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Ford Ranger EV (2001 year). Manual - part 110

414-03A-36

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect power steering assembly high-voltage C1895.

No =

REPLACE the power

•

Connect Power Steering Interlock Tool to power steering assembly

steering assembly. REFER

C1895.

to Section 211-02.

•

With key ON, monitor BCM PID LKRESB-.

•

Wait approximately 50 seconds.

•

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

A43 CHECK FOR CURRENT LEAKAGE IN A/C COMPRESSOR

•

With key OFF, disconnect A/C inverter motor controller (IMC)

Yes =

GO to A44.

high-voltage C1902 (to A/C compressor).

•

With key ON, monitor BCM PID LKRESB-.

No =

REPLACE the A/C

•

Wait approximately 50 seconds.

compressor. REFER to

•

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

Section 412-03.

A44 CHECK FOR CURRENT LEAKAGE IN A/C IMC

•

With key OFF, remove the high voltage power distribution box

Yes =

GO to A45.

(HVPDB) cover and disconnect HVPDB C1917 (to A/C IMC).

•

Reinstall the HVPDB cover.

No =

REPLACE the A/C IMC.

•

With key ON, monitor BCM PID LKRESB-.

REFER to Section 412-03.

•

Wait approximately 50 seconds.

•

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

A45 CHECK FOR CURRENT LEAKAGE IN POSITIVE

TEMPERATURE COEFFICIENT (PTC) HEATER

•

With key OFF, disconnect PTC switching module high-voltage C1912.

Yes =

GO to A46.

•

With key ON, monitor BCM PID LKRESB-.

No =

REPLACE the PTC heater.

•

Wait approximately 50 seconds.

REFER to Section 412-02.

•

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

A46 CHECK FOR CURRENT LEAKAGE IN PTC SWITCHING

MODULE

•

With key OFF, remove the HVPDB cover and disconnect HVPDB

Yes =

GO to A47.

C1920 (to PTC switching module).

•

Reinstall the HVPDB cover.

No =

REPLACE the PTC

•

With key ON, monitor BCM PID LKRESB-.

switching module. REFER

•

Wait approximately 50 seconds.

to Section 412-02.

•

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

A47 CHECK FOR CURRENT LEAKAGE IN DC/DC CONVERTER

•

With key OFF, remove the HVPDB cover and disconnect HVPDB

Yes =

GO to A48.

C1914 (to DC/DC converter).

•

Reinstall the HVPDB cover.

No =

REPLACE the DC/DC

•

With key ON, monitor BCM PID LKRESB-.

converter. REFER to Section

•

Wait approximately 50 seconds.

414-02.

•

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

A48 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 LKRESB-.

battery charger.

•

Wait approximately 50 seconds.

•

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

A49 CHECK FOR CURRENT LEAKAGE IN HIGH-VOLTAGE

POSITIVE BUS (TB+) (INSIDE TRACTION BATTERY SUPPORT

TRAY)

(Continued)

414-03A-37

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

NOTE: The ignition key must be in the OFF position when performing

Yes =

GO to A58 (leakage is in

this test step and you must wait approximately three minutes for the

contactor box or battery

results.

module voltage sense lines).

•

With key OFF, monitor BCM PID LKRESB+.

•

Wait approximately three minutes.

•

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

No =

GO to A50 (leakage is in

auxiliary load + bus, TIM,

or traction motor).

A50 CHECK FOR CURRENT LEAKAGE IN THE AUXILIARY

POSITIVE (+) BUS (INSIDE TRACTION BATTERY SUPPORT TRAY)

BETWEEN THE CONTACTOR BOX RELAYS AND TB+

•

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

Yes =

GO to A51 (leakage is in

the traction battery support tray.

TIM or traction motor)

NOTE: The active command PRECHG IN must be sent before sending the No =

GO to A53 (leakage is in

active command POS MAIN. If not, New Generation STAR (NGS) Tester

auxiliary load + bus or

will indicate UNABLE TO PERFORM TEST/FUNCTION.

traction battery charger +

•

With key ON, enter TIM active command mode CONTACTOR

bus).

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

commands PRECHG IN to CLOSE and POS MAIN to CLOSE.

•

Wait approximately 50 seconds.

•

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

A51 CHECK FOR CURRENT LEAKAGE IN TIM OR TRACTION

MOTOR

•

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

Yes =

GO to A52 (leakage is in

C3994 and the traction motor three-phase cables from the TIM, and

TIM or high-voltage cables

reconnect the traction battery high-voltage two-pin C3994.

leading to TIM).

•

With key ON, enter TIM active command mode CONTACTOR

No =

REPLACE the

OUTPUT CONTROL, monitor BCM PIDs LKRESB+ and LKRESB-,

motor/transaxle. REFER to

and set the active commands PRECHG IN to CLOSE and POS MAIN to

Section 303-01.

CLOSE.

•

Wait approximately 50 seconds.

•

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

ohms?

A52 CHECK FOR CURRENT LEAKAGE IN TIM OR

HIGH-VOLTAGE CABLES LEADING TO TIM

•

With key OFF, check the high-voltage cable 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.

A53 CHECK FOR CURRENT LEAKAGE IN AUXILIARY LOAD

POSITIVE (+) BUS OR TRACTION BATTERY CHARGER POSITIVE

(+) BUS

•

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

Yes =

GO to A60 (leakage is in

C3994 and connect Traction Battery High-Voltage Lockout and

auxiliary load + bus).

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

•

With key OFF, reconnect high-voltage auxiliary load in-line C1935 to the No =

GO to A54 (leakage is in

traction battery support tray.

traction battery charger +

•

With key ON, monitor BCM PID LKRESB+.

bus).

•

Wait approximately 50 seconds.

•

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

A54 CHECK FOR CURRENT LEAKAGE IN CONTACTOR BOX,

BATTERY HEATER HARNESS (IF EQUIPPED), TRACTION

BATTERY CHARGER, OR HVPDB

(Continued)

414-03A-38

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: DTC C1839 LEAKAGE FAULT

TEST STEP

ACTION TO TAKE

•

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

Yes =

GO to A55 (leakage is in

the traction battery support tray.

battery heater harness or

contactor box).

•

Connect Auxiliary Interlock Tool to the high-voltage auxiliary load

No =

GO to A59 (leakage is in

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

traction battery charger or

C1948 (located behind the HVPDB).

HVPDB).

•

With key OFF, disconnect interface adapter assembly (IAA) module

C1945.

•

With key ON, enter BCM active command mode CONTACTOR

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

command CHARGER to CLOSE.

•

Wait approximately 50 seconds.

•

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

A55 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 A56 (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.

•

Verify IAA module C1945 is still disconnected.

•

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?

A56 CHECK FOR CURRENT LEAKAGE IN LOWER BATTERY

HEATER

•

With key OFF, reconnect contactor box C1864 and disconnect lower

Yes =

GO to A57.

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?

A57 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?

A58 CHECK FOR CURRENT LEAKAGE IN BATTERY MODULE

VOLTAGE SENSE LINES

(Continued)

414-03A-39

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 =

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?

A59 CHECK FOR CURRENT LEAKAGE IN TRACTION BATTERY

CHARGER OR HVPDB

•

With key OFF, remove (if connected) Auxiliary Interlock Tool, and

Yes =

REPLACE the HVPDB.

reconnect in-line interlock C1948 and high-voltage auxiliary load in-line

C1935 to the traction battery support tray.

•

With key OFF, remove the high-voltage power distribution box

No =

REPLACE the traction

(HVPDB) cover and disconnect HVPDB C1923 (to traction battery

battery charger.

charger).

•

Reinstall the HVPDB cover.

•

With key ON, enter BCM active command mode CONTACTOR

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

command CHARGER to CLOSE.

•

Wait approximately 50 seconds.

•

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

A60 CHECK FOR CURRENT LEAKAGE IN AUXILIARY LOAD

POSITIVE (+) BUS, CONTACTOR BOX, OR HVPDB

•

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

Yes =

REPLACE the contactor

the traction battery support tray.

box.

•

Connect Auxiliary Interlock Tool to the high-voltage auxiliary load

No =

GO to A61 (leakage is in

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

auxiliary load + bus or

C1948 (located behind the HVPDB).

HVPDB).

•

With key ON, monitor BCM PID LKRESB+.

•

Wait approximately 50 seconds.

•

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

A61 CHECK FOR CURRENT LEAKAGE IN POWER STEERING

ASSEMBLY

•

With key OFF, remove Auxiliary Interlock Tool and reconnect in-line

Yes =

GO to A62.

interlock C1948 and high-voltage auxiliary load in-line C1935 to the

traction battery support tray.

•

With key OFF, disconnect power steering assembly high-voltage C1895.

No =

REPLACE the power

•

Connect Power Steering Interlock Tool to power steering assembly

steering assembly. REFER

C1895.

to Section 211-02.

•

With key ON, monitor BCM PID LKRESB+.

•

Wait approximately 50 seconds.

•

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

A62 CHECK FOR CURRENT LEAKAGE IN A/C COMPRESSOR

•

With key OFF, disconnect A/C inverter motor controller (IMC)

Yes =

GO to A63.

high-voltage C1902 (to A/C compressor).

•

With key ON, monitor BCM PID LKRESB+.

No =

REPLACE the A/C

•

Wait approximately 50 seconds.

compressor. REFER to

•

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

Section 412-03.

(Continued)

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