Download G1-W42-Electrical Systems and Wiring Diagrams
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Service Manual 10 Electrical Systems and Wiring Diagrams. Figure 28 Fuse Pane Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 113 Service Manual Figure 29 Fuse Label Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 114 Service Manual Figure 30 12 V Dual Battery Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 115 Service Manual 1 A/C SYSTEM BLOCK DIAGRAM Scale: NTS 2 ESC CLUTCH CONTROLLED DIAGRAM Scale: NTS Figure 31 Cab AC System Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 116 Service Manual Figure 32 Inertia Switch Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 117 Service Manual Figure 33 PCM Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 118 Service Manual Figure 34 Driver Input and Fuel Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 119 Service Manual Figure 35 Gear Selector See REF500334-PB -- ELEC LOOP, GEAR SELECTOR, MY06 W42 GAS SB. Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 120 Service Manual Figure 36 Powertrain CAN Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 121 Service Manual Figure 37 DUO CAN Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 122 Service Manual Figure 38 Instrument Cluster Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 123 Service Manual Figure 39 HV System Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 124 Service Manual Figure 40 DUO Inverter Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 125 Service Manual Figure 41 HV Battery Pack Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 126 Service Manual Figure 42 300VDC to 12 VDC Inverter Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 127 TEMP1 TEMP2 Service Manual Figure 43 Power Assist System Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 128 Service Manual Figure 44 Pumps and Fans Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 129 Service Manual Figure 45 Misc Workhorse Harnesses Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 130 Service Manual Figure 46 ABS System Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 131 Service Manual Powertrain CAN – DB9 Powertrain - CAN bus: 500k bps IGN KEY CAN2-23+/37Key Start (12VHi Effect) Vcsw Vign KeyOn-16 Crash Switch Vbat PS-HSOUT-14 PS-HSOUT-28 PS-HSOUT-42 PS-MC-30 Fuse Fuse Fuse Fusible Link - EV Switch – dash mounted NO 12V + Battery Engine Coolant Temperature Sensor 12V 2kΩ ADIN8-27 10VREF Accelerator Pedal POT1 Accelerator Pedal POT2 A Chassis PWR-8 PWM 1 RTN-3 Throttle 1 Throttle 2 (Siemens) Flash: 512 kbytes RAM: 256 kbytes EEPROM: 8kbytes REF-4 J2-G PPS1 AN-1 PWM to Analog Converter (PAC) RET-12 J2-F PPS1-RET Throttle Actuator Control Module (TAC) PPS2-5V REF REF-5 PWM 2-11 RET-11 GND-7 J2-B PPS2 AN-2 A ABS Active ABS Module Sensor Ground ABS Pump Vign NC Brake Switch J2-C ADIN4-25 +10Vext-32 ADIN2-24 ADIN7-41 J1-14 Engine J2-46 Controller Engine Oil Pressure J1-63 J2-58 Vcsw Cab Heating Pump ICE Enb, DOL Engine On Vbat Transmission Range Sensor (GM) NO A B P P 0 1 0 C R 0 0 1 P N 1 0 0 D 1 0 1 J1-19 33Ω 12Ω Vign J2-47 DUO Inverter Mot & Gen J2-53 Vign ADIN3-39 DO20-10 Emergency STOP (mandatory for Shuttle Bus only) Safety Cut off (DOH) ABS Rear Wheel Speed (P42 chassis only) T. Resistor:120Ω DO19-11 Power Assist Switch HV+ L41 HV- M2 KeyOn-19 T TEMP_RTN - 27 o Temperature from Inductor CAN-16+/26- DUO-CAN Vign DB9 9 CAN 7+/2- 820Ω 10VREF Diode only mandatory when buzzer present GND-9 Vbat ABS Module Vign NC Low Pressure Enb-25 NC PWM22-8 ADIN5-40 Park Brake TEMP_EXT - 15 DUO-CAN bus Brake Failure J2-3 Batt-8 220Ω J2-51 J1-17 Wake Vbat 33Ω AGND-15 T. Resistor:120Ω 3 12V Starter, DOH, 2.5A 1kΩ Vcsw Vbat Vcsw Vbat Pin-5 12V Starter 6 8 Sw P 4 Sw B 5 Sw A B A DIN12-21 Instrumentation Ground DO25-2 Rad. Cooling Fan, DOL ADIN1-38 Low Temp Fan 1 DIN14-22 PWM21-9 X01-1 X01-4 Power Assist Low Pressure Warning Buzzer (Mandatory for Shuttle Bus only) 5Ω J2-6 J2-2 Low Temp Fan 2 HV+ DO28-5 Power Assist Enable, DOL Regen Disable Switch (Shuttle Bus only) X01-2 J1-13 Fuel Level Sender (240Ω) J2-48 Trans “Mode B”, DOH, 2.5A J2-5 Fuel Level J2-54 Engine Fuel Pump Vign PE (GM) J1-75 Vcsw DIN11-35 DO18-12 Pin-5 T. Resistor: 120Ω J3-2+/3Back Light Dimmer J3-15 Vbat J1-11 Hi Beam Vign J1-9 J2-12 Left Turn Instrument J1-10 Cluster Right Turn (Vansco) J1-12 Seat Belt J1-1 Headlights On J1-5 ABS Warning J2-19 D1 D2 D3 Check Engine J1-07 CAN1-31+/17- Fuel Level HV- Z e A Brake Switch HV+ J2-D PPS2-RET J2-8 (Purolator only; disconnect on Shuttle Bus) Neutral Vcsw (Cobasys) PWM 2 RTN-2 DO27-4 240VAC/16A A+/Ba NiMH N Battery Pack U 336V 8.5Ah L Gen II Vbat J2-J (Axiomatic) PWM 1-10 CPU: C167, 16bit, 20MHz 12V (GM) Powertrain Control Module PWM24-6 DICO PWM23-7 DIN10-20 10VREF °C Alternator ADIN6-26 T. Resistor: 120Ω PPS1-5V REF Pin-9 Vign Pin-7+/2- Pin-3 Vign Ch-On X02-1 MES-DEA Charger X02-8 X02-3/5 HV- HV+ Note: This is an external battery charger not normally connected to vehicle. PWM note CH-Plug Charger On, Hi (12V) Effect PWM(305Hz) Conn-On-Dmy 1k Vign NO Vbat LGND-29 Casing GND (Thermo King) Air Con P1-01 Control Panel ClimaAIRE 2 Vign Air Con Dimmer 220kΩ Vbat Air Con Clutch Relay GND-1 (Thermo King) P2-09 P2-09 P1-10 P1-18 Vign HV+ J6-1 J6-13 Vbat HV- Chassis Ground A DICO Sensor Ground PA Motor Inverter (Satcon) HV+ HV- 2.2kΩ DCDC Converter Enable,DOH DIN9-34 2 10VREF DO26-3 GND Charger Connector Note: During normal operation, only CH_Plug is connected to ground DO17-13 DIN13-36 1 1 3 2 DCDC Converter 1 3 2 DCDC Converter (Satcon) 12V Chassis LT Pump 2 LT Pump 1 HV- Air Con Motor Inverter DMOC 245 HV+ HV- (Satcon) 12V Chassis (Shuttle Bus only) (Azure) (Shuttle Bus only) Figure 47 Vehicle Interface Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 132 Service Manual ABS Rear Wheel Speed, Active Low PWM Safety Cut Off , Active High ICE Enable, Active Low E-Drive, Active Low DICO Powertrain Control Module (PCM PRND Accel 3 2 BRK ABS Active Oil Pressure Charger On, 12V effect Fuel Level Brake Switch (NC, Active High) Conn-On-Dmy (Active Low) Engine Coolant Temp Key-Start Crash Switch Regen Disable Gauges – Vehicle Speed (km/h) – Battery SOC (%) – Fuel Level (%) – Powertrain Temperature (C) Powertrain CAN—500Kbps Throttle B Throttle A PWM to Analog Converter TAC -- Key Start Acknowledge -- Precharge active -- Precharge state -- BMS mode -- Isolation Resistance -- Total Batt Voltage -- Total Batt Current -- Max discharge-current -- Min regen-current -- Max Batt volt -- Min Batt volt -- SOC -- BMS status -- BMS Fault Battery Control Module (BCM) Junction Box 1.0mF ECU Gasoline Engine ( GM 4.8L max. 161kw @ 4000rpm ) Battery Pack (336V x 8.5Ah NiMH, Liquid Cooling) 336V DUO CAN Warning Lights LCD Text 1 – Charging Line 1 – 8x ASCII 2 – Wait Line 2 – 8x ASCII 3 – Check Engine Low Side Outputs 4 – Cruise 1 – Output 1 5 – Economy Mode 2 – Output 2 6 – DRL On Warning 3 – Output 3 7 – Water in Fuel 8 – Engine brake Warning 9 – Stop Warning 10 – RBS Disabled 11 – Generic Indicator 12 – High Voltage Hazard 13 – 12V Charge System 14 – Seat Belt 15 – Brake Warning 16 – ABS 17 – Service Required 18 – Oil Pressure 19 – Low Fuel Level 20 – Drive Enabled 21 – E Drive 22 – Power Limit Rad Cooling Fan, Active Low DC-DC and LT pump Enable, Active High 12V Starter Enable, Active High Charger Control, Active Low PWM (305Hz) Power Assist Enable, Active Low Engine Throttle Position A, Active Low PWM Engine Throttle Position B, Active Low PWM Transmission DTC Fix, Active High 1.1mH/ 240A max Instrument Cluster (IC) # 1 CAN ID (hex) 21A 2 3 250 252 4 253 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 254 255 256 257 258 259 25E 25F 700 701 702 703 7B0 7B1 7B2 7B3 7B4 7B5 7B6 7B7 7B8 7B9 7BA 7BB Update Rate (ms) Type From To Data 50 cmd PCM BCM Pack connect command, clear faults Pack state, precharge state, isolation resistance, 100 data BCM PCM fault codes, SOC, coolant temp 100 data BCM PCM Pack voltage, current Max and min module voltage, w/ corresponding 200 data BCM PCM temperature and number Max and min module temperature, w/ 200 data BCM PCM corresponding voltage and number 1000 data BCM PCM Pack trip amp-hours in, out 100 data BCM PCM Pack max power limits, discharge and charge 100 data BCM PCM Pack lifetime amp-hours in 100 data BCM PCM Pack lifetime amp-hours out 100 data BCM PCM Pack percent of life remaining 1000 data BCM PCM Pack stored faults one-shot data BCM PCM Pack software version 50 cmd PCM IC IC vehicle speed, SOC, fuel level, temperature 50 cmd PCM IC IC indicator lamps and outputs 100 cmd PCM IC IC text line 1 100 cmd PCM IC IC text line 2 100 data PCM (diag) accelerator and brake inputs 100 data PCM (diag) generator and engine speed feedback 100 data PCM (diag) HV power variables 100 data PCM (diag) generator power 100 data PCM (diag) motor torque, battery power 100 data PCM (diag) motor, generator, inverter temperature 100 data PCM (diag) bit flags 100 data PCM (diag) modes/control bits 100 data PCM (diag) vehicle control feedback its 100 data PCM (diag) vehicle control feedback bits 100 data PCM (diag) accelerator and engine variables 100 data PCM (diag) bit flags Siemens DUO Inverter (650V) Generator: Siemens 90kW(max. cont) & 110kW(max. peak)@ 4000rpm Power steering Controller Motor:Siemens 80kw(max. cont), 110kw(max. peak)@ 9000rpm Power steering motor 300V DC – 12V DC Converter Figure 48 Block Diagram Azure Dynamics Series Hybrid Electric Vehicle – 2006/7 Shuttle Bus MAN500666 Rev A 133