Ford Electric Ranger 1998 Student Manual

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1998 Electric Ranger

Student Guide

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IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to

be under the vehicle.

• Be sure that the ignition switch is always in the OFF

position, unless otherwise required by the procedure.

• Set the parking brake when working on the vehicle. If you

have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation. If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation.

• Operate the engine only in a well-ventilated area to avoid

the danger of carbon monoxide.

• To prevent serious burns, avoid contact with hot metal

parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• To avoid injury, always remove rings, watches, loose

hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind your head.

• Keep hands and other objects clear of the radiator fan

blades. Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood.

• Keep yourself and your clothing away from moving parts

when the engine is running, especially the fan and belts.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may be used. The right is reserved to make changes at any time without notice.

WARNING: Many brake linings contain asbestos fibers. When working on brake components, avoid breathing the dust. Breathing the asbestos dust can cause asbestosis and cancer.

Breathing asbestos dust is harmful to your health. Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when

made airborne by cleaning with compressed air or by dry brushing. Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.

Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag.

If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators.

OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with performing brake or clutch service should be present in the area.

Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division

January, 1998

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SERVICE ST ANDARDS

Mission Statement:

All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a professional image which embraces honesty and concern for customer wants and needs.

Dealer-to-Customer Service Standards:

Appointment available within one day of the customer’s requested service day.

Write-up begins within four minutes of arrival.

Service needs courteously identified, accurately recorded on Repair Order, and verified with customer.

These seven service standards provide a process and product value that are compelling reasons for owners to purchase and repurchase Ford or Lincoln-Mercury products. These standards also help to attract new owners through favorable testimonials and improved owner satisfaction.

Vehicles serviced right on the first visit.

Service status provided within one minute of inquiry.

Vehicle ready at agreed upon time.

Thorough explanation of work done, coverages and changes.

Standard 4 “Fix It Right the First Time, on Time.”

The technician is the most important player when it comes to Standard #4. Why

Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced.

Technician Training

It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.”

Technician’s Role

Acquire the skills and knowledge for competency in your specialty via

STST New Model

— Self Study — Self Study — Ford Multimedia Training (FMT) — Instructor Led — Instructor Led

The Benefits

The successful implementation of standards means

— Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are

“the Best in the Business”

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TABLE OF CONTENTS

LESSON 1: VEHICLE OVERVIEW .................................................................................................. 1-1

Electric Vehicle (EV) History.................................................................................................. ......... 1-2

Electric Ranger Introduction ............................................................................................................ 1-3

Specifications ...................................................................................................................................1-4

Battery System ................................................................................................................................. 1-5

Traction In verter Module (TIM) ..................................................................................................... 1-15

Interface Adapter Assembly (IAA).................................................................................................1-17

Motor/Transaxle ............................................................................................................................. 1-19

High Voltage Po wer Distribution Box............................................................................................ 1-24

DC/DC Converter ..........................................................................................................................1-25

Liquid Cooling System .................................................................................................................. 1-26

Power Steering System .................................................................................................................. 1-30

Braking System ..............................................................................................................................1-32

Electronic Throttle Control............................................................................................................. 1-36

Climate Control System .................................................................................................................1-37

Networks and Multiplexing............................................................................................................ 1-42

High V oltage Interlocks .................................................................................................................. 1-44

Inertia Shutoff Switch .................................................................................................................... 1-45

Current Leakage Detection ............................................................................................................ 1-46

Suspension System......................................................................................................................... 1-47

Traction Battery Charging Components......................................................................................... 1-48

High V oltage Wiring....................................................................................................................... 1-52

Activity 1 – Vehicle Overview – Component Location Activity 1 – Worksheet A – Component Location

Student Answer Sheet ............................................................................................................ 1-59

Activity 1 – Worksheet B – Component Function Exercise

Student Answer Sheet ................................................................................................................ 1-60

Activity 1 – Worksheet C – Safety Feature Identification

Student Answer Sheet ................................................................................................................ 1-61

LESSON 2: VEHICLE OPERATION ................................................................................................2-1

V ehicle Operation.............................................................................................................................2 -2

Instrument Cluster Gauges ............................................................................................................... 2-4

Instrument Cluster W arning Lamps................................................................................................ 2-15

Economy Mode.............................................................................................................................. 2-34

Traction Battery Char ging .............................................................................................................. 2-35

Driver Response to an Emergency Situation .................................................................................. 2-37

Activity 2 – Vehicle Familiarization Activity 2 – Worksheet D – Operating Characteristics of the Electric Ranger

Student Answer Sheet ................................................................................................................ 2-39

Activity 2 – Worksheet E – W arning and Indicator Lamps

Student Answer Sheet ................................................................................................................ 2-40

Activity 2 – Worksheet F – Instrument Gauges and Lights

Student Answer Sheet ................................................................................................................ 2-41

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TABLE OF CONTENTS

LESSON 3: SAFETY AND EMERGENCY INFORMATION ........................................................ 3-1

Lead-Acid Battery Design ............................................................................................................... 3-2

Lead-Acid Module Specifications .................................................................................................... 3-4

High Voltage Color Coding.............................................................................................................. 3-5

High V oltage W arnings .................................................................................................................... 3-5

High V oltage Hazards ...................................................................................................................... 3-6

Electrical Accidents..........................................................................................................................3-8

Accident Prevention .........................................................................................................................3-9

First Aid Procedures ....................................................................................................................... 3-12

Fire Prevention ...............................................................................................................................3-14

Activity 3 – EV Safety and Emergency Information Activity 3 –Worksheet G – Safety and Emergency Procedures

Student Answer Sheet ................................................................................................................ 3-17

LESSON 4: SPECIAL SERVICE TOOLS AND PROCEDURES ................................................ 4-1

Special Service T ools and Equipment .............................................................................................. 4-2

High V oltage Diagnostic and

Service Procedures ....................................................................................................................4-19

Towing Procedure.......................................................................................................................... 4-22

Hoist Lift Points ............................................................................................................................ 4-24

Service Publication Navigation ................................................................................................. .... 4-26

Activity 4 – Special Service Tools and Procedures Activity 4 – Worksheet H – Special T ools and Service Procedures

Student Answer Sheet ................................................................................................................ 4-29

Activity 4 – Worksheet I – Service Publication Navigation

Student Answer Sheet ................................................................................................................ 4-30

Activity 4 – Worksheet J – Special Service T ools

Student Answer Sheet ................................................................................................................ 4-31

Activity 4 – Worksheet J1 – Electrical Connector Identification

Student Answer Sheet ................................................................................................................ 4-32

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TABLE OF CONTENTS

LESSON 5: DIAGNOSIS ....................................................................................................................5-1

Introduction to Ranger EV Diagnosis and Service Procedures ........................................................5-2

Symptom-to-System-to-Component-to-Cause Diagnosis ................................................................. 5-2

Ranger EV Diagnostic Flowchart ....................................................................................................5-4

Multiplexing System Diagnosis........................................................................................................ 5-6

New Generation STAR Tester ......................................................................................................... 5-8

Contactor Box Diagnosis ...............................................................................................................5-11

Activity 5 – Worksheet K – NGS Operation and Improperly Closed Contactor Relay Diagnosis

Student Answer Sheet ................................................................................................................ 5-13

Charging Concerns ........................................................................................................................ 5-17

Activity 6 – Worksheet L – Charging System Diagnosis

Student Answer Sheet ................................................................................................................ 5-20

Power Control Station (PCS) Diagnostic Procedures..................................................................... 5-22

Traction Battery Remov al ..............................................................................................................5-25

Activity 7 – Worksheet M – Traction Battery Remov al

Student Answer Sheet ................................................................................................................ 5-27

Activity 8 – Worksheet N – PTC Heater Diagnosis Demonstration

Student Answer Sheet ................................................................................................................ 5-31

Activity 9 – Worksheet O – Power Steering and Air Conditioning Diagnosis

Student Answer Sheet ................................................................................................................ 5-33

Activity 9 – Worksheet P – Air Conditioning Diagnosis

Student Answer Sheet ................................................................................................................ 5-35

Electric Motor/Transaxle Diagnosis ............................................................................................... 5-36

Traction Battery P ack Components Demonstration........................................................................5-38

Traction Battery Diagnosis.............................................................................................................5-40

Activity 12 – Diagnosis – Worksheet Q – Current Leakage and Multiple Auxiliary Load

Failure Diagnosis

Student Answer Sheet ................................................................................................................ 5-43

W orksheet R

Student Answer Sheet ................................................................................................................ 5-44

Activity 13 – Worksheet S1 – Battery Sense Lead and EPO Diagnosis

Student Answer Sheet ................................................................................................................ 5-52

Activity 13 – Worksheet S2 – Battery and Sense Lead Diagnosis (Non-BDS)

Student Answer Sheet ................................................................................................................ 5-53

Activity 13 – Worksheet T – EPO Diagnosis

Student Answer Sheet ................................................................................................................ 5-57

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TABLE OF CONTENTS

GLOSSARY

Ranger EV Acron yms.......................................................................................................... Glossary-1

ACTIVITY SHEETS

Written Acti vity Sheet 1

Student Answer Sheet ............................................................................................. Activity Sheet-1

Activity Sheet 2

Student Answer Sheet ............................................................................................. Activity Sheet-2

Generic W orksheet ...................................................................................................... Activity Sheet-3

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LESSON 1: VEHICLE OVERVIEW

TECHNICIAN OBJECTIVES

• Identify major components and systems.

• Describe the operation of major components and systems.

CONTENTS

• Electric Vehicle (EV) History

• Electric Ranger Introduction

• Specifications

• Battery System

• Traction Inverter Module (TIM)

• Interface Adapter Assembly (IAA)

• Motor/Transaxle

• High Voltage Power Distribution Box

• DC/DC Converter

• Liquid Cooling System

• Power Steering System

• Braking System

• Electronic Throttle Control

• Climate Control System

• Networks and Multiplexing

• High Voltage Interlocks

• Inertia Shutoff Switch

• Current Leakage Detection

• Suspension System

• Traction Battery Charging Components

• High Voltage Wiring

• Activity 1 – Vehicle Overview – Component Location

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• Worksheet A – Component Location

• Worksheet B – Component Function Exercise

• Worksheet C – Safety Feature Identification

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LESSON 1: VEHICLE OVERVIEW

ELECTRIC VEHICLE (EV) HISTORY

Current legistration requires the development and distribution of zero-emission vehicles. Today, only electric vehicles qualify as zero-emission vehicles. This legislation also states all automobile manufacturers who sell over 5,000 vehicles a year in regulated states must develop and manufacture electric vehicles.

Electric vehicles (EVs) were first developed in the early 1900s. These early EVs traveled at low speeds (24 km/h [15 mph]) and had limited range (48-64 kilometers [30-40 miles]).

Ford Motor Company began its recent EV development in 1982 with the introduction of the ETX 1, a converted Lynx LN7. A lead-acid battery and a 37-kW (50-hp) AC motor powered this experimental vehicle. The ETX 2 followed. The ETX 2 is a converted Aerostar using a refined 53-kW (70-hp) motor; several battery types were used and tested.

In 1993, Ford began a demonstration program to help potential customers gain real-world experience in the use of electric-powered vehicles. With the participation of utility companies and other commercial organizations, this program has now reached the one million-mile mark in vehicle miles driven. The vehicle platform for this demonstration is the Ecostar; a two-passenger electric vehicle based on the European Ford Escort Van. This demonstration program paved the way for production of the Electric Ranger.

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ELECTRIC RANGER INTRODUCTION

LESSON 1: VEHICLE OVERVIEW

1998 Electric Ranger

The 1998 Electric Ranger is a low-volume production electric vehicle. The Electric Ranger is built on the 1998 gasoline-powered Ranger platform and is sold and serviced through Ford dealerships.

A traction battery mounted under the vehicle between the frame rails supplies the electric power. The traction battery provides 312 volts direct current (DC), which is converted to three-phase alternating current (AC) that drives the motor/transaxle.

The Electric Ranger is a rear-wheel drive vehicle and operates much like the gasoline-powered models.

The most noticeable difference between the Electric Ranger and the gasoline-powered Ranger is the operating noise is very low. Because of the quiet operation of the vehicle, a motor enabled gauge is provided and is located on the right side of the instrument cluster. The motor enabled gauge indicates ON with the ignition switch in the RUN or START position and indicates OFF with the ignition switch in the OFF position or the powertrain becomes disabled.

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LESSON 1: VEHICLE OVERVIEW

SPECIFICATIONS Vehicle

Model Year 1998 Body Style Styleside, Regular Cab Pick-Up Wheelbase Short Wheelbase of 2,831 mm (111.4 inch) Payload 315 kg (700 lb) Dimensions Similar to 1998 Gasoline-Powered Ranger

Performance

0-50 Mph 12.5 seconds Top Speed 120 km/h (75 mph) Range 93 kilometers (58 miles)

Powertrain

Motor High-Efficiency, 3-Phase AC Induction Horsepower 67 kw (90 hp) Transaxle Single-Speed Constant-Ratio Drive Wheels Rear Gear Ratio 12.518:1

(without A/C or Heater Operation)

Equipment

Standard Dual Air Bags

Electro-Hydraulic Power Steering Regenerative Braking 4-Wheel ABS Aluminum Wheels Low Rolling Resistance Tires

Optional Air Conditioning

Battery Heater Spare Tire and Jack

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LESSON 1: VEHICLE OVERVIEW

BATTERY SYSTEM Battery System Warnings

WARNING: THE TRACTION BATTERY CAN DELIVER 312 VOLTS OF DC POWER. IMPROPER HANDLING OF THE TRACTION BATTERY CAN RESULT IN INJURY OR FATALITY. ONLY AUTHORIZED PERSONNEL TRAINED TO WORK WITH TRACTION BATTERY COMPONENTS ARE PERMITTED TO HANDLE THE BATTERIES.

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 VENTILATION.

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.

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LESSON 1: VEHICLE OVERVIEW

WARNING: HIGH VOLTAGE COMPONENT SERVICE SHOULD ONLY BE PERFORMED BY TRAINED PERSONNEL. INCORRECTLY PERFORMING SERVICE PROCEDURES MAY RESULT IN INJURY OR DEATH. ALL HIGH VOLTAGE COMPONENTS ON THIS VEHICLE ARE MARKED WITH THE FOLLOWING WARNING LABEL.

High Voltage Warning Label

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Traction Battery

LESSON 1: VEHICLE OVERVIEW

Traction Battery

• The traction battery is located underneath the vehicle between the

frame rails.

• The traction battery consists of 39 8-volt lead-acid battery modules

stored in a supporting tray.

• The supporting tray is constructed of an extremely strong non-

conductive composite material with bonded metal mounting brackets. – The tray is about 8 feet long and weighs almost 900 kg (2000 lb)

with battery modules and associated components in place.

– The supporting tray has a cover which is bolted on. There are

individual battery modules and other components contained within the traction battery supporting tray.

• The 39 battery modules are arranged in 2 levels, 12 on the upper

level and 27 on the lower level.

• The battery modules are wired in series and produce 312 volts DC.

• A battery control module is located in the upper level at the front of

the assembly. – The battery control module is secured with Velcro

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• A contactor box is located in the upper level at the rear of the assembly.

– The contractor box is secured with Velcro

• A cooling system and a (optional) heating system (for cold climate

areas) are used to maintain optimal temperature within the traction battery.

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LESSON 1: VEHICLE OVERVIEW

Traction Battery Cooling System

• The traction battery cooling system consists of:

– four temperature sensors. – a two-speed fan. – a battery control module.

• The cooling fan is located in the center of the traction battery.

• The cooling function is controlled by the battery control module

(BCM).

• During charging, the cooling fan is used for ventilation and

cooling of the traction battery: – For ventilation, the cooling fan operates at low speed all the

time.

– For cooling, the cooling fan operates at high speed based on the

temperature of the traction battery.

– For ventilation purposes, the cooling fan operates for 10 minutes

following the completion of the charge cycle.

• During driving, the cooling fan is used for cooling the traction

battery: – For cooling, the cooling fan operates at high speed based on the

temperature of the traction battery.

– Air is drawn in from the rear of the traction battery and exits

through the front.

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NOTE: Be sure vent openings are clear of obstructions before connecting charger.

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Traction Battery Heating System (Optional)

LESSON 1: VEHICLE OVERVIEW

Optional Traction Battery Heating System

• To maintain proper temperature during charging in cold climates,

• The lower level of battery modules is heated using a blanket

• The upper level uses individual heating elements (A) wired in series.

• The battery heating function is controlled by the battery control

an optional traction battery-heating system is available.

heater (B) to heat the entire lower level. – The lower level blanket heater is located underneath the battery

modules.

– The upper level heating elements are mounted directly to the

side of each battery module.

module. – The module will activate the battery heating system if the

traction battery temperature falls below 15°C (59°F) while connected to an activated charge station.

– Heating function is deactivated when the traction battery

temperature rises above 25°C (77°F). The upper and lower heating elements may function independently based on input from temperature sensors.

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LESSON 1: VEHICLE OVERVIEW

Traction Battery Wiring and Circuit Protection

Traction Battery Circuit Protection

• The traction battery uses low and high voltage wiring.

• The high voltage circuit is protected by a 400-volt 250 amp fuse

installed between batteries 20 and 21.

• If the fuse opens or is removed, the high voltage circuit is

interrupted.

• Two high voltage connectors connect the traction battery to the

vehicle systems.

• The primary power (2-pin) connector is located at the rear of the

battery tray and transfers power to the motor/transaxle.

• The auxiliary power (4-pin) connector is located near the front of

the battery tray on the passenger side. It transfers high voltage power to the vehicle’s auxiliary high voltage circuits.

• Both high voltage circuits are part of the vehicle high voltage

interlock circuit (covered later in this lesson).

• The low voltage connector is located near the front of the battery

tray on the driver side and transfers low voltage to the vehicle’s low voltage circuits.

– The low voltage connector is a 76-pin connector.

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Contactor Box Assembly (CBA)

LESSON 1: VEHICLE OVERVIEW

Contactor Box

• The contactor box assembly (CBA) (arrow) is located in the rear of

the traction battery at the upper left side.

• The contactor box serves as the on/off switches for the traction

battery.

• Relays are used to interrupt the flow of high voltage when the

driver’s key is turned to the OFF position, the inertia shutoff switch is activated or the system is in shutdown mode actuated by an electronic control module.

• The contactor box supports these additional functions:

– high voltage circuit precharging – the high voltage circuits

require precharging. Otherwise, the large voltage differential might weld contactors as circuits are switched on. Precharging is accomplished through two relays and two 20-ohm resistors located in the contactor box.

– traction battery current sensing – the contactor box contains two

Hall effect sensors that monitor the current from the traction battery. One sensor monitors the current flow into the traction inverter module (TIM) (power for the motor/transaxle), and the other monitors current flow into the high voltage auxiliary circuits.

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– high voltage circuit protection – the charging, battery heater and

high voltage auxiliary circuits are protected by three fuses in the contactor box.

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LESSON 1: VEHICLE OVERVIEW

12-Volt Battery

12-Volt Battery Location

• The 12-volt battery is located in the left front corner of the

underhood compartment.

• The 12-volt battery is used for lighting and other low-voltage

circuits and systems.

• The DC/DC converter acts as an alternator to charge the

12-volt battery.

• The 12-volt battery in the Electric Ranger is different than that used

in the gasoline-powered Ranger. – The Electric Ranger does not require large 12-volt battery

capacity due to the absence of a high current starter circuit.

– The Electric Ranger battery is a 31 amp-hour deep cycle battery.

NOTE: Never attempt to jump-start the 12-volt battery.

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Battery Control Module (BCM)

LESSON 1: VEHICLE OVERVIEW

Battery Control Module (BCM)

• The battery control module (BCM) (arrow) is located in the upper

front section of the traction battery.

• The BCM is a high and low voltage module that controls all battery

system operations.

• The BCM monitors the temperature and state of charge of the

39 battery modules in the traction battery.

• The BCM controls battery charging and cooling.

• The BCM controls the optional battery heating system operation

if equipped.

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LESSON 1: VEHICLE OVERVIEW

INPUTS

Battery Temperature Sensor 1-4

Emergency Power Off (EPO)

Battery V oltage Sensors

Battery Pack State Of Charge (SOC)

Digital T ransmission Range (DTR) Sensor

Charge Cord Plugged In Signal

BATTERY

CONTROL

MODULE

(BCM)

OUTPUTS

High V oltage Power Distribution Box (HVDB)

Emergency Power Off (EPO)

Battery Heaters

Battery Charger

Battery Pack Cooling Fan

Charger Contactor Relay

Negative Contactor Relay

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TRACTION INVERTER MODULE (TIM)

HIGH VOLTAGE COMPONENT

LESSON 1: VEHICLE OVERVIEW

ER011-A

Traction Inverter Module (TIM)

• The traction inverter module (TIM) (arrow) is located underneath

the center rear of the vehicle.

• The TIM is a high and low voltage module that performs two

functions: – vehicle powertrain control – electric current conversion for the motor/transaxle

• The TIM controls the vehicle powertrain by processing driver,

module, and sensor inputs, and calculating a motor torque command.

• The TIM converts high voltage DC from the traction battery into

three phase AC used by the motor/transaxle.

• The TIM consists of:

– three high power, high-speed insulated gate bipolar transistor

modules (IGBTs).

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– four large filter capacitors (used during precharging functions). – two-phase current sensors. – a high-performance microcontroller. – logic circuitry and control circuits.

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LESSON 1: VEHICLE OVERVIEW

• The IGBTs are used to switch on and off the three motor phases.

– As they switch on and off, the IGBTs produce voltage spikes

– Capacitors are used as a filters to protect the TIM and maintain

– These capacitors retain traction battery voltage and provide

NOTE: The TIM is equipped with a bleed down system which ensures that the capacitors are discharged to less than 50 volts within two minutes after the driver’s key is turned to the OFF position.

• Be sure to allow for capacitor bleed down time before attempting

maintenance or repair.

that have the potential to damage the TIM.

traction bus voltage during IGBT switching.

current capability for instantaneous torque.

INPUTS

Motor Temperature Sensor

Emergency Power Off (EPO)

Accelerator Pedal Sensors 1-3

Anti-Lock Brake Module

Brake Pedal Sensor

Digital T ransmission Range (DTR) Sensor

Charge Cord Plugged In Signal

Oil Pressure Sensor

TRACTION INVERTER

MODULE

(TIM)

OUTPUTS

Vehicle Speed Signal

Emergency Power Off (EPO)

Electric Motor/ Transaxle

Precharge Contactor Relay

Main Contactor Relay

Oil Pump Relay

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LESSON 1: VEHICLE OVERVIEW

INTERFACE ADAPTER ASSEMBLY (IAA)

Interface Adapter Assembly (IAA)

• The interface adapter assembly (IAA) is located on the bulkhead

under the instrument panel, the same location as the gasolinepowered Ranger EEC-V module.

• The IAA is a low voltage multi-function module that manages the

climate control system, the auxiliary systems and most instrument cluster gauges and lamps.

• The IAA is networked with the TIM and the BCM to support

instrument cluster functions, contactor box operations, and diagnostics.

• The IAA diagnostics are accessible through the OBD-II diagnostic

connector under the instrument panel next to the steering column.

• Diagnostic functions as well as parameter identification (PID) data

and active command modes are available.

• Based on operator and vehicle demands, the IAA controls these

functions: – High voltage A/C compressor (optional). – High voltage positive temperature coefficient (PTC) heater.

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– Air distribution blend door and climate control blower fan

motor. – Power steering. – DC/DC converter. – Vacuum pump. – Liquid cooling system coolant pump and two-speed radiator fan. – Instrument cluster operation.

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LESSON 1: VEHICLE OVERVIEW

INPUTS

Blower Motor Speed

Emergency Power Off (EPO)

A/C Pressure Sensor

Vacuum Pressure Sensor

Coolant Temperature Sensor

Brake Fluid Level Switch

PTC Heater Switching Module

Steering Wheel Sensors

INTERF ACE

ADAPTER

ASSEMBLY

(IAA)

OUTPUTS

PTC Heater Cores

Emergency Power Off (EPO)

Vacuum Pump

A/C Compressor

DC/DC Converter

Cooling Fan Relay

Auxiliary Contactor Relay

Power Steering Control

Instrument Gauges and Lights

Air Distribution Blend Doors

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LESSON 1: VEHICLE OVERVIEW

MOTOR/TRANSAXLE

Motor/Transaxle Assembly

• The motor/transaxle is mounted just behind the traction battery.

• The motor/transaxle assembly consists of a:

– four-pole, three phase AC induction motor. – single-speed transaxle with a planetary gearset.

• The motor/transaxle supplies power through halfshafts to the

rear wheels. – A peak power of 67 kW (90 hp) is produced at 190 Nm

(140 lb ft) torque.

• The assembly is packaged in an aluminum case and weighs

approximately 91 kg (200 lb).

1998 Ranger EV New Model Training 1-19

Page 28

LESSON 1: VEHICLE OVERVIEW

Motor

A B

Motor Components

ER014-A

• The AC induction motor consists of a:

– stator (A). – cast aluminum rotor (B). – rotor speed sensor (C).

• The motor has a maximum operating speed of 13,000 rpm and

maximum current draw of 305 amps.

1-20 1998 Ranger EV New Model Training

Page 29

LESSON 1: VEHICLE OVERVIEW

• Alternating current is supplied from the TIM to the motor through

high voltage cables. – Current flows through the stator windings generating a

magnetic field. – The magnetic field causes the rotor to spin. – Varying the amount of current controls torque. – Varying the AC current frequency controls speed. – During deceleration and braking, a negative torque is produced,

and the motor acts as a generator and regenerates charge in the

traction battery.

1998 Ranger EV New Model Training 1-21

Page 30

LESSON 1: VEHICLE OVERVIEW

Transaxle

Transaxle Components

• The transaxle consists of a:

– two-stage direct reduction planetary gear system (similar to

other automatic transaxle planetary gear sets). – 50/50 planetary differential.

• The transaxle is a constant-ratio (one-speed) unit and uses no apply

components. – There are no clutches, bands, or valves as in multiple-speed

transaxle units.

• A cam-operated parking pawl is operated manually by the gear

selector assembly through the shift cable and shift lever.

• The cam has five detent positions:

– Park (P) – Reverse (R) – Neutral (N) – Drive (D) – Economy (E)

1-22 1998 Ranger EV New Model Training

Page 31

LESSON 1: VEHICLE OVERVIEW

• Direction (clockwise or counterclockwise) and speed of the motor

are monitored by a speed sensor mounted inside the transaxle case. – The speed sensor detects passing teeth on the speed wheel as it

rotates. – The speed wheel is mounted to the input shaft. – The speed (rpm) signal is sent to the TIM.

• The transaxle is lubricated by Tribolube-L6 (Pro Gear 21), a

synthetic, low-viscosity oil.

• A 12-volt DC oil pump mounted inside the case supplies oil to

lubricate the gears and bearings. – The pump is controlled by the TIM. – Normal pressure is approximately 103 kPa (15 psi). – If pressure drops below 28 kPa (4 psi), the oil pressure switch

opens and signals the TIM.

• Motor/transaxle cooling is provided by the vehicle liquid cooling

system (covered later in this lesson).

NOTE: Adding transaxle oil is not a standard maintenance item. Change transaxle oil at 3 year intervals.

1998 Ranger EV New Model Training 1-23

Page 32

LESSON 1: VEHICLE OVERVIEW

HIGH VOLTAGE POWER DISTRIBUTION BOX

HIGH VOLTAGE COMPONENT

ER016-A

High Voltage Power Distribution Box

• The high voltage power distribution box (arrow) is located in the

underhood compartment on top of the battery charger.

• The high voltage power distribution box is similar in function to

the fuse box in your home. – It distributes high voltage to components and systems. – It contains fuses.

• The power distribution box directs fuse protected high voltage to:

– DC/DC converter. – Heating system. – Air conditioning system (optional). – Power steering system. – Battery charger.

• The power distribution box has a protective cover that is part of the

high voltage interlock circuit (covered later in this lesson).

1-24 1998 Ranger EV New Model Training

– When the cover is removed, a limit switch will open the relays

in the contactor box, which interrupts high voltage to the

vehicle systems.

Page 33

DC/DC CONVERTER

HIGH VOLTAGE COMPONENT

LESSON 1: VEHICLE OVERVIEW

ER017-A

DC/DC Converter

• The DC/DC converter (arrow) is located in the underhood

compartment on the driver side of the battery charger.

• The DC/DC converter acts as an electronic alternator, charging the

12-volt battery and supplying power for low voltage components and systems.

• The DC/DC converter steps down traction battery voltage from

312 volts to 12 volts.

• A temperature sensor mounted near the 12-volt battery tray allows

the converter to adjust voltage to the 12-volt battery as temperature changes.

• The DC/DC converter is controlled by the IAA.

• The DC/DC converter operates when the key is in the ON position

and with the key in the OFF position when the vehicle is connected to the power control station (PCS) for charging.

1998 Ranger EV New Model Training 1-25

Page 34

LESSON 1: VEHICLE OVERVIEW

LIQUID COOLING SYSTEM

Liquid Cooling System Components

Item Description

1 Two-Speed Electric Cooling Fan 2 Radiator

• The high voltage electronics used on the Electric Ranger require

cooling under normal use.

• Excess heat is removed by a liquid cooling system controlled by

the IAA.

• The liquid cooling system cools the:

– TIM. – motor/transaxle. – DC/DC converter. – A/C inverter motor controller.

1-26 1998 Ranger EV New Model Training

Page 35

LESSON 1: VEHICLE OVERVIEW

• The liquid cooling system consists of:

– an Explorer radiator. – a two-speed electric cooling fan. – a 12-volt electric coolant pump. – rubber coolant hoses. – metal coolant tubes. – a 50/50 mix of water and glycol Ford specification WSS-

M97B44-C. (Do not mix with previous specification.)

• The 12-volt coolant pump incorporates a:

– centrifugal impeller design. – 12-volt DC motor. – magnetic motor-to-impeller clutch.

NOTE: Adding coolant is not a standard maintenance item. Do not mix the new glycol with the previous specification. Change coolant at 100,000 miles or 5 years whichever comes first.

1998 Ranger EV New Model Training 1-27

Page 36

LESSON 1: VEHICLE OVERVIEW

Coolant Hose Routing

1-28 1998 Ranger EV New Model Training

Item Description

1 A/C Inverter Motor Controller 2 DC/DC Converter 3 Coolant Temperature Sensor 4 12-Volt Electric Coolant Pump Motor 5 Rubber Coolant Hoses 6 Electric Cooling Fan Module (not shown) 7 Metal Coolant Tubes

Page 37

LESSON 1: VEHICLE OVERVIEW

• Coolant is circulated by the electric pump located below the

DC/DC converter.

• Rubber hoses carry coolant to the DC/DC converter and the

A/C inverter motor controller.

• Rubber hoses and metal tubes carry coolant to the motor/transaxle

and TIM.

• An electric cooling fan module is mounted on the lower right

section of the radiator.

• The coolant temperature sensor is located in the hose connector

above the electric pump.

• The liquid cooling system operates whenever the driver’s key in the

ON position. – It also operates during battery charging if the DC/DC converter

is charging the 12-volt battery.

1998 Ranger EV New Model Training 1-29

Page 38

LESSON 1: VEHICLE OVERVIEW

POWER STEERING SYSTEM

Power Steering System Components

Item Description

1 Power Steering Controller Assembly 2 Power Steering Gear and Linkage

• The power steering controller assembly is located on the right side

of the underhood compartment.

• The power steering controller assembly consists of an electric

controller attached to a high voltage AC electric motor and pump.

• The electronic controller has its own inverter to convert DC voltage

from the traction battery into the high voltage AC required by the motor.

• The assembly has one high voltage connector and one low voltage

connector.

• The steering linkage and power steering gear are carryover from

gasoline-powered Ranger.

• The steering column is a Ranger tilt column to accommodate a

steering wheel rotation sensor that provides input for additional power assist when the vehicle is at a stop.

1-30 1998 Ranger EV New Model Training

Page 39

NOTES

LESSON 1: VEHICLE OVERVIEW

1998 Ranger EV New Model Training 1-31

Page 40

LESSON 1: VEHICLE OVERVIEW

BRAKING SYSTEM

Braking System Components

• The base brake system is a conventional hydraulic/friction braking

system.

• The brake booster and master cylinder are carryover from the

gasoline-powered Ranger.

• The master cylinder includes a modified pressure sensor that

provides input for the regenerative braking system.

• The front and rear discs and calipers (above) are carryover

Explorer. – The hubs are similar to those used on Thunderbird.

1-32 1998 Ranger EV New Model Training

Page 41

LESSON 1: VEHICLE OVERVIEW

Motor Driven Vacuum Pump

• A motor driven vacuum pump is mounted beneath the

battery charger.

• The anti-lock braking system (ABS) is a 4-sensor 3-channel

system.

• ABS components include:

– an electronic control unit (ECU). – an Explorer hydraulic control unit (HCU). – a Ranger mounting bracket.

• The ABS system sends active line output to the TIM for use with

the regenerative braking system.

• All of the electric components in the braking system operate off

low voltage circuits.

1998 Ranger EV New Model Training 1-33

Page 42

LESSON 1: VEHICLE OVERVIEW

Regenerative Braking System (RBS)

Electrical energy

Kinetic energy

ER024-A

Regenerative Braking System (RBS)

• In a conventional friction braking system, the kinetic energy of

deceleration is transformed into heat. – This heat is dissipated into the surrounding air.

• The function of the regenerative braking system (RBS) is to

recover some of this kinetic energy during deceleration and improve overall vehicle efficiency.

• Regenerative braking is accomplished by using vehicle

deceleration to drive the motor/transaxle. – This causes the motor to act as a generator and convert vehicle

kinetic energy into electrical energy that is stored by the traction

battery.

1-34 1998 Ranger EV New Model Training

Page 43

LESSON 1: VEHICLE OVERVIEW

• The accelerator pedal and the brake pedal are inputs of the RBS.

• RBS supplements the hydraulic braking system.

• The RBS operates when the vehicle is moving either forward or

backward.

• It is possible for RBS motor torque to cause rear wheel slip in

certain circumstances. – To prevent excessive wheel slip, the RBS is designed to work

with the anti-lock brake system (ABS) module. – Whenever an ABS event occurs, the ABS module signals the

TIM, which reduces regenerative braking. – The RBS is returned to its prior state after the ABS event.

NOTE: The IAA triggers the red BRAKE warning lamp in the instrument cluster if an RBS fault occurs. The vehicle can be safely operated without RBS.

1998 Ranger EV New Model Training 1-35

Page 44

LESSON 1: VEHICLE OVERVIEW

ELECTRONIC THROTTLE CONTROL

Electronic Throttle Control Components

ER025-A

Item Description

1 Accelerator Position Sensor (APS) 2 Accelerator Pedal Assembly

• Electronic throttle control is in use on vehicles other than

Electric Ranger.

• On the Electric Ranger, electronic throttle control replaces the

cable between the accelerator pedal and the powertrain.

• Instead of a mechanical request for power, electronic throttle

control uses electrical signals.

• The sensing component of electronic throttle control is an

accelerator position sensor (APS) mounted to the accelerator pedal assembly.

– Three potentiometers in the APS sense the position of the

accelerator pedal. – The APS sends signals to the TIM, which commands the

motor/transaxle to respond accordingly.

1-36 1998 Ranger EV New Model Training

Page 45

CLIMATE CONTROL SYSTEM Heating System Description

HIGH VOLTAGE COMPONENT

LESSON 1: VEHICLE OVERVIEW

Heating System

ER026-A

• In place of using engine coolant to heat the passenger

compartment, the Electric Ranger uses a positive temperature coefficient (PTC) heater.

• A PTC switching module (A) provides high voltage to the

PTC heater.

• The PTC switching module is located in the underhood

compartment in front of the high voltage power distribution box (B).

• The module is controlled by the IAA, and provides fault feedback

to the IAA, if any of the following faults occur: – A short in the PTC switching module – A heater core over-temperature condition – A heater core fault

1998 Ranger EV New Model Training 1-37

• Feedback is provided on heater core fault conditions (open, short,

or over current).

Page 46

LESSON 1: VEHICLE OVERVIEW

Heating System Operation

Heater Assembly

• The PTC heater is an electric resistance heater with a two-stage

heater core that operates on two separate circuits.

• The heater core uses high voltage DC from the traction battery to

defrost the windshield and heat the passenger compartment.

• The heater core is housed in the heater plenum under the

instrument panel. – The plenum is modified from the gasoline-powered

Ranger assembly. – The vacuum system, blend door actuator, fresh/recirculation

solenoid, over-temperature switch, and wiring harness are new,

and the seals are modified. – The evaporator assembly is a modified gasoline-powered

Ranger assembly. – The blower motor and serviceable air filter are new (the air filter

is replaced annually). Air filter is located inside the blower

motor housing.

1-38 1998 Ranger EV New Model Training

Page 47

LESSON 1: VEHICLE OVERVIEW

• The manual control head is a modified gasoline-powered Ranger

design with a: – mode switch. – blower switch. – temperature potentiometer.

• A new recirculation switch allows heat to be recirculated.

• The ambient and in-vehicle temperature sensors are carryover from

Explorer.

• Heating temperature in the passenger compartment is limited to

27°C (80°F) to conserve traction battery power.

1998 Ranger EV New Model Training 1-39

Page 48

LESSON 1: VEHICLE OVERVIEW

Air Conditioning System

HIGH VOLTAGE COMPONENTS

ER028-A

Air Conditioning System Components

• The air conditioning compressor (B) is located in the lower center

of the under hood compartment.

• The absence of an internal combustion engine means there is no

drive belt to power a pulley-driven compressor.

• The Electric Ranger uses an AC high voltage variable-speed

compressor. – The AC high voltage is supplied by the A/C inverter motor

controller (A). – The A/C inverter motor controller has a case similar to the

design of the DC/DC converter and is located next to the battery

charger. – The controller contains three IGBTs for high speed current

switching.

1-40 1998 Ranger EV New Model Training

Page 49

LESSON 1: VEHICLE OVERVIEW

• The compressor is located in the lower center of the underhood

compartment and: – is a 33 cc scroll design. – has an integral 3.5 kW (4.7 hp) motor. – has a maximum shaft speed of 7812 rpm.

• The A/C system is a modified Ranger clutch cycling orifice tube

(CCOT) system that: – requires .8 kg (1.75 lb) of R134a – uses a carryover gasoline-powered Ranger condenser unit. – has refrigerant lines and evaporator/blower assemblies that are

new for Electric Ranger.

• The lower limit of the cooling temperature in the passenger

compartment is 18°C (65°F) to conserve traction battery power.

1998 Ranger EV New Model Training 1-41

Page 50

LESSON 1: VEHICLE OVERVIEW

NETWORKS AND MULTIPLEXING

Multiplexing System

• A network is an electronic system composed of control module(s)

and/or diagnostic tester (scan tool) that are connected with at least one wire. This hardware allows the modules to communicate with each other.

• The use of networks provides several benefits. These include:

– Input sensor information can be shared between control

modules. This means that they do not have to be hard wired into

each module that requires the data they provide. – Complex vehicle actions requiring the participation of more than

one module can be performed. – Improved diagnostic capability is available over the network.

1-42 1998 Ranger EV New Model Training

Page 51

LESSON 1: VEHICLE OVERVIEW

• Multiplexing is an operating strategy where control modules can

communicate with each other during normal vehicle operation.

• Multiplexing only occurs over the J1850 network.

• Modules that are multiplexed use the J1850 network and standard

corporate protocol (SCP) to communicate (a protocol is a type of computer language).

• The International Standard Organization (ISO) 9141 network is

NOT a multiplexed network.

• The ISO 9141 network is only used for diagnostic purposes and is

not active during normal vehicle operation.

• In order for the ISO 9141 network to be active, a scan tool must be

connected to the network.

• The Electric Ranger has both a J1850 (SCP) and an ISO 9141

network.

• The J1850 (SCP) network consists of:

– a twisted pair of connecting wires (known as a data bus) in the

wiring harness (Circuits 914 and 915). – traction inverter module (TIM). – battery control module (BCM). – interface adapter assembly (IAA). – data link connector (DLC) (located next to the steering column).

• The ISO 9141 network consists of:

– a single wire data bus (circuit 70). – anti-lock brake system (ABS) module. – central timer module (CTM). – electronic crash sensor (ECS) module. – DLC.

• Diagnostics for both networks is accessed through the DLC using

New Generation STAR (NGS) Tester (covered in Lesson 5).

1998 Ranger EV New Model Training 1-43

Page 52

LESSON 1: VEHICLE OVERVIEW

HIGH VOLTAGE INTERLOCKS

High Voltage Interlocks

• High voltage interlocks help prevent electrical accidents by

disabling high voltage power when:

ER030-A

– connectors are disconnected. – the top cover (A) of the high voltage power distribution box (B)

is removed.

• The Electric Ranger has interlocks on the following components

and wiring: – The high voltage power distribution box cover. – The high voltage connector from the traction battery to the high

voltage power distribution box. – The high voltage connector from the traction battery to the TIM.

1-44 1998 Ranger EV New Model Training

Page 53

INERTIA SHUTOFF SWITCH

Inertia Shutoff Switch Location

LESSON 1: VEHICLE OVERVIEW

ER031-A

• The inertia shutoff switch (arrow) is located above the carpet line

and below the evaporator assembly on the passenger side of the vehicle.

• The inertia shutoff switch on the Electric Ranger performs a similar

function as the inertia shutoff switch on the gasoline-powered Ranger.

– On both vehicles, the inertia shutoff switch disables the vehicle

powertrain in the case of an accident. – On the gasoline-powered Ranger, the inertia shutoff switch

disables the fuel pump. – On the Electric Ranger, the inertia shutoff switch interrupts the

high voltage power to the vehicle systems.

• The POWER RESET lamp illuminates whenever the inertia shutoff

switch is triggered. – The reset button is located on top of the inertia shutoff switch.

Emergency Power Off (EPO)

• The EPO is a fail-safe system designed to safeguard against

personal injury and prevent vehicle damage.

1998 Ranger EV New Model Training 1-45

• EPO is activated when the inertia shutoff switch is triggered or a

high voltage interlock is disconnected. – An EPO signal is sent to disable all high voltage loads and shut

down the vehicle. – TIM, BCM, and IAA can initiate an EPO signal.

Page 54

LESSON 1: VEHICLE OVERVIEW

CURRENT LEAKAGE DETECTION

Current Leakage Detection

• The Electric Ranger uses a current leakage detection system to

monitor the integrity of the electrical system.

• The BCM monitors the high voltage system for current leakage by

checking the DC circuitry for a low impedance path.

• Current leakage detection is performed by relays, leakage current

shunts and current limiting resistors within the BCM.

• This internal circuitry interfaces with either terminal of the traction

battery to measure impedance path between the terminal and the vehicle chassis.

• If the BCM detects severe leakage, the electric hazard warning

lamp in the instrument cluster will illuminate.

NOTE: If the electric hazard warning lamp remains illuminated after lamp prove out, service the vehicle.

1-46 1998 Ranger EV New Model Training

Page 55

LESSON 1: VEHICLE OVERVIEW

SUSPENSION SYSTEM

Rear Suspension Components

• The rear suspension system is designed specifically for the Electric

Ranger.

• The DeDion rear axle (B) consists of:

– a thick-walled aluminum tube. – sand-cast aluminum ends with Bearing carriers and spring seats. – aluminum ends that are welded to the aluminum tube.

• The rear axle utilizes a Watts linkage (A) for handling and control.

• The rear shock absorbers and jounce bumper brackets are unique.

• Composite single-rate leaf springs are used for weight reduction.

• Carryover Ranger spring mounts and shackles are used.

Front Suspension System

• The front suspension consists of Ranger 4x4 control arms and

modified Explorer 4x2 steering knuckle and spindle assemblies.

1998 Ranger EV New Model Training 1-47

• A unique stabilizer bar is tuned for proper roll stiffness.

• Unique torsion bars and shock absorbers attach to carryover

Ranger mounts.

Page 56

LESSON 1: VEHICLE OVERVIEW

TRACTION BATTERY CHARGING COMPONENTS Power Control Station (PCS)

ER036-A

Power Control Station (PCS)

• The Electric Ranger’s traction battery is charged by an off-board

power control station (PCS).

• The PCS requires 240-volt 40 amp AC service.

• When connection is made from the PCS to the vehicle:

– self test and vehicle confirmation tests are initiated. – if the system is operational, the green charging light will

illuminate on the PCS. – the green charging light indicates the self test and the vehicle

confirmation tests are compete and charging has begun. – the charger fans will start cooling the on-vehicle charger

approximately four minutes after the charging light illuminates

steadily.

1-48 1998 Ranger EV New Model Training

Page 57

LESSON 1: VEHICLE OVERVIEW

• If the green START light goes out and the amber CHARGE

INTERRUPT light illuminates: – operation has been discontinued by the Class A ground fault

detection system. – due to the high sensitivity of this system, the charge operation

will be shut down if either the charge cord plug or the charge

inlet is wet or damp.

• Press the STOP button to reset the system.

– If further attempts are unsuccessful, it is likely that a ground

fault exists. – If a ground fault exists, it must be repaired to continue the

charging operation.

• Complete charging procedure is covered in Lesson 2.

1998 Ranger EV New Model Training 1-49

Page 58

LESSON 1: VEHICLE OVERVIEW

Charge Inlet

HIGH VOLTAGE COMPONENT

ER037-A

Charge Inlet

• The charge inlet is equivalent to the fuel filler port on a gasoline-

powered vehicle.

• The Electric Ranger receives power in the form of 240-volt

AC current.

• An EV industry standard plug fits into the charge inlet.

– Located between the headlights behind a grille access door.

• The high voltage wiring that connects the charge inlet to the

on board battery charger is energized only during charging.

1-50 1998 Ranger EV New Model Training

Page 59

Battery Charger

HIGH VOLTAGE COMPONENT

LESSON 1: VEHICLE OVERVIEW

ER038-A

Battery Charger

• The on-board battery charger (arrow) is located in the underhood

compartment beneath the high voltage power distribution box.

• The on-board battery charger receives 240-volt 40 amp AC current

from the power control station (PCS) and converts it into DC current.

• The on-board battery charger operates only with a charger cord

plugged into the charge inlet. – The vehicle cannot be started or driven with the charger cord

attached to the charge inlet.

• Internal fans provide cooling during battery charger operation.

1998 Ranger EV New Model Training 1-51

Page 60

LESSON 1: VEHICLE OVERVIEW

HIGH VOLTAGE WIRING

High Voltage Wiring

ER039-A

• All high voltage wiring is covered with color-coded with orange

convolute.

• High voltage wiring connects the following components:

A. From battery charger to high voltage power distribution box B. From TIM to motor/transaxle C. From traction battery to TIM D. From high voltage power distribution box to DC/DC converter E. From traction battery to high voltage power distribution box F. From high voltage power distribution box to power steering

controller assembly G. From A/C inverter motor controller to A/C compressor H. From charge inlet to battery charger I. From high voltage power distribution box to A/C inverter

motor controller J. From high voltage power distribution box to PTC switching

module K. From PTC switching module to PTC heater

• The illustrations on the following pages provide a reference for the

high voltage cables on the Electric Ranger.

1-52 1998 Ranger EV New Model Training

Page 61

LESSON 1: VEHICLE OVERVIEW

High Voltage Wiring from Charge Inlet (1) to Battery Charger (2)

High Voltage Wiring from Battery Charger (1) to High Voltage Power Distribution Box (2)

1998 Ranger EV New Model Training 1-53

Page 62

LESSON 1: VEHICLE OVERVIEW

High Voltage Wiring from High Voltage Power Distribution Box (1) to Traction Battery High Voltage Wiring from High Voltage Power Distribution Box (1) to Power Steering Controller Assembly (2)

High Voltage Wiring from High Voltage Power Distribution Box (3) to DC/DC Converter (4)

ER043-A

1-54 1998 Ranger EV New Model Training

Page 63

High Voltage Wiring from Traction Battery (1) to TIM (2)

LESSON 1: VEHICLE OVERVIEW

High Voltage Wiring from TIM (3) to Motor/Transaxle (4)

ER045-A

1998 Ranger EV New Model Training 1-55

Page 64

LESSON 1: VEHICLE OVERVIEW

High Voltage Wiring from High Voltage Power Distribution Box (1) to PTC Switching Module (2)

ER046-A

High Voltage Wiring from PTC Switching Module (3) to PTC Heater

1-56 1998 Ranger EV New Model Training

Page 65

LESSON 1: VEHICLE OVERVIEW

High Voltage Wiring from High Voltage Power Distribution Box (1) to A/C Inverter Motor Controller (2)

High Voltage Wiring from A/C Inverter Motor Controller (3) to A/C Compressor (4)

1998 Ranger EV New Model Training 1-57

Page 66

LESSON 1: VEHICLE OVERVIEW

NOTES

1-58 1998 Ranger EV New Model Training

Page 67

LESSON 1: VEHICLE OVERVIEW

EV151-A

ACTIVITY 1 – VEHICLE OVERVIEW – WORKSHEET A

COMPONENT LOCATION

STUDENT ANSWER SHEET

OBJECTIVE: To identify the location of EV Ranger components. DIRECTIONS: Go to the classroom vehicles. You will find the components listed below have tags attached to

them. Write the letter/number on the tag that is attached to each of the listed components.

High Voltage Components

_____ A/C Compressor (H) _____ A/C Inverter Motor Controller _____ Charge Inlet _____ DC/DC Converter _____ Motor/Transaxle (H) _____ High Voltage Power Distribution Box _____ Power Steering Controller Assembly _____ PTC Heater Core (inside of Chamber

1998 Ranger EV New Model Training 1-59

Assembly-Heater Plenum)

_____ PTC Switching Module _____ Traction Battery (includes BCM and

Contactor Box) (H) _____ Battery Charger _____ Traction Inverter Module (TIM) (H) _____ Vacuum Pump _____ Coolant Pump _____ Auxiliary Battery _____ Inertia Switch

END OF WORKSHEET A

Page 68

LESSON 1: VEHICLE OVERVIEW

ACTIVITY 1 – VEHICLE OVERVIEW – WORKSHEET B

COMPONENT FUNCTION EXERCISE

STUDENT ANSWER SHEET

OBJECTIVE: To identify the function of the Electric Ranger components and systems. DIRECTIONS: Match the listed items with the correct definitions:

1. Interface Adapter Assembly (IAA)

2. Regenerative Braking System (RBS)

3. DC/DC Converter

4. Vacuum Pump

5. Contactor Box

6. PTC Switching Module

7. Traction Inverter Module (TIM)

_____ manages all functions of the traction battery. _____ charges the 12-volt battery. _____ allows module to module communication during normal vehicle operation. _____ converts high voltage DC into three-phase AC. _____ interacts directly with the heating and braking system. _____ replaces the accelerator cable.

8. Battery Charger

9. Electronic Throttle Control

10. Battery Control Module (BCM)

11. Auxiliary Battery

12. Multiplexing System

13. Inertia Switch

_____ controls the PTC heating system. _____ is cooled by internal cooling fans. _____ contains two relays and two resistors for high voltage circuit precharging _____ converts vehicle kinetic energy into electrical energy. _____ is located directly in front of the high voltage power distribution box. _____ powers the lighting system. _____ interrupts power in the event of a collision.

END OF WORKSHEET B

1-60 1998 Ranger EV New Model Training

Page 69

LESSON 1: VEHICLE OVERVIEW

ACTIVITY 1 – VEHICLE OVERVIEW – WORKSHEET C

SAFETY FEATURE IDENTIFICATION

STUDENT ANSWER SHEET

OBJECTIVES: To describe the safety features found on the Electric Ranger. DIRECTIONS: Select the correct response for each statement or question.

1. The inertia shutoff switch is located: A. Beside the 12-volt battery in the underhood compartment. B. Below the evaporator assembly in the passenger compartment. C. Next to the diagnostic connector in the underhood compartment. D. Above the TIM and close to the left rear fender.

2. When does the electric hazard warning lamp illuminate? A. When the driver’s key is turned to the ON position (lamp prove-out). B. When a high level of current leakage is detected. C. When a high voltage interlock is disconnected. D. All of the above.

3. What color identifies a high voltage cable? A. Red. B. Orange. C. Yellow. D. All of the above.

4. Which of the following is not equipped with a high voltage interlock? A. The cover of the high voltage power distribution box. B. The connector from the traction battery to the high voltage power distribution box (4-pin connector). C. The connector from the traction battery to the TIM (2-pin connector). D. The cover of the traction battery.

5. High voltage components are identified by: A. Identification tags. B. Red color coding. C. Warning labels. D. Plastic insulation.

1998 Ranger EV New Model Training 1-61

END OF WORKSHEET C

Page 70

NOTES

Page 71

LESSON 2: VEHICLE OPERATION

TECHNICIAN OBJECTIVES

• Describe vehicle operation.

• Identify instrument cluster components and functions.

• Describe the economy mode.

• Describe traction battery charging procedures.

CONTENTS

• Vehicle Operation

• Instrument Cluster Gauges

• Instrument Cluster Warning Lamps

• Economy Mode

• Traction Battery Charging

• Driver Response to an Emergency Situation

• Activity 2 – Vehicle Familiarization

• Worksheet D – Operating Characteristics of the Electric Ranger

• Worksheet E – Warning and Indicator Lamps

• Worksheet F – Instrument Gauges and Lights

1998 Ranger EV New Model Training 2-1

Page 72

LESSON 2: VEHICLE OPERATION

VEHICLE OPERATION Vehicle Controls

ER051-A

Vehicle Controls

• Driving the Electric Ranger is similar to operating a gasoline-

powered vehicle.

• The key positions are the same as other Ford vehicles (positions are

listed from full rearward to full forward): – ACC – LOCK – OFF –ON – START

• The major controls are operated in the same manner as other

Ford vehicles. – gear selector lever (except for unique economy mode) – accelerator pedal

2-2 1998 Ranger EV New Model Training

– brake pedal – parking brake

Page 73

LESSON 2: VEHICLE OPERATION

• The instrument cluster has several new gauges and warning lamps

(covered later in this lesson).

• When the driver key is turned to the START position, there is no

starter motor noise (although the vehicle is activated).

• The Electric Ranger “creeps” forward like a gasoline-powered

vehicle with an automatic transmission that is in gear (after the vehicle is “started” and the key remains in the ON position foot off brake).

• During deceleration, a higher drag is felt due to the regenerative

braking system (covered later in this lesson).

1998 Ranger EV New Model Training 2-3

Page 74

LESSON 2: VEHICLE OPERATION

INSTRUMENT CLUSTER GAUGES Battery State of Charge Gauge

100

ECON

MILES

DISTANCE

TO EMPTY

60 80

000000

MPH

P RNDE

100

120

km/h

OFF

Battery State of Charge Gauge

ER052-A

• The Battery State of Charge Gauge is the equivalent of the fuel

gauge on a gasoline-powered vehicle. – F is indicated when the traction battery is fully charged. – E is indicated when the traction battery is discharged to the point

where additional operation will reduce traction battery life.

• The BCM monitors the percent of charge of each battery module

and calculates the average state of charge of the traction battery.

• The BCM sends battery state of charge information to the IAA

through the J1850 (SCP) network.

• The IAA uses the Battery State of Charge Gauge to indicate the

traction battery state of charge.

2-4 1998 Ranger EV New Model Training

Page 75

LESSON 2: VEHICLE OPERATION

BCM

IAA

INSTRUMENT CLUSTER

BATTERY STATE OF CHARGE GAUGE

ER119-A

Battery State of Charge Gauge Inputs NOTE: The POWER LIMIT and Low Fuel Warning Lamps flash

when the gauge reads empty. Vehicle performance will be extremely limited at this point; the driver must pull over off the road (to the shoulder) as quickly and safely as possible.

1998 Ranger EV New Model Training 2-5

Page 76

LESSON 2: VEHICLE OPERATION

ECON (Economy) Gauge

ECON

MILES

ECON

100

DISTANCE TO EMPTY

P RNDE

60 80

000000

100

120

km/h

OFF

MPH

ER053-A

ECON (Economy) Gauge

• The Economy Gauge not only shows the driver that his/her actions

affect vehicle range, but that driving more economically can increase the vehicle range.

• The gauge reading reflects:

– drivetrain power usage. – vehicle speed. – climate control usage. – regeneration effects.

• The needle will move toward the plus (+) sign (green band) when

the driver minimizes power usage or puts power back into the vehicle.

• The needle will move toward the minus (-) sign (yellow band)

when the driver accelerates quickly or turns on loads that reduce vehicle range.

2-6 1998 Ranger EV New Model Training

• The IAA monitors several inputs and uses this information to

control the ECON Gauge.

Page 77

REAR ABS

SPEED SENSOR

HEATER/AC

LESSON 2: VEHICLE OPERATION

ABS

MODULE

INSTRUMENT CLUSTER

TIM

Economy Gauge Inputs

IAA

ECON GAUGE

ER120-A

1998 Ranger EV New Model Training 2-7

Page 78

LESSON 2: VEHICLE OPERATION

DISTANCE TO EMPTY Gauge

100

MILES

100

MILES

DISTANCE

TO EMPTY

ECON

DISTANCE TO EMPTY

P RNDE

000000

60 80

100

120

km/h

OFF

MPH

ER054-A

DISTANCE TO EMPTY Gauge

• The DISTANCE TO EMPTY Gauge estimates the remaining

distance that can be traveled before the traction battery needs to be recharged.

– This estimate is calculated by the BCM.

• The DISTANCE TO EMPTY Gauge is controlled by the IAA and

varies as driving conditions change.

• Some conditions that affect the DISTANCE TO EMPTY

Gauge are: – city/highway driving. – hilly terrain. – climate control usage. – driving habits.

• The BCM monitors power consumption and sends this information

to the IAA.

2-8 1998 Ranger EV New Model Training

• The IAA controls the DISTANCE TO EMPTY Gauge based on

this information.

Page 79

LESSON 2: VEHICLE OPERATION

INSTRUMENT CLUSTER

BCM

IAA

DISTANCE TO EMPTY Gauge Inputs

DISTANCE TO EMPTY GAUGE

ER121-A

1998 Ranger EV New Model Training 2-9

Page 80

LESSON 2: VEHICLE OPERATION

Motor Enabled Gauge

100

ECON

MILES

DISTANCE

TO EMPTY

60 80

000000

MPH

P RNDE

OFF

100

120

km/h

OFF

ER055-A

Motor Enabled Gauge

• The Motor Enabled Gauge indicates that the vehicle is ready to be

driven.

• The needle will point to ON when the vehicle is enabled.

• The needle will return to OFF if the key is turned to the OFF

position or the powertrain becomes disabled.

• The IAA monitors the TIM and uses the Motor Enabled Gauge to

indicate the motor state (enabled or disabled).

2-10 1998 Ranger EV New Model Training

Page 81

LESSON 2: VEHICLE OPERATION

INSTRUMENT CLUSTER

TIM

IAA

Motor Enabled Gauge Inputs

MOTOR ENABLED GAUGE

ER122-A

1998 Ranger EV New Model Training 2-11

Page 82

LESSON 2: VEHICLE OPERATION

Temperature Gauge

100

ECON

MILES

DISTANCE

TO EMPTY

60 80

000000

MPH

P RNDE

100

120

km/h

OFF

ER056-A

Temperature Gauge

• The Temperature Gauge indicates the extreme temperature of

major components: – Traction battery – TIM – Motor/transaxle – Coolant

• If the temperature of any of these components is not within

desirable limits, the needle will move into the H (hot) or C (cold) areas.

– The traction battery is the only component that can cause the

needle to move into the cold area.

– If the traction battery is too cold and another component is too

hot, the temperature gauge will display the hot condition.

• The IAA monitors systems that produce heat and uses the

Temperature Gauge to indicate an overheating condition or a cold condition in the case of the traction battery.

2-12 1998 Ranger EV New Model Training

Page 83

LESSON 2: VEHICLE OPERATION

TRACTION BATTERY

TIM

MOTOR/

TRANSAXLE

Temperature Gauge Inputs

DC/DC

CONVERTER

IAA

INVERTER

INSTRUMENT CLUSTER

TEMPERATURE GAUGE

COOLANT

ER123-A

1998 Ranger EV New Model Training 2-13

Page 84

LESSON 2: VEHICLE OPERATION

Speedometer/Odometer/Tripmeter

ECON

MILES

Speedometer/Odometer/Tripmeter

100

DISTANCE

TO EMPTY

MPH

P RNDE

60 80

000000

100

120

km/h

OFF

• The speedometer (A) is an electronically driven 0-130 km/h

(0-80 mph) gauge with a carryover Ranger odometer (B) and tripmeter.

• The IAA monitors the ABS module for input from the rear

anti-lock brake system speed sensor. This input is used to indicate vehicle speed.

ER057-A

REAR ABS

SPEED SENSOR

IAA

ABS

MODULE

SPEEDOMETER/ODOMETER

Speedometer/Odometer/Tripmeter Inputs

INSTRUMENT CLUSTER

ER136-A

2-14 1998 Ranger EV New Model Training

Page 85

INSTRUMENT CLUSTER WARNING LAMPS Malfunction Indicator Lamp (MIL)

100

MILES

DISTANCE

TO EMPTY

ECON

LESSON 2: VEHICLE OPERATION

000000

MPH

P RNDE

60 80

100

120

km/h

OFF

Malfunction Indicator Lamp (MIL)

ER058-A

• The yellow MIL indicates a vehicle malfunction that requires

service.

• The MIL will illuminate during these conditions:

– a concern exists where long-term damage may result – when a less serious concern occurs twice within five key cycles

• The IAA monitors the other “smart” modules and uses the MIL to

indicate a concern.

BCM TIM

INSTRUMENT CLUSTER

IAA

1998 Ranger EV New Model Training 2-15

MIL

ER124-A

MIL Inputs

Page 86

LESSON 2: VEHICLE OPERATION

Low Fuel Warning Lamp

ECON

MILES

100

DISTANCE

TO EMPTY

MPH

P RNDE

60 80

000000

100

120

km/h

OFF

ER135-A

Low Fuel Warning Lamp

• The Low Fuel Warning Lamp alerts the driver when the state of

charge is low.

• This lamp illuminates when the traction battery state of charge

reaches 10%. – Limited operating strategy is in effect when the lamp is

illuminated to conserve remaining power.

• The Low Fuel Warning Lamp will flash when the battery state of

charge reaches 0% (the vehicle has very limited range at this point). – Speed is limited to 10 km/h (6 mph).

2-16 1998 Ranger EV New Model Training

Page 87

LESSON 2: VEHICLE OPERATION

BCM

INSTRUMENT CLUSTER

IAA

LOW FUEL WARNING LAMP

ER125-A

Low Fuel Warning Lamp Inputs NOTE: When this lamp flashes, range is very limited and the vehicle

should be returned to the repair facility. The Low Fuel Warning Lamp will also illuminate or flash if a fault occurs in the system.

1998 Ranger EV New Model Training 2-17

Page 88

LESSON 2: VEHICLE OPERATION

POWER LIMIT Warning Lamp

100

MILES

DISTANCE

TO EMPTY

ECON

60 80

000000

MPH

P RNDE

POWER

LIMIT

100

120

km/h

OFF

ER059-A

POWER LIMIT Warning Lamp

• The IAA monitors input from the TIM through the J1850 (SCP)

network and uses the POWER LIMIT Warning Lamp to indicate the vehicle’s performance is limited to conserve remaining battery power (lamp illuminated).

• As the traction battery nears complete discharge, the lamp begins to

flash to indicate performance is further limited to allow for safe parking of the vehicle before the battery is completely drained.

2-18 1998 Ranger EV New Model Training

Page 89

LESSON 2: VEHICLE OPERATION

TIM

INSTRUMENT CLUSTER

IAA

POWER LIMIT Warning Lamp Inputs

POWER LIMIT LAMP

ER126-A

1998 Ranger EV New Model Training 2-19

Page 90

LESSON 2: VEHICLE OPERATION

BRAKE Warning Lamp

BRAKE

100

MILES

ECON

DISTANCE TO EMPTY

P RNDE

60 80

000000

100

120

km/h

OFF

MPH

ER060-A

BRAKE Warning Lamp

• The red BRAKE Warning Lamp will illuminate during the

following conditions: – parking brake engaged. – low brake fluid level in the master cylinder. – regenerative braking system (RBS) malfunction. – anti-lock brake system (ABS) malfunction.

• The IAA monitors several inputs and illuminates the red

BRAKE Warning Lamp if the parking brake is engaged, there is a RBS failure, or there is a brake system concern.

2-20 1998 Ranger EV New Model Training

Page 91

LESSON 2: VEHICLE OPERATION

PARKING BRAKE

ABS

MODULE

MASTER CYLINDER PRESSURE SENSOR (LINE PRESSURE)

RED BRAKE WARNING LAMP

BRAKE Warning Lamp Inputs

TIM (RBS)

IAA

INSTRUMENT CLUSTER

MASTER CYLINDER (FLUID LEVEL)

NOTE: If the lamp illuminates, be sure the parking brake is not engaged and the brake fluid level is correct before attempting further diagnosis.

ER127-A

1998 Ranger EV New Model Training 2-21

Page 92

LESSON 2: VEHICLE OPERATION

Electric Hazard Warning Lamp

100

ECON

MILES

DISTANCE

TO EMPTY

60 80

000000

MPH

P RNDE

100

120

km/h

OFF

ER061-A

Electric Hazard Warning Lamp

• The red Electric Hazard Warning Lamp will illuminate during the

following conditions: – severe current leakage is detected. – a high voltage interlock is opened.

• If current leakage is detected, the vehicle will continue to operate.

• To prevent possible damage to the vehicle or personal injury, the

vehicle must be repaired immediately.

• If a high voltage interlock is opened, the emergency power off

(EPO) system will cause all high voltage to be disabled and shut down the vehicle (for more information on EPO see Lesson 1).

• The BCM monitors for current leakage. If current leakage is

present or a high voltage interlock is open the BCM will signal the IAA to illuminate the Electric Hazard Warning Lamp.

2-22 1998 Ranger EV New Model Training

Page 93

LESSON 2: VEHICLE OPERATION

INSTRUMENT CLUSTER

BCM

IAA

ELECTRIC HAZARD WARNING LAMP

ER128-A

Electric Hazard Warning Lamp Inputs NOTE: If an electrical hazard is present, the electric hazard warning

lamp only illuminates with the key in the START or ON position.

1998 Ranger EV New Model Training 2-23

Page 94

LESSON 2: VEHICLE OPERATION

Charging Indicator Lamp

100

ECON

MILES

DISTANCE

TO EMPTY

60 80

000000

MPH

P RNDE

100

120

km/h

OFF

ER062-A

Charging Indicator Lamp

• The red Charging Indicator Lamp will illuminate during charging

if the key is turned to the START or ON position.

• The vehicle cannot be “started” and should not be moved while the

charging cord is plugged into the charge inlet.

• The IAA monitors several inputs to indicate if it is safe to charge

the traction battery.

• If the driver attempted to start the vehicle with the charger

connected the lamp will illuminate to indicate it is not possible to operate the vehicle with the charger connected.

• The charging indicator lamp also indicates if it is not safe to charge

the battery pack. – The lamp will flash if a charging fault exists.

2-24 1998 Ranger EV New Model Training

Page 95

LESSON 2: VEHICLE OPERATION

CHARGE INLET

DTR SWITCH

IAA

IGNITION SWITCH

INSTRUMENT CLUSTER

CHARGING INDICATOR LAMP

ER129-A

Charging Indicator Lamp Inputs NOTE: The Charging Indicator Lamp will flash when the key is in

the ON position and it is unsafe to charge (vehicle not in PARK [P]), severe current leakage, open interlock or activated inertia shutoff switch).

1998 Ranger EV New Model Training 2-25

Page 96

LESSON 2: VEHICLE OPERATION

POWER RESET Indicator Lamp

100

ECON

MILES

DISTANCE

TO EMPTY

POWER

RESET

60 80

000000

MPH

P RNDE

100

120

km/h

OFF

ER063-A

POWER RESET Indicator Lamp

• The yellow POWER RESET Indicator Lamp will illuminate when

the inertia shutoff switch has been activated.

• When activated the inertia shutoff switch disables all high voltage

power to the vehicle electrical system.

• If no special service is required, pressing the reset button on top of

the inertia shutoff switch can restore power to the high voltage circuits.

• The IAA monitors the inertia shutoff switch. If the switch is

activated, high voltage circuits are interrupted and the POWER RESET Indicator Lamp is illuminated.

• The IAA opens the negative contactor relay and signals the BCM to

command the TIM to open the positive contactor relay.

• The IAA uses the J1850 (SCP) network to communicate these

commands to the other control modules.

2-26 1998 Ranger EV New Model Training

Page 97

LESSON 2: VEHICLE OPERATION

INERTIA SHUTOFF SWITCH

INSTRUMENT CLUSTER

IAA

POWER RESET INDICATOR LAMP

CONTACTOR BOX

BCM TIM

POWER RESET Indicator Lamp Inputs NOTE: The inertia shutoff switch is located in the passenger

compartment, above the carpet line and below the evaporator assembly.

ER130-A

1998 Ranger EV New Model Training 2-27

Page 98

LESSON 2: VEHICLE OPERATION

ECON MODE Indicator Lamp

100

ECON

MILES

DISTANCE

TO EMPTY

60 80

000000

MPH

P RNDE

100

km/h

ECON

MODE

120

OFF

ER064-A

ECON MODE Indicator Lamp

• The green ECON MODE Indicator Lamp will illuminate when the

driver has selected the economy driving mode (E).

• The economy mode will increase the level of regenerative braking

to improve vehicle range.

• The brightness of this lamp is controlled by the instrument cluster

lamp dimmer control.

• The TIM monitors the DTR sensor and relays information to

the IAA.

• When the driver selects economy mode, the TIM informs the IAA

and the IAA illuminates the ECON MODE Indicator Lamp.

2-28 1998 Ranger EV New Model Training

Page 99

LESSON 2: VEHICLE OPERATION

DTR

P R N D E

TIM

INSTRUMENT CLUSTER

IAA

ECON MODE INDICATOR LAMP

ECON MODE Indicator Lamp Inputs

ER132-A

1998 Ranger EV New Model Training 2-29

Page 100

LESSON 2: VEHICLE OPERATION

Auxiliary Battery Warning Lamp

100

MILES

DISTANCE

TO EMPTY

ECON

60 80

000000

MPH

P RNDE

100

120

km/h

OFF

ER065-A

Auxiliary Battery Warning Lamp

• The red Auxiliary Battery Warning Lamp will illuminate during the

following conditions: – the auxiliary battery voltage exceeds 15.75 volts. – the auxiliary battery voltage falls below 11.5 volts.

• If the auxiliary battery voltage warning lamp illuminates, the driver

must pull over to a safe area and have the vehicle repaired.

• The IAA monitors the auxiliary battery voltage. If voltage exceeds

15.75 volts or falls below 11.5 volts the IAA illuminates the Auxiliary Battery Warning Lamp.

2-30 1998 Ranger EV New Model Training