Content .. 37 38 39 40 ..

Ford Ranger EV. Electric Manual - part 39

LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES

4-29

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.

1. What class of rubber insulating gloves is to be used, how often do the gloves need to be recertified, and

when do they need to be tested? ____________________________________________________________

______________________________________________________________________________________

PAGE # ____________

2. What are the methods of towing specified for the Ranger EV? ____________________________________

______________________________________________________________________________________

PAGE # ____________

3. What lift points and hoist pad positions are recommended for the Ranger EV? _______________________

______________________________________________________________________________________

PAGE # ____________

4. What is the correct buffer boundary that should be established around an EV, and how is this boundary

marked? _______________________________________________________________________________

______________________________________________________________________________________

PAGE # ____________

5. What is the tool number for the Power Steering Interlock Tool? ___________________________________

______________________________________________________________________________________

PAGE # ____________

6. What piece of equipment is specially designed for the Ranger EV battery pack removal and installation? __

______________________________________________________________________________________

PAGE # ____________

END OF WORKSHEET H

LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES

4-30

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.

1. On what page of the service manual will you find directions for retrieving diagnostic trouble codes? ______

______________________________________________________________________________________

2. What information will the Diagnostic Preface provide you? ______________________________________

______________________________________________________________________________________

3. Which pinpoint test should you perform if you retrieve DTC C1184 after cycling the ignition on and off

quickly? _______________________________________________________________________________

______________________________________________________________________________________

4. What procedure does DP1 have you perform? _________________________________________________

______________________________________________________________________________________

5. What is the description of TIM DTC C1750? __________________________________________________

______________________________________________________________________________________

6. What is the description of BCM PID CCNTBCM? _____________________________________________

______________________________________________________________________________________

7. What is the meaning of IAA operation state (OPSTATE) PID 12? _________________________________

______________________________________________________________________________________

8. If a vehicle comes in that has no DTCs but will not charge, what section of the workshop manual should you

refer to for diagnostic direction based upon the symptom? _______________________________________

______________________________________________________________________________________

9. What diagnostic routine are you directed to for the symptom described in question 8? _________________

______________________________________________________________________________________

10. You have retrieved a DTC C1755 from the TIM. In which section and page number can the pinpoint test

you will need to perform be found? __________________________________________________________

______________________________________________________________________________________

END OF WORKSHEET I

LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES

4-31

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.

TAG #

TOOL NAME

DESCRIPTION

BCM/TIM Breakout Box

Utilized when performing low voltage diagnostics on the

Adapter Cable and Overlay

BCM or TIM.

In-line Bypass Battery

Used when a traction battery module replacement is required.

Module

Traction Battery

Connects between the traction battery LV 76-pin connector

Low Voltage Service Cord

at the left front of the battery tray and the vehicle harness.

Capacitor Discharge Tool

Used to ensure that capacitors have discharged prior to

performing vehicle service.

Auxiliary Interlock Tool

Used to close the interlock loop on the vehicle during

diagnostics.

Electric Motor/

Confirm the operation of the speed sensors within the

Transaxle Test Box

motor assembly.

Battery Module Lifting

Aids in lifting, carrying, and removing the battery module

Tool

from the traction battery pack.

Battery Lift Table

Uses pressure from a shop air source to raise and lower the

traction battery.

Traction Battery

Is used as a safety device when the TIM is disconnected

High Voltage (HV) Lockout

from the traction battery.

and Diagnostic Tool

Traction Battery

Connects between the traction battery auxiliary load

High Voltage

HV connector at the right front of the battery tray and

Service Cord

the vehicle harness.

Insulated Battery Post

Allows safe tightening of battery post connectors.

Torque Wrench

Power Steering

Used to close interlock loop at power steering connector

Interlock Tool

during diagnostics.

END OF WORKSHEET J

LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES

4-32

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.

DIRECTIONS:

Your instructor has labeled several of the vehicle connectors. Locate the correct connector on

the vehicle or battery pack, note the tag letter/number, number of pins, and indicate if the

connector has any high voltage circuits.

HIGH

CONNECTOR

VOLTAGE CIRCUITS

TAG #

NAME

NUMBER OF PINS

(YES/NO)

C1865

YES

C1866

YES

C1895

YES

C1914

YES

C1917

YES

C1920

YES

C1923

YES

C1935

YES

C1939

C1945

104

C3994

YES

C5000

YES

END OF WORKSHEET J1

Content .. 37 38 39 40 ..