rhit ess build book_yr3
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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
• Install Battery Module #2 using 4, M-10 Class 12.9 bolts
M-10 Bolts
Module 2
ESS BUILD BOOK-STEP 3
Module 3
M-10 Bolts
• Install Battery Module #3 using 4, M-10 Class 12.9 bolts
ESS BUILD BOOK-STEP 4
• Wire the Low-Voltage (LV) connections on the fronts of Modules 1through 3
Low-Voltage Harness (LV)
ESS BUILD BOOK-STEP 5
• Install the Component Shelf using qty 4, M-5 Bolts
Component Shelf
M-5 Bolts
M-5 Bolts
ESS BUILD BOOK-STEP 6
• Wire the LV connection on the rear of Modules 1 through 3
Low-Voltage Harness
ESS BUILD BOOK-STEP 7
• 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
ESS BUILD BOOK-STEP 8
• 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
ESS BUILD BOOK-STEP 9
• 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
ESS BUILD BOOK-STEP 10
• Install connection with Lexan protective cover
LEXAN Cover (M3P)
ESS BUILD BOOK-STEP 11
Module 4
M10 Bolts
• Install Battery Module #4 using 4, M-10 Class 12.9 bolts
ESS BUILD BOOK-STEP 12
Module 5
M10 Bolts
• Install Battery Module #5 using 4, M-10 Class 12.9 bolts
ESS BUILD BOOK-STEP 13
Module 6
M10 Bolts
• Install Battery Module #6 using 4, M-10 Class 12.9 bolts
ESS BUILD BOOK-STEP 14
Module 7
M10 Bolts
• Install Battery Module #7 using 4, M-10 Class 12.9 bolts
ESS BUILD BOOK-STEP 15
• 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
ESS BUILD BOOK-STEP 22
• 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
ESS BUILD BOOK-STEP 24
• Attach EDM/CSM subassembly to component shelf using qty 4 M6 bolts
ESS BUILD BOOK-STEP 25
• Install HV flex connection connecting M5P M6N
ESS BUILD BOOK-STEP 26
• Install Lexan cover over HV flex connection (M5P M6N)
ESS BUILD BOOK-STEP 27
• Attach HV M4P M5N
ESS BUILD BOOK-STEP 28
• Install Lexan cover over HV flex connection (M4P M5N)
Lexan cover
ESS BUILD BOOK-STEP 29
• Attach HV EDM M7P
HV EDM M7P
ESS BUILD BOOK-STEP 30
• Install Lexan cover over HV connection (HV EDM M7P)
ESS BUILD BOOK-STEP 31
• Attach HV CSMM1N
HV CSMM1N
ESS BUILD BOOK-STEP 32
• 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
ESS BUILD BOOK-STEP 35 & 36
35) Attach HV flex connection M6P M7N
36) Install Lexan cover over HV connection (M6PM7N)
ESS BUILD BOOK-STEP 37 & 38
• Attach M4N MSD lug
• Attach M3P MSD lug
M4N MSD lug
M3P MSD lug
ESS BUILD BOOK-STEP 39
• 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-STEP 41 & 42
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
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