Ford Ranger EV (2001 year). Manual — part 100

414-02-7

414-02-7

Auxiliary Battery Charging

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: DTC C1775 DC/DC CONVERTER FAILURE

TEST STEP

ACTION TO TAKE

•

Measure the resistance between circuit 3117 (DB wire) and circuit 3118

Yes =

GO to C14.

(W wire) on HVPDB DC/DC converter C1914F.

•

Is the resistance greater than 10,000 ohms?

No =

REPLACE the HVPDB.

REFER to

Section 414-03A

or

Section 414-03B

.

C14 CHECK SYSTEM

•

With key OFF, reconnect all component connectors that were

Yes =

REPLACE the DC/DC

disconnected.

converter. REPLACE the

10A DC/DC fuse. REFER to

Section 414-03A

or

Section 414-03B

.

•

Reconnect the 12-volt auxiliary battery negative cable.

No =

System OK.

•

Key ON.

•

Does the 10A DC/DC high-voltage fuse fail again?

PINPOINT TEST D: AUXILIARY BATTERY WARNING INDICATOR ILLUMINATED (AUXILIARY BATTERY
TEMPERATURE SENSOR FAILURE)

TEST STEP

ACTION TO TAKE

D1 CHECK DC/DC CONVERTER OPERATION

NOTE: Before proceeding, verify the power control station (PCS) is not

Yes =

System OK. CARRY OUT

plugged into the vehicle and all accessories (radio, A/C, heater, etc.) are

instrument cluster diagnosis.

turned off.

REFER to

Section 413-01

.

•

With key OFF, monitor the IAA module PID VBATIAA.

•

While monitoring the IAA module PID VBATIAA, turn the ignition key

No =

GO to D2.

to the ON position.

•

Does the VBATIAA PID increase to approximately 13.7 volts?

D2 CHECK DC/DC CONVERTER

•

With key OFF, disconnect auxiliary battery temperature sensor C1953.

Yes =

GO to D6.

•

With key ON, monitor IAA module PID VBATIAA. Voltage should be

No =

GO to D3.

between 12.8 and 13.0 volts.

•

Connect a jumper wire between the DG/P wire and Y/R wire on

auxiliary battery temperature sensor C1953. Voltage should be between

14.6 and 15.1 volts.

•

Does the voltage increase as indicated when auxiliary battery

temperature sensor C1953 is jumpered?

D3 CHECK CIRCUITS 3223 (Y/R) AND 3224 (DG/P) FOR OPEN(S)

•

With key OFF, disconnect DC/DC converter C1943 and measure the

Yes =

GO to D4.

resistance of the Y/R wire between auxiliary temperature sensor C1953

and pin 1 on DC/DC converter C1943.

•

With key OFF, measure the resistance of the DG/P wire between

No =

REPAIR the wire(s) in

auxiliary battery temperature sensor and pin 2 on DC/DC converter

question.

C1943.

•

Are the resistances less than 5 ohms?

D4 CHECK CIRCUITS 3223 (Y/R) AND 3224 (DG/P) FOR SHORT(S)

TO GROUND

•

With key OFF, measure the resistance between Y/R wire, DG/P wire on

Yes =

GO to D5.

auxiliary temperature sensor C1953 and ground.

•

Are the resistances greater than 10,000 ohms?

No =

REPAIR the wire(s) in

question.

D5 CHECK CIRCUITS 3223 (Y/R) AND 3224 (DG/P) FOR SHORT(S)

TO POWER

(Continued)

414-02-8

414-02-8

Auxiliary Battery Charging

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST D: AUXILIARY BATTERY WARNING INDICATOR ILLUMINATED (AUXILIARY BATTERY
TEMPERATURE SENSOR FAILURE)

TEST STEP

ACTION TO TAKE

•

With key ON, measure the voltage between Y/R wire, DG/P wire on

Yes =

REPAIR the wire(s) in

auxiliary temperature sensor C1953 and ground.

question.

•

Are any of the voltages greater than 0 volts?

No =

REPLACE the DC/DC

converter.

D6 CHECK AUXILIARY BATTERY TEMPERATURE SENSOR

•

With key OFF, reconnect auxiliary battery temperature sensor C1953.

Yes =

System OK. CHECK wiring

for intermittent connections.

•

With key ON, monitor IAA module PIDs EXT UT2 and VBATIAA

No =

REPLACE the auxiliary

and compare the readings to the values below:

battery temperature sensor.

Temperature
— 0

°

C (32

°

F) = 14.1-14.7 volts

— 5

°

C (41

°

F) = 14.0-14.6 volts

— 10

°

C (50

°

F) = 13.9-14.5 volts

— 15

°

C (59

°

F) = 13.8-14.4 volts

— 20

°

C (68

°

F) = 13.7-14.3 volts

— 25

°

C (77

°

F) = 13.6-14.3 volts

— 30

°

C (86

°

F) = 13.5-14.2 volts

— 35

°

C (95

°

F) = 13.4-14.2 volts

— 40

°

C (104

°

F) = 13.3-14.1 volts

— 45

°

C (113

°

F) = 13.3-14.0 volts

— 50

°

C (122

°

F) = 13.3-13.9 volts

— 55

°

C (131

°

F) = 13.3-13.8 volts

— 60

°

C (140

°

F) = 13.3-13.8 volts

•

Is the voltage OK?

GENERAL PROCEDURES

Auxiliary Battery Charging

1. For additional information, refer to 2001

Ranger Workshop Manual Section 414-00.

Auxiliary Battery Capacity Test

1. For additional information, refer to 2001

Ranger Workshop Manual Section 414-00.

414-02-9

414-02-9

Auxiliary Battery Charging

REMOVAL AND INSTALLATION

DC/DC Converter

Removal

1. Disconnect the traction battery high-voltage

2-pin connector. Refer to

Section 100-05

.

2.

WARNING: Do not remove the

radiator pressure relief cap if the coolant is
hot or if the pump is running.
Turn the radiator pressure relief cap to the first
stop to relieve any remaining pressure.

3. Remove the high voltage power distribution

Box (HVPDB) cover.
1 Remove the screws.
2 Remove the cover.

4. Disconnect the direct current to direct current

(DC/DC) converter electrical connectors.
1 Remove the ground strap nut.
2 Disconnect the cable connector.
3 Disconnect the electrical connector.

•

Unclip the harness.

414-02-10

414-02-10

Auxiliary Battery Charging

REMOVAL AND INSTALLATION (Continued)

5. Clamp off and disconnect the coolant lines at

the DC/DC converter.

6. Remove the hold-down bolts and remove the

converter.

Installation

1. NOTE: There are two locating tabs on the

lower back side of the DC/DC converter. These
tabs locate and hold the converter in the card
table.
Position the DC/DC converter in the card table
and install the bolts.