Form No.

: QAD-QMO-FMT-042 Log9 Intellectual Property, Infringement Restricted

Rev. No: 01 Confidential Information
Rev. Date: 17.04.2023

WORK INSTRUCTION
Process PED Production Quality PED HOD
Harness-189 Sub-Assembly(SA:3)
Description Prepared By Verified By Approved By Approved By
Process No. B200 WI Serial No. PED-WI-B8K-042
Product Name RapidX 8000_11_V04_48.3V_160Ah WI Released Date 18-04-2023 Yashaswini K R Sign & Name Sign & Name Sign & Name

Product Number L1D295020040 WI Revision No. 03

Cycle Time WI Revised Date 07-06-2023 Date: Date: Date: Date:
Sl.
Process / Part Parameter Specification Checking Method Special Characteristics Control Method Frequency Incharge
No.

Sl. Tools & Equipment's

Details and sequence of Operation Images Part Number Part Name Qty. Pre Check / Post Check
No. Required

WIRE HARNESS -
Post Check: Ensure that the
189 ( DO, CAN,
L1A725280171 1 sealant Should be applied at
Pick the silicon sealant 7091 Using a UART, AEROSOL
the tip of the HST
stir stick & pre-filled syringe, apply SENSOR)
1
silicon sealant 7091 to the harness
outside gland side as shown in Fig.
Dowsil 7091 silicon
L1A340030008
sealant

Pick the 600mm pre-cut cotton tape & Post Check: Ensure that the
ETI,Black cloth
wrap the cotton tape to the sealant cotton tape Should be wrapped
2 L1A595010001 tape,MPN:ETI-FRI- 600mm
applied part (wrapping of the cotton without any gap & Sealant
BL-18M-01
tape can be from any end). should not be visible

Pick the cotton tape & wrap the

insulation tape to cover the cotton
Steel grip insulation Post Check: Ensure that no
3 tape (Wrapping of the insulation tape L1A595010004 -
tape-Balck sealant should not be visible
should be opposite of the cotton tape
end).
Heat shrink the HST using a hot air
gun (150° temp) & Pick the silicon
sealant 7091 Using a stir stick & pre- Dowsil 7091 silicon
4 Hot air gun L1A340030008 -
filled syringe, apply silicon sealant sealant
7091 to the C5-CAN cable coupler Post Check: Ensure that the
side edge. sealant Should be applied at
the tip of the HST without any
Pick the 80mm pre-cut cotton tape & ETI,Black cloth gap if there is any gap
5 wrap the cotton tape to the sealant L1A595010001 tape,MPN:ETI-FRI- 80mm observed heat shrink the HST.
applied part. BL-18M-01 Sealant setting time is 24Hr

Ensure that gap must be 15-

25mm from the coupler end.
Pick the Insulation tape & wrap the
Steel grip insulation
6 insulation tape to cover the cotton L1A595010004 -
tape-Balck
tape

Heat shrink the HST using a hot air

gun (150° temp) &Pick the silicon
sealant 7091 Using a stir stick & pre- Dowsil 7091 silicon
7 Hot air gun L1A340030008 -
filled syringe, apply silicon sealant sealant
7091 to the C10-KEY wire coupler Post Check: Ensure that the
side edge sealant Should be applied at
the tip of the harness without
Pick the 80mm pre-cut cotton tape & ETI,Black cloth any gap if there is any gap
8 wrap the cotton tape to the sealant L1A595010001 tape,MPN:ETI-FRI- 80mm observed heat shrink the HST.
applied part. BL-18M-01 Sealant setting time is 24Hr

Ensure that gap must be 15-

25mm from the coupler end.
Pick the Insulation tape & wrap the
Steel grip insulation
9 insulation tape to cover the cotton L1A595010004 -
tape-Balck
tape

Heat shrink the HST using a hot air Post Check: Ensure that the
gun (150° temp) & Pick the silicon sealant Should be applied at
sealant 7091 Using a stir stick & pre- the tip of the HST without any
10 Hot air gun - - -
filled syringe, apply silicon sealant gap if there is any gap
7091 to the C7- UART Cable coupler observed heat shrink the HST.
side edge Sealant setting time is 24Hr
RECOMMENDED PPE's
Safety Shoes ESD Aprons Hand Gloves ESD wrist strap REMARKS :

Page No. -5
 Form No.: QAD-QMO-FMT-042 Log9 Intellectual Property, Infringement Restricted
Rev. No: 01 Confidential Information
Rev. Date: 17.04.2023

WORK INSTRUCTION
Process PED Production Quality
Harness-189 Sub-Assembly(SA:3)
Description Prepared By Approved By Approved By Approved By
Process No. B200 WI Serial No. PED-WI-B8K-042
Product Name RapidX 8000_11_V04_48.3V_160Ah WI Released Date 18-04-2023 Yashaswini K R Sign & Name Sign & Name Sign & Name

Product Number L1D295020040 WI Revision No. 03

Cycle Time WI Revised Date 07-06-2023 Date: Date: Date: Date:
Sl. Tools & Equipment's
Details and sequence of Operation Images Part Number Part Name Qty. Pre Check / Post Check
No. Required

Pick the 80mm pre-cut cotton tape & ETI,Black cloth Post Check: Ensure that the
11 wrap the cotton tape to the sealant L1A595010001 tape,MPN:ETI-FRI- 80mm sealant Should be applied at
applied part. BL-18M-01 the tip of the harness without
any gap if there is any gap
observed heat shrink the HST.
Sealant setting time is 24Hr
Pick the Insulation tape & wrap the
Steel grip insulation Ensure that gap must be 15-
12 insulation tape to cover the cotton L1A595010004 -
tape-Balck 25mm from the coupler end.
tape

Heat shrink the HST using a hot air

gun (150° temp) & Pick the silicon
Dowsil 7091 silicon
sealant 7091 Using a stir stick & pre- L1A340030008 -
13 sealant
filled syringe, apply silicon sealant
7091 to the C6-Smoke sensor Cable Post Check: Ensure that the
coupler side edge sealant Should be applied at
the tip of the harness without
ETI,Black cloth any gap if there is any gap
Pick the 80mm pre-cut cotton tape &
L1A595010001 tape,MPN:ETI-FRI- 80mm observed heat shrink the HST.
14 wrap the cotton tape to the sealant
BL-18M-01 Sealant setting time is 24Hr
applied part.
Ensure that gap must be 15-
25mm from the coupler end.
Pick the Insulation tape & wrap the
Steel grip insulation
15 insulation tape to cover the cotton L1A595010004 -
tape-Balck
tape

'Post Check: Ensure that the

Pick the corrugated tube and insert the
HST should not visible at the
16 tube into the gland outside the harness- - Corrugated tube -
cable branches end after
189 as shown in fig.
inserting the corrugated tube

Post Check: Ensure that the

Pick the Insulation tape & wrap the
Steel grip insulation Insulation tape Should be
17 insulation tape around the corrugated L1A595010004 -
tape-Balck covered with corrugated tube
tube.
completely

Post Check: Ensure that a 15-

25mm gap should be
Pick the 4no,s of the corrugated tube
maintained at the couper end
(which comes along with the harness-
18 189) and insert the tubes into C10- - Corrugated tube -
Ensure that the HST should
KEY, C5-CAN, C6-Smoke sensor,
not visible at the cable
and C7-UART cables.
branches end after inserting
the corrugated tube

Pick the Insulation tape (which comes Post Check: Ensure that the
along with the harness-189) & wrap Steel grip insulation Insulation tape Should cover
19 L1A595010004 -
the insulation tape around the tape-Balck the a corrugated tube
corrugated tube for all the 4 cable completely

RECOMMENDED PPE's
Safety Shoes ESD Aprons Hand Gloves ESD wrist strap REMARKS :

Page No. -5
 Form No.: QAD-QMO-FMT-042 Log9 Intellectual Property, Infringement Restricted
Rev. No: 01 Confidential Information
Rev. Date: 17.04.2023

WORK INSTRUCTION
Process PED Production Quality
Harness-189 Sub-Assembly(SA:3)
Description Prepared By Approved By Approved By Approved By
Process No. B200 WI Serial No. PED-WI-B8K-042
Product Name RapidX 8000_11_V04_48.3V_160Ah WI Released Date 18-04-2023 Yashaswini K R Sign & Name Sign & Name Sign & Name

Product Number L1D295020040 WI Revision No. 03

Cycle Time WI Revised Date 07-06-2023 Date: Date: Date: Date:
Sl. Tools & Equipment's
Details and sequence of Operation Images Part Number Part Name Qty. Pre Check / Post Check
No. Required
Pre Check: Check for
Heat the HST inside the gland side by damages, the correct type of
WIRE HARNESS -
using a hot air gun (150° temp)(Do stickering of (DO, CAN,
189 ( DO, CAN,
20 not Heat shrink completely there Hot air Gun L1A725280171 1 UART, SMOKE SENSOR &
UART, AEROSOL
should be some gap for applying KEY) &
SENSOR)
sealant) Ensure that HST has some gap
for applying sealant after heat

Post Check: Ensure that the

Turn the harness towards the side of
the inside gland, and pick the silicon
sealant 7091 Using a stir stick & pre-
21
filled syringe, apply sealant 7091 to
the harness Inside gland side as
shown in the figure.
sealant Should be applied
Particularly at the tip of the
Dowsil 7091 silicon
- L1A340030008 - harness without any gap if
sealant
there is any gap observed heat
shrink the HST. Sealant setting
time is 24Hr

Pick the 400mm pre-cut cotton tape & Post Check: Ensure that the
ETI,Black cloth
wrap the cotton tape to the sealant cotton tape Should be wrapped
22 - L1A595010001 tape,MPN:ETI-FRI- 400mm
applied part. (wrapping of the cotton without any gap & Sealant
BL-18M-01
tape can be from any end). should not be visible

Pick the Insulation tape & wrap the

Post Check: Ensure that the
insulation tape to cover the cotton
Steel grip insulation Insulation tape Should be
23 tape. (Wrapping of the insulation tape - L1A595010004 -
tape-Balck cover the cotton tape without
should be opposite of the cotton tape
any gap
end).

Post Check: Ensure that the

Pick the Harness-189 and heat the
HST for all the wire harness C9-KEY
switch, C3-PCB, C4-UART, C2-Do,
C1-CAN, & C8- KEY wire branches
24
and then Pick the silicon sealant 7091
Using a stir stick & pre-filled syringe
and apply silicon sealant 7091 to all
the HST on the wire harness.
sealant Should be applied at
the tip of the harness without
any gap if there is any gap
Dowsil 7091 silicon observed heat shrink the HST.
Hot air Gun L1A340030008 -
sealant The sealant setting time is
24Hr
Ensure that gap must be 15-
25mm from the coupler end.

Post Check: Ensure that the

Pick the 80mm pre-cut cotton tape &
cotton tape Should be wrapped
wrap the cotton tape to the sealant
ETI,Black cloth without any gap & Sealant
applied part for all the harness wires
25 - L1A595010001 tape,MPN:ETI-FRI- 80mm should not be visible
end C9-KEY switch, C3-PCB, C4-
BL-18M-01
UART, C2-Do, C1-CAN, & C8- KEY
Ensure that gap must be 15-
wire.
25mm from the coupler end.

Pick the Insulation tape & wrap the

Post Check: Ensure that the
insulation tape to cover the cotton
Steel grip insulation Insulation tape Should be
26 tape for all the harness wires end C9- - L1A595010004 -
tape-Balck covered with cotton tape
KEY switch, C3-PCB, C4-UART, C2-
without any gap
Do, C1-CAN, & C8- KEY wire.

Post Check: Ensure that the

Pick the silicon sealant 7091 Using a
sealant Should be applied at
stir stick & pre-filled syringe, apply
Dowsil 7091 silicon the tip of the harness without
27 silicon sealant 7091 to the inside of - L1A340030008 -
sealant any gap if there is any gap
the sub-branches harness -189 as
observed heat shrink the HST.
shown in the fig.
Sealant setting time is 24Hr
RECOMMENDED PPE's
Safety Shoes ESD Aprons Hand Gloves ESD wrist strap REMARKS :

Page No. -5
 Form No.: QAD-QMO-FMT-042 Log9 Intellectual Property, Infringement Restricted
Rev. No: 01 Confidential Information
Rev. Date: 17.04.2023

WORK INSTRUCTION
Process PED Production Quality
Harness-189 Sub-Assembly(SA:3)
Description Prepared By Approved By Approved By Approved By
Process No. B200 WI Serial No. PED-WI-B8K-042
Product Name RapidX 8000_11_V04_48.3V_160Ah WI Released Date 18-04-2023 Yashaswini K R Sign & Name Sign & Name Sign & Name

Product Number L1D295020040 WI Revision No. 03

Cycle Time WI Revised Date 07-06-2023 Date: Date: Date: Date:
Sl. Tools & Equipment's
Details and sequence of Operation Images Part Number Part Name Qty. Pre Check / Post Check
No. Required

Post Check: Ensure that the

cotton tape Should be wrapped
Pick the 200mm pre-cut cotton tape & ETI,Black cloth
without any gap & Sealant
28 wrap the cotton tape to the sealant - L1A595010001 tape,MPN:ETI-FRI- 200mm
should not be visible
applied part BL-18M-01

Post Check: Ensure that the

Pick the Insulation tape & wrap the
Steel grip insulation Insulation tape Should be
29 insulation tape to cover the cotton - L1A595010004 -
tape-Balck covered with cotton tape
tape
without any gap

Pre-Check: Ensure to press

the Red rubber cap before
Pick the glue gun and apply the Glue
30 Glue Gun L1A340010002 Glue stick - applying the Glue
to the C7 UART dummy coupler end
Ensure the Glue should not
overflow

Pre-Check: Ensure to press

Pick the glue gun and apply the Glue the Red rubber cap before
31 to the C6-Smoke sensor dummy Glue Gun L1A340010002 Glue stick - applying the Glue
coupler end Ensure the Glue should not
overflow

Post Check: Ensure that the

Pick the C5 CAN Sticker and stick it
correct label is pasted to the
onto the C5 CAN wire corrugated
32 respective wire
tube
Ensure that all sticker should
2 Pin White connector
be toward the coupler

RECOMMENDED PPE's
Safety Shoes ESD Aprons Hand Gloves ESD wrist strap REMARKS :

Page No. -5
 Form No.: QAD-QMO-FMT-042 Log9 Intellectual Property, Infringement Restricted
Rev. No: 01 Confidential Information
Rev. Date: 17.04.2023

WORK INSTRUCTION
Process PED Production Quality
Harness-189 Sub-Assembly(SA:3)
Description Prepared By Approved By Approved By Approved By
Process No. B200 WI Serial No. PED-WI-B8K-042
Product Name RapidX 8000_11_V04_48.3V_160Ah WI Released Date 18-04-2023 Sign & Name Sign & Name Sign & Name Sign & Name

Product Number L1D295020040 WI Revision No. 03

Cycle Time WI Revised Date 07-06-2023 Date: Date: Date: Date:
Sl. Tools & Equipment's
Details and sequence of Operation Images Part Number Part Name Qty. Pre Check / Post Check
No. Required

Pick the C6 SMOKE SENSOR

Post Check: Ensure that the
Sticker and stick it on to the C6
correct label is pasted to the
33 SMOKE SENSOR wire corrugated
respective wire
tube.
6 pin white connector

Pick the C10 KEY Sticker and stick it Post Check: Ensure that the
onto the C10 KEY wire corrugated correct label is pasted to the
34
tube respective wire
2 Pin Black connector

Pick the C7 UART Sticker and stick it Post Check: Ensure that the
onto the C7 UART wire corrugated correct label is pasted to the
35
tube respective wire
3 Pin White Connector

Post check: Ensure that all the

sticker should be in same
direction

RECOMMENDED PPE's
Safety Shoes ESD Aprons Hand Gloves ESD wrist strap REMARKS :

Page No. -5