Ford Ranger EV. Electric Manual - part 53

LESSON 5: DIAGNOSIS

5-53

ACTIVITY 13 – DIAGNOSIS – WORKSHEET S2 (NON-BDS)

BATTERY AND SENSE LEAD DIAGNOSIS

STUDENT ANSWER SHEET

OBJECTIVE:

The student will safely and accurately diagnose a Ranger EV concern.

DIRECTIONS:

Go to the workstation as directed by the instructor. Read the repair order on the vehicle and

isolate the cause of the concern.

1. Retrieve DTCs from the classroom vehicle. In what order should the modules be checked for DTCs? _____

______________________________________________________________________________________

2. List any DTCs present and in which module you found them? ____________________________________

______________________________________________________________________________________

3. What section of the workshop manual will provide diagnostic direction? ____________________________

______________________________________________________________________________________

4. What does this DTC indicate? ______________________________________________________________

______________________________________________________________________________________

5. What is the next step you should perform? ____________________________________________________

______________________________________________________________________________________

6. Are there any indications of the source of the concern? __________________________________________

______________________________________________________________________________________

7. Is the vehicle at the correct state of charge to measure the battery voltage to determine if there is a battery

module fault? ___________________________________________________________________________

8. Exactly what is the state of charge of this vehicle? ______________________________________________

______________________________________________________________________________________

9. While monitoring SOC PID, turn heat on high for three minutes. What is the state of charge at the end of the

three minutes? __________________________________________________________________________

______________________________________________________________________________________

10. What is the state of charge supposed to be when testing for a bad battery module? ____________________

______________________________________________________________________________________

LESSON 5: DIAGNOSIS

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11. Check the individual voltage of all the battery modules. Use the attached Battery Module Record Sheet

found on the next page.

12. If any modules are suspect, list the module number. Module number will vary depending upon where bad

module is installed.

13. Does the information on the Battery Module Record Sheet indicate any other concerns are present? ______

______________________________________________________________________________________

______________________________________________________________________________________

14. In order to verify your diagnosis of the component(s) that are indicating a fault, what steps should you

perform? _______________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

15. Perform the verification tests. Was your diagnosis correct? _______________________________________

16. Prior to installing a new battery module what should be done? ____________________________________

______________________________________________________________________________________

ACTIVITY 13 – DIAGNOSIS – WORKSHEET S2 (NON-BDS)

BATTERY AND SENSE LEAD DIAGNOSIS

STUDENT ANSWER SHEET (Continued)

END OF WORKSHEET S2 (NON-BDS)

LESSON 5: DIAGNOSIS

5-55

Battery Module Record Sheet

Directions

1. Enter BCM ACTIVE COMMANDS.

2. Enter BATTERY MODULE SELECT menu.

3. Enter PID menu.

4. Select BAT_MV PID.

5. Press START.

6. Press SETUP button (8).

7. Press AUTO (4).

8. Press CANCEL to return to ACTIVE COMMAND menu.

9. With battery module highlighted, press TRIGGER. This will shrink highlighted (darkened) area to only

include the battery module number.

10. Read and record the voltage for battery module # 1. Record the reading in the table below.

11. Rotate the scroll bar (center knob) and the module number will change. Read the voltage and record it.

12. Continue for each of the 39 battery modules. Record each reading in the table below.

BATTERY VOLTAGE

BATTERY VOLTAGE

BATTERY VOLTAGE

READINGS

READINGS

READINGS

1.

14.

27.

2.

15.

28.

3.

16.

29.

4.

17.

30.

5.

18.

31.

6.

19.

32.

7.

20.

33.

8.

21.

34.

9.

22.

35.

10.

23.

36.

11.

24.

37.

12.

25.

38.

13.

26.

39.

LESSON 5: DIAGNOSIS

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13. Select the lowest five PIDS from above, and again view their voltage readings using the BAT_MV PID.

Record their voltage readings.

   BATTERY VOLTAGE READINGS

Battery #

14. Select the lowest three readings from the modules above.

   BATTERY VOLTAGE READINGS

Battery #

Module Replacement Criteria

•

If the lowest voltage battery is 0.1 less than the second lowest voltage battery, replace the lowest voltage

battery module.

•

If the second lowest voltage battery is more than 0.08-volts less than the third lowest voltage battery, replace

the second lowest voltage battery.

•

Prior to replacing the module, verify the serviceability of the battery’s sense lead (measure for resistance of

30.9 K ohms), and verify the module’s voltage reading with a DVOM.

Sense Lead Criteria

•

If two adjoining modules are indicating incorrectly, the sense lead should be suspected and its resistance

should be measured.

•

Resistance specification is 30.9 K ohms.