rhit ess build book_yr3

RESS Final Assembly Steps

Remember to follow all high-voltage safety procedures during ESS assembly

Torque and mark all bolts

Never “force fit” any component.

ESS BUILD BOOK

ESS BUILD BOOK- STEP 1

• Install Battery Module #1 using 4, M-10 Class 12.9 bolts

M-10 Bolts

Z-Frame

Module 1

ESS BUILD BOOK-STEP 2


M-10 Bolts

Module 2


Module 3

M-10 Bolts



• Wire the Low-Voltage (LV) connections on the fronts of Modules 1through 3

Low-Voltage Harness (LV)


• Install the Component Shelf using qty 4, M-5 Bolts

Component Shelf

M-5 Bolts

M-5 Bolts


• Wire the LV connection on the rear of Modules 1 through 3

Low-Voltage Harness


• Install the HV flex connection between the positive terminal of Module 1 (M1P) and the negative terminal of Module 2 (M2N) using 4, M-6 bolts

M-6 Bolts


• Install Lexan cover over the HV connection between the positive terminal of Module 1 (M1P) and the negative terminal of Module 2 (M2N)

LEXAN Cover


• Wire the High-Voltage connection from the positive terminal of Module 3 (M3P) and the MSD using qty 2, M-6 bolts. Tie off the MSD connection.

MSD Lug

M3P


• Install connection with Lexan protective cover

LEXAN Cover (M3P)


Module 4

M10 Bolts



Module 5

M10 Bolts



Module 6

M10 Bolts



Module 7

M10 Bolts



• Wire the Low-Voltage connections on the fronts of Modules 4through 7

EDM/CSM SUBASSEMBLY-STEP 16-18

17) Attach HV EDM Negative M7P connection lug +cable to EDM. Tie off M7P lug.

Note: The EDM/CSM Subassembly will be built outside of the pack, then installed as a unit

18) Attach HV EDM CSM connection lug +cable to EDM. Tie off CSM lug.

EDM EDM-CSM

EDM-External

Module 7-EDM

16) With the top of the EDM removed, attach the EDM-External lug + cable to appropriate lug on EDM

EDM/CSM SUBASSEMBLY – STEP 19

• Mount CSM to EDM using quantity 4 M-6 bolts

Module 7-EDM

EDM-CSM

EDM-External

EDM

CSM

EDM/CSM SUBASSEMBLY – STEP 20 & 21 20) Attach CSM M1N to CSM and tie off M1N lug

21) Attach EDM-CSM RADSTOCK HV connection to CSM

EDM-CSM

Module 7-EDM

EDM-External

M1N to CSM


• Install HV M4N MSD and tie off

M4NMSD tie off

ESS BUILD BOOK- STEP 23

• Install Lexan protective cover at HV M4N MSD tie off

Lexan cover


• Attach EDM/CSM subassembly to component shelf using qty 4 M6 bolts


• Install HV flex connection connecting M5P M6N


• Install Lexan cover over HV flex connection (M5P M6N)


• Attach HV M4P M5N


• Install Lexan cover over HV flex connection (M4P M5N)

Lexan cover


• Attach HV EDM M7P

HV EDM M7P


• Install Lexan cover over HV connection (HV EDM M7P)


• Attach HV CSMM1N

HV CSMM1N


• Install Lexan cover over HV connection (HV CSMM1N )

Lexan cover

ESS BUILD BOOK-STEP 33 & 34

33) Attach HV flex connection M2P M3N

34) Install Lexan cover over HV connection (M2P M3N)

HV M2P M3N

Lexan cover


35) Attach HV flex connection M6P M7N

36) Install Lexan cover over HV connection (M6PM7N)


• Attach M4N MSD lug

• Attach M3P MSD lug

M4N MSD lug

M3P MSD lug


• Install battery case

MSD

ESS Case

Pack-to-vehicle HV connector

ESS BUILD BOOK-STEP 40 • Attach the battery control module (BCM) to battery casing using supplied

isolation mounts

BCM ESS Case


ESS Build Book-

• Install battery control module cover; secure to battery case using 4, M-5 bolts (locations shown below)e

HVIL-BCM and LV- BCM connection points

• Connect HVIL and LV routing wires to BCM

ESS VEHICLE INTEGRATION – STEP 43

• Mount Energy Storage System (ESS) to ESS subframe via qty 6, M14 bolt holes in ESS Z-Frame (see red arrows in the top section view below)

ESS Subframe

Energy Storage System (ESS)

ESS Z-Frame

Front

rhit ess build book_yr3

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