TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training

TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training TÀI LIỆU ĐÀO TẠO STOP START SYSTEM CITROEN training

Stop and Start AFTER-SALES TECHNICAL TRAINING Ref: C_12229 Date: DD/MM/2010 List of modifications Date Page Reason for modification OBJECTIVES At the end of this training course you should be able to: Situate the changes in the 3rd generation Stop and Start system in relation to the 2nd generation To quote the characteristics of the components of the 3rd generation Stop and Start system To give the functioning phases To work on the 3rd generation Stop and Start system and apply the safety precautions To apply correct maintenance to the Stop and Start system NOTE TO READERS This document is a training support document Consequently, it is strictly for use by the trainees on the training course, and in no way may be used as a service document NOTE TO READERS The present document may not be reproduced or issued without formal authorisation Symbol for a link to the service documentation Symbol for comments on connection hardware Symbol for comments on accessibility Symbol for comments on an important point Symbol for comments on a diagnostic point Symbol for comments on spare parts Symbol for comments on a maintenance or adjustment point Symbol for comments on ecology (Recycling ) CONTENTS Presentation Presentation 2nd generation Stop and Start 2nd generation Stop and Start 3rd3generation Stop and Start 3rd generation Stop Current situation Alternator and Start components Alternator components Battery Battery Central voltage hold device voltage Very high power Central hold device capacitor Starter motor Functioning phases Very high power capacitor Functioning of the UCAP (very high power capacitor) and the DMTC (central voltage hold device) 10 Precautions and safety Precaution and safety 11 Ancillary equipment Maintenance 12 Wiring diagram 13 Maintenance Page deliberately left blank to enable training to start on a right-hand page Do not delete PRESENTATION Today, the 3rd generation Stop and Start system can be fitted to diesel powered vehicles The Peugeot-Citroën policy is to fit all of the range with this new device The "commercial" name is e-HDI Other car makers offer diesel engine vehicles but fitted with a heavy duty starter motor Using a reversible alternator, the "Stop and Start" system enables the immediate cut-off and starting of the engine in certain situations in which the vehicle is stationary (traffic lights, heavy traffic, etc.) The automatic "Stop and Start" function is totally transparent for the driver Other car manufacturers using an automatic stop and restarting system Mini "Auto Start Stop" BMW Series "Auto Star" Toyota "Stop and start system" Fiat "Start/Stop system" PRESENTATION ADVANTAGES OF THE "Stop and Start" Dispense with the idling consumption phases when stationary and automatic re-start of the engine Lower fuel consumption Reduction in CO2 emissions from 5.5 g/km 20 to 30% in a traffic jam to 3.5 g/km to 10% in urban conditions Provides instantaneous starting and restarting with a system which is transparent for the driver Absence of noise and vibration when starting and stopping the engine This transparency is even more appreciable on a diesel engine on which noise and vibration is more difficult to control than on a petrol engine vehicle Notwithstanding the compression ratios normally encountered on today's diesel engines, more starting power is required than for a petrol engine Faster engine starting than with a conventional starter motor In 400 ms, or twice as fast as conventional starting and 40% faster than a heavy duty starter motor REMARKS: A car fitted with a reversible alternator is not a "hybrid" car as the electrical system does not contribute to the vehicle propulsion system The term "micro-hybrid" is more appropriate PRESENTATION Advantages Consumption (l/100 km) 119 gr 5.8 l 109 gr 4.7 l 99 gr 4.3 l Manual box Multimode gearbox STOP&START multimode gearbox Optimisation of savings in terms of fuel consumption When starting, the engine consumes the equivalent of seconds at idle Therefore, with seconds at idle, the system provides a non-negligible fuel savings HISTORY 1998 10 2010 2004 1st generation STT Prototype 2nd generation STT reversible alternator fitted to C2/C3 3rd generation STT reversible alternator New generation The first generation "Stop and Start " system was the prototype of the "Stop and Start" system designed for the Citroën XSARA It was never launched commercially The second generation "Stop and Start " system was fitted only to the C2/C3 with a petrol engine (ET3) and the electronically controlled gearbox In August 2010, the 3rd generation "Stop and Start" system will be fitted to the C5 X7 In September 2010, the new "C4 " and the C4 Picasso and seaters will be fitted with it In 2011, the DS3 and C3 Picasso will be fitted with it The diesel engines are the first to be fitted with the 3rd generation "Stop and Start" systems but certain petrol engine vehicles will be fitted with it in the future STOP AND START FUNCTIONING PHASES 64 Central Voltage Hold Device: Charge cut-off phase - + ENGINE ECU LIN The DC/DC interrupts recharging Battery DC/DC K2 L + K1 VHPC (Very High Power Capacitor) DEM (Starting) ISTARS Network loads 5V - CVHD When the engine is running The central voltage hold device measures the charge status of the very high power capacitor The very high power capacitor is measured re-charged The central voltage hold device controls the following actions: Holds electronic switch K1 always closed Holds electronic switch K2 always open Opening of 12V/ 5V transformer switch The 12V / 5V transformer cuts off recharging of the very high power capacitor The very high power capacitor is ready for use for the next stop/restart function STOP AND START FUNCTIONING PHASES 65 Central Voltage Hold Device: Restarting with the reversible alternator - + ENGINE ECU The DC/DC interrupts the current Battery K2 closes LIN DC/DC K2 L K1 opens + VHPC (Very High Power Capacitor) K1 5V DEM (Starting) ISTARS Network loads - CVHD The engine is restarted by the reversible alternator after a sequence The driver takes his foot off the brake pedal (Multimode transmission - BVMP) or the driver presses the clutch and engages first gear (Manual gearbox) The central voltage hold device receives the restart by the reversible alternator information transmitted over the LIN network The central voltage hold device controls the following actions: Opening of electronic switch K1, Closing of electronic switch K2 Opening of 12V/ 5V transformer switch The reversible alternator activates the transformer function in order to power the stator for the engine function (starter motor) The very high power capacitor is linked in series to the original battery capacity The operation continues until the engine starts The very high power capacitor discharges as starting is activated STOP AND START FUNCTIONING PHASES 66 Central Voltage Hold Device: Driving Phase - + ENGINE ECU The DC/DC interrupts recharging Battery LIN DC/DC K2 L + K1 VHPC (Very High Power Capacitor) 5V - DEM (Starting) ISTARS Network loads CVHD The vehicle has started The engine running signal is transmitted over the LIN multiplexed network The central voltage hold device controls the following actions: Electronic switch K1 closing Electronic switch K2 opening 12V/ 5V transformer switch closing The 12V / 5V transformer is active The very high power capacitor is recharged The system will be operational after the VHP capacitor has recharged PRECAUTIONS AND SAFETY VERY HIGH POWER CAPACITOR 67 The precautions and safety symbols are clearly displayed on the component casing If there are traces of a leak, put into a leakproof sealed bag and wear protective gloves and mask Plastic bag P/N: 9985 - 32 Procedure to follow when carrying out work following: • accident, • if the unit is dropped heavily, • mechanical impact, • casing corroded, holed, • overload of VHP capacitor, • overheating of unit, • polarity inversion Examine the unit external condition for distortion Check there is no leakage of a light brown, very liquid fluid Wear protective gloves (Solvex 37-900) Wear protective goggles Remove the VHP capacitor unit (see methods and tools) Put the unit into sealed packings Store in ventilated premises with restricted access Store away from dripping water and heat sources or flames PRECAUTIONS AND SAFETY 68 ACETONITRILE R 11 - Highly inflammable R 20/21/22 - Toxic if inhaled, skin contact or if swallowed R 36 - Irritant for the eyes S 16 S 36/37 - Store away from flames or sparks - Do not smoke - Wear a safety garment and suitable gloves 200-835- - European community (CE) label The VHP capacitors contain ACETONITRILE The aluminium casing is completely sealed One cell contains 85 ml of electrolyte therefore the VHP capacitor contains 170 ml of the chemical There is a chemical risk only if the casing leaks If subjected to extreme stresses or an accident, the casing may release its fluid and toxic vapours If the human body absorbs acetonitrile (due to swallowing, inhaling or by contact), it systematically converts it into hydrogen cyanide (HCN) or prussic acid Cyanide poisoning mainly affects the respiratory and neurological systems The symptoms only appear after around ten minutes, and depending on the quantities absorbed, may result in a feeling of drunkenness accompanied by a headache, difficult in breathing, then suffocation, a severe drop in the oxygen level in the blood, loss of consciousness, and even more serious effects Recycling with dangerous products PRECAUTIONS AND SAFETY 69 In addition to the immediate danger, there is a long-term risk of lesions to the respiratory system In case of contact with the eyes or the skin: not smell the product, rinse with fresh water for 15 minutes rinse out the mouth with water and spit it out (if ingested) not induce vomiting take the exposed person into the fresh air call the emergency services Reminder of the safety symbols: Warning, danger Toxic Electrical hazard Highly inflammable Safety goggles must be worn Safety gloves must be worn Protective clothing must be worn Read the instructions Wash out the eyes abundantly Drink water Sick bay Take a shower Specific recycling not throw into the waste bin Recycling Do not set on fire BATTERY RECHARGING PRECAUTIONS Battery BAT+ to vehicle network + 70 LIN Network BAT - BAT+ VHP capacitor + - Battery charger, power supply Control unit CVHD Very High Power Capacitor VEHICLE EARTH OK The vehicles fitted with the Stop and Start system have the central voltage hold device The central voltage hold device is wired in series between the battery negative terminal and the vehicle chassis This is why care should be taken when recharging the battery Use a self-regulating charger to protect the circuit components To connect a charter, put the clamps directly on the battery terminals or between the positive terminal and the separate earth terminal BATTERY RECHARGING PRECAUTIONS 71 If access to the battery negative terminals is difficult (requires removal of the Power Supply Management and Protection module and the battery charge status module), you may connect the charger directly to the body-mounted earthing terminal provided for this purpose RECHARGING PRECAUTIONS BAT+ to vehicle network 72 LIN Network BAT+ + - VHP capacitor + BAT - Battery It is forbidden to disconnect the battery positive terminal and connect the charger between the battery positive terminal and the vehicle earth NOK At this moment, the VHP capacitors may be over-charged and destroyed It is forbidden to disconnect the central voltage hold device earth and to connect the battery charger between the battery positive terminal and the body earth At this moment, the VHP capacitors may be over-charged and destroyed STARTING AID 73 LIN Network BAT+ to vehicle network + BAT - BAT+ VHP capacitor + - Battery Control unit CVHD Very High Power Capacitor + Backup battery OK Starting aid with a back-up battery is possible by connecting directly to the vehicle battery terminals Starting aid with a back-up battery is possible by connecting between the battery positive terminal and the separate body earthing point MAINTENANCE 74 ALTERNATOR BELT REPLACEMENT tension tool 0194.E 0188.Z removal position locking pins 0194.F Diagnostic tool To remove the ancillaries belt you require: Tensioning tool: 0194-E part of the DV4 engine kit Tensioning tool: 0188-Z removal position locking pins: 0194-F The diagnostic tool Replacement of the belt only is recommended at 120000 Kms (whatever the type of conditions of use: normal or harsh) Depending on countries, this may vary in the future When reading the parameters with the diagnostic tool, a line tells you whether you need to change the alternator belt or not This is a synthesised information taken from a wear counter inside the engine ECU The drive torque applied to the reversible alternator will vary as it depends on the engine temperature, and the state of the battery Depending on the number of stops and re-starts, the wear on the belt will vary The counter enables you to inform the customer as soon as possible MAINTENANCE 75 If the counter is not reset, two fault codes may be flagged up: •Fault code P16AB ancillaries belt worn: the vehicle is 100% functional, the purpose of this first warning is to inform the customer and propose an ancillaries belt replacement as a preventive measure •Fault code P1383 ancillaries belt – breakage imminent: in order to avoid breaking the belt during re-starting, the "Stop and Start" function is automatically inhibited and the fault light will come on in order to inform the driver When changing the ancillaries belt, you must go into the "Repair pack" menu in the engine ECU to re-align the belt wear monitoring function Removal methods in the service documentation MAINTENANCE 76 TO DISCHARGE THE VHP CAPACITOR Before removing the VHP capacitor unit you must use tool 9780 HF in order to discharge the capacitors If the capacitors are not discharged, there is a risk of damage to the very high power capacitor cells and therefore leakage of the acetonitrile and/or you may receive and electric shock Connect the battery positive rapid connector after the networks have gone to sleep Connect the discharge tool to the VHP capacitor power terminals or, if the terminals are not easily accessible, to the VHP capacity LEV terminal of the central voltage hold device Start the tool The discharge may take around minutes for a VHP capacitor with a maximum charge level Once the Very high power capacitor has been discharged, you may remove the central voltage hold device module Discharge using the diagnostic tool is not planned Removal methods in the service documentation MAINTENANCE 77 REMOVAL OF THE CENTRAL VOLTAGE HOLD DEVICE - battery Positive power supply 1288-A 10-pin signal connector VHP capacitor + Vehicle earth To remove the central voltage hold device ECU once the capacitors are discharged, you must use tool 1288-A The profile of the nuts is designed so that it can only be removed by the network with the special tool The central voltage hold device nuts are identical It is essential to apply a torque of 10Nm +/- 15% for all of the power terminals (VHP capacitor and the central voltage hold device) Over-tightening will destroy internal parts of the control unit, making it unusable Insufficient tightening will increase the connection impedance, with a high risk of overheating Removal methods in the service documentation 78 ... generation Stop and Start system To give the functioning phases To work on the 3rd generation Stop and Start system and apply the safety precautions To apply correct maintenance to the Stop and Start system. .. generation "Stop and Start " system was the prototype of the "Stop and Start" system designed for the Citroën XSARA It was never launched commercially The second generation "Stop and Start " system. .. automatic "Stop and Start" function is totally transparent for the driver Other car manufacturers using an automatic stop and restarting system Mini "Auto Start Stop" BMW Series "Auto Star" Toyota "Stop