Ford Ranger EV (2001 year). Manual — part 115

414-03A-56

414-03A-56

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H: CHARGER UNDER CURRENT FAULT

TEST STEP

ACTION TO TAKE

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

No =

REPLACE high-voltage

BCM.

harness (14B326) between

•

With key OFF, disconnect contactor box C3985 and measure the

traction battery support tray

resistance of the O wire between contactor box C3985F and traction

in-line C1935F and

battery support tray in-line C1935F.

contactor box C3985.

•

With key OFF, measure the resistance of the W wire between contactor

box C3985F and traction battery support tray in-line C1935F.

•

Is the resistance less than 5 ohms?

H5 CHECK CHARGER CONTACTOR RELAY

•

Reconnect contactor box C3985.

Yes =

GO to H6.

•

Connect Traction Battery High-Voltage Service Cord to traction battery

No =

GO to H7.

support tray in-line C1935F and in-line C1935M.

•

Connect Traction Battery Low-Voltage Service Cord to traction battery

support tray in-line C1939F and in-line C1939M.

•

Enter BCM active command mode CONTACTOR OUTPUT CONTROL,

set the active command CHARGER to CLOSE, and listen for the charger

contactor relay closing.

•

Does the charger contactor relay close?

H6 CHECK CONTACTOR BOX HIGH-VOLTAGE FUSE

•

Remove the 25A CHARGER fuse from the contactor box. Refer to

Yes =

REPLACE the 25A

Contactor Box Fuses Removal and Installation procedure in this section.

CHARGER fuse.

•

Measure the resistance of the 25A CHARGER fuse.

No =

REPLACE the contactor

•

Is the resistance greater than 1,000 ohms?

box.

H7 CHECK CHARGER CONTACTOR RELAY CONTROL (CLOSE

SIGNAL)

•

Reconnect contactor box C3985.

Yes =

GO to H9.

•

Connect Traction Battery High-Voltage Service Cord to traction battery

No =

GO to H8.

support tray in-line C1935F and in-line C1935M.

•

Connect Traction Battery Low-Voltage Service Cord to traction battery

support tray in-line C1939F and in-line C1939M.

•

Connect 104-Pin Breakout Box (BOB) to BCM and BCM C1986, C1987

using the BCM/TIM BOB Adapter Cable and Overlay.

•

Enter BCM active command mode CONTACTOR OUTPUT CONTROL,

set the active command CHARGER to CLOSE, and measure the voltage

between BOB pin B9 and ground (BOB pin A33).

•

Is the voltage greater than 10 volts?

H8 CHECK CIRCUIT 3137 (GY/Y) FOR SHORT TO GROUND

•

With key OFF, disconnect BOB from BCM; leave BOB connected to

Yes =

REPLACE the BCM.

BCM C1986 and C1987.

•

With key OFF, disconnect contactor box C1982 and measure the

No =

REPAIR the GY/Y wire.

resistance between BOB pin B9 and ground (BOB pin A33).

•

Is the resistance greater than 10,000 ohms?

H9 CHECK CIRCUIT 3137 (GY/Y) FOR OPEN

•

With key OFF, disconnect contactor box C1982 and measure the

Yes =

REPLACE the contactor

resistance of the GY/Y wire between pin 20 on contactor box C1982 and

box.

BOB pin B9.

•

Is the resistance less than 5 ohms?

No =

REPAIR the GY/Y wire.

H10 CHECK OUTPUT OF TRACTION BATTERY CHARGER

•

Connect the power control station (PCS) to the charger inlet connector

Yes =

GO to H11.

and press the START button on the PCS.

(Continued)

414-03A-57

414-03A-57

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST H: CHARGER UNDER CURRENT FAULT

TEST STEP

ACTION TO TAKE

NOTE: Measure the voltage immediately after pressing the START button

No =

GO to H12.

on the PCS. If no voltage output, monitor the voltage for approximately

two minutes.

•

With vehicle on-charge, measure the voltage between circuit 3170 (O

wire) and circuit 3171 (W wire) on HVPDB traction battery charger

high-voltage C1923M.

•

Is the voltage greater than 200 volts?

H11 CHECK CHARGER OVER-TEMPERATURE FAULT STATUS

•

With key OFF, reconnect HVPDB traction battery charger high-voltage

Yes =

GO to Pinpoint Test E.

C1923.

•

Connect the vehicle to the PCS and press the START button to begin

No =

System OK. CHECK wiring

charging.

for intermittent connections.

•

With vehicle on-charge, monitor BCM PID CHG OTF for

approximately five minutes.

•

Does the CHG OTF PID indicate YES?

H12 CHECK CIRCUITS 3401 (DB/LG) AND 3985 (PK) (OUTSIDE OF

TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S)

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to H13.

connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction

Battery Low-Voltage Service Cord; do not connect Traction Battery

Low-Voltage Service Cord to in-line C1939F.

•

With key OFF, disconnect traction battery charger C1991 and C1993.

No =

REPAIR the wire(s) in

•

With key OFF, measure the resistance of the DB/LG wire between pin 3

question.

on traction battery charger C1993 and BOB pin 63.

•

With key OFF, measure the resistance of the PK wire between pin 3 on

traction battery charger C1991 and BOB pin 50.

•

Are the resistances less than 5 ohms?

H13 CHECK CIRCUITS 3401 (DB/LG) AND 3985 (PK) (INSIDE OF

TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S)

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

REPLACE the traction

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

battery charger.

to the traction battery high-voltage two-pin C3994M.

•

Connect 104-Pin Breakout Box (BOB) to traction battery support tray

No =

REPAIR the wire(s) in

in-line C1939F using Traction Battery Low-Voltage Service Cord; do not

question.

connect Traction Battery Low-Voltage Service Cord to in-line C1939M.

WARNING: The traction battery contains high-voltage

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

shield must be worn when performing the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

With key OFF, disconnect BCM C1986 and C1987.

•

Measure the resistance of the DB/LG wire between pin 11 on BCM

C1986 and BOB pin 63.

•

Measure the resistance of the PK wire between pin 13 on BCM C1986

and BOB pin 50.

•

Are the resistances less than 5 ohms?

PINPOINT TEST J: CHARGER OVER CURRENT FAULT

TEST STEP

ACTION TO TAKE

J1 CHECK CONTACTOR BOX AUXILIARY CURRENT SENSOR

FOR IN-RANGE FAILURE

•

With key ON, monitor BCM PID AUX CNT.

Yes =

REPLACE the traction

battery charger.

(Continued)

414-03A-58

414-03A-58

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST J: CHARGER OVER CURRENT FAULT

TEST STEP

ACTION TO TAKE

•

Turn the A/C on and turn the steering wheel back and forth.

No =

GO to J2.

•

Does the amperage for the AUX CNT PID increase and decrease?

J2 CHECK AUXILIARY CURRENT SENSOR VOLTAGE STATUS

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

REPLACE the BCM.

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

C3994M.

No =

REPLACE the contactor

WARNING: The traction battery contains high-voltage

box.

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

shield must be worn when performing the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

With key OFF, disconnect contactor box C1982.

•

With key ON, monitor BCM PID AUX SEN.

•

Does the AUX SEN PID indicate greater than 1 volt?

PINPOINT TEST K: CHARGER OVER VOLTAGE FAULT

TEST STEP

ACTION TO TAKE

K1 CHECK TRACTION BATTERY POSITIVE (+) SENSE LINE

CIRCUIT BETWEEN IN-LINE C1885F AND BATTERY MODULE 39

FOR SHORTED RESISTOR

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

GO to K2.

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

C3994M.

No =

REPLACE high-voltage

harness (14A280-WD).

WARNING: The traction battery contains high-voltage

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

shield must be worn when performing the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

With key OFF, disconnect in-line C1885 (label W) and measure the

resistance between the LB wire on in-line C1885F and battery module 39

positive (+) post.

•

Is the resistance between 28,000 and 34,000 ohms?

K2 CHECK TRACTION BATTERY NEGATIVE (-) SENSE LINE

CIRCUIT BETWEEN IN-LINE C1882F AND BATTERY MODULE 1

FOR OPEN

•

With key OFF, disconnect in-line C1882 (label R) and measure the

Yes =

REPLACE the BCM.

resistance between the PIK/BK wire on in-line C1882F and battery

module 1 negative (-) post.

•

Is the resistance between 28,000 and 34,000 ohms?

No =

REPLACE high-voltage

harness (14A280-RF).

PINPOINT TEST M: CHARGER LINE CAPACITY FAULT

TEST STEP

ACTION TO TAKE

M1 VERIFY POWER CONTROL STATION (PCS) OPERATION

•

Perform Power Control Station (PCS) Operation Verification Test. Refer

Yes =

GO to M2.

to Pinpoint Test S.

•

Is the PCS OK?

No =

PERFORM the required

action as indicated in

Pinpoint Test S.

M2 CHECK FOR CHARGING SYSTEM FAULT

(Continued)

414-03A-59

414-03A-59

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST M: CHARGER LINE CAPACITY FAULT

TEST STEP

ACTION TO TAKE

•

Connect the power control station (PCS) to the vehicle and the depress

Yes =

REPLACE the traction

the START button to begin charging.

battery charger.

•

Wait approximately five minutes.

No =

System OK. CHECK wiring

•

With key OFF and vehicle on-charge, retrieve continuous DTCs from the

for intermittent connections.

BCM.

•

Does DTC C1838 Charging System Fault occur?

PINPOINT TEST N: CHARGER MODE FEEDBACK FAULT

TEST STEP

ACTION TO TAKE

N1 CHECK CHARGER UNDER CURRENT STATUS

•

Verify the vehicle is connected to the power control station (PCS) and

Yes =

GO to Pinpoint Test H.

the START button has been depressed to begin charging.

NOTE: Wait approximately one to five minutes to allow the CHG UCF

No =

DISCONNECT the PCS

PID to set.

from the vehicle. GO to N2.

•

With key OFF and vehicle on-charge, monitor BCM PID CHG UCF.

•

Does the CHG UCF PID indicate YES?

N2 CHECK POWER SIGNAL TO TRACTION BATTERY CHARGER

•

With key OFF, disconnect traction battery charger C1993.

Yes =

GO to N7.

•

With key ON, measure the voltage between pin 1 (W wire) on traction

No =

GO to N3.

battery charger C1993 and ground.

•

Is the voltage greater than 10 volts?

N3 CHECK CIRCUIT 3826 (W) (OUTSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to N4.

connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction

Battery Low-Voltage Service Cord; do not connect Traction Battery

Low-Voltage Service Cord to in-line C1939F.

•

With key OFF, measure the resistance of the W wire between pin 1 on

No =

REPAIR the W wire.

traction battery charger C1993 and BOB pin 38.

•

Is the resistance less than 5 ohms?

N4 CHECK CIRCUIT 3826 (W) (OUTSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 38 and ground

Yes =

GO to N5.

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the W wire.

N5 CHECK CIRCUIT 3826 (W) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

GO to N6.

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

to the traction battery high-voltage two-pin C3994M.

No =

REPAIR the W wire.

WARNING: The traction battery contains high-voltage

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

shield must be worn when performing the following steps. Failure to

follow this warning may result in severe personal injury or death.

•

Connect 104-Pin Breakout Box (BOB) to traction battery support tray

in-line C1939F using Traction Battery Low-Voltage Service Cord; do not

connect Traction Battery Low-Voltage Service Cord to in-line C1939M.

•

With key OFF, disconnect BCM C1986 and measure the resistance of the

W wire between pin 5 on BCM C1986 and BOB pin 38.

•

Is the resistance less than 5 ohms?

(Continued)