Ford Electric Ranger 2001 Manual page 415

414-03A-12
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE
• With key OFF, disconnect traction battery support tray in-line C1939 and Yes =
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.
• 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
battery.
WARNING: The traction battery contains high-voltage
components and wiring. High-voltage insulated safety gloves and face
shield must be worn when performing 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.
• Turn the ignition key to the START position.
• Does the BAT PV PID indicate between 50 and 385 volts?
A5 CHECK MAIN CONTACTOR RELAY
NOTE: The active command PRECHG IN must be sent before sending the
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.
• 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 =
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
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
DG wire between pin 8 on TIM C4998 and BOB pin 23.
• Is the resistance less than 5 ohms?
(Continued)
High Voltage/Traction Battery
TEST STEP
414-03A-12
ACTION TO TAKE
GO to A3.
No = REPAIR the BK wire.
Yes = REPLACE the contactor
box.
No = REPAIR the BK wire.
Yes = System OK. CHECK wiring
for intermittent connections.
No = If less than 50 volts, GO to
A5.
If greater than 385 volts,
GO to A12.
GO to A6.
Yes =
GO to A12.
No =
GO to A9.
No = GO to A7.
GO to A8.
Yes =
No = REPAIR the DG wire.
2001 Ranger EV, 01/2001