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Ford Ranger EV. Electric Manual - part 43

LESSON 5: DIAGNOSIS

5-13

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.

DIRECTIONS:

Go to the assigned classroom vehicles and using the special tools supplied, and the publica-

tions provided, perform the tasks and answer the questions below.

1. Once the NGS is booted, what is the first item that must be programmed into the tester? ________________

______________________________________________________________________________________

2. Which menu item must be selected to perform on-board diagnostic tests? ___________________________

______________________________________________________________________________________

3. Once you have entered this menu, which test should always be performed first? ______________________

______________________________________________________________________________________

Why? _________________________________________________________________________________

______________________________________________________________________________________

IRQ

: The SCP network may be able to communicate with the scan tool even if one of the two data bus wires are

cut. However, tests are invalid because the information displayed may be inaccurate.

4. Perform the test indicated in question 3. List the results below. ____________________________________

______________________________________________________________________________________

5. Do the results of the test performed in question 4 indicate that the system is OK? _____________________

______________________________________________________________________________________

6. If this system has a fault, you should:

A. Ignore the fault and continue on-board diagnostics.

B. Repair the fault then retest the vehicle to see if the concern is corrected.

C. Jumper the circuit in question, then repeat the test to see if the fault clears.

D. Perform an active command to determine if the circuit is actually functional. If it is, continue with

on-board diagnostics.

7. Retrieve continuous and on-demand DTCs from the IAA, TIM, and BCM. Will all these modules support

these functions? _________________________________________________________________________

______________________________________________________________________________________

WORKSHEET K CONTINUED ON NEXT PAGE

LESSON 5: DIAGNOSIS

5-14

WORKSHEET K CONTINUED ON NEXT PAGE

8. List any DTCs retrieved. __________________________________________________________________

______________________________________________________________________________________

9. If any continuous codes are stored in memory, the faults that set these DTCs:

A. may not be occurring now.

B. may be occurring now.

C. have occurred at some time in the last 40 drive cycles (intermittent).

D. all of the above.

IRQ

: Review continuous DTCs.

10. Faults that set on-demand DTCs:

A. may not be occurring now.

B. are occurring now.

C. have occurred at some time in the last 40 drive cycles (intermittent).

D. all of the above.

IRQ

: Review on-demand DTCs.

11. Return to the Diagnostic Data Link menu.

– Select IAA module.

– Select PID Data Monitor and record.

– KEY ON.

– Select VACPRES, CM_SPD, SET_TMP, PIDs.

– Press START.

– Randomly operate the climate control system by turning the temperature dial and A/C dial for 15 seconds.

– Press trigger to CAPTURE DATA.

– Again randomly operate the climate control system by turning the temperature dial and A/C dial for

15 seconds.

– Press trigger again to STORE DATA.

– Store data in area 2.

– Follow the directions on the NGS screen.

– Once data is stored, press cancel.

– After saving, return to STORE DATA menu and select VIEW RECORDING.

– Select all three PIDs to view.

ACTIVITY 5 – DIAGNOSIS – WORKSHEET K

NGS OPERATION AND IMPROPERLY CLOSED

CONTACTOR RELAY DIAGNOSIS

STUDENT ANSWER SHEET (Continued)

LESSON 5: DIAGNOSIS

5-15

12. View the PID activity in the table mode. Press REW. How many seconds before you pressed the trigger is

data available? __________________________________________________________________________

______________________________________________________________________________________

13. Press PLAY. How many seconds after you pressed the trigger is data available? ______________________

______________________________________________________________________________________

14. Press CANCEL to exit the table mode. Enter the graph mode. How many PIDs can you view at the same

time? _________________________________________________________________________________

______________________________________________________________________________________

15. On the right and left sides there are numbers. What do these numbers indicate? _______________________

______________________________________________________________________________________

16. What NGS button do you press to move the graph forward? ______________________________________

______________________________________________________________________________________

What button do you press to move the graph backward? _________________________________________

______________________________________________________________________________________

17. Looking at these PIDs, do these sensors appear to be functioning normally? _________________________

______________________________________________________________________________________

18. In the workshop manual, refer to Negative Contactor Relay Control Pinpoint Test step A2 in Section 414-

03. Perform the test procedure described. What occurs to the voltage displayed? ______________________

______________________________________________________________________________________

19. What would it indicate if this PID indicated greater than 200 volts? ________________________________

______________________________________________________________________________________

IRQ

: Explain that if voltage is not falling, main and negative contactors are stuck closed. Stuck contactors can

cause the vehicle not to recharge. This could cause a safety concern if you are disconnecting the traction battery

HV 2-pin connector C3994, because high voltage would be present at the connector. Whenever this connector is

open use the traction battery high voltage lockout and diagnostic tool.

20. While in the TIM active command mode select the following PIDs: BAT_PV, TPCCO, and TPMCO. Press

START. Highlight PRECHG IN and command it to close. What occurs to the BAT_PV and TPCCO PID?

______________________________________________________________________________________

ACTIVITY 5 – DIAGNOSIS – WORKSHEET K

NGS OPERATION AND IMPROPERLY CLOSED

CONTACTOR RELAY DIAGNOSIS

STUDENT ANSWER SHEET (Continued)

LESSON 5: DIAGNOSIS

5-16

21. Highlight POS MAIN and send a closed command. What occurs? _________________________________

______________________________________________________________________________________

IRQ

. 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. The precharge contactor must close before main.

22. What are the definitions of the following PIDs?

BAT_PV ______________________________________________________________________________

______________________________________________________________________________________

TPCCO ________________________________________________________________________________

______________________________________________________________________________________

TPMCO _______________________________________________________________________________

______________________________________________________________________________________

ACTIVITY 5 – DIAGNOSIS – WORKSHEET K

NGS OPERATION AND IMPROPERLY CLOSED

CONTACTOR RELAY DIAGNOSIS

STUDENT ANSWER SHEET (Continued)

END OF WORKSHEET K

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