General Information - Ford Electric Ranger 2001 Manual

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DESCRIPTION AND OPERATION

General Information

Format and Usage
The Electric Ranger is a combination of
conventional and unique electric vehicle (EV)
components and systems. The following procedures
are designed to supplement the standard Ranger
Workshop Manual for the EV specific components.
This supplement is designed to be the primary
manual when working on the EV. All of the EV
specific components are covered in this supplement.
If a procedure is not outlined in this supplement,
refer to the standard Ranger Workshop Manual.
Because the EV uses an electric motor rather than a
gasoline engine, there are different and unique
warnings and cautions. The procedures outlined are
designed to encourage safe repair of the vehicle and
should be carefully followed. The EV uses many
electronic components that can be easily damaged if
the procedures are not followed.
Acids
WARNING: Lead-acid batteries contain
sulfuric acid. Avoid contact with skin, eyes or
clothing. Also, shield your eyes when working
near batteries to protect against possible
splashing of the acid solution. In case of acid
contact with the skin or eyes, flush immediately
with water for a minimum of fifteen minutes and
get prompt medical attention. If acid is
swallowed, drink large quantities of milk or
water, followed by milk of magnesia, a beaten
egg, or vegetable oil. Call a physician
immediately.
The drive battery pack for the Electric Ranger is
composed of 39 8-volt lead acid battery modules
which are wired in series. These batteries are
similar in design to the battery in a gasoline
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.
General Information
WARNING: Batteries normally produce
explosive gases which can cause personal injury
or death. Do not allow flames, sparks or lighted
substances to come near the batteries. When
charging or working near the batteries, always
shield your face and protect your eyes. Always
provide adequate ventilation.
Electric Shock
WARNING: The battery pack assembly
can deliver in excess of 312 volts of DC power.
Improper handling of the battery pack can result
in injury or fatality. Only authorized personnel
trained to work with battery pack components
are permitted to handle the batteries.
There are two electrical systems on the EV. A high
voltage system is used to power the motor/transaxle
and many auxiliary loads such as the A/C system,
power steering pump, heater and certain control
components. High voltage wiring is identified by its
orange color or orange wrapping on the harness.
Components that have larger connectors, orange
coverings on the wires, or warning labels contain
high voltage. The second voltage system is used to
operate the standard Ranger systems such as
interior/exterior lighting, radio, blower motor and
instrumentation. These components should be
treated with extreme caution. Do not perform any
service on them until all high voltage power has
been disconnected.
EV-Specific Precautions
When working on the traction battery the following
precautions must be taken.
1. A buffer zone must be placed around the
vehicle or traction battery.
2. Rubber insulating gloves must be worn.
3. A face shield must be worn to shield the face
and protect the eyes from electric arc.
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2001 Ranger EV, 01/2001