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Ford Ranger EV (2001 year). Manual - part 15

100-09-5

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

REPLACE the BCM.

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

REFER to

Section

C3994M.

414-03A

No =

REPLACE the battery

WARNING: The traction battery contains high-voltage

temperature sensor in

components and wiring. High-voltage insulated safety gloves and face

question.

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect Traction Battery High Voltage Service Cord to traction battery

support tray in-line C1935F and in-line C1935M.

•

Connect Traction Battery Low Voltage Service Cord to traction battery

support tray in-line C1939F and in-line C1939M.

•

With key OFF, disconnect the battery temperature sensor in question and

one of the other temperature sensors.

•

Connect jumper wires between the connector for the temperature sensor

in question and the known good temperature sensor that was

disconnected.

•

With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, TMPSEN3,

and TMPSEN4.

•

Does the TMPSEN PID that indicated less than -20

C (-4

F) still

indicate -20

C (-4

F)?

1-10 CHECK STATUS OF KEY START SIGNAL TO TRACTION

INVERTER MODULE (TIM)

•

With key ON, monitor TIM PID IGN S.

Yes =

GO to 1-13.

•

Turn the ignition key to the START position.

No =

GO to 1-11.

•

Does the IGN S PID indicate YES when the ignition key is turned

to the START position?

1-11 CHECK FUSE (HOT IN START) TO TIM

•

Check 7.5A fuse 24, 10A fuse 9 and 7.5A fuse 11 in the I/P fuse panel.

Yes =

GO to 1-12.

•

Is the fuse OK?

No =

REPLACE the fuse. If the

fuse fails again,

CHECK/REPAIR for a short

to ground, or TIM internal

failure.

1-12 CHECK KEY START SIGNAL TO TIM

•

Connect 104-Pin Breakout Box (BOB) to TIM C4998, C4999 using the

Yes =

REPLACE the TIM. REFER

BCM/TIM BOB Adapter Cable & Overlay; leave the TIM disconnected.

Section 303-14

•

Connect a multimeter between BOB pins B8 and A29.

No =

REPAIR the W/BK wire

•

Turn the ignition key to the START position.

between pin 8 on TIM

•

Is the voltage greater than 10 volts when the ignition key is turned to

C4999 and the I/P fuse

the key START position?

panel.

1-13 CHECK EMERGENCY POWER OFF (EPO) STATUS TO TIM

•

With key ON, monitor TIM PID EMG PO.

Yes =

GO to 1-14.

•

Does the EMG PO PID indicate ENABLE?

No =

GO to 1-19.

1-14 CHECK EPO SIGNAL TO TIM

•

Connect 104-Pin Breakout Box (BOB) to TIM and TIM C4998, C4999

Yes =

GO to 1-15.

using the BCM/TIM BOB Adapter Cable & Overlay.

•

With key ON, monitor TIM PID EMG PO.

No =

GO to 1-17.

•

Connect a jumper wire between BOB pins A19 and A35.

•

Does the EMG PO PID indicate DISABLE?

1-15 CHECK CIRCUIT 3997 (DG) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect BOB from TIM and TIM C4998, C4999.

Yes =

GO to 1-16.

(Continued)

100-09-6

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect in-line C1939 on the traction battery support

No =

REPAIR the DG wire.

tray and connect BOB to in-line C1939M using Traction Battery Low

Voltage Service Cord; do not connect Traction Battery Low Voltage

Service Cord to traction battery support tray in-line C1939F.

•

With key OFF, measure the resistance of the DG wire between pin 35 on

TIM C4998 and BOB pin 24.

•

Is the resistance less than 5 ohms?

1-16 CHECK CIRCUIT 3997 (DG) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

Disconnect BOB from in-line C1939M, remove the traction battery, and

Yes =

REPLACE the contactor

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

box. REFER to

Section

the traction battery high-voltage two-pin C3994M.

414-03A

No =

REPAIR the DG wire.

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect BOB to traction battery support tray in-line C1939F using

Traction Battery Low Voltage Service Cord; do not connect Traction

Battery Low Voltage Service Cord to in-line C1939M.

•

With key OFF, disconnect contactor box C1982 and measure the

resistance of the DG wire between pin 16 on contactor box C1982 and

BOB pin 24.

•

Is the resistance less than 5 ohms?

1-17 CHECK CIRCUIT 3997 (DG) (OUTSIDE TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, disconnect BOB from TIM and TIM C4998, C4999.

Yes =

GO to 1-18.

•

With key OFF, disconnect in-line C1939 on the traction battery support

No =

REPAIR the DG wire.

tray and connect BOB to in-line C1939M using Traction Battery Low

Voltage Service Cord; do not connect Traction Battery Low Voltage

Service Cord to traction battery support tray in-line C1939F.

•

With key OFF, measure the resistance between BOB pin 24 and ground

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

1-18 CHECK CIRCUIT 3997 (DG) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

Disconnect BOB from in-line C1939M, remove the traction battery, and

Yes =

REPLACE the TIM. REFER

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

Section 303-14

the traction battery high-voltage two-pin C3994M.

No =

REPAIR the DG wire.

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect BOB to traction battery support tray in-line C1939F using

Traction Battery Low Voltage Service Cord; do not connect Traction

Battery Low Voltage Service Cord to in-line C1939M.

•

With key OFF, disconnect contactor box C1982 and measure the

resistance BOB pin 24 and ground (BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

1-19 CHECK STATUS OF TIM OPERATING STATE

•

With key ON, monitor TIM PID TIM OP.

Yes =

GO to 1-20.

•

Does the TIM OP PID indicate 20 (shutdown)?

No =

System OK.

(Continued)

100-09-7

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

1-20 CHECK KEY RUN/START SIGNAL TO CONTACTOR BOX AT

TRACTION BATTERY SUPPORT TRAY

•

With key OFF, disconnect in-line C1939 on the traction battery support

Yes =

GO to 1-21.

tray.

•

Connect BOB to in-line C1939M using Traction Battery Low Voltage

No =

REPAIR circuit 295

Service Cord; do not connect Traction Battery Low Voltage Service Cord

(LB/BK).

to traction battery support tray in-line C1939F.

•

With key ON, measure the voltage between BOB pin 21 and ground

(BOB pin 65).

•

Is the voltage greater than 10 volts?

1-21 CHECK CIRCUIT 295 (LB/PK) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

REPLACE the contactor

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

box. REFER to

Section

to the traction battery high-voltage two-pin C3994M.

414-03A

No =

REPAIR the LB/PK wire.

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect BOB to traction battery support tray in-line C1939F using

Traction Battery Low Voltage Service Cord; do not connect Traction

Battery Low Voltage Service Cord to in-line C1939M.

•

With key OFF, disconnect contactor box C1982 and measure the

resistance of the LB/PK wire between pin 13 on contactor box C1982

and BOB pin 21.

•

Is the resistance less than 5 ohms?

ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

2-1 CHECK AUXILIARY BATTERY VOLTAGE

•

With key OFF, measure the voltage of the 12-volt auxiliary battery.

Yes =

GO to 2-2.

•

Is the voltage greater than 11.5 volts?

No =

CARRY OUT the Auxiliary

Battery Capacity Test.

REFER to

Section 414-02

2-2 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

•

With key ON, monitor BCM PID BCM OP.

Yes =

If BCM OP PID indicates

48, GO to 2-3.
If BCM OP PID indicates

49, CHARGE the traction

battery. REFER to

Section

100-05

If BCM OP PID indicates

51, GO to 2-6.
If BCM OP PID indicates

54, GO to 2-9.

•

Does the BCM OP PID indicate 48 (shutdown-low battery module

No =

GO to 2-10.

voltage), 49 (shutdown-low SOC), 51 (no start-battery under

temperature), or 54 (shutdown-battery over temperature)?

2-3 CHARGE TRACTION BATTERY TO FULL STATE OF CHARGE

(SOC)

(Continued)

100-09-8

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

•

Disconnect and reconnect the 12-volt auxiliary battery negative cable.

Yes =

GO to 2-4.

•

Charge the traction battery to full SOC.

No =

System OK.

•

With key ON, monitor BCM PID BCM OP.

•

Does the BCM OP PID still indicate 48 (shutdown-low battery

module voltage)?

2-4 CHECK STATUS OF TRACTION BATTERY MODULES BY

CARRYING OUT THE BATTERY MODULE DIAGNOSTIC TEST

•

With key ON, carry out the Battery Module Diagnostic Test. Refer to the Yes =

REPLACE the battery

procedure in Traction Battery System

Section 414-03B

module(s) in question.

REFER to

Section

414-03B

•

Does the Battery Module Diagnostic Test indicate to replace any

No =

CHARGE the traction

battery modules?

battery to full SOC. Go to

2-5.

2-5 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

UNDERTEMPERATURE CONDITION

•

With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, and

Yes =

PARK the vehicle indoors in

TMPSEN3.

a warmer environment.

CONNECT the vehicle to a

power control station (PCS)

to allow self-heating. GO to

2-6.

•

Do any of the TMPSEN PIDs indicate less than -30

C (-22

F)?

No =

DISCONNECT and

RECONNECT the 12-volt

auxiliary battery negative

cable and RECHECK the

BCM OP PID. If the

BCM OP PID still

indicates 51, REPLACE the

BCM. REFER to

Section

414-03B

2-6 CHECK IF UNDERTEMPERATURE STATE IS CAUSED BY AN

ACTUAL UNDERTEMPERATURE CONDITION

NOTE: Allow adequate time for vehicle to warm before checking for

Yes =

ALLOW temperature(s) to

temperature increase.

increase above -25

•

While vehicle is connected to the PCS, monitor BCM PIDs TMPSEN1,

(-13

F). System OK.

TMPSEN2, and TMPSEN3.

•

Do the TMPSEN PIDs that were less than -30

C (-22

F) increase?

No =

GO to 2-7.

2-7 CHECK BATTERY TEMPERATURE SENSORS

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

REPLACE the BCM.

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

REFER to

Section

C3994M.

414-03B

No =

REPLACE the battery

WARNING: The traction battery contains high-voltage

temperature sensor in

components and wiring. High-voltage insulated safety gloves and face

question.

shield must be worn when carrying out the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect Traction Battery Low Voltage Service Cord to traction battery

support tray in-line C1939F and in-line C1939M.

•

With key OFF, disconnect the battery temperature sensor in question and

one of the other temperature sensors.

(Continued)

Content .. 13 14 15 16 ..