Ford Ranger EV. Electric Manual - part 1

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LESSON 1: VEHICLE OVERVIEW

TECHNICIAN OBJECTIVES

•

Identify major components and systems.

•

Describe the operation of major components and systems.

CONTENTS

•

Electric Vehicle (EV) History

•

Electric Ranger Introduction

•

Specifications

•

Battery System

•

Traction Inverter Module (TIM)

•

Interface Adapter Assembly (IAA)

•

Motor/Transaxle

•

High Voltage Power Distribution Box

•

DC/DC Converter

•

Liquid Cooling System

•

Power Steering System

•

Braking System

•

Electronic Throttle Control

•

Climate Control System

•

Networks and Multiplexing

•

High Voltage Interlocks

•

Inertia Shutoff Switch

•

Current Leakage Detection

•

Suspension System

•

Traction Battery Charging Components

•

High Voltage Wiring

•

Activity 1 – Vehicle Overview – Component Location

•

Worksheet A – Component Location

•

Worksheet B – Component Function Exercise

•

Worksheet C – Safety Feature Identification

LESSON 1: VEHICLE OVERVIEW

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ELECTRIC VEHICLE (EV) HISTORY

Current legistration requires the development and distribution of

zero-emission vehicles. Today, only electric vehicles qualify as

zero-emission vehicles. This legislation also states all automobile

manufacturers who sell over 5,000 vehicles a year in regulated states

must develop and manufacture electric vehicles.

Electric vehicles (EVs) were first developed in the early 1900s. These

early EVs traveled at low speeds (24 km/h [15 mph]) and had limited

range (48-64 kilometers [30-40 miles]).

Ford Motor Company began its recent EV development in 1982 with

the introduction of the ETX 1, a converted Lynx LN7. A lead-acid

battery and a 37-kW (50-hp) AC motor powered this experimental

vehicle. The ETX 2 followed. The ETX 2 is a converted Aerostar

using a refined 53-kW (70-hp) motor; several battery types were used

and tested.

In 1993, Ford began a demonstration program to help potential

customers gain real-world experience in the use of electric-powered

vehicles. With the participation of utility companies and other

commercial organizations, this program has now reached the one

million-mile mark in vehicle miles driven. The vehicle platform for

this demonstration is the Ecostar; a two-passenger electric vehicle

based on the European Ford Escort Van. This demonstration program

paved the way for production of the Electric Ranger.

LESSON 1: VEHICLE OVERVIEW

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ELECTRIC RANGER INTRODUCTION

The 1998 Electric Ranger is a low-volume production electric vehicle.

The Electric Ranger is built on the 1998 gasoline-powered Ranger

platform and is sold and serviced through Ford dealerships.

A traction battery mounted under the vehicle between the frame rails

supplies the electric power. The traction battery provides 312 volts

direct current (DC), which is converted to three-phase alternating

current (AC) that drives the motor/transaxle.

The Electric Ranger is a rear-wheel drive vehicle and operates much

like the gasoline-powered models.

The most noticeable difference between the Electric Ranger and the

gasoline-powered Ranger is the operating noise is very low. Because

of the quiet operation of the vehicle, a motor enabled gauge is

provided and is located on the right side of the instrument cluster. The

motor enabled gauge indicates ON with the ignition switch in the

RUN or START position and indicates OFF with the ignition switch

in the OFF position or the powertrain becomes disabled.

1998 Electric Ranger

LESSON 1: VEHICLE OVERVIEW

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SPECIFICATIONS

Vehicle

Model Year

1998

Body Style

Styleside, Regular Cab Pick-Up

Wheelbase

Short Wheelbase of 2,831 mm (111.4 inch)

Payload

315 kg (700 lb)

Dimensions

Similar to 1998 Gasoline-Powered Ranger

Performance

0-50 Mph

12.5 seconds

Top Speed

120 km/h (75 mph)

Range

93 kilometers (58 miles)
(without A/C or Heater Operation)

Powertrain

Motor

High-Efficiency, 3-Phase AC Induction

Horsepower

67 kw (90 hp)

Transaxle

Single-Speed Constant-Ratio

Drive Wheels

Rear

Gear Ratio

12.518:1

Equipment

Standard

Dual Air Bags

Electro-Hydraulic Power Steering

Regenerative Braking

4-Wheel ABS

Aluminum Wheels

Low Rolling Resistance Tires

Optional

Air Conditioning

Battery Heater

Spare Tire and Jack