Table of contents Introduction 2 Instrumentation 3 Controls and features 9 Charging 13 Starting 22 Driving 25 Roadside emergencies 31 Maintenance and care 45 Capacities and specifications 55 Accessories 57 Index 62 All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company.
Introduction WELCOME TO THE RANGER ELECTRIC VEHICLE The 1999 Ranger Electric Vehicle is very similar to the gas-powered Ranger in appearance, interior and controls. The Ranger Electric Vehicle was built to be transparent from the gas-powered Ranger. There are enough differences that you should read this manual. Operation is the same, but some functions are different. The regular Ranger owner’s manual covers common systems.
Instrumentation WARNING LIGHTS AND CHIMES Service indicator lamp The service indicator lamp indicates that a vehicle malfunction has occurred. The vehicle should be returned to an authorized Ford Electric Vehicle (EV) Dealer for service. Brake warning lamp The brake warning lamp illuminates when there is a regenerative braking ! system malfunction, low fluid level BRAKE in the master cylinder or low fluid pressure in the hydraulic lines, or when the parking brake is engaged.
Instrumentation Electrical hazard warning lamp The electrical hazard warning lamp indicates a malfunction in the high-voltage system. The vehicle will not charge and must be returned to an authorized Ford EV Dealer immediately. Auxiliary battery lamp The auxiliary battery lamp indicates there is an auxiliary battery charging malfunction. Return the vehicle to an authorized Ford EV Dealer immediately.
Instrumentation Anti-lock brake system (ABS) lamp The ABS lamp indicates that there is a malfunction with the ABS. If the light stays on or continues to flash after the vehicle is started, return the vehicle to an authorized Ford EV Dealer for service. ABS Econ mode lamp The econ mode lamp indicates that the gearshift is in the E (Economy) position.
Instrumentation The inertia shutoff switch is located by the passenger kick panel. If there is damage to the vehicle, have the vehicle towed to an authorized Ford EV Dealer. RANGER EV FOR MEXICO AND CANADA The instrument cluster on the Ranger EV for Mexico and Canada will be equipped with metric gauges. All gauges operate as described below.
Instrumentation Battery state of charge gauge The battery state of charge gauge is the equivalent of a fuel gauge on a gasoline-powered vehicle. F (Full) indicates that the battery is completely charged. E (Empty) indicates the battery has been discharged to the point where additional operation will damage vehicle systems. F E Economy gauge The economy gauge provides information about the vehicle’s energy usage.
Instrumentation Motor enabled gauge The motor enabled gauge indicates that the vehicle is ready to drive. Turning the ignition switch to the full START position and releasing will turn the vehicle on, and the gauge will move to the ON position. ON OFF Temperature gauge The temperature gauge indicates the temperature of the vehicle’s components. Unlike conventional H temperature gauges, it does not start cold and move to normal. The gauge sits at normal and moves to C hot or cold when there is a problem.
Controls and features CLIMATE CONTROL SYSTEM Your vehicle is equipped with an automatic temperature control (ATC) system designed to maintain a selected temperature with a combination A/C-Heater system. Air conditioning (A/C) and heater controls The control for your air conditioning and heater system is located at the center of the instrument panel below the radio and will operate in the KEY-ON position.
Controls and features Icon MAX A/C A/C OFF Recirculation Switch Operation Mode Max A/C A/C Panel OFF Panel/Floor Floor Floor/Defrost Defrost Recirculation Automatic Automatic Selectable Not Available Selectable Selectable Not Available Not Available Fan speed knob The left knob on the control is the fan control knob, which controls the volume of air flow. Rotate the knob to the right to increase fan speed and increase the amount of air entering the vehicle.
Controls and features Mode selector knob The right knob on the control is the mode selector, which controls the direction of the airflow inside the vehicle. OFF A/C MAX A/C • MAX A/C-Select to distribute recirculated air through the instrument panel registers. This position produces cool air more rapidly to provide faster cooling of your vehicle. Using MAX A/C may be noisier and less economical than A/C. • A/C-Select to distribute cool recirculated air through the instrument panel registers.
Controls and features • (defrost)-Select to distribute outside air through the windshield defroster ducts. Defrost can be used to clear ice or fog from the windshield. If the outside air temperature is 10°C (50°F) or warmer the air conditioner will dehumidify the air to prevent fogging. The air may be heated and/or cooled based on temperature selection. Operating tips • In humid weather, select defrost before driving. This prevents your windshield from fogging.
Charging CHARGING Charging the Ford Ranger Electric Vehicle is a safe, simple process. In-garage charging of the Ranger Electric Vehicle has received UL approval. To maximize range, the vehicle should be connected to a power control station (PCS) whenever possible to keep the battery fully charged. A conductive power control station (PCS) is required to recharge your Ranger Electric Vehicle.
Charging 1. Park the Ranger Electric Vehicle. The vehicle’s charge inlet is at the right front of the vehicle in the grille, next to the right headlamp. 2. Place the gearshift lever in P (Park) and set the parking brake. 3. Turn the “ignition” to LOCK and remove the key from the “ignition.” 4. Open the charge inlet access door in the front grille. The door is hinged toward the right headlamp and opens in the same manner as the fuel filler door. 5.
Charging 8. The time required to charge the vehicle depends on the battery temperature and the state of charge when the vehicle is plugged in. The normal charge time is 6–8 hours. Reduced supply voltage, from the recommended 240 volts, may adversely affect the normal charge time. Estimated charge time The amount of time required to fully charge the battery pack varies depending upon the beginning state of charge and battery temperature.
Charging hours. Completely charging the drive battery is important to ensure maximum range and battery life. Ford recommended practice is that the vehicle should always be left on-plug when not in use and be allowed to fully charge before driving. Charge time may increase at colder or hotter temperatures. The drive battery must be above 5°C (41°F) and below 60°C (140°F) before charging will begin. After being connected to a PCS, the vehicle will automatically heat or cool the drive battery, as needed.
Charging To disconnect the PCS: 1. Push the STOP button on the PCS. 2. Grasp the charge connector and press the button in the center of the handle. 3. Pull the charge connector upward and pull it out of the inlet. 4. Close the charge inlet access door in the front grille. 5. Return the connector and cable to their proper location.
Charging Charging troubleshooting using SCI systems (SCIT) equipment If your vehicle fails to charge, follow this procedure to determine if your Power Control Station (PCS) is operating properly: 1. Make note of any lights that are flashing or steadily illuminated on your PCS. 2. Determine if the charge connector is properly inserted in the vehicle inlet and locked in place. 3.
Charging 3. Is the protection light illuminated? If yes, your vehicle may have undergone a series of faults which forced the PCS to terminate the charge process. • Push the stop button. • Unplug the PCS charge connector from the vehicle inlet, to clear the fault. • Inspect the charge cable and connector for any signs of possible damage (i.e. cuts, tears or breaks in the cable insulation). If damage is found, stop any further attempts to charge the vehicle and call the PCS manufacturer for repair.
Charging The systems are designed to maintain battery pack temperatures when on-plug as well as during the drive cycle, and may not be able to heat or cool batteries that have reached excessive temperatures. Battery temperatures tend to be warmer than outside temperature if driven and fully charged each day. If left off-plug, the batteries will eventually equalize to outside underbody temperature, although this process can take several days to occur.
Charging outdoor temperatures can cause the batteries to cool to below –25°C (–13°F) and prevent both charging and self-heating. The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. Battery self-heating following a complete charge will maintain the battery at approximately –10°C (14°F). The cooling fan utilizes outside air, and therefore cooling effectiveness depends upon the temperature difference between the batteries and outside air.
Starting POSITIONS OF THE IGNITION SWITCH 1. ACCESSORY allows the accessories such as the radio to operate while the motor is not powered up. 2. LOCK locks the steering wheel gearshift lever. Allows key removal. 3. OFF disconnects all high-voltage power from the traction battery. 4. ON, warning lights momentarily illuminated. Key position when driving. 5. START powers up the motor and turns the Motor Enable Gauge to the ON position. Powers up all high-voltage power from the drive battery.
Starting 1. Make sure all vehicle occupants have buckled their safety belts. For more information on safety belts and their proper usage, refer to the seating and safety restraints chapter in the Ranger owner guide. 1. Make sure the parking brake is set. 2. Make sure the gearshift lever is in P (Park). 3. Turn the key to the START position and release. The Motor Enabled gauge will point to the ON position, indicating the vehicle is on.
Starting 4. Check the drive Battery State of Charge gauge to confirm that the drive battery is charged sufficiently for the planned trip. F E 5. Pull the release lever to release the parking brake. The Ranger electric vehicle is now ready to be driven.
Driving REGENERATIVE BRAKING Your Ranger Electric Vehicle uses a unique feature known as regenerative braking. This is used to simulate the engine braking of an internal combustion engine and assist the standard brake system while recovering some of the energy of motion back into the battery. The standard brake system is designed to fully stop the truck if regenerative braking is not available. Once the accelerator pedal is released, the vehicle automatically decelerates slowly.
Driving An ABS fault will also illuminate the BRAKE warning lamp. The base hydraulic brake system will still be effective. Have your vehicle serviced as soon as possible. ! BRAKE Using ABS • In an emergency or when maximum efficiency from the ABS is required, apply continuous full force on the brake pedal.
Driving Hold the brake pedal down while you move the gearshift lever from P (Park) to another position. If you do not hold the brake pedal down, your vehicle may move unexpectedly and injure someone. P (Park) Always set the parking brake fully and make sure the gearshift is latched in P (Park). Turn off the ignition whenever you leave your vehicle. Always come to a complete stop before shifting into P (Park). Make sure the gearshift lever is in P (Park).
Driving E (Economy) With the gearshift lever in E (Economy), the Ranger operates as in drive, but the effects of regenerative braking are increased and top speed is limited to 105 km/h (65 mph). This selection is recommended for urban operation when extended driving range is desired. The economy mode is used to maximize the vehicle’s range. A stronger deceleration from regenerative braking results from releasing the accelerator pedal. In this regard, it feels similar to low gear on a typical transmission.
Driving Driving the vehicle to complete discharge will damage the battery, resulting in reduced battery life. Driving on snow and ice The regenerative braking system interacts with the ABS so if the wheels begin to slide, ABS will activate and regenerative braking will be disabled. Vehicle coasting distance will increase when regenerative braking is reduced by ABS activation.
Driving ENERGY TIPS The Ranger Electric Vehicle has a customer range of approximately 80 kilometers (50 miles) with the standard lead-acid type traction battery or approximately 160 kilometers (100 miles) with the optional nickel metal hydride type traction battery. This range is affected by the use of vehicle accessories, driving habits and weather conditions. To maximize the vehicle’s range, follow these steps: • Use the E (Economy) gear. • Keep the tires properly inflated to 350 kpa (50 psi).
Roadside emergencies INERTIA SHUTOFF SWITCH If the Power Reset Lamp illuminates, it indicates that the inertia shutoff switch has been activated. If there is no damage to the vehicle, reset the switch to reactivate the high-voltage power systems and restart the vehicle. The inertia shutoff switch is located by the passenger kick panel. If there is damage to the vehicle, have the vehicle towed to an authorized Ford EV repair facility.
Roadside emergencies PASSENGER COMPARTMENT FUSE PANEL The fuse panel is on the left-hand side of the instrument panel facing the driver side door. Pull the panel cover outward to access the fuse. To remove a fuse, use the fuse puller provided on the fuse panel cover.
Roadside emergencies The passenger compartment fuse panel fuses are coded as follows: Fuse/relay Fuse amp location rating 1 10 2 7.5 3 — 4 10 5 7.5 6 — 7 7.5 8 10 9 10 10 7.5 11 12 13 7.5 — 10 14 15 16 10 7.5 30 17 18 19 10 — 15 20 21 22 10 15 15 23 24 15 7.
Roadside emergencies Fuse/relay Fuse amp location rating 25 7.5 26 15 27 10 28 29 30 31 32 33 34 35 36 7.
Roadside emergencies Always replace the cover to the power distribution box before reconnecting the auxiliary battery or refilling fluid reservoirs.
Roadside emergencies Fuse/relay Fuse amp location rating 15 MINI 20 16 — 17 MINI 20 18 — 19 MAXI 40 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 36 MAXI 20 MAXI 20 MAXI 30 — — MINI 5 J50 J50 J50 — — — 150 — J50 J50 J50 150 — Description I/P fuse panel fuses 23 and 27 Not used Battery charger Not used Heater blower motor relay, heater blower motor, interface adapter assembly (IAA) Coolant pump relay, coolant pump Oil pump relay, transaxle oil pump Headlamps, multi-function switch Not used Not
Roadside emergencies CHANGING TIRES If you get a flat tire while driving, do not apply the brakes heavily. Instead, gradually decrease your speed. Hold the steering wheel firmly and slowly move to a safe place on the side of the road. Conventional spare tire information If you have the optional spare tire, you can use the spare as a regular tire. The spare is identical to the other tires on your vehicle.
Roadside emergencies • one wheel nut wrench. Depress button and slide together. 6. Remove the spare tire security lock and cable. 7. Remove the retaining bolt and retainer. If you cannot remove the bolt by hand, remove it using the jack handle. 8. Remove the spare tire. Tire changing procedure 1. Park on a level surface, activate hazard flashers, and place gearshift lever in P (Park).
Roadside emergencies 2. Set the parking brake. 3. Block the diagonally opposite wheel. 4. Insert tapered end of the lug wrench behind center caps and twist them off. 5. Loosen each wheel lug nut one-half turn counterclockwise, but do not remove them until the wheel is raised off the ground. 6. Position the jack as shown below and turn the jack handle clockwise until the tire is a maximum of 25 mm (1 in) off the ground. Never position a jack or hoist underneath the traction battery pack.
Roadside emergencies • Front • Rear 7. Remove the wheel lug nuts with the lug wrench. 8. Replace the flat tire with the spare tire, making sure the valve stem is facing outward. Reinstall the lug nuts until the wheel is snug against the hub. Do not fully tighten 3 the lug nuts until the wheel has been lowered to the ground. 5 1 4 2 9. Lower the wheel by turning the jack handle counterclockwise. 10. Install the wheel lug nuts with the lug wrench. 11. Secure the flat tire. 12.
Roadside emergencies JUMP-STARTING THE AUXILIARY BATTERY The Ford Electric Ranger can be jump-started like a gasoline-powered Ranger. Note that if the traction battery is dead, jumping the auxiliary battery will not fix the problem. Look at the battery state of charge gauge to verify the traction battery is not discharged. The auxiliary battery might be dead from accessories that were left on accidentally, like the headlights, or dome lamp. Preparing your vehicle to be jump started 1.
Roadside emergencies 4. Connect one end of the second lead to the negative (-) terminal of the booster battery (3) and the other end to the module mounting stud (4), not to the negative (-) terminal of the discharged battery. 5. Make sure that the jump leads are clear of moving parts. Do not connect the end of the second cable to the negative ([-]) terminal of the battery to be jumped. A spark may cause an explosion of the gases that surround the battery. Starting your vehicle 1.
Roadside emergencies Removing the jumper cables 1. Remove the jumper cables in reverse order. Take the cable off the metallic surface (1) first, followed by the cable on the negative (-) booster battery terminal (2). 2. Remove the cable from the positive (+) terminal of the booster battery (3) and then the discharged battery (4).
Roadside emergencies WRECKER TOWING There are three approved towing methods: • Front-wheel lift towing (transaxle in Neutral [N]). Do not tow the vehicle more than 80 km (50 miles) when front-wheel lift towing. • Rear-wheel lift towing. • Flatbed transporting. If you need to have your vehicle towed, contact a profession towing service or your roadside assistance center. Do not tow with slingbelt equipment. Ford Motor Company has not developed or approved a slingbelt towing procedure.
Maintenance and care SERVICE RECOMMENDATIONS This vehicle should only be serviced by a Ford trained electric vehicle technician. Scheduled maintenance chart Item Interval 1 2 3 4 5 6 7 8 9 10 yr. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs.
Maintenance and care Item Interval 1 2 3 4 5 6 7 8 9 10 yr. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. x x x Replace transaxle fluid* Inspect power x steering fluid Inspect brake x fluid x x x x x x x x x x x x x x x x x x *Replace transaxle fluid every 3 years or 36,000 miles, whichever comes first. HOW TO OPEN THE HOOD 1. Inside the vehicle, pull the hood release handle located under the bottom right of the steering wheel.
Maintenance and care 2. Go to the front of the vehicle and release the auxiliary latch that is located under the front center of the hood. Lift the hood and support it with the prop rod. Identifying components in the underhood compartment: 1 5 2 3 4 1. Windshield washer fluid reservoir 2. Coolant reservoir 3. Power steering fluid reservoir 4. Auxiliary battery 5. Brake fluid reservoir The underhood compartment contains many high-voltage components and wiring.
Maintenance and care WINDSHIELD WASHER FLUID Check the washer fluid periodically. If the level is low, add enough fluid to fill the reservoir. In very cold weather, do not fill the reservoir all the way. Do not put engine coolant in the container for the windshield washer fluid. COOLANT The EV Ranger is equipped with a cooling system to cool running temperatures of electrical components and the electric drive motor. Check the level of the coolant in the reservoir at least once a month.
Maintenance and care Adding coolant If sprayed on the windshield, coolant could make it difficult to see through the windshield. Add a 50/50 mixture of coolant and water to the coolant reservoir. DO NOT ADD IT DIRECTLY TO THE RADIATOR. Add straight water only in an emergency, and replace it with a 50/50 mixture of coolant and distilled water as soon as possible. Check the coolant level in the coolant recovery reservoir the next few times you drive the vehicle.
Maintenance and care POWER STEERING FLUID LEVEL Check the power steering fluid at least twice a year. If adding fluid is necessary, use only MERCONt ATF. 1. Turn the “ignition” ON. 2. Turn the steering wheel left and right to the steering stops several times. Do not keep wheel at steering stops longer than 5 seconds. 3. Turn the “ignition” OFF. 4. Check the fluid level. It should be between the MAX and MIN lines on the reservoir. Do not add fluid above the MAX level. 5. If the fluid is low, add fluid.
Maintenance and care If you use a brake fluid that is not DOT 3, you will cause permanent damage to your brakes. AUXILIARY BATTERY Your vehicle is equipped with a sealed maintenance-free battery. For longer, trouble-free operation, keep the top of the battery clean and dry. Also, make certain the battery cables are always tightly fastened to the battery terminals. If you see any corrosion on the battery or terminals, remove the cables from the terminal(s) and clean with a wire brush.
Maintenance and care SERVICING YOUR TIRES Checking the tire pressure • Use an accurate tire pressure gauge. • Check the tire pressure when tires are cold, after the vehicle has been parked for at least one hour or has been driven less than 5 km (3 miles). • Check and adjust tire pressure to recommended specifications found on the Safety Compliance Certification Label located on the driver door pillar every 30 days.
Maintenance and care • Five-tire rotation (if equipped) Replacing the tires Replace the tires when the wear band is visible through the tire treads. Your Ranger Electric Vehicle is equipped with a low rolling resistance high pressure designed tire to extend vehicle range. Only the same type of tire should be used as a replacement. When replacing full size tires, never mix radial, bias-belted, or bias-type tires. Use only the tire sizes that are listed on the tire pressure decal.
Maintenance and care Make sure that all replacement tires are of the same size, type, load-carrying capacity and tread design (e.g., “All Terrain”, etc.), as originally offered by Ford. Failure to follow these precautions may adversely affect the handling of the vehicle and make it easier to lose control and roll over. SNOW TIRES AND CHAINS The use of snow tires and chains is strongly discouraged on the Ranger Electric Vehicle.
Capacities and specifications MOTORCRAFT PART NUMBERS Component Climate control air filter Auxiliary battery Part Number F8YZ-19N619-AA BXE-U1 REFILL CAPACITIES Fluid Brake fluid Power steering fluid Coolant Windshield washer fluid Ford part name Ford high performance DOT 3 motor vehicle brake fluid Motorcraft MERCONt ATF Ford extended life engine coolant (New for 1999 model year) Ultra-clear windshield Vehicle type All All All All Capacity-litres (quarts) Fill to line in reservoir Fill to line in
Capacities and specifications FLUID SPECIFICATIONS Fluid Brake fluid Power steering fluid Coolant Windshield washer fluid Transaxle fluid Ford part name or equivalent High performance DOT 3 motor vehicle brake fluid Motorcraft MERCONt ATF Ford extended life engine coolant (New for 1999 model year) Ultra-clear windshield concentrate Tribolube - L-6 (Pro Gear 21) Ford part number Ford specification C6AZ-19542-AB WSA-M6C25-A and DOT 3 XT-2ODX MERCONt WSA-M2C195-A WSS-M97B44-D F6AZ-19544-AA C9AZ-1955
Accessories MOBILE RADIO INSTALLATION GUIDELINES General information Ford Motor Company vehicles are designed and tested for safe operation with properly installed and properly used land mobile/amateur radio communications equipment with up to 100 Watt transmitter power. This resource is provided as a supplement to the radio manufacturer’s installation communication equipment in Ford vehicles. Additional sources of information are included in this resource.
Accessories Radio wiring and routing Power connections should be made directly to the battery and fused as close to the battery as possible. On the Ranger Electric Vehicle make the connections as follows: • For the +12V circuit, connect a weatherproof fuse holder to the end of the 10 gauge circuit pigtail that is taped into the harness at the auxiliary battery positive terminal. Route and secure the wire as close as possible to the vehicle body from the battery to the transceiver.
Accessories • Connect to the auxiliary battery ground connection using a ring terminal at the ground M6 weldnut behind the LH (driver’s) side kick panel. Maintain as great a distance as possible between mobile radio power leads and the vehicle’s wiring. Avoid running power leads in parallel with vehicle wiring over long distances.
Accessories Mount the antenna only on the center of the Ranger Electric Vehicle roof if it is a sheet metal mount antenna. Glass mounted antennas should be mounted as high as possible in the center of the rear window. Antenna Tuning: It is important that the antenna be tuned properly and reflected power be kept to less than 10% (VSWR less than 2:1). Note: Your installation should be checked periodically for proper SWR and any signs of damage or deterioration to maintain proper operation with your vehicle.
Accessories Troubleshooting Most interaction problems can be eliminated by following these installation guidelines. If vehicle/radio interaction develops following installation, the source of the problem should be identified prior to further operation of the vehicle.
Index Air conditioning ............................9 Battery .........................................19 auxiliary battery .......................51 battery pack heating/cooling system (lead-acid type) ...........19 battery pack heating/ cooling system (nickel metal hydride type) ............................20 equalization ..........................20,21 Brakes ..........................................25 anti-lock .....................................25 anti-lock brake system (ABS) warning light ..........
