DANA SUMO TM4 - Default Chapter; Table of Contents

Installation Guide
CONFIDENTIAL
TG-0259_9 TM4 CO200-A3 Installation Guide
© Dana TM4 inc., 2020-2022
Page 3 of 42
Table of contents
1 Introduction ........................................................................................................................... 7
1.1 Purpose ........................................................................................................................ 7
1.2 Scope ............................................................................................................................ 7
1.3 What’s new ................................................................................................................... 7
1.4 Comparison between CO200-A1 and A3 ..................................................................... 7
1.5 Disclaimer ..................................................................................................................... 8
1.6 Safety instructions ........................................................................................................ 8
1.6.1 Format and location of safety warnings in this guide ............................................. 8
1.7 Definitions, acronyms and abbreviations ...................................................................... 9
1.8 References ................................................................................................................... 9
2 Transport and storage conditions ....................................................................................... 10
3 Receiving and unpacking the MCU ..................................................................................... 11
3.1 Safety warnings related to handling Dana TM4 products ........................................... 11
3.2 Inspecting and moving the MCU ................................................................................. 11
4 Installing the MCU in the vehicle ......................................................................................... 12
4.1 Planning to install the MCU ........................................................................................ 12
4.1.1 Respecting CSC and MKC markings on interface drawings ............................... 12
4.2 Preventing damage to the MCU ................................................................................. 12
4.2.1 Using separate brackets to support MCU and motor ........................................... 13
4.2.2 Respecting the physical integrity of the MCU ...................................................... 13
4.2.3 Protecting the casing from external loads ............................................................ 13
4.2.4 Correctly positioning the MCU ............................................................................. 13
4.3 Securing the MCU ...................................................................................................... 14
4.4 Installing the cooling system ....................................................................................... 15
4.4.1 Safety warnings related to handling the cooling agent ........................................ 15
4.4.2 Parallel configuration ........................................................................................... 16
4.4.3 Serial configuration .............................................................................................. 16
4.4.4 Coolant inlet/outlet specifications ........................................................................ 17
4.4.5 Coolant specifications .......................................................................................... 17
4.5 Electrical installation ................................................................................................... 18
4.5.1 Safety instructions related to electrical installation .............................................. 18
4.5.2 General information for installing and handling cables/harnesses ...................... 19
4.5.3 Suggested installation sequence ......................................................................... 20
4.5.4 Grounding the system .......................................................................................... 20
4.5.5 Phase cables ....................................................................................................... 22
4.5.6 Motor sensor interface harness ........................................................................... 23
4.5.7 Connecting the VMU interface harness ............................................................... 26
4.5.8 Connecting the high-voltage battery .................................................................... 30
4.5.9 Connecting the auxiliary battery to the MCU ....................................................... 35
4.5.10 CAN interface ...................................................................................................... 36