saf-t-liner hdx saf-t-liner ef minotour conventional/fs65 student guide tbb 2003 thomas body pcb...

Saf-T-Liner HDX

Saf-T-Liner EF

Minotour

Conventional/FS65

Student Guide

TBB 2003

Thomas Body

PCB Electrical

Thomas Body Electrical TBB2003

Course Objectives

• understanding of printed circuit boards

• read and understand Thomas schematics

• identify body harness routing

• understand chassis-body interface

• follow troubleshooting procedure

• access service publications and info

Thomas Body PCB Electrical TBB2003

Course Content:

1. Printed Circuit Boards

2. Battery, Ignition, Ground

3. Wiring

4. Understanding Thomas Drawings

5. School Bus Options

6. Service Publications

7. Evaluation 8. Reference

Thomas Body PCB Electrical

Section

1

Printed Circuit Boards


Page 1-2

Minotour Conventional

Saf-T-Liner HDX Saf-T-Liner EF


Page 1-3


This electrical system was designed by market,AMPs, and option demand.Make a list of consumers found in every bus

____________________________ ____________________________ ____________________________ ____________________________ ____________________________

it makes sense to control these consumers by the same device and in the same area on every bus

Make a list of consumers by market

School Transit Chick ________ _________ __________________ _________ __________ These consumers would also be controlled by a common device mount in the same area


Page 1-4

Printed Circuit Boards Initial Production Configuration

• Began in production with 2000 model Type D “New Look” pushers


Page 1-5

Conventional/FS65, Saf-T-Liner HDX

•Conventional/FS65 new external access April, 2003

• New Look Pusher started 2000 ER-Transit MVP-ER HD HDX



Page 1-6

MVP-EFStarted 2004

MinotourStarted 2005



Page 1-7

How many amps is required to provide power to a typical bus body?_________

The rear box pictured above from ER-Transit model



Page 1-8


• non-conductive platform with printed circuit paths• non-repairable component

Front side of B2 is pictured

Thomas Body PCB Electrical TBB2003

Page 1-9


reference Drawing# 52004770

AMP Load Capacity

List examples of circuits for each load:

1 amp ________________________

5 amp ________________________

15 amp _______________________

30 amp _______________________


Page 1-10


4 buss bars for parallel circuits


Page 1-11


How many large cables connect to

B1_____

B2_____

4 internal buss bars but 2 cables?


Page 1-12


What is role

of diodes

D5_________

D6_________

D7_________


Page 1-13


LED lightsHave 1000 ohmResistors/diodes

Why?

Diodes installedBetween D6Ignition & GroundD3 between Switched Power& Ground

Where is the bias?

See Drawing 52004770 & 52005370


Page 1-14

Relay#3 LED#4

Hands-on Activity#1

LED#29

LED#4 tells me___________________________LED#29 tells me__________________________



Page 1-15

Hands On Activity#1 using LED lights

Complaint: front dome lights are inop

Are front dome lights a body or chassis option?___________

Are front dome lights an option found on all busesor just school buses?___________

Which PCB will control this option?___________

Locate the decal on the service compartment doorfor B#1What relay controls the front dome lights?___________



Page 1-16

Hands-on Activity #2

R&R both PCB Board#1 and #2

What tools are required to remove?________________________________________

Remember to first disconnect the batteries


Page 1-17

Hands-on Activity#3

You will need a DVOM

With the ignition key in the on position Remove P5-B1 and locate circuit LT174 yellowAt pin 8

Test the circuit for voltage__________

Disconnect the flasher or flasher fuse at the chassis


Reinstall P5-B1 and flasher fuse and remove P4-B1

Test circuit LT10 yellow for voltage_____

Reinstall P4-B1 and remove P29-B1

Test circuit LT174 yellow for voltage_______


Page 1-18

Hands-on Activity #4

You will need a DVOM

Disconnect P5-B1 and locate circuit LB172 red


Step on the service brake and test voltage

See LED#31 amber

Re-connect P5-B1 and disconnect P4-B1

Test voltage at pins 3 and 8 red/white wire

Depress service brake and test voltage ____


Section 2

Battery, Ignition, and Ground


Page 2-2

Hands-on Activity# 5

Battery, Ignition and Ground

Trace the battery cable for the body Where is the body breaker for B1HDX_________________________EF__________________________Conventional_________________Minotour______________________


Page 2-3


Minotour

GMC

Ford


Page 2-4

Battery, Ground and Ignition

HDX

Battery cable to body from chassis


Page 2-5


Cable routes from solid state breaker on left Frame rail under driver’s seat to B1

Saf-T-Liner-EF


Page 2-6


61202164 solid state breaker

Used on HDX and EF as breakerfor battery to body and chassis

HDX- mounted on right frame rail just forward of engine compartmentEF-mounted to left frame rail below driver’s seat


Page 2-7


Body Breaker on Conventional

• located in lower switch cabinet


Page 2-8

Battery, Ground, and Ignition

Follow the Ground cable from B1

Where does it go?

HDX________________________

EF__________________________

CONVENTIONAL______________

MINOTOUR___________________

Using drawing#52004770 and 52005370

Why is there no main ground cable on B2?______________________________

Locate drawing#52004993This is a jumper harness from B1 to B2Follow GND on Pin 1 to ground buss Inside B! and B2


Page 2-9


See note B on drawing 52004778 and 52005555

Maximum tightening torque on power connections65 in-lbs


Page 2-10

Battery, Ground and Ignition

Shunts

Refer to drawing 52004770Locate J1 Shunts are non-keyed jumpers Easily changes safety buzzer behavior


Page 2-11

Battery, Ground, and Ignition

Use drawings 52004770, 52005370 and 52004993

Locate relay#5 on B1

Pin 87 of relay#5 power the ignition buss bar in B1

Follow the ignition/key switch signal from pin 86 of Relay#5

The chassis delivers the key switch signal atP_____ pin______

What powers the ignition buss bar in B2?_________________________________

Locate relay#10 on B2

What circuit connects at pin 86 of relay#10?____

-


Page 2-12


Switched Power

See Drawings 52004770 & 52005370

The school bus market requests an unusual option;at rail road crossings we want to turn off allnoise so the driver can hear an on-coming train

Noise suppression requires control of specific consumerswhen the ignition is on

Locate the Noise Suppression relay#9 on B1 schematic

Like other relays power to pin 30 comes from battery Pin 87 output goes to switched power buss bar

Locate the relays controlling defroster fansWhat powers pin 30?_________________

From P28-B1 pin 4 delivers switched power to B2B2 noise suppression controls the radio


Section 3

Wiring


Page 3-2

• Wire is color coded• Ground wires are white• Wire printed with circuit number

Wiring


Page 3-3

LW-Warning Light JP-JumperLD-Light POW-Power from fuseSA-Safety RLY-RelayLB-Brake Light LGT-Output to lightLR-Rear Light IGN-IgnitionLT-Turn Light GA-GaugeFD-Fan PWR-PowerLS-Strobe Light ST-StartMH-Mirror SW-Switch DF-Door DIM-DimmerLM-Marker Light EL-HeadlightGND-Ground AL-AlternatorSP-Spare, Speaker AD-Air DryerIGN-Ignition ICU-DashBATT-Battery SG-Shielded GroundLP-Panel Light EL-HeadlightSW-Switch DRL-Daytime Running

* Abbreviation printed on wire and used on electrical drawings/schematics

Example: circuit# 10 is yellow and found in the body harnessWith prefix I know LT10 is the front & rear left turn lights

Wiring


Page 3-4

• Each PCB board has keyed connector locations on the back

• Each PCB board will have many of the same number of connector locations • These connector locations are referred to as “J” • the corresponding harness connector for each J location in the back is labeled “P” or plug

• these “J” and “P” numbers allow you to locate on the bus specific circuits shown in schematics

Wiring


Page 3-5

Wiring• Pre-made harnesses come color coded from the vendor• This color coding assists in production and service

Where do I installthese connections?

_______________

_______________


Page 3-6

Wiring

Switch Cabinets

• pre-assembled sub components during production• switch base harnesses route to the controlling PCB


Page 3-7

WiringChassis Interface Connector

Saf-T-Liner EF


Page 3-8

J10 interface connector located on left side rear cross-member

WiringChassis Interface Connector

Minotour / Ford and GMC


Page 3-9

Harness Routing

Transition path for harnesses from switch cabinet to body harness

HDX, EF and Conventional

Body harness

Front harness

Wiring


Page 3-10

Harness Routing

Minotour

Rear side ofOverhead Compartment

• Interface harness

• main body harness from PCBs

• switch cabinet harness

• battery cable to B1

Wiring


Page 3-11

Wiring

Body harness routing in left curtain rail for all models

What circuits would I find in this harness?___________________________________________

Where would I find connections to this harness?__________________________________________What types of electrical failures may I see in the bodyharness?_________________________________


Page 3-12

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


Section

4

Understanding Thomas Drawings


Page 4-2


Drawing Numbers beginning with 5 body

Drawing Numbers beginning with 6 chassis

Newest TBB Drawing numbers are 6 digit like 112034They are sequentially assigned


Page 4-3


Types

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 4-4


Assembly Drawings

Using drawing#52005500

How long is the wire from P34-B2 to the intersection at the left curtain rail?___________

What is the connector part number for P99?________

In P4-B1 what is the pin location for circuit LM12?____

What is circuit SP-2?__________________________

Installation Drawings


How many fasteners must be removed to R&R B2?___

Where is the Weldon flasher mounted?_____________

Are the PCBs mounted per this drawing?____________


Page 4-5


Schematics

Use Drawing#52007002 to answer the following questions:

Do the dome lights work on battery or ignition?__________

How could I change the board to change the first question?________________

What PCB controls the dome lights?_________

What Amber LED lit tells me that Relay#4 has power?_____

Where would I look for S3 on circuit LD19 in the bus?_________________________________________

If diode D3 went bad inside B1 what would the driver report?___________________________________

What failure/s would result in front, rear and driver’s dome lights being inop?_______________________________


Page 4-6



Please draw a straight-line type schematic for the front passenger heater


Page 4-7


Use drawing#52006970 to answer the following questions:

How many PCBs control the warning light option?______

Which relay controls the red lights?_________________

When the driver opens the door what is the circuit number that tells the Weldon that the door is open?____________

LED#39 tells me power is being delivered to______________

What would happen if the GND circuit in jumper P28-B1 went open?_____________________________________

Where does the stop arm connect to B2?___________

What connects at connector#CSA ?_________________

What would happen if circuit JP3 was open?____________


Section 5

School Bus Options

Weldon 7000-100Pin Location & TBB Circuits

5 4 3 2 1 12 11 10 9 8 7 6

1 = Left Amber = LW55 yellow2 = Left Red = LW57 red3 = Stop Arm = LW82-2 gray4 = Right Red = LW56 red5 = Right Amber = LW58 yellow6 = Battery Power = LW149-1-A orange7 = Battery Power = LW149-1-B orange8 = Override Power 9 = Start Switch = LW80 tan10 =Seq. Door Switch(GND) = LW59 pink11 =Nonseq. Door Switch(GND) = LW81 purple12 =Ground = GND white

(Use 6 inch jumper with #16 Deutsch pins to troubleshoot)


Page 5-2


Page 5-3

Passenger Advisory-Check Mate

See PSB 07-11R4


Page 5-4

School Bus Options

Doran Light Monitor

• follow calibration sequence in PSB 07-13


Page 5-5

Aftermarket Add-ons

List consumers you may want to addTo the body after delivery

__________________________________________________________

How many amps are required?

Where is the consumer to be mounted?

When will it work? Key off or key on


Page 5-6

Aftermarket Add-ons

Using drawing 52004770

If I connect a consumer in series to the large terminals on B1either Battery or Ignition, what effect will it have on B1?___________________________________________


Page 5-7

Aftermarket Add-ons


Locate J32 on the drawing

This connection supplies the required datato correctly wire two relays(#2 and #8)

What is the maximum amp size of the addedconsumer?_______

What pin #s would be your output wires to your consumer?__________

What pin# goes to your switch?_______

Be Consistent and Keep RecordsWhat unit# and How is it wired

See Drawing 52006999 Fog Lamps


Page

Section 6

Service Resources-Printed-Electronic


Page 6-2

Service Publications

Printed Publications can be orderedBut more easily accessible on-line

3

Mytbb.thomasbusonline.comHome page• Service training calendar• TBB news• support or sales• select tab for desired topic


Service Resources


Page 6-4

Electronic Service Resources

The “Parts” tab will provide • viewing/copying the bill of materials• parts look up • viewing of drawings

There are two “parts” tabsParts = Conventional, HDX, EF and MinotourC2 Parts = C2 only


Page 6-5


Information for the Body and Chassis BOM are group together in ModulesThe module number are a part of the number listedunder moduleUsing the module reference page will expedite locating the correction info


Page 6-6


Once the module has been selected The parts list for that module will appear at the right

The PDF files will be drawings you can open, then view save, print or email

Parts Tab


Page 6-7


Parts Tab-Drawings

The PDF drawing file is linked to specific Body Number

Mytbb.thomasbusonline.com

Manuals Tab- Product Support Bulletin

1. Click on desired Document Group 2. Topics are in sequence by release Topics are listed , not linked, on Home Page at TBB News

Page 6-8



Mytbb.thomasbusonline.com

Manuals Tab

1. Click on desired manual type at left

Page 6-9




Page 6-10


Manuals Tab-Electrical Manuals

These electrical manuals are PDF files of printedmanuals by year by modelYou will note that the newer the model the more pagesin the manual


Page 6-11


Manuals Tab-Product Support Bulletins

Product Support Bulletins • not available in any other way• organized by product (C2 separate)• organized by Body and Chassis then Category


Page 6-12


Manuals Tab-Product Support Bulletins

PSBs are in PDF files that you can view, print or email


Page 6-13


Manuals Tab-Electrical Manuals

PDF or Zip files organized by Body or Chassisthen by functional group like “Lights”* Best to know your order option number


Page 6-14


Manuals Tab-Reference

Within the Reference group you will find complete instructions on using this web site


Evaluation

7

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


Reference 8

-Modules-Identifying your bus-Circuit numbers


Page 8-2

Reference


Page 8-3

Reference

Locating Body

Identification Numbers

• Data plates are normally found above the driver’s window or on the front bulkhead


Reference

Page 8-4

NC VEH MFD BY:DATE:

GVWR:GAWR FRONT: WITH

TIRESRIMS

PSI COLDGAWR INTERMEDIATE: WITH TIRES

RIMSPSI COLD

GAWR REAR:WITH WITH TIRESRIMS

PSI COLDTHIS VEHICLE CONFORMS TO ALL APPLICABLE MAX CAPFEDERAL MOTOR VEHICLE SAFETY STANDARDS SUB TO DESIGNIN EFFECT IN: LIMITS:V.I.N.: CHAS. ID. NO: 27230VEH. TYPE: EQUIP. CAP.:BODY ID.: 82508 - 9952194 - 1308S

(order #) - (body #) - (model #)

HIGH POINT, NORTH CAROLINAWOODSTOCK, ONTARIOMONTERREY, M.L., MEXICO

MFD. BY THOMAS BUILT BUSES, INC.MADE IN U.S.A. DATE:

Body Identification Number

Reference


Page 8-5

Three Groups of Numbers

82508 - 9952194 - 1308S


Order# (first group) -Assigned consecutively to an order when it is received in High Point -Each Pusher has its own order#

Body# (second group) -Assigned consecutively to each body -First two digits are year built

Body Model ID (third group) -First three digits are body length -Fourth digit is type of bus -Fifth digit indicates school or non-school


Reference

Page 8-6

HIGH POINT, NORTH CAROLINAWOODSTOCK, ONTARIOMONTERREY, M.L., MEXICO

MFD. BY THOMAS BUILT BUSES, INC.MADE IN U.S.A. DATE:

CHASSIS MODEL YARD NO. YEAR

ENGINE: SER NO

TRANS: SER NO

FRONT MODAXLE NO

INT MODAXLE NO

REAR MODAXLE NO

BODY ID.:


Chassis Data Plate• Body Id# found here as well as standard data plate


Reference

Page 8-7

Locating Body Identification

Numbers By Model

Minotour, SRW & DRW

Order# & Body#


Reference

Page 8-8


Numbers By Model

Conventional

Order# & Body#


Reference

Page 8-9


Numbers By Model

Saf-T-Liner ER and HD

(butyl tape applied trim)

Order# & Model#

Reference


Page 8-10


Numbers By Model

Saf-T-Liner ER , HD and HDX

(fastener applied trim on D/door post)

Order # & Body# on welded plate mounted on firewall below treadle valve


Reference

Page 8-11

ReferenceLocating ID Numbers

Chassis number stamped


Page 8-12

13

1 T 7 Y R 4 B 2 8 4 1 1 3 2 5 4 0


Use this vin # to answer these questionsWhat model is ______________________________?What type of engine does it have _______________?What is the headroom________________________?What was the year of manufacture______________?Does this bus have air or hydraulic brakes________?

Reference

Identifying the Bus

MERCEDES

CUMMINS

Thomas Body Electrical

Reference

Page 8-14

Body Circuit Numbers

Circuit# Description Color

176 Doran Monitor Feed Red

177 Doran Monitor Ground White

AV599 LED Pilot Light Pink

Batt Battery Power Green

BRK_INTERLOCK Signal to Chassis disrupts brake Orange

CHILD_ALARM Signal to Chassis for Child Alarm Horn Purple/White

CROSS_ARM Signal to Chassis for Crossing Arm Purple/White

DF426 Door Switch Open Green

DF427 Door Switch Override Yellow

DF428 Door Signal Red

DOOR_RTN Signal to Chassis for Door DK Blue

DS27 Destination Sign Pink

F_L Front Passenger Heater Low Purple

F_P_H Front Passenger Heater High Yellow

F317 Hatch Fan Orange

FD34 Left Defroster Fan Gray

FD35 Right Defroster Fan Tan

FD36 Left Defroster Fan Black

FD37 Right Defroster Fan Blue

GND Ground White

Horn Horn Output Blue

Thomas Body Electrical Reference

Page 8-15

HTR_CBLE_F Front Heater Red

HTR_CBLE_R Rear Heater Red

IGN Ignition Power Red

IGN_F_P Ignition Front Passenger Heater Blue

IGN_R_P Ignition Right Passenger Heater Blue

KNEEL_CKT Signal to Chassis for kneel Black

LB13 Brake Light Blue

LB15 Right Brake Light Red

LB16 Left Brake Light Red/White

LB172 Brake Light Indicator Red

LD19 Rear Dome Lights Black

LD20 Front Dome Lights White/Black

LD20 Driver's Dome Light Black

LE74 Front Entrance Light Blue

LM12 Marker Light Brown/White

LM168 Marker Light Brown

LM40 Side Marker Lights Brown

Low_SPD_SIG Signal from Chassis for low speed Tan

LP70 Panel Lamp Orange

LP70-A Dimmer Black

LR14 Reverse Light Blue/White

LR170 Reverse Light Blue

LR170A Reverse Light Feed Brown

LS38 Strobe Light Purple



Thomas Body Electrical Reference

Page 8-16

LT10 Front & Rear Left Turn Lamp Yellow

LT174 Left Turn Lamp Yellow

LT175 Right Turn Lamp Green

LT9 Front & Rear Right Turn Lamp D Green

LW1 Left Rear Red Warning Light Black

LW149 Warning Light Flasher Power Orange

LW2 Right Front Red Warning Light Brown

LW3 Right Rear Red Warning Light Orange

LW4 Left Front Red Warning Light Yellow

LW5 Left Rear Amber Warning Light Blue

LW55 Amber Warning Light Yellow

LW56 Red Warning Light Red

LW57 Red Warning Light Red

LW58 Amber Warning Light Yellow

LW59 Door Switch Signal (ground) Pink

LW6 Right Front Amber Warning Light White

LW7 Right Rear Amber Warning Light Red

LW8 Left Front Amber Warning Light Green

LW80 Start Switch 12V+ Tan

LW81 Door Open Purple

LW82 Stop Arm Signal Gray

MH468 Left Heated Mirror Orange

MH469 Right Heated Mirror Blue


Thomas Body PCB Electrical Reference

Page R-4

Neutral Signal from Chassis for neutral Black

Pump Coolant Pump Brown

R_L Rear Passenger Heater Low Pink

R_P_H Rear Passenger Heater High Yellow

SA29 Buzzer (GND) Blue

SA32 Vandalock Ground Signal to Chassis Yellow

SA32-A Vandalock Ground Signal from Rear Gray

SA32-B Vandalock Yellow

SA33 Buzzer Power Pink

SD59 Door SW Open to Flasher Pink

SP1 Spare Wire for Front Door Purple

SP2 Spare Wire to Rear Green

SP3 Spare Wire for Child Alarm Black

SP4 Spare Wire for Dome Light Yellow

SW+ Rear Door Switch Purple

SW1+ Switched Ign Power to Switch Gray

SW2+ Switched Ign Power to Switch Gray



saf-t-liner hdx saf-t-liner ef minotour conventional/fs65 student guide tbb 2003 thomas body pcb...

Documents

printed circuit boardshow

printed circuit boardswhat

printed circuit boards2

typical bus body

chassisbody interface

body harness routing

thomas schematics

liner hdxsaft