Ford Electric Ranger 2001 Manual page 618

414-03B-15
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: DTC C1862 CONTACTOR CIRCUIT FAILURE
• Is the resistance greater than 10,000 ohms?
B8 CHECK CIRCUIT 3991 (T) BETWEEN CONTACTOR BOX AND
TRACTION BATTERY SUPPORT TRAY FOR OPEN
• With key OFF, disconnect the BOB from traction battery support tray
in-line C1939F and 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 carrying out the following steps. Failure to
follow this warning may result in severe personal injury or death.
• Reconnect 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.
• With key OFF, disconnect contactor box C1982 and measure the
resistance of the T wire between pin 18 on contactor box C1982 and
BOB pin 22.
• Is the resistance less than 5 ohms?
B9 CHECK CIRCUIT 3991 (T) BETWEEN CONTACTOR BOX AND
TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND
• With key OFF, measure the resistance between BOB pin 22 and ground
(BOB pin 65).
• Is the resistance greater than 10,000 ohms?
B10 CHECK TRACTION BATTERY VOLTAGE
• With key ON, monitor BCM PID BAT PV and TIM PID BAT PV.
• Is there more than a 30-volt difference between the BAT PV PIDs?
B11 CHECK FOR WELDED MAIN CONTACTOR RELAY
• Enter TIM active command mode CONTACTOR OUTPUT CONTROL
and monitor TIM PID BAT PV.
• Does the voltage for the BAT PV PID decrease?
B12 CHECK MAIN AND PRECHARGE CONTACTOR RELAY
OUTPUTS
• Connect 104-Pin Breakout Box (BOB) to TIM and TIM C4998, C4999
using the BCM/TIM BOB Adapter Cable and Overlay.
• Enter traction inverter module (TIM) active command mode
CONTACTOR OUTPUT CONTROL.
• With key ON, measure the voltage between BOB pins A8, A18 and
ground (BOB pin A29).
• Is either voltage greater than 10 volts?
B13 CHECK CIRCUITS 3991 (T) AND 3986 (DG) FOR SHORT(S) TO
POWER
• With key OFF, disconnect the TIM from the BOB; leave BOB connected Yes =
to TIM C4998, C4999.
• With key ON, measure the voltage between BOB pins A8, A18 and
ground (BOB pin A29).
• Is either voltage greater than 1 volt?
High Voltage/Traction Battery — Nickel Metal Hydride
TEST STEP
414-03B-15
ACTION TO TAKE
No = REPAIR the T wire.
Yes = GO to B9.
No = REPAIR the T wire.
Yes = REPLACE the contactor
box.
No = REPAIR the T wire.
Yes = REPLACE the TIM. REFER
to Section 303-14.
No = System OK. CHECK wiring
for intermittent connections.
Yes = System OK. CHECK wiring
for intermittent connections.
No = GO to B12.
GO to B13.
Yes =
No = REPLACE the contactor
box.
REPAIR the wire(s) in
question.
No = REPLACE the TIM. REFER
to Section 303-14.
2001 Ranger EV, 01/2001