Ford Ranger EV (2001 year). Manual — part 16
100-09-9
100-09-9
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
•
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, and
TMPSEN3.
•
Does the TMPSEN PID that indicated less than -30
°
C (-22
°
F) still
indicate the same value?
2-8 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR
OVERTEMPERATURE CONDITION
•
With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, and
Yes =
PARK the vehicle indoors in
TMPSEN3.
a cooler environment.
CONNECT the vehicle to a
power control station (PCS)
to allow the traction battery
fans to operate. GO to 2-9.
•
Do any of the TMPSEN PIDs indicate greater than 70
°
C (158
°
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 54, REPLACE the
BCM. REFER to
Section
2-9 CHECK IF OVERTEMPERATURE STATE IS CAUSED BY AN
ACTUAL OVERTEMPERATURE CONDITION
NOTE: Allow adequate time for vehicle to cool before checking for
Yes =
ALLOW temperature(s) to
temperature decrease.
decrease below 55
°
C
•
While vehicle is connected to the PCS, monitor BCM PIDs TMPSEN1,
(131
°
F). System OK.
TMPSEN2, and TMPSEN3.
•
Do the TMPSEN PIDs that were greater than 70
°
C (158
°
F)
No =
GO to 2-10.
decrease?
2-10 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.
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, and
TMPSEN3.
•
Does the TMPSEN PID that indicated greater than 70
°
C (158
°
F) still
indicate the same value?
(Continued)
100-09-10
100-09-10
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
2-11 CHECK STATUS OF KEY START SIGNAL TO TRACTION
INVERTER MODULE (TIM)
•
With key ON, monitor TIM PID IGN S.
Yes =
GO to 2-14.
•
Turn the ignition key to the START position.
No =
GO to 2-12.
•
Does the IGN S PID indicate YES when the ignition key is turned
to the START position?
2-12 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 2-13.
•
Is the fuse OK?
No =
REPLACE the fuse. If the
fuse fails again,
CHECK/REPAIR for a short
to ground.
2-13 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.
to
•
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.
2-14 CHECK EMERGENCY POWER OFF (EPO) STATUS TO TIM
•
With key ON, monitor TIM PID EMG PO.
Yes =
GO to 2-15.
•
Does the EMG PO PID indicate ENABLE?
No =
2-15 CHECK EPO SIGNAL TO TIM
•
Connect 104-Pin Breakout Box (BOB) to TIM and TIM C4998, C4999
Yes =
GO to 2-16.
using the BCM/TIM BOB Adapter Cable & Overlay.
•
With key ON, monitor TIM PID EMG PO.
No =
•
Connect a jumper wire between BOB pins A19 and A35.
•
Does the EMG PO PID indicate DISABLE?
2-16 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 2-17.
•
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?
2-17 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.
(Continued)
100-09-11
100-09-11
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
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?
2-18 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 2-19.
•
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?
2-19 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 contactor
connect Traction Battery High-Voltage Lockout and Diagnostic Tool to
box. REFER to
Section
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?
2-20 CHECK STATUS OF TIM OPERATING STATE
•
With key ON, monitor TIM PID TIM OP.
Yes =
GO to 2-21.
•
Does the TIM OP PID indicate 20 (shutdown)?
No =
System OK.
2-21 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 2-22.
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?
2-22 CHECK CIRCUIT 295 (LB/PK) (INSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR OPEN
(Continued)
100-09-12
100-09-12
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 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.
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 3: VEHICLE STARTS, BUT DOES NOT MOVE
TEST STEP
ACTION TO TAKE
3-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)
OPERATING STATE
•
With key ON, monitor BCM PID BCM OP.
Yes =
CHARGE the traction
battery. REFER to
Section
•
Does the BCM OP PID indicate 69 (limited operating strategy
drive-low state of charge )?
No =
GO to 3-2.
3-2 CHECK FOR PARK MECHANISM FAILURE
•
Disconnect the shift linkage.
Yes =
GO to 3-3.
•
Set the transmission range selector lever to the any position except P
No =
REPLACE the
(Park).
motor/transaxle. REFER to
•
Raise the vehicle on a hoist.
Section 303-01.
•
Rotate both rear wheels simultaneously in the same direction.
•
Do the wheels rotate freely?
3-3 CHECK VEHICLE SPEED SENSORS
NOTE: The traction inverter module (TIM) diagnostic trouble code (DTC)
Yes =
REPAIR as indicated in
C1856 Traction Motor Encoder Circuit Failure will not be set if either
Pinpoint Test B.
vehicle speed sensor (VSS) fails below 3 km/h (2 mph).
•
Carry out Pinpoint Test B: DTC C1856 Traction Motor Encoder Circuit
Failure. Refer to
Section 303-14
.
•
No =
REPLACE the
motor/transaxle. REFER to
303-01.
ROUTINE 4: VEHICLE OPERATES AT REDUCED POWER (LEAD ACID VEHICLES)
TEST STEP
ACTION TO TAKE
4-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)
OPERATING STATE
•
With key ON, monitor BCM PID BCM OP.
Yes =
If BCM OP PID indicates
67, GO to 4-2.
If BCM OP PID indicates
68, GO to 4-5.
(Continued)
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