2024-06-05

母排，快充接触器至直流母线，负极 ((拆卸和更换))

校正代码 1630010062 FRT 1.56 注意：除非本程序中另有明确规定，否则上述校正代码和 FRT 反映的是执行本程序（包括关联程序）所需的所有工作。除非明确要求，否则请勿堆叠校正代码。 注意：请参阅平均维修工时，深入了解 FRT 及其创建方式。要提供有关 FRT 值的反馈，请发送电子邮件至ServiceManualFeedback@tesla.com。 注意：请参阅人员保护，确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。

表 1. 扭矩规格： 母排，快充接触器至直流母线，负极 ((拆卸和更换))
描述 扭矩值 推荐工具 重复使用/更换 备注
用于固定母排罩检修盖板的螺栓
9 Nm (6.6 lbs-ft)
  • 绝缘工具：
    • 棘轮/扭矩扳手 - 1057602-00-A
    • 10 毫米 12 角深套筒 - 1133768-00-C
    • 1/4 英寸钻头加长件，摆角 10.5"
  • 电工保护手套
  • 棘轮/扭矩扳手
 重复使用
将充电接口母排套件固定到高压接头的螺栓（2 个）
9 Nm (6.6 lbs-ft)
  • 绝缘工具：
    • 1/4 英寸钻头加长件，摆角 10.5"
    • 棘轮/扭矩扳手 - 1057602-00-A
    • 10 毫米 12 角深套筒 - 1133768-00-C
  • 电工保护手套
  • 棘轮/扭矩扳手
 重复使用
将快充母排直流链路侧负极固定到快充触点开关的螺纹胶螺栓
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
    • 13 毫米套筒
  • 油性记号笔
  • 带角度测量的扭矩扳手
 更换
将快充母排直流链路侧正极固定到快充触点开关的螺纹胶螺栓
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
    • 13 毫米套筒
  • 油性记号笔
  • 带角度测量的扭矩扳手
 更换
将快充母排输入侧负极固定到直流输入总成母排负极的螺纹胶螺栓
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
    • 13 毫米套筒
  • 电工保护手套
  • 油性记号笔
  • 带角度测量的扭矩扳手
 更换
将快充母排输入侧正极固定到直流输入总成母排正极的螺纹胶螺栓
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
    • 13 毫米套筒 - 1057606-00-A
  • 电工保护手套
  • 油性记号笔
  • 棘轮/扭矩扳手
  • 带角度测量的扭矩扳手
 更换
将直流输入母排总成固定到高压电池仓的螺栓（4 个）
10 Nm (7.4 lbs-ft)
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
  • 电工保护手套
  • 棘轮/扭矩扳手
  • 外梅花五角套筒 E10 - 1059330-00-B
  • 油性记号笔
  • 1/4 英寸至 3/8 英寸适配器
 更换
将快充总成固定到高压电池仓的螺栓（2 个）
5.5 Nm (4.1 lbs-ft)
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
    • 10 毫米套筒
  • 电工保护手套
  • 油性记号笔
 重复使用
将快充母排直流链路侧负极固定到快充触点开关的螺纹胶螺栓
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • 绝缘工具：
    • 4 英寸加长件
    • 棘轮/扭矩扳手
    • 13 毫米套筒
  • 油性记号笔
  • 带角度测量的扭矩扳手
 更换

拆卸

  1. Open all the doors and lower all the windows.
  2. Disconnect the LV power. See 低压电池 - 锂离子（断开和连接） (Modify).
  3. Remove the LH 2nd row seat cushion bracket. See 第二排座椅坐垫支架 ((拆卸和更换)).
  4. 执行车辆高压禁用程序。请参阅车辆电气绝缘程序 (Test/Adjust)。
  5. Remove the bolt that secures the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 棘轮/扭矩扳手 - 1057602-00-A
      • 10 毫米 12 角深套筒 - 1133768-00-C
      • 1/4 英寸钻头加长件，摆角 10.5"
    • 电工保护手套
    • 棘轮/扭矩扳手
  6. Remove bolts (x2) that secure the charge port busbar kit to the HV header.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 1/4 英寸钻头加长件，摆角 10.5"
      • 棘轮/扭矩扳手 - 1057602-00-A
      • 10 毫米 12 角深套筒 - 1133768-00-C
    • 电工保护手套
    • 棘轮/扭矩扳手
  7. Release the AC charge port inlet harness clip.
  8. 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.
  9. Position the charge port busbar connector on the cross-member in front of the ancillary bay for access.
  10. Remove the ancillary bay cover. See 高压电池仓盖总成 ((拆卸和更换)).
  11. Remove the pyrotechnic battery disconnect. See 电池烟火断开装置 ((拆卸和更换)).
  12. Remove the HV battery negative contactor. See 高压电池包接触器总成 ((拆卸和更换)).
  13. Press the tabs on both sides by hand, and lift the connector upwards to disconnect the LV fast charge contactor connector.
  14. Disconnect the PCS to AC harness connector.
    Informational PurposesAn informational icon, calling your attention
    注
    Pull the locking tab upward to release. Use a plastic trim tool to help lift the connector upward as necessary.
  15. Release the locking tab, and then disconnect the AC filter harness from the FC contactor cover.
  16. Release harness clips (x2) from the FC contactor cover, and then move the wiring harness aside around the FC contactor cover.
  17. Remove the LH Ancillary Bay terminal cover.
  18. Remove and discard the patch bolt that secures the DC link side negative fast charge busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 油性记号笔
    • 带角度测量的扭矩扳手
  19. Remove and discard the patch bolt that secures the DC link side positive fast charge busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 油性记号笔
    • 带角度测量的扭矩扳手
  20. Disconnect the megaharness connector from the DC input assembly.
  21. Remove the insulator for DC input assembly to both inlet side fast charge busbars.
  22. Remove and discard the patch bolt that secures the inlet side negative fast charge busbar and the negative DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 电工保护手套
    • 油性记号笔
    • 带角度测量的扭矩扳手
  23. Remove and discard the patch bolt that secures the inlet side positive fast charge busbar and the positive DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒 - 1057606-00-A
    • 电工保护手套
    • 油性记号笔
    • 棘轮/扭矩扳手
    • 带角度测量的扭矩扳手
  24. Remove and discard the bolts (x4) that secure the DC input busbar assembly to Ancillary Bay, and then remove the DC input busbar assembly from Ancillary Bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
    • 电工保护手套
    • 棘轮/扭矩扳手
    • 外梅花五角套筒 E10 - 1059330-00-B
    • 油性记号笔
    • 1/4 英寸至 3/8 英寸适配器
  25. Remove the bolts (x2) that secure the fast charge assembly to Ancillary Bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 10 毫米套筒
    • 电工保护手套
    • 油性记号笔
  26. Remove the fast charge assembly from Ancillary Bay.
  27. Remove and discard the fast charge insulator cover from the fast charge assembly.
    Informational PurposesAn informational icon, calling your attention
    注
    Pull the insulator cover upward to release it from the clips (x8) and alignment pin.
  28. Remove and discard the patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor, and then remove the DC link side negative fast charge busbar from the fast charge contactor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 油性记号笔
    • 带角度测量的扭矩扳手

安装

  1. Install a new patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    注
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 油性记号笔
    • 带角度测量的扭矩扳手
  2. Install new fast charge insulator cover to the fast charge assembly.
  3. Position the fast charge assembly to Ancillary Bay for installation.
  4. Install the bolts (x2) that secure the fast charge assembly to Ancillary Bay.
    5.5 Nm (4.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 10 毫米套筒
    • 电工保护手套
    • 油性记号笔
  5. Install the DC input busbar assembly to Ancillary Bay.
    Informational PurposesAn informational icon, calling your attention
    注
    Ensure the seal is not damaged and seated properly.
  6. Install new bolts (x4) that secure the DC input busbar assembly to Ancillary Bay.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    注
    Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
    • 电工保护手套
    • 棘轮/扭矩扳手
    • 外梅花五角套筒 E10 - 1059330-00-B
    • 油性记号笔
    • 1/4 英寸至 3/8 英寸适配器
  7. Install a new patch bolt that secures the inlet side negative fast charge busbar and the negative DC input assembly busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    注
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 电工保护手套
    • 油性记号笔
    • 带角度测量的扭矩扳手
  8. Install a new patch bolt that secures the inlet side positive fast charge busbar and the positive DC input assembly busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    注
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒 - 1057606-00-A
    • 电工保护手套
    • 油性记号笔
    • 棘轮/扭矩扳手
    • 带角度测量的扭矩扳手
  9. Perform a Hioki resistance test at both HV joints of the DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    注
    The resistance should be 60𝜇Ω or less. Test from the negative fast charge busbar to the negative DC input busbar, and from the positive fast charge busbar to the positive DC input busbar.
  10. Install the insulator for DC input assembly to both inlet side fast charge busbars.
  11. Connect the megaharness connector to the DC input assembly.
  12. Install a new patch bolt that secures the DC link side positive fast charge busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    注
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    注
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 油性记号笔
    • 带角度测量的扭矩扳手
  13. Perform a Hioki resistance test at the positive HV joint of the DC link side fast charge busbar.
    Informational PurposesAn informational icon, calling your attention
    注
    The resistance should be 25𝜇Ω or less.
  14. Install a new patch bolt that secures the DC link side negative fast charge busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    注
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    注
    推荐使用以下工具：
    • 绝缘工具：
      • 4 英寸加长件
      • 棘轮/扭矩扳手
      • 13 毫米套筒
    • 油性记号笔
    • 带角度测量的扭矩扳手
  15. Perform a Hioki resistance test at the negative HV joint of the DC link side fast charge busbar.
    Informational PurposesAn informational icon, calling your attention
    注
    The resistance should be 55𝜇Ω or less.
  16. Install the LH Ancillary Bay terminal cover.
  17. Install the harness clips (x2) to the FC contactor cover.
  18. Connect the LV fast charge connector.
  19. Secure the locking tab to install the AC filter harness to the FC contactor cover.
  20. Connect the PCS to AC harness connector.
    Informational PurposesAn informational icon, calling your attention
    注
    Push the connector downward, and then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  21. Install the HV battery negative contactor. See 高压电池包接触器总成 ((拆卸和更换)).
  22. Install the pyrotechnic battery disconnect. See 电池烟火断开装置 ((拆卸和更换)).
  23. Position the Ancillary Bay cover to HV battery for installation.
    Informational PurposesAn informational icon, calling your attention
    注
    Ensure all accessible insulators are present.
  24. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    注
    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.
  25. 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.
  26. Position the busbar kit connector and lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    注
    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.
  27. Install the AC charge port inlet harness clip.
  28. Install the bolts (x2) that secure the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    推荐使用以下工具：
    • 绝缘工具：
      • 1/4 英寸钻头加长件，摆角 10.5"
      • 棘轮/扭矩扳手 - 1057602-00-A
      • 10 毫米 12 角深套筒 - 1133768-00-C
    • 电工保护手套
    • 棘轮/扭矩扳手
  29. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    注
    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.
  30. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    推荐使用以下工具：
    • 绝缘工具：
      • 棘轮/扭矩扳手 - 1057602-00-A
      • 10 毫米 12 角深套筒 - 1133768-00-C
      • 1/4 英寸钻头加长件，摆角 10.5"
    • 电工保护手套
    • 棘轮/扭矩扳手
  31. Install the Ancillary Bay cover. See 高压电池仓盖总成 ((拆卸和更换)).
    Informational PurposesAn informational icon, calling your attention
    注
    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.
  32. Install the LH 2nd row seat cushion bracket. See 第二排座椅坐垫支架 ((拆卸和更换)).
  33. Connect the LV power. See 低压电池 - 锂离子（断开和连接） (Modify).
  34. Raise all the windows and close all the doors.