23/08/2024 06:33:37

Fuse - Pyrotechnic - HV Battery 1.0/1.5 (Remove and Install)

FRT No. 16308701

  • 2024-06-25: Added alternative sealants to replace Threebond 1216E due to non-availability of Threebond in certain markets.
  • 2024-01-19: Added Tesla-approved sealants to steps.
  • 2024-01-18: Updated Warning to permit performing this procedure by technicians in EMEA that have completed the training course HV Battery Fuse Remove and Replace ILT - EMEA.
  • 2023-09-25: Updated to retain the fuse cover bolts and fuse mounting bolts.
  • 2023-09-19: Updated title and HV insulating glove information.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1059330-00-A SOCKET,DR 5LOBE,E-TORX MAG,0.25INCH
Tesla 1057606-00-A 1/4" DRIVE 13MM SOCKET - CEMENTEX
Tesla 1006653-00-A FLAG,REMOVED FUSE,HVBAT,MDLS
Tesla 1076921-00-A FLUKE 1587 MULTI-METER
Tesla 1076927-00-A HIOKI MODEL 3548 RESISTANCE METER
Tesla 1060071-00-A TORQUE WRENCH 1-5 NM
Select one of the tools listed below based on the region:
Tesla 1055662-00-A ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP– NORTH AMERICA
Tesla 1056154-01-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – EU SCHUKO
Tesla 1056154-02-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – UK, IRELAND
Tesla 1056154-03-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – SWITZERLAND
Tesla 1056154-04-B ANTI-STATIC MAT/W WRIST GROUNDING CORD AND WRIST STRAP – DENMARK
Sealant required for this procedure:
  • Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A), or Dowsil 7091 (1962594-00-A)
Warning IconA warning icon, calling your attention to a possibly risky situation
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
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Remove the HV battery assembly. See HV Battery (AWD) (Remove and Install).
  2. Inspect the fuse cover area for rust or corrosion, and if any is found, refer to Toolbox article #32901 for further guidance.
  3. Remove all items from pockets and make sure not to wear any metal items.
  4. 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.
  5. Put on the HV insulating gloves and the leather over gloves.
  6. Put on the HV-safe static control wrist strap. Clip the strap's ground connection to a threaded hole on the edge of the HV battery enclosure.
  7. Vacuum the area around the fuse cover to remove all dust and debris.
  8. Clean the area around the fuse cover with alcohol wipes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not set the fasteners on top of the HV battery. Place each fastener in an appropriate receptacle to reduce the chances of omitting fasteners during reinstallation or leaving fasteners inside the HV battery.
  9. Remove the bolts (x9) that attach the fuse cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    One or more of the bolts might be covered or partially covered by sealant. If necessary, scrape off the sealant to expose the bolt head.
  10. Use an insulated blade to score the sealant around the edge of the fuse cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the red gasket or metal carrier.
  11. Use a non-conductive tool to lift the fuse cover.
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    Note
    If necessary, use a hammer or mallet to tap the tool so that it penetrates the sealant.
  12. Once partially separated, remove and discard the fuse cover.
  13. Visually inspect the fuse cavity for water, dirt, evidence of arcing, or any other kind of damage. If any damage is found, escalate a Toolbox session, as appropriate.
  14. Remove the bolts (x2) that attach the hybrid pyro fuse to the busbars.
  15. Carefully remove the hybrid pyro fuse from the cavity.
    Informational PurposesAn informational icon, calling your attention
    Note
    Minor arcing is possible. Be sure to have proper PPE, including goggles, worn for this step.
  16. Visually inspect the hybrid pyro fuse and the busbars within the fuse cavity for evidence of arcing. If there is any evidence of arcing, escalate the Toolbox session, as appropriate.
  17. Place the green fuse service flag in the fuse cavity to prevent the fuse from being re-inserted, and to indicate that the fuse has been removed.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Always make sure that the green fuse service flag has been installed.
  18. Record the part number and serial number on the fuse.
  19. Use this table to determine the type of fuse and action to take.
    Part Number Fuse Type Action
    1056211-00-* Battery Powered Replace with self-powered fuse
    1077177-00-*
    1086649-00-*
    1112479-00-*
    1112553-00-*
    1111445-00-* Self-Powered Reinstall fuse and ensure gateway configuration
    1111313-00-*
    1090924-00-*
    Various part numbers Sand Fuse Reinstall fuse and ensure gateway configuration
  20. Use a non-conducting tool to remove excess sealant from around the fuse cavity.
  21. Use an ESD safe vacuum to remove debris from around and in the fuse cavity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not remove the green fuse service flag, work around it.
  22. Use an IPA wipe to clean the battery surface where sealant was removed around the fuse cavity.

Install

  1. Consider the action to take for the type of fuse removed.
  2. Perform a zero adjust of the Hioki resistance meter in prepartion to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  3. Remove the green fuse service flag.
  4. Use an IPA wipe to thoroughly clean the busbars within the fuse cavity and the terminals of the hybrid pyro fuse and allow at least 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    There is a dull busbar, and a shiny busbar.
  5. Position the hybrid pyro fuse with the embossed arrow pointing rearward, and then install the fuse into the fuse cavity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Minor arcing is possible. Be sure to have proper PPE, including goggles, worn for this step.
    Informational PurposesAn informational icon, calling your attention
    Note
    The dull terminal of the hybrid pyro fuse mates with the dull busbar, the copper terminal of the fuse mates with the shiny busbar.
  6. Install the bolts (x2) that attach the hybrid pyro fuse to the busbars, and then mark the bolts with a paint pen after tightening.
    9 Nm (6.6 lbs-ft)
  7. Use the Hioki resistance meter to meassure the resistance at the HV joint of the hybrid pyro fuse copper terminal and the shiny busbar.
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    Note
    Do not short the side of the probe tip to the edge of the fuse terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is not within this range, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed, proceed with the installation procedure. For more information on Hioki resistance testing, refer to article https://toolbox.teslamotors.com/articles/218200.
  8. Use the Hioki resistance meter to meassure the resistance at the HV joint of the hybrid pyro fuse dull terminal and the dull busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not short the side of the probe tip to the edge of the fuse terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is not within this range, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed, proceed with the installation procedure. For more information on Hioki resistance testing, refer to article https://toolbox.teslamotors.com/articles/218200.
  9. Use an IPA wipe to clean the sealing surface and gasket of the fuse cavity, the sealing surface of the new fuse cover, the top surface of the new fuse cover, and allow at least 1 minute to dry.
  10. Install a new warning label onto the top of the fuse cover.
  11. Apply sealant to the gasket around the fuse cavity.
  12. Install the fuse cover to the HV battery, install the bolts (x9) that attach the fuse cover to the HV battery, and then mark the bolts with a paint pen after tightening.
    2.2 Nm (1.6 lbs-ft)
  13. Remove the leather glove protectors and the HV insulating gloves.
  14. Put on disposable nitrile gloves.
  15. Apply sealant around the perimeter of the fuse cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply additional sealant to where the spacer interferes with the cover.
  16. Wet a nitrile gloved finger with isopropyl alcohol and then spread out the sealant, creating a fillet.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use the HV insulating gloves or leather glove protectors for this step.
  17. Remove the nitrile gloves, and put on the HV insulating gloves and leather glove protectors.
  18. Install the HV battery assembly. See HV Battery (AWD) (Remove and Install).
  19. If the vehicle is configured with a Tegra MCU, perform these substeps:
    1. Update the vehicle firmware to feature/2022.8.10.12 or later. See Firmware Update.
    2. Enable Service Mode Plus. See Service Mode Plus.
    3. Unlock the gateway. See Gateway Unlock.
    4. On the vehicle touchscreen, touch Service Mode > Set Pyro-Fuse Type, and then read the instructions.
    5. Touch SELF-POWERED or SAND, as determined previously, touch Set, and allow the routine to complete.
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      Note
      Touch the X in the upper left corner to close.
    6. Disable Service Mode Plus. See Service Mode Plus.
  20. If the vehicle is configured with an Intel MCU, perform these substeps:
    1. Update the vehicle firmware to develop/2023.12 or later. See Firmware Update.
    2. Enable Service Mode Plus. See Service Mode Plus.
    3. Unlock the gateway. See Gateway Unlock.
    4. On the vehicle touchscreen, touch HV Battery (Lightning Bolt), touch the green fuse in the graphic, touch Read/Write Fuse Type, and then read the instructions.
    5. From the Pyro fuse type drop down menu, select either SELFPOWERED_HYBRIDPYRO or SAND_FUSE, as determined previously, from the Write or read drop down menu, select WRITE, touch Run, and allow the routine to complete.
    6. Disable Service Mode Plus. See Service Mode Plus.
  21. Touch and hold the CALIBRATE button on the Model X touchscreen until the rear doors have been fully calibrated, close completely, and the message "CALIBRATION COMPLETE" is displayed.
  22. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.