Ford 2001 Ranger, Manual

Page: 653 / 1218

414-03B-50 414-03B-50 High Voltage/Traction Battery — Nickel Metal Hydride
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST H: CHARGER UNDER CURRENT FAULT
TEST STEP ACTION TO TAKE
•
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 Low-Voltage Service Cord to traction battery No = GO to H8.
support tray in-line C1939F and in-line C1939M.
•
Connect Traction Battery High-Voltage Service Cord to traction battery
support tray in-line C1935F and in-line C1935M.
•
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.
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 2
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.
(Continued)
2001 Ranger EV, 01/2001