Ford Ranger EV (2001 year). Manual — part 119

414-03A-72

414-03A-72

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1755 POWER LIMIT SHUTDOWN FAULT

TEST STEP

ACTION TO TAKE

Yes =

Go to A5

•

WARNING: Make sure the cooling system temperature is not

hot. Failure to follow these instructions, may result in personal

injury or death.

Turn the ignition key ON, remove the radiator cap, and check for coolant

flow.

•

Is there coolant flow?

No =

Check the cooling system

for restrictions. Refer to

Section 303-03

, Coolant

Pump does not operate.

A5 MONITOR THE TIM AND TRANSAXLE TEMPERATURE

•

Monitor PID TIMTEMP during a road test.

Yes =

Check for cooling system

restrictions at TIM.

•

Is the temperature above 80

°

C (176

°

F)?

No =

Intermittant problem in the

water pump circuit or the

water pump.

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)

•

Perform the on-demand self-test for the BCM.

Yes =

GO to Pinpoint Test C.

•

Does DTC C1864 Battery Module Fault occur?

No =

GO to B2.
If DTC B1676 Battery Pack

Voltage Out of Range

occurs, GO to B7.

B2 CHECK BATTERY MODULE FAULT STATUS

•

With key ON, monitor BCM PIDs BTM 1FT thru BTM39FT.

Yes =

GO to B3.

•

Do any of the battery module fault PIDs indicate YES?

No =

GO to B6.

B3 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 B4.

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

C3994M.

No =

REPLACE high-voltage

harness (10B694). GO to

B5.

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when performing 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 BTM39FT) indicates YES, check the battery module in

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

cable polarity is OK, GO to B6.

•

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

(Continued)

414-03A-73

414-03A-73

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

— 1: circuit 3089 (LB/W) between in-line C1882M (label R) and pin 13

on BCM C1865

— 1, 2: circuit 3072 (PIK/Y) between in-line C1884M (label A) and pin

19 on BCM C1865

— 2, 3: circuit 3073 (R/W) between in-line C1876M (label B) and pin

20 on BCM C1865

— 3, 4: circuit 3074 (BK/O) between in-line C1884M (label A) and pin

21 on BCM C1865

— 4, 5: circuit 3075 (Y) between in-line C1876M (label B) and pin 15

on BCM C1865

— 5, 6: circuit 3076 (Y/W) between in-line C1881M (label C) and pin 9

on BCM C1865

— 6, 7: circuit 3077 (O/LB) between in-line C1880M (label D) and pin

3 on BCM C1865

— 7, 8: circuit 3078 (LB/O) between in-line C1879M (label G) and pin

4 on BCM C1865

— 8, 9: circuit 3079 (W/PIK) between in-line C1879M (label G) and pin

10 on BCM C1865

— 9, 10: circuit 3080 (R/LB) between in-line C1879M (label G) and pin

16 on BCM C1865

— 10, 11: circuit 3081 (W/R) between in-line C1877M (label H) and pin

22 on BCM C1865

— 11, 12: circuit 3082 (BK/LG) between in-line C1879M (label G) and

pin 23 on BCM C1865

— 12, 13: circuit 3083 (Y/W) between in-line C1874M (label J) and pin

24 on BCM C1865

— 13, 14: circuit 3084 (BK/PIK) between in-line C1877M (label H) and

pin 18 on BCM C1865

— 14, 15: circuit 3085 (O/LG) between in-line C1872M (label K) and

pin 12 on BCM C1865

— 15, 16: circuit 3086 (W/P) between in-line C1874M (label J) and pin

6 on BCM C1865

— 16, 17: circuit 3087 (DG/P) between in-line C1873M (label L) and

pin 1 on BCM C1866

— 17, 18: circuit 3088 (DB/O) between in-line C1869M (label F) and

pin 11 on BCM C1866

— 18, 19: circuit 3090 (P) between in-line C1869M (label F) and pin 21

on BCM C1866

— 19, 20: circuit 3091 (LB/BK) between in-line C1868M (label M) and

pin 31 on BCM C1866

— 20, 21: circuit 3092 (GY/O) between in-line C1869M (label F) and

pin 32 on BCM C1866

— 21, 22: circuit 3093 (W/LB) between in-line C1868M (label M) and

pin 33 on BCM C1866

— 22, 23: circuit 3094 (LB/R) between in-line C1871M (label E) and

pin 23 on BCM C1866

— 23, 24: circuit 3095 (O/Y) between in-line C1867M (label P) and pin

13 on BCM C1866

— 24, 25: circuit 3096 (W) between in-line C1870M (label N) and pin 3

on BCM C1866

— 25, 26: circuit 3097 (R/LG) between in-line C1870M (label N) and

pin 4 on BCM C1866

(Continued)

414-03A-74

414-03A-74

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

— 26, 27: circuit 3098 (R/Y) between in-line C1870M (label N) and pin

5 on BCM C1866

— 27, 28: circuit 3099 (BR) between in-line C1873M (label L) and pin

15 on BCM C1866

— 28, 29: circuit 3200 (R/BK) between in-line C1875M (label S) and

pin 25 on BCM C1866

— 29, 30: circuit 3201 (LG/BK) between in-line C1875M (label S) and

pin 35 on BCM C1866

— 30, 31: circuit 3202 (T/Y) between in-line C1874M (label J) and pin

36 on BCM C1866

— 31, 32: circuit 3203 (LG/R) between in-line C1875M (label S) and

pin 26 on BCM C1866

— 32, 33: circuit 3204 (LG/O) between in-line C1878M (label T) and

pin 16 on BCM C1866

— 33, 34: circuit 3205 (O/Y) between in-line C1878M (label T) and pin

6 on BCM C1866

— 34, 35: circuit 3206 (LG/Y) between in-line C1878M (label T) and

pin 7 on BCM C1866

— 35, 36: circuit 3207 (P/LB) between in-line C1886M (label U) and

pin 8 on BCM C1866

— 36, 37: circuit 3208 (GY/BK) between in-line C1886M (label U) and

pin 18 on BCM C1866

— 37, 38: circuit 3209 (W/BK) between in-line C1886M (label U) and

pin 28 on BCM C1866

— 38, 39: circuit 3210 (LG/W) between in-line C1887M (label V) and

pin 38 on BCM C1866

— 39: circuit 3211 (W/LB) between in-line C1885M (label W) and pin

39 on BCM C1866

•

Is the resistance less than 5 ohms?

B4 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:

No =

REPLACE the harness(es)

(14A280) in question. GO to

B5.

Battery Module Faults
— 1: between circuit 3089 (LB/W) on in-line C1882F (label R) and

battery module 1 (-) post

— 1, 2: between circuit 3072 (PIK/Y) on in-line C1884F (label A) and

battery module 1 (+) post

— 2, 3: between circuit 3073 (R/W) on in-line C1876F (label B) and

battery module 2 (+) post

— 3, 4: between circuit 3074 (BK/O) on in-line C1884F (label A) and

battery module 3 (+) post

— 4, 5: between circuit 3075 (Y) on in-line C1876F (label B) and

battery module 4 (+) post

— 5, 6: between circuit 3076 (Y/W) on in-line C1881F (label C) and

battery module 5 (+) post

— 6, 7: between circuit 3077 (O/LB) on in-line C1880F (label D) and

battery module 6 (+) post

(Continued)

414-03A-75

414-03A-75

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

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

TEST STEP

ACTION TO TAKE

— 7, 8: between circuit 3078 (LB/O) on in-line C1879F (label G) and

battery module 7 (+) post

— 8, 9: between circuit 3079 (W/PIK) on in-line C1879F (label G) and

battery module 8 (+) post

— 9, 10: between circuit 3080 (R/LB) on in-line C1879F (label G) and

battery module 9 (+) post

— 10, 11: between circuit 3081 (W/R) on in-line C1877F (label H) and

battery module 10 (+) post

— 11, 12: between circuit 3082 (BK/LG) on in-line C1879F (label G)

and battery module 11 (+) post

— 12, 13: between circuit 3083 (Y/W) on in-line C1874F (label J) and

battery module 12 (+) post

— 13, 14: between circuit 3084 (BK/PIK) on in-line C1877F (label H)

and battery module 13 (+) post

— 14, 15: between circuit 3085 (O/LG) on in-line C1872F (label K) and

battery module 14 (+) post

— 15, 16: between circuit 3086 (W/P) on in-line C1874F (label J) and

battery module 15 (+) post

— 16, 17: between circuit 3087 (DG/P) on in-line C1873F (label L) and

battery module 16 (+) post

— 17, 18: between circuit 3088 (DB/O) on in-line C1869F (label F) and

battery module 17 (+) post

— 18, 19: between circuit 3090 (P) on in-line C1869F (label F) and

battery module 18 (+) post

— 19, 20: between circuit 3091 (LB/BK) on in-line C1868F (label M)

and battery module 19 (+) post

— 20, 21: between circuit 3092 (GY/O) on in-line C1869F (label F) and

battery module 20 (+) post

— 21, 22: between circuit 3093 (W/LB) on in-line C1868F (label M)

and battery module 21 (+) post

— 22, 23: between circuit 3094 (LB/R) on in-line C1871F (label E) and

battery module 22 (+) post

— 23, 24: between circuit 3095 (O/Y) on in-line C1867F (label P) and

battery module 23 (+) post

— 24, 25: between circuit 3096 (W) on in-line C1870F (label N) and

battery module 24 (+) post

— 25, 26: between circuit 3097 (R/LG) on in-line C1870F (label N) and

battery module 25 (+) post

— 26, 27: between circuit 3098 (R/Y) on in-line C1870F (label N) and

battery module 26 (+) post

— 27, 28: between circuit 3099 (BR) on in-line C1873F (label L) and

battery module 27 (+) post

— 28, 29: between circuit 3200 (R/BK) on in-line C1875F (label S) and

battery module 28 (+) post

— 29, 30: between circuit 3201 (LG/BK) on in-line C1875F (label S)

and battery module 29 (+) post

— 30, 31: between circuit 3202 (T/Y) on in-line C1874F (label J) and

battery module 30 (+) post

— 31, 32: between circuit 3203 (LG/R) on in-line C1875F (label S) and

battery module 31 (+) post

— 32, 33: between circuit 3204 (LG/O) on in-line C1878F (label T) and

battery module 32 (+) post

(Continued)