Ford Electric Ranger 2001 Manual page 460

414-03A-57
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST H: CHARGER UNDER CURRENT FAULT
NOTE: Measure the voltage immediately after pressing the START button
on the PCS. If no voltage output, monitor the voltage for approximately
two 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
C1923.
• Connect the vehicle to the PCS and press the START button to begin
charging.
• With vehicle on-charge, monitor BCM PID CHG OTF for
approximately five minutes.
• Does the CHG OTF PID indicate YES?
H12 CHECK CIRCUITS 3401 (DB/LG) AND 3985 (PK) (OUTSIDE OF
TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S)
• With key OFF, disconnect traction battery support tray in-line C1939 and Yes =
connect 104-Pin Breakout Box (BOB) to 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, disconnect traction battery charger C1991 and C1993.
• With key OFF, measure the resistance of the DB/LG wire between pin 3
on traction battery charger C1993 and BOB pin 63.
• With key OFF, measure the resistance of the PK wire between pin 3 on
traction battery charger C1991 and BOB pin 50.
• Are the resistances less than 5 ohms?
H13 CHECK CIRCUITS 3401 (DB/LG) AND 3985 (PK) (INSIDE OF
TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S)
• Disconnect the BOB from in-line C1939M, remove the traction battery,
and connect Traction Battery High-Voltage Lockout and Diagnostic Tool
to the traction battery high-voltage two-pin C3994M.
• Connect 104-Pin Breakout Box (BOB) to traction battery support tray
in-line C1939F using Traction Battery Low-Voltage Service Cord; do not
connect Traction Battery Low-Voltage Service Cord to in-line C1939M.
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.
• With key OFF, disconnect BCM C1986 and C1987.
• Measure the resistance of the DB/LG wire between pin 11 on BCM
C1986 and BOB pin 63.
• Measure the resistance of the PK wire between pin 13 on BCM C1986
and BOB pin 50.
• Are the resistances less than 5 ohms?
PINPOINT TEST J: CHARGER OVER CURRENT FAULT
J1 CHECK CONTACTOR BOX AUXILIARY CURRENT SENSOR
FOR IN-RANGE FAILURE
• With key ON, monitor BCM PID AUX CNT.
(Continued)
High Voltage/Traction Battery
TEST STEP
TEST STEP
414-03A-57
ACTION TO TAKE
No = GO to H12.
Yes = GO to Pinpoint Test E.
No = System OK. CHECK wiring
for intermittent connections.
GO to H13.
No = REPAIR the wire(s) in
question.
Yes = REPLACE the traction
battery charger.
No = REPAIR the wire(s) in
question.
ACTION TO TAKE
Yes = REPLACE the traction
battery charger.
2001 Ranger EV, 01/2001