Ford ESCAPE HYBRID FCS-15101-10 User Manual
20102010
ESCAPE HYBRID
MARINER HYBRID
MODIFIERS GUIDE
FCS-15101-10
2 Electrical
3 Mounting
4 Reference
INTRODUCTION
All rights reserved. Reproduction by any means, elec tron ic or me chan i cal, in clud ing pho to copy ing,
SECTIONS
TABLE
OF
CONTENTS
SECTION 0
Introduction.......................................................................................0-1
Genuine Ford Accessories For Your Vehicle ..............................0-1
Introduction
Contents
Considerations When Using or Installing Accessories ............0-2
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
Introduction 0-1
Introduction
Note: The descriptions and specifications contained in this manual were in effect at the time this
manual was approved for printing. Ford Motor Company reserves the right to discontinue
models at any time, or change specifications or design without notice and without incurring
any obligation. 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.
Ford Motor Company has assembled this Escape/Mariner Hybrid Modifier Guide to assist vehicle
modifiers in producing safe and quality products. Ford believes that safety and quality come first.
To achieve customer satisfaction, we want to assist modifiers in achieving the highest standards of
safety and quality in their products.
This book is divided into topics pertinent to modifiers of vehicles. Reference is made to the current
Escape/Mariner Hybrid Workshop Manual for appropriate service procedures, torque specifications,
component separation clearances and other standard information which is common with the
unmodified vehicle. Specifications which are unique to the guide are designated.
This modifier guide is not a ‘‘how-to’’ book, it should be used as a checklist to help make sure that
certain important steps in the modification process are considered. While Ford is providing this
information to assist modifiers, it does not warrant the products, methods, materials or the
workmanship of the modifier. Nor does it warrant against failures that result from the modification
of a vehicle.
Following the guidelines contained in this guide does not assure individual modifiers that the
products they modify comply with U.S. Federal or Canadian Motor Vehicle Safety Standards in
effect at the time of the modification. The guidelines set forth are based on engineering analysis of
typical vehicles. If followed, the modifier’s efforts in certifying vehicles to applicable standards
should be aided. Compliance testing that may be required for certification of specific vehicle
configurations or construction is, however, the sole responsibility of the individual modifier.
Genuine Ford Accessories For Your Vehicle
A wide selection of Genuine Ford Accessories are available for your vehicle through your local
authorized Ford or Ford of Canada dealer. These quality accessories have been specifically
engineered to fulfill your automotive needs; they are custom designed to complement the style and
aerodynamic appearance of your vehicle. In addition, each accessory is made from high quality
materials and meets or exceeds Ford’s rigorous engineering and safety specifications. Ford Motor
Company will repair or replace any properly dealer-installed Genuine Ford Accessory found to be
defective in factory-supplied materials or workmanship during the warranty period, as well as any
component damaged by the defective accessory. The accessory will be warranted for whichever
provides you the greatest benefit:
• 12 months or 12,000 miles (20,000 km) (whichever occurs first), or
• the remainder of your new vehicle limited warranty.
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
0-2 Introduction
Introduction
This means that Genuine Ford Accessories purchased along with your new vehicle and installed
by the dealer are covered for the full length of your New Vehicle’s Limited Warranty — 3 years or
36,000 miles (60,000 km) (whichever occurs first). Contact your dealer for details and a copy of
the warranty.
Considerations When Using or Installing Accessories
For maximum vehicle performance, keep the following information in mind when adding
accessories or equipment to your vehicle:
• When adding accessories, equipment, passengers and luggage to your vehicle, do not exceed
the total weight capacity of the vehicle or of the front or rear axle (GVWR or GAWR as indicated
on the Safety Compliance Certification label). Consult your dealer for specific weight information.
• The Federal Communications Commission (FCC) and Canadian Radio Telecommunications
Commission (CRTC) regulate the use of mobile communications systems — such as 2-way
radios, telephones and theft alarms that are equipped with radio transmitters. Any such
equipment installed in your vehicle should comply with FCC or CRTC regulations and should be
installed only by a qualified service technician.
• Mobile communications systems may harm the operation of your vehicle, particularly if they are
not properly designed for automotive use.
• To avoid interference with other vehicle functions, such as anti-lock braking systems, amateur
radio users who install radios and antennas onto their vehicle should not locate the Amateur
Radio Antennas in the area of the driver’s side hood.
• Electrical or electronic accessories or components that are added to the vehicle by the dealer or
the owner may adversely affect battery performance and durability.
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
SECTION 1
Section 1: General Information........................................................1-1
Important Safety Notice................................................................1-1
General Information
Contents
Notes, Notices and Warnings...................................................1-2
Making Safety Devices and Elements Inoperative...................1-3
Good Practices .............................................................................1-3
Process and Quality Assurance Systems ................................1-3
Quality Assurance.....................................................................1-4
Minimum and Maximum Screw Sizes ......................................1-4
Tires and Loading.........................................................................1-4
Tire Replacement Requirements ..............................................1-4
Using Snow Tires and Traction Devices ..................................1-5
Vehicle Loading ........................................................................1-5
Vehicle Storage ............................................................................1-6
Vehicle Storage — General......................................................1-6
Vehicle Storage — Electrical....................................................1-6
Vehicle Storage — Body ..........................................................1-7
Vehicle Storage — Engine .......................................................1-7
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
SECTION 1
Contents (Continued)
Vehicle Storage — Fuel System ..............................................1-7
Vehicle Storage — Tires...........................................................1-7
General Information
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
General Information 1-1
Section 1: General Information
Important Safety Notice
Note: The descriptions and specifications contained in this guide were in effect at the time this
manual was approved for printing. Ford Motor Company reserves the right to discontinue
models at any time, or change specifications or design without notice and without incurring
obligation.
Appropriate repair methods and 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 and guidelines for performing modifications to the Escape/Mariner
Hybrid. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for modifying 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
the 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.
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1-2 General Information
Section 1: General Information
Notes, Notices and Warnings
As you read through this guide, you will come across NOTES, NOTICES and WARNINGS. Each
one is there for a specific purpose. NOTES give you added information that will help you to
complete a particular procedure. NOTICES 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 you personal injury. The following list contains some general warnings
that you should follow when you work on a vehicle.
WARNING:
• Before carrying out any vehicle modifications, the high-voltage traction battery (HVTB)
must be depowered. Failure to follow these instructions may result in severe personal
injury or death.
• The nominal HVTB voltage is 330 volts DC. A buffer zone must be set up and high-voltage
insulated safety gloves and a face shield must be worn when modifying the vehicle in
close proximity to the high-voltage system. Failure to follow these instructions may result
in severe injury or death.
• The HVTB and charging system contain high-voltage components and wiring.
High-voltage cables and wiring are orange in color. High-voltage insulated safety gloves
and a face shield must be worn when modifying the vehicle in close proximity to the
high-voltage system. Failure to follow these instructions may result in severe personal
injury or death.
• The high-voltage insulated safety rubber insulating gloves that are to be worn when
modifying the vehicle in close proximity to the high-voltage system should be of the
appropriate safety and protection rating for use on the high-voltage system. They must be
inspected before use and must always be worn in conjunction with the leather outer
gloves. Any hole in the rubber insulating glove is a potential entry point for high voltage.
Failure to follow these instructions may result in severe personal injury or death.
• Exposure to high voltage may result in severe personal injury or death. High-voltage
components must be serviced by a trained service technician.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires you to be under the vehicle.
• Make 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. The gear selector should be set in
PARK unless instructed otherwise for a specific operation. Place wood blocks (4 inch x 4
inch or larger) against the front and rear surfaces of the tires to help prevent the vehicle
from moving.
• Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide
poisoning.
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General Information 1-3
Section 1: General Information
• Keep yourself and your clothing away from moving parts when the engine is running,
especially the drive belts.
• To reduce the risk of serious burns, avoid contact with hot metal parts such as the
radiator, exhaust manifold, tailpipe, catalytic converter and muffler.
• Do not smoke while working on a vehicle.
• To reduce the risk of injury, always remove rings, watches, loose hanging jewelry and
loose clothing before beginning to work on a vehicle.
• When it is necessary to work under the hood, keep hands and other objects clear of the
radiator fan blades.
• Failure to follow these instructions may result in personal injury.
NOTICE:
• Do not disable the A/C system. The high voltage traction battery (HVTB) cooling system
uses the cabin air to cool the HVTB.
• Before placing the vehicle in a paint booth, make sure that the high-voltage traction
battery (HVTB) is not installed in the vehicle. High paint booth temperatures may damage
the HVTB.
• Place the service disconnect plug into the SERVICING SHIPPING position while carrying
out any vehicle modifications. If the service disconnect plug is left out and placed on the
bench or toolbox, dirt or other contaminants may enter the HVTB, which can cause
damage.
Making Safety Devices and Elements Inoperative
The vehicle contains many safety features required by Federal or Canadian Motor Vehicle Safety
Standards. These features, which include the key-in-ignition chime and brake lights, should never
be disabled or modified.
CFR 49 Section 30122 states that ‘‘A manufacturer, distributor, dealer or motor vehicle repair
business may not knowingly make inoperative any part of a device or element of design installed
on or in a motor vehicle or motor vehicle equipment in compliance with an applicable motor vehicle
safety standard prescribed under this chapter unless the manufacturer, distributor, dealer or repair
business reasonably believes the vehicle or equipment will not be used (except for testing or a
similar purpose during maintenance or repair) when the device or element is inoperative.’’
Good Practices
Process and Quality Assurance Systems
A formalized Process and Quality Assurance Systems check may be helpful in consistently
producing high quality products. An overview of some of the key items for such a system are
outlined in this section.
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1-4 General Information
Section 1: General Information
Quality Assurance
Completed unit sign-off: All control items should be inspected with a written sign-off. All labels
should be inspected and signed off, including verification that the information on the labels is
correct. All appropriate systems should be checked for leaks. A road test should be performed to
verify that all systems are operating correctly. All systems and functions that were provided by
Ford should be checked to make sure that they function correctly after the build process.
The modifier’s Process and Quality Assurance Systems should also make sure that appropriate
training is provided to the employees.
Minimum and Maximum Screw Sizes
When installing aftermarket equipment, avoid using fasteners that are too long for the application
or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank
and lines, powertrain components, exhaust system and suspension.
Tires and Loading
Tire Replacement Requirements
WARNING: Only use replacement tires and wheels that are the same size and type
(such as P-metric versus LT-metric or all-season versus all-terrain) as those originally
provided by Ford. Use of any tire or wheel not recommended by Ford can affect the safety
and performance of your vehicle, which could result in an increased risk of loss of vehicle
control, vehicle rollover, personal injury and death. Additionally the use of
non-recommended tires and wheels could cause steering, suspension, axle or transfer
case/power transfer unit failure. If you have questions regarding tire replacement, see an
authorized Ford or Lincoln Mercury dealer.
WARNING: Do not install an offroad, aggressive tread or incorrectly sized tire. Any of
these may cause elevated stress to the steering system. This can cause the power steering
system to overheat and shut off the power assist, which can affect the safety and
performance of your vehicle.
Note: The Escape/Mariner Hybrid vehicle is equipped with a reduced rolling resistance tire
design. The use of a different tire can effect the fuel economy of your vehicle.
Make sure all tires and wheels on the vehicle are of the same size, type, tread design, brand,
load-carrying capacity and speed rating because it can affect the safety and performance of your
vehicle, which could result in an increased risk of loss of vehicle control, vehicle rollover, personal
injury and death.
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General Information 1-5
Section 1: General Information
Using Snow Tires and Traction Devices
Note: Snow tires must be the same size and grade as originally equipped on your vehicle.
The tires on your vehicle have all-weather treads to provide traction in rain and snow. However, in
some climates, using snow tires or traction devices may be necessary.
Follow these guidelines when using snow tires and traction devices:
• SAE Class ‘‘S’’ cables should ONLY be used on the front axle tires.
• Install cables or chains securely, verifying that the cables or chains do not touch any wiring,
brake lines or fuel lines.
• Drive cautiously. If you hear the cables or chains rub or bang against the vehicle, stop and
retighten them. If this does not work, remove the cables or chains to prevent vehicle damage.
• Avoid overloading your vehicle.
• Remove the cables or chains when they are no longer needed.
• Do not use cables or chains on dry roads.
• Do not exceed 48 km/h (30 mph) with tire cables or chains on your vehicle.
Consult your dealer for information on other Ford approved methods of traction control.
Vehicle Loading
WARNING: The appropriate loading capacity of your vehicle can be limited either by
volume capacity (how much space is available) or by payload capacity (how much weight
the vehicle should carry). Once you have reached the maximum payload of your vehicle, do
not add more cargo, even if there is space available. Overloading or improperly loading
your vehicle can contribute to loss of vehicle control and vehicle rollover.
WARNING: Exceeding the Safety Compliance Certification Label axle and/or vehicle
weight rating limits could result in substandard vehicle handling or performance, engine,
transmission and/or structural damage, serious damage to the vehicle, loss of control and
personal injury.
Gross Vehicle Weight Rating (GVWR) — is the maximum allowable weight of the fully loaded
vehicle (including all options, equipment, passengers and cargo). The GVWR is shown on the
Safety Compliance Certification Label located on the B-pillar or the edge of the driver’s door.
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1-6 General Information
Section 1: General Information
Gross Axle Weight Rating (GAWR) — is the maximum allowable weight that can be carried by a
single axle (front or rear). These numbers are shown on the Safety Compliance Certification Label
located on the B-pillar or the edge of the driver’s door. The total load on each axle must never
exceed its GAWR.
WARNING: Do not use replacement tires with lower load carrying capacities than the
original tires because they may lower the vehicle’s Gross Vehicle Weight Rating (GVWR)
and Gross Axle Weight Rating (GAWR) limitations. Replacement tires with a higher limit
than the originals do not increase the GVWR and GAWR limitations.
Steps for determining the correct load limit:
• Locate the statement ‘‘The combined weight of occupants and cargo should never exceed XXX
kg or XXX lb’’ on your vehicle’s placard.
• Determine the combined weight of the driver and passengers that will be riding in your vehicle.
• Subtract the combined weight of the driver and passengers from XXX kg or XXX lb.
• The resulting figure equals the available amount of cargo and luggage load capacity. For
example, if the ‘‘XXX’’ amount equals 1,400 lb and there will be five 150 lb passengers in your
vehicle, the amount of available cargo and luggage load capacity is 650 lb (1400 - 750 (5 x 150)
= 650 lb). In metric units (635 - 340 (5 x 68) = 295 kg).
• Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight
may not safely exceed the available cargo and luggage load capacity calculated in the step
above.
Vehicle Storage
Vehicle Storage — General
• Vehicles should be stored in a dry, ventilated place and protected from sunlight, if possible.
• If vehicles are stored outside, maintenance against rust and damage, as described below, is
recommended.
NOTICE: Keep all rubber parts free from oil and solvents.
Vehicle Storage — Electrical
Note: Extended storage times which result in the discharge of the low- or high-voltage batteries
may result in the setting of DTCs and/or a no start condition.
Your vehicle must be started and run for a minimum of 10 minutes once a month in order to
maintain the high-voltage battery charge. This will maintain the high-voltage battery but it is not
enough to maintain the low-voltage (underhood) battery and additional low-voltage (underhood)
battery charging may be required after 60 days.
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General Information 1-7
Section 1: General Information
If your vehicle is to be stored for 30 days or longer, the low-voltage (underhood) battery negative
terminal must be disconnected. Failure to do this could damage your vehicle’s battery systems.
Vehicle Storage — Body
• Wash vehicle thoroughly to remove dirt, grease, oil, tar or mud from exterior surfaces and
underside of front fender.
• Periodically wash vehicles stored in exposed locations.
• Touch up exposed raw or primed metal to provide rust protection.
• Cover chrome and stainless steel parts with a thick coat of auto wax to prevent discoloration.
Rewax as necessary when the vehicle is washed.
• Lubricate all hood, door hinges and latches with a light grade oil.
• Cover the interior soft trim to prevent fading.
Vehicle Storage — Engine
• Start the engine every month. Run it at fast idle until it reaches normal operating temperature.
• With foot on brake pedal (and brake applied), shift the transmission into all gears while the
engine is running.
Vehicle Storage — Fuel System
• Regularly move vehicles short distances to mix fuel anti-oxidation agents.
Note: During extended periods of vehicle storage (60 days or more), gasoline may deteriorate
due to oxidation. This can damage rubber and other polymers in the fuel system and may
clog small orifices. A commercially available gasoline fuel stabilizer (Sta-Bil or equivalent)
should be added to gasoline-powered vehicles whenever actual or expected storage
periods exceed 60 days. The manufacturer’s instructions packaged with the product should
be followed. The vehicle should then be operated at an idle speed to circulate the additive
throughout the fuel system.
Vehicle Storage — Tires
Most high performance tires are made with nylon overlay.
As such, the following steps should be taken to avoid flat spotting when the vehicles are not used
for a period of time.
• Store the vehicles with 303 kPa (44 psi) in the tires. If the cars are to be driven, the air pressure
should be reduced to recommended operating pressure and then increased back up to 303 kPa
(44 psi) when returned to storage.
• If the vehicle is stored for periods longer than 30 days, it should be moved several feet at least
once during each 30-day period, so that a different portion of the tread contacts the ground.
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SECTION 2
Section 2: Electrical .........................................................................2-1
Electrical Basics ...........................................................................2-1
Electrical
Contents
Electrical Terms ........................................................................2-1
Control Modules — Red Area......................................................2-2
Controller Area Network (CAN) Bus ............................................2-2
General Electrical Considerations ................................................2-2
Communication Equipment.......................................................2-2
Vehicle Speed Signal................................................................2-2
Disabling Brake Lights ..............................................................2-2
High- and Low-Voltage Systems..................................................2-2
12-Volt Battery ..........................................................................2-3
High-Voltage Traction Battery (HVTB) .....................................2-3
DC/DC Converter......................................................................2-4
DC/AC Inverter and AC Power Point .......................................2-4
Auxiliary Power Point — 12V ...................................................2-5
Buffer Zone...................................................................................2-5
Rubber Insulating Gloves Testing................................................2-6
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SECTION 2
Contents (Continued)
High-Voltage Traction Battery (HVTB) Systems
Depowering.................................................................................2-7
Electrical Systems Management ..................................................2-9
Electrical
Generator Output..........................................................................2-9
Vehicle Component Electrical Loads ...........................................2-9
Typical Police/Taxi Equipment................................................2-10
General Guidelines.....................................................................2-11
Keep-Alive Memory Power .....................................................2-12
Equipment Grounding Guidelines...........................................2-12
Wire Insulation ........................................................................2-12
Terminals and Connectors......................................................2-12
Circuit Protection and Electrical Load ....................................2-13
Wire Protection Requirements................................................2-14
Grommets and Sealing Requirements ...................................2-16
Wire Routing ...........................................................................2-16
Wire Retention and Routing ...................................................2-18
Splices and Repairs ...................................................................2-20
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SECTION 2
Contents (Continued)
Recommended Splicing Method — Solder (For 16
AWG and Smaller Diameter Wire Only)...............................2-20
Heat Shrinkable Tubing (Heat Shrink) (Ford
Specification ESB-M99D56-A2) ............................................2-23
Electrical
Recommended Splicing Method — Crimp (For 10 -
22 AWG Diameter Wire to Like Wire Diameter) ..................2-23
Wiring Reference Information.....................................................2-26
Wiring Diagrams .....................................................................2-26
Connector End Views .............................................................2-29
Connector and Ground Locator..............................................2-31
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Electrical 2-1
Section 2: Electrical
Electrical Basics
Inside a vehicle, electricity is supplied through ‘‘hot’’ wires, comparable to the pressurized supply
pipes of a plumbing system. At various points along the wires are outlets in the form of lights,
switches and receptacles. Turning on a light switch is somewhat like opening a faucet to let water
run, an electric current flows through the hot wire to make the light glow. Once the electricity has
done its work, its potential drops to zero, just as water loses pressure after flowing through a sink
or laundry tub. The electrical system has ‘‘drains’’, which are the ground wires that return the
current to its source, just as a plumbing system has drain pipes through which water runs into the
sewer mains or the ground.
The light or equipment powered by the current, technically called the load, can be compared to a
water wheel that remains motionless until a stream of water causes it to turn. A load may be one
of 2 kinds. The first consists of a resistance, a material that permits the passage of electric
current, but only with difficulty and thereby creates heat. The tungsten filament of an incandescent
bulb is resistance; so is the heating element of an electric heater of a coffee pot. A load may also
be an inductance, typically a motor with windings of copper wire, in which the magnetic fields
generated by the current create motion. At any moment, the demand on an electrical system
depends on the number of loads in operation and their consumption of energy, just as demand on
a water system depends on how many faucets are opened and how wide they are opened.
The mechanics and physical fittings of the system are simple. Current moves throughout the
vehicle in wires of different sizes, according to the current a circuit may have to carry. Power is
supplied directly to equipment through connectors.
Electrical Terms
VOLT is the unit of electrical potential, equal to the difference of electrical potential between 2
points on a circuit.
AMPERE is the unit used to measure the amount of current, that is, the number of electrically
charged particles called electrons, that flows past a given point on a circuit each second. It is
similar to measuring the amount of water flowing through a pipe at any given point. The larger the
pipe is, the more water that can flow past the point per second. Similarly, the bigger the wire is,
the more current that can flow through it at any given point. Current that has lost its voltage still
has amperage as it completes the circuit and returns to the battery.
WATT is the unit of power. It indicates that rate at which a device converts electric current to
another form of energy, either heat or motion, or to put it another way, the rate at which a device
consumes energy.
The relationship of volts, amperes and watts to one another is expressed in a simple equation that
enables you to make any calculations you may need for proper and safe electrical modifications to
the vehicle. Volts x amperes = watts. If the current is at 12 volts and a device requires 4 amperes
of current, the equation will read 12 volts x 4 amperes = 48 watts.
To figure the current needed for a device rated in watts, turn the equation around: Watts/volts =
amperes. For example, if you have a piece of equipment, such as a communications radio, that
uses 120 watts: 120 watts/12 volts = 10 amperes.
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2-2 Electrical
Section 2: Electrical
Control Modules — Red Area
Do not install any components into the control modules or module harness. Connecting into this
system may affect control module operation. As an example: connection of aftermarket electrical
equipment into the brake light circuit or any other circuit which is connected to the PCM, anti-lock
brake computer, air bag system or any other vehicle system will cause vehicle malfunction.
Controller Area Network (CAN) Bus
NOTICE: Wiring faults in the controller area network (CAN) bus may shut down the vehicle
and prevent further operation.
Do not splice or connect any equipment to the controller area network (CAN) bus wiring.
General Electrical Considerations
Communication Equipment
Mobile communication systems may harm the operation of the vehicle, particularly if they are not
properly designed for automotive use or are not properly installed. For example, when operated,
such systems may cause the engine to stumble or stall. Citizen band (CB) transceivers, garage
door openers and other transmitters whose power output is 5 watts or less will not ordinarily affect
the operation of the vehicle.
Vehicle Speed Signal
The vehicle speed signal is sent from the PCM to other vehicle modules through the CAN bus.
There is no specific wire or circuit that carries the vehicle speed signal pulses.
Disabling Brake Lights
Do not disable the brake light circuits for any reason.
Disabling the A/C System
Do not disable the A/C system. The cabin air is used to cool the high voltage traction battery
(HVTB).
High- and Low-Voltage Systems
NOTICE: Do not splice the high-voltage system. Voltage in the system is in the range of 216
to 397 volts. Damage may occur to equipment added to the system.
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Electrical 2-3
Section 2: Electrical
The high-voltage system has a floating ground. When the engine is operating or the vehicle is
moving, the high-voltage generator begins to generate high voltage, AC electricity. High-voltage
AC electricity can be consumed or generated by the motor generator, the traction motor or a
combination of both motors. Excess high-voltage current is converted from high-voltage AC to
high-voltage DC electrical power inside the motor generator unit and transmitted through the
high-voltage cables. The high-voltage DC electrical power is converted to low-voltage DC electrical
power through the DC/DC converter. This low-voltage DC electrical power is then supplied to the
12-volt battery through the low-voltage battery cables.
12-Volt Battery
The 12-volt battery is a standard automotive battery. It is a DC source connected in a negative
ground system. The battery case is sealed, with 2 vent holes to release gases. The battery has 3
major functions:
• Storage of electricity for later use
• Voltage stabilizer for the electrical system
• Temporary power source when electrical loads exceed the DC/DC converter output current
High-Voltage Traction Battery (HVTB)
NOTICE: Do not splice the high-voltage wiring. Voltage in the system is in the range of 216
to 397 volts. Damage may occur to equipment added to the system.
The high-voltage traction battery (HVTB) is a 216-397 volt DC source connected in a floating
ground system. The battery receives, stores and delivers high-voltage electrical power when
required. It contains the traction battery control module (TBCM), which controls the higher
functions of the battery. The TBCM also estimates the state of charge, estimates the power
available, estimates the power it can absorb and controls the battery temperature. The TBCM
controls the battery temperature by activating or deactivating the fans contained within the HVTB.
Figure 1.
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
2-4 Electrical
Section 2: Electrical
1. High-voltage connector shield
2. Service disconnect
3. High-voltage battery case
DC/DC Converter
The DC/DC converter is a liquid-cooled component that converts high-voltage (216-397 volts) DC
power to low-voltage (12 volts) DC power while maintaining electrical isolation between the 2 DC
power systems. The converter steps down the high voltage to 12 volts, providing power to the
vehicle low-voltage battery systems. The PCM controls the operation of the DC/DC converter
through an enable input from the PCM to the DC/DC converter.
DC/AC Inverter and AC Power Point
Note: Do not keep electrical devices plugged in the power point whenever the device is not in
use. It is not recommended to use any extension cord with the 110 VAC power point, since
it will defeat the safety protection design provided by the cap and twist tab. It will also
cause the power point to overload due to powering multiple devices that can reach beyond
the 150 watt load limit.
The DC/AC inverter converts 12-volt DC to 110-volt AC to power a device that uses AC current
with a rating of less than 150 watts. The power point will automatically shut off if the load exceeds
150 watts. This prevents damage to the inverter or load. The inverter supplies 110-volt AC power
only when the key is in the ON/START position. This reduces the draw on the 12-volt system
when the vehicle is not running. The DC/AC inverter outlet (AC power point) is equipped with a
green LED that indicates the system integrity. The green LED illuminates continuously when the
key is in the ON/START position and the system is operating normally. The green LED flashes
constantly if the key is in the ON/START position and a fault is detected. Short circuits, overloads
or overheating of the inverter will cause the green LED to flash and the power to be cut off to the
outlet. If the LED is flashing, the problem must be corrected (that is, short circuit or excessive
load). If the inverter is overheated, it must be allowed time to cool off (without the load connected).
The power outlet is not designed for the following electric appliances; they may not work properly:
• Cathode ray tube-type televisions
• Motor loads, such as vacuum cleaners, electric saws and other electric power tools,
compressor-driven refrigerators
• Measuring devices, which process precise data, such as medical equipment, measuring
equipment
• Other appliances requiring an extremely stable power supply: microcomputer-controlled electric
blankets, touch sensor lamps
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
Electrical 2-5
Section 2: Electrical
Auxiliary Power Point — 12V
NOTICE: Power outlets are designed for accessory plugs only. Do not insert any other
object in the power outlet as this will damage the outlet and blow the fuse. Do not hang any
type of accessory or accessory bracket from the plug. Improper use of the power outlet can
cause damage not covered by your warranty.
Note: Do not use the power point for operating the cigarette lighter element (if equipped).
To prevent the fuse from being blown, do not use the power point(s) over the vehicle capacity of
12-VDC/180W.
To prevent the battery from being discharged, do not use the power point longer than necessary
when the engine is not running.
Buffer Zone
WARNING: The nominal high-voltage traction battery (HVTB) voltage is 330 volt DC. A
buffer zone must be set up and high-voltage insulated safety gloves and a face shield must
be worn when modifying the vehicle in close proximity to the high-voltage system. Failure
to follow these instructions may result in severe injury or death.
WARNING: The high-voltage traction battery (HVTB) and charging system contains
high-voltage components and wiring. High-voltage cables and wiring are orange in color.
High-voltage insulated safety gloves and a face shield must be worn when carrying out any
modifications on this vehicle. Failure to follow these instructions may result in severe
personal injury or death.
WARNING: Before carrying out any vehicle modifications, the high-voltage traction
battery (HVTB) must be depowered. Failure to follow these instructions may result in severe
personal injury or death.
WARNING: The high-voltage insulated safety rubber insulating gloves that are to be
worn while working on the high-voltage system should be of the appropriate safety and
protection rating for use on the high-voltage system. They must be inspected before use
and must always be worn in conjunction with the leather outer gloves. Any hole in the
rubber insulating glove is a potential entry point for high voltage. Failure to follow these
instructions may result in severe personal injury or death.
1. Position the vehicle in the repair bay.
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
2-6 Electrical
Section 2: Electrical
2. Position 4 orange cones around the corners of the vehicle to mark off a 1 m (3 ft) perimeter
around the vehicle.
3. Do not allow any unauthorized personnel into the buffer zone during repairs involving the
high-voltage system. Only personnel trained for repair on the high-voltage system are to be
permitted in the buffer zone.
Rubber Insulating Gloves Testing
WARNING: The high-voltage insulated safety rubber insulating gloves that are to be
worn when modifying the vehicle in close proximity to the high-voltage system, should be
of the appropriate safety and protection rating for use on the high-voltage system. They
must be inspected before use and must always be worn in conjunction with the leather
outer gloves. Any hole in the rubber insulating glove is a potential entry point for high
voltage. Failure to follow these instructions may result in severe personal injury or death.
Note: The high-voltage insulated safety gloves must be re-certified every 6 months to remain
within OSHA guidelines.
1. Roll the glove up from the open end until the lower portion of the glove begins to balloon from
the resulting air pressure. If the glove leaks any air, it must not be used.
2. The gloves should not be used if they show any signs of wear and tear.
3. The leather gloves must always be worn over the rubber insulating gloves in order to protect
them.
4. The rubber insulating gloves must be class ‘‘00’’ and meet all of the American Society for
Testing and Materials (ASTM) standards.
2010 Escape Hybrid, Mariner Hybrid Modifiers Guide, 07/2009
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