xxi Chapter 27 Hybrid Drive Systems Diagnosis and Repair . . . . . . . . . . . . . . . . . . . . . . 453 Hybrid Problem Diagnosis. . . . . . . . . . . . . . . .453 Hybrid Service Safety. . . . . . . . . . . . . . . . . . . .454 Remove Jewelry. . . . . . . . . . . . . . . . . . . . . . . .454 Wear Eye Protection. . . . . . . . . . . . . . . . . . . . .454 Wear Insulating Gloves . . . . . . . . . . . . . . . . . .454 Wear Rubber-Soled Shoes. . . . . . . . . . . . . . . .454 Keep a Fire Extinguisher Nearby . . . . . . . . . . .455 Follow Towing Safety Procedures. . . . . . . . . . .456 Disable the Hybrid Drive when Working. . . . . .456 Set Up a High-Voltage Buffer Zone . . . . . . . . .456 Remove the High-Voltage Disconnect . . . . . . .456 HV Battery Service . . . . . . . . . . . . . . . . . . . . . .458 Diagnosing HV Battery Problems . . . . . . . . . . .458 Checking HV Battery Relays and Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . .458 HV Power Cable Service . . . . . . . . . . . . . . . . .459 HV Power Control Module Service . . . . . . . . .460 HV Power Control Module Replacement . . . . .461 Hybrid Cooling System Service . . . . . . . . . . .462 Motor-Generator Service . . . . . . . . . . . . . . . . .463 Testing a Motor-Generator . . . . . . . . . . . . . . . .464 Removing and Installing a Motor-Generator. . .465 Hybrid Wiring Problems . . . . . . . . . . . . . . . . . .467 Chapter 28 12-Volt and HV Battery Technology . . 471 Battery Principles . . . . . . . . . . . . . . . . . . . . . . .471 Basic Battery Cell . . . . . . . . . . . . . . . . . . . . . . .472 Battery Functions . . . . . . . . . . . . . . . . . . . . . . .472 12-Volt Batteries . . . . . . . . . . . . . . . . . . . . . . . .473 12-Volt Battery Construction. . . . . . . . . . . . . . . 474 12-Volt Battery Cables . . . . . . . . . . . . . . . . . . .475 Battery Tray and Retainer . . . . . . . . . . . . . . . . .476 12-Volt Battery Types . . . . . . . . . . . . . . . . . . . .476 12-Volt Battery Ratings. . . . . . . . . . . . . . . . . . .477 Battery Temperature and Efficiency . . . . . . . . .477 HV Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . .477 HV Battery Construction. . . . . . . . . . . . . . . . . .478 HV Battery ECM. . . . . . . . . . . . . . . . . . . . . . . .480 HV Power Cables . . . . . . . . . . . . . . . . . . . . . . .481 HV Battery Ratings. . . . . . . . . . . . . . . . . . . . . .481 HV Capacitor Banks . . . . . . . . . . . . . . . . . . . . .482 Fuel Cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482 Flywheel Generator . . . . . . . . . . . . . . . . . . . . .483 Chapter 29 12-Volt and HV Battery Service. . . . 487 12-Volt Battery Maintenance . . . . . . . . . . . . . .487 12-Volt Battery Service. . . . . . . . . . . . . . . . . . .488 12-Volt Battery Leakage Test . . . . . . . . . . . . . .488 12-Volt Battery Terminal Test . . . . . . . . . . . . . .488 Checking 12-Volt Battery Electrolyte Level . . . .490 Checking 12-Volt Battery Charge . . . . . . . . . . .491 Discharged 12-Volt Battery. . . . . . . . . . . . . . . .493 Battery Drain Test . . . . . . . . . . . . . . . . . . . . . . .494 12-Volt Battery Chargers . . . . . . . . . . . . . . . . .494 Charging a 12-Volt Battery . . . . . . . . . . . . . . . .495 12-Volt Jump Starting . . . . . . . . . . . . . . . . . . . .496 12-Volt Battery Load Test . . . . . . . . . . . . . . . . .497 Activating Dry-Charged 12-Volt Batteries . . . . .498 Removing and Installing a 12-Volt Battery . . . .499 HV Battery Service . . . . . . . . . . . . . . . . . . . . . .499 Hybrid Jump Starting . . . . . . . . . . . . . . . . . . . .500 Checking HV Battery Condition . . . . . . . . . . . . 501 Testing HV Battery Voltage. . . . . . . . . . . . . . . . 501 Charging an HV Battery . . . . . . . . . . . . . . . . . .502 HV Battery Load Test Drive . . . . . . . . . . . . . . .502 In-Shop HV Battery Load Test . . . . . . . . . . . . .503 HV Battery Removal and Replacement . . . . . .504 HV Cable Connections Service . . . . . . . . . . . .506 HV Battery Control Module Service . . . . . . . .507 Chapter 30 Engine Starting Systems. . . . . . . . . . 511 12-Volt Starting System Principles . . . . . . . . .512 Starting System Action . . . . . . . . . . . . . . . . . . .512 Starting Motor Fundamentals . . . . . . . . . . . . .512 Simple Electric Motor . . . . . . . . . . . . . . . . . . . .512 Changing Electricity into Motion. . . . . . . . . . . .513 Increasing Motor Power . . . . . . . . . . . . . . . . . .513 12-Volt Starting Motor Construction. . . . . . . .513 Armature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514 Field Windings . . . . . . . . . . . . . . . . . . . . . . . . .514 Field Magnets. . . . . . . . . . . . . . . . . . . . . . . . . .514 Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .515 Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .515 Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . .516 Reduction Gearing . . . . . . . . . . . . . . . . . . . . . .517 12-Volt Starting Motor Types . . . . . . . . . . . . . .517 12-Volt Neutral Safety Switch . . . . . . . . . . . . .517 Neutral Safety Switch Operation . . . . . . . . . . .517 12-Volt Starter Relay. . . . . . . . . . . . . . . . . . . . .518 Starter Relay Operation . . . . . . . . . . . . . . . . . .519