2011 FORD KUGA power

Component Description
Rear parking aid speaker
The rear parking aid speaker, in addition to its
actual function, is also used for audible indication
of various types of error in the front and rear
parking aids. If the rear parking aid speaker
becomes defective, the front parking aid speaker
will then be used to indicate failure modes.
If an error is detected in the system, a signal tone
is emitted via the speaker for 3 seconds.
Parking aid sensors
CAUTIONS:
Always keep sensors free from dirt, ice and
snow. Do not use any sharp objects to
clean the sensors.
If a high-pressure cleaner is used to wash
the vehicle, the jet must only be aimed at
the sensors briefly at a distance of at least
20 cm.
The parking aid sensor consists of the following:
• Plastic housing
• Aluminum membrane with Piezo disc
• Decoupling ring
• Printed circuit board (PCB)
The parking aid sensor consists of a sensor and a
holder. The holder makes sure that each parking
aid sensor is correctly orientated in relation to its
location in the rear bumper.
The sensors have a 3-pin connector which is
connected to the wiring harness of the front
bumper. This in turn is connected to the main body
wiring harness. Three pins provide for power
supply, ground and signal lines to and from the
parking aid module. The disc resonates at a frequency of ca. 50kHz,
producing the ultrasonic output. The disc also
receives the reflected echo signal from any objects
within range.
Parking aid module
The parking aid module has three connectors which
provide for power, ground and MS CAN bus
connections, as well as the front and rear parking
aid sensors, the parking aid switch and parking aid
speaker.
The parking aid module carries out self-check
routines and when the parking aid is active, checks
the parking aid sensor wiring for short or open
circuits. If a concern is detected, a diagnostic
trouble code (DTC) is stored in a memory in the
parking aid module and the front and rear parking
aid sensors will be disabled until the DTC is cleared
and the ignition cycled. The driver recognizes a
problem through the flashing LED and a shrill
continuous tone, which is emitted for 3 seconds
when the parking aid is activated. If the parking aid
is working properly, short tones are emitted instead
of this continuous tone. DTCs can be read using
the Ford approved diagnostic tool through the data
link connector (DLC).
G1034399en
2008.50 Kuga 8/2011 413-13-15
Parking Aid
413-13-15
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Action
Battery Tester Reading WARNING: Do not recharge the battery.
Make sure that the surface charge was removed. A "REPLACE BATTERY" result could also mean
a poor connection between the battery cables and the battery. Check the connections are OK and
retest. If the result remains the same, INSTALL a NEW battery
REFER to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
REPLACE BATTERY or BAD CELL BATTERY
In addition it is advisable to check the vehicle electrical system. Check that the generator is functioning
correctly and the vehicle does not have an excessive key-off load (in general this should be under
20mA after 40 minutes of key off).
Midtronics EXP-1050 Battery Tester Test
Code
At the end of the test, use the arrow keys to scroll
down the screens to see additional information.
One of these is the TEST CODE.
The TEST CODE has 11 digits, for example:
0021U-B88WKX.
Using the Midtronics GR-590-2 The Midtronics GR-590-2 is both a battery charger
and battery tester and automatically removes the
surface charge as part of the normal operating
procedure.
The Midtronics GR-590-2 can be used on a battery
in-vehicle or out-of-vehicle.
• Disconnect the battery ground cable.
• Connect the positive red clamp from the
Midtronics GR-590-2 to the battery positive
terminal.
• Connect the negative black clamp from the Midtronics GR-590-2 to the battery negative
terminal.
• Connect the AC power cable to the mains outlet
and switch ON.
• Follow the instructions supplied with the Midtronics GR-590-2 to charge the battery.
• To disconnect the Midtronics GR-590-2, reverse
the connection procedure.
The Midtronics GR-590-2 will automatically carry
out a charge cycle before giving the resulting test
code. It will bring the battery into a serviceable
condition and if required can proceed to fully
charge the battery.
Functions on the front panel of the Midtronics
GR-590-2
• UP and DOWN button: The UP and DOWN buttons allow the operator to scroll through
selections on the display and increase or
decrease values.
• ENTER button: The ENTER button allows the operator to accept a selection and continue to
the next step. G1055063en
2008.50 Kuga 8/2011 414-00-6
Charging System - General Information
414-00-6
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Battery Disconnect and Connect
Disconnect
WARNINGS:
Batteries normally produce explosive
gases which may cause personal injury,
therefore do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near
the battery always shield your face and
protect your eyes. Always provide
adequate ventilation. Failure to follow
these instructions may result in personal
injury.
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Audio unit key code saving devices must
not be used when working on
supplemental restraint or fuel systems.
When using these devices the vehicle
electrical system is still live but with a
reduced current flow. Failure to follow this
instruction may result in personal injury.
CAUTION: Make sure the engine is not
running before disconnecting the battery
ground cable to avoid damage to the
vehicle electrical system.
NOTE: Disconnecting the battery will erase fault
codes, drive values and customer data stored in
the modules.
NOTE: This procedure should be used to
disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Refer to: Battery and Battery Charging Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. Obtain and record the audio unit keycode and
preset radio frequencies. 3.
G1062389en
2008.50 Kuga 8/2011 414-01-2
Battery, Mounting and Cables
414-01-2
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Generator
General information
The powertrain control module (PCM) controls the
alternator charging voltage. The connection
between the PCM and the generator is made via
the control module subnetwork (LIN) bus.
If the load on the alternator is high, the PCM can
increase the idle speed.
The alternator is temporarily deactivated during
engine starting so that the engine drag moment is
minimized and it is reactivated again after the
starting procedure.
The PCM controls the charge control lamp in the
instrument cluster via the controller area network
(CAN) bus.
Smart Charge system
In addition to the familiar functions, the Smart
Charge system also performs the following
functions:
•
Automatic deactivation of non-critical high power
electrical consumers when the battery voltage
is low in order to reduce the level of current
drawn.
• Automatic activation of non-critical high power electrical consumers when the battery voltage
is excessively high in order to protect
components which are sensitive to increased
voltages.
The battery charging current is optimized through
continuous calculation of the battery temperature
and monitoring of the alternator output voltage.
By receiving the forwarded alternator load signal,
the PCM is given early warning whenever an
electric consumer is switched on or off. This means
that the PCM receives information about imminent
changes in the torque drawn by the alternator. By
evaluating this information the PCM can provide a
higher level of idling stability.
The two remaining functions of the Smart Charge
System are controlled by the GEM.
Electrical consumers are switched off due to low
voltage when the GEM determines (on the basis
of the message received from the PCM on the CAN
bus via the instrument cluster) that the battery
voltage has dropped below the threshold.
When the threshold for low battery voltage is
reached the GEM automatically deactivates the following consumers - in this order and with a gap
of 5 seconds between each:
• Electric booster heater (vehicles with diesel
engines)
• Heated exterior mirrors
• Heated rear window
• Heated windscreen
If the battery voltage rises back above the lower
threshold then the GEM re-enables all of the
electrical consumers which were previously
disabled. They then have switched off status and
must be switched back on by the driver.
Electrical consumers are switched on due to
excessively high voltage if the GEM determines
that the battery voltage is above the threshold for
overvoltage and the charge control lamp has been
switched on.
When the threshold is reached the GEM
automatically activates the following consumers -
in this order and with a gap of 5 seconds between
each:
• Heated rear window
• Heated exterior mirrors
• Electric booster heater (vehicles with diesel engines)
• Blower motor
If the battery voltage drops back below the
threshold then the GEM automatically deactivates
any consumers that were switched on. However,
if they were switched on by the driver before the
automatic activation, they will then be switched on
again in turn with a 5-second time interval. G964174en
2008.50 Kuga 8/2011 414-02-2
Generator and Regulator
414-02-2
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Direct Current/Alternating Current (DC/AC) Inverter – Overview
Function indicator
WARNING: For workshop repairs, it is only
permissible to replace the converter as a
complete unit together with the wiring
harness and the socket. The component
must not be opened, as charged capacitors
inside can still carry dangerously high
residual voltages.
The LED in the socket lights up orange when the
converter is supplying a voltage.
In the event of a fault the system switches off and
indicates the cause of the fault by flashing a trouble
code via the LED in the socket:
• 1x flash – High temperature
• 2x flashes – Overload
• 3x flashes – Internal overvoltage
• 4x flashes – Internal undervoltage
• Continuous flashing – Short circuit to power
If the converter switches off due to high
temperature then it switches back on again
automatically once the temperature has cooled
down sufficiently.
With all of the other faults which are displayed, the
converter can be reset by switching the ignition off
and back on again or by unplugging and reinserting
the consumer in the socket.
If these measures are unsuccessful then there are
no further options for directly influencing the
function yourself. G1055637en
2008.50 Kuga 8/2011 414-05-3
Voltage Converter/Inverter
414-05-3
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Direct Current/Alternating Current (DC/AC) Inverter – System
Operation and Component Description
System Diagram Description
Item
DC/AC converterRefer to Component Description: (page
?)
1
AC mains outletRefer to Component Description: (page
?)
2 Description
Item
AC mains outlet switch
3
Battery
4
Ignition relay
5
Keylesss vehicle module
6
System Operation
DC/AC converter
In the rear part of the center console there is an
optional 230 V socket instead of the outlet of the
standard 12 V electrical system.
In this case a DC/AC converter supplies a
continuous power of 150 W at 230 V/50 Hz. It can
also absorb temporary power peaks of up to 300
W when consumers are switched on. For example, an output of 150 W is sufficient to
run laptops, games consoles and mobile phone
chargers.
G1055639en
2008.50 Kuga 8/2011 414-05-4
Voltage Converter/Inverter
414-05-4
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Component Description
DC/AC converter
The converter operates with a series connection
of two power converter circuits. The primary power
converter here is a push-pull converter. It converts
the 12 V supply from the electrical system of the
vehicle to an intermediate direct current link of
approx. 320 V.
From this intermediate direct current link, the
downstream full H-bridge circuit generates a
pulse-width modulated output voltage with 230
V/50 Hz.
A controller modulates the pulse width of the
square-wave output voltage and maintains an
effective output voltage of 230 V under varying
load conditions and under different input voltages.
Here, the rising and falling edge of the positive and
negative square wave pulse are controlled
symmetrically to the ideal shape of a sine wave,
which - among other things - also makes a positive
contribution to electromagnetic compatibility.
DC/AC converters which supply a modified square
wave output voltage are referred to as 'Modified
Sine Wave Inverters".
With this type of system there is no need for a
residual current operated device for protection in
the event of accidental contact, as all of the 230 V
lines are double-insulated. Potential-free separation
of the entire 230 V voltage part from the vehicle is
provided (electrical isolation).
The output voltage of 230 V/50 Hz is not generated
until the switching voltage is present at terminal 1
of the converter via the AC mains outlet switch.
The converter operates with the ignition switched
on and a vehicle electrical supply of between 11
V and 16 V. Internal voltage monitoring in the converter deactivates the system if the input
voltage is outside this range.
AC mains outlet
Description
Item
230 V/50 Hz outlet
1
LED (light emitting diode)
2
Cover3 Description
Item
230 V/50 Hz outlet (for UK vehicles)
1
LED2
Cover3
In order to prevent accidents and the risk of
electrical shock, the outlet is protected with a child
safety device and the AC outlet switch.
In order to make the system safer for children, the
safety catches for the 230 V contacts can only be
pushed to one side by pressing a Euro plug evenly
into both of the connector openings.
The AC mains outlet switch only activates the
system when a consumer is connected to the
outlet. G1055639en
2008.50 Kuga 8/2011 414-05-5
Voltage Converter/Inverter
414-05-5
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The contacts of the outlet exert a more powerful
grip on the plug so that it does not shake loose on
poor road surfaces. An orange LED lights up to
show that the unit has been activated.
G1055639en
2008.50 Kuga 8/2011 414-05-6
Voltage Converter/Inverter
414-05-6
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