Hybrid Assembly Course

Transcription

1 ELECTRIC AUTO SHOP Hybrid Assembly Course WESTCOASTPOP PUBLICATIONS

2 2011 by Electric Auto Shop All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other noncommercial uses permitted by copyright law. For permission requests, write to the publisher, addressed Attention: Permissions Coordinator, at the address below. WestCoastPop Publications 5907 Van Keppel Road Forestville, CA Ordering Information: Quantity sales. Special discounts are available on quantity purchases by schools, associations, and others. For details, contact the publisher at the address above. Orders by U.S. trade bookstores and wholesalers. Please contact Big Distribution: Tel: (888) ; Fax: (707) or visit Printed in the United States of America i

3 CHAPTER 1 Course Overview This course identifies the main components in a hybrid electric vehicle. It describes their interaction and connection within the hybrid system. It also outlines regular maintenance and service procedures for the Ford Hybrid Escape.

4 Course Design The Hybrid Service Course features several sections which focus on various hybrid topics: Chapter 1 Overview This chapter discusses general physical features of the Ford Escape. It also covers the general energy flow, special equipment, dealer requirements and service checkpoint locations specific to this vehicle. Chapter 6 Ford Escape Electrical System This chapter motor electronics, how to jump start, DC /DC battery charging and disconnects. Appendices This section contains related material for references and other information. Chapter 2 General Hybrid Safety This chapter focuses on safety practices, the use of equipment, wiring, voltage, switching and shutoff, batteries and general safety during vehicle service. Chapter 3 General Hybrid Service This chapter discusses general service points for all hybrid vehicles. These include valves, transmission, steering and oil. Chapter 4 Ford Escape Chassis This chapter discusses service point on the Escape chassis, especially those related to braking and steering. Chapter 5 Ford Escape Power Train This chapter discusses service to the Ford Escape engine, cooling, fuel, accessory drives and other power train related service. 3

5 SECTION 1 Hybrid Electric Vehicle (HEV) Overview What is an HEV? An HEV is a vehicle that uses two sources of propulsion: - an ICE (Internal Combustion Engine) - electric motor(s) powered by batteries that are kept charged by a generator powered by the ICE Which Components are Different in the HEV? OBJECTIVES 1. What items are different about hybrids? 2. What items are the same compared to other vehicles? 3. HEV history and terminology 4. Tools and equipment needed to work on hybrid electric vehicles 5. How to disable the high voltage system on hybrids and other safety issues Engines? Transmissions? Electrical systems? (Hint: YES) Suspension systems? Brakes? HVAC? Servicing? (Hint: YES) Which Components are the Same? Engines? Oil? Transmissions? Brakes? HVAC? 4

6 Brief History of Electrics Pre 1830 Steam-powered transportation Faraday s law and the invention of the DC motor Non-rechargeable battery-powered electric car Development of lead storage battery Battery-powered carriage Gasoline-powered tricycle car ,200 automobiles sold: 1970 s 40% steam powered 38% electric powered 22% gasoline powered Gasoline prices increase as the energy crisis increases. This lead to interest in electric vehicles (EV). Arab oil embargo of 1973 increased the demands for alternate energy sources. Less dependence on foreign oil becomes desirable. In 1976, Congress enacted Public Law , the Electric and Hybrid Vehicle Research, Development and Demonstration Act of This act authorized a federal program to promote electric and hybrid vehicle technologies and to demonstrate the commercial feasibility of electric vehicles s & 1990 s EVs get more Organizational Support Legislation passed by the California Air Resources Board: By 1998, 2% of all vehicles (about 40,000) would be zero emission vehicle (ZEV). By 2003, 10% (about 500,000) would be classified as ZEV. The law has changed, but started the process and the need for alternative propulsion systems. Other states also adopted this law to comply with federal regulations on emission standards. SERA (Solar & Electric Racing Association) organizes electric car races around the country. This organization wants to do for electric vehicles what Indy Racing does for internal combustion engines (improvements and developments through racing). In 1975, 352 electric vans were delivered to the US postal service for testing. 5

7 Key Drawbacks of ICE Vehicles Key Advantages of HEVs High energy consumption: resources, independent of foreign oil High emission, air pollution, global warming(co2 emissions) Environmental hazards Noisy Hybrid Vehicle Pros & Cons - Generally increases MPG INTERACTIVE 1.1 HOV qualifying decal - Hybrids optimize the fuel economy. Hybrids optimize the operating point of ICE (CVT and other methods). Hybrid s electric motors are more efficient than internal combustion engines (95% compared to 35%). Hybrids reduce the size (hp and volume) of ICE. - Hybrids are OK for HOV Lane (HOV=High Occupancy Vehicle). - Consumers like hybrids - Engine will be on all the time when heat or air conditioning is needed. MPG will be much lower. The hybrids fell as much as 40 percent below the EPA mileage figures for combined city and highway driving during a recent test, which covered a mix of Detroit-area roads. Detroit Free Press, TOP STORIES, Thursday, February 03, _2.htm Key Concerns of HEVs -High initial cost: increased components such as battery, electric machines, motor controller, etc. - Reliability concern: increased components, especially power system, electronics, sensors. - Service issues: issues on major electric components. Dealerships and repair shops may not be familiar with new components. - Safety issues with high-voltage system employed in HEV. - Benefits may not pay back the cost increase 6

8 Engine vs. Electric Motor Power Internal combustion engines are rated in horsepower. This rating is the maximum and usually produced at high RPMs. An electric motor is usually rated in kilo-watts (kw) and represents its average power over a period of operation. 746 Watts equals one horsepower. Driving a Hybrid A hybrid electric vehicle does not need to be plugged into an electrical outlet. The batteries are charged by the ICE/ generator. This seems strange at first when driving a hybrid The electric motor/generator then starts the ICE when the brake pedal is released or if needed. Engine Starting Under most conditions, the ICE is started using the integrated starter alternator (ISA) (IMA) to crank the engine. The ISA spins the engine at about 1000 RPM. The starter and auxiliary battery are used as a backup only or during very cold weather conditions. The brakes may feel funny at low speeds (5-15 MPH) as the system switches between regenerative braking to the base hydraulic system. Stealth or Quiet Mode Toyota/Lexus and Ford hybrid electric vehicles can operate on electric motor power alone at low speeds. This is called stealth or quiet mode. This can be a hazard around the shop or while parking because the vehicle cannot be heard. Idle Stop All hybrid electric vehicles incorporate idle stop. Idle stop means that the ICE stops running when the engine is at idle speed if the specified conditions are met. 7

9 Mild Hybrid A Mild Hybrid uses relatively low voltage three 12- volt batteries connected in series to equal 36 volts ;42-volt charging voltage (GM PHT). Mild Hybrid features include: - idle stop capable INTERACTIVE 1.2 Mild hybrid vehicle - electric power steering - torque smoothing - regenerative Braking - not able to propel the vehicle using the electric motor alone Examples: General Motor s PHT and Saturn VUE 8

10 Medium Hybrid A Medium Hybrid uses high voltage batteries at about volts. Medium Hybrid features include: - capable of providing idle stop - uses electric power steering - regenerative braking - newer models are capable of powering the vehicle, but not from a stop, using electric motor power only Examples Include Toyota/Lexus Hybrids 9

11 Full Hybrid A Full Hybrid uses a high voltage system range from 300 to 650 volts. Full Hybrid features include: - capable of powering the vehicle, using the electric motor alone from a stop INTERACTIVE 1.3 Full hybrid vehicle - regenerative braking - uses idle stop, as well as electric power steering Examples Include Toyota/Lexus Hybrids 10

12 Parallel & Series Hybrids Parallel hybrid systems, which are most commonly produced at present, have both an internal combustion engine (ICE) and an electric motor coupled. Series hybrids have also been referred to as range-extended electric vehicles (REEV) where they are designed to be run mostly by the battery, but have a petrol or diesel generator to recharge the battery when going on a long drive. INTERACTIVE 1.4 Parallel or Series hybrids 11

13 Series Hybrid Architecture INTERACTIVE 1.5 Series Hybrid component layout 12

14 Parallel Hybrid Architecture INTERACTIVE 1.6 Parallel Hybrid component layout 13

15 Hybrid Sales & Market Predictions in the USA Year Number of Models Units Sold , , ,000 INTERACTIVE 1.7 Hybrid sales ,000 Hybrid Models in the USA Toyota Highlander Hybrid 4x4, V6, $34,430: 31/27 mpg (conventional model: $31,580, 18/24 mpg) Toyota Prius, 1.5L, $20,975, 60/51 mpg. Ford Escape, SUV, 2.3L, 33/29 mpg 4X4, 36/31 mpg, 4X2 Honda Civic Hybrid, 1.3L, MT: $19,900, 46/51 mpg, CVT: $20,900, 48/47 mpg (conventional model, AT, $18,310, 1.7L I4, 31/38) Honda Insight, 5-spd MT, $19,330, 1.0L, 60/66 mpg, CVT: $21530, 57/56 mpg (source J.D. Power and Associates) 14

16 Toyota Prius Specs INTERACTIVE 1.8 Toyota Prius specifications 15

17 Honda Civic Specs INTERACTIVE 1.9 Honda Civic specifications 16

18 Honda Accord Specs INTERACTIVE 1.10 Honda Accord specifications 17

19 Ford Escape Specs INTERACTIVE 1.11 Ford Escape specifications 18

20 Hybrid Truck Specs INTERACTIVE 1.12 Hybrid Truck specifications 19

21 INTERACTIVE 1.13 Voltage warning label 20

22 other Hybrid manufacturers:

23 SECTION 2 Ford Escape Introduction The Hybrid Electric Vehicle delivers improved fuel economy and fewer pollutants than a conventional SUV, without the complications of daily recharging an electric vehicle. As a hybrid, the Escape Hybrid runs on electric battery power supplemented by a gasoline engine, depending on the driving situation. An advanced powertrain control module (PCM) chooses the best power method to run the vehicle at maximum efficiency. OBJECTIVES 1. Describe hybrid electric vehicle systems and component interrelationship 2. Describe operating characteristics 3. Identify exterior features 4. Identify interior features 5. Identify safety concerns 6. Identify maintenance points The Escape Hybrid is able to achieve EPA fuel economy between 6.7 liters per 100 kilometers (35 miles per gallon) and 5.9 liters per 100 kilometers (40 miles per gallon) for city driving and nearly 7.8 liters per 100 kilometers (30 miles per gallon) for highway driving in front-wheel-drive configuration. Fuel economy for the 4WD is slightly lower. The Escape Hybrid meets strict super ultra-low emission vehicle (SULEV) and partial zero emission vehicle (PZEV) emissions standards. The Escape Hybrid features several all new systems, including throttle control, braking, shifting and steering. 22

24 Electronically Controlled Continuously Variable Transmission The Escape Hybrid combines an electric transaxle (known as the electronically controlled continuously variable transmission, or ecvt) with an internal-combustion engine (2.3L I4) to effectively meet peak demands for power and to capture energy that is wasted during braking. Captured energy is converted to electricity and stored in the high voltage battery. Understanding how the ecvt works is the key to understanding many other components of the Escape Hybrid. The ecvt houses the: electric motor (known as the traction motor) generator planetary gear set During operation, the ecvt coordinates power among the engine, traction motor, generator and drive wheels. We will cover more of the description and operation of the ecvt later in this course. 23

25 Operating Characteristics The Escape Hybrid exhibits unique operating characteristics. Customers may not understand that all of these characteristics of the Escape Hybrid are normal. Driving habits, use of the defrost mode, and use of the A/C affect the fuel economy more than a conventional gasoline powered engine. Starting: Engine starts and then may shut off. Driving: The engine starts automatically as needed. The transmission changes between operating modes but there is no actual shifting. The engine may shut off automatically as needed. The engine may shut off when the vehicle comes to a stop to conserve fuel. Engine speed is different from a conventional vehicle. The engine speed in a hybrid is not directly tied to the vehicle speed. Under certain conditions the engine speed may appear much higher than that of a conventional automobile. This is normal. Other: Unique noises from the traction battery cooling system. 24

26 SECTION 3 Exterior Features Exterior Features The exterior of the Escape Hybrid is very similar to the regular Escape. A few changes to the badging are the only indicators that this is a hybrid electric vehicle. An additional air intake, for the traction battery cooling system, is disguised as part of the left-hand rear window. OBJECTIVES 1. Identify distinguishing exterior features of the Ford Escape Hybrid 2. Describe function of exterior features 25

27 INTERACTIVE 1.14 Exterior features Hybrid Badging Air Intake 26

28 SECTION 4 Interior Features Interior Features The interior of the Escape Hybrid is very similar to the 2005 Escape. A few of the changes include: The HV (or traction) battery and its cooling system are located in the rear of the vehicle. These items will be covered in more detail later in this course. OBJECTIVES 1. Identify interior features 2. Describe function of various interior features A 110 volt AC electrical power outlet is located on the shift console. The 110 volt accessory outlet is protected by fuse 14 (30 amps) in the power distribution box. Additional gauges and warning indicators on the instrument panel: Tach and EV mode gauges - The tachometer gauge displays the internal combustion engine revolution speed and indicates when the vehicle is operating on electric power only (EV mode). A small segment below 0 indicates EV mode when the vehicle is using electric power only. Charge and Discharge gauge - The charge/assist gauge feature lets the driver know when the HV battery is being charged by the internal combustion engine or regenerative braking system or when energy from the HV battery is being used to assist in moving the vehicle. The gauge movement is referenced from the HV battery and displays in kilowatts. Discharge (assist) is positive current and the gauge pointer rotates clockwise. Charging is negative current and the gauge pointer rotates counterclockwise. The charge/assist 27

29 CHAPTER 3 General Hybrid Service This chapter discusses general service points for all hybrid vehicles.

30 SECTION 1 Braking System The Escape Hybrid has a new electro-hydraulic brake (EHB) system that replaces a portion of the conventional hydraulic brake system found on the Escape. OBJECTIVES 1. Understand hybrid braking system 2. Identify components in the brake system 3. Explain the interaction of braking components 4. Explain the concept of electro-hydraulic braking 5. Explain the function of the actuation control unit 6. Explain the function of the Rotunda Twin Pressure Bleeder 70

31 The EHB system includes: A new actuation control unit (ACU), which is similar to a modified master cylinder. The EHB system has no conventional brake booster. The booster was deleted because the gasoline engine does not run constantly and cannot provide a sufficient vacuum to the braking system. A pedal feel emulator, which is a chamber built into the ACU, provides the familiar sensation of braking. A modified brake system control module (BSCM) assembly. - The hydraulic control unit (HCU) portion of the BSCM assembly has two additional lines that provide fluid from the ACU reservoir to the HCU pump (source line) and return fluid to the ACU reservoir (return line). INTERACTIVE 4.1 Hybrid Brake System Hydraulic Control Unit - The brake control module assembly also has an additional fluid accumulator below the unit. - The brake control module assembly is located on the right hand side of the cowl. - New heat shields protect the brake control module assembly from high catalytic converter temperatures. Actuation Control Unit The EHB system uses sensor inputs to regulate the amount of hydraulic pressure. supplied by the HCU. that is applied to the conventional four wheel disc brakes (including the antilock braking system). Sensor inputs to the BSCM include: - A pedal travel sensor (a magnetic resonant travel sensor mounted on the ACU that measures how fast and how far the brake pedal has moved). - A stability assist sensor cluster (although this vehicle does not have stability assist. it uses the same inputs for the braking system). 71

32 The EHB system is coordinated with the powertrain management to re-capture energy that would normally be lost to braking. 72

33 Rotunda Drain Twin Pressure Bleeder Brake bleeding procedures require the use of the new Rotunda Drain Twin pressure bleeder in addition to the Worldwide Diagnostic System (WDS). A pressure bleeder is capable of maintaining constant 241 kpa (35 psi) of fluid pressure throughout the bleeding process. INTERACTIVE 4.2 Rotunda Drain Twin Pressure Bleeder Do not use a vacuum bleeder. More information on the operation of the pressure bleeder will be given in the classroom course. Replacement brake fluid is High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Service Part Number ESA-M6C25-A). 73

34 SECTION 2 Regenerative Braking OBJECTIVES 1. Define regenerative braking 2. Identify the components within the regenerative braking system 3. Explain the benefits of regenerative braking 4. Explain the function of the PCM 5. Explain the function of the BSCM In addition to the new EHB system, the PCM can control the traction motor so it is used as a generator to recharge the HV battery during certain braking events. Regenerative braking captures energy that would otherwise be lost to friction. This results in increased fuel economy. The regenerative braking feature isolates the driver brake demand from the friction brakes in order to allow the front wheels to turn the traction motor during braking. The turning traction motor acts as a generator causing the vehicle to slow down. The generated electricity is sent to the high voltage battery. Both the traction motor and the friction brakes are used to slow the vehicle. Regenerative braking is used in conjunction with the base brakes when possible. Regenerative braking is automatically controlled by the PCM along with the BSCM. 74

35 INTERACTIVE 4.3 Series Regenerative Braking Traction Battery gine Traction Motor Generator eshaft 75

36 SECTION 3 Steering System An electric power assist steering (EPAS) system replaces the conventional hydraulic valve steering system. The 12 volt EPAS system consists of: an electric motor coupled directly to the steering gear. a rotational sensor mounted between the input shaft and steering gear. OBJECTIVES 1. Define the term EPAS 2. Identify components in the steering system 3. Describe function of individual components in the steering system 4. Describe component interaction within the steering system a power steering control module (PSCM). The PSCM mounts on the cowl where the brake booster used to be located. With the exception of the new steering gear assembly and PSCM, the rest of the steering system uses conventional steering system components. During operation, the rotational sensor senses the driver s steering effort and sends a signal to the PSCM. The PSCM combines the rotational sensor input with other inputs from the PCM, such as vehicle speed, and sends a signal to the steering gear electric motor. 76

37 There are two major reasons for using an EPAS system in the Escape Hybrid: EPAS allows power steering to be delivered under all operating conditions, since the engine is not always running to turn a power steering pump. EPAS improves fuel economy due to lower energy losses since the EPAS is only used on demand whereas a conventional system runs all the time. INTERACTIVE 4.4 Hybrid Steering System The EPAS is lubricated for life. There is no reservoir, fluid or hoses. Electric Motor Power Steering Control Module Drain Wire 77

38 CHAPTER 5 Ford Escape Power Train The Hybrid vehicle uses a combination of mechanical and energy power sources for driving its powertrain.

39 SECTION 1 Engine Ford Escape Engine The Escape Hybrid uses an Escape 2.3L I4 engine that has been modified to use an Atkinson cycle for the valve timing. OBJECTIVES 1. Describe the operation of a hybrid power system 2. Explain how an Atkinson system works 3. Identify and describe the function of the main mechanical components in the hybrid powertrain 4. Describe the interaction of the drive components within the hybrid powertrain 79

40 Atkinson Cycle The Atkinson Cycle was invented in 1881 by James Atkinson. It delays the closing of the intake valve to create a higher expansion ratio, which increases efficiency at the expense of a loss of low-speed torque. The electric motor assist helps provide the low speed torque to INTERACTIVE 5.1 Atkinson Camshaft compensate. The Atkinson cycle allows the intake valve to remain open during a portion of the compression stroke. A modified camshaft lobe design alters the duration of the intake valve opening. Atkinson Intake Lobe Four Stroke Intake Lobe The Atkinson cycle reduces the amount of energy used to compress the air/fuel mixture (known as pumping loss) which increases the fuel mileage by 7-10%. Starter Motor The Escape Hybrid has no starter. A dust seal covers the opening where the starter used to be mounted. The starter function is performed by the 330 volt generator inside the ecvt. 80

41 Oil Change The Escape Hybrid uses a new cartridge style oil filter (service part number FL-2017A). 5W20 oil is used and the change interval is every 15,000 miles. The Escape Hybrid also has an acoustical engine cover with molded-in logo. INTERACTIVE 5.2 Work range within the Atkinson Cycle 81

42 SECTION 2 Front End Accessories OBJECTIVES 1. Define the main hybrid accessories 2. Point out the locations of the main accessories The front end accessory drive on the Escape Hybrid powers only the coolant pump and the A/C compressor. There is no hydraulic power steering pump. As mentioned earlier, the Escape Hybrid uses an electric motor to provide power assist to the steering system. There is no belt-driven generator. The belt-driven generator function is now carried out by the generator inside the ecvt and the DC/DC converter. The front end accessory drive belt is shorter. The tensioner has been relocated. 3. Describes the maintenance and service of accessories 4. Describe the power flow from the engine to the accessories 82

43 INTERACTIVE 5.3 Front End Accessory Drive Tensioner Coolant Pump A/C Compressor Crankshaft 83

44 SECTION 3 Switchable Powertrain Mount In addition to the conventional powertrain mounts, the Escape Hybrid uses one switchable liquid-type powertrain mount to reduce noise, vibration, and harshness (NVH) at idle and engine start up and shut down. The switchable powertrain mount consists of: The mount OBJECTIVES 1. Explain the function of the Switchable Powertrain Mount A vacuum source - vacuum is supplied by the engine intake manifold during engine idle operation A solenoid control valve - the control valve is located on the left side of the climate control system vacuum reservoir Vacuum hoses 84

45 At or near idle, the PCM commands the solenoid control ON which allows the vacuum to open a second flow path (orifice) inside the powertrain mount. The secondary flow path (orifice) changes the damping characteristics of the powertrain mount. INTERACTIVE 5.4 Switchable Powertrain Mount Solenoid Control Valve Switchable Powertra Mount Vacuum Reservoir 85

46 SECTION 4 Intake Air Distribution & Filtering OBJECTIVES The intake air system features: a new side branch resonator a modified fender well resonator a carbon trap to retain hydrocarbon emissions during engine off The intake air system uses a conventional air filter (service number 5M6Z-9601-AA). 1. Describe the function of the Air Distribution & Filtering System 2. Define the components within the system 3. Identify component locations 4. Explain component interaction within the system 86

47 INTERACTIVE 5.5 Hybrid Air Intake System Fender Well Resonator Side Branch Resonator 87

48 SECTION 5 Fuel System The Escape Hybrid uses electronic throttle control (ETC) Components of the ETC system are similar to other ETC systems but the strategy is very different. OBJECTIVES 1. Explain the strategy of electronic throttle control 88

49 Electronic Throttle Control INTERACTIVE 5.6 Electronic Throttle Control 89

50 SECTION 6 Inertia Switches The Escape Hybrid has a rear inertia switch in addition to a front inertia switch. Either switch tripping results in a no start and a no crank condition. The front inertia switch cuts off both fuel and high voltage. OBJECTIVES 1. Define the term inertia switch The rear inertia switch cuts off only power to the high voltage contactors located inside the battery case. In response to the loss of power at the contactors, fuel is shut off indirectly by the PCM. The additional rear inertia switch disconnects faster which provides an extra margin of safety. 2. Explain the reason for use of inertia switches 3. Explain the different performance of front and rear switches 4. Identify specific locations of the front and rear inertia switches 90

51 INTERACTIVE 5.7 Lorem Ipsum dolor amet, consectetur Front Inertia Switch Rear Inertia Switch 91

52 SECTION 7 Engine Cooling The Escape Hybrid uses an engine cooling system similar to the one used on the Escape but with one significant change. A PCM-controlled helper pump is located in series with the hoses leading to the heater core. The 12 volt helper pump is needed because the gasoline engine is not always running and driving the enginedriven cooling pump. OBJECTIVES 1. Explain the function of the hybrid engine cooling system If the driver requests cabin heating while the engine is off, the PCM commands the helper pump to turn on. The engine cooling system uses Motorcraft Premium Gold Engine Coolant like the Escape. The service interval is 5 years/100,000 miles for the first change, then 3 years/ 50,000miles for subsequent changes. 92

53 Helper Pump INTERACTIVE 5.8 Helper Pump 93

54 SECTION 8 Transmission System The new electronically controlled continuously variable transmission (ecvt) consists of: a 65 kw (87 HP) traction motor a 36 kw (48 HP) generator motor a planetary gear set OBJECTIVES 1. Describe the operation of the transmission system a transmission control module (TCM) located on top of the ecvt case The planetary gear set connects the engine, traction motor, and generator with the drive wheels. Based on commands from the PCM for optimum fuel efficiency, the TCM continuously adjusts the contribution of the engine, traction motor and generator. Either the electric motor or the engine can be used to provide power to the wheels. The ecvt operates in several modes: The electric motor in the ecvt can be used to accelerate the vehicle from a stop. When the need for extra power is detected, the gasoline engine automatically turns on. 94

55 At slower speeds (up to 64 kph/40 mph) and while the vehicle is idling, the gasoline engine may automatically shut off to save fuel. The gasoline engine may remain on to charge the battery or maintain the air conditioning. At higher speeds the gasoline engine is mainly used to power the vehicle. The traction motor is used as a generator to recover the vehicle energy during braking that would otherwise be lost to friction. This process is called regenerative braking. The generator motor is used to start the gasoline engine quickly and automatically when required. The generator motor is used Generator Motor in combination with the electronic throttle to control the speed of the gasoline engine. It does this by generating electricity which is used directly in the traction motor or stored in the high voltage battery forlater use. INTERACTIVE 5.9 Electronically Controlled Continuously Variable Transmission Traction Motor The on-board generator eliminates the need to plug in the Escape Hybrid. The ecvt incorporates the functions of both the starter and the belt-driven generator. The DC/DC converter provides the equivalent output of the beltdriven generator. 95

56 SECTION 9 Floor Mounted Shifter The floor-mounted shifter has been modified from three (D-1-2) to two drive positions (D-L). Located on the side of the floor shifter assembly is a new transmission range sensor for the shift feature. There are no gears to change in the ecvt. The range sensor only sends a signal to the PCM. OBJECTIVES The shift cable controls only the parking pawl in the ecvt and provides shifter feel to the driver. 1. Describe the function of the floor mounted shifter 96

57 INTERACTIVE 5.10 Lorem Ipsum dolor amet, consectetur Shift Cable for Parking Pawl Transmission Range Sensor 97

58 SECTION 10 Motor Electronics Cooling Systems The Escape Hybrid has a motor electronics (M/E) cooling system that is completely separate from the engine cooling system. The M/E cooling system cools: the ecvt power electronics (the TCM) the electric motors inside the ecvt OBJECTIVES 1. Explain the purpose of the Motor Electronics Cooling System the DC/DC converter The M/E cooling system consists of: An additional M/E radiator filled with Motorcraft Premium Gold Engine Coolant. The service interval is 5 years/100,000 miles for the first change, then 3 years/50,000 miles for subsequent changes. A PCM-controlled 12 volt electric coolant pump. The coolant pump is mounted near the bottom-rear of the radiator assemblies. 98

59 A separate degas bottle. The M/E degas bottle is part of a single assembly that includes the engine cooling degas bottle. Hoses. There is no conventional transaxle cooler on the Escape Hybrid because the M/E cooling system cools the transaxle. INTERACTIVE 5.11 Motor Electronics Cooling System DC/DC Converter System 99

60 CHAPTER 6 Ford Escape Electrical System This section will describe the electrical communication network and how it interacts with the charging system. It also reviews the climate control system and other safety equipment and procedures.

61 SECTION 1 Module Communication Network The Escape Hybrid has a motor electronics (M/E) cooling system that is completely separate from the engine cooling system. The M/E cooling system cools: the ecvt power electronics (the TCM) the electric motors inside the ecvt OBJECTIVES 1. Describe the function of the electrical network 2. Explain the function of the High Speed CAN 3. Explain the function of the Medium Speed CAN the DC/DC converter The M/E cooling system consists of: An additional M/E radiator filled with Motorcraft Premium Gold Engine Coolant. The service interval is 5 years/100,000 miles for the first change, then 3 years/50,000 miles for subsequent changes. 4. Describe the components within the network 5. Describe the interaction of components within the network A PCM-controlled 12 volt electric coolant pump. The coolant pump is mounted near the bottom-rear of the radiator assemblies. A separate degas bottle. The M/E degas bottle is part of a single assembly that includes the engine cooling degas bottle. 101

62 Hoses. There is no conventional transaxle cooler on the Escape Hybrid because the M/E cooling system cools the transaxle. INTERACTIVE 6.1 High Speed Controller Area Network (CAN) 102

63 Medium Speed CAN The medium speed CAN contains the following modules: instrument cluster (IC) smart junction box (SJB) INTERACTIVE 6.2 Medium Speed CAN 103

64 SECTION 2 Charging System The charging system on the Escape Hybrid includes a conventional low voltage (12 volt DC) system and a new high voltage (330 volt DC) system. The low voltage battery is the same one that is used in the Escape. The low voltage battery: is charged by the DC/DC converter. is not the source to spin the engine during cranking. OBJECTIVES 1. Describe the components within the hybrid Charging System 2. Explain the function of each component 3. Describe component interaction within the Charging System provides for the low voltage needs of the Escape Hybrid, such as the electric power assisted steering, headlights, climate control and audio. There is no belt-driven generator on the Escape Hybrid. The belt-driven generator function is performed by the generator inside the ecvt. The output of the generator is 110 amps at 12 volts. The high voltage (330 volt) battery, also known as the traction battery, is designed to provide electrical power to the traction motor, generator motor and DC/DC converter. 104

65 High Voltage System The high voltage system includes: The nickel metal hydride (NiMH) batteries. The battery case contains 250 individual cells. All 250 cells are connected to produce the 330 volts. The jump start battery charger and contactor box, which are built into the battery case. The traction battery control module (TBCM), which is built into the battery case. The TBCM is capable of detecting faults within the high voltage battery subsystem and controlling the high voltage battery function. Thermal sensors provide information to the TBCM and the PCM. Ground fault detection is also performed by the TBCM. The battery cooling system fans. INTERACTIVE 6.3 Hybrid Charging System Low Voltage Battery C Converter Electronically Controlled Continuously Variable Transaxle The high voltage service disconnect switch. This switch opens to disconnect the HV battery and isolate the 330 volts inside the HV battery during service procedures. This switch also contains the HV fuse which may open under unusual circumstances. An opened HV fuse requires a new service disconnect switch to be installed. High Voltage Cable High Voltage Battery All of the above components contained inside the HV battery case are not serviceable except for the service disconnect switch. The high voltage and the low voltage wiring. 105

66 SECTION 3 Jump Start Strategy OBJECTIVES 1. Understand the Jump Start procedure Jump Start Switch A jump start switch is located on the driver s side kick panel. Pushing the jump start switch starts an 8 minute timer and a dedicated 12 volt to high voltage battery charger located inside the HV battery case. This battery charger allows a customer to charge the high voltage battery from a 12 volt donor source. The jump start feature is needed because the starter function is built into the ecvt which is powered by the high voltage system. Over extended periods of time at high temperatures the HV battery can lose its charge just as a low voltage battery can. The 12 volt donor is initially the Escape Hybrid s own 12 volt battery. If this fails, the jump start procedure can be repeated using an auxiliary 12 volt power supply connected to the Escape Hybrid s 12 volt battery like a conventional jump start procedure. 106

67 INTERACTIVE 6.4 Jump Start Switch 107

68 SECTION 4 DC/DC Converter DC/DC Converter The DC/DC converter converts high voltage (330 volt) battery power to low voltage (12 volt) battery power. The DC/DC converter is located near the right side shock tower. High voltage cables enter the DC/DC converter and low voltage cables leave the DC/DC converter. OBJECTIVES 1. Explain the function of the DC/DC Converter The DC/DC converter is PCM controlled. The maximum output of the DC/DC converter is 110 amps at 12 volts. The DC/DC converter is cooled, along with the ecvt, by the M/E cooling system. DC-DC video 108

69 INTERACTIVE 6.5 DC/DC Converter 109

70 SECTION 5 Climate Control System The air conditioning (A/C) system for the Escape Hybrid has been modified to provide cooling to the traction battery in addition to the passenger compartment cooling function. A traction battery cooling request to the PCM results in the engine turning on in order to drive the compressor. A serviceable air filter (Service Part Number FP-51, interval 1 year or 15,000 miles) is accessible in the left rear interior panel. OBJECTIVES 1. Explain the operation of the Climate Control System The A/C system has two parallel refrigerant loops; one for the passenger compartment and a new one for the traction battery cooling unit evaporator. Each refrigerant loop has its own shut off valve. The A/C system can cool each zone independently of the other. A single compressor is used to pump refrigerant through both loops. The A/C compressor and the condenser on the Escape Hybrid are different than the Escape to handle the change in capacity. An air temperature thermistor was added to the front and rear A/C systems to control compressor cycling. 110

71 The TBCM requests A/C, controls the battery refrigerant solenoid valve, and sends the evaporator temperature status and solenoid status to the PCM. The TBCM is built into the battery case and is not serviceable. The TBCM communicates with the PCM over the CAN. INTERACTIVE 6.6 Traction Battery Cooling System Traction Battery Cooling Unit The TBCM controls the airflow mode actuator on the rear A/C cooling unit. This electric actuator moves two baffles to use either outside air or recirculated air to cool the traction battery. The air inlet for the traction battery cooling unit is in the left rear quarter window. The air outlet is below the inlet and behind the bumper. ompressor Traction B erant Line 111

72 SECTION 6 Idle Shutdown Override Another change to the climate control system is a full A/C function, shown as Max A/C on the mode selection switch. Max A/C, defrost and defrost/floor modes run the engine continuously, overriding the hybrid engine shut down. These modes impact the ability of the Escape Hybrid to obtain the maximum fuel economy. OBJECTIVES 1. Explain the function of the Idle Shutdown Override A/C and A/C recirculation modes operate the A/C only when the engine is normally on, which provides better fuel economy than Max A/C. The air coming out the vents gets warmer when the engine is off. HV battery cooling needs override the engine shutdown as well. You may hear some unique sounds with an Escape Hybrid. You may hear a slight clunk or tap noise as the vent door operates. In addition, you may hear a fan noise in the rear of the vehicle. This is the traction battery cooling fan. These noises are normal and do not require service. A vacuum aspirator has been added by the throttle to boost the available vacuum level in order to operate the climate control vacuum acuators. 112

73 INTERACTIVE 6.7 Idle Shutdown Override Settings Max AC Setting Defrost Setting 113

74 SECTION 7 Electrical Safety The 2005 Escape Hybrid high voltage related components include: The high voltage battery The high voltage service disconnect The high voltage wiring - orange colored for easy identification OBJECTIVES 1. Explain basic electrical safety 2. Describe components with special electrical safety considerations The front inertia switch The rear inertia switch The DC/DC converter The ecvt 3. Describe safety procedures when working with component connections 4. Explain the theory of redundant switching 114

75 INTERACTIVE 6.8 High Voltage Safety Features High Voltage Disconnect S h High Voltage T High Voltage Wiring Harness 115

76 High Voltage Connector Electrical safety on the Escape Hybrid is enhanced by many redundant disconnect features: Two inertia switches which are located in the front and rear. Key off disconnect. There is no high voltage present, outside of the battery, when the key is off. INTERACTIVE 6.9 High Voltage Connector A service disconnect fuse which is located on the battery pack. Ground fault detection which is performed by the TBCM. An electrical connector interlock circuit. Whenever any high voltage cable is disconnected, the electrical connector interlock circuit shuts off all high voltage power. terlock Circuit High Voltage Circu 116

77 Safety Gloves and Cones Safety is also enhanced by properly using high voltage safety equipment: Buffer zone - Place orange cones around the vehicle during all service procedures to alert the entire shop to the presence of lethal electricity. HV rubber safety gloves The HV gloves are designed for working around equipment rated up to 1,000 volts. The HV rubber insulated safety gloves are protected by durable leather gloves that serve as an outer shell. Use the HV gloves when working around the high voltage components of the Escape Hybrid. INTERACTIVE 6.10 Safety Cones, Face Shield, Electrical Gloves Safety gloves must checked before each use and be re-certified every six months or new ones must be purchased. Face shields - Wear a face shield when working around the high voltage components of the Escape Hybrid. 117

78 SECTION 8 High Voltage Disconnect Switch High Voltage Service Disconnect Switch Always follow high voltage safety procedures: Use the cones to establish a buffer zone around the Escape Hybrid. Disconnect the high voltage service disconnect switch before performing any service procedures related to the high voltage components. Store the switch in the battery case. OBJECTIVES 1. Explain the function of the High Voltage Disconnect Switch Wear HV rubber gloves, HV leather outer gloves and a face shield. Follow approved diagnostic tests. Do not use a digital multimeter on any high voltage circuit unless told to do so by the diagnostic tests in the workshop manual or the PCED manual. 118

79 Perform the safety procedure as written into the diagnostic procedures. Before disconnecting the high voltage components, you must wait five minutes after key off and the removal of the high voltage service disconnect switch from the high voltage battery pack. This procedure allows for the internal capacitors to discharge in the event there is a system failure that prevents automatic dis- INTERACTIVE 6.11 High Voltage Service Disconnect Switch charge. 119

80 High Voltage Warning Hybrid vehicle identification alerts the technician to the presence of high voltage components: Badging on the exterior of the vehicle Warning decals on high voltage components INTERACTIVE 6.12 High Voltage Warning Label 120

81 Accessory Battery Battery used to provide power for accessories Related Glossary Terms HV Battery, Traction Battery Index Find Term

82 ACU Actuation Control Unit Related Glossary Terms Drag related terms here Index Find Term

83 BSCM Brake System Control Module Related Glossary Terms Drag related terms here Index Find Term

84 TBCM Traction Battery Control Module Related Glossary Terms Drag related terms here Index Find Term

85 TCM Transmission Control Module Related Glossary Terms Drag related terms here Index Find Term

86 Traction Battery Combination of cells that form a battery used for the vehicle s main source of power Related Glossary Terms Accessory Battery, HV Battery Index Find Term