SERVICE MANUAL BOOK - 1 TIGOR .EV UPGRADE
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 TIGOR .EV UPGRADE. 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 4 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK – 1 CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEM LOW VOLTAGE (LV) ELECTRICAL SYSTEM 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
TABLE OF CONTENT SR. NO GROUP 1 HV ELECTRICAL SYSTEM 2 LV ELECTRICAL SYSTEM 3 BRAKE 5 FATC 6 BODY SRS 7
HV ELECTRICAL SYSTEM HV ELECTRICAL SYSTEM
HV ELECTRICAL SYSTEM CONTENTS 1. GENERAL INFORMATION..................................................................................................... 1 A. TOOLS................................................................................................................................ 1 B. HAND GLOVES .................................................................................................................. 1 C. PPES FOR HV.................................................................................................................... 2 D. MEASURING TOOLS ......................................................................................................... 5 E. SAFETY INSTRUCTIONS .................................................................................................. 6 F. DO’S AND DON’TS ............................................................................................................. 7 G. SAFETY WHILE SERVICING ........................................................................................... 10 H. WASHING INSTRUCTIONS ............................................................................................. 14 I. ELECTRICAL COMPONENT INFORMATION.................................................................... 15 J. MOTOR COMPARTMENT................................................................................................. 17 2. TYPES OF CHARGING ........................................................................................................ 18 A. NORMAL CHARGING....................................................................................................... 19 B. FAST CHARGING............................................................................................................. 24 3. TIGHTENING TORQUES...................................................................................................... 26 4. SPECIAL TOOLS ................................................................................................................. 31 5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE .............................. 33 6. HV CONNECTOR CONNECTION & LOCKING PROCESS.................................................. 34 7. ON VEHICLE REMOVAL...................................................................................................... 38 A. 3 IN 1 UNIT ....................................................................................................................... 38 B. VEHICLE CONTROL UNIT ............................................................................................... 40 C. VACCUM PUMP REMOVAL............................................................................................. 41 D. E - DRIVE REMOVAL ....................................................................................................... 41 E. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS............................. 45 8. TRACTION COOLING SYSTEM (TCS) ................................................................................ 46 A. SYSTEM LAYOUT ............................................................................................................ 46
HV ELECTRICAL SYSTEM B. CIRCUIT SCHEMATICS ................................................................................................... 46 C. TCS COOLANT DRAINING PROCEDURE....................................................................... 47 D. TCS COOLANT FILLING PROCEDURE........................................................................... 47 E. TCS COOLANT PUMP REMOVAL ................................................................................... 48 F. RADIATOR FAN REMOVAL ............................................................................................. 48 G. RADIATOR REMOVAL ..................................................................................................... 49 H. CONDENSOR REMOVAL ................................................................................................ 50 I. AUX TANK RESERVIOR REMOVAL ................................................................................. 52 9. HV BATTERY ....................................................................................................................... 53 A. SYSTEM LAYOUT ............................................................................................................ 53 B. BATTERY PACK STORAGE GUIDELINE......................................................................... 53 C. HV BATTERY REMOVAL ................................................................................................. 54 10. BATTERY COOLING SYSTEM (BCS).................................................................................. 58 A. SYSTEM LAYOUT ............................................................................................................ 58 B. CIRCUIT SCHEMATICS ................................................................................................... 58 C. BCS COOLANT DRAINING PROCEDURE ...................................................................... 59 D. BCS COOLANT FILLING PROCEDURE .......................................................................... 59 E. COMPRESSOR ................................................................................................................ 60 F. BATTERY COOLING PUMP REMOVAL ........................................................................... 61 G. BCS COOLANT TANK REMOVAL ................................................................................... 62 H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL ........................................................... 63 I. HV / LV CHARGER PORT & CABLE REMOVAL ............................................................... 64 11. CRADLE ............................................................................................................................... 67 A. CRADLE EXPLODED VIEW ............................................................................................. 67 B. CRADLE REMOVAL ......................................................................................................... 69 D. A, B, & C MOUNT FITMENT SEQUENCE ........................................................................ 71
HV ELECTRICAL SYSTEM 1 1. GENERAL INFORMATION A. TOOLS These tools are to be use while working on High voltage system and components: PDU, OBC, DCDC, E Drive, Battery Pack, PTC Heater, Compressor and HV Harnesses. a) General Tools - Can be sued on mechanical components and maintain specified torque. b) Insulated tools- Must & should use insulated tools while working on High voltage system components and maintain recommended torques. And Proper range of measuring tools should be used. B. HAND GLOVES: a) Nitrile - Must and should use nitrile gloves while working on High voltage system components. b) ESD - must and should use while removing and assembling of any component of LV System. c) Cotton - must use while working on mechanical components (brakes, suspension etc).
HV ELECTRICAL SYSTEM 2 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 to avoid.
HV ELECTRICAL SYSTEM 3 Insulating mats: Insulating mats are used to isolate person working on vehicle from ground. Insulated rescue hook: Insulated rescue hook should be placed near working area and should easily accessible Incase of any person gets shock, other person should not touch with hands and pull the person who got shock. Instated other person should pull the person who got shock with insulated rescue hook shown below. Lock out and tag out: In the workplace always have lock-outs on items with a potential safety concern. Lock-out/de-energize high voltage equipment before debugging, working, or installing new equipment. Ensure that only qualified people are working on the vehicle. Minimizes the chance of injury for curious “passers-by” when nobody is around.
HV ELECTRICAL SYSTEM 4 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. 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
HV ELECTRICAL SYSTEM 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 6 E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM
HV ELECTRICAL SYSTEM 7 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. Image for Illustration purpose only Do not use both hands together while working on electrical vehicle components. Image for Illustration purpose only During vehicle build, keep the 12V LV battery negative disconnected. Do not connect the 12V LV battery negative during vehicle build.
HV ELECTRICAL SYSTEM 8 DO’S DON’TS Each EV components enclosures shall be connected to chassis with cable. Do not keep the earthing point in loose condition; apply the torque as per the drawing. HV battery pack power connector and service disconnect shall be connected at the 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 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 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.
HV ELECTRICAL SYSTEM 10 G. SAFETY WHILE SERVICING Example: Changing HV fuse inside 3 IN 1 Image for Illustration purpose only Wear PPE for HV system Disconnect the MSD switch of HV and LV, wait foor min for capacitor discharge.
HV ELECTRICAL SYSTEM 11 Remove 3 IN 1 unit cover, follow one hand rule. Image for Illustration purpose only Image for Illustration purpose only
HV ELECTRICAL SYSTEM 12 Put the 3 IN 1 unit cover, Tighten the fasteners and connect the service disconnect. Image for Illustration purpose only
HV ELECTRICAL SYSTEM 13
HV ELECTRICAL SYSTEM 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 pre-vent malfunction / failure of electrical system due to water ingress. High-pressure washing is not allowed in the motor bay and on the battery connectors. When using high-pressure washers, make sure to maintain sufficient distance from the vehicle. Insufficient clearance or excessive pressure can lead to component damage or water penetration. Do not spray the camera, sensors or its surrounding area directly with a high-pressure washer. Shock from high-pressure water may cause the device to not operate normally. Do not bring the nozzle tip close to boots (rubber or plastic covers) or connectors, as they may be damage if they are exposed to high-pressure water. Pressure washing is not recommended at under hood area (Bonnet), under body & near rear LH.wheel arch. WASHING PROCEDURE Following these tips while washing your vehicle. 1. Always wash your vehicle in shade and the surface is at room tempera-ture. 2. Wash with mild vehicle wash soap like ‘Car Shampoo’ and use a soft bristle brush, sponge or soft cloth and rinse it frequently while washing to avoid scratches. 3. To avoid scratches, please wear soft gloves. Remove finger rings, nails, wristwatch while washing. 4. To remove stubborn stains and contaminant like tar, use turpentine or cleaners like ‘Stain remover’, which are safe for, paint surfaces. 5. Avoid substances like petrol, diesel, kerosene, benzene, thinner, acids or other solvents that cause damage to paint. 6. Dry your vehicle thoroughly to pre-vent any damp spots. 7. Rinse all surfaces thoroughly to pre-vent any traces of soap and other cleaners as this may lead to the formation of stains on the painted sur-face later.
HV ELECTRICAL SYSTEM 15 I. ELECTRICAL COMPONENT INFORMATION SR. NO. DESCRIPTION 1 E DRIVE 2 3 IN 1 UNIT 3 VECU 4 CABLE ASSY,PDU TO BATTERY 5 HIGH VOLTAGE BATTERY 6 CHARGER 7 CHARGING PORTS 8 AC SLOW / DC FAST CHARGING HV CABLE 9 GEARBOX
HV ELECTRICAL SYSTEM 16 COMPONENT DETAILS 1. E Drive A device that converts electrical energy into rotational mechanical energy, which is then transfer as rotational torque to the wheels through the gearbox. 2. 3 IN 1 UNIT A 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. B Power Distribution Unit Distributes power from the high voltage battery to the HV components like inverter, DC-DC converter, E-compressor etc. C Motor Control Unit A device to control traction motor. 3. VECU It control electrical systems and sub systems of vehicle 4. High Voltage Cable Use for high voltage electrical energy. 5. High Voltage Battery (lithium - ion) An on board high voltage electrical energy storage device. 6. Cable HV AC Charging Gun Provided for charging purpose. 7. Charging Port Provided for charging purpose. 8. AC SLOW / DC FAST CHARGING HV CABLE Use for high voltage electrical energy
HV ELECTRICAL SYSTEM 17 J. MOTOR COMPARTMENT SR. NO. DESCRIPTION 1 COOLANT TANK (BCS) 2 COOLANT TANK (TCS) 3 12-V BATTERY 4 MOTOR COMPARTMENT FUSE BOX 5 BRAKE FLUID CONTAINER 6 WINDSHIELD WASHER CONTAINER
HV ELECTRICAL SYSTEM 18 2 TYPES OF CHARGING Normal charging (AC charging) It takes about 8.5 hours at room temperature and normal operating conditions for the EV to charge from 10% to 90% with Normal Charging. The charging gun will be locked after switching on the AC supply. Fast charging (DC charging) 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. TYPRS OF CHARGING CHARGING SPECIFICATIONS CHARGE PORT CHARGE GUN POWER SOURCE Normal / AC Charging Nominal voltage: 230 V ac RMS Single phase, 50Hz supply. Voltage range : Minimum voltage = 190V ac RMS Maximum voltage = 250V ac RMS Power rating = 3kW as RMS Rated current 13A ac RMS. 3 pin wall socket Fast / DC Charging Nominal voltage: 320V DC. Charging station (CCS Type 2) voltage capability should be greater than or equal to 370V DC.
HV ELECTRICAL SYSTEM 19 A. NORMAL / AC CHARGING Precautions for Normal Charging 1. Proper maintenance of earthling pit is must. Add water & add salts at regular intervals into the earth pits in order to maintain the value of earth resistance. Check annually the condition of the electrodes so as to add or replace electrodes. 2. The electrical socket used for EV charging and its associated wiring should be able to supply 15A dedicated load continuously. 3. Check the charging inlet for accumulation of dust or any foreign objects. 4. Don’t try to pull off the charging gun during charging. 5. Don’t pull out the charging gun if it is in locked condition as excess force can break or damage the locking mechanism. Charging instructions 1. Vehicle must be parked with park brake in engaged state before connecting the charging gun. 2. Vehicle charging port must be free of dust, water or snow while connecting the charging gun; if not proper cleaning method must be used to remove dust, water and ice. 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 facia 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. Normal Charging procedure: 1. Engage the park brake. (Charging will not start without engaging the park brake). 2. Connect the plug to the AC power socket. 3. DO NOT plug into a power strip. 4. Open the protective cap on Charging Gun. 5. Pull the ‘Charging-inlet Flap Open Lever’ to open the charging inlet flap. 6. Open the protective cap on Charging Inlet. 7. Before connecting the charging gun to vehicle charging socket, make sure the gun lock is released. CAUTION: If the Gun Lock is not released please don’t insert the Charging Gun forcefully into the socket. It may damage the Charging Socket. 8. If the actuator is engaged and the gun is not getting inserted properly, contact TML service center.
HV ELECTRICAL SYSTEM 20 9. Remove any dust on the Charging Gun and Charging Inlet. Connect the charging gun to vehicle AC Charging Inlet. 10. Switch on the AC supply. 11. Charging Gun will be locked after switching on the AC supply. You will hear a “click” sound, when the gun is connected correctly. Image for Illustration purpose only NOTE When vehicle is in Charging Mode, it will not go in Drive (D), Sport (S) or Reverse(R). 12. Normally the car starts automatically charging. If not, please refer ‘Troubleshooting Guide for Normal Charging’ table. 13. Open the driver door and see instrument cluster to know SoC, time to charge and gun connection status. 14. In case the park brake is not engaged or partially engaged the charging won’t start and ‘Engage Park Brake to start charging’ message will be displayed on instrument cluster. NOTE Infotainment and cabin cooling can be used during charging of the vehicle by putting the vehicle in Ignition. 15. To stop the charging, switch off the AC power supply. 16. The charging gun will be unlocked by pressing unlock switch at fascia switch. 17. Pull out the plug. 18. Put on the protective caps on both Charging Gun and Vehicle Inlet. NOTE Once Normal/Fast charging is completed, 90 seconds of time gap is required before the vehicle can be started. After turning off the vehicle, wait for four seconds if you want to start the vehicle again. In emergency charging shutdown conditions, Gun won’t be unlocked. Contact authorised TATA Service Centre. In unforeseeable circumstances if the charging gun is stuck to the socket after charging is done, user has to contact the service personnel. No mechanical override to remove the charging gun is available for user.
HV ELECTRICAL SYSTEM 21 MAINTENANCE OF NORMAL CHARGING GUN The Portable Charger for Normal charging requires no maintenance other than occasional cleaning. WARNING: To reduce the risk of electrical shock or equipment damage, be cautious while cleaning the connectors and case. Clean the charging gun using a soft cloth lightly moistened with mild detergent solution. Never use any type of abrasive pad, scouring powder, or flammable solvents such as alcohol or benzene. 1. The electrical socket used for EV charging and its associated wiring should be able to supply 15A dedicated load continuously. 2. Do not use charging gun if it is wet in interface area. Allow it to dry before use. CAUTION: Changes or modifications to this product by other than an authorized service facility may void SAEJ1772 compliance. State of charge (SoC) gauge for high voltage battery Provided in the instrument cluster as a tell-tale. It shows the charging status of the high voltage battery. Low charge or minimum position on the indicator indicates that there is not enough energy in the high voltage battery. Full charge or max position indicates that the HV battery is fully charged. When driving on highways, make sure to check in advance if the HV battery is charged enough. When the bar turns red on the high voltage charge indicator, the low charge warning lamp turns ON to alert you of the battery level. When the charge percentage is less than 25% in the high voltage battery, the vehicle speed is limited and then eventually the vehicle will be turned OFF. Charge the vehicle immediately.
HV ELECTRICAL SYSTEM 22 NORMAL CHARGING CONTROL BOX INDICATIONS: 1. Home 2. Control Box 3. Vehicle 4. Fault Normal Charging Control Box Normal Charging control box indications Working state Home Control box Vehicle Fault Example Description Selfinspection state Blink Blink Blink Blink Self-inspection for system Standby state On Off Off Off No fault Blink Plug temperature is high Charging state On On Blink Off No fault Blink Plug temperature is high Charging stopped On On On Off No fault Blink Plug temperature is high
HV ELECTRICAL SYSTEM 23 TROUBLESHOOTING GUIDE FOR NORMAL CHARGING Refer the below table if charging is not starting or if it stops abruptly. The below symbols of ‘House’, ‘Control Box’, ‘Vehicle’ and ‘Fault’ can be seen on the control box beside the respective LEDs. Fault category Indication Home Control box Vehicle Fault Recommended action Interface fault in home Blink 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 Legend
HV ELECTRICAL SYSTEM 24 B. FAST CHARGING 1. Engage the parking brake. (Charging won’t start without engaging the parking brake). 2. Pull out the Charging Gun from DC/Fast Charging Station. 3. Open the protective cap on Charging Gun. 4. Pull the ‘Charging-inlet Flap Open Lever’ to open the charging door. 5. Open the charger-inlet flap. 6. If the actuator is engaged and the gun is not getting inserted properly, contact TML service center. CAUTION: If the Gun Lock is not released please don’t insert the Charging Gun forcefully into the socket. It may damage the Charging Socket. 7. Remove any dust on the Charging Gun and Charging Inlet. 8. Connect the charging gun to vehicle AC and DC Charging Inlet. 9. You hear a “click”, when the Gun is connected correctly. 10. Switch on the DC charging station supply. Image for Illustration purpose only 11. Charging Gun will be locked after switching on the DC charging station. Image for Illustration purpose only 12. Normally the car starts automatically charging. If not, please refer Charging Gun’s Fault Indication & Indi-cation Priority. NOTE: When vehicle is in Charging Mode, it will not go in Drive (D), Sport (S) or Reverse(R). 13. Open the driver door and see instrument cluster to know SoC, time to charge and gun connection status. 14. In case the park brake is not engaged or partially engaged the charging won’t start and ‘Engage Park Brake to start charging’ message will be displayed on instrument cluster. NOTE: Infotainment and cabin cooling can be used during charging of the vehicle by putting the vehicle in Ignition. 15. To stop the charging, switch off DC charging station. 16. The charging gun will be unlocked 15 to 19 seconds after switching off the supply from DC charging station. 17. Put on the protective caps on both Charging Gun and Vehicle Inlet.
HV ELECTRICAL SYSTEM 25 NOTE: If you remove the charging gun from the vehicle and if you wish to reinsert the gun to recharge the vehicle, please wait for at least 10 seconds before charging gun is plugged again. In emergency charging shutdown conditions, Gun won’t be unlocked. Contact authorised TATA Service Centre. Action to be taken when charging stops abruptly Check the reason for interruption of charging. (Refer ‘Troubleshooting guide for Normal Charging’ table). Switch off the supply. Remove the charging gun from the charging inlet. Wait for 5 minutes. Restart the charging. (Refer charging procedure). Cleaning of Charging Inlet: Covering the charging gun and charging in-let by dust cap will ensure protection from water and dust. Precautions to be taken while cleaning the charging inlet: Keep the vehicle lid always closed. When the lid is open ensure that dust caps are in closed position. During normal charging, make sure that DC charging cap is closed. In case of dust/mud accumulation in charging port, it can be cleaned by 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.
HV ELECTRICAL SYSTEM 26 3 TIGHTENING TORQUES: SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 1 MOTOR MOUNTING SUPPORT LH SIDE M10X1.25X65 SPRING WASHER B10 WASHER A10.5 4.6 2 MOTOR MOUNTING SUPPORT RH SIDE M10X1.25X65 SPRING WASHER B10 WASHER A10.5 4.6 3 3IN1 UNIT MTG ON BRACKET M8 X 20 2.5 4 3IN1 UNIT MTG BRACKET ON CRADLE M8 X 25 2.5
HV ELECTRICAL SYSTEM 27 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 5 MOTOR MOUNTING TO RH SIDE M10X1.25X30 6 – 6.5 6 COMPRESSOR BRACKET MOUNTING M10X1.25X50 4 - 4.5 7 WELDED STRUCTURE TO TIEROD MOUNTING M8X25 2 - 2.5 8 HIGH VOLTAGE BATTERY ASSY MTG M10X1.25X70 – 4 Nos SPRING WASHER B10 - 4 Nos 6.4
HV ELECTRICAL SYSTEM 28 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION M10X1.25X50 – 2 Nos SPRING WASHER B10 - 2 Nos 6.4 9 C-MOUNT BRACKET ASSY, E DRIVE HEX FL SCR M10X25 4.5 – 5.0 10 C-MOUNT LINK H/FL BOLT M10X75 H/FL BOLT M10X80 5.0 – 5.5 11 C-MOUNT BRACKET FL SCR M10X1.25X25 - 3 Nos FL SCR M10X1.5X40 – 2 Nos 4.5 -5.0
HV ELECTRICAL SYSTEM 29 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 12 A-MOUNT BRACKET SCR M10X1.25X30 5.5 – 6.0 13 A-MOUNT ASSY SCR M10X1.25X30 5.5 – 6.0 14 A-MOUNT ARM NYLOC NUT M10 WASHER 6 - 6.5 A-MOUNT ARM HEX FL BOLT M10X40 6 - 6.5
HV ELECTRICAL SYSTEM 30 SR. NO. DESCRIPTION FASTENER TIGHTENING TORQUE (Kg-m) LOCATION 15 B-MOUNT BRACKET SCR M10X1.25X30 6 – 6.5 B-MOUNT BRACKET HEX FL BOLT M10 X 1.25 X 40 6 – 6.5 16 B-MOUNT ASSY HEX. FL BOLT M8X28 3.0 – 3.5 B-MOUNT ASSY HEX. FL NUT M12X1.5 - 10 11.0-11.5 17 B-MOUNT ASSY SCREW M10x1.25x50 6 – 6.5
HV ELECTRICAL SYSTEM 31 4 SPECIAL TOOLS LIST: SR.NO. DISCRIPTION 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 4 E Drive Fixture 5123 5890 2408
HV ELECTRICAL SYSTEM 32 SR.NO. DISCRIPTION PART NO TOOL IMAGE 5 E Drive Fixture Attachment Kit (Upgrade) 5123 5890 2409 6 Transmission Jack 8855 WORK 0083 7 RTB Removal/Refitment Fixture 5467 5890 24 03.
HV ELECTRICAL SYSTEM 33 5 INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE: 1. Turn off the vehicle Ignition. 2. Open the bonnet of the vehicle. 3. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 4. Disconnect the Service disconnect switch of HV and LV.
HV ELECTRICAL SYSTEM 34 6 HV CONNECTOR CONNECTION & LOCKING PROCESS 1. 3 IN 1 TO E DRIVE 1. Slide the primary lock in outward direction as shown in below image. 2. Lift the lever in upward direction as shown in below image and remove the connector 2. 3 IN 1 TO HV BATTERY 3 IN 1 UNIT SIDE 1. Slide the primary lock in outward direction as shown in below image. 2. Lift the lever in upward direction as shown in below image and remove the connector
HV ELECTRICAL SYSTEM 35 HV BATTERY SIDE 1. Slide the primary lock in outward direction as shown in below image. 2. Lift the lever in upward direction as shown in below image and remove the connector. 3. BATTERY PACK TO FAST CHARGING 1. Slide the primary lock in outward direction as shown in below image. 2. Lift the lever in upward direction as shown in below image and remove the connector.
HV ELECTRICAL SYSTEM 36 4. 3 IN 1 TO AC INPUT 1. Slide the primary lock in outward direction as shown in below image 2. Press the secondary lock. 3. Press the 3rd lock and disconnect the connector. 5. 3 IN 1 TO AC PTC 1. Slide the primary lock in outward direction as shown in below image. 2. Press the secondary lock and disconnect the connector
HV ELECTRICAL SYSTEM 37 6. 3 IN 1 TO E-COMPRESSOR 1. Slide the primary lock in outward direction as shown in below image. 2. Press the secondary lock and disconnect the connector.
HV ELECTRICAL SYSTEM 38 7. ON VEHICLE REMOVAL A. 3 IN 1 UNIT REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Refer Instructions of HV connector Lock removal process before starting work 3. Disconnect the negative terminal of LV battery. 4. Disconnect the service disconnect switch. 5. Remove the LV wiring harness cable and connector connected to 3 in 1 Unit. 6. Remove the connector and cable of AC input to 3 in 1 Unit. 7. Remove the connector and cable of PTC to 3 in 1 Unit. 8. Remove the connector and cable of ECompressor to3 in 1 Unit. 9. Loosen the fastener and Remove the ground terminal cable from 3 in 1 Unit.
HV ELECTRICAL SYSTEM 39 10. Remove the connector and cable of E Drive connected to 3 in 1 Unit. 11. Remove the connector and cable of battery connected to 3 in 1 Unit. 12. Disconnect the coolant inlet and outlet hose from 3 in 1 Unit. 13. Disconnect the LV battery wiring harness to 3 in 1 unit. 14. Remove the four screws mounted on the bracket and safely remove the 3 in 1 Unit. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 40 B. VEHICLE CONTROL UNIT REMOVAL 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 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.
HV ELECTRICAL SYSTEM 41 C. VACUUM 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. D. E-DRIVE REMOVAL A. Refer Instructions for working on HV Components mention before starting work. B. Refer Instructions of HV connector Lock removal process before starting work C. Loosen and Remove the mounting screws & grommet of splashguard. D. Loosen and Remove the mounting grommet & nut of Mud Liner RH and LH side E. Loosen and remove the mounting nut of tyre & take out (LH / RH side )
HV ELECTRICAL SYSTEM 42 F. Loosen and remove the boll joint bolt of lower arm both LH & RH side. G. Apply brake and remove drive shaft lock nut on both LH and RH side. H. Drain the TCS coolant and Remove the pump (Refer Coolant draining & Pump proceduer for removal process). I. Remove drive shaft by pulling disk brake and Take out drive shaft LH / RH from gearbox. (Drain oil before carrying out this process). J. Remove the 3 in 1 Unit (Refer 3 in 1 Unit removal procedure). K. Remove of ground cables of E-drive.
HV ELECTRICAL SYSTEM 43 L. Remove electrical connection from MCU. M. Remove the Hose pipe from Motor coolant Out to Radiator coolant IN and drain the coolant. N. Remove the coolant Hose from Motor controller unit. O. Remove Compressor (Refer compressor removal procedure). P. Loosen and remove the mounting bolts of motor bracket support. Q. Loosen and remove the mounting bolts of motor bracket support.
HV ELECTRICAL SYSTEM 44 R. Loosen the fastener and remove the plate. S. Loosen the fastener and remove the suspension tie rod. T. Loosen and remove the mounting bolt nuts of C-Mount link. U. Loosen and remove the mounting bolt of CMount bracket. V. Use special tool to keep E drive safely down take it out. Fitment Follow reverse procedure for assembly. NOTE: Before assembly Check C-Mount BIW bracket. Replace if found bend / deformed.
HV ELECTRICAL SYSTEM 45 E. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS 1. OIL LEVEL CHECK 1. Before checking the oil level, stop the motor and lift the vehicle horizontally. 2. With the vehicle raised check for oil leakage if there is oil leakage, it should be repaired. 3. Remove the oil level plug, check whether the oil reaches the bottom of the oil level plug, and check whether the oil is polluted. Relationship between oil level and oil level plug 4. If the oil level is in is insufficient, replenish the lubricating oil to the oil level line shown in the figure. if the lubricating oil is polluted, replace the lubricating oil. 2. DISCHARGE AND FILLING OF LUBRICATING OIL 1. Before checking the oil level, stop the motor and lift the vehicle horizontally. 2. With the vehicle-raised check for oil leakage if there is oil leakage, it should be repaired. 3. Remove the drain plug and drain the waste oil, the position of the drain plug. The position of Drain oil plug and oil level plug 4. Apply a small amount of sealant(LT5910) to the drain plug and tighten it according to the specified torque (15±3Nm) 5. Remove the oil level plug, The position of the oil level plug. The position of Drain oil plug and oil level plug 6. According to the specified model (BOT 350M3) and oil quantity (0.6L-0.8L) add new lubricating oil to the oil level plug. 7. Apply a small amount of ssealant (LT5910) to the oil level plug and tighten it according to the specified torque (15±3Nm).
HV ELECTRICAL SYSTEM 46 8. TRACTION COOLING SYSTEM (TCS) A. SYSTEM LAYOUT B. CIRCUIT SCHEMATIC
HV ELECTRICAL SYSTEM 47 C. TCS COOLANT DRAINING PROCEDURE COOLANT QUANTITY: 3.0 Lit COOLANT SPECIFICATIONS: Ratio 50:50 - GLYCOL WATER DRAINING PROCEDURE NOTE: ‘While draining the coolant TCS Aux. tank Cap must be in open condition’. 1. Ensure Traction coolant temperature is normal / ambient temperature. 2. Remove Aux Tank cap. 3. Place the container to collect coolant. 4. Remove the Hose spring band clamp before pump inlet & disconnect the inlet pipe. 5. Remove the Motor outlet Hose spring band clamp. 6. Collect the Coolant in the container & wait till coolant get drain from Traction cooling system. D. TCS COOLANT FILLING PROCEDURE 1. Open the Aux Tank and fill coolant up to Max mark on Aux Tank. 2. Ensure that all hoses are connected and clamps are fitted properly before filling coolant from auxiliary tank. 3. Fill coolant up to the Max level in auxiliary tank. 4. Start the vehicle and after 5 minutes check the coolant level, If it drops then top up till MAX level. NOTE After filling the coolant, the coolant pump can be run through the service tool for the deaeration of coolant circuit. Or the vehicle can be cranked to run the pump, because in vehicle cranked state the pump operation starts in default speed which will in turn deaerate the circuit.
HV ELECTRICAL SYSTEM 48 E. TCS COOLING PUMP REMOVAL 1. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 2. Drain the coolant (Refer TCS Coolant Draining procedure). NOTE: ‘While draining the coolant TCS Aux. tank Cap must be in open condition’. 3. Loosen the Hose spring band clamp and disconnect the Coolant hoses. 4. Disconnect the electrical connection of TCS coolant pump. 5. Remove the mounting bolt of cooling pump & take it out. Fitment Follow reverse procedure for assembly. F. RADIATOR FAN REMOVAL 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Loosen and Remove the Mud liner LH / RH. 4. Loosen and Remove the mounting screws splashguard. 5. Drain the coolant (Refer TCS Coolant Draining procedure). 6. Remove the TCS cooling pump (Refer TCS Coolant pump removal procedure).
HV ELECTRICAL SYSTEM 49 7. Remove LV electrical wiring harness connection to PWM controller unit. 8. Loosen and remove the mounting 4 nuts and 2 bolts of radiator fan assy both side safety take it out. 9. Loosen and remove the mounting nut of fan and take it out. Fitment Follow reverse procedure for assembly. G. RADIATOR REMOVAL NOTE: Drain the coolant (Refer TCS Coolant Draining procedure). ‘While draining the coolant TCS Aux. tank Cap must be in open condition’. 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove front bumper assembly (For procedure (refer front bumper removal procedure in body section). 4. Remove the Radiator to E-drive hose. (Refer removal procedure in E drive section). 5. Remove the hose Radiator to coolant pump. 6. Remove the mounting nut of Liquid Line Condenser to Chiller Unit.
HV ELECTRICAL SYSTEM 50 7. Remove the mounting hose of Air Vent Hose, Radiator to Aux Water Tank. 8. Remove the mounting screw of radiator. Fitment Follow reverse procedure for assembly. H. CONDENSER REMOVAL NOTE: Drain the coolant (Refer TCS Coolant Draining procedure). ‘While draining the coolant TCS Aux. tank Cap must be in open condition’. 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove front bumper assembly (For procedure (refer front bumper removal procedure in body section). 4. Remove the Radiator to E-drive hose. 5. Remove the hose Radiator to coolant pump. 6. Remove the mounting nut of Liquid Line Condenser to Chiller Unit.
HV ELECTRICAL SYSTEM 51 7. Remove the mounting hose of Air Vent Hose, Radiator to Aux Water Tank. 8. Remove the mounting screw of radiator. 9. Remove the mounting Sealing Rivet of Radiator Sealing both sides. 10. Remove the mounting screw of Condenser Unit Assy take it out. Fitment Follow reverse procedure for assembly. NOTE Ensure condenser front area is clean and side sealing are fitted properly. Clogging of condenser and absence of side sealing lead to higher operating pressures of AC system.
HV ELECTRICAL SYSTEM 52 I. AUX TANK RESERVIOR REMOVAL 1. Open the bonnet of vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove the pump hose and drain the coolant and (Refer coolant pump section for removal process) 4. Remove rubber hoses connected to aux. tank. 5. Loosen and remove the fastener and remove the aux tank. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 53 9. HV BATTERY A. SYSTEM LAYOUT HV Battery specifications: Pack Nominal Voltage: 320 V Operating Voltage Range: 250 ~ 365 Nominal Capacity: 75 Ah Product weight: ≤ 220 Kg B. BATTERY PACK STORAGE GUIDELINE: If battery pack is not in use for long time, store the pack as per below guidelines: 1. Store at ambient temperature 20 to 35℃ and ambient humidity less than 75%. 2. SOC should not be less than 10%. 3. Avoid exposure to direct sunlight. 4. Charge and discharge the battery pack once a month to ensure that the battery pack is not less than 10% SOC anytime during storage. 5. The low voltage power should be turned on at least once a month when the vehicle is not in use for a long time. Pack should be inspected to check whether lowest cell voltage is less than 2.7V
HV ELECTRICAL SYSTEM 54 C. HV BATTERY REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Refer Instructions of HV connector Lock removal process before starting work 3. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 4. Disconnect the Service disconnect switch of HV and LV. NOTE: Wait for 10 minutes. 5. Remove the 4 bolts and 4 push on nuts and remove the stone gaurd. 6. Remove the chassis ground cable connected to HV battery assembly. 7. Disconnect and Remove the connector and powertrain harness connected to HV battery assembly 8. NOTE: ‘BCS aux. tank cap must be in open condition while draining coolant’. 9. Loosen the coolant hose and drain the coolant 10. Disconnect the coolant hoses.
HV ELECTRICAL SYSTEM 55 11. Disconnect the cable connecting 3 in 1 unit to HV battery. 12. Disconnect the cable connecting CCS to HV battery. 13. Loosen the fatener and remove the paring brake cable bracket from Rear Twist Beam (RTB). 14. Detach the CCS HV cable from RTB. 15. Loosen the parking brake adjustment nut and disconnect connection. 16. Loosen the mounting fasteners as shown and move aside the cable. 17. Remove the tyre for better access.
HV ELECTRICAL SYSTEM 56 18. Disconnect the wheel speed sensor connection. 19. Loosen the brake bundy tube and drain the brake oil from both side. 20. Disconnect the brake lines. 21. Support the RTB suitably 22. Use special tool 5467 5890 24 03. 23. Loosen the fasteners and disconnect the both shock absorbers. 24. Loosen the fasteners of RTB mounting bracket from both side. 25. Remove the RTB.
HV ELECTRICAL SYSTEM 57 26. Use special tool 5468 5890 24 01 to support the HV battery. 27. Align the battery over support stand carefully. 28. Loosen the mounting fasteners of HV battery. 29. Remove the HV battery. Fitment Follow reverse procedure for HV battery assembly.
HV ELECTRICAL SYSTEM 58 10. BATTERY COOLING SYSTEM (BCS) A. SYSTEM LAYOUT B. CIRCUIT SCHEMATIC
HV ELECTRICAL SYSTEM 59 C. BCS COOLANT DRAINING PROCEDURE MIN COOLANT LEVEL: 5 ± 0.5 Lit MAX COOLANT LEVEL: 7 ± 0.5 Lit COOLANT SPECIFICATIONS: Ratio 50:50 - Ethylene Glycol + Water DRAINING PROCEDURE NOTE: ‘While draining the coolant BCS Aux. tank Cap must be in open condition’. Ensure MSD (Manual service disconnect) is remove before coolant draining. 1. Ensure that BCS is coolant temperature is normal (equal to ambient temperature) before draining. 2. Remove coolant, Use drain plug connectors to remove coolant from system. 3. Remove cap of auxiliary coolant tank. 4. Wait until coolant gets drain from drain plugs. 5. Pass pressurized air from battery inlet port to and coolant will come out from battery outlet port. It is to flush out coolant battery side. 6. Close auxiliary tank cap and pass pressurized air from mating hose of battery outlet port and coolant will come out from battery inlet hose. It is to flush out coolant from chiller unit, BCS pump and BCS hoses. D. BCS COOLANT FILLING PROCEDURE 1. Open the Aux Tank and fill coolant up to Max mark on Aux Tank. 2. Ensure that all hoses are connected and clamps are fitted properly before filling coolant from auxiliary tank 3. Initially fill coolant till neck of auxiliary tank 4. Turn ON ignition and BCS pump will start working 5. After starting BCS pump, coolant will start circulating in the system and coolant level will drop in the auxiliary tank 6. Fill the coolant up to the MAX level in the auxiliary tank and after filling keep system running for 10 minutes. If coolant level drops then top up till MAX level. 7. After completion of work drive vehicle for 1.5 - 2 kilometres and check coolant level. If it drops then top up till MAX level. NOTE As soon as ignition is turn ON, coolant pump start operating. If coolant doesn’t reach up to pump then pump gets OFF (detects dry run) to avoid dry run of pump. It starts again after fix time interval. This type of ON / OFF attempts of pump happens 20 times. Once coolant reaches to pump, it keeps running continuously.
HV ELECTRICAL SYSTEM 60 E. E-COMPRESSOR Type Scroll Capacity 27cc Oil quantity 120ml REMOVAL 1. Refer Instructions for working on HV Components mention before starting work. 2. Refer Instructions of HV connector Lock removal process before starting work 3. Discharge the refrigerant using standard recovering equipment. (Refer maintenance section.) 4. Remove Electrical Connection to compressor. 5. Loosen and Remove the ground terminal cable screw to compressor. 6. Remove the mounting nut and disconnect the Suction pipe of compressor to Heat Exchanger. 7. Remove the mounting nut and disconnect the Discharge pipe of compressor to front end module assy. 8. Loosen and remove the mounting cap screw of compressor and take it out. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 61 NOTE • Always use compressor vibration dampers Do’s and Don'ts • Use only recommended refrigerant (R134a) and correct charge quantity (490 gms) in the AC system • Use only recommended lubricating oil for AC compressor (POE RL68H oil) • Ensure HV and LV connections of PTC heater are properly connected • Don’t remove connections of PTC heater when it is working • Always check coolant level in BCS tank • Avoid coolant leakage in BCS system • Do not change routing of coolant hoses. If hose get pinch then coolant flow will be restricted leading to battery over heat. F. BATTERY COOLING PUMP REMOVAL NOTE: Drain the coolant. (Refer BCS Coolant draining procedure). 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Loosen and Remove the LH side Mud liner. 4. Remove Electrical Connection of pump. 5. Remove the Inlet & outlet hoses connected to the cooling pump. 6. Remove the mounting bolt of cooling pump & take it out. Fitment Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 62 G. BCS COOLANT TANK REMOVAL 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Remove the Drain the coolant and pump hose (Refer coolant pump section for removal process) 4. Remove rubber hoses connected to aux. tank. 5. Loosen and remove the mounting screw of tank & take it out. Fitment. Follow reverse procedure for assembly.
HV ELECTRICAL SYSTEM 63 H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL Type – Plate type chiller REMOVAL 1. Open the bonnet of the vehicle. 2. Remove Aux Battery negative terminal and Put masking tape on Aux Battery negative terminal & cable. 3. Discharge the refrigerant using standard recovering equipment. (Refer maintenance section.) 4. Remove Electrical connection of chiller unit. 5. Remove the mounting nut and disconnect the Suction line and the discharge line of Heat Exchanger. 6. Remove the hose and drain the coolant of heat exchanger to coolant pump. 7. Remove the hose and drain the coolant of heat exchanger to HV battery.
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