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Ford Ranger EV (2001 year). Manual - part 19

100-09-21

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 6: NOTICEABLE DECREASE IN VEHICLE DRIVING RANGE (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

•

Is the vehicle equipped with traction battery heaters?

No =

INFORM the customer that

the decrease in vehicle

driving range may be due to

harsh driving or storage

conditions, or not allowing

the vehicle to charge to the

full state of charge (SOC).

6-3 CHECK STATUS OF HEATER PRESENT SIGNAL

•

With key ON, monitor BCM PID HTRPRST.

Yes =

INFORM the customer that

the decrease in vehicle

driving range may be due to

harsh driving or storage

conditions, or not allowing

the vehicle to charge to the

full state of charge (SOC).

•

Does the HTRPRST PID indicate YES?

No =

GO to 6-4.

6-4 CHECK HEATER PRESENT SIGNAL FROM CONTACTOR BOX

•

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 =

GO to 6-5.

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 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.

•

Connect 104-Pin Breakout Box (BOB) to BCM C1986, C1987 using the

BCM/TIM BOB Adapter Cable and Overlay; leave the BCM

disconnected.

•

With key OFF, measure the resistance between BOB pin A31 and ground

(BOB pin A33).

•

Is the resistance less than 20 ohms?

6-5 CHECK CIRCUIT 3007 (P/Y) FOR OPEN

•

With key OFF, disconnect contactor box C1982 and measure the

Yes =

GO to 6-6.

resistance of the P/Y wire between pin 14 on contactor box C1982 and

BOB pin A31.

•

Is the resistance less than 5 ohms?

No =

REPAIR the P/Y wire.

6-6 CHECK HEATER JUMPER CIRCUIT 1161 (DB/O) FOR OPEN

•

With key OFF, disconnect contactor box C1864 and measure the

Yes =

REPLACE the contactor

resistance of the DB/O wire between pins D and E on contactor box

box. REFER to

Section

C1864.

414-03A

•

Is the resistance less than 5 ohms?

No =

REPLACE high-voltage

harness (10B700).

100-09-22

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 7: NOTICEABLE DECREASE IN VEHICLE DRIVING RANGE (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

7-1 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 =

INFORM the customer that

battery modules?

the decrease in vehicle

driving range may be due to

harsh driving or storage

conditions, or not allowing

the vehicle to charge to the

full state of charge (SOC).

ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

8-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

•

Verify the ignition key is in the OFF position and the gear selector is in

the P (Park) position.

•

Connect the vehicle to a power control station (PCS) and press the

START button to begin charging.

NOTE: Wait approximately five minutes to allow the BCM OP PID to

be set.

•

With key OFF and vehicle on-charge, monitor BCM PID BCM OP.

Check for the following numbers:

— 48 (shutdown-low battery module voltage)

Yes =

If 48, GO to 8-2.

— 83 (no charge-battery overtemperature)

If 83, GO to 8-5.

— 84 (no charge-battery undertemperature)

If 84, GO to 8-8.

— 87 (no charge-battery full)

If 87, the traction battery is

at full state of charge

(SOC). System OK.

— 96 (no charge-EPO detected)

If 96, GO to 8-12.

— 99 (no charge-line capacity out of range)

If 99, GO to 8-15.

— 101 (no charge-no AC to charger)

If 101, GO to 8-24.

•

Does the BCM OP PID indicate 48, 83, 84, 87, 96, 99, or 101?

No =

GO to 8-29.

8-2 CHARGE TRACTION BATTERY TO FULL STATE OF CHARGE

(SOC)

•

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

Yes =

GO to 8-3.

•

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)?

8-3 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 414-03A

module(s) in question.

REFER to

Section

414-03A

(Continued)

100-09-23

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

•

Does the Battery Module Diagnostic Test indicate to replace any

No =

CHARGE the traction

battery modules?

battery to full SOC. CHECK

the BCM OP PID. If the

BCM OP PID still

indicates 48, REPLACE the

BCM. REFER to

Section

414-03A

8-4 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

OVERTEMPERATURE CONDITION

•

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

Yes =

GO to 8-5.

and TMPSEN4.

If all TMPSEN PIDs are

greater than 60

C (140

F),

PARK the vehicle in a cool

environment to cool down

below 60

C (140

F).

•

Do any of the TMPSEN PIDs indicate greater than 60

C (140

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 83, REPLACE the

BCM. REFER to

Section

414-03A

8-5 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY

TEMPERATURE SENSORS

•

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

Yes =

GO to 8-6.

and TMPSEN4.

•

Is there a temperature difference of greater than 25

C (45

No =

PARK the vehicle in a cool

between the temperature sensor that is above 60

C (140

F) and the

environment to cool the

other temperature sensors?

vehicle below 60

C (140

for the temperature sensor in

question.

8-6 CHECK BATTERY TEMPERATURE SENSOR

(OVERTEMPERATURE CONDITION)

•

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

•

Connect Traction Battery High Voltage Service Cord to traction battery

No =

REPLACE the battery

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

temperature sensor in

question.

(Continued)

100-09-24

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

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 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 greater than 60

C (140

F) still

indicate 60

C (140

F)?

8-7 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

UNDERTEMPERATURE CONDITION

•

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

Yes =

GO to 8-8.

and TMPSEN4.

If all TMPSEN PIDs are

less than 5

C (41

F), PARK

the vehicle indoors and if

the vehicle is equipped with

traction battery heaters,

CONNECT it to the power

control station (PCS) to

warm the traction battery to

a temperature greater than

C (45

F).

•

Do any of the TMPSEN PIDs indicate less than 5

C (41

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 84, REPLACE the

BCM. REFER to

Section

414-03A

8-8 IDENTIFY VEHICLE OPTION

•

Determine if the vehicle is equipped with traction battery heaters.

Yes =

GO to 8-9.

•

Is the vehicle equipped with traction battery heaters?

No =

GO to 8-10.

8-9 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY

TEMPERATURE SENSORS

•

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

Yes =

GO to 8-10.

and TMPSEN4.

(Continued)

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