Balance Hybrid Service Manual
Contents
1. Figure 38 AC DM oC Junction Box 10 Connect the negative lead of the insulation tester using the clamp not the probes to a chassis ground point where a ground strap is connected M ake sure that any paint Is removed from chassis at ground location 11 Connect the positive lead of the isolation tester using the clamp not the probes to the HV positive terminal inside the HV junction box refer to illustration Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 207 AZD Service Manual Isolation Resistance eee Testing Motor DC DC High Voltage Junction Box JI OV i Traction Motor AC Motor Solid Red lines indicate HV jumper wires 5 Dashed orange lines A represent HV cabling Figure 39 Isolation Testing Connection Diagram The Insulation Tester can produce potentially dangerous voltages Do not touch the vehicle or test leads when performing this test High Voltage capacitors may be charged during the isolation resistance test Wait minimum 5 minutes before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads and test equipment Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 208 AZD Service Manual 12 13 14 15 16 17 Set the insulation tester to 500 volts and perform the test for 30 seconds or unt2. until itis verified that there is no voltage Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 198 AZD Service Manual 1 Using a 4mm hex driver remove the 6 service disconnect cover screws from the front of the battery pack Figure 60 service Disconnect Cover High Voltage Cover To remove the cover remove the 6 hex socket head screws 4mm Figure 60 Service disconnect cover and attaching screws 2 Remove the service disconnect cover Figure 60 3 While wearing insulated High V oltage gloves remove the high voltage service disconnect pin from the battery While applying inward pressure to the service disconnect pin turn it turn counter clockwise and then pull it out refer to illustration To remove the orange pin push it in then turn it 14 _ turn counter clockwise After turning the pin pull it straight out 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 turn clockwise until it pops into place the handle groove will be in the horizontal position Figure 61 Removing high voltage service disconnect pin Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 199 AZD Service Manual 4 Once the service disconnect pin has been removed you MUST verify there is no voltage present on
3. Before Actually Tightening The Fastener To The Desired Torque Using Loctite thread locking product If a Loctite thread locking product is required l 2 Clean oil and contamination from both male and female threads of fastener and mating component using a residue free cleaning agent Identify which Loctite thread locking product should be used based on the appropriate work instruction Shake product thoroughly before use Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 227 AZD Service Manual If a Loctite primer is not specified go to Step 5 Apply Loctite primer to threads and allow it to dry completely Apply afew drops of the thread locking product to the first few threads of the fastener approximately one diameter of thread length 6 Assemble the fastener and tighten to the specified torque 7 Note When utilizing nuts as jam nuts the torque specification remains the same as the equivalent sized nut eae od Applying Loctite product on screws Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 228 AZD Service Manual Fastener Tightening Specifications W hen tightening nuts bolts and screws refer to the assembly drawing for torque specifications If itis not shown in the drawing refer to the table below The torque values are shown in NM and foot Ib If thread locking product is required it will be detailed in the assembly drawing or i
4. Program DMoC Enable High Voltage Calibrate DMoC Figure 47 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 224 AZD Service Manual A Checksum window will appear click ok Balance Diagnostic Tool Eg Figure 48 n Congratulations DMoC Reprogramming complete Balance Diagnostic Tool Ed EPAS DMoC Reprogramming Complete Figure 49 8 Close DM oC screen 9 Cycle key to Disable diagnostic mode Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 225 AZD Service Manual 10 Go to the DT Cs Info Codes tab and confirm that no codes were set during the reprogramming process Balance Hybrid Electric Vehicle Diagnostic Tool File DTCs InfoCodes Options A 60hOm28s active DTC s PRP RPP RPP RR RR FP 1919 9101010901909191 9101 0O JOH PP ie PliPlie wim amp Figure 50 11 Repeat for each DM oC 12 Remove Diagnostic Cables 13 Road test V ehicle Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 226 AZD Service Manual 9 5 Fastener Tightening Procedure l E nsure male and female threads of fastener and mating component are clean and free of oil debris or other contaminants Assemble fastener loosely to a finger tight condition Choose the appropriate torque wrench and set it to the specifi
5. Voltage Section above 2 Useamultimeter to check fuse for continuity The value should be approximately zero ohms 3 Using an HV insulated socket remove replace the nut that secures the fuse 4 Place the 2 Belleville washers concave down and torque the nuts to 90 in Ibs 10 Nm Figure 51 M easuring points Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 231
6. not meet specification testing of the individual components while isolated from the rest of the system will be required 9 3 1 Isolation T est Preperation Disconnecting High Voltage l Remove the vehicle key from the ignition and store in secure area Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 202 AZD Service Manual 2 Disconnect the negative terminal from the 12 volt battery and isolate from the battery terminal Note Some vehicles may be equipped with a second 12 volt battery This must also be disconnected 3 Waita minimum of 5 minutes after the 12 volt battery s have been disconnected before handling any high voltage wiring or component 4 Remove the high voltage HV battery service disconnect from the high voltage battery pack Refer to Section Disconnecting the Energy Storage System 5 Remove the cover from the high voltage HV junction box e Always wear high voltage gloves when connecting and disconnecting high voltage leads and test equipment 6 Using an appropriate voltmeter confirm that the HV DC bus voltage is less than 30 volts recommended less than 5 volts to prevent arcing by o Measuring across HV positive terminal and HV negative terminals in the high voltage junction box refer to illustration O M easuring between the HV positive terminal and clean chassis ground o Measuring between HV negative terminal and chassis ground If a v
7. of the fuse and have HV present When handling any individual circuit the absence of voltage on that circuit should be verified Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 201 AZD Service Manual 9 3 Isolation Resistance Testing Isolation Resistance Testing is a direct current DC resistance measurement of all circuits that are required to have electrical isolation from the chassis The resistance must be above the specified value in this procedure An appropriate insulation tester M egOhm M eter such as a Fluke 1507 is required This procedure requires working with potentially dangerous high voltage Any voltage above 30 volts should be considered potentially dangerous and is referred to as high voltage HV Only trained qualified personnel should service a hybrid electric vehicle Before servicing the high voltage system refer to Section Disconnecting the Energy Storage System The Insulation T ester can produce potentially dangerous voltages Do not touch the vehicle or test leads when performing this test High V oltage capacitors may be charged during the isolation resistance test W ait minimum 5 minutes before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads and test equipment Care must be taken to follow the procedure below to get accurate results If the high voltage system isolation test does
8. the high voltage bus before proceeding Use extreme caution when working inside the HV J unction box as high voltage may be present Use HV Insulated Gloves when working or taking measurements inside the HV J unction box 5 Remove the high voltage junction box cover i GET ie i Positive Meg ative ey RTO53 RToO42 TOSS MTOSB RTOF79 RTOS RTOs 1 ETOH f Figure 61 HV Junction Box Terminals and Connections 6 Wearing high voltage gloves and using a multimeter check for voltage on the high voltage bus and between the high voltage bus and isolated chassis ground Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 200 AZD Service Manual a Across the HV positive and HV negative junction box studs circled in green refer to illustration b Between the HV positive junction box stud and chassis ground c Between the HV negative junction box stud and chassis ground If the voltage is less than 5 volts it is now safe to continue If there is more than 5 volts wait a few minutes for the voltage to dissipate and recheck If the voltage is still greater than 5 volts refer to the service manual for further diagnosis This procedure confirms the absence of voltage only at the main junction box studs If a HV junction box fuse has blown there is a possibility that a capacitor could remain charged on an individual circuit downstream
9. AZD Service Manual 9 Special Procedures 9 1 Securing a Damaged Hybrid Vehicle ssssssssnssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 195 9 2 Disconnecting the E nergy Storage System sssssssasssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 196 9 3 Isolation Resistance T esting ssscsssscessssessseesssseeessseesnsseeenseesnseeesnseeesnsenesssnnesssenensaayy 202 9 4 Programming a Digital M otor Controller DM OC ssssssnsssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 218 9 6 Fastener Tightening Procedure sssssssssnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 227 9 7 ESS Fuse Replacement ssssssssnssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnn 231 Note 1 Additional procedures that are not covered in this manual may be found on the Product Support Extranet https extranet azuredynamics com Note 2 Before servicing any high voltage component the ESS must be disabled as per the instructions in this Section Disconnecting the Energy Storage System Furthermore once the ESS is disconnected the voltage must be checked across the positive and negative terminals in the high voltage junction box and must be less than 1 volt This procedure requires working with potentially dangerous high voltage Any voltage above 30 volts should be considered potentially dangerous and is referred to as high voltage HV Only trained qualified personnel should service a hybrid elec
10. PAS M otor Controller DM oC 145 High Voltage Cabling when isolated from the high 500 volts greater than 10 M ohms voltage bus Cobasys B attery 280 330 Note the ESS performs it s own isolation volts resistance diagnostic at each key on cycle and also monitors the isolation during normal Hybrid operation No additional testing is required Greater than2 M ohms at initial K ey on not cranked greater than 500 K ohms running in HV mode as reported by diagnostic tool Table 5 Component Isolation Resistance Specification Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 210 AZD Service Manual 9 3 3 EPAS Motor Isolation T esting l Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage 2 Remove connector C337P 4 position HV from EPAS DM oC 4 prong connector 4 prang connector C3375 k Figure 40 EPAS DM OC Connectors Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 211 AZD Service Manual 3 4 5 10 11 12 13 14 Install jumper wires across pins A B C in C337P Ensure that the jumpers do not touch the DM oC body or pin D Connect the positive lead of the Insulation T ester using the clamp not the probes to terminal A of connector C337P Ensure that the positive test probe does not touch the housing of the connector or pin D Connect the negative lead of the Insulation T ester using the c
11. Rated for a working voltage of at least 500 volts DC e A multi meter and proper test leads suitable for use with the high voltages involved in this system is a required piece of safety equipment as well as for diagnostics Circuits must be checked for high voltage before making contact with any terminal or junction M eters must be rated for a minimum of 600 volts e Electrical safety gloves Rated for a working voltage of at least 500V i e ASTM class 00 or better Procedure 1 Turn the ignition key OFF and remove the Key from the ignition 2 Always wait a minimum of 5 minutes after the key has been turned off and removed from the vehicle before disconnecting or exposing any high voltage cable or component 3 Clean the front of the battery pack around the LV connector C053S and the service disconnect covers to remove dirt and debris 4 Remove the low voltage connector C053S from the front of the battery pack by turning counter clockwise approximately turn Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 197 AZD Service Manual Figure 34 Removing the LV connector from ESS HV Battery Removing the high voltage service disconnect pin cuts off high voltage from the vehicle but the individual cells inside the ESS will remain charged Do not cut into the high voltage ESS case or penetrate the ESS in any way Always assume the ESS and all high voltage components may still be electrically active
12. Several Buttons M ay Turn Red M omentarily This Is Normal The Diagnostic Tool Reprogramming Steps 4 amp 8 Will Be Grayed Out And Not Performed For TM Programming Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 220 AZD Service Manual Balance DMoC Programmer Enable High Voltage a ee One Moment Please __ Do not press any buttons TT Figure 42 Step 5 Click the Extended Diagnostic M ode button and it should turn Green Step 6 Click the Program DM oC button and then click on the Select ehx File Select the ehx file for the appropriate DM oC you are programming and then click AIC wu 3032 ehx e TM 3033 ehx e ISG 3034 ehx e EPAS 3035 ehx Example P1X 06PM 3035 000 ehx would be for an EPAS Electric Power Assist System DM oC Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 221 AZD Service Manual Balance DMeC Programmer Please select the desired ehx file to program with Look in E DMoC R4 Calibrations e e Ea 2 E P 1x 03FB 3032 000 ehx EP 1x 03FB 3034 000 ehx My Recent P1X 06PM 3035 000 ehx Documents el p1x 13FB 3033 000 ehx i I Program DMoC P1X D6PM 3035 000 ehx x EHX Files ehx Warning Enabling High Voltage freq Figure 43 The Calibration file will load and a Success window will pop up when complete Cycle the key off for 10 secon
13. asurement Reading should be greater than 4 M ohms Component Isolation Resistance Specification chart Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 215 AZD Service Manual The insulation tester can produce potentially dangerous voltages Do not touch the vehicle or test leads when performing this test High V oltage capacitors may be charged during the insulation test W ait 5 min before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads 9 3 7 ISG HV WIRING ISG motor to DM oC ae e oe Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage Disconnect the positive RT048 A RT049 B RT050 C leads from the junction box Disconnect C302S from ISG motor Install jumper wires across RT048 A RT049 B RT050 C cable Side Connect the positive lead of the insulation tester using the clamp not the probes to RT 048 Connect the negative lead of the insulation tester using the clamp not the probes to the chassis ground lug The insulation tester can produce potentially dangerous voltages Do not touch the vehicle or test leads when performing this test High V oltage capacitors may be charged during the insulation test W ait 5 min before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads Set the insulation test
14. communications cable Boot key O o pm Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 218 AZD Service Manual DM oC Reprogramming Procedure Connect the diagnostic cables to the connectors located under the steering column as follows e 103298 D CAN diagnostic harness to connector C073P e KVASER CAN to USB to 103298 D CAN diagnostic harness CAN 2 C006BS and the USB end to one of the Laptop USB ports e 103460 A Hrns Serial Program DM oC to C336S e Connect DB9 ext cable to the appropriate connection 0n103460 A for the DM oC you are programming EPAS MPT ISG or AC and connect the other end of the DB 9 extension cable to the laptop RS 232 port 9 pin communications port Important N ote Open Do not disconnect these cables during the programming process This may permanently damage the components M ake Sure That Only The Programs That Are Required For Programming A Dmoc Are Turn on ignition key Double Click on the Balance Diagnostic Tool Icon Confirm that the CAN is connected to CAN 2 and then select the DM oCs Tab Go to the DTCs and Info Codes page and confirm there are no stored DTCs before proceeding If codes are stored then save the faults for reference and retest after reprogramming is complete From the DM oC screen select the required DM oC tab TM ISG EPAS or AC Click the Program DM oC button There are 8 defined steps in the DM oC reprogramming software tha
15. ds and then back to the on position Balance DMoC Programmer Select an extended hex ehx file to begin programming the DMoC Select ehx File C Documents and Settings kcrerar Desktop DMoC R4 Calibrations P 1X Completed C2000Prog c codeskin com running with JRE version 1 5 0_06 CodeSkin core 2 0p 0 CRC Info added 772c b758 5fa4 0 Stable Library SSSSSSSSeeS eee SSS SSS SSS SSS SSS SS SSS SSS SSS Native lib Version RXTX 2 1 7 DTR Patch Program DMoC Reminder Stay in for at least 10 seconds Warning Enabling High Voltage frequently results in an inhibited state Please wait five minutes between programming each DMOC Figure 44 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 222 AZD Service Manual A window with Warning Vehicle is not in diagnostics mode will appear Click OK to continue Balance Diagnostic Tool fx Warning Vehide is not in diagnostics mode Figure 45 Step 7 Click the Enable High Voltage button It may take several seconds for the Enable High V oltage button to turn green Notes Several Buttons M ay Turn Red M omentarily This Is Normal The Diagnostic Tool Reprogramming Steps 4 amp 8 Will Be Greyed Out And Not Performed For TM Programming Step 8 Click the Calibrate DM oC button and then Load Parameter File Select the par file for the appropriate DM oC you are programming and then clic
16. ed torque value Once the torque value is set ensure the torque wrench locking ring is in place Use the torque wrench to tighten the fastener in a continuous fluid motion until the wrench clicks off This step MUST be done without allowing the wrench to stop before it clicks off If the wrench is stopped before clicking off the fastener must be loosened and the procedure repeated from Step 2 Use a Torque Seal lacquer or equivalent to mark the fastener immediately after tightening The mark should extend radially from the head center of the fastener to the surrounding material include any vertical or sloped surface N ote e If A NutAnd Bolt A re Assembled To Create A Bolted Connection The Head Of The Bolt Should Be Held And The Nut Tightened If The Nut Is Readily Visible The M ark Should Be M ade On The Nut And The Surrounding M aterial As Per Step 5 See Photo 1b e However If The NutIls Not Readily Visible And The Bolt Head Is M ark The Bolt Head As Per Step 5 Back off torque wrench to minimum value and return to tool chest N ote e AnAppropriate Torque Wrench Has A Range Covering The Desired Torque V alue Do Not UseA Torque Wrench Outside Its Calibrated R ange e TheReason Why A Torque Wrench M ust Not Be Stopped And Started During The Tightening Procedure Is That Once Stopped The Force Required To Initiate Turning The Fastener A gain M ay Be Higher Than The Specified Torque This W ould Result In The Wrench Clicking Off
17. em i Always remember to consult the safety section Section 1 before servicing any Hybrid Component 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 personnel who are qualified to service A zure hybrid vehicle systems The ESS HV Battery must be properly disconnected before opening any high voltage component enclosure or contacting any high voltage wiring V arious components in the hybrid system contain capacitors that store high voltage charges Always wait a minimum of 5 minutes after the key has been turned off and removed from the vehicle before disconnecting or exposing any high voltage cable or component Once the ESS HV battery service disconnect has been removed a multimeter high voltage rated must be used to verify that there is no voltage present Removing the ESS HV Battery involves contact with potential deadly voltages All safety procedures M UST be followed to prevent the possibility of an electrical shock W hen working on the ESS HV Battery the keys to the vehicle should be in the possession of the technician The keys should NOT be left in the ignition Use proper lifting equipment as the ESS HV Battery is heavy Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 196 AZD Service Manual Figure 63 High V oltage Battery Pack Tools e Multimeter
18. er to 500 volts and perform the test for 30 seconds Record measurement and compare to table above for EPAS DM oC resistance Component Isolation Resistance Specification chart Replace the ISG motor high voltage cable if itis less thanl0 M ohms Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 216 AZD Service Manual 9 3 8 Isolation testing a HV Cable l Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage 2 Disconnect the conductor proton of the cable form the component s it connects to on both ends M ake sure to leave the gland nuts secured to the vehicle component so the shield is connected to the Chassis ground 3 Connect the positive lead of the insulation tester using the clamp not the probes to one end of the cable conductor 4 Connect the negative lead of the insulation tester using the clamp not the probes to the chassis ground lug The insulation tester can produce potentially dangerous voltages Do not touch the vehicle or test leads when performing this test High V oltage capacitors may be charged during the insulation test W ait 5 min before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads 5 Set the insulation tester to 500 volts and perform the test for 30 seconds Record measurement and compare to table above for High V oltage Cabling when isolated from the high voltage bus C
19. he probes to the RT071 connection in the access panel 5 Connect the negative lead of the insulation tester using the clamp not the probes to the DM oC body or ground lug The insulation tester can produce potentially dangerous voltages Do not touch the vehicle or test leads when performing this test High V oltage capacitors may be charged during the insulation test W ait 5 min before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads 6 Set the insulation tester to 500 volts and perform the test for 30 seconds Record measurement and compare to the motor ISG controller resistance refer to illustration 7 Replace the ISG DM oC if itis less than4 M ohms 9 3 5 ISG Motor Isolation T est l Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage 2 Disconnect C302S at the ISG motor oy Connect jumper wire s rated to 600 volts DC across terminals A B and C of C302p motor side 4 Connect the positive lead of the insulation tester using the clamp not the probes to the terminal A connection 5 Connect the negative lead of the insulation tester using the clamp not the probes to the ISG motor body Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 213 AZD Service Manual The insulation tester can produce potentially dangerous voltages Do not touch the vehicle or test leads when perfo
20. il the reading stabilizes and record measurement HV Positive Stud M easurement T he resistance value should be greater than 1 M ohm If less than 1 M ohm then each individual component will need to be isolated from the system by disconnecting the high voltage leads to that component and following the procedures for that given component outlined in sections 9 3 3 9 3 4 9 3 5 9 3 6 or 9 3 7 W hen the voltage reading on the insulation tester has decreased to less than 30 volts remove the insulation tester test leads and all jumper wires If your insulation tester does not read voltage use a voltmeter to ensure there is less than 30 volts present before removing any test leads or jumper wires Remove connector C 337P 4 position HV from EPAS DM 0C Pe F a 4 prong connector C33 7P 4 prong conne ctor 5 oa Cag 75 a Figure 39 EPAS DMOC Connectors Install an insulated jumper wire rated to 600 volts across pins A B C in C337P E nsure that the jumper wire does not touch the DM oC body or pin D Connect the positive lead of the insulation tester using the clamp not the probes to terminal A of connector C337P Ensure that the positive test leads do not touch the housing of the connector or pin D Connect the negative lead of the insulation tester using the clamp not the probes to a chassis ground point where a ground strap is connected or to the body of the EPAS M otor M ake sure that any paint is re
21. k Open AJC sa 3032 par e TM 3033 par e ISG 3034 par EPAS iran 3035 par Example P1X 06PM 3035 000 par would be for an EPAS Electric Power Assist System DM oC Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 223 AZD Service Manual Balance DMoC Programmer Load Parameter File ORDI Vale i Ne EE1EncoderDirection TIN EE 1EncoderPulses T_INT C aa EEtEncoderType T_INT C wo EETHallSequenceDirection SIAT Please select the desired par file to load Verid Conners f EE1 EEIN Lookin DMoC R4 Calibrations Oca 1x 038 3032 000 0000 par l 2 amp P 1x 03FB 3034 000 0001 par My Recent Documents CITISE IIE Eremit bamwe haats Arimen OMi Enable High Voiizsz Calibrate NMoC P1X 06PM 3035 000 0000 par Fles of type par Files par Figure 46 Select Save to EEPROM and a Success Saved to EEPROM window should appear click ok Balance DMoC Programmer Load Parameter File Save to EEPROM EE1EncoderDirection T_IN EE1EncoderPulses T_INT C EE1EncoderType T_INT C EE1HallSequenceDirection EE1HardOVLimit T_INT C Vehicle Connected EE1LoggingRate T_INT C EE1MaxSwitchingVde T_IN EE1MotorP T_INT C EE1PosPIIKi T_INT C EE1PosPIIKp T_ Extended Diagnostic Mode
22. lamp not the probes to a chassis ground point where a ground strap is connected or to the body of the EPAS M otor M ake sure that any paint is removed from chassis at ground location Set the Insulation T ester to 500 volts and perform the test for 30 seconds or until the reading stabilizes Record measurement EPAS M otor AC M easurement Note The resistance value should be greater than 10 M ohm If less than 10M ohm replace the EPAS motor Remove the Insulation T ester and jumper wires Connect C337P to EPAS DM oC Install the cover to access panel at the ISG DM oC Install the cover to access panel at the traction DM oC Install the cover to the high voltage junction box Install the high voltage battery service disconnect pin and the cover to battery pack Reconnect the 12 volt batteries Return vehicle key to the ignition 9 3 4 ISG DMoC Isolation T est Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage Remove all high voltage wires RT048 A RT049 B RT050 C RT 0 1 and RT072 from the DM oC at the access panel With the DM oC high voltage wiring disconnected from the rest of the vehicle connect a jumper wire rated to 600V across all terminals in the ISG access panel from RT 048 A to RT049 B to RT050 C to RT071 to RT072 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 212 AZD Service Manual 4 Connect the positive lead of the insulation tester using the clamp not t
23. moved from chassis at ground location Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 209 AZD Service Manual 18 Set the insulation tester to 500 volts and perform the test for 30 seconds or until the reading stabilizes Record the measurement EPAS M otor AC M easurement Note The resistance value should be greater than 10 M ohm If less than 10M ohm replace the EPAS motor 19 When the voltage reading on the insulation tester has decreased to less than 30 volts remove the insulation tester test leads and all jumper wires If your insulation tester does not read voltage use a voltmeter to ensure there is less than 30 volts present before removing any test leads or jumper wires 20 Connect C337P to EPAS DM oC 21 Install the ISG DM oC junction box cover 22 Install the traction motor junction box cover 23 Install the HV junction box cover 24 Install the high voltage battery service disconnect pin and the cover to battery pack 25 Reconnect the 12 volt battery s 26 Return the vehicle key to the ignition 27 Start the vehicle and verify the correct operation of the hybrid system Component Test Minimum Isolation Resistance M ohm s V oltage after 60 seconds Complete system as measured from the High 500 volts greater than 1 M ohms V oltage J unction Box Traction M otor Traction M otor Controller DM oC SI SG M otor ISG M otor Controller DM oC 445 EPAS M otor Satcon E
24. n M otor unction Box 7 Attach an insulated jumper wire rated to 600 volts across all 5 high voltage terminals RT048 A RT049 B RT050 C and RT071 amp RT 0 2 in the SG DM oC junction box To avoid false readings the jumper wires must not contact the junction box case or chassis ground refer to illustration Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 205 AZD Service Manual OMOC 445 ISG Not used for isolation test a S Ss am S z m i lt lt lt e z i r Figure 37 ISG Junction Box 8 Connect an insulated jumper wire rated to 600 volts between the HV positive terminal and HV negative terminal in the HV junction box refer to illustration 9 Shuttle Bus Only Attach an insulated jumper wire rated to 600 volts across all 5 high voltage terminals RT048 A RT049 B RT050 C and RT071 amp RT072 inthe AC DMoC junction box To avoid false readings the jumper wires must not contact the junction box case or chassis ground Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 206 AZD Service Manual Not used for Isolation test RTIS4 A RT135 B8 RT137 C Aa oO o Oo V 3SVHd 09 E VZO 8 3SVHd 09 M B8201 J 3SVHd 0 9 H V6Z0 SNG AH S EL ZS01 A NIVY Zi 1 YELO H SNG AH S EI g vest
25. nstructions M etric flanged fasteners M ajor Diameter amp Strength Class 8 8 Strength Class 10 9 Thread Pitch mome ps M6x1 0 M8x 1 25 M10x1 5 M ajor Diameter amp Strength Class 4 8 Strength Class 8 8 Strength Class 10 9 Thread Pitch E FT LB FT LB ee a oe ee a M4x0 7 M5x0 8 M6x 1 0 M8x 1 25 M10x1 5 mae Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 229 AZD Service Manual US Standard non flanged fasteners Thread Pitch BL A A O ee aa ae r C 10 32 UNC 1 4 20 UNC r moe NE e es mem m High V oltage B attery Component Size HV electrical studs 10 20 Nm 90 in Ibs Strain Relief Lock Nut 7 45 Nm 66 in Ibs Strain Relief Dome Nut pe 4 97Nm 44 in lbs Covers Covers High Voltage V oltage ee eee 15 in USinIbs Nata Exhaust Port 3 4 NPT ree m 95 Nm 35 in Opening hole High V oltage J unction Box PEC stud 8 16 Nm 72 in lbs Traction M otor Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 230 AZD Service Manual Access Panel Studs 5 16 e 716 Nm 120 5 in lbs A B C See Note Note Use a small torque wrench say 3 8 drive to reduce the bending moment on the modular post DC DC Converter SV GND stud Driveshaft B olts compere SE Driveshaft bolts pe 103 Nm 75 ft lbs 9 6 ESS Fuse Replacement 1 Verify there is no voltage as described in Verify No
26. oltage greater than 30 volts is present wait 5 minutes and measure again Any voltage greater than 30 volts should be considered dangerous If voltage greater than 30 volts is still present after steps 1 through 6 have been completed contact A zure T echline immediately at 1 866 473 1636 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 203 AZD Service Manual Negative RT053 RT055 RT079 Figure 35 High Voltage J unction Box 7 Inspect all HV connections for signs of arcing loose connections water damage or other damage 9 3 2 High Voltage System Isolation Resistance T est l Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage 2 Test all HV fuses with an ohm meter and ensure they are functioning properly The fuse must be checked for continuity to ensure accurate isolation test results All fuses should have a resistance of less than 5 ohms 3 Remove the cover from the traction motor junction box 4 Remove the cover from the ISG DM oC junction box 5 Shuttle Bus Only Remove the cover from the AC DM oC junction box 6 Attach an insulated jumper wire rated to 600 volts across the A B C terminals inside the traction motor junction box and to the positive high voltage terminal inside the ISG DM oC junction box refer to illustration Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 204 AZD Service Manual Figure 36 Tractio
27. omponent Isolation Resistance Specification chart 6 If resistance value Is less than 10 M ohm Replace the cable 9 3 9 Isolation testing AC DM oC Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 AZD Service Manual 9 4 Programming a Digital Motor Controller DMoC This procedure provides details to load or update the software and or calibrations on a Digital M otor Controller DM OC Note This Procedure Applies To Balance Hybrid V ehicles Equipped With VCU Software R4 Or N ewer The Software And Calibrations Used In This Procedure Will Not Work With R2 Or R3 Level Software Always remember to consult the vehicle safety section before servicing any Hybrid Component Important e Makesure the 12 V battery is fully charged before programming components in the vehicle e Obtain the latest version of the Balance Diagnostic Tool and the most recent released DM oC calibrations from the A zure Extranet Support site https extranet azuredynamics com Tools 1 Laptop Latest version of the Balance Diagnostic Full Version Tool V4 0_0 or newer DM oC calibration files which consists of 3 files ccs ehx and par fe N ote the numeric identifiers in the filename Indicates which motor controller the file should be written to e A C 3032 e TM 3033 e ISG 3034 e EPAS 3035 103460 A Hrns Serial Program DM oC 103298 D CAN diagnostic harness DB9 Extension cable 9 pin
28. rming this test High V oltage capacitors may be charged during the insulation test W ait 5 min before disconnecting jumper wires and isolation tester Always wear high voltage gloves when connecting and disconnecting high voltage leads 6 Set the insulation tester to 500 volts and perform the test for 30 seconds Record measurement and compare to ISG DM oC in the Component Isolation Resistance Specification chart r Replace the ISG M otor if itis less than10 M ohms Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 214 AZD Service Manual 9 3 6 EPAS DMoC Motor Isolation T est l Perform 9 3 1 Isolation Test Preparation Disconnecting High V oltage 2 Remove connector C337P 4 position HV from EPAS DM OC X prong connector C3375 EPAS DM oC connector 337P 3 Install jumper wires Connect jumper wire s rated to 600 volts DC across pins A B C in C337S on EPAS DM oC side of the connector Ensure that the jumpers do not touch the DM oC body or pin D 4 Connect the positive lead of the M ohm tester using the clamp not the probes to terminal A of connector C337S Ensure that the positive test probe does not touch the housing of the connector or pin D 5 Connect the N egative lead of the M ohm tester using the clamp not the probes to clean chassis ground or body of the DM oC 8 Set the insulation tester to 500 volts and perform the test for 30 seconds Record me
29. t need to be followed Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 219 AZD Service Manual Step 1 check the Using Boot K ey tab yes if boot key is installed in the DM oC or No if programming without Bootkey Refer to illustration detail A Note Boot K ey Is Only Necessary If Programming Fails Midway In The First A ttempt Step 2 Check the box for the DM oC you are connected to Refer to illustration detail B K Balance DMoC Programmer Balance DMoC Programmer info Welcome to Balance DMoC Programmer Make sure the vehicle is keyed on Follow the steps in the DMoC Programmer panel The current step will have its title blink A successful step will display a green button A failed step will display a red button For specific topic help click the 7 buttons in the DMoC Programmer panel Reminder Stay in Key o seconds Warning Enabling High Voltage frequently results in an inhibited state Please wait five minutes between programming each DMOC Figure 41 Step 3 Click the Connect to V ehicle Refer to illustration detail C button and it will turn Green when connected If button turns Red verify that key is on and the diagnostic cables are connected correctly Step 4 ISG and EPAS DM oCs Only Click the Enable High V oltage button It may take several seconds for the Enable High voltage button to turn green Notes
30. tric vehicle Disconnect the Energy Storage System ESS before servicing the high voltage system Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 194 AZD Service Manual 9 1 Securing a Damaged Hybrid Vehicle Disable the vehicle and its high voltage electrical system by performing as many of these steps as possible 1 Put the shift lever into Park 2 Remove the ignition key Removing the ignition key or turning it to the OFF position will disconnect the high voltage system unless the battery is damaged 3 Block the wheels if necessary 4 Disconnect the negative cable black from the 12 volt battery it is located in the engine compartment this will also disconnect the high voltage circuit 5 Disconnect the low voltage connector from front of the battery pack Turn counter clockwise turn and pull it out 6 If the battery is not accessible remove or cut the low voltage cable connected to the vehicle interface connector Do not cut the high voltage orange cable If the high voltage battery pack was damaged physically or electronically during an accident there is a possibility that high voltage may still be present on the orange cables even after the 12 volt battery is disconnected Always follow high voltage training Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 195 AZD Service Manual 9 2 Disconnecting the Energy Storage Syst
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