19/04/2024 09:20:41

Vehicle Electrical Isolation Procedure

Correction code 17010000 0.45 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 proper PPE is worn when performing the below procedure.

  • 2024-04-19: Updated the order of measuring the voltage at each terminal to ground first before measuring the voltage at both terminals.
  • 2023-06-22: Updated photos to show CAT III probes being used and corrected photo for HV harness connection.
  • 2023-05-02: Updated current measurement step sequence and consistency.
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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
  • 1146175-00-A, Current Clamp; Fluke 374 FC

Isolate

  1. Move the vehicle to a 2 post lift.
  2. Disconnect LV power. See LV Power (Disconnect and Connect).
  3. Set the high voltage multimeter to DC voltage, lightly touch the probes to the auxiliary battery connector contacts, and verify that the multimeter displays a voltage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery voltage is typically 14.5 to 15.5 volts. If the battery voltage is 0 volts, the battery may have switched off internally. Use a 12V lead acid battery for testing. Lead acid battery voltage is typically 10 to 14 volts.
  4. Raise the vehicle. See Raise Vehicle - 2 Post Lift.
  5. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  6. Power on the current clamp meter, and then zero out the meter for measurement.
  7. Install the current clamp meter onto one cable of the rear drive unit HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the meter is facing the correct direction as shown.
    Figure 1. Long Range
    Figure 2. Plaid - Rear Drive Unit LH HV Harness
  8. Measure the current in the HV cable.
    • If the current is within the range of -0.5 A to 0.5 A, continue to the next step.
    • If the current is outside the range of -0.5 A to 0.5 A, for example -0.8 A or 1.3 A, re-perform the LV power disconnect procedure. See LV Power (Disconnect and Connect). If the measurement is still outside the range of -0.5 A to 0.5 A, escalate for assistance.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      DO NOT DISCONNECT any HV harness when the current measurement is outside the range of -0.5 A to 0.5 A.
  9. Remove all items from pockets and make sure not to wear any metal items.
  10. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  11. Put on the HV insulating gloves and then leather over gloves.
  12. Slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit HV harness from the HV battery LH HV header.
  13. Use the high voltage multimeter with CAT III probes to verify that no high voltage is present at the HV battery LH HV header.
    Measure the following voltages:
    • B+ to ground
    • B- to ground
    • B+ to B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If any voltage is greater than 10V, the contactors are closed or welded. Escalate to Service Engineering.
  14. If the procedure that required vehicle electrical isolation does not need the rear drive unit HV harness disconnected from the HV battery, verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  15. Return to the procedure that required vehicle electrical isolation.

Integrate

  1. If removed, put on the HV insulating gloves and leather over gloves.
  2. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  3. Remove the leather glove protectors and the HV insulating gloves.
  4. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  5. Lower the vehicle. See Raise Vehicle - 2 Post Lift.
  6. Connect LV power. See LV Power (Disconnect and Connect).
  7. Remove the vehicle from the lift.