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

Thomas Built Buses TBB 6002 Saf-T-Liner HDX Chassis Electrical Student Guide. Saf-T-Liner HDX Chassis Electrical. Course Objectives locate primary system components locate harness and wiring routing read and understand Thomas drawings understand J1587 and J1939

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

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

  2. Saf-T-Liner HDX Chassis Electrical • 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 Page TBB6002

  3. Saf-T-Liner HDX Chassis Electrical • Course Content • Primary System Components • Battery, Ignition, Ground • Wiring and Harnesses • Understanding Thomas Drawings • J1587 and J1939 • Retrieving fault codes • Evaluation Page TBB6002

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

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

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

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

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

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

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

  11. Saf-T-Liner HDX Chassis Electrical Primary System Components Transmission Control Center • located on left frame rail at front axle • contains transmission TCU and VIM See Drawing# 62180452 Page 1-8 TBB6002

  12. Saf-T-Liner HDX Chassis Electrical 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 Page 1-9 TBB6002

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

  14. Saf-T-Liner HDX Chassis Electrical Primary System Components Rear Box See drawing#62204035 VEC 9 pin Data Link 100 amp Contactor Page 1-11 TBB6002

  15. Saf-T-Liner HDX Chassis Electrical 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 Page 1-12 TBB6002

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

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

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

  19. Saf-T-Liner HDX Chassis Electrical Battery, Ignition and Ground Use Drawings#6220419 & 62205231 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: ____________________________________________ Page 2-4 TBB6002

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

  21. Saf-T-Liner HDX Chassis Electrical Wiring • Harnesses Types: • Interior- dash • Exterior- chassis inside left frame rail, front bumper • Rear Box –inside the box See Drawing#62204066 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 Page 3-2 TBB6002

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

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

  24. Saf-T-Liner HDX Chassis Electrical Wiring Terminal Board See drawing#62204066 • 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 Page 3-5 TBB6002

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

  26. Saf-T-Liner HDX Chassis Electrical Wiring Circuit Numbers 52#1104 Thomas # SAE 52 1104 • See drawing#62205231 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 Page 3-7 TBB6002

  27. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-8 TBB6002

  28. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-9 TBB6002

  29. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-10 TBB6002

  30. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-11 TBB6002

  31. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-12 TBB6002

  32. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-13 TBB6002

  33. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-14 TBB6002

  34. Saf-T-Liner HDX Chassis Electrical Circuit Numbers Page 3-15 TBB6002

  35. Saf-T-Liner HDX Chassis Electrical 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 TBB6002 Page 3-16

  36. Saf-T-Liner HDX Chassis Electrical 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 Page 3-17 TBB6002

  37. Saf-T-Liner HDX Chassis Electrical Page 3-18 TBB6002

  38. Saf-T-Liner HDX Chassis Electrical Harness Plug Locations Page 3-19 TBB6002

  39. Saf-T-Liner HDX Chassis Electrical Harness Plug Locations Page 3-20 TBB6002

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

  41. Understanding Thomas Drawings Thomas Body PCB Electrical 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 Page 4-2

  42. Saf-T-Liner HDX Chassis Electrical Understanding Thomas Drawings Installation Drawing Answer the following questions using Drawing#130479 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#62180452 What is the part number of the VIM?________________ How many fasteners are required to install the TCU?___ Page 4-3 TBB6002

  43. Saf-T-Liner HDX Chassis Electrical Understanding Thomas Drawings Assembly Drawings Use Drawing#62205207 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? _________ Page 4-4 TBB6002

  44. Saf-T-Liner HDX Chassis Electrical Understanding Thomas Drawings Locate Drawing#62204008 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?____________________ Page 4-5 TBB6002

  45. Saf-T-Liner HDX Chassis Electrical Understanding Thomas Drawings Answer the following questions using Drawings#62203615 and 62203126 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 _____________________________ Page 4-6 TBB6002

  46. Saf-T-Liner HDX Chassis Electrical Understanding Thomas Drawings Locate Drawing#62204008 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?______________________ Page 4-7 TBB6002

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

  48. Saf-T-Liner HDX Chassis Electrical J1587 ICU3 TCU VCU ECU ABS • 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? • _________________________________________ Page 5-2 TBB6002

  49. Saf-T-Liner HDX Chassis Electrical J1939 Hydraulic Control module TCU VCU ECU ABS • 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?_______________ Page 5-3 TBB6002

  50. Saf-T-Liner HDX Chassis Electrical J1939 120 ohm Terminating Resistors-TR Required to maintain consistent environment for data Locate at front and rear of harness (bus) Page 5-4 TBB6002

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