The High Voltage System of a Mach-E GT
See the high voltage (HV) components of a 2021 Ford Mustang Mach E GT! Almost every electric vehicle has these same high voltage components. Learn their names and their basic functions.
I have been away from KZread for eight months developing a new training curriculum for my college classes and the hybrid and electric vehicle classes I offer to the public. I am back now and will be releasing new videos as quickly as I am able.
CORRECTIONS:
I was wrong about the hood electric open hood only, there is a release handle, but it is behind electrically opened doors. If the doors were locked when the 12V battery died, then a special procedure shown here is needed.
TIMELINE:
0:00 Start
0:08 Introduction
1:38 HV common component - The Front Motor Inverter
3:18 HV common component - The DC-to-DC Converter
4:45 The 12V AGM battery
5:28 MUST SEE: The under frunk Jump Start terminals
6:17 Remote auxiliary stud box to open the frunk if the 12V battery is dead
6:43 MUST SEE: The green colored under frunk Low Voltage Service Disconnect (LVSD) connector
7:28 MUST SEE: The low voltage low current and high current fuse blocks.
8:55 HV common component - The Electric Air-Conditioning Compressor
9:18 The coolant chiller
10:00 HV common component - The On-Board Charger Module
12:16 The two coolant expansion tanks (Reservoirs)
12:54 Passenger compartment heat and the four-way switching valve.
13:36 Why there are a few more coolant hoses than some other electric vehicles
14:23 HV common component - The Front Drive Unit and Motor
15:30 HV common component - The High Voltage Battery
16:18 The Electrical connections at the high voltage battery
16:26 The small orange connector receives up to 43 amps of DC current from the onboard charger when using an AC Level 1 or AC Level 2 plug-in charge cable.
16:26 The large orange connector receives up to 300 amps of DC current from a DC Fast Charge station when using a DC Level 2 plug-in charge cable.
17:25 The metal electrical connector feeds DC power to the front motor inverter
17:37 The black low voltage data and power connector
18:18 The coolant hose connections at the front of the battery
18:42 HV common component - The Cabin Coolant Heater
19:00 HV common component - The Rear Drive Unit and Motor
19:30 The coolant hose connections at the rear of the battery
20:00 Mercon ULV Drive Unit Fluid
20:28 Special adapters are required to lift the vehicle and remove the high voltage battery
24:00 Video Summary and EV Common Components
ABOUT US
Weber State University (WSU) - Davis Campus - Department of Automotive Technology - Ardell Brown Technology Wing - Transmission Lab. We teach current vehicle technologies to our automotive students at Weber State University and online. For more information visit: www.weber.edu/automotive
This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see www.weber.edu/automotive/J_Kel...
ADDITIONAL TRAINING FOR YOU
Join us for hybrid and electric vehicle training with two online courses and in a 5-day on-campus boot camp with Professor John D. Kelly. See www.weber.edu/evtraining
DONATE TO OUR DEPARTMENT
Please consider a donation to the Department of Automotive Technology at Weber State University here: advancement.weber.edu/Automotive
Пікірлер: 285
This is excellent! Chiltons manual- $24.99 Motor all-data subscription- $199 per month Weber auto on KZread- Priceless
@WeberAuto
Жыл бұрын
Awesome, thanks for watching
Glad to have you back Kelly! I love recommending your videos to the newer techs we get in the shop, great content as always
@WeberAuto
Жыл бұрын
Thank you very much!
Great to see you again Professor Kelly. Best regards from Vancouver Island.
@WeberAuto
Жыл бұрын
Thank you very much!
"I'm back." with an austrian accent should be the intro of the Prof. John "Explainiator" Kelly! 😎 Great to see you back, giving us starving crowds some brain food! 👍👍😁
@WeberAuto
Жыл бұрын
Thank you very much!
This is such a important KZread Channel. The electrification of ground transportation is here and growing.
@WeberAuto
Жыл бұрын
Thank you so much!
Great to see you back Prof. Kelly! When I talk to anyone that wants hybrid/ev information I send them to your channel. I hope you get a Rivian R1T to show at some point. Thank you for all the videos you do.
@WeberAuto
Жыл бұрын
Thanks Mike, I hope so too!
Hi Professor! I was starting to worry. Glad to see you again!
@WeberAuto
Жыл бұрын
Thank you! I am glad to be back
Welcome back professor. Great to see a new video from you.
@WeberAuto
Жыл бұрын
Thank you
We miss you Mr Kelly nice to have you in the front, the stage is yours, and valuble information you always have ,thank you.
@WeberAuto
Жыл бұрын
Thank you very much!
Glad to see you back uploading again. I really learn so much watching your videos. Thank you.
@WeberAuto
Жыл бұрын
Thank you, I am glad you like them.
Welcome back Professor John Kelly.
@WeberAuto
Жыл бұрын
Thank you!
Thank you Professor! It's great to see you and your latest video!
@WeberAuto
Жыл бұрын
Thank you, more to come!
Glad you are back making videos, Professor. Ford doesn't seem to have considered that the battery would need to be removed. Ouch.
@WeberAuto
Жыл бұрын
Thank you!
Prof, we missed your juicy contents. Welcome back.
@WeberAuto
Жыл бұрын
Thank you very much!
nice to have you back Prof. Kelly
@WeberAuto
Жыл бұрын
Thank you very much
If I were surrounded by students, I'd be thinking about adding a locating pin or screw to the lift foot and adaptor block. Thanks for taking the trouble to share the clear information that's hard to get anywhere else.
@WeberAuto
Жыл бұрын
Thank you very much, That is a great idea.
We are blessed to have you give such valuable time to us.
@WeberAuto
Жыл бұрын
Thank you very much!
I really wish i could take a course from you. The way you explain everything is very easy to understand and very clear. I been watching your videos for a while now and just wanted to say thanks for all the knowledge you share online.
You were really missed and I am glad we will be educated on car design.
@WeberAuto
Жыл бұрын
Thank you!
Glad to see you are back making videos. I have to say that needing a battery to open the “frunk" in order to jump start the battery is the closest I have seen yet to a car manufacturer welding the hood shut. I used to be really excited about electric cars, but the more I learn about them and the obstacles that manufacturers seem to put in the way of people being able to fix them on their own, the less I am inclined to want to get one anytime soon.
@WeberAuto
Жыл бұрын
Thanks! I was wrong about electric open only, there is a release handle, but it is behind electrically opened doors. If the doors were locked when the 12V battery died, then the special procedure is needed.
You have been sorely missed. Great to see you back. And to think I thought electric vehicles could potentially simple!
@WeberAuto
Жыл бұрын
Thank you very much
Found your video on one of the Mach E owner forums, and bonus, you even covered my trim. Excellent work. great to learn more about my vehicle.
@WeberAuto
Жыл бұрын
Thank you very much
Happy to see you back Kellly!
@WeberAuto
Жыл бұрын
Thank you so much!
Great to see you back! Would be great to hear something about the new Honda Civic Hybrid vs Honda CRV Hybrid. Both are ehev and probably are not sold in US.
@WeberAuto
Жыл бұрын
I would like that. Thanks for the suggestion
Great video as always, thanks for sharing it.
@WeberAuto
Жыл бұрын
Thanks for watching!
Welcome back, Professor! Thanks for a great video. Looking forward to the more in depth videos coming. Be well!
@WeberAuto
Жыл бұрын
More to come! Thank you
So glad to see you are back and doing well. You surely have been busy. I have seen one report and photo of a Mach E that fell off a rack. I know you are diligent and safety conscious, stay safe. Hope to see your Honda Clarity battery some day 😀. Thank you so much for your efforts.
@WeberAuto
Жыл бұрын
Oh wow! Yes, we lift the vehicle a few inches and then purposely try to rock is off the rack. I have a solid mounting for this video, but I can see where someone who is not paying attention could make a mistake, especially on older hoists with swing arms that do not lock.Thanks for the information.
I glad to see you again, and appreciate your efforts
@WeberAuto
Жыл бұрын
Thank you so much!
THIS KING IS BACK!
@WeberAuto
Жыл бұрын
LOL, thank you!
Nice, looking forward to more on this Mustang!
@WeberAuto
Жыл бұрын
Coming soon!
Glad to see you back!
@WeberAuto
Жыл бұрын
Thank you very much!
Welcome back Professor Kelly!... always look forward for continuing educational videos.
@WeberAuto
Жыл бұрын
Thank you kindly!
Nice to see you back professor Kelly , thanks for sharing
@WeberAuto
Жыл бұрын
My pleasure! Thank you
Really great to see you back, Professor Kelly. Your videos are always excellent regardless of the topic at hand.
@WeberAuto
Жыл бұрын
Thank you very much!
I'm glad you're ok. Busy is good. Thanks for the video
@WeberAuto
Жыл бұрын
My pleasure. Thank you!
I am glad Thatcher l coud hear and see your new video. Greetings from Poland.
@WeberAuto
Жыл бұрын
Thank you!
great to see you back, thanks for new series, I'll watch it, and I appreciate all work you're doing for popularizing engineering held under car manufacturing process
@WeberAuto
Жыл бұрын
Thank you very much!
It's always a pleasure!
@WeberAuto
Жыл бұрын
Thank you!
Awesome! I can't wait to see more of this vehicle. Your video on the Volt battery was extremely helpful in disassembling my own. Much appreciated.
@WeberAuto
Жыл бұрын
Great to hear! Thank you
Great Info John.. Thanks for these very informative videos.
Well we're happy to wait for your high quality videos. Looking forward to this series. You point out the hoses and their functionality, the Munro team likes to make fun of excess hoses!
@WeberAuto
Жыл бұрын
Thank you very much!
Great to see you back Professor Kelly
@WeberAuto
Жыл бұрын
Thank you very much!
glad to see you again sir!
@WeberAuto
Жыл бұрын
More to come! Thank you.
Welcome back to the world of the internet! Excited for some more Mach-e content. Another item that most don't consider about jumpstarting any modern vehicle is that the jump points should ALWAYS be used. Besides the risk of sparks igniting any pooled hydrogen gas that you mentioned, anything recent uses a sensor to monitor power into and out of the battery. Charging or jumping the 12V battery at the terminals bypasses the sensor and will result in an incorrect learned charge state of the battery. Especially an issue with programming modules, which can take quite a while. The sensor just sees the battery being discharged, but not that a charger is connected, and will shut the ignition off and cause programming to fail. Common issue I've seen at dealers.
@WeberAuto
Жыл бұрын
Thanks Jake, that is great information!
Finally you are back. I was worried. Xmas is early this year.
@WeberAuto
Жыл бұрын
Thank you!
Thank you for your insights. As always the knowledge you share is a gold mine. I can't wait the next steps.
@WeberAuto
Жыл бұрын
Thanks for watching!
I have no reason to be interested in this but great to see you back and am genuinely excited about what we have to learn coming up. Thank you.
@WeberAuto
Жыл бұрын
Awesome, thank you!
Nice to see you back sensei, i was worried :c
@WeberAuto
Жыл бұрын
Thank you!
Welcome back, Professor! Thanks for a great video is Very informative 👍👍👍
@WeberAuto
Жыл бұрын
Thank you very much!
Heyyy professor .... un gusto verlo bien. Saludos desde republica dominicana!!!
@WeberAuto
Жыл бұрын
Thank you!
Nice to see your still there, I look forward to your tutorials, 👍👍👍 And iam not even a mech, iam a air-conditioning/ refrigeration engineer
@WeberAuto
Жыл бұрын
Thank you very much
Thank you professor. I always enjoy your videos.
@WeberAuto
Жыл бұрын
You are very welcome
SO GLAD YOUR BACK PROFESSOR .
@WeberAuto
Жыл бұрын
Thank you!
@SEXYTECH1000
Жыл бұрын
@@WeberAuto YOU'RE VERY WELCOME , LOVE YOUR VIDEOS BRO!
Good to see you again
@WeberAuto
Жыл бұрын
Thank you very much
Thankyou for sharing your wealth of knowledge
@WeberAuto
Жыл бұрын
My pleasure
Wellcom back professor, what a great video 👍🏻
@WeberAuto
Жыл бұрын
Thank you kindly!
Welcome back professor so great to see you 👋😎👋😎
@WeberAuto
Жыл бұрын
Thank you kindly
Very informative video again! We are waiting for your next future videos of this car. Good luck
@WeberAuto
Жыл бұрын
Coming soon! thank you
Thanks! Very glad to see you, and have to say again that the video is great, such a presentation is always good for knowledge and enjoyable too!
@WeberAuto
Жыл бұрын
Thank you very much!
Welcome back! Mach-e has been a fun one so far, the recall is something ford has been doing lately as in updating software in hopes to prevent a hardware failure but the failure can still occur. If the contactors stick it’s usually the dc fast charge contactors are welding from the heat and so far I’ve seen all happen at electrify America stations. To repair the battery has to come out and high voltage battery junction box has to be replaced.
@WeberAuto
Жыл бұрын
Thank you, you are correct. The battery has to come out to replace the contactors
Good day. Thank you for a great dose of interesting knowledge about electric drives. Best regards.
@WeberAuto
Жыл бұрын
Thanks for watching!
Good you came back professional
@WeberAuto
Жыл бұрын
Thank you!
Brilliant stuff . Very interesting indeed thanks a lot
Great to see your well👍
@WeberAuto
Жыл бұрын
Thanks 👍
Welcome back sir 🍻
@WeberAuto
Жыл бұрын
Thank you John
Wooot! The Professor is back!!!
@WeberAuto
Жыл бұрын
Thank you!
Glad to see you bud. I keep asking what happened to John. And I’m retired now. Still love to watch your videos though.
@WeberAuto
Жыл бұрын
Thank you!
Hi John Lovely to hear from you again, you have been missed ! Glad that everything is all right. The heating loop is a clever thing that many other can learn from. Regarding charting, level one and two. Many people call them charter however it is only Communication port and a Power contactor. This is often misunderstood especially when we talk prices. How do I get hold of the charging communication, I am especially interested in state of chart and the amount of amps going into the battery. Lovely video from you again, nice to have you back 👍
@WeberAuto
Жыл бұрын
Thank you very much. Yes, you are correct, the terminology is confusing for many people. I call it a charger cord, not a charger. See the SAE J1772 standard for that information.
After long time mr.kelly!!
@WeberAuto
Жыл бұрын
Yes, a long time
Terima kasih Prof Kelly. Amat menarik video EV yang disampaikan kepada semua
@WeberAuto
Жыл бұрын
terima kasih banyak-banyak
I like see you again Mr Kelly and thanks for share this video
@WeberAuto
Жыл бұрын
You are so welcome
Happy to see you again🤗🤗🤗🤗
@WeberAuto
Жыл бұрын
Thank you so much 😀
Thank you for these interesting and informative videos Professor Kelly. The technology and engineering used on these EV's is quite impressive. It's a fusion of electrical and mechanical technology applied to transportation. The series on both the Tesla vehicles and this Mach E GT have been especially interesting and a good primer for anyone wanting to understand the underlying technology that make electric vehicles possible and practical.
17:38 the grey metallic connector is for DC to the inverter? For the front motor? I’m surprised it isn’t orange. It also doesn’t look big enough for the front inverter u less that front motor isn’t that powerful and I just over estimated the size needed. Welcome back, Professor. It’s always a pleasure to hear your voice and see your work.
@WeberAuto
Жыл бұрын
It is for the front inverter. Only the cables are required to be orange, not connectors. Thank you!
Cant' wait to see those contactors opened inside 👋😎👋😎💥💥💥💥💥
@WeberAuto
Жыл бұрын
You and me both!
Many thanks, another great video! Please do keep them coming as they are very interesting & your delivery is always entertaining. Any chance of an ID4 strip down please?
@WeberAuto
Жыл бұрын
Thank you. I hope so
Tank you. This was great info. I actually have two Mach-Es. Both awdxr and both premiums.
@WeberAuto
Жыл бұрын
Thank you very much
great content!,
Thank you!
@WeberAuto
Жыл бұрын
You are welcome, thanks for watching
Truly enjoyed the EV bootcamp a couple of weeks back! Thanks for everything you do!
@WeberAuto
Жыл бұрын
Glad you enjoyed it! Thanks for attending!
I see a new Weber Auto video, I click. I totally understand taking some time away from KZread to do your work, but I’m glad to see a new video. Even though I no longer work as a tech (and I’ve had quite a bit of training on hybrids and BEVs in the past) I’m still really tempted to find time to come to the 5 day boot camp. It’s interesting that Ford chose to put an insulating wrap on the front drive motor. Do you believe that is for noise insulation or trying to insulate the front motor from under hood heat? I know the AC and battery cooling can cause a lot of heat under the hood, and I’ve actually seen the effects of this heat in the transmission fluid (motor) temperature sensors on my Bolt (I’m sure it’s even worse on my Ioniq5 but I haven’t seen fluid temperatures on it)
@WeberAuto
Жыл бұрын
Awesome, thank you!
@BentheEVguy
Жыл бұрын
I totally recomme d the boot camp
Thank you.
@WeberAuto
Жыл бұрын
You are welcome, thanks for watching.
You rock. Thank you!
Great video, thanks for for posting. I Got a good laugh at a high end electric car has a AGM 12 volt battery under the hood, even my Ioniq doesn't have a separate battery anymore. The BMS does a good job keeping the battery from draining till is not useable.
@WeberAuto
Жыл бұрын
The Ionic is unique, all the other ones I have seen still use a 12V battery. Thanks for sharing!
@eviljagtech
Жыл бұрын
@@WeberAuto Learn something new everyday
Another fabulous video!! I really enjoy all of what you do!! Would it be possible to support the vehicle by the wheels when removing the battery?
@WeberAuto
Жыл бұрын
Thank you very much! I suspect it is possible if you had that type of lift, but would there be room to safely lower the battery and move it out from under the car? The adapters I use in the video are official the Ford service tools for battery service on the Mach-E.
Nice to have you back. The fill and drain plugs on the electric motors are for the lubricating oil aren't they? Not for the coolant?
@WeberAuto
Жыл бұрын
Thank you, yes, they are for the Mercon ULV transmission fluid. I did not mean to say coolant drain and fill plugs. Good catch!
Díky!
@WeberAuto
Жыл бұрын
Thank you very much!
Do an f150 hybrid and lightning! It would be very interesting to compare the two cars and how their architecture and design compare
@WeberAuto
Жыл бұрын
Thank you, I suspect they have many similarities.
Thank you wish you make a video short for all components brifly
That lifting situation does seem a little sketchy. I think I would either have some stationary supports at the suspension like the Munro guys sometimes use, or column lifts like Leno's shop has, if I were removing battery packs on a regular basis.
@WeberAuto
Жыл бұрын
Agreed, but the challenge is being able to lower the battery and move it out from under the car without interference from the vehicle lifting system being used. Finding proper vehicle lift points for stationary supports without damaging the vehicle is also a challenge. Unlike the Munro guys, these vehicles need to function again when the work is completed. Thanks for your feedback.
New video, cooool ⚡ 🤜🤛
@WeberAuto
Жыл бұрын
Thank you!
I'd find a way to augment those lift brackets. Either by adding an extension or an adapter on the lift that interfaces better. Relying on the lift arm lock to keep that pad under there is not the smartest idea.
@WeberAuto
Жыл бұрын
Thanks for the suggestions, I am working on finding a more secure method.
Hi John great content and your courses are the best out there . I have a question about the silver plug on the high voltage battery . I thought all high voltage wires and plugs are orange that was industry normal and i think it is required . Can you explain why on this car the high voltage plug is silver. Thank you.
@WeberAuto
Жыл бұрын
Thanks Dan! Yes, U.S. Federal Motor Vehicle Safety Standard (FMVSS) 305 states "Cables for high voltage sources which are not located within electrical protection barriers shall be identified by having an outer covering with the color orange." Cables are required to be orange, but not the connectors. Most high voltage connectors are orange, but there are many I have seen that are not.
@reallone5
Жыл бұрын
Thanks John with all the connectors I have seen are orange but thank you for the clarification.
Very informative video Mr. Kelly! I'm curious, did Ford label things with the yellow stickers or did you guys go through & do that? Very convenient if Ford did it:-)
@WeberAuto
Жыл бұрын
Thanky you, it was me. I am well known for my yellow labels. There is even one on the thumbnail for this video ;)
@alrui
Жыл бұрын
@@WeberAuto The modern thermal labels/makers sure beat the old embossed labels😀
That's ingenious how the 4 way switching valve uses wasted heat from the inverters and rear drive units to heat the passenger compartment, waste not want not.
Good video. Why do we need heater for the battery? Thanks.
@WeberAuto
Жыл бұрын
For maximum battery efficiency it needs to stay within a certain temperature range.
@cck0728
Жыл бұрын
@@WeberAuto Thanks for your excellent work. Keep it up.
Is it still 50/50 ethylene glycol antifreeze and water mixture for the cooling system?
I'd have safety stands under the car, given those sketchy lift blocks. It looks like the lift pads' pins are being side loaded instead of vertically loaded by the pads....just a matter of time for the pins to fatigue & fail with being load cycled each time the Mach-E is lifted, imo.
@WeberAuto
Жыл бұрын
Thanks, good idea!
Wonder if the remote column style lifts are safer for battery removal . Or is the weight stress on center of car to great
@WeberAuto
Жыл бұрын
I do not know. Thanks for watching
Will these vehicles be compatible with OBD2 comms? I took a Tesla class and having the equipment to communicate and diagnose those vehicles is difficult due to so much proprietary equipment. Being that it's a Ford I wonder if we'll be able to use a normal obd2 port and look at live data etc.
@WeberAuto
Жыл бұрын
There is a normal DLC on this car, so yes for some PIDS, but since these cars are emissions free, they are not required to comply with OBD regulations. However, My Snap-On Apollo D9 scan tool works great with this car and the Explorer hybrid.