Ford Ranger EV (2001 year). Manual — part 154

414-03B-12

414-03B-12

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

Special Tool(s)

Pinpoint Tests

Traction Battery Low-Voltage Service Cord 418-F219

Special Tool(s)

Traction Battery High-Voltage Lockout and Diagnostic

104-Pin Breakout Box (BOB) 418-049 (014-00950) or

Tool 418-F207

equivalent

High-Voltage Insulated Safety Gloves 100-F036 or

BCM/TIM Breakout Box (BOB) Adapter Cable

equivalent

418-F212

Face Shield 100-F035 or equivalent

BCM/TIM Breakout Box (BOB) Overlay 418-F220

(Continued)

PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

A1 CHECK FOR INTERFACE ADAPTER ASSEMBLY (IAA)

MODULE DIAGNOSTIC TROUBLE CODES (DTCs)

NOTE: Make sure low voltage TIM fuse(s) #9 (10A), #11 (7.5A), and #24 Yes =

GO to A2.

(7.5A) are good before performing test A1. If fuse(s) are OK, proceed with

A1, if not, install new fuse(s) and perform test A1.

NOTE:

Using High-Voltage Insulated Safety Gloves and Face Shield, disconnect

and check the traction battery high-voltage two-pin C3994 for damage

before carrying out the following test steps. Repair as necessary. If OK,

reconnect and verify the connection is secure.

•

Carry out the on-demand self-test for the IAA module.

•

Do IAA module DTCs C1862 Contactor Circuit Failure and U2015

No =

GO to A4.

Signal Link Fault (Non SCP) occur?

A2 CHECK GROUND TO CONTACTOR BOX

•

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

GO to A3.

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

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 between BOB pin 65 and ground. No =

REPAIR the BK wire.

•

Is the resistance less than 5 ohms?

A3 CHECK CIRCUIT 57 (BK) FOR OPEN

•

Disconnect the BOB from in-line C1939M and remove the traction

Yes =

REPLACE the contactor

battery.

box.

No =

REPAIR the BK wire.

WARNING: The traction battery contains high-voltage

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

shield must be worn when carrying out the following steps. Failure to

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

•

Connect BOB to traction battery support tray in-line C1939F using

Traction Battery Low-Voltage Service Cord.

•

With key OFF, disconnect contactor box C1982 and measure the

resistance between pin 8 (BK wire) on contactor box C1982 and BOB

pin 65.

•

Is the resistance less than 5 ohms?

A4 CHECK STATUS OF HIGH-VOLTAGE POWER TO TIM

•

With key ON, monitor TIM PID BAT PV.

Yes =

System OK. CHECK wiring

for intermittent connections.

•

Turn the ignition key to the START position.

No =

If less than 50 volts, GO to

•

Does the BAT PV PID indicate between 50 and 385 volts?

A5.
If greater than 385 volts,

GO to A12.

(Continued)

414-03B-13

414-03B-13

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

A5 CHECK MAIN CONTACTOR RELAY

NOTE: The active command PRECHG IN must be sent before sending the Yes =

GO to A6.

active command POS MAIN. If not, New Generation STAR (NGS) Tester

will indicate UNABLE TO PERFORM TEST/FUNCTION.

•

Enter the TIM active command mode CONTACTOR OUTPUT

CONTROL, monitor the TIM PID BAT PV, and set the active

commands PRECHG IN and POS MAIN to CLOSE.

•

Set the active command PRECHG IN to OPEN.

No =

GO to A12.

•

Does the BAT PV PID indicate less than 50 volts?

A6 CHECK TIM MAIN CONTACTOR CONTROL SIGNAL TO

CONTACTOR BOX AT TRACTION BATTERY SUPPORT TRAY

•

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

GO to A9.

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

in-line C1939F and in-line C1939M using Traction Battery Low-Voltage

Service Cord.

•

Turn the ignition key to the START position and measure the voltage

No =

GO to A7.

between BOB pin 23 and ground (BOB pin 65).

•

Is the voltage greater than 10 volts?

A7 CHECK CIRCUIT 3986 (DG) BETWEEN TIM AND TRACTION

BATTERY SUPPORT TRAY FOR OPEN

•

With key OFF, disconnect TIM C4998 and measure the resistance of the

Yes =

GO to A8.

DG wire between pin 8 on TIM C4998 and BOB pin 23.

•

Is the resistance less than 5 ohms?

No =

REPAIR the DG wire.

A8 CHECK CIRCUIT 3986 (DG) BETWEEN TIM AND TRACTION

BATTERY SUPPORT TRAY FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 23 and ground

Yes =

REPLACE the TIM. REFER

(BOB pin 65).

to Section 303-14.

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the DG wire.

A9 CHECK CIRCUIT 3986 (DG) BETWEEN CONTACTOR BOX AND

TRACTION BATTERY SUPPORT TRAY FOR OPEN

•

With key OFF, disconnect the BOB from traction battery support tray

Yes =

GO to A10.

in-line C1939F and in-line C1939M and remove the traction battery.

No =

REPAIR the DG wire.

WARNING: The traction battery contains high-voltage

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

shield must be worn when carrying out the following steps. Failure to

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

•

Reconnect 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 contactor box C1982 and measure the

resistance of the DG wire between pin 11 on contactor box C1982 and

BOB pin 23.

•

Is the resistance less than 5 ohms?

A10 CHECK CIRCUIT 3986 (DG) BETWEEN CONTACTOR BOX

AND TRACTION BATTERY SUPPORT TRAY FOR SHORT TO

GROUND

•

With key OFF, measure the resistance between BOB pin 23 and ground

Yes =

GO to A11.

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the DG wire.

A11 CHECK TRACTION BATTERY HIGH-VOLTAGE FUSE

(Continued)

414-03B-14

414-03B-14

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE

TEST STEP

ACTION TO TAKE

•

Measure the resistance between the terminals of the 250A traction battery Yes =

REPLACE the contactor

high-voltage fuse.

box.

•

Is the resistance less than 5 ohms?

No =

REPLACE the fuse.

A12 CHECK TRACTION BATTERY VOLTAGE

•

With key ON, monitor BCM PID BAT PV and TIM PID BAT PV.

Yes =

REPLACE the TIM. REFER

to Section 303-14.

•

Turn the ignition key to the START position.

No =

System OK. CHECK wiring

•

Is there more than a 30-volt difference between the BAT PV PIDs?

for intermittent connections.

PINPOINT TEST B: DTC C1862 CONTACTOR CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

B1 CHECK FOR INTERFACE ADAPTER ASSEMBLY (IAA)

MODULE DIAGNOSTIC TROUBLE CODES (DTCs)

NOTE: Using High-Voltage Insulated Safety Gloves and Face Shield,

Yes =

GO to Pinpoint Test A.

disconnect and check the traction battery high-voltage two-pin C3994 for

damage before carrying out the following test steps. Repair as necessary. If

OK, reconnect and verify the connection is secure.

•

Carry out the on-demand self-test for the IAA module.

•

Do IAA module DTCs C1862 Contactor Circuit Failure and U2015

No =

GO to B2.

Signal Link Fault (Non SCP) occur?

B2 CHECK FOR TRACTION INVERTER MODULE (TIM)

PRECHARGE FAULT

•

With key ON, monitor TIM PID PRECH F.

Yes =

GO to B3.

•

Does the PRECH F PID indicate YES?

No =

GO to B11.

B3 CHECK STATUS OF TIM PRECHARGE BUS VOLTAGE

•

With key ON, monitor TIM PID BAT PV.

Yes =

GO to B4.

•

Does the BAT PV PID indicate less than 50 volts?

No =

GO to B10.

B4 CHECK PRECHARGE CONTACTOR RELAY

•

Enter the TIM active command mode CONTACTOR OUTPUT

Yes =

GO to B5.

CONTROL, monitor the TIM PID BAT PV, and set the active

command PRECHG IN to CLOSE.

•

Does the BAT PV PID indicate less than 50 volts?

No =

GO to B10.

B5 CHECK TIM PRECHARGE CONTACTOR CONTROL SIGNAL

TO TRACTION BATTERY SUPPORT TRAY

•

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

GO to B8.

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

in-line C1939F and in-line C1939M using Traction Battery Low-Voltage

Service Cord.

•

With key ON, measure the voltage between BOB pin 22 and ground

No =

GO to B6.

(BOB pin 65).

•

Is the voltage greater than 10 volts?

B6 CHECK CIRCUIT 3991 (T) BETWEEN TIM AND TRACTION

BATTERY SUPPORT TRAY FOR OPEN

•

With key OFF, disconnect TIM C4998 and measure the resistance of the

Yes =

GO to B7.

T wire between pin 18 on TIM C4998 and BOB pin 22.

•

Is the resistance less than 5 ohms?

No =

REPAIR the T wire.

B7 CHECK CIRCUIT 3991 (T) BETWEEN TIM AND TRACTION

BATTERY SUPPORT TRAY FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 22 and ground

Yes =

REPLACE the TIM. REFER

(BOB pin 65).

to Section 303-14.

(Continued)

414-03B-15

414-03B-15

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: DTC C1862 CONTACTOR CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the T wire.

B8 CHECK CIRCUIT 3991 (T) BETWEEN CONTACTOR BOX AND

TRACTION BATTERY SUPPORT TRAY FOR OPEN

•

With key OFF, disconnect the BOB from traction battery support tray

Yes =

GO to B9.

in-line C1939F and in-line C1939M and remove the traction battery.

No =

REPAIR the T wire.

WARNING: The traction battery contains high-voltage

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

shield must be worn when carrying out the following steps. Failure to

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

•

Reconnect 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 contactor box C1982 and measure the

resistance of the T wire between pin 18 on contactor box C1982 and

BOB pin 22.

•

Is the resistance less than 5 ohms?

B9 CHECK CIRCUIT 3991 (T) BETWEEN CONTACTOR BOX AND

TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 22 and ground

Yes =

REPLACE the contactor

(BOB pin 65).

box.

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the T wire.

B10 CHECK TRACTION BATTERY VOLTAGE

•

With key ON, monitor BCM PID BAT PV and TIM PID BAT PV.

Yes =

REPLACE the TIM. REFER

to Section 303-14.

•

Is there more than a 30-volt difference between the BAT PV PIDs?

No =

System OK. CHECK wiring

for intermittent connections.

B11 CHECK FOR WELDED MAIN CONTACTOR RELAY

•

Enter TIM active command mode CONTACTOR OUTPUT CONTROL

Yes =

System OK. CHECK wiring

and monitor TIM PID BAT PV.

for intermittent connections.

•

Does the voltage for the BAT PV PID decrease?

No =

GO to B12.

B12 CHECK MAIN AND PRECHARGE CONTACTOR RELAY

OUTPUTS

•

Connect 104-Pin Breakout Box (BOB) to TIM and TIM C4998, C4999

Yes =

GO to B13.

using the BCM/TIM BOB Adapter Cable and Overlay.

•

Enter traction inverter module (TIM) active command mode

No =

REPLACE the contactor

CONTACTOR OUTPUT CONTROL.

box.

•

With key ON, measure the voltage between BOB pins A8, A18 and

ground (BOB pin A29).

•

Is either voltage greater than 10 volts?

B13 CHECK CIRCUITS 3991 (T) AND 3986 (DG) FOR SHORT(S) TO

POWER

•

With key OFF, disconnect the TIM from the BOB; leave BOB connected Yes =

REPAIR the wire(s) in

to TIM C4998, C4999.

question.

•

With key ON, measure the voltage between BOB pins A8, A18 and

No =

REPLACE the TIM. REFER

ground (BOB pin A29).

to Section 303-14.

•

Is either voltage greater than 1 volt?