Instructor’s Resource Manual for
Electric and Hybrid Electric Vehicles First Edition James D. Halderman
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Content Producer: Isha Sachdeva Supplement Project Manager: Yohalakshmi Segar, Integra Software Services Pvt. Ltd. Copyright © 2023 by Pearson Education, Inc. or its affiliates, 221 River Street, Hoboken, NJ 07030. All Rights Reserved. Manufactured in the United States of America. This publication is protected by copyright, and permission should be obtained from the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise. For information regarding permissions, request forms, and the appropriate contacts within the Pearson Education Global Rights and Permissions department, please visit http://www.pearsoned.com/permissions/ PEARSON and ALWAYS LEARNING are exclusive trademarks owned by Pearson Education, Inc. or its affiliates, in the United States, and/or other countries. Unless otherwise indicated herein, any third-party trademarks, logos, or icons that may appear in this work are the property of their respective owners, and any references to third-party trademarks, logos, icons, or other trade dress are for demonstrative or descriptive purposes only. Such references are not intended to imply any sponsorship, endorsement, authorization, or promotion of Pearson’s products by the owners of such marks, or any relationship between the owner and Pearson Education, Inc., or its affiliates, authors, licensees, or distributors.
ISBN-10: 0-13-753212-4 ISBN-13: 978-0-13-753212-4
Table of Contents CHAPTER 1 – HYBRID AND ELECTRIC VEHICLE SAFETY
1
CHAPTER 2 – INTRODUCTION TO ELECTRIC AND HYBRID ELECTRIC VEHICLES
4
CHAPTER 3 – HEALTH AND ENVIRONMENTAL CONCERNS
7
CHAPTER 4 – HYBRID ENGINE SYSTEMS
10
CHAPTER 5 – HYBRID AND ELECTRIC VEHICLE PREVENTATIVE MAINTENANCE 13 CHAPTER 6 – DIGITAL STORAGE OSCILLOSCOPE TESTING
16
CHAPTER 7 – ENERGY AND POWER
19
CHAPTER 8 – ADVANCED AC AND DC ELECTRICITY
22
CHAPTER 9 – LOW VOLTAGE BATTERIES & STOP/START MICRO HYBRIDS
25
CHAPTER 10 – HIGH-VOLTAGE BATTERIES
28
CHAPTER 11 – E V AND H E V MOTORS, CONVERTERS AND INVERTERS
31
CHAPTER 12 – E V AND P H E V CHARGING
34
CHAPTER 13 – ELECTRIC VEHICLE CHARGING EQUIPMENT
37
CHAPTER 14 – REGENERATIVE BRAKING SYSTEM
40
CHAPTER 15 – ELECTRIC POWER STEERING
43
CHAPTER 16 – E V AND H E V HVAC
46
CHAPTER 17 – E V AND H E V TRANSMISSIONS
49
CHAPTER 18 – E V AND H E V DRIVER ASSIST SYSTEMS
52
CHAPTER 19 – FUEL CELLS AND ADVANCED TECHNOLOGIES
55
CHAPTER 20 – FIRST RESPONDER PROCEDURES
58
iii Copyright © 2023 Pearson Education, Inc.
CHAPTER 1 HYBRID AND ELECTRIC VEHICLE SAFETY REVIEW QUESTIONS AND ANSWERS 1.
What actions are needed to disable the high-voltage (HV) circuit? (Text page 9) To safely depower the vehicle, always follow the instructions found in service information for the exact vehicle being serviced. The steps usually include the following: STEP 1 Turn the ignition off and remove the key (if equipped) from the ignition and store it in a lock box to prevent accidental starting. STEP 2 Remove the 12-volt power source to the HV controller and wait 10 minutes for all capacitors to discharge. This step could involve: • Removing a fuse or a relay • Disconnecting the negative battery cable from the auxiliary 12-volt battery STEP 3 Remove the high-voltage fuse or service plug or switch. STEP 4 Confirm there is no high-voltage power present before beginning the repair.
2.
What are the personal safety precautions that service technicians should adhere to when servicing hybrid or electric vehicles? (Text pages 4–6) The personal safety precautions that service technicians should adhere to when servicing hybrid or E V include:
3.
•
Wear eye protection
•
Wear high-voltage gloves
•
Wear long sleeves
•
Wear insulted shoes or boots
What are the recommended tools and equipment that should be used when working on the HV circuits of a hybrid or electric vehicle? (Text pages 5–6) The recommended tools and equipment that should be used when working on the HV circuits of a hybrid or electric vehicle include: •
Insulated rubber mats and blankets
•
Fire extinguishers
•
Some manufacturers recommend that a 10-foot insulated fiberglass pole be available outside the safety zone to be used to pull a technician away from the vehicle in the unlikely event of an accident where the technician is shocked or electrocuted.
•
CAT III rated digital multimeter
•
Megohmmeter (insulation tester)
•
Insulated hand tools 1 Copyright © 2023 Pearson Education, Inc.
4.
What precautions should be taken when hoisting a hybrid or electric vehicle? (Text page 9) When hoisting or using a floor jack, refer to the manufacturer’s service information for proper lift points. Orange cables run under the vehicle just inside the frame rails on most hybrid and electric vehicles.
5.
When should the HV system be depowered? (Text page 9) If work is going to be performed on any of the following components, service information procedures must be followed to prevent possible electrical shock and personal injury. •
HV battery pack
•
Any of the electronic controllers that use orange cables, such as the inverter and converters.
•
The air-conditioning compressor, if electrically driven, and has orange cables attached.
CHAPTER QUIZ QUESTIONS AND ANSWERS 1.
Rubber gloves should be worn whenever working on or near the HV circuits or components of a hybrid electric vehicle. Technician A says that the rubber gloves should be rated at 1,000 volts or higher. Technician B says that leather gloves should be worn over the high-voltage rubber gloves. Which technician is correct? (Text page 4) a. Technician A only b. Technician B only c. Both Technician A and Technician B X d. Neither Technician A nor Technician B
2.
A CAT III certified DMM should be used whenever measuring high-voltage circuits or components. The CAT III rating relates to ____________. (Text page 7) a. high voltage b. high energy c. high electrical resistance d. both high energy and high voltage X
3.
All of the following will shut off the high voltage to components and circuits, except ____________. (Text page 9) a. opening the driver’s door X b. turning off the ignition c. disconnecting the auxiliary 12-volt battery d. removing the main fuse, relay, or HV plug
4.
What can occur if a hybrid electric vehicle is pushed in the shop? (Text page 10) a. The HV battery pack can be damaged. b. The tires will be locked unless the ignition is on. c. Damage to the electric control will occur. d. High voltage will be generated by the motor/generator as the wheels turn. X 2 Copyright © 2023 Pearson Education, Inc.