2026-10-23

Busbar - Fast Charge Contactor to DC Bus - Positive (Remove and Replace)

교정 코드 1630010072 FRT 1.44 메모: 절차에서 명시적으로 언급하지 않는 한 교정 코드 및 해당 관련 FRT는 연결된 절차를 포함하여 이 절차를 수행하는 데 필요한 모든 작업을 반영합니다. 명시적으로 지시하지 않는 한 교정 코드를 누적하지 마십시오. 참고: FRT와 그 생성 방법에 대한 자세한 내용은 표준 정비 작업시간의 내용을 참조하십시오. 참고: 아래 절차를 수행할 때 개인 보호의 내용을 참조하여 적절한 PPE를 착용했는지 확인하십시오. 참고: 안전하고 건강한 작업 사례는 인체공학적 주의 사항의 내용을 참조하십시오.

경고
모든 필수 인증 교육을 완료한 기술자만 이 절차를 수행할 수 있습니다. Tesla는 타사 서비스 제공업체 기술자가 이 절차를 수행하기 전에 동등한 교육을 받을 것을 권장합니다. Tesla 기술자 요구 사항에 대한 자세한 내용이나 타사 기술자에 대한 분야별 설명은 HV Certification Requirements를 참조하십시오. 고전압 케이블, 버스바 또는 피팅을 다룰 때에는 항상 적합한 개인 보호 장비(PPE)와 클래스 0(1000V)의 최소 정격을 갖는 절연 HV 장갑을 착용해야 합니다. 추가 안전 정보는 기술 노트 TN-15-92-003고압 인식 주의 사항을 참조하십시오.
  • 2026-10-09: Updated the torque data for the bolt that attaches the positive fast charge busbar to the fast charge contactor and added additional Hioki impedance tests.
  • 2026-08-12: Reorganized the procedure per the latest validation.

토크 규격

표 1. 토크 규격: Busbar - Fast Charge Contactor to DC Bus - Positive (Remove and Replace)
설명 토크 값 권장 공구 재사용/교체 참고
버스바 커버 접근 도어를 고정하는 볼트
9 Nm (6.6 lbs-ft)
  • 10mm 12 포인트 딥소켓
 재사용
충전 포트 버스바 키트를 HV 헤더에 고정하는 볼트
9 Nm (6.6 lbs-ft)
  • 10mm 12 포인트 딥소켓
 재사용
음극 및 양극 급속 충전 버스바 DC 링크측을 고정하는 패치 볼트
  • 볼트를 다음 토크로 조입니다.
    10 Nm (7.4 lbs-ft)
  • 볼트를 180° 돌려서 풀어줍니다.
  • 볼트를 다음 토크로 다시 조입니다.
    10 Nm (7.4 lbs-ft)
  • 13mm 소켓
  • 각도 측정 토크 렌치
 교체 1104475-00-F
양극 급속 충전 버스바를 급속 충전 컨택터에 고정하는 패치 볼트
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 13mm 소켓
  • 각도 측정 토크 렌치
 교체 1084662-00-C
급속 충전 어셈블리를 보조 베이에 고정하는 볼트
5.5 Nm (4.1 lbs-ft)
  • 10mm 소켓
 재사용
음극 급속 충전 버스바를 급속 충전 컨택터에 고정하는 패치 볼트
15 Nm (11.1 lbs-ft) - 180 degrees
  • 13mm 소켓
  • 각도 측정 토크 렌치
 교체

탈거

  1. Open all doors and lower all windows.
  2. Move both front seats forward.
  3. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  4. Remove the 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  5. Verify the operation of the multimeter.
    참고
    Set the multimeter to DC voltage. Confirm the multimeter is properly measuring voltage by testing the 16v battery.
  6. 차량 HV 비활성화 절차를 수행합니다. 참조 항목: Vehicle HV Disablement Procedure (Test/Adjust).
  7. Remove the bolt that attaches the busbar cover access door.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 10mm 12 포인트 딥소켓
  8. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 10mm 12 포인트 딥소켓
  9. Remove the A/C charge port inlet harness clip.
  10. Lift the busbar kit connector and shift the rear end of the busbar assembly upward to remove the aluminum connector housing from the HV header.
  11. Position the charge port busbar connector on the cross-member in front of the ancillary bay for access.
  12. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
  13. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  14. Install the pyrotechnic disconnect dummy.
  15. Remove the ancillary bay harness clip around the negative pack contactor area.
  16. Press the tabs on both sides by hand, and lift the connector upwards to disconnect the LV fast charge contactor connector.
  17. Disconnect the connector that attaches the power conversion system to the A/C harness.
    참고
    Release the locking tab by pulling upward. Use plastic trim tool to help lift the connector upward as needed.
  18. Release the locking tab to remove the A/C filter harness from the fast charge contactor cover.
  19. Remove the harness clips (x2) from the fast charge contactor cover.
    참고
    Move the wiring harness around the fast charge cover aside.
  20. Remove the ancillary bay left terminals cover.
  21. Remove and discard the patch bolts (x2) that attach the negative and the positive fast charge busbar DC link sides.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 13mm 소켓
    • 각도 측정 토크 렌치
  22. Remove Busbar DC input assembly from ancillary bay. See Header - Busbar DC Input (Remove and Replace).
  23. Remove the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 10mm 소켓
  24. Remove the guide pins (x2) to remove the fast charge assembly from the ancillary bay.
  25. Release the clips (x8) and the alignment pin to remove and discard the fast charge insulator cover from the fast charge assembly.
  26. Remove and discard the patch bolt that attach the positive fast charge busbar to the fast charge contactor, and then remove and discard the positive fast charge busbar.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 13mm 소켓
    • 각도 측정 토크 렌치

장착

  1. Install and torque a new patch bolt that attaches the positive fast charge busbar to the fast charge contactor to the first value, then loosen the bolt by 180 degrees, and then torque to the final value.
    • 볼트를 다음 토크로 조입니다.
      10 Nm (7.4 lbs-ft)
    • 볼트를 180° 돌려서 풀어줍니다.
    • 볼트를 다음 토크로 다시 조입니다.
      10 Nm (7.4 lbs-ft)
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 13mm 소켓
    • 각도 측정 토크 렌치
  2. Perform a Hioki impedance test at the positive HV joints of the fast charge contactor on the DC link busbar and inlet busbar.
    참고
    Perform a zero adjust to the Hioki meter prior to testing. See 저항계(영점 조정)
    • If the resistance is greater than 0.040 mΩ (40 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean the areas with isopropyl alcohol, install the fastener back and test again.
  3. Install the clips (x8) and the alignment pin to install the new fast charge insulator cover to the fast charge assembly.
  4. Position the fast charge assembly to the ancillary bay, and then secure the guide pins (x2).
  5. Install the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    5.5 Nm (4.1 lbs-ft)
    참고
    Mark after torque.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 10mm 소켓
  6. Install Busbar DC input assembly to ancillary bay and perform the Hioki resistance test. See Header - Busbar DC Input (Remove and Replace).
  7. Install new patch bolts (x2) that attach the negative and the positive fast charge busbar DC link sides to the first value, then loosen 180 degrees, and then torque to the final value.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    참고
    Mark after torque.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 13mm 소켓
    • 각도 측정 토크 렌치
  8. Perform Hioki impedance test at the positive and the negative HV joints of the fast charge busbar DC link side.
    참고
    The resistance at the positive and negative HV joint should be 60 𝜇Ω or less.
  9. Install the insulator for the DC input assembly.
    참고
    2x tabs, 1x datum
  10. Connect the megaharness connector to the DC input assembly.
  11. Install the bolts that attach the positie and negative fast charge busbars at the DC link side.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Torque each bolt to the first value, then loosen it by 180 degrees, then torque the bolt to the final value.

    Positive busbar

    Negative busbar

  12. Perform a Hioki test at the positive HV joint of the fast charge busbar at the DC link side.
    참고
    The resistance at the positive HV joint at the DC link side should be 25 𝜇Ω or less.
  13. Perform a Hioki test at the negative HV joint of the fast charge busbar at the DC link side.
    참고
    The resistance at the negative HV joint at the DC link side should be 40 𝜇Ω or less.
  14. Install the ancillary bay left terminals cover.
  15. Install the harness clips (x2) to the fast charge contactor cover.
  16. Connect the LV fast charge connector.
  17. Attach the locking tab to install the AC filter harness to the fast charge contactor cover.
  18. Connect the connector that attaches the power conversion system to the A/C harness.
    참고
    Push the connector downward, and then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  19. Install the ancillary bay harness clip around the negative pack contactor area.
  20. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
    참고
    Stop this step after inspecting the ancillary bay walls and cover seal for damage.
  21. Position the ancillary bay cover to the HV battery.
    참고
    Ensure all accessible insulators are present.
  22. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox.
    참고
    Allow 1 minute dry time for each surface. The new busbar comes with the penetrox applied to the HV connector. It is necessary to clean the HV connector during the re-use of the busbar.
  23. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads on the HV connector joints, and then spread the liquid evenly until the contact surface is fully covered.
  24. Position the busbar kit connector and lower it onto the HV header.
    참고
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat the busbar, they may have been bent. Inspect for damage and replace if necessary.
  25. Install the A/C charge port inlet harness clip.
  26. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    참고
    On 3-phase vehicles, also connect the AC charging interface connector.
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 10mm 12 포인트 딥소켓

    AC Charging Interface Connector

  27. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    참고
    The 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), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    • 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 the next step.
  28. Install the bolt that attaches the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    팁
    다음 공구를 사용하는 것이 좋습니다.
    • 10mm 12 포인트 딥소켓
  29. Install the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
    참고
    Before installing the ancillary bay cover, inspect the ancillary bay cover seal and confirm there is no visual damage. If the seal is torn and/or delaminated, replace the ancillary bay cover.
  30. Install the 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  31. Connect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  32. Move the front seats back to their original position.
  33. Raise all windows and close the doors.