1. Hybrid Vehicle Operation and Diagnosis Course Code 30N10T1

2. Instructor Information
Instructor Name Here
Instructor information here
Fill in instructor information

3. Course Description Two Day Course
Designed to provide students with hands-on activities to learn and improve their skills on hybrid vehicles.
All classroom activities are guided by worksheets.
Give a brief review of the course structure

4. Prerequisite Requirements
Hybrid Vehicle Training Web Course 30N26W1
Ensure that all students have completed the hybrid web course

5. Course Requirements
Each student will complete a written post test that will require a minimum score of 80% to pass
Each student will complete a pass or fail hands on evaluation
Review student evaluation requirements

6. Course Objectives
Describe Ford and Lincoln-Mercury Hybrid Vehicle Components and Operation
Describe unique hybrid vehicle safety procedures
Perform visual inspections and selected tests on various hybrid vehicle components
Diagnose hybrid vehicle performance concerns
Perform tests to verify hybrid vehicle concerns and identify causes of these concerns
Perform hybrid vehicle service procedures
Review course objectives

7. Course Agenda LESSON ONE: LESSON TWO
Introductions, Safety Briefing, Prerequisite Review, Lesson 1 Workstations
LESSON TWO
Lesson 2 Workstation Reviews, Lesson 2 Workstations, Final Review, Post-Test
Ensure that all students have completed the hybrid web course

8. History of Ford Electric and Hybrid Vehicles
Give a brief review of the history of Ford Electric and Hybrid Vehicles. Refer to IGK pg. Intro – 4 for detailed information. for detailed information..

9. Prerequisite Review
Review the answers with the class as a refresher lesson from the previous courses they have taken.
Display each answer key slide for each question. This will help to jog their memories about material covered already (in WBT course).
NOTE: Key points should be used to help generate discussion.
Ask leading questions and provide technicians an opportunity to participate in discussions.
Control the agenda, lead the discussions and clear up misconceptions.
Make sure that technicians understand the answers.

10. Prerequisite Review
1. What components are cooled by the M/E cooling system?
The TCM
eCVT
DC/DC Converter
Discuss the components cooled by the M/E cooling system
Go to next slide

11. ME Cooling System
Discuss the components cooled by the M/E cooling system
The M/E cooling system uses the same coolant as the gasoline engine cooling system
ME cooling system overheating event will illuminate the engine temp warning light

12. Prerequisite Review
What internal engine components are unique on the Hybrid gasoline engine, and why?
The intake camshaft is unique because the engine uses the Atkinson cycle. Pistons are domed to create higher compression.
Discuss the operation of the Atkinson cycle engine
Current engines are 2.5L
All hybrids used 2.3L engines until 2009 MY

13. Unique Engine Components
Intake cam is unique
Pistons have a 0.15 inch dome
Due to piston type engine has very high compression

14. Prerequisite Review 3.What is the function of the DC/AC inverter?
A. To reduce HV battery voltage to charge the low voltage battery.
B. To convert 12 volt DC voltage to 110 AC voltage.
C. To convert 330 or 275 DC voltage (vehicle dependant) to 110 AC voltage.
D. There is no DC/AC inverter on hybrid vehicles.
Review the purpose of the DC/AC inverter.
Go to next slide for review

15. DC/AC Inverter 2010 Fusion/Milan
Review the purpose of the DC/AC inverter.
Emphasize that this is a low voltage component (converts 12V DC to 110V AC)
It is used to power the 110V accessory plug
Discuss the green light on the plug (flashes when there is a fault)

16. Prerequisite Review
What type of cooling system does the Fusion/Milan use to cool the HV battery?
Cabin air drawn into the battery compartment by a fan.
An AUX A/C system that is connected to the air conditioning system.
An independent A/C system that is driven by the gasoline engine.
A fan that draws outside air into the battery compartment.
Describe battery compartment cooling
Go to next 2 slides

17. Battery Pack Cooling Fusion/Milan HVBP Cooling Fan
Describe battery compartment cooling.
Compare and contrast fan cooling with AUX A/C system used on Escape.
Supplement the question with additional question about battery pack heating.
Q. Below what temperatures will the battery heater turn on? A. 50° F or 10° C
Fusion/Milan HVBP Cooling Fan

18. Battery Pack Cooling Escape/Mariner AUX A/C HVBP Cooling System
Describe battery compartment cooling.
Compare and contrast fan cooling with AUX A/C system used on Escape.
Supplement the question with additional question about battery pack heating.
Q. Below what temperatures will the battery heater turn on? A. 50° F or 10° C

19. Prerequisite Review
Where is the HV fuse located on both the Escape/Mariner and Fusion Milan?
The HV fuse is located inside the service disconnect switch on both vehicles
Discuss the location of the HV fuses on both vehicles
Go to next slide

20. Service Disconnect Switches
On the Fusion/Milan it is located beneath the rear passenger seat on the battery case
The Fusion/Milan has an additional high voltage low current fuse in the Bussed Electrical Center (BEC) (covered later in this review)
Entire switch must be replaced if fuse is blown
On the Escape Mariner it is located on the battery case beneath the rear battery cover

21. Prerequisite Review
6. Which of the functions listed below is performed by the shift cable?
A. Engages the eCVT in Drive.
B. Engages the eCVT in Reverse.
C. Engages the parking pawl.
D. All of the above.
Explain that the shift cable only engages the transaxle parking pawl.
Go to next slide

22. Hybrid TR Sensor Fusion /Milan TR Sensor Escape/Mariner TR Sensor
Point out that engagement into forward and reverse are controlled by the PCM based upon signals from the TR sensor.
Escape/Hybrid requires replacement of shifter and cable if TR is bad. Fusion/Milan TR is located on shift lever of eCVT and can be replaced without other components.
Fusion /Milan TR Sensor
Escape/Mariner TR Sensor

23. Prerequisite Review
Which components are part of the hybrid vehicle high voltage system?
Review the components of the HV system
Use following 5 slides for this review

24. Traction Battery
Traction Battery for Escape/Mariner is 330 Volts
Traction Battery for Fusion/Milan is 275 Volts
Fusion/Milan HVBP
Escape/Mariner HVBP
Traction Battery also called High Voltage Battery Pack (HVBP)

25. eCVT
eCVT contains a motor and a generator that controls a planetary gearset.
Gearset components will be discussed in detail later in this review.
Fusion/Milan uses Variable Voltage eCVT that reduces energy use, thus can have lower voltage battery
Traction Motor/Generator Motor called the Electronic Continuously Variable Transmission (eCVT)

26. High Voltage Cables High Voltage (Orange) Cables
Orange color of HV cables indicate high voltage is present.
High Voltage (Orange) Cables

27. DC/DC Converter DC/DC Converter Fusion/Milan DC/DC Converter
DC/DC converter is a electronically reduces voltage from the HVBP to charge the low voltage system and also separates the two DC voltage systems.
Fusion/Milan DC/DC Converter
Escape/Mariner DC/DC Converter
DC/DC Converter

28. Electric A/C Compressor
Electrical A/C compressor reduces load on gasoline engine to improve fuel economy and provides cabin cooling when the gasoline engine is not running.
Electric A/C Compressor (if equipped)

29. Prerequisite Review
What measures were taken in the design of hybrid vehicles to prevent current leakage from the HV battery?
There is no ground between the HV battery and the vehicle chassis
Discuss how current leakage is prevented by not having a ground to the chassis.
Q. What control module monitors the HV battery for leakage? A. TBCM, BCM, or BECM
Explain that all these modules perform the same function but may be called be different names in different service publications.

30. Prerequisite Review
What type of EPAS systems can be found on hybrid vehicles?
Remote PSCM rack-type system
Column mounted EPAS system
Rack mounted PSCM EPAS system
All of the above.
Discuss the 3 types of EPAS systems found on hybrid vehicles
Go to next slide

31. EPAS Systems on Hybrids
Insert photos of EPAS systems
Remote PSCM rack-type used in MY Escape/Mariner
Column Mounted EPAS began in 2008 Escape/Mariner
Rack mounted PSCM EPAS installed in 2010 Fusion/Milan

32. Prerequisite Review
What is the purpose of the regenerative braking system?
Regenerative braking converts energy that would otherwise be lost to friction, into voltage that is sent to the HV battery
Review regenerative braking operation
Go to next slide

33. Regenerative Braking Review regenerative braking operation
Explain that during normal braking the regenerative system performs the majority of braking
Explain that all hybrid vehicles use brake by wire systems to accommodate this action
These brake systems will be covered in more detail later in the review

34. Prerequisite Review
What unique information is displayed on the Escape/Mariner Hybrid tachometer?
Not only does the tach display gasoline engine rpm, but also indicates when the vehicle is operating on electric power only
Discuss the Escape/Mariner hybrid tachometer
Go to next slide

35. Escape/Mariner Tachometer
Show students where the E portion of the Tach is
Point out that the Escape/Mariner and Fusion/Milan have different IC displays
Fusion/Milan IC system will be discussed later in this review

36. Prerequisite Review
Where is the gasoline engine starter motor located on a hybrid vehicle?
At the rear of the engine lower right side
It is integrated into the FEAD system
Near the front left side of the engine
None of the above
Trick question to see which technicians took the web course
Explain that the generator motor starts the gasoline engine
The starter hole on the engine has a dust cover installed

37. Prerequisite Review
What control module adjusts the contributions of the gasoline engine, the traction motor and generator during hybrid operation?
PCM
TCM
BCM
PSCM
Discuss the functions of the various hybrid-specific control modules on hybrid vehicles
Explain that the TCM adjusts contributions of the traction motor and generator during vehicle operation
Explain that the BECM contains the majority of the hybrid specific strategies
For detailed descriptions of transaxle control and hybrid software strategies in various operating modes refer to Section 1 of the 2009 Escape Hybrid PC/ED under “Hybrid Electric System” and “Hybrid Electric Control Software”, which contains good descriptions.
Go to next 2 slides

38. TCM/eCVT OPERATION Gasoline Engine Connected to Planetary Carrier
Transaxle Control
Module (TCM)
adjusts
contribution of
each by changing
speed and direction
of planetary
sun gear
Traction Motor
Connected to
Planetary
Ring Gear
The planetary gear set functions as an electronically controlled CVT between the carrier gear (engine) and the ring gear (traction motor) which is connected to the drive wheels. This is achieved by controlling the sun gear (generator) speed and direction.
Go to next slide
Generator
Connected to
Planetary
Sun Gear

39. TCM/eCVT OPERATION
The reason this is an electronically controlled CVT is due to the property of the planetary gear set in which the torque relationships between the sun gear, the carrier gear, and ring gear are fixed for this mechanical design. Therefore, the planetary gear set can also be viewed as a device that splits the engine output power to the driveline and to the generator motor.

40. Prerequisite Review
The A/C compressor on a 2008 Escape/Mariner hybrid vehicle is _________________ (select the best answer from the list below).
Driven by the FEAD of the gasoline engine
A swashplate type pump
Electrically driven
A scroll type pump
Explain that the Escape/Mariner uses a conventional A/C compressor.
In 2010 all hybrids were converted to electric A/C compressors.

41. Prerequisite Review
What is the function of the high voltage interlock ?
To prevent the vehicle from being started in any gear but Park of Neutral..
To disable the high voltage system if any HV connectors are disconnected.
To prevent the vehicle from being placed into gear without the brake pedal being depressed.
All of the above
Go to next slide

42. High Voltage Interlock Circuit
The interlock system is a monitoring circuit that stops voltage to the system in the event a connector is open or a HV cable is cut

43. Prerequisite Review
What is the service interval for the air cleaner on the 2010 Fusion/Milan?
Lifetime so there is no service interval
Explain that there is no service interval for the air filter on the Fusion Milan
Go to next slide

44. 2010 Fusion/Milan Air Filter
Point out that if an air filter restriction exists, DTC P1548 will set
The air filter is located beneath the left front fender

45. Prerequisite Review
When the service disconnect switch is removed from a Fusion/Milan Hybrid vehicle, which of the following components will still have high-voltage current running to them (select all that apply)?
The BPSM
The BECM
The DC/DC Converter
The High-Voltage Low-Current Fuse
The Battery Pack Sensor Module on the Fusion/Milan always has high voltage going to it
Go to next slide

46. Battery Pack Sensor Module (BPSM)
The Escape/Mariner does not have a separate BPSM
The BPSM connects only to the BECM, via a dedicated network bus

47. Prerequisite Review
What system provides power to the A/C compressor on the Fusion/Milan Hybrid?
The high-voltage high-current system
The 12-volt system
The high-voltage low-current system
The gasoline engine
The electrical A/C compressor system on the Fusion/Milan is powered by the High-Voltage Low-Current System
This system contains a 40 amp replaceable fuse
Go to next slide

48. High-Voltage Low-Amperage System
The electrical A/C compressor system on the Fusion/Milan is powered by the High-Voltage Low-Current System
This system contains a 40 amp replaceable fuse

49. Prerequisite Review The Restraints Control Module (RCM)
What component on the Fusion/Milan hybrid performs the same function as the inertia switch on the Escape/Mariner Hybrid?
The Restraints Control Module (RCM)
The RCM on the Fusion/Milan replaces the two inertia switches which shuts down the HV and gasoline fuel system.

50. Prerequisite Review
A customer needs information on the operation of the instrument cluster in their 2010 Fusion. Where can you direct them to get an interactive tutorial for the operation if the IC?
The IC has a tutorial feature that explains the operation and interpretation of the IC gauges and symbols
Go to next slide

51. Fusion/Milan Instrument Cluster (IC)
Insert art of menu on IC
Explain that to access tutorial on IC you must enter the Setup Menu then highlight Tutorial

52. Prerequisite Review
What type of conventional brake system is used on 2009 MY and later Escape/Mariner and 2010 Fusion/Milan Hybrids?
Simulation Brake Activation system
Electronic Hydraulic Brake system
Hydro Boost
Hydro Max
The SBA system is used on the vehicles listed in the question.
Go to the next slide

53. Simulation Brake Activation (SBA)
The SBA features a active brake booster for conventional brake application
The pedal assembly contains a large spring that provides pedal feel. This assembly is only replaceable as a unit.

54. Prerequisite Review
What type of conventional brake system is used on Escape/Mariner Hybrids?
Simulation Brake Activation system
Electronic Hydraulic Brake system
Hydro Boost
Hydro Max
The EHB system also contains a brake feel emulator that is contained in the master cylinder.
Go to next slide

55. Electronic Hydraulic Brakes (EHB)
The ECU is part of the HCU, which also has an accumulator on the bottom.
These type of brakes intermittently apply the brake pads, even when the ignition is in the off position.
Brake pad replacement requires specific procedures that will be covered in detail later in the course.

56. High Voltage Safety Hybrid Safety
Explain that Ford and L-M hybrids are very safe for both drivers and service technicians. However, as with any type of energy, high voltage electricity must be treated with respect, and unique safety procedures must be adhered to.
Compare and contrast electricity with gasoline.

57. Hybrid Electrical Safety Training
High Voltage Warning Label
Discuss warning labels

58. Battery System Warnings
Batteries produce EXPLOSIVE gases
Ni-MH Batteries
Contain Potassium Hydroxide
Avoid Skin, Eyes, Respiratory Contact
High Voltage Component Repair
ONLY done by trained Personnel
Although the HVBP of hybrids do not create excessive gas under normal circumstances, these warnings must be reviewed.
Emphasize that only trained personnel are authorized to work on hybrid vehicles.

59. High Voltage Hazards Hazard One: Electric Shock Muscle Contraction
Fibrillation
Tissue Damage
Emphasize the Need for safety when working with high voltage
Explain how muscle contraction can prevent a victim from releasing HV wires
Point out that it only takes 60 volts to disrupt a persons heartbeat.
Discuss the impact electricity can have on body tissue.

60. High Voltage Hazards Hazard Two: Arcing
The primary danger of this hazard is the burn that a person can receive. The heat at each end of an arc reaches up to and beyond 35,000°F.
Arcing can result in insulation damage, melting of conductors, and the vaporization of metal.
Point out that a spark plug is an example of controlled arcing
Emphasize the temperature of an arc
Explain that arcs can occur to technicians that are wearing jewelry

61. High Voltage Hazards Hazard Three: Blast
Electric blast is the pressure expansion caused by an arc. The expansion is actually the rapid heating of the surrounding air and the boiling of a metal, usually copper. Both expand at incredible proportions under the intense heat of an arc. Copper expands by a factor of 67,000 when vaporized.
Point out the danger of electrical blast
Describe the expansion rate of copper which is a factor of 67,000 when vaporized to emphasize the point

62. Electrical Accidents Unsafe Equipment or Installation
Unsafe Work Areas
Unsafe Acts by Workers
Review and discuss the content of this section. Emphasize the common causes of electrical accidents, including:
•Unsafe Equipment or Installation – serious problems can occur when using improper equipment. Not only must equipment have a safe design, but it must be installed correctly.
•Unsafe Work Areas – poor lighting, moisture, flammable liquids, flammable gases, poor labeling, and covered labels are all items of concern around high voltage.
•Unsafe Acts by Workers – failure to follow established procedures can result in an electrical accident.

63. Driver Response to Accident
If possible, carry out the following steps in the event of a collision, fire or some other emergency situation. However, never endanger yourself or others who are near the vehicle.
1. Stop and put the gear selector in the Park (P) position.
2. Turn the ignition switch to the OFF position and remove the key.
3. Set the parking brake.
4. Exit the vehicle.
5. Contact crash/fire/rescue emergency personnel and inform them of the type of vehicle (Hybrid) and the nature of the emergency.
Review and discuss the content of this section.
Explain that emergency responder guides on the PTS website will be covered in detail later in this section.

64. Accident Prevention Buffer Zone
Explain to the students the buffer zone
Point out that use of the buffer zone was deleted from 2010 Fusion/Milan WSM. However, use of the buffer zone should be recommended until all publications have been updated.

65. Accident Prevention High Voltage Safety Gloves
Describe the use, requirements and limitations of HV Gloves
Perform glove inspection demonstration
New glove specifications have been issued for 2009 and later MY hybrids (500 Volts). However, until all WSM information has been updated these specifications should be used.

66. Glove Suppliers Reed City Power Line Supply 420 S Roth St
Reed City, MI 49677
Explain that this is one supplier of HV gloves. However, they may be purchased locally if another supplier is available.

67. Accident Prevention Face Shield
Discuss the advantages of using a full face shield when working with high voltage
Protection from arcing for eyes and face

68. Accident Prevention Safety Hook
Discuss the requirements for a fiberglass reach pole
Explain that wood poles should not be used since the moisture in the wood can be conductive

69. Accident Prevention See list 1 through 34 in Student Guide
Discuss the various accident prevention steps listed in student guide
Emphasize cotton clothing, removing jewelry, working with 1 hand when possible.
Review the list yourself and select those areas that you feel are important to emphasize.
The students will be forced to read the list in it’s entirety in order to pass the safety quiz given later in the course.

70. First Aid Procedures First Aid for Electric Shock
Cardio-Pulmonary Resuscitation (CPR)
When to Use CPR
Where to Get CPR Training
Discuss first aid procedures

71. Fire Prevention Shop Cleanliness Fire Resistant Storage Compartments
Keep Flammable Material Away
Liquids, Rags, Cleaning Solvents, Etc…
Review fire prevention procedures
Emphasize shop cleanliness and caution around chemicals

72. Classes of Fire Class A Class B Class C Typical Fire Chemical Fire
Electrical
Discuss classes of fires

73. Types of Fire Extingushers
Types of Fire Extinguishers
Water
Regular Dry Chemical
Multi-Purpose Dry Chemical
Carbon Dioxide (CO2)
Review types of fire extinguishers
Explain that only Class C extinguishers can be used on electrical fires
Point out the location of extinguishers in the classroom

74. Fire Extinguisher Ratings
Light Hazard 2A, 5B:C or greater (possibility of small fires)
Ordinary Hazard 2A, 10B:C or greater (possibility of moderate fires)
Extra Hazard 4A, 40B:C or greater (possibility of severe fires)
Review types of fire extinguishers
Explain that only Class C extinguishers can be used on electrical fires
Point out the location of extinguishers in the classroom

75. Emergency Responder Guides
Emergency Responder Guides are available on the PTS Website
A copy of the 2010 Fusion/Milan Emergency Responder Guide can be found in the back of the student guide.
Explain to students how to find Emergency Responder Guide on PTS website.

76. Responder Guides
From Tech Central select New Model/Technology Menu

77. Responder Guides
From the menu select the appropriate hybrid vehicle

78. Responder Guides
From the popup box select the Emergency Responder Guide

79. Responder Guides
This will bring up the guide as an Adobe Acrobat file.
An example of an Emergency Response Guide is in the Appendix of the REF.

80. Lesson One Workstations 1 - 3
Written– Escape/Mariner
Component Location and Operation
Workstation 2
Hands On – Fusion/Milan
Component Location and Operation
Use CMT Active Student Program shortcut to launch the service information.
Workstation: Summary:
1 Escape/Mariner Component Location and Function (written)
2 Fusion/Milan Component Location and Function (hands-on)
3 Safety Quiz (written)
Workstation 3
Written
High Voltage Safety Quiz 80