Hybrid Vehicle Operation and Diagnosis Training
Hybrid Vehicle
Operation and Diagnosis
Course Code 30N10T1
Hybrid Vehicle Operation and Diagnosis Training
Instructor Information
Instructor Name Here
 Instructor email information here

Hybrid Vehicle Operation and Diagnosis Training
Course Description
Two Day Course
 Designed to provide students with hands-on
activities to learn and improve their skills on
hybrid vehicles.
 All classroom activities are guided by worksheets.

Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Requirements

Hybrid Vehicle Training Web Course 30N26W1
Hybrid Vehicle Operation and Diagnosis Training
Course Requirements
Each student will complete a written post test that
will require a minimum score of 80% to pass
 Each student will complete a pass or fail hands on
evaluation

Hybrid Vehicle Operation and Diagnosis Training
Course Objectives
Describe Ford and Lincoln-Mercury Hybrid
Vehicle Components and Operation
 Describe unique hybrid vehicle safety procedures
 Perform visual inspections and selected tests on
various hybrid vehicle components
 Diagnose hybrid vehicle performance concerns
 Perform tests to verify hybrid vehicle concerns
and identify causes of these concerns
 Perform hybrid vehicle service procedures

Hybrid Vehicle Operation and Diagnosis Training
Course Agenda

LESSON ONE:
– Introductions, Safety Briefing, Prerequisite Review,
Lesson 1 Workstations

LESSON TWO
– Lesson 2 Workstation Reviews, Lesson 2 Workstations,
Final Review, Post-Test
Hybrid Vehicle Operation and Diagnosis Training
History of Ford Electric and
Hybrid Vehicles
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
1. What components are cooled by the M/E cooling
system?



The TCM
eCVT
DC/DC Converter
Hybrid Vehicle Operation and Diagnosis Training
ME Cooling System
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
2.
What internal engine components are unique on
the Hybrid gasoline engine, and why?
The intake camshaft is unique because the engine
uses the Atkinson cycle. Pistons are domed to create
higher compression.
Hybrid Vehicle Operation and Diagnosis Training
Unique Engine Components
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
3.What is the function of the DC/AC inverter?
A. To reduce HV battery voltage to charge the low
voltage battery.
B. To convert 12 volt DC voltage to 110 AC voltage.
C. To convert 330 or 275 DC voltage (vehicle
dependant) to 110 AC voltage.
D. There is no DC/AC inverter on hybrid vehicles.
Hybrid Vehicle Operation and Diagnosis Training
DC/AC Inverter
2010 Fusion/Milan
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
4.
What type of cooling system does the
Fusion/Milan use to cool the HV battery?
A. Cabin air drawn into the battery compartment by a fan.
B. An AUX A/C system that is connected to the air
conditioning system.
C. An independent A/C system that is driven by the
gasoline engine.
D. A fan that draws outside air into the battery
compartment.
Hybrid Vehicle Operation and Diagnosis Training
Battery Pack Cooling
 Fusion/Milan
HVBP Cooling Fan
Hybrid Vehicle Operation and Diagnosis Training
Battery Pack Cooling
 Escape/Mariner
AUX A/C HVBP
Cooling System
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
5.

Where is the HV fuse located on both the
Escape/Mariner and Fusion Milan?
The HV fuse is located inside the service disconnect
switch on both vehicles
Hybrid Vehicle Operation and Diagnosis Training
Service Disconnect Switches
On the Fusion/Milan it is located
beneath the rear passenger seat
on the battery case
On the Escape Mariner it is
located on the battery case
beneath the rear battery cover
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
6.
Which of the functions listed below is
performed by the shift cable?
A. Engages the eCVT in Drive.
B. Engages the eCVT in Reverse.
C. Engages the parking pawl.
D. All of the above.
Hybrid Vehicle Operation and Diagnosis Training
Hybrid TR Sensor
Fusion /Milan TR Sensor
Escape/Mariner TR Sensor
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
7.
Which components are part of the hybrid vehicle
high voltage system?
Hybrid Vehicle Operation and Diagnosis Training
Traction Battery
Fusion/Milan HVBP
 Traction
Escape/Mariner HVBP
Battery also called High Voltage
Battery Pack (HVBP)
Hybrid Vehicle Operation and Diagnosis Training
eCVT
 Traction
Motor/Generator Motor called
the Electronic Continuously Variable
Transmission (eCVT)
Hybrid Vehicle Operation and Diagnosis Training
High Voltage Cables
 High
Voltage (Orange) Cables
Hybrid Vehicle Operation and Diagnosis Training
DC/DC Converter
Fusion/Milan DC/DC
Converter
 DC/DC
Converter
Escape/Mariner DC/DC
Converter
Hybrid Vehicle Operation and Diagnosis Training
Electric A/C Compressor
 Electric
A/C Compressor (if equipped)
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
8.
What measures were taken in the design of
hybrid vehicles to prevent current leakage from
the HV battery?
There is no ground between the HV battery and the
vehicle chassis
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
9.
A.
B.
C.
D.
What type of EPAS systems can be found on
hybrid vehicles?
Remote PSCM rack-type system
Column mounted EPAS system
Rack mounted PSCM EPAS system
All of the above.
Hybrid Vehicle Operation and Diagnosis Training
EPAS Systems on Hybrids
 Insert
photos of EPAS systems
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
10.
What is the purpose of the regenerative braking
system?
Regenerative braking converts energy that would
otherwise be lost to friction, into voltage that is sent
to the HV battery
Hybrid Vehicle Operation and Diagnosis Training
Regenerative Braking
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
11.
What unique information is displayed on the
Escape/Mariner Hybrid tachometer?
Not only does the tach display gasoline engine rpm,
but also indicates when the vehicle is operating on
electric power only
Hybrid Vehicle Operation and Diagnosis Training
Escape/Mariner Tachometer
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
12.
A.
B.
C.
D.
Where is the gasoline engine starter motor
located on a hybrid vehicle?
At the rear of the engine lower right side
It is integrated into the FEAD system
Near the front left side of the engine
None of the above
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
13.
A.
B.
C.
D.
What control module adjusts the contributions of
the gasoline engine, the traction motor and
generator during hybrid operation?
PCM
TCM
BCM
PSCM
Hybrid Vehicle Operation and Diagnosis Training
TCM/eCVT OPERATION
Gasoline Engine
Connected to
Planetary Carrier
Transaxle Control
Module (TCM)
adjusts
contribution of
each by changing
speed and direction
of planetary
sun gear
Traction Motor
Connected to
Planetary
Ring Gear
Generator
Connected to
Planetary
Sun Gear
Hybrid Vehicle Operation and Diagnosis Training
TCM/eCVT OPERATION
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
14.
A.
B.
C.
D.
The A/C compressor on a 2008 Escape/Mariner
hybrid vehicle is _________________ (select
the best answer from the list below).
Driven by the FEAD of the gasoline engine
A swashplate type pump
Electrically driven
A scroll type pump
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
15.
A.
B.
C.
D.
What is the function of the high voltage
interlock ?
To prevent the vehicle from being started in any gear but
Park of Neutral..
To disable the high voltage system if any HV connectors
are disconnected.
To prevent the vehicle from being placed into gear
without the brake pedal being depressed.
All of the above
Hybrid Vehicle Operation and Diagnosis Training
High Voltage Interlock Circuit
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
16.

What is the service interval for the air cleaner on
the 2010 Fusion/Milan?
Lifetime so there is no service interval
Hybrid Vehicle Operation and Diagnosis Training
2010 Fusion/Milan Air Filter
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
17.
A.
B.
C.
D.
When the service disconnect switch is removed
from a Fusion/Milan Hybrid vehicle, which of
the following components will still have highvoltage current running to them (select all that
apply)?
The BPSM
The BECM
The DC/DC Converter
The High-Voltage Low-Current Fuse
Hybrid Vehicle Operation and Diagnosis Training
Battery Pack Sensor Module
(BPSM)
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
18.
A.
B.
C.
D.
What system provides power to the A/C
compressor on the Fusion/Milan Hybrid?
The high-voltage high-current system
The 12-volt system
The high-voltage low-current system
The gasoline engine
Hybrid Vehicle Operation and Diagnosis Training
High-Voltage Low-Amperage
System
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
19.
What component on the Fusion/Milan hybrid
performs the same function as the inertia switch
on the Escape/Mariner Hybrid?
The Restraints Control Module (RCM)
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
20.
A customer needs information on the operation
of the instrument cluster in their 2010 Fusion.
Where can you direct them to get an interactive
tutorial for the operation if the IC?

The IC has a tutorial feature that explains the
operation and interpretation of the IC gauges
and symbols
Hybrid Vehicle Operation and Diagnosis Training
Fusion/Milan Instrument
Cluster (IC)
 Insert
art of menu on IC
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
21.
A.
B.
C.
D.
What type of conventional brake system is used
on 2009 MY and later Escape/Mariner and 2010
Fusion/Milan Hybrids?
Simulation Brake Activation system
Electronic Hydraulic Brake system
Hydro Boost
Hydro Max
Hybrid Vehicle Operation and Diagnosis Training
Simulation Brake Activation
(SBA)
Hybrid Vehicle Operation and Diagnosis Training
Prerequisite Review
22.
A.
B.
C.
D.
What type of conventional brake system is used
on 2005 -2008 Escape/Mariner Hybrids?
Simulation Brake Activation system
Electronic Hydraulic Brake system
Hydro Boost
Hydro Max
Hybrid Vehicle Operation and Diagnosis Training
Electronic Hydraulic Brakes
(EHB)
Hybrid Vehicle Operation and Diagnosis Training
High Voltage Safety
Hybrid Vehicle Operation and Diagnosis Training
Hybrid Electrical Safety Training
 High
Voltage Warning Label
Hybrid Vehicle Operation and Diagnosis Training
Battery System Warnings
 Batteries
produce EXPLOSIVE gases
 Ni-MH Batteries
– Contain Potassium Hydroxide
– Avoid Skin, Eyes, Respiratory Contact
 High
Voltage Component Repair
– ONLY done by trained Personnel
Hybrid Vehicle Operation and Diagnosis Training
High Voltage Hazards

Hazard One: Electric Shock
Muscle Contraction
Fibrillation
Tissue Damage
Hybrid Vehicle Operation and Diagnosis Training
High Voltage Hazards
Hazard Two: Arcing

–
–
The primary danger of this hazard is the burn
that a person can receive. The heat at each
end of an arc reaches up to and beyond
35,000°F.
Arcing can result in insulation damage,
melting of conductors, and the vaporization
of metal.
Hybrid Vehicle Operation and Diagnosis Training
High Voltage Hazards
Hazard Three: Blast

–
Electric blast is the pressure expansion caused
by an arc. The expansion is actually the rapid
heating of the surrounding air and the boiling
of a metal, usually copper. Both expand at
incredible proportions under the intense heat
of an arc. Copper expands by a factor of
67,000 when vaporized.
Hybrid Vehicle Operation and Diagnosis Training
Electrical Accidents
 Unsafe
Equipment or Installation
 Unsafe Work Areas
 Unsafe Acts by Workers
Hybrid Vehicle Operation and Diagnosis Training
Driver Response to Accident
If possible, carry out the following steps in the event of a
collision, fire or some other emergency situation. However,
never endanger yourself or others who are near the vehicle.
1. Stop and put the gear selector in the Park (P) position.
2. Turn the ignition switch to the OFF position and
remove the key.
3. Set the parking brake.
4. Exit the vehicle.
5. Contact crash/fire/rescue emergency personnel and
inform them of the type of vehicle (Hybrid) and the
nature of the emergency.
Hybrid Vehicle Operation and Diagnosis Training
Accident Prevention
 Buffer
Zone
Hybrid Vehicle Operation and Diagnosis Training
Accident Prevention
 High
Voltage Safety Gloves
Hybrid Vehicle Operation and Diagnosis Training
Glove Suppliers
 Reed
City Power Line Supply
420 S Roth St
Reed City, MI 49677
231-832-2297
Hybrid Vehicle Operation and Diagnosis Training
Accident Prevention
 Face
Shield
Hybrid Vehicle Operation and Diagnosis Training
Accident Prevention
 Safety
Hook
Hybrid Vehicle Operation and Diagnosis Training
Accident Prevention
 See
list 1 through 34 in Student Guide
Hybrid Vehicle Operation and Diagnosis Training
First Aid Procedures
 First
Aid for Electric Shock
 Cardio-Pulmonary Resuscitation
(CPR)
When to Use CPR
Where to Get CPR Training
Hybrid Vehicle Operation and Diagnosis Training
Fire Prevention
 Shop
Cleanliness
 Fire Resistant Storage Compartments
 Keep Flammable Material Away
Liquids, Rags, Cleaning Solvents, Etc…
Hybrid Vehicle Operation and Diagnosis Training
Classes of Fire
 Class
A
– Typical Fire
 Class
B
– Chemical Fire
 Class
C
– Electrical
Hybrid Vehicle Operation and Diagnosis Training
Types of Fire Extingushers
 Types
–
–
–
–
of Fire Extinguishers
Water
Regular Dry Chemical
Multi-Purpose Dry Chemical
Carbon Dioxide (CO2)
Hybrid Vehicle Operation and Diagnosis Training
Fire Extinguisher Ratings
 Light
Hazard 2A, 5B:C or greater
(possibility of small fires)
 Ordinary Hazard
2A, 10B:C or greater
(possibility of moderate fires)
 Extra Hazard 4A, 40B:C or greater
(possibility of severe fires)
Hybrid Vehicle Operation and Diagnosis Training
Emergency Responder
Guides
 Emergency
Responder Guides are available
on the PTS Website
 A copy of the 2010 Fusion/Milan
Emergency Responder Guide can be found
in the back of the student guide.
Hybrid Vehicle Operation and Diagnosis Training
Responder Guides
Hybrid Vehicle Operation and Diagnosis Training
Responder Guides
Hybrid Vehicle Operation and Diagnosis Training
Responder Guides
Hybrid Vehicle Operation and Diagnosis Training
Responder Guides
Hybrid Vehicle Operation and Diagnosis Training
Lesson One
Workstations 1 - 3
Workstation 1
Written– Escape/Mariner
Component Location and Operation
Workstation 2
Hands On – Fusion/Milan
Component Location and Operation
Use CMT Active
Student Program
shortcut to launch the
service information.
Workstation 3
Written
High Voltage Safety Quiz