Mahindra Tech X Quick Reference 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

07

09

10

12

13

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

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

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

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