17/10/2023 18:57:15

HV Harnesses - HVCON, PLG, 2P, 600V, HVIL (Remove and Replace)

Correction code 4450010062 FRT 0.90 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-A Insulation Multimeter, Fluke 1587
  • 1130480-02-A Slim Test Probes
  • 1617321-00-A Busbar HV Connector Clamp
  • 1076927-00-A Hioki RM 3548
  • 1076928-00-A Test Probes - Hioki 9461
Warning IconA warning icon, calling your attention to a possibly risky situation
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 safety information.

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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.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper Personal Protective Equipment (PPE) is required to perform this procedure:

  • High Voltage (HV) insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

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Warning
Make sure that the HV gloves are not expired.
  • North America: HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12 month period. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: Class 0 (1000V) HV gloves have no expiration date and may be used if they pass the pre-use assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.

Torque Specifications

Table 1. Torque Specifications: HV Harnesses - HVCON, PLG, 2P, 600V, HVIL (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Screws (x2) that attach the HV busbar leads to the HV connector
4 Nm (2.9 lbs-ft)
  • Torx T20 socket
  • 4 in extension
  • Ratchet/torque wrench
 Reuse

Remove

  1. Remove the charge port to HV battery busbars. See HV Harnesses - High Voltage Busbar, 1P, CP (Remove and Replace).
  2. Remove the screws (x2) that attach the HV busbar leads to the HV connector.
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 4 in extension
    • Ratchet/torque wrench
  3. Release the clips (x2) that attach the HV busbar leads to the HV connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
  4. Remove the HV busbar connector plug from the HV Busbar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the HV connector straight away from the busbars. The busbar leads will not separate from the connector if pulled at an angle.
  5. Remove the HV busbar connector sealing retainers (x2) and clips from the HV Busbar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The new HV busbar connector includes sealing retainers and clips.

Install

  1. Install the HV busbar connector plug onto the HV busbar leads. The connector is fully seated when the busbar lead screw holes are aligned with the connector housing screw holes.
  2. Install the screws (x2) that attach the HV busbar leads to the HV connector.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 socket
    • 4 in extension
    • Ratchet/torque wrench
  3. Install the charge port to HV battery busbars. See HV Harnesses - High Voltage Busbar, 1P, CP (Remove and Replace).