Balance Hybrid Service Manual
Contents
1. AZD Service Manual 2 General Information 21 VGRICIE D CSC EID ON ca 14 22 VIN e isesauscidunsausereseussstinscartsunisieas 14 ZS Weding ON TNE V eniClE sssini in naia ETERA aai 14 24 Lifingand acko siisii aani aana aaaNaa aa 15 29S TONNO an 16 2 6 Low Voltage C harging s ssssssssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnan 16 2 amp 7 B dy SNOD A CHVIV sitar nnn 17 This manual covers the general servicing of the2008 Balance hybrid electric vehicle 2 1 Vehicle Description A zure Dynamics has released into service a model year 2008 Ford E 450 Balance hybrid electric Vehicle These vehicles function in the same manner as a non hybrid vehicle except as noted in this manual This vehicle is built on a 2008 Ford E 450 commercial stripped chassis with a modified drive train and modified electronic system controls 2 2 VIN There are no characters in the VIN to identify it as a hybrid vehicle 2 3 Welding on the Vehicle Any electrical welding on the vehicle should be avoided if possible If electrical welding must be performed follow the guidelines from the Ford Service M anual In Addition to following the Ford Service manual the following hybrid components must be disconnected before welding to prevent damage e VCU C308S C309S and C310S e Low voltage 12 volt battery 12 volt battery terminals e High voltage battery pack control connector C053S e Control connector on the ISG inte2. c Vehicle 2008 Ford E 450 15 AZD Service Manual W hen jacking or lifting a vehicle do not place the jack or hoist on any of the hybrid high voltage components or cables 2 5 Towing W hen towing the vehicle follow the guidelines found in the Ford E 450 Owner s Guide for more information Inform the tow truck operator that chains or straps are not to be attached to or placed over high voltage components or cables The high voltage cables can be identified by the bright orange colored loom refer to illustration i Never place chains or straps on or across any high voltage components or orange cables Figure 3 2 6 Low Voltage Charging The 12 volt battery can be charged the same as non hybrid vehicles Do not use 24 volts to jump start the vehicle Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 16 AZD Service Manual 2 7 Body Shop Activity e When baking Azure hybrid vehicle do not expose it to prolonged temperatures above 65 C This will cause the high voltage battery pack to release hydrogen Do not bake or expose A zure Hybrid vehicles to temperatures above 65 C e Follow proper welding procedures as outlined above e If any hybrid component is physically damaged it must be replaced Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 17
3. grated starter generator DM oC C251S C252S C2538 Azure Dynamics Balance Hybrid electric Vehicle 2008 Ford E 450 14 AZD Service Manual e Control connector on the traction motor DM oC C153S C154S amp C155S e Control connector on the electrical power assist DM oC C156S C158S amp C3385 e DC DC converter control connector C060S e Cab harness C020S e Disconnect FORD PCM Also refer to Ford service manual instructions for welding on a vehicle coms Cab WF wea Front of Vehicle cae cssap Ford Harness Ford Splic l i c24 ISG Motor Feedback 7 z ltenato Power Distribution b corap czasmi Chassis GND es i Y S jassia LAF N ISG Bmoc RTGS YEP P 7 r Canes F Paa n n caw yest T2535 A ara gwia eroo a if AC90 Dmoc A A aii Chassis GMD To Batt Cals fr 4 pas 5 C1555 as TS OO ee As Cisas i a JL i CORP Ao 7 ZA po cars Gan Terminato Plenum Fan pP Ee N at 5 i je Th 31405 f F RTE na ow Po i eTORO j j cans ni l i W ae i h a TI47P AC 90 pz DEBE COSAP CIM Charging cose Ess u a Can Terminator COS35 arts CH PAS In Line Figure 2 Location of Components and Electrical Connectors 2 4 Lifting and J acking Refer to Ford 2008 E 450 Service M anual for Ford recommended lifting locations W hen lifting the vehicle do not place the jack or hoist on any of the high voltage electrical components or orange cables Azure Dynamics Balance Hybrid electri
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