Ford Ranger EV (2001 year). Manual — part 18

100-09-17

100-09-17

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

5-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)

OPERATING STATE

•

With key ON, monitor BCM PID BCM OP.

Yes =

If BCM OP PID indicates

67, GO to 5-2.
If BCM OP PID indicates

68, GO to 5-5.
If BCM OP PID indicates

69, CHARGE the traction

battery. REFER to

Section

100-05

.

•

Does the BCM OP PID indicate 67 (limited operating strategy

drive-battery overtemperature), 68 (LOS drive-battery

No =

GO to 5-8.

undertemperature), or 69 (LOS drive-low state of charge )?

5-2 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 5-3.

•

Do any of the TMPSEN PIDs indicate greater than 55

°

C (131

°

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 67, REPLACE the

BCM. REFER to

Section

414-03B

.

5-3 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 55

°

C

•

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

(131

°

F). System OK.

TMPSEN2, and TMPSEN3.

•

Do the TMPSEN PIDs that were greater than 55

°

C (131

°

F)

No =

GO to 5-4.

decrease?

5-4 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)

100-09-18

100-09-18

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (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 55

°

C (131

°

F) still

indicate the same value?

5-5 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

5-6.

•

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 68, REPLACE the

BCM. REFER to

Section

414-03B

.

5-6 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 -25

°

C

•

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

(-13

°

F). System OK.

TMPSEN2, and TMPSEN3.

•

Do the TMPSEN PIDs that were less than -25

°

C (-13

°

F) increase?

No =

GO to 5-7.

5-7 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)

100-09-19

100-09-19

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (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?

5-8 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

Section 414-03B

.

module(s) in question.

REFER to

Section

414-03B

.

•

Does the Battery Module Diagnostic Test indicate to replace any

No =

GO to 5-9.

battery modules?

5-9 CHECK MOTOR TEMPERATURE

•

Drive the vehicle until the vehicle runs at reduced power.

Yes =

GO to 5-10.

•

With key ON, monitor the traction inverter motor (TIM) PID TRNTEMP No =

GO to 5-11.

and note the temperature.

•

Is the temperature greater than 170

°

C (338

°

F)?

5-10 CHECK MOTOR TEMPERATURE SENSOR

•

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

Yes =

REPLACE the

Motor/Transaxle Test Box.

motor/transaxle. REFER to

Section 303-01.

•

Measure the resistance between the motor temperature ports on the test

No =

GO to 5-12.

box and determine the motor temperature from the following resistance

values:

Resistance
— 493 ohms = 0

°

C (32

°

F)

— 533 ohms = 10

°

C (50

°

F)

— 576 ohms = 20

°

C (68

°

F)

— 598 ohms = 25

°

C (77

°

F)

— 621 ohms = 30

°

C (86

°

F)

— 668 ohms = 40

°

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)

— 1,000 ohms = 100

°

C (212

°

F)

— 1,063 ohms = 110

°

C (230

°

F)

(Continued)

100-09-20

100-09-20

Powertrain Diagnostic Routines Identification

DIAGNOSIS AND TESTING (Continued)

ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (NIMH VEHICLES)

TEST STEP

ACTION TO TAKE

— 1,129 ohms = 120

°

C (248

°

F)

— 1,197 ohms = 130

°

C (266

°

F)

— 1,268 ohms = 140

°

C (284

°

F)

— 1,340 ohms = 150

°

C (302

°

F)

— 1,415 ohms = 160

°

C (320

°

F)

— 1,493 ohms = 170

°

C (338

°

F)

— 1,572 ohms = 180

°

C (356

°

F)

— 1,654 ohms = 190

°

C (374

°

F)

— 1,738 ohms = 200

°

C (392

°

F)

— 1,825 ohms = 210

°

C (410

°

F)

— 1,914 ohms = 220

°

C (428

°

F)

— 2,006 ohms = 230

°

C (446

°

F)

— 2,088 ohms = 240

°

C (464

°

F)

— 2,196 ohms = 250

°

C (482

°

F)

— 2,293 ohms = 260

°

C (500

°

F)

— 2,392 ohms = 270

°

C (518

°

F)

— 2,490 ohms = 280

°

C (536

°

F)

— 2,584 ohms = 290

°

C (554

°

F)

— 2,688 ohms = 300

°

C (572

°

F)

•

Is the TRNTEMP PID approximately equal to the motor

temperature?

5-11 CHECK TIM

•

Measure the resistance between the motor temperature ports on the

Yes =

REPLACE the TIM. REFER

Electric Motor/Transaxle Test Box, determine the motor temperature, and

to

Section 303-14

.

compare the temperature to the TRNTEMP PID from test step 5-10.

•

Is the TIMTEMP PID approximately equal to the motor

No =

GO to 5-12.

temperature?

5-12 VERIFY THE MEASURED RESISTANCE/TEMPERATURE IS IN

RANGE

•

Note the measured resistance in test step 5-11.

Yes =

REPLACE the TIM. REFER

to

Section 303-14

.

•

Is the resistance within the range indicated in the list in test step

No =

REPLACE the

5-10?

motor/transaxle. REFER to

Section 303-01.

ROUTINE 6: NOTICEABLE DECREASE IN VEHICLE DRIVING RANGE (LEAD ACID VEHICLES)

TEST STEP

ACTION TO TAKE

6-1 CHECK STATUS OF TRACTION BATTERY MODULES BY

CARRYING OUT THEBATTERY 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

Section 414-03A

.

module(s) in question.

REFER to

Section

414-03A

.

•

Does the Battery Module Diagnostic Test indicate to replace any

No =

GO to 6-2.

battery modules?

6-2 IDENTIFY VEHICLE OPTION

•

Determine if the vehicle is equipped with traction battery heaters.

Yes =

GO to 6-3.

(Continued)