Ford Ranger EV (2001 year). Manual - part 1

 

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Ford Ranger EV (2001 year). Manual - part 1

 

 

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.

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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