Ford Electric Ranger 2001 Manual page 650

414-03B-47
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: CHARGER CHARGING AFTER BEING DISABLED FAULT
• 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 measure
the resistance of the GY/W wire between pin 4 on traction battery
charger C1991 and BOB pin 57.
• Is the resistance less than 5 ohms?
D4 CHECK CIRCUIT 3827 (GY/W) (OUTSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR SHORT TO GROUND
• With key OFF, measure the resistance between BOB pin 57 and ground
(BOB pin 65).
• Is the resistance greater than 10,000 ohms?
D5 CHECK CIRCUIT 3827 (GY/W) (INSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR OPEN
• 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.
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 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.
• With key OFF, disconnect BCM C1986 and measure the resistance of the
GY/W wire between pin 8 on BCM C1986 and BOB pin 57.
• Is the resistance less than 5 ohms?
D6 CHECK CIRCUIT 3827 (GY/W) (INSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR SHORT TO GROUND
• With key OFF, measure the resistance between BOB pin 57 and ground
(BOB pin 65).
• Is the resistance greater than 10,000 ohms?
PINPOINT TEST F: CHARGER LATCHUP FAULT
F1 CHECK CHARGER OVER-TEMPERATURE STATUS
• Verify the vehicle is connected to the power control station (PCS) and
the START button has been depressed to begin charging.
NOTE: Wait approximately five minutes to allow the CHG OTF PID to
be set.
• With key OFF and vehicle on-charge, monitor BCM PID CHG OTF.
• Does the CHG OTF PID indicate YES?
F2 CHECK CIRCUIT 3800 (LG/BK) (OUTSIDE OF TRACTION
BATTERY SUPPORT TRAY) FOR OPEN
• 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.
(Continued)
High Voltage/Traction Battery — Nickel Metal Hydride
TEST STEP
TEST STEP
414-03B-47
ACTION TO TAKE
GO to D4.
No = REPAIR the GY/W wire.
Yes = GO to D5.
No = REPAIR the GY/W wire.
GO to D6.
Yes =
No = REPAIR the GY/W wire.
Yes = REPLACE the traction
battery charger.
No = REPAIR the GY/W wire.
ACTION TO TAKE
Yes = GO to Pinpoint Test E.
No = DISCONNECT the PCS
from the vehicle. GO to F2.
GO to F3.
2001 Ranger EV, 01/2001