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Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstations 1 - 3 Workstation 1 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 3 Written High Voltage Safety Quiz Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 DIRECTIONS: Use the 2008 Escape Hybrid service publications to answer the following questions. Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 1. List the PSCM connector number that contains the connector pin for circuit CBP35, and where is the connector located? C 2231A is located at the lower left of the instrument panel Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 2. List all of the connectors that run to the DC/DC converter. Also list the location of the converter, and specify which connector contains the HV interlock circuits. C 1457a, C 1457b, C 1457c, C 1457d. It is located in the right front engine compartment behind coolant reservoir. Interlock circuits are located in C 1457d Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 3. What cell in the Wiring Diagrams contains the safety warnings for the high voltage system? In the Introduction Cell 3-6 Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 4. Where is the TCM located, and which TCM connector contains the Hybrid Transaxle Generator Shutdown circuit? Also list the pin, circuit number, and color of the wire for the circuit. The TCM is located on the left side of the engine compartment near the battery junction box (inside eCVT). The connector that contains the circuit is C1458b, it is pin 10 of the connector, the circuit # is CYT07 (VT) Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 5. A 2008 Escape Hybrid is brought to you with a no start condition. You believe there is an open circuit between the TBCM and the High Voltage Cutoff Switch. What circuit, should be tested between which connectors to verify your diagnosis? Circuit CYB15 (GN) between C4227A and C4229 Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 6. What is the function of the Engine Cranking Diagnostic Mode? The engine cranking diagnostic mode is a powertrain control module (PCM) strategy which is separate from the normal operating strategy. It allows the engine to crank in a similar fashion as a conventional vehicle with the fuel disabled. Hybrid Vehicle Operation and Diagnosis Training Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 7. What indicates that the vehicle is in the Engine Cranking Diagnostic Mode? The Hazard Indicator (Red Triangle) flashes once per second when the gear selector is shifted to the Park position. Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 1 8. What indicates that the vehicle is in the Engine Running Diagnostic Mode? The Powertrain Malfunction Indicator (Wrench) flashes once per second when the gear selector is shifted to the Park position. Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 DIRECTIONS: Go to the classroom vehicle. Locate the components that perform the functions listed in the right hand column. List the name of the component in the center column, and the tag letter/number that is attached to the component on the vehicle in the left column. Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name HVBP Tag ??? Component Function Stores high voltage energy Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name Component Function Electrical A/C Compressor A high voltage low-amperage pump for passenger comfort Tag ??? Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name Brake Booster Tag ??? Component Function Contains vacuum solenoids Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name Electric Coolant Pump Tag ??? Component Function When the driver requests cabin heating and the engine is not running, this component is commanded on. Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name DC/DC Converter Tag ??? Component Function Converts high voltage to low voltage Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name Vacuum Pump Tag ??? Component Function Provides vacuum when the gasoline engine is not running Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name Component Function Service Disconnect Switch Prior to performing any HV service procedures this component must be removed. Tag ??? Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name RCM Tag ??? Component Function Cuts off high voltage and fuel in an emergency situation Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name BEC Tag ??? Component Function Contains a serviceable high-voltage lowcurrent fuse Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name DC/AC Inverter Tag ??? Component Function Converts DC voltage to AC Voltage Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name 110 volt plug Tag ??? Component Function Provides a 110 volt AC power source Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name BPSM Tag ??? Component Function HV current is always present at this component, even with the service disconnect switch removed Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name EPAS Tag ??? Component Function Provides steering assist Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name BECM Tag ??? Component Function Contains most strategies for the high voltage system Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name ME Coolant Pump Tag ??? Component Function Provides coolant flow to various electronic components Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name HVBP Cooling Fan Tag ??? Component Function Provides airflow to cool the HVBP Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name eCVT Tag ??? Component Function Splits power for Traction Motor and Gasoline Engine Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 Component Name Brake Pedal Simulator Tag ??? Component Function Simulates Pedal Feel to the driver Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 2 2. List the steps required to depower the HVBP? The ignition must be turned off The service disconnect switch must be removed then wait for 5 minute Store service disconnect switch where it cannot be accidently reinstalled Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstation 3 – Safety Quiz Objective: To describe the emergency instructions provided in this section. DIRECTIONS: Using the High Voltage Safety information and the Emergency Response Guide in the Appendix, find the correct answers for the questions below. Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 1. What color are high voltage cables on hybrid vehicles? ORANGE Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 2. When performing diagnostic or service on the high voltage system of a hybrid vehicle, what personal items must you remove? Rings, Watches, Jewelry, other metallic items (coins) Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 3. What clothing material is recommended for working around high voltage? Cotton Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 4. A. B. C. D. Identify the hazard that is associated with high voltage. Electric shock Blast Arcing All of the above Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 5. A. B. C. D. Choose the cause that usually leads to electrical accidents. Unsafe acts by workers Unsafe work areas Unsafe equipment or installation All of the above Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz Match the classes of fire with the descriptions shown on the right. 3 Class A 1. Chemical fire 1 Class B 2. Electrical fire 2 Class C 3. Typical fire 6. Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 7. Review the accident prevention steps in this student guide. List what you feel are the three most important steps of those presented. Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 8. A. B. C. D. Which of the following types of fire extinguisher should never be used on an electrical fire? Regular dry chemical Multi-purpose dry chemical Carbon dioxide Water Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 9. A. B. If a person is in contact with an electrical current, you should break the electrical connection as quickly as possible without exposing yourself to the current. True False Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 10. What is the first thing you should do if you see someone that has been disabled by an electric shock? Call for help Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 11. What should you use to move a person that is in unconscious and in contact with a high voltage wire? A fiberglass reach pole Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 12. An emergency responder calls and wants to know how to determine by a VIN if a vehicle is a hybrid. What VIN letters/numbers will provide that information? VIN positions 5,6, and 7 will provide that information (POL = Fusion Hybrid, MOL= Milan Hybrid). Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 13. At what temperature will the high-voltage battery be disabled when the key is in the ON position? 600 C (1400 F) Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 14. If a hybrid vehicle is submerged underwater, how can you tell when the battery has been fully discharged? The battery will be fully discharged when the fizzing or bubbling from the battery pack has stopped Hybrid Vehicle Operation and Diagnosis Training Lesson One Safety Quiz 15. If a hybrid vehicle is on fire, what type of vapors might be released from the battery pack? Hydrogen Hybrid Vehicle Operation and Diagnosis Training Lesson One Workstations 4 - 6 Workstation 5 Hands On – Fusion/Milan High Voltages Service Workstation 4 Escape/Mariner Brake Service Procedures WARNING: THESERVICE DISCONNECT SWITCH MUST BE REMOVED WHENEVER THE BEC COVER IS REMOVED Use CMT Active Student Program shortcut to launch the service information. Workstation 6 Diagnosis and Service Procedures