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Ford Ranger EV (2001 year). Manual - part 20

100-09-25

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

•

Is there a temperature difference of greater than 7

C (13

F) between

No =

CONNECT the vehicle to

the temperature sensor that is below 5

C (41

F) and the other

the power control station

temperature sensors?

(PCS) to warm the traction

battery to a temperature

greater than 7

C (45

F).

MONITOR the TMPSEN

PIDs while the vehicle is

connected to the PCS. If the

temperature of the battery

temperature sensor that was

less than 5

C (41

F) does

not increase, GO to 8-11.

8-10 CHECK BATTERY TEMPERATURE SENSOR

(UNDERTEMPERATURE 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.

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 battery control module (BCM) PIDs TMPSEN1,

TMPSEN2, TMPSEN3, and TMPSEN4.

•

Does the TMPSEN PID that indicated less than 5

C (41

F) still

indicate less than 5

C (41

F)?

8-11 CHARGE TRACTION BATTERY TO FULL STATE OF

CHARGE (SOC)

•

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

Yes =

REPEAT this test step. The

traction battery has not

reached full SOC.

NOTE: If the EMG PO PID indicates ENABLE after pressing the

No =

System OK.

START button on the power control station (PCS), GO to 8-13.

•

Charge the traction battery to full SOC.

•

With key OFF and vehicle on-charge, monitor BCM PIDs EMG PO

and BCM OP.

•

Does the BCM OP PID still indicate 96 (no charge-EPO detected)?

8-12 CHECK EMERGENCY POWER OFF (EPO) SIGNAL TO

BATTERY CONTROL MODULE (BCM)

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

GO to 8-13.

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

C3994M.

(Continued)

100-09-26

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

No =

REPLACE the BCM.

WARNING: The traction battery contains high-voltage

REFER to

Section

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

414-03A

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 and BCM C1986, C1987

using the BCM/TIM BOB Adapter Cable and Overlay.

•

With key ON, monitor BCM PID EMG PO.

•

Connect a jumper wire between BOB pins A10 and A18.

•

Does the EMG PO PID indicate DISABLE?

8-13 CHECK CIRCUIT 3006 (P/LG) FOR OPEN

•

With key OFF, disconnect contactor box C1982 and measure the

Yes =

REPLACE the contactor

resistance of the P/LG wire between pin 9 on contactor box C1982 and

box. REFER to

Section

BOB pin A18.

414-03A

•

Is the resistance less than 5 ohms?

No =

REPAIR the P/LG wire.

8-14 CHECK CHARGER PILOT SIGNAL CIRCUIT FOR OPEN

•

Disengage the locks on the charger inlet connector, push the swing plate

Yes =

GO to 8-15.

forward, and hold the swing plate in the forward position to access the

terminals on the charger inlet connector.

•

With key OFF, measure the resistance between pin 5 (R wire) on charger No =

GO to 8-16.

inlet C5000 and ground.

•

Is the resistance greater than 2.5 megaohms?

8-15 CHECK CIRCUIT 3984 (R) FOR OPEN

•

With key OFF, disconnect traction battery charger C1993 and measure

Yes =

REPLACE the traction

the resistance of the R wire between pin 5 on traction battery charger

battery charger. REFER to

C1993 and pin 5 on charger inlet C5000.

Section 414-03A

•

Is the resistance less than 5 ohms?

No =

REPAIR the R wire.

8-16 CHECK NEUTRAL CIRCUIT FOR OPEN

•

With key OFF, measure the resistance between pin 7 (DG wire) on

Yes =

GO to 8-17.

charger inlet C5000 and ground.

•

Is the resistance greater than 100 ohms?

No =

GO to 8-18.

8-17 CHECK CIRCUIT 3174 (DG) FOR OPEN

•

With key OFF, disconnect traction battery charger C1938 and measure

Yes =

REPLACE the traction

the resistance of the DG wire between pin 7 on charger inlet C5000 and

battery charger. REFER to

traction battery charger C1938.

Section 414-03A

•

Is the resistance less than 5 ohms?

No =

REPLACE the charger inlet.

REFER to

Section

414-03A

8-18 CHECK CIRCUITS 3172 (O) AND 3173 (W) FOR OPEN(S)

•

With key OFF, disconnect traction battery charger C1938 and measure

Yes =

GO to 8-19.

the resistance of the O wire between pin 4 on charger inlet C5000 and

traction battery charger C1938.

•

With key OFF, measure the resistance of the W wire between pin 3 on

No =

REPLACE the charger inlet.

charger inlet C5000 and traction battery charger C1938.

REFER to

Section

•

Are the resistances less than 5 ohms?

414-03A

8-19 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (OUTSIDE OF

TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S)

(Continued)

100-09-27

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to 8-20.

connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction

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

Voltage Service Cord to in-line C1939F.

•

With key OFF, disconnect traction battery charger C1991 and C1993.

No =

REPAIR the wire(s) in

•

With key OFF, measure the resistance of the O/LB wire between pin 4

question.

on traction battery charger C1991 and BOB pin 61.

•

With key OFF, measure the resistance of the LB/R wire between pin 2

on traction battery charger C1993 and BOB pin 28.

•

Are the resistances less than 5 ohms?

8-20 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (OUTSIDE OF

TRACTION BATTERY SUPPORT TRAY) FOR SHORT(S) TO

GROUND

•

With key OFF, measure the resistance between BOB pins 28, 61 and

Yes =

GO to 8-21.

ground (BOB pin 65).

•

Are the resistances greater than 10,000 ohms?

No =

REPAIR the wire(s) in

question.

8-21 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (INSIDE OF

TRACTION BATTERY SUPPORT TRAY) FOR OPEN

•

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

Yes =

GO to 8-22.

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

the traction battery high-voltage two-pin C3994M.

•

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

No =

REPAIR the wire(s) in

Traction Battery Low Voltage Service Cord; do not connect Traction

question.

Battery Low Voltage Service Cord to in-line C1939M.

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.

•

With key OFF, disconnect BCM C1986 and C1987.

•

Measure the resistance of the O/LB wire between pin 5 on BCM C1987

and BOB pin 61.

•

Measure the resistance of the LB/R wire between pin 35 on BCM C1986

and BOB pin 28.

•

Are the resistances less than 5 ohms?

8-22 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (INSIDE OF

TRACTION BATTERY SUPPORT TRAY) FOR SHORT(S) TO

GROUND

•

With key OFF, measure the resistance between BOB pins 28, 61 and

Yes =

REPLACE the traction

ground (BOB pin 65).

battery charger. REFER to

Section 414-03A

•

Are the resistances greater than 10,000 ohms?

No =

REPAIR the wire(s) in

question.

8-23 VERIFY POWER CONTROL STATION (PCS) OPERATION

•

Perform Power Control Station (PCS) Operation Verification Test. Refer

Yes =

GO to 8-24.

to Traction Battery Charging/Heating System in

Section 414-03A

•

Is the PCS OK?

No =

CARRY OUT the required

action as indicated in the

Power Control Station (PCS)

Operation Verification Test.

8-24 CHECK CIRCUIT 3009 (O/R) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

(Continued)

100-09-28

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to 8-25.

connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction

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

Voltage Service Cord to in-line C1939F.

•

With key OFF, disconnect traction battery charger C1993.

No =

REPAIR the O/R wire.

•

With key OFF, measure the resistance of the O/R wire between pin 7 on

traction battery charger C1993 and BOB pin 56.

•

Is the resistance less than 5 ohms?

8-25 CHECK CIRCUIT 3009 (O/R) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pins 56 and ground

Yes =

GO to 8-26.

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the O/R wire.

8-26 CHECK CIRCUIT 3009 (O/R) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

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

Yes =

GO to 8-27.

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

the traction battery high-voltage two-pin C3994M.

No =

REPAIR the O/R 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 BCM C1986.

•

Measure the resistance of the O/R wire between pin 6 on BCM C1986

and BOB pin 56.

•

Is the resistance less than 5 ohms?

8-27 CHECK CIRCUIT 3009 (O/R) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pins 56 and ground

Yes =

REPLACE the traction

(BOB pin 65).

battery charger. REFER to

Section 414-03A

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the O/R wire.

8-28 CHECK CHARGER CORD INPUT STATUS

NOTE: Verify the power control station (PCS) charger cord is connected

Yes =

REPLACE the traction

to the charger inlet before carrying out this test step.

battery charger. REFER to

•

With key OFF, connect the PCS to the charger inlet connector and

Section 414-03A

monitor BCM PID CHGCORD.

•

Does the CHGCORD PID indicate IN?

No =

GO to 8-29.

8-29 CHECK CHARGER INLET

•

With key OFF, disconnect in-line C1969 (located on the chassis next to

Yes =

GO to 8-30.

the right headlamp inside the underhood compartment).

•

With key OFF, connect the PCS to the charger inlet connector and

No =

REPLACE the charger inlet.

measure the resistance between the Y wire and BK wire on in-line

REFER to

Section

C1969F.

414-03A

•

Is the resistance less than 5 ohms?

8-30 CHECK CIRCUIT 3404 (Y) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

(Continued)

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