02/12/2024 10:04:54

Vehicle HV Disablement Procedure

Correction code 17010000 FRT 0.36 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.

  • 2024-06-05: Added warning to measure the specified order of locations for high voltage.
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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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Warning
This procedure verifies that high voltage power is no longer available to high voltage components (A/C compressor, inverters, etc). Perform this procedure before servicing high voltage components.
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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning
Always wear High Voltage (HV) gloves and safety glasses when handling any high voltage component, including test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired.
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Warning
All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment.
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Warning
Assume that high voltage is present at all times when working on a Tesla vehicle, associated high voltage components, or associated high voltage test equipment until proven otherwise. Be aware that energy states can change during testing, so err on the side of caution.
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Warning
Always have an electrical safety hook in the area when working with HV components. Electrical safety hooks are used to remove an injured person from a live high voltage circuit without risking additional injury.
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Warning
Use a high voltage digital multimeter to check for the presence of high voltage on both sides of the connector every time a high voltage connector is disconnected.
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Warning
Make sure that the insulation meter and leads are capable of handling at least 500V DC.
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Warning
Obey all instructions when using test equipment or servicing a Tesla vehicle or associated high voltage components. If repair instructions are not clear or if there are any questions about how to use the test equipment, escalate a Toolbox session before proceeding.
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Warning
If any test equipment fails to operate as expected, do not attempt to diagnose or repair the vehicle. Follow the appropriate lock out – tag out procedure for the equipment, notify your manager.
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Warning
When using test equipment, make sure that all cables are connected before turning equipment on or otherwise initiating use.
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Warning
High voltage is present on battery recovery chargers whenever the HV LEDs are lit. However, indicators and LEDs can fail. Do not assume that if an LED is not lit no high voltage is present. Assume high voltage is present at all times until proven otherwise by use of a multimeter.
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Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.

  • 1076921-00-B, Insulation Multimeter, Fluke 1507
  • 1130480-00-A, Test Probes, Slim, Fluke TP38

Isolate

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  3. Disconnect MV power. See Disconnect MV Power.
  4. Verify the operation of the multimeter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage. Confirm multimeter is properly measuring voltage by testing MV battery. Touch lightly and do not damage terminals.
  5. Remove the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
  6. Remove all items from pockets and ensure not wearing metal items.
  7. Inspect HV insulating gloves.
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    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  8. Put on HV insulating gloves and leather over gloves.
  9. Verify no HV - Install amp clamp to the RDU HV harness. If this amp clamp test passes, proceed to the next step.
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    Note
    Verify meter is zeroed out before performing measurement.
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    Note
    Measure single cable.
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    Note
    Verify ammeter is installed in correct direction.
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    Note
    If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as required.
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    Note
    If current < 0.5A, OK to disconnect and check voltage at HV plug on the battery side.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component.
  10. Release locking tab and rotate the release lever up to disengage the connector. Release the harness clip. Do not force the release lever up. Remove the harness from the HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component.
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    Note
    Make sure the alignment tabs on the RDU header are not damaged.
  11. Use the insulation multimeter to measure for HV according to the sequence of locations specified below.
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    Warning
    If voltage is greater than 10V, pack contactors are not open or welded. Stop work and reach out to Service Engineering
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    In order to limit potential exposure to high voltage, measure for high voltage in the order specified below.
    1. B+ to ground
    2. B- to ground
    3. B+ to B-
    Figure 1. B+ to Ground
    Figure 2. B- to Ground
    Figure 3. B+ to B-

Integrate

  1. Secure the RDU header electrical connector to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the lever is in the upright and in the open position. Carefully seat the connector and allow lever to engage. Fully secure the lever and verify red tab is locked.
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    CAUTION
    Do not damage any pins.
  2. Remove leather over gloves and HV insulating gloves.
  3. Install the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
  4. Reconnect MV power. See Disconnect MV Power.
  5. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  6. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.