31/05/2024 10:37:35

Cover - Pyrotechnic Fuse - HV Battery 2.0 (Inspect)

FRT No. 16100600

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Warning
Only technicians who have been certified to remove HV battery switches and fuses and have completed all required certification courses (if applicable) or, in EMEA, technicians who have successfully completed the training course HV Battery Fuse Remove and Replace ILT - EMEA 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 any time a high voltage cable is handled. Refer to TN-15-92-003, “High Voltage Awareness Care Points” for additional safety information.
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Warning
Proper personal protective equipment (PPE) is required to perform this procedure:
  • High voltage insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
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Warning
Make sure that the HV insulating gloves are not expired. Refer to TN-15-92-003 for glove regional expiration information.
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Warning
Use a glove inflator to test the HV insulating gloves before beginning this procedure. Gloves that fail the test must be discarded. If one glove fails, discard both gloves of the pair.
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Warning
While performing this procedure, always wear both rubber HV insulating gloves and leather glove protectors. Do not remove the gloves until the fuse cover has been reinstalled.
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Warning
When performing this procedure, use only one hand whenever possible. Keep your other hand behind your back to prevent the circuit from closing if you touch a component with high voltage.
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Warning
When using a multimeter, never use an e-coated surface as a path to ground.
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Warning
Only use tools that have been specifically designated for use with this procedure.
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Warning
Obey these safe work practices while performing this procedure:
  • Do not wear headphones.
  • No loud music in HV battery repair areas.
  • Do not perform this procedure alone. Always have a certified assistant on hand, and alert the on-site manager that you will be performing this procedure.
  • Always use 2 people to lift heavy equipment.
  • Absolutely no horseplay.
  • Avoid cluttering the battery rework area. Only tool carts that have tools that are needed for this procedure should be allowed in the battery rework area. Maintain tools and consumables in appropriate cabinets.
  • Label all secondary chemical containers.
  • Dispose of hazardous waste (such as adhesive, coolant, and other chemicals) in appropriate bins or containers.

Procedure

  1. Move the vehicle to a 2-post lift. See Raise Vehicle - 2 Post Lift.
  2. On the vehicle touchscreen, enable Jack Mode.
  3. Disconnect 12V power. See Disconnect 12V Power.
  4. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  5. Raise the vehicle and inspect the HV battery exterior for damage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check for dents, cracks, holes, fluid leaks, etc. If damage is found, stop work and contact Service Engineering.
  6. Inspect the pyrotechnic fuse cover for damage, corrosion, or water intrusion.
  7. Remove the HV battery from the vehicle, and move it away from the vehicle. See HV Battery (AWD) (Remove and Install).
  8. Put on proper PPE, including high voltage gloves and leather outer gloves.
  9. Use the multimeter to measure the voltages at the high voltage Rapid Mate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Measure B+ to B-, B+ to ground, and B- to ground. If any measurement is greater than 10V, contact Service Engineering.
  10. Install the Rapid Mate covers to the high voltage and low voltage Rapid Mates.
  11. Cordon off the HV battery work area with stanchions and High Voltage Warning signs.
  12. Use a pick to remove the cap from the vent cover.
  13. Use the pick to remove the breather from the vent cover.
  14. Insert a rubber plug into the hole in the vent cover.
  15. Use a flashlight to shine the light into the slots of the side skis, and look for breathers between the umbrella valves.
    • No breathers are seen - Go to step 24.
    • Breathers are seen - Continue to the next step.
    Figure 1. Breather between umbrella valves, as seen through the slots of the side skis
  16. Use clamps to secure the LH side rail ski at the front and rear of the HV battery.
  17. Remove and discard the horizontal screws (x10) that attach the LH side rail ski to the HV battery.
  18. With the help of an assistant, remove the clamps from the HV battery, pull the LH side rail ski out from the battery, pivot the rail ski down, and away from the battery.
  19. Use a nylon brush and ESD safe vacuum to clean dirt and debris from where the LH side rail ski was removed.
  20. Inspect the condition of the LH side rail umbrella valves, and replace any that appear to be damaged.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the damage affects the sealing of a new umbrella valve, contact Service Engineering.
  21. Remove the breathers (x7) from among the LH side rail umbrella valves, and install rubber plugs (x7).
  22. Clean the LH side rail area of the HV battery with IPA wipes, and allow at least one minute to dry.
  23. Repeat step 16 through 22 on the RH side of the HV battery.
  24. Remove and discard the leak test plug from the LH rear corner of the HV battery.
  25. Install the leak test port adapter into the LH rear corner of the HV battery.
    8 Nm (5.9 lbs-ft)
  26. Close both the outlet (left) and inlet (right) valves on the leak tester.
  27. Set the pressure gauge to measure in PSI.
  28. Fully close the regulator.
  29. Connect the air supply to the leak tester.
  30. Open the inlet (right) valve.
  31. Adjust the regulator so that 0.190 PSI is displayed on the pressure gauge.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Setting to 0.200 PSI or greater damages the HV battery.
  32. Connect the leak tester hose to the leak test port adapter.
  33. Slowly open the outlet (left) valve to inject air into the HV battery enclosure, and monitor the pressure gauge.
  34. When the pressure guage indicates 0.165 psi, close the inlet (right) valve.
  35. Wait 60 seconds to allow the pressure to stabilize.
  36. Record the starting pressure value.
  37. Start a 60 second timer.
  38. During the countdown, spray leak detection fluid generously onto the hybrid pyro fuse cover, observing for bubbles.
  39. When the timer completes, record the ending pressure value.
  40. If bubbles were seen at the hybrid pyro fuse cover, refer to Toolbox article 3207900.
  41. Subtract the ending pressure from the starting pressure.
    • If the difference between the pressures is greater than 0.010 psi, inspect the HV battery enclosure for leaks. See HV Battery Air Leak Test. After the leak has been rectified, return to this step.
    • If the difference between the pressures is 0.010 psi or less, continue to the next step.
  42. Disconnect the air supply from the leak tester.
  43. Slowly open both the outlet (left) and inlet (right) valves on the leak tester to vent pressure.
  44. Disconnect the leak tester hose from the leak test port adapter.
  45. Remove the leak test port adapter from the LH rear corner of the HV battery.
  46. Install a new leak test plug to the LH rear corner of the HV battery, and then mark the plug with a paint pen after tightening.
    8 Nm (5.9 lbs-ft)
  47. If the side rail skis:
    • If the side rail skis were not removed, go to step 55.
    • If the side rail skis were removed, continue to the next step.
  48. Remove the rubber plugs (x7) from among the LH side rail umbrella valves, and reinstall the breathers (x7).
  49. With the help of an assistant, raise the LH side rail ski to the LH side rail of the HV battery, so that the large tabs of the rail ski fit into the slot on the underside of the battery.
  50. Pivot the LH side rail ski up and attach clamps to secure the rail ski at the front and rear of the HV battery.
  51. Press up on the LH side rail ski, install, and hand-tighten a new horizontal screw at the center of the side ski.
  52. Repeat for the remaining horizontal screws (x9), installing new screws, and working from the center out to the ends.
  53. Remove the clamps, and tighten the horizontal screws (x10).
    12 Nm (8.8 lbs-ft)
  54. Repeat step 48 through step 53 for the RH side rail ski.
  55. Remove the rubber plug from the hole in the vent cover.
  56. Install a new breather into the hole of the vent cover.
  57. Install a new cap onto the vent cover and mark with a paint pen.
  58. Put on proper PPE, including high voltage gloves and leather outer gloves.
  59. Remove the Rapid Mate covers from the high voltage and low voltage Rapid Mates.
  60. Install the HV battery. See HV Battery (AWD) (Remove and Install).
  61. Connect 12V power. See Disconnect 12V Power.
  62. Perform a coolant air purge. See Coolant System - Check and Fill.
  63. Remove the vehicle from the 2-post lift. See Raise Vehicle - 2 Post Lift.
  64. Disable Jack Mode.