Ford 2001 Ranger, Manual

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414-03B-17 414-03B-17 High Voltage/Traction Battery — Nickel Metal Hydride
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE
TEST STEP ACTION TO TAKE
A2 CHECK FOR WELDED MAIN CONTACTOR RELAY
•
Press the STOP button on the PCS and disconnect the PCS from the Yes = GO to A3.
charger inlet.
•
Enter traction inverter module (TIM) active command mode No = REPLACE the contactor
CONTACTOR OUTPUT CONTROL and monitor TIM PID BAT PV. box.
•
Does the voltage for the BAT PV PID decrease?
A3 CHECK (MANUALLY) FOR WELDED CONTACTOR RELAY(S)
NOTE: Do not connect the Traction Battery High-Voltage Lockout and
Yes = REPLACE the contactor
Diagnostic Tool or any of the traction battery service cords until indicated
box.
to do so.
•
Remove the traction battery.
No = GO to A4.
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.
•
NOTE: The high-voltage input to the contactor box is on the passenger
side of the contactor box. The high-voltage negative input to the
contactor box is the post towards the front of the vehicle and the
high-voltage positive input is the post towards the rear of the vehicle.
The high-voltage negative output pin for the traction battery two-pin
connector (C3994) is the pin towards the front of the vehicle and the
high-voltage positive output pin is the pin towards the rear of the
vehicle.
Measure the voltage between the high-voltage positive post on the
contactor box and the high-voltage negative pin on the traction battery
two-pin connector.
•
Measure the voltage between the high-voltage negative post on the
contactor box and the high-voltage positive pin on the traction battery
two-pin connector.
•
Are any of the voltages greater than 200 volts?
A4 CHECK NEGATIVE CONTACTOR RELAY CONTROL (OPEN
SIGNAL)
•
Connect Traction Battery High-Voltage Lockout and Diagnostic Tool to Yes = GO to A6.
the traction battery high-voltage two-pin C3994M.
•
Connect Traction Battery High-Voltage Service Cord to traction battery No = GO to A5.
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 battery control module (BCM)
and BCM C1986, C1987 using BCM/TIM BOB Adapter Cable and
Overlay.
•
Enter BCM active command mode CONTACTOR OUTPUT CONTROL,
set the active command NEG MAIN to OPEN, and measure the voltage
between BOB pin B7 and ground (BOB pin A33).
•
Is the voltage greater than 10 volts?
A5 CHECK CIRCUIT 3136 (W) 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 W wire.
resistance between BOB pin B7 and ground (BOB pin A33).
•
Is the resistance greater than 10,000 ohms?
(Continued)
2001 Ranger EV, 01/2001