Fuse - Power Conversion System - HV Battery (Remove and Replace)

Correction code 1630440216304402
  • 1057602-00-ARatchet, 1/4" Sq Dr, HV Insulated
  • 1057603-00-AExt Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057604-00-ASkt, 1/4" Sq Dr, 8mm, HV Insulated
  • 1057607-00-AMagnet, Flexible, HV Insulated, 18"
  • 1127845-00-AAsy, Service Cover, Penthouse, Model 3

SPECIAL TOOLS

Ratchet, 1/4" Sq Dr, HV Insulated (1057602-00-A)
Ext Bar, Wobble, 1/4" Dr, HV Insulated (1057603-00-A)
Skt, 1/4" Sq Dr, 8mm, HV Insulated (1057604-00-A)
Magnet, Flexible, HV Insulated, 18" (1057607-00-A)
Asy, Service Cover, Penthouse, Model 3 (1127845-00-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. Raise the high voltage controller, release the clips that attach the fuse access insulator to the RH penthouse bus cover, and remove the insulator.
  3. Remove and discard the nuts that attach the power conversion system fuse to the RH penthouse bus and remove the fuse.
1Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
2Raise the high voltage controller, release the clips that attach the fuse access insulator to the RH penthouse bus cover, and remove the insulator.
3Remove and discard the nuts that attach the power conversion system fuse to the RH penthouse bus and remove the fuse.

Install

  1. Install the power conversion system fuse to the RH penthouse bus, and then install new nuts to attach the fuse to the bus.
    Torque 2.5 Nm
  2. Use the Hioki resistance meter to measure the resistance at the HV joint between the penthouse bus and the LH side of the power conversion system fuse body .
    Note: The maximum acceptable resistance is 0.105 mΩ (105 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  3. Use the Hioki resistance meter to measure the resistance at the HV joint between the RH side of the power conversion system fuse and the respective ring terminal plating.
    Note: The maximum acceptable resistance is 0.145 mΩ (145 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Generic Measurement - Actual busbars and fasteners might appear different
  4. Install the fuse access insulator on the RH penthouse bus cover, fasten the clips that attach the insulator to the cover, and lower the high voltage controller.
  5. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
1Install the power conversion system fuse to the RH penthouse bus, and then install new nuts to attach the fuse to the bus.
Torque 2.5 Nm
Generic Measurement - Actual busbars and fasteners might appear different
2Use the Hioki resistance meter to measure the resistance at the HV joint between the penthouse bus and the LH side of the power conversion system fuse body .
Note: The maximum acceptable resistance is 0.105 mΩ (105 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
Generic Measurement - Actual busbars and fasteners might appear different
3Use the Hioki resistance meter to measure the resistance at the HV joint between the RH side of the power conversion system fuse and the respective ring terminal plating.
Note: The maximum acceptable resistance is 0.145 mΩ (145 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.
4Install the fuse access insulator on the RH penthouse bus cover, fasten the clips that attach the insulator to the cover, and lower the high voltage controller.
5Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).