Ford Electric Ranger 2001 Manual page 420

414-03A-17
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE
A1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM)
OPERATING STATE
• Connect the vehicle to the power control station (PCS) and press the
START button (if necessary) to begin charging.
• With key OFF, monitor BCM PID BCM OP.
• Does the BCM OP PID indicate 106 (negative contactor relay
welded/stuck closed) or 107 (no charge-TIM SCP message: main
contactor relay welded/stuck closed)?
A2 CHECK FOR WELDED MAIN CONTACTOR RELAY
• Press the STOP button on the PCS and disconnect the PCS from the
charger inlet.
• Enter traction inverter module (TIM) active command mode
CONTACTOR OUTPUT CONTROL and monitor TIM PID BAT PV.
• 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
Diagnostic Tool or any of the traction battery service cords until indicated
to do so.
• 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.
• 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
the traction battery high-voltage two-pin C3994M.
(Continued)
High Voltage/Traction Battery
TEST STEP
414-03A-17
ACTION TO TAKE
If 106, GO to A2.
Yes =
If 107, GO to Pinpoint Test
B in Main/Precharge
Contactor Relay Control.
No = System OK.
GO to A3.
Yes =
No = REPLACE the contactor
box.
Yes = REPLACE the contactor
box.
GO to A4.
No =
Yes = GO to A6.
2001 Ranger EV, 01/2001