Correction code NA NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

1. Remove all items from pockets and ensure not wearing metal items

   

2. Inspect the leads, probes, and insulation on all multimeter and insulation meter wires for damage

   

3. Ensure entire work area is clear
   Note

   Including above and below battery

   

4. Place HV Danger placard on top of battery

   

5. Place barricades around work area
   Note

   Note location of extinguishers and HV rescue hook

   

6. Inspect HV battery for dents, fluid leaks, or other signs of instability
   Note

   If found, refer to Toolbox Article 7396600

   

7. Disconnect pressurized pack lines
   Note

   2x VOSS fittings, 12mm, 8Nm

   

8. Inspect HV insulating gloves
   Note

   Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf

   

9. Put on HV insulating gloves and leather over gloves
   Note

   Make sure to wear Electrical Protective Gloves any time Hioki tester is used

   

10. Remove Pyro Fuse Access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm

    

11. Remove primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

12. Remove secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

13. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

14. Release low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

15. Release fasteners securing ancillary cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

16. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

17. Remove High Side pack contactor terminal bolt
    Note

    1x bolt, Torx Plus 55, 5Nm + 60 Degrees, Captured bolt with insulated cover, Pull upwards firmly to release from device cluster housing

    

    

18. Install contactor terminal adapter to High Side contactor terminal
    Note

    Hand tight only

    

    

19. Install Contactor Bypass adapter positive lead to High Side pack contactor terminal
    Note

    1x bolt, Torx Plus 55, Hand tight only, Red lead is positive

    

    

20. Install Contactor Bypass adapter negative lead to High Side pack shunt terminal
    Note

    1x bolt, 13mm, 5 Nm + 60 degrees

    

    

21. Inspect the HV battery discharger tool HV cables and adapters for any damage

    

22. Connect the power cable to the HV battery discharger and an electrical outlet

    

23. Turn on the HV battery discharger

    

24. Ensure the emergency stop button is pushed in

    

25. Connect the DC cable to the HV battery discharger

    

26. Connect the other end of the DC cable to the Contactor bypass adapter

    

27. Pull out the emergency stop button

    

28. Set the mode
    Note

    Rotate the mode switch to MODE, Rotate the data entry knob until "CAN: Smt" and "Contactors: Bypassed" is shown

    

29. Set the limits
    Note

    Rotate the mode switch to LIMITS, Rotate the data entry knob to select the proper battery type (kWh rating) and desired discharge limit (shippingmethod), The “LAND” setting is applicable for discharging the majority of HV batteries, HV batteries are rarely shipped by air. Use the “AIR” option when discharging a HV battery with physical damage, or when isolation is lower than nominal

    

    

30. Rotate the MODE switch to the RUN position

    

31. Press the START/STOP button and follow the instructions on the display
    Note

    After each hour of operation, the HV battery discharger prompts the operator to press the START/STOP button again, so as to enforce proper monitoring of the discharge process, If the START/STOP button is not pressed within 5 minutes, the HV battery discharger stops the discharge cycle, To stop the discharge process early, press the START/STOP button again, The discharger will automatically shut down when the previously selected SOC is reached and display one of the following messages: Min Pack V Met, SOC Voltage Met, SOC Level Met, Min Cell V Met

    

32. Remove HV insulating gloves

    

33. Discharge Complete
    Note

    The discharger will automatically shut down when the previously selected SOC is reached and display the following message:SOC Voltage Met.
34. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves

    

35. Put on HV insulating gloves and leather over gloves
    Note

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

36. Ensure the emergency stop button is pushed in

    

37. Disconnect the DC cable from the HV battery discharger

    

38. Disconnect the DC cable from the Contactor bypass adapter

    

39. Disconnect the low voltage harness from the socket on the front of the HV battery discharger

    

40. Turn off the HV battery discharger

    

41. Remove the power cable from the HV battery discharger and electrical outlet

    

42. Remove Contactor Bypass adapter positive lead from High Side pack contactor terminal
    Note

    1x bolt, Torx Plus 55, 5Nm + 60 Degrees, Captured bolt with insulated cover, Red lead is positive

    

    

43. Remove Contactor Bypass adapter negative lead from High Side pack shunt terminal
    Note

    1x bolt, 13mm, 5 Nm + 60 degrees, Black lead is negative

    

    

44. Remove contactor terminal adapter from High Side pack contactor terminal
    Note

    Thread out by hand

    

    

45. Install High Side pack contactor terminal bolt
    Note

    1x bolt, Torx Plus 55, 5Nm + 60 Degrees, Captured bolt with insulated cover, Push downwards firmly to secure in device cluster housing

    

    

46. Remove Low Side pack contactor terminal bolt
    Note

    1x bolt, Torx Plus 55, 5Nm + 60 Degrees, Captured bolt with insulated cover, Score edge with insulated knife then break off corner to allow captured bolt to be removed

    

    

    

47. Install contactor terminal adapter to Low Side contactor terminal
    Note

    Hand tight only

    

    

48. Install Contactor Bypass adapter negative lead to Low Side pack contactor terminal
    Note

    1x bolt, Torx Plus 55, Hand tight only, Black lead is negative

    

    

49. Install Contactor Bypass adapter positive lead to Low Side pack shunt terminal
    Note

    1x bolt, 13mm, 5 Nm + 60 degrees, Red lead is positive

    

    

50. Inspect the HV battery discharger tool HV cables and adapters for any damage

    

51. Connect the power cable to the HV battery discharger and an electrical outlet

    

52. Turn on the HV battery discharger

    

53. Ensure the emergency stop button is pushed in

    

54. Connect the DC cable to the HV battery discharger

    

55. Connect the other end of the DC cable to the Contactor bypass adapter

    

56. Pull out the emergency stop button

    

57. Set the mode
    Note

    Rotate the mode switch to MODE, Rotate the data entry knob until "CAN: Smt" and "Contactors: Bypassed" is shown

    

58. Set the limits
    Note

    Rotate the mode switch to LIMITS, Rotate the data entry knob to select the proper battery type (kWh rating) and desired discharge limit (shippingmethod), The “LAND” setting is applicable for discharging the majority of HV batteries, HV batteries are rarely shipped by air. Use the “AIR” option when discharging a HV battery with physical damage, or when isolation is lower than nominal

    

    

59. Rotate the MODE switch to the RUN position

    

60. Press the START/STOP button and follow the instructions on the display
    Note

    After each hour of operation, the HV battery discharger prompts the operator to press the START/STOP button again, so as to enforce proper monitoring of the discharge process, If the START/STOP button is not pressed within 5 minutes, the HV battery discharger stops the discharge cycle, To stop the discharge process early, press the START/STOP button again, The discharger will automatically shut down when the previously selected SOC is reached and display one of the following messages: Min Pack V Met, SOC Voltage Met, SOC Level Met, Min Cell V Met

    

61. Remove HV insulating gloves

    

62. Low Side Discharge Complete
    Note

    The discharger will automatically shut down when the previously selected SOC is reached and display the following message:SOC Voltage Met.
63. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf

    

64. Put on HV insulating gloves and leather over gloves
    Note

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

65. Ensure the emergency stop button is pushed in

    

66. Disconnect the DC cable from the HV battery discharger

    

67. Disconnect the DC cable from the Contactor bypass adapter

    

68. Disconnect the low voltage harness from the socket on the front of the HV battery discharger

    

69. Turn off the HV battery discharger

    

70. Remove the power cable from the HV battery discharger and electrical outlet

    

71. Remove Contactor Bypass adapter negative lead from Low Side pack contactor terminal
    Note

    1x bolt, Torx Plus 55, 5Nm + 60 Degrees, Captured bolt with insulated cover, Black lead is negative

    

    

72. Remove Contactor Bypass adapter positive lead from Low Side pack shunt terminal
    Note

    1x bolt, 13mm, 5 Nm + 60 degrees, Red lead is positive

    

    

73. Remove contactor terminal adapter from Low Side pack contactor terminal
    Note

    Thread out by hand

    

    

74. Install Low Side pack contactor terminal bolt
    Note

    1x bolt, Torx Plus 55, 5Nm + 60 Degrees, Captured bolt with insulated cover

    

    

75. Clean inside the ancillary bay with an ESD-safe vacuum

    

76. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

77. Secure fasteners of cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

78. Secure low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

79. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

80. Install secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts

    

    

81. Install primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts

    

    

82. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
    Note

    4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

    

    

    

83. Install Pyro Fuse Access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged

    

    

84. Remove HV insulating gloves

    

85. Install pressurized pack lines
    Note

    2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings if installing new fuse cover, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

    

    

86. Remove the HV Danger placard from the top of the battery

    

87. Remove barriers from around battery