Ford Ranger EV (2001 year). Manual — part 23

100-09-37

100-09-37

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

9-34 CHECK CIRCUIT 3404 (Y) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

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

GO to 9-35.

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, measure the resistance of the Y wire between BOB pin

No =

REPAIR the Y wire.

54 and in-line 1969M.

•

Is the resistance less than 5 ohms?

9-35 CHECK CIRCUIT 3404 (Y) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

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

Yes =

REPLACE the BCM.

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

REFER to

Section

the traction battery high-voltage two-pin C3994M.

414-03B

.

No =

REPAIR the Y 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 C1987.

•

Measure the resistance of the Y wire between pin 12 on BCM C1987

and BOB pin 54.

•

Is the resistance less than 5 ohms?

ROUTINE 10: VEHICLE CHARGING TAKES LONGER THAN NORMAL TO REACH FULL STATE OF
CHARGE (SOC) (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

10-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

NOTE: Following charging, wait approximately five minutes to allow the

Yes =

GO to 10-2.

BCM OP PID to be set.

•

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

START button to begin charging.

•

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

No =

INFORM customer the

•

Does the BCM OP PID indicate 112 (limited operating strategy

charge-high battery temperature)?

vehicle may take longer to

charge due to high

environmental temperature

conditions.

10-2 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

OVERTEMPERATURE CONDITION

•

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

Yes =

GO to 10-3.

and TMPSEN4.

If all TMPSEN PIDs are

between 50

°

C (122

°

F) and

60

°

C (140

°

F), PARK the

vehicle in a cool

environment to cool down

below 50

°

C (122

°

F).

(Continued)

100-09-38

100-09-38

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 10: VEHICLE CHARGING TAKES LONGER THAN NORMAL TO REACH FULL STATE OF
CHARGE (SOC) (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

•

Do any of the TMPSEN PIDs indicate between 50

°

C (122

°

F) and

No =

DISCONNECT and

60

°

C (140

°

F)?

RECONNECT the 12-volt

auxiliary battery negative

cable and RECHECK the

BCM OP PID. If the

BCM OP PID still

indicates 112, REPLACE

the BCM. REFER to

Section 414-03A

.

10-3 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY

TEMPERATURE SENSORS

•

With key ON, monitor battery control module (BCM) PIDs TMPSEN1,

Yes =

GO to 10-4.

TMPSEN2, TMPSEN3, and TMPSEN4.

•

Is there a temperature difference of greater than 25

°

C (45

°

F)

No =

PARK the vehicle in a cool

between the temperature sensor that is between 50

°

C (122

°

F) and

environment to cool the

60

°

C (140

°

F), and the other temperature sensors?

vehicle below 65

°

C (149

°

F)

for the temperature sensor in

question.

10-4 CHECK BATTERY TEMPERATURE SENSOR

•

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 between 50

°

C (122

°

F) and

60

°

C (140

°

F) still indicate between 50

°

C (122

°

F) and 60

°

C (140

°

F)?

ROUTINE 11: VEHICLE CHARGING TAKES LONGER THAN NORMAL TO REACH FULL STATE OF
CHARGE (SOC) (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

11-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

NOTE: Following charging, wait approximately five minutes to allow the

Yes =

GO to 11-2.

BCM OP PID to be set.

•

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

START button to begin charging.

(Continued)

100-09-39

100-09-39

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 11: VEHICLE CHARGING TAKES LONGER THAN NORMAL TO REACH FULL STATE OF
CHARGE (SOC) (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

•

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

No =

INFORM customer the

•

Does the BCM OP PID indicate 118 (limited operating strategy

charge-battery under temperature)?

vehicle may take longer to

charge due to low

environmental temperature

conditions.

11-2 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

OVERTEMPERATURE CONDITION

•

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

Yes =

GO to 11-3.

TMPSEN3.

If any of the TMPSEN PIDs

are below -15

°

C (5

°

F),

PARK the vehicle in a

warm environment to warm

up above -15

°

C (5

°

F).

•

Do any of the TMPSEN PIDs indicate below -15

°

C (5

°

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 118, REPLACE

the BCM. REFER to

Section 414-03B

.

11-3 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY

TEMPERATURE SENSORS

•

With key ON, monitor battery control module (BCM) PIDs TMPSEN1,

Yes =

GO to 11-4.

TMPSEN2, and TMPSEN3.

•

Is there a temperature difference of greater than 20

°

C (36

°

F)

No =

PARK the vehicle in a

between the temperature sensor that is below -15

°

C (5

°

F), and the

warm environment to warm

other temperature sensors?

the vehicle above -15

°

C

(5

°

F) for the temperature

sensor in question.

11-4 CHECK BATTERY TEMPERATURE SENSOR

•

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 414-03B

C3994M.

•

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, and TMPSEN3.

•

Does the TMPSEN PID that indicated below -15

°

C (5

°

F) and still

indicate below -15

°

C (5

°

F)?

100-09-40

100-09-40

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 12: COOLANT PUMP AND DC/DC CONVERTER OPERATE WHEN POWER CONTROL STATION
(PCS) IS DISCONNECTED FROM THE CHARGER INLET CONNECTOR

TEST STEP

ACTION TO TAKE

12-1 CARRY OUT RESET

NOTE: The coolant pump and DC/DC converter sometimes operate after

Yes =

System OK.

disconnecting the power control station (PCS) from the charger inlet

connector. This is normal operation. They will continue to operate for

approximately 10 minutes if the ignition key is NOT cycled.

•

Cycle the ignition key ON/OFF.

•

Was the ignition key cycled ON/OFF?

No =

CYCLE the ignition key

ON/OFF.