28/10/2020 11:48:45

Connector - DC Input - Busbar - Charge Port to HV Battery (Remove and Replace)

Correction code 440181020.90 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 wearing proper PPE when performing the below procedure.

  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1130480-00-A Test Probes, Slim, Fluke TP38
  • 1617321-00-A Busbar HV Connector Clamp
  • 1076927-00-A Hioki RM 3548 (includes alligator clip leads L2107)
  • 1076928-00-A Test Probes - Hioki 9461
Warning IconA warning icon, calling your attention to a possibly risky situation
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 safety information.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper Personal Protective Equipment (PPE) is required to perform this procedure:

  • High Voltage (HV) 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

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

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Warning
Make sure that the HV gloves are not expired.
  • North America: HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12 month period. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: Class 0 (1000V) HV gloves have no expiration date and may be used if they pass the pre-use assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.

Torque Specifications

Table 1. Torque Specifications: Connector - DC Input - Busbar - Charge Port to HV Battery (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Screw that attaches the busbar leads to the DC input connector
1.5 Nm (1.1 lbs-ft)
  • Torx T20 x 70 mm bit
  • Ratchet/torque wrench
  • Electronic torque wrench (installation only)
  • 1/4 inch dr. to 1/4 inch hex bit quick change (Installation only)
  • Short bit extension (Installation only)
 Reuse

Remove

  1. Remove the charge port to HV battery busbars. See Busbars - Charge Port to HV Battery (Remove and Replace).
  2. Remove the screws that attach the busbar leads to the DC input connector.
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 x 70 mm bit
    • Ratchet/torque wrench
    • Electronic torque wrench (installation only)
    • 1/4 inch dr. to 1/4 inch hex bit quick change (Installation only)
    • Short bit extension (Installation only)
  3. Pull the DC input connector away from the busbars.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull straight away from the busbars. The busbar leads will not separate from the connector if pulled at an angle.
    Tip: If needed, wedge a flat head screwdriver between the inside of the connector housing and the end of the busbar lead (highlighted in red), and then carefully pry the leads away from the connector. DO NOT damage the busbar lead contact surfaces.
  4. Use IPA wipes to clean residual electrical joint compound from the busbar leads.

Install

  1. Install the busbar HV connector clamp on the busbars, and then secure the clamp and busbars in a bench vise, as illustrated.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT secure the busbars on the vise without using the busbar HV connector clamp. Doing so could damage the busbars, potentially causing an isolation failure.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the busbar leads are clamped perpendicular to the bench vise. This will aid in installing the DC input connector in the next step.
  2. Install the DC input connector on the busbar leads. The connector is fully seated when the busbar lead screw holes are aligned with the connector housing screw holes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the textured side of the busbar leads is facing away from the connector door.
    Tip: If needed, carefully use a dead blow hammer to install the connector.
  3. Install the screws that attach the busbar leads to the DC input connector.
    1.5 Nm (1.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 x 70 mm bit
    • Ratchet/torque wrench
    • Electronic torque wrench (installation only)
    • 1/4 inch dr. to 1/4 inch hex bit quick change (Installation only)
    • Short bit extension (Installation only)
  4. Remove the busbars and HV connector clamp from the vise, and then remove the clamp from the busbars.
  5. Install the charge port to HV battery busbars. See Busbars - Charge Port to HV Battery (Remove and Replace).