The tangs on the high voltage (HV) connectors are designed to make a solid electrical connection to the battery pack enclosure. The paint on the enclosure was not masked on some packs and hence the connection between HV shield and the enclosure is NOT guaranteed and is intermittent.
This rework instruction outlines the necessary steps to rectify this issue in the field.
Equipment #
- Use appropriate high voltage PPE
- Use appropriate ESD controls
Rework Steps #
1. Remove ALL Harnesses and MSD from Pack (Figure 1) #
Figure 1
2. Open BDU Lid (Figure 2) #
Using a T30 torx head driver, remove 12 x M6X16mm screws & M6 nylon washers from BDU lid. It is recommended to loosen all screws first. Then leave one of the top screws until last.​
Figure 2
3. Remove BDU lid and disconnect BDU lid grounding strap (Figure 3) #
Using a T25 torx head driver, remove 1 x M5X10mm screw to disconnect BDU lid from grounding strap.​
Figure 3
4. Remove HV connector busbar screws (Figures 4 and 5) #
3 pin HV connectors:
Using a T40 torx head driver:
- Remove 3 x M8X25mm screws from HV POS busbar.
- Remove 3 x M8X25mm screws from HV NEG busbar.
Using a T40 torx head driver:
- Remove 2 x M8X25mm screws from HV POS busbar.
- Remove 2 x M8X25mm screws from HV NEG busbar​.
Figure 4
Figure 5
5. Remove Screws from HV receptacles (Figures 6 and 7) #
Using a T30 torx head driver, remove 6 x M6X14mm HV receptacle screws on each of the HV receptacles.
Figure 6
Figure 7
6. Remove each of the HV receptacles and remove HVIL pins (Figure 8-10) #
Remove 2 x HVIL pins using pin extractor tool HVTOOL11R or similar.
Figure 8
Figure 9
Figure 10
7. Remove paint using deburring tool (Figures 11-13) #
Area should be masked off to prevent any debris entering the Pack. Clean off (vacuum & wipe down) any excess debris / shavings.
Figure 11
Figure 12
Figure 13
8. Inspect / clean receptacle tangs (Figure 14) #
Figure 14
9. Reinsert HVIL pins and reseat receptacle (Figures 15 and 16) #
Figure 15
Figure 16
10. Replace screws on HV receptacles (Figures 17) #
Replace 6 x M6X16mm flanged head screws for each receptacle. Torque to 8.5Nm.
Check the electrical connection of HV Connector Shield to the battery pack enclosure.
Figure 17
11. Replace BDU Lid Seal (Figures 18-23) #
- Remove old seal by gently peeling it away from the BDU
- Use IPA Wipes to clean the BDU surface free of any contaminants or remnants of old seal
- Obtain a new BDU seal and peel the backing off
Figure 18
Figure 19
Start at top corner, line up seal and align the holes with the BDU. Gently apply pressure to the seal to retain it in place and then work around the seal anti-clockwise. Ensure each screw hole is aligned with the seal before putting pressure on the seal as you work your way around the BDU.
Figure 20
Figure 21
Figure 22
Figure 23
12. Reconnect BDU lid grounding strap (Figure 24) #
Replace 1 x M5X10mm screw. Torque to 4.5Nm.
Figure 24
13. Reposition and attach BDU lid with screws (Figure 25) #
Replace 12 x M6X16mm screws & M6 nylon washers. Apply Loctite 243 and torque to 6.6Nm.
Figure 25
