Ford Ranger EV (2001 year). Manual - part 109

414-03A-32

414-03A-32

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

•

Reinstall the HVPDB cover. 

No =

REPLACE the DC/DC

•

With key ON, monitor BCM PID LEAKRES. 

converter. REFER to Section

•

Wait approximately 50 seconds. 

414-02.

•

Does the LEAKRES PID indicate less than 50,000 ohms?

A23 CHECK FOR CURRENT LEAKAGE IN TRACTION BATTERY

CHARGER

•

With key OFF, remove the HVPDB cover and disconnect HVPDB

Yes =

REPLACE the HVPDB.

C1923 (to traction battery charger). 

•

Reinstall the HVPDB cover. 

No =

REPLACE the traction

•

With key ON, monitor BCM PID LEAKRES. 

battery charger.

•

Wait approximately 50 seconds. 

•

Does the LEAKRES PID indicate less than 50,000 ohms?

A24 CHECK FOR CURRENT LEAKAGE IN TRACTION BATTERY

SUPPORT TRAY, TIM, OR TRACTION MOTOR

•

With key OFF, disconnect the traction battery high-voltage two-pin

Yes =

GO to A27 (leakage is in

C3994 and connect Traction Battery High-Voltage Lockout and

traction battery support

Diagnostic Tool to the traction battery high-voltage two-pin C3994M. 

tray).

•

With key ON, monitor BCM PID LEAKRES. 

No =

GO to A25 (leakage is in

•

Wait approximately 50 seconds. 

TIM or traction motor).

•

Does the LEAKRES PID indicate less than 50,000 ohms?

A25 CHECK FOR CURRENT LEAKAGE IN TIM OR TRACTION

MOTOR

•

With key OFF, disconnect the traction motor three-phase cables from the

Yes =

GO to A26 (leakage is in

TIM, and reconnect the traction battery high-voltage two-pin C3994. 

TIM or high-voltage cables

to TIM).

•

With key ON, monitor BCM PID LEAKRES. 

No =

REPLACE the

•

Wait approximately 50 seconds. 

motor/transaxle. REFER to

•

Does the LEAKRES PID indicate less than 50,000 ohms?

Section 303-01.

A26 CHECK FOR CURRENT LEAKAGE IN TIM OR

HIGH-VOLTAGE CABLES LEADING TO TIM

•

With key OFF, check the high-voltage cables to the TIM to see if the

Yes =

REPLACE high-voltage

positive (+) or negative (-) cables are touching chassis ground. 

harness (14B322).

•

Are any of the cables touching chassis ground?

No =

REPLACE the TIM. REFER

to Section 303-14.

A27 CHECK FOR CURRENT LEAKAGE IN HIGH-VOLTAGE

NEGATIVE BUS (TB-) (INSIDE TRACTION BATTERY SUPPORT

TRAY)

NOTE: The BCM active command CHARGER must be sent before the

Yes =

GO to A28 (leakage is in

BCM active command NEG MAIN is sent.

battery module voltage sense

•

With key ON, enter BCM active command mode CONTACTOR

lines or contactor box).

OUTPUT CONTROL, monitor BCM PID LEAKRES, and set the active

command CHARGER to CLOSE. 

•

Set the active command NEG MAIN to OPEN. 

No =

GO to A29 (leakage is in

•

Wait approximately 50 seconds. 

battery heater harness  or

•

Does the LEAKRES PID indicate less than 50,000 ohms?

contactor box).

A28 CHECK FOR CURRENT LEAKAGE IN BATTERY MODULE

VOLTAGE SENSE LINES

•

With key ON, monitor BCM PID LEAK ID and note the indicated

Yes =

REPLACE high-voltage

battery module. 

harness (10B694) and/or the

high-voltage harness

(14A280) in question.

(Continued)

414-03A-33

414-03A-33

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

NOTE: If there is no continuity between the indicated battery module and

No =

REPLACE the contactor

chassis ground, check for continuity between chassis ground and the

box.

positive (+) posts of the two battery modules before and after the indicated

battery module.

•

With key OFF, disconnect BCM C1865 and C1866, and check for

continuity between the positive (+) post of the indicated battery module

and chassis ground. 

•

Is there continuity?

A29 CHECK FOR CURRENT LEAKAGE IN CONTACTOR BOX OR

BATTERY HEATER HARNESS (IF EQUIPPED)

NOTE: If vehicle is not equipped with traction battery heaters, REPLACE

Yes =

REPLACE the contactor

the contactor box.

box.

•

Remove the traction battery and connect Traction Battery High-Voltage

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

C3994M. 

•

Connect Traction Battery Low-Voltage Service Cord to traction battery

No =

GO to A30 (leakage is in

support tray in-line C1939F and in-line C1939M. 

battery heater harness).

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when performing the following steps. Failure to

follow this warning may result in severe personal injury or  death.

•

With key OFF, disconnect contactor box C1864. 

•

With key ON, monitor BCM PID LEAKRES. 

•

Wait approximately 50 seconds. 

•

Does the LEAKRES PID indicate less than 50,000 ohms?

A30 CHECK FOR CURRENT LEAKAGE IN LOWER BATTERY

HEATER

•

With key OFF, reconnect contactor box C1864 and disconnect lower

Yes =

GO to A31.

battery heater C1862 and C1863. 

•

With key ON, monitor BCM PID LEAKRES. 

No =

REPLACE the lower battery

•

Wait approximately 50 seconds. 

heater.

•

Does the LEAKRES PID indicate less than 50,000 ohms?

A31 CHECK FOR CURRENT LEAKAGE IN UPPER BATTERY

HEATER

•

With key OFF, disconnect upper battery heater C1859 and C1861. 

Yes =

REPLACE high-voltage

harness (10B700).

•

With key ON, monitor BCM PID LEAKRES. 

No =

REPLACE the upper battery

•

Wait approximately 50 seconds. 

heater.

•

Does the LEAKRES PID indicate less than 50,000 ohms?

A32 CHECK FOR CURRENT LEAKAGE IN HIGH-VOLTAGE

NEGATIVE BUS (TB-) (INSIDE TRACTION BATTERY SUPPORT

TRAY)

NOTE: The BCM active command CHARGER must be sent before the

Yes =

GO to A33 (leakage is in

BCM active command NEG MAIN is sent.

contactor box or battery

•

With key ON, enter BCM active command mode CONTACTOR

module voltage sense lines).

OUTPUT CONTROL, monitor BCM PID LKRESB-, and set the active

command CHARGER to CLOSE. 

•

Set the active command NEG MAIN to OPEN. 

No =

GO to A35.

•

Wait approximately 50 seconds. 

•

Does the LKRESB- PID indicate less than 50,000 ohms?

A33 CHECK FOR CURRENT LEAKAGE IN BATTERY MODULE

VOLTAGE SENSE LINES

(Continued)

414-03A-34

414-03A-34

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

•

With key ON, monitor BCM PID LEAK ID and note the indicated

Yes =

REPLACE high-voltage

battery module. 

harness (10B694) and/or the

high-voltage harness

(14A280) in question.

NOTE: If there is no continuity between the indicated battery module and

No =

GO to A34.

chassis ground, check for continuity between chassis ground and the

positive (+) posts of the two battery modules before and after the indicated

battery module.

•

With key OFF, disconnect BCM C1865 and C1866, and check for

continuity between the positive (+) post of the indicated battery module

and chassis ground. 

•

Is there continuity?

A34 CHECK FOR CURRENT LEAKAGE IN CONTACTOR BOX

•

With key OFF, disconnect the negative contactor box cable leading to the Yes =

REPLACE the BCM.

traction battery 250A high-voltage fuse. 

NOTE: The BCM active command CHARGER must be sent before the

No =

REPLACE the contactor

BCM active command NEG MAIN is sent.

box.

•

With key ON, enter BCM active command mode CONTACTOR

OUTPUT CONTROL, monitor BCM PID LKRESB-, and set the active

command CHARGER to CLOSE. 

•

Set the active command NEG MAIN to OPEN. 

•

Wait approximately 50 seconds. 

•

Does the LKRESB- PID indicate less than 50,000 ohms?

A35 CHECK FOR CURRENT LEAKAGE IN TRACTION BATTERY

SUPPORT TRAY, TRACTION INVERTER MODULE (TIM),

MOTOR/TRANSAXLE, OR IN THE AUXILIARY NEGATIVE BUS

FOR THE HIGH-VOLTAGE AUXILIARY LOAD  COMPONENTS

•

With key OFF, disconnect high-voltage auxiliary load in-line C1935 on

Yes =

GO to A36 (leakage is in

the traction battery support tray. 

contactor box, battery heater

harness , TIM, or traction

motor).

•

With key ON, enter the TIM active command mode CONTACTOR

No =

GO to A42 (leakage is in

OUTPUT CONTROL, monitor the BCM PID LKRESB-, and set the

the auxiliary negative bus).

active command PRECHG IN to CLOSE. 

•

Wait approximately 50 seconds. 

•

Does the LKRESB- PID indicate less than 50,000 ohms?

A36 CHECK FOR CURRENT LEAKAGE IN CONTACTOR BOX,

BATTERY HEATER HARNESS (IF EQUIPPED), TIM, OR

TRACTION MOTOR

•

With key OFF, disconnect the traction battery high-voltage two-pin

Yes =

GO to A39 (leakage is in

C3994 and connect Traction Battery High-Voltage Lockout and

battery heater harness  or

Diagnostic Tool to the traction battery high-voltage two-pin C3994M. 

contactor box).

•

With key ON, enter the TIM active command mode CONTACTOR

No =

GO to A37 (leakage is in

OUTPUT CONTROL, monitor the BCM PID LKRESB-, and set the

TIM or traction motor).

active command PRECHG IN to CLOSE. 

•

Wait approximately 50 seconds. 

•

Does the LKRESB- PID indicate less than 50,000 ohms?

A37 CHECK FOR CURRENT LEAKAGE IN TIM OR TRACTION

MOTOR

•

With key OFF, remove the Traction Battery High-Voltage Lockout and

Yes =

GO to A38 (leakage is in

Diagnostic Tool, disconnect the traction motor three-phase cables from

TIM or high-voltage cables

the TIM, and reconnect the traction battery high-voltage two-pin C3994. 

to TIM).

(Continued)

414-03A-35

414-03A-35

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

•

With key ON, monitor BCM PIDs LKRESB+ and LKRESB-. 

No =

REPLACE the

•

Wait approximately 50 seconds. 

motor/transaxle. REFER to

•

Does the LKRESB+ or LKRESB- PID indicate less than 50,000

Section 303-01.

ohms?

A38 CHECK FOR CURRENT LEAKAGE IN TIM OR

HIGH-VOLTAGE CABLES LEADING TO TIM

•

With key OFF, check the high-voltage cables to the TIM to see if the

Yes =

REPLACE high-voltage

positive (+) or negative (-) cables are touching chassis ground. 

harness (14B322).

•

Are any of the cables touching chassis ground?

No =

REPLACE the TIM. REFER

to Section 303-14.

A39 CHECK FOR CURRENT LEAKAGE IN CONTACTOR BOX OR

BATTERY HEATER HARNESS (IF EQUIPPED)

NOTE: If vehicle is not equipped with traction battery heaters, replace the

Yes =

REPLACE the contactor

contactor box.

box.

•

Remove the traction battery and connect Traction Battery High-Voltage

Lockout and Diagnostic Tool to the traction battery high-voltage two-pin

C3994M. 

•

Connect Traction Battery Low-Voltage Service Cord to traction battery

No =

GO to A40 (leakage is in

support tray in-line C1939F and in-line C1939M. 

battery heater harness).

WARNING: The traction battery contains high-voltage

components and wiring. High-voltage insulated safety gloves and face

shield must be worn when performing the following steps. Failure to

follow this warning may result in severe personal injury or  death.

•

Connect Auxiliary Interlock Tool to the high-voltage auxiliary load

in-line C1935 on the traction battery support tray and in-line interlock

C1948 (located behind the high voltage power distribution box ). 

•

With key OFF, disconnect contactor box C1864. 

•

With key ON, monitor BCM PIDs LKRESB+ and LKRESB-. 

•

Wait approximately 50 seconds. 

•

Does the LKRESB+ or LKRESB- PID indicate less than 50,000

ohms?

A40 CHECK FOR CURRENT LEAKAGE IN LOWER BATTERY

HEATER

•

With key OFF, reconnect contactor box C1864 and disconnect lower

Yes =

GO to A41.

battery heater C1862 and C1863. 

•

With key ON, monitor BCM PIDs LKRESB+ and LKRESB-. 

No =

REPLACE the lower battery

•

Wait approximately 50 seconds. 

heater.

•

Does the LKRESB+ or LKRESB- PID indicate less than 50,000

ohms?

A41 CHECK FOR CURRENT LEAKAGE IN UPPER BATTERY

HEATER

•

With key OFF, disconnect upper battery heater C1859 and C1861. 

Yes =

REPLACE high-voltage

harness (10B700).

•

With key ON, monitor BCM PIDs LKRESB+ and LKRESB-. 

No =

REPLACE the upper battery

•

Wait approximately 50 seconds. 

heater.

•

Does the LKRESB+ or LKRESB- PID indicate less than 50,000

ohms?

A42 CHECK FOR CURRENT LEAKAGE IN POWER STEERING

ASSEMBLY

•

With key OFF, reconnect high-voltage auxiliary load in-line C1935 to the Yes =

GO to A43.

traction battery support tray. 

(Continued)