25/06/2024 08:01:06
Vehicle HV Disablement Procedure
Correction Code 17010000
- 2024-06-25: Added part numbers for silicone lubricant.
- 2024-06-05: Added warning to measure the specified order of locations for high voltage.
Warning
This procedure
verifies that high voltage power is no longer available to high voltage components
(PTC heater, A/C compressor, inverters, etc). Perform this procedure before
servicing high voltage components.
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.
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.
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.
Warning
All repair and operating instructions should be reviewed and
understood before working on Tesla vehicles, associated components, or associated
repair equipment.
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.
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.
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.
Warning
Make sure that the
insulation meter and leads are capable of handling at least 500V DC.
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, send feedback to
ServiceManualFeedback@tesla.com.
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.
Warning
When using test equipment, make sure that all cables are connected
before turning equipment on or otherwise initiating use.
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.
Warning
Only technicians who have been
trained in High Voltage (HV) 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 any time a high voltage cable is
handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness
Care Points" for additional safety information.
Warning
If the 12V power
supply is disconnected, do not attempt to open any doors with door glass in
closed position. Failure to follow this instruction could result in door glass
shatter.
Note
Before
disconnecting the 12V power supply, ensure that the driver’s door window is
fully open. Failure to follow this instruction could result in vehicle
lockout.
Special tool(s) required for this procedure:
Supplier | Part Number | Description |
1076921-00-A | Fluke 1587 Insulation Multimeter |
Preparation
- Open the liftgate.
- If equipped, fold down the 3rd row seats.
-
Disconnect 12V power. See
Disconnect 12V Power.
WarningEnsure that the first responder loop has been disconnected for at least 2 minutes.
-
Set the isolation meter to
measure DC high voltage, and touch the probe tips together.
WarningIf the meter displays greater than 0.1 volts, the leads are defective and must be replaced.
-
Measure the voltage across
the 12V auxiliary battery terminals.
WarningIf the voltage is less than 10 volts or greater than 14 volts, the multimeter is not measuring reliably and must not be used.
Check for HV at the Charger
Note
After disconnecting 12V power,
the rear doors and liftgate are inoperable. Open any necessary closures before
proceeding.
- Remove the LH rear trunk side trim (refer to procedure).
-
Remove the foam HVAC ducting.
-
Remove and discard the warranty label from the charger access panel.
NoteComponents have been removed in this graphic to aid clarity.
-
Remove and discard the screws (x11) that secure the charger access panel
(torque 2 Nm).
CAUTIONReplace all patchbolt(s).WarningOnly technicians who have been trained in High Voltage (HV) 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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
-
Gently peel back the rubber cover to expose the HV fasteners.
-
Use the charger casing as a chassis ground. Measure the following
voltages:
WarningEnsure that the multimeter and leads are capable of handling at least 500V.WarningDo not use a probe with an exposed tip length that is greater than 3 mm.WarningIn order to limit potential exposure to high voltage, measure for high voltage in the order specified below.
- B+ to ground
- B- to ground
- B+ to B-
WarningIf any voltage reading is more than 10V, the High Voltage (HV) contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before performing any further work. - Return to the procedure that required the HV disablement check.
-
When repairs are complete,
replace components that were removed for access.
NoteClean the adhesive residue on the charger and charger access panel with an alcohol wipe before installing a new warranty label.
Check for HV at the Drive Inverter (Large RDU Only)
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
-
Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
WarningProper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn while performing the remainder of this procedure.WarningEnsure that the multimeter and leads are capable of handling at least 500V.
- Disconnect the low voltage harness, then release the bolt and remove the orange drive inverter cover (torque 3 Nm).
- Remove both O-rings from the drive inverter cover and discard.
- Empty all pockets and remove all metal items from your body.
-
Inspect the HV insulating gloves for damage.
WarningRefer to TN-15-92-003 to learn more about working with High Voltage components.
- Put on the HV insulating gloves, and then put on the leather over gloves.
-
Using the drive inverter case as a chassis ground, measure the following
voltages:
WarningIn order to limit potential exposure to high voltage, measure for high voltage in the order specified below.
- B+ to ground
- B- to ground
- B+ to B-
WarningIf any voltage reading is more than 10V, the High Voltage (HV) contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before performing any further work. - Return to the procedure that required the HV disablement check.
-
When repairs are complete, replace components that were removed for
access.
NoteInstall new O-rings on the drive inverter cover; apply Silicone Lubricant (1010251-00-A or 1083744-01-A) to both O-rings prior to installation.NoteInstall the rear-facing part of the cover first to prevent pinching the O-rings.