Ford Electric Ranger 2001 Manual page 620

414-03B-17
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE
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 carrying out 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.
• 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 battery control module (BCM)
and BCM C1986, C1987 using BCM/TIM BOB Adapter Cable and
Overlay.
• Enter BCM active command mode CONTACTOR OUTPUT CONTROL,
set the active command NEG MAIN to OPEN, and measure the voltage
between BOB pin B7 and ground (BOB pin A33).
• Is the voltage greater than 10 volts?
A5 CHECK CIRCUIT 3136 (W) 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 B7 and ground (BOB pin A33).
• Is the resistance greater than 10,000 ohms?
(Continued)
High Voltage/Traction Battery — Nickel Metal Hydride
TEST STEP
414-03B-17
ACTION TO TAKE
GO to A3.
Yes =
No = REPLACE the contactor
box.
Yes = REPLACE the contactor
box.
GO to A4.
No =
GO to A6.
Yes =
GO to A5.
No =
Yes = REPLACE the BCM.
No = REPAIR the W wire.
2001 Ranger EV, 01/2001