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

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

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Course Content

1. Primary System Components

2. Battery, Ignition, Ground

3. Wiring and Harnesses

4. Understanding Thomas Drawings

5. J1587 and J1939

6. Retrieving fault codes

7. Evaluation

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Section

1

Primary System Components

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Primary Components Locations

•Front Interior Compartment

•Transmission Control Center

•Engine Compartment

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Front Interior Compartment

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Signal Stat

PCB#4

ABS ECU

Printed Circuit Board 4, ABS Control Module Signal Stat Module

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9 pin Data Link

Daytime Running Light Module

Option VEC Centers, Daytime Running Light Module, 9 pin Data Link Connector

Front VEC Centers

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Mercedes Engine VCU

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• identified as P190, P220, P221 in drawings• provides additional connections and control for various options

Front VEC Centers

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Transmission Control Center

• located on left frame rail at front axle• contains transmission TCU and VIM

See Drawing# 62180452

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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

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Rear Box

• standard size• rear ignition, start

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Rear Box

VEC

100 amp Contactor

9 pin Data Link

See drawing#62204035

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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

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Section

2

Battery , Ignitionand Ground

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Battery, Ignition and Ground

Battery

Switches onRear Box signal to Breaker

Solid State PowerSwitchcontrolsbattery toBody andChassis

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Battery

From Power Switch to Bulkhead studsthen to PCB1 & 2 for Body and PCB4 for Chassis

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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:____________________________________________

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Section

3

Wiring and Harnesses

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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

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Wiring

• 3 panel design allows easy access to front exterior harness and bulkhead connections

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Wiring

Bulk Head

• Transition from Interior Harness to Exterior Harness• Junction for battery and ground cables

J75J76

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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

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Wiring

• color coded• SAE J2191 standards• numbered every 4 inches

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Wiring

Circuit Numbers

Thomas # SAE 52 1104

52#1104

See drawing#62205231 start circuitLocate 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

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(SAE number has been omitted)

Circuit number Description Color

1 Engine ECM bat gnd (in) W

6 Engine ECM bat power (in) R

19 Gauge power rear box PK

21 Headlamp high LTG

47 Fuel sender signal PK-W

48 Fuel level+ PK-W

52 Ignition Power PK

52 Ignition PK

102 Marker power BR

116 Panel lamp ground W

122 Roll back module power BL

173 Man trans clutch sw grnd(out) LTBL-W

196 Fuel water/separator power DKG-W

200 Remote throttle sig analog PRP

250 Ecm Ground(out) GY

278 Right control switch supply PRP-W

279 Left control switch supply PRP-W

289 Transmission neutral signal W

294 Air tank drain R/R-W

305 Ignition switch power PK

305 Ignition access supply PK

306 Ignition run signal PK

Circuit Numbers

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307 Headlamp power GY

307 Headlamp power LTG

309 Park brake input R-W

320 Windshield wiper PRP-W

335 A/C signal LTBL

342 Ammeter signal PK

385 DRL power LTG

392 Adj pedal signal R-W

393 Adj pedal return R-W

431 Preheater power DKG

443 Door signal T-W

446 Snow chain R-W

108A Stepwell light PRP-W

1139Y Water in fuel light gnd GY

122A Roll back module signal BL

136B Neutral signal BL

14BS Gauge power R

14E Chassis power LED R

18G Low air pressure SW jumper W

200J PTO set speed B signal PRP

222F Hdlmp dim sig flash to pass LTG

222L Hdlmp dim sig lh turn LTG

233B Opt indicator lamp RW

23C Backup lights BR

262B Retarder signal (in) R-W

Circuit Numbers

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262G Retarder in use R-W

262K Brake switch signal R-W

278A Right wiper motor park supply PRP-W

278B Right wiper motor low supply PRP-W

278C Right wiper motor high supply PRP-W

279A Left wiper motor park supply PRP-W

279B Left wiper motor low supply PRP-W

279C Left wiper motor high supply PRP-W

294A Air tank drain R-W

29A Lamp power supply BR

29D Lamp ground GY/BR

30G Transmission Temp- LTBL-W

315A Wiper module park DKBL

315B Wiper module low DKBL

315C Wiper module high DKBL

342A Ammeter common W

376A Battery power R

376C Ignition power O

376II ABS relay active signal O

376J ABS ECU serv brake signal O

376LI ABS lamp O

376R Retarder disable signal O

377LF+ Left Front wheel speed signal BR

377LFO Left front modulator exhaust O

377LR- Left rear wheel speed return W

Circuit Numbers

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377LR+ Left rear wheel speed signal BR

377RF- Right front wheel speed return O

377RF+ Right front wheel speed signal BR

377RR- Right rear wheel speed return O

377RR+ Right rear wheel speed signal BR

378LF- Left front modulator common W

378LFI Left front modulator hold O

378LR- Left rear modulator common W

378LRI Left rear modulator hold O

378RF- Right front modulator common W

378RFI Right front modulator hold O

378RFO Right front modulator exhaust O

378RR- Right rear modulator common W

378RRI Right rear modulator hold O

378RRO Right rear modulator exhaust O

38L Left turn signal Y

38R Right turn signal DKG

392A Adj pedal return R-W

393A Adj pedal signal R-W

406D Crossing arm PRP-W

406E Child alarm PRP-W

431C Intake Grid Heater Lamp O

431H Grid heater ground(out) W

439+ CAN+ (out) GY

439A Ignition power GY

Circuit Numbers

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439D- CAN- (in) GY

439S- V speed signal (return)

439S+ V speed signal (in) GY

439U Ignition ground(out) PRP

439V Fast idle indicator lamp sig PRP

439W- H2O in fuel sensor return GY

439W+ H2O in fuel sensor signal GY

440A Dash check eng lamp GY

440B Dash park brake lamp GY

440B Service brake switch GY

440E Cruise set signal GY

440F Cruise set signal GY

440G Serv brake SW W

440OT TPS sensor ground GY

440P- TPS sensor signal- GY

440P+ TPS sensor signal+ GY

440S Dash buzzer ground W

440S Stop eng dash lamp W

440V1 Idle validation(NC) signal GY

440V2 Idle validation(NO) signal GY

443G Door return DKBL

461A Reverse signal BL

47G Fuel sender ground W

48G Fuel level- PK-W

52B Ignition PK

Circuit Numbers

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52C Start signal PK

58E Coolant pump LTBL

60A Right turn signal Y

61A Left turn signal DKG

6A Battery power R

6B Battery power R

6C Battery power R

6D Battery power R

6E Battery power R

6F Battery power R

71AA Ignition power R

71B Key SW starter interlock PK

98A Heater fan low LTBL

98AD Defrost fan low LTBL

98B Heater fan medium LTBL

98H Heater fan high LTBL

98HD Defrost fan high LTBL

98PD Defrost fan low LTBL

BAT Battery power R

C840 Emission signal GY

C844 Emission signal return GY

C857 Starter lockout GY

C857 Engine running signal GY

C998 Emission return GY

E002 Battery power BK

Circuit Numbers

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E003 Battery power sensor BK

E008 Retarder enable W

E009 Ground W

E014 Reverse signal BK

E033 Dimmer power PK

E107 Solenoid G return BK

E110 Solenoid F return BK

E1106 Key SW aux range inhibit BK

E1107 Second shift schedule BK

E1109 Exhaut brake signal BK

E1110 Retarder disable signal BK

E1123 Range inhibit BK

E1125 Trans Ind Lamp W

E1125 Range inhibit signal BK

E1126 Trans TCU speed signal T

E1128 Brake return signal BK

E119 Exhaust brake signal BK

E120 Solenoid A return BK

E121 Solenoid B,E supply BK

E1212 Transmission temp lamp W

E123 Power for neutral signal BK

E128 Solenoid B return BK

E130 Solenoid C,G supply BK

E131 Solenoid D return BK

E139 Output speed sensor BK

Circuit Numbers

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E141 Engine speed sensor T

E144 Sensor ground BK

E147 Sump temp signal BK

E162 C3 pressure signal BK

E165 Oil level signal BK

E169 Exhaust brake signal BK

E170 Shift selector data bit 1 BK




E174 Shift selector parity bit BK

E180 Shift selector display BK

E195 Transm Idle signal BK

GND Ground W

GNDE Electronics ground W

GNDH Heater ground W

J1587- J1587- O

J1587+ J1587+ DKG

J1587S J1587 shield shield

J1939- J1939- DKG

J1939+ J1939+ Y

J1939S J1939 shield shield

N23 Idle signal GY

N31 Wait to start light gnd GY

N98A ECM power GY

N98B ECM power GY

N98C ECM power GY

Circuit Numbers

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


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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

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Harness Plug Location

Number Description Location

B58 Butt splice at Back-up Alarm Engine Compartment

B59 Butt splice at Back-up Alarm Engine Compartment

BS14 Butt splice at luggage compartment light Luggage Compartment

BS20 Butt splice at Booster Pump Engine Compartment

BS22 Butt splice at Engine Compartment Door Kill Switch Engine Compartment

P100 ABS ECM Interior Chassis Elec Center

P102 Right Front ABS Modulator Front Axle

P103 Right Front ABS Sensor Front Axle

P104 Left Front ABS Modulator Front Axle

P105 Left Front ABS Sensor Front Axle

P109 Adjustable foot pedal switch Dash

P111 Throttle Postion Sensor Pedal

P115 Shift Selector Dash

P12 Right Turn Dash

P120 Adjustable foot pedal motor Cab at pedal

P122 9 pin Deutch connector Interior Chassis Elec Center

P13 Left Turn Dash

P167 Single pin connector at fan controller Engine Compartment

P168 Two pin connector at fan controller Engine Compartment

P17 Engine ECM Engine Compartment

P183 Air Tank Pressure Sender Air Tank

P184 Air Tank Pressure Sender Air Tank

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P190 Fuse center below PCB#4 Interior Chassis Elec Center

P192 Heater at floor on left side of heater Cab

P196 Diode Block mounted to inside firewall Interior Chassis Elec Center

P207 Right Front Turn Signal Front External Bulkhead

P209 Left Front Turn Light Front External Bulkhead

P211 Left Wiper Motor Front External Bulkhead

P217 Wiper Module Interior Chassis Elec Center

P218 Steering Column Steering Column

P221 Fuse center below PCB#4 Interior Chassis Elec Center

P229 Rear Ignition Switch Rear Box Engine Compartment

P230 Engine Start Switch Rear Box Engine Compartment

P231 Engine Compartment Light Switch Engine Compartment

P232 Chassis Power Switch Rear Box Engine Compartment

P233 Body Power Switch Rear Box Engine Compartment

P246 Mercedes VCU/brown Interior Chassis Elec Center

P247 Mercedes VCU/gray Interior Chassis Elec Center

P248 Mercedes VCU/purple Interior Chassis Elec Center

P276 Luggage Compartment Switch Cab Switch Panel

P287 J1939 Data Link connection to Transm TCU Forward of Front Axle

P288 Air Dryer Air Dryer

P43 Daytime Running Light Module Interior Chassis Elec Center

P46 Wiper Module Interior Chassis Elec Center

P50 Key Switch Dash

P53 Cruise On/Off Switch Dash

P54 Cruise Set/Resume Switch Dash

Harness Plug Locations

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Harness Plug Locations

P60 Dimmer Switch Steering Column

P64 Pink connector to ICU Dash

P65 Pink connector to ICU Dash

P74 Stepwell light Stepwell

P75 62 pin Bulkhead Connector Front External Bulkhead

P76 102 pin chassis bulkhead connector Front External Bulkhead

P78 VEC/Black outside rear box Engine Compartment

P79 VEC/Gray outside rear box Engine Compartment

P8 Right Head Light Front External Bulkhead

P80 VEC/Blue outside rear box Engine Compartment

P81 VEC/Green outside rear box Engine Compartment

P83 Rear electrical box Engine Compartment

P85 VEC 2 pin outside rear box Engine Compartment

P9 Left Head Light Front External Bulkhead

P93 J1939 terminating resistor Interior Chassis Elec Center

P96 Fuel/Water Separator Sensor Engine Compartment

P99 ABS ECM Interior Chassis Elec Center

T12 Single ring terminal at Battery+ Battery Box

T13 Single ring terminal at Battery- Battery Box

T14 Single ring terminal at Battery- Battery Box

T16 Single ring terminal at alternator Alternator

T18 Single spade terminal at washer motor Front External Bulkhead

T19 Single spade terminal at washer motor Front External Bulkhead

TB2-1 Terminal Board 2 inside Rear Box Engine Compartment



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Section

4

Understanding Thomas Drawings

Thomas Body PCB Electrical

Page 4-2


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

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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?___

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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?_________

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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?____________________

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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 _____________________________

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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?______________________

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Section

5

J1587 & J1939

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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 infovia 1587 from engine

If J1587 is open what behavior will the driver report?_________________________________________

ICU3

VCU ECU

TCU

ABS

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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 J1939for outputs or inputs?_______________

HydraulicControl module

VCU ECU

TCU

ABS

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J1939

120 ohm Terminating Resistors-TR

Required to maintain consistent environment for data

Locate at front and rear of harness (bus)

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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

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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 54-15 to conduct testing of J1939

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J1587 & J1939

Hydraulic Fan Control Module

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Hydraulic Fan Control Module

J1587 & J1939

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Section

6

Retrieving Fault Codes

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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

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Before Code Retrieval:• locate Reset Mode button• set Park Brake• turn key switch to on


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1. 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


Using the Reset/Mode Button

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Hands-on Activity

Using the ICU Dash

Retrieve the Active Fault Codes

MID___________

SID/PID________

FMI___________

MID___________

SID/PID________

FMI___________

Using Drawing 62204870Translate the codes_____________________________________________________________

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Section

7

Evaluation

Training Evaluation

Class:__________________________Date:___________Instructor: _____________________

1. Student manuals and handouts were?Excellent Good Poor 1 2 3 4 5 6 7 8 9 10

2. Overheads, presentations, and video tapes were?Excellent Good Poor 1 2 3 4 5 6 7 8 9 10

3. Shop demonstrations were?Excellent Good Poor 1 2 3 4 5 6 7 8 9 10

4. The length of the course was?Too Long Just Right Too Short 1 2 3 4 5 6 7 8 9 10

5. The pace of the presentation was?Too Fast Just Right Too Slow 1 2 3 4 5 6 7 8 9 10

6. The amount of shop time was?Too Much Just Right Not Enough 1 2 3 4 5 6 7 8 9 10

Please circle the number on each scale which most closely reflects your opinion

Training Evaluation page 2

7. Did the class provide the expected instruction? Yes Somewhat No 1 2 3 4 5 6 7 8 9 10Comments:_______________________________________________________________________

8. Would you recommend this class to others?Definitely To Some No 1 2 3 4 5 6 7 8 9 10

9. Do you feel that what you’ve learned will help you do your job better? Help A Lot Help Some No Help 1 2 3 4 5 6 7 8 9 10

10. What was your overall impression of the course?Excellent Good Poor 1 2 3 4 5 6 7 8 9 10

11. 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

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

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