© 2016 Mahindra REVA Electric Vehicles Ltd (MREVA), Bangalore. All rights reserved. This Manual
cannot be reproduced or copied, in whole or part without the written permission of MREVA, Bangalore.
Released by:
Technical Hub Mahindra Reva
Electric Vehicle Pvt. Ltd.
Rev 1 - 2016
SAFETY, ROADSIDE ASSISTANCE &
MAN No: 00340
FIRST RESPONDERS MANUAL
Models applicable: e o City & Tech X
2
FOREWORD
This user manual explains on safety, road assistance and first responders operations with related
information including warnings, cautions that needs to be followed while providing support and
assistance to occupants.
This is an electric vehicle powered by battery pack. Improper and wrong operations / techniques /
procedures while providing support may cause serious personal injury or result in death.
Please read this manual carefully in advance for understanding the features of the vehicle and to provide
assistance in incidents involving this vehicle. Following recommended given procedures are the best
practices for helping in providing support with required informations.
1
2
2.0 IMPORTANT INFORMATION
Safety symbols
Please carefully read, understand & follow the safety symbols / instructions in this manual.
Legend of the symbols
You will see various safety symbols in this manual & are used in the below following ways. Obey all safety
messages with words DANGER, WARNING, CAUTION & NOTE having special meanings.
This indicates a hazardous situation which, if not avoided, will result in death or serious personal injury.
DANGER
Indicates the presence of a hazard situation that could cause death or serious personal injury.
All information, illustrations and specifications in this ‘Manual’ were in effect at the time of printing.
Mahindra Reva Electric Vehicles Ltd. in the course of product development reserves the right to discontinue
or change / modify information /specifications or design at any time without notice, without any liability &
obligation whatsoever.
WARNING
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION
Note indicates important information on vehicle’s use & maintenance to which particular attention should be
paid.
The symbol below indicates NO , Do Not do this or Never
Note
CAUTION
Caution without safety alert indicates a potentially hazardous situation which, if not avoided, may result in
property damage.
Copyright reserved 03 2016 REV -R0
! In case if you use any medical electric devices like implantable cardiac pace maker or cardio vascular
defibrillator, do check the electric medical device supplier / manufacturer on concerns of effects that
EV charging or discharging system on implanted such devices prior to their operation.
! It is also advised not to stay in the vehicle or access vehicle during charging as it may effect function
of electric medical devices and could result in personal injury or death.
! Also make sure that there is no foreign particles or water traces in charge plug or port as any of
these can result in electric short circuit or shock causing serious injury or death. Hence do not
touch metal contacts on the cable or plug.
! Ensure that power socket is switched off before accessing charge cable.
! Do not handle the charge cable or port with wet hands as it may cause electric shock resulting to
injury or death.
WARNING
1.0 Foreword.................................................................................
2.0 Important information............................................................
3.0 About Mahindra Reva Electric Vehicle....................................
4.0 Vehicle identification number.................................................
5.0 Vehicle specification...............................................................
6.0 High voltage components identification and location............
7.0 Emergency response steps.....................................................
8.0 Identifying of high voltage system status................................
9.0 Vehicle battery disconnect......................................................
10.0 Operational procedures..........................................................
11.0 Fuse box details......................................................................
12.0 Lubricant chart.......................................................................
13.0 Personal protective equipments and insulated tools.............
14.0 Accessing occupants and rescue............................................
15.0 Process for shutting down high voltage system......................
16.0 Handling damaged car at accident location............................
17.0 Airbag access, deployment and dismantling..........................
18.0 Road side assistance...............................................................
19.0 Changing flat tyre...................................................................
20.0 Caution note...........................................................................
01
02
05
06
06
07
09
10
12
13
14
14
15
16
18
19
20
22
24
26
3
CONTENTS
4
3.0 ABOUT MAHINDRA REVA ELECTRIC VEHICLE
5
This is an electric vehicle that is powered by high voltage battery pack. It has two type of battery used for
its operation. Car has 72V electric system with battery that powers drive system and other is a 12 volts
auxiliary battery that powers 12Volt accessories and other control units. The 72V battery pack is housed
in the battery compartment located beneath front seats of the vehicle.
Vehicle requires to be plugged in for charging battery pack once stored energy is discharged in drive. The
vehicle has a regenerative braking system that tops up battery pack when ever accelerator is released and /
or brake is applied while vehicle is in motion.
Vehicle Identification:
Interior:
Gear lever
Infotainment screen
Instrument panel cluster
Start / Stop button
Steering wheel with Logo
Hood release lever
electric
Logo
Logo
Model
Vehicle
Type
Exterior:
6
4.0 VEHICLE IDENTIFICATION NUMBER
LOCATION OF VEHICLE IDENTIFICATION NUMBER PLATE:
The VIN plate is located under the front hood. Open hood, and the cover to see vehicle identification plate is
riveted on chassis strut cross member and it is a 17 digit alpha numeric number.
eg. VIN number- 17 digits MB7D8RXBACJH00001
5.0 VEHICLE SPECIFICATION
General
2 door hatch-back
right hand drive
4 adults [driver(D)+3]
3278 mm
1575 mm
1570 mm
1958 mm
172 mm
942 Kgs.
1262 Kgs.
320Kgs
3850 mm
Rack & pinion
Welded tubular steel space
frame
Type
Seating capacity
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Kerb weight
Gross vehicle weight
Pay load
Turning radius
Steering gear box
Frame type
Tyre (front & rear)
Tyre pressure- (Laden):
driver(D), D+1 or D+2:
Tyres
165 / 60 R 14 / 79T, tubeless
Front: 32psi & rear: 38psi
Front & rear : 32psi
The RNFB mode selection lever provides reverse /
neutral / forward / boost modes of operation.
2 pedal operation (brake and accelerator)
4 operating modes (R,N,F,B)
Controls
VIN plate
VIN punch
7
6.0 HIGH VOLTAGE COMPONENTS IDENTIFICATION AND LOCATION
REAR TUB OVERVIEW:
Over view:
1. Fast charge port
2. Fast charge port contactor
3. Charger input - 220V AC
4. Charge port
5. Charge port harness
6. Charger
7. Charger - 72V output
8. Shunt
9. Traction control unit
10. Main contactor
11. Battery pack power cables
12. Battery power pack
13. Air conditioner motor
14. Air conditioner controller
15. Data port
16. Wake up relay
17. Auxiliary 12V battery
18. IEMS
19. Telematic unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Main
contactor
Motor
Controller
Charger
Fast charge
contactor
Data port
IEMS
8
Near rear hatch lock
On the rear bumper & next
to rear number plate
Rear tub
Electronics
Under the rear tub &
on the trailing arm
Below front
seats
Under Hood
Rear tub
Electronics
Rear tub
Electronics
Plug socket for charging vehicle battery
with 220V15A AC input.
Rear tub
Electronics
Rear tub
Electronics
Rear tub electronics
& near LH side trim seat
LOCATION
FUNCTIONAL DESCRIPTION
COMPONENT
Plug socket for Fast charging vehicle battery
with 200A DC input.
Contactor for Fast charging vehicle battery
with 200A DC input.
Charges vehicle battery with 72V O/P at 23A &
provides low voltage(12V)supply to accessories.
Converts 72V DC to 3-phase AC for propelling
vehicle.
Comes on at key authentification & powers
Motor controller.
Gets power from Controller and propels
vehicle through transmission and wheels.
Accepts & stores energy, provides energy for
vehicle drive & accessory system.
It is an integrated system which in turn coupled
with compressor for vehicle HVAC operation.
It provides power supply to many control
systems for monitoring & recording.
It monitors & manages the complete working
of the system and records data.
Idle mode Drive mode Regenerative mode
COMPONENTS LOCATION AND LAYOUT
1 2
3 4
5
6
7
8
Vehicle status on infotainment screen
1. Bus Bar
2. BMS & CB Board
3. Pack sense Harness
4
. Contactor HV Positive
5. Contactor HV Negative
6
. Pre charge Board
7 . Main Fuse
8 . Battery number 23
Battery compartment layout and
components location
For road accident incidents:
! Do a visual check for any leak from bottom side of the vehicle due to impact, refer battery handling
document.
! In the event of fire, follow procedures as this is an EV and should use AB type extinguisher for dozing
fire.
! In the event of rear collision, check extent of damage to on board regular / fast charging ports, check
vehicle system layout.
CAUTION
ACCIDENTS:
The vehicle 72V battery is of Li-ion type and has solvents as electrolyte. In the event of fire or any high
impact accident damaging battery / battery compartment, first responder is advised to check vehicle for
extent of damage, damages to 72V DC system. Then check the damage to battery and its compartment.
Battery electrolyte is colour less and has sweet odor, in the event of coming in contact may irritate skin and
eyes. Use excess water to rinse area of contact and see a doctor immediately. This is highly flammable and in
the event of any fire, ABC type fire extinguisher (Recommended for electrical hazards) to be used for
dozing it. Since battery modules are sealed and small in size, electrolyte will not leak in large quantity.
9
7.0 EMERGENCY RESPONSE STEPS
CAUTION
JUMP STARTING
Vehicle system has an 72volts battery pack
& auxiliary battery that powers the control
systems. Do not ‘jump start’ any battery in
the system & do not use vehicle battery to
jump start any other vehicles.
! The vehicle has sealed Li-ion battery pack. Improper handling of battery could lead to risk of severe burns and
electrical shock that may result in serious injury or death and also may cause damage to environment.
! As vehicle uses a 72 volts battery system, some of the systems could be hot before & after their usage. Hence
pay attention and follow warning labels located at places in vehicle.
! Never try to access, remove parts / cables / connectors which can cause shock or severe burns or result in
serious injury or death. 72 volts cables are colour coded in Orange and systems are not user serviceable.
For accident cases:
1. If vehicle is in drivable condition, move vehicle off the road, park and switch off drive system.
2. Check for any exposed 72 volts cables / parts. To do so check the picture indicating voltage layout of system.
Never touch any exposed 72 volts wiring and avoid any possible electric shock.
3. For any reason to tow the vehicle, do it with recovery vehicle support. In the event of not doing so, drive motor
may generate electricity, can cause damage to EV components and may result in fire.
4. If vehicle cannot be assessed for extent of damage, do not touch vehicle and contact nearest authorised service
center or customer care executive.
5. For any requirements of body repair due to accidents, vehicle should be delivered to authorised service center to
evaluate damage and take necessary precautions. Damaged Li-ion battery modules could pose safety risks to
untrained technicians & repair person.
WARNING
BATTERY PACK VOLTAGE
BATTERY CAPACITY
NUMBER OF MODULES
BATTERY DIMENSION
BATTERY PACK WEIGHT
210 Ah
72 Volts
215 X 135 X 220
23 (69 cells)
165 Kilograms
72V SAFETY MEASURES
The below safety measures are set with 72V system.
1. The 72V positive(+) and negative(-) are insulated from the vehicle chassis.
2. The 72V components are labelled and harnesses are orange colour coded for easy identification to isolate
/ help, protect occupants & emergency responders from any electric shock.
IDENTIFYING 72V SYSTEM IS ON:
1. If the key switch LED is illuminated green then 72V system is active.
2. If the charge indicator on cluster is blinking then 72V system and also 230V AC supply is active.
3. If the HVAC is operating then the 72V system is active.
8.0 IDENTIFYING HIGH VOLTAGE SYSTEM STATUS
OFF
START
STOP
(72V drive system active)
i) Drive or Idle:
3. WATER SUBMERSION:
In the event of ‘Water submersion’, to isolate the vehicle:
a) Power switch should be turned off, if possible & then remove the vehicle out of water.
b) Using appropriate PPE, drain water from vehicle.
c) Do not access any vehicle parts when vehicle is submerged in water.
10
2. FIRE HAZARD:
In the event of ‘Fire hazards’ to extinguish the fire use large amount of water possibly from hydrants.
Using less water may cause generation of toxic gasses from the chemical reaction of battery pack. In case
of vehicle fire, do contact ‘fire department’ for immediate support for extinguishing the fire. Shut down the
‘High voltage system’ by following the safety procedure. In the event of major damages to EV components,
use appropriate PPE’s for accessing the ‘High voltage components’.
The battery compartment, rear tub houses major electronic and electrical components. For any emergency
access, do check reference page to identify parts and observe high voltage symbol to take appropriate
precaution while working on the system.
If it is necessary to touch any of these high voltage systems, do wear appropriate personal protective
equipments to isolate and shut off the high voltage system. To avoid any shock / electrocution risk, never
touch with bare hands as the battery pack may maintain charge even when the high voltage system is
isolated. Insulate the high voltage damaged parts to prevent accidental access.
SSB BUTTON
ii) Charging:
72V charge system active
230V AC power supply system active
Fast charge port
If yes, turn off the switch, pull out the plug from the socket to cut off the 230 volts power supply. And then
pull out the charge cable from the vehicle.
iii) Drive or Charge or Idle:
Check if ‘Cooling’ or ‘Heating’ light on climate controls is ON / blinking . If so turn off by rotating the knob to
off position.
11
EVSE
CHARGE LIGHT
(Green)
EVSE
Close charge port lid
Climate controls (Heating & cooling)
AC COOLING / HEATER KNOB
OFF
1
2
3
4
If central door lock is working, to open doors, do operate
key fob buttons as below.
1. Press to lock
2. Press to unlock
3. Rear hatch release
4. Slide the button to release manual key for key fob
KEY FOB OPERATION
12
Unlock
(anti-clockwise)
VEHICLE DISCONNECT BUTTON
Battery disconnect:
In the event of any requirement, if first responder or user wants to deactivate the vehicle, same can be done by
pressing the ‘Battery Disconnect Button’ once after opening the data port cover by a screw driver. The vehicle
72V electric system gets disconnected immediately from battery system and low voltage lines get disconnected
within 2 minutes. To activate , press the button once again and to activate the car by press, hold wake up button
for 10 seconds.
Data port
In the event of requirement to disconnect the 72 volts battery system, below procedure has to be followed.
9.0 VEHICLE BATTERY DISCONNECT
Screw to open cover
A) Check if the vehicle door operations are working fine, lower the door window glasses using power
window switch & using key fob or button on climate control open the rear hatch.
B) Turn off the start stop button (SSB)- Check the status LED on the switch and if in ‘Green’ then press the
switch once to turn it off. Verify by checking the status LED on the switch if it has turned off.
C) Open the hood, remove close out cover and isolate the power to other switched 72V systems by removal
of ignition relay 1 & 2
Power
window switch
Hatch
release
Rear Hatch Release Button
Key fob
13
10.0 OPERATIONAL PROCEDURES
Identifying 72V system is on:
1. If key switch LED is illuminated green then 72V system is
active.
2. If charge indicator on cluster is blinking then 72V system and
also 230V AC supply is active.
3. If HVAC is operating then 72V system is active.
START
STOP
OFF
START
STOP
ON
Emergency exit:
To come out of car in emergency due to central door lock
failure / accident, use rear hatch glass release on tail light trim
panel by removing grommet and pulling release cable. Rear
hatch will open.
HOOD RELEASE LEVER
+
+
Fuse box
11.0 FUSE BOX DETAILS
Fluid leaks:
Check for leaks from battery and take appropriate measures to prevent personal injuries. Other fluids like wind
shield washer fluid, brake fluid & AC gas are same as in conventional cars that are to be dealt in same way.
14
RELAY CN 188
FR.FOG LAMP
RELAY CN 185
PARK LAMP
RELAY CN 186
REMOTE
BLOWER
RELAY CN 184
A/C HEATER
RELAY CN 182
HI BEAM
RELAY CN 187
CONDENSOR
RELAY CN 166
KEY RELAY
DRIVER
DUMMY
RELAY CN 183
LOW BEAM
RELAY CN 192
LATCH
RELAY CN 199
WIPER
(Hood open-
Wiper off)
RELAY CN 155
WASHER
MOTOR REAR
RELAY CN 169
IGNITION-2
RELAY CN 168
IGNITION-1
F1 F7
F8
F9
F10
F11
F12F6
F5
F4
F3
F2
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
Fuse box
F1 15A Head lamp low beam LH & RH
F2 3A Relay H/L low & high beam, position lamp
F3 20A Brake lamp, hazard, side indicator & HMSL
F4 5A Horn
F5 15A Front & rear wiper
F6 15A LH & RH door lock & rear hatch release
F7 15A Head lamp high beam LH & RH
F8 5A Position, roof, license lamps & back illumination
F9 5A Remote blower, A/C heater relay, cooling fan coil
F10 5A Rear washer motor
F11 10A Relay coil, BLDC condenser fan
F12 15A Blower fan & speed regulator module (SRM)
F13 30A Power window motor LH & RH
F14 20A Electric vacuum pump (EVP)
F15 15A Rear hatch defroster
F16 7.5A Front fog lamp-DRL
F17 3A Relay -key ON/OFF (ignition)
F18 3A OVRM, H/L adjuster LH & RH, switch
F19 3A Instrument cluster
F20 10A Infotainment system
F21 3A HVAC module(hatch & hazard) & IP cluster
F22 5A Anti-lock brake system (ABS)
F23 3A Air-bag
F24 3A Seat belt reminder (SBR)
F25 3A Ignition I/P to BCM & IEMS
F26 7.5A Aux 12V socket
F27 3A Ignition I/P to KSI SSR
F28 10A Tree switch- wiper & washer supply
F29 3A IGN I/P to HVAC, infotainment & OBD
F30 10A PRNDL, reverse lamp, camera & motor fan
Fuse no Rating (A) Circuit protected
Relay no Relay name
CN166 Key relay driver
CN168 Key relay 1
CN169 Key relay 2
CN182 Head light low beam
CN183 Head light high beam
CN184 Air condition-heater
CN185 Park lamp
CN186 Remote blower
CN187 Condenser fan
CN188 Front fog lamp
CN192 Latch
CN199 Wiper
Fuse box location
TYPE MATERIAL QUANTITY
A/C HFO- 1234YF (tetrafluropropane) 475±5grams
Brake fluid DOT-3 (Glycol Ether) 400 ML
Transmission oil Klubersynth GE475W90APIGL5 600 ML
12.0 LUBRICANTS CHART
15
13.0 PERSONAL PROTECTIVE EQUIPMENTS AND INSULATED TOOLS
Always while performing any inspection, wear appropriate personal protective equipments before accessing
and working on car. Do not use damaged equipments at all instances to prevent personal injury. Always inspect
personal protective equipments periodically for deterioration and damages before use.
INSULATED TOOLS:
Always while performing any inspection, check or accessing electrical components in car, do use appropriate
insulated tools and equipments. Usage of these will prevent shock, personal injury ensuring safety during working
on car.
Insulated gloves (1000V)
Mask
Head gear
Goggles
Safety shield
Safety shoes
UNLOCK
(anti-clockwise)
UNLOCK
14.0 ACCESSING OCCUPANTS AND RESCUE (Emergency response)
Hatch
release
Door unlock
DOOR LOCK:
TO UNLOCK MANUALLY:
To unlock the vehicle manually
in the event of central locking
inoperative, turn the key in anti-
clockwise direction respectively
as shown in the figure.
To unlock from inside, push door
lock lever backward as indicated
in the figure.
CENTRAL DOOR LOCK
TO UNLOCK :
To unlock using key fob, press the ‘Door unlock’ button once and both
the doors gets unlocked. In the event of not unlocking and central door
locking is inoperative, use general tools to open the doors and in
emergency cut open the doors at the hinges or at the door latch catcher.
II. Use the key fob to open the rear hatch by pressing the hatch release
button on the key fob once. The hatch gets released, if the key fob is not
working use the hatch release button on the climate control to release
the hatch.
DOOR LOCK
TO OPEN:
To open the doors, pull the door handle towards you to
unlock the door latch. And from inside use the door inner
handle to open by pulling it gently towards you as
indicated in the figure.
HAZARD WARNING:
Press the switch to activate the hazard warning lights.
All six external turn signal indicators will flash
simultaneously. To turn off the lights, press the switch
once again. This should be used to warn the traffic in the
event of any emergency.
1
2
3
PARKING BRAKE OPERATION
To Engage brake:
(1) Pull parking brake lever upwards.
To Disengage:
Press the button (2) on the lever and release the handle (3)
with a slight downward push while holding the release button
pressed. Make sure the handle has gone down fully for
complete release of parking brake prior to driving the vehicle.
The car has been equipped with
factory fitted central door
locking (CDL) system. Hence the
keys must be used to lock/
unlock the doors only when the
CDL system is not functional. It
is advisable to operate the
remote while the car is within
range.
Note
16
17
REAR SEAT LOCK LATCH
IN EMERGENCY:
1. Remove the window glass if not lowered.
2. Open the doors.
3. Adjust the front seats for easy access by sliding and reclining as shown below.
PRESS
I. TO ACCESS THE FRONT SEAT FROM REAR
For accessing & adjusting the front seating position in the event
of evacuation either the recliner lever or tab can be used. To
adjust pull them and seat will slide and recline forward, release
the lever for locking.
II. RECLINING THE REAR SEAT REST
To adjust and fold the rear back rest to access from rear hatch,
release the rear seat rest latch by pulling both side tabs upwards
simultaneously and pushing the rest forward.
III. SEAT BELT
The seat belts are supplement restraint systems and to
release / remove the seta belts press the catcher downwards
as shown in the figure. The seat belt gets disengaged to access
and if seat belt cannot be unfastened, cut the belt in the event
of any emergency.
Recliner lever
15.0 PROCESS FOR SHUTTING DOWN HIGH VOLTAGE SYSTEM
For shutting down the high voltage systems in the vehicle, first evaluate the extent of damage. Turning off
the key switch, isolate battery positive, insulating it will cuts off power supply to other components and
systems.
If the vehicle is damaged heavily, like battery pack damage / deformed, broken, use appropriate PPE’s
for battery handling.
Guidelines:
a) Always ensure to wear appropriate PPE’s during accessing the vehicle.
b) If the charge cable is connected to the vehicle, remove the same by refering the charge cable
disconnecting procedure (ii) in page .
c) Check for ‘key switch’ being ‘off’
d) Check for ‘HVAC’ if the remote air conditioning is operational and disable it.
Note: The remote air conditioning system is a feature that can be enabled by the user via telematics by
a ‘personal computer’ or ‘Mobile App’.
Flow chart for easy understanding & shutting down the vehicle high voltage supply.
Evaluate level of damage in the vehicle
Is vehicle have any
damage? (72V system
damaged / cuts / cracks)
Is the hood is operational
& Open the hood
Is vehicle rear tub can be
accessed & are insulated
tools / PPE’s available?
Is vehicle 72V system
is active?
Remove the key relays
from the fuse box.
Check fuse box layout
Open & access the rear tub
electronics and isolate 72 volts
system by disconnecting battery
positive and insulating it
Turn off the key switch.
Follow the procedure as
in the next page
In the event of not able to isolate the high voltage system, use appropriate
‘personal protective equipment’ and perform the rescue actions.
Yes
No
No
No
No
Yes
Yes
Yes
In the event of not able to do 1,2 & 3 then do the step 4
STEP 1
STEP 2
STEP 3
STEP 4
18
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