DTC Troubleshooting Master Document for BMS Version: 1.0 Date: 30th Nov 2022 Copyright © TATA MOTORS Ltd. This document must not be used in anyway, such as copying and redistributing to third parties, without the consent of author. INTRODUCTION The HV battery packs across all PV EV projects (Kanger 1.0 Gen3, Kanger 1.0 AIO, Kanger 2.0, Limber, Challenger LR & Challenger MR) have built-in Battery Management System (BMS) which communicates in real time with the powertrain e-VCU for ensuring safe and reliable operation of the powertrain system during vehicle operations like drive and charging. The BMS is located internal to the sealed battery pack and is only accessible through the LV connector that is present on the front face of the battery pack as referred in the pictures shown in Appendix-A . This female connector is coupled with the male connector coming from the vehicle LV harness. IMPORTANT INFORMATION Any internal repairs to the HV battery pack cannot be performed at the TML service station and any such activity may void the battery pack’s warranty. The only removable component from the battery pack assembly represented by 8060R group in PLM is during the SW troubleshooting is the HV Manual Service Disconnect (MSD) switch. HV MSD disconnection instructions are provided in the APPENDIX-B. But Challenger LR & Challenger MR battery packs don’t have HV MSD. Instead LV MSD which is located in vehicle bay area/ under hood area needs to be in open state before working on the battery packs of Challenger LR & Challenger MR. Under ideal and intended operating conditions for all the HV components, the battery pack is not supposed to show any DTCs during any of the vehicle operations. Powertrain e-VCU is already incorporated with safety locks the ensure that the battery pack operates within the intended limitations. The DTCs are likely to be triggered when the battery pack has been operated in scenarios that are not design-intended. The operation manual covers the conditions for intended usage, handling and storage of the battery pack. PURPOSE OF DOCUMENT The purpose of this document is to serve as a detailed guide for servicing of HV battery pack for all TML PV EV projects (Kanger 1.0 Gen3, Kanger 1.0 AIO, Kanger 2.0, Limber, Challenger LR & Challenger MR) for reaching conclusions of diagnostics and troubleshooting in case the vehicle inwarded for servicing has battery faults.
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