04/06/2024 18:01:31

Contactor - Fast Charge - HV Battery (Structural Pack) (Remove and Replace)

Correction code 16302122 2.28 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.

  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
  • 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1057607-00-A Magnet, Flexible, HV Insulated, 18"
  • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
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.

Torque Specifications

Table 1. Torque Specifications: Contactor - Fast Charge - HV Battery (Structural Pack) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the AC filter harness to the negative DC inlet busbar
15 Nm (11.1 lbs-ft) -180 deg
5 Nm (3.7 lbs-ft) +60 deg
  • Insulated tools:
    • 13 mm socket
    • Magnetic pick up tool
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
 Replace
Bolt that attaches the AC filter harness to the positive DC inlet busbar
15 Nm (11.1 lbs-ft) -180 deg
5 Nm (3.7 lbs-ft) +60 deg
  • Insulated tools:
    • 13 mm socket
    • Magnetic pick up tool
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
 Replace
Bolts (x2) that attach the FC positive outlet jumper to the ancillary bay
15 Nm (11.1 lbs-ft) -180 deg
5 Nm (3.7 lbs-ft) +60 deg
  • Insulated tools:
    • 13 mm socket
    • Magnetic pick up tool
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
 Replace
Bolts (x2) that attach the FC negative outlet jumper to the ancillary bay
15 Nm (11.1 lbs-ft) -180 deg
5 Nm (3.7 lbs-ft) +60 deg
  • Insulated tools:
    • 13 mm socket
    • Magnetic pick up tool
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
 Replace
Bolts (x3) that attach the HV battery fast charge contactor to the ancillary bay
5.5 Nm (4.1 lbs-ft)
  • Insulated tools:
    • Socket External Torx 1/4in Dr. E8
    • Magnetic pick up tool
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
 Reuse

Remove

  1. Remove the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace).
  2. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  3. Release the clip that attaches the DC fast charge HVIL connector to the tray.
  4. Release the connector lock, and then disconnect the ancillary bay harness from the HV connector harness.
  5. Slide the DC fast charge HV connector straight up to remove it from the assembly.
  6. Release the clip that attaches the fast charge contactor harness branch to the tray.
    Informational PurposesAn informational icon, calling your attention
    Note
    The clip location may vary.
  7. Disconnect the fast charge contactor connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push on both sides of the connector to release the tabs, and then pull upward to disconnect.
  8. Remove and discard the bolt that attaches the AC filter harness to the negative DC inlet busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  9. Remove and discard the bolt that attaches the AC filter harness to the positive DC inlet busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  10. Release the clips (x2) that attach the AC filter harness to the tray.
  11. Release the securing tabs (x3), and then remove the FC contactor cover.
  12. Lift the HV battery fast charge positive inlet busbar straight up to remove it.
  13. Lift the HV battery fast charge negative inlet busbar straight up to remove it.
  14. Remove and discard the bolts (x2) that attach the FC positive outlet jumper to the ancillary bay, and then remove the FC positive outlet jumper from the ancillary bay.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  15. Remove and discard the bolts (x2) that attach the FC negative outlet jumper to the ancillary bay, and then remove the FC negative outlet jumper from the ancillary bay.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  16. Remove the bolts (x3) that attach the HV battery fast charge contactor to the ancillary bay, and then remove the HV battery fast charge contactor from the ancillary bay.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Socket External Torx 1/4in Dr. E8
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Install the bolts (x3) that attach the HV battery fast charge contactor to the ancillary bay.
    5.5 Nm (4.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Socket External Torx 1/4in Dr. E8
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  3. Use IPA wipes to clean the high voltage mating surfaces of the fast charge contactor and the positive and negative DC inlet and outlet busbars.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time.
  4. Position the FC negative outlet jumper onto the ancillary bay, and then install new bolts (x2) that attach the FC negative outlet jumper to the ancillary bay.
    15 Nm (11.1 lbs-ft) -180 deg
    5 Nm (3.7 lbs-ft) +60 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm +60 degrees.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  5. Position the FC positive outlet jumper onto the ancillary bay, and then install new bolts (x2) that attach the FC positive outlet jumper to the ancillary bay.
    15 Nm (11.1 lbs-ft) -180 deg
    5 Nm (3.7 lbs-ft) +60 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm +60 degrees.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  6. Use a Hioki resistance meter to measure the resistance at the HV joint between the FC negative outlet jumper busbar and the DC negative link busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.060 mΩ (60 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  7. Use a Hioki resistance meter to measure the resistance at the HV joint between the FC contactor negative joint to the FC negative outlet jumper busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.150 mΩ (150 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  8. Use a Hioki resistance meter to measure the resistance at the HV joint between the FC positive outlet jumper busbar to the DC positive link busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.060 mΩ (60 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  9. Use a Hioki resistance meter to measure the resistance at the HV joint between the FC contactor positive joint to the FC positive outlet jumper busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.150 mΩ (150 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  10. Position the DC inlet negative busbar onto the ancillary bay.
  11. Position the DC inlet positive busbar onto the ancillary bay.
  12. Install the fast charge contactor cover and make sure the the tabs (x3) are properly secured.
  13. Install the clips (x2) that attach the AC filter harness to the tray.
  14. Install a new bolt that attaches the AC filter harness to the positive DC inlet busbar.
    15 Nm (11.1 lbs-ft) -180 deg
    5 Nm (3.7 lbs-ft) +60 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm +60 degrees.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  15. Install a new bolt that attaches the AC filter harness to the negative DC inlet busbar.
    15 Nm (11.1 lbs-ft) -180 deg
    5 Nm (3.7 lbs-ft) +60 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm +60 degrees.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Magnetic pick up tool
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench
  16. Use a Hioki resistance meter to measure the resistance at the HV joint between the FC contactor positive joint and the positive DC inlet busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.150 mΩ (150 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  17. Use a Hioki resistance meter to measure the resistance at the HV joint between the FC contactor negative joint and the negative DC inlet busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.150 mΩ (150 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again
  18. Connect the fast charge contactor connector.
  19. Install the clip that attaches the fast charge contactor harness branch to the tray.
  20. Install the DC fast charge HV connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to pinch the harness.
  21. Secure the DC fast charge HVIL connector to the tray.
  22. Connect the ancillary bay harness to the HV connector harness, and then engage the connector lock.
  23. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  24. Install the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  25. Verify the operation of the charging system.
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm the AC and DC charging functions are OK.