Topic: The Hybrids are here! By: Scott Sine FALL TRAINING 2006 Topic: The Hybrids are here! By: Scott Sine

What is a Hybrid? A hybrid vehicle uses more than one source of producing, storing and delivering power to increase overall efficiency. The “primary” source is the diesel engine, and the “secondary” or “hybrid” source is electrical or hydraulic. A hybrid can capture and store energy during braking that otherwise would be lost as heat through braking. It then can reuse this energy for driving demands such as launch and acceleration. A hybrid might combine the power from the diesel engine with stored energy from a second source and deliver both to the driveline. In this way, the hybrid system can cause both sources to operate most of the time near their optimum conditions rather than pushing either source’s capacity limits during high demand or wasting energy during low-demand excursions. Courtesy of TMC

DIFFERENT TYPES OF HYBRIDS

HYBRID DEFINITIONS Hybrid-Electric - Primary engine is diesel or gas; secondary motor is electric. Hybrid-Hydraulic - Primary engine is diesel or gas; secondary motor is hydraulic. AC/DC Inverter - Electrical device that converts AC voltage to DC voltage or DC voltage to AC voltage. The electric motor on a hybrid uses and creates AC voltage. The hybrid batteries store electricity as DC voltage. DC-DC Converter - Electrical device that converts high voltage DC current to a lower voltage DC current. APG (Auxiliary Power Generator)- Electrical device that converts high voltage DC current into 120/240 AC current. High Voltage Cables - Electrical cables that conduct more that 50 AC or DC volts. Industry standard is to wrap the cables in bright orange conduit. Battery Pack - Batteries that store high DC volts. They are used to store energy from regenerative braking, the diesel engine or provide energy to drive a hybrid electric motor. Courtesy of TMC

HYBRID APPLICATIONS Dry Van – Stop and go driving & regenerative braking. Utility trucks – Pto applications & ePto –engine off hydraulic functions. Bus applications Example: 24 Hybrid Test Units 4300 Chassis, Altec L42M Body DT466 215HP, 560 lb-ft Engine 44KW Electric Motor 340V, 50kW Li-lon Battery (4) Engine On/Off PTO Capable Auxiliary Power Generation Telematics Added for Vehicle Performance Monitoring

What Makes The System Work? Diamond Logic Electrical System Eaton Hybrid Electric Powertrain Aware® Vehicle Intelligence System Body Integration

DIAMOND LOGIC BUILDER

What Makes The System Work? Diamond Logic Electrical System Hybrid Electric Powertrain Aware® Vehicle Intelligence System Body Integration

Direct Hybrid – Engine Starting Mode AutoClutch Motor AutoShift (AMT) Engine Torque Neutral Gear Position Engaged Discharging Mode Battery System

Direct Hybrid – Electric Only Mode Engine AutoClutch Motor AutoShift (AMT) Motor Torque Drive Torque Disengaged where, Drive Torque = Motor Torque (Tm) x Gear Ratio Discharge Mode Battery System

Direct Hybrid – Engine & Motor Drive Mode AutoClutch Motor AutoShift (AMT) Engine Torque Combined Torque Drive Torque Engaged Discharge Mode where, Drive Torque = Engine Torque (Te) + Motor Torque (Tm) x Gear Ratio Battery System

Direct Hybrid - Engine Only Mode AutoClutch Generator AutoShift (AMT) Engine Torque Engine Torque Drive Torque Engaged Charging Mode Optional where, Drive Torque = Engine Torque (Te) x Gear Ratio Battery System

Direct Hybrid – Regen Braking Mode Generator Engine AutoClutch AutoShift (AMT) Engine Torque Regen Torque Inertial Torque Engaged or Disengaged Charging Mode where, Regen Torque = Inertial Torque (T) x Gear Ratio Battery System

What Makes The System Work? Diamond Logic Electrical System Eaton Hybrid Electric Powertrain Aware® Vehicle Intelligence System Body Integration

Integration of The Three Systems J1939 Data Link EATON Altec INTERNATIONAL Auto shift Transmission Hybrid Controller Auxiliary Power Generator Remote Power Modules Fiber Optic System Hydraulic System DT 466 Engine Electronic System Controller Center Panel Switches ABS System Chassis Wiring AWARE Telematics Gauge Cluster Internet Portal Geo-Synchronous GPS Satellite 1xRTT

Benefits Fuel Consumption Quiet Operation 1/3 from Driving 2/3 from Work Site Quiet Operation Public Operators

HEV Utility Vehicle Benefits Noise Driving: Potential for Quieter Launches Jobsite: Significant Engine Off Time Drivability Equal to or Better Drivability Engine Downsizing Future Potential to Downsize Engine and Electrify Accessories Auxiliary Power Generation 25 KW Exportable Power Available

Operators’ & Supplemental Manuals Eaton Hybrid System Operators’ Manual International Chassis Operators’ Manual Altec Operators’ Manual Supplement

HYBRID TECH SUPPORT International Tech support to take the initial calls. -Tech support will guide tech through the diagnostic procedures. -If problem is not found, then the Vehicle Programming Group will take over the call and do more advanced diagnostics. -If the Vehicle Programming Group is unable to resolve the issues, an Application Engineer will resolve any or all issues. -Tech support will also have the ability to do remote diagnostics using the web site www.logmein123.com. Vendor Tech Support - Eaton & Enova will have tech support for hybrid specific questions. -International will forward tech support calls to appropriate vendor if the problem is within the hybrid system. -Hybrid vendors have mobile service technician to travel to dealerships to do diagnostics and repair work until the International tech is trained.

HYBRID TRAINING Hybrid System Specific Training -Eaton Hybrid System -Enova Hybrid System -High Voltage Training? -Hybrid Computer Based Training (CBT) -Diamond Logic Builder Hybrid Specific -TSI 06-08-05 High Voltage Best Practices.

Safety Considerations: High Voltage Cables Bright Orange to Correspond with Established Industry Practices (Prius and Insight) Orange High Voltage Cable on Eaton Utility truck Orange High Voltage Cable on underside of Honda Insight

Electric Shock Protection High voltage system, including the motor & battery, is isolated from the vehicle chassis and body. Contact with the HEV battery or other high voltage components can only occur if the Power Electronics Carrier (PEC) is damaged and the contents are exposed, or the PEC is deliberately opened without authorization. PPE (Personal Protective Equipment) – gloves, face shield, boots, & insulated tools. The high voltage cables are protected by bright orange rubber casing and orange plastic conduit. Additionally, the high voltage AC cables have no current in them after the vehicle has been shut down or disabled for at least one minute.

High Voltage Electrical System Disablement Option 1 (Preferred) Turn Ignition (Key) off on Dash Engine will shut down Dash lights will shut down HEV system will shut down HEV batteries are still “live” but are isolated in PEC Option 2 See hybrid vendors procedures for further maintenance disablement.

Eaton System Eaton System Overview

Eaton System

Eaton System

Eaton System

Eaton System

Eaton System

Eaton System

Eaton High Voltage Component Locations on a 4300. Hybrid Electric Motor Battery Pack AC/DC Inverter DC/DC Converter

ENOVA SYSTEM Enova System Overview

ENOVA SYSTEM

ENOVA SYSTEM

Hybrid documents on ISIS and Sales page G letter https://evalue.internationaldelivers.com/sales/adobe/productinfo/pg2461.pdf SFN https://evalue.internationaldelivers.com/service/sfns/sfn0602.htm

Emergency Response Procedures Vendors responsible for emergency response procedures All emergency response documents found in ISIS Trucks are labeled as a hybrid and high voltage components are clearly identified Fleets to Alert Local Emergency Personnel of Hybrid Truck Presence

Questions & Answers Q: What is the life of the Eaton HEV battery pack? A: The life of the battery pack on the Eaton hybrid system is estimated at 6-8 years. Q: Type of batteries used in the HEVs? A: The Eaton hybrid system utilizes Lithium Ion batteries. Q: What is the up-charge for the hybrid feature? A: Base system will be around $47,000 to $50,000. The optional ePTO adder will be roughly $15,000. The exportable power option is not yet available. These prices are subject to change.