Navistar IC Bus Electric CE Series User manual

InstructionSheet
FIRSTRESPONDERGUIDE-ICBus®ElectricCESeries
4328785R1
Purpose
Thepurposeofthisdocumentistoprovidedetailedinstructiononthefollowingforrstresponders:
•SafetyInformation
•High-VoltageLabels
•PersonalProtectionEquipment(PPE)
•IdentifytheVehicle:Exterior
•IdentifytheVehicle:Interior
•IdentifytheVehicle:UnderHood
•Overview:VehicleSystemsandComponents
•High-VoltageBattery
•DriveMotor
•High-VoltageCables
•Immobilization
•DisableDirectHazards
•StoredEnergy/Liquids
•HazardousMaterialEmergencyCleanup
•InCaseofFire
•InCaseofSubmersion
•Towing/Transportation/Storage
•ImportantAdditionalInformation
1
Readallsafetyinstructionsinthe"SafetyInformation"sectionoftheappropriateEngineServiceorDiagnosticManual.
Followallwarnings,cautions,andnotes.
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

SafetyInformation
NOTE:Certainwarningsmayberepeatedthroughoutthismanual.
WARNING:Topreventpersonalinjuryand/ordeath,removealljewelrysuchaswatches,
necklaces,andearrings.Removeallmetalobjectsthatareconductorsofelectricity.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSapproachthevehiclefromthesides
wheneverpossibletostayoutofpotentialtravelpath.Itmaybedifculttodetermineifthevehicleis
runningduetolackofenginenoise.
WARNING:Topreventpersonalinjuryand/ordeath,ordamagetoproperty,removeanycharge
cablefromthevehicle,turnignitionOFF,setparkingbrake,andinstallwheelchockstopreventvehicle
frommovingineitherdirectionduringfurtheraction.
WARNING:Topreventpersonalinjuryand/ordeath,donottouchthehigh-voltagesystemorany
ORANGEdevicewithoutwearingappropriatehigh-voltagePersonalProtectionEquipment(PPE).The
PPEshouldinclude:
a.Class0electricalinsulatinggloves,safetygoggles,andElectricalHazard(EH)ratedsafetyshoes
orboots,whichmustbeatleastappropriateupto1000volts.
b.Anon-conductiveobject,about5ft(1.5m)long,tosafelypushsomeoneawayfromthevehicle
iftheyaccidentallycomeincontact.
WARNING:Topreventpersonalinjuryand/ordeath,turnOFFthe12Vdisconnectswitchand
high-voltagedisconnectswitchbeforeinteractingwithadamagedvehicle.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthe12VoltBattery
DisconnectSwitchonlydisablesthevehicle12voltsystem,NOTthehigh-voltagebatterysystem.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthatturningOFFthe
high-voltagedisconnectswitchwillnotdissipatevoltageinsidethehigh-voltagebatteriesorinlevel
2or3highvoltagecables.ALWAYSASSUMEthehigh-voltagebatteries,high-voltagecables,and
high-voltagecomponentsremainliveanddangerous.Contactwiththehigh-voltagebatterypackor
high-voltagecomponentinternalsmayresultinseriouspersonalinjuryordeath.
WARNING:Topreventpersonalinjuryand/ordeath,handleasubmergedvehiclewithappropriate
PersonalProtectionEquipment(PPE).Considertheentirevehicleasenergized.
WARNING:Topreventpersonalinjuryand/ordeath,alwayswearfullPersonalProtection
Equipment(PPE),includingSelf-ContainedBreathingApparatus(SCBA)whenreisinvolved.Fires
incrash-damagedelectricvehiclescouldemittoxicorcombustiblegasses.Smallamountsofeye,
skin,orlungirritantsmaybepresent.Ifexposed,rinsewithlargeamountsofwaterfor10-15minutes.
Considertheentirevehicleasenergized.
WARNING:Topreventpersonalinjuryand/ordeath,NEVERcutorattempttobreachhigh-voltage
batteries,high-voltagecomponents,orhigh-voltagewiring.
WARNING:Topreventpersonalinjuryand/ordeath,payattentiontosecondaryreevents.Even
dayslatersecondaryreeventscannotbeexcluded.
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High-VoltageLabels
Figure1.ExtractofAvailableHigh-VoltageLabelsThroughouttheEntireVehicle
Varioushigh-voltagecomponentsareinstalledthroughouttheentirevehicle.Atrianglewithalightningboltis
usedtoidentifyhigh-voltagecomponents.Thelightningtrianglecanbesingleorpartofacombination.Also,any
vehiclecomponentsthatareORANGEincolorand/orORANGEwithstripesidentifyhigh-voltagecomponents.
High-voltagecomponentsinthevehiclearedividedinto3levels/zones.Onlycomponentsatlevel1/zone1
areisolatedafterthehigh-voltagedisconnectswitchisturnedOFF.Componentsinzone2andzone3remain
live.
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High-VoltageLabels(cont.)
2
0000469818
Figure2.Level2/Zone2:High-voltagecablesareorangewithbluestripingandhavewhiteand
bluesafetyags.
3
0000469819
Figure3.Level3/Zone3:High-voltagecablesareorangewithwhitestripingandhaveblackand
whitesafetyags.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthatturningOFFthe
high-voltagedisconnectswitchwillnotdissipatevoltageinsidethehigh-voltagebatteriesorinlevel
2or3highvoltagecables.ALWAYSASSUMEthehigh-voltagebatteries,high-voltagecables,and
high-voltagecomponentsremainliveanddangerous.Contactwiththehigh-voltagebatterypackor
high-voltagecomponentinternalsmayresultinseriouspersonalinjuryordeath.
Componentsinhigh-voltagezone2andhigh-voltagezone3remainliveafterthehigh-voltagedisconnectswitch
isturnedOFF.Thesezonesaremostlylocatedbetweentheframerailsontheundersideofthevehicleandare
labeledasindicatedinFigure2andFigure3.However,theexactlocationofzones2and3variesbylocation
andnumberofbatteriespacksinstalled.
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High-VoltageLabels(cont.)
3
2
0000469815
LEVEL 1 LEVEL 2 LEVEL 3
Figure4.High-VoltageIsolationLevels/Zonesfor2-StringVehicles(ViewedfromBottom)
Iftherearenohigh-voltagebatterystacksbetweentherearwheelsofthevehicleandtherearbumper,thelevel
2and3zonesarelocatedasshowninFigure4.Thisiscalleda“2-String”conguration.
3 32
0000469816
LEVEL 1 LEVEL 2 LEVEL 3
Figure5.High-VoltageIsolationLevels/Zonesfor3-StringVehicles(ViewedfromBottom)
Ifthereisabatterystackbetweentherearwheelsofthevehicleandtherearbumper,thelevel2and3zones
arelocatedasshowninFigure5.Thisiscalleda“3-String”conguration.
54328785R1
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PersonalProtectionEquipment(PPE)
WARNING:Topreventpersonalinjuryand/ordeath,removealljewelrysuchaswatches,
necklaces,andearrings.Removeallmetalobjectsthatareconductorsofelectricity.
WARNING:Topreventpersonalinjuryand/ordeath,donottouchthehigh-voltagesystemorany
ORANGEdevicewithoutwearingappropriatehigh-voltagePersonalProtectionEquipment(PPE).The
PPEshouldinclude:
a.Class0electricalinsulatinggloves,safetygoggles,andElectricalHazard(EH)ratedsafetyshoes
orboots,whichmustbeatleastappropriateupto1000volts.
b.Anon-conductiveobject,about5ft(1.5m)long,tosafelypushsomeoneawayfromthevehicle
iftheyaccidentallycomeincontact.
OnanICBus®ElectricCESeriesWITHOUTanydamage,theignition,12Vdisconnectswitch,andhigh-voltage
disconnectswitchcanbeoperatedwithoutanyspecialhigh-voltagePersonalProtectionEquipment(PPE).Do
nottouchanyhigh-voltagecomponentorORANGEcoloreddevicefornoreason.
AvehiclewithDAMAGEDhigh-voltagecomponentsorwithUNKNOWNsafetystatusshouldonlybehandled
byspecialtrainedandequippedpersonnel.ThePersonalProtectionEquipmentmustbeatleastappropriateup
to1000volts.Considertheentirevehicleasenergized.
AlwayswearfullappropriatePersonalProtectionEquipment(PPE),includingSelf-ContainedBreathing
Apparatus(SCBA)whenreisinvolvedorthevehiclewassubmergedduetothehighriskofreignition.
4328785R16
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IdentifytheVehicle:Exterior
Figure6.ExteriorBadges
TheICBus®ElectricCESeriescanbedistinguishedontheexteriorfromcommonbusmodelsbybadgesoverthe
entrancedoorandoverthedriver-sidewindowwithBLUEstripes,theYELLOWIClogoandBLUEELECTRIC
lettering.Additionally,there,isanICBusElectricCESeriesbadgeontheleftsideoftheentrancedoorandan
ELECTRICPOWEREDstickeronboththefrontbumperandtherearbumper.
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IdentifytheVehicle:UnderHood
Figure7.UnderHood
Underhood,theICBus®ElectricCESerieshasseveralhigh-voltagemodules,whichcanbedistinguishedby
theORANGEcablesandhigh-voltagelabels.
4328785R18
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IdentifytheVehicle:Interior
Figure8.Cluster
1.Chargingstationicon
TheICBus®ElectricCESeriescanbedistinguishedfromcommonschoolbusmodelsbythechargingstation
icon(Figure8,Item1)onthetopleftoftheinstrumentcluster.
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VehicleSystemsandComponents
Figure9.VehicleOverview
1.High-voltagebatterypack(uptovetotal,dependentonvehicleoptions)
2.TractionPowerInverterModule(TPIM)
3.AuxiliaryHeater
4.DCDCconvertersand12Vbatteries(DCDC)
5.5kW2-in-1inverter
6.11kWOnboardCharger(OBC)(2)
7.High-voltagepowersteeringpump
8.High-VoltageDistributionUnit(HVDU)
9.Chargeportfront(AC&DC)andOnboardChargingInterface(OCI)module
10.Airbrakepressuretanks
11.BatteryThermalManagementSystem(BTMS)
12.High-VoltageDistributionModule(HVDM)
13.S-box
14.Drivemotor
15.Chargeportrear(AC&DC)andOnboardChargingInterface(OCI)Module
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VehicleSystemsandComponents(cont.)
Figure10.ServiceAccessCovers
1.High-voltageservicedisconnectcover
2.12Vbatterydisconnectcover
TheHigh-Voltageand12VBatteryServiceaccesscovers(Figure10,Items1&2)arelocatedonthedriverside
ofthevehicle.Eachcoverisequippedwithalock.Inanemergencysituation,ifkeysarenotavailable,access
coversmustbeopenedbyforce.
114328785R1
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High-VoltageBatteries
Figure11.High-VoltageBatteries
TheICBus®ElectricCESeriesmaybeequippedwithuptovehigh-voltagebatterypacklocations.Each
batterypackcancontaintwoverticallystackedhigh-voltagebatteries.Thisarrangementdependsonthevehicle
conguration.However,therearmostlocationisalwaysasinglebattery.Thehigh-voltagebatteriesarelocated
underthebuscabinbetweentheframerails.Fourbatterylocationsarebetweentheaxlesandoneislocated
behindthedriveunit.Therearmostpackofthefrontlocationsandthepacklocatedbehindtherearaxleare
optional.
DriveMotor
Figure12.DriveMotor
Thedrivemotorislocatedbehindtherearaxleandispoweredby6-phaseAlternatingCurrent(AC).Thedrive
motorandthedifferentialareconnectedbyadriveshaft.
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High-VoltageCables
Figure13.High-VoltageCables
High-voltagecablesarecoloredinORANGEand/orORANGEwithstripes.Nevercut,breach,orstress
ORANGEhigh-voltagecomponentsorcabling.
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DisableDirectHazards
TurnOFFIgnition
Figure14.Dashboard
1.Parkingbrake(parkposition)
2.Neutralselectorbutton
3.Vehiclekey(OFFposition)
1.PushNeutral(N)button(Figure14,Item2).
2.Pulltheparkingbrake(Figure14,Item1).
3.Turnthekey(Figure14,Item3)tothelefttoturnOFFignition.
4.Removethekey.
4328785R114
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DisableDirectHazards(cont.)
TurnOffthe12VoltBatteryDisconnect
Figure15.12VoltBatteryDisconnectLocation
1.12voltbatterydisconnectcover
2.12voltbatterydisconnectswitch(OFFposition)
WARNING:Topreventpersonalinjuryand/ordeath,turnOFFthe12VoltBatteryDisconnectand
theHigh-VoltageServiceDisconnectbeforeinteractingwithadamagedvehicle.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthe12VoltBattery
DisconnectSwitchonlydisablesthevehicle12voltsystem,NOTthehigh-voltagebatterysystem.
1.Openthe12VoltBatteryDisconnectcover(Figure15,Item1).Thecoverhasalock.Inemergency
andifkeysnotavailableopenbyforce.
2.TurntheRED12VoltBatteryDisconnectswitchtoOFFposition(Figure15,Item2).
3.LocktheswitchwithapadlocktoavoidanyonefromturningitbackON.
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DisableDirectHazards(cont.)
TurnOfftheHigh-VoltageDisconnectSwitch
Figure16.High-VoltageDisconnectLocation
1.High-VoltageDisconnectcover
2.High-VoltageDisconnectSwitch(OFFposition)
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERtheHigh-Voltage
DisconnectSwitchonlydisablesthevehicle’shigh-voltagesystem.TheHigh-VoltageDisconnect
SwitchdoesNOTturnOFFthevoltageintheS-box,thehigh-voltagebatteries,andthecables
betweentheseitems.Thevehicle12voltsystemcouldstillbeenergized.ALWAYSturnOFFboththe
High-VoltageDisconnectswitchandthe12VoltBatteryDisconnectSwitchwheneverinteractingwith
adamagedvehicle.NEVERtouchORANGEcableswithoutwearingappropriatePersonalProtection
Equipment(PPE).
1.Openthehigh-voltageservicedisconnectswitchcover(Figure16,Item1).Thecoverhasalock.In
emergencyandifkeysnotavailableopenbyforce.
2.TurntheBLACKhigh-voltageservicedisconnectswitchtoOFFposition(Figure16Item2).
3.LocktheswitchwithapadlocktoavoidanyonefromturningitbackON.
Componentsinhigh-voltagezone2andhigh-voltagezone3remainliveafterthehigh-voltagedisconnectswitch
isturnedOFF.Thesezonesarelocatedentirelybetweentheframerailsontheundersideofthevehicleandare
labeledasindicatedinFigure2andFigure3.
4328785R116
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DisableDirectHazards(cont.)
DisconnectingManualServiceDisconnects(MSD)
Figure17.S-BoxLocation
1.S-box
ThevehicleS-box(Figure17,Item1)islocatedbetweenthevehicleframerails,forwardoftherearaxle.The
ManualServiceDisconnects(MSD),locatedontheS-boxare,accessiblefromthedriver-sideofthevehicle.
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DisableDirectHazards(cont.)
Figure18.MasterServiceDisconnects(MSD)
1.S-box
2.MSD(2total)
TheManualServiceDisconnects(Figure18,Item2),locatedontheS-box(Figure16,Item1)areaccessible
fromthedriver-sideofthevehicle.
TheMSDcanberemovedbypressingdownthelockingtabwhilepullingthereleasehandledownward
approximately45degrees.
RemovingthetwoManualServiceDisconnects(MSD)physicallydisconnectshigh-voltageaftertheS-box,
isolatinghigh-voltageawayfromHigh-voltageIsolationzone1.High-voltagewillstillexistinhigh-voltage
isolationzones2and3.
4328785R118
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StoredEnergy/Liquids
Lithium-ionbatteriesareusedintheHigh-Voltage(HV)system.Thesecellsaredrycells.Mostoftheelectrolyte
storedinthesebatteriesisabsorbedbyactivematerials.Thereisonlyasmallamountofuid,whichmayleakif
damaged.Leakingelectrolytewilloccurindrops,notpuddles.Theuidisclearincolorwithasweetether-type
odor.Thesmellmayindicateabatteryleak.Calltheredepartmentimmediately.
Thehigh-voltagebatteries,OnboardChargers,DC-DCconverters,TractionPowerInverterModule(TPIM),and
drivemotorareliquidcooledwithaglycol-basedautomotivecoolant.ThisliquidisREDincolorandmayleak
incaseofadamagedcoolingsystem.
HazardousMaterialEmergencyCleanup
Followinganelectricvehicleaccident/incident,hazardousmaterialsneedtobecleanedupappropriately.
Pleasecontactyourlocalandstateauthoritiesformoreinformationregardingproperresponseandcleanup
ofhazardousmaterials.
InCaseofFire
WARNING:Topreventpersonalinjuryand/ordeath,alwayswearfullPersonalProtection
Equipment(PPE),includingSelf-ContainedBreathingApparatus(SCBA)whenreisinvolved.Fires
incrash-damagedelectricvehiclescouldemittoxicorcombustiblegasses.Smallamountsofeye,
skin,orlungirritantsmaybepresent.Ifexposed,rinsewithlargeamountsofwaterfor10-15minutes.
Considertheentirevehicleasenergized.
WARNING:Topreventpersonalinjuryand/ordeath,payattentiontosecondaryreevents.There
isahighriskofreignitionafterreisextinguished.
Flames,smoke,arcingorhotspotslikemeltedplasticmayindicatereorthepresenceofhighvoltage.A
thermalcameraorIRtemperatureprobemaybeusefultoidentifyhotspots.Ifsignsofrearenoted,callthe
localredepartmentimmediately.Cleartheareaaroundthevehicleifpossibleandopenthevehicledoorsto
avoidbuild-upofgasesinthepassengercompartment.Ifabatteryhasstartedburning,itwilltrytoburnto
completion.Cooldownthebatterieswithdirectandlargeamountsofwater.Ifpossible,removecombustible
materialsfromaroundthevehicletopreventregrowth.
Batteriesmustbecompletelycooleddownbeforereleasingthevehicletosecondresponder.Advisesecond
responderthatthereisalwaysariskofreignition
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InCaseofSubmersion
Incaseofsubmersion,secondaryimpactdamagecanneverbeexcluded.Damagedhigh-voltagecomponents
poseanincreasedelectricalshockhazard.Stayawayfromdamagedhigh-voltagecomponents.Handleany
fullyorpartiallysubmergedvehiclewhilewearingtheappropriatePersonalProtectionEquipment(PPE).
Asubmergedvehiclewithoutimpactdamagehasalowelectricalshockhazardrisk.Smallbubblesmaybe
noticedexitingthevehicle.Thisisduetoelectrolysisofthewateranddoesnotcreateahigherriskofshock
hazard.
WARNING:Topreventpersonalinjuryand/ordeath,considertheentirevehicleasenergized.
AlwayswearfullPersonalProtectionEquipment(PPE).
WARNING:Topreventpersonalinjuryand/ordeath,payattentiontosecondaryreevents.There
isahighriskofreignitionduetodamageandcorrosion.Saltwaterincreasesthisriskforelectrical
shortspostincident.KeepfullPersonalProtectionEquipment(PPE),includingSelf-Contained
BreathingApparatus(SCBA)ready.
WARNING:Topreventpersonalinjuryand/ordeath,avoidanycontactwithasubmerged
high-voltagesystem.DonotattempttodisabletheMainBatteryDisconnectwhilethevehicleis
submerged.TheignitionmaybeturnedOFF .
1.TurntheignitionOFF(ifpossible).
2.Recoverthevehicle
3.Drainthewateroutofthevehicle
4.InitiatethedeactivationoftheMainBatteryDisconnect
Towing/Transportation/Storage
Towing
Thepreferredmethodistotowthevehiclewiththefrontwheelssuspended.Iftowedwiththerearwheelson
theground,thedriveshaft/propellershaftmustberemovedbetweenthedrivemotorandrearaxle.
ToimprovetrafcsafetytheICBus®ElectricCESeriesmaybeslowly[max5mph(8km/h)]movedanytime
oververyshortdistances.Theelectricdrivemotorisconnectedtothewheelsandgenerateselectricvoltage
asthewheelsarerotated.Higherspeedcouldcausedamagetothedrivemotor,thehigh-voltagesystemand
representsapotentialhazard.
Transportation
Informthetowtruckdriverthatreignitionispossibleatanytimewithadamagedhigh-voltagesystem.Ifpossible,
useathermalorinfraredcameratocheckwhetherthebatterystacksarecoldbeforetowingthetruck.Toensure
thatelectricmotorisnotrotating,removethedriveshaft/propellershaftbeforetowingthevehicletothenext
location.
Storage
Damagedvehiclesshouldbeisolatedoutdoorsuntilinspected.Openwindowsanddoorsduringisolationto
avoidbuild-upofgasesinthecompartment.Separatethevehiclefromallcombustiblesandstructuresbya
distanceofatleast50feet(15m).
4328785R120
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