HV Battery Contactor Seize Check
Correction code 16309000 0.84 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.
- 1076921-00-B Insulation Multimeter Fluke 1507 FC
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 safety
information.
Make sure that the insulation multimeter and leads are capable of handling at least 500V DC.
Procedure
- Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
-
Set the insulation
multimeter to measure resistance, and touch the probe tips together.
CAUTIONIf the multimeter displays greater than 0.2 ohms, the leads are defective and must be replaced. Do not use defective leads.
-
Consider your next
step:
- If the positive contactor is suspect to have seized, go to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-E657854C-4EDC-40D2-A845-AF83BEEEA6F8.
- If the negative contactor is suspect to have seized, go to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-EAE2A1A9-9888-4D6E-B602-605DF1FB0922.
- If both contactors are suspect, or there is uncertainty, start with step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-E657854C-4EDC-40D2-A845-AF83BEEEA6F8.
-
Inspect the center of the
insulator caps on top of the HV battery positive contactor terminals:
- If the insulator caps have a probing hole, continue to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-90CABBBA-CCDD-42E1-9EE7-2D4EA06876C1.
- If the insulator caps are solid, remove the insulator caps and continue to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-90CABBBA-CCDD-42E1-9EE7-2D4EA06876C1.
-
Set the multimeter to
measure the DC voltage across both terminals of the HV battery positive
contactor, either through the probing hole of the insulator caps or directly
onto the terminals:
- If the measured voltage is outside the range of -0.1V to 0.1V, then the HV battery positive contactor is not seized. Continue to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-814511C9-2B47-496F-866E-CEBF31AAB454.
- If the measured
voltage is between -0.1V and 0.1V, set the multimeter to measure
resistance and measure the resistance across the HV battery positive
contactor terminals:
- If the measured resistance is greater than 1M Ohm (1000K Ohm), then the HV battery positive contactor is not seized. Proceed to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-814511C9-2B47-496F-866E-CEBF31AAB454.
- If the measured resistance is lower than 1M Ohm, then the HV battery positive contactor might be seized. Discontinue this procedure and replace the HV battery positive contactor. See HV Pack Contactor (Remove and Replace), and then retest.
-
Set the multimeter to
measure resistance, and then perform the following measurements:
Resistance Test
Battery Negative
(LH terminal of HV battery negative contactor)
B-
(RH probe opening)
GND
Measured Resistance More Than 1 M Ohm
Measured Resistance Less Than 1 M Ohm
Battery negative to chassis
Positive (+) lead
Negative (-) lead
Pass
Fail
Resistance is lower than expected in the battery pack itself. Escalate a Toolbox session.
B- to chassis
Positive (+) lead
Negative (-) lead
Pass
Fail
Resistance is lower than expected in the HV battery negative contactor or ancillary bay. Replace the HV battery negative contactor. See HV Pack Contactor (Remove and Replace), and then retest.
- Reinstall the HV battery positive contactor insulator caps, if they were removed earlier.
- If the HV battery negative contactor is also suspect to have seized, or there is uncertainty, go to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-EAE2A1A9-9888-4D6E-B602-605DF1FB0922. Otherwise, return to the Vehicle HV Disablement Procedure.
-
Inspect the center of the
insulator caps on top of the HV battery negative contactor terminals:
- If the insulator caps have a probing hole at the center, continue to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-6EEBF42E-A70E-4201-8A64-308D09DE5AFC.
- If the insulator caps are solid, remove the insulator caps and continue to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-6EEBF42E-A70E-4201-8A64-308D09DE5AFC.
-
Set the multimeter to
measure the DC voltage across both terminals of the HV battery negative
contactor, either through the probing hole of the insulator caps or directly
onto the terminals:
- If the measured voltage is outside the range of -0.1V to 0.1V, then the HV battery negative contactor is not seized. Continue to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-9BC494B9-B7DB-4F32-B44B-504039BA83DB.
- If the measured
voltage is between -0.1V and 0.1V, set the multimeter to measure
resistance and measure the resistance across the HV battery negative
contactor terminals:
- If the measured resistance is greater than 1M Ohm (1000K Ohm), then the HV battery negative contactor is not seized. Proceed to step #GUID-87FD8D3D-05FF-471F-B2AC-EC4D65ED3E08__GUID-9BC494B9-B7DB-4F32-B44B-504039BA83DB.
- If the measured resistance is lower than 1M Ohm, then the HV battery negative contactor might be seized. Discontinue this procedure and replace the HV battery negative contactor. See HV Pack Contactor (Remove and Replace), and then retest.
-
Set the multimeter to
measure resistance, and then perform the following measurements:
Resistance Test
Battery Negative
(LH terminal of HV battery negative contactor)
B-
(RH probe opening)
GND
Measured Resistance More Than 1 M Ohm
Measured Resistance Less Than 1 M Ohm
Battery negative to chassis
Positive (+) lead
Negative (-) lead
Pass
Fail
Resistance is lower than expected in the battery pack itself. Escalate a Toolbox session.
B- to chassis
Positive (+) lead
Negative (-) lead
Pass
Fail
Resistance is lower than expected in the HV battery negative contactor or ancillary bay. Replace the HV battery negative contactor. See HV Pack Contactor (Remove and Replace), and then retest.
- Reinstall the HV battery negative contactor insulator caps, if they were removed earlier.
- Return to the Vehicle HV Disablement Procedure.