Ford Ranger EV (2001 year). Manual — part 21

100-09-29

100-09-29

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 8-31.

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, measure the resistance of the Y wire between BOB pin

No =

REPAIR the Y wire.

54 and in-line 1969M.

•

Is the resistance less than 5 ohms?

8-31 CHECK CIRCUIT 3404 (Y) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

Disconnect BOB from in-line C1939M, remove the traction battery, and

Yes =

REPLACE the BCM.

connect Traction Battery High-Voltage Lockout and Diagnostic Tool to

REFER to

Section

the traction battery high-voltage two-pin C3994M.

414-03A

.

No =

REPAIR the Y 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 C1987.

•

Measure the resistance of the Y wire between pin 12 on BCM C1987

and BOB pin 54.

•

Is the resistance less than 5 ohms?

ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

9-1 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 9-2.

— 83 (no charge-battery overtemperature)

If 83, GO to 9-5.

— 84 (no charge-battery undertemperature)

If 84, GO to 9-8.

— 85 (no charge-high temperature delta)

If 85, GO to 9-11.

— 87 (no charge-battery full)

If 87, the traction battery is

at full state of charge

(SOC). System OK.

— 96 (no charge-EPO detected)

If 96, GO to 9-12.

— 99 (no charge-line capacity out of range)

If 99, GO to 9-15.

— 101 (no charge-no AC to charger)

If 101, GO to 9-28.

•

Does the BCM OP PID indicate 48, 83, 84, 85, 87, 96, 99, or 101?

No =

GO to 9-33.

9-2 CHARGE TRACTION BATTERY TO FULL STATE OF CHARGE

(SOC)

•

Disconnect and reconnect the 12-volt auxiliary battery negative cable.

Yes =

GO to 9-3.

(Continued)

100-09-30

100-09-30

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

•

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)?

9-3 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

414-03B

.

No=

CHARGE the traction

battery to full (SOC).

CHECK the BCM_OP PID.

IF the BCM_OP PID still

indicates 48. REPLACE the

BCM. REFER to

Section

414-03B

.

9-4 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 9-6.

•

Do any of the TMPSEN PIDs indicate greater than 45

°

C (113

°

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

BCM. REFER to

Section

414-03B

.

9-5 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 42

°

C

•

While vehicle is connected to the PCS, monitor BCM PIDs TMPSEN1,

(108

°

F). System OK.

TMPSEN2, and TMPSEN3.

•

Do the TMPSEN PIDs that were greater than 45

°

C (113

°

F)

No =

GO to 9-6.

decrease?

9-6 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.

414-03B

.

(Continued)

100-09-31

100-09-31

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

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 45

°

C (113

°

F) still

indicate the same value?

9-7 CHECK TRACTION BATTERY TEMPERATURE SENSORS FOR

UNDERTEMPERATURE CONDITION

•

With key ON, monitor BCM PIDs TMPSEN1, TMPSEN2, and

Yes =

PARK the vehicle indoors in

TMPSEN3.

a warmer environment.

CONNECT the vehicle to a

power control station (PCS)

to allow self-heating. GO to

9-8.

•

Do any of the TMPSEN PIDs indicate less than -25

°

C (-13

°

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

BCM. REFER to

Section

414-03B

.

9-8 CHECK IF UNDERTEMPERATURE STATE IS CAUSED BY AN

ACTUAL UNDERTEMPERATURE CONDITION

NOTE: Allow adequate time for vehicle to warm before checking for

Yes =

ALLOW temperature(s) to

temperature increase.

increase above -24

°

C

•

While vehicle is connected to the PCS, monitor BCM PIDs TMPSEN1,

(-11

°

F). System OK.

TMPSEN2, and TMPSEN3.

•

Do the TMPSEN PIDs that were less than -25

°

C (-13

°

F) increase?

No =

GO to 9-9.

9-9 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.

414-03B

.

(Continued)

100-09-32

100-09-32

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

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 less than -25

°

C (-13

°

F) still

indicate the same value?

9-10 CHECK BATTERY TEMPERATURE SENSOR (HIGH

TEMPERATURE DELTA 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

REFER to

Section

C3994M.

414-03B

.

•

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, and TMPSEN3.

•

Does the TMPSEN PID that indicated a greater than 20

°

C (36

°

F)

difference from the other TMPSEN PIDs still indicate a greater than

20

°

C (36

°

F) difference?

9-11 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 indicates ENABLE after pressing the START

No =

System OK.

button on the power control station (PCS), GO to 9-13.

•

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)?

(Continued)