Ford Ranger EV. Electric Manual - part 44

LESSON 5: DIAGNOSIS

5-17

CHARGING CONCERNS

The Power Control Station (PCS) recharges the traction battery.

Under normal conditions all the driver has to do is plug the vehicle

into the PCS, and the vehicle batteries will automatically be

recharged.

If the PCS is connected to the vehicle and the green start button on the

PCS is flashing, the vehicle is not charging.

Certain conditions may result in a failure of the recharging system.

Let’s look at some of the things that may cause a failure.

Determining the Source of a Charging Concern

The first thing that must be considered when diagnosing a charging

concern is to determine if the cause is a failure of the charging system,

or if it is the result of a Battery Control Module (BCM) strategy.

The BCM strategy is to prevent charging if:

•

The battery is too hot or cold, as determined by signals sent from

the four battery pack temperature sensors to the BCM. Each sensor

monitors the temperature of the batteries in a certain region of the

pack, and transmits this information to the BCM. If the indicated

temperature is above 60°C (141ºF) or below -5° C (23ºF), BCM

strategy will prevent charging of the battery pack.

•

The BCM loses the ability to monitor the voltage of more than five

battery modules, it will prevent the battery pack from charging.

•

The state of charge of the battery is 99% or above, the BCM

prevents charging voltage from reaching the pack.

•

There is a difference of 30°C (86ºF) between any of the battery

pack temperature sensors, the BCM strategy will prevent charging

of the battery pack.

LESSON 5: DIAGNOSIS

5-18

•

The BCM strategy is to prevent charging if:

– There is a failure of the high voltage auxiliary bus current sensor

in the contactor box it will also prevent charging of the battery

pack.

– A battery module fails open.

– A battery module internally shorts, the increased resistance will

significantly reduce recharging capability.

– The inertia switch is tripped, or there is an inertia switch fault.

– Current leakage exists between the traction battery and chassis

ground that reduces resistance to less than 10K ohms.

– The vent fan is inoperative.

– More than three battery pack temperature sensors fail.

– The vehicle is not in Park, or the digital transmission range

(DTR) sensor has a fault that indicates that it is not in Park.

If any of the above strategies are implemented, the BCM should store

a DTC to indicate the cause of the no charge condition.

No DTC Charging Diagnosis

In some cases a fault in the AC power charging system will not result

in a DTC being stored in the BCM memory. In these cases, certain

procedures should be followed.

•

When diagnosing an “Unable to Charge” concern, (as with all

concerns), perform the preliminary diagnostic steps as described in

Section 100-07 of the Ranger EV workshop manual supplement.

•

As with all concerns where no DTC is present, refer to the

symptom-based diagnostic procedures in Section 100-09, or to the

symptom chart in the individual section of the workshop manual

that pertains to the component that has malfunctioned.

LESSON 5: DIAGNOSIS

5-19

NOTES

LESSON 5: DIAGNOSIS

5-20

ACTIVITY 6 – DIAGNOSIS – WORKSHEET L

CHARGING SYSTEM DIAGNOSIS

STUDENT ANSWER SHEET

OBJECTIVE:

The student will accurately diagnose the cause of an “unable to charge” concern.

DIRECTIONS:

Go to assigned classroom vehicle. Read the repair order, then using the special tools supplied,

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

1. What customer concern is listed on this repair order? (SYMPTOM) ________________________________

______________________________________________________________________________________

2. What section of the service publications should you refer to when performing preliminary diagnostic

procedures? ____________________________________________________________________________

______________________________________________________________________________________

3. What SYSTEM(S) is affected by this fault? ___________________________________________________

______________________________________________________________________________________

4. If a charging system DTC is stored, in which module would you expect to find it? ____________________

______________________________________________________________________________________

5. List any DTCs present. ___________________________________________________________________

______________________________________________________________________________________

6. If any DTCs are present, do they seem to be valid? _____________________________________________

IRQ

: Discuss phantom DTCs (especially U prefixed DTCs) and point out that if DATA LINK Diagnostics

passes, U DTCs should generally be ignored.

7. Diagnose the concern. List the steps you perform and their results in the table below. NOTE: The number of

rows in the table does not indicate the number of steps in the diagnostic procedure. Use additional paper if

required.

DIAGNOSTIC STEP

RESULT

100-09

GO TO POWERTRAIN DIAGNOSTIC

ROUTINES INDEX

POWERTRAIN DIAGNOSTIC

ROUTINE 5

ROUTINES INDEX

5-1

YES, OPSTATE PID 99

5-17

YES

5-18

NO REPAIR CIRCUIT 3984 RED WIRE

8. What is the cause of this concern? ___________________________________________________________

______________________________________________________________________________________

WORKSHEET L CONTINUED ON NEXT PAGE