Tesla Model 3: HV Battery Contactor Seize Check
SPECIAL TOOLS
Insulation Multimeter Fluke 1587 FC (1076921-00-A)
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:
Only technicians who have been trained in High Voltage Awareness 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:
Make sure that the insulation multimeter and leads are capable of
handling at least 500V DC.
Procedure
- Remove the penthouse cover. See
Cover - Penthouse (Remove and Replace).
- Set the insulation multimeter to measure resistance, and touch the probe
tips together.
Caution:
If the multimeter displays greater than 0.2 ohms, the leads are
defective and must be replaced. Do not use defective leads.
- Consider your next step:
- If the positive contactor is suspect to have seized, go to step
4.
-
If the negative contactor is suspect to have seized, go to step
9.
-
If both contactors are suspect, or there is uncertainty, start with step
4.
- Inspect the center of the insulator caps on top of the HV battery
positive contactor terminals:
- If the insulator caps have a probing hole, continue to step
5.
- If the insulator caps are solid, remove the insulator caps and continue
to step
5.
- Set the multimeter to measure the DC voltage across both terminals of
the HV battery positive contactor, either through the probing hole of the
insulator caps or directly onto the terminals:
- If the measured voltage is outside the range of -0.1V to 0.1V, then the
HV battery positive contactor is not seized. Continue to step
6.
Caution: Do not make the resistance measurement below because it
could damage the multimeter.
- If the measured voltage is between -0.1V and 0.1V, set the multimeter to
measure resistance and measure the resistance across the HV battery positive
contactor terminals:
- If the measured resistance is greater than 1M Ohm (1000K Ohm), then the
HV battery positive contactor is not seized. Proceed to step
6.
- If the measured resistance is lower than 1M Ohm, then the HV battery
positive contactor might be seized. Discontinue this procedure and replace
the HV battery positive contactor. See
Contactor - Positive - HV Battery (Remove and Replace), and then retest.
- Set the multimeter to measure resistance, and then perform the following
measurements:
- Reinstall the HV battery positive contactor insulator caps, if they were
removed earlier.
- If the HV battery negative contactor is also suspect to have seized, or
there is uncertainty, go to step
9. Otherwise, return to the
Vehicle Electrical Isolation Procedure.
- Inspect the center of the insulator caps on top of the HV battery
negative contactor terminals:
- If the insulator caps have a probing hole at the center, continue to
step
10.
- If the insulator caps are solid, remove the insulator caps and continue
to step
10.
- Set the multimeter to measure the DC voltage across both terminals of
the HV battery negative contactor, either through the probing hole of the
insulator caps or directly onto the terminals:
- If the measured voltage is outside the range of -0.1V to 0.1V, then the
HV battery negative contactor is not seized. Continue to step
11.
Caution: Do not make the resistance measurement below because it could
damage the multimeter.
- If the measured voltage is between -0.1V and 0.1V, set the multimeter to
measure resistance and measure the resistance across the HV battery negative
contactor terminals:
- If the measured resistance is greater than 1M Ohm (1000K Ohm), then the
HV battery negative contactor is not seized. Proceed to step
11.
- If the measured resistance is lower than 1M Ohm, then the HV battery
negative contactor might be seized. Discontinue this procedure and replace
the HV battery negative contactor. See
Contactor - Negative - HV Battery (Remove and Replace), and then retest.
Set the multimeter to measure resistance, and then perform the following
measurements:
- Reinstall the HV battery negative contactor insulator caps, if they were
removed earlier.
- Return to the
Vehicle Electrical Isolation Procedure.
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SPECIAL TOOLS
Extractor, Battery HV Header, Model 3 (1140423-00-B)
Lever Lock, HV Connector, Model 3 (1140311-00-A)
Warning:
Only technicians who have been trained in High Voltage Awareness are
perm
Install
Install the HV header onto the HV battery.
Note: Push and pull on the header to make sure it is secured.
Install and hand-tighten the bolts that attach the HV header to the HV
batte
SEE MORE:
DRAFT
Warning:
This procedure was derived from pre-production computer
models, and might not reflect the real-world situation. Warnings
and cautions might be missing. Follow safety requirements and
use extreme caution when working on or near
Remove
Open the hood.
Release the seal from the underhood storage unit, and then remove the
seal from the underhood storage unit.
Install
Installation procedure is the reverse of removal, except for the following:
During installation, align the line from the seal to the line from the