Contactor - Negative - HV Battery (Remove and Replace)

Correction code 1630200216302002
  • 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 clip that attaches the HV battery penthouse harness to the HV battery fast charge contactor.
  3. Disconnect the electrical harness from the HV battery negative contactor connectors.
  4. Remove the insulator caps from the HV battery negative contactor.
  5. Remove and discard the bolt that attaches the HV battery negative contactor to the negative busbar.
  6. Remove and discard the nut that attaches the HV battery negative contactor to the battery terminal.
  7. Remove the nuts that attach the HV battery negative contactor to the penthouse, 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 clip that attaches the HV battery penthouse harness to the HV battery fast charge contactor.
3Disconnect the electrical harness from the HV battery negative contactor connectors.
4Remove the insulator caps from the HV battery negative contactor.
5Remove and discard the bolt that attaches the HV battery negative contactor to the negative busbar.
6Remove and discard the nut that attaches the HV battery negative contactor to the battery terminal.
7Remove the nuts that attach the HV battery negative contactor to the penthouse, and then remove the contactor from the penthouse.

Install

  1. Use an IPA wipe to clean the high voltage mating surfaces of the HV battery terminal, negative busbar, and the HV battery negative contactor.
  2. Install the HV battery negative contactor into the penthouse, and then install the nuts that attach the contactor into the penthouse.
    Torque 8 Nm
  3. Install a new nut to attach the HV battery negative contactor onto the HV battery terminal, and then mark the nut with a paint pen after it is torqued.
    Torque 9 Nm
  4. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery negative 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
  5. Install a new bolt to attach the HV battery negative contactor onto the negative busbar, and then mark the bolt with a paint pen after it is torqued.
    Torque 9 Nm
  6. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery negative contactor and the negative 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
  7. Install the insulator caps to the HV battery negative contactor.
  8. Connect the electrical harness to the HV battery negative contactor connectors.
  9. Install the clip that attaches the HV battery penthouse harness to the HV battery fast charge contactor.
  10. 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, negative busbar, and the HV battery negative contactor.
2Install the HV battery negative contactor into the penthouse, and then install the nuts that attach the contactor into the penthouse.
Torque 8 Nm
3Install a new nut to attach the HV battery negative 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
4Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery negative 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.
5Install a new bolt to attach the HV battery negative contactor onto the negative 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
6Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery negative contactor and the negative 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.
7Install the insulator caps to the HV battery negative contactor.
8Connect the electrical harness to the HV battery negative contactor connectors.
9Install the clip that attaches the HV battery penthouse harness to the HV battery fast charge contactor.
10Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).