Sheet Assembly - Initial Sheet

FRT No: 16030203

    Remove


  1. Remove Battery Monitoring Board (BMB) cover. (Refer to procedure)


  2. Using an insulated tool, release connectors (x2) from BMB. Position connectors out of enclosure and position harness away from sheet.

  3. Remove front cover. (Refer to procedure)

  4. Reduce potential difference across the battery. (Refer to procedure)


  5. Remove nut securing PEM negative cable busbar to contactor and release terminals (x2) (torque - 9 Nm / 80 in-lbs).


  6. Carefully release PEM negative and HVAC cable from retaining tabs (x22) on sheets.


  7. Using the top RH edge, release and remove the E-connector insulators (x4) from the target sheet and the adjacent left and right sheets.


  8. Using a torquing tool, loosen but do not remove screws (x4) securing E-connector to sheets (torque - 4.5 Nm / 40 in-lbs).

  9. Install extended E-connector insulators to the sheets left and right of the first E-connector.


  10. Remove outer screws (x2) securing E-connector to sheet and replace with guide pins.

  11. Remove inner screws (x2) securing E-connector to sheet.

  12. Slide the E-connector along the pins and remove from sheet.

  13. Remove the guide pins (x2) from the sheets.

  14. Remove the extended E-connector insulator from the sheets to the left of the target sheet and install it to cover the LH collector plate on the target sheet.

  15. Install an E-connector insulator to the adjacent sheet to the left.

  16. Remove the extended E-connector insulator from the sheets to the right of the target sheet.

  17. Using the top RH edge, release and remove the E-connector insulator from the next sheet to the right of the target sheet.


  18. Using a torquing tool, loosen but do not remove screws (x4) securing E-connector to sheets (torque - 4.5 Nm / 40 in-lbs).

  19. Install an extended E-connector insulator on the sheets to the right of the target sheet.


  20. Remove outer screws (x2) securing E-connector to sheet and replace with guide pins.

  21. Remove inner screws (x2) securing E-connector to sheet.

  22. Slide the E-connector along the pins and remove from sheet.

  23. Remove the guide pins (x2) from the sheets.

  24. Remove both extended E-connector insulators and install regular E-connector insulators on the sheets to the left and right of the target sheet.

  25. Using assistance, carefully rotate rotisserie to invert battery.

  26. Position absorbent cloth underneath hose connections.


  27. Note fitted position of red and gold hose clips and release clips (x4) securing hoses to sheet.

  28. Note position of hoses BEFORE removal and carefully release hoses from sheet.
    29. CAUTION: Plug hose connections and install caps on sheet tubes to prevent ingress of moisture or dirt.
     

    CAUTION: Do not allow coolant to leak down to Battery Monitoring Board (BMB) cover and enclosure filters.
     


  29. Remove and discard clamp securing boot seal to sheet and release boot seal from sheet.


  30. Remove upper bolt and seal securing sheet to enclosure (torque - 15 Nm / 133 in-lbs).


  31. Remove bolts and seals (x2) securing sheet to ankle of enclosure (torque - 9 Nm / 80 in-lbs).

    32. NOTE: Sheets 1 and 11 only have a single ankle bolt securing them to the enclosure.


  32. Remove bolts and seals (x2) securing sheet to heel of enclosure (torque - 9 Nm / 80 in-lbs).


  33. Remove bolts and seals (x2) securing sheet to toe of enclosure (torque - 11.3 Nm / 100 in-lbs).

  34. Position sheet trolley to enclosure ensuring that the trolley platform is level with the base of the enclosure and the center of the platform is in line with the center of the sheet. Lock the trolley in position and recheck height.
    35. CAUTION: Ensure that the front cover seal is not damaged when adjusting trolley height.
     


  35. Perform a final check to ensure that the BMB connectors have been disconnected and that all bolts have been removed.

  36. Insert sheet removal tool into front cover bolt hole.


  37. Remove sheet halfway using upwards pressure on the center handling area of the sheet and the removal tool avoiding contact with the adjacent E-connector terminals.
    38. WARNING: Do not touch E-connector contacts.
     


  38. Using assistance if necessary, remove sheet fully using the upper and lower handling areas. Adjust trolley height as required.

  39. If sheet removal is tight, release rotisserie clamp bolts (x2) by 1/4 turn increments until sheet is free. Ensure that the clamp bolt threads are still fully engaged.

  40. Position trolley to sheet holder and carefully slide sheet in to holder.
    41. CAUTION: Never leave a sheet unattended while in the vertical position.
     

    CAUTION: Always place sheet in sheet holder or sheet rack.
     

    Installation


  1. Installation procedure is the reverse of removal except for the following:

  2. Ensure that the correct sheet is being installed. Fused sheets (labelled 'F') and unfused sheets (labelled 'U') are positioned alternately in the enclosure.

  3. Inspect all external fastening holes and remove any rubber seal residue before installing sheets.

  4. When inserting the sheet, ensure that the BMB connectors (x2) are positioned aside outside the enclosure to prevent damage.

  5. When inserting the sheet, use guides on base of enclosure to align the sheet.
    6. CAUTION: Do not push on coolant hose connection to align sheet.
     


  6. Install boot seal on enclosure using a rotating action ensuring that it seats fully around its circumference.

  7. Ensure that boot seal is seated well over, not flush with edge of the rubber block seal surrounding the sheet cooling tubes.

  8. Ensure boot seal clamp tab is orientated at the 12 o'clock position.

  9. Ensure that the hoses are installed on sheet end fitting as far as possible and the hose clips are between 1mm and 3mm from the end of the hose.

  10. Ensure that the countersunk holes on the E-connector face outwards.


  11. If any sheets were removed, use pitch plate to ensure proper alignment of E-connectors. Install pitch plate to enclosure using screws (x3). Align sheets with holes in pitch plate and loosely install screws (x11) securing pitch plate to sheets.

    12. NOTE: Only use the screws that are supplied with the pitch plate.


  12. If a sheet front mount has too much side-to-side misalignment, then using the upper handling area, reposition the sheet until it aligns with the pitch plate and then install screw.

  13. If a sheet front mount has too much vertical misalignment, use assistance to reposition the sheet using the upper handling area, until it aligns with the pitch plate and then install screw.

  14. Tighten all E-connector screws lightly until all screws are fitted then perform a final torque tighten using the torquing tool.

  15. Mark fastenings after tightening using torquing pen to identify tightened fastenings.

  16. Ensure E-connector insulators are correctly seated and are flush with other insulators.

  17. When installing the nut on the contactor, ensure that the HVAC cable terminal is positioned at 9 o'clock position and the fuse holder cable terminal is at the 12 o'clock position.

  18. Perform final tightening of sheet fasteners after front cover has been loosely installed in following order:

  19. Tighten bolts (x2) securing sheet to ankle of enclosure (torque - 9 Nm / 80 in-lbs).
    20. CAUTION: The screw and seal assembly must remain concentric as indicated during installation to ensure a watertight seal.
     


  20. Using assistance, carefully rotate rotisserie to invert battery.

  21. Tighten bolts (x2) securing sheet to heel of enclosure (torque - 9 Nm / 80 in-lbs).
    22. CAUTION: The screw and seal assembly must remain concentric as indicated during installation to ensure a watertight seal.
     


  22. Tighten bolts (x2) securing sheet to toe of enclosure (torque - 11.3 Nm / 100 in-lbs).
    23. CAUTION: The screw and seal assembly must remain concentric as indicated during installation to ensure a watertight seal.
     


  23. Tighten bolt securing sheet to top of enclosure (torque - 15 Nm / 133 in-lbs).
    24. CAUTION: The screw and seal assembly must remain concentric as indicated during installation to ensure a watertight seal.
     


  24. Mark fastenings after tightening using torquing pen to identify tightened fastenings.

(c) 2008 TESLA MOTORS, INC.

All right reserved. This material may not be reproduced or copied, in whole or in part, without written permission of Tesla Motors, Inc.