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1、本章学习内容本章学习内容本章学习目标本章学习目标本章难点重点本章难点重点6.1 General Trouble Diagnosis Procedure and Safety Equipments 一般故障诊断程序和安全设备一般故障诊断程序和安全设备 6.2 Toyota Prius Hybrid Trouble Diagnosis丰田丰田普锐斯混合动力电动汽车故障诊断普锐斯混合动力电动汽车故障诊断1. 掌握电动汽车一般诊断程序；掌握电动汽车一般诊断程序；2. 掌握丰田普锐斯汽车的基本诊断方法；掌握丰田普锐斯汽车的基本诊断方法；重点：使用手持式测试仪进行故障诊断重点：使用手持式测试仪进行故障诊断
2、难点：难点：电动汽车故障码诊断电动汽车故障码诊断Chapter 6 Trouble Diagnosis and Service of Electric Vehicles 电动汽车故障诊断与维护电动汽车故障诊断与维护 6.1 General Trouble Diagnosis Procedure and Safety Equipments 一般故障诊断程序和安全设备一般故障诊断程序和安全设备Safety EquipmentsTesting Equipments and Diagnostic ProceduresLeak Monitoring and Testing of Loss of Insu
3、lation6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电丰田普锐斯混合动力电动汽车故障诊断动汽车故障诊断General Diagnostic Flow and HV system components service safetyPosition of the main Toyota Prius Hybrid components 回回 顾顾oBriefly describe the functions of safety equipments. 简述安全设备的功能。简述安全设备的功能。 oHow to test LOI？ 怎样测试怎
4、样测试绝缘损失？绝缘损失？提提 问问6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断abnormalitybn:mltin.反常，反常，变态complaint kmplentn.抱怨抱怨concludeknklu:dvt.& vi.推断推断(出出)confirm knf:mvt.确确认crank krkvt.起起动fail-safefel sefn.&adj.故障安全（的），失故障安全（的），失效保效保护New Words and Phrases6.2 Toyota Prius Hybrid
5、 Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断insufficientnsfntadj.不足的不足的interphase ntfezn.相相间的的malfunctionmlfknn.故障，失灵故障，失灵meggermegn.高阻表，高阻表，摇表表pertainptenvi.有关，附有关，附属，从属属，从属pinpointpnpntvt.确定确定removalrmu:vln.除去，移走除去，移走6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车
6、故障诊断resolverrzlvn.解析器解析器resortrz:t n.应急措施急措施retrievertri:vvt.取回，恢取回，恢复复stressstresn.强强调，压力，力，应力力subset sbsetn.子集，子系子集，子系统swing sw n.摆动，摆程，程，振幅振幅symptomsmptmn.症状，征兆症状，征兆6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断active test主主动测试associated with与与有关的有关的freeze frame冻结数据数
7、据帧hand-held tester手持式手持式检测仪in series 串串联megger tester绝缘测试仪motor generator（MG）电动机机/发电机机总成成6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断one more time再一次再一次open circuit断路断路short circuit短路，短接短路，短接smart key智能智能钥匙匙stall test 失速失速试验wiring harness线束束6.2 Toyota Prius Hybrid Tro
8、uble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断6.2.3 The Diagnosis of Toyota Prius Hybrid 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 inst
9、alled in series producing 273.6V. In the 04 and later Prius, 28 modules are connected for 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 Fi
10、gure 6.4.6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断Figure 6.4 The position and components of HV battery pack6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断The battery ECU calculates the SOC (state of charge) of the HV battery based on vo
11、ltage, current and temperature. It then sends the results to the HV ECU. The system main relay (SMR) (Figure 6.5) connects 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 sys
12、tem also controls the battery blower motor controller in order to maintain a proper temperature at the HV battery assembly.6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断Figure 6.5 The HV battery pack connecting circuit6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电
13、动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断 HV Battery Diagnosis Since the battery modules are all connected in series, a poor connection at any of the modules can lead to HV battery failure. For this reason, cleanliness of the connections and proper torque on the module fasteners is critical with these battery design
14、s. 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 special wiring harness that allows measurement of the voltage available across pairs of battery modules. 6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐
15、斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断These voltage readings can be read as parameter identification (PID) on a scan tool. If the onboard computer recognizes a problem in a module, wiring, or anything that could cause a potential problem, the MIL is illuminated, a code is set, and a freeze frame is stored.
16、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 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断 Using the hand-held tester, you can read the value of the switches, sensors, actuators and so on w
17、ithout 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 tester ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD / HV ECU. Select DTC INFO, R
18、ead 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 INFORMATION CODEsThe DTCs of the HV battery pack is listed in Table 6.1.Table 6.1 Toyota Prius Hybrid HV Battery
19、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 while viewing the Min/Max voltage on the Diagnostic Tester. For example, drive up a steep hill very slowly. This k
20、ind 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 voltage between the data MAX V and MIN V.DTC P3076Abnormal Battery Cooling Fan Air Flow If foreign matter clogs t
21、he 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 permits the flow of cooling air when the vehicle is stopped after driving. When washing the car, do not allow large
22、quantities of water to enter the duct.6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断6.2.4 The Diagnosis of Toyota Prius Hybrid Control System Reading Diagnostic Trouble Codes and Information The procedures to read the DTCs and freeze frame data has described in the prev
23、ious 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 diagnose the vehicles condition. The diagnostic trouble codes of Toyota Prius hybrid control system
24、 are listed in the Table 6.2.6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断Table 6.2 Toyota Prius Hybrid HV Control System DTCsDTCDescriptionDTC P0A4BGenerator Position Sensor Circuit(04 & later Prius)DTC P0A4B will set when the HV ECU detects output signals that are ou
25、t 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 513 - Resolver output is out of range 255 - Open or short in resolver circuitDT
26、C 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 could include the ECM, HV ECU or wire harness.6.2 Toyota Prius Hybrid Trouble Di
27、agnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断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 symptoms may not indicate problems. It also can be used to view
28、 the driving patterns of the customer so that the concern can be diagnosed and fixed.6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断 To view operation history data, the diagnostic tester is operated as follows: Connect the diagnostic tester to the DLC3. Turn the power sw
29、itch 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 in the Table 6.3. For more operation history
30、 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 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断Table 6.3 Operation History Data6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电动丰田普锐斯混合动力电动汽车故障诊断汽车故障诊断 Accessing Active
31、 Tests Some useful HV ECU active tests can be performed by using the diagnostic tester. Operate the tester, enter Diagnostic Menu and Active Test, and select the Inverter Stop mode. This mode can be used to determine if there is an internal leak in the inverter or the HV control ECU. The test condit
32、ion is power switch ON (IG), P position, HV system normal, inverter actuation not being disabled, shutting down inverter, and other active tests not being executed. In this mode, keep the inverter power transistor actuation ON.6.2 Toyota Prius Hybrid Trouble Diagnosis 丰田普锐斯混合动力电丰田普锐斯混合动力电动汽车故障诊断动汽车故
33、障诊断General Diagnostic Flow and HV system components service safetyPosition of the main Toyota Prius Hybrid componentsThe Diagnosis of Toyota Prius Hybrid HV Battery systemThe Diagnosis of Toyota Prius Hybrid Control System 小小 结结作业作业oHow to Use the hand-held tester to diagnose the HV battery pack?怎样使用手持式怎样使用手持式测试仪（解码器）来诊断高压电池的故障？测试仪（解码器）来诊断高压电池的故障？oHow to Read Diagnostic Trouble Codes and Information ？ 怎样读取故障码和故障信息怎样读取故障码和故障信息？
