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1、本章學(xué)習(xí)內(nèi)容本章學(xué)習(xí)目標(biāo)本章難點(diǎn)重點(diǎn)6.1 General Trouble Diagnosis Procedure and Safety Equipments 一般故障診斷程序和安全設(shè)備 6.2 Toyota Prius Hybrid Trouble Diagnosis豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷1. 掌握電動(dòng)汽車一般診斷程序;2. 掌握豐田普銳斯汽車的基本診斷方法;重點(diǎn):使用手持式測試儀進(jìn)行故障診斷難點(diǎn):電動(dòng)汽車故障碼診斷Chapter 6 Trouble Diagnosis and Service of Electric Vehicles 電動(dòng)汽車故障診斷與維護(hù) 6.1 Genera

2、l Trouble Diagnosis Procedure and Safety Equipments 一般故障診斷程序和安全設(shè)備Safety EquipmentsTesting Equipments and Diagnostic ProceduresLeak Monitoring and Testing of Loss of Insulation6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷General Diagnostic Flow and HV system components service safetyPos

3、ition of the main Toyota Prius Hybrid components 回 顧Briefly describe the functions of safety equipments. 簡述安全設(shè)備的功能。 How to test LOI? 怎樣測試絕緣損失?提 問6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷abnormalitybn:mltin.反常,變態(tài)complaint kmplentn.抱怨concludeknklu:dvt.& vi.推斷(出)confirm knf:mvt.確認(rèn)cran

4、k krkvt.起動(dòng)fail-safefel sefn.&adj.故障安全(的),失效保護(hù)New Words and Phrases6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷insufficientnsfntadj.不足的interphase ntfezn.相間的malfunctionmlfknn.故障,失靈meggermegn.高阻表,搖表pertainptenvi.有關(guān),附屬,從屬pinpointpnpntvt.確定removalrmu:vln.除去,移走6.2 Toyota Prius Hybrid Troubl

5、e Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷resolverrzlvn.解析器resortrz:tn.應(yīng)急措施retrievertri:vvt.取回,恢復(fù)stressstresn.強(qiáng)調(diào),壓力,應(yīng)力subset sbsetn.子集,子系統(tǒng)swing swn.擺動(dòng),擺程,振幅symptomsmptmn.癥狀,征兆6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷active test主動(dòng)測試associated with與有關(guān)的freeze frame凍結(jié)數(shù)據(jù)幀hand-held tester手持式檢測儀in ser

6、ies 串聯(lián)megger tester絕緣測試儀motor generator(MG)電動(dòng)機(jī)/發(fā)電機(jī)總成6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷one more time再一次open circuit斷路short circuit短路,短接smart key智能鑰匙stall test 失速試驗(yàn)wiring harness線束6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷6.2.3 The Diagnosis of Toyota Prius Hy

7、brid HV Battery system Battery Pack Components In the battery pack, six nickel metal hydride type 1.2V cells are connected in series to form one module, therefore, one module equals 6.2 volts, 38 modules were installed in series producing 273.6V. In the 04 and later Prius, 28 modules are connected f

8、or a rated voltage of 201.6V. Prius battery pack contains battery modules, wiring, system main relay (SMR), computer, a manual disconnect service plug, and a strong metal box to contain every thing, as shown in Figure 6.4.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷Figure 6.4 The posi

9、tion and components of HV battery pack6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷The battery ECU calculates the SOC (state of charge) of the HV battery based on voltage, current and temperature. It then sends the results to the HV ECU. The system main relay (SMR) (Figure 6.5) connect

10、s and disconnects the power source of the high-voltage circuit on command from the HV ECU (Figure 6.5). As a result, the proper charge and discharge control is performed. This system also controls the battery blower motor controller in order to maintain a proper temperature at the HV battery assembl

11、y.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷Figure 6.5 The HV battery pack connecting circuit6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷 HV Battery Diagnosis Since the battery modules are all connected in series, a poor connection at any of the modules can lead to HV

12、 battery failure. For this reason, cleanliness of the connections and proper torque on the module fasteners is critical with these battery designs. A factory scan tool can be used for diagnosing problems that may be related to the high-voltage battery. Toyota high-voltage battery packs have a specia

13、l wiring harness that allows measurement of the voltage available across pairs of battery modules. 6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷These voltage readings can be read as parameter identification (PID) on a scan tool. If the onboard computer recognizes a problem in a module,

14、 wiring, or anything that could cause a potential problem, the MIL is illuminated, a code is set, and a freeze frame is stored. The battery pack may be limited in its power output or charging capacity and, as a last resort, the vehicle may be shut down.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯

15、混合動(dòng)力電動(dòng)汽車故障診斷 Using the hand-held tester, you can read the value of the switches, sensors, actuators and so on without parts removal. Diagnose the HV battery pack using the tester as the following steps: Connect the hand-held tester to the DLC3. Turn the power switch ON (IG). Turn the hand-held teste

16、r ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD / HV ECU. Select DTC INFO, Read the DTCs, FREEZE FRAME data (Figure 6.6) and the INFORMATION CODEs (Figure 6.7).Figure 6.6 Using a tester, read DTCs and FREEZE FRAME dataFigure 6.7 Using a tester, read the DTCs and IN

17、FORMATION CODEsThe DTCs of the HV battery pack is listed in Table 6.1.Table 6.1 Toyota Prius Hybrid HV Battery System DTCs (01-03 Prius)DTCDescriptionDTC P3006Battery SOC UnevenThe charging rate of each battery is monitored through the battery voltage detection line. Drive the vehicle under load whi

18、le viewing the Min/Max voltage on the Diagnostic Tester. For example, drive up a steep hill very slowly. This kind of load stresses the battery and will allow detection of weak modules.If P3006 is the only DTC, refer to the Repair Manual to do a stall test. Monitor the swing and the difference in vo

19、ltage between the data MAX V and MIN V.DTC P3076Abnormal Battery Cooling Fan Air Flow If foreign matter clogs the duct, the HV battery might not be able to cool sufficiently. Insufficient cooling will cause the output control warning light to illuminate and may cause DTC P3076.A flesh air duct permi

20、ts the flow of cooling air when the vehicle is stopped after driving. When washing the car, do not allow large quantities of water to enter the duct.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷6.2.4 The Diagnosis of Toyota Prius Hybrid Control System Reading Diagnostic Trouble Codes a

21、nd Information The procedures to read the DTCs and freeze frame data has described in the previous HV Battery Diagnosis section. Information Codes are some three-digit subset of codes that provide data pertaining to HV ECU DTCs. They provide additional information and freeze frame data to help diagn

22、ose the vehicles condition. The diagnostic trouble codes of Toyota Prius hybrid control system are listed in the Table 6.2.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷Table 6.2 Toyota Prius Hybrid HV Control System DTCsDTCDescriptionDTC P0A4BGenerator Position Sensor Circuit(04 & late

23、r Prius)DTC P0A4B will set when the HV ECU detects output signals that are out of normal range or specification concluding that there is a malfunction of the generator resolver (speed sensor). The following Information Codes can help isolate the problem: 253 - Interphase short in resolver circuit 51

24、3 - Resolver output is out of range 255 - Open or short in resolver circuitDTC P1525Resoiver Malfunction(01 & 03 Prius)DTC P1525 will set when vehicle speed signals are not input from the resolver (speed sensor) for 16 seconds or more while running at a speed of 20km/h or more. The trouble areas cou

25、ld include the ECM, HV ECU or wire harness.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷Accessing Operation History Data Sometimes symptoms caused by the customers driving habits may be mistaken for problems in the Prius. Operation History Data can be used for explaining that these sym

26、ptoms may not indicate problems. It also can be used to view the driving patterns of the customer so that the concern can be diagnosed and fixed.6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷 To view operation history data, the diagnostic tester is operated as follows: Connect the diagn

27、ostic tester to the DLC3. Turn the power switch ON (IG). Enter the following menus(Figure 6.8): DIAGNOSIS / ENHANCED OBD II HV ECU DATA LIST. Select the menu to view the number of special operations or controls that have been affected. See Figure 6.8. Example of diagnostic tester displays is shown i

28、n the Table 6.3. For more operation history data, refer to the Appendix 1 at the back of this book.Figure 6.8 Accessing Operation History Data6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷Table 6.3 Operation History Data6.2 Toyota Prius Hybrid Trouble Diagnosis 豐田普銳斯混合動(dòng)力電動(dòng)汽車故障診斷 Accessing Active Tests Some useful HV ECU active

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