High Voltage Receptacle Replacement

The high voltage (HV) connectors are designed to make a solid electrical connection to the battery pack enclosure and provide electrical connection to the battery pack’s terminals. If any portion of the high voltage connection is damaged, ingress protection and current-carrying capacity cannot be guaranteed.

This rework instruction manual outlines the necessary steps to rectify this issue in the field.+

Equipment needed #

For this procedure, you will need appropriate high voltage personal protective equipment (PPE) and the appropriate electrostatic discharge (ESD) controls.

1. Remove ALL harnesses and mechanical safety disconnect from the pack (Figure 1) #

Figure 1

2. Open the Battery Disconnect Unit Lid (Figure 2) #

Using a T30 torx head driver, remove the 12 x M6X16mm screws and the M6 nylon washers from the battery disconnect unit (BDU) lid. It is recommended to loosen all screws first, and leave one of the top screws until last.

Figure 2

3. Remove the BDU lid and disconnect the BDU lid grounding strap (Figure 3) #

Using a T25 torx head driver, remove 1 x M5X10mm screw to disconnect the BDU lid from the grounding strap.

Figure 3

4. Remove the high voltage connector busbar screws (Figure 4) #

For the 3-pin high voltage connectors, use a T40 torx head driver to:

1. Remove 3 x M M8X25mm screws from the high voltage positive (HV POS) busbar
2. Remove 3 x M M8X25mm screws from the high voltage negative (HV NEG) busbar

For the 2-pin high voltage connectors, use a T40 torx head driver to:

1. Remove 2 x M M8X25mm screws from the high voltage positive (HV POS) busbar
2. Remove 2 x M M8X25mm screws from the high voltage negative (HV NEG) busbar

Figure 4

5. Remove screws from the high voltage receptacles (Figure 5) #

Using a T30 torx head driver, remove 6 x M6X14mm high voltage receptacle screws on each of the high voltage receptacles.

Figure 5

6. Remove each of the high voltage receptacles and remove high voltage interlock loop pins (Figure 6) #

Remove the 2 high voltage interlock loop (HVIL) pins using a pin extractor tool such as HVTOOL11R or similar (Figure 7).

Figure 6

Figure 7

7. Inspect the receptacle tangs and clean if necessary (Figure 8) #

Figure 8

8. Insert High Voltage Interlock Loop (HVIL) pins and seat new receptacle (Figures 9 and 10). #

If inserted successfully, skip to step 17.

Figure 9

Figure 10

9. If the HVIL pins are too difficult to insert due to insufficient length of the HVIL wire, the following steps can be carried out to provide better access. #

1. To remove the HV NEG busbar (Figure 11), use a T30 torx head driver to remove the M6X25mm HV link busbar screw and loosen the M6X25mm printed circuit board (PCB) screw. Position the link busbar away from the main busbar.
2. Using a 13mm socket, remove the M8X1.25 right-hand side contactor nut and split ring washer.
3. Remove the HV NEG busbar.

Figure 11

11. Remove HV POS busbar (Figure 12) #

1. Using a T30 torx head driver, remove 3 x M6X25mm screws and loosen the M6X25mm PCB screw. Position the link busbar away from the main busbar.
2. Remove the HV POS busbar.

Figure 12

12. Reseat the HV NEG receptacle #

13. Re-install the HV NEG busbar (Figure 13) #

1. Reposition the HV NEG bsubar.
2. Replace the M8X1.25 right-hand side contactor nut and split ring washer.
3. Torque to 10Nm.
4. Replace 3 x M8X25mm screws from HV NEG busbar.
5. Torque to 20Nm.
6. Replace the M6X25mm HV link busbar screw and re-tighten the M6X25mm PCB screw.
7. Torque to 8.5Nm.

Figure 13

14. Reseat HV POS receptacle #

15. Re-install HV POS busbar (Figure 14) #

1. Re-position HV POS busbar.
2. Hand tighten 2 x M8X25mm screws from HV POS busbar to hold in place.
3. Replace 2 x M6X25mm bottom side current sensor screws. Ensure the temperature sensor ring terminal is placed between the current sensor screw and conductor.
4. Torque to 8.5Nm.
5. Replace the M6X25mm HV link busbar screw and re-tighten the M6X25mm PCB screw.
6. Torque to 8.5Nm.
7. Fit all 3 x M8X25mm screws from HV POS busbar.
8. Torque to 20Nm.

Figure 14

16. Replace the screws on the HV receptacles (Figure 15) #

1. Replace 6 x M6X16mm flanged head screws for each receptacle.
2. Torque to 8.5Nm.

Figure 15

17. Replace BDU lid seal #

1. Remove the old seal by gently peeling it away from the BDU.
2. Use isopropyl alcohol (IPA) wipes to clean the BDU surface of any contaminants or remnants of the old seal.
3. Retrieve the new BDU seal and peel the backing off (Figure 16).
4. Starting from the top, right-hand corner, line up the seal and align the holes with the BDU. Gently apply pressure to the seal to retain it in place and work the seal around in an anti-clockwise direction. Ensure each screw hole is aligned with the seal before putting pressure on the seal as you work your way around the BDU (Figure 17).

Figure 16

Figure 17

18. Reconnect the BDU lid grounding strap (Figure 18) #

1. Replace the M5X10mm screw.
2. Torque to 4.5Nm.

Figure 18

20. Replace BDU lid and reconnect BDU lid screws (Figure 19) #

1. Replace 12 x M6X16mm screws and M6 nylon washers.
2. Apply Loctite 243 and torque to 6.6Nm.

Figure 19