Ford Ranger EV. Electric Manual - part 49

LESSON 5: DIAGNOSIS

5-37

NOTES

LESSON 5: DIAGNOSIS

5-38

TRACTION BATTERY PACK COMPONENTS
DEMONSTRATION

The traction battery pack contains many different components. The

following is a list of these components. As your instructor points out

these components, note the workshop manual section where service

information on the components can be found.

•

Thirty-nine 8-volt battery modules. SECTION ________________

•

High voltage wiring that connects the battery modules in a series

circuit. SECTION _______________________________________

•

A 250 amp busman fuse located between batteries 21 and 22.

SECTION _____________________________________________

•

The contactor box. SECTION _____________________________

•

The battery control module (BCM). SECTION ________________

•

Battery pack cooling system. SECTION _____________________

•

One sense lead connects between each two battery modules, except

for modules 1 and 39, each of which has their own sense lead.

SECTION _____________________________________________

•

Four temperature sensors to monitor battery operating

temperatures. SECTION _________________________________

•

An optional battery heating system to maintain battery temperature

in cold climates. SECTION _______________________________

•

A low-voltage wiring harness. SECTION ____________________

LESSON 5: DIAGNOSIS

5-39

NOTES

LESSON 5: DIAGNOSIS

5-40

TRACTION BATTERY DIAGNOSIS

Current Leakage Diagnosis

Current leakage is a condition that occurs if a short develops between

the traction battery positive and/or negative bus and chassis ground. If

this occurs, resistance is reduced due to the additional current path to

ground. This additional path can result in reduction of vehicle range.

Current leakage is monitored by the battery control module (BCM),

which monitors the resistance between the traction battery positive

and negative bus and chassis ground. Normal resistance is usually

greater than 100 K ohms.

The following symptoms may occur if current leakage is present.

•

A short that reduces resistance between the traction battery and

chassis ground below 50 K ohms but above 10 K ohms will set a

DTC and illuminate the Electrical Hazard Warning Lamp.

•

A short that reduces resistance between the traction battery and

chassis ground below 10 K ohms will set a DTC and illuminate the

Electrical Hazard Warning Lamp. If the vehicle is connected, the

Power Control Station (PCS) for charging the on-board charger will

not activate.

Multiple High Voltage Load Failure

Multiple high voltage load failure will cause the loss of all accessories

connected to the high voltage auxiliary circuit. These include:

•

the DC/DC converter (auxiliary battery charging).

•

the A/C inverter motor controller (air conditioning).

•

the positive temperature coefficient (PTC) heater.

•

the power steering controller assembly.

This type of failure can be caused by a failure in various vehicle

components including:

•

the high voltage power distribution box (HVPDB).

•

the high voltage wiring harness.

•

the auxiliary load 40 amp fuse in the contactor box.

•

the contactor box.

If a failure of this type occurs, the IAA module will store a DTC

relating to the cause of the failure.