Ford Ranger EV (2001 year). Instruction - page 1
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100-00-2
100-00-2
General Information
DESCRIPTION AND OPERATION
WARNING: Batteries normally produce
General Information
explosive gases which can cause personal injury
or death. Do not allow flames, sparks or lighted
Format and Usage
substances to come near the batteries. When
The Electric Ranger is a combination of
charging or working near the batteries, always
conventional and unique electric vehicle (EV)
shield your face and protect your eyes. Always
components and systems. The following procedures
provide adequate ventilation.
are designed to supplement the standard Ranger
Workshop Manual for the EV specific components.
Electric Shock
This supplement is designed to be the primary
WARNING: The battery pack assembly
manual when working on the EV. All of the EV
can deliver in excess of 312 volts of DC power.
specific components are covered in this supplement.
Improper handling of the battery pack can result
If a procedure is not outlined in this supplement,
in injury or fatality. Only authorized personnel
refer to the standard Ranger Workshop Manual.
trained to work with battery pack components
are permitted to handle the batteries.
Because the EV uses an electric motor rather than a
gasoline engine, there are different and unique
There are two electrical systems on the EV. A high
warnings and cautions. The procedures outlined are
voltage system is used to power the motor/transaxle
designed to encourage safe repair of the vehicle and
and many auxiliary loads such as the A/C system,
should be carefully followed. The EV uses many
power steering pump, heater and certain control
electronic components that can be easily damaged if
components. High voltage wiring is identified by its
the procedures are not followed.
orange color or orange wrapping on the harness.
Components that have larger connectors, orange
Acids
coverings on the wires, or warning labels contain
WARNING: Lead-acid batteries contain
high voltage. The second voltage system is used to
sulfuric acid. Avoid contact with skin, eyes or
operate the standard Ranger systems such as
clothing. Also, shield your eyes when working
interior/exterior lighting, radio, blower motor and
near batteries to protect against possible
instrumentation. These components should be
splashing of the acid solution. In case of acid
treated with extreme caution. Do not perform any
contact with the skin or eyes, flush immediately
service on them until all high voltage power has
with water for a minimum of fifteen minutes and
been disconnected.
get prompt medical attention. If acid is
EV-Specific Precautions
swallowed, drink large quantities of milk or
water, followed by milk of magnesia, a beaten
When working on the traction battery the following
egg, or vegetable oil. Call a physician
precautions must be taken.
immediately.
1. A buffer zone must be placed around the
The drive battery pack for the Electric Ranger is
vehicle or traction battery.
composed of 39 8-volt lead acid battery modules
2. Rubber insulating gloves must be worn.
which are wired in series. These batteries are
3. A face shield must be worn to shield the face
similar in design to the battery in a gasoline
and protect the eyes from electric arc.
powered vehicle. The batteries contain sulfuric acid
which can cause severe skin or eye damage if
allowed to contact these areas. Follow all safety
precautions outlined in EV-Specific Precautions
prior to working on the drive battery pack.
100-00-3
100-00-3
General Information
DESCRIPTION AND OPERATION (Continued)
Welding Precautions
4. Remove any electrical modules within 300 mm
(12 in) of the welding area.
The EV requires special care when welding is
performed. The sensitive electric components can be
5. Disarm the passive restraint system. Follow the
damaged by the heat associated with gas welding
procedures outlined in the standard Ranger
and the electrical current from electric resistance
Workshop Manual.
welding. The following steps must be taken before
6. Verify that the ignition is in the OFF position.
any welding is done on the EV.
The traction battery can be stored out of the vehicle
1. Disconnect the 12 volt battery ground cable.
for up to 30 days without the serious damage to the
2. If welding within 300 mm (12 in) of the
battery. If possible, the traction battery should be
traction battery, remove the traction battery
fully charged prior to storage. After thirty days of
storage, the battery should be fully charged. Proper
3. If welding more than 300 mm (12 in) away
storage will maximize traction battery life.
from the traction battery, disconnect the 76 pin
low voltage connector.
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100-01-1
Identification Codes
SECTION 100-01 Identification Codes
VEHICLE APPLICATION:
Ranger EV
CONTENTS
PAGE
DESCRIPTION AND OPERATION
Identification Codes ...................................................................................
100-01-2
Warnings ...............................................................................................
100-01-2
100-01-2
100-01-2
Identification Codes
DESCRIPTION AND OPERATION
The Traction Battery Tray warning label is located
Identification Codes
on the left and right sides of the traction battery.
NOTE: For Electric Ranger Only.
The label warns of the potential for electric shock if
an unauthorized person attempts to service the
traction battery. The label also cautions against
lifting the vehicle by the traction battery.
High Voltage Warning Label
The Vehicle Identification Number (VIN) is located
on a tab on the driver’s side dashboard and on the
Vehicle Certification Label. The Electric Vehicle
(EV) can be identified by checking the engine
identification number on the VIN tag. This is the
The High Voltage warning label has three icons that
eighth digit on the tag, which indicates the battery
contain a general warning, a high voltage warning,
pack that is installed in the Electric Vehicle. A
and an icon to inform technicians that the proper
number 7 indicates a Lead Acid Battery Pack (PbA)
service information should be used prior to
and a number 1 indicates a Nickel Metal Hydride
servicing the vehicle.
Battery Pack (NiMH). For other VIN information,
refer to the Ranger Workshop Manual.
High-Voltage Label - High-Voltage Power
Distribution Box
Warnings
The Electric Ranger contains many unique electrical
components. The components that operate using
high voltage are labeled to warn of the potential
danger for electric shock. In addition to the high
voltage, some of the components also generate high
levels of heat. These are labeled to protect people
from possible burns.
Traction Battery Tray Label
The High-Voltage - High-Voltage Power
Distribution Box warning label is located on the
high- voltage power distribution box (HVPDB)
below the HVPDB cover. This label warns of the
need to allow the vehicle to discharge electrically
for one minute before removing the inner HVPDB
cover.
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