Ford Ranger Electric Vehicle Owner's Manual
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Ford Ranger Electric Vehicle Owner's Manual

Ford Ranger Electric Vehicle Owner's Manual

1999
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Table of Contents

All rights reserved. Reproduction by any means, electronic or mechanical
including photocopying, recording or by any information storage and retrieval
system or translation in whole or part is not permitted without written
authorization from Ford Motor Company.
Copyright
1999 Ford Motor Company

Table of contents

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  • Page 1: Table Of Contents

    All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Copyright 1999 Ford Motor Company...

  • Page 2: Introduction

    Introduction WELCOME TO THE RANGER ELECTRIC VEHICLE The 1999 Ranger Electric Vehicle is very similar to the gas-powered Ranger in appearance, interior and controls. The Ranger Electric Vehicle was built to be transparent from the gas-powered Ranger. There are enough differences that you should read this manual. Operation is the same, but some functions are different.

  • Page 3: Instrumentation

    Oil cannot be added by the owner. The vehicle should be returned to an authorized Ford EV Dealer as soon as possible. Driving in excess of 50 miles to reach an authorized dealer may damage the transaxle.
  • Page 4 Auxiliary battery lamp The auxiliary battery lamp indicates there is an auxiliary battery charging malfunction. Return the vehicle to an authorized Ford EV Dealer immediately. Low fuel lamp The low fuel lamp indicates that the vehicle’s drive battery has reached a 10% state of charge.
  • Page 5 ABS. If the light stays on or continues to flash after the vehicle is started, return the vehicle to an authorized Ford EV Dealer for service. Econ mode lamp The econ mode lamp indicates that the gearshift is in the E (Economy) position.
  • Page 6 The inertia shutoff switch is located by the passenger kick panel. If there is damage to the vehicle, have the vehicle towed to an authorized Ford EV Dealer. RANGER EV FOR MEXICO AND CANADA The instrument cluster on the Ranger EV for Mexico and Canada will be equipped with metric gauges.
  • Page 7 Instrumentation Battery state of charge gauge The battery state of charge gauge is the equivalent of a fuel gauge on a gasoline-powered vehicle. F (Full) indicates that the battery is completely charged. E (Empty) indicates the battery has been discharged to the point where additional operation will damage vehicle systems.
  • Page 8 Instrumentation Motor enabled gauge The motor enabled gauge indicates that the vehicle is ready to drive. Turning the ignition switch to the full START position and releasing will turn the vehicle on, and the gauge will move to the ON position. Temperature gauge The temperature gauge indicates the temperature of the vehicle’s...

  • Page 9: Controls And Features

    Controls and features CLIMATE CONTROL SYSTEM Your vehicle is equipped with an automatic temperature control (ATC) system designed to maintain a selected temperature with a combination A/C-Heater system. Air conditioning (A/C) and heater controls The control for your air conditioning and heater system is located at the center of the instrument panel below the radio and will operate in the KEY-ON position.
  • Page 10 Controls and features Recirculation Switch Operation Icon Mode Recirculation MAX A/C Max A/C Automatic Automatic Panel Selectable Not Available Panel/Floor Selectable Floor Selectable Floor/Defrost Not Available Defrost Not Available Fan speed knob The left knob on the control is the fan control knob, which controls the volume of air flow.
  • Page 11 Controls and features Mode selector knob The right knob on the control is the mode selector, which controls the direction of the airflow inside the vehicle. MAX A/C-Select to distribute recirculated air through the instrument panel registers. This position produces cool air more rapidly to provide faster cooling of your vehicle.
  • Page 12 Controls and features (defrost)-Select to distribute outside air through the windshield defroster ducts. Defrost can be used to clear ice or fog from the windshield. If the outside air temperature is 10°C (50°F) or warmer the air conditioner will dehumidify the air to prevent fogging. The air may be heated and/or cooled based on temperature selection.

  • Page 13: Charging

    A conductive power control station (PCS) is required to recharge your Ranger Electric Vehicle. The PCS consists of a “smart” box and a connector and cable assembly that safely conducts AC power from the utility supply grid to the vehicle inlet (located at the right front of the vehicle, next to the right headlamp).
  • Page 14 Charging 1. Park the Ranger Electric Vehicle. The vehicle’s charge inlet is at the right front of the vehicle in the grille, next to the right headlamp. 2. Place the gearshift lever in P (Park) and set the parking brake.
  • Page 15 Refer to charging troubleshooting later in this section. If none of the above apply, the vehicle should be returned to the PCS to attempt to complete charging or taken to an authorized Ford EV Dealer. Lead-acid traction battery At 25°C (77°F), the drive battery can be charged to 80% capacity in...
  • Page 16 Charging hours. Completely charging the drive battery is important to ensure maximum range and battery life. Ford recommended practice is that the vehicle should always be left on-plug when not in use and be allowed to fully charge before driving.
  • Page 17 Charging To disconnect the PCS: 1. Push the STOP button on the PCS. 2. Grasp the charge connector and press the button in the center of the handle. 3. Pull the charge connector upward and pull it out of the inlet. 4.
  • Page 18 Charging Charging troubleshooting using SCI systems (SCI ) equipment If your vehicle fails to charge, follow this procedure to determine if your Power Control Station (PCS) is operating properly: 1. Make note of any lights that are flashing or steadily illuminated on your PCS.
  • Page 19 Call the PCS manufacturer for repair or replacement. The toll free number is located on the PCS. The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. Battery pack heating/cooling system (lead-acid type)
  • Page 20 Equalization is automatically performed approximately every three weeks. The fuel gauge will indicate if insufficient charge time has been allowed. The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. Battery pack heating/cooling system (nickel metal hydride type) The battery pack assembly contains 25 twelve-volt batteries, wiring, two fans for ventilation and cooling and a control system.
  • Page 21 –25°C (–13°F) and prevent both charging and self-heating. The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. Battery self-heating following a complete charge will maintain the battery at approximately –10°C (14°F).

  • Page 22: Starting

    Motor Enable Gauge to the ON position. Powers up all high-voltage power from the drive battery. STARTING THE RANGER ELECTRIC VEHICLE 1. If connected, disconnect the PCS plug from the charge inlet and close the charge inlet access door.
  • Page 23 Starting 1. Make sure all vehicle occupants have buckled their safety belts. For more information on safety belts and their proper usage, refer to the seating and safety restraints chapter in the Ranger owner guide. 1. Make sure the parking brake is set.
  • Page 24 Starting 4. Check the drive Battery State of Charge gauge to confirm that the drive battery is charged sufficiently for the planned trip. 5. Pull the release lever to release the parking brake. The Ranger electric vehicle is now ready to be driven.

  • Page 25: Driving

    Driving REGENERATIVE BRAKING Your Ranger Electric Vehicle uses a unique feature known as regenerative braking. This is used to simulate the engine braking of an internal combustion engine and assist the standard brake system while recovering some of the energy of motion back into the battery.
  • Page 26 Regenerative braking is disabled while ABS is active allowing ABS full control. STEERING Your Ranger Electric Vehicle has variable assist power steering. The power steering uses energy from the battery to help steer your vehicle. If the amount of effort needed to steer your vehicle changes at a constant speed, have the power steering system checked.
  • Page 27 Driving Hold the brake pedal down while you move the gearshift lever from P (Park) to another position. If you do not hold the brake pedal down, your vehicle may move unexpectedly and injure someone. P (Park) Always set the parking brake fully and make sure the gearshift is latched in P (Park).
  • Page 28 When the battery is almost fully charged, the amount of regenerative braking is limited. Low charge As the Ranger Electric Vehicle is driven, the Battery State of Charge Gauge indicates the battery’s...
  • Page 29 (ABS). Regenerative braking is disabled when the ABS is activated. TRAILER TOWING The Ranger Electric Vehicle should not be used for towing a trailer. TONNEAU COVER The cover is intended to improve energy efficiency at freeway speeds.
  • Page 30 Driving ENERGY TIPS The Ranger Electric Vehicle has a customer range of approximately 80 kilometers (50 miles) with the standard lead-acid type traction battery or approximately 160 kilometers (100 miles) with the optional nickel metal hydride type traction battery. This range is affected by the use of vehicle accessories, driving habits and weather conditions.

  • Page 31: Roadside Emergencies

    The inertia shutoff switch is located by the passenger kick panel. If there is damage to the vehicle, have the vehicle towed to an authorized Ford EV repair facility.
  • Page 32 Roadside emergencies PASSENGER COMPARTMENT FUSE PANEL The fuse panel is on the left-hand side of the instrument panel facing the driver side door. Pull the panel cover outward to access the fuse. To remove a fuse, use the fuse puller provided on the fuse panel cover.
  • Page 33 Roadside emergencies The passenger compartment fuse panel fuses are coded as follows: Fuse/relay Fuse amp Description location rating Instrument cluster Driver air bag module — Not used Left headlamp Data link connector (DLC) — Not used Exterior lighting Right headlamp Traction inverter module (TIM) Generic electronic module (GEM), shift lock actuator...
  • Page 34 Roadside emergencies Fuse/relay Fuse amp Description location rating Generic electronic module (GEM) Backup lamps Battery saver realy, dimmer module, interior lamps relay, generic electronic module (GEM) Generic electronic module (GEM) Radio — Not used — Not used — Not used Highbeam headlamp —...
  • Page 35 Roadside emergencies Always replace the cover to the power distribution box before reconnecting the auxiliary battery or refilling fluid reservoirs. The high-current fuses are coded as follows: Fuse/relay Fuse amp Description location rating MAXI 50 Fan speed relays, cooling fan, interface adapter assembly (IAA) module MAXI 60 MAXI 30...
  • Page 36 Roadside emergencies Fuse/relay Fuse amp Description location rating MINI 20 I/P fuse panel fuses 23 and 27 — Not used MINI 20 Battery charger — Not used MAXI 40 Heater blower motor relay, heater blower motor, interface adapter assembly (IAA) MAXI 20 Coolant pump relay, coolant pump MAXI 20...
  • Page 37 Roadside emergencies CHANGING TIRES If you get a flat tire while driving, do not apply the brakes heavily. Instead, gradually decrease your speed. Hold the steering wheel firmly and slowly move to a safe place on the side of the road. Conventional spare tire information If you have the optional spare tire, you can use the spare as a regular tire.
  • Page 38 Roadside emergencies one wheel nut wrench. Depress button and slide together. 6. Remove the spare tire security lock and cable. 7. Remove the retaining bolt and retainer. If you cannot remove the bolt by hand, remove it using the jack handle. 8.
  • Page 39 Roadside emergencies 2. Set the parking brake. 3. Block the diagonally opposite wheel. 4. Insert tapered end of the lug wrench behind center caps and twist them off. 5. Loosen each wheel lug nut one-half turn counterclockwise, but do not remove them until the wheel is raised off the ground.
  • Page 40 Roadside emergencies Front Rear 7. Remove the wheel lug nuts with the lug wrench. 8. Replace the flat tire with the spare tire, making sure the valve stem is facing outward. Reinstall the lug nuts until the wheel is snug against the hub.
  • Page 41 Roadside emergencies JUMP-STARTING THE AUXILIARY BATTERY The Ford Electric Ranger can be jump-started like a gasoline-powered Ranger. Note that if the traction battery is dead, jumping the auxiliary battery will not fix the problem. Look at the battery state of charge gauge to verify the traction battery is not discharged.
  • Page 42 Roadside emergencies 4. Connect one end of the second lead to the negative (-) terminal of the booster battery (3) and the other end to the module mounting stud (4), not to the negative (-) terminal of the discharged battery. 5.
  • Page 43 Roadside emergencies Removing the jumper cables 1. Remove the jumper cables in reverse order. Take the cable off the metallic surface (1) first, followed by the cable on the negative (-) booster battery terminal (2). 2. Remove the cable from the positive (+) terminal of the booster battery (3) and then the discharged battery (4).
  • Page 44 If you need to have your vehicle towed, contact a profession towing service or your roadside assistance center. Do not tow with slingbelt equipment. Ford Motor Company has not developed or approved a slingbelt towing procedure. When calling for a tow truck, tell the operator what kind of vehicle you...

  • Page 45: Maintenance And Care

    Maintenance and care SERVICE RECOMMENDATIONS This vehicle should only be serviced by a Ford trained electric vehicle technician. Scheduled maintenance chart Item Interval yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. Rotate tires 5000 miles Inspect disc brake system,...
  • Page 46 Maintenance and care Item Interval yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. Replace transaxle fluid* Inspect power steering fluid Inspect brake fluid *Replace transaxle fluid every 3 years or 36,000 miles, whichever comes first. HOW TO OPEN THE HOOD 1.
  • Page 47 Maintenance and care 2. Go to the front of the vehicle and release the auxiliary latch that is located under the front center of the hood. Lift the hood and support it with the prop rod. Identifying components in the underhood compartment: 1.
  • Page 48 Maintenance and care WINDSHIELD WASHER FLUID Check the washer fluid periodically. If the level is low, add enough fluid to fill the reservoir. In very cold weather, do not fill the reservoir all the way. Do not put engine coolant in the container for the windshield washer fluid.
  • Page 49 Use Ford Extended Life Engine Coolant F6AZ-19544–AA or an equivalent DEX-COOL coolant or a coolant meeting Ford specifications WSS-M97B44–D. Ford Extended Life Engine Coolant is an orange colored silicate-free coolant that does not need to be replaced for the life of your vehicle.
  • Page 50 3. If necessary, add brake fluid until the level reaches MAX. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet Ford specifications. Refer to Lubricant specifications in the Capacities and specifications chapter.
  • Page 51 Maintenance and care If you use a brake fluid that is not DOT 3, you will cause permanent damage to your brakes. AUXILIARY BATTERY Your vehicle is equipped with a sealed maintenance-free battery. For longer, trouble-free operation, keep the top of the battery clean and dry.
  • Page 52 Maintenance and care SERVICING YOUR TIRES Checking the tire pressure Use an accurate tire pressure gauge. Check the tire pressure when tires are cold, after the vehicle has been parked for at least one hour or has been driven less than 5 km (3 miles).
  • Page 53 Replace the tires when the wear band is visible through the tire treads. Your Ranger Electric Vehicle is equipped with a low rolling resistance high pressure designed tire to extend vehicle range. Only the same type of tire should be used as a replacement.
  • Page 54 Make sure that all replacement tires are of the same size, type, load-carrying capacity and tread design (e.g., “All Terrain”, etc.), as originally offered by Ford. Failure to follow these precautions may adversely affect the handling of the vehicle and make it easier to lose control and roll over.

  • Page 55: Capacities And Specifications

    Capacities and specifications MOTORCRAFT PART NUMBERS Component Part Number Climate control air filter F8YZ-19N619-AA Auxiliary battery BXE-U1 REFILL CAPACITIES Ford part Capacity-litres Fluid Vehicle type name (quarts) Brake fluid Ford high Fill to line in performance reservoir DOT 3 motor...
  • Page 56 Capacities and specifications FLUID SPECIFICATIONS Ford part Ford part Ford Fluid name or number specification equivalent Brake fluid High C6AZ-19542-AB WSA-M6C25-A performance and DOT 3 DOT 3 motor vehicle brake fluid Power steering Motorcraft XT-2ODX MERCON fluid MERCON ATF WSA-M2C195-A...

  • Page 57: Accessories

    Accessories MOBILE RADIO INSTALLATION GUIDELINES General information Ford Motor Company vehicles are designed and tested for safe operation with properly installed and properly used land mobile/amateur radio communications equipment with up to 100 Watt transmitter power. This resource is provided as a supplement to the radio manufacturer’s installation communication equipment in Ford vehicles.
  • Page 58 Radio wiring and routing Power connections should be made directly to the battery and fused as close to the battery as possible. On the Ranger Electric Vehicle make the connections as follows: For the +12V circuit, connect a weatherproof fuse holder to the...
  • Page 59 Accessories Connect to the auxiliary battery ground connection using a ring terminal at the ground M6 weldnut behind the LH (driver’s) side kick panel. Maintain as great a distance as possible between mobile radio power leads and the vehicle’s wiring. Avoid running power leads in parallel with vehicle wiring over long distances.
  • Page 60 Accessories Mount the antenna only on the center of the Ranger Electric Vehicle roof if it is a sheet metal mount antenna. Glass mounted antennas should be mounted as high as possible in the center of the rear window. Antenna Tuning: It is important that the antenna be tuned properly and reflected power be kept to less than 10% (VSWR less than 2:1).
  • Page 61 Accessories Troubleshooting Most interaction problems can be eliminated by following these installation guidelines. If vehicle/radio interaction develops following installation, the source of the problem should be identified prior to further operation of the vehicle. Possible causes of vehicle/radio interaction include: Antenna location (move antenna to a position on the vehicle roof) Antenna feed line routing (locate as far as possible from vehicle electronics and wiring)

  • Page 62: Index

    Index Air conditioning ......9 Jump-starting your vehicle ..41 Battery .........19 Lights, warning and indicator ..3 auxiliary battery .......51 anti-lock brakes (ABS) ....5 battery pack heating/cooling auxiliary battery ......4 system (lead-acid type) ...19 brake ..........3 battery pack heating/ charging system ......3 cooling system (nickel metal econ mode ........5 hydride type) ......20...

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