Ford Ranger EV (2001 year). Manual — part 20
100-09-25
100-09-25
Powertrain Diagnostic Routines Identification
DIAGNOSIS AND TESTING (Continued)
ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)
TEST STEP
ACTION TO TAKE
•
Is there a temperature difference of greater than 7
°
C (13
°
F) between
No =
CONNECT the vehicle to
the temperature sensor that is below 5
°
C (41
°
F) and the other
the power control station
temperature sensors?
(PCS) to warm the traction
battery to a temperature
greater than 7
°
C (45
°
F).
MONITOR the TMPSEN
PIDs while the vehicle is
connected to the PCS. If the
temperature of the battery
temperature sensor that was
less than 5
°
C (41
°
F) does
not increase, GO to 8-11.
8-10 CHECK BATTERY TEMPERATURE SENSOR
(UNDERTEMPERATURE 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.
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 less than 5
°
C (41
°
F) still
indicate less than 5
°
C (41
°
F)?
8-11 CHARGE TRACTION BATTERY TO FULL STATE OF
CHARGE (SOC)
•
Disconnect and reconnect the 12-volt auxiliary battery negative cable.
Yes =
REPEAT this test step. The
traction battery has not
reached full SOC.
NOTE: If the EMG PO PID indicates ENABLE after pressing the
No =
System OK.
START button on the power control station (PCS), GO to 8-13.
•
Charge the traction battery to full SOC.
•
With key OFF and vehicle on-charge, monitor BCM PIDs EMG PO
and BCM OP.
•
Does the BCM OP PID still indicate 96 (no charge-EPO detected)?
8-12 CHECK EMERGENCY POWER OFF (EPO) SIGNAL TO
BATTERY CONTROL MODULE (BCM)
•
Remove the traction battery and connect Traction Battery High-Voltage
Yes =
Lockout and Diagnostic Tool to the traction battery high-voltage two-pin
C3994M.
(Continued)
100-09-26
100-09-26
Powertrain Diagnostic Routines Identification
DIAGNOSIS AND TESTING (Continued)
ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)
TEST STEP
ACTION TO TAKE
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 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 and BCM C1986, C1987
using the BCM/TIM BOB Adapter Cable and Overlay.
•
With key ON, monitor BCM PID EMG PO.
•
Connect a jumper wire between BOB pins A10 and A18.
•
Does the EMG PO PID indicate DISABLE?
8-13 CHECK CIRCUIT 3006 (P/LG) FOR OPEN
•
With key OFF, disconnect contactor box C1982 and measure the
Yes =
REPLACE the contactor
resistance of the P/LG wire between pin 9 on contactor box C1982 and
BOB pin A18.
•
Is the resistance less than 5 ohms?
No =
REPAIR the P/LG wire.
8-14 CHECK CHARGER PILOT SIGNAL CIRCUIT FOR OPEN
•
Disengage the locks on the charger inlet connector, push the swing plate
Yes =
GO to 8-15.
forward, and hold the swing plate in the forward position to access the
terminals on the charger inlet connector.
•
With key OFF, measure the resistance between pin 5 (R wire) on charger No =
GO to 8-16.
inlet C5000 and ground.
•
Is the resistance greater than 2.5 megaohms?
8-15 CHECK CIRCUIT 3984 (R) FOR OPEN
•
With key OFF, disconnect traction battery charger C1993 and measure
Yes =
REPLACE the traction
the resistance of the R wire between pin 5 on traction battery charger
C1993 and pin 5 on charger inlet C5000.
•
Is the resistance less than 5 ohms?
No =
REPAIR the R wire.
8-16 CHECK NEUTRAL CIRCUIT FOR OPEN
•
With key OFF, measure the resistance between pin 7 (DG wire) on
Yes =
GO to 8-17.
charger inlet C5000 and ground.
•
Is the resistance greater than 100 ohms?
No =
GO to 8-18.
8-17 CHECK CIRCUIT 3174 (DG) FOR OPEN
•
With key OFF, disconnect traction battery charger C1938 and measure
Yes =
REPLACE the traction
the resistance of the DG wire between pin 7 on charger inlet C5000 and
traction battery charger C1938.
•
Is the resistance less than 5 ohms?
No =
REPLACE the charger inlet.
8-18 CHECK CIRCUITS 3172 (O) AND 3173 (W) FOR OPEN(S)
•
With key OFF, disconnect traction battery charger C1938 and measure
Yes =
GO to 8-19.
the resistance of the O wire between pin 4 on charger inlet C5000 and
traction battery charger C1938.
•
With key OFF, measure the resistance of the W wire between pin 3 on
No =
REPLACE the charger inlet.
charger inlet C5000 and traction battery charger C1938.
•
Are the resistances less than 5 ohms?
8-19 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (OUTSIDE OF
TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S)
(Continued)
100-09-27
100-09-27
Powertrain Diagnostic Routines Identification
DIAGNOSIS AND TESTING (Continued)
ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)
TEST STEP
ACTION TO TAKE
•
With key OFF, disconnect traction battery support tray in-line C1939 and Yes =
GO to 8-20.
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, disconnect traction battery charger C1991 and C1993.
No =
REPAIR the wire(s) in
•
With key OFF, measure the resistance of the O/LB wire between pin 4
question.
on traction battery charger C1991 and BOB pin 61.
•
With key OFF, measure the resistance of the LB/R wire between pin 2
on traction battery charger C1993 and BOB pin 28.
•
Are the resistances less than 5 ohms?
8-20 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (OUTSIDE OF
TRACTION BATTERY SUPPORT TRAY) FOR SHORT(S) TO
GROUND
•
With key OFF, measure the resistance between BOB pins 28, 61 and
Yes =
GO to 8-21.
ground (BOB pin 65).
•
Are the resistances greater than 10,000 ohms?
No =
REPAIR the wire(s) in
question.
8-21 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (INSIDE OF
TRACTION BATTERY SUPPORT TRAY) FOR OPEN
•
Disconnect BOB from in-line C1939M, remove the traction battery, and
Yes =
GO to 8-22.
connect Traction Battery High-Voltage Lockout and Diagnostic Tool to
the traction battery high-voltage two-pin C3994M.
•
Connect BOB to traction battery support tray in-line C1939F using
No =
REPAIR the wire(s) in
Traction Battery Low Voltage Service Cord; do not connect Traction
question.
Battery Low Voltage Service Cord to in-line C1939M.
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.
•
With key OFF, disconnect BCM C1986 and C1987.
•
Measure the resistance of the O/LB wire between pin 5 on BCM C1987
and BOB pin 61.
•
Measure the resistance of the LB/R wire between pin 35 on BCM C1986
and BOB pin 28.
•
Are the resistances less than 5 ohms?
8-22 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (INSIDE OF
TRACTION BATTERY SUPPORT TRAY) FOR SHORT(S) TO
GROUND
•
With key OFF, measure the resistance between BOB pins 28, 61 and
Yes =
REPLACE the traction
ground (BOB pin 65).
•
Are the resistances greater than 10,000 ohms?
No =
REPAIR the wire(s) in
question.
8-23 VERIFY POWER CONTROL STATION (PCS) OPERATION
•
Perform Power Control Station (PCS) Operation Verification Test. Refer
Yes =
GO to 8-24.
to Traction Battery Charging/Heating System in
•
Is the PCS OK?
No =
CARRY OUT the required
action as indicated in the
Power Control Station (PCS)
Operation Verification Test.
8-24 CHECK CIRCUIT 3009 (O/R) (OUTSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR OPEN
(Continued)
100-09-28
100-09-28
Powertrain Diagnostic Routines Identification
DIAGNOSIS AND TESTING (Continued)
ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES)
TEST STEP
ACTION TO TAKE
•
With key OFF, disconnect traction battery support tray in-line C1939 and Yes =
GO to 8-25.
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, disconnect traction battery charger C1993.
No =
REPAIR the O/R wire.
•
With key OFF, measure the resistance of the O/R wire between pin 7 on
traction battery charger C1993 and BOB pin 56.
•
Is the resistance less than 5 ohms?
8-25 CHECK CIRCUIT 3009 (O/R) (OUTSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR SHORT TO GROUND
•
With key OFF, measure the resistance between BOB pins 56 and ground
Yes =
GO to 8-26.
(BOB pin 65).
•
Is the resistance greater than 10,000 ohms?
No =
REPAIR the O/R wire.
8-26 CHECK CIRCUIT 3009 (O/R) (INSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR OPEN
•
Disconnect BOB from in-line C1939M, remove the traction battery, and
Yes =
GO to 8-27.
connect Traction Battery High-Voltage Lockout and Diagnostic Tool to
the traction battery high-voltage two-pin C3994M.
No =
REPAIR the O/R 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 C1986.
•
Measure the resistance of the O/R wire between pin 6 on BCM C1986
and BOB pin 56.
•
Is the resistance less than 5 ohms?
8-27 CHECK CIRCUIT 3009 (O/R) (INSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR SHORT TO GROUND
•
With key OFF, measure the resistance between BOB pins 56 and ground
Yes =
REPLACE the traction
(BOB pin 65).
•
Is the resistance greater than 10,000 ohms?
No =
REPAIR the O/R wire.
8-28 CHECK CHARGER CORD INPUT STATUS
NOTE: Verify the power control station (PCS) charger cord is connected
Yes =
REPLACE the traction
to the charger inlet before carrying out this test step.
•
With key OFF, connect the PCS to the charger inlet connector and
monitor BCM PID CHGCORD.
•
Does the CHGCORD PID indicate IN?
No =
GO to 8-29.
8-29 CHECK CHARGER INLET
•
With key OFF, disconnect in-line C1969 (located on the chassis next to
Yes =
GO to 8-30.
the right headlamp inside the underhood compartment).
•
With key OFF, connect the PCS to the charger inlet connector and
No =
REPLACE the charger inlet.
measure the resistance between the Y wire and BK wire on in-line
C1969F.
•
Is the resistance less than 5 ohms?
8-30 CHECK CIRCUIT 3404 (Y) (OUTSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR OPEN
(Continued)
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