Ford Ranger EV (2001 year). Manual - part 161

 

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Ford Ranger EV (2001 year). Manual - part 161

 

 

414-03B-40

414-03B-40

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: DTC C1849 MASTER CYLINDER PRESSURE OUT OF RANGE

TEST STEP

ACTION TO TAKE

With key ON, measure the resistance between BOB pin B22 and ground

Yes =

REPLACE the master

(BOB pin A29). 

cylinder brake pressure

sensor.

Is the resistance greater than 10,000 ohms?

No =

REPAIR the R/W wire.

B4 CHECK TIM VOLTAGE REFERENCE TO MASTER CYLINDER

BRAKE PRESSURE SENSOR

With key OFF, disconnect master cylinder brake pressure sensor C1940. 

Yes =

REPLACE the master

cylinder brake pressure

sensor.

With key ON, measure the voltage between the R wire on master

No =

GO to B5.

cylinder brake pressure sensor C1940 and ground. 

Is the voltage greater than 4.8 volts?

B5 CHECK CIRCUIT 3603 (R) FOR OPEN

Connect 104-Pin Breakout Box (BOB) to TIM C4998, C4999 using the

Yes =

GO to B6.

BCM/TIM BOB Adapter Cable and Overlay; leave the TIM

disconnected. 

With key OFF, measure the resistance of the R wire between master

No =

REPAIR the R wire.

cylinder brake pressure sensor C1940 and BOB pin B23. 

Is the resistance less than 5 ohms?

B6 CHECK CIRCUIT 3603 (R) FOR SHORT TO GROUND

With key OFF, measure the resistance between BOB pin B23 and ground Yes =

REPLACE the TIM. REFER

(BOB pin A29). 

to Section 303-14.

Is the resistance greater than 10,000 ohms?

No =

REPAIR the R wire.

Traction Battery Charging/Heating
System

Diagnostic Trouble Code (DTC) Definition

The following DTCs relate to the traction battery
charging/heating system:

DTC C1836 Battery Temperature Out of Range 
— The battery control module (BCM) uses four

temperature sensors to monitor the temperature
of the traction battery. The normal range of
the temperature sensors is between 430 and
280,000 ohms. The BCM sets DTC C1836 if
it detects any of the temperature sensor
readings out of range. The BCM uses PIDs to
indicate the temperature sensor that is out of
range. 

414-03B-41

414-03B-41

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

DTC C1838 Charging System Fault 

signal indicates  zero. 

— The battery control module (BCM) sets DTC

— A charger mode fault occurs if the BCM

C1838 when a failure occurs in the traction

detects the charger mode signal is not being

battery charging system. The BCM uses PIDs

pulled up to auxiliary battery voltage by the

to indicate the charging system failure that

charger. If this occurs, the BCM does not

occurred. The possible failures are: 

enable the charger. 

— A charger charging after being disabled fault

— An independent observer module (IOM) to

occurs if the charger charging signal or the

BCM diagnostic signal stuck low fault occurs

auxiliary current sensor indicates that the

when the IOM to BCM diagnostic input is

charger is still outputting significant current

shorted to ground or if the BCM to IOM

several seconds after the BCM has

diagnostic output is open. 

commanded the charger off. 

— An independent observer module (IOM) to

— A charger overtemperature fault occurs if the

BCM diagnostic signal stuck high fault occurs

charger fault signal is asserted and the charger

if any of the following occur: IOM is

ready signal is deasserted during a charge

disconnected, the IOM to BCM diagnostic

cycle. 

input is open, the BCM to IOM diagnostic
output is shorted to ground, or there  is an

— A charger latchup fault occurs if the charger

IOM diagnostic fault due to an IOM battery

fault signal and charger ready signal are

temperature sensor is out of range or the IOM

asserted during a charge cycle. 

has detected a high/rapid change in battery

— A charger cycling fault occurs if the charger is

temperature. 

cycled on and off several times within a short

DTC C1859 PRNDL Input #2 Circuit Failure 

period of time due to a reoccurring fault
condition. If this occurs, the BCM disables the

— The battery control module (BCM) sets DTC

charger. 

C1859 during the BCM on-demand self test if
it detects the PRNDE TR2 signal is not

— A charger undercurrent fault occurs if the

grounded. An open or short in the TR2 signal

BCM commands maximum power output from

wire or the gear selector not in the PARK

the charger and little or no current is detected

position during the on-demand self-test will

at the auxiliary current sensor for an extended

cause DTC C1859. 

period of time. There are several potential
causes for this  fault. 

DTC C1861 PRNDL Input #4 Circuit Failure 

— A charger overcurrent fault occurs if the BCM

— The battery control module (BCM) sets DTC

commands zero power output from the charger

C1861 during the BCM on-demand self test if

and significant current is detected at the

it detects the PRNDE TR4 signal is not

auxiliary current sensor for an extended period

grounded. An open or short in the TR4 signal

of time. 

wire or the gear selector not in the PARK
position during the on-demand self-test will

— A charger overvoltage fault occurs if the BCM

cause DTC C1861. 

detects the traction battery voltage to be
greater than 385 volts during a charge cycle.

DTC C1863 External Charging Fault 

If this occurs, the BCM disables the charger. 

— The battery control module (BCM) sets DTC

— A charger over amp-hours fault occurs the

C1863 if the on-plug circuit indicates the

BCM detects that more than 105 amp-hours of

vehicle is plugged into a power control station

current have been put into the traction battery

(PCS) and the traction inverter module (TIM)

during the charge cycle. If this occurs, the

indicates the vehicle is traveling faster than 15

BCM disables the charger. 

km/h (9.4 mph). 

— A charger line capacity fault occurs if the

Electrical Schematic

BCM commands maximum power output from

Refer to Electrical and Vacuum Troubleshooting

the charger and little or no current is detected

Manual, Cell 18, Traction Battery Charging/Heating

at the auxiliary current sensor for an extended
period of time and the charger line capacity

System for schematic and connector information.

414-03B-42

414-03B-42

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

Inspection and Verification

Refer to 

 Section 100-07

.

Symptom Chart

Symptom Chart

Condition

Possible Sources

Action

DTC C1836 Battery

Circuit(s). 

GO to Pinpoint Test A. 

Temperature Out of Range 

Battery temperature sensor. 

Battery control module

(BCM). 

DTC C1838 Charging System

Charger charging after being

GO to Pinpoint Test C. 

Fault 

disabled fault. 

Charger over-temperature

fault. 

Charger latchup fault. 

Charger cycling fault. 

Charger under current fault. 

Charger over current fault. 

Charger over voltage fault. 

Charger over amp-hours fault.

Charger line capacity fault. 

Charger mode feedback fault.

IOM to BCM diagnostic input

stuck high fault. 

IOM to BCM diagnostic input

stuck low fault. 

Charger Charging After Being

Contactor box. 

GO to Pinpoint Test D. 

Disabled Fault 

Circuit(s). 

Traction battery charger. 

Battery control module

(BCM). 

Charger Latchup Fault 

Circuit(s). 

GO to Pinpoint Test F. 

Traction battery charger. 

Battery control module

(BCM). 

Charger Cycling Fault 

Current leakage condition. 

GO to Pinpoint Test G. 

Traction battery charger. 

Charger Under Current Fault 

High voltage power

GO to Pinpoint Test H. 

distribution box (HVPDB). 

High-voltage harness

(14B326). 

Contactor box high-voltage

fuse. 

Contactor box. 

Battery control module

(BCM). 

Circuit(s). 

Traction battery charger. 

Charger Over Current Fault 

Traction battery charger. 

GO to Pinpoint Test J. 

Contactor box. 

Battery control module

(BCM). 

414-03B-43

414-03B-43

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

Charger Over Voltage Fault 

High-voltage harness

GO to Pinpoint Test K. 

(14A280-NC). 

High-voltage harness

(14A280-AB). 

Battery control module

(BCM). 

Charger Over Amp-Hours

Traction battery module(s). 

GO to Pinpoint Test L. 

Fault 

Traction battery charger. 

Charger Line Capacity Fault 

Power control station (PCS). 

GO to Pinpoint Test M. 

Traction battery charger. 

Charger Mode Feedback Fault

Circuit(s). 

GO to Pinpoint Test N. 

Traction battery charger. 

Battery control module

(BCM). 

IOM to BCM Diagnostic

Circuit(s). 

GO to Pinpoint Test P. 

Input Stuck High Fault 

IOM battery temperature

sensors. 

Independent observer module

(IOM). 

Battery module(s). 

Battery control module

(BCM). 

IOM to BCM Diagnostic

Circuit(s). 

GO to Pinpoint Test Q. 

Input Stuck Low Fault 

Independent observer module

(IOM). 

DTC C1859 PRNDL Input #2

Circuit(s). 

GO to Pinpoint Test R. 

Circuit Failure 

Battery control module

(BCM). 

DTC C1861 PRNDL Input #4

Circuit(s). 

GO to Pinpoint Test S. 

Circuit Failure 

Battery control module

(BCM). 

DTC C1863 External

Circuit(s). 

GO to Pinpoint Test T. 

Charging Fault 

Charger inlet assembly. 

Battery control module

(BCM). 

Power Control Station (PCS)

Improper PCS connection to

GO to Pinpoint Test U.

Operation Verification Test 

charger inlet. 

PCS. 

Vehicle charging system

failure. 

Special Tool(s)

Pinpoint Tests

Traction Battery High-Voltage Service Cord 418-F218

Special Tool(s)

Traction Battery Low-Voltage Service Cord 418-F219

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

Traction Battery High-Voltage Lockout and Diagnostic

equivalent 

Tool 418-F207

BCM/TIM Breakout Box (BOB) Adapter Cable

High-Voltage Insulated Safety Gloves 100-F036 or

418-F212

equivalent

BCM/TIM Breakout Box (BOB) Overlay 418-F220

Face Shield 100-F035 or equivalent

(Continued)

 

 

 

 

 

 

 

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