User manual FORD RANGER -1999

Table of contents Introduction Instrumentation Controls and features Charging Starting Driving Roadside emergencies Maintenance and care Capacities and specifications Accessories Index 2 3 9 13 22 25 31 45 55 57 62 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 1 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. The regular Ranger owner's manual covers common systems. This Owner's Guide Supplement contains the information specific to the Ranger Electric Vehicle. ICONS The warning icon. Read the following section on Warnings for a full explanation. WARNINGS Provide information which may reduce the risk of personal injury or prevent possible damage to others, your vehicle and its equipment. INFORMATION ABOUT THIS GUIDE The information found in this guide was in effect at the time of printing. Ford may change the coctents without notice and without incurring obligation. 2 Instrumentation WARNING LIGHTS AND CHIMES Service indicator lamp The service indicator lamp indicates that a vehicle malfunction has occurred. The vehicle should be returned to an authorized Ford Electric Vehicle (EV) Dealer for service. Brake warning lamp The brake warning lamp illuminates when there is a regenerative braking ! system malfunction, low fluid level BRAKE in the master cylinder or low fluid pressure in the hydraulic lines, or when the parking brake is engaged. If the lamp remains illuminated after the parking brake is fully released and the master cylinder is full, the vehicle should be taken to an authorized Ford EV Dealer. Charging lamp The charging lamp illuminates when the key is turned to the ON or START position while the vehicle is connected to the power control station (PCS). If the lamp flashes when the key is in the ON position, there is a vehicle malfunction and the drive battery cannot be charged. Confirm the vehicle is in park and the PCS cord is properly attached. If the vehicle is in P (Park) and the PCS cord is properly connected and the charging lamp continues to flash, then the vehicle should be taken to an authorized Ford EV Dealer. Low oil pressure lamp The low oil pressure lamp indicates that the transaxle oil lubrication system is operating below the desired pressure. 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. 3 Instrumentation Electrical hazard warning lamp The electrical hazard warning lamp indicates a malfunction in the high-voltage system. The vehicle will not charge and must be returned to an authorized Ford EV Dealer immediately. 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. The vehicle must be placed on charge. The indicator will flash when the battery reaches a 0% state of charge. Power limit lamp The power limit lamp indicates a system fault or reduced vehicle performance to conserve remaining drive battery power. As the vehicle nears complete discharge, the power limit lamp will illuminate. High-voltage accessories (A/C and heat) will be disabled. You will notice a decrease in vehicle performance and you must return to a PCS (power control station) immediately. The lamp will begin to flash and the performance of the vehicle will be severely limited. The vehicle will continue to operate until the drive battery is completely drained; however, driving under this condition will damage the battery, resulting in reduced battery life. 4 Instrumentation Anti-lock brake system (ABS) lamp The ABS lamp indicates that there is a malfunction with the 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. ABS Econ mode lamp The econ mode lamp indicates that the gearshift is in the E (Economy) position. This mode is recommended for urban traffic and will improve range by increasing the effects of regenerative braking and limiting top speed to 105 km/h (65 mph). The D (Drive) position is recommended for highway operation at steady speeds. Power reset lamp The power reset lamp indicates that the inertia shutoff switch has been tripped and all high-voltage power has been disconnected and power has been limited to the traction battery. If there is no damage to the vehicle, reset the switch to reactivate the high-voltage power systems. 5 Instrumentation 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. All gauges operate as described below. GAUGES 60 40 ECON 40 30 60 50 80 100 100 60 70 ON 20 MILES 50 DISTANCE TO EMPTY km 20 10 20 40 000000 OFF 120 0 0 MPH km/h 80 F E H C 6 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. Economy gauge The economy gauge provides information about the vehicle's energy usage. Economical usage of the vehicle is indicated by the gauge reading near the plus (+) side and will maximize the vehicle's range. F E ECON Distance to empty gauge The distance to empty gauge estimates the remaining distance the vehicle can travel before requiring a drive battery recharge. The gauge reading is based on remaining drive battery energy, driving conditions and recent vehicle usage. 60 40 20 MILES 50 100 DISTANCE TO EMPTY km 0 0 7 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. ON OFF Temperature gauge The temperature gauge indicates the temperature of the vehicle's components. Unlike conventional H temperature gauges, it does not start cold and move to normal. The gauge sits at normal and moves to C hot or cold when there is a problem. If the gauge moves to H (Hot), vehicle performance will be limited until the coolant temperature or drive battery temperature returns to normal. The vehicle should be stopped and plugged into a PCS until it has cooled down. The vehicle may need servicing. If the gauge moves to C (Cold), the vehicle may have an extended charge time and a reduced driving range. 8 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. Your air conditioner and heater will heat and/or cool your vehicle interior depending on the function position and temperature you select. The mode selector knob allows you to select heating or cooling, and determine where the air will be directed. The temperature control knob setting determines the desired interior temperature of the vehicle. To turn your air conditioner or heater system on, select any position except OFF. This will turn the fan on and allows air flow into the vehicle. To turn your air conditioner or heater system off, select OFF. This will turn the fan off and stop airflow from coming into the vehicle. OFF A/C MAX A/C Recirculation switch The recirculation switch is located at the center of the instrument panel just right of the radio. It allows switching from outside air to recirculated air in Panel, Panel/Floor, and Floor modes. The recirculation switch operates for five minutes, then shuts off. If more recirculation operation is desired, press the control again. Note that in MAX A/C and A/C modes, the function is automatic (stays in recirculation mode) and cannot be switched off. A table of recirculation switch operation follows. 9 Controls and features Icon MAX A/C A/C OFF Recirculation Switch Operation Mode Max A/C A/C Panel OFF Panel/Floor Floor Floor/Defrost Defrost Recirculation Automatic Automatic Selectable Not Available Selectable Selectable Not Available Not Available Fan speed knob The left knob on the control is the fan control knob, which controls the volume of air flow. Rotate the knob to the right to increase fan speed and increase the amount of air entering the vehicle. Four fan speed positions are available and are indicated by dots beside the control knob. The largest dot is the high-speed position. Temperature control knob The temperature control knob is the rotating knob located at the center of the control with tapered red and blue bands surrounding most of the knob. The wide red part of the band (full right) is the warm temperature area. The wide blue part of the band (full left) is the cool temperature area. Any position selected between full right and full left will give a temperature between maximum heating 29°C (84°F) and maximum cooling 18°C (64°F) (A/C and MAX A/C modes only). 10 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. OFF A/C MAX A/C · 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. Using MAX A/C may be noisier and less economical than A/C. · A/C-Select to distribute cool recirculated air through the instrument panel registers. This position should be used for cooling except when it is extremely hot or fast cooling of the vehicle is needed. (panel)-Select to distribute outside air or recirculated air through · the instrument panel registers. The air may be heated based on temperature selection. The air cannot be cooled below the outside temperature regardless of the temperature setting. · (panel and floor)-Select to distribute outside air or recirculated air through the instrument panel registers and to the floor ducts at the same time. The air may be heated based on temperature selection. The air cannot be cooled below the outside temperature regardless of the temperature setting. (floor)-Select to distribute outside air or recirculated air through · the floor ducts. The air may be heated based on temperature selection. The air cannot be cooled below the outside temperature regardless of the temperature setting. · (floor and defrost)-Select to distribute outside air through the floor ducts and the windshield defroster ducts at the same time. 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. 11 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. Operating tips · In humid weather, select defrost before driving. This prevents your windshield from fogging. After a few minutes of operation, you may select another function. · Remove any snow, ice or leaves from the air intake area of your heater system that could block the air intake. The intake area is located at the bottom of the windshield. · If temperatures below -18°C (0°F), select recirculation before driving. This will help warm the vehicle interior and minimize degraded performance at low outside temperatures. · The use of climate controls will reduce the vehicle's range. Limit the use of maximum heating and cooling of the vehicle interior. 12 Charging CHARGING Charging the Ford Ranger Electric Vehicle is a safe, simple process. In-garage charging of the Ranger Electric Vehicle has received UL approval. To maximize range, the vehicle should be connected to a power control station (PCS) whenever possible to keep the battery fully charged. 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). An important feature of the PCS is an integrated control pilot circuit, which performs safety functions such as verifying the vehicle is present and safely connected, start/stop control, confirming the smart box is ready to send power, confirming the vehicle is ready to accept power, and continuously verifying the presence of an equipment ground. The PCS supplies the power commanded by the vehicle. These stations will be in private locations (for example, residential or fleet garages) or in public sites (for example, shopping malls, restaurants, parking lots and so on). The PCS uses a 40 amp, 240 volt, AC electrical supply. The customer is responsible for ordering the PCS and getting it installed. Your Ford Dealer will provide information on how to purchase and how to get your PCS installed. Consult your PCS owner's manual for specific instruction on using your PCS. Additional installations or service requirements that you might need should be performed by a full service installer. Contact your Ford dealer for a complete listing. If your installer finds any PCS malfunctions, contact the PCS manufacturer. Always follow charging instructions carefully. Failure to do so may result in vehicle damage, personal injury or death. To connect the PCS: Always set the parking brake fully. Make sure the gearshift lever is placed in P (Park) position. Turn off the "ignition" whenever you leave your vehicle. 13 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. 3. Turn the "ignition" to LOCK and remove the key from the "ignition." 4. Open the charge inlet access door in the front grille. The door is hinged toward the right headlamp and opens in the same manner as the fuel filler door. 5. Pick up the PCS connector and position it so that the release button is facing upwards. 6. Align the PCS connector to the charge inlet, fully insert the connector and make sure that the tabs on both sides of the connector engage the slots in the inlet. 7. Gently push the connector down, toward the bumper, until you hear a click. The click means that the connector is locked into the inlet. 14 Charging 8. The time required to charge the vehicle depends on the battery temperature and the state of charge when the vehicle is plugged in. The normal charge time is 6­8 hours. Reduced supply voltage, from the recommended 240 volts, may adversely affect the normal charge time. Estimated charge time The amount of time required to fully charge the battery pack varies depending upon the beginning state of charge and battery temperature. Note that battery temperature is not necessarily the same as outside temperature. The use of outside temperature to plan charge times, however, is the most straightforward approach. Typically it will take 6­8 hours for the vehicle to fully charge from "empty" to "full." Use the battery state of charge gauge as a guide to assess whether enough charge time was allowed. If the gauge does not indicate "full" when the "ignition" is moved to the ON position, one of the following may have happened: · The battery pack may be too warm or too cold. Charge times can increase to 10 hours or more for warmer or cooler batteries. In sever temperature conditions (battery temperature less than 5°C [41°F], or greater than 60°C [140°F] for the lead-acid type and less than ­25°C [­13°F] or greater than 45°C [113°F] for the nickel metal hydride type) the vehicle will not charge at all. · The PCS may be malfunctioning. · The battery pack may be out of electrical balance. The vehicle will perform a balancing charge, which may take up to four hours for the lead-acid type or two hours for the nickel metal hydride type over the normal charging time, and then indicate "full." · The gearshift lever was not in P (Park). · The battery pack (lead-acid type only) may be new. Vehicles that have experienced less than 10 drive/charge cycles need an additional few hours of charge time. 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 about three hours; 100% capacity requires approximately six to eight 15 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. Charge time may increase at colder or hotter temperatures. The drive battery must be above 5°C (41°F) and below 60°C (140°F) before charging will begin. After being connected to a PCS, the vehicle will automatically heat or cool the drive battery, as needed. When the battery reaches the necessary temperature, charging will begin. Following a complete charge in colder climates, charging will continue at periodic intervals to maintain the battery at ­10°C (14°F). The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. If a PCS is not available, the vehicle may be stored off-plug for up to 28 days without suffering permanent damage as long as the initial state of charge is greater than 50%. The frequency of this type of storage should be limited to a few occurrences over the life of the vehicle. Nickel metal hydride traction battery At 25°C (77°F), the drive battery can be charged to 80% capacity in about five to six hours; 100% capacity requires approximately six to eight 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. Charge time may increase at colder or hotter temperatures. The drive battery must be above ­25°C (­13°F) and below 45°C (113°F) before charging will begin. After being connected to a PCS, the vehicle will automatically cool the drive battery as needed. When the battery reaches the necessary temperature, charging will begin. Following a complete charge in colder climates, charging will continue at periodic intervals to maintain the battery at ­10°C (14°F). The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. If a PCS is not available, the vehicle may be stored off-plug for up to 28 days without suffering permanent damage as long as the initial state of charge is greater than 50%. The frequency of this type of storage should be limited to a few occurrences over the life of the vehicle. 16 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. Close the charge inlet access door in the front grille. 5. Return the connector and cable to their proper location. 17 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. 2. Determine if the charge connector is properly inserted in the vehicle inlet and locked in place. 3. Is the charge interrupt light illuminated? If yes, your vehicle may have undergone a series of faults which forced the PCS to terminate the charge process. · Push the stop button. · Unplug the connector from the vehicle inlet, to clear the fault. · Inspect the cable and connector for any signs of possible damage (i.e. cuts, tears or breaks in the cable insulation). If damage is found, stop any further attempts to charge the vehicle and call the PCS manufacturer for repair. · If the cable and connector are undamaged reconnect the PCS to the vehicle inlet. Is the charge interrupt light still illuminated or flashing? Consult your authorized Ranger EV dealer to determine possible vehicle fault. 4. Is the service light illuminated? If yes, · Disconnect the charge connector vehicle inlet. · Turn off the power to your PCS at the service or disconnect panel. Turning off the power may allow the PCS to clear the fault. · Turn the power back on and reconnect the PCS to the vehicle inlet. Is the service light still illuminated? If so, call the PCS manufacturer for repair or replacement. The toll free number is located on the PCS. Charging troubleshooting using Electric Vehicle Infrastructure (EVI ) 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 illuminated or any messages being issued by your PCS. 2. Determine if the charge connector is properly inserted in the vehicle inlet and locked in place. 18 Charging 3. Is the protection light illuminated? If yes, your vehicle may have undergone a series of faults which forced the PCS to terminate the charge process. · Push the stop button. · Unplug the PCS charge connector from the vehicle inlet, to clear the fault. · Inspect the charge cable and connector for any signs of possible damage (i.e. cuts, tears or breaks in the cable insulation). If damage is found, stop any further attempts to charge the vehicle and call the PCS manufacturer for repair. · If the charge cable and connector are undamaged, reconnect the vehicle. Is the charge interrupt light illuminated or flashing? Consult your authorized Ranger EV dealer to determine possible fault. 4. Is the service light illuminated? If yes, · Disconnect the PCS charge connector from the vehicle inlet. · Turn off the power to your PCS at the service or disconnect panel. Turning off the power may allow the PCS to clear the fault. · Turn the power back on and reconnect the PCS to the vehicle. Is the service light still illuminated? If so, call the PCS manufacturer for repair or replacement. · Are the ready or charging lights illuminated? If yes, your PCS is operating correctly. Consult your authorized Ranger EV dealer to determine vehicle fault. · If turning the PCS power on and off or unplugging and plugging the charge connector in the vehicle inlet does not cause any of the lights to illuminate on the PCS, the PCS has either failed or has a damaged charge cord. 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) The battery pack assembly contains 39 eight-volt batteries, wiring, a fan for ventilation and cooling, a control system and optional heaters for cold weather climates. These components work automatically when the vehicle is on-plug charging, and are monitored by the battery pack control system. Heating and cooling do NOT occur key OFF and off-plug. 19 Charging The systems are designed to maintain battery pack temperatures when on-plug as well as during the drive cycle, and may not be able to heat or cool batteries that have reached excessive temperatures. Battery temperatures tend to be warmer than outside temperature if driven and fully charged each day. If left off-plug, the batteries will eventually equalize to outside underbody temperature, although this process can take several days to occur. Extended periods off-plug in cold outdoor temperatures can cause the batteries to take several days to warm up. The heaters maintain the battery pack at approximately 20° (68°F) and are effective to at least ­20°C (­4°F). The cooling fan utilizes outside air, and therefore cooling effectiveness depends upon the temperature difference between the batteries and outside air. The cooling system works to maintain the batteries at approximately 35°C (95°F). Equalization The battery control system will periodically equalize the charge in the batteries, which smooths out battery-to-battery differences in the ability to deliver energy. This results in optimum range and battery life. 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. Following a complete charge, battery heating is accomplished by periodically overcharging the batteries to maintain a minimum acceptable temperature. These components work automatically when the vehicle is on-plug charging, and are monitored by the battery pack control system. Heating and cooling do NOT occur key OFF and off-plug. The systems are designed to maintain battery pack temperatures when on-plug as well as during the drive cycle, and may not be able to heat or cool batteries that have reached excessive temperatures. Battery temperatures tend to be warmer than outside temperature if driven and fully charged each day. If left off-plug, the batteries will eventually equalize to outside underbody temperature, although this process can take several days to occur. Extended periods off-plug in cold 20