05/06/2024 14:31:06

Vehicle HV Disablement Procedure (Structural Pack)

Correction code 17010020 0.45 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.

  • 2024-06-05: Added warning to measure the specified order of locations for high voltage.
  • 2023-12-05: Updated references to other Vehicle Isolation Procedures.
  • 2023-11-08: Added/updated HV insulating glove steps.
  • 2023-05-02: Updated current measurement step sequence and consistency.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure verifies that high voltage power is no longer available to high voltage components (A/C compressor, inverters, etc). Perform this procedure before servicing high voltage components.
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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.
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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.
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Warning
All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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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.
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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.
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Warning
Make sure that the insulation meter and leads are capable of handling at least 500V DC.
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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, escalate a Toolbox session before proceeding.
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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.
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Warning
When using test equipment, make sure that all cables are connected before turning equipment on or otherwise initiating use.
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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.
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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.

  • 1146175-00-A Current Clamp, Fluke 374FC
  • 1130480-02-A Test Probes, Slim

Isolate

Informational PurposesAn informational icon, calling your attention
Note
This procedure is for Structural Pack 5 seat vehicles. For instructions on checking HV disablement on Non-Structural Pack 5 seat vehicles, see Vehicle HV Disablement Procedure. For instructions on checking HV disablement on Non-Structural Pack 7 seat vehicles, see Vehicle HV Disablement Procedure (7-Seater)
  1. Open all the doors and lower all the windows.
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  4. Set the current clamp to measure voltage , and then measure the voltage across the 12V/LV auxiliary battery terminals using the test probes.
    Informational PurposesAn informational icon, calling your attention
    Note
    For LV (Li-Ion) auxiliary battery: if the voltage across the battery terminals is 0, the battery may have switched off internally. Use a 12V Lead Acid battery for testing. For mobile technicians: use the 12V Lead Acid battery in the Mobile Service vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    For LV (Li-Ion) auxiliary battery: if the voltage across the battery terminals is less than 13 volts or greater than 16 volts, the current clamp is not measuring reliably and must not be used.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    For 12V (Lead Acid) auxiliary battery: if the voltage measured is less than 10 volts or greater than 14 volts, the current clamp is not measuring reliably and must not be used.
  5. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  6. Remove all items from pockets and ensure not wearing metal items.
  7. Inspect HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
  8. Put on HV insulating gloves, leather outer gloves, and safety glasses.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Continue to wear the gloves until instructed to remove them.
  9. Power on the current clamp meter, and then zero out the meter for measurment.
  10. Install the current clamp meter onto one cable of the rear drive unit HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the meter is facing the correct direction.
  11. Measure the current in the HV cable.
    • If the current is within the range of -0.5 A to 0.5 A, continue to the next step.
    • If the current is outside the range of -0.5 A to 0.5 A, for example -0.8 A or 1.3 A, re-perform the LV power disconnect procedure. See 12V/LV Power (Disconnect and Connect). If the measurement is still outside the range of -0.5 A to 0.5 A, escalate for assistance.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      DO NOT DISCONNECT any HV harness when the current measurement is outside the range of -0.5 A to 0.5 A.
  12. Disconnect the RDU HV cable from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab, and then rotate the release lever upward to disengage the connector. Do not force the release lever up. Ensure the alignment tabs on the RDU header are not damaged.
  13. Verify no high voltage at the rear drive unit HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    In order to limit potential exposure to high voltage, measure for high voltage in the order specified below.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify test equipment is rated CATIII or higher. Measure B+ to Ground, B- to Ground, B+ to B-. If the voltage is greater than 10V, the pack contactors are not open or welded. Stop work and reach out to Service Engineering.

    Component Test

    B+

    (LH probe opening)

    B-

    (RH probe opening)

    GND

    Measured Voltage Less Than 10 V

    Measured Voltage 10 V Or More
    1

    HV battery positive contactor

    Positive (+) Lead

    Negative (-) Lead

    Pass

    Fail

    HV battery positive contactor might be seized. See HV Battery Contactor Seize Check.
    2

    HV battery negative contactor

    Positive (+) Lead

    Negative (-) Lead

    Pass

    Fail

    HV battery negative contactor might be seized. See HV Battery Contactor Seize Check.
    3

    HV

    Positive (+) Lead

    Negative (-) Lead

    Pass

    Fail

    Perform a HV battery contactor seize check. See HV Battery Contactor Seize Check.
  14. Return to the procedure that required the vehicle to be electrically isolated.
    Informational PurposesAn informational icon, calling your attention
    Note
    If you are no longer exposed to high voltage, the HV insulating gloves may be removed.

Integrate

  1. If removed, put on the HV insulating gloves and leather over gloves.
  2. Connect the RDU HV cable to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that the lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.
  3. Remove the leather glove protectors and the HV insulating gloves.
  4. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply Loctite 222 onto the mid aero shield bolts.
  5. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  6. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Raise all the windows and close all the doors.