Ford Ranger EV (2001 year). Manual - part 151

414-03A-200

414-03A-200

High Voltage/Traction Battery

DISASSEMBLY AND ASSEMBLY (Continued)

95. Clip the heating element connector into the

contactor box harness.

96. Connect the contactor box harness to the HVJ.

1 Position the bracket.
2 Install the screw.
3 Connect the harness to the jumper.

97. Connect the HVJs to the contactor box. The

traction battery is now energized.
1 Position the HVJs.
2 Install the bolts.

98. Install the traction battery cover.

1 Position the cover.
2 Install the 22 bolts.

X

Apply Locktite 242 (Threadlock and
Sealer) to the bolts prior to installation.

414-03B-1

414-03B-1

High Voltage/Traction Battery — Nickel Metal Hydride

Manual Table of Contents

SECTION 414-03B High Voltage/Traction Battery — Nickel

Metal Hydride

VEHICLE APPLICATION:

Ranger EV

CONTENTS

PAGE

SPECIFICATIONS ..................................................................................... 414-03B-3

DESCRIPTION AND OPERATION

High Voltage/Traction Battery ..................................................................... 414-03B-4

DIAGNOSIS AND TESTING

Auxiliary Contactor Relay Control ................................................................ 414-03B-6

Electrical Schematic ............................................................................. 414-03B-6
Inspection and Verification ...................................................................... 414-03B-6
Pinpoint Tests ..................................................................................... 414-03B-6
Symptom Chart ................................................................................... 414-03B-6

Contactor Box Current Sensors..................................................................414-03B-22

Electrical Schematic ............................................................................414-03B-22
Inspection and Verification .....................................................................414-03B-22
Pinpoint Tests ....................................................................................414-03B-22
Symptom Chart ..................................................................................414-03B-22

Current Leakage Detection .......................................................................414-03B-25

Electrical Schematic ............................................................................414-03B-25
Inspection and Verification .....................................................................414-03B-25
Pinpoint Tests ....................................................................................414-03B-26
Symptom Chart ..................................................................................414-03B-26

Emergency Power Off (EPO)/Interlock System ...............................................414-03B-18

Electrical Schematic ............................................................................414-03B-18
Inspection and Verification .....................................................................414-03B-18
Pinpoint Tests ....................................................................................414-03B-19
Symptom Chart ..................................................................................414-03B-18

Main/Precharge Contactor Relay Control ......................................................414-03B-11

Electrical Schematic ............................................................................414-03B-11
Inspection and Verification .....................................................................414-03B-11
Pinpoint Tests ....................................................................................414-03B-12
Symptom Chart ..................................................................................414-03B-11

Multiple Auxiliary Load Failure Diagnosis ......................................................414-03B-79

Electrical Schematic ............................................................................414-03B-79
Inspection and Verification .....................................................................414-03B-79
Pinpoint Tests ....................................................................................414-03B-79
Symptom Chart ..................................................................................414-03B-79

Negative Contactor Relay Control ...............................................................414-03B-16

Electrical Schematic ............................................................................414-03B-16
Inspection and Verification .....................................................................414-03B-16
Pinpoint Tests ....................................................................................414-03B-16
Symptom Chart ..................................................................................414-03B-16

Regenerative Braking..............................................................................414-03B-37

Electrical Schematic ............................................................................414-03B-37
Inspection and Verification .....................................................................414-03B-37
Pinpoint Tests ....................................................................................414-03B-38
Symptom Chart ..................................................................................414-03B-38

Traction Battery Charging/Heating System ....................................................414-03B-40

Electrical Schematic ............................................................................414-03B-41

414-03B-2

414-03B-2

High Voltage/Traction Battery — Nickel Metal Hydride

CONTENTS

PAGE

Inspection and Verification .....................................................................414-03B-42
Pinpoint Tests ....................................................................................414-03B-43
Symptom Chart ..................................................................................414-03B-42

Traction Battery Cooling/Ventilation System ...................................................414-03B-63

Electrical Schematic ............................................................................414-03B-63
Inspection and Verification .....................................................................414-03B-63
Pinpoint Tests ....................................................................................414-03B-63
Symptom Chart ..................................................................................414-03B-63

Traction Battery System ..........................................................................414-03B-69

Battery Module Diagnostic Test ...............................................................414-03B-69
Electrical Schematic ............................................................................414-03B-71
Inspection and Verification .....................................................................414-03B-71
Pinpoint Tests ....................................................................................414-03B-72
Symptom Chart ..................................................................................414-03B-71

GENERAL PROCEDURES

Battery Tray Seal ..................................................................................414-03B-92
Module Charging ...................................................................................414-03B-93
Traction Battery Module Replacement ..........................................................414-03B-80
Traction Battery Tray Repair .....................................................................414-03B-88

REMOVAL AND INSTALLATION

Battery Control Module (BCM) ...................................................................414-03B-94
Charge Inlet .........................................................................................414-03B-96
Contactor Box ......................................................................................414-03B-99
Contactor Box Fuses ............................................................................ 414-03B-103
Flow Through Blower ............................................................................ 414-03B-124
HVPDB Fuses .................................................................................... 414-03B-105
High Voltage Power Distribution Box (HVPDB) ............................................. 414-03B-107
High Voltage Wiring ............................................................................. 414-03B-113
High Voltage Wiring — Sensor Lead Harness (10B694) .................................. 414-03B-108
Independent Observer Module — (IOM) ..................................................... 414-03B-171
Recirculating Blower ............................................................................. 414-03B-126
Traction Battery .................................................................................. 414-03B-116
Traction Battery Charger ........................................................................ 414-03B-121
Traction Battery High Voltage Fuse (250A) .................................................. 414-03B-131
Traction Battery Module — Modules 1, 7, 8, 9, 25 ......................................... 414-03B-142
Traction Battery Module — Modules 10, 11, 12, 23, 24 ................................... 414-03B-149
Traction Battery Module — Modules 13-15 .................................................. 414-03B-153
Traction Battery Module — Modules 16, 19, 20, 22 ........................................ 414-03B-165
Traction Battery Module — Modules 17, 18, 21 ............................................ 414-03B-158
Traction Battery Module — Modules 2-6 ..................................................... 414-03B-136
Traction Battery Temperature Sensor ........................................................ 414-03B-133

DISASSEMBLY AND ASSEMBLY

Traction Battery .................................................................................. 414-03B-174

414-03B-3

414-03B-3

High Voltage/Traction Battery — Nickel Metal Hydride

SPECIFICATIONS

Torque Specifications

Torque Specifications

Description

Nm

Lb-Ft

Lb-In

Description

Nm

Lb-Ft

Lb-In

High-Voltage Power

12

—

107

A/C Inverter Motor

12

—

107 

Distribution Box Bolts

Control Bolts

High-Voltage Power

2

—

18

Battery Control Module

5

—

44

Distribution Box Cover

Bolts

Screws

Battery Control

5

—

44

High-Voltage Power

2

—

18

Module/Independent

Distribution Box Fuse

Observer Module

Safety Cover Screws

Bracket Bolts

Recirculating Blower

14

—

10

Battery Control Module

3

—

27

Cover Bolts

Multi-Pin Connector

Bolts

Recirculating Blower

3

—

27

Bracket Bolts

Battery Hold Down

14

10

—

Bolts

Recirculating Blower

6

—

53

Nuts

Battery Hold Down

5

—

44

Strap Bolts

Traction Battery Charger

22

16

—

Bolts

Charger Inlet Bracket

7

—

62.5

Bolts

Traction Battery Cover

17

12.5

—

Bolts

Composite Bar Bolts

5

—

44

Traction Battery

126

92.5

—

Contactor Box Screws

2

—

18

Mounting Bolts

Flow Through Blower

12

—

107

Two-Pin High-Voltage

5

—

44.5

Cover Bolts

Connector Nuts

Flow Through Blower

3

—

27

76-Pin Connector Bolt

4.8

—

43

Bracket Bolts
Flow Through Blower

6

—

53

General Specifications

Nuts

Item

Specification

Grille Screws

1.5

—

13.5

Locktite 242 (Threadlock

WSK-M2G351A5 (Type

Ground Strap Bolt

12

—

107

and Sealer)

II) 

Harness Bracket Bolt

5.4

—

48

EOAZ-19554-AA

High-Voltage Fuse Bolts

12

—

107

Nyogel 760G

WSB-M1C239-A

High-Voltage Jumper to

12

—

107

Thermal Grease

ESF-M99G123-A

Battery Module Nuts

(Continued)