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Ford FOCUS 2015 Battery Replacement

Ford FOCUS 2015 Battery Replacement

Electric vehicle (ev)
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2015 FOCUS
ELECTRIC VEHICLE (EV)
BATTERY REMOVAL GUIDE
FCS-21201-15
2015 Focus Electric Battery Removal Guide
1

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Summary of Contents for Ford FOCUS 2015

  • Page 1 2015 FOCUS ELECTRIC VEHICLE (EV) BATTERY REMOVAL GUIDE FCS-21201-15 2015 Focus Electric Battery Removal Guide...

  • Page 2: Table Of Contents

    If The High-Voltage Battery Case Has Been Ruptured ......Page 18 Moving Damaged Vehicles ..............Page 18-19 Electric and Hybrid- Electric Vehicle Considerations ......Page 19 DAMAGED VEHICLE GUIDANCE FOR FORD MOTOR COMPANY ELECTRIC AND HYBRID-ELECTRIC VEHICLES EQUIPPED WITH HIGH VOLTAGE BATTERIES ................ Page 20 DAMAGED BATTERY ELECTRIC VEHICLE STORAGE PLACARD ..

  • Page 3: Foreword

    FOREWORD The emergency response procedures for the Focus Electric vehicles are similar to those for hybrid electric vehicles with the same considerations for the high-voltage electric system components. Focus Electric vehicles use an electric motor to power the vehicle. Electricity is stored in high-voltage battery packs.

  • Page 4: Electric Vehicle Identification

    ELECTRIC VEHICLE IDENTIFICATION Focus Electric vehicles can easily be identified by the “Electric” badges located on the left and right front doors. There is an “Electric” nameplate on the trunk lid that also in- cludes the green leaf/blue highway icon. Electric nameplate and icon on Electric nameplate and icon front doors.

  • Page 5: Vin Layout

    ELECTRIC VEHICLE IDENTIFICATION - CONTINUED • The Focus Electric powertrain can be identified by the orange high-voltage underhood cabling. Orange high-voltage cabling from the high-voltage battery packs. • The 5th, 6th and 7th digits of the Vehicle Identification Number (VIN) identify the Focus Electric line.

  • Page 6: High-Voltage Electrical Disconnect Features

    PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGEN- CY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

  • Page 7: High-Voltage Warning Decals

    HIGH-VOLTAGE WARNING DECALS • On Ford electric vehicles, WARNING decals are located on components in the high-voltage system throughout the vehicle. Please see example below. CU5A-14B218-FA FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 6 of 38...

  • Page 8: Component Location And Identification

    COMPONENT LOCATION AND IDENTIFICATION The illustrations and defining chart below on Page 8 and 9, provide the location, description and basic function of the Focus Electric system components. NOTE: All high-voltage wires and harnesses are wrapped in orange-colored insulation. FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 7 of 38...
  • Page 9 COMPONENT LOCATION AND IDENTIFICATION - CONTINUED COMPONENT LOCATION / DESCRIPTION FUNCTION High-Voltage • Upper disconnect is located Provides means to disconnect Service Disconnects behind the rear seatback. high-voltage batteries for safely Lower disconnect is below servicing vehicle. the upper pack near the right hand rear tire.
  • Page 10 COMPONENT LOCATION AND IDENTIFICATION - CONTINUED COMPONENT LOCATION / DESCRIPTION FUNCTION • Liquid cooled 3-phase AC Electric Motor Turns energy from the high- permanent magnet motor. voltage traction battery into movement that is applied the transmission for vehicle • Attached to gearbox,centrally propulsion.

  • Page 11: High-Voltage Service Disconnects

    PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGEN- CY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.
  • Page 12 HIGH-VOLTAGE SERVICE DISCONNECTS - CONTINUED • Depress the release tab at the top of the service disconnect and rotate the release handle down approximately 45 degrees. • Depress the release tab again, and rotate the handle another 45 degrees to the fully released position.
  • Page 13 HIGH-VOLTAGE SERVICE DISCONNECTS - CONTINUED NOTE : The lower service disconnect is removed in the same fashion as the upper. To gain access to the lower battery high-voltage service disconnect, raise the rear of the vehicle using a suitable jack. •...

  • Page 14: High-Voltage Battery Packs

    PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGEN- CY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

  • Page 15: Approaching A Damaged High-Voltage Vehicle

    PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGEN- CY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

  • Page 16: Follow Existing Training And Incident Commander Direction

    APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED WARNING FIRES IN CRASH-DAMAGED ELECTRIC VEHICLES MAY EMIT TOxIC OR COMBUSTIBLE GASSES. SMALL AMOUNTS OF EYE, SKIN OR LUNG IRRITANTS MAY BE PRESENT. WEAR PERSONAL PROTECTIVE EQUIPMENT (PPE) AND SELF-CONTAINED BREATHING APPARATUS WHEN WORKING IN CLOSE PROxIMITY OR IN A CONFINED AREA, SUCH AS A TUNNEL OR GARAGE.

  • Page 17: Approaching A Damaged Vehicle

    APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED 2. APPROACHING A DAMAGED VEHICLE • Disable the high-voltage electrical system using as many of the following steps as possible: — Secure the vehicle: Place the shift lever into the PARK position. Place the ignition in the OFF position to disconnect the high-voltage system.

  • Page 18: High Voltage System - Do Not Cut Zones

    APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED 3. High-Voltage System - Do Not Cut zones • If possible, remove the high-voltage battery service disconnect(s) before attempting any extrication procedure. Always assume the high-voltage cabling and components are powered up. • If occupant extrication is necessary, always use caution when cutting near the vehicle high-voltage system components.

  • Page 19: If The High-Voltage Battery Case Has Been Ruptured

    • Be alert. There is potential for delayed fire with damaged lithium-ion batteries. • Call an authorized Ford Dealer or vehicle manufacturer representative, if necessary, to determine additional steps that you should take to safely recover or transport the vehicle.

  • Page 20: Electric And Hybrid-Electric Vehicle Considerations

    APPROACHING A DAMAGED HIGH-VOLTAGE VEHICLE - CONTINUED MOVING DAMAGED VEHICLES — WRECKER DRIVERS (CONTINUED) • Place vehicle into park, set the parking brake, turn off the vehicle, activate the hazard lights, and remove the key fobs to a distance at least 16 feet from the vehicle until loading the vehicle for transport.

  • Page 21: Damaged Vehicle Guidance For Ford Motor Company Electric And Hybrid-Electric Vehicles Equipped With High Voltage Batteries

    Damaged Vehicle Guidance for Ford Motor Company Electric and Hybrid-Electric Vehicles Equipped with High-Voltage Batteries (Towing and Recovery Operators and Vehicle Storage Facilities) For questions contact Ford USA 1-800-392-3673 / Ford Canada 1-800-565-3673 In the event of damage or fire involving an Electric Vehicle (EV) or Hybrid-Electric Vehicle (HEV): •...
  • Page 22 HV battery and vehicle. • For vehicles in Canada, notify Ford Motor Company 1-800-565-3673 (then follow the prompts on the voice response menu), or an authorized Ford dealer as soon as possible as there may be additional steps necessary to secure, discharge, handle, and/or store the HV battery and vehicle.
  • Page 23 PROTECTIVE EQUIPMENT (PPE) SAFETY GEAR, INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC jEWELRY, INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY THE FORD EMERGEN- CY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INjURY OR DEATH.

  • Page 24: Damaged Battery Electric Vehicle Storage Placard

    --------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------------------------------- Copyright 2012, Ford Motor Company. All rights reserved. This document may be reproduced in its en- tirety and distributed for emergency responder use only. It may not be excerpted for any purpose. FCS-21201-15 2015 Focus Electric Battery Removal Guide...

  • Page 25: High Voltage Upper Battery Removal

    2015 Focus Electric High Voltage Upper Battery - Removal Special Tools / General Equipment 303-050 Lifting Bracket, Engine Hydraulic Jib Crane WARNING TO PREVENT THE RISK OF HIGH-VOLTAGE SHOCK, ALWAYS FOLLOW PRECISELY ALL WARNINGS AND SERVICE INSTRUCTIONS, INCLUDING INSTRUCTIONS TO DEPOWER THE SYSTEM. THE HIGH-VOLTAGE SYSTEM UTILIzES APPROxIMATELY 300 VOLTS DC, PROVIDED THROUGH HIGH-VOLTAGE CABLES TO ITS COMPONENTS AND MODULES.
  • Page 26 4. Remove the lower HV battery cover retainers and then the lower cover. E162895 5. Disconnect the two upper HV battery cooling hoses and drain the coolant. E145081 6. Position the drivers side rear seat cushion up. E133809 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 25 of 38...
  • Page 27 7. Remove the safety belt buckle retainer and position the buckle aside. E161434 8. Release the seatback latch mechanism and remove the RH seatback. GENERAL EQUIPMENT: Flat headed screwdriver E134966 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 26 of 38...
  • Page 28 9. Release the seatback latch mechanism and remove the LH seatback. E136464 10. Remove the 6 retainers and the upper HV battery cover. E163012 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 27 of 38...
  • Page 29 11. Remove the luggage compartment cover. E133518 12. Remove the floor trim cover. E163009 13. Remove the spare tire cover. E163010 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 28 of 38...
  • Page 30 14. Release the two push-pin retainers and the upper battery cover. E163011 15. Unclip the keyless rear vehicle antenna from the upper HV battery and position the antenna aside. E164126 16. Remove the bolt and the HV battery junction box cover. E145436 FCS-21201-15 2015 Focus Electric Battery Removal Guide...
  • Page 31 17. Fully loosen the low-voltage wire connector captured bolt and disconnect the electrical connector. Disconnect the two HV connectors. Remove the two nuts at the HV battery junction box and the wire retainer bolt. Disconnect the wire harness retainer from the upper HV battery. E145437 CAUTION: To avoid spillage, position a shop towel around the coolant hose to HV upper battery connections before disconnecting.
  • Page 32 CAUTION: Position a shop towel on top of the lift arm to avoid damage to the roof opening panel. Special Tool(s): Lifting Bracket, Engine 303-F047 Special Tool(s): Lifting Brackets, 303-050 General Equipment: Hydraulic Jib Crane Install the four lift brackets (303-050) to the upper HV battery, attach a chain between the lift brackets and the Engine Lifting Bracket 303-F047 to the floor crane (300-OTC1819E) or equivalent.
  • Page 33 22. Rotate the upper HV battery 90 degrees counterclockwise and remove the battery from the vehicle. E145442 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 32 of 38...

  • Page 34: High Voltage Lower Battery Removal

    2015 Focus Electric High Voltage Lower Battery - Removal General Equipment Transmission Jack WARNING TO PREVENT THE RISK OF HIGH-VOLTAGE SHOCK, ALWAYS FOLLOW PRECISELY ALL WARNINGS AND SERVICE INSTRUCTIONS, INCLUDING INSTRUCTIONS TO DEPOWER THE SYSTEM. THE HIGH-VOLTAGE SYSTEM UTILIzES APPROxIMATELY 300 VOLTS DC, PROVIDED THROUGH HIGH-VOLTAGE CABLES TO ITS COMPONENTS AND MODULES.
  • Page 35 4. Remove the lower HV battery cover retainers and then the lower cover. E162895 5. Remove the ground bolt from the RH side of the lower HV battery. E144804 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 34 of 38...
  • Page 36 6. Disconnect the HV wire connector at the front of the lower HV battery. Fully loosen the low-voltage wire connector captured bolt at the front of the lower HV battery and disconnect the electrical connector. E144805 7. Disconnect the three HV wire connectors and the two wire retainers at the LH side of the lower HV battery.
  • Page 37 9. Position a lift table under the lower HV battery. GENERAL EQUIPMENT: Transmission Jack E144810 10. Remove the six bolts and the lower HV battery. NOTE: The two rear bolts are longer than the other bolts. E144808 FCS-21201-15 2015 Focus Electric Battery Removal Guide Page 36 of 38...

  • Page 38: Special Note To Salvage Yards

    Applicable Laws/Regulations The following is a general explanation of certain applicable laws; however, these laws change from time to time, additional regulations are under development and Ford makes no representation that this is a complete summary. Packaging and Transport The U.S.
  • Page 39 Li-Ion batteries may be regulated as hazardous waste under federal and state regulations. Though Ford Motor Company makes no representations or endorsements, there are companies that have the capability to accept, consolidate and recycle Li-Ion HVBs, and a few are listed below.

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