SERVICE MANUAL BOOK - 1 PUNCH.EV
Developed by: Technical Literature Cell. Release Date : JAN 2024 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2024 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 PUNCH.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 5 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK – 1 CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEM LOW VOLTAGE (LV) 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 SYSTEM THE BOOK – 4 CONTAINS INFO. FITMENT DRAWINGS THE BOOK – 5 CONTAINS BODY REPAIR MANUAL
TABLE OF CONTENT SR. NO GROUP 1 HV ELECTRICAL SYSTEM 2 LV ELECTRICAL SYSTEM 3 DRIVESHAFT 4 SUSPENSION - LR SUSPENSION - MR 5 WHEELS & TYRES 6 STEERING 7 BRAKE - LR BRAKE - MR 8 FATC 9 BODY 10 SRS
HIGH VOLTAGE ELECTRICAL SYSTEM (HV) HIGH VOLTAGE ELECTRICAL SYSTEM (HV)
TABLE OF CONTENTS 1. GENERAL INFORMATION ........................................................................................................................1 A. TOOLS..................................................................................................................................................1 INSULATED TOOLS......................................................................................................................1 I. GENERAL TOOLS.........................................................................................................................1 II. B. HAND GLOVES....................................................................................................................................2 C. PPES FOR HV .....................................................................................................................................3 D. MEASURING TOOLS...........................................................................................................................7 E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM..................................................................8 F. DO’S AND DON’TS..............................................................................................................................9 G. SAFETY WHILE SERVICING.............................................................................................................12 H. WASHING INSTRUCTIONS...............................................................................................................16 ELECTRICAL COMPONENT INFORMATION ...................................................................................17 I. J. MOTOR COMPARTMENT .................................................................................................................26 2. TYPES OF CHARGING............................................................................................................................27 A. NORMAL / AC CHARGING................................................................................................................29 B. AC CHARGING (WALL MOUNT UNIT)..............................................................................................36 C. FAST CHARGING..............................................................................................................................38 3. TIGHTENING TORQUES.........................................................................................................................41 4. SPECIAL TOOL LIST...............................................................................................................................51 5. HV CONNECTOR CONNECTION AND LOCKING PROCESS...............................................................54 A. 3IN1 COMBO BOX TO MCU..............................................................................................................54 B. 3IN1 COMBO BOX TO HV BATTERY................................................................................................54 C. 3IN1 TO CCS PORT...........................................................................................................................55 D. 3IN1 TO E-COMPRESSOR................................................................................................................56 E. 3IN1 TO AC INPUT.............................................................................................................................57 F. 3IN1 TO PTC......................................................................................................................................57 G. 3IN1 COMBO BOX TO SIGNAL.........................................................................................................58 6. HV COMPONENT IN UNDER BONNET COMPARTMENT.....................................................................59 A. 3IN1 UNIT ASSY REMOVAL..............................................................................................................59 B. 3 IN 1 SERVICEABILITY....................................................................................................................61 C. VEHICLE CONTROL UNIT REMOVAL..............................................................................................63 D. VACCUM PUMP REMOVAL...............................................................................................................64 E. E-DRIVE REMOVAL...........................................................................................................................65 HIGH VOLTAGE ELECTRICAL SYSTEM (HV)
F. CHARGING PORT HOUSING...........................................................................................................69 G. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS.............................................71 OIL LEVEL CHECK......................................................................................................................71 I. DISCHARGE AND FILLING OF LUBRICATING OIL...................................................................71 II. 7. TRACTION COOLING SYSTEM (TCS)...................................................................................................72 A. SYSTEM LAYOUT..............................................................................................................................72 B. CIRCUIT SCHEMATIC.......................................................................................................................72 C. TCS COOLANT DRAINING PROCEDURE........................................................................................73 D. TCS COOLANT FILLING PROCEDURE............................................................................................73 E. TCS COOLING PUMP REMOVAL.....................................................................................................74 F. RADIATOR / RADIATOR FAN REMOVAL..........................................................................................75 G. CONDENSER REMOVAL..................................................................................................................76 H. TCS AUX TANK RESERVIOR REMOVAL..........................................................................................78 8. HV BATTERY............................................................................................................................................79 A. SYSTEM LAYOUT..............................................................................................................................79 B. BATTERY PACK STORAGE GUIDELINES........................................................................................80 C. HV BATTERY REMOVAL...................................................................................................................80 D. REPLACMENT OF CONTACTORS...................................................................................................82 E. REPLACMENT OF FUSE...................................................................................................................84 F. REPLACMENT OF PYRO SWITCH...................................................................................................86 G. REPLACMENT OF SMOKE SENSOR...............................................................................................88 H. REPLACMENT OF PRECHARGE.....................................................................................................89 REPLACMENT OF CURRENT SENSOR ..........................................................................................91 I. J. REPLACMENT OF HV CONNECTOR...............................................................................................92 K. REPLACMENT OF MODULE TO SLAVE HARNESS........................................................................93 L. REPLACMENT OF LV HARNESS......................................................................................................95 9. BATTERY COOLING SYSTEM (BCS).....................................................................................................99 A. SYSTEM LAYOUT..............................................................................................................................99 B. CIRCUIT SCHEMATIC.......................................................................................................................99 C. BCS COOLANT DRAINING PROCEDURE.....................................................................................100 D. BCS COOLANT FILLING PROCEDURE.........................................................................................100 E. COMPRESSOR................................................................................................................................101 F. BATTERY COOLING PUMP REMOVAL..........................................................................................103 G. BCS COOLANT TANK REMOVAL...................................................................................................104 H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL..........................................................................105 HIGH VOLTAGE ELECTRICAL SYSTEM (HV)
HV / LV CHARGER PORT & CABLE REMOVAL.............................................................................106 I. CRADLE ................................................................................................................................................108 10. A. CRADLE EXPLODED VIEW - LR....................................................................................................108 B. CRADLE REMOVAL - LR.................................................................................................................110 C. CRADLE EXPLODED VIEW - MR....................................................................................................112 D. CRADLE REMOVAL - MR................................................................................................................114 HIGH VOLTAGE ELECTRICAL SYSTEM (HV)
1. GENERAL INFORMATION A. TOOLS These tools are to be use while working on High voltage system and components: 3 IN 1 COMBO UNIT (If applicable) or PDU, OBC, DCDC, E Drive, Battery Pack, PTC Heater, Compressor and HV Harnesses. INSULATED TOOLS I. 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. (Required while working on HV battery.) GENERAL TOOLS II. It Can be used on mechanical components and maintain specified torque. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 1
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). • HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 3
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. • Insulating mats: Insulating mats are used to isolate person working on vehicle from ground. Image for Illustration purpose only HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 4
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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 5
Buddy system Do not work alone on high voltage system. Make sure somebody is there to monitor and help you. • Image for Illustration purpose only HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 6
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. • HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 7
E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 8
F. 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 9
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. 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 10
DO’S DON’TS 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 paint. Do not carry out any welding work when high voltage battery is active. After removing service, disconnect LOTO practice to be followed. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 11
G. SAFETY WHILE SERVICING Example: Changing HV fuse inside PDU Image for Illustration purpose only HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 12
Wear PPE for HV system. Disconnect the HV and LV service disconnect, after removal wait for 10 min for capacitors to discharge HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 13
Image for Illustration purpose only Close and tighten the 3 in 1 Combo Cover HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 14
First Aid HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 15
H. WASHING INSTRUCTIONS HIGH-PRESSURE WASHING INSRTUCTION 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 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 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. 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 VOLTAGE ELECTRICAL SYSTEM (HV) 16
ELECTRICAL COMPONENT INFORMATION I. SR NO DESCRIPTION 1 HIGH VOLTAGE BATTERY 2 3 in 1 COMBO UNIT 3 MCU 4 TRACTION MOTOR 5 HV CABLES 6 CHARGING PORTS 7 CHARGING GUN 8 LV BATTERY 9 HV GROUND CABLE HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 17
COMPONENT DETAILS 1. High Voltage Battery An on board high voltage electrical energy storage device. Option of 2 Efficient liquid cooled battery packs Battery Pack Capacity for LR 34.7 kWh and for MR is 24.8 KWh SPECIFICATIONS PARAMETER SPECIFICATION Battery Type LFP 320V 75Ah Nominal Voltage [V] 326.4 Operating Voltage Range [V-V] 255–372.3 Nominal Capacity [Ah] 106.4 Rated Energy [kWh] 34.7 (@0.33C, 25°C) Water and Dust Protection IP67 Peak Discharge Current [A] 320 A for 10 sec Peak Charge Current [A] 213 A for 10 sec Operating temperature range (Charging) [°C ] 0 - 50 Recommended storage temperature range [°C ] -20-45 ≤ 1 month 0-45 ≤ 3 month 0-25 ≤ 1 year Weight of pack [kg] 296.5 ± 3% Cooling Mode Liquid Cooling HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 18
2. 3 IN 1 Unit The 3in1 Combo Unit contains PDU, unidirectional OBC and DC-DC converter 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. Power Distribution Unit Distributes power from the high voltage battery to the HV components like inverter, DC-DC converter, Ecompressor etc. 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 19
Technical Specification PARAMETER SPECIFICATION OBC AC Input Voltage [V] 80 ~ 270 AC Input Current (A) < 32 A Nominal Capacity [Ah] 75 Output Voltage [V] 200 ~ 450 Water and Dust Protection IP67 Output Power [Kw] 6.6 DC DC Converter Input Voltage [V] 200 ~ 450 Input Current (A) < 12 A Output Rated Voltage [V] 13.8 DC Output Rated Current [A} 185 Output Rated Power [Kw] 2.5 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 20
3. Motor Control Unit (MCU) This device is used to control the traction motor. Traction Motor 4. A device that converts electrical energy into rotational mechanical energy, which is then transfer as rotational torque to the wheels through the gearbox. Permanent Magnet Synchronous Motor with 215 Nm Instant torque. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 21
EXPLODED VIEW SR NO DESCRIPTION Motor and Gearbox Parts A Terminal Cover Motor B Motor Rear End Cover C Rotor D Stator Body with Housing E Transaxle Motor Controller Part a Case Of Resolver b Control Board c U/V/W Bus bars d HV Input HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 22
5. High Voltage Cable Use for high voltage electrical energy. SR NO DESCRIPTION e IGBT f Case Of Inverter g Capacitor h Drive Board HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 23
6. Charging Port Provided for charging purpose. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 24
7. Cable HV AC Charging Gun Provided for charging purpose. LV Battery 8. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 25
J. MOTOR COMPARTMENT SR NO DESCRIPTION 1 WINDSHIELD WASHER CONTAINER 2 COOLANT TANK (TCS) 3 COOLANT TANK (BCS) 4 12-V BATTERY 5 MOTOR COMPARTMENT FUSE BOX 6 BRAKE FLUID CONTAINER HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 26
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. AC charging (WMU) Approximately 2.6** Hrs. to 3.6**Hrs. (time for a 0 to 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) EV vehicle 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. TYPES OF CHARGI NG 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 = 3kW as RMS Rated current 13A ac RMS. 3 pin wall socket AC Charging (WMU) Nominal Voltage: 230 V AC RMS single 50Hz (L1,N ,PE,3 - Phase) Power Rating: 7.5Kw AC RMS Rated Current 32A AC RMS HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 27
TYPES OF CHARGI NG CHARGING SPECIFICATIONS CHARGE PORT CHARGE GUN POWER SOURCE Fast / DC Charging Nominal voltage: 320V DC. Charging station (CCS Type 2) voltage capability should be greater than or equal to 370V DC. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 28
A. NORMAL / AC CHARGING AC Charging Architecture 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. 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 Gun unlocking for AC charging is done through fascia switch. After AC slow charging, AC power supply to be switched off. Fascia switch on dashboard panel to be pressed to unlock the AC slow charging gun. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 29
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. 8. If the actuator is engaged and the gun is not getting inserted properly, contact TML service center. 9. Remove any dust on the Charging Gun and Charging Inlet. Connect the charging gun to vehicle AC Charging Inlet 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 30
Switch on the AC supply. 10. Charging Gun will be locked after switching on 11. the AC supply. You will hear a “click” sound, when the gun is connected correctly. Normally the car starts automatically charging. 12. If not, please refer ‘Troubleshooting Guide for Normal Charging’ table. Open the driver door and see instrument 13. cluster to know SoC, time to charge and gun connection status. In case the park brake is not engaged or 14. partially engaged the charging won’t start and ‘Engage Park Brake to start charging’ message will be displayed on instrument cluster. To stop the charging, switch off the AC power 15. supply. The charging gun will be unlocked by pressing 16. unlock switch at fascia switch. Pull out the plug. 17. Put on the protective caps on both Charging 18. Gun and Vehicle Inlet. NOTE When vehicle is in Charging Mode, it will not go in Drive (D), Sport (S) or Reverse(R). NOTE Infotainment and cabin cooling can be used during charging of the vehicle by putting the vehicle in Ignition. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 31
MAINTENANCE OF NORMAL CHARGING GUN The Portable Charger for Normal charging requires no maintenance other than occasional cleaning. 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. The electrical socket used for EV charging and its associated wiring should be able to supply 15A dedicated load continuously. Do not use charging gun if it is wet in interface area. Allow it to dry before use. 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 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. 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. WARNING To reduce the risk of electrical shock or equipment damage, be cautious while cleaning the connectors and case. CAUTION Changes or modifications to this product by other than an authorized service facility may void SAEJ1772 compliance. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 32
NORMAL CHARGING CONTROL BOX INDICATIONS: 1. Home 2. Control Box 3. Vehicle 4. Fault Normal Charging Control Box HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 33
Normal Charging control box indications WORKING STATE HOME CONTR OL BOX VEHIC LE 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 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 34
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. Legend FAULT CATEG ORY INDICATION HOME CONTRO L BOX VEHICL E FAULT RECOMMENDED ACTION Interface fault in home Blink Off Off On 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 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 35
B. AC CHARGING (WALL MOUNT UNIT) EPB should be in engaged condition (Charging 1. 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. Charging gun will be locked automatically. You 10. will hear a “click” sound, when the gun is connected correctly. Normally the car starts automatically charging. 11. If not, please refer ‘Troubleshooting Guide in WMU’s owners' manual. Open the door and see instrument cluster for 12. State of Charge, Time to Charge and Gun connection status. To stop the charging, scan the RFID on WMU. 13. The charging gun will be unlocked after 14. pressing the fascia switch on the dashboard panel. Pull out the gun. Put on the protective caps on both Charging 15. Gun and Vehicle Inlet. Place the Charging gun back and close the charging inlet flap. WMU (WALL MOUNT UNIT) INPUT POWER REQUIREMENT SAFETY PRECAUTIONS Make sure that the equipment is well-grounded to avoid electric shock before opening the equipment Do not modify, add, or alter any part of this product under any circumstances Please make sure the input voltage, frequency, and other conditions have conformed to equipment requirements before power on 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. 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. AC Supply System 1-Phase, 3 Wire AC system (Ph + N + E) Nominal Input voltage Single Phase of 3Ø, 230VAC (Range: 90VAC to 265VAC) Input Current 32 Amp Input Frequency 45/63Hz Input Power 7.5kW (As per the System Capacity) HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 36
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 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 37
C. FAST CHARGING Fast Charging Architecture VECU Application software – Charging Initiation VECU Application software – Charging Shutdown 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. 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. Switch on the DC charging station supply. 10. 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 38
Charging Gun will be locked after switching on 11. the DC charging station. Normally the car starts automatically charging. 12. If not, please refer Charging Gun’s Fault Indication & Indi-cation Priority. Open the driver door and see instrument 13. cluster to know SoC, time to charge and gun connection status. In case the park brake is not engaged or 14. partially engaged the charging won’t start and ‘Engage Park Brake to start charging’ message will be displayed on instrument cluster. To stop the charging, switch off DC charging 15. station. The charging gun will be unlocked 15 to 19 16. seconds after switching off the supply from DC charging station. Put on the protective caps on both Charging 17. Gun and Vehicle Inlet. 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 supply. • Remove the charging gun from the charging • inlet. Wait for 5 minutes. • Restart the charging. (Refer charging • procedure. NOTE When vehicle is in Charging Mode, it will not go in Drive (D), Sport (S) or Reverse(R). NOTE Infotainment and cabin cooling can be used during charging of the vehicle by putting the vehicle in Ignition. 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 39
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. In case of dust/mud accumulation in charging • port, it can be cleaned by blowing air to clean the CCS2. Allow the water to drain completely through • drain holes. Allow the charging port to dry completely. • NOTE In case of any water ingress in the socket cavity, allow it to drain through the drain hole. Make sure the charging port is dry. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 40
3. TIGHTENING TORQUES SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 1 MOTOR MOUNTING SUPPORT RH SIDE H/BOLT M10X1.25X 55 4.9 2 MOTOR MOUNTING SUPPORT LH SIDE H/BOLT M10X1.25X 55 4.9 3 3 IN 1 COMBO UNIT HEX FL SCREW M8X20 2.5 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 41
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 4 BRACKET MOTOR MTG RH, LH & GUSSET MTG WITH FRAME ASSY & FORGING BRACKET LH HEX FL SCR M10X65 TS17130 10.9SS845 1S2-YH 6.0 – 6.5 LR MR HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 42
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 5 BRACKET MOTOR MTG RH, LH & GUSSET MTG WITH FRAME ASSY & FORGING BRACKET LH HEX FL SCR M10X65 TS17130 10.9SS845 1S2-YH WITH WASHER A10.5 IS5370 ST SS8451S2Y 6.0 – 6.5 LR MR HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 43
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 6 FRAME ASSY & FORGING BRACKET LH MTG H/FL BOLT M12X60 TS17130 10.9SS845 1S2-YH 10.5 - 11.0 LR MR NOTE: M12 fasteners are critical, Ensure Torque value of highlighted fasteners are checked at every periodic service. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 44
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 7 FRAME ASSY & FORGING BRACKET RH MTG FL SCR M12X55 TS1713010.9 SS8457S1BL-C 10.5 - 11.0 LR MR NOTE: M12 fasteners are critical, Ensure Torque value of highlighted fasteners are checked at every periodic service. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 45
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 8 FRAME ASSY & FORGING BRACKET RH MTG H/FL SCR M10X40TS17130-1 0.9SS8451S2YH 6.0 – 6.5 LR MR 9 SUPPORT BRACKET CRADLE ASSY & GUSSET MTG H/FL SCR M8X30 TS17130 8.8 SS8457S1BL-B 2.0 - 2.5 LR MR HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 46
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 10 BRACKET COMPRESSOR MTG H/FL BOLT M8X45 TS1713010.9SS845 1S2-YH 2.0 - 2.5 LR MR 11 CRADLE – STUD STUD M10X1.5 both side threaded 3.5 - 4.0 12 C-MOUNT H/FL BOLT M12X1.25X 77 10.5-11 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 47
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 13 C-MOUNT BRACKET H/FL BOLT M12X1.75X 40 8.5 - 9.0 14 B-MOUNT BRACKET HEX FL NUT AM12X1.25 10.5 - 11.0 15 B-MOUNT BRACKET ON LONG MEMBER SIDE HEX BOLT M10X1.25X 30 6.0 - 6.5 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 48
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 16 C-MOUNT LR HEX FL BOLT M12X1.25X 105 10.5 – 11 16 C-MOUNT MR HEX FL SCREW M12X45 7.5 – 8.0 17 A-MOUNT BRACKET ON LONG MEMBER SIDE SCREW M10X1.25X 30 6 - 6.5 A-MOUNT ARM HEX FL BOLT M12X60 9 - 10 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 49
SR NO DESCRIPTION FASTENER TIGHTENING TORQUE (KG-M) LOCATION 18 UNDER BODY COVER TO VOLTAGE BATTERY PACK/SUBFRAME M8x25 2.3 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 50
4. SPECIAL TOOL LIST SR NO DESCRIPTION PART NO TOOL IMAGE 1 BATTERY PACK LIFTING HANGER / E DRIVE LIFTING HANGER TACKLE UNIT 5123 5890 2407 2 E DRIVE SUPPORT STAND 5123 5890 2412 3 BATTERY PACK FIXTURE 5468 5890 2401 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 51
SR NO DESCRIPTION PART NO TOOL IMAGE 4 E DRIVE FIXTURE 5123 5890 2408 5 E DRIVE FIXTURE ATTACHMENT KIT (UPGRADE) 5123 5890 2409 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 52
SR NO DESCRIPTION PART NO TOOL IMAGE 6 TRANSMISSION JACK 8855 WORK 0083 HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 53
5. HV CONNECTOR CONNECTION AND LOCKING PROCESS A. 3IN1 COMBO BOX TO MCU 1. Slide the primary lock in the direction of arrow. 2. Pull the lever as shown in image. 3. Disconnect the connector. B. 3IN1 COMBO BOX TO HV BATTERY 3IN1 SIDE CONNECTOR 1. Slide the primary lock in the direction of arrow. 2. Pull the lever as shown in image. 3. Disconnect the connector. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 54
HV BATTERY SIDE CONNECTOR 1. Slide the primary lock in the direction of arrow. 2. Pull the lever as shown in image. 3. Disconnect the connector. C. 3IN1 TO CCS PORT 3IN1 SIDE CONNECTOR 1. Slide the primary lock in the direction of arrow. 2. Rotate the lever as shown in image. 3. Disconnect the connector. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 55
D. 3IN1 TO E-COMPRESSOR 3IN1 SIDE CONNECTOR 1. Press the primary lock suitably. 2. Slide the secondary lock outward direction as shown. 3. Disconnect the connector. E-COMPRESSOR SIDE CONNECTOR Slide the primary lock outward direction as 1. shown. 2. Push secondary lock and disconnect the connector. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 56
E. 3IN1 TO AC INPUT 1. Slide the primary lock in outward direction. 2. Press the secondary lock and disconnect the connector. F. 3IN1 TO PTC 1. Press the primary lock suitably. 2. Slide the secondary lock outward direction as shown. 3. Disconnect the connector. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 57
G. 3IN1 COMBO BOX TO SIGNAL 1. Slide the primary lock in the direction of arrow. 2. Pull the lever as shown in image. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 58
6. HV COMPONENT IN UNDER BONNET COMPARTMENT A. 3IN1 UNIT ASSY REMOVAL 1.Refer Instructions for working on HV Components mention before starting work. 2. Remove the LV wiring harness cable & connector connected to 3in1 Unit Assy. 3. Remove the connector and cable of HV junction box to PTC heater. 4. Remove AC SLOW charging connector and cable from 3 in 1 combo unit assembly. 5. Remove the connector and cable of AC compressor connector assembly. 6. Loosen and Remove the ground terminal cable screw. 7. Remove DC FAST charging connector and cable from 3 in 1 combo unit assembly. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 59
8. Remove the connector and cable of motor controller connected to 3in1 Unit Assy. 9. Remove HV Battery connector and cable from 3 in 1 combo unit assembly. Drain Coolant and remove Hose connection on 10. 3in1 Unit Assy. Remove the four screws mounted on the 11. bracket and safely remove the 3in1 Unit Assy having weight 12.5 kg. Fitment Follow reverse procedure for assembly. NOTE If any issues of DTC related to OBC, DC - DC Converter need to replace 3in1 Unit. For PDU/3in1 related DTC issue, PDU/3in1 serviceability need to perform. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 60
B. 3 IN 1 SERVICEABILITY 1.Refer Instructions for working on HV Components mention before starting work. 2. Open the bonnet. 3. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 4. Loosen and remove the 3 IN 1 unit service cover screws (11 Nos). 5. Remove the 3 IN 1 service cover. 6. Loosen the screws (M4x8, Qty 2) and remove the PTC fuse. 7. Loosen the screws (M4x8, Qty 2) and remove the AC Compressor fuse. 8. Loosen the screws (M4x8, Qty 2) and remove the OBC fuse. 9. Loosen the screws (M8x14, Qty 2) and remove the MCU fuse. Loosen the screws (Qty 2) and remove the 10. PTC Relay. CAUTION Be careful while loosening screws, Don’t scratch the Service cover, especially the sealing area. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 61
Loosen the screws (Qty 4) and remove the 11. MCU Relay. Fitment Follow reverse procedure for assembly. For torque values refer below table. When Mounting the PTC Fuse or Compressor Fuse, please follow the orientation given in below image. NOTE PTC, Compressor & OBC Fuses have exact same size, pay attention to avoid any Mismounting. SCREW TYPE QUANTIT Y DRIVE BIT (TORX) FIXATIO N TORQUE (NM) M4x8 6 T20 2.5 ± 10% M8x14 4 T40 9 ± 10% HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 62
C. 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. 3. Disconnect the connectors and wiring harness connected to the controller. 4. Loosen and Remove the screws of supporting bracket. 5. Loosen and Remove the screws mounted on the bracket and safely take out the controller. Fitment Follow reverse procedure for assembly. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 63
D. VACCUM PUMP REMOVAL 1. Open the bonnet of the vehicle. 2. Refer Instructions of HV connector Lock removal process before starting work 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 64
E. E-DRIVE REMOVAL 1.Refer Instructions for working on HV Components mention before starting work. 2. Disconnect and remove all LV electrical wiring harness. 3. Remove Mud Liner LH and RH. 4. Loosen and Remove the mounting screws & nut of splashguard. 5. Loosen and remove the mounting nut of tyre & take out (LH / RH side ) 6. Loosen and remove the boll joint bolt of lower arm to axle both LH & RH side. 7. Apply brake and remove drive shaft lock nut on both LH and RH side. 8. Drain the coolant and Remove the pump. (Refer coolant pump section for removal process). 9. Remove drive shaft by pulling disk brake and Take out drive shaft LH / RH from gearbox. (Drain oil before carrying out this process). HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 65
Remove the connector cable connected 10. between 3in1 Assy. & E-Drive. Disconnect the wiring harness of E Drive. 11. Remove of ground cables of E-drive. 12. Remove the Hose Pipe from E-drive. 13. Loosen the clamps and disconnect the coolant 14. hoses. Loosen the fasteners and remove the coolant 15. pump. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 66
Remove the Hose Pipe Charger out to Motor 16. Inlet and drain coolant. Collect the refrigerant using standard 17. recovering equipment. Remove the compressor. (Refer compressor 18. removal section for removal process.) Support Motor E-Drive from Bottom side using 19. special Tool. Loosen and remove the mounting bolts of 20. motor bracket support. Loosen and remove the mounting bolts of 21. motor bracket support. Loosen and remove the mounting bolt on C- 22. Mount Bracket. Use special tool to keep E drive safely down 23. take it out. Fitment Follow reverse procedure for assembly. 1. After connecting the LV battery, Start the vehicle and after 5 minutes if the coolant level drops below the max level then top up the coolant till max level. 2. Connect the diagnostic tool to OBD connector. 3. Turn the IGN ON. 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. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 67
4. Read the DTCs and clear all the DTCs from EDrive ECU with the help of diagnostic tool. Unlock security to E-Drive ECU. Please follow the procedure available in service tool to Unlock the security access. 5. Perform the following diagnostics activities:- Read HW, SW part numbers and it’s version numbers of E-drive ECU and compare against server. a. Vehicle Manufacturer Spare Part Number (F187) b. ECU Application Software Number (7241) c. Application Software Identification (F181) d. ECU Calibration Software Number (7242) CAUTION This is an essential step without unlocking the security access further steps will not be executed. HIGH VOLTAGE ELECTRICAL SYSTEM (HV) 68
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