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Balance Hybrid Service Manual

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1. 7 6 22M odule Module Sense L ev 2 Description This indicates the loss of 2 or more of the 4 battery module temperature sensors in the pack Temperature data for that section of the pack is invalid Possible Causes M ultiple internal battery pack module temperature sensor or wiring failures Diagnostic Aids e Replace ESS 7 6 23C ritical State of C harge SOC Description The ESS state of Charge has went above 95 SOC or below 5 SOC This does not necessarily mean there is a battery issue Possible Causes e Pack SOC is too high or too low e Hybrid systems is overcharging or over discharging pack V CU software traction motor ISG motor dc dc converter EPAS Air Condition Diagnostic Aids e Check for other VCU DTC s before continuing e Most likely not an ESS failure but a vehicle fault Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 147 AZD Service Manual 7 6 24C ritical Control Parameter Description The following conditions have occurred at the same time e Keyln FALSE e CAN Link Lost Fault TRUE POSSIDIE CAUSES e Disconnected pack CAN wiring OR pack microcontroller ignition low voltage connector pin a Unless this is intermittent then pack will not be able to restart or re enable high voltage e Internal battery pack software fault Replace pack Diagnostic Aids e f ahistory fault this can be ignored as it
2. Description The ISG DM oC state does not match the state being commanded by the VCU The Body Builder AC will be shut off and the engine will be forced on and stay running and the HY BRID SERVICE light will be on solid Possible e ISG DMOC was just reprogrammed with new software without the voltage Causes calibration being performed e Faulty ISG DMoC e Incorrect DM oC Software Diagnostic e Compare the ESS buss voltage to the reported voltage from the ISG DM OC and Aids use ccShell to recalibrate DM oC voltage Ensure that Save Box Config has been performed Voltage Calibration DMoC Reported Voltage V 324 02 Measured Voltage _ calibrate BoxConfiguration DCVoltageScaleFactor T_INT C 2 4043 Save Box Config Reprogram ISG DM OC with latest software from A zure Contact A zure TechLine techline azuredynamics com for support POA1F Battery Energy Control Module Description The ESS does not respond to a connect command from the V CU for greater than 2 seconds The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e ESS Isolation resistance is too low less that 2 M ohms at key on e Internal ESS failure Diagnostic A ids e Using Balance Diagnostic Tool check for any ESS Info codes repair as required e Using the BDT verify that the isolation resistance of the ESS diagnostics are 2 mohms at key on e
3. e Use Balance diagnostic tool to monitor Accelerator Pedal Track 1 2 3 inputs e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor track 2 signal P0222 Throttle Pedal Position Sensor Switch B Circuit Low Description MY 2008 The VCU has detected that the A ccelerator Pedal track 2 input signal to the VCU has a short Circuit to Ground or an Open Circuit The input voltage is less than 0 53 volts If no faults are present on tracks 1 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid If faults are present for track 1 track 3 or both as well as the P0222 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash MY 2009 The VCU has detected that the A ccelerator Pedal track 2 input signal to the VCU has a short Circuit to Ground or an Open Circuit The input voltage is less than 0 14 volts The vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash Possible Causes e APP Sensor track 2 wiring short circuit to ground e Faulty APP sensor e Open Circuit Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related to A ccelerator Pedal track 2 e UseBDT to monitor Accelerator Pedal track 2 e Refer to appropriate Ford Diagnost
4. Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 139 AZD Service Manual motor DC to DC converter EPAS Air Con e Pack modules are weak or poorly balanced e Pack is cold below 0 C e Internal battery pack fault module voltages are being misread due to hardware or software fault Diagnostic A ids e Use Balance Diagnostic too and record all faults If a Critical SOC fault is found refer to Critical State of Charge soc first e Confirm SOC is greater than 10 7 6 14M odule Over Voltage Description At least one of the module voltages in the battery pack is greater than or 16 0 volts and remains in this condition for 2 sec GE e Hybrid system is over charging pack V CU software traction motor ISG motor e Pack modules are weak or poorly balanced e Pack is cold below 0 C e Internal battery pack fault module voltages are being misread due to hardware or software fault Diagnostic A ids e Use Balance Diagnostic too and record all faults If a Critical SOC fault is found refer to Critical State of Charge SOC fault first e Confirm SOC is less than 90 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 140 AZD Service Manual 7 6 15M odule Delta Voltage Description U Volts Difference between average module voltage and maximum or minimum module voltage exceeds predetermined level
5. e Refer to appropriate Ford Diagnostics for APP sensor P250A Engine Oil Level Sensor Circuit Description The Engine Oil Level switch input to the VCU switches faster than max defined frequency of 1 Hz Possible Causes Engine Oil Level switch Circuit intermittent connection Diagnostic A ids e Use Balance diagnostic tool to monitor Engine Oil Level switch Input e Refer to appropriate A zure wiring schematics and check all electrical connections related to Engine Oil Level switch Input to VCU P2519 A C Request A Circuit Description The Body Builder A C request input to the VCU switches faster than max defined frequency of 25 Hz The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes A C request intermittent connection Diagnostic A ids e Use Balance diagnostic tool to monitor A C request Input e Refer to appropriate A zure wiring schematics and check all electrical connections related to A C request Input to VCU P2533 Ignition Switch Run Start Position Circuit Description The K ey Start input to the VCU switches faster than max defined frequency of 5 Hz The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes K ey Start circuit intermittent connection Diagnostic A ids e UseBDT to monitor K ey Start input e Confirm
6. C Minimum Stop Performance Description The accelerator pedal track 3 signal is below 9 The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e APP track 3 short to ground e APP track 3 connectivity e APP sensor fault Diagnostic A ids e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 110 AZD Service Manual P2163 Throttle Pedal Position Sensor A Maximum Stop Performance Description MY 2008 The accelerator pedal track 1 signal is above 91 If no faults are present on tracks 2 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light be on solid If faults are present for track 2 track 3 or both as well as the P02163 then the vehicle will be set to a Forced Conventional Limp Home M ode and the HY BRID SERVICE light will flash Note APP track 1 is an inverted signal when compared to tracks 2 amp 3 MY 2009 The accelerator pedal track 1 signal is above 98 The vehicle will be set to a Forced Conventional Limp Home M ode and the HY BRID SERVICE light will flash Possible Causes e APP track 1 short to ground e APP track 1 connectivity e APP sensor fault Diagnostic A ids e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford D
7. M Y 2009 The accelerator pedal track 1 signal is below 2 The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will Flash Possible Causes e APP track 1 short to V bat or VREF e APP track 1 connectivity e APP sensor fault Diagnostic A ids e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 109 AZD Service Manual P2113 Throttle Pedal Position Sensor B Minimum Stop Performance Description MY 2008 The accelerator pedal track 2 signal is below 9 If no faults are present on tracks 1 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid If faults are present for track 1 track 3 or both as well as the P02113 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will Flash MY 2009 The accelerator pedal track 2 signal is below 2 The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will Flash Possible Causes e APP track 2 short to ground e APP track 2 connectivity e APP sensor fault Diagnostic A ids e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor P2114 Throttle Pedal Position Sensor
8. greater than volt One of the following conditions is TRUE for 20 seconds e The average module voltage of the pack minus the minimum module voltage is 2 5 volts e Themaximum module voltage minus the average module voltage of the pack is 1 2V Average Volts 14 volts 2 5 volts 1 2 volts Pack modules may be weak or poorly balanced A single or multiple modules may be failing or have failed Internal battery pack fault module voltages are being misread due to hard or software fault This may be more evident during cold below 0 C operation or during aggressive operation where there are longer and heavier charge discharge rates Possible Causes Pack modules are weak or poorly balanced Replace pack Pack is cold below 0 C Internal battery pack fault module voltages are being misread due to hardware or software fault Diagnostic Aids See pinpoint test below Test step Result Action 1 Perform preliminary diagnostics Yes e Perform preliminary diagnostic section Repair and retest No Go to step 2 Were any issues found 2 Check for Battery Faults and Software Version Yes e KeyON using the A zure Battery Diagnostic Diagnose any SOC faults After repairs are complete Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 141 AZD Service Manual Test step Result Action software verify the latest software is loaded to clear all
9. 35m t R Dim SE Molded ans e Gi L pen LOWER i Hose NIMH BATTERY PACK L 0 52nt 1 Hose AP 5 psi 12 L min Maided elbow HR 600 W Max Inlet Temp 45 C E Si H w Noes Es 5 8 Hosa Molded NOTES Q 1 NOT TO SCALE Es DEGAS 2 ARROWS INDICATE FLOW DIRECTION TAEA 3 BLUE REFERS TO CO D FLUID ORANGE IS WARM RED IS HOT D BOTZ 4 HOSE LENGTH TOLERANCE TO BE WITHIN at Dm CAP v Hose 4 L 3 30m Ss d Sg 4 in The cooling system as shown In this Satcon DC DC diagram to the Satcon DC DC Converter is CONVERTER 3a Vent Hose not installed on P4 and P5 HR 455 W L 042m P4 and P5 use an alr cooled system instead is Max Inlet Temp 55 C UPPER amp d LI CRO 27 Hose Note install lag Molded Elbow si Highest poai Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 AZD Service Manual POA92 Hybrid Generator Performance Description The ISG fails to crank engine above a calibrated threshold of 125 rpm 3 consecutive times The HY BRID SERVICE light will be on solid VCU will attempt to start the engine with the starter If both starter and ISG starts fail the HYBRID SERVICE light will flash and the vehicle will be set to Forced EV mode with delayed traction disabled depending on the state of charge Possible Causes e ISG motor failure ISG DMoC failure ISG belt failure ISG belt slippage or failed belt tensioner Speed sensor failed or intermittent Diagno
10. 7 6 7 Misc Invalid Pack State Description System has entered an invalid state PER e Internal battery pack software fault Diagnostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software 7 6 8 Misc Invalid Precharge State Description System has entered an invalid state ROSSI CAUSES e Internal battery pack software fault Diagnostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software 7 6 9 Input Default Param L oaded Description This fault indicates that the proper parameters were not loaded to the battery during a software update The system is operating using default values which may affect the system operation NOTE This code will be set during battery programming and must be cleared Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 137 AZD Service Manual when programming is completed Failure to clear the code may result in unnecessary diagnostics Possible Causes e ESS was programmed and faults were not cleared e ESS was programmed and parameters were not loaded Diagnostic A ids e Use Balance Diagnostic tool and record
11. C310S D3 connectivity e Refer to appropriate A zure wiring schematics and check all electrical connections related to K ey Start Input to VCU Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 112 AZD Service Manual U0100 ENG Lost Communication with ECM PCM A Description Fault monitoring begins 2 seconds after the PCM has been powered on by the VCU TheVCU will monitor the PCM CAN messages If any PCM message is arriving too slow or any message is not being received at all this fault will set The vehicle will be set to Forced Conventional Limp Home mode and the HY BRID SERVICE light will flash Possible Causes e External E Stop circuitry short to ground pre production only e Failed Can terminator resistor e Failed PCM e Faulty power and ground circuits to PCM module e Faulty wiring routing or connection problems on CAN 1 Diagnostic Aids e Place vehicle in conventional mode and perform Ford base vehicle diagnostics to confirm the PCM is operating normally e UseBDT Balance Diagnostic Tool to manually enable PCM relay and confirm V batt at Ford PCM fuse 23 at Ford under hood power distribution panel e Refer Azure wiring schematic e Refer to pinpoint test procedure Loss of CAN 1 Communications U010F Lost Communication With Air Conditioning Module Description If any Traction M otor DM oC CAN message is arriving too slow or
12. Description The SW revision reported by the TM DMoC is NOT 4 The vehicle will be set Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 116 AZD Service Manual to a Forced Conventional M ode and The HY BRID SERVICE light will be on solid Possible Causes e TheTM DMoC has the incorrect software level loaded Diagnostic A ids e Reprogram the TM DM oC with the correct software level Refer to https extranet azuredynamics com for the latest software version U1030 Software Incompatibility With Air Conditioning Module Description The SW revision reported by the A C DM oC is NOT 4 The vehicle will be set to a Forced Conventional M ode and The HY BRID SERVICE light will be on solid Possible Causes e TheA C DMoC has the incorrect software level loaded Diagnostic A ids e Reprogram the A C DM oC with the correct software level Refer to https extranet azuredynamics com for the latest software version U1031 Software Incompatibility With Power Steering Control Module Description The SW revision reported by the EPAS DMoC is NOT 4 The vehicle will be set to a Forced Conventional M ode and The HY BRID SERVICE light will be on solid Possible Causes e TheEPAS DMoC has the incorrect software level loaded Diagnostic Aids e Reprogram the EPAS DM oC with the correct software
13. Engine Running using the Azure Battery Diagnostic software check the minimum and maximum module voltages e Pack voltage divided by 28 the average module voltage Yes Allow the system to charge the pack with no load If the voltages do not recover to within the limits replace the pack e Subtract the minimum module voltage from the No average voltage Go to step 6 e Subtract the average module voltage from the maximum module voltage Are the results of the first greater than 1 2 volts or the second greater than 0 7V Note this would indicate weak modules 6 Check M odule V oltages Under Load e Use the Balance Diagnostic software to record Yes minimum and maximum module voltages e Inasafe area perform several heavy acceleration and deceleration runs Do not violate any laws NOTE It is recommended that one person drives while a second operates the software e Save the trace NOTE save as raw data It may be necessary to send the recording to Azure Dynamics for analysis Does the Delta Voltage go higher than 1 2 volts for greater than 2 seconds Replace the pack No No fault at this time This may be an indication of a weakening pack that may exhibit problems in colder operation Module Voltages Maximum Module Minimum Modk 7 6 16C ritical Delta V oltage Description Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 143 AZD S
14. P0222 Throttle Pedal Position Sensor Switch B Circuit Low 84 P0223 Throttle Pedal Position Sensor Switch B Circuit High 86 P0224 Throttle Pedal Position Sensor Switch B Circuit Intermittent 0 cect cette eeeeeees 86 P0226 Throttle Pedal Position Sensor Switch C Circuit Range Performance 87 P0227 Throttle Pedal Position Sensor Switch C Circuit Low 87 P0228 Throttle Pedal Position Sensor Switch C Circuit High 88 P0229 Throttle Pedal Position Sensor Switch C Circuit Intermittent A 88 P0504 Brake Switch A B Correlation dsivevusu tata edel Deg 88 P0531 A C Refrigerant Pressure Sensor A Circuit Rangelbertomance serere 89 P0705 Transmission Range Sensor A Circuit PRNDL Input ccssscesessscssssssesssssssseessrsesrsenes 89 P0915 Gear Shift Position Circuit Range Performance ccceccecececeeeeeeeeeeececeeeneesieieteneneeeteneeeteees 89 POAOF Eng Engine Failed to Startiniame aaa aaia 90 POA1B Drive Motor A Control Module 90 POA1E Starter Generator Control Module AAA 91 POA1F Battery Energy Control Module 91 POA3C Drive Motor A Inverter Over Temperature 92 POA 3E Generator Inverter Over Temperature NENNEN 92 RRE Re ellene e 92 POA7E Hybrid Battery Pack Over Temperature 93 POA 92 Hybrid Generator Performance 94 POAA6 Hybrid Battery Voltage System Isolation Fault 0c cceceseeetenetetseseeeteeeieieteneneteteeeteeeees 94 POAE1 Hybrid B
15. Product Support Techline Support 10 PS_FLT_DC_BUS UNDER VOLTAGE Description The DC bus voltage drops below the EE 2PSOffB at The minimum Powerstage Operating Threshold typically 100 volts while the power stage is enabled Note that the battery voltage must be above EE2PSOnB at typically 120 volts before the powerstage will enable Since in many applications the DM oC does not receive an OFF signal the HV bleeding away is anormal shutdown event therefore this fault is only flagged if the DM oC was switching torque was commanded when the DC Bus Voltage drops out This fault is meant to highlight abnormal shutdown sequences it is really more a warning than a fault Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 123 AZD Service Manual Possible Causes Abnormal shutdown sequence Wrong or corrupt Software calibration Faulty HV battery Faulty VCU control Diagnostic Aids Confirm the shutdown sequence for the DM oC was correct with all torque request being zeroed at least EE 2PSIdleT ime before the HV dropped below EE2PSOffBat e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software 11 PS_FLT_OVERSPEED Description The motor Controller has detected that the motor speed in RPM has exceeded the calibrated limit of EE2PosOverspeed in the positive direction or
16. Temperature sensor e Failed sensor e Motor has overheated due to blocked air flow to motor Diagnostic A ids e Check wiring for opens and shorts to ground M easure resistance between C174P pin G and pin H pin of the 19 pin connector at traction motor A functioning sensor should read between 150K and 250K e room temperature M easure resistance between C174P pin U and pin V pin of the 19 pin connector at traction motor A functioning sensor should read between 25K and 45K room temperature Note pins U amp V are not populated on all models of traction motor Refer To Azure Wiring Schematic P1A04 Drive Motor A Position Sensor Transmission Output Speed Sensor Correlation Description The motor speed reported by traction DM oC differs from the PCM reported OSS by more than 1500 rpm The vehicle will be set to a Forced Conventional M ode and The HY BRID SERVICE light will be on solid The VCU will switch from using the Traction M otor OSS for the vehicle controls and the Instrument Cluster speed display and instead use the PCM reported transmission output shaft speed signal OSS and calculated vehicle speed Possible Causes e Check traction motor speed sensor e Speed sensor wiring issue e Broken slipping traction motor drive coupler Diagnostic A ids e Using Balance Diagnostic tool and the ford IDS tool monitor and compare the OSS reading to the traction moto
17. all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software 7 6 10Precharge Positive R elay Short Description The battery pack current exceeded 5 0A when only the precharge contactor was closed Possible Causes e Internal ESS fault Diagnostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software 7 6 11Precharge System Short Description The battery pack has detected a system short fault either because the link voltage failed to rise or the current failed to decrease during the precharge sequence The system monitors how long it takes for the link voltage to rise to the same level as the pack voltage and for the current flow to drop This would normally indicate an external short on the high voltage buss A short will prevent the voltage from achieving the proper level and cause the current to continue to flow Possible Causes e Vehicle high voltage buss is shorted positive to negative e Component on high voltage buss is drawing current during precharge Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 138 AZD Service Manual when it should be off e Internal battery pack hardware of software fault Diag
18. checked In addition since they are enumerated it is easier to understand what the fault is Both the EE3PSFaults and EE3LastError history can ONLY be cleared via ccShell as they are stored within the DM oC The Balance Diagnostic Tool currently does not support this functionality The Active Inverter State will display any currently active DM oC faults If history faults are displayed but no VCU DTC s are present than there is not a current issue with the DMoC Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 75 AZD Service Manual Figure 30 DM oC info Codes Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 76 AZD Service Manual 7 4 VCU DTC s NOTE When performing diagnostics on vehicles with multiple active DT C s always perform diagnostics for active Communications DT C s first C1000 Inertia Switch Bal 79 P0121 Throttle Pedal Position Sensor Switch A Circuit Range Performance 80 P0122 Throttle Pedal Position Sensor Switch A Circuit LOW sessesssssississisiisrssiesrssiniisrsnrnrssenienress 81 P0123 Throttle Pedal Position Sensor Switch A Circuit High 82 P0124 Throttle Pedal Position Sensor Switch A Circuit lntermftent A 83 P0217 ENG Engine Coolant Over Temperature Condition oo ccc cccceee ee eeeeeeteneteteteieteteteeeteseeeseees 83 P0221 Throttle Pedal Position Sensor Switch B Circuit Range Performance 84
19. e Repair harness or connection issue 128 DESAT There are three levels of over current protection in the DM oCs each with the ability to act with different response times and trip levels The three levels are Software Over Current slowest response time trip level can be adjusted by changing software parameters Hardware Over Current medium response time trip level is fixed in hardware high trip level Desaturation Detection fastest response time trip level is fixed in hardware highest trip level Description This fault indicates that one or more of the IGBT s experienced an excessive current This is the last level of hardware protection triggering a critical fault which requires power cycling the DM oC to re enable Possible e Motor that is being driven by the DM oC has a phase to phase short Causes e Thecable to the motor has a phase to phase short e Failed DM oC Current sensor failure or disconnected The IGBT or other internal circuitry of the DM oC DM oC has catastrophically failed e Faulty DMoC grounding Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 125 AZD Service Manual Diagnostic Aids The electrical system in this vehicle is capable of producing lethal voltage levels All hybrid drivetrain and control systems must be maintained and serviced by trained personnel who are qualified to service Azure hybrid vehicle systems e
20. freeze frame data and a DM oC Info Code is stored The engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes Faulty EPAS motor Controller Faulty EPAS M otor Faulty Wiring Diagnostic A ids Refer to M otor Controller info Codes DM oC Info Codes and freeze frame data for additional information P1A45 Electric Power Steering Control Module Description The EPAS DM oC state does not match the state being commanded by the VCU The engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes EPAS motor control was just reprogrammed to new software without the V oltage calibration performed Faulty EPAS motor Controller Incorrect DM oC software Diagnostic A ids Compare the ESS buss voltage to the reported voltage from the EPAS DM oC and use ccShell to recalibrate DM oC voltage Reprogram M otor Controller with latest software from A zure P1A46 Electric Power Steering under Speed Fault Description The reported EPAS speed has dropped 600 rpm below the requested set point for greater than 1 second The engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes Faulty EPAS M otor Tight or seized Pump bearings Slipping pump belt Low fluid level or air in the PS lines Diagnostic A ids Remove EPAS belt and manu
21. is a known bug that has no negative effect e If Active ESS should be replaced and A zure Techline notified 7 6 25M isc Contactor Description The CBCM has found that either the positive or negative contactor has opened while being commanded to close i e Link V oltage does not match Pack V oltage even though contactors have been closed POSSIDIE CAUSES e Internal battery pack fault contactor shorted or welded shut link or pack voltage being misread software fault Diagnostic A ids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 148
22. lower voltage Possible Causes e Inaccurate software voltage calibration allows the DC bus to go to too high a voltage e Other component on high voltage bus is causing a voltage spike e Failed DM oC Noisy signal from power board where high voltage DC is scaled down to 0 5 volts range e Contactor opening or fuse blowing during regen e PM motor overspeed and back EMF voltage is too high e Battery is over charged Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 121 AZD Service Manual Diagnostic A ids Verify Battery voltage is within the recommended range Recalibrate DM oC voltage with ccShell Check that grounding and shielding is done properly to prevent noise Log ISR1UsDC ISR2EstB atCurrent ISR 2H ertz A loss of motor control stability at high speed might put too much current onto the bus particularly for permanent magnet motors Contact Azure Dynamics Product Support Techline Support 7 PS_FLT_HARDWARE oC Description All hardware over current faults will trigger the enumerated fault code PS FLT HARDWARE_OC The EE3LastError detects each fault individually Possible Causes Wrong or corrupt Software calibration Damaged motor M otor inductance is not correct Bad speed sensor or noisy speed sensor Bad reading of rotor position causes DM oC to produce voltage vectors that are incorrect and cause an over current Syste
23. 2 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 78 AZD Service Manual P250A Engine Oil Level Sensor Circuit 112 P2519 A C Request A ef re EE 112 P2533 Ignition Switch Run Start Position Clrouft ccseseeeeeeetececeeeee eee ceceseeeeneeieieieneneneteteseeeees 112 U0100 ENG Lost Communication with ECM DCH AT 113 U010F Lost Communication With Air Conditioning Module 113 U0110 Lost Communication with Drive M otor Control Module AT 114 U0111 Lost Communication with Battery Control Module 114 U0120 Lost Communication with Starter Generator Control Module ANNE 115 U0121 ABS Lost Communication with Anti Lock Brake System ABS Control Module 115 U0131 Lost Communication with Power Steering Control Module 116 U0151 Lost Communication with Restraint Control Module AA 116 U0155 Lost Communication with Instrument Panel Cluster IPC control Panel ssec 116 U0311 Software Incompatibility With Drive M otor Control Module 116 U 1030 Software Incompatibility With Air Conditioning Module 117 U 1031 Software Incompatibility With Power Steering Control Module 117 U 1032 Software Incompatibility With Starter Generator Control Module 117 U 1300 U 1301 U 1302 U 1303 1304 U 1305 U 1306 U 1307 VCU Low Memory Margin 118 U 1310 U 1311 U 1312 U 1313 1314 U 1315 U 1316 VCU CPU uaea secere 118 C1000 Inertia Switch Tripped Description The Inertia switch input
24. APP track 1 2 3 and compare signals Refer to appropriate A zure wiring schematics Refer to appropriate Ford Diagnostics for APP sensor track 3 signal P0504 Brake Switch A B Correlation Description VCU brake switch digital input does not correspond with CAN reported PCM brake ON OFF BOO The HY BRID SERVICE light will be on solid Possible Causes e Wiring harness or connection problem from brake switch to VCU e Wiring harness or connection problem from brake switch to PCM Diagnostic A ids e UseBDT Balance Diagnostic Tool on CAN 1 and monitor Brake ON OFF signal Compare Brake ON OFF signal on the BDT display with the BOO on FORD IDS tool Refer to appropriate A zure wiring schematics Refer to appropriate Ford wiring schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 88 AZD Service Manual P0531 A C Refrigerant Pressure Sensor A Circuit Range Performance Description The Cab AC switch input to the VCU switches faster than max defined frequency of 25 Hz The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e AC Switch circuit intermittent connection e Faulty AC switch if equipped Diagnostic A ids e Use Balance diagnostic tool to monitor AC switch Input Refer to appropriate A zure wiring schematics and check all electrical connectio
25. AZD Service Manual 7 Diagnostics 7 1 7 2 7 3 7 4 7 5 7 6 Preliminary DiaghoStiCS siscscssssssississssssstesssssstsscsscsasentsssassscssnsssssssnisrssnssconssssscancessesaenies 70 Ford PCM Hybrid VCU Interaction ssssssssssssusunnnnnnnnnnnnnnnnnnnnnnununnnunnnnnananananananananan 72 Overview of Hybrid DIC S sssscscssssiscestssscssssesscsssarencescsssssescssassestsscsssesissnsesinsentossasastas 74 VCU DT GS E 77 DM OC Info Codes castictiitiiincitinictnninaiini en 119 ACHT Trei 129 7 1 Preliminary Diagnostics The procedures in this section must be performed by certified technicians who have been trained in the use and service of high voltage hybrid electric vehicles and high voltage components V oltage above 30 volts should be considered potentially dangerous and are referred to as High Voltage or HV Always wear appropriate personal safety equipment and take appropriate precautions when working with high voltage components or wiring Never service a component if high voltage is present Before starting with any diagnostic procedures always verify the complaint Next perform a visual inspection of the following 1 All fluid levels are within proper operating levels Note the PAS fluid level must be checked and or filled at a system fluid temp not less than 10C If circumstances arise where it does need to be filled at a temp less than 10C then it will need re checking later at a system temp above 10C to avoid ove
26. Diagnostic A ids Follow diagnostic by description EPAS DM oC not functioning or not communicating Follow diagnostic by description Loss of CAN 2 communications Refer to appropriate A zure wiring schematics U0151 Lost Communication with Restraint Control Module Description RCM CAN message is arriving too slow or any RCM message is not being received at all this fault will set The Hybrid Service light will be on solid Possible Causes Can terminator resistor failure CAN 1 Faulty Restraint Control M odule Wiring or connection problems Diagnostic A ids Follow diagnostic by description Loss of CAN 1 communications Refer to appropriate A zure wiring schematics Refer to Ford diagnostic relating to restraint control module U0155 Lost Communication with Instrument Panel Cluster IPC control Panel Description The VCU will monitor the IPC CAN messages If any IPC message is arriving too slow or any message is not being received at all this fault will set The HYBRID SERVICE light will be on solid Possible Causes Can terminator resistor failure CAN 2 Failed instrument cluster Faulty wiring or connection problems Diagnostic A ids Refer to appropriate A zure wiring schematics Refer to pinpoint test procedure Loss of CAN 2 communications Refer to Ford diagnostics for IPC U0311 Software Incompatibility With Drive Motor Control Module
27. Disconnect motor cables and measure the resistance between each phase and ground The resistance should be greater than 1 0 M egaOhm e Perform Isolation Resistance test Isolation Resistance T esting e Disconnect motor cables and safely isolate them from both the motor and the phase windings For ISG or TM Restart the vehicle in hybrid mode and attempt to move the vehicle forward in forward or reverse If faultisonaEPAS DM 0C Using the BDT enable diagnostic mode and then enable high voltage mode M anually engage EPAS system If fault reappears replace DM oC 129 PS_FLT_CURRENT_CALIB_FAULT Description The DM oC has detected an internal hardware failure current calibration outside of allowed bounds indicating a possible problem with the current sensors Possible Causes Offset calibration out of range due to extreme cold temperatures below 20 C on some hardware Failed DM oC Current sensor failure or disconnect internal failure Diagnostic A ids e Verify temperature is not extremely cold e UseccShell scope tool to log currents and voltages at 10kHz logging rate log the following ISR2IdF ISR2IqF ISR1IsV and ISR1IsW send the captured data to A zure for analysis e If the above test okay replace the DM oC Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 126 AZD Service Manual an PS_FLT_EXTERNAL_PS DISABLE_AT ENABLED Description This fa
28. EE2N egOverspeed in the reverse direction Possible Causes Over speed of the M otor Noisy speed sensor signal Failed speed sensor connection issue Diagnostic Aids Confirm the shutdown sequence for the DM oC was correct with all torque request being zeroed at least EE 2PSIdleT ime before the HV dropped below EE2PSOffBat e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software 12 PS_FLT_SVPWM_ERROR Description This results from calibration settings which reference an unsupported operating mode Note This fault cannot be cleared so it is really more like a critical fault Contact A zure for details Possible Causes e Incorrect Software Diagnostic Aids e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software e Contact Azure Dynamics Product Support Techline Support 13 PS_FLT_SPEED SENSOR ERROR Description Speed discontinuity which exceeds the calibratable threshold Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 124 AZD Service Manual EE 2SpeedD eltaF aultT hr Possible Causes e Speed Sensor Noise or Disconnect e Speed sensor harness or connector connectivity Diagnostic Aids e LogISR2Hertz and or ISR1FluxPosition and ISR 1M Position
29. Fault e isolation failure in EPAS M otor or EPAS M otor controller e Isolation failure in ISG M otor or ISG M otor Controller e isolation failure in Traction M otor or Traction M otor Controller e High Voltage cabling Isolation failure e Isolation failure in DC DC converter e Isolation failurein AC M otor or Controller Diagnostic Aids e Confirm ESS service disconnect pin is installed e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software e Turn key on high voltage off contactors open and read pack s reported isolation resistance value If less than 2000 kohms pack has internal isolation fault replace pack e Turn key on high voltage on contactors closed and monitor the reported isolation resistance value for 10 minutes and if less than 1000 kohms high voltage buss has a isolation fault R efer to Isolation Resistance T esting Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 136 AZD Service Manual 7 6 6 ESS MISC Invalid DBS State Description The CBCM has entered an invalid state e e Internal battery pack software fault Diagnostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software
30. Fault input e Refer to the appropriate Ford Wiring schematics P1A5B Charge Lamp Circuit High Description The VCU has detected that Engine Alternator Fault input signal to the VCU has a short Circuit to battery power or short circuit to VREF 5 volt The input voltage is has exceeded 4 98 volt Possible Causes e Wiring short circuit to power e Wiring short circuit to VSENS power e Open circuit in the wiring Diagnostic Aids e Refer to appropriate A zure wiring schematics and check all electrical connections related to Engine Alternator Fault input e Refer to the appropriate Ford Wiring schematics P1A5C Inclinometer Fault Description The VCU has detected that the Inclinometer value fails to change value over 5 km distance The engine will remain on and the Hybrid Service light be on solid Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 106 AZD Service Manual Possible Causes e Failed inclinometer Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related Inclinometer input e UseBDT to confirm inclinometer operation Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 107 AZD Service Manual P1A70 A C Inverter Over Temperature Description The Air Conditioning EPAS DM oC temperature has exceeded 75 C The Hybrid Serv
31. Hybrid electric Vehicle 2008 2009 2010 Ford E 450 108 AZD Service Manual Possible Causes e Faulty A C DMoC e Faulty A C M otor e Faulty Wiring Diagnostic Aids e Refer to DMoC info Codes DM oC Info Codes and freeze frame data for additional information P1A75 A C Control Module Description The A C DM oC state does not match the state being commanded by the VCU The A C will be disabled and the Hybrid Service light be on solid Possible Causes e A C DMOC was just reprogrammed to new software without the V oltage calibration performed e Faulty A C DMoC e Incorrect DM oC software Diagnostic Aids e Compare the ESS buss voltage to the reported voltage from the EPAS DM oC and use ccShell to recalibrate DM oC voltage e Verify Software level and Reprogram DM oC with the latest software from Azure if necessary P2109 Throttle Pedal Position Sensor A Minimum Stop Performance Description M Y 2008 The accelerator pedal track 1 signal is below 9 If no faults are present on tracks 2 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light be on solid If faults are present for track 2 track 3 or both as well as the P02109 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will Flash Note APP track 1 is an inverted signal when compared to tracks 2 amp 3
32. Manual Check cooling system pumps and fans Check for kinks or obstructions in the coolant hoses Check for air trapped in coolant system 7 6 20C ritical Over Temperature Description At least battery module temperature is greater than or 75 C Critical fault contactors will open after 2 minutes Possible Causes Coolant level and temperature Failed cooling system pumps and fans K inks or obstructions in the coolant hoses air trapped in coolant system M ultiple internal battery pack module temperature sensor or wiring failures Replace pack Internal battery pack thermal failure Replace pack Diagnostic Aids Check coolant level and temperature Check cooling system pumps and fans Check for kinks or obstructions in the coolant hoses Check for air trapped in coolant system 7 6 21M odule Module Sense L el Description This indicates the loss of 1 of the 4 battery module temperature sensors in the pack Possible Causes One of the four module temperature sensors in the battery pack has failed the secondary sensor is being used to report module temperatures One of the four module temperature sensors in the battery pack has failed the secondary sensor is being used to report module temperatures Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 146 AZD Service Manual Diagnostic A ids e Replace ESS
33. NEENEANEAAEANANEANEANENEENEANENNENN ENEAK EEREN EEE 139 7 6 13 Module Under Voltage prsesia e a E 139 7 6 14 Module Over Voltage sinisiin a aaa 140 7 6 15 Module Delta Voltage ciena aa a ta iaai a 141 7 6 16 Critical Delta Voltage A 143 7 6 17 Module H eg CET 144 7 6 18 Module Delta Temperature EEN 145 7 6 19 Critical Over Ti emperdture dccvavict mses ia EEN 145 7 6 20 Critical Over Temperature 146 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 129 AZD Service Manual 7 6 21 Module Module Sense L V1 NENNEN 146 7 6 22 Module M odule Sense Lev esge eedegeseggetereiiergr eat deeger pa tataladacenpetieinasaceiecavealsataniatnets 147 7 6 23 Critical State of Charge IG 147 7 6 24 Criti al Ciontrol Parameter ET 148 7 6 25 E ele 148 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 130 AZD Service Manual 7 6 1 ESS INPUT PILOT Description a TheESS measured Pilot voltage external 12 volt ignition supply for the pack s contactors on pin U of the pack s 31 position low voltage connector has dropped below 7 5 volts while the ignition is ON b NOTE If the Pilot Fault has been triggered the CBCM can no longer guarantee the operation of the battery pack contactors If the contactors are open when this fault occurs the CBCM will prevent any precharge attempts If the contactors are closed when the fault occurs the contactors may open o
34. OC_FAULT_CAUSE_NO_DMOCQUIZ_CAN DMOC_FAULT_CAUSE_CAN_OVERFLOW DMOC FAULT CAUSE UNKNOWN CAN FAULT DMOC_FAULT_CAUSE_UNKNOWN_SW_FAULT DMOC FAULT CAUSE CAN BUS ERROR DMOC_FAULT_CAUSE_IS_NOT_ ASSIGNED VD ON DUM SS DO M ka NON CRITICAL FAULTS CRITICAL Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 119 AZD Service Manual Enumerated Fault Codes EE 3PSF aulto New code since November 2007 also includes an enumerated error the ISR 2PSA ctiveE rror which will display the worst case error that occurred in a human readable form The fault history EE3PSFault0 EE3PSFault1 etc provides the enumerated history for the last 4 faults These error codes were released for external use on P1 in November 2007 so the following codes are fixed Additional codes may be added as the fault handling improves below from ctl_pub h 0 PS_FLT_NO FAULTS This is the desired state NO_FAULTS 0 indicates that no fault condition is active Or in the error history means no fault has occurred since the error history was cleared 1 PS_FLT_UNKNOWN_FAULT This fault should never occur in production code This indicates that the powerstage state machine detected that the PWM outputs were disabled but no known cause could be attributed Usually this results during code development when new fault handling has not been implemented completely correctly All instances of this fault should be treated seriously and
35. Refer to wiring schematics P1A33 AUX Alternator DC DC System Performance Description Fault monitoring begins after the system has been started in hybrid mode Fault is set if the engine is on the dc dc is enabled and the 12 volt battery voltage drops below 11 5 volts for 15 seconds with the radiator fans off or below 11 0 volts with the Radiator fans running The hybrid service light will be on solid Possible Causes e DC DC failure e Alternator failure e Blown fuse or faulty wiring Diagnostic Aids e Using Balance Diagnostic Tool monitor input variable 12 volt Battery Voltage when the system is running in hybrid mode with the engine off Refer to Alternator and DC DC System Performance Refer to appropriate wiring Schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 102 AZD Service Manual P1A40 Electric Power Steering Inverter Over Temperature Description The EPAS DM oC temperature has exceeded 75 C The instrument Cluster temperature gauge will read H or inthe RED The EPAS shroud fan will be on Possible Causes e Faulty EPAS DM ot e Blockage of air flow to cooling fins e Faulty EPAS DM ot fan operation Diagnostic Aids e Visually inspect traction motor Controller cooling fins plenum fan shroud for blockages e Refer to Azure wiring Schematic P1A41 Electric power Steering Motor Stator Over Temperature De
36. Repair as required If no replace the Inclinometer Refer to appropriate A zure wiring schematics and check all electrical connections related to Inclinometer Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 105 AZD Service Manual P1A58 Inclimometer Circuit High Description The VCU has detected that Inclinometer analog input signal to the VCU has short Circuit to battery power or short circuit to VREF 5 volt or an open Circuit The Inclinometer analog input voltage to the VCU is greater than 4 8 volts to set this fault The engine will always stay running and the Hybrid Service light be on solid Possible Causes Faulty Inclinometer Wiring short circuit to power Wiring short circuit to VSENS power Open circuit in the wiring Diagnostic A ids Check for open circuit to Inclinometer e Refer to appropriate A zure wiring schematics and check all electrical connections related to Inclinometer e Refer to Diagnostic by Description Inclinometer does not read correctly P1A5A Charge Lamp Circuit low Description The VCU has detected that Engine Alternator Fault input signal to the VCU has a short Circuit to Ground The input voltage is less than 0 1 volt Possible Causes Wiring short circuit to ground Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related to Engine Alternator
37. S ESS Diagnostics There are two controller hardware revision levels in the NiMH battery pack the newer Algonia and older CBCM type controllers Unfortunately the stored fault definitions conflict on two faults The BDT accommodates the conflict by displaying both codes and the diagnosis will need to proceed based on the controller type The codes displayed for these two faults are as follows e Input DBS CBCM or Service Disconnect A lagonia e Input Default Param Loaded CBCM or DBS Alagonia Note No ESS DTC P1A 20 is flagged by the V CU when the only active ESS fault reported by the pack is a failed CBCM Alagonia HW however the CBCM Alagonia HW Failed fault will be recorded in the ESS fault buffer This DTC has been disabled by the VCU due to frequent invalid reporting of the fault by the ESS 7 6 CT Taube TN 129 TOL ESS INPUT PILOT meeste deninedautarianintig Avoidant ae unianindesanaaaies 131 T62 ESS Input Pack UD nunn aa a a a a G 132 76 3 ESS Input CAN II 134 POA ESS Nout A 2D Paul tess nti eidele aaa Ea aE 135 7 65 ESS Input DBS Faults est AER 136 7 60 62 ESS M SC Invalid DBS Stettin iererereg eegene a Ree 137 7 6 7 Misc Invalid Pack State 137 LED Misc Invalid Precharge State airin usnisa inania a naaar h anisa aiia 137 7 6 9 Input Default Param Loadel AAA 137 7 6 10 Precharge Positive Relay Short 138 7 6 11 Precharge System Short 138 7 6 12 Precharge T Imeout tnnt A uN EKAAANENAENN
38. Tool check the Yes Clear faults and recheck Pilot Voltage refer to illustration No Go to step 5 Analog Input Voltages Pin Number Controller12V Voltage 13 4 a Key in Voltage 13 8 L Pilot Voltage 139V U Pack ID Voltage 13 9 N Is battery voltage higher than 7 5 volts 5 Check Power to the Battery Pack Yes e Key OFF connector C0535 disconnected from GO to step 6 the battery pack N 0 e KeyON measure the voltage from pin U 12 volt power to pin Z ground Is battery voltage present Refer to the proper wiring diagram and repair fault Check inertia switch 6 Check Connector e Key OFF connector C053S disconnected e Check for loose or pushed pins at both sides of the connector e Confirm that the ESS access panel lid is securely fastened Are any issues found Yes Repair as required No Replace battery pack 7 6 2 ESS Input Pack ID Description The Pack Identifier Signal was measured and found to be invalid This condition is checked just once after the CBCM wakes up If the Pack Identifier signal is lost after the CBCM initialization sequence is complete it will not be noticed Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 132 AZD Service Manual Fault will be set as well NOTE If the Pack Identifier Fault is set it is likely that the CAN Link Lost Possible Causes key ON e 12 volt batt
39. V N Is battery voltage higher than 7 5 volts 5 Check Power to the Battery Pack e Key OFF connector C053S disconnected from the battery pack e KeyON measure the voltage from pin U 12 volt power to pin Z ground Is battery voltage present NOTE this circuit is fed from the fuse panel and is live at all times Yes Go to step 6 No Refer to the proper wiring diagram and repair fault Check inertia switch 6 Check Connector e Check both sides of the connector for loose or pushed pins corrosion or other electrical faults Are any issues found Yes Repair as required No Replace battery pack 7 6 3 ESS Input CAN 21A e Failed VCU Description The CBCM has not received a properly formatted 21A message within the timeout period 2000ms NOTE If this fault occurs and the pack was connected contactors closed then the pack will stay connected Possible Causes e Electrical Noise on CAN 2 e CAN 2 terminator resistor failure e Faulty power and ground circuits to ESS e Faulty wiring or connection problems Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 134 AZD Service Manual Diagnostic Aids e Use the Balance Diagnostic tool and confirm the latest ESS software has been loaded Refer to https extranet azuredynamics com for the latest software e Confirm VCU communications with Balance Diagnostic tool e Follow diagnostic
40. ZD Service Manual Sensor range is 40 C to 85 C 87 C sensor failure 7 6 18M odule Delta Temperature Description The maximum module temperature minimum module temperature is greater than or 15 C and remains in this condition for 5 sec Possible Causes e Check coolant level and temperature e Check cooling system pumps and fans e Check for kinks or obstructions in the coolant hoses e Check for air trapped in coolant system Diagnostic Aids e Use Balance Diagnostic tool to monitor readings If all sensors read close to the same readings then check for a coolant issue If only one sensor reads high then replace ESS Sensor range is 40 C to 85 C 87 C sensor failure 7 6 19C ritical Over Temperature Description At least one of the modules is greater than65 C for greater than 5 sec Note Typical temperature change from coolant to max module temperature shouldn t exceed 20 C Possible Causes Coolant level and temperature Failed cooling system pumps and fans K inks or obstructions in the coolant hoses air trapped in coolant system M ultiple internal battery pack module temperature sensor or wiring failures Replace pack Internal battery pack thermal failure Replace pack Diagnostic Aids e Check coolant level and temperature Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 145 AZD Service
41. ally spin EPAS pump If pump is hard to turn by hand replace pump Check belt tension For intermittent faults turn the steering wheel to full lock and hold to see if fault re appears Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 104 AZD Service Manual P1A47 Electric Power Steering Position Sensor Fault Description The reported EPAS speed is less than 300 rpm and the then torques reported by the EPAS motor Controller is greater than 13 NM The engine will be forced on and stay running and the HY BRID SERV CIE light will be on solid Possible Causes Faulty EPAS Motor speed senor Tight or seized Pump bearings Diagnostic A ids Remove EPAS belt and manually spin EPAS pump If pump is hard to turn by hand replace pump Check belt tension P1A57 Inclimometer Circuit low Description The VCU has detected that Inclinometer analog input signal to the VCU has a short Circuit to Ground The Inclinometer output voltage is less than 2 volts The engine will always stay running and the Hybrid Service light be on solid Possible Causes Failed Inclinometer Wiring short circuit to ground Diagnostic A ids Unplug Inclinometer and clear fault with Balance diagnostic tool Start the vehicle and see if the fault reappears Note An unplugged sensor should cause a P1A 58 If the P1A57 reappears then there is a short circuit in the harness
42. any message is not being received at all this fault will set The Body Air conditioning will be disabled and The HY BRID SERVICE light will be on solid Possible Causes e CAN terminator resistor failure CAN 2 e Faulty A C DMoC e Failed 12 volt power or grounds toA C DMoC e Wiring or connection problems Diagnostic A ids Use BDT Balance Diagnostic Tool to check A C function e Refer Azure wiring schematic e Refer to pinpoint test procedure Loss of CAN 2 communications Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 113 AZD Service Manual U0110 Lost Communication with Drive Motor Control Module A Description If any Traction M otor DMoC CAN message is arriving too slow or any message is not being received at all this fault will set The vehicle will be set to a Forced Conventional M ode and The HY BRID SERVICE light will be on solid Possible Causes e CAN terminator resistor failure CAN 2 e Faulty traction DM oC e Failed 12 volt power or grounds to ISG DM oC e Wiring or connection problems Diagnostic A ids e Follow diagnostic by description Traction DM oC not functioning or not communicating e Follow diagnostic by description Loss of CAN 2 communications e Refer to appropriate A zure wiring schematics U0111 Lost Communication with Battery Control Module A Description Fault monitoring begins 1 second after
43. attery Precharge Contactor CIrCult cc cccceeetsteteteteceeeeeeeseeeceseeeeiesieieieneneeeteneteteees 95 POC2F ENG Internal Control Module Drive M otor G enerator Engine Speed Sensor Performance 95 P0C76 Hybrid Battery System Discharge Time too Jong 96 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 77 AZD Service Manual P1A 00 Drive motor A Critical is e ENEE 96 PIAOL Drive Motor A Inverter Faults siririna aaia 96 P1A 02 Drive M otor A Stator Over Temperature cccccceeeceeeetenetenetensesceeesseieisisieteneneeeteteeesites 97 P1A 04 Drive M otor A Position Sensor Transmission Output Speed Sensor Correlation 0 97 P1A 10 Generator Inverter Critical Faute 98 PIATI Generator Inverter Faults iraniana a NEEN 98 P1A 12 Generator Stator Over Temperature s sssssssssrssrsrssrnrunnnsstnnnurnuunenuuennnurnnonnnnuununurnuenenuuunuenrnuonenann 99 P1A 20 Battery Control Moduletailt NENNEN 99 P1A21 Battery Control Module Critical Fault ccc ccc eeeeenenenenensescececeesssisieieieteneneteteeeteses 100 P1A 22 System Isolation Fault W amimg innnan en an 100 P1A30 Hybrid Voltage M easurement Correlation ssessssissssiesisisiissesinsisenrisisnininnnnieninniniininnnns 101 P1A 31 Starter Performance AAA 101 P1A32 Hybrid Control Module Command Engine Pedal Correlation ccsercrrrreeees 102 P1A33 AUX Alternator DC DC System Performance AAA 102 P1A 40 Electric Power Steering Inverter Over T
44. by description Loss of CAN 2 communications Refer to appropriate A zure wiring schematics 7 6 4 ESS Input A2D Fault Description The CBCM has lost communication with its on board external A 2D chip or the power on calibration of the current sensor has failed Possible Causes e Internal battery pack fault Diagnostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 135 AZD Service Manual 7 6 5 ESS Input DBS Fault Description The high voltage battery pack is electrically isolated from the vehicle chassis It monitors the system to detect any faults that would allow a high voltage connection to the vehicle chassis This fault indicates that the ESS has detected a ground fault that would allow current flow to the chassis If the ground fault isn t internal to the pack it could mean there is a ground fault elsewhere on the HV buss This fault could also mean that the pack was keyed on with the service disconnect pin not installed as the isolation resistance can t be properly measured with the service disconnect pin out With the key on and the disconnect pin out it will read 0 kohms Possible Causes e ESS Service disconnect Pin is removed e Internal ESS ground
45. conventional mode jumper wire and jumper pins 30 and 87a on relays K12 and K8 Clear fault codes and retest in conventional mode If faults are still present follow Ford diagnostic procedures with the inclusion of the A zure transmission control wiring and repair as necessary If faults do not reappear refer to A zure wiring schematics and repair wiring or relays as required Refer to wiring diagrams 7 2 3 Ford APP Faults The VCU controls the APP signal by sending outa PWM signal to the PAC PWM to Analog Controller and the PAC in turn sends out an Analog signal to the PCM APP inputs For any APP related faults please check for VCU faults first and verify PAC operation Use Balance Diagnostic tool to manual control APP inputs and use the Ford IDS tool to monitor A PP inputs If the inputs and outputs do not match refer to A zure wiring diagrams and repair as required Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 72 AZD Service Manual PWM 1 PWM to Analog 1 Engine WS Analog PCM Accelerator Analog 1 Analog 2 Analog 3 Ener Driver gt M eier gt Signal gt Engine Demand Algorithms Converter Controller 7 2 4 Instrument Cluster The VCU acts as a gateway between the instrument cluster and any Ford installed control modules including RCM and ABS Any loss of instrument cluster functionality or intermittent instrument cluster displays should be verified with the Bala
46. diagnosed so that proper fault reporting can be implemented 2 PS_FLT_ERROR_ON ENABLE Description This fault is flagged if after enabling the gate drivers a fault is immediately detected Possible Causes e Problem with fault clearing circuit e Fault active while trying to enable Hardware overvoltage might cause this Diagnostic Aids e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software If fault persists replace controller 3 PS_FLT_RELAY_ERROR AT_READY 4 PS_FLT_RELAY_ ERROR AT_ENABLED These faults are very similar indicating that the contactor was detected to be open when it was commanded closed These faults only distinguish if the DM oC was switching enabled at the time the fault was detected This hardware configuration is controlled by parameter change EE ZC ontactorlsInternal will default to TRUE 1 for most applications If your DM oC does not have an internal contactor this parameter should be set to FALSE 0 Follow the appropriate diagnostics path below Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 120 AZD Service Manual Description Contactor state is not closed when powerstage state is READY or ENABLED Possible Causes Blown Fuse internal to DM oC Calibration error check that your unit is calibrated for an external contactor Shielding grounding pr
47. e faults and contact Email saved DTC s to techline azuredynamics com If faults frequently reappear or are continually active contact e Product Support Techline Support Toll Free Number 1 866 473 1636 Phone 905 607 3486 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 118 AZD Service Manual 7 5 DMOC Info Codes When a fault occurs on the DM oC it is logged into a short 4 fault error history that is read with the BDT under the DTC s Info codes under EE3PSFault0 1 2 or 3 A VCU DTC will also be set with any DM 0C s info code and the specific DM oC info code is captured in the Freeze Frame Data under ISG TM AC or EPAS The table below shows both critical and non critical faults related to the DM 0C s Note All DMoC s EPAS ISG AC and TM report the same info codes DMOC INFO CODES PS FLT NO FAULTS PS FLT UNKNOWN FAULT PS FLT ERROR ON ENABLE PS FLT RELAY ERROR AT READY PS FLT RELAY ERROR AT ENABLED PS FLT CHARGED ERROR PS FLT HARDWARE OV PS FLT HARDWARE OC PS FLT SOFTWARE OC PS FLT SOFTWARE OV PS FLT DC BUS UNDER VOLTAGE PS FLT OVERSPEED PS FLT SVPWM ERROR PS FLT SPEED SENSOR ERROR PS FLT DESAT PS FLT CURRENT CALIB FAULT PS FLT EXTERNAL PS DISABLE AT ENABLED PS FLT KERNAL DISPATCHER ERROR PS FLT UNDEFINED CASE ERROR DMOC_FAULT_CAUSE_PS_OFF DMOC_FAULT_CAUSE_NO_COMMAND1_CAN DMOC_FAULT_CAUSE_NO_COMMAND2_CAN DMOC_FAULT_CAUSE_NO_VCUQUIZ_CAN DM
48. e in DC DC converter Isolation failure in AC M otor or Controller Diagnostic A ids Refer to Isolation Resistance T esting Refer to ESS Info Codes ESS Input DBS Fault Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 94 AZD Service Manual POAE1 Hybrid Battery Precharge Contactor Circuit Description ESS reports a precharge state of Precharge failed The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e ESS failure e Short or unintended load on the high voltage B uss at time of precharge Diagnostic A ids e Using Balance Diagnostic tool check for any ESS Info codes repair as required e Isolate the Battery from the other HV components and attempt to start vehicle using the Balance Diagnostic tool monitor the Precharge state and determine if the precharge Fail is still active if yes replace ESS if No perform individual component testing of each HV component and look for a short in a component or wiring e Refer to appropriate A zure wiring schematics POC2F ENG Internal Control Module Drive Motor Generator Engine Speed Sensor Performance Description The reported ISG speed differs from 2 5 x the reported engine speed by 1000rpm for more than 5 seconds The hybrid system will set to Forced Conventional mode and the hybrid service light will be on solid Poss
49. electric Vehicle 2008 2009 2010 Ford E 450 122 AZD Service Manual https extranet azuredynamics com for the latest software e Check the value of EE1SoftOCLimit is zero or negative e Contact Azure Dynamics Product Support Techline Support 9 ba FLT_SOFTWARE_O volts Description The software O volts fault is flagged when software detects an overvoltage condition The threshold for this error detection is set by parameter calibration In case of a Hardware OV this fault may be triggered simultaneously Triggered when the filtered DC V oltage exceeds the calibrated value of EE1M axSwitchingV dc Possible Causes e Inaccurate software voltage calibration allows the DC bus to go to too high a voltage e Other component on high voltage bus is causing a voltage spike Failed DM oC Noisy signal from power board where high voltage DC is scaled down to 0 5 volts range Contactor opening or fuse blowing during regen PM motor over speed and back EM F voltage is too high Battery is over charged Diagnostic A ids Verify Battery voltage is within the recommended range Recalibrate DM oC voltage with ccShell Check that grounding and shielding is done properly to prevent noise Log ISR1UsDC ISR2EstB atCurrent ISR 2H ertz A loss of motor control stability at high speed might put too much current onto the bus particularly for permanent magnet motors e Contact Azure Dynamics
50. emperature AAA 103 P1A 41 Electric power Steering Motor Stator Over Temperature 103 P1A 43 Electric Power Steering Inverter Critical Fault cccccceseseneteeeeecceeeseieeieieneneneneteeesetes 103 P1A 44 Electric power Steering Inverter Faul 104 P1A 45 Electric Power Steering Control Module 104 P1A 46 Electric Power Steering under Speed Fault AA 104 P1A 47 Electric Power Steering Position Sensor EFault cccccceceeetetetensescecceseeisieieieteeeteteteeeeeees 105 PIA57 Inclimometer Circuit low ET 105 P1A58 Inclimometer Circuit High NENNEN 106 PLASA Charge Lamp Circuit le 106 PIA5B Charge Lamp Circuit High 106 PIASCHIinclinometer RUE 106 P1A70 A C Inverter Over Temperature ceeeeseesecensteeseeeeceetsneeseeeeseeeeeatneeceeseenasaneeseneenatantesenatas 108 P1A71 A C M otor Stator Over Temperature 108 P1A73 A C Inverter Critical Eat 108 PIA 74 A C Inverter Fault inira tated Miva abve doa hatin andi adden shiva tiadbeds 108 PIA 75 A C Control Module siisii aa 109 P2109 Throttle Pedal Position Sensor A Minimum Stop Performance scssererererrns 109 P2113 Throttle Pedal Position Sensor B Minimum Stop Performance 110 P2114 Throttle Pedal Position Sensor C Minimum Stop Performance 110 P2163 Throttle Pedal Position Sensor A M aximum Stop Reriormance 111 P2164 Throttle Pedal Position Sensor B Maximum Stop Performance 111 P2165 Throttle Pedal Position Sensor C Maximum Stop Bertomance 11
51. equests an acceleration torque 7 3 Overview of Hybrid DTC s 7 3 1 Vehicle Control Unit VCU The hybrid system is made up of several components Each component has its own fault reporting The VCU monitors these components via CAN communications and depending on the severity of the fault condition will seta DTC Diagnostic Trouble Code and will illuminate the HY BRID SERVICE LED There are two types of V CU faults 1 Active Vehicle DTCs the fault is currently in fault mode 2 Stored Vehicle DT Cs The fault has been active at some point in the past e Upto 16 Faults are stored in the fault buffer along with freeze frame data until they are cleared with the diagnostic tool Diagnostic Disabling If the 12V battery voltage falls below 9 5V all diagnostics are disabled After 1s to allow for momentary voltage drops during 12V starter cranks low voltage diagnostics for the PCM and the ESS are re enabled as these components are able to operate below the 9 5V threshold All other diagnostics will remain disabled until the battery voltage is greater than or equal to 10V Diagnostic M ode All diagnostics are disabled when the vehicle is in diagnostic mode Diagnostic mode can only be entered using the BDT Balance Diagnostic Tool when the vehicle is in K ey on but not start or run This mode allows for manual control of the various output controls from the V CU and allows for module reprogramming 7 3 2 ESS Energy St
52. ervice Manual This code indicates that the system has detected a Delta V oltage sufficiently high to cause a critical fault Once the critical fault has been set the system will limit the power to 0 kW and the contactors will open after 2 minutes Once the critical fault has been set the system has to be powered down before the contactors can reset Possible Causes e Pack modules are weak or poorly balanced Replace pack e Pack is cold below 0 C e Internal battery pack fault module voltages are being misread due to hard or software fault Replace pack Diagnostic Aids e UseBDT to monitor pack Minimum and M aximum module voltages modules If the SOC is greater than 45 amp the voltage delta is greater than 2 volts replace the ESS Module Voltages Maximum Module 147W Minimum Module 14 5 Figure 31 7 6 17 M odule Over Temperature Description At least one of the module temperatures in the battery pack is greater than or 65 C and remains in this condition for 5 sec Possible Causes e Faulty ESS temperature Sensor e Low orno coolant e Blocked or kinked coolant hose Diagnostic Aids e Use Balance Diagnostic tool to monitor readings e If all sensors read close to the same readings then check for a coolant issue e f only one sensor reads high then replace ESS Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 144 A
53. ery voltage is low below 7 5V e Open intermittent or corroded 12 volt battery connection to pin N at Diagnostic A ids e See pinpoint test below Test step Result Action 1 Perform preliminary diagnostics Yes Repair and retest No Were any issues found Go to step 2 2 Check the Battery Software Yes e KeyON do not go to the high volt mode Go to step 3 e Using the Balance Diagnostic Tool check the software version No Is the latest version of software loaded Refer to https extranet azuredynamics com for the latest software Load latest software and retest 3 Clear Codes e KeyON but do not start the vehicle e Using the Balance Diagnostic tool clear all battery codes e Cycle the key OFF and then back ON and restart the vehicle e Check for codes Does the Input Pack ID Fault return Yes Go to step 4 No No fault found 4 Check Power to the Battery Pack e Key OFF connector C053S reconnected e Key ON do not go to the high volt mode e Using the Balance Diagnostic Tool check the Pilot Voltage refer to illustration Yes Clear faults and recheck No Go to step 5 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 133 AZD Service Manual Test step Result Action Analog Input Voltages Pin Number Controller12V Voltage 1344 a Key in Voltage 138V L Pilot Voltage 139V U Pack ID Voltage 138
54. faults and retest the battery pack e Check for active and historic faults No Go to step 3 Areany critical SOC faults present Note Delta voltage faults are easily set if the SOC is ata critical point Fix SOC faults before proceeding with this or any other faults 3 Check M odule V oltages e Key ON using the Azure Battery Diagnostic Yes software check the minimum and maximum Replace the pack module voltages NOTE Only proceed if the SOC is greater than No 40 and the pack has not undergone recent Go to step 4 heavy charge discharge e Pack voltage divided by 28 the average module voltage e Subtract the minimum module voltage from the average voltage e Subtract the average module voltage from the maximum module voltage Are the results of the first greater than 2 5 volts or the second greater than 1 2 volts N ote this would indicate weak modules Under resting conditions the module voltages should be within 0 2 volts minimum to maximum 4 Attempt to go to the High Volt Mode e Key ON Using the Azure Battery Diagnostic Yes software clear the battery faults Go to step 5 e Attempt to go to the high volt mode No Replace the pack Is battery voltage higher than 7 5 volts Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 142 AZD Service Manual Test step Result Action 5 Monitor M odule V oltages e Key ON
55. he electric radiator cooling fans will be on Engine On Only Possible Causes e Base vehicle issue thermostat or mechanical engine failure Low coolant level e e Radiator Blockage e Radiator fan failure e Fan control or wiring Diagnostic A ids e Using Balance Diagnostic Tool verify manual fan control if fans operate normally then follow ford E450 2008 diagnostic procedures else refer to appropriate wiring schematics e Refer to Temperature gauge reads H overheating for fan on off temperatures 83 Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 AZD Service Manual P0221 Throttle Pedal Position Sensor Switch B Circuit Range Performance Description MY 2008 The accelerator pedal tracks 1 amp 2 and 2 amp 3 are different by more than 5 If no faults are present on tracks 1 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid If faults are present for track 1 track 3 or both as well as the P0221 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash MY 2009 The accelerator pedal tracks 1 amp 2 are different by more than 5 The vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash Possible Causes e APP track 2 connectivity e APP sensor fault Diagnostic A ids
56. high voltage reading is greater than 30 volts The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e Wiring or connection problem e Improper V oltage calibration on one of the DM oCs e Motor controller or ESS internal failure e Blown high voltage fuse in junction box or ESS Diagnostic Aids e Use Balance Diagnostic tool to compare voltage readings from each component to the ES buss voltage All voltages should be 5 volts of each other If a DM oC is out of voltage specification Use ccShell to recalibrate the voltage e Refer to appropriate A zure wiring schematics P1A31 Starter Performance Description If the 12 volt starter fails to crank engine rpm above 125 rpm 3 consecutive times this fault will be set The VCU will attempt to start the engine with the ISG The HYBRID FAULT light will be on unless the attempt to start with the ISG also fails If both starter and ISG starts fail the HY BRID SERVICE light will flash and the vehicle will be set to Forced EV mode with delayed traction disabled depending on the state of charge Possible Causes e 12 volt starter failure e Low 12 volt battery voltage e Wiring issue to starter Note All starter wiring is done by A zure Diagnostic A ids e UseBDT Balance Diagnostic Tool to manually enable the starter relay control e Check power and ground connections including F007 30 Amp fu
57. iagnostics for APP sensor P2164 Throttle Pedal Position Sensor B Maximum Stop Performance Description MY 2008 The accelerator pedal track 2 signal is above 91 If no faults are present on tracks 1 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid If faults are present for track 1 track 3 or both as well as the P02164 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will be Flash MY 2009 The accelerator pedal track 2 signal is above 98 The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will be Flash Possible Causes e APP track 2 short to power e APP track 2 connectivity e APP sensor fault Diagnostic A ids e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 111 AZD Service Manual P2165 Throttle Pedal Position Sensor C Maximum Stop Performance Description The accelerator pedal track 3 signal is above 91 The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e APP track 3 short to power e APP track 3 connectivity e APP sensor fault Diagnostic A ids e Refer to appropriate A zure wiring schematics
58. ible Causes Broken or slipping ISG belt Failed or maladjusted ISG speed sensor Wiring issue between DM oC and speed sensor Failed belt tensioner Failed DM oC speed sensor circuit Diagnostic Aids e If accompanied by DTC U0120 follow diagnostic procedures for U0120 first e Using the Balance Diagnostic Tool record ISG speed and engine speed and compare the values Note The ISG spins 2 5 times faster than the engine RMP e Check ISG belt and tensioner condition e Refer to diagnostic by Description ISG speed sensor not functioning e Refer to appropriate A zure wiring schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 95 AZD Service Manual POC76 Hybrid Battery System Discharge Time too long Description The ESS reports disconnected but the high voltage buss remains above 100 volts for greater than45 seconds This indicates a high voltage Powertrain shutdown fault The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e ESS contactors did not open e Buss voltage incorrect Diagnostic A ids e Using Balance Diagnostic tool check for any ESS Info codes e Using Balance Diagnostic tool check for any VCU DTC s P1A00 Drive motor A Critical Fault Description The Traction M otor Controller has reported inverter state is critical fault Specific fault state reported by ECU cap
59. ice light be on solid Possible Causes e Faulty A C DM oC e Blockage of air flow to cooling fins e Faulty A C DM oC fan operation Diagnostic Aids e Visually inspect A C DM oC cooling fins A C fan for blockages e Refer to Azure wiring Schematic P1A71 A C Motor Stator Over Temperature Description The A C motor stator temperature has hit it s Overheat limit of 200 C The Hybrid Service light be on solid Possible Causes e Open circuit on Stator Temperature sensor e Failed sensor e Motor has overheated due to blocked air flow to motor Diagnostic Aids P1A73 A C Inverter Critical Fault Description The A C DM oC has reported inverter state is critical fault Specific fault state reported by V CU captured in freeze frame data and a DM oC Info Code is stored The A C will be disabled and the Hybrid Service light be on solid Possible Causes e Faulty A C motor Controller e Faulty A C M otor e Faulty Wiring Diagnostic A ids e Refer to A C DM oC info Codes DM oC Info Codes and freeze frame data for additional information P1A74 A C Inverter Fault Description The A C DM oC has reported an inverter non critical fault Specific fault state reported by V CU captured in freeze frame data and a DM oC Info Code is stored The A C will be disabled and the Hybrid Service light be on solid Azure Dynamics Balance
60. ics for APP sensor e Refer to the appropriate Ford Wiring schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 84 AZD Service Manual Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 85 AZD Service Manual P0223 Throttle Pedal Position Sensor Switch B Circuit High Description MY 2008 The VCU has detected that the A ccelerator Pedal track 2 input signal to the VCU has short Circuit to battery power or short circuit to VREF 5 volt The Accelerator Pedal track 2 signal voltage to the VCU is greater than 4 67 volts to set this fault If no faults are present on tracks 1 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid If faults are present for track 1 track 3 or both as well as the P0223 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash MY 2009 The VCU has detected that the A ccelerator Pedal track 2 input signal to the VCU has short Circuit to battery power or short circuit to VREF 5 volt The Accelerator Pedal track 2 signal voltage to the VCU is greater than 3 75 volts to set this fault the vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash Possible Causes e APP track 2 Wiring short circuit to power e APP track 2 Wiring short circuit to VREF powe
61. is F orced Disconnect The ESS has detected a critical system fault The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes ESS internal Failure Ground Isolation Fault Diagnostic A ids Using Balance Diagnostic tool check for any ESS Info codes repair as required P1A22 System Isolation Fault Warning Description The ESS continuously monitors isolation resistance between the high voltage buss and chassis ground If the Isolation resistance drops below a calibrated threshold this fault will be set The Pack state is in Alert M ode but the contactors are still closed The HY BRID SERVICE light will be on solid Possible Causes ESS Service disconnect Pin is removed Internal ESS ground fault Isolation failure in EPAS M otor or EPAS DM oC Isolation failure in ISG Motor or ISG DM oC Isolation failure in Traction M otor or Traction M otor DM oC High voltage cabling Isolation failure Isolation failure in DC DC converter Isolation failure in AC M otor or Controller Diagnostic A ids Refer to Isolation Resistance T esting Refer to ESS Info Codes ESS Input DBS Fault Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 100 AZD Service Manual P1A30 Hybrid Voltage Measurement Correlation Description The Difference between the maximum and minimum reported component
62. is open The vehicle will be set to a Forced Traction Disable and The HY BRID SERVICE light will flash Possible Causes e Inertia Switch has been tripped open Circuit e Faulty Inertia Switch e Connection or Wiring fault e Blown Fuse F014 Diagnostic Aids e Refer to appropriate A zure wiring schematics e Reset inertia switch and retest Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 79 AZD Service Manual P0121 Throttle Pedal Position Sensor Switch A Circuit Range Performance Description MY 2008 The accelerator pedal tracks 1 amp 2 and 1 amp 3 are different by more than 5 If no faults are present on tracks 2 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light be on solid If faults are present for track 2 track 3 or both as well as the P0121 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash MY 2009 The accelerator pedal tracks 1 amp 2 are different by more than 5 The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash Possible Causes e APP track 1 connectivity e APP sensor fault Diagnostic A ids e Use Balance diagnostic tool to monitor Accelerator Pedal Track 1 2 3 inputs e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostic
63. l Position Sensor Switch C Circuit Range Performance Description MY 2008 only T he accelerator pedal tracks 1 amp 3 and 2 amp 3 are different by more than 5 If no faults are present on tracks 1 amp 2 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e APP track 3 connectivity e APP sensor fault e 2008 software loaded in 2009 platform Diagnostic A ids e Use Balance diagnostic tool to monitor Accelerator Pedal Track 1 2 3 inputs Refer to appropriate A zure wiring schematics Refer to appropriate Ford Diagnostics for APP sensor track 3 signal P0227 Throttle Pedal Position Sensor Switch C Circuit Low Description MY 2008 only The VCU has detected that the A ccelerator Pedal track 3 input signal to the VCU has a short Circuit to Ground or an Open Circuit The input voltage is less than 25 volts The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e Accelerator Pedal track 3 wiring short circuit to ground e Faulty APP sensor e Open circuit e 2008 software loaded in 2009 platform Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related to Accelerator Pedal track 3 Use BDT to monitor Accelerator Pedal track 3 Refer to appropriate Ford Diagnostics for APP sensor Refer to the appropriate Ford Wiring sche
64. level Refer to https extranet azuredynamics com for the latest software version U1032 Software Incompatibility With Starter Generator Control Module Description The SW revision reported by the ISG DM oC is NOT 4 The vehicle will be set to a Forced Conventional M ode and The HY BRID SERVICE light will be on solid Possible Causes e ThelSG DMoC has the incorrect software level loaded Diagnostic Aids e Reprogram the SG DM oC with the correct software level Refer to https extranet azuredynamics com for the latest software version Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 117 AZD Service Manual Margin Description These are internal V CU software monitors that aid in development Possible Causes e NA Diagnostic Aids e Save then Clear faults using Balance Diagnostic Tool If faults reoccur record the faults and contact Email saved DTC s to techline azuredynamics com If faults frequently reappear or are continually active contact e Product Support Techline Support Toll Free Number 1 866 473 1636 Phone 905 607 3486 U1310 U1311 U1312 U1313 1314 U1315 U1316 VCU CPU Description These are internal VCU software monitors that aid in development Possible Causes e NA Diagnostic Aids e Save then Clear faults using Balance Diagnostic Tool If faults reoccur record th
65. m dynamics are too fast for DMoC to control A rotor speed that quickly changes or is spinning very fast may need carefully tuned current loop parameters to avoid over current Faulty DMoC IGBT problems A blown IGBT or gate driver may cause the DM OC to poorly control the current Current sensor may be damaged Diagnostic Aids e Use ccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software Use ccShell scope tool to capture current waveforms ISR1IsU ISR1lsV and ISR1IsW at highest sampling rate 10kHz EE1LoggingRate 1 Also check rotor position waveform ISR1FluxPosition Contact Azure Dynamics Product Support Techline Support 8 PS_FLT_SOFTWARE_OC The Software Over Current fault is primarily used for testing or in applications where additional motor protection is required The easiest way to trigger a fault is to set an artificially low value for EE1SoftOCLimit A ny time the motor current exceeds this value the Software Over Current fault will be triggered Description This fault is flagged if the motor currents exceed the calibratible threshold EE1SoftOCLimit Note that a value less than or equal to zero will disable this fault handling Possible Causes e Wrong or corrupt Software calibration Diagnostic Aids e Use ccShell to load the latest software and calibrations Refer to Azure Dynamics Balance Hybrid
66. matics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 87 AZD Service Manual P0228 Throttle Pedal Position Sensor Switch C Circuit High Description MY 2008 only The VCU has detected that the A ccelerator Pedal track 3 input signal to the VCU has short Circuit to battery power or short circuit to V REF 5 volt The Accelerator Pedal track 3 input signal voltage to the VCU is greater than 4 39 volts to set this fault The vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e Accelerator Pedal track 3 Wiring short circuit to power e Accelerator Pedal track 3 short circuit to VREF power e Faulty APP sensor Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related to Accelerator Pedal track 3 input signal Use BDT to monitor AAP track 3 Refer to appropriate Ford Diagnostics for APP sensor Refer to the appropriate Ford Wiring schematics P0229 Throttle Pedal Position Sensor Switch C Circuit Intermittent Description The raw accelerator pedal track 3 slew rate exceeds 300 s If no faults are present on tracks 1 amp 2 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid Possible Causes e APP track 3 connectivity e APP sensor fault Diagnostic A ids e Use Balance diagnostic tool to record
67. med Has the fuel injection system been properly maintained Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 71 AZD Service Manual 7 2 Ford PCM Hybrid VCU Interaction The hybrid system interacts with many of the Ford base vehicle controls Always verify the hybrid VCU DTC s and all items listed in this section before investigating Ford base vehicle complaints or PATS related issues Follow the recommended procedures for retrieving and clearing Diagnostic Trouble Codes DTC as described in the Ford E 450 5 4 L Service M anual Note The PCM Calibration used in the Azure Hybrid V ehicle is not part of the Ford Released calibrations Do not Reprogram the Ford PCM with a Factory calibration For PCM failures contact A zure for a pre programmed Ford PCM When connecting the Ford IDS service tool to a 2008 or 2009 Balance Production Hybrid vehicle the technician may need to manually enter the PCM part number 8C2A 12A 650 SD to establish communications between the PCM and IDS tool 7 2 1 FORD DTC P0605 is always present on early production 2008 Balance H ybrid vehicles This DTC is set because a development PCM calibration is used in these vehicles There are no drivability concerns or fault lights related to the P0605 fault code 7 2 2 FORD DTC P0743 P0748 P0960 P0962 The hybrid VCU takes control of the transmission control solenoids If any transmission solenoid faults are present remove the C163
68. n their own The Pilot input is the Contactor Power supply posse dust e 12 volt battery low voltage below 7 5 volts e Open circuit Pilot contactor 12 volt supply blown fuse tripped inertia switch intermittent corroded connection e Open service disconnect access panel contact switch e ESS 12 volt ignition input pin L shorted to battery 12V Diagnostic Aids See pinpoint test below Test step Result Action 1 Perform preliminary diagnostics Yes Repair and retest Were any issues found i 0 Go to step 2 2 Check the Battery Software e KeyON do not go to the high volt mode Yes e Using the Balance Diagnostic Tool check the Go to step 3 software version No Is the latest version of software loaded Load latest software and retest Refer to https extranet azuredynamics com for the latest software 3 Check for Battery Faults e Key ON do not go to the high volt mode Yes e Using the Balance Diagnostic Tool Record and Go to step 4 clear codes e Cycle the key OFF and back ON No Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 131 AZD Service Manual Test step Result Action e Check for faults Does the Pilot F ault return No fault found 4 Check Power to the Battery Pack e Key OFF connector C053S reconnected e Key ON do not go to the high volt mode e Using the Balance Diagnostic
69. nce Diagnostic Tool before continuing with Ford Diagnostics Refer to Pin Point Tests for Loss of CAN 1 communications and Loss of CAN 2 communications The VCU also controls Brake warning lamp Oil Lamp and Charge Lamp inputs to the instrument cluster Refer to the Azure wiring schematics and the Ford diagnostic material for additional details about these circuits Instrument Cluster IC Diagnostics There are 2 nuisance faults that may be flagged by the IC 1 U100 Lost communication with ECM PCM 2 B1352 Ignition key in circuit failure These faults do not indicate a problem with the IC unless there is another functional issue observed with the IC Verify the VCU functionality communications before investigating any RCM and ABS communications faults 7 2 5 PATS The VCU acts as a gateway for the PATS CAN signals to the instrument cluster If power ground or CAN communications to the VCU are lost a PATS fault may be set and cause the vehicle not to operate Use the Balance Diagnostic tool to check VCU communication and function first when a PATS fault is present The vehicles do not support the Ford E 450 CEI option for PATS based on a computer chip embedded ignition key Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 73 AZD Service Manual 7 2 6 ABS Strategy If ABS is active or faulty regenerative braking will be disabled It will be restored once the ABS condition clears AND the driver r
70. ngine off Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 91 AZD Service Manual POA3C Drive Motor A Inverter Over Temperature Description The traction DM oC temperature exceeds 75 C The instrument Cluster temperature gauge will read H The DM oC plenum fans will be on Possible Causes Faulty traction motor DM oC Blockage of air flow to cooling fins Faulty DM oC Plenum fan operation Diagnostic A ids Use Balance Diagnostic tool to manually turn on Plenum fans to confirm Operation Visually inspect traction motor Controller cooling fins plenum fan shroud for blockages Refer to Azure wiring Schematic POA3E Generator Inverter Over Temperature Description The ISG DM oC temperature has exceed 75 C The instrument cluster temperature gauge will read H The DM oC plenum fans will be on Possible Causes Faulty ISG DM oC temperature sensor Blockage of air flow to cooling fins Faulty DM OC plenum fan operation Diagnostic A ids Use BDT to manually turn on Plenum fans to confirm operation AirCooled Over temp as Plenum Fan Plenum Components displayed on On temp Fan Off temperature gauge temp ISG Inverter 75 C Eng on 30 C 35 C 35 C Eng Off 40 C Visually inspect ISG motor Controller cooling fins plenum fan shroud for blockages Refer to diagnostic by description Ple
71. nostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software e Check for short on high voltage buss e Isolate each component and retest 7 6 12 Precharge Timeout Description ESS precharge timeout This code is set during ESS precharge timeouts If the vehicle key is cycled three or more times within a minute the ESS will timeout allowing its precharge resistor to cool After the timeout the ESS will allow precharge automatically The link voltage failed to rise to 95 of pack voltage within 1500 ms peed e Vehicle high voltage buss is shorted positive to negative e Component on high voltage buss is drawing current during precharge when it should be off e Internal battery pack hardware of software fault Diagnostic Aids e Use Balance Diagnostic tool and record all faults e Reprogram ESS to latest software clear codes and retest Refer to https extranet azuredynamics com for the latest software e Check for short on high voltage buss e Isolate each component and retest 7 6 13M odule Under Voltage Description At least one of the module voltages in the battery pack is less than 7 5 volts and remains in this condition for 2 sec Possible Causes e Hybrid system is over discharging pack V CU software traction motor ISG
72. ns related to AC switch Input to VCU P0705 Transmission Range Sensor A Circuit PRNDL Input Description The PCM reports lever position fault The engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes e Base vehicle failure L ever position Diagnostic A ids e Refer to Ford Diagnostics P0915 Gear Shift Position Circuit Range Performance Description Possible Causes The PCM reports gear position fault The vehicle will be set to a forced Convention Limp Home M ode and the HY BRID SERVICE light will flash e Base vehicle failure with transmission gear position Diagnostic A ids e Refer to Ford Diagnostics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 89 AZD Service Manual POAOF Eng Engine Failed to Start Description The engine has failed to start when cranked above calibrated threshold of 125 rpm The HY BRID SERVICE light will flash and the vehicle will be set to Forced EV mode with delayed traction disabled depending on the state of charge Possible Causes e Base vehicle engine failure including loss of fuel spark or sensor signal e Loss of VCU to PCM enable signal e Loss of PCM power or ground Diagnostic A ids e Verify communication with PCM with either Balance Diagnostic Tool or IDS If no communication test for prope
73. num Fan not functioning POA77 A C Position Sensor Circuit Description The reported air conditioning speed reported by the A C DM oC is less than 5 rpm and the A C reported torque is greater than 10 Nm Possible Causes Failed A C motor speed sensor Diagnostic A ids Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 92 AZD Service Manual POA7E Hybrid Battery Pack Over Temperature Description Maximum ESS module temperature has exceeded 70 C The temperature will be inthe H Possible Causes e Low temp coolant pump inoperable e Radiator fans inoperable e Low coolant level e Blocked or kinked coolant hose e Internal ESS M odule failure Diagnostic A ids e Using Balance Diagnostic tool check for any ESS Info codes e Using Balance Diagnostic tool check ESS module temperatures If all temperatures are close to being equal than look for external cooling system issue If module temperature is greater than 10 C higher than the other modules replace ESS e Check Electronics cooling level or kinked hose e Using the Balance Diagnostic Tool manually activate the low temperature cooling pump and Radiator Fans to confirm operation e Check radiator fan fuse F039 80 amp e Check Coolant pump fuse F011 10 amp and K 3 low Temp Cooling Pump Relay a Hose L 3 60m Ww Hose I Hose s 4 Hose L 4 0
74. oblem If the CAPS_ CHARGED signal is still noisy the contactor state may still register a fault Diagnostic Aids e Verify that EE2Contactorlsinternal 0 e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software if fault persists replace controller e Look at variable ISR 2ContactorState it should be EXTERNAL if noisy it may be possible to trigger EXTERNAL CRITICAL FAULT in which case you need to resolve the noise issue 5 PS_FLT_CHARGED_ERROR Description The Charged Error fault is often observed as a nuisance in systems with a lot of noise or bad grounding Possible Causes e Problem with vehicle 12 volt supply input to DM oC Bad grounding cable routing or external noise Incorrect software Diagnostic Aids e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software e Verify grounding is correct 6 PS_ FLT HARDWARE_O volt Description The hardware over voltage fault is caused by the controller hardware detecting a voltage above 90 of full scale 500 volts This almost always corresponds to 450 volts DC The purpose of the hardware protection is to stop the DM OC from switching when it detects a dangerously high voltage In general this protection is faster than any software over voltage protection which is usually set to a
75. orage System Info Codes 1 Active Codes the code is currently active 2 Stored Codes ESS stored codes are saved in the Battery Control Module BCM memory until they are manually cleared Active or stored critical codes may also be accompanied by aVCU DTC Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 74 AZD Service Manual 7 3 3 DMoC Info Codes When a DM oC fault is set the VCU sets a fault and also stores an additional DM oC info code in the freeze frame data and in the DM OC INFO CODES tab of the Balance Diagnostic Tool BDT DM oC faults are put into 2 categories a Non critical Faults EE3LastError or EE3PSFaults 0 127 can be reset by the V CU and the hybrid system affected will continue to operate normally until the fault occurrence exceeds a predetermined rate b Critical Faults EE3LastErroro r EE3PSFaults greater thanl28 A DM oC critical fault will disable the DMoC until the following power cycle The fault history EE3PSFaultsl 2 3 provides the enumerated history for the most recent 4 fault entries stored whereas the fault history EE 3LastError provides a bit field error code history also 4 entries that can log multiple faults simultaneously K eep in mind that for the majority of faults both fault histories correlate with each other ie if only 1 fault occurred at any given time but some faults are ONLY displayed under EE 3PSF aults and so they should be the first ones to be
76. r e Faulty APP sensor Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related to Accelerator Pedal track 2 input signal e UseBDT to monitor Accelerator Pedal track 2 e Refer to appropriate Ford Diagnostics for APP sensor e Refer to the appropriate Ford Wiring schematics P0224 Throttle Pedal Position Sensor Switch B Circuit Intermittent Description MY 2008 The raw accelerator pedal track 2 slew rate exceeds 300 s If no faults are present on tracks 1 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light will be on solid If faults are present for track 1 track 3 or both as well as the P0224 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash MY 2009 The raw accelerator pedal track 2 slew rate exceeds 300 s The vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash Possible Causes e APP track 2 connectivity e APP sensor fault Diagnostic A ids e Use Balance diagnostic tool to record APP track 1 2 3 and compare signals e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor track 2 signal Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 86 AZD Service Manual P0226 Throttle Peda
77. r powers grounds If other CAN communications faults are present troubleshoot and resolve them first e C163 conventional mode jumper and test for vehicle start If no start refer to Ford diagnostics e Refer to appropriate A zure wiring schematics POA1B Drive Motor A Control Module Description The traction motor DM oC state does not match the state being commanded by the VCU The vehicle will be set to a Forced Conventional Mode and The HY BRID SERVICE light will be on solid Possible e Traction motor DM oC was just reprogrammed to new software without the Causes V oltage calibration performed e Faulty traction motor DM oC e NoHV toDMoC blown Fuse e Incorrect DM oC software Diagnostic e Compare the ESS buss voltage to the reported voltage from the traction motor Aids DM OC and use ccShell to recalibrate DM oC voltage Ensure that Save B ox Config has been performed Voltage Calibration DMoC Reported Voltage V 324 02 Measured Voltage Calibrate BoxConfiguration DCVoltageScaleFactor T_LINT C 2 4043 less Box Config Use ccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software Contact A zure Tech ine techline azuredynamics com for support Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 90 AZD Service Manual POA1E Starter Generator Control Module
78. r reported speed Check sensor function refer to Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 97 AZD Service Manual P1A10 Generator Inverter Critical Fault Description The ISG DM oC has reported the state is critical fault Specific fault state reported by DM oC is captured in V CU freeze frame data ISG Info code The Body Builder AC will be shut off the engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes e Faulty ISG DM oC e Faulty ISG M otor Diagnostic A ids e Refer to DM oC info Codes DM oC Info Codes P1A11 Generator Inverter Fault Description The ISG DM oC has reported inverter state is non critical fault Specific fault state reported by DM OC is captured in V CU freeze frame data ISG Info code The HYBRID SERVICE light will be on solid If the fault monitor count exceeds 3 the Body Builder AC will be shut off and the engine will be forced on and stay running Possible Causes e Faulty ISG DMoC e Faulty ISG Motor e Wiring fault Diagnostic A ids e Refer to DMoC info Codes DM oC Info Codes and freeze frame data for additional information Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 98 AZD Service Manual P1A12 Generator Stator Over Temperature Description The ISG stator temperature has hit it
79. redynamics com for the latest software e f software level is correct replace DM oC 206 DMOC_FAULT_CAUSE_UNKNOWN_CAN_FAULT Description This is a CAN fault that is not specifically enumerated in the P1 extension module refer to the ISR2CA NComState for more information Possible Causes e Can Bus Errors or other problems grounding Diagnostic A ids e Verify that ISR2CANComState is not ONLINE e Useother CAN analyzer tool to look for CAN bus errors CA NK ing for Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 127 AZD Service Manual example e Check grounding and CAN wiring 208 DMOC_FAULT_CAUSE_CAN_BUS ERROR Description This CAN fault is triggered if ISR2CANComState is not ONLINE Possible Causes Can Bus Errors or other problems grounding DM oC failure Diagnostic A ids Verify that ISR2CANComState is not ONLINE Use other CAN analyzer tool to look for CAN bus errors CANK ing for example e Check grounding and CAN wiring Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 128 AZD Service Manual 7 6 ESS INFO Codes The ESS Energy Storage System Info codes are the component level faults that are monitored and stored in the ESS The VCU monitors the fault status of the ESS and will set and store system level faults based on the state and level of fault stored in the ES
80. rflowing when the system is at the maximum operating temperature Fluid will need to be removed from the reservoir if the reservoir is overfilled beyond the prescribed marks 12 volt battery condition and state of charge have been tested AIl electrical connectors connected and secure Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 70 AZD Service Manual 10 11 Test for blown fuses Check all connectors to ensure they are properly mated Check that the Inertia Switches have not been tripped Look for other wiring concerns Check all ground connections to ensure they are clean and tight V acuum hoses are connected All intake and exhaust components are secure and not leaking Check for hybrid vehicle operation and verify if any service lights are on If HYBRID ENABLED LED is OFF check that the conventional mode jumper connector C163P has not been removed from under the dash it is typically tie strapped to the steering column Check for DTCs and info codes on PCM ESS and VCU Repair any Faults before proceeding Fuel lines secure and not leaking Verify fuel supply Verify there is tank or greater of fuel and does the fuel pump operate Has the fuel filter been serviced Verify engine condition Is the compression good with less than a 10 variation between cylinders V erify that the valve train is operating as per manufactures specifications Has normal maintenance been perfor
81. rid electric Vehicle 2008 2009 2010 Ford E 450 81 AZD Service Manual P0123 Throttle Pedal Position Sensor Switch A Circuit High Description MY 2008 The VCU has detected that the A ccelerator Pedal track 1 input signal to the VCU has short Circuit to battery power or short circuit to VREF 5 volt The Accelerator Pedal track 1 signal voltage to the VCU is greater than 4 78 volts to set this fault If no faults are present on tracks 2 amp 3 then the vehicle will continue to operate normally and the HY BRID SERVICE light will be on solid If faults are present for track 2 track 3 or both as well as the P0123 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash MY 2008 The VCU has detected that the A ccelerator Pedal track 1 input signal to the VCU has short Circuit to battery power or short circuit to VREF 5 volt The Accelerator Pedal track 1 signal voltage to the VCU is greater than 4 95 volts to set this fault The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash Possible Causes e Accelerator Pedal track 1 Wiring short circuit to power e Accelerator Pedal track 1 Wiring short circuit to VREF power e Faulty APP sensor Diagnostic A ids e Refer to appropriate A zure wiring schematics and check all electrical connections related to A ccelerator Pedal track 1 inp
82. ropriate A zure wiring schematics U0121 ABS Lost Communication with Anti Lock Brake System ABS Control Module Description The VCU will start to monitor this CAN message 5 seconds after the ABS module is powered up If any ABS message is arriving too slowly or any message is not being received at all this fault will set The VCU will disable the regenerative braking The hybrid service light will be on solid and the vehicle will continue in hybrid operation Possible Causes e Failed Can terminator resistor e Failed ABS module e Faulty power and ground circuits to ABS module e Faulty wiring routing or connection problems on CAN 1 Diagnostic Aids e Perform Ford base vehicle diagnostics and confirm ABS system is operating normally e Refer to pinpoint test procedure Loss of CAN 1 communications Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 115 AZD Service Manual U0131 Lost Communication with Power Steering Control Module Description The VCU has detected a message period greater than 2x specified rate or no message received at all for any EPAS CAN message The engine will be forced on and stay running and the Hybrid Service light be on solid Possible Causes Electrical noise on CAN 2 Can terminator resistor failure CAN 2 Faulty EPAS motor Controller Failed power or grounds to EPAS DM oC Wiring or connection problems
83. s Overheat limit of 200 C The instrument cluster temperature gauge will read H Possible Causes e Open circuit on stator temperature sensor e Failed sensor e ISG motor has overheated due to blocked air flow to motor Diagnostic A ids e Check wiring for open circuits and shorts to ground e Inspect for blocked air flow to ISG motor Cooling fins e Measure resistance across C261P pin H and Pin resistance should be 9 4 Kohm 21 C refer to chart below If sensor out of spec visually inspect for damaged wiring to sensor If wiring ok replace ISG M otor e Refer To Azure Wiring Schematic ISG Temperature Sensor Resistance Vs Temperature Resistance Kohm Resistance KOhm 0 50 100 150 200 250 Temperature F P1A20 Battery Control Module Fault Description The VCU has detected that the ESS pack state is Alert The ESS has detected a non critical system fault The HY BRID SERVICE light will be on solid Possible Causes e ESS internal Failure e Failure of ESS inputs Diagnostic A ids e Using Balance Diagnostic tool check for any ESS Info codes repair as required e Refer to appropriate A zure wiring schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 99 AZD Service Manual P1A21 Battery Control Module Critical Fault Description The VCU has detected that the ESS pack state
84. s for APP sensor track 1 signal Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 80 AZD Service Manual P0122 Throttle Pedal Position Sensor Switch A Circuit Low Description MY 2008 The VCU has detected that the Accelerator Pedal track 1 input signal to the VCU has a short Circuit to Ground or an Open Circuit The input voltage is less than 0 16 volts If no faults are present on tracks 2 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light be on solid If faults are present for track 2 track 3 or both as well as the P0122 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash MY 2009 The VCU has detected that the A ccelerator Pedal track 1 input signal to the VCU has a short Circuit to Ground or an Open Circuit The input voltage is less than 0 3 volts The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash Possible Causes APP Sensor track 1 wiring short circuit to ground Faulty APP sensor Open Circuit Diagnostic A ids Refer to appropriate A zure wiring schematics and check all electrical connections related to A PP input Use BDT to monitor Accelerator Pedal track 1 Refer to appropriate Ford Diagnostics for APP sensor Refer to the appropriate Ford W iring schematics Azure Dynamics Balance Hyb
85. scription The EPAS motor stator temperature has hit it s Overheat limit of 200 C The instrument cluster temperature gauge will bein the Red or H Possible Causes e Open circuit on Stator Temperature sensor e Failed sensor e Motor has overheated due to blocked air flow to motor Diagnostic A ids e With the Motor at Room temperature M easure resistance across C 338P pins 9 and pin 10 resistance should be less than lohms if greater than1 ohms replace EPAS M otor e f motor temperature sensor is within spec Refer To Azure Wiring Schematic and repair wiring issue P1A43 Electric Power Steering Inverter Critical Fault Description The traction DM oC has reported inverter state is critical fault Specific fault state reported by ECU captured in freeze frame data and a DM oC Info Codeis stored The engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes e Faulty EPAS motor Controller e Faulty EPAS M otor e Faulty Wiring Diagnostic Aids e Refer to M otor Controller info Codes DM oC Info Codes and freeze frame data for additional information Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 103 AZD Service Manual P1A44 Electric power Steering Inverter Fault Description The EPAS DM oC has reported an inverter non critical fault Specific fault state reported by ECU captured in
86. se and K 7 starter relay e Refer to appropriate A zure wiring schematics e Jumper pin 30 and pin 87 of K 7 the starter relay to confirm wiring to the starter Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 101 AZD Service Manual P1A32 Hybrid Control Module Command Engine Pedal Correlation Description This is an engine Pedal Command Fault The difference between VCU s PCM APP command and actual PCM APP feedback from the PCM exceeds 10 for more than 2 seconds The vehicle will be set to Forced Conventional Limp Home mode and the HYBRID SERVICE light will flash Possible Causes Faulty wiring between VCU and PAC circuit Faulty wiring between PAC and PCM circuit PAC power or ground faults Faulty PAC module Diagnostic A ids Check PCM for APP faults To verify APP functionality use the Balance Diagnostic Tool in Diagnostics M ode to manually control individual PAC APP command outputs and confirm they match the corresponding APP signals read by the IDS tool If the AAP readings in the above step do not match then remove accelerator pedal intercept at C122P and remove connector C238 at APP sensor and test Ford wiring by installing C122S into the APP Clear faults with IDS tool and verify APP operation following Ford vehicle diagnostics if the pedal functions normally then the problem is with the Hybrid wiring or PAC module on the hybrid harness
87. stic A ids If DTC POC2F is present investigate first If ISG Info codes are present investigate them first Using Azure Balance Diagnostic T ool record the ISG Rotational Speed and PCM Engine Speed confirm that the signal profiles are the same The ISG Rotational Speed should be 2 5 x the Engine Speed If the profiles match then diagnose a ISG DM oC or ISG Motor issue If the profiles do not match or the ISG Rotational Speed is erratic when compared to Engine Speed look for slipping belt miss adjusted of Faulty ISG Speed sensor Refer to appropriate A zure wiring schematics Check ISG speed sensor adjustment and operation refer to ISG speed sensor not functioning POAAG Hybrid Battery Voltage System Isolation Fault Description The ESS continuously monitors isolation resistance between the high voltage buss and chassis ground If the isolation resistance is less than 2 M ohms at key on or less than 500 K ohms while the vehicle is running this fault will be set The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e ESS Service disconnect Pin is removed Internal ESS ground fault Isolation failure in EPAS M otor or EPAS Motor Controller Isolation failure in ISG M otor or ISG M otor Controller Isolation failure in Traction M otor or Traction M otor Controller High Voltage cabling Isolation failure Isolation failur
88. the ESS has been powered on by the VCU The VCU will monitor the ESS CAN messages If any ESS message is arriving too slow or any message is not being received at all this fault will set The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e Can terminator resistor failure CAN 2 e Failed ESS e Failed power or grounds to ESS e Wiring or connection problems Diagnostic A ids Follow diagnostic by description ESS not communicating e Follow diagnostic by description Loss of CAN 2 communications e Refer to appropriate A zure wiring schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 114 AZD Service Manual U0120 Lost Communication with Starter Generator Control Module Description The VCU has detected a message is being received too slowly or no message is received at all for any ISG CAN message The Body Builder AC will be shut off the engine will be forced on and stay running and the Hybrid Service light will be on solid Possible Causes e CAN terminator resistor failure CAN 2 e Faulty ISG DMoC e NoHV power blown fuse e Failed 12 volt power or grounds to ISG DM oC e Wiring or connection problems Diagnostic A ids e Follow diagnostic by description ISG DM oC not functioning or not communicating e Follow diagnostic by description Loss of CAN 2 communications e Refer to app
89. tured in freeze frame data and a DM OC Info Code is stored The vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e Faulty traction motor Controller DM oC e Faulty Traction M otor e Faulty Wiring Diagnostic Aids e Refer to M otor Controller info Codes DM oC Info Codes and freeze frame data for additional information P1A01 Drive Motor A Inverter Fault Description The traction motor DM oC has reported an DM oC non critical fault Specific fault state reported by ECU captured in freeze frame data and a DM oC Info Codeis stored The Hybrid Service light will be on solid If the fault monitor count exceeds three the vehicle will be set to Forced Conventional mode and the HY BRID SERVICE light will be on solid Possible Causes e Faulty traction motor Controller e Faulty traction M otor e Faulty Wiring Diagnostic Aids e Refer to M otor Controller info Codes DM oC Info Codes and freeze frame data for additional information Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 96 AZD Service Manual P1A02 Drive Motor A Stator Over Temperature Description The traction motor stator temperature has hit it s Overheat limit of 200 C The instrument cluster temperature gauge will bein the Red or H Possible Causes e Open circuit on Stator
90. ult is flagged if the DM oC receives an external disable signal from the VCU via a hardware input signal while the Powerstage was enabled Possible Causes Problem with external disable wiring If the external disable signal is not wired properly then noise could trigger this fault Wiring connectivity issue between VCU and DM oC Diagnostic Aids e Check that the External Disable input to the DM oC is wired properly e Verify VCU shutdown sequencing is correct 131 PS_FLT_KERNEL_DISPATCHER_ERROR Description The DM oC has run out of code execution time Usually only seen during software development Possible Causes e Wrong or corrupt Software calibration e Motor controller failure Diagnostic Aids e UseccShell to load the latest software and calibrations Refer to https extranet azuredynamics com for the latest software e f software level is correct replace DM oC 132 PS_FLT_UNDEFINED_CASE_ERROR Description This fault indicates a corruption of the powerstage state variable This variable has been set to an invalid state All changes in software to the powerstage state variable should happen through the powerstage FSM No other code should write to the state Possible Causes e Wrong or corrupt Software calibration e Motor controller failure Diagnostic Aids e UseccShell to load the latest software and calibrations Refer to https extranet azu
91. ut signal e Use Balance Diagnostic tool to monitor Accelerator Pedal track 1 e Refer to appropriate Ford Diagnostics for APP sensor e Refer to the appropriate Ford Wiring schematics Azure Dynamics Balance Hybrid electric Vehicle 2008 2009 2010 Ford E 450 82 AZD Service Manual P0124 Throttle Pedal Position Sensor Switch A Circuit Intermittent Description MY 2008 The accelerator pedal track 1 slew rate exceeds 300 s If no faults are present on tracks 2 amp 3 then the vehicle will continue to operate normally and the Hybrid Service light be on solid If faults are present for track 2 track3 or both as well as the P0124 then the vehicle will be set to a Forced Conventional Limp Home M ode and The HYBRID SERVICE light will flash MY 2009 The accelerator pedal track 1 slew rate exceeds 300 s The vehicle will be set to a Forced Conventional Limp Home M ode and The HY BRID SERVICE light will flash Possible Causes e APP track 3 connectivity e APP sensor fault Diagnostic A ids e Use Balance diagnostic tool to record APP track 1 2 3 and compare signals e Refer to appropriate A zure wiring schematics e Refer to appropriate Ford Diagnostics for APP sensor track 1 signal P0217 ENG Engine Coolant Over Temperature Condition Description The VCU has detected that engine temperature has exceeded 123 C The temperature gauge in the instrument cluster will read H t

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