Ford Ranger EV (2001 year). Manual — part 61

303-03-22

303-03-22

Engine Cooling

REMOVAL AND INSTALLATION (Continued)

Installation

1. To install, reverse the removal procedure.

•

After installation, bleed the cooling system.
Refer to

Cooling System Drain,

Fill and

Bleed.

303-14-1

303-14-1

Electric Motor Management

Manual Table of Contents

SECTION 303-14 Electric Motor Management

VEHICLE APPLICATION:

Ranger EV

CONTENTS

PAGE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . ...

303-14-2

DESCRIPTION AND OPERATION

Electric Motor Management . . . . . . . . . . . . . . . . . . .

303-14-2

DIAGNOSIS AND TESTING

Traction Inverter Module (TIM) Control System . . . . . . . . . . . . ..

303-14-2

Electrical Schematic . . . . . . . . . . . . . . . . . . . ...

303-14-2

Inspection and Verification . . . . . . . . . . . . . . . . . .

303-14-3

Pinpoint Test . . . . . . . . . . . . . . . . . . . . . .

303-14-3

Symptom Chart . . . . . . . . . . . . . . . . . . . . . .

303-14-3

REMOVAL AND INSTALLATION

Traction Inverter Module (TIM). . . . . . . . . . . . . . . . . ..

303-14-6

303-14-2

303-14-2

Electric Motor Management

SPECIFICATIONS

Torque Specifications

Torque Specifications

Description

Nm

Lb-Ft

Lb-In

Description

Nm

Lb-Ft

Lb-In

TIM B,+ Cable

30

22

—

Ground Strap Bolt

12

—

107

Connector Nuts

TIM Bracket Bolts

20

14.5

—

TIM C Cable Connector

20

14.5

—

TIM Bracket to Frame

22

16

—

Nut

Bolts

TIM +,- Cable Sleeve

5

—

44.5

TIM Cover Plate Screws

5

—

44.5

Nuts

TIM A, B, C Cable

3

—

26

TIM Electrical

3

—

26.5

Sleeve Nuts

Connectors

TIM A,- Cable

15

11

—

TIM Mounting Bolts

22

16

—

Connector Nuts

(Continued)

DESCRIPTION AND OPERATION

Electric Motor Management

Electric motor management is accomplished by the
traction inverter module (TIM). The TIM is located
in the rear of the vehicle under the bed of the truck.
The TIM converts high-voltage direct current from
the traction battery into high-voltage, three-phase
alternating current to power the motor/transaxle.
Output from the TIM to the motor/transaxle is based
upon driver, sensor, and other module inputs.

•

DTC C1856 Traction Motor Encoder Circuit

DIAGNOSIS AND TESTING

Failure

Traction Inverter Module (TIM) Control

— The traction motor contains two vehicle speed

System

sensors (encoders) to provide two signals

Diagnostic Trouble Code (DTC) Definition

(channels A and B) to indicate the speed and
direction of the vehicle to the TIM. At speeds

The following DTCs relate to the traction inverter

greater than 16 km/h (10 mph), only one

module (TIM) control system:

signal is used to indicate speed. If one signal

•

DTC C1854 Motor Temperature Out of Range

fails, the other one will be used. Below 16

— The traction motor contains a temperature

km/h (10 mph), both signals are needed to

sensor in its stator field windings to indicate

determine direction. If one signal fails, DTC

the motor temperature. The TIM uses this

C1856 is set and the vehicle shuts down. The

input signal to determine current sinked and

TIM also uses the vehicle speed signal to

sourced to the motor. DTC C1854 is set if the

calculate the output to the speedometer.

signal is out of the normal range of 0.8 to 4.0

Electrical Schematic

volts. If this failure occurs, the malfunction
indicator lamp (MIL), red brake warning Refer to Electrical and Vacuum Troubleshooting

indicator, and power limit warning indicator Manual, Cell 26, Motor/Transaxle Control for

illuminate, and the TIM operates the motor at schematic and connector information.

reduced power.

303-14-3

303-14-3

Electric Motor Management

DIAGNOSIS AND TESTING (Continued)

Inspection and Verification

Refer to

Section 100-07

.

Symptom Chart

Symptom Chart

Condition

Possible Sources

Action

•

DTC C1854 Motor

•

Motor/transaxle.

•

GO to

Pinpoint Test A.

Temperature Out of Range

•

Circuit(s).

•

Traction inverter module

(TIM).

•

DTC C1856 Traction Motor

•

Motor/transaxle.

•

GO to

Pinpoint Test B.

Encoder Circuit Failure

•

Traction inverter module

(TIM).

•

Circuit(s).

Pinpoint Test

Special Tool(s)

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

equivalent

BCM/TIM Breakout Box (BOB) Adapter Cable

418-F212

BCM/TIM Breakout Box (BOB) Overlay 418-F220

Electric Motor/Transaxle Test Box 418-F211

PINPOINT TEST A: DTC C1854 MOTOR TEMPERATURE OUT OF RANGE

TEST STEP

ACTION TO TAKE

A1 CHECK MOTOR TEMPERATURE SENSOR

•

Monitor the motor PID TRNTEMP and note the temperature.

Yes =

GO to A3.

•

With key OFF, disconnect motor/transaxle C4993 and connect the

Electric Motor/Transaxle Test Box.

•

Measure the resistance between the motor temperature ports on the test

box and determine the motor temperature from the following resistance

values below:

Resistances
—493 ohms=493

°

C (32

°

F)

—533 ohms=0

°

C (32

°

F)

—576 ohms=10

°

C (50

°

F)

—598 ohms=20

°

C (68

°

F)

—668 ohms=30

°

C (104

°

F)

—718 ohms=50

°

C (122

°

F)

—769 ohms=60

°

C (140

°

F)

—824 ohms=70

°

C (158

°

F)

—880 ohms=80

°

C (176

°

F)

—939 ohms=90

°

C (194

°

F)

—1000 ohms=100

°

C (212

°

F)

—1063 ohms=110

°

C (230

°

F)

—1129 ohms=120

°

C (248

°

F)

—1197 ohms=130

°

C (266

°

F)

—1268 ohms=140

°

C (284

°

F)

(Continued)