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Ford Ranger EV (2001 year). Manual - part 99

414-02-3

Auxiliary Battery Charging

DIAGNOSIS AND TESTING (Continued)

•

DTC B1318 Battery Voltage - Low

•

DTC C1775 DC/DC Converter Failure

— The interface adapter assembly (IAA) module

monitors the auxiliary battery voltage at pins

75, 76 (hot at all times). If the auxiliary

75, 76 (hot at all times). If the IAA module

battery voltage decreases below 10 volts, the

senses the auxiliary battery voltage is too high

IAA module generates DTC B1318 and enters

for more than 250 milliseconds, it will begin

a limited operating mode where it will

to isolate the reason for the increase. This

attempt to close the auxiliary contactor relay

strategy may include up to five attempts to

and reenable the direct current to direct

enable the direct current to direct current

current (DC/DC) converter. If the auxiliary

(DC/DC) converter at 30-second intervals. The

contactor relay is already closed and the

IAA module may also open the auxiliary

DC/DC converter is already enabled, they will

contactor relay. If the IAA module suspects

remain so. As the auxiliary voltage continues

the DC/DC converter is supporting the

to decrease, the IAA module will continue to

auxiliary battery voltage too high (more than

try to run the DC/DC converter as long as

16.5 volts) when commanded off, DTC C1775

possible. The vacuum system will remain

is generated. The IAA module also generates

active until the auxiliary battery voltage drops

DTC C1775 when the auxiliary battery voltage

below 9 volts. The IAA module will shut

decreases below 11.5 volts and the DC/DC

down below 9 volts.

converter is not indicating an overcurrent
(current limit) condition.

Electrical Schematic

Refer to Electrical and Vacuum Troubleshooting
Manual, Cell 12, Auxiliary Battery Charging
System and Cell 13, Power Distribution (High
Voltage) for schematic and connector information.

Inspection and Verification

Refer to

Section 100-07

Symptom Chart

Condition

Possible Sources

Action

•

DTC B1317 Battery Voltage -

•

Circuit(s).

•

GO to Pinpoint Test A.

High

•

Auxiliary battery temperature

sensor.

•

Direct current to direct

current (DC/DC) converter.

•

DTC B1318 Battery Voltage -

•

Circuit(s).

•

GO to Pinpoint Test B.

Low

•

Auxiliary battery temperature

sensor.

•

Direct current to direct

current (DC/DC) converter.

414-02-4

Auxiliary Battery Charging

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

DTC C1775 DC/DC

•

Circuit(s).

•

GO to Pinpoint Test C.

Converter Failure

•

MEGA fuse.

•

Auxiliary battery cables.

•

Direct current to direct

current (DC/DC) converter.

•

Interface adapter assembly

(IAA) module.

•

High voltage power

distribution box (HVPDB).

•

High-voltage DC/DC fuse.

•

Auxiliary Battery Warning

•

Circuit(s).

•

GO to Pinpoint Test D.

Indicator Illuminated

•

Direct current to direct

(Auxiliary Battery

current (DC/DC) converter.

Temperature Sensor Failure)

•

Auxiliary battery temperature

sensor.

Pinpoint Tests

Special Tool(s)

104-Pin Breakout Box (BOB) 418-049 (014-00950) or

equivalent

High Voltage Insulated Safety Gloves 100-F036 or

equivalent

Face Shield 100-F035 or equivalent

PINPOINT TEST A: DTC B1317 BATTERY VOLTAGE - HIGH

TEST STEP

ACTION TO TAKE

A1 CHECK FOR DC/DC CONVERTER FAILURE DIAGNOSTIC

TROUBLE CODE (DTC)

•

Carry out on-demand self-test for the interface adapter assembly (IAA)

Yes =

GO to Pinpoint Test C.

module and check for DTC C1775 DC/DC Converter Failure.

•

Did DTC C1775 DC/DC Converter Failure occur?

No =

GO to A2.

A2 CHECK AUXILIARY BATTERY VOLTAGE

•

With key ON, monitor the IAA module PID VBATIAA.

Yes =

GO to Pinpoint Test D.

•

Is the voltage greater than 14 volts?

No =

System OK. CHECK wiring

for intermittent connections.

PINPOINT TEST B: DTC C1318 BATTERY VOLTAGE - LOW

TEST STEP

ACTION TO TAKE

B1 CHECK FOR OTHER INTERFACE ADAPTER ASSEMBLY (IAA)

MODULE DIAGNOSTIC TROUBLE CODES (DTCs)

•

Carry out on-demand self-test for the IAA module and check for IAA

Yes =

REFER to IAA Module

module DTCs.

Diagnostic Trouble Code

(DTC) Index in

Section

100-07

•

Did other IAA module DTCs occur?

No =

GO to B2.

B2 CHECK AUXILIARY BATTERY VOLTAGE

•

With key ON, monitor the IAA module PID VBATIAA.

Yes =

GO to Pinpoint Test D.

•

Is the voltage less than 13.4 volts?

No =

System OK. CHECK wiring

for intermittent connections.

414-02-5

Auxiliary Battery Charging

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: DTC C1775 DC/DC CONVERTER FAILURE

TEST STEP

ACTION TO TAKE

C1 CHECK DC/DC CONVERTER OPERATION

NOTE: Before proceeding, verify the power control station (PCS) is not

Yes =

System OK. CHECK wiring

plugged into the vehicle and all accessories (radio, A/C, heater, etc.) are

for intermittent connections.

turned off. If the New Generation STAR (NGS) Tester indicates UNABLE

TO PERFORM TEST/FUNCTION and MODULE NOT RESPONDING

for the interface adapter assembly (IAA) module when attempting to

monitor the IAA module PID VBATIAA, measure the voltage of the

auxiliary battery. If the voltage is less than 11 volts, recharge the auxiliary

battery. Refer to General Procedures in this section.

•

With key OFF, monitor the IAA module PID VBATIAA.

•

While monitoring the IAA module PID VBATIAA, turn the ignition key

No =

GO to C2.

to the ON position.

•

Does the VBATIAA PID increase from approximately 12.5 volts to

approximately 13.7 volts?

C2 CHECK DC/DC CONVERTER OPERATION USING NGS ACTIVE

COMMAND

•

Enter the IAA module active command mode AUXILIARY SYSTEM

Yes =

System OK. CHECK wiring

CONTROL, monitor the IAA module PID VBATIAA, and set the active

for intermittent connections.

command SUPPT SLI to YES.

•

Is the voltage indicated by the VBATIAA PID between 13.4 and 13.8

No =

GO to C3.

volts?

C3 CHECK AUXILIARY CONTACTOR RELAY STATUS

•

With key ON, monitor the IAA module PID AUX HVC.

Yes =

GO to C4.

•

Does the AUX HVC PID indicate CLOSED?

No =

CARRY OUT pinpoint test

for IAA DTC C1862

Contactor Circuit Failure.

REFER to Auxiliary

Contactor Relay Control in

Section 414-03A

Section 414-03B

C4 CHECK MEGA FUSE

•

With key OFF, measure the resistance of the 175A MEGA fuse attached

Yes =

GO to C6.

to the electric vehicle power distribution box (EVPDB).

•

Is the resistance less than 5 ohms?

No =

REPLACE the MEGA fuse.

GO to C5.

C5 CHECK POSITIVE BATTERY CABLES FOR SHORT(S) TO

GROUND

•

With key OFF, disconnect the cables from the auxiliary battery, and

Yes =

REPLACE the DC/DC

measure the resistance between the positive and negative auxiliary battery

converter.

cables.

•

With key OFF, disconnect the positive battery cable from the DC/DC

No =

REPLACE the positive

converter and measure the resistance between the positive cable on the

cable(s) in question.

MEGA fuse stud and the negative auxiliary battery post.

•

Are the resistances greater than 10,000 ohms?

C6 CHECK IAA MODULE DC/DC CONVERTER ENABLE SIGNAL

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

Yes =

GO to C7.

module C1945.

•

With key ON, measure the voltage between BOB pin 100 and ground

No =

GO to C8.

(BOB pin 80).

•

Is the voltage greater than 10 volts?

C7 CHECK CIRCUIT 3259 (Y/BK) FOR SHORT TO POWER

•

With key OFF, disconnect the IAA module from the BOB; leave the

Yes =

REPAIR the Y/BK wire.

BOB connected to IAA module C1945.

(Continued)

414-02-6

Auxiliary Battery Charging

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: DTC C1775 DC/DC CONVERTER FAILURE

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect DC/DC converter C1943.

No =

REPLACE the IAA module.

•

With key ON, measure the voltage between BOB pin 100 and ground

REFER to

Section 412-04

(BOB pin 80).

•

Is the voltage greater than 1 volt?

C8 CHECK CIRCUITS 3259 (Y/BK) AND 3994 (BK/Y) FOR OPEN(S)

•

With key OFF, disconnect DC/DC converter C1943 and measure the

Yes =

GO to C9.

resistance of the Y/BK wire between pin 3 on DC/DC converter C1943

and BOB pin 100.

•

With key OFF, measure the resistance of the BK/Y wire between pin 4

No =

REPAIR the wire(s) in

on DC/DC converter C1943 and BOB pin 73.

question.

•

Are the resistances less than 5 ohms?

C9 CHECK HIGH-VOLTAGE POWER TO DC/DC CONVERTER

•

Disconnect the 12-volt auxiliary battery negative cable.

Yes =

REPLACE the DC/DC

converter.

•

Remove the high voltage power distribution box (HVPDB) cover.

No =

GO to C10.

WARNING: The following test steps contain high-voltage

procedures. High-voltage insulated safety gloves, leather over

protectors, 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.

•

Disconnect HVPDB DC/DC converter high-voltage C1914.

•

Reinstall the HVPDB cover.

•

Reconnect the 12-volt auxiliary battery negative cable.

•

With key ON, measure the voltage between circuit 3117 (DB wire) and

circuit 3118 (W wire) on HVPDB DC/DC converter C1914F.

•

Is the voltage greater than 300 volts?

C10 CHECK HIGH-VOLTAGE FUSE

•

With key OFF, disconnect the 12-volt auxiliary battery negative cable.

Yes =

REPLACE the 10A DC/DC

fuse. GO to C11.

•

Disconnect high voltage auxiliary load in-line C1935 on the traction

No =

REPLACE the HVPDB.

battery support tray.

REFER to

Section 414-03A

•

Disconnect all HVPDB high-voltage connectors.

Section 414-03B

•

Disconnect power steering assembly high-voltage C1895.

•

Measure the resistance of the 10A DC/DC fuse.

•

Is the resistance greater than 1,000 ohms?

C11 CHECK DC/DC CONVERTER FOR CAPACITOR DISCHARGE

FAILURE

Yes =

REPLACE the DC/DC

WARNING: Carefully probe the terminals of the DC/DC

converter.

converter. The DC/DC converter contains high-voltage capacitors

which can retain high voltage if there is a capacitor discharge failure.

Shorting the probes together may cause an electrical arc.

•

Wait approximately two minutes to allow the high-voltage capacitors in

the DC/DC converter to discharge.

•

Measure the voltage between circuit 3117 (BK wire) and circuit 3118 (W

wire) on HVPDB DC/DC converter C1914M.

•

Is the voltage greater than 30 volts?

No =

GO to C12.

C12 CHECK DC/DC CONVERTER FOR SHORT

•

Measure the resistance between circuit 3117 (BK wire) and circuit 3118

Yes =

REPLACE the DC/DC

(W wire) on HVPDB DC/DC converter C1914M.

converter.

•

Is the resistance less than 30 ohms?

No =

GO to C13.

C13 CHECK HVPDB FOR SHORT

(Continued)

Content .. 97 98 99 100 ..