Ford Electric Ranger 1998 Student Manual
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Ford Electric Ranger 1998 Student Manual

Ford Electric Ranger 1998 Student Manual

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1998 Electric Ranger
Student Guide
34n07t0

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Summary of Contents for Ford Electric Ranger 1998

  • Page 1 1998 Electric Ranger Student Guide 34n07t0...

  • Page 3: Important Safety Notice

    The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc.
  • Page 4 Order, and verified with customer. These seven service standards provide a process and product value that are compelling reasons for owners to purchase and repurchase Ford or Lincoln-Mercury products. These standards also help to attract new owners through favorable testimonials and improved owner satisfaction.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS LESSON 1: VEHICLE OVERVIEW ....................1-1 Electric Vehicle (EV) History ......................1-2 Electric Ranger Introduction ......................1-3 Specifications ........................... 1-4 Battery System ..........................1-5 Traction Inverter Module (TIM) ..................... 1-15 Interface Adapter Assembly (IAA) ....................1-17 Motor/Transaxle ..........................1-19 High Voltage Power Distribution Box ....................
  • Page 6 TABLE OF CONTENTS LESSON 3: SAFETY AND EMERGENCY INFORMATION ............3-1 Lead-Acid Battery Design ....................... 3-2 Lead-Acid Module Specifications ....................3-4 High Voltage Color Coding ......................3-5 High Voltage Warnings ........................3-5 High Voltage Hazards ........................3-6 Electrical Accidents .......................... 3-8 Accident Prevention .........................
  • Page 7 TABLE OF CONTENTS LESSON 5: DIAGNOSIS ........................5-1 Introduction to Ranger EV Diagnosis and Service Procedures ............5-2 Symptom-to-System-to-Component-to-Cause Diagnosis ..............5-2 Ranger EV Diagnostic Flowchart ....................5-4 Multiplexing System Diagnosis ......................5-6 New Generation STAR Tester ......................5-8 Contactor Box Diagnosis ....................... 5-11 Activity 5 –...
  • Page 8 TABLE OF CONTENTS GLOSSARY Ranger EV Acronyms ......................Glossary-1 ACTIVITY SHEETS Written Activity Sheet 1 Student Answer Sheet ..................... Activity Sheet-1 Activity Sheet 2 Student Answer Sheet ..................... Activity Sheet-2 Generic Worksheet ...................... Activity Sheet-3 1998 Ranger EV New Model Training...

  • Page 9: Lesson 1: Vehicle Overview

    LESSON 1: VEHICLE OVERVIEW TECHNICIAN OBJECTIVES • Identify major components and systems. • Describe the operation of major components and systems. CONTENTS • Electric Vehicle (EV) History • Electric Ranger Introduction • Specifications • Battery System • Traction Inverter Module (TIM) •...

  • Page 10: Electric Vehicle (Ev) History

    EVs traveled at low speeds (24 km/h [15 mph]) and had limited range (48-64 kilometers [30-40 miles]). Ford Motor Company began its recent EV development in 1982 with the introduction of the ETX 1, a converted Lynx LN7. A lead-acid battery and a 37-kW (50-hp) AC motor powered this experimental vehicle.

  • Page 11: Electric Ranger Introduction

    The 1998 Electric Ranger is a low-volume production electric vehicle. The Electric Ranger is built on the 1998 gasoline-powered Ranger platform and is sold and serviced through Ford dealerships. A traction battery mounted under the vehicle between the frame rails supplies the electric power.

  • Page 12: Specifications

    LESSON 1: VEHICLE OVERVIEW SPECIFICATIONS Vehicle Model Year 1998 Body Style Styleside, Regular Cab Pick-Up Wheelbase Short Wheelbase of 2,831 mm (111.4 inch) Payload 315 kg (700 lb) Dimensions Similar to 1998 Gasoline-Powered Ranger Performance 0-50 Mph 12.5 seconds Top Speed 120 km/h (75 mph) Range 93 kilometers (58 miles)

  • Page 13: Battery System

    LESSON 1: VEHICLE OVERVIEW BATTERY SYSTEM Battery System Warnings WARNING: THE TRACTION BATTERY CAN DELIVER 312 VOLTS OF DC POWER. IMPROPER HANDLING OF THE TRACTION BATTERY CAN RESULT IN INJURY OR FATALITY. ONLY AUTHORIZED PERSONNEL TRAINED TO WORK WITH TRACTION BATTERY COMPONENTS ARE PERMITTED TO HANDLE THE BATTERIES.
  • Page 14 LESSON 1: VEHICLE OVERVIEW WARNING: HIGH VOLTAGE COMPONENT SERVICE SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL. INCORRECTLY PERFORMING SERVICE PROCEDURES MAY RESULT IN INJURY OR DEATH. ALL HIGH VOLTAGE COMPONENTS ON THIS VEHICLE ARE MARKED WITH THE FOLLOWING WARNING LABEL. High Voltage Warning Label 1998 Ranger EV New Model Training...
  • Page 15 LESSON 1: VEHICLE OVERVIEW Traction Battery Traction Battery • The traction battery is located underneath the vehicle between the frame rails. • The traction battery consists of 39 8-volt lead-acid battery modules stored in a supporting tray. • The supporting tray is constructed of an extremely strong non- conductive composite material with bonded metal mounting brackets.
  • Page 16 LESSON 1: VEHICLE OVERVIEW Traction Battery Cooling System Traction Battery Cooling System • The traction battery cooling system consists of: – four temperature sensors. – a two-speed fan. – a battery control module. • The cooling fan is located in the center of the traction battery. •...
  • Page 17 LESSON 1: VEHICLE OVERVIEW Traction Battery Heating System (Optional) Optional Traction Battery Heating System • To maintain proper temperature during charging in cold climates, an optional traction battery-heating system is available. • The lower level of battery modules is heated using a blanket heater (B) to heat the entire lower level.
  • Page 18 LESSON 1: VEHICLE OVERVIEW Traction Battery Wiring and Circuit Protection Traction Battery Circuit Protection • The traction battery uses low and high voltage wiring. • The high voltage circuit is protected by a 400-volt 250 amp fuse installed between batteries 20 and 21. •...
  • Page 19 LESSON 1: VEHICLE OVERVIEW Contactor Box Assembly (CBA) Contactor Box • The contactor box assembly (CBA) (arrow) is located in the rear of the traction battery at the upper left side. • The contactor box serves as the on/off switches for the traction battery.
  • Page 20 LESSON 1: VEHICLE OVERVIEW 12-Volt Battery 12-Volt Battery Location • The 12-volt battery is located in the left front corner of the underhood compartment. • The 12-volt battery is used for lighting and other low-voltage circuits and systems. • The DC/DC converter acts as an alternator to charge the 12-volt battery.
  • Page 21 LESSON 1: VEHICLE OVERVIEW Battery Control Module (BCM) Battery Control Module (BCM) • The battery control module (BCM) (arrow) is located in the upper front section of the traction battery. • The BCM is a high and low voltage module that controls all battery system operations.
  • Page 22 LESSON 1: VEHICLE OVERVIEW INPUTS OUTPUTS Battery Temperature High Voltage Power Sensor 1-4 Distribution Box (HVDB) Emergency Power Off Emergency Power Off (EPO) (EPO) Battery Heaters Battery Voltage Sensors BATTERY CONTROL Battery Pack State Battery Charger MODULE Of Charge (SOC) (BCM) Digital Transmission Battery Pack Cooling...

  • Page 23: Traction Inverter Module (Tim)

    LESSON 1: VEHICLE OVERVIEW TRACTION INVERTER MODULE (TIM) HIGH VOLTAGE COMPONENT ER011-A Traction Inverter Module (TIM) • The traction inverter module (TIM) (arrow) is located underneath the center rear of the vehicle. • The TIM is a high and low voltage module that performs two functions: –...
  • Page 24 LESSON 1: VEHICLE OVERVIEW • The IGBTs are used to switch on and off the three motor phases. – As they switch on and off, the IGBTs produce voltage spikes that have the potential to damage the TIM. – Capacitors are used as a filters to protect the TIM and maintain traction bus voltage during IGBT switching.

  • Page 25: Interface Adapter Assembly (Iaa)

    LESSON 1: VEHICLE OVERVIEW INTERFACE ADAPTER ASSEMBLY (IAA) Interface Adapter Assembly (IAA) • The interface adapter assembly (IAA) is located on the bulkhead under the instrument panel, the same location as the gasoline- powered Ranger EEC-V module. • The IAA is a low voltage multi-function module that manages the climate control system, the auxiliary systems and most instrument cluster gauges and lamps.
  • Page 26 LESSON 1: VEHICLE OVERVIEW INPUTS OUTPUTS Blower Motor Speed PTC Heater Cores Emergency Power Off Emergency Power Off (EPO) (EPO) Vacuum Pump A/C Pressure Sensor Vacuum Pressure A/C Compressor Sensor INTERFACE ADAPTER Coolant Temperature DC/DC Converter ASSEMBLY Sensor (IAA) Brake Fluid Level Cooling Fan Relay Switch PTC Heater Switching...

  • Page 27: Motor/Transaxle

    LESSON 1: VEHICLE OVERVIEW MOTOR/TRANSAXLE Motor/Transaxle Assembly • The motor/transaxle is mounted just behind the traction battery. • The motor/transaxle assembly consists of a: – four-pole, three phase AC induction motor. – single-speed transaxle with a planetary gearset. • The motor/transaxle supplies power through halfshafts to the rear wheels.
  • Page 28 LESSON 1: VEHICLE OVERVIEW Motor ER014-A Motor Components • The AC induction motor consists of a: – stator (A). – cast aluminum rotor (B). – rotor speed sensor (C). • The motor has a maximum operating speed of 13,000 rpm and maximum current draw of 305 amps.
  • Page 29 LESSON 1: VEHICLE OVERVIEW • Alternating current is supplied from the TIM to the motor through high voltage cables. – Current flows through the stator windings generating a magnetic field. – The magnetic field causes the rotor to spin. – Varying the amount of current controls torque. –...
  • Page 30 LESSON 1: VEHICLE OVERVIEW Transaxle Transaxle Components • The transaxle consists of a: – two-stage direct reduction planetary gear system (similar to other automatic transaxle planetary gear sets). – 50/50 planetary differential. • The transaxle is a constant-ratio (one-speed) unit and uses no apply components.
  • Page 31 LESSON 1: VEHICLE OVERVIEW • Direction (clockwise or counterclockwise) and speed of the motor are monitored by a speed sensor mounted inside the transaxle case. – The speed sensor detects passing teeth on the speed wheel as it rotates. – The speed wheel is mounted to the input shaft. –...

  • Page 32: High Voltage Power Distribution Box

    LESSON 1: VEHICLE OVERVIEW HIGH VOLTAGE POWER DISTRIBUTION BOX HIGH VOLTAGE COMPONENT ER016-A High Voltage Power Distribution Box • The high voltage power distribution box (arrow) is located in the underhood compartment on top of the battery charger. • The high voltage power distribution box is similar in function to the fuse box in your home.

  • Page 33: Dc/Dc Converter

    LESSON 1: VEHICLE OVERVIEW DC/DC CONVERTER HIGH VOLTAGE COMPONENT ER017-A DC/DC Converter • The DC/DC converter (arrow) is located in the underhood compartment on the driver side of the battery charger. • The DC/DC converter acts as an electronic alternator, charging the 12-volt battery and supplying power for low voltage components and systems.

  • Page 34: Liquid Cooling System

    LESSON 1: VEHICLE OVERVIEW LIQUID COOLING SYSTEM Liquid Cooling System Components Item Description Two-Speed Electric Cooling Fan Radiator • The high voltage electronics used on the Electric Ranger require cooling under normal use. • Excess heat is removed by a liquid cooling system controlled by the IAA.
  • Page 35 – a two-speed electric cooling fan. – a 12-volt electric coolant pump. – rubber coolant hoses. – metal coolant tubes. – a 50/50 mix of water and glycol Ford specification WSS- M97B44-C. (Do not mix with previous specification.) • The 12-volt coolant pump incorporates a: –...
  • Page 36 LESSON 1: VEHICLE OVERVIEW Coolant Hose Routing Coolant Hose Routing Item Description A/C Inverter Motor Controller DC/DC Converter Coolant Temperature Sensor 12-Volt Electric Coolant Pump Motor Rubber Coolant Hoses Electric Cooling Fan Module (not shown) Metal Coolant Tubes 1-28 1998 Ranger EV New Model Training...
  • Page 37 LESSON 1: VEHICLE OVERVIEW • Coolant is circulated by the electric pump located below the DC/DC converter. • Rubber hoses carry coolant to the DC/DC converter and the A/C inverter motor controller. • Rubber hoses and metal tubes carry coolant to the motor/transaxle and TIM.

  • Page 38: Power Steering System

    LESSON 1: VEHICLE OVERVIEW POWER STEERING SYSTEM Power Steering System Components Item Description Power Steering Controller Assembly Power Steering Gear and Linkage • The power steering controller assembly is located on the right side of the underhood compartment. • The power steering controller assembly consists of an electric controller attached to a high voltage AC electric motor and pump.
  • Page 39 LESSON 1: VEHICLE OVERVIEW NOTES 1998 Ranger EV New Model Training 1-31...

  • Page 40: Braking System

    LESSON 1: VEHICLE OVERVIEW BRAKING SYSTEM Braking System Components • The base brake system is a conventional hydraulic/friction braking system. • The brake booster and master cylinder are carryover from the gasoline-powered Ranger. • The master cylinder includes a modified pressure sensor that provides input for the regenerative braking system.
  • Page 41 LESSON 1: VEHICLE OVERVIEW Motor Driven Vacuum Pump • A motor driven vacuum pump is mounted beneath the battery charger. • The anti-lock braking system (ABS) is a 4-sensor 3-channel system. • ABS components include: – an electronic control unit (ECU). –...
  • Page 42 LESSON 1: VEHICLE OVERVIEW Regenerative Braking System (RBS) Electrical energy Kinetic energy ER024-A Regenerative Braking System (RBS) • In a conventional friction braking system, the kinetic energy of deceleration is transformed into heat. – This heat is dissipated into the surrounding air. •...
  • Page 43 LESSON 1: VEHICLE OVERVIEW • The accelerator pedal and the brake pedal are inputs of the RBS. • RBS supplements the hydraulic braking system. • The RBS operates when the vehicle is moving either forward or backward. • It is possible for RBS motor torque to cause rear wheel slip in certain circumstances.

  • Page 44: Electronic Throttle Control

    LESSON 1: VEHICLE OVERVIEW ELECTRONIC THROTTLE CONTROL ER025-A Electronic Throttle Control Components Item Description Accelerator Position Sensor (APS) Accelerator Pedal Assembly • Electronic throttle control is in use on vehicles other than Electric Ranger. • On the Electric Ranger, electronic throttle control replaces the cable between the accelerator pedal and the powertrain.

  • Page 45: Climate Control System

    LESSON 1: VEHICLE OVERVIEW CLIMATE CONTROL SYSTEM Heating System Description HIGH VOLTAGE COMPONENT ER026-A Heating System • In place of using engine coolant to heat the passenger compartment, the Electric Ranger uses a positive temperature coefficient (PTC) heater. • A PTC switching module (A) provides high voltage to the PTC heater.
  • Page 46 LESSON 1: VEHICLE OVERVIEW Heating System Operation Heater Assembly • The PTC heater is an electric resistance heater with a two-stage heater core that operates on two separate circuits. • The heater core uses high voltage DC from the traction battery to defrost the windshield and heat the passenger compartment.
  • Page 47 LESSON 1: VEHICLE OVERVIEW • The manual control head is a modified gasoline-powered Ranger design with a: – mode switch. – blower switch. – temperature potentiometer. • A new recirculation switch allows heat to be recirculated. • The ambient and in-vehicle temperature sensors are carryover from Explorer.
  • Page 48 LESSON 1: VEHICLE OVERVIEW Air Conditioning System HIGH VOLTAGE COMPONENTS ER028-A Air Conditioning System Components • The air conditioning compressor (B) is located in the lower center of the under hood compartment. • The absence of an internal combustion engine means there is no drive belt to power a pulley-driven compressor.
  • Page 49 LESSON 1: VEHICLE OVERVIEW • The compressor is located in the lower center of the underhood compartment and: – is a 33 cc scroll design. – has an integral 3.5 kW (4.7 hp) motor. – has a maximum shaft speed of 7812 rpm. •...

  • Page 50: Networks And Multiplexing

    LESSON 1: VEHICLE OVERVIEW NETWORKS AND MULTIPLEXING Multiplexing System • A network is an electronic system composed of control module(s) and/or diagnostic tester (scan tool) that are connected with at least one wire. This hardware allows the modules to communicate with each other.
  • Page 51 LESSON 1: VEHICLE OVERVIEW • Multiplexing is an operating strategy where control modules can communicate with each other during normal vehicle operation. • Multiplexing only occurs over the J1850 network. • Modules that are multiplexed use the J1850 network and standard corporate protocol (SCP) to communicate (a protocol is a type of computer language).

  • Page 52: High Voltage Interlocks

    LESSON 1: VEHICLE OVERVIEW HIGH VOLTAGE INTERLOCKS ER030-A High Voltage Interlocks • High voltage interlocks help prevent electrical accidents by disabling high voltage power when: – connectors are disconnected. – the top cover (A) of the high voltage power distribution box (B) is removed.

  • Page 53: Inertia Shutoff Switch

    LESSON 1: VEHICLE OVERVIEW INERTIA SHUTOFF SWITCH ER031-A Inertia Shutoff Switch Location • The inertia shutoff switch (arrow) is located above the carpet line and below the evaporator assembly on the passenger side of the vehicle. • The inertia shutoff switch on the Electric Ranger performs a similar function as the inertia shutoff switch on the gasoline-powered Ranger.

  • Page 54: Current Leakage Detection

    LESSON 1: VEHICLE OVERVIEW CURRENT LEAKAGE DETECTION Current Leakage Detection • The Electric Ranger uses a current leakage detection system to monitor the integrity of the electrical system. • The BCM monitors the high voltage system for current leakage by checking the DC circuitry for a low impedance path.

  • Page 55: Suspension System

    LESSON 1: VEHICLE OVERVIEW SUSPENSION SYSTEM Rear Suspension Components • The rear suspension system is designed specifically for the Electric Ranger. • The DeDion rear axle (B) consists of: – a thick-walled aluminum tube. – sand-cast aluminum ends with Bearing carriers and spring seats. –...

  • Page 56: Traction Battery Charging Components

    LESSON 1: VEHICLE OVERVIEW TRACTION BATTERY CHARGING COMPONENTS Power Control Station (PCS) ER036-A Power Control Station (PCS) • The Electric Ranger’s traction battery is charged by an off-board power control station (PCS). • The PCS requires 240-volt 40 amp AC service. •...
  • Page 57 LESSON 1: VEHICLE OVERVIEW • If the green START light goes out and the amber CHARGE INTERRUPT light illuminates: – operation has been discontinued by the Class A ground fault detection system. – due to the high sensitivity of this system, the charge operation will be shut down if either the charge cord plug or the charge inlet is wet or damp.
  • Page 58 LESSON 1: VEHICLE OVERVIEW Charge Inlet HIGH VOLTAGE COMPONENT ER037-A Charge Inlet • The charge inlet is equivalent to the fuel filler port on a gasoline- powered vehicle. • The Electric Ranger receives power in the form of 240-volt AC current. •...
  • Page 59 LESSON 1: VEHICLE OVERVIEW Battery Charger HIGH VOLTAGE COMPONENT ER038-A Battery Charger • The on-board battery charger (arrow) is located in the underhood compartment beneath the high voltage power distribution box. • The on-board battery charger receives 240-volt 40 amp AC current from the power control station (PCS) and converts it into DC current.

  • Page 60: High Voltage Wiring

    LESSON 1: VEHICLE OVERVIEW HIGH VOLTAGE WIRING ER039-A High Voltage Wiring • All high voltage wiring is covered with color-coded with orange convolute. • High voltage wiring connects the following components: A. From battery charger to high voltage power distribution box B.
  • Page 61 LESSON 1: VEHICLE OVERVIEW High Voltage Wiring from Charge Inlet (1) to Battery Charger (2) High Voltage Wiring from Battery Charger (1) to High Voltage Power Distribution Box (2) 1998 Ranger EV New Model Training 1-53...
  • Page 62 LESSON 1: VEHICLE OVERVIEW High Voltage Wiring from High Voltage Power Distribution Box (1) to Traction Battery High Voltage Wiring from High Voltage Power Distribution Box (1) to Power Steering Controller Assembly (2) ER043-A High Voltage Wiring from High Voltage Power Distribution Box (3) to DC/DC Converter (4) 1-54 1998 Ranger EV New Model Training...
  • Page 63 LESSON 1: VEHICLE OVERVIEW High Voltage Wiring from Traction Battery (1) to TIM (2) ER045-A High Voltage Wiring from TIM (3) to Motor/Transaxle (4) 1998 Ranger EV New Model Training 1-55...
  • Page 64 LESSON 1: VEHICLE OVERVIEW ER046-A High Voltage Wiring from High Voltage Power Distribution Box (1) to PTC Switching Module (2) High Voltage Wiring from PTC Switching Module (3) to PTC Heater 1-56 1998 Ranger EV New Model Training...
  • Page 65 LESSON 1: VEHICLE OVERVIEW High Voltage Wiring from High Voltage Power Distribution Box (1) to A/C Inverter Motor Controller (2) High Voltage Wiring from A/C Inverter Motor Controller (3) to A/C Compressor (4) 1998 Ranger EV New Model Training 1-57...
  • Page 66 LESSON 1: VEHICLE OVERVIEW NOTES 1-58 1998 Ranger EV New Model Training...

  • Page 67: Student Answer Sheet

    LESSON 1: VEHICLE OVERVIEW ACTIVITY 1 – VEHICLE OVERVIEW – WORKSHEET A COMPONENT LOCATION STUDENT ANSWER SHEET OBJECTIVE: To identify the location of EV Ranger components. DIRECTIONS: Go to the classroom vehicles. You will find the components listed below have tags attached to them.

  • Page 68: Student Answer Sheet

    LESSON 1: VEHICLE OVERVIEW ACTIVITY 1 – VEHICLE OVERVIEW – WORKSHEET B COMPONENT FUNCTION EXERCISE STUDENT ANSWER SHEET OBJECTIVE: To identify the function of the Electric Ranger components and systems. DIRECTIONS: Match the listed items with the correct definitions: 1. Interface Adapter Assembly (IAA) 8.

  • Page 69: Student Answer Sheet

    LESSON 1: VEHICLE OVERVIEW ACTIVITY 1 – VEHICLE OVERVIEW – WORKSHEET C SAFETY FEATURE IDENTIFICATION STUDENT ANSWER SHEET OBJECTIVES: To describe the safety features found on the Electric Ranger. DIRECTIONS: Select the correct response for each statement or question. 1. The inertia shutoff switch is located: A.
  • Page 70 NOTES...

  • Page 71: Lesson 2: Vehicle Operation

    LESSON 2: VEHICLE OPERATION TECHNICIAN OBJECTIVES • Describe vehicle operation. • Identify instrument cluster components and functions. • Describe the economy mode. • Describe traction battery charging procedures. CONTENTS • Vehicle Operation • Instrument Cluster Gauges • Instrument Cluster Warning Lamps •...

  • Page 72: Vehicle Operation

    Vehicle Controls • Driving the Electric Ranger is similar to operating a gasoline- powered vehicle. • The key positions are the same as other Ford vehicles (positions are listed from full rearward to full forward): – ACC – LOCK – OFF –...
  • Page 73 LESSON 2: VEHICLE OPERATION • The instrument cluster has several new gauges and warning lamps (covered later in this lesson). • When the driver key is turned to the START position, there is no starter motor noise (although the vehicle is activated). •...

  • Page 74: Instrument Cluster Gauges

    LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER GAUGES Battery State of Charge Gauge DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER052-A Battery State of Charge Gauge • The Battery State of Charge Gauge is the equivalent of the fuel gauge on a gasoline-powered vehicle.
  • Page 75 LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER BATTERY STATE OF CHARGE GAUGE ER119-A Battery State of Charge Gauge Inputs NOTE: The POWER LIMIT and Low Fuel Warning Lamps flash when the gauge reads empty. Vehicle performance will be extremely limited at this point; the driver must pull over off the road (to the shoulder) as quickly and safely as possible.
  • Page 76 LESSON 2: VEHICLE OPERATION ECON (Economy) Gauge ECON DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER053-A ECON (Economy) Gauge • The Economy Gauge not only shows the driver that his/her actions affect vehicle range, but that driving more economically can increase the vehicle range.
  • Page 77 LESSON 2: VEHICLE OPERATION REAR ABS SPEED SENSOR MODULE HEATER/AC INSTRUMENT CLUSTER ECON GAUGE ER120-A Economy Gauge Inputs 1998 Ranger EV New Model Training...
  • Page 78 LESSON 2: VEHICLE OPERATION DISTANCE TO EMPTY Gauge DISTANCE TO EMPTY MILES DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER054-A DISTANCE TO EMPTY Gauge • The DISTANCE TO EMPTY Gauge estimates the remaining distance that can be traveled before the traction battery needs to be recharged.
  • Page 79 LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER DISTANCE TO EMPTY GAUGE ER121-A DISTANCE TO EMPTY Gauge Inputs 1998 Ranger EV New Model Training...
  • Page 80 LESSON 2: VEHICLE OPERATION Motor Enabled Gauge DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER055-A Motor Enabled Gauge • The Motor Enabled Gauge indicates that the vehicle is ready to be driven.
  • Page 81 LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER MOTOR ENABLED GAUGE ER122-A Motor Enabled Gauge Inputs 1998 Ranger EV New Model Training 2-11...
  • Page 82 LESSON 2: VEHICLE OPERATION Temperature Gauge DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER056-A Temperature Gauge • The Temperature Gauge indicates the extreme temperature of major components: – Traction battery – TIM –...
  • Page 83 LESSON 2: VEHICLE OPERATION DC/DC CONVERTER INVERTER COOLANT TRACTION BATTERY MOTOR/ INSTRUMENT CLUSTER TRANSAXLE TEMPERATURE GAUGE ER123-A Temperature Gauge Inputs 1998 Ranger EV New Model Training 2-13...
  • Page 84 LESSON 2: VEHICLE OPERATION Speedometer/Odometer/Tripmeter DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER057-A Speedometer/Odometer/Tripmeter • The speedometer (A) is an electronically driven 0-130 km/h (0-80 mph) gauge with a carryover Ranger odometer (B) and tripmeter.

  • Page 85: Instrument Cluster Warning Lamps

    LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER WARNING LAMPS Malfunction Indicator Lamp (MIL) DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER058-A Malfunction Indicator Lamp (MIL) • The yellow MIL indicates a vehicle malfunction that requires service.
  • Page 86 LESSON 2: VEHICLE OPERATION Low Fuel Warning Lamp DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER135-A Low Fuel Warning Lamp • The Low Fuel Warning Lamp alerts the driver when the state of charge is low.
  • Page 87 LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER LOW FUEL WARNING LAMP ER125-A Low Fuel Warning Lamp Inputs NOTE: When this lamp flashes, range is very limited and the vehicle should be returned to the repair facility. The Low Fuel Warning Lamp will also illuminate or flash if a fault occurs in the system.
  • Page 88 LESSON 2: VEHICLE OPERATION POWER LIMIT Warning Lamp POWER LIMIT DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER059-A POWER LIMIT Warning Lamp • The IAA monitors input from the TIM through the J1850 (SCP) network and uses the POWER LIMIT Warning Lamp to indicate the vehicle’s performance is limited to conserve remaining battery power (lamp illuminated).
  • Page 89 LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER POWER LIMIT LAMP ER126-A POWER LIMIT Warning Lamp Inputs 1998 Ranger EV New Model Training 2-19...
  • Page 90 LESSON 2: VEHICLE OPERATION BRAKE Warning Lamp BRAKE DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER060-A BRAKE Warning Lamp • The red BRAKE Warning Lamp will illuminate during the following conditions: –...
  • Page 91 LESSON 2: VEHICLE OPERATION PARKING BRAKE MASTER CYLINDER TIM (RBS) (FLUID LEVEL) MODULE MASTER CYLINDER PRESSURE SENSOR (LINE PRESSURE) INSTRUMENT CLUSTER RED BRAKE WARNING LAMP ER127-A BRAKE Warning Lamp Inputs NOTE: If the lamp illuminates, be sure the parking brake is not engaged and the brake fluid level is correct before attempting further diagnosis.
  • Page 92 LESSON 2: VEHICLE OPERATION Electric Hazard Warning Lamp DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER061-A Electric Hazard Warning Lamp • The red Electric Hazard Warning Lamp will illuminate during the following conditions: –...
  • Page 93 LESSON 2: VEHICLE OPERATION INSTRUMENT CLUSTER ELECTRIC HAZARD WARNING LAMP ER128-A Electric Hazard Warning Lamp Inputs NOTE: If an electrical hazard is present, the electric hazard warning lamp only illuminates with the key in the START or ON position. 1998 Ranger EV New Model Training 2-23...
  • Page 94 LESSON 2: VEHICLE OPERATION Charging Indicator Lamp DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER062-A Charging Indicator Lamp • The red Charging Indicator Lamp will illuminate during charging if the key is turned to the START or ON position. •...
  • Page 95 LESSON 2: VEHICLE OPERATION CHARGE INLET DTR SWITCH IGNITION SWITCH INSTRUMENT CLUSTER CHARGING INDICATOR LAMP ER129-A Charging Indicator Lamp Inputs NOTE: The Charging Indicator Lamp will flash when the key is in the ON position and it is unsafe to charge (vehicle not in PARK [P]), severe current leakage, open interlock or activated inertia shutoff switch).
  • Page 96 LESSON 2: VEHICLE OPERATION POWER RESET Indicator Lamp POWER RESET DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER063-A POWER RESET Indicator Lamp • The yellow POWER RESET Indicator Lamp will illuminate when the inertia shutoff switch has been activated.
  • Page 97 LESSON 2: VEHICLE OPERATION INERTIA SHUTOFF SWITCH INSTRUMENT CLUSTER POWER RESET INDICATOR LAMP CONTACTOR ER130-A POWER RESET Indicator Lamp Inputs NOTE: The inertia shutoff switch is located in the passenger compartment, above the carpet line and below the evaporator assembly. 1998 Ranger EV New Model Training 2-27...
  • Page 98 LESSON 2: VEHICLE OPERATION ECON MODE Indicator Lamp ECON MODE DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER064-A ECON MODE Indicator Lamp • The green ECON MODE Indicator Lamp will illuminate when the driver has selected the economy driving mode (E).
  • Page 99 LESSON 2: VEHICLE OPERATION P R N D E INSTRUMENT CLUSTER ECON MODE INDICATOR LAMP ER132-A ECON MODE Indicator Lamp Inputs 1998 Ranger EV New Model Training 2-29...
  • Page 100 LESSON 2: VEHICLE OPERATION Auxiliary Battery Warning Lamp DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER065-A Auxiliary Battery Warning Lamp • The red Auxiliary Battery Warning Lamp will illuminate during the following conditions: –...
  • Page 101 LESSON 2: VEHICLE OPERATION 12-VOLT BATTERY INSTRUMENT CLUSTER AUXILIARY BATTERY WARNING LAMP ER133-A Auxiliary Battery Warning Lamp Inputs 1998 Ranger EV New Model Training 2-31...
  • Page 102 LESSON 2: VEHICLE OPERATION Low Oil Pressure Warning Lamp DISTANCE ECON TO EMPTY 0 0 0 0 0 0 MILES km/h R N D E ER066-A Low Oil Pressure Warning Lamp • The red Low Oil Pressure Warning Lamp will illuminate if the transaxle oil pressure falls below 28 kPa (4 psi).
  • Page 103 LESSON 2: VEHICLE OPERATION TRANSAXLE TRANSAXLE OIL INSTRUMENT CLUSTER PRESSURE SWITCH LOW OIL PRESSURE WARNING LAMP ER134-A Low Oil Pressure Warning Lamp Inputs Other Indicator Lamps • The following indicator lamps operate in the same manner as those used on gasoline-powered vehicles: –...

  • Page 104: Economy Mode

    LESSON 2: VEHICLE OPERATION ECONOMY MODE ER067-A Economy Mode • When the driver selects the economy operating mode using the gear selector lever, the regenerative brake function is enhanced to increase vehicle range. • The economy mode applies a higher regenerative motor torque to the rear wheels, allowing more power to be recovered and stored in the Traction Battery.

  • Page 105: Traction Battery Charging

    BATTERY MAY RELEASE EXCESS HYDROGEN GAS THROUGH VENTS IN THE BATTERY CASE. ALWAYS ENSURE THAT THE LEAD-ACID BATTERIES ARE PROPERLY RECHARGED USING ONLY FORD- SPECIFIED EQUIPMENT AND PROCEDURES. NOTE: About four hours of equalization charging for the traction battery modules can occur at three-week intervals.
  • Page 106 LESSON 2: VEHICLE OPERATION Charging Procedure Connecting Charging Cord 1. Place the front of the vehicle within 3 m (10 ft) of the charging station. 2. Place the gear selector in Park (P) and set the parking brake. 3. Turn the key to the OFF position and remove the key. 4.

  • Page 107: Driver Response To An Emergency Situation

    LESSON 2: VEHICLE OPERATION DRIVER RESPONSE TO AN EMERGENCY SITUATION • If possible, perform the following steps in the event of a collision, fire or some other emergency situation. However, never endanger yourself or others near the vehicle. 1. Stop and put the gear selector in the Park (P) position. 2.
  • Page 108 LESSON 2: VEHICLE OPERATION NOTES 2-38 1998 Ranger EV New Model Training...

  • Page 109: Activity 2 - Vehicle Familiarization

    LESSON 2: VEHICLE OPERATION ACTIVITY 2 – VEHICLE FAMILIARIZATION – WORKSHEET D OPERATING CHARACTERISTICS OF THE ELECTRIC RANGER STUDENT ANSWER SHEET OBJECTIVE: To identify the operating characteristics of the Electric Ranger. DIRECTIONS: Use your experience driving the Electric Ranger to answer the questions below. 1.

  • Page 110: Student Answer Sheet

    LESSON 2: VEHICLE OPERATION ACTIVITY 2 – VEHICLE FAMILIARIZATION – WORKSHEET E WARNING AND INDICATOR LAMPS STUDENT ANSWER SHEET OBJECTIVE: To identify the warning and indicator lamp functions. DIRECTIONS: Match each lamp with its correct definition. POWER LIMIT ECON POWER BRAKE MODE RESET...
  • Page 111 LESSON 2: VEHICLE OPERATION ACTIVITY 2 – VEHICLE FAMILIARIZATION – WORKSHEET F INSTRUMENT GAUGES AND LIGHTS STUDENT ANSWER SHEET OBJECTIVE: To describe various functions and indications of the gauges and instrument panel lights on the Electric Ranger. DIRECTIONS: Select the correct answer for each question. 1.
  • Page 112 LESSON 2: VEHICLE OPERATION ACTIVITY 2 – VEHICLE FAMILIARIZATION – WORKSHEET F INSTRUMENT GAUGES AND LIGHTS STUDENT ANSWER SHEET (Continued) 6. How many hours of charging are required to replenish a fully discharged Traction Battery at 25°C (77°F)? A. 2-4 hours. B.
  • Page 113 LESSON 2: VEHICLE OPERATION ACTIVITY 2 – VEHICLE FAMILIARIZATION – WORKSHEET F INSTRUMENT GAUGES AND LIGHTS STUDENT ANSWER SHEET (Continued) 10. The ECON Mode Indicator Lamp illuminates: A. during braking. B. during deceleration. C. if the driver selects the Economy Mode. D.
  • Page 114 NOTES...

  • Page 115: Lesson 3: Safety And Emergency Information

    LESSON 3: SAFETY AND EMERGENCY INFORMATION TECHNICIAN OBJECTIVES • Describe high voltage color coding. • Recognize high voltage warnings. • Identify the hazards associated with high voltages. • Identify the causes of most electrical accidents. • Identify safety rules that should be followed for accident prevention.

  • Page 116: Lead-Acid Battery Design

    LESSON 3: SAFETY AND EMERGENCY INFORMATION LEAD-ACID BATTERY DESIGN ER071-A Lead-Acid Battery Modules • The Electric Ranger uses advanced technology, valve-regulated, starved electrolyte lead-acid batteries. • The 39 individual battery modules in the Traction Battery are sealed and maintenance-free. • Each 8-volt battery is made up of a polypropylene case, stainless steel terminals and sulfuric acid electrolyte.
  • Page 117 LESSON 3: SAFETY AND EMERGENCY INFORMATION WARNING: LEAD-ACID BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR BATTERIES TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF FIFTEEN MINUTES AND GET PROMPT MEDICAL ATTENTION.

  • Page 118: Lead-Acid Module Specifications

    LESSON 3: SAFETY AND EMERGENCY INFORMATION LEAD-ACID MODULE SPECIFICATIONS Dimensions Length 399 mm (15.275 in) Width 116 mm (5.567 in) Height 175 mm (6.890 in) Weight 19.5 kg (42 lb) Terminals Stainless Steel Threads With Lead Contacts Vent Mechanism Pressure Relief Valve [Activated at 13.8 kPa (2 psi)] Contents Lead/Lead Oxide Plates (Electrodes)

  • Page 119: High Voltage Color Coding

    LESSON 3: SAFETY AND EMERGENCY INFORMATION HIGH VOLTAGE COLOR CODING High Voltage Color Coding • All high voltage cables on the Electric Ranger are orange-colored by covering the cables with: – orange-colored convolute. – orange-colored insulation in the battery pack assembly. HIGH VOLTAGE WARNINGS High Voltage Warning Labels •...

  • Page 120: High Voltage Hazards

    LESSON 3: SAFETY AND EMERGENCY INFORMATION HIGH VOLTAGE HAZARDS This portion of the course will examine the three hazards associated with high voltage. Later we’ll discuss how to avoid mistakes that can lead to electrical accidents. The three high voltage hazards are shock, arcing and blast.
  • Page 121 LESSON 3: SAFETY AND EMERGENCY INFORMATION Hazard Two: Arcing An arc is a discharge of electricity across a circuit gap. 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 19,427°C (35,000°F), or about 4 times the surface temperature of the sun.

  • Page 122: Electrical Accidents

    LESSON 3: SAFETY AND EMERGENCY INFORMATION ELECTRICAL ACCIDENTS Electrical accidents can usually be attributed to one or more of the following causes: • Unsafe Equipment or Installation – Serious problems can occur when using improper equipment. Not only must equipment have a safe design, but also it must be installed correctly.

  • Page 123: Accident Prevention

    LESSON 3: SAFETY AND EMERGENCY INFORMATION ACCIDENT PREVENTION The Electric Ranger operates on a system that is isolated from the earth ground and its high voltage system is isolated from the vehicle chassis ground. A person must join the positive and the negative to become part of the high voltage circuit.
  • Page 124 LESSON 3: SAFETY AND EMERGENCY INFORMATION 16. Do not attempt to work on complex equipment or circuits before you’re fully trained. There may be hidden dangers. 17. Some of the best safety information for electrical and electric equipment is in the literature prepared by the manufacturer. Find and use it.
  • Page 125 LESSON 3: SAFETY AND EMERGENCY INFORMATION 30. Welding on an EV requires special procedures. Damage to components can result if improper practices are used. Consult with your supervisor to determine the correct procedure for your specific application. 31. When performing a visual inspection, check for damaged wiring. This includes exposed copper;...

  • Page 126: First Aid Procedures

    LESSON 3: SAFETY AND EMERGENCY INFORMATION FIRST AID PROCEDURES In case of acid contact with the skin, eyes or clothing, flush immediately with a mixture of clean water and baking soda for a minimum of 15 minutes. Know where the first aid station is located. If acid is accidentally swallowed, drink large quantities of milk or water, followed by milk of magnesia, a beaten egg or vegetable oil.
  • Page 127 LESSON 3: SAFETY AND EMERGENCY INFORMATION Cardio-Pulmonary Resuscitation (CPR) If a person has received an electric shock, it may be necessary to administer CPR. The goal of CPR is to provide oxygen to the brain, heart, and other vital organs until medical help arrives. When to Use CPR CPR should only be administered by a trained individual.

  • Page 128: Fire Prevention

    LESSON 3: SAFETY AND EMERGENCY INFORMATION FIRE PREVENTION General fire precautions should be observed at all times. Shop cleanliness is a good fire preventative. Storage lockers, drawers and partitions should be made of fire-resistant material. Flammable materials should be kept at a safe distance from heating units and open flames.
  • Page 129 LESSON 3: SAFETY AND EMERGENCY INFORMATION Types of Fire Extinguishers Listed below are common types of fire extinguishers: Water Class A fires only. Inappropriate for Class B and C fires. Water can conduct electrical current and increase the risk of severe injury. Regular Dry Primarily sodium bicarbonate, effective Chemical...
  • Page 130 LESSON 3: SAFETY AND EMERGENCY INFORMATION NOTES 3-16 1998 Ranger EV New Model Training...

  • Page 131: Activity 3 - Ev Safety And Emergency Information

    LESSON 3: SAFETY AND EMERGENCY INFORMATION ACTIVITY 3 – EV SAFETY AND EMERGENCY INFORMATION – WORKSHEET G SAFETY AND EMERGENCY PROCEDURES STUDENT ANSWER SHEET OBJECTIVE: To describe the emergency instructions provided in this section. DIRECTIONS: Write the correct answers in the blank spaces provided. 1.
  • Page 132 NOTES...

  • Page 133: Lesson 4: Special Service Tools And Procedures

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES TECHNICIAN OBJECTIVES • Identify the special service tools and equipment required for repair on the Ranger EV. • Identify approved towing methods. • Describe how to correctly hoist the vehicle. CONTENTS • Special Service Tools and Equipment •...

  • Page 134: Special Service Tools And Equipment

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES SPECIAL SERVICE TOOLS AND EQUIPMENT Global Tool Number Description 502-F002 Battery Lift Table 502-F003 Battery Lift Table Pallet 418-F205 Insulated Battery Post Torque Wrench 418-F206 Battery Module Lifting Tool (2 Required) 418-F207 Traction Battery High Voltage (HV) Lockout and Diagnostic Tool 418-F208 Auxiliary Interlock Tool...
  • Page 135 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Traction Battery Lift Table and Pallet ER074-A Battery Lift Table Item Description Battery Lift Table Battery Lift Table Pallet • The Battery Lift Table and Battery Lift Table Pallet are specially designed for the Ranger EV. –...
  • Page 136 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Insulated Battery Post Torque Wrench ER137-A Insulated Battery Post Torque Wrench • The Insulated Battery Post Torque Wrench enables you to safely tighten the battery post connectors. • The insulation on the wrench prevents arcing in the event of inadvertent contact between a battery positive terminal and ground.
  • Page 137 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Traction Battery High Voltage (HV) Lockout and Diagnostic Tool ER139-A Traction Battery High Voltage (HV) Lockout and Diagnostic Tool • It is a dual-purpose tool that allows the vehicle to be powered up when performing current leakage diagnostics.
  • Page 138 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Auxiliary Interlock Tool ER140-A Auxiliary Interlock Tool • It is used to close the interlock loop on the vehicle during diagnostics. – After disconnecting the traction battery high-voltage auxiliary load connector at the right front side of the traction battery, connect this tool between the traction battery and in-line interlock connector C1948 located behind the high voltage power distribution box (HVPDB).
  • Page 139 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Power Steering Interlock Tool ER141-A Power Steering Interlock Tool • The Power Steering Interlock Tool connects to the power steering connector pigtail from the high voltage power distribution box (HVPDB) to the power steering assembly. •...
  • Page 140 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Electric Motor/Transaxle Test Box 1U14 TRANSAXLE TEST BOX Lube Pump Pressure RPM Sensor Channel A Channel B Sensor Temp ER150A-A Electric Motor/Transaxle Test Box • The Electric Motor/Transaxle Test Box is used to perform tests that are necessary for diagnosing internal electric motor/transaxle components.
  • Page 141 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES • Oil Pressure Switch Operation – The Electric Motor/Transaxle Test Box interfaces directly with the oil pressure switch. By manually turning on and off the oil pump, the Electric Motor/Transaxle Test Box turns a light on and off respectively. •...
  • Page 142 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES 104-Pin Breakout Box (BOB) and BCM/TIM Breakout Box Adapter Cable and Overlay ER143-A BCM/TIM Breakout Box Adapter Cable ER144-A Breakout Box (BOB) Overlay • The breakout box (BOB) is used in the same manner on the Ranger EV as on conventional vehicles.
  • Page 143 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Capacitor Discharge Tool ER145-A Capacitor Discharge Tool • The Capacitor Discharge Tool is used to ensure that capacitors have discharged prior to performing vehicle service. • Connects to a Digital Volt-Ohmmeter (DVOM) to determine when the voltage has completely discharged.
  • Page 144 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES 8-Volt Battery Charger • It is used to charge the 8-volt battery modules of the traction battery pack. – It is only used when an individual battery module requires charging prior to being inserted into the traction battery pack. –...
  • Page 145 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Battery Terminal Cap Opener ER146-A Battery Terminal Cap Opener • The Battery Terminal Cap Opener is a plastic device used to pry open the battery module terminal cap covers to access the terminal retaining nuts.
  • Page 146 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Power Control Station ER036-A Power Control Station • The Power Control Station (PCS) provides 240 volts of AC to the Ranger EV’s on-board battery charger. • The on-board battery charger uses this voltage to charge the traction battery pack.
  • Page 147 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Traction Battery High Voltage Service Cord ER147-A Traction Battery High Voltage Service Cord • It connects between the traction battery high-voltage auxiliary load connector at the right front of the battery tray and the vehicle harness.
  • Page 148 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Traction Battery Low Voltage Service Cord ER148-A Traction Battery Low Voltage Service Cord • Connects between the traction battery low-voltage 76-pin connector at the left front of the battery tray and the vehicle harness. •...
  • Page 149 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES High Voltage Insulated Safety Gloves High Voltage Insulated Safety Gloves • When working around high voltage circuits, High-Voltage Insulated Safety Gloves (A) must be worn. • The gloves specified for the Ranger EV are Class “O” rubber gloves.
  • Page 150 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Face Shield Face Shield • When working with energized high-voltage equipment, to protect your face and eyes from the possibility of an electrical arc, debris, or spark that could be generated from a short circuit, a non- conductive, OSHA-approved face shield must be worn.

  • Page 151: High Voltage Diagnostic And Service Procedures

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES HIGH VOLTAGE DIAGNOSTIC AND SERVICE PROCEDURES • High voltage diagnostic and service procedures on the Ranger EV require caution and strict adherence to service publication warnings. It is essential that extra care be used when working with high voltage equipment.
  • Page 152 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES High Voltage Wiring ER073-A High Voltage Wiring • Wiring that distributes high voltage to components that operate on high voltage are connected as follows: A. From the battery charger to the high voltage power distribution box (HVPDB) B.
  • Page 153 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES Buffer Zone Buffer Zone • When interacting with a high voltage system, unnecessary personnel in the work area pose a safety threat to those directly involved in the repair of an EV. • The area immediately surrounding the vehicle is designated as a “buffer zone.”...

  • Page 154: Towing Procedure

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES TOWING PROCEDURE (Neutral only) ER078-A Towing Procedure • The towing procedure specified for the Ranger EV is similar to those of other vehicles. • Be sure to observe the following warnings and cautions when towing a Ranger EV: WARNING: TOW TRUCK OPERATORS SHOULD NOT ATTEMPT TO SERVICE, RECHARGE OR OPERATE...
  • Page 155 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES CAUTION: Do not disconnect the halfshafts if the motor/ transaxle is inoperable. This may cause further damage to the motor/transaxle. • Because the Ranger EV is made up of complex electrical systems, it is equipped with fail-safe components that can electrically disconnect the traction battery from the vehicle electrical system.

  • Page 156: Hoist Lift Points

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES HOIST LIFT POINTS FRONT ER079-A Hoist Lift Points • Front lift point – front cab mount extension (A). – Hoist pad in the lowest position. CAUTION: Position the front hoist pads just outboard of the torsion bars so they do not contact them.
  • Page 157 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES • Rear lift point – rear leaf spring (B) at the front hanger eye (C). – Hoist pad in the first raised position (D). WARNING: USE CAUTION WHEN OPERATING THE VEHICLE ON A HOIST. MOVING WHEELS COULD CAUSE SEVERE PERSONAL INJURY OR DEATH.

  • Page 158: Service Publication Navigation

    – Diagnostic Preface – This sub-section will spell out several of the specific changes in the Ranger EV manual in contrast to other Ford workshop manuals. – Retrieving Diagnostic Trouble Codes (DTCs) – This sub-section will provide directions on the correct procedure to follow when retrieving DTCs.
  • Page 159 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES – Parameter Identification (PID) Index – These charts will provide a definition of the PIDs available in each module. They also give an expected value for each PID. – Miscellaneous Diagnostics – These diagnostics refer to DTCs that are set and relate to the operating condition of the control modules themselves.
  • Page 160 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES NOTES 4-28 1998 Ranger EV New Model Training...

  • Page 161: Activity 4 - Special Service Tools And Procedures

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES ACTIVITY 4 – SPECIAL SERVICE TOOLS AND PROCEDURES – WORKSHEET H SPECIAL TOOLS AND SERVICE PROCEDURES STUDENT ANSWER SHEET OBJECTIVE: To identify special service procedures for the Ranger EV. DIRECTIONS: Write the correct answers in the blank spaces provided. Note the page number where the information was found.

  • Page 162: Student Answer Sheet

    LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES ACTIVITY 4 – SPECIAL SERVICE TOOLS AND PROCEDURES – WORKSHEET I SERVICE PUBLICATION NAVIGATION STUDENT ANSWER SHEET OBJECTIVE: Perform service publication navigation using Ranger EV service publications. DIRECTIONS: Using the Ranger EV service publications and your student reference guide, answer the following questions.
  • Page 163 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES ACTIVITY 4 – SPECIAL SERVICE TOOLS AND PROCEDURES – WORKSHEET J SPECIAL SERVICE TOOLS STUDENT ANSWER SHEET OBJECTIVE: To identify special service tools for Ranger EV. DIRECTIONS: Go to the special service tools on the table. Find the tool that performs the function listed on the right, write in the number/letter of the tag on the tool, and write in the tool’s name.
  • Page 164 LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES ACTIVITY 4 – SPECIAL SERVICE TOOLS AND PROCEDURES – WORKSHEET J1 ELECTRICAL CONNECTOR IDENTIFICATION STUDENT ANSWER SHEET OBJECTIVE: To locate and identify EV Ranger electrical connectors and determine if the circuits of that connector contain high voltage.

  • Page 165: Lesson 5: Diagnosis

    LESSON 5: DIAGNOSIS TECHNICIAN OBJECTIVES • Explain diagnostic strategy (symptom-to-system-to-component-to- cause) • Accurately and safely perform diagnostic and service procedures on a 1998 Ranger EV. CONTENTS • Introduction to Ranger EV Diagnosis and Service Procedures • Symptom-to-System-to-Component-to-Cause Diagnosis • Ranger EV Diagnostic Flowchart •...

  • Page 166: Introduction To Ranger Ev Diagnosis And Service Procedures

    The differences in this vehicle mean that the diagnosis and service procedures are also unique. Ford’s service goal for all vehicles is to “Fix it Right the First Time, On Time.” This goal also applies to the Ranger EV.
  • Page 167 LESSON 5: DIAGNOSIS • Once you identify the particular system, you then want to determine which “Component(s)” within that system could be the cause for the customer concern. – This usually consists of a series of isolation tests. – These specific tests and routines can be found in the Workshop Manual or the Electrical and Vacuum Troubleshooting Manual (EVTM).

  • Page 168: Ranger Ev Diagnostic Flowchart

    Verify Repair, Clear DTCs and Preform Actions Described for Corrected? Return Vehicle to Customer DTC Retrieved. Contact Ford Technical Hotline for Assistance. ER094-A Ranger EV Diagnostic Flowchart The Ranger EV Diagnostic Flowchart will help provide you with a standardized procedure for diagnosing the Ranger EV.
  • Page 169 • During visual inspection check only the low voltage fuses. Check for Non-Factory Add-On Equipment – Many calls that come into the Ford Technical Hotline are the result of incorrectly installed add-on equipment. • Because the Ranger EV will be used in many fleets, add-ons such as radios and light bars may be suspected causes of malfunctions.

  • Page 170: Multiplexing System Diagnosis

    LESSON 5: DIAGNOSIS MULTIPLEXING SYSTEM DIAGNOSIS Multiplexing System Operation • The Ranger EV uses two module communications networks. – J1850 (SCP) network (two-way communication during normal vehicle operation) used by the battery controller module (BCM), interface adapter assembly (IAA) module, and traction inverter module (TIM).
  • Page 171 LESSON 5: DIAGNOSIS • The SCP network may remain operational even if one of the bus wires is open or shorted (to ground or power). However, all data may be corrupt and the network should be repaired prior to performing diagnostics. –...

  • Page 172: New Generation Star Tester

    LESSON 5: DIAGNOSIS NEW GENERATION STAR TESTER Ranger EV NGS Program Card Main Menu New Generation STAR (NGS) Tester is essential to Ranger EV diagnosis. While technicians are familiar with NGS tester use on conventional vehicles, the Program Card for the Ranger EV has unique features that will be covered in this lesson.
  • Page 173 – DIAGNOSTIC TROUBLE CODE LIBRARY • The Module Menu selections and functions are similar to other Ford vehicles and should be familiar to technicians. NOTE: Use of parameter identification data (PID) is critical when diagnosing a Ranger EV. Technicians who are unfamiliar with the operation and utilization of the PID menu should refer to the New Generation STAR Tester Reference Guide.
  • Page 174 LESSON 5: DIAGNOSIS Parameter Identification Data (PID) Monitor and Record This menu will allow you to monitor and record the operation of many of the vehicle’s components. • Since there are so many PIDs available, there is also a definition (DEFN) function that will tell you the meaning of the acronym used to identify the component/function.

  • Page 175: Contactor Box Diagnosis

    LESSON 5: DIAGNOSIS CONTACTOR BOX DIAGNOSIS ER096-A Contactor Box • Diagnostic trouble code (DTC) C1862 is associated with the Contactor Box and its circuits. • The Contactor Box Assembly (CBA) is basically an on/off switch for the traction battery. • The CBA contains the high voltage contactor relays, fuses, and resistors.
  • Page 176 LESSON 5: DIAGNOSIS NOTES 5-12 1998 Ranger EV New Model Training...

  • Page 177: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 5 – DIAGNOSIS – WORKSHEET K NGS OPERATION AND IMPROPERLY CLOSED CONTACTOR RELAY DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will be able to navigate and utilize the various functions of the NGS, and be able to verify contactor relay operation.
  • Page 178 LESSON 5: DIAGNOSIS ACTIVITY 5 – DIAGNOSIS – WORKSHEET K NGS OPERATION AND IMPROPERLY CLOSED CONTACTOR RELAY DIAGNOSIS STUDENT ANSWER SHEET (Continued) 8. List any DTCs retrieved. __________________________________________________________________ ______________________________________________________________________________________ 9. If any continuous codes are stored in memory, the faults that set these DTCs: A.
  • Page 179 LESSON 5: DIAGNOSIS ACTIVITY 5 – DIAGNOSIS – WORKSHEET K NGS OPERATION AND IMPROPERLY CLOSED CONTACTOR RELAY DIAGNOSIS STUDENT ANSWER SHEET (Continued) 12. View the PID activity in the table mode. Press REW. How many seconds before you pressed the trigger is data available? __________________________________________________________________________ ______________________________________________________________________________________ 13.
  • Page 180 LESSON 5: DIAGNOSIS ACTIVITY 5 – DIAGNOSIS – WORKSHEET K NGS OPERATION AND IMPROPERLY CLOSED CONTACTOR RELAY DIAGNOSIS STUDENT ANSWER SHEET (Continued) 21. Highlight POS MAIN and send a closed command. What occurs? _________________________________ ______________________________________________________________________________________ . Explain that if you try to close the main contactor (POS MAIN) before closing the precharge contactor (PRECHG IN), the NGS will kick you out of the menu.

  • Page 181: Charging Concerns

    LESSON 5: DIAGNOSIS CHARGING CONCERNS The Power Control Station (PCS) recharges the traction battery. Under normal conditions all the driver has to do is plug the vehicle into the PCS, and the vehicle batteries will automatically be recharged. If the PCS is connected to the vehicle and the green start button on the PCS is flashing, the vehicle is not charging.
  • Page 182 LESSON 5: DIAGNOSIS • The BCM strategy is to prevent charging if: – There is a failure of the high voltage auxiliary bus current sensor in the contactor box it will also prevent charging of the battery pack. – A battery module fails open. –...
  • Page 183 LESSON 5: DIAGNOSIS NOTES 1998 Ranger EV New Model Training 5-19...

  • Page 184: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 6 – DIAGNOSIS – WORKSHEET L CHARGING SYSTEM DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will accurately diagnose the cause of an “unable to charge” concern. DIRECTIONS: Go to assigned classroom vehicle. Read the repair order, then using the special tools supplied, and the publications provided, perform the tasks and answer the questions below.
  • Page 185 LESSON 5: DIAGNOSIS ACTIVITY 6 – DIAGNOSIS – WORKSHEET L CHARGING SYSTEM DIAGNOSIS STUDENT ANSWER SHEET (Continued) 9. List three possible causes that could cause a strategy to be implemented that will prevent the vehicle from charging. ______________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ 10.

  • Page 186: Power Control Station (Pcs) Diagnostic Procedures

    PCS may be required. • Be aware that Ford is not responsible for the operation, diagnosis, or repair of customer power control stations. • It is the responsibility of the customer and the PCS manufacturer to ensure correct operation.
  • Page 187 LESSON 5: DIAGNOSIS Diagnostic Procedure for SCI Power Control Station If the vehicle fails to charge, and it is connected to an SCI PCS, use this procedure to determine if it is operating properly. • Make note of any lights that are flashing or steadily illuminated on the PCS.
  • Page 188 LESSON 5: DIAGNOSIS Diagnostic Procedure EVI Power Control Station If the vehicle fails to charge, and it is connected to an EVI PCS, use this procedure to determine if it is operating properly. • Make note of any lights that are illuminated or any messages being issued by your PCS.

  • Page 189: Traction Battery Removal

    LESSON 5: DIAGNOSIS TRACTION BATTERY REMOVAL In the event diagnostic procedures require that the traction battery must be removed from the vehicle for diagnostic and/or service procedures, strict adherence to the service publication procedures must be maintained. Before removal of a the traction battery, read and follow the service procedures in Section 100-05: •...
  • Page 190 LESSON 5: DIAGNOSIS NOTES 5-26 1998 Ranger EV New Model Training...

  • Page 191: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 7 – DIAGNOSIS – WORKSHEET M TRACTION BATTERY REMOVAL STUDENT ANSWER SHEET OBJECTIVE: The student will remove the traction battery. DIRECTIONS: Go to the assigned classroom vehicle. The instructor will designate students to perform traction battery removal procedures. When not actually working on the vehicle, follow along in the workshop manual supplement and answer the questions on this worksheet.
  • Page 192 LESSON 5: DIAGNOSIS High Voltage Auxiliary Load System Diagnosis The high voltage auxiliary load system includes all the high voltage components connected to the high voltage power distribution box (HVPDB). These components include: • the DC/DC converter (auxiliary battery charging). •...
  • Page 193 LESSON 5: DIAGNOSIS NOTES 1998 Ranger EV New Model Training 5-29...
  • Page 194 LESSON 5: DIAGNOSIS NOTES 5-30 1998 Ranger EV New Model Training...

  • Page 195: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 8 – DIAGNOSIS – WORKSHEET N PTC HEATER DIAGNOSIS DEMONSTRATION STUDENT ANSWER SHEET OBJECTIVE: This is a demonstration of the correct safety and diagnostic procedures to follow when diag- nosing a vehicle with a PTC heater concern. It will also show correct safety procedures to follow when diagnosing HV components that are connected to the HVPDB.
  • Page 196 LESSON 5: DIAGNOSIS NOTES 5-32 1998 Ranger EV New Model Training...

  • Page 197: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 9 – DIAGNOSIS – WORKSHEET O POWER STEERING DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation designated by your instructor. Read the repair order, then using the Ranger EV service publications, perform the tasks and answer the questions below.
  • Page 198 LESSON 5: DIAGNOSIS ACTIVITY 9 – DIAGNOSIS – WORKSHEET O POWER STEERING DIAGNOSIS STUDENT ANSWER SHEET (Continued) 9. Diagnose this concern using the procedures in the service publications. List the test steps you perform and their results in the table below. (NOTE: The number of rows in the table do not indicate the number of steps in the procedure.

  • Page 199: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 9 – DIAGNOSIS – WORKSHEET P AIR CONDITIONING DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation designated by your instructor. Read the repair order, then using the Ranger EV service publications, perform the tasks and answer the questions below.

  • Page 200: Electric Motor/Transaxle Diagnosis

    The unit is not field serviceable, and is only serviced as an assembly. To determine if a component of the motor/transaxle assembly is the source of a concern, Ford has developed the Electric Motor/ Transaxle Test Box. This tool can test: •...
  • Page 201 LESSON 5: DIAGNOSIS NOTES 1998 Ranger EV New Model Training 5-37...

  • Page 202: Traction Battery Pack Components Demonstration

    LESSON 5: DIAGNOSIS TRACTION BATTERY PACK COMPONENTS DEMONSTRATION The traction battery pack contains many different components. The following is a list of these components. As your instructor points out these components, note the workshop manual section where service information on the components can be found. •...
  • Page 203 LESSON 5: DIAGNOSIS NOTES 1998 Ranger EV New Model Training 5-39...

  • Page 204: Traction Battery Diagnosis

    LESSON 5: DIAGNOSIS TRACTION BATTERY DIAGNOSIS Current Leakage Diagnosis Current leakage is a condition that occurs if a short develops between the traction battery positive and/or negative bus and chassis ground. If this occurs, resistance is reduced due to the additional current path to ground.
  • Page 205 LESSON 5: DIAGNOSIS NOTES 1998 Ranger EV New Model Training 5-41...
  • Page 206 LESSON 5: DIAGNOSIS NOTES 5-42 1998 Ranger EV New Model Training...

  • Page 207: Activity 12 - Diagnosis - Worksheet Qcurrent Leakage And Multiple Auxiliary Load Failure Diagnosis Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 12 – DIAGNOSIS – WORKSHEET Q CURRENT LEAKAGE AND MULTIPLE AUXILIARY LOAD FAILURE DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation as directed by your instructor. Read the repair order on the vehicle and isolate the cause of the concern.

  • Page 208: Student Answer Sheet

    LESSON 5: DIAGNOSIS ACTIVITY 12 – DIAGNOSIS – WORKSHEET R STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation as directed by the instructor. Read the repair order on the vehicle and isolate the cause of the concern.
  • Page 209 LESSON 5: DIAGNOSIS Battery Diagnostic System (BDS) Battery Module and Sense Lead Diagnostics Diagnosing a battery module or sense lead fault can be of critical importance when a vehicle is brought in for service. • It is important to note that a single bad module or single sense lead will not usually illuminate any of the warning lights in the instrument cluster.
  • Page 210 LESSON 5: DIAGNOSIS • This is due to the fact that each sense lead monitors the voltage of two battery modules. • For example, the sense lead that monitors the voltage for module 15 also monitors module 16’s voltage. • So a failure of the sense lead will cause both modules to indicate bad.
  • Page 211 LESSON 5: DIAGNOSIS • Return the vehicle to the repair facility. • Actuate heater/defroster mode on high fan and leave on headlamps to discharge battery pack. • When battery pack reaches 10% SOC, view BAT_MV PID for each of the 39 battery modules. •...
  • Page 212 LESSON 5: DIAGNOSIS Battery Voltage Record Sheet Directions 1. Enter BCM ACTIVE COMMANDS. 2. Enter BATTERY MODULE SELECT menu. 3. Enter PID menu. 4. Select BAT_MV PID. 5. Press START. 6. Press SETUP button (8). 7. Press AUTO (4). 8. Press CANCEL to return to ACTIVE COMMAND menu. 9.
  • Page 213 LESSON 5: DIAGNOSIS 13. Select the lowest five PIDS from above, and again view their voltage readings using the BAT_MV PID. Record their voltage readings. BATTERY VOLTAGE READINGS Battery # 14. Select the lowest three readings from the modules above. BATTERY VOLTAGE READINGS Battery # Module Replacement Criteria...
  • Page 214 LESSON 5: DIAGNOSIS Emergency Power Off (EPO) In the event an unsafe condition occurs that will disable an interlock or if the inertia switch is triggered, an EPO signal will be sent to disable all high voltage loads. • Can be set by IAA, BCM, or TIM. •...
  • Page 215 LESSON 5: DIAGNOSIS NOTES 1998 Ranger EV New Model Training 5-51...
  • Page 216 LESSON 5: DIAGNOSIS ACTIVITY 13 – DIAGNOSIS – WORKSHEET S1 (BDS) BATTERY AND SENSE LEAD DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation as directed by the instructor. Perform the tasks and answer the question below.
  • Page 217 LESSON 5: DIAGNOSIS ACTIVITY 13 – DIAGNOSIS – WORKSHEET S2 (NON-BDS) BATTERY AND SENSE LEAD DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation as directed by the instructor. Read the repair order on the vehicle and isolate the cause of the concern.
  • Page 218 LESSON 5: DIAGNOSIS ACTIVITY 13 – DIAGNOSIS – WORKSHEET S2 (NON-BDS) BATTERY AND SENSE LEAD DIAGNOSIS STUDENT ANSWER SHEET (Continued) 11. Check the individual voltage of all the battery modules. Use the attached Battery Module Record Sheet found on the next page. 12.
  • Page 219 LESSON 5: DIAGNOSIS Battery Module Record Sheet Directions 1. Enter BCM ACTIVE COMMANDS. 2. Enter BATTERY MODULE SELECT menu. 3. Enter PID menu. 4. Select BAT_MV PID. 5. Press START. 6. Press SETUP button (8). 7. Press AUTO (4). 8. Press CANCEL to return to ACTIVE COMMAND menu. 9.
  • Page 220 LESSON 5: DIAGNOSIS 13. Select the lowest five PIDS from above, and again view their voltage readings using the BAT_MV PID. Record their voltage readings. BATTERY VOLTAGE READINGS Battery # 14. Select the lowest three readings from the modules above. BATTERY VOLTAGE READINGS Battery # Module Replacement Criteria...
  • Page 221 LESSON 5: DIAGNOSIS ACTIVITY 13 – DIAGNOSIS – WORKSHEET T EPO DIAGNOSIS STUDENT ANSWER SHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation as directed by the instructor. Read the repair order on the vehicle and isolate the cause of the concern.
  • Page 222 NOTES...

  • Page 223: Glossary

    GLOSSARY RANGER EV ACRONYMS ABS – Anti-Lock Brake System HVPDB – High Voltage Power Distribution Box AC – Alternating Current IAA – Interface Adapter Assembly A/C – Air Conditioning ICE – Internal Combustion Engine APS – Accelerator Position Sensor IGBT – Insulated Gate Bipolar Transistor BCM –...
  • Page 224 NOTES...

  • Page 225: Written Activity Sheet 1

    10. What symptoms may occur if a DTC C1750 is set in the TIM? ____________________________________ ______________________________________________________________________________________ 11. Which diagnostic strategy does Ford recommend be used when diagnosing a vehicle? _________________ ______________________________________________________________________________________ 12. What personal safety steps should always be performed before working on the Ranger EV? _____________...

  • Page 226: Student Answer Sheet

    ACTIVITY SHEET ACTIVITY SHEET 2 STUDENT ANSWER SHEET DIRECTIONS: Using the information provided in your Student Reference Guide, read and answer the following questions. 1. Which circuits are the data bus for the J1850 (SCP) network? _____________________________________ ______________________________________________________________________________________ 2. When testing for an improperly closed contactor relay, what PID should you monitor? _________________ ______________________________________________________________________________________ 3.

  • Page 227: Generic Worksheet

    ACTIVITY SHEET GENERIC WORKSHEET OBJECTIVE: The student will safely and accurately diagnose a Ranger EV concern. DIRECTIONS: Go to the workstation as directed by the instructor. Read the repair order on the vehicle and isolate the cause of the concern. 1.
  • Page 228 NOTES...

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