Руководство по ремонту автомобилей HYBRID - Toyota (EN)

HYBRID SYSTEMS FOR COLLISION REPAIR Course 601 Technician Handbook © 2013 Toyota Motor Sales, U.S.A., Inc. TOYOTA Technical Training All rights reserved. This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc. Revision Date: July 12, 2013

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Table of Contents 601 Hybrid Systems for Collision Repair Hybrid Systems for Collision Course Overview ................................................................................... 1 Course Topics ...................................................................................... 3 Repair Section 1: Hybrid System Section 1 – Hybrid System ................................................................... 5 Hybrid System Components ................................................................. 6 Engine ..............................................................................................

6 Hybrid Transaxle .............................................................................. 6 Inverter Assembly ............................................................................. 6 HV Battery ........................................................................................ 7 Frame Wire ....................................................................................... 7 HV EVU ............................................................................................ 7 ECM ..................................................................................................

7 Skid Control ECU ............................................................................. 7 Engine .................................................................................................. 8 Electric Water Pump ......................................................................... 8 Inspection Mode ............................................................................... 8 Air Conditioning .................................................................................... 9 Electric A/C Compressor .................................................................. 9 PTC Heater .......................................................................................

9 Hybrid Transaxle ................................................................................ 10 MG1 .................................................................................................... 11 MG2 .................................................................................................... 12 Compound Gear Unit .......................................................................... 13 HV Battery .......................................................................................... 14 Battery Cells ...................................................................................

14 Service Plug ................................................................................... 14 System Main Relays ....................................................................... 14 Battery Smart Unit .......................................................................... 14 Cooling Fan .................................................................................... 14 HV Battery Cooling System ................................................................ 15 Auxiliary Battery Service ..................................................................... 16 Charging .........................................................................................

16 Jump Start ...................................................................................... 16 Testing ............................................................................................ 16 Neutralizing Electrolyte Spills ............................................................. 17 NiMH ............................................................................................... 17 Li-ion ............................................................................................... 17 Inverter and Cooling System ..............................................................

18 Shift Positions ..................................................................................... 20 B Range .......................................................................................... 20 Power Modes ...................................................................................... 21 HV System OFF ................................................................................. 22 System Faults ................................................................................. 22 DTCs & Self-Check ........................................................................ 22 Service Plug ...................................................................................

22 Collision Repair & Refinish Training i

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Table of Contents 601 Hybrid Systems for Collision Repair HV System READY ............................................................................ 23 Alternate Power OFF Procedures ...................................................... 24 State of Charge .................................................................................. 25 Hybrid System Control Modes ............................................................ 26 Ready ............................................................................................. 27 Starting Out ....................................................................................

28 Engine Starting ............................................................................... 29 Light Acceleration ........................................................................... 30 Constant-Speed Cruise .................................................................. 31 Full Acceleration ............................................................................. 32 Deceleration ................................................................................... 33 Reverse .......................................................................................... 34 Drive Modes .......................................................................................

35 EV Mode ......................................................................................... 35 ECO Mode ...................................................................................... 35 PWR Mode ..................................................................................... 35 Underhood .......................................................................................... 36 Coolant Heat Storage ......................................................................... 37 Inverter Connections .......................................................................... 38 Inverter Assembly ...............................................................................

39 Inverter ........................................................................................... 39 Boost Convertor .............................................................................. 39 DC-DC Converter ........................................................................... 39 MG ECU ......................................................................................... 39 Drive ................................................................................................... 40 Power Generation ...............................................................................

41 Regeneration ...................................................................................... 42 Aux. Batt. Recharge ........................................................................... 43 A/C Operation ..................................................................................... 44 Rear Compartment ............................................................................. 45 4WD Hybrids ...................................................................................... 46 Brakes ................................................................................................

47 Input ................................................................................................ 47 Processing ...................................................................................... 47 Output ............................................................................................. 47 Backup Power Supply .................................................................... 47 Electric Power Steering (EPS) ............................................................ 48 Step Up Systems ............................................................................ 48 Step Down Systems .......................................................................

48 Prius PHV ........................................................................................... 49 Charging Indicator .......................................................................... 49 Lithium-ion Battery .......................................................................... 49 Vehicle Proximity Notification System ............................................ 49 ii Collision Repair & Refinish Training

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Table of Contents 601 Hybrid Systems for Collision Repair Section 2: TIS Section 2 – TIS ................................................................................... 51 TIS Login ............................................................................................ 52 Home Page ......................................................................................... 54 Library Search .................................................................................... 55 Keyword Search ............................................................................. 55 Search Results ...................................................................................

56 Quick Training Guide .......................................................................... 57 Repair Plan ......................................................................................... 58 Section 3: Techstream Section 3 – Techstream ...................................................................... 59 Techstream ......................................................................................... 60 Connecting Techstream ..................................................................... 61 Vehicle Features .................................................................................

62 Vehicle ECUs ................................................................................. 62 System Features ................................................................................ 63 Health Check Setup ............................................................................ 64 Health Check Results ......................................................................... 65 Data List ............................................................................................. 66 Active Test ..........................................................................................

67 Utility ................................................................................................... 68 Section 4: High-Voltage Section 4 – High-Voltage Safety ......................................................... 69 High-Voltage Caution ......................................................................... 70 Make a Repair Plan ............................................................................ 71 Prepare Yourself .................................................................................. 72 Health Check ......................................................................................

73 Turn OFF and Secure Key ................................................................. 74 Disconnect Aux. Battery ..................................................................... 75 Personal Protective Equipment (PPE) ................................................. 76 Safety Inspection ....................................................................................... 76 Protection ....................................................................................... 76 Storage ........................................................................................... 76 Replacement ..................................................................................

76 Remove Service Plug ......................................................................... 77 Wait 10 Minutes .................................................................................. 78 Worksheet Review .............................................................................. 80 Conclusion .......................................................................................... 81 Collision Repair & Refinish Training i

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