Ford Electric Ranger 1998 Student Manual page 7

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 - Worksheet K - NGS Operation and Improperly Closed Contactor Relay Diagnosis
Student Answer Sheet ................................................................................................................ 5-13
Charging Concerns ........................................................................................................................ 5-17
Activity 6 - Worksheet L - Charging System Diagnosis
Student Answer Sheet ................................................................................................................ 5-20
Power Control Station (PCS) Diagnostic Procedures ..................................................................... 5-22
Traction Battery Removal .............................................................................................................. 5-25
Activity 7 - Worksheet M - Traction Battery Removal
Student Answer Sheet ................................................................................................................ 5-27
Activity 8 - Worksheet N - PTC Heater Diagnosis Demonstration
Student Answer Sheet ................................................................................................................ 5-31
Activity 9 - Worksheet O - Power Steering and Air Conditioning Diagnosis
Student Answer Sheet ................................................................................................................ 5-33
Activity 9 - Worksheet P - Air Conditioning Diagnosis
Student Answer Sheet ................................................................................................................ 5-35
Electric Motor/Transaxle Diagnosis ............................................................................................... 5-36
Traction Battery Pack Components Demonstration ........................................................................ 5-38
Traction Battery Diagnosis ............................................................................................................. 5-40
Activity 12 - Diagnosis - Worksheet Q - Current Leakage and Multiple Auxiliary Load
Failure Diagnosis
Student Answer Sheet ................................................................................................................ 5-43
Worksheet R
Student Answer Sheet ................................................................................................................ 5-44
Activity 13 - Worksheet S1 - Battery Sense Lead and EPO Diagnosis
Student Answer Sheet ................................................................................................................ 5-52
Activity 13 - Worksheet S2 - Battery and Sense Lead Diagnosis (Non-BDS)
Student Answer Sheet ................................................................................................................ 5-53
Activity 13 - Worksheet T - EPO Diagnosis
Student Answer Sheet ................................................................................................................ 5-57
1998 Ranger EV New Model Training
TABLE OF CONTENTS
iii