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Thomas Built Buses TBB 6002 Saf-T-Liner HDX Chassis Electrical Student Guide.

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Presentation on theme: "Thomas Built Buses TBB 6002 Saf-T-Liner HDX Chassis Electrical Student Guide."— Presentation transcript:

1 Thomas Built Buses TBB 6002 Saf-T-Liner HDX Chassis Electrical Student Guide

2 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Course Objectives locate primary system components locate harness and wiring routing read and understand Thomas drawings understand J1587 and J1939 utilize ICU for diagnostics follow troubleshooting procedure

3 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Course Content 1.Primary System Components 2.Battery, Ignition, Ground 3.Wiring and Harnesses 4.Understanding Thomas Drawings 5.J1587 and J Retrieving fault codes 7.Evaluation

4 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 1 Primary System Components

5 Page 1-2 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary Components Locations Front Interior Compartment Transmission Control Center Engine Compartment

6 Page 1-3 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Front Interior Compartment

7 Page 1-4 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Front Interior Compartment Signal Stat PCB#4 ABS ECU Printed Circuit Board 4, ABS Control Module Signal Stat Module

8 Page 1-5 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Front Interior Compartment 9 pin Data Link Daytime Running Light Module Option VEC Centers, Daytime Running Light Module, 9 pin Data Link Connector Front VEC Centers

9 Page 1-6 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Front Interior Compartment Mercedes Engine VCU

10 Page 1-7 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components identified as P190, P220, P221 in drawings provides additional connections and control for various options Front VEC Centers

11 Page 1-8 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Transmission Control Center located on left frame rail at front axle contains transmission TCU and VIM See Drawing#

12 Page 1-9 Saf-T-Liner HDX Chassis Electrical TBB6002 Transmission Control Center Vehicle Interface Module - VIM service brake active signal to TCU neutral start neutral sense- fast idle, lift operation reverse- signal from TCU for back-up alarm retarder active – signal for brake lights

13 Page 1-10 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Rear Box standard size rear ignition, start

14 Page 1-11 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components Rear Box VEC 100 amp Contactor 9 pin Data Link See drawing#

15 Page 1-12 Saf-T-Liner HDX Chassis Electrical TBB6002 Primary System Components VEC-Vehicle Electrical Center rear ignition relay fan controller relay air dryer relay engine ignition power rear start relay power and ground to engine-mounted ecu

16 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 2 Battery, Ignition and Ground

17 Page 2-2 Saf-T-Liner HDX Chassis Electrical TBB6002 Battery, Ignition and Ground Battery Switches on Rear Box signal to Breaker Solid State Power Switch controls battery to Body and Chassis

18 Page 2-3 Saf-T-Liner HDX Chassis Electrical TBB6002 Battery, Ignition and Ground Battery From Power Switch to Bulkhead studs then to PCB1 & 2 for Body and PCB4 for Chassis

19 Page 2-4 Saf-T-Liner HDX Chassis Electrical TBB6002 Battery, Ignition and Ground Use Drawings# & to answer these questions Where is PCB4 grounded?_______________________ The intake heater has a _____amp breaker> The positive cable go from the battery to the _________. The negative cable on the alternator goes to the ______. The key switch on signal goes from the key switch to ___________ then to__________ then to ___________ What is the circuit number controlled by the engine compartment door?___________ What circuit number tells the start circuit the bus is in neutral?_________ List the fuse/s that could cause the ignition circuit to fail: ____________________________________________

20 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 3 Wiring and Harnesses

21 Page 3-2 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring Harnesses Types: Interior- dash Exterior- chassis inside left frame rail, front bumper Rear Box –inside the box See Drawing# This is a list by harness type (location) Note there are 17 interior harnesses, each bus only has 1. On older pusher models each system had its own harness like engine, ABS, Transmission These harnesses were combined into only 2 harnesses Only use the drawings that match your bus components like MBE,WABCO, Allison 3000 series

22 Page 3-3 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring 3 panel design allows easy access to front exterior harness and bulkhead connections

23 Page 3-4 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring Bulk Head Transition from Interior Harness to Exterior Harness Junction for battery and ground cables J75 J76

24 Page 3-5 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring Terminal Board See drawing# attached to bulkhead behind PCB#4 used to combine common circuits; J1587, GND identified as TB1 in drawings older models had a TB#2 inside rear box

25 Page 3-6 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring color coded SAE J2191 standards numbered every 4 inches

26 Page 3-7 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring Circuit Numbers Thomas # SAE #1104 See drawing# start circuit Locate circuit 52#1104 Locate circuit 52B#1104 use the Thomas circuit number when tracing a wire The SAE number will be the same for circuits with similar functions

27 Page 3-8 Saf-T-Liner HDX Chassis Electrical TBB6002 (SAE number has been omitted) Circuit numberDescriptionColor 1Engine ECM bat gnd (in)W 6Engine ECM bat power (in)R 19Gauge power rear boxPK 21Headlamp highLTG 47Fuel sender signalPK-W 48Fuel level+PK-W 52Ignition PowerPK 52IgnitionPK 102Marker powerBR 116Panel lamp groundW 122Roll back module powerBL 173Man trans clutch sw grnd(out)LTBL-W 196Fuel water/separator powerDKG-W 200Remote throttle sig analogPRP 250Ecm Ground(out)GY 278Right control switch supplyPRP-W 279Left control switch supplyPRP-W 289Transmission neutral signalW 294Air tank drainR/R-W 305Ignition switch powerPK 305Ignition access supplyPK 306Ignition run signalPK Circuit Numbers

28 Page 3-9 Saf-T-Liner HDX Chassis Electrical TBB Headlamp powerGY 307Headlamp powerLTG 309Park brake inputR-W 320Windshield wiperPRP-W 335A/C signalLTBL 342Ammeter signalPK 385DRL powerLTG 392Adj pedal signalR-W 393Adj pedal returnR-W 431Preheater powerDKG 443Door signalT-W 446Snow chainR-W 108AStepwell lightPRP-W 1139YWater in fuel light gndGY 122ARoll back module signalBL 136BNeutral signalBL 14BSGauge powerR 14EChassis power LEDR 18GLow air pressure SW jumperW 200JPTO set speed B signalPRP 222FHdlmp dim sig flash to passLTG 222LHdlmp dim sig lh turnLTG 233BOpt indicator lampRW 23CBackup lightsBR 262BRetarder signal (in)R-W Circuit Numbers

29 Page 3-10 Saf-T-Liner HDX Chassis Electrical TBB GRetarder in useR-W 262KBrake switch signalR-W 278ARight wiper motor park supplyPRP-W 278BRight wiper motor low supplyPRP-W 278CRight wiper motor high supplyPRP-W 279ALeft wiper motor park supplyPRP-W 279BLeft wiper motor low supplyPRP-W 279CLeft wiper motor high supplyPRP-W 294AAir tank drainR-W 29ALamp power supplyBR 29DLamp groundGY/BR 30GTransmission Temp-LTBL-W 315AWiper module parkDKBL 315BWiper module lowDKBL 315CWiper module highDKBL 342AAmmeter commonW 376ABattery powerR 376CIgnition powerO 376IIABS relay active signalO 376JABS ECU serv brake signalO 376LIABS lampO 376RRetarder disable signalO 377LF+Left Front wheel speed signalBR 377LFOLeft front modulator exhaustO 377LR-Left rear wheel speed returnW Circuit Numbers

30 Page 3-11 Saf-T-Liner HDX Chassis Electrical TBB LR+Left rear wheel speed signalBR 377RF-Right front wheel speed returnO 377RF+Right front wheel speed signalBR 377RR-Right rear wheel speed returnO 377RR+Right rear wheel speed signalBR 378LF-Left front modulator commonW 378LFILeft front modulator holdO 378LR-Left rear modulator commonW 378LRILeft rear modulator holdO 378RF-Right front modulator commonW 378RFIRight front modulator holdO 378RFORight front modulator exhaustO 378RR-Right rear modulator commonW 378RRIRight rear modulator holdO 378RRORight rear modulator exhaustO 38LLeft turn signalY 38RRight turn signalDKG 392AAdj pedal returnR-W 393AAdj pedal signalR-W 406DCrossing armPRP-W 406EChild alarmPRP-W 431CIntake Grid Heater LampO 431HGrid heater ground(out)W 439+CAN+ (out)GY 439AIgnition powerGY Circuit Numbers

31 Page 3-12 Saf-T-Liner HDX Chassis Electrical TBB D-CAN- (in)GY 439S-V speed signal (return) 439S+V speed signal (in)GY 439UIgnition ground(out)PRP 439VFast idle indicator lamp sigPRP 439W-H2O in fuel sensor returnGY 439W+H2O in fuel sensor signalGY 440ADash check eng lampGY 440BDash park brake lampGY 440BService brake switchGY 440ECruise set signalGY 440FCruise set signalGY 440GServ brake SWW 440OTTPS sensor groundGY 440P-TPS sensor signal-GY 440P+TPS sensor signal+GY 440SDash buzzer groundW 440SStop eng dash lampW 440V1Idle validation(NC) signalGY 440V2Idle validation(NO) signalGY 443GDoor returnDKBL 461AReverse signalBL 47GFuel sender groundW 48GFuel level-PK-W 52BIgnitionPK Circuit Numbers

32 Page 3-13 Saf-T-Liner HDX Chassis Electrical TBB CStart signalPK 58ECoolant pumpLTBL 60ARight turn signalY 61ALeft turn signalDKG 6ABattery powerR 6BBattery powerR 6CBattery powerR 6DBattery powerR 6EBattery powerR 6FBattery powerR 71AAIgnition powerR 71BKey SW starter interlockPK 98AHeater fan lowLTBL 98ADDefrost fan lowLTBL 98BHeater fan mediumLTBL 98HHeater fan highLTBL 98HDDefrost fan highLTBL 98PDDefrost fan lowLTBL BATBattery powerR C840Emission signalGY C844Emission signal returnGY C857Starter lockoutGY C857Engine running signalGY C998Emission returnGY E002Battery powerBK Circuit Numbers

33 Page 3-14 Saf-T-Liner HDX Chassis Electrical TBB6002 E003Battery power sensorBK E008Retarder enableW E009GroundW E014Reverse signalBK E033Dimmer powerPK E107Solenoid G returnBK E110Solenoid F returnBK E1106Key SW aux range inhibitBK E1107Second shift scheduleBK E1109Exhaut brake signalBK E1110Retarder disable signalBK E1123Range inhibitBK E1125Trans Ind LampW E1125Range inhibit signalBK E1126Trans TCU speed signalT E1128Brake return signalBK E119Exhaust brake signalBK E120Solenoid A returnBK E121Solenoid B,E supplyBK E1212Transmission temp lampW E123Power for neutral signalBK E128Solenoid B returnBK E130Solenoid C,G supplyBK E131Solenoid D returnBK E139Output speed sensorBK Circuit Numbers

34 Page 3-15 Saf-T-Liner HDX Chassis Electrical TBB6002 E141Engine speed sensorT E144Sensor groundBK E147Sump temp signalBK E162C3 pressure signalBK E165Oil level signalBK E169Exhaust brake signalBK E170Shift selector data bit 1BK E171Shift selector data bit 2BK E172Shift selector data bit 4BK E173Shift selector data bit 8BK E174Shift selector parity bitBK E180Shift selector displayBK E195Transm Idle signalBK GNDGroundW GNDEElectronics groundW GNDHHeater groundW J1587- O J1587+ DKG J1587SJ1587 shieldshield J1939- DKG J1939+ Y J1939SJ1939 shieldshield N23Idle signalGY N31Wait to start light gndGY N98AECM powerGY N98BECM powerGY N98CECM powerGY Circuit Numbers

35 Page 3-16 Wiring Maintenance Dos: inspect wires repair properly protect Don’ts: damage when testing make poor repairs leave loose Return to manufacture’s standard or improve it Saf-T-Liner HDX Chassis Electrical TBB6002

36 Page 3-17 Saf-T-Liner HDX Chassis Electrical TBB6002 Wiring Each harness connector is labeled with a “Plug Number” The plug number will be referenced in the drawings Don’t remove the white labels

37 Page 3-18 Saf-T-Liner HDX Chassis Electrical TBB6002 Harness Plug Location NumberDescriptionLocation B58Butt splice at Back-up AlarmEngine Compartment B59Butt splice at Back-up AlarmEngine Compartment BS14Butt splice at luggage compartment lightLuggage Compartment BS20Butt splice at Booster PumpEngine Compartment BS22Butt splice at Engine Compartment Door Kill SwitchEngine Compartment P100ABS ECMInterior Chassis Elec Center P102Right Front ABS ModulatorFront Axle P103Right Front ABS SensorFront Axle P104Left Front ABS ModulatorFront Axle P105Left Front ABS SensorFront Axle P109Adjustable foot pedal switchDash P111Throttle Postion SensorPedal P115Shift SelectorDash P12Right TurnDash P120Adjustable foot pedal motorCab at pedal P1229 pin Deutch connectorInterior Chassis Elec Center P13Left TurnDash P167Single pin connector at fan controllerEngine Compartment P168Two pin connector at fan controllerEngine Compartment P17Engine ECMEngine Compartment P183Air Tank Pressure SenderAir Tank P184Air Tank Pressure SenderAir Tank

38 Page 3-19 Saf-T-Liner HDX Chassis Electrical TBB6002 P190Fuse center below PCB#4Interior Chassis Elec Center P192Heater at floor on left side of heaterCab P196Diode Block mounted to inside firewallInterior Chassis Elec Center P207Right Front Turn SignalFront External Bulkhead P209Left Front Turn LightFront External Bulkhead P211Left Wiper MotorFront External Bulkhead P217Wiper ModuleInterior Chassis Elec Center P218Steering Column P221Fuse center below PCB#4Interior Chassis Elec Center P229Rear Ignition Switch Rear BoxEngine Compartment P230Engine Start Switch Rear BoxEngine Compartment P231Engine Compartment Light SwitchEngine Compartment P232Chassis Power Switch Rear BoxEngine Compartment P233Body Power Switch Rear BoxEngine Compartment P246Mercedes VCU/brownInterior Chassis Elec Center P247Mercedes VCU/grayInterior Chassis Elec Center P248Mercedes VCU/purpleInterior Chassis Elec Center P276Luggage Compartment SwitchCab Switch Panel P287J1939 Data Link connection to Transm TCUForward of Front Axle P288Air Dryer P43Daytime Running Light ModuleInterior Chassis Elec Center P46Wiper ModuleInterior Chassis Elec Center P50Key SwitchDash P53Cruise On/Off SwitchDash P54Cruise Set/Resume SwitchDash Harness Plug Locations

39 Page 3-20 Saf-T-Liner HDX Chassis Electrical TBB6002 Harness Plug Locations P60Dimmer SwitchSteering Column P64Pink connector to ICUDash P65Pink connector to ICUDash P74Stepwell lightStepwell P7562 pin Bulkhead ConnectorFront External Bulkhead P76102 pin chassis bulkhead connectorFront External Bulkhead P78VEC/Black outside rear boxEngine Compartment P79VEC/Gray outside rear boxEngine Compartment P8Right Head LightFront External Bulkhead P80VEC/Blue outside rear boxEngine Compartment P81VEC/Green outside rear boxEngine Compartment P83Rear electrical boxEngine Compartment P85VEC 2 pin outside rear boxEngine Compartment P9Left Head LightFront External Bulkhead P93J1939 terminating resistorInterior Chassis Elec Center P96Fuel/Water Separator SensorEngine Compartment P99ABS ECMInterior Chassis Elec Center T12Single ring terminal at Battery+Battery Box T13Single ring terminal at Battery-Battery Box T14Single ring terminal at Battery-Battery Box T16Single ring terminal at alternatorAlternator T18Single spade terminal at washer motorFront External Bulkhead T19Single spade terminal at washer motorFront External Bulkhead TB2-1Terminal Board 2 inside Rear BoxEngine Compartment TB2-2Terminal Board 2 inside Rear BoxEngine Compartment TB2-3Terminal Board 2 inside Rear BoxEngine Compartment

40 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 4 Understanding Thomas Drawings

41 Thomas Body PCB Electrical Page 4-2 Understanding Thomas Drawings Types Charts- a visual graph displaying routing and/or options information used as reference Installation- a visual representation of either the component installation like harness routing or the installed component Assembly- a visual representation of every piece used to make the assembly includes dimensions and part numbers assembly drawing numbers are the part number for the assembly Schematic- a visual representation of the flow of electricity through a specific path including all components used primarily for diagnostic purposes

42 Page 4-3 Saf-T-Liner HDX Chassis Electrical TBB6002 Understanding Thomas Drawings Installation Drawing Answer the following questions using Drawing# On a MBE engine when is the fan turned on?________ How long does it take for the fan to Ramp UP?_______ Where is the battery supply connected to the module? _____________________________________ At what temperature is the alarm activated?________ Answer the following questions using Drawing# What is the part number of the VIM?________________ How many fasteners are required to install the TCU?___

43 Page 4-4 Saf-T-Liner HDX Chassis Electrical TBB6002 Understanding Thomas Drawings Assembly Drawings Use Drawing# to answer these questions What is the distance from the Bulkhead to the Body Chassis Interface?_________ Where would I find CHAS_H_PCB_P22-C?__________ Describe a plan to locate splice S7 on the bus?______ ____________________________________________ How many cavity positions are in P76?______ Circuit 200#1413 starts at plug______ pin no______ and goes to plug______ pin no______. What is the function of wire 379A ?_____________ What is the vendor’s part number for circuit 37 in P220? _________

44 Page 4-5 Saf-T-Liner HDX Chassis Electrical TBB6002 Understanding Thomas Drawings Locate Drawing# Common Systems Where would I find P11-C? _____________________ What is the plug number for the DRL module?______ What color is circuit 37#1313?___________ What is the pin location for circuit 279C#2102 at the wiper module?_____________ The bold vertical dotted line indicates________________ Locate J76, the connector is drawn different at the top than at the bottom; why?_________________________ What major system component is located at grid location D3?_______________________ Locate circuit 439A#1512 at grid C5; where would I find the other end of this wire?____________________

45 Page 4-6 Saf-T-Liner HDX Chassis Electrical TBB6002 Understanding Thomas Drawings Answer the following questions using Drawings# and Relay#_____ on PCB4 supplies B4 buss bar with ignition power. PCB4 has ______ 30amp buss bars. LED#17 on PCB4 is ________ and tells the bus the ________________ is in use. The decal found on the back of the front interior compartment will tell me what each LED light indicates. Yes or No What is the horn fuse number?________ _______amps Relay K-1 is used for _____________________. Where can I located the wire that signals the body that the key switch is on?_________________________________ PCB4 supplies the ABS _____________________________

46 Page 4-7 Saf-T-Liner HDX Chassis Electrical TBB6002 Understanding Thomas Drawings Locate Drawing# Common Systems Complaint: left headlight does not come Draw a straight line schematic for this circuit What could cause this complaint?___________________ Where should I begin testing?______________________

47 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 5 J1587 & J1939

48 Page 5-2 Saf-T-Liner HDX Chassis Electrical TBB6002 J1587 Used for Communicating outputs – dash indicators, active fault code, ICU BAUD rate 9,600 bits per second orange and green wires twisted once per inch Each of the system modules uses these wires The ICU3 gets its gauge, voltage and odometer info via 1587 from engine If J1587 is open what behavior will the driver report? _________________________________________ ICU3 VCUECU TCU ABS

49 Page 5-3 Saf-T-Liner HDX Chassis Electrical TBB6002 J1939 Used for Communicating outputs – digital signals to other systems BAUD rate 256,000 bits per second yellow and green wires twisted once per inch bi-directional path What does the Engine tell the Transmission? _____________________________________ What does the Transmission tell the Engine? _____________________________________ Does the Hydraulic Fan Control Module use J1939 for outputs or inputs?_______________ Hydraulic Control module VCUECU TCU ABS

50 Page 5-4 Saf-T-Liner HDX Chassis Electrical TBB6002 J ohm Terminating Resistors-TR Required to maintain consistent environment for data Locate at front and rear of harness (bus)

51 Page 5-5 Saf-T-Liner HDX Chassis Electrical TBB6002 J1939 Construction and Repair round Deutsch pins special crimper required gold plated pins replace bad connectors replace harness by section or solder twice per color

52 Page 5-6 Saf-T-Liner HDX Chassis Electrical TBB6002 J1939 Hands-on Activity If J1939 is open between the engine and transmission, what behavior would the driver report? _______________________________________ What happens if the Hydraulic Fan module does not receive temperature data? ______________________________________ Use handout to conduct testing of J1939

53 Page 5-7 Saf-T-Liner HDX Chassis Electrical TBB6002 J1587 & J1939 Hydraulic Fan Control Module

54 Page 5-8 Saf-T-Liner HDX Chassis Electrical TBB6002 Hydraulic Fan Control Module J1587 & J1939

55 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 6 Retrieving Fault Codes

56 Page 6-2 Saf-T-Liner HDX Chassis Electrical TBB6002 Retrieving Active Fault Codes ICU dash cluster is a micro-processor receives data via J1587 and displays any system module with an active fault will transmit code via J1587 code will be displayed in LED screen

57 Page 6-3 Saf-T-Liner HDX Chassis Electrical TBB6002 Before Code Retrieval: locate Reset Mode button set Park Brake turn key switch to on Retrieving Active Fault Codes

58 Page 6-4 Saf-T-Liner HDX Chassis Electrical TBB Push/Release diag diagnostics 1 #faults 2.Push/Hold Fault 1 first 3.Push/Release MID# Module Identifier 3.Push/Release PID/SID# Parameter Subsystem 4.Push/Release FMI# Failure Mode Identifier 5.Push/Hold Fault 2 second Retrieving Active Fault Codes Using the Reset/Mode Button

59 Page 6-5 Saf-T-Liner HDX Chassis Electrical TBB6002 Hands-on Activity Using the ICU Dash Retrieve the Active Fault Codes MID___________ SID/PID________ FMI___________ MID___________ SID/PID________ FMI___________ Using Drawing Translate the codes ______________________________ _______________________________

60 Page Saf-T-Liner HDX Chassis Electrical TBB6002 Section 7 Evaluation

61 Training Evaluation Class:__________________________ Date:___________ Instructor: _____________________ 1. Student manuals and handouts were? Excellent Good Poor Overheads, presentations, and video tapes were? Excellent Good Poor Shop demonstrations were? Excellent Good Poor The length of the course was? Too Long Just Right Too Short The pace of the presentation was? Too Fast Just Right Too Slow The amount of shop time was? Too Much Just Right Not Enough Please circle the number on each scale which most closely reflects your opinion

62 Training Evaluation page 2 7. Did the class provide the expected instruction? Yes Somewhat No Comments:_______________________________ ________________________________________ 8. Would you recommend this class to others? Definitely To Some No Do you feel that what you’ve learned will help you do your job better? Help A Lot Help Some No Help What was your overall impression of the course? Excellent Good Poor If you were to make changes, what would they be? ___________________________________________ Thanks for attending our class Please circle the number on each scale which most closely reflects your opinion


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