Ford Ranger EV (2001 year). Manual — part 13

100-07-23

100-07-23

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

Battery Control Module (BCM) Active Command

Traction Inverter Module (TIM) Active

Index — Lead Acid

Command Index

Active

Active Command

Traction Inverter Module (TIM) Active Command

Command

Mode

Signal

Index

FAN SPEED

BCM Packeted

PWM (%)

Active

Active Command

Commands

Command

Mode

Signal

NEG MAIN

BCM Packeted

OPEN,

SPDOMETER Speedometer Control

PWM (%)

Commands

CLOSE

POS MAIN

Contactor Output

OPEN,

CHARGER C BCM Packeted

OPEN,

Control

CLOSE

Commands

CLOSE

PRECHG IN

Contactor Output

OPEN,

CHG PWR

BCM Packeted

ENABLE,

Control

CLOSE

Commands

DISABLE

PUMP

Fluid Control

ENABLE,

CHG PILOT

BCM Packeted

ENABLE,

DISABLE

Commands

DISABLE

CHG MODE

BCM Packeted

VOLT, CURR

Battery Control Module (BCM) Active

Commands

Command Index — Lead Acid

CHARGER E BCM Packeted

ENABLE,

Commands

DISABLE

Battery Control Module (BCM) Active Command

CURRENT S BCM Packeted

ENABLE,

Index — Lead Acid

Commands

DISABLE

Active

Active Command

BLOWER P

BCM Packeted

ENABLE,

Command

Mode

Signal

Commands

DISABLE

CHG LEVEL Charging Level

PWM (%)

BAT HTR 1

BCM Packeted

ENABLE,

Control

Commands

DISABLE

FAN SPEED

Fan Speed Control

PWM (%)

BAT HTR2

BCM Packeted

ENABLE,

RESET

Parameter Reset

LDATA

Commands

DISABLE

Command

BATTERY #

Battery Module Select

1-39

Battery Control Module (BCM) Active
Command Index — NiMH

RESET

Reset Historical Data

1-39, SOC,

ALL

Battery Control Module (BCM) Active Command

FAN PWR

Thermal Regulation

ENABLE,

Index — NiMH

Output Control

DISABLE

Active

Active Command

BAT HTR 1

Thermal Regulation

ENABLE,

Command

Mode

Signal

Output Control

DISABLE

CHG LEVEL Charging Level

PWM (%)

BAT HTR 2

Thermal Regulation

ENABLE,

Control

Output Control

DISABLE

FAN SPEED

Fan Speed Control

PWM (%)

CHG PWR

Charging System

ENABLE,

Output Control

DISABLE

RESET

Parameter Reset

LDATA

Command

CHG PILOT

Charging System

ENABLE,

Output Control

DISABLE

BATTERY #

Battery Module Select

1-25

CHG MODE

Charging System

VOLT, CURR

RESET

Reset Historical Data

1-25, SOC,

Output Control

ALL

CHARGER

Charging System

ENABLE,

FAN FL

Thermal Regulation

ENABLE,

Output Control

DISABLE

Output Control

DISABLE

NEG MAIN

Contactor Output

OPEN,

FAN RE

Thermal Regulation

ENABLE,

Control

CLOSE

Output Control

DISABLE

CHARGER

Contactor Output

OPEN,

CHG PWR

Charging System

ENABLE,

Control

CLOSE

Output Control

DISABLE

CHG LVL

BCM Packeted

PWM (%)

CHG PILOT

Charging System

ENABLE,

Commands

Output Control

DISABLE

(Continued)

(Continued)

100-07-24

100-07-24

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

Battery Control Module (BCM) Active Command

•

DTC B1555 Ignition Run/Start - Circuit Failure

Index — NiMH

— The interface adapter assembly (IAA) module

Active

Active Command

uses the key RUN/START input at pin 97 to

Command

Mode

Signal

begin control of all the vehicle system

CHG MODE

Charging System

VOLT, CURR

functions for which it is responsible. The IAA

Output Control

module sets DTC B1555 if it does not detect

CHARGER

Charging System

ON, OFF

the key RUN/START input within two

Output Control

seconds of receiving a message from the

NEG MAIN

Contactor Output

OPEN,

traction inverter module (TIM).

Control

CLOSE

The following DTC relates to the traction inverter

CHARGER

Contactor Output

OPEN,

module (TIM):

Control

CLOSE

CHG LVL

BCM Packeted

PWM (%)

•

DTC B2477 Module Configuration Failure

Commands

— The TIM supports the downloading of new

NEG MAIN

BCM Packeted

OPEN,

software for module updates. The TIM sets

Commands

CLOSE

DTC B2477 if a software update is attempted

CHARGER C BCM Packeted

OPEN,

and is not successful.

Commands

CLOSE

The following DTC relates to the battery control

CHG PWR

BCM Packeted

ENABLE,

Commands

DISABLE

module (BCM):

CHG PILOT

BCM Packeted

ENABLE,

•

DTC B2477 Module Configuration Failure

Commands

DISABLE

— The BCM supports the downloading of new

CHG MODE

BCM Packeted

VOLT, CURR

software for module updates. The BCM sets

Commands

DTC B2477 if a software update is attempted

CHARGER E BCM Packeted

ENABLE,

and is not successful. The BCM also sets DTC

Commands

DISABLE

B2477 in conjunction with DTC B1342 ECU

CURRENT S BCM Packeted

ENABLE,

Is Defective if its read-only memory (ROM)

Commands

DISABLE

or random-access memory (RAM) has failed

FAN RE

BCM Packeted

ENABLE,

the BCM self-test.

Commands

DISABLE

FAN FL

BCM Packeted

ENABLE,

Electrical Schematic

Commands

DISABLE

Refer to Electrical and Vacuum Troubleshooting
Manual, Cell 13, Power Distribution (Low Voltage)

Miscellaneous Diagnostics

for schematic and connector information.

Diagnostic Trouble Code (DTC) Definition

The following DTCs relate to the interface adapter
assembly (IAA) module:

•

DTC B1342 ECU Is Defective
— The interface adapter assembly (IAA) module

carries out an internal self-test when the
ignition key is turned to the ON position. The
IAA module sets DTC B1342 if it does not
pass its self-test at key ON.

100-07-25

100-07-25

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

Symptom Chart

Symptom Chart

Condition

Possible Sources

Action

•

DTC B1342 ECU Is

•

Interface adapter assembly

•

GO to Pinpoint Test A.

Defective (IAA Module)

(IAA) module.

•

DTC B1555 Ignition

•

Fuse.

•

GO to Pinpoint Test B.

Run/Start - Circuit Failure

•

Circuit.

•

Interface adapter assembly

(IAA) module.

•

DTC B2477 Module

•

Traction inverter module

•

GO to Pinpoint Test C.

Configuration Failure

(TIM).

•

Battery control module

(BCM).

Pinpoint Tests

Special Tool(s)

104-Pin Breakout Box (BOB) 418-049 (014-00950) or

equivalent

PINPOINT TEST A : DTC B1342 ECU IS DEFECTIVE (IAA MODULE)

TEST STEP

ACTION TO TAKE

A1 CHECK INTERFACE ADAPTER ASSEMBLY (IAA) MODULE

OPSTATE PID

•

With key ON, monitor the IAA module PID OPSTATE.

Yes

REPLACE the IAA module.

=

REFER to

Section 412-04

.

•

Does the OPSTATE PID indicate 32 (Power On Self-Test Failed)?

No =

GO to A2.

A2 PERFORM ON-DEMAND SELF-TEST

•

Perform the On-Demand Self-Test for the IAA module.

Yes

REPLACE the IAA module.

=

REFER to

Section 412-04

.

•

Does DTC B1342 occur?

No =

System OK. CLEAR the

DTCs from the IAA

module’s continuous

memory.

PINPOINT TEST B: DTC B1555 IGNITION RUN/START - CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

B1 CHECK FUSE

•

Check 15A fuse 19 in the I/P fuse panel.

Yes =

GO to B2.

•

Is the fuse OK?

No =

REPLACE the fuse. If the

fuse fails again,

CHECK/REPAIR for a short

to ground.

B2 CHECK POWER (KEY RUN SIGNAL) TO INTERFACE

ADAPTER ASSEMBLY (IAA) MODULE

•

Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =

REPLACE the IAA module.

module disconnected.

REFER to

Section 412-04

.

•

With key ON, measure the voltage between BOB pin 97 and ground

No =

REPAIR circuit 295 (LB/PK

(BOB pin 80).

wire).

•

Is the voltage greater than 10 volts?

100-07-26

100-07-26

Electric Vehicle (EV) Diagnostic Direction

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C : DTC B2477 MODULE CONFIGURATION FAILURE

TEST STEP

ACTION TO TAKE

C1 CARRY OUT SOFTWARE DOWNLOAD

NOTE: If the battery control module (BCM) sets DTC B2477, check the

Yes =

RETRY the software

traction battery support tray in-line C1939 for secure connection.

download procedure. If DTC

•

Verify all connections to the module in question are secure and the New

B2477 keeps occurring,

Generation STAR (NGS) Tester is securely connected to data link

REPLACE the module.

connector (DLC) C209.

REFER to

Section 303-14

•

Clear the diagnostic trouble codes (DTCs) from the module.

(TIM) or

Section 414-03A

(BCM).

NOTE: Do not turn the ignition key to the OFF position, disconnect any

No =

System OK. CLEAR the

connectors, or press the CANCEL button on the NGS Tester while

DTCs from the module’s

downloading the software.

continuous memory.

•

Retry downloading the new software.

•

Retrieve DTCs from the module.

•

Does DTC B2477 reoccur?