Ford Ranger EV. Electric Manual - part 41

LESSON 5: DIAGNOSIS

5-5

Preliminary Diagnostic Procedures

As with all vehicles, when a Ranger EV is brought in with a concern

certain preliminary diagnostic procedures should always be

performed. These steps should include the following actions.

Verify the Concern – This step is critical in the diagnostic process.

It is important that you understand exactly what the concern is in

order for you to initiate the correct diagnostic steps.

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It is especially important that you determine if the customer

concern is actually a vehicle malfunction, or if the concern may

arise from the driver’s lack of familiarity with the vehicle.

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Since electric vehicles are new to the driving public, it is possible

that what the driver feels is a concern is just a normal operating

characteristic of the vehicle.

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If this is the case, take the time to explain how the vehicle operates.

Perform a Visual Inspection – The reason for this is self-

explanatory. Nothing is more frustrating than performing hours of

diagnostics only to find a disconnected wire that was easily visible if a

thorough visual inspection had been performed.

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Refer to Inspection and Verification in Section 100-07 of the

workshop manual supplement for additional information on areas

to focus on and what to look for during the visual inspection.

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During visual inspection check only the low voltage fuses.

Check for Non-Factory Add-On Equipment – Many calls that come

into the Ford Technical Hotline are the result of incorrectly installed

add-on equipment.

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Because the Ranger EV will be used in many fleets, add-ons such

as radios and light bars may be suspected causes of malfunctions.

Retrieve Diagnostic Trouble Codes (DTCs) – Retrieving DTCs

from the control modules of the Ranger EV is unique.

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DTCs must be retrieved from the modules in a specific order

(IAA, then TIM, then BCM).

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There are also other important considerations when retrieving

DTCs that are unique to the Ranger EV.

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Refer to Retrieving Diagnostic Trouble Codes (DTCs) and the

Diagnostic Process (DP Pinpoint Tests) in Section 100-07 of the

workshop manual supplement.

LESSON 5: DIAGNOSIS

5-6

MULTIPLEXING SYSTEM DIAGNOSIS

Multiplexing System

Operation

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The Ranger EV uses two module communications networks.

– J1850 (SCP) network (two-way communication during normal

vehicle operation) used by the battery controller module (BCM),

interface adapter assembly (IAA) module, and traction inverter

module (TIM).

– International standards organization (ISO) 9141 network

communication used by the anti-lock brake system (ABS)

module, central timer module (CTM), and electronic crash

sensor (ECS) module operates air bag system.

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The SCP network consists of a twisted pair cable data bus.

– Circuit 914 data bus plus.

– Circuit 915 data bus minus.

LESSON 5: DIAGNOSIS

5-7

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The SCP network may remain operational even if one of the bus

wires is open or shorted (to ground or power). However, all data

may be corrupt and the network should be repaired prior to

performing diagnostics.

– The fault will be detected and a DTC will be set in the host

module (IAA).

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The ISO 9141 network consists of a single wire, circuit 70.

– If the wire is open or shorted (to ground or power) diagnostic

communication between one or more of the modules will not

be possible.

Network Diagnosis

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Before running any NGS diagnostics, perform the data link

diagnostic test.

– If a network concern exists, DTC(s) may be inaccurate.

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To perform the diagnostic Data Link Diagnostic Test routine

(System Precheck) refer to the Ranger EV Workshop Manual,

Section 418-00.

– The System Precheck will direct you to the proper pinpoint test

or symptom chart, according to test results.

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When network concerns are resolved normal diagnostic routines

may be continued if needed.

– It is possible that a network problem may be the cause of the

original concern.

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For an electrical schematic, refer to the Electrical and Vacuum

Troubleshooting Manual (EVTM).

LESSON 5: DIAGNOSIS

5-8

NEW GENERATION STAR TESTER

Ranger EV NGS Program Card Main Menu

New Generation STAR (NGS) Tester is essential to Ranger EV

diagnosis. While technicians are familiar with NGS tester use on

conventional vehicles, the Program Card for the Ranger EV has

unique features that will be covered in this lesson.

The Main Menu is similar to the conventional vehicle Program Card

Main Menu.

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The Ranger EV Program Card Main Menu selections are:

– VEHICLE AND ENGINE SELECTION

– DIAGNOSTIC DATA LINK

– VIEW RECORDER AREA

– DIGITAL MEASUREMENT SYSTEM

– GENERIC OBD II FUNCTIONS

– SPECIAL FUNCTIONS

– NEW GENERATION STAR SETUP

– INTERNAL SYSTEM TESTS

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The most noticeable difference is the Vehicle and Engine Selection

Function.

– The Ranger EV Program Card is dedicated to the Ranger EV and

no other selections are available.

Ranger EV Program Card Diagnostic Data Link Menu

To continue diagnostic routines, select DIAGNOSTIC DATA LINK.

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The Ranger EV Program Card Diagnostic Data Link Menu

Selections are:

– ABS-ANTI LOCK BRAKE MODULE

– BCM-BATTERY CONTROLLER MODULE

– CTM-CENTRAL TIMER MODULE

– ECS-ELECTRONIC CRASH SENSOR

– IAA-INTERFACE ADAPTER ASSEMBLY

– TIM-TRACTION INVERTER MODULE

– DATA LINK DIAGNOSTICS