Ford Electric Ranger 2001 Manual page 459

414-03A-56
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST H: CHARGER UNDER CURRENT FAULT
NOTE: Contactor box C3985 is mounted on the passenger side of the
BCM.
• With key OFF, disconnect contactor box C3985 and measure the
resistance of the O wire between contactor box C3985F and traction
battery support tray in-line C1935F.
• With key OFF, measure the resistance of the W wire between contactor
box C3985F and traction battery support tray in-line C1935F.
• Is the resistance less than 5 ohms?
H5 CHECK CHARGER CONTACTOR RELAY
• Reconnect contactor box C3985.
• Connect Traction Battery High-Voltage Service Cord to traction battery
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
Contactor Box Fuses Removal and Installation procedure in this section.
• Measure the resistance of the 25A CHARGER fuse.
• Is the resistance greater than 1,000 ohms?
H7 CHECK CHARGER CONTACTOR RELAY CONTROL (CLOSE
SIGNAL)
• Reconnect contactor box C3985.
• Connect Traction Battery High-Voltage Service Cord to traction battery
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 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
BCM C1986 and C1987.
• With key OFF, disconnect contactor box C1982 and measure the
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
resistance of the GY/Y wire between pin 20 on contactor box C1982 and
BOB pin B9.
• Is the resistance less than 5 ohms?
H10 CHECK OUTPUT OF TRACTION BATTERY CHARGER
• Connect the power control station (PCS) to the charger inlet connector
and press the START button on the PCS.
(Continued)
High Voltage/Traction Battery
TEST STEP
414-03A-56
ACTION TO TAKE
No = REPLACE high-voltage
harness (14B326) between
traction battery support tray
in-line C1935F and
contactor box C3985.
GO to H6.
Yes =
No = GO to H7.
Yes = REPLACE the 25A
CHARGER fuse.
No = REPLACE the contactor
box.
GO to H9.
Yes =
No = GO to H8.
Yes = REPLACE the BCM.
No = REPAIR the GY/Y wire.
Yes = REPLACE the contactor
box.
No = REPAIR the GY/Y wire.
Yes = GO to H11.
2001 Ranger EV, 01/2001