Ford Ranger EV (2001 year). Manual — part 118
414-03A-68
414-03A-68
High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE
TEST STEP
ACTION TO TAKE
•
With key OFF, disconnect BOB from BCM; leave BOB connected to
Yes =
REPLACE the traction
BCM C1986, C1987.
battery cooling fan.
•
With key OFF, measure the resistance between BOB pin A28 and ground No =
REPAIR the Y/LG wire.
(BOB pin A33).
•
Is the resistance greater than 10,000 ohms?
A15 CHECK CIRCUIT 3395 (O/LB) FOR SHORT TO POWER
•
Remove the traction battery and connect Traction Battery High-Voltage
Yes =
REPAIR the O/LB wire.
Lockout and Diagnostic Tool to the traction battery high-voltage two-pin
C3994M.
No =
REPLACE the BCM.
WARNING: The traction battery contains high-voltage
components and wiring. High-voltage insulated safety gloves and face
shield must be worn when performing 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, disconnect traction battery cooling fan C1984.
•
With key ON, measure the voltage between BOB pin A32 and ground
(BOB pin A33).
•
Is the voltage greater than 0 volts?
Traction Battery System
Battery Module Diagnostic Test
The Battery Module Diagnostic Test is the method
used to analyze electric vehicle traction battery
modules. All 39 battery modules are analyzed
simultaneously.
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High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
Battery Module Diagnostic Test
— The traction inverter module (TIM) sets DTC
C1755 when the vehicle is shut down for one
NOTE: This is a two-step process. Battery module
of four reasons: the temperature protection
voltage information must be recorded within five
within the TIM has limited current to zero
minutes of completing discharge of the traction
amps, the battery control module (BCM) sent
battery.
the TIM a request to limit source current to
NOTE: Discharge the traction battery until the
zero, an overspeed shutdown or due to lack of
Power Limit Light flashes, preferably by driving the
coolant flow causing a quick rise in
vehicle.
temperature within the TIM. If any of these
occur, the vehicle shuts down, the malfunction
•
Step 1
indicator lamp (MIL) illuminates and the
•
Using the NGS Tester, select the current year and
power limit warning indicator flashes. The
model for the vehicle being serviced.
cause of the shutdown is not necessarily due
•
Select Diagnostic Data Link.
to the TIM. The cooling system loop and
traction battery should be checked for faults.
•
Select Battery Control Module.
The TIM should not be replaced unless the
•
Select Active Commands Modes.
vehicle continues to shut down and no other
failures can be detected.
•
Select Battery Module Select.
•
DTC P1794 Battery Voltage Circuit Malfunction
•
Press #8 SETUP button.
— The battery control module (BCM) monitors
•
Select Auto and Hit CANCEL button.
the 39 individual 8-volt traction battery
modules through voltage sense lines. The
•
Press #7 PIDS button and highlight BAT_MV.
BCM can sense the battery module voltages if
they are within the range of 3 and 14 volts.
•
Hit START button.
The BCM sets DTC P1794 if it cannot sense
•
Press TRIGGER and rotate knob to view each
five or more battery module voltages.
battery module. SCROLL through each battery
•
DTC B1671 Battery Module Voltage Out of
module and record the information.
Range
•
Step 2
— The battery control module (BCM) monitors
•
Press CANCEL.
the 39 individual 8-volt traction battery
modules through voltage sense lines. The
•
Select Battery Module Select and press ENTER.
BCM can sense the battery module voltages if
•
Press the SETUP button and select Auto Send.
they are within the range of 3 and 14 volts.
The BCM sets DTC B1671 if it cannot sense
•
Press CANCEL.
between one and four battery module voltages.
•
Press #7 (PIDS) and select BAT_MC and SOC.
•
DTC B1676 Battery Pack Voltage Out of Range
— Do not select BAT_SOC.
— The battery control module (BCM) monitors
the traction battery voltage through the TB+
•
Press START.
and TB- voltage sense lines. The TB+ voltage
•
Press TRIGGER and SCROLL through the
sense line is connected to battery module 39
Battery Modules recording the information.
and TB- voltage sense line is connected to
battery module 1. The BCM sets DTC B1676
•
Contact the National Hotline 1-800-826-4694.
if it detects the traction battery voltage to be
Diagnostic Trouble Code (DTC) Definition
less than 50 volts or greater than 450 volts.
This is usually due to an open or shorted TB+
The following DTCs relate to the traction battery
or TB- voltage sense line.
system:
•
DTC C1755 Power Limit Shutdown Fault
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High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
•
DTC C1864 Battery Module Fault
•
DTC B2236 Weak or Defective Electric Vehicle
Battery Module Fault
— The battery control module (BCM) monitors
the 39 individual 8-volt traction battery
— The battery control module (BCM) monitors
modules through voltage sense lines. The
the 39 individual 8-volt traction battery
BCM sets DTC C1864 if it detects a reverse
modules through voltage sense lines. The
battery module voltage due to incorrect
BCM sets DTC B2236 if it detects a bad
installation (at initial 12-volt powerup), or if it
battery module during discharge or if it detects
detects a 12-volt battery module has been
any weaker battery modules that are much
installed instead of an 8-volt battery module,
weaker than the rest at the end of charge.
or if it detects the wrong hardware (lead acid
Electrical Schematic
BCM in a NiMH battery pack) has been
installed into the battery pack.
Refer to Electrical and Vacuum Troubleshooting
Manual, Cell 16, Traction Battery System for
schematic and connector information.
Inspection and Verification
Symptom Chart
Symptom Chart
Condition
Possible Sources
Action
•
DTC C1755 Power Limit
•
Cooling system.
•
Shutdown Fault
•
Traction battery fault.
•
Motor/transaxle.
•
Traction inverter module
(TIM).
•
DTC B1671 Battery Module
•
Battery module(s).
•
Voltage Out of Range
•
High-voltage harness
(10B694).
•
High-voltage harness(es)
(14A280).
•
Battery control module
(BCM).
•
DTC B1676 Battery Pack
•
High-voltage harness
•
Voltage Out of Range
(10B694).
•
High-voltage harness(es)
(14A280).
•
Battery control module
(BCM).
•
DTC P1794 Battery Voltage
•
Battery module(s).
Circuit Malfunction
•
High-voltage harness
(10B694).
•
High-voltage harness(es)
(14A280).
•
Battery control module
(BCM).
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High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
Symptom Chart (Continued)
Condition
Possible Sources
Action
•
DTC C1864 Battery Module
•
Battery module(s) installed
•
Fault
incorrectly (reverse cable
polarity).
•
Incorrect battery module
(12-volt) installed.
•
Wrong hardware (lead acid
BCM in a NiMH battery
pack) has been installed in
the battery pack.
•
Battery control module
(BCM).
•
DTC B2236 Weak or
•
Battery module(s).
•
Defective Electric Vehicle
Battery Module Fault
•
Battery Pack/Module
•
None.
•
Verification Test
Special Tool(s)
Pinpoint Tests
Traction Battery High-Voltage Service Cord 418-F218
Special Tool(s)
Traction Battery Low-Voltage Service Cord 418-F219
104-Pin Breakout Box (BOB) 418-049 (014-00950) or
Traction Battery High-Voltage Lockout and Diagnostic
equivalent
Tool 418-F207
BCM/TIM Breakout Box (BOB) Adapter Cable
High-Voltage Insulated Safety Gloves 100-F036 or
418-F212
equivalent
BCM/TIM Breakout Box (BOB) Overlay 418-F220
Face Shield 100-F035 or equivalent
(Continued)
PINPOINT TEST A: DTC C1755 POWER LIMIT SHUTDOWN FAULT
TEST STEP
ACTION TO TAKE
A1 CHECK FOR OTHER TRACTION INVERTER MODULE (TIM)
DIAGNOSTIC TROUBLE CODES (DTCs)
NOTE: DTCs must be retrieved from the interface adapter assembly (IAA) Yes =
module before retrieving DTCs from the TIM. If IAA module DTC C1774
Coolant Temperature Sensor Out of Range occurs, refer to Section 303-03
before proceeding.
•
Retrieve DTCs from the TIM.
•
Does DTC C1854 Motor Temperature Out of Range also occur?
No =
GO to A2.
A2 CHECK BATTERY CONTROL MODULE (BCM) FOR DTCs
•
Retrieve DTCs from the BCM.
Yes =
REFER to the BCM DTC
•
Do any BCM DTCs occur?
No =
GO to A3.
A3 CHECK WATER PUMP CIRCUIT
•
Disconnect water pump C1998, key ON, measure voltage between the
Yes =
Go to A4
W/R and BK wires.
•
Is the voltage above 12Volts?
No =
Go to B1 in
A4 CHECK COOLANT FLOW
(Continued)
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