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Ford Ranger EV (2001 year). Manual - part 116

414-03A-60

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST N: CHARGER MODE FEEDBACK FAULT

TEST STEP

ACTION TO TAKE

N6 CHECK CIRCUIT 3826 (W) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 38 and ground

Yes =

REPLACE the BCM.

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the W wire.

N7 CHECK CIRCUIT 3992 (BR/Y) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to N8.

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, measure the resistance of the BR/Y wire between pin 8

No =

REPAIR the BR/Y wire.

on traction battery charger C1993 and BOB pin 49.

•

Is the resistance less than 5 ohms?

N8 CHECK CIRCUIT 3992 (BR/Y) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 49 and ground

Yes =

GO to N9.

(BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the BR/Y wire.

N9 CHECK CIRCUIT 3992 (BR/Y) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

GO to N10.

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

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

No =

REPAIR the BR/Y wire.

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 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

BR/Y wire between pin 7 on BCM C1986 and BOB pin 49.

•

Is the resistance less than 5 ohms?

N10 CHECK CIRCUIT 3992 (BR/Y) (INSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, measure the resistance between BOB pin 49 and ground

Yes =

REPLACE the traction

(BOB pin 65).

battery charger.

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the BR/Y wire.

PINPOINT TEST P: DTC C1859 PRNDL INPUT #2 CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

P1 CHECK STATUS OF DIGITAL TRANSMISSION RANGE (DTR)

SENSOR SIGNAL TR2 TO BATTERY CONTROL MODULE (BCM)

NOTE: Verify the transmission range selector lever is in the park (P)

Yes =

System OK. CHECK wiring

position.

for intermittent connections.

•

With key ON, monitor BCM PID TRANSGR.

•

Does the TRANSGR PID indicate D6 PRK?

No =

GO to P2.

P2 CHECK CIRCUIT 3501 (DB) (OUTSIDE OF TRACTION

BATTERY SUPPORT TRAY) FOR OPEN

(Continued)

414-03A-61

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST P: DTC C1859 PRNDL INPUT #2 CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to P3.

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 digital transmission range (DTR) sensor

No =

REPAIR the DB wire.

C4996 and measure the resistance of the DB wire between pin 5 on DTR

sensor C4996 and BOB pin 40.

•

Is the resistance less than 5 ohms?

P3 CHECK CIRCUIT 3501 (DB) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

GO to P4.

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

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

No =

REPAIR the DB wire.

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 104-Pin Breakout Box (BOB) to traction battery support tray

in-line C1939F and in-line C1939M using Traction Battery Low-Voltage

Service Cord.

•

With key OFF, disconnect BCM C1987 and measure the resistance of the

DB wire between pin 17 on BCM C1987 and BOB pin 40.

•

Is the resistance less than 5 ohms?

P4 CHECK FOR INTERMITTENT CONCERN(S)

•

With key OFF, reconnect DTR sensor C4996 and BCM C1987.

Yes =

REPLACE the BCM.

•

Perform the on-demand self-test for the BCM.

No =

System OK. CHECK wiring

•

Does DTC C1859 PRNDL Input #2 Circuit Failure occur?

for intermittent connections.

PINPOINT TEST Q: DTC C1861 PRNDL INPUT #4 CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

Q1 CHECK STATUS OF DIGITAL TRANSMISSION RANGE (DTR)

SENSOR SIGNAL TR4 TO BATTERY CONTROL MODULE (BCM)

NOTE: Verify the transmission range selector lever is in the park (P)

Yes =

System OK. CHECK wiring

position.

for intermittent connections.

•

With key ON, monitor BCM PID TRANSGR.

•

Does the TRANSGR PID indicate D6 PRK?

No =

GO to Q2.

Q2 CHECK CIRCUIT 3503 (Y) (OUTSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

With key OFF, disconnect traction battery support tray in-line C1939 and Yes =

GO to Q3.

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 digital transmission range (DTR) sensor

No =

REPAIR the Y wire.

C4996 and measure the resistance of the Y wire between pin 6 on DTR

sensor C4996 and BOB pin 52.

•

Is the resistance less than 5 ohms?

Q3 CHECK CIRCUIT 3503 (Y) (INSIDE OF TRACTION BATTERY

SUPPORT TRAY) FOR OPEN

•

Disconnect the BOB from in-line C1939M, remove the traction battery,

Yes =

GO to Q4.

and connect Traction Battery High-Voltage Lockout and Diagnostic Tool

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

(Continued)

414-03A-62

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST Q: DTC C1861 PRNDL INPUT #4 CIRCUIT FAILURE

TEST STEP

ACTION TO TAKE

No =

REPAIR the Y wire.

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 104-Pin Breakout Box (BOB) to traction battery support tray

in-line C1939F and in-line C1939M using Traction Battery Low-Voltage

Service Cord.

•

With key OFF, disconnect BCM C1987 and measure the resistance of the

Y wire between pin 18 on BCM C1987 and BOB pin 52.

•

Is the resistance less than 5 ohms?

Q4 CHECK FOR INTERMITTENT CONCERN(S)

•

With key OFF, reconnect DTR sensor C4996 and BCM C1987.

Yes =

REPLACE the BCM.

•

Perform the on-demand self-test for the BCM.

No =

System OK. CHECK wiring

•

Does DTC C1861 PRNDL Input #4 Circuit Failure occur?

for intermittent connections.

PINPOINT TEST R: DTC C1863 EXTERNAL CHARGING FAULT

TEST STEP

ACTION TO TAKE

R1 CHECK CHARGER CORD INPUT STATUS

NOTE: Verify the power control station (PCS) charger cord is not plugged

Yes =

GO to R2.

into the charger inlet before performing this test step.

•

With key ON, monitor BCM PID CHGCORD.

•

Does the CHGCORD PID indicate IN?

No =

System OK. CHECK wiring

for intermittent connections.

R2 CHECK CHARGER INLET CONNECTOR

•

With key OFF, disconnect in-line C1969 (located on the chassis next to

Yes =

GO to R3.

the right headlamp inside the underhood compartment).

•

With key ON, monitor BCM PID CHGCORD.

No =

REPLACE the charger inlet

•

Does the CHGCORD PID indicate IN?

assembly.

R3 CHECK CHARGER CORD INPUT STATUS CIRCUIT FOR

SHORT TO GROUND

•

With key OFF, measure the resistance between the Y wire on in-line

Yes =

REPLACE the BCM.

C1969M and ground.

•

Is the resistance greater than 10,000 ohms?

No =

GO to R4.

R4 CHECK TRACTION INVERTER MODULE (TIM) FOR SHORT

TO GROUND

•

With key OFF, disconnect TIM C4998 and measure the resistance

Yes =

REPLACE the TIM. REFER

between the Y wire on in-line C1969M and ground.

to Section 303-14.

•

Is the resistance greater than 10,000 ohms?

No =

GO to R5.

R5 CHECK CIRCUIT 3404 (Y) (OUTSIDE TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

•

With key OFF, disconnect in-line C1939 on the traction battery support

Yes =

GO to R6.

tray and measure the resistance between the Y wire on in-line C1969M

and ground.

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the Y wire (outside

the traction battery support

tray).

R6 CHECK CIRCUIT 3404 (Y) (INSIDE TRACTION BATTERY

SUPPORT TRAY) FOR SHORT TO GROUND

(Continued)

414-03A-63

High Voltage/Traction Battery

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST R: DTC C1863 EXTERNAL CHARGING FAULT

TEST STEP

ACTION TO TAKE

•

Remove the traction battery and connect Traction Battery High-Voltage

Yes =

REPLACE the BCM.

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

C3994M.

•

Connect 104-Pin Breakout Box (BOB) to traction battery support tray

No =

REPAIR the Y wire (inside

in-line C1939F using Traction Battery Low-Voltage Service Cord; do not

the traction battery support

connect Traction Battery Low-Voltage Service Cord to in-line C1939M.

tray).

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 BCM C1987 and measure the resistance

between BOB pin 54 and ground (BOB pin 65).

•

Is the resistance greater than 10,000 ohms?

PINPOINT TEST S: DTC B2247 ELECTRIC VEHICLE BATTERY PACK TEMPERATURE FAULT

TEST STEP

ACTION TO TAKE

S1 CHECK STATUS OF BATTERY PACK TEMPERATURE FAULT

•

With key ON, monitor battery control module (BCM) PIDs HIGHTMP

Yes =

If PID HIGHTMP indicates

and FAN DIS.

YES, ALLOW vehicle to

cool. Monitor BCM PIDs

TMPSEN1, TMPSEN2,

TMPSEN3, and TMPSEN4

until the temperature

difference between all

temperature sensors is less

than 6

C (43

F).

If PID FAN DIS indicates

YES, ALLOW vehicle to

cool. Monitor BCM PIDs

TMPSEN1, TMPSEN2,

TMPSEN3, and TMPSEN4

until all temperature sensors

are less than 70

C (158

F).

•

Do either of the PIDs indicate YES?

No =

System OK.

PINPOINT TEST T: POWER CONTROL STATION (PCS) OPERATION VERIFICATION TEST

TEST STEP

ACTION TO TAKE

T1 CHECK POWER CONTROL STATION (PCS) SERVICE LIGHT

NOTE: If turning the power on and off or unplugging and plugging the

Yes =

GO to T2.

PCS from the charger inlet connector does not cause any of the lights on

the PCS to illuminate, the PCS has either failed or has a damaged cord.

Call the manufacturer for repair or replacement.

•

Verify the PCS is properly inserted into the vehicle’s charger inlet

connector and locked in place.

•

Check the Protection light (EVI manufacturer) or the Charge Interrupted

No =

GO to T3.

light (SCI manufacturer) on the PCS.

•

Is the Protection light (EVI manufacturer) or the Charge Interrupted

light (SCI manufacturer) illuminated?

T2 CLEAR THE FAULT AND RECHECK

(Continued)

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