Contactor - Positive - HV Battery (Remove and Replace)

Correction code 1630210216302102
  • 1057602-00-ARatchet, 1/4" Sq Dr, HV Insulated
  • 1057603-00-AExt Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057607-00-AMagnet, Flexible, HV Insulated, 18"
  • 1133768-00-ASocket, 1/4" Dr, Deep,10 mm,Thin Wall, Insul
  • 1076927-00-AResistance meter, microohm, Hioki RM 3548

SPECIAL TOOLS

Ratchet, 1/4" Sq Dr, HV Insulated (1057602-00-A)
Ext Bar, Wobble, 1/4" Dr, HV Insulated (1057603-00-A)
Magnet, Flexible, HV Insulated, 18" (1057607-00-A)
Socket, 1/4" Dr, Deep,10 mm,Thin Wall, Insul (1133768-00-A)
Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)
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.

Remove

  1. Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
  2. Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
  3. Remove the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Remove and Replace).
  4. Disconnect the electrical harness from the power conversion system LV connector and DC bus HV connector, and from the HV battery positive contactor connectors.
  5. Remove the insulator caps from the HV battery positive contactor.
  6. Remove and discard the bolt that attaches the HV battery positive contactor to the positive busbar.
  7. Remove and discard the nut that attaches the HV battery positive contactor to the battery terminal.
  8. Remove the nuts (x3) that attach the positive HV battery power switch to the penthouse.
  9. Tilt the rear of the HV battery positive contactor up, and then remove the contactor from the penthouse.
1Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
2Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
3Remove the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Remove and Replace).
4Disconnect the electrical harness from the power conversion system LV connector and DC bus HV connector, and from the HV battery positive contactor connectors.
5Remove the insulator caps from the HV battery positive contactor.
6Remove and discard the bolt that attaches the HV battery positive contactor to the positive busbar.
7Remove and discard the nut that attaches the HV battery positive contactor to the battery terminal.
8Remove the nuts (x3) that attach the positive HV battery power switch to the penthouse.
9Tilt the rear of the HV battery positive contactor up, and then remove the contactor from the penthouse.

Install

Caution:

Replace all patchbolts.

Replace all nyloc nuts.

  1. Use an IPA wipe to clean the high voltage mating surfaces of the HV battery terminal, positive busbar, and the HV battery positive contactor.
  2. Tilt the rear of the HV battery positive contactor up, and then install the contactor into the penthouse.
  3. Install the nuts (x3) that attach the HV battery positive contactor into the penthouse.
    Torque 8 Nm
  4. Install a new nut to attach the HV battery positive contactor onto the HV battery terminal, and then mark the nut with a paint pen after it is torqued.
    Torque 9 Nm
  5. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the HV battery terminal.
    Note: The maximum acceptable resistance is 0.110 mΩ (110 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  6. Install a new bolt to attach the HV battery positive contactor onto the positive busbar, and then mark the bolt with a paint pen after it is torqued.
    Torque 9 Nm
  7. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the positive busbar.
    Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  8. Install the insulator caps to the HV battery positive contactor.
  9. Connect the electrical harness to the HV battery positive contactor, and power conversion system LV and DC bus HV connectors.
  10. Install the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Remove and Replace).
  11. Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
  12. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
1Use an IPA wipe to clean the high voltage mating surfaces of the HV battery terminal, positive busbar, and the HV battery positive contactor.
2Tilt the rear of the HV battery positive contactor up, and then install the contactor into the penthouse.
3Install the nuts (x3) that attach the HV battery positive contactor into the penthouse.
Torque 8 Nm
4Install a new nut to attach the HV battery positive contactor onto the HV battery terminal, and then mark the nut with a paint pen after it is torqued.
Torque 9 Nm
Generic Measurement - Actual busbars and fasteners might appear different
5Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the HV battery terminal.
Note: The maximum acceptable resistance is 0.110 mΩ (110 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
6Install a new bolt to attach the HV battery positive contactor onto the positive busbar, and then mark the bolt with a paint pen after it is torqued.
Torque 9 Nm
Generic Measurement - Actual busbars and fasteners might appear different
7Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the positive busbar.
Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
8Install the insulator caps to the HV battery positive contactor.
9Connect the electrical harness to the HV battery positive contactor, and power conversion system LV and DC bus HV connectors.
10Install the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Remove and Replace).
11Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
12Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).