Ford Ranger EV (2001 year). Manual — part 169

414-03B-72

414-03B-72

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

DTC C1864 Battery Module

•

Battery module(s) installed

•

GO to Pinpoint Test C.

Fault

incorrectly (reverse cable

polarity).

•

Incorrect battery module

(12-volt) installed.

•

Battery control module

(BCM).

•

DTC B2236 Weak or

•

Battery module(s).

•

GO to Pinpoint Test D.

Defective Electric Vehicle

Battery Module Fault

•

Battery Pack/Module

•

None.

•

GO to Pinpoint Test E.

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 P1755 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 =

REFER to Section 303-14.

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

Index in Section 100-07.

•

Do any BCM DTCs occur?

No =

GO to A3.

A3 CHECK DIFFERENCE BETWEEN COOLANT TEMPERATURE

AND MOTOR/TRANSAXLE TEMPERATURE

•

With key ON, monitor IAA module PID CLNTTMP and TIM PID

Yes =

REPLACE the

MTRTMP.

motor/transaxle. REFER to

Section 303-01.

•

Is the temperature difference between the CLNTTMP and

No =

REPLACE the TIM. REFER

MTRTEMP PIDs greater than 30

°

C (86

°

F)?

to Section 303-14.

PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

B1 CHECK FOR OTHER BATTERY CONTROL MODULE (BCM)

DIAGNOSTIC TROUBLE CODES (DTCs)

•

Carry out the on-demand self-test for the BCM.

Yes =

GO to Pinpoint Test C.

(Continued)

414-03B-73

414-03B-73

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

•

Does DTC C1864 Battery Module Fault occur?

No =

GO to B2.
If DTC B1676 Battery Pack

Voltage Out of Range

occurs, GO to B8.

B2 CARRY OUT THE BATTERY MODULE DIAGNOSTIC TEST

•

With key ON, carry out the Battery Module Diagnostic Test. Refer to the Yes =

If the B integer value is 1 or

procedure in Traction Battery System.

2, GO to B7.
If the Battery Module

Diagnostic Test integer

value is 4 or 5, GO to B3.
If the Battery Module

Diagnostic Test integer

value is 3, REFER to the

Lead-Acid Traction Battery,

Battery Module Diagnostic

Test Integer Values Chart to

determine the required

action.

•

Does the Battery Module Diagnostic Test Function Test indicate to

No =

System OK.

replace any battery modules or to correct any other concerns?

B3 CHECK BATTERY MODULE FAULT STATUS

•

With key ON, monitor BCM PIDs BTM 1FT thru BTM25FT.

Yes =

GO to B4.

•

Do any of the battery module fault PIDs indicate YES?

No =

GO to B7.

B4 CHECK VOLTAGE SENSE LINE CIRCUIT BETWEEN BCM AND

IN-LINE CONNECTOR FOR OPEN

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

GO to B5.

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

C3994M.

No =

REPLACE high-voltage

harness (10B694). GO to

B6.

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 high-voltage C1865, C1866 and the

appropriate in-line connector for the battery module(s) in question.

NOTE: If a single battery module fault PID (with the exception of

BTM 1FT and BTM25FT) indicates YES, check the battery module in

question for reverse cable polarity. Reinstall (correctly) if necessary. If the

cable polarity is OK, GO to B7.

•

Measure the resistance of the wire between the BCM high-voltage

connector and in-line connector for the indicated battery module fault(s).

Use the following information:

Battery Module Faults
— 1: circuit 3089 (LB/W) between in-line C1750M (label A) and pin 4

on BCM C1865

— 1, 2: circuit 3072 (PK/Y) between in-line C1752M (label C) and pin

10 on BCM C1865

— 2, 3: circuit 3073 (R/W) between in-line C1751M (label B) and pin

16 on BCM C1865

(Continued)

414-03B-74

414-03B-74

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

— 3, 4: circuit 3074 (BK/O) between in-line C1752M (label C) and pin

22 on BCM C1865

— 4, 5: circuit 3075 (Y) between in-line C1751M (label B) and pin 23

on BCM C1865

— 5, 6: circuit 3076 (Y/W) between in-line C1753M (label D) and pin

24 on BCM C1865

— 6, 7: circuit 3077 (O/LB) between in-line C1753M (label D) and pin

18 on BCM C1865

— 7, 8: circuit 3078 (LB/O) between in-line C1754M (label E) and pin

12 on BCM C1865

— 8, 9: circuit 3079 (W/PK) between in-line C1753M (label D) and pin

6 on BCM C1865

— 9, 10: circuit 3080 (R/LB) between in-line C1754M (label E) and pin

1 on BCM C1866

— 10, 11: circuit 3081 (W/R) between in-line C1755M (label F) and pin

11 on BCM C1866

— 11, 12: circuit 3082 (BK/LG) between in-line C1754M (label E) and

pin 21 on BCM C1866

— 12, 13: circuit 3083 (DG/LG) between in-line C1755M (label F) and

pin 31 on BCM C1866

— 13, 14: circuit 3084 (BK/PK) between in-line C1756M (label G) and

pin 32 on BCM C1866

— 14, 15: circuit 3085 (O/LG) between in-line C1756M (label G) and

pin 33 on BCM C1866

— 15, 16: circuit 3086 (W/P) between in-line C1757M (label H) and pin

23 on BCM C1866

— 16, 17: circuit 3087 (DG/P) between in-line C1758M (label J) and

pin 13 on BCM C1866

— 17, 18: circuit 3088 (DB/O) between in-line C1759M (label K) and

pin 3 on BCM C1866

— 18, 19: circuit 3090 (P) between in-line C1758M (label J) and pin 4

on BCM C1866

— 19, 20: circuit 3091 (LB/BK) between in-line C1749M (label L) and

pin 5 on BCM C1866

— 20, 21: circuit 3092 (GY/O) between in-line C1758M (label J) and

pin 15 on BCM C1866

— 21, 22: circuit 3093 (W/LB) between in-line C1759M (label K) and

pin 25 on BCM C1866

— 22, 23: circuit 3094 (LB/R) between in-line C1749M (label L) and

pin 35 on BCM C1866

— 23, 24: circuit 3095 (O/Y) between in-line C1748M (label M) and pin

36 on BCM C1866

— 24, 25: circuit 3096 (W) between in-line C1748M (label M) and pin

26 on BCM C1866

— 25: circuit 3097 (R/LG) between in-line C1747M (label N) and pin

16 on BCM C1866

•

Is the resistance less than 5 ohms?

B5 CHECK VOLTAGE SENSE LINE CIRCUIT BETWEEN BATTERY

MODULE AND IN-LINE CONNECTOR FOR OPEN

•

Measure the resistance between the wire on the in-line connector and

Yes =

GO to B7.

battery module post (+ or -) for the indicated battery module fault(s).

Use the following information:

(Continued)

414-03B-75

414-03B-75

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

No =

REPLACE the harness(es)

(14A280) in question. GO to

B6.

Battery Module Faults
— 1: between circuit 3089 (LB/W) on in-line C1750F (label A) and

battery module 1 (-) post

— 1, 2: between circuit 3072 (PK/Y) on in-line C1752F (label C) and

battery module 1 (+) post

— 2, 3: between circuit 3073 (R/W) on in-line C1751F (label B) and

battery module 2 (+) post

— 3, 4: between circuit 3074 (BK/O) on in-line C1752F (label C) and

battery module 3 (+) post

— 4, 5: between circuit 3075 (Y) on in-line C1751F (label B) and

battery module 4 (+) post

— 5, 6: between circuit 3076 (Y/W) on in-line C1753F (label D) and

battery module 5 (+) post

— 6, 7: between circuit 3077 (O/LB) on in-line C1753F (label D) and

battery module 6 (+) post

— 7, 8: between circuit 3078 (LB/O) on in-line C1754F (label E) and

battery module 7 (+) post

— 8, 9: between circuit 3079 (W/PK) on in-line C1753F (label D) and

battery module 8 (+) post

— 9, 10: between circuit 3080 (R/LB) on in-line C1754F (label E) and

battery module 9 (+) post

— 10, 11: between circuit 3081 (W/R) on in-line C1755F (label F) and

battery module 10 (+) post

— 11, 12: between circuit 3082 (BK/LG) on in-line C1754F (label E)

and battery module 11 (+) post

— 12, 13: between circuit 3083 (Y/W) on in-line C1755F (label F) and

battery module 12 (+) post

— 13, 14: between circuit 3084 (BK/PK) on in-line C1756F (label G)

and battery module 13 (+) post

— 14, 15: between circuit 3085 (O/LG) on in-line C1756F (label G) and

battery module 14 (+) post

— 15, 16: between circuit 3086 (W/P) on in-line C1757F (label H) and

battery module 15 (+) post

— 16, 17: between circuit 3087 (DG/P) on in-line C1758F (label J) and

battery module 16 (+) post

— 17, 18: between circuit 3088 (DB/O) on in-line C1759F (label K) and

battery module 17 (+) post

— 18, 19: between circuit 3090 (P) on in-line C1758F (label J) and

battery module 18 (+) post

— 19, 20: between circuit 3091 (LB/BK) on in-line C1749F (label L)

and battery module 19 (+) post

— 20, 21: between circuit 3092 (GY/O) on in-line C1758F (label J) and

battery module 20 (+) post

— 21, 22: between circuit 3093 (W/LB) on in-line C1759F (label K) and

battery module 21 (+) post

— 22, 23: between circuit 3094 (LB/R) on in-line C1749F (label L) and

battery module 22 (+) post

— 23, 24: between circuit 3095 (O/Y) on in-line C1748F (label M) and

battery module 23 (+) post

(Continued)