2013-2021 Ford Fusion Hybrid Li-Ion Battery |
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2013-2021 Ford Fusion Hybrid Li-Ion Battery Service
0:00 Introduction 0:54 Battery kWh rating Main battery components 1:32 Service Plug Grip 1:44 DC-DC Converter 1:52 Battery Energy Control Module (BECM) 1:59 Battery Junction Block 2:12 Battery Cells 2:26 Air-cooled battery airflow 2:30 Battery fan 2:50 Battery vent 3:00 Inlet air temperature sensor 3:06 Internal cell temperature sensors 4:00 High voltage (HV) disconnect procedure 4:45 Service plug grip removal warning 6:30 HV Interlock circuit 9:20 Removal of battery covers 10:00 Battery safety warning label 10:55 BECM electrical connections 13:40 BECM Warning label 14:02 **(see note below) Personal Protective Equipment needed 14:40 Service grip connector bracket removal 15:20 Cooling fan removal 15:36 Side and front cover removal 15:48 Rear cover removal 16:00 DC-DC converter electrical connections and operation 17:05 DC-DC converter cooling 18:40 HV Voltmeter checking 21:45 DC-DC converter output 23:22 Hybrid battery junction block harnesses and removal 27:20 Hybrid battery junction block connections and components 29:17 DC-DC converter fuse 30:30 Positive battery harness and connections 31:28 Positive battery harness and connections 32:00 Auxiliary harness connections 34:00 Li-Ion battery cover removal 35:20 Under the cover inspection 37:42 Tamper-resistant nuts 39:07 Cell stack voltages 29:50 Individual cell voltages 40:00 Cell pair voltage addition 41:31 Total cell stack and battery pack voltages 41:59 Battery vent system The Li-Ion battery from a Ford Fusion Hybrid has 76 3.7V cells (281.2V) nominal and a ~5 Ah rating = 281.2 x 5 = 1406 Watt-hours or 1.406 kWh **I failed to comply with three OSHA standards in this video: - 1910.137(c)(2)(vii) - Protector gloves shall be worn over insulating gloves in this video. - 1910.137(c)(2)(vii)(D) - Insulating gloves that have been used without protector gloves may not be reused until they have been tested under the provisions of paragraphs (c)(2)(viii) and (c)(2)(ix) of this section. - 1910.137(c)(2)(vii)(A) - Protector gloves need not be used with Class 0 gloves, under limited-use conditions, when small equipment and parts manipulation necessitate unusually high finger dexterity. I apologize for the error on my part. I was not aware of the requirement at that time. I now offer full updated training on PPE usage and following the proper OSHA regulations. See http://www.weber.edu/evtraining for more information. Weber State University (WSU) - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab. This episode covers High Voltage Hybrid Electrical Systems - Specifically the 2nd generation (2013-2016) Ford Fusion Hybrid 281.2 Volt Li-Ion battery system. Learn what is serviceable and how it works. This topic is taught as part of our 4-year bachelor's degree program. For more information on the Weber Automotive program, visit: http://www.weber.edu/automotive This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see http://www.weber.edu/automotive/J_Kelly.html |