ISP Harness Assembly Procedures

1. Take HV harnesses with label (IHV2) and transfer on the Stacking table.

1.1 Inspect HV harnesses visually. 2.1 Insulate HV Flex with 3M™ VHB™ Tape and kapton. (3M™ Tape + Kapton+ 3M™ Tape, Use VHB ™ Tape Surface Preparation Technical Bulletin )2.2 Do not remove the foil from the latest 3M ™ Tape.2.3 Separate harness in the channel. (Check the position wires in the

Inner Service Panel PP0 to PP1B Connectivity plan.)2.2 Inspect HV harnesses visually and check voltage .

3. Take HV harnesses pin board with label (IHV1) and transfer it on the table.

4. Inspect HV harnesses visually .4.1 Insulate HV Flex with 3M™ VHB™ Tape and

kapton. (3M™ Tape + Kapton+ 3M™ Tape , Use VHB ™ Tape Surface Preparation Technical

Bulletin) 4.2 Do not remove the foil from the latest 3M ™ Tape. 5.1 Inspect HV harnesses visually and check voltage .5.3 Remove the foil from the latest 3M ™ tape and laminate together HV tape.

6.Take HV harnesses with label (IHV1) and transfer on the Stacking table.

7.Separate harness in the channels. (Check the position wires in the Inner Service Panel PP0 to

PP1B Connectivity plan.)8. Inspect HV harnesses visually and check voltage .9.Pre-laminate together HV harnesses with label (IHV2) and

label (IHV1) with 3M™ VHB™ Tape . (Use VHB ™ Tape Surface Preparation Technical Bulletin)

9.1 Check the position Penetration Flex before laminating .

8. Take NTC harnesses pin board with label (NTC2) and transfer it on the table.

9. Inspect NTC harnesses visually .10. Insulate NTC Flex with 3M™ VHB™ Tape and

kapton. (3M™ Tape + Kapton+ 3M™ Tape , Use VHB ™ Tape Surface Preparation Technical

Bulletin)

10.1 Do not remove the foil from the latest 3M ™ Tape.

11.Transfer NTC harnesses with label (NTC2) on the Stacking table.

12. Separate harness in the channels. (Check the position wires in the Inner Service Panel

PP0 to PP1B Connectivity plan.)13. Inspect NTC harnesses visually and check voltage .

14. Remove the foil from the latest 3M ™ tape and laminate together HV and NTC tape.

15.Take NTC harnesses pin board with label (NTC1) and transfer it on the table.

16. Inspect NTC harnesses visually. 17. Transfer NTC harnesses with label (NTC1 ) on the

Stacking table.18. Separate harness in the channels. (Check the position wires in the Inner Service Panel

PP0 to PP1B Connectivity)19. Inspect NTC harnesses visually and check voltage 20. Remove the foil from the latest 3M ™ tape and laminate together NTC tape. (Use VHB ™ Tape Surface Preparation Technical

Bulletin)21. Fix every bunch of wires.

transfer plate

22. Transfer NTC/HV harness stacking to the soldering table.22.1 Use the device to transfer NTC/HV harness .

Potential problems with the wiring bundles

23. Transfer ISP harnesses with label (ISP3) on the Stacking table. 24. Inspect IPS harnesses visually and check voltage . 25. Separate harness in the channels. (Check the position wires in the Inner Service Panel PP0 to PP1B Connectivity plan.)26. Insulate ISP3 Flex with 3M™ VHB™ Tape and kapton. 26.1 Use VHB ™ Tape Surface Preparation Technical Bulletin.26.2 Do not remove the foil from the latest 3M ™ Tape. 27. Take IPS harnesses pin board with label (ISP2) and transfer it on the Stacking . 28. Separate harness in the channels. (Check the position wires in the Inner Service Panel PP0 to PP1B Connectivity plan.) 29. Inspect IPS harnesses visually and check voltage . 30. Remove the foil from the 3M ™ tape and laminate together ISP tape.30.1 Use VHB ™ Tape Surface Preparation Technical Bulletin.

31. Take IPS harnesses pin board with label (ISP1) and transfer it on the Stacking . 32. Separate harness in the channels. (Check the position wires in the Inner Service Panel PP0 to PP1B Connectivity plan.) 33. Inspect IPS harnesses visually and check voltage . 34. All IPS harnesses Insulate kapton tape and Pre-laminate together with 3M™ VHB™ Tape . 34.1 Use VHB ™ Tape Surface Preparation Technical Bulletin.

kaptontape

3M™ VHB™ Tape

kapton tape

35. Separate harness the top and bottom PP0 Flex Flat. ( HV on the bottom PP0 Flex Flat , NTC on the top ). 36. Inspect harnesses visually and check voltage . 37. Cut NTC/HV harness . 38. Soldering NTC harness . (Use INNER SERVICE PANEL PP0 to PP1B Connectivity Plan) 39. Transfer ISP harness stacking to the soldering table. 40. Inspect harnesses visually and check voltage . 41. Cut ISP harness . 42. Soldering ISP harness . (Use INNER SERVICE PANEL PP0 to PP1B Connectivity Plan) 43. Install the ISP Corrugated Panel and ISP Bottom Panel, 44. Fix the wire in the ISP Corrugated Panel. 44.1 Install a carbon panel. 44.2 Soldering ENV connectors . 44.3 Fix ENV wire on the carbon panel. 45. Overturn harness . 46. Soldering HV harness . (Use INNER SERVICE PANEL PP0 to PP1B Connectivity Plan )

47. After all soldering , transfer ISP Panel to the stacking table.

cutsoldering table

48. Fix the wires on the PP0 Panel. 49. Use the tools and tape for correctly installation of the wires. 50. Take up Extra length wires to the corrugated panel. 51. Fix the wires with glue.

glue.

tape

tools

52. Final bonding flange 53. Spray silicone on the tool. 54. Install ½ flanges in device. 55. Put glue on stacks and 2 shims. 56. Fix stacking in the tool. 57. Install Tool for bending . 58. Bend the bundles.

Tool for bending