Ford Ranger EV (2001 year). Manual — part 112
414-03A-44
414-03A-44
High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
•
DTC C1838 Charging System Fault
signal indicates zero.
— The battery control module (BCM) sets DTC
— A charger mode fault occurs if the BCM
C1838 when a failure occurs in the traction
detects the charger mode signal is not being
battery charging system. The BCM uses PIDs
pulled up to auxiliary battery voltage by the
to indicate the charging system failure that
charger. If this occurs, the BCM does not
occurred. The possible failures are:
enable the charger.
— A charger charging after being disabled fault
•
DTC C1859 PRNDL Input #2 Circuit Failure
occurs if the charger charging signal or the
— The battery control module (BCM) sets DTC
auxiliary current sensor indicates that the
C1859 during the BCM on-demand self test if
charger is still outputting significant current
it detects the PRNDE TR2 signal is not
several seconds after the BCM has
grounded. An open or short in the TR2 signal
commanded the charger off.
wire or the gear selector not in the PARK
— A charger overtemperature fault occurs if the
position during the on-demand self-test will
charger fault signal is asserted and the charger
cause DTC C1859.
ready signal is deasserted during a charge
•
DTC C1861 PRNDL Input #4 Circuit Failure
cycle.
— The battery control module (BCM) sets DTC
— A charger latchup fault occurs if the charger
C1861 during the BCM on-demand self test if
fault signal and charger ready signal are
it detects the PRNDE TR4 signal is not
asserted during a charge cycle.
grounded. An open or short in the TR4 signal
— A charger cycling fault occurs if the charger is
wire or the gear selector not in the PARK
cycled on and off several times within a short
position during the on-demand self-test will
period of time due to a reoccurring fault
cause DTC C1861.
condition. If this occurs, the BCM disables the
•
DTC C1863 External Charging Fault
charger.
— The battery control module (BCM) sets DTC
— A charger undercurrent fault occurs if the
C1863 if the on-plug circuit indicates the
BCM commands maximum power output from
vehicle is plugged into a power control station
the charger and little or no current is detected
(PCS) and the traction inverter module (TIM)
at the auxiliary current sensor for an extended
indicates the vehicle is traveling faster than 15
period of time. There are several potential
km/h (9.4 mph).
causes for this fault.
•
DTC B2247 Electric Vehicle Battery Pack
— A charger overcurrent fault occurs if the BCM
Temperature Fault
commands zero power output from the charger
— The battery control module (BCM) uses four
and significant current is detected at the
temperature sensors to monitor the temperature
auxiliary current sensor for an extended period
of the traction battery. The BCM sets DTC
of time.
B2247 if it detects a change in temperature
— A charger overvoltage fault occurs if the BCM
(Tmax-Tmin) greater than 15
°
C (59
°
F)
detects the traction battery voltage to be
between any of the temperature sensors in the
greater than 425 volts during a charge cycle.
battery pack or if it detects any of the
If this occurs, the BCM disables the charger.
temperature sensors at a temperature greater
— A charger over amp-hours fault occurs the
than or equal to 83
°
C (181
°
F). If Tmax
BCM detects that more than 110 amp-hours of
(maximum temperature of any of the four
current have been put into the traction battery
battery temperature sensors) is greater than or
during the charge cycle. If this occurs, the
equal to 83
°
C (181
°
F), the BCM will turn off
BCM disables the charger.
the traction battery cooling/ventilation fan to
prevent oxygen from entering the traction
— A charger line capacity fault occurs if the
battery. The BCM will prevent charging if the
BCM commands maximum power output from
temperature difference between any of the
the charger and little or no current is detected
temperature sensors is greater than 30
°
C
at the auxiliary current sensor for an extended
period of time and the charger line capacity
(86
°
F).
414-03A-45
414-03A-45
High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
Electrical Schematic
Inspection and Verification
Refer to Electrical and Vacuum Troubleshooting
Refer to
Manual, Cell 18, Traction Battery Charging/Heating
System for schematic and connector information.
Symptom Chart
Symptom Chart
Condition
Possible Sources
Action
•
DTC C1836 Battery
•
Circuit(s).
•
Temperature Out of Range
•
Battery temperature sensor.
•
Battery control module
(BCM).
•
DTC C1837 Battery Heater
•
Charging system fault.
•
Circuit Failure
•
Circuit(s).
•
High-voltage harness 10B700.
•
Contactor box high-voltage
fuse.
•
Contactor box.
•
Battery control module
(BCM).
•
Upper battery module
heater(s).
•
Lower battery heater.
•
DTC C1838 Charging System
•
Charger charging fault.
•
Fault
•
Charger over-temperature
fault.
•
Charger latchup fault.
•
Charger cycling fault.
•
Charger under current fault.
•
Charger over current fault.
•
Charger over voltage fault.
•
Charger over amp-hours fault.
•
Charger line capacity fault.
•
Charger mode feedback fault.
•
Charger Charging After Being
•
Contactor box.
•
Disabled Fault
•
Circuit(s).
•
Traction battery charger.
•
Battery control module
(BCM).
•
Charger Over-Temperature
•
Circuit(s).
•
Fault
•
Traction battery charger.
•
Battery control module
(BCM).
•
Charger Latchup Fault
•
Circuit(s).
•
•
Traction battery charger.
•
Battery control module
(BCM).
•
Charger Cycling Fault
•
Current leakage condition.
•
•
Traction battery charger.
414-03A-46
414-03A-46
High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
Symptom Chart (Continued)
Condition
Possible Sources
Action
•
Charger Under Current Fault
•
High voltage power
•
distribution box (HVPDB).
•
High-voltage harness
(14B326).
•
Contactor box high-voltage
fuse.
•
Contactor box.
•
Battery control module
(BCM).
•
Circuit(s).
•
Traction battery charger.
•
Charger Over Current Fault
•
Traction battery charger.
•
•
Contactor box.
•
Battery control module
(BCM).
•
Charger Over Voltage Fault
•
High-voltage harness
•
(14A280-WD).
•
High-voltage harness
(14A280-RF).
•
Battery control module
(BCM).
•
Charger Line Capacity Fault
•
Power control station (PCS).
•
•
Traction battery charger.
•
Charger Mode Feedback Fault
•
Circuit(s).
•
•
Traction battery charger.
•
Battery control module
(BCM).
•
DTC C1859 PRNDL Input #2
•
Circuit(s).
•
Circuit Failure
•
Battery control module
(BCM).
•
DTC C1861 PRNDL Input #4
•
Circuit(s).
•
Circuit Failure
•
Battery control module
(BCM).
•
DTC C1863 External
•
Circuit(s).
•
Charging Fault
•
Charger inlet assembly.
•
Battery control module
(BCM).
•
DTC B2247 Electric Vehicle
•
Battery pack overtemperature
Battery Pack Temperature
condition.
Fault
•
Power Control Station (PCS)
•
Improper PCS connection to
•
Operation Verification Test
charger inlet.
•
PCS.
•
Vehicle charging system
failure.
Special Tool(s)
Pinpoint Tests
BCM/TIM Breakout Box (BOB) Overlay 418-F220
Special Tool(s)
Traction Battery High-Voltage Service Cord 418-F218
104-Pin Breakout Box (BOB) 418-049 (014-00950) or
Traction Battery Low-Voltage Service Cord 418-F219
equivalent
(Continued)
BCM/TIM Breakout Box (BOB) Adapter Cable
418-F212
(Continued)
414-03A-47
414-03A-47
High Voltage/Traction Battery
DIAGNOSIS AND TESTING (Continued)
Special Tool(s)
Traction Battery High-Voltage Lockout and Diagnostic
Tool 418-F207
High-Voltage Insulated Safety Gloves 100-F036 or
equivalent
Face Shield 100-F035 or equivalent
PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE
TEST STEP
ACTION TO TAKE
A1 CHECK FOR BATTERY TEMPERATURE SENSOR OUT OF
RANGE FAULT
•
With key ON, monitor battery control module (BCM) PIDs BATTMP1,
Yes =
GO to A2.
BATTMP2, BATTMP3, and BATTMP4.
•
Do any of the BATTMP PIDs indicate YES?
No =
System OK. If DTC C1836
reoccurs intermittently, GO
A2 CHECK WIRES TO BATTERY TEMPERATURE SENSOR FOR
OPEN(S)
•
Remove the traction battery and connect Traction Battery High-Voltage
Yes =
Lockout and Diagnostic Tool to the traction battery high-voltage two-pin
C3994M.
No =
REPAIR the wire(s) in
question.
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.
•
Connect 104-Pin Breakout Box (BOB) to BCM C1986, C1987 using the
BCM/TIM BOB Adapter Cable and Overlay; leave the BCM
disconnected.
•
Measure the resistance of the wires indicated below for the battery
temperature sensor in question.
Battery Temperature Sensor #1:
•
With key OFF, disconnect upper front pack temperature sensor #1 C1988
and measure the resistance of the BR wire between BOB pin A40 and
temperature sensor #1 C1988.
•
With key OFF, measure the resistance of the BR/W wire between BOB
pin A9 and temperature sensor #1 C1988.
Battery Temperature Sensor #2:
•
With key OFF, disconnect rear upper pack temperature sensor #2 C1989
and measure the resistance of the GY/BK wire between BOB pin A21
and temperature sensor #2 C1989.
•
With key OFF, measure the resistance of the DG wire between BOB pin
A22 and temperature sensor #2 C1989.
Battery Temperature Sensor #3:
•
With key OFF, disconnect lower front pack temperature sensor #3 C1981
and measure the resistance of the LG/BK wire between BOB pin A24
and temperature sensor #3 C1981.
•
With key OFF, measure the resistance of the R/W wire between BOB
pin A25 and temperature sensor #3 C1981.
Battery Temperature Sensor #4:
(Continued)
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