Azure Dynamics Parallel Hybrid Electric Vehicle
Contents
1. Body Builders Layout Book Supplement Contents Figures Tables Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement Printed versions of this document are not controlled CO DESCRIPTION BY CHECKED APPROVED INITIAL RELEASE BASED ON MAN500689 T STOKER M STRANGE J MANC USO 27FEBO9 EE eee eee ELLE es Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A li Body Builders Layout Book Supplement Contents Figures Tables Table of Contents l FORV ARD ore E a nec we ao I T E E dean tee eae coleua saree anes ieaeneeensuis l decd FA OU TFC ONO AI eeir A EAA S 2 Z PERINI ON aeir E E NE EE EE AEE 3 LLADD Va S e E E E E EEE 3 3 val ed 0 G25 11 i oae er E E A E E eee NEA E eee 4 4 ADDED CYRDA EN AE r E A T A E O O NTA 5 5 ABOUT HYBRID VEHICLES and the BALANCE HYBRID DRIVE SYSTEMG 6 6 VE PITT CY irane E A TI EN ENTOTE NE eee oaeraees 7 Sl FIC VON A Sy Sella aac A A AN 7 6 2 Disconnecting the High Voltage SYSteM cccccececsceeececeesececeeseeeeeeeeseeeeeeeseeeeeeeaeeeeseseaeaeres 8 ON OO Sas eas seen wg see seco eee eee bea setae vetiase onset E ion cane E ree seosseteneu 8 6 22 Di connection Procedur Grassa een escuekeeasbontiacomnecauineense 8 so Ven NO OG Orre ran N E E E E ceaeepesecusmeanetnnee 10 7 OO IVI OIN NG Te Te Oa oe NEE EN E TEN NE 12 TA DIMENS ond Data eni na2. If the chassis is equipped with an additional 12 V battery the battery will be mounted on the inside of the frame rail behind the transmission The additional battery will be wired in parallel with the stock 12V battery If a battery disconnect switch is required refer to Figure 38 to determine an adequate location Figure 38 outlines the routing of the 12V wiring between the 2 batteries 2 12V battery Cable Routing oy Vehicle Forward Figure 38 2 12V Battery Cable Routing a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 36 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 6 Cabin Heater Installation This section only pertains to stripped chassis as the cab heater pump is installed on cut away variants during hybridization An electric powered cab heater pump is to be installed in line with the conventional heater circulation system The purpose of this additional pump is to circulate engine coolant through the heater core while the conventional engine is off The additional circulation pump will be provided in the dunnage kit and must be installed after the SUB is built e On stripped chassis the pump is to be installed when the cab heater core is installed 8 6 1 Mounting The mounting location of the pump is the SUB builder s discretion however the mounting must meet the following criteria
3. e The pump must be mounted such that it is protected its mounting hardware does not compromise any other wire or hose routing and its hoses and wires will not chafe over time e The pump must not be mounted on any Azure bracketry without written consent of Azure Dynamics Inc e The pump must be located in the position indicated by ELECTRIC POWERED CIRCULATION PUMP in Figure 39 the loop diagram Figure 39 Engine Coolant Circulation Layout Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 37 Body Builders Layout Book Supplement Precautions Requirements Procedures The supplied pump is not self priming and should be mounted such that it is always flooded The orientation of the pump can be either o Vertical such that the inlet is above the pump body see Figure 40 ont HEX Figure 40 Coolant Pump Vertical o Horizontally such that the outlet is above the pump body see Figure 41 which illustrates the 90 of freedom SUB builders have in outlet fitting orientation nlet Figure 41 Coolant Pump Horizontal E Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 38 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 6 2 Wiring Pump wiring will also be included with the chassis the wiring includes butt splice conn
4. the pole shall be connected to 12V battery power and the normally open side to the 12V supply side of the Body AC Fans amp Controller This signal is used to control Body AC if the vehicle enters a derated mode The SUB builder will be required to supply Yazaki Socket terminal 0 75 1 00sqmm P N 7116 4101 02 for terminal 2 of the EPC 2 position connector and 12V relay s equivalent to Tyco P N VF4 65F11 S05 for control of the Body AC Fans amp Controller Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 30 Body Builders Layout Book Supplement Precautions Requirements Procedures Lf Battery 12V Ignition Body AC Controller Power amp Fans C3I1L8P Terminal 2 2Amps hax Use l or more relays tor the Body C Controller amp Fans as hece ssary Azure Dynamics provides an electric drive system to run the rear AC compressor Azure Dynamics also provides a pulley in the Dunnage kit that 1s to be used on the electric drive motor The SUB builder is to provide the compressor and the remainder of the AC system The condenser and evaporator must be roof mounted since the packaging space between the frame rails is consumed by hybrid components It is recommended that the SUB builder perform a test to determine the appropriate refrigerant charge for the selected AC components NOTE Balance hybrid shuttle bus chassis are equippe
5. E ovaeceyaeaacete pose N 12 7 1 1 2009 Ford E 450 Balance Hybrid Cut Away Chassis 158 wheelbase ccsseeeeeeee 12 7 1 2 2009 Ford E 450 Balance Hybrid Cut Away Chassis 176 wheelbase ssssececeeees 13 7 1 3 2009 Ford E 450 Balance Hybrid Stripped Chassis 158 wheelbase cssseeeeeees 14 7 1 4 2009 Ford E 450 Balance Hybrid Stripped Chassis 176 wheelbase ccccceeceeee 15 7 1 5 2009 Ford E 450 Balance Hybrid Cutaway Chassis Shuttle Bus Prep 158 wheelbase 16 Ta FAO WPI EY OI sce es E E E E 17 7 2 1 Power Train Wiring Harness ccccccececeneeeeceeeeeeseeeeeseeeeeaeeseeeaeeseseaeeseseeeeseaenseneaegss 17 7 2 2 High Voltage CQO WING ec coerce es catecece te cce cas ate Er Ee EEA TE AE ETENE 18 7 225 POWEr DISTIDUUION Harness ercovccanncdonedetsatanadieninmnnscevangencuavengouubhonnesttisetadewesidenethnsaateed 19 i2 A CUUCAWaAY Cad Harness lt cssicaccncncesevacaaaeacenaccaceauosacusaceesavananaeccieeatacnentavacuseueecatuenoaceaceaes 20 7 2 5 Stripped Chassis Cab Harness sasscsssisacncscvnscnndas eiecarweeoandas sednnndadeianeanwtsoeniassearsacvansansees 21 8 BODY BUILD PRECAUTIONS REQUIREMENTS and SPECIAL PROCEDURES 22 8 1 No Ste uA CaS sc csnsccatacccacratseaaec soneiaecasneneatancaacecasaenseeienaeass nies eaauceienceenniciesannesanmmaneaiontaenenin 22 2 VVC IOVS OLN NE VENCE ea E E tent ncasattenns 23 Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009
6. Ford E 450 Body Builders Layout Book Supplement MAN500721 A ill Body Builders Layout Book Supplement Contents Figures Tables 8 3 Air Conditioning INSTA ATION wiiasiscwscnsidsevesshdacweendvedasbeacsdsnwasveadueessnodiiswsadedeesasddaeusteabssesetenesaetiens 30 8 4 Dashboard LED and Switch Installation cc ceccecceec eee eeceeeeeeeeeneeeeeeeeeeeeeeaeeeeeaeeaeeneeaeen sees 33 8 4 1 Hybrid Enabled and Hybrid Service INGiCAtOrs ccceccececeeeeeeeeeeececeeseeeeeseeeeseseeenenes 33 8 4 2 Optional Hybrid Switches and Indicators cceccecececeececeesececeeseeeeeceeseeaeceeseeeseaeaeees 34 8 5 Additional 12V Battery Installation ccccecccsececeeeeeeeceeeececseseeeeeseeseseseseseeeeseeeaeeeeeeegeaenas 36 8 0 Capin Heater INS callie COU sea cterca cele coat caeG E E E 37 Oe LIVI UI NS ence onc ates ct npenat poreepenureg nae yee epee noon sn noaeaenee se A 37 sO 2 WV INE corecnsctacesasceutecatcenutecaes tas cncataneaecnngnseiae ngiseoisatoieses E 39 8 7 Front End Accessory Drive FEAD comerssuuxdnsdiusodesuecanvesnatsloxenusastendaeoscave TE a Naaien 40 SEUNA OAN e E re ee eee een eee eee tee 41 oe IV RG FN Saeco sees S vc deve ae es aoe cei os tong nee meg E E E E TE 41 BO TOW SWI Cecenia a E E EET ETEEN RE 41 8 11 Minim m Skirt Requirements xcsccescecensacctacwerraceseseaacececesserdencersuencee ta a N kaa ie ra a ias 41 OZ UMNO OC DECA G irsreianr saon E E ENRE E N EE E O EA 42 8 15 Body Bui
7. Layout Book Supplement Precautions Requirements Procedures 8 3 Air Conditioning Installation This section only pertains to shuttle bus variants which are to be fitted with a secondary rear air conditioning unit to condition the passenger cabin Shuttle Bus Prep chassis are equipped with connector C318P on the Switch and LED Harness which is located to the right of the steering column near the bottom of the dash board Refer to section 7 2 4 Cut Away Cab Harness for the switch and LED harness location C318P is the connector for Body AC demand signal and Body AC Power Relay Control These two signals shall be connected to the body wiring harness for rear AC driver controls Figure 32 C318P Body AC Demand amp Power Figure 33 C318P Body AC Demand amp Power Relay Control Relay Control Location C318P terminal 1 should be supplied with a 12V trigger signal when AC is desired This signal would be equivalent to the signal used to activate a FEAD AC clutch C318P is on wire 4253 the mating connector and terminal that the SUB builder will require are EPC Engineering Plastics Components 2 position unsealed connector P N E 3665 and Yazaki Socket terminal 0 75 1 00sqmm P N 7116 4101 02 C318P terminal 2 should be connected to the control side of a 12V relay s Figure 34 The other control side of the relay s shall be connected to ignition power The control side can sink a maximum of 2 Amps On the switched side of the relay s
8. axle on passenger side Figure 24 EPAS Control Connectors e DC to DC converter control connector o C060S DC DC Converter Front of Vehicle pa Traction Motor 4 tr CO60S E Figure 25 DC DC Control Connector Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 27 Body Builders Layout Book Supplement Precautions Requirements Procedures e PWM control connectors e C147SX C148SX e Stripped Chassis Mounting Location wt ay gt 4 Figure 26 SC PWM Control Connectors Figure 27 SC PWM Location e Cut Away Mounting Location C147SX C148SX Figure 28 CA PWM Control Figure 29 CA PWM Location Connectors Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 28 Body Builders Layout Book Supplement Precautions Requirements Procedures Rear Air Conditioning Motor Controller Shuttle Bus Only e NOTE All three connectors circled in Figure 30 need to be disconnected C259S e C259S C260S and the unlabeled connector C260S And 1 unlabeled AZI C onnector PART NO CTR 010066 REV 002 SERIAL NO Figure 30 Rear AC Control Figure 31 Rear AC Mounting Location Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 29 Body Builders
9. front end accessories to this system A minimum of 30 mm of clearance is required between the FEAD belts and any other components mounted in the area ME 4 paar piatli ial ii EETETETLEEE TE T Geen dismania AAAA ee POTTY ieee in 5 A 5 es z T x er b D E oer 5 4L ISG 5 4L DRIVE BELT BELT INSTALLATION INSTALLATION INSTALLATION DE LA SS ee ER uate BE A L ALTERNO DEMARREUR ISG 5 4L 104410 A Figure 43 FEAD Belt Routing Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 40 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 8 Undercoating Applying undercoating to any hybrid component or wiring is prohibited due to color coding and cooling requirements If applying undercoating to a Hybrid Chassis the undercoat must be applied to the body prior to installation on the chassis or all hybrid components and wiring must be masked off 8 9 Mud Flaps In order to eliminate water and other road debris spray from the wheels to the hybrid components the following is required e Full width mud flaps are required behind the front wheels e Full width mud flaps are required in front of the rear wheels It is the SUB builder s option to install mud flaps behind the rear wheels Caution should be exercised during the installation of mud flaps to ensure that no hybrid components or wiring
10. it straight out turn counter clockwise Service Disconnect Pin e When reassembling insert the pin into the receptacle aligning the keyed pin with the notch the handle groove will be in the vertical position e Push the pin in and turn it 4 tum clockwise until it pops into place the handle groove will be in the horizontal position Figure 3 Removing High Voltage Disconnect Pin Remove the high voltage cover from the front of the battery pack Figure 3 6 2 3 Verify No Voltage While wearing insulated gloves use a multimeter to verify there is zero or lt 1 V across the following points Figure 4 before handling or disconnecting any high voltage cables positive terminal to negative terminal e positive terminal to chassis negative terminal to chassis e positive side right of fuse to negative terminal positive side right of fuse to chassis Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 10 Body Builders Layout Book Supplement Vehicle Safety Chassis Right side of fuse Negative terminal Positive terminal Figure 4 Measuring Points The meter should show lt 1 volt If the voltage is higher wait five minutes and repeat procedure Contact Azure Dynamics if the voltage does not drop to lt 1 volt Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Bo
11. of the steering column Figure 36 shows the required orientation of the LED s Figure 36 Hybrid LED Mountin g Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 33 Body Builders Layout Book Supplement Precautions Requirements Procedures Hybrid Service and Hybrid Enabled lights will be installed prior to arrival at the body builders in most cases If this is not the case or if these indicators need to be moved follow these steps Prepare a location that meets the following criteria e Within reach of the driver while seated e Clearly visible to the driver while seated e Installed in such a way to eliminate the possibility of wire chaffing over time e Mounted in an esthetically pleasing and flush manner To install the yellow Hybrid Service LED e Prepare the dashboard mounting location e Connect C313P on the LED with C313S on the Switch and LED harness e Insert the LED into the prepared location To install the green Hybrid Enabled LED e Prepare the dashboard mounting location e Connect C314P on the LED with C314S on the Switch and LED harness e Insert LED into the prepared location 8 4 2 Optional Hybrid Switches and Indicators Depending on the application stripped chassis cutaways or cutaways for shuttle buses optional switches may need to be installed on the vehicle dashboard If the optional switches are to be installe
12. see section 6 2 Disconnecting the High Voltage System 2 If welding on the chassis the hybrid controllers must be disconnected see section 8 2 Welding on the Vehicle 3 Install Mud flaps see section 8 9 Mud Flaps 4 Install body skirts see section 8 11 Minimum Skirt Requirements 5 For Strip Chassis Only a Install Cabin Heater Pump see section 8 6 Cabin Heater Installation b Install Hybrid Indicator Lights to Dash see section 8 4 Dashboard LED and Switch Installation c Install Decals to under hood area see section 8 12 Underhood Decals 6 For Shuttle Bus Cutaway Chassis Only a Install TM16 Compressor and plumbing to Body A C system see section 8 3 Air Conditioning Installation This document does not replace any publications by Ford Truck Body Builder Advisory Service Ford s Body Builder Layout Book should be referenced for all Ford specific information At the time this document was released the Ford Body Builder Layout Book for the 2009 E 450 was found at the following web link https www fleet ford com truckbbas topics 2009 eseries_wagonvan html Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Forward Contact 1 1 About The Company Azure Dynamics AZD develops hybrid electric and electric drive technology for commercial trucks and shuttle buses AZD is a leader in
13. will be damaged 8 10 Tow Haul Switch The tow haul switch has been disabled by the hybrid vehicle controller on all Balance Hybrid Chassis 8 11 Minimum Skirt Requirements Minimum skirt requirements are intended to ensure hybrid components are out of reach of untrained individuals The Minimum requirement for the skirt is to be at least 250 mm 9 85 inches below the top of the flat portion of the frame rail This skirt must extend the entire length of the vehicle This is particularly relevant to cut away vehicles outfitted with boxes that generally do not have skirts Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 41 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 12 Underhood Decals This section only pertains to stripped chassis which do not have a hood when delivered to the SUB builder Two decals with part numbers 104407 and 104408 are provided to the SUB builder in the chassis dunnage kit The two labels are to be placed under the hood as shown in Figure 44 Prior to installing the decals the SUB builder must ensure the installation area 1s e Clean of any grime or debris e Smooth and flat e Dry 104407 104408 Se ene ee ns Figure 44 Underhood Decal Placement Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721
14. A 42 Body Builders Layout Book Supplement Post Build Inspection 8 13 Body Builder Electrical Loads The need for additional 12 V electrical loads to support customer specific features may be required If these additional loads are needed the following guidelines must be met e The 12V battery 1st and 2nd 12V batteries on SB only and HV ESS shall be disconnected prior to any electrical work e 70A continuous is the maximum allowable current to be added to the electrical 12V system e The appropriately sized Mega fuse is to be located in the AZD high current Fuse panel as indicated in Figure 45 A buss bar in place of a Mega fuse is not acceptable RAD FANS BODY BUILDER AZD FUSE PANEL 2 12V BATTERY if equipped DC DC CONVERTER SC CA ONLY Fi gure 45 Underhood High Current Fuse Panel 9 POST BUILD INSPECTION AND VEHICLE SIGN OFF The following section is to be completed once the SUB is complete The purpose of this section is to ensure the system is fully functional and safe to operate prior to delivery to the customer This inspection must be completed prior to customer delivery unless the SUB builder has the signed written consent of Azure Dynamics Inc Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 43 Body Builders Layout Book Supplement Post Build Inspection If the SUB builder completes a post build bo
15. AN500721 A 50 Body Builders Layout Book Supplement Appendix A 1 2 Body Inspection Body Inspection Complete the following table If any item fails document the failure and corrective action in as much detail as possible in the comments section and then retest to ensure a pass 1 Headlights functional low beams Z Headlights functional high beams 3 Turn signals are functional Pp 4 Sidelights roof lights functional Pe 5 Brake lights functional e Reverse lights functional 4 way flashers functional with ignition on 8 4 way flashers functional with ignition off pe 9 Hom functional S S S S y O 12 All dash switches and indicators are properly seated and functional Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 51 Body Builders Layout Book Supplement Appendix A 2 IMAGES 7 X 7 Warning Label 2 Azure ISG and Drive Belt Routing 5 4L ISG 5 4L DRIVE BELT Sticker INSTALLATION INSTALLATION DE LA CARESS AE AD EUERE BE SOUR L ALTERNO DEMARREUR i ISG 5 4L 104410 A ER Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 52 Body Builders Layout Book Supplement Appendix Key Positions Starting the vehicle Green HYBRID ENABLED light will be illuminated All electrical circuits operational and warning lights il
16. Builders Layout Book Supplement Vehicle Safety When the vehicle comes to a stop e g when a driver stops at a red light the engine will typically shut off in order to save fuel When this happens the Electric Power Assist System EPAS is enabled to maintain power steering and power brakes and the DC DC Converter is also enabled in order to charge the 12 Volt battery The vehicle also has an Integrated Starter Generator ISG mounted to the front of the engine which is used to provide quick re starts of the engine when accelerating from a stationary position and also to generate power to charge the high voltage ESS The high voltage system is self contained and it does not have to be plugged into an external power source for charging 6 VEHICLE SAFETY 6 1 High Voltage System All of the components highlighted in Figure 1 except 12V batteries are high voltage and pose a shock hazard if handled incorrectly or compromised during SUB installation The high voltage cabling is identified by orange cable orange looming or orange tape around the loom Only qualified technicians should touch these high voltage components and cables Safety procedures in Azure Dynamics Service Manual MAN500727 for 2009 Ford E 450 parallel hybrid electric vehicles should be closely followed The electrical system in this vehicle is capable of producing lethal voltage levels All drivetrain and control systems must be maintained and serviced by trained pers
17. D 1 t 1 ie Be E gi _ E ue PT E l z fe iL a ree NOTE All Dimensions in mm Figure 8 176 Wheel Base SC Dimensional Data Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 15 Body Builders Layout Book Supplement Component Layout 7 1 5 2009 Ford E 450 Balance Hybrid Cutaway Chassis Shuttle Bus Prep 158 wheelbase NO PACKAGE SPACE TS J a i io 2p oe L beara i Fes ae ce Et N T BE ff kis al que E z AW po T o A ri n E a PE AET Tae E ON HE 1 F F r NOTE All Dimensions in mm Figure 9 158 Wheel Base SB Dimensional Data Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 16 Body Builders Layout Book Supplement Component Layout 7 2 Hybrid Wiring Layout The following subsections provide images of electrical routing on the Balance Hybrid Chassis Care should be taken to carefully inspect these layout diagrams and ensure that no hybrid wiring is moved cut pulled stretched or has chafe points added to its routing If any wiring is compromised during the body build contact Product Support at productsupport azuredynamics com 7 2 1 Power Train Wiring Harness CAB HARNES
18. ER SIDE OF THE CONVENTIONAL ENGINE AN IMAGE OF THE VCU CAN BE FOUND IN Figure 16 Azure Balance Hybrid Architecture Figure 15 Step No Step Diagram Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 22 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 2 Welding on the Vehicle Any electrical welding on the vehicle should be avoided if possible If electrical welding must be performed follow the guidelines in the Ford Service Manual In addition to the Ford Service Manual the following hybrid components must be disconnected before welding to prevent damage The appropriate connecter numbers are listed below the hybrid component e VCU communication connectors o C308S C309S C310S C3085 Figure 16 VCU Communication Connectors Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 23 Body Builders Layout Book Supplement Precautions Requirements Procedures Low Voltage 12 V Batteries o Disconnect Battery Terminals A 7 l 7 Figure 17 SC 12 Battery Second Battery aw Ny pititi Wi iA ry ee a lt Transmission Output Shaft 4 r WH N Figure 19 Second 12V Battery 1f equip ped Azure Dynamics Balance Parallel Hybrid Elect
19. Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A vi Body Builders Layout Book Supplement Contents Figures Tables List of Tables Table Description Table 1 Vehicle Applicability Table 2 Added Curb Weight due to Balance Hybrid System Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A vil Body Builders Layout Book Supplement Forward Contact 1 FORWARD This document is a supplement to the Ford 2009 Body Builder Layout Book The purpose of this document is to inform Second Unit Body SUB builders of additional components that are added to Ford E series stripped chassis and cutaway chassis once hybridized with an Azure Dynamics model year 2009 Balance Hybrid Electric Drive System The information herein is intended to aid SUB manufacturers in the design and installation of SUB s onto Balance Hybrid chassis Specifically to ensure that SUB manufacturers are aware of all additional component functionality location weights and requirements for the purposes of designing SUB s that do not damage or interfere with the Balance Hybrid System In General the following steps must be followed when installing a body or other accessories to the Hybrid E 450 chassis 1 Disconnect High Voltage Battery in order to minimize the risk of any inexperienced assemblers or technicians getting hurt
20. S I F TRANSMISSION VCU ISG MOTOR n CONTROLLER TM MOTOR E CONTROLLER PAS MOTOR CONTROLLER n HV BATTERY PICTORIAL VIEW Figure 10 Power Train Wiring Harness Routing Stripped Chassis Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 17 Body Builders Layout Book Supplement Component Layout 7 2 2 High Voltage Cabling HV JUNCTION BOX ISG MOTOR CONTROLLER TM MOTOR PAS MOTOR CONTROLLER CONTROLLER PICTORIAL VIEW Figure 11 High Voltage Cable Routing Stripped Chassis Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 18 Body Builders Layout Book Supplement Component Layout 7 2 3 Power Distribution Harness POWER TRAIN DRIVERS HIGH CURRENT HRNS VF _ ISLAND FUSE PANEL gt i 12V BATTERY kT RAD FANS RELAYS FORD FUSE BOX LOW TEMP PUMP FUSE BOX PICTORIAL VIEW Figure 12 Power Distribution Routing Stripped Chassis Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 19 Body Builders Layout Book Supplement Component Layout 7 2 4 Cut Away Cab Harness Fa LED INDICATORS INSTRUMENT CLUSTER PWM INCLINOMETER INERTIA SWITCH VEHICLE FORWARD ye POWERTRAIN HARNESS I F PICTORIAL VIEW F
21. a pass DC to DC DCtoDCConverter s T a the yellow Hybrid Service and the green Hybrid Enabled LED s are illuminated temporarily when the ignition key is turned to position 4 See key position diagram in appendix A 2 IMAGES Confirm that only the green Hybrid Enabled LED is illuminated when the key is momentarily rotated to position 5 If the yellow Hybrid Service LED is illuminated then this is a fail See key position diagram in appendix A 2 IMAGES Caution The engine may start a SL Confirm the engine power steering is functional by depressing the brake pedal and rotating the steering wheel from lock to lock while the engine is idling Confirm the engine shuts off once the vehicle has warmed up while in park with the key and the green Hybrid Enabled light on Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 4 N Body Builders Layout Book Supplement Appendix Hybrid Chassis Inspection Complete the following table If any item fails document the failure and corrective action in as much detail as possible in the comments section and then retest to ensure a pass Confirm the electric power steering is functional by depressing the brake pedal and rotating the steering wheel from lock to lock while the engine is off the Hybrid Enabled light is on and the shifter is in Neutral Retur
22. al Data 0 ce ccceccecceeeeeeesnnnceeceeeeeeeeeceessesessssnaaaaes 15 Figure 9 158 Wheel Base SB Dimensional Data 0 cece ccccceeeesesnnecceeceeeeeeeeeeeeessesesssnnaaeaes 16 Figure 10 Power Train Wiring Harness Routing Stripped Chassis cc csesssseccceeeeeeeeeeeeeees 17 Figure 11 High Voltage Cable Routing Stripped Chassis cccccccccccccccceceececeeeeeceeeeeeeeeeeees 18 Figure 12 Power Distribution Routing Stripped Chassis 0 ccccseecssseccccccceeesseeeeeeeeeeeeeeaeeeeeees 19 Figure 13 Cut Away Cab Harness Routing ccccccsssseeeecceeeeeeeeeeeaaaaaeessssseseeeeceeeeeeeeeeeeeaaaaas 20 Figure 14 Stripped Chassis Cab Harness Routing ccceccccccccccccccceeeeeeeeseeeeeeeeeecceeeeeeeeeeneaaaaaas 21 Meie tor N ING ES D aeee E E A NEE 22 Figure 16 VCU Communication ConneCtOrS sisses e aan aina iena N E 23 Poote pc Oe y BI a A EE E E A E EE EE 24 Poue Io CA VB ACY ra O E E E E E E 24 Figure 19 Second 12V Battery if equipped cz seosiecsiinetorereaneessindedeiasconsocadneetoesecaswnonsebeneiuaverwnanboct 24 Figure 20 HV Battery Pack Control Connectors ccccccccccccccccccceeeeeeeeeseseeeeseeeceeeeeeeeeeenenaaaaas 23 Fegeure 21 ISG Control Connectors seiersen siis anene ne n nn nE as EErEE A AAE AEAEE AE E EEA AAE 26 Figure 22 Traction Motor Control Connectors sseseeeeeeeesssssssssssseseeererereeeesssssssssssseeeeerreeeeeee 26 Figure 23 Traction Mot
23. d they will be supplied with the chassis The switches will be connected and hanging from the Switch and LED harness as shown in Figure 37 The switches will need to be installed to meet the following criteria e Within reach of the driver while seated e Clearly visible to the driver while seated e Installed in such a way to eliminate the possibility of wire chaffing over time e Mounted in an aesthetically pleasing and flush manner Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 34 Body Builders Layout Book Supplement Precautions Requirements Procedures Switches and LED s hanging from Switch and LED Harness Figure 37 Switch and LED Harness To install the switches e Disconnect the switches from the Switch and LED Harness e Prepare a suitable mounting location on the dashboard e Re Connect the switch leads to the switch and LED Harness ensuring the following connection numbers match and are routed through the mounting location o C 150S mated with C150P Regenerative Braking off Switch o C167S mated with C167P EV mode Switch e Insert the switches into the prepared mounting location Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 35 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 5 Additional 12V Battery Installation
24. d with an electric rear AC compressor drive since an additional compressor cannot be mounted as a front end accessory The electric compressor drive is mounted between the frame rails at the rear of the vehicle behind the fuel tank Figure 35 a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 31 Body Builders Layout Book Supplement Precautions Requirements Procedures Front of Vehicle Floats 35 Rear AC Sen The electric drive is mounted to a universal compressor mounting plate shown in pink in Figure 35 e The Universal Compressor mounting plate is designed to accommodate all Seltec model TM 16 compressors but the compressor must o Have a type 2A pulley and appropriate belt o Have a 12V clutch o Have a pulley diameter of either 125mm or 135mm NOTE Although the electric drive system is designed and optimized for use with a TM16 compressor a TM08 or TM21 compressor may also be used A TM08 compressor can be installed using existing brackets and hardware whereas a TM21 compressor will require an adapter bracket along with new fasteners Note the adapter bracket design and fasteners for a TM21 compressor configuration is the responsibility of the body builder Also note that the electric drive system is not capable of providing enough power to obtain full output from a TM21 compressor Compressor mounting must meet the following requirements e Para
25. dded Curb Weight due to Balance Hybrid System a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Vehicle Safety 5 ABOUT HYBRID VEHICLES and the BALANCE HYBRID DRIVE SYSTEMS Balance Hybrid Electric drive systems are classified as a full parallel hybrid The major components are highlighted in Figure 1 below Integrated Starter Generator High 12 Volt Voltage Battery Junction Box Integrated Starter Generator Motor Second 12 Traction Controller Volt Battery Motor Controller DC DC Converter Second DC DC Converter High Voltage Service Disconnect Pin and Low Voltage Interface N Energy Storage System ESS High Voltage Battery Pack R Traction Motor Air Conditioning Unit Electric Power Assist System Motor and Motor Controller Figure 1 Balance Hybrid Architecture Cutaway Chassis with Shuttle Bus Prep The vehicle is propelled by the Traction Motor in addition to the conventional gasoline engine and automatic transmission The Traction Motor is used for torque assist during vehicle acceleration and to capture energy from regenerative braking events in which case the regenerative energy is stored in the Energy Storage System ESS Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body
26. dy check similar to the body check outlined in this section please contact Product Support at productsupport azuredynamics com to discuss the option of deferring the body check section 9 1 Hybrid Chassis Inspection Follow the instructions in the Hybrid Chassis Inspection table and record pass or fail where required If the item fails record the problem and corrective actions in the comments field then re test to ensure a pass To diagnose and repair some problems the Balance Hybrid Diagnostic tool may be required To obtain a diagnostic tool and training contact Product Support at productsupport azuredynamics com Hybrid Chassis Inspection Table is located in A 1 1 Hybrid Chassis Inspection and it is required that a copy of this table is printed completed and signed off for each vehicle 9 2 Body Inspection Follow the instructions in the Body Inspection table and record pass or fail where required If the item fails record the problem and corrective actions in the comments field and re test to ensure a pass Body Inspection Table is located in A 1 2 Body Inspection and it is required that a copy of this table is printed completed and signed off for each vehicle a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 44 Body Builders Layout Book Supplement Appendix A 1 APPENDIX 1 POST BUILD INSPECTION AND SIGN OFF The following subsections n
27. e Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Applicability 3 APPLICABILTY This supplemental Body Builder Layout Book applies to the following Azure Dynamics Balance Parallel Hybrid Ford E 450 platforms e 2009 E 450 Stripped Chassis SC 158 and 176 inch wheelbase e 2009 E 450 Cutaway CA Chassis 158 and 176 inch wheelbase e 2009 E 450 Cutaway Chassis 158 inch wheelbase Shuttle Bus Prep SB In all cases the common specifications of the Ford E 450 Chassis are 5 4L Triton V8 S5R110 Automatic Torqueshift with tow haul and without PTO 14 050 lbs Rear Axle Ratio 4 56 1 non limited slip 155 Amp Table 1 Vehicle Applicability a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Added Curb Weight 4 ADDED CURB WEIGHT The following table lists the curb weight that is added to the stock Ford E 450 due to the hybrid system Note that the Ford Body Builder Layout Book should be referenced for the curb weights of the stock chassis corresponding to the appropriate Ford Body Code and Wheel Base 2009 E 450 Stripped E49 Ga O 2009 E 450 Stripped E49 nae Chassis 2009 E 450 Cutaway E45 Chassis 158 176 158 176 2009 E 450 Cutaway E45 Chassis Shuttle Bus Prep Table 2 A
28. ectors part 103743 and a long wire extension with connector CO61P on one end part 103875 To wire the heater pump e Connect CO6IP to CO6IS on the power distribution harness located on the drivers side of the engine bay Route the long extension wire from CO61P to the heater pump such that o Wire will not be chafed on sharp edges o Wire is clear of any moving parts o The wire is securely clipped and restrained e Trim the long extension wire to length such that there is enough to connect the pump lead to the extension wire with the supplied butt splice connectors e Attach wire 2043AC on the pump lead to wire 2043AB on the wire extension using the butt splice connectors and heat shrink e Attach wire 9004AC on the pump lead to 9004A on the extension wire using the butt splice connectors and heat shrink e Ensure the wire routing is secured by clipping and will not chafe on sharp edges EE eee eee EEE Ee Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 39 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 7 Front End Accessory Drive FEAD The Balance hybrid chassis is equipped with an Integrated Starter Generator ISG that is connected to the engine crankshaft via a 2 belt spider bracket assembly Figure 42 shows the ISG Figure 43 shows the belt routings for the FEAD It is not acceptable to mount any additional
29. eed to be completed prior to customer delivery ER Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 45 Body Builders Layout Book Supplement Appendix A 1 1 Hybrid Chassis Inspection Hybrid Chassis Inspection Complete the following table If any item fails document the failure and corrective action in as much detail as possible in the comments section and then retest to ensure a pass ae a I 2 ans ie sata S ee R E ee eaaa a a Electronics coolant level sufficient Coolant must be 50 50 DexCool orange coolant water mixture Confirm all hoses and harnesses are routed and secured to original design Confirm all connectors removed for welding are e Ps Mr Co D D ISG Motor Controller oo ee Traction Motor Motor Controller a a AC Motor Controller Shuttle Bus Only PWM to analog converter a a ee Low Voltage 12V Battery s a a int dn cms A SO Azure Dynamics Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 4 Ov Body Builders Layout Book Supplement Appendix Hybrid Chassis Inspection Complete the following table If any item fails document the failure and corrective action in as much detail as possible in the comments section and then retest to ensure
30. igure 13 Cut Away Cab Harness Routing Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 20 Body Builders Layout Book Supplement Component Layout 7 2 5 Stripped Chassis Cab Harness INSTRUMENT CLUSTER LED INDICATORS INCLINOMETER 7 a INERTIA SWITCH PWM POWERTRAIN HARNESS I F PICTORIAL VIEW Figure 14 Stripped Chassis Cab Harness Routing Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 21 Body Builders Layout Book Supplement Precautions Requirements Procedures 8 BODY BUILD PRECAUTIONS REQUIREMENTS and SPECIAL PROCEDURES The following subsections outline precautions requirements and procedures that are specific to the Balance Hybrid chassis and must be closely followed to prevent damage or injury 8 1 No Step Areas Many hybrid components are not to be used as a step at any point during the body build Figure 15 below shows the components that are added to the stock chassis and identifies whether it 1s suitable to stand on during the SUB build In addition all Hybrid wiring should not be stepped on refer to section7 2 Hybrid Wiring Layout for reference to where these cables are routed NOTE PARTICULAR ATTENTION IS TO BE PAID TO AVOIDING THE APPLICATION OF ANY PRESSURE ON THE VCU THE VCU IS LOCATED NEAR THE REAR PASSENG
31. lder Electrical LOadSiercneniiiiirser riietas E ea EE Ea 43 9 POST BUILD INSPECTION AND VEHICLE SIGN OFF eccccccssseeeeeeeeeeeees 43 9 LAHy rid Chassis INSPECTION nasere EE N E EENE EEA 44 Dad BOOY epe ON cieri EE E EE EEE EAS 44 A 1 APPENDIX 1 POST BUILD INSPECTION AND SIGN OFF ec eececeeeeeeeeeee 45 ALA AHyoria Chassis INSpECtOT sincinennrseras iiec e E EE 46 Pile Body MEDEOT arrisco tirri E E A E 51 PEATE E E ane ES A aces T A EA EN ade Geld once Ua AT E E E 52 E Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Contents Figures Tables List of Figures Figure Description Figure 1 Balance Hybrid Architecture Cutaway Chassis with Shuttle Bus Prep 0 0 0 000 6 Figure 2 Removing Low Voltage Connector from High Voltage Battery Pack eee 9 Figure 3 Removing High Voltage Disconnect Pin ccc ccccccccccccccceeceeeeeeeeeesseeeseeeeeeeeeeeeeeeeees 10 Peura Mea Ut PO 8 ce osctecnaarinecieses E 11 Figure 5 158 Wheel Base CA Dimensional Data ce ceccccceeesessnnneeeeeeeeeeeeeeeeeeseeessssnaaeaes 12 Figure 6 176 Wheel Base CA Dimensional Data ccceccccccccccccceececeeeccececeeeeeeeeeeeeeeeeeeeeees 13 Figure 7 158 Wheel Base SC Dimensional Data cccecccccccccccccceccceceeeeceeeeeeeceeeeeeeeeeeeeeeeees 14 Figure 8 176 Wheel Base SC Dimension
32. lights do not illuminate on the instrument cluster during the road test except for their bulb check ot FL Confirm the drive train does not have abnormal vibrations at highway speeds Confirm there are no power steering system leaks and the level is sufficient after the road test 1s complete Confirm there are no engine coolant system leaks and the level is sufficient after the road test is complete Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 4 O Body Builders Layout Book Supplement Appendix Hybrid Chassis Inspection Complete the following table If any item fails document the failure and corrective action in as much detail as possible in the comments section and then retest to ensure a pass 19 Confirm there are no low temperature coolant system leaks and the level is sufficient after the road test is complete Ensure there is at least 15mm 5 8 inch clearance between the FEAD ISG motor and any cables wires or hoses Ensure there is at least 30mm 1 inch clearance between FEAD belts and any other parts 7 X 7 Yellow warning label mounted under the hood See A 2 IMAGES Ford drive belt routing sticker replaced with Azure drive belt ISG belt routing sticker See A 2 IMAGES R Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement M
33. llel alignment between the compressor pulley and the drive motor pulley must be within 1mm o This can be achieved by adjusting the taper bushing position on the electric drive motor shaft Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 32 Body Builders Layout Book Supplement Precautions Requirements Procedures e Refrigerant supply and return lines to the compressor require between 70cm to 90cm of extra hose length This additional hose is required to lower the entire compressor mounting plate during AC servicing o Hoses must be constrained such that they will not chafe on sharp edges during operation 8 4 Dashboard LED and Switch Installation In order to install dashboard LEDs C348P must be mated with C348S on the passenger compartment side of the firewall This connection will connect the Switch and LED harness to the cab harness Detailed wiring diagrams for these circuits can be found in the electrical diagrams section of the Azure Dynamics 2009 Ford E 450 Parallel Hybrid Electric Vehicle Service Manual and general layout schematics are shown in the Wiring layout section of this document 8 4 1 Hybrid Enabled and Hybrid Service Indicators A green Hybrid Enabled and a yellow Hybrid Service LED indicator light is installed in the dashboard of stripped chassis cutaways and shuttle bus cutaways These lights are installed to the right
34. luminated R Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 53 Body Builders Layout Book Supplement Appendix Notes Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 54 Body Builders Layout Book Supplement AZURE DYNAMICS part of the solution EE eee eee EEE Ee Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 55
35. n shifter to Park after test aa 13 Confirm the DC DC converter is functional by measuring the 12V battery voltage while the engine 1s off the Hybrid Enabled light is on and the shifter is in Park The voltage should be greater than 13 5V aa Confirm the electric cab heater pump is functional and fluid is circulating by feeling the electric cab heater pump for vibrations while the engine is off and the Hybrid Enabled light is on Confirm the rear AC system is functional and that it cycles on and off as demand is requested Shuttle Bus Only Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 48 Body Builders Layout Book Supplement Appendix Hybrid Chassis Inspection Complete the following table If any item fails document the failure and corrective action in as much detail as possible in the comments section and then retest to ensure a pass Perform a road test which Isamimimum of 20 km 12 miles Reaches vehicle speed of 100km h 62 mph Incorporates frequent stops Incorporates at least 3 key cycles Turn off and on Incorporates forward and reverse motion Incorporates at least one 3 point turn 16 Confirm the yellow Hybrid Service light does not illuminate during the road test except for its bulb check Confirm the Check Engine light shape of an engine or any other warning
36. ok Supplement MAN500721 A 11 Body Builders Layout Book Supplement Component Layout 7 COMPONENT LAYOUT 7 1 Dimensional Data 7 1 1 2009 Ford E 450 Balance Hybrid Cut Away Chassis 158 wheelbase oO oe ee NOTE All Dimensions in mm Figure 5 158 Wheel Base CA Dimensional Data Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 12 Body Builders Layout Book Supplement Component Layout 7 1 2 2009 Ford E 450 Balance Hybrid Cut Away Chassis 176 wheelbase aS Sra et i ML ILE i To S 4A NOTE All Dimensions in mm ea ape i ou eein me UATH i Figure 6 176 Wheel Base CA Dimensional Data Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 13 Body Builders Layout Book Supplement Component Layout 7 1 3 2009 Ford E 450 Balance Hybrid Stripped Chassis 158 wheelbase NOTE All Dimensions in mm Figure 7 158 Wheel Base SC Dimensional Data Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 14 Body Builders Layout Book Supplement Component Layout 7 1 4 2009 Ford E 450 Balance Hybrid Stripped Chassis 176 wheelbase U pe Po mao ha 5 hi ih
37. onnel wha are qualified to service Azure hybrid vehicle systems Never use water to extinguish electrical fires doing so greatly increases the risk of shock Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Vehicle Safety 6 2 Disconnecting the High Voltage System Always remember to consult the vehicle safety section before servicing any hybrid component It is recommended that the high voltage battery be disconnected before any hybrid chassis has any body build operations completed on it Various components in the hybrid system contain capacitors that store high voltage charges Once the battery is disconnected a multimeter high voltage must be used to verify that there is no voltage present Follow the proper procedures in this manual to disconnect the high voltage battery Removing the high voltage battery pack involves contact with potential deadly voltages All safety procedures MUST be followed to prevent the possibility of an electrical shock When working on the battery pack the keys to the vehicle should be in the possession of the technician Keys should not be in the ignition 6 2 1 Tools e Multimeter Rated for a working voltage of at least 500 V DC e Electrical safety gloves Rated for a working voltage of at least 500 V 1 e ASTM class 00 or better 6 2 2 Disconnection Procedure Tu
38. or Control Location sseseeeeeeeeeesssssssssssseseeeeererrseesssssssssssssseeeereeeeeee 26 Figure 24 EPAS Control Connectors sacciessstcahecesssancacaaeaueseasaneosatsaseedegeaavesiy sagadedaviegadettasuesessiessars 2l Penre DC DECC Onor Connotea E E E E 27 Figure 26 SC PWM Control Connectors ssssessssssssessssssssssssssssssssssssssssseseseseseesseseeseesseeeeeeeeeeeee 28 Fre A aE PNM EOC O E eie e EE EE E EEE EEES 28 Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Contents Figures Tables List of Figures Figure Description Figure 28 CA PWM Control Connectors Figure 29 CA PWM Location Figure 30 Rear AC Control Connectors Figure 31 Rear AC Mounting Location Figure 32 C318P Body AC Demand amp Power Relay Control Figure 33 C318P Body AC Demand amp Power Relay Control Location Figure 34 C318P Terminal 2 Connection Figure 35 Rear AC System Figure 36 Hybrid LED Mounting Figure 37 Switch and LED Harness Figure 38 2 12V Battery Cable Routing Figure 39 Engine Coolant Circulation Layout Figure 40 Coolant Pump Vertical Figure 41 Coolant Pump Horizontal Figure 42 Integrated Starter Generator ISG Figure 43 FEAD Belt Routing Figure 44 Underhood Decal Placement Figure 45 Underhood High Current Fuse Panel EE eee eee ELLE es Azure Dynamics Balance Parallel
39. ric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 24 Body Builders Layout Book Supplement Precautions Requirements Procedures e High voltage battery pack control connector o CO053S Electric Power Assist Motor Controller Figure 20 HV Battery Pack Control Connectors Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 25 Body Builders Layout Book Supplement Precautions Requirements Procedures e Control connectors on the integrated starter generator motor controller o C2518 C252S and C253S gt 4 ISG Motor Controller Pea ey a E Fetes Tee Tete Figure 21 ISG Control Connectors e Control connectors on the traction motor controller o C153S C154S C155S High Voltage Junction Box ISG Motor Controller CS A oan re z4 am Figure 22 Traction Motor Control Figure 23 Traction Motor Control Connectors Location Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A 26 Body Builders Layout Book Supplement Precautions Requirements Procedures e Control connectors on the Electrical Power Assist EPAS motor controller o Stripped Chassis and Cut Away Variant C156S C158S C338S Located as shown in Figure 1 o Shuttle Bus Variant C350S C351S C338S Located aft of rear
40. rn the ignition key OFF and remove the key from the ignition Clean the front area of the battery pack to remove dirt and debris Remove the low voltage connector CO53S from the front of the battery pack by turning counter clockwise approximately 1 4 turn Figure 2 a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Vehicle Safety C WP oi Figure 2 Removing Low Voltage Connector from High Voltage Battery Pack e Remove the service disconnect cover from the front of the battery pack Figure 3 Remove the high voltage service disconnect pin from the battery While wearing insulated gloves push the Service Disconnect Pin in turn it 1 4 turn counter clockwise and then pull it out Figure 3 Removing the high voltage service disconnect pin cuts off high voltage from the vehicle but the individual cells inside the battery pack will remain charged Do not cut into the high voltage battery case or penetrate the battery in anyway Always assume the battery may still be electrically active until it is verified that there is no voltage Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Vehicle Safety service Disconnect Cover High Voltage Cover After tuming the pin pull
41. the delivery of electric and hybrid electric systems with an accumulation of over 25 million miles of experience Azure Dynamics Corporation is a public company trading in Canada TSX AZD in the United Kingdom AIM ADC and in the US OTCQX AZDDF Azure Dynamics power trains are protected in the United States under the following patents U S 6 909 200 6 879 054 6 768 621 6 643 149 6 555 991 6 242 873 5 898 282 and may be the subject of pending patent applications Contact Information Azure Dynamics Inc Product Support Toll Free Number 1 866 473 1636 Phone 905 607 3486 Fax 905 569 0592 Email productsupport azuredynamics com Web hitp www azuredynamics com a Azure Dynamics Balance Parallel Hybrid Electric Vehicle 2009 Ford E 450 Body Builders Layout Book Supplement MAN500721 A Body Builders Layout Book Supplement Definitions 2 DEFINITIONS Unless otherwise defined all terms used in this document are consistent with the definitions found in the Ford 2009 body builder layout book Some terms used in this document may be followed by an abbreviation that will be used thereafter within the document 2 1 Abbreviations AC Air Conditioning AZD Azure Dynamics Inc CA Cut Away EPAS Electric Power Assist FEAD Front End Accessory Drive VF Interface ISG Integrated Starter Generator TM Traction Motor SB Shuttle Bus SC Stripped Chassis SUB Second Unit Body WB Wheel Base a Azur
Download Pdf Manuals
Related Search