Ford Ranger EV (2001 year). Manual — part 101

414-02-11

414-02-11

Auxiliary Battery Charging

REMOVAL AND INSTALLATION (Continued)

2. Connect the DC/DC converter electrical

connectors.
1 Position the electrical cross bar and install

the ground strap nut.

2 Position the cable and install the nuts.
3 Connect the electrical connector.

3. Connect the DC/DC converter coolant lines.

4. Install the HVPDB cover.

•

Install the screws.

5. Connect the traction battery high-voltage 2-pin

connector. Refer to

Section 100-05

.

6. Bleed the cooling system. Refer to

Section

303-03

.

414-03A-1

414-03A-1

High Voltage/Traction Battery

Manual Table of Contents

SECTION 414-03A High Voltage/Traction Battery

VEHICLE APPLICATION:

Ranger EV

CONTENTS

PAGE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 414-03A-3

DESCRIPTION AND OPERATION

High Voltage/Traction Battery . . . . . . . . . . . . . . . . . . 414-03A-3

DIAGNOSIS AND TESTING

Auxiliary Contactor Relay Control . . . . . . . . . . . . . . . . 414-03A-5

Electrical Schematic . . . . . . . . . . . . . . . . . . . . 414-03A-5
Inspection and Verification . . . . . . . . . . . . . . . . . .. 414-03A-5
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . . 414-03A-5
Symptom Chart . . . . . . . . . . . . . . . . . . . . ... 414-03A-5

Contactor Box Current Sensors. . . . . . . . . . . . . . . . ..414-03A-22

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-22
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-22
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-23
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-23

Current Leakage Detection . . . . . . . . . . . . . . . . . ...414-03A-26

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-26
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-26
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-27
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-27

Emergency Power Off (EPO)/Interlock System . . . . . . . . . . . ...414-03A-18

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-18
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-18
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-19
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-19

Main/Precharge Contactor Relay Control . . . . . . . . . . . . . ..414-03A-10

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-10
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-10
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-11
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-11

Multiple Auxiliary Load Failure Diagnosis . . . . . . . . . . . . . ..414-03A-79

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-79
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-79
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-80
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-80

Negative Contactor Relay Control . . . . . . . . . . . . . . . ...414-03A-16

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-16
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-16
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-16
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-16

Regenerative Braking. . . . . . . . . . . . . . . . . . . ..414-03A-40

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-40
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-40
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-41
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-41

Traction Battery Charging/Heating System . . . . . . . . . . . . . 414-03A-43

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-45
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-45

414-03A-2

414-03A-2

High Voltage/Traction Battery

CONTENTS

PAGE

Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-46
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-45

Traction Battery Cooling/Ventilation System . . . . . . . . . . . . ...414-03A-65

Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-65
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-65
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-65
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-65

Traction Battery System . . . . . . . . . . . . . . . . . . ..414-03A-68

Battery Module Diagnostic Test . . . . . . . . . . . . . . . ...414-03A-68
Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03A-70
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03A-70
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03A-71
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03A-70

GENERAL PROCEDURES

Battery Tray Seal . . . . . . . . . . . . . . . . . . . . ..414-03A-97
Module Charging . . . . . . . . . . . . . . . . . . . . ...414-03A-81
Traction Battery Module Replacement . . . . . . . . . . . . . . ..414-03A-82
Traction Battery Tray Repair . . . . . . . . . . . . . . . . . .414-03A-93

REMOVAL AND INSTALLATION

Battery Control Module (BCM) . . . . . . . . . . . . . . . . ...414-03A-98
Charge Inlet . . . . . . . . . . . . . . . . . . . . . ... 414-03A-101
Contactor Box . . . . . . . . . . . . . . . . . . . . .... 414-03A-103
Contactor Box Fuses . . . . . . . . . . . . . . . . . . .... 414-03A-107
HVPDB Fuses . . . . . . . . . . . . . . . . . . . . .... 414-03A-109
High Voltage Power Distribution Box (HVPDB) . . . . . . . . . . . . 414-03A-111
High Voltage Wiring . . . . . . . . . . . . . . . . . . . . 414-03A-117
High Voltage Wiring — Sensory Lead Harness (10B694) . . . . . . . . . 414-03A-112
Traction Battery . . . . . . . . . . . . . . . . . . . . .. 414-03A-120
Traction Battery Charger . . . . . . . . . . . . . . . . . . 414-03A-125
Traction Battery Cooling/Ventilation Fan . . . . . . . . . . . . . . 414-03A-128
Traction Battery Heating Elements (U/L) — Lower . . . . . . . . . . . 414-03A-130
Traction Battery Heating Elements (U/L) — Upper . . . . . . . . . . . 414-03A-130
Traction Battery High Voltage Fuse (250A) . . . . . . . . . . . . .. 414-03A-131
Traction Battery Module — Modules 1-7 . . . . . . . . . . . . . . 414-03A-133
Traction Battery Module — Modules 12-15, 28-31 . . . . . . . . . . . 414-03A-138
Traction Battery Module — Modules 16, 25-27 . . . . . . . . . . . . 414-03A-139
Traction Battery Module — Modules 17-18 . . . . . . . . . . . . .. 414-03A-134
Traction Battery Module — Modules 19-21 . . . . . . . . . . . . .. 414-03A-134
Traction Battery Module — Modules 22-24 . . . . . . . . . . . . .. 414-03A-140
Traction Battery Module — Modules 34-39 . . . . . . . . . . . . .. 414-03A-136
Traction Battery Module — Modules 8-11 . . . . . . . . . . . . ... 414-03A-135
Traction Battery Temperature Sensor — Modules 22-24 . . . . . . . . .. 414-03A-142

DISASSEMBLY AND ASSEMBLY

Traction Battery Temperature Sensor . . . . . . . . . . . . . . 414-03A-144

414-03A-3

414-03A-3

High Voltage/Traction Battery

SPECIFICATIONS

Torque Specifications

Torque Specifications

Description

Nm

Lb-Ft

Lb-In

Description

Nm

Lb-Ft

Lb-In

High-Voltage Power

12

—

107

A/C Inverter Motor

12

—

107

Distribution Box Bolts

Control Bolts

High-Voltage Power

2

—

18

Battery Control Module

3

—

27

Distribution Box Cover

Multi-Pin Connector

Screws

Bolts

High-Voltage Power

2

—

18

Blower Motor Relay

3

—

27

Distribution Box Fuse

Screw

Safety Cover Screws

Blower Bracket to Cross

10

—

89

Traction Battery Charger

22

16

—

Bar Bolts

Bolts

Charger Inlet Bracket

7

—

62.5

Traction Battery Cooling

4

—

35.5

Bolts

Fan Screws

Contactor Box Screws

2

—

18

Traction Battery Cover

17

12.5

—

Cross Bar to Battery

5

—

44.5

Bolts

Tray Nuts

Traction Battery

126

92.5

—

Crossbar to Traction

10

—

89

Mounting Bolts

Battery Fan Nuts and

Two-Pin High-Voltage

5

—

44.5

Bolts

Connector Nuts

Grille Screws

1.5

—

13.5

76-Pin Connector Bolt

4.8

—

43

Ground Strap Bolt

12

—

107

Harness Bracket Bolt

5.4

—

48

General Specifications

High-Voltage Fuse Bolts

12

—

107

Item

Specification

High-Voltage Fuse

5

—

44.5

Locktite 242 (Threadlock

WSK-M2G351A5 (Type

Bracket Nut

and Sealer)

II)

High-Voltage Harness

5.5

—

49

EOAZ-19554-AA

Bracket Bolt

Nyogel 760G

WSB-M1C239-A

High-Voltage Jumper to

12

—

107

Thermal Grease (Dow

ESF-M99G123-A

Battery Module Nuts

Corning



340)

(Continued)

DESCRIPTION AND OPERATION

High Voltage/Traction Battery

The traction battery is the primary source of power
for the Ranger EV. It is located between the frame
rails and underneath the vehicle. The supporting tray
contains all of the traction battery components. The
tray is made of a strong, non-conductive composite
material and has brackets molded into it at various
locations. The traction battery, when fully loaded
with all necessary components, weighs 884.5 kg
(1,950 lb).