Presentation on theme: "Hybrid Vehicle Operation and Diagnosis Course Code 30N10T1"— Presentation transcript:
1 Hybrid Vehicle Operation and Diagnosis Course Code 30N10T1
2 Instructor Information Instructor Name HereInstructor information hereFill 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 30N26W1Ensure that all students have completed the hybrid web course
5 Course RequirementsEach student will complete a written post test that will require a minimum score of 80% to passEach student will complete a pass or fail hands on evaluationReview student evaluation requirements
6 Course ObjectivesDescribe Ford and Lincoln-Mercury Hybrid Vehicle Components and OperationDescribe unique hybrid vehicle safety proceduresPerform visual inspections and selected tests on various hybrid vehicle componentsDiagnose hybrid vehicle performance concernsPerform tests to verify hybrid vehicle concerns and identify causes of these concernsPerform hybrid vehicle service proceduresReview course objectives
7 Course Agenda LESSON ONE: LESSON TWO Introductions, Safety Briefing, Prerequisite Review, Lesson 1 WorkstationsLESSON TWOLesson 2 Workstation Reviews, Lesson 2 Workstations, Final Review, Post-TestEnsure 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 ReviewReview 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 Review1. What components are cooled by the M/E cooling system?The TCMeCVTDC/DC ConverterDiscuss the components cooled by the M/E cooling systemGo to next slide
11 ME Cooling SystemDiscuss the components cooled by the M/E cooling systemThe M/E cooling system uses the same coolant as the gasoline engine cooling systemME cooling system overheating event will illuminate the engine temp warning light
12 Prerequisite ReviewWhat 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 engineCurrent engines are 2.5LAll hybrids used 2.3L engines until 2009 MY
13 Unique Engine Components Intake cam is uniquePistons have a 0.15 inch domeDue 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 plugDiscuss the green light on the plug (flashes when there is a fault)
16 Prerequisite ReviewWhat 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 coolingGo 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° CFusion/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 ReviewWhere 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 vehiclesDiscuss the location of the HV fuses on both vehiclesGo to next slide
20 Service Disconnect Switches On the Fusion/Milan it is located beneath the rear passenger seat on the battery caseThe 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 blownOn the Escape Mariner it is located on the battery case beneath the rear battery cover
21 Prerequisite Review6. 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 SensorEscape/Mariner TR Sensor
23 Prerequisite ReviewWhich components are part of the hybrid vehicle high voltage system?Review the components of the HV systemUse following 5 slides for this review
24 Traction BatteryTraction Battery for Escape/Mariner is 330 VoltsTraction Battery for Fusion/Milan is 275 VoltsFusion/Milan HVBPEscape/Mariner HVBPTraction Battery also called High Voltage Battery Pack (HVBP)
25 eCVTeCVT 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 batteryTraction 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 ConverterEscape/Mariner DC/DC ConverterDC/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 ReviewWhat 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 chassisDiscuss 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 BECMExplain that all these modules perform the same function but may be called be different names in different service publications.
30 Prerequisite ReviewWhat type of EPAS systems can be found on hybrid vehicles?Remote PSCM rack-type systemColumn mounted EPAS systemRack mounted PSCM EPAS systemAll of the above.Discuss the 3 types of EPAS systems found on hybrid vehiclesGo to next slide
31 EPAS Systems on Hybrids Insert photos of EPAS systemsRemote PSCM rack-type used in MY Escape/MarinerColumn Mounted EPAS began in 2008 Escape/MarinerRack mounted PSCM EPAS installed in 2010 Fusion/Milan
32 Prerequisite ReviewWhat 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 batteryReview regenerative braking operationGo to next slide
33 Regenerative Braking Review regenerative braking operation Explain that during normal braking the regenerative system performs the majority of brakingExplain that all hybrid vehicles use brake by wire systems to accommodate this actionThese brake systems will be covered in more detail later in the review
34 Prerequisite ReviewWhat 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 onlyDiscuss the Escape/Mariner hybrid tachometerGo to next slide
35 Escape/Mariner Tachometer Show students where the E portion of the Tach isPoint out that the Escape/Mariner and Fusion/Milan have different IC displaysFusion/Milan IC system will be discussed later in this review
36 Prerequisite ReviewWhere is the gasoline engine starter motor located on a hybrid vehicle?At the rear of the engine lower right sideIt is integrated into the FEAD systemNear the front left side of the engineNone of the aboveTrick question to see which technicians took the web courseExplain that the generator motor starts the gasoline engineThe starter hole on the engine has a dust cover installed
37 Prerequisite ReviewWhat control module adjusts the contributions of the gasoline engine, the traction motor and generator during hybrid operation?PCMTCMBCMPSCMDiscuss the functions of the various hybrid-specific control modules on hybrid vehiclesExplain that the TCM adjusts contributions of the traction motor and generator during vehicle operationExplain that the BECM contains the majority of the hybrid specific strategiesFor 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 ControlModule (TCM)adjustscontribution ofeach by changingspeed and directionof planetarysun gearTraction MotorConnected toPlanetaryRing GearThe 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 slideGeneratorConnected toPlanetarySun Gear
39 TCM/eCVT OPERATIONThe 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 ReviewThe 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 engineA swashplate type pumpElectrically drivenA scroll type pumpExplain that the Escape/Mariner uses a conventional A/C compressor.In 2010 all hybrids were converted to electric A/C compressors.
41 Prerequisite ReviewWhat 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 aboveGo 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 ReviewWhat is the service interval for the air cleaner on the 2010 Fusion/Milan?Lifetime so there is no service intervalExplain that there is no service interval for the air filter on the Fusion MilanGo to next slide
44 2010 Fusion/Milan Air Filter Point out that if an air filter restriction exists, DTC P1548 will setThe air filter is located beneath the left front fender
45 Prerequisite ReviewWhen 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 BPSMThe BECMThe DC/DC ConverterThe High-Voltage Low-Current FuseThe Battery Pack Sensor Module on the Fusion/Milan always has high voltage going to itGo to next slide
46 Battery Pack Sensor Module (BPSM) The Escape/Mariner does not have a separate BPSMThe BPSM connects only to the BECM, via a dedicated network bus
47 Prerequisite ReviewWhat system provides power to the A/C compressor on the Fusion/Milan Hybrid?The high-voltage high-current systemThe 12-volt systemThe high-voltage low-current systemThe gasoline engineThe electrical A/C compressor system on the Fusion/Milan is powered by the High-Voltage Low-Current SystemThis system contains a 40 amp replaceable fuseGo 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 SystemThis 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 ReviewA 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 symbolsGo to next slide
51 Fusion/Milan Instrument Cluster (IC) Insert art of menu on ICExplain that to access tutorial on IC you must enter the Setup Menu then highlight Tutorial
52 Prerequisite ReviewWhat type of conventional brake system is used on 2009 MY and later Escape/Mariner and 2010 Fusion/Milan Hybrids?Simulation Brake Activation systemElectronic Hydraulic Brake systemHydro BoostHydro MaxThe 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 applicationThe pedal assembly contains a large spring that provides pedal feel. This assembly is only replaceable as a unit.
54 Prerequisite ReviewWhat type of conventional brake system is used on Escape/Mariner Hybrids?Simulation Brake Activation systemElectronic Hydraulic Brake systemHydro BoostHydro MaxThe 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 LabelDiscuss warning labels
58 Battery System Warnings Batteries produce EXPLOSIVE gasesNi-MH BatteriesContain Potassium HydroxideAvoid Skin, Eyes, Respiratory ContactHigh Voltage Component RepairONLY done by trained PersonnelAlthough 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 FibrillationTissue DamageEmphasize the Need for safety when working with high voltageExplain how muscle contraction can prevent a victim from releasing HV wiresPoint 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 arcingEmphasize the temperature of an arcExplain 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 blastDescribe 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 AreasUnsafe Acts by WorkersReview 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 zonePoint 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 GlovesPerform glove inspection demonstrationNew 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 49677Explain 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 voltageProtection from arcing for eyes and face
68 Accident Prevention Safety Hook Discuss the requirements for a fiberglass reach poleExplain 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 guideEmphasize 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 CPRWhere to Get CPR TrainingDiscuss first aid procedures
71 Fire Prevention Shop Cleanliness Fire Resistant Storage Compartments Keep Flammable Material AwayLiquids, Rags, Cleaning Solvents, Etc…Review fire prevention proceduresEmphasize shop cleanliness and caution around chemicals
72 Classes of Fire Class A Class B Class C Typical Fire Chemical Fire ElectricalDiscuss classes of fires
73 Types of Fire Extingushers Types of Fire ExtinguishersWaterRegular Dry ChemicalMulti-Purpose Dry ChemicalCarbon Dioxide (CO2)Review types of fire extinguishersExplain that only Class C extinguishers can be used on electrical firesPoint 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 extinguishersExplain that only Class C extinguishers can be used on electrical firesPoint out the location of extinguishers in the classroom
75 Emergency Responder Guides Emergency Responder Guides are available on the PTS WebsiteA 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 GuidesFrom Tech Central select New Model/Technology Menu
77 Responder GuidesFrom the menu select the appropriate hybrid vehicle
78 Responder GuidesFrom the popup box select the Emergency Responder Guide
79 Responder GuidesThis 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/MarinerComponent Location and OperationWorkstation 2Hands On – Fusion/MilanComponent Location and OperationUse 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 3WrittenHigh Voltage Safety Quiz80