Ford Ranger EV (2001 year). Manual — part 121

414-03A-80

414-03A-80

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

Symptom Chart

Symptom Chart

Condition

Possible Sources

Action

•

All High-Voltage Auxiliary

•

High-voltage harness

•

GO to Pinpoint Test A.

Load Systems Do Not

(14B326).

Operate

•

High-voltage power

distribution box (HVPDB).

•

Contactor box.

Pinpoint Tests

Special Tool(s)

Traction Battery High-Voltage Service Cord 418-F218

PINPOINT TEST A: ALL HIGH-VOLTAGE AUXILIARY LOAD SYSTEMS DO NOT OPERATE

TEST STEP

ACTION TO TAKE

A1 VERIFY ALL HIGH-VOLTAGE AUXILIARY LOAD SYSTEMS DO

NOT OPERATE

•

With key ON, turn the steering wheel. If there is no power assist, the power Yes

System OK. CHECK wiring

steering system does not operate.

=

for intermittent connections.

•

With key ON, measure the voltage of the 12-volt auxiliary battery. The

No =

If none of the high-voltage

voltage should be greater than 13 volts.

auxiliary load systems

operate, GO to A2.

•

With key ON, operate the heater and air conditioner (if equipped).

If some of the high-voltage

•

Do all the high-voltage auxiliary load systems operate?

auxiliary load systems

operate, REFER to the

appropriate section(s) for the

system(s) in question.

A2 CHECK HIGH-VOLTAGE NEGATIVE BUS (OUTSIDE TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect high-voltage auxiliary load in-line C1935 on the

Yes

GO to A3.

traction battery support tray and power steering assembly high-voltage

=

C1895.

•

Measure the resistance between circuit 3141 (W wire) on power steering

No =

REPLACE the high-voltage

assembly C1895 and circuit 3133 (W wire) on high-voltage auxiliary load

power distribution box

in-line C1935M.

(HVPDB).

•

Is the resistance less than 5 ohms?

A3 CHECK HIGH-VOLTAGE NEGATIVE BUS (INSIDE TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

Remove the traction battery.

Yes

REPLACE the contactor

=

box.

No =

REPLACE high-voltage

harness 14B326 between

traction battery support tray

in-line C1935F and

contactor box C3985.

(Continued)

414-03A-81

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High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: ALL HIGH-VOLTAGE AUXILIARY LOAD SYSTEMS DO NOT OPERATE

TEST STEP

ACTION TO TAKE

WARNING: The traction battery contains high-voltage components

and wiring. High-voltage insulated safety gloves and face shield must be

worn when performing the following steps. Failure to follow this warning

may result in severe personal injury or death.

•

Connect Traction Battery High-Voltage Service Cord to high-voltage

auxiliary load in-line C1935F on the traction battery support tray and in-line

C1935M.

NOTE: Contactor box C3985 is mounted on the passenger side of the BCM.

•

With key OFF, disconnect contactor box C3985 and measure the voltage

between the R wire on contactor box C3985 and chassis ground.

•

Is the voltage greater than 10 volts?

GENERAL PROCEDURES

Module Charging

Special Tool(s)

8-Volt Battery Charger

418-F214

1.

CAUTION: Do not use any charger

other than the recommended 8-Volt Battery
Charger.
Plug the 8-Volt Battery Charger in and ensure
that it is turned OFF.

2. Connect the 8-Volt Battery Charger to the

module. Connect the RED lead to the positive
terminal and the BLACK lead to the negative
terminal on the module. Turn the charger on. A
red light on the charger will indicate that the
charger is operating and that the module is
being charged. During the charging cycle, the
charger will produce approximately 9.6 volts
DC.

3. The steady red light on the charger indicates

that the charger is in the charge mode and is
working properly. The time that the charger
remains in this mode depends on the size and
state of charge of the module being charged.

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414-03A-82

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

4. When the module reaches an 80% state of

charge, the green light will start to flash while
the red light is steadily lit.

5. When the module reaches 100% state of charge,

the red light goes out and the green light will
stop flashing and steadily illuminate. The steady
green light indicates that the charger has
completed charging the module and has entered
the maintenance mode.

6. If the green and red lights flash sequentially,

the charger to module polarity is incorrect and
must be corrected before module charging can
begin.

Traction Battery Module Replacement

Special Tool(s)

Special Tool(s)

New Generation STAR (NGS)

Battery Post Torque Wrench

Tester or equivalent

307-026

418-F048 (007-00500)

Traction Battery High-Voltage

Battery Terminal Cap Opener

Lockout and Diagnostic Tool

418-F215

418-F207

Traction Battery High-Voltage

Battery Module Lifting Tool

Service Cord

418-F206

418-F218

Traction Battery Low-Voltage

In-Line Bypass Battery Module

Service Cord

418-F210

418-F219

(Continued)

414-03A-83

414-03A-83

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

Module Replacement Times

1. The battery module replacement time for an

upper-level battery module is 0.5 hours, not
including traction battery removal and charge
time.

2. The battery module replacement time for an

lower-level battery module is 1.5 hours, not
including traction battery removal and charge
time.

3. Traction battery charge time can be up to 10

hours for a completely discharged, cold battery.
The battery must be charged during battery
module replacement.

4. If necessary, charge all new replacement battery

modules prior to installation. Refer to

Module

Charging

to determine battery module charging

conditions.

5. NOTE: If more than two battery modules need

to be replaced, do not replace the traction
battery cover or install the traction battery at
the end of the procedure. Repeat the battery
module removal and installation process until
all battery modules have been replaced. Only
two battery modules can be replaced at a time,
as there are only two In-Line Bypass Battery
Modules in the special service tool kit.
NOTE: Position the vehicle near a charging
station before beginning the procedure.
Remove the traction battery. Refer to

Traction

Battery

.

6.

WARNING: The nominal voltage of

the traction battery is 312 volts. The buffer
zone must be set up and insulated rubber
gloves and a face shield must be worn.
Failure to follow these precautions may
result in severe personal injury or death.
Observe the EV-specific precautions. Refer to

Section 100-00

.

1 Set up the buffer zone.
2 Test and wear the insulated rubber gloves.
3 Wear the face shield.