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Ford Ranger Electric Vehicle, Owner'S Manual

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Ford Ranger Electric Vehicle Owner'S Manual Download Page 51

If you use a brake fluid that is not DOT 3, you will cause
permanent damage to your brakes.

AUXILIARY BATTERY

Your vehicle is equipped with a sealed maintenance-free battery.

For longer, trouble-free operation, keep the top of the battery clean and
dry. Also, make certain the battery cables are always tightly fastened to
the battery terminals.

If you see any corrosion on the battery or terminals, remove the cables
from the terminal(s) and clean with a wire brush. You can neutralize the
acid solution with a solution of baking soda and water. Reinstall the
cables when you are done cleaning them, and apply a small quantity of
grease to the top of each terminal to help prevent corrosion.

TRACTION BATTERY PACK ASSEMBLY

No regular maintenance, other than regular charging is required.

The traction battery pack assembly is located underneath the vehicle
between the wheel base and frame rails. The battery pack assembly
contains wiring, a fan for ventilation and cooling, and a control system.
The standard lead acid battery pack contains 39 eight-volt batteries and
optional heater for cold weather climates. The optional nickel metal
hydride battery pack contains 25 twelve-volt batteries, and an additional
cooling system exhaust fan. The traction battery provides energy to
propel the vehicle and also maintains energy for accessory functions. The
battery pack assembly is a 2,000–pound unit lead-acid type or
1,300–pound unit nickel metal hydride type.

Never position a jack or hoist underneath the traction battery
pack. Doing so may result in damage to your vehicle.

This battery pack should only be serviced by an authorized
electric vehicle technician. Improper handling can result in

personal injury or death.

Maintenance and care

51

Summary of Contents for Ranger Electric Vehicle

Page 1: ... specifications 55 Accessories 57 Index 62 All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company Copyright r 1999 Ford Motor Company Table of contents 1 ...

Page 2: ...r Ranger owner s manual covers common systems This Owner s Guide Supplement contains the information specific to the Ranger Electric Vehicle ICONS The warning icon Read the following section on Warnings for a full explanation WARNINGS Provide information which may reduce the risk of personal injury or prevent possible damage to others your vehicle and its equipment INFORMATION ABOUT THIS GUIDE The...

Page 3: ...inates when the key is turned to the ON or START position while the vehicle is connected to the power control station PCS If the lamp flashes when the key is in the ON position there is a vehicle malfunction and the drive battery cannot be charged Confirm the vehicle is in park and the PCS cord is properly attached If the vehicle is in P Park and the PCS cord is properly connected and the charging...

Page 4: ...e indicator will flash when the battery reaches a 0 state of charge Power limit lamp The power limit lamp indicates a system fault or reduced vehicle performance to conserve remaining drive battery power As the vehicle nears complete discharge the power limit lamp will illuminate High voltage accessories A C and heat will be disabled You will notice a decrease in vehicle performance and you must r...

Page 5: ... recommended for urban traffic and will improve range by increasing the effects of regenerative braking and limiting top speed to 105 km h 65 mph The D Drive position is recommended for highway operation at steady speeds Power reset lamp The power reset lamp indicates that the inertia shutoff switch has been tripped and all high voltage power has been disconnected and power has been limited to the...

Page 6: ...Ford EV Dealer RANGER EV FOR MEXICO AND CANADA The instrument cluster on the Ranger EV for Mexico and Canada will be equipped with metric gauges All gauges operate as described below GAUGES ECON F E ON OFF H C 20 10 30 40 50 60 70 80 0 0 0 0 0 0 20 40 60 80 100 120 MPH km h 0 2 4 6 DISTANCE TO EMPTY km MILES 0 0 0 0 50 100 Instrumentation 6 ...

Page 7: ...economy gauge provides information about the vehicle s energy usage Economical usage of the vehicle is indicated by the gauge reading near the plus side and will maximize the vehicle s range Distance to empty gauge The distance to empty gauge estimates the remaining distance the vehicle can travel before requiring a drive battery recharge The gauge reading is based on remaining drive battery energ...

Page 8: ...conventional temperature gauges it does not start cold and move to normal The gauge sits at normal and moves to hot or cold when there is a problem If the gauge moves to H Hot vehicle performance will be limited until the coolant temperature or drive battery temperature returns to normal The vehicle should be stopped and plugged into a PCS until it has cooled down The vehicle may need servicing If...

Page 9: ...the desired interior temperature of the vehicle To turn your air conditioner or heater system on select any position except OFF This will turn the fan on and allows air flow into the vehicle To turn your air conditioner or heater system off select OFF This will turn the fan off and stop airflow from coming into the vehicle Recirculation switch The recirculation switch is located at the center of t...

Page 10: ...Four fan speed positions are available and are indicated by dots beside the control knob The largest dot is the high speed position Temperature control knob The temperature control knob is the rotating knob located at the center of the control with tapered red and blue bands surrounding most of the knob The wide red part of the band full right is the warm temperature area The wide blue part of the...

Page 11: ...elow the outside temperature regardless of the temperature setting panel and floor Select to distribute outside air or recirculated air through the instrument panel registers and to the floor ducts at the same time The air may be heated based on temperature selection The air cannot be cooled below the outside temperature regardless of the temperature setting floor Select to distribute outside air ...

Page 12: ...prevents your windshield from fogging After a few minutes of operation you may select another function Remove any snow ice or leaves from the air intake area of your heater system that could block the air intake The intake area is located at the bottom of the windshield If temperatures below 18 C 0 F select recirculation before driving This will help warm the vehicle interior and minimize degraded...

Page 13: ...rifying the presence of an equipment ground The PCS supplies the power commanded by the vehicle These stations will be in private locations for example residential or fleet garages or in public sites for example shopping malls restaurants parking lots and so on The PCS uses a 40 amp 240 volt AC electrical supply The customer is responsible for ordering the PCS and getting it installed Your Ford De...

Page 14: ...he front grille The door is hinged toward the right headlamp and opens in the same manner as the fuel filler door 5 Pick up the PCS connector and position it so that the release button is facing upwards 6 Align the PCS connector to the charge inlet fully insert the connector and make sure that the tabs on both sides of the connector engage the slots in the inlet 7 Gently push the connector down to...

Page 15: ...rge times can increase to 10 hours or more for warmer or cooler batteries In sever temperature conditions battery temperature less than 5 C 41 F or greater than 60 C 140 F for the lead acid type and less than 25 C 13 F or greater than 45 C 113 F for the nickel metal hydride type the vehicle will not charge at all The PCS may be malfunctioning The battery pack may be out of electrical balance The v...

Page 16: ...he vehicle Nickel metal hydride traction battery At 25 C 77 F the drive battery can be charged to 80 capacity in about five to six hours 100 capacity requires approximately six to eight hours Completely charging the drive battery is important to ensure maximum range and battery life Ford recommended practice is that the vehicle should always be left on plug when not in use and be allowed to fully ...

Page 17: ...sp the charge connector and press the button in the center of the handle 3 Pull the charge connector upward and pull it out of the inlet 4 Close the charge inlet access door in the front grille 5 Return the connector and cable to their proper location Charging 17 ...

Page 18: ... cable and connector are undamaged reconnect the PCS to the vehicle inlet Is the charge interrupt light still illuminated or flashing Consult your authorized Ranger EV dealer to determine possible vehicle fault 4 Is the service light illuminated If yes Disconnect the charge connector vehicle inlet Turn off the power to your PCS at the service or disconnect panel Turning off the power may allow the...

Page 19: ...er back on and reconnect the PCS to the vehicle Is the service light still illuminated If so call the PCS manufacturer for repair or replacement Are the ready or charging lights illuminated If yes your PCS is operating correctly Consult your authorized Ranger EV dealer to determine vehicle fault If turning the PCS power on and off or unplugging and plugging the charge connector in the vehicle inle...

Page 20: ...s in optimum range and battery life Equalization is automatically performed approximately every three weeks The fuel gauge will indicate if insufficient charge time has been allowed The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven Battery pack heating cooling system nickel metal hydride type The battery pack assembly contains 25 twelve volt batteries wiring ...

Page 21: ...es in the ability to deliver energy This results in optimum range and battery life Equalization is automatically performed approximately every three weeks The fuel gauge will indicate if insufficient charge time has been allowed The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven Partial recharges A partial recharge is charging the battery pack to less than 100...

Page 22: ...ction battery 4 ON warning lights momentarily illuminated Key position when driving 5 START powers up the motor and turns the Motor Enable Gauge to the ON position Powers up all high voltage power from the drive battery STARTING THE RANGER ELECTRIC VEHICLE 1 If connected disconnect the PCS plug from the charge inlet and close the charge inlet access door The car will not start until the plug is re...

Page 23: ...er usage refer to the seating and safety restraints chapter in the Ranger owner guide 1 Make sure the parking brake is set 2 Make sure the gearshift lever is in P Park 3 Turn the key to the START position and release The Motor Enabled gauge will point to the ON position indicating the vehicle is on ON OFF Starting 23 ...

Page 24: ...y State of Charge gauge to confirm that the drive battery is charged sufficiently for the planned trip 5 Pull the release lever to release the parking brake The Ranger electric vehicle is now ready to be driven F E Starting 24 ...

Page 25: ...braking is limited to avoid overcharging Regenerative braking does not take the place of the standard friction brakes it only assists them Regenerative braking has also been designed to interact with the anti lock brake system ABS Regenerative braking is disabled when the ABS is activated or the battery is fully charged ANTI LOCK BRAKE SYSTEM ABS A noise from the hydraulic pump motor and pulsation...

Page 26: ...t power steering The power steering uses energy from the battery to help steer your vehicle If the amount of effort needed to steer your vehicle changes at a constant speed have the power steering system checked If the power steering system breaks down or if the vehicle is turned off you can steer the vehicle manually but it takes more effort Avoid holding the steering wheel to the extreme right o...

Page 27: ...e braking is applied in reverse too at a level similar to the D Drive gear When the drive battery is almost fully charged the amount of regenerative braking is limited to avoid overcharging N Neutral With the gearshift lever in N Neutral the vehicle can be started and is free to roll Hold the brake pedal down while in this gear to prevent movement D Drive With the gearshift lever in D Drive the ve...

Page 28: ...he battery s remaining charge like a fuel gauge does on a conventional gasoline powered vehicle When the gauge approaches the Empty E position the vehicle should be connected to a PCS before the drive battery is completely drained If the Ranger is driven while the Battery State of Charge Gauge reads E there are two warning lights that illuminate in stages to alert the driver of the vehicle s condi...

Page 29: ... This recharges the traction battery and slows the vehicle In effect once the accelerator pedal is released the motor changes from an energy user to an energy producer When the battery is fully charged regenerative braking is eliminated to prevent overcharging of the traction batteries As the traction batteries state of charge begins to diminish with driving usage the amount of regenerative brakin...

Page 30: ...s Use the E Economy gear Keep the tires properly inflated to 350 kpa 50 psi Keep payloads as light as possible Avoid frequent full throttle usage Maintain a steady speed while driving Cruise at moderate speeds Select routes that minimize the number of starts and stops encountered Limit the use of max cooling or heating of the vehicle interior Avoid hard acceleration and deceleration Leave the tonn...

Page 31: ...ivated If there is no damage to the vehicle reset the switch to reactivate the high voltage power systems and restart the vehicle The inertia shutoff switch is located by the passenger kick panel If there is damage to the vehicle have the vehicle towed to an authorized Ford EV repair facility Roadside emergencies 31 ...

Page 32: ...strument panel facing the driver side door Pull the panel cover outward to access the fuse To remove a fuse use the fuse puller provided on the fuse panel cover 1 2 3 4 5 6 7 8 9 1 0 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 29 30 31 32 35 36 33 34 27 28 Roadside emergencies 32 ...

Page 33: ...ion inverter module TIM 12 Not used 13 10 Brake on off BOO relay brake on off BOO switch 14 10 ABS 15 7 5 Main light switch instrument cluster 16 30 Windshield wiper motor windshield wiper relays 17 10 Cigar lighter 18 Not used 19 15 Steering wheel sensor interface adapter assembly IAA module contactor box battery controller module BCM power steering controller assembly 20 10 Radio generic electro...

Page 34: ...adio 30 Not used 31 Not used 32 Not used 33 15 Highbeam headlamp 34 Not used 35 Not used 36 Not used LOW VOLTAGE POWER DISTRIBUTION BOX The power distribution box is located in the underhood compartment near the auxiliary battery The power distributon box contains high current fuses that protect your vehicle s main electrical systems from overloads Always disconnect the battery before servicing hi...

Page 35: ...es 1 5 9 13 17 21 25 and 29 5 MAXI 50 Ignition switch 6 MINI 10 Interface adapter assembly IAA module 7 MINI 10 Contactor box 8 MINI 15 Inertia switch contactor box 9 MINI 10 Driver air bag module 10 MINI 20 Vacuum relay vacuum pump 11 MINI 10 Battery controller module BCM 12 MINI 10 Horn relay horn switch horn 13 MINI 30 Power point 14 MINI 15 Cooling venting blower relay battery control module B...

Page 36: ...ant pump 21 MAXI 20 Oil pump relay transaxle oil pump 22 MAXI 30 Headlamps multi function switch 23 Not used 24 Not used 25 MINI 5 ABS active signal 26 J50 Windshield wiper park relay 27 J50 Brake on off BOO relay 28 J50 Windshield wiper hi low relay 29 Not used 30 Not used 31 Not used 32 150 Coolant pump relay 33 Not used 34 J50 Vacuum pump relay 35 J50 Horn relay 36 J50 Windshield washer pump re...

Page 37: ...cation of the spare tire and tools The spare tire and tools for your vehicle are stowed in the following locations Tool Location Spare tire In the pickup bed Jack jack handle wheel nut wrench Behind the passenger seat Removing the spare tire 1 Position or remove the tonneau cover to gain access to the spare tire 2 Fold the passenger seat back fully forward 3 Remove the jack handle and lug wrench f...

Page 38: ...ty lock and cable 7 Remove the retaining bolt and retainer If you cannot remove the bolt by hand remove it using the jack handle 8 Remove the spare tire Tire changing procedure 1 Park on a level surface activate hazard flashers and place gearshift lever in P Park Roadside emergencies 38 ...

Page 39: ... nut one half turn counterclockwise but do not remove them until the wheel is raised off the ground 6 Position the jack as shown below and turn the jack handle clockwise until the tire is a maximum of 25 mm 1 in off the ground Never position a jack or hoist underneath the traction battery pack Doing so may result in damage to your vehicle Roadside emergencies 39 ...

Page 40: ...b Do not fully tighten the lug nuts until the wheel has been lowered to the ground 9 Lower the wheel by turning the jack handle counterclockwise 10 Install the wheel lug nuts with the lug wrench 11 Secure the flat tire 12 Install the tonneau cover 13 Stow the jack and lug wrench Make sure the jack is snug to the wire clamp by raising the jack until tight 14 Unblock the wheels 1 2 3 4 5 Roadside em...

Page 41: ...volt power supply you can damage your electrical components 2 Do not disconnect the battery of the disabled vehicle as this could damage the vehicle s electrical system 3 Park the booster vehicle close to the hood of the disabled vehicle making sure they do not touch Set the parking brake on both vehicles and stay clear of moving parts 4 Check all battery terminals and remove any excessive corrosi...

Page 42: ... that surround the battery Starting your vehicle 1 Turn the ignition ON and start the booster vehicle 2 Turn the ignition ON and start the vehicle with the discharged battery 3 Once the vehicle has been started allow the vehicle to run for approximately 5 minutes before disconnecting the leads to insure the auxiliary battery is completely charged back up The gases around the battery can explode if...

Page 43: ...verse order Take the cable off the metallic surface 1 first followed by the cable on the negative booster battery terminal 2 2 Remove the cable from the positive terminal of the booster battery 3 and then the discharged battery 4 1 3 2 4 Roadside emergencies 43 ...

Page 44: ...owing Rear wheel lift towing Flatbed transporting If you need to have your vehicle towed contact a profession towing service or your roadside assistance center Do not tow with slingbelt equipment Ford Motor Company has not developed or approved a slingbelt towing procedure When calling for a tow truck tell the operator what kind of vehicle you have Roadside emergencies 44 ...

Page 45: ...Rotate tires 5000 miles MAX x x x x x x x x x x Inspect disc brake system lubricate caliper slides x x x x x x x x x x Climate control filter More frequent changes may be necessary in dusty and dirty conditions x x x x x x x x x x Replace vacuum pump 2A451 x x Inspect and lubricate front wheel bearings x x x Inspect parking brake system x x x Inspect cooling system x x x x x x x x x x Maintenance ...

Page 46: ...pect power steering fluid x x x x x x x x x x Inspect brake fluid x x x x x x x x x x Replace transaxle fluid every 3 years or 36 000 miles whichever comes first HOW TO OPEN THE HOOD 1 Inside the vehicle pull the hood release handle located under the bottom right of the steering wheel Maintenance and care 46 ...

Page 47: ...rvoir 3 Power steering fluid reservoir 4 Auxiliary battery 5 Brake fluid reservoir The underhood compartment contains many high voltage components and wiring Do not attempt to service any of these components Service must be performed by qualified personnel only The high voltage wiring is covered in orange convolute for easy identification Underhood high voltage components have warning labels with ...

Page 48: ...electrical components and the electric drive motor Check the level of the coolant in the reservoir at least once a month Be sure to read and understand Precautions in this chapter when servicing your vehicle If the coolant has not been checked for a long period of time the coolant reservoir may eventually empty If this occurs add coolant to the coolant reservoir Automotive fluids are not interchan...

Page 49: ...hicle Do not add conventional green coolant or recycled coolant to your vehicle if originally equipped with orange coolant The use of an improper coolant may void your warranty of your vehicle s cooling system Always dispose of used automotive fluids in a responsible manner Follow your community s regulations and standards for recycling and disposing of automotive fluids Coolant refill capacity Ha...

Page 50: ...Do not add fluid above the MAX level 5 If the fluid is low add fluid BRAKE FLUID Checking and adding brake fluid Brake fluid should be checked and refilled as needed at least once each year 1 Check the reservoir cap before removal to prevent dirt or water from entering the reservoir 2 Visually inspect the fluid level 3 If necessary add brake fluid until the level reaches MAX Do not fill above this...

Page 51: ...ng is required The traction battery pack assembly is located underneath the vehicle between the wheel base and frame rails The battery pack assembly contains wiring a fan for ventilation and cooling and a control system The standard lead acid battery pack contains 39 eight volt batteries and optional heater for cold weather climates The optional nickel metal hydride battery pack contains 25 twelve...

Page 52: ...illar every 30 days Note Driving the Electric Ranger with tires below recommended inflation pressure will significantly affect range between charges Tire pressure will increase decrease with every 10 F change in outside air temperature decreasing with temperature decreases Tire rotation Because your vehicle s tires perform different jobs they often wear differently To make sure your tires wear eve...

Page 53: ...ly the same type of tire should be used as a replacement When replacing full size tires never mix radial bias belted or bias type tires Use only the tire sizes that are listed on the tire pressure decal Make sure that all tires are the same size speed rating and load carrying capacity Use only the tire combinations recommended on the decal If you do not follow these precautions your vehicle may no...

Page 54: ...l Terrain etc as originally offered by Ford Failure to follow these precautions may adversely affect the handling of the vehicle and make it easier to lose control and roll over SNOW TIRES AND CHAINS The use of snow tires and chains is strongly discouraged on the Ranger Electric Vehicle Maintenance and care 54 ...

Page 55: ...quarts Brake fluid Ford high performance DOT 3 motor vehicle brake fluid All Fill to line in reservoir Power steering fluid Motorcraft MERCONt ATF All Fill to line in reservoir Coolant Ford extended life engine coolant New for 1999 model year All Fill to line in reservoir Windshield washer fluid Ultra clear windshield All Fill to line in reservoir Capacities and specifications 55 ...

Page 56: ...nt Ford extended life engine coolant New for 1999 model year F6AZ 19544 AA WSS M97B44 D Windshield washer fluid Ultra clear windshield concentrate C9AZ 19550 AC or BC ESR M17P5 A Transaxle fluid Tribolube L 6 Pro Gear 21 F8AZ 19M544 A MOTOR DATA Motor Data Horsepower 67 kw 90 hp Torque 190 Nm 140 lb ft Traction battery modules Standard Lead acid type 312 volts 39 8 volts each Optional Nickel metal...

Page 57: ...ronic systems mobile radio and telephone equipment must be properly installed by trained personnel with experience in this area The following guidelines should be observed The antenna cable should be a fully shielded coaxial cable and kept as short as practical Avoid routing the antenna cable in parallel with vehicle wiring over long distances Carefully match the antenna and cable to the radio to ...

Page 58: ...he 10 gauge circuit pigtail that is taped into the harness at the auxiliary battery positive terminal Route and secure the wire as close as possible to the vehicle body from the battery to the transceiver Pass the wire from the engine to passengers compartment through a hole in the accelerator s cable hole plug Use care when routing this wire to avoid chafing or pinching Seal the hole to prevent m...

Page 59: ...unt any transceiver microphones speakers or any other item in the deployment path of the airbag system Before using screws to mount the transceiver equipment be sure to check for vehicle wiring under the carpet or behind the instrument panel which could be pinched cut or otherwise damaged Antenna location and installation Permanently installed sheet metal mount antennas are preferable over magneti...

Page 60: ...r deterioration to maintain proper operation with your vehicle Antenna Cable Routing Always use a high quality one piece coaxial cable at least 95 shield coverage Connector quality and termination techniques are just as important The ARRL handbook provides excellent guidelines for terminating coaxial cables The antenna cable should be treated in the same way as the control and power cables Avoid s...

Page 61: ...line Mismatched antenna or high SWR Power feeds not connected directly to the vehicle battery Power feed routing locate as far as possible away from vehicle electronics and wiring If any vehicle radio interaction problems exist after following these guidelines contact your radio equipment manufacturer for additional assistance Additional sources of information The American Radio Relay League Inc T...

Page 62: ...s 6 battery state of charge gauge 7 distance to empty gauge 7 economy gauge 7 motor enabled gauge 8 Hood 46 Jump starting your vehicle 41 Lights warning and indicator 3 anti lock brakes ABS 5 auxiliary battery 4 brake 3 charging system 3 econ mode 5 electrical hazard warning 4 low fuel 4 oil pressure 3 power limit 4 power reset 5 service indicator 3 Motorcraft parts 55 Parts see Motorcraft parts 5...

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