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HybriDrive
System Manual
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BAE systems HybriDrive, HDS 100, HDS 200 System Manual

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HDS System Manual
HYBRIDRIVE® Propulsion System
HybriDrive® Series System (HDS) System Manual
System Model Number(s)
Prepared for:
SARTA OHIO
Bus No’s: 401393-397
Model: Axess 40’
2
This Page Intentionally Left Blank
TO:HoldersofHybriDrive®SeriesSystem(HDS)SystemManual,SystemModel
Number(s)HDS100andHDS200
FROM:BAESystems
CAGE:89954 ILS/ProductSupport 1098ClarkStreet Endicott,NY13760USA
Web:http://www.hybridrive.com/
SUBJECT:HybriDrive®SeriesSystem(HDS),Revision4,datedDec04/2015
ThesubjectRevisionisattachedtothisletteroftransmittal.Becauseoftheextentofchangesto thismanualitisbeingreprintedandissuedinitsentirety.Pleasediscardthepreviousedition.
Pleasedirectanyquestionsorcommentstotheaddressabove.
BAESYSTEMSPROPRIETARYINFORMATION
ThisinformationisownedbyBAESystemsandcontainsproprietaryinformationofBAESystems. Thisinformationiscopyrightedbytheownerandislicensedtotherecipient.Thisinformationmay notbedisclosedtoanyoneotherthantherecipient,orusedforotherthanitsintendedpurpose withoutexpresswrittenconsentofBAESystems.COPYRIGHT2015BAESYSTEMS.Allrights reserved.
EXPORTCONTROLLEDDATA
ThisdocumentcontainstechnicaldatawhoseexportisgovernedbytheU.S.ExportAdministration Regulations(EAR).Thesecommodities,technologyorsoftwarewereexportedfromtheUnited StatesinaccordancewiththeExportAdministrationRegulations.DiversioncontrarytoU.S.lawis prohibited.ECCN:EAR99,NLR(NoLicenseRequired).
HDS100andHDS200
TO:AllHoldersofHybriDrive®SeriesSystem(HDS)SystemManualACS17051
Revision4,datedDec04/2015
TITLE:
HybriDrive®SeriesSystem(HDS)
SystemModelNumber(s)
HDS100
HDS200
ThefollowingHIGHLIGHTSlistallpageswithtechnicalchanges,includingaddedanddeleted pages.EachHIGHLIGHTSentryincludesabriefgeneraldescriptionofthechange.
Achangebarinthemarginoftheaffectedlineindicatestechnicalchanges,additions,and/or deletionsofthismanual

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OVERVIEW:
UpdatedHybridrivetoHybriDrive®throughoutthemanual.
UpdatedEAStoAPS1throughoutthemanual.
UpdatedElectronicAlternatorSupplytoAccessoryPowerSystemthroughoutthemanual.
UpdatedAPStoAPS2throughoutthemanual.
Removed“T orquevaluesare±10%”fromtextthroughoutthemanual.
INTRODUCTION
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7
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10Updatedparagraphs11and12.
CHAPTER1-DESCRIPTIONANDOPERATION
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Updatedparagraph4.D.(3)(c).
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35Updatedparagraph4.F.
45UpdatedTable1-1.
CHAPTER2-SCHEDULEDMAINTENANCE
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CHAPTER3-SPECIFICA TIONSANDCAP ABILITIES
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2Updatedparagraphs2and3.
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8Updatedparagraph8.
CHAPTER4-TESTINGANDFAULTISOLATION
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HDS100andHDS200
ACS17051
BAESYSTEMSPROPRIETARYINFORMATION
ThisinformationisownedbyBAESystemsandcontainsproprietaryinformationofBAESystems. Thisinformationiscopyrightedbytheownerandislicensedtotherecipient.Thisinformationmay notbedisclosedtoanyoneotherthantherecipient,orusedforotherthanitsintendedpurpose withoutexpresswrittenconsentofBAESystems.COPYRIGHT2015BAESYSTEMS.Allrights reserved.
EXPORTCONTROLLEDDATA
ThisdocumentcontainstechnicaldatawhoseexportisgovernedbytheU.S.ExportAdministration Regulations(EAR).Thesecommodities,technologyorsoftwarewereexportedfromtheUnited StatesinaccordancewiththeExportAdministrationRegulations.DiversioncontrarytoU.S.lawis prohibited.ECCN:EAR99,NLR(NoLicenseRequired).
SYSTEMMANUAL
FOR
HYBRIDRIVE
HybriDrive®SeriesSystem(HDS)
SYSTEMMODELNUMBER(S)
®
PropulsionSystem
HDS100
HDS200
Dec04/2015
BAESYSTEMSPROPRIET ARYINFORMA TION/WARNING:EXPORTCONTROLLED—SubjecttotherestrictionsontheTitlepage

TITLE

Page1
Revision4
HDS100andHDS200

RECORDOFREVISIONS

Rev.No.DateIssuedDateInsertedBy
0
1
2
3
4
Apr12/2012
Jul04/2013
Sep12/2013
Mar24/2014
Dec04/2015
THETECHNICALCONTENTOFTHISCOMPONENTMAINTENANCEMANUALISAPPROVED BYBAESYSTEMS.
Retainthisrecordinthefrontofthemanual.Onreceiptofrevisions,insertrevisedpagesinmanual.
Enterrevisionnumber,dateissued,dateinserted,andinitials.
RECORDOFREVISIONS
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SERVICEBULLETINLIST

ThefollowingisalistofServiceBulletins,applicabletothismanual.ServiceBulletinsaffectingthis manualareshownbythedateofincorporation.
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SERVICEBULLETINLIST
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TABLEOFCONTENTS

SECTION PAGE
INTRODUCTION .................................................................................................................................1
1.PurposeofManual
2.ScopeofManual
3.AssociatedManuals
4.ShopPractices
5.ImportantSafetyInstructions
6.SafetyGuidelines
7.OverallSystemDangers
8.OverallSystemWarnings
9.OverallSystemCautions
10.MotorVehicleAccidentProcedures
11.TowingInstructions
12.WeldingPrecautions
13.MetricEquivalents
14.Organization
........................................................................................................................11
................................................................................................................3
...................................................................................................................3
..............................................................................................................3
......................................................................................................................4
................................................................................................4
..................................................................................................................5
.......................................................................................................6
......................................................................................................6
.......................................................................................................7
......................................................................................8
..............................................................................................................10
...........................................................................................................10
...............................................................................................................10
CHAPTER1-DESCRIPTIONANDOPERA TION ..............................................................................1
1.General
2.SystemDescription
3.PropulsionRequirements
4.ComponentDescription
5.AutomaticProtection
6.CoolingSystem
7.ShippingandHandling
8.StorageRequirements
9.LeadingParticulars
CHAPTER2-SCHEDULEDMAINTENANCE
1.ScheduledMaintenance
2.ItemsNeededforMaintenance
3.MaintenanceConcept
4.TypicalFieldAssessmentandRepair
5.UseIDStocheckforlatentfaults
6.InspecttheESSairlterandairinletsforblockagesanddebris
.................................................................................................................................1
...............................................................................................................1
......................................................................................................5
.........................................................................................................6
...........................................................................................................40
...................................................................................................................42
........................................................................................................43
........................................................................................................43
.............................................................................................................44
....................................................................................1
........................................................................................................2
.............................................................................................2
...........................................................................................................3
...................................................................................4
..........................................................................................6
..........................................8
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7.CleanorReplacetheAirFiltersforthe ESS .........................................................................9
8.InspectHCPwaterpumpforexcessiveleakage
9.InspectEngineBellhousingforuidresidue
10.CheckforleaksandreplaceTractionMotoroilandlter
11.InspectformissingordamagedLabels
..............................................................................22
12.Inspectair-to-water/glycolheatexchangers
13.Inspectallexternalconnectorsandwiringforloosenessordamage
14.Inspectcoolingsystemforleaksordamage
15.InspectallVibrationMounts
16.Replacewater/glycolcoolant
17.VerifyACTMOilLevel
................................................................................................26
..............................................................................................27
.........................................................................................................28
.................................................................15
.......................................................................16
....................................................17
........................................................................23
..................................24
.......................................................................25
CHAPTER3-SPECIFICA TIONSANDCAPABILITIES
1.HEVVehicle/OperatorInterfaces
2.MasterRun/Key-OnSwitch
..........................................................................................1
...................................................................................................2
3.PCSEmergencyOverride/StopEngineOverrideSwitch
4.Start/StopDriveMode
5.DepotDriveMode
6.GearSelectorSwitch
7.InstrumentPanelIndicators
8.Regen
Switch(optional) ........................................................................................................8
9.HighIdleSwitch(optional)
10.EngineTestSwitch
...........................................................................................................3
.................................................................................................................4
............................................................................................................6
..................................................................................................7
....................................................................................................8
................................................................................................................9
11.EmergencyStopButton(optional)
12.HEVMaintenanceLight
13.IntuitiveDiagnosticSystem
........................................................................................................9
.................................................................................................10
14.SoftwareProgrammableConguration
15.ElectronicThrottleandBrakePedals
16.Event-DrivenDataRecording
.............................................................................................10
........................................................................................9
...............................................................................10
..................................................................................10
......................................................................1
......................................................2
CHAPTER4-TESTINGANDFAULTISOLATION .............................................................................1
1.SystemDescription
2.SystemHealthT ests
3.TroubleshootingFaultConditions
...............................................................................................................2
.............................................................................................................4
.......................................................................................10
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4.ElectricalDisconnectVericationProcedure .......................................................................13
5.SpeedandDirectionSensorFaultIsolationandTroubleshootingProcedure
6.ACGroundFaultIsolationandTroubleshootingProcedure
7.CommunicationLossFaultIsolationandTroubleshootingProcedure
...............................................30
................................60
....................15
CHAPTER5-REMOVEANDREPLACE...........................................................................................1
1.ESS(EnergyStorageSystem)
2.SCU(SystemControlUnit)
3.PCS(PropulsionControlSystem)
4.APS1
( AccessoryPowerSystem ) .....................................................................................115
5.ACTM(AlternatingCurrentTractionMotor)
6.ISG(IntegratedStarterGenerator)
®
7.HCP(HybriDrive
8.APS2
(AccessoryPowerSystem) .....................................................................................270
CoolingPackage) ................................................................................251
..............................................................................................3
.................................................................................................77
.......................................................................................85
......................................................................138
...................................................................................231
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INTRODUCTION

DONOTPERFORMMAINTENANCEUNLESSYOUHAVEBEENTRAINEDONHIGHVOLTAGE SAFETYANDHYBRIDRIVE
®
SYSTEMCOMPONENTS.
THISDOCUMENTCONTAINSIMPORT ANTPROCEDURESTHATCOULDAFFECT THERELIABILITYOFTHEHYBRIDRIVE
®
SYSTEMCOMPONENTSIFDONE
INCORRECTLY.
DONOTCHANGETHEPROCEDURESINTHISDOCUMENTUNLESSTHE REPAIRSOURCEGETSAPPROVALFROMBAESYSTEMS.UNAUTHORIZED CHANGESORMODIFICATIONSMAYVOIDTHEPRODUCTWARRANTY.
APPROVALDOESNOTRELEASETHEREPAIRSOURCEFROMCOMPLETE RESPONSIBILITYFORALLWORKDONE.
DISCLAIMEROFLIABILITY!
THESEMATERIALSAREINTENDEDTOASSISTEMPLOYERS,WORKERS,ANDOTHERS ASTHEYSTRIVETOMAINTAINWORKPLACEHEALTHANDSAFETYWHENPERFORMING MAINTENANCEONHYBRIDRIVE®PROPULSIONSYSTEMS.BAESYSTEMSCONTROLSINC. MAYMAKEMODIFICA TIONSORUPDATETHESEMATERIALSFROMTIME-TO-TIMEWITHOUT NOTICE.WHILEWEA TTEMPTTOACCURATELYADDRESSTHESUBJECTSCOVEREDINTHIS TRAINING,ITISNOTPOSSIBLETOINCLUDEDISCUSSIONOFEVERYTHINGNECESSARY TOENSUREAHEALTHYANDSAFEWORKINGENVIRONMENTINAPRESENT ATIONOF THISNATURE.BAESYSTEMSANDITSAFFILIATESSHALLNOTBEHELDLIABLEFORANY IMPROPERORINCORRECTUSEOFTHEMATERIALSORINFORMATIONASSOCIA TEDWITH THESEMATERIALSANDASSUMESNORESPONSIBILITYFORANYUSER'SUSEOFTHEM. INNOEVENTSHALLBAESYSTEMSORITSAFFILIA TESBELIABLEFORANYINDIRECT , INCIDENTAL,SPECIAL,EXEMPLARYORCONSEQUENTIALDAMAGES(INCLUDING,BUT NOTLIMITEDTO,BUSINESSINTERRUPTIONORLOSSOFUSE,DATA,ORPROFITS) REGARDLESSOFCAUSE,ANDONANYTHEORYOFLIABILITY ,WHETHERINCONTRACT, STRICTLIABILITY ,ORTORT(INCLUDINGNEGLIGENCEOROTHERWISE)ARISINGINANY WAYOUTOFTHEUSEOFITSMATERIALS,EVENIFADVISEDOFTHEPOSSIBILITYOFSUCH DAMAGE.THISDISCLAIMEROFLIABILITYALSOAPPLIESTOANYDAMAGESTOPROPERTY ORINJURYORDEA THTOPERSONSARISINGOUTOFUSEOFTHESEMATERIALSOR PARTICIPA TIONINATRAININGCOURSE,INCLUDINGBUTNOTLIMITEDTOTHOSECAUSED BYANYACTIONSORFAILURETOACTONTHEPARTOFBAESYSTEMS,WHETHERFOR BREACHOFCONTRACT ,TORTIOUSBEHAVIOR,NEGLIGENCE,ORUNDERANYOTHER CAUSEOFACTION,EXCEPTTOTHEEXTENTSUCHDAMAGESARECAUSEDBYTHE GROSSNEGLIGENCEORWILLFULMISCONDUCTOFBAESYSTEMS.
WhenperformingmaintenanceonHybridrive
®
propulsionsystems,itistheresponsibilityof employersandtheiremployeestocomplywithallapplicablelaws,includinghealthandsafety regulations,withintheirjurisdictions.
INTRODUCTION
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DIRECTCORRESPONDENCETO:
BAESystems 1098ClarkStreet Endicott,NY13760 Attn:HybriDrive
®
CustomerSupport
Phone:1-800-576-3346(fromUSA,Canada,PuertoRico) Phone:1-607-770-4167(fromallotherregions) Fax:1-607-755-781 1 Hours:Monday–Friday8:00amto5:00pmEST E-mail:ps.hybridrivesupport@baesystems.com Websiet:www.hybridrive.com
InstructionsforTroubleshootingaregivenintheTESTINGANDFAULTISOLATION sectionofthismanual.HybriDrive
®
LineReplaceableUnits(LRUs)thathavebeen identiedtorequirerepairshouldbeshippedtotheBAESystemsservicecenter. ContactHybriDrive
®
ProductSupportaddressgivenaboveforreturnprocedures.
Shiptheassemblyto:
BAESystems 1098ClarkStreet Endicott,NY13760 Attn:HybriDrive
®
CustomerSupport
INTRODUCTION Page2
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