do not touch any live part in the system while the system is ON. Do not modify, add, or alter any part of this product under any circumstances. Do not try to open the system by self in case of any issue as it may lead to warranty termination of the product. Do not install the equipment in a flammable environment. Do read the complete manual before starting operating the system.
HV ELECTRICAL SYSTEM_MR & LR 20 ALARM LIST FOR WMU Alarms Reason LED Indication EPO Pressed Emergency button pressed by someone. Solid Red + Alarm NE Voltage High Neutral Earth voltage comes more than 10V or False read by charger or Phase-neutral terminal interchange. Blinking – Type 2 Red for 500 msec Earth Fault Earth Wire not connected/Phase- neutral terminal interchange Solid Red + Alarm RFID Comm Fail RFID Card stops communicating with the main Board or Energy meter not connected or energy meter addressing not done. Blinking – Type 1 Red for 1 Sec Earth Leakage Internally current leakage to earth or false reading CT damage or circuitry issue. Solid Red + Alarm O/P Current High When the load current increases from 32-35 A Blinking – Type 1 Red For 1 Sec Mains Fail When the input voltage is not in its limit. Blinking – Type 1 Red For 1 Sec Mains Low When the input voltage is less than 150V Blinking – Type 1 Red For 1 Sec Mains high When the input voltage is greater than 270V. Blinking – Type 1 Red For 1 Sec
HV ELECTRICAL SYSTEM_MR & LR 21 B. 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 should be in a “P” mode (Park Mode) 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 After AC normal/slow charging, once AC power supply is switched off, Fascia switch( on dashboard panel) need to be pressed to unlock the charging gun. In case of fast charging it will take around 15 seconds for the charging gun to unlock automatically after completion of charging or after switching off charging. Charging gun unlock through fascia switch. (For slow charging only). Normal Charging procedure: 1. Engage “P” mode if it is not engaged. 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_MR & LR 22 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 “p” mode 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_MR & LR 23 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 Charge percentage is less than 25%, sport mode will be deactivated and cannot be further activated. When charge percentage goes below 10%, vehicle speed will get limited (limp home mode will get activated).
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