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