Ford Electric Ranger 2001 Manual page 626

414-03B-23
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE
• Does the MAINSEN PID indicate between 0.5 and 4.5 volts?
A3 CHECK STATUS OF CONTACTOR BOX MAIN CURRENT
SENSOR WHILE DRIVING
• Lift the vehicle on a hoist. Refer to Section 100-02.
• Start the vehicle, move the transmission range selector lever to the Drive
(D) position, and depress/release the accelerator pedal two or three times
while monitoring BCM PID MAINSEN.
• Does the MAINSEN PID voltage increase upon acceleration?
A4 CHECK AUXILIARY CURRENT SENSOR SIGNAL TO BCM
• Remove the traction battery and connect Traction Battery High-Voltage
Lockout and Diagnostic Tool to the traction battery high-voltage two-pin
C3994M.
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.
• 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 C1986, C1987 using the
BCM/TIM BOB Adapter Cable and Overlay; leave the BCM
disconnected.
• With key ON, measure the voltage between BOB pin A17 and ground
(BOB pin A33).
• Is the voltage between 5 and 8 volts?
A5 CHECK CIRCUITS 3996 (R/Y) AND 3705 (LB) FOR OPEN(S)
• With key OFF, disconnect contactor box C1982 and measure the
resistance of the R/Y wire between pin 21 on contactor box C1982 and
BOB pin A16.
• With key OFF, measure the resistance of the LB wire between pin 22 on
contactor box C1982 and BOB pin A17.
• Are the resistances less than 5 ohms?
A6 CHECK CIRCUIT 3705 (LB) FOR SHORT TO GROUND
• With key OFF, measure the resistance between BOB pin A17 and ground Yes =
(BOB pin A33).
• Is the resistance greater than 10,000 ohms?
A7 CHECK CIRCUIT 3705 (LB) FOR SHORT TO POWER
• With key ON, measure the voltage between BOB pin A17 and ground
(BOB pin A33).
• Is the voltage greater than 0 volts?
A8 CHECK MAIN CURRENT SENSOR SIGNAL TO BCM
• Remove the traction battery and connect Traction Battery High-Voltage
Lockout and Diagnostic Tool to the traction battery high-voltage two-pin
C3994M.
(Continued)
High Voltage/Traction Battery — Nickel Metal Hydride
TEST STEP
414-03B-23
ACTION TO TAKE
No = GO to A8.
Yes = GO to A12.
No = REPLACE the contactor
box.
Yes = REPLACE the BCM.
No = GO to A5.
GO to A6.
Yes =
No = REPAIR the wire(s) in
question.
GO to A7.
No = REPAIR the LB wire.
Yes = REPAIR the LB wire.
No = REPLACE the contactor
box.
Yes = REPLACE the BCM.
2001 Ranger EV, 01/2001