September 2014 Trainee manual Automotive Training Courses pr ev ie w Hybrid propulsion systems diagnosis INDEX pr ev ie w 1. SOME HISTORY… 2. VEHICLE FEATURES AND IDENTIFICATION 2.1 VIN - VEHICLE IDENTIFICATION 3. BUS NETWORKS 3.1 CAN 3.2 BEAN 3.3 AVC-LAN 4. TRADITIONAL ELECTRIC POWER SUPPLY AND NETWORK AND RESET PROCEDURES 4.1 12 V BATTERY CHARGING PROCEDURE 4.2 How to start the vehicle with a low 12 V battery 5. TOYOTA HYBRID SYSTEM (THS e THS II) INTRODUCTIOHN 5.1 THS (TOYOTA HYBRID SYSTEM) 5.2 THS II AND HSD - HYBRID SINERGY DRIVE 6. OPERATION OF THE ELECTRIC-FUEL HYBRID VEHICLE WITH THSII 6.1 HYBRID SYSTEM: DESCRIPTION OF THE MAIN COMPONENTS 6.1.1 SAFETY PROCEDURES 6.2 HV (HYBRID VEHICLE) BATTERY 6.3. INVERTER/CONVERTER UNIT (ICU) 6.4. MG1 AND MG2 ELECTRIC GENERATOR-MOTORS 6.4.1 GENERAL OVERVIEW OF BRUSHLESS MOTORS 6.4.2 THE BRUSHLESS MOTORS OF THE PRIUS 6.4.3 RESOLVER 6.4.4 TEMPERATURE SENSOR 6.5 THE TRANSMISSION 6.5.1 POWER SPLIT DEVICE (PSD) 6.5.2 THE OPERATING PRINCIPLE OF THE PSD 6.5.3 TRANSAXLE DAMPER 6.5.4 GEAR SELECTOR LEVER 6.5.5 P PARKING LOCK AND ACTIVATION BUTTON 6.6 HYBRID VEHICLE START-UP AND DRIVING 6.7 DRIVING STYLE 7. 1NZ-FXE 54 HEAT ENGINE 7.1 Main components of the engine control 7.1.1 VVT-I SYSTEM 7.1.2 ETCS-i SYSTEM 7.2 MAINTENANCE: TAPPET CLEARNACE ADJUSTMENT 8. HYBRID ECB (ELECTRONICALLY CONTROLLED BRAKE) SYSTEM 8.1 GENERAL INFORMATION 8.2 DESCRIPTION 8.3 SYSTEM COMPONENTS 8.4 ECB OPERATION 8.5 COMMUNICATION SYSTEM 8.6 REGENERATIVE BRAKE DIAGRAM 8.7 EMERGENCY STRATEGY 8.8 MAIN COMPONENTS 8.8.1 BRAKE PEDAL TRAVEL SENSOR 8.8.2 BRAKE LIGHTS SWITCH 8.8.3 BRAKE PEDAL FEEL SIMULATOR 8.8.4 PROCEDURE FOR VERIFYING THE TEST VALUES ON THE MASTER CYLINDER 8.8.5 HYDRAULIC ACTUATOR UNIT 8.8.6 ANTI-SLIP CONTROL UNIT 8.8.7 YAW RATE AND LATERAL ACCELERATION SENSOR 8.8.8 STEERING ANGLE SENSOR 8.8.9 ADDITIONAL BRAKING SYSTEM SUPPLY UNIT 8.8.10 HYDRAULIC ACTUATOR BLEEDING PROCEDURE 8.8.11 MASTER CYLINDER BLEEDING PROCEDURE 8.8.12 FRONT AND REAR BRAKES BLEEDING PROCEDURE 8.8.13 CALIBRATION AND INITIALISATION PROCEDURES FOR THE LINEAR SOLENOID VALVES TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 2014 <2 S7 “Hybrid propulsion systems diagnosis” - Automotive Training Courses pr ev ie w 8.8.14 YAW RATE (DECELERATION) SENSOR CALIBRATION 9. ELECTRIC DRIVE 9.1 MAIN COMPONENTS 9.1.1 ELECTRIC MOTOR 9.1.2 TORQUE SENSOR 10. AIR CONDITIONING 10.1 MAIN COMPONENTS 10.1.1 A/C COMPRESSOR 10.1.2 VERIFYING THE AMOUNT OF REFRIGERANT IN THE A/C SYSTEM 10.1.3 HEATER WATER PUMP 11. MAINTENANCE and procedures 11.1 12 V BATTERY CHARGING PROCEDURE 11.2 How to start the vehicle with a low 12 V battery 11.3 MAINTENANCE: TAPPET CLEARNACE ADJUSTMENT 11.4 HYDRAULIC ACTUATOR BLEEDING PROCEDURE 11.5 MASTER CYLINDER BLEEDING PROCEDURE 11.6 FRONT AND REAR BRAKES BLEEDING PROCEDURE 11.7 CALIBRATION AND INITIALISATION PROCEDURES FOR THE LINEAR SOLENOID VALVES 11.8 YAW RATE (DECELERATION) SENSOR CALIBRATION 11.9 SCHEDULED MAINTENANCE 12. SERVICE OIL RESETTING PROCEDURE (MAINT REQD WARNING LIGHT) 13. EXHAUST GAS CONTROL PROCEDURE FOR 2ND AND 3RD GENERATION PRIUS 14. SAFETY AND INTERVENTION PROCEDURES 14.1 FIRST AID INTERVENTIONS 14.1.1 CONTACT WITH EYES 14.1.2 CONTACT WITH SKIN 14.2 FIRE PREVENTION MEASURES 14.2.1 FIRE EXTINGUISHING METHOS AND AGENTS 14.2.2 CHECKING THE RISK EXPOSURE AND PROTECTION OF FIRE PREVENTION PERSONNEL 14.2.3 PREVENTING FIRES FROM SPREADING 14.3 MEASURES IN CASE OF ACCIDENTAL LEAKAGE 15. Last developments of the HSD system 15.1 What has changed? 15.1.1. New Auris Hybrid and Lexus CT200h 15.1.2. New Yaris Hybrid 15.1.3. Prius plug -in Exercise S7 – Operation and diagnosis of the Toyota hybrid system - Fault analysis sheet n° 1 S7 – Operation and diagnosis of the Toyota hybrid system - Fault analysis sheet n° 2 3 > TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 2014
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