Ford Ranger EV (2001 year). Manual — part 19
100-09-21
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.
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.
•
Is the resistance less than 5 ohms?
No =
REPLACE high-voltage
harness (10B700).
100-09-22
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
module(s) in question.
REFER to
Section
•
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)
— 84 (no charge-battery undertemperature)
— 87 (no charge-battery full)
If 87, the traction battery is
at full state of charge
(SOC). System OK.
— 96 (no charge-EPO detected)
— 99 (no charge-line capacity out of range)
— 101 (no charge-no AC to charger)
•
Does the BCM OP PID indicate 48, 83, 84, 87, 96, 99, or 101?
No =
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
module(s) in question.
REFER to
Section
(Continued)
100-09-23
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
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
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
°
F)
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
°
F)
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
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.
(Continued)
100-09-24
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
7
°
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
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 =
8-9 CHECK TEMPERATURE DIFFERENCE BETWEEN BATTERY
TEMPERATURE SENSORS
•
With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, TMPSEN3,
Yes =
and TMPSEN4.
(Continued)
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