Econ mode lamp The econ mode lamp indicates that the gearshift is in the E (Economy) position. This mode is recommended for urban traffic and will improve range by increasing the effects of regenerative braking and limiting top speed to 105 km/h (65 mph). The D (Drive) position is recommended for highway operation at steady speeds. Power reset lamp The power reset lamp indicates that the inertia shutoff switch has been tripped and all high-voltage power has been disconnected and power has been limited to the traction battery. If there is no damage to the vehicle, reset the switch to reactivate the high-voltage power systems.
The inertia shutoff switch is located by the passenger kick panel. If there is damage to the vehicle, have the vehicle towed to an authorized Ford EV Dealer.
RANGER EV FOR MEXICO AND CANADA The instrument cluster on the Ranger EV for Mexico and Canada will be equipped with metric gauges. All gauges operate as described below. GAUGES

80 100

DISTANCE TO EMPTY km
Battery state of charge gauge The battery state of charge gauge is the equivalent of a fuel gauge on a gasoline-powered vehicle. F (Full) indicates that the battery is completely charged. E (Empty) indicates the battery has been discharged to the point where additional operation will damage vehicle systems. Economy gauge The economy gauge provides information about the vehicles energy usage. Economical usage of the vehicle is indicated by the gauge reading near the plus (+) side and will maximize the vehicles range.
Distance to empty gauge The distance to empty gauge estimates the remaining distance the vehicle can travel before requiring a drive battery recharge. The gauge reading is based on remaining drive battery energy, driving conditions and recent vehicle usage.

50 100

Motor enabled gauge The motor enabled gauge indicates that the vehicle is ready to drive. Turning the ignition switch to the full START position and releasing will turn the vehicle on, and the gauge will move to the ON position.
Temperature gauge The temperature gauge indicates the temperature of the vehicles components. Unlike conventional H temperature gauges, it does not start cold and move to normal. The gauge sits at normal and moves to C hot or cold when there is a problem. If the gauge moves to H (Hot), vehicle performance will be limited until the coolant temperature or drive battery temperature returns to normal. The vehicle should be stopped and plugged into a PCS until it has cooled down. The vehicle may need servicing. If the gauge moves to C (Cold), the vehicle may have an extended charge time and a reduced driving range.

Controls and features

CLIMATE CONTROL SYSTEM Your vehicle is equipped with an automatic temperature control (ATC) system designed to maintain a selected temperature with a combination A/C-Heater system. Air conditioning (A/C) and heater controls The control for your air conditioning and heater system is located at the center of the instrument panel below the radio and will operate in the KEY-ON position. Your air conditioner and heater will heat and/or cool your vehicle interior depending on the function position and temperature you select. The mode selector knob allows you to select heating or cooling, and determine where the air will be directed. The temperature control knob setting determines the desired interior temperature of the vehicle. To turn your air conditioner or heater system on, select any position except OFF. This will turn the fan on and allows air flow into the vehicle. To turn your air conditioner or heater system off, select OFF. This will turn the fan off and stop airflow from coming into the vehicle.

A/C MAX A/C

Recirculation switch The recirculation switch is located at the center of the instrument panel just right of the radio. It allows switching from outside air to recirculated air in Panel, Panel/Floor, and Floor modes. The recirculation switch operates for five minutes, then shuts off. If more recirculation operation is desired, press the control again. Note that in MAX A/C and A/C modes, the function is automatic (stays in recirculation mode) and cannot be switched off. A table of recirculation switch operation follows.
Icon MAX A/C A/C OFF Recirculation Switch Operation Mode Max A/C A/C Panel OFF Panel/Floor Floor Floor/Defrost Defrost Recirculation Automatic Automatic Selectable Not Available Selectable Selectable Not Available Not Available
Fan speed knob The left knob on the control is the fan control knob, which controls the volume of air flow. Rotate the knob to the right to increase fan speed and increase the amount of air entering the vehicle. Four fan speed positions are available and are indicated by dots beside the control knob. The largest dot is the high-speed position. Temperature control knob The temperature control knob is the rotating knob located at the center of the control with tapered red and blue bands surrounding most of the knob. The wide red part of the band (full right) is the warm temperature area. The wide blue part of the band (full left) is the cool temperature area. Any position selected between full right and full left will give a temperature between maximum heating 29C (84F) and maximum cooling 18C (64F) (A/C and MAX A/C modes only).

Mode selector knob The right knob on the control is the mode selector, which controls the direction of the airflow inside the vehicle.
MAX A/C-Select to distribute recirculated air through the instrument panel registers. This position produces cool air more rapidly to provide faster cooling of your vehicle. Using MAX A/C may be noisier and less economical than A/C. A/C-Select to distribute cool recirculated air through the instrument panel registers. This position should be used for cooling except when it is extremely hot or fast cooling of the vehicle is needed. (panel)-Select to distribute outside air or recirculated air through the instrument panel registers. The air may be heated based on temperature selection. The air cannot be cooled below the outside temperature regardless of the temperature setting. (panel and floor)-Select to distribute outside air or recirculated air through the instrument panel registers and to the floor ducts at the same time. The air may be heated based on temperature selection. The air cannot be cooled below the outside temperature regardless of the temperature setting. (floor)-Select to distribute outside air or recirculated air through the floor ducts. The air may be heated based on temperature selection. The air cannot be cooled below the outside temperature regardless of the temperature setting. (floor and defrost)-Select to distribute outside air through the floor ducts and the windshield defroster ducts at the same time. If the outside air temperature is 10C (50F) or warmer, the air conditioner will dehumidify the air to prevent fogging. The air may be heated and/or cooled based on temperature selection.
(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 10C (50F) or warmer the air conditioner will dehumidify the air to prevent fogging. The air may be heated and/or cooled based on temperature selection.
Operating tips In humid weather, select defrost before driving. This prevents your windshield from fogging. After a few minutes of operation, you may select another function. Remove any snow, ice or leaves from the air intake area of your heater system that could block the air intake. The intake area is located at the bottom of the windshield. If temperatures below -18C (0F), select recirculation before driving. This will help warm the vehicle interior and minimize degraded performance at low outside temperatures. The use of climate controls will reduce the vehicles range. Limit the use of maximum heating and cooling of the vehicle interior.

6. Align the PCS connector to the charge inlet, fully insert the connector and make sure that the tabs on both sides of the connector engage the slots in the inlet. 7. Gently push the connector down, toward the bumper, until you hear a click. The click means that the connector is locked into the inlet.
8. The time required to charge the vehicle depends on the battery temperature and the state of charge when the vehicle is plugged in. The normal charge time is 68 hours. Reduced supply voltage, from the recommended 240 volts, may adversely affect the normal charge time.
Estimated charge time The amount of time required to fully charge the battery pack varies depending upon the beginning state of charge and battery temperature. Note that battery temperature is not necessarily the same as outside temperature. The use of outside temperature to plan charge times, however, is the most straightforward approach. Typically it will take 68 hours for the vehicle to fully charge from empty to full. Use the battery state of charge gauge as a guide to assess whether enough charge time was allowed. If the gauge does not indicate full when the ignition is moved to the ON position, one of the following may have happened: The battery pack may be too warm or too cold. Charge times can increase to 10 hours or more for warmer or cooler batteries. In sever temperature conditions (battery temperature less than 5C [41F], or greater than 60C [140F] for the lead-acid type and less than 25C [13F] or greater than 45C [113F] for the nickel metal hydride type) the vehicle will not charge at all. The PCS may be malfunctioning. The battery pack may be out of electrical balance. The vehicle will perform a balancing charge, which may take up to four hours for the lead-acid type or two hours for the nickel metal hydride type over the normal charging time, and then indicate full. The gearshift lever was not in P (Park). The battery pack (lead-acid type only) may be new. Vehicles that have experienced less than 10 drive/charge cycles need an additional few hours of charge time. Refer to charging troubleshooting later in this section. If none of the above apply, the vehicle should be returned to the PCS to attempt to complete charging or taken to an authorized Ford EV Dealer.
Lead-acid traction battery At 25C (77F), the drive battery can be charged to 80% capacity in about three hours; 100% capacity requires approximately six to eight 15

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 troubleshooting using SCI systems (SCI) equipment If your vehicle fails to charge, follow this procedure to determine if your Power Control Station (PCS) is operating properly: 1. Make note of any lights that are flashing or steadily illuminated on your PCS. 2. Determine if the charge connector is properly inserted in the vehicle inlet and locked in place. 3. Is the charge interrupt light illuminated? If yes, your vehicle may have undergone a series of faults which forced the PCS to terminate the charge process. Push the stop button. Unplug the connector from the vehicle inlet, to clear the fault. Inspect the cable and connector for any signs of possible damage (i.e. cuts, tears or breaks in the cable insulation). If damage is found, stop any further attempts to charge the vehicle and call the PCS manufacturer for repair. If the cable and connector are undamaged reconnect the PCS to the vehicle inlet. Is the charge interrupt light still illuminated or flashing? Consult your authorized Ranger EV dealer to determine possible vehicle fault. 4. Is the service light illuminated? If yes, Disconnect the charge connector vehicle inlet. Turn off the power to your PCS at the service or disconnect panel. Turning off the power may allow the PCS to clear the fault. Turn the power back on and reconnect the PCS to the vehicle inlet. Is the service light still illuminated? If so, call the PCS manufacturer for repair or replacement. The toll free number is located on the PCS. Charging troubleshooting using Electric Vehicle Infrastructure (EVI) equipment If your vehicle fails to charge follow this procedure to determine if your Power Control Station (PCS) is operating properly: 1. Make note of any lights that are illuminated or any messages being issued by your PCS. 2. Determine if the charge connector is properly inserted in the vehicle inlet and locked in place.

outdoor temperatures can cause the batteries to cool to below 25C (13F) 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 10C (14F). The cooling fan utilizes outside air, and therefore cooling effectiveness depends upon the temperature difference between the batteries and outside air. The cooling system works to maintain the batteries at approximately 25C (77F). Equalization The battery control system will periodically equalize the charge in the batteries, which smooths out battery-to-battery differences in the ability to deliver energy. This results in optimum range and battery life. Equalization is automatically performed approximately every three weeks. The fuel gauge will indicate if insufficient charge time has been allowed. The Ranger Electric Vehicle should be connected to a PCS whenever it is not being driven. Partial recharges A partial recharge is charging the battery pack to less than 100% state of charge and can be performed occasionally without loss of range or performance. However, long term multiple partial charges tend to create imbalances in battery-to-battery state of charge and are strongly discouraged. Usage patterns should be planned to include a full recharge each time the vehicle is discharged. On vehicles equipped with the nickel-metal hydride drive batteries, a full discharge is recommended periodically to minimize battery memory effect.

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.

ON OFF START

ACCESSORY
STARTING THE RANGER ELECTRIC VEHICLE 1. If connected, disconnect the PCS plug from the charge inlet and close the charge inlet access door.
The car will not start until the plug is removed.
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.

Always disconnect the battery before servicing high current fuses.
Always replace the cover to the power distribution box before reconnecting the auxiliary battery or refilling fluid reservoirs.
The high-current fuses are coded as follows: Fuse/relay Fuse amp Description location rating 1 MAXI 50 Fan speed relays, cooling fan, interface adapter assembly (IAA) module 2 MAXI 60 ABS 3 MAXI 30 ABS 4 MAXI 40 I/P fuse panel fuses 1,5,9,13,17,21,25 and MAXI 50 Ignition switch 6 MINI 10 Interface adapter assembly (IAA) module 7 MINI 10 Contactor box 8 MINI 15 Inertia switch, contactor box 9 MINI 10 Driver air bag module 10 MINI 20 Vacuum relay, vacuum pump 11 MINI 10 Battery controller module (BCM) 12 MINI 10 Horn relay, horn switch, horn 13 MINI 30 Power point 14 MINI 15 Cooling/venting blower relay, battery control module (BCM), cooling/venting blower
Fuse/relay Fuse amp location rating 15 MINI 17 MINI 19 MAXI MAXI 20 MAXI 20 MAXI 30 MINI 5 J50 J50 J50 150 J50 J50 JDescription 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 used ABS active signal Windshield wiper park relay Brake on/off (BOO) relay Windshield wiper hi/low relay Not used Not used Not used Coolant pump relay Not used Vacuum pump relay Horn relay Windshield washer pump relay Blower motor relay Not used
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. Your Ranger EV 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. Location of the spare tire and tools The spare tire and tools for your vehicle are stowed in the following locations: Tool Spare tire Jack, jack handle, wheel nut wrench Location In the pickup bed Behind the passenger seat

Maintenance and care

SERVICE RECOMMENDATIONS This vehicle should only be serviced by a Ford trained electric vehicle technician. Scheduled maintenance chart Item Interval yr. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. yrs. x x x x x x x x x x
Rotate tires 5000 miles MAX Inspect disc x brake system, lubricate caliper slides x Climate control filter (More frequent changes may be necessary in dusty and dirty conditions) Replace vacuum pump 2A451 Inspect and lubricate front wheel bearings Inspect parking brake system Inspect x cooling system
Item Interval 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
*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.
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. 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. Do not attempt to service any of these components. Service must be performed by qualified personnel only. The high-voltage wiring is covered in orange convolute for easy identification. Underhood high voltage components have warning labels with one or all of the following icons.
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. Be sure to read and understand Precautions in this chapter when servicing your vehicle. If the coolant has not been checked for a long period of time, the coolant reservoir may eventually empty. If this occurs, add coolant to the coolant reservoir. Automotive fluids are not interchangeable; do not use coolant, antifreeze or windshield washer fluid outside of its specified function and vehicle location.
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. If necessary, add enough of a 50/50 mixture of coolant and water to bring the liquid level to the fill line on the reservoir. Use Ford Extended Life Engine Coolant F6AZ-19544AA or an equivalent DEX-COOL coolant or a coolant meeting Ford specifications WSS-M97B44D. Ford Extended Life Engine Coolant is an orange colored silicate-free coolant that does not need to be replaced for the life of your vehicle. Do not add conventional, green coolant or recycled coolant to your vehicle if originally equipped with orange coolant. The use of an improper coolant may void your warranty of your vehicles cooling system. Always dispose of used automotive fluids in a responsible manner. Follow your communitys regulations and standards for recycling and disposing of automotive fluids. Coolant refill capacity Have your dealer check the cooling system for leaks if you have to add more than a litre (quart) of coolant per month. Severe winter climate If you drive in extremely cold climates (less than 36C [-33F]), it may be necessary to increase the coolant concentration above 50%. Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle is such that the coolant will not freeze at the temperature level in which you drive during the winter months. Never increase the coolant concentration above 60%. Leave a 50/50 mixture of coolant and water in your vehicle year-round in non-extreme climates.

POWER STEERING FLUID LEVEL Check the power steering fluid at least twice a year. If adding fluid is necessary, use only MERCON 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. BRAKE FLUID Checking and adding brake fluid Brake fluid should be checked and refilled as needed at least once each year: 1. Check the reservoir cap before removal to prevent dirt or water from entering the reservoir. 2. Visually inspect the fluid level. 3. If necessary, add brake fluid until the level reaches MAX. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet Ford specifications. Refer to Lubricant specifications in the Capacities and specifications chapter. Brake fluid is toxic.
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. You can neutralize the acid solution with a solution of baking soda and water. Reinstall the cables when you are done cleaning them, and apply a small quantity of grease to the top of each terminal to help prevent corrosion. TRACTION BATTERY PACK ASSEMBLY No regular maintenance, other than regular charging is required. The traction battery pack assembly is located underneath the vehicle between the wheel base and frame rails. The battery pack assembly contains wiring, a fan for ventilation and cooling, and a control system. The standard lead acid battery pack contains 39 eight-volt batteries and optional heater for cold weather climates. The optional nickel metal hydride battery pack contains 25 twelve-volt batteries, and an additional cooling system exhaust fan. The traction battery provides energy to propel the vehicle and also maintains energy for accessory functions. The battery pack assembly is a 2,000pound unit lead-acid type or 1,300pound unit nickel metal hydride type. Never position a jack or hoist underneath the traction battery pack. Doing so may result in damage to your vehicle. This battery pack should only be serviced by an authorized electric vehicle technician. Improper handling can result in personal injury or death.
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. Note: Driving the Electric Ranger with tires below recommended inflation pressure will significantly affect range between charges. Tire pressure will increase/decrease with every 10F change in outside air temperature, decreasing with temperature decreases. Tire rotation Because your vehicles tires perform different jobs, they often wear differently. To make sure your tires wear evenly and last longer, rotate them every 5,000 miles or six months. If you notice that the tires wear unevenly, have them checked. Four-tire rotation.

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. Make sure that all tires are the same size, speed rating, and load-carrying capacity. Use only the tire combinations recommended on the decal. If you do not follow these precautions, your vehicle may not drive properly and safely.
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 REFILL CAPACITIES Fluid Brake fluid Ford part name Ford high performance DOT 3 motor vehicle brake fluid Motorcraft MERCON ATF Ford extended life engine coolant (New for 1999 model year) Ultra-clear windshield Vehicle type All Capacity-litres (quarts) Fill to line in reservoir Part Number F8YZ-19N619-AA BXE-U1
Power steering fluid Coolant

All All

Fill to line in reservoir Fill to line in reservoir

Windshield washer fluid

Fill to line in reservoir
FLUID SPECIFICATIONS Fluid Brake fluid Ford part name or equivalent High performance DOT 3 motor vehicle brake fluid Motorcraft MERCON ATF Ford extended life engine coolant (New for 1999 model year) Ultra-clear windshield concentrate Tribolube - L-6 (Pro Gear 21) Ford part number C6AZ-19542-AB Ford specification WSA-M6C25-A and DOT 3

XT-2ODX F6AZ-19544-AA

MERCON WSA-M2C195-A WSS-M97B44-D
Windshield washer fluid Transaxle fluid MOTOR DATA
C9AZ-19550-AC or BC F8AZ-19M544-A

ESR-M17P5-A

Motor Horsepower Torque Traction battery modules
Data 67 kw (90 hp) 190 Nm (140 lb/ft) Standard Lead-acid type, 312 volts, 39 (8 volts each) Optional Nickel metal hydride, 300 volts, 25 (12 volts each)

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 manufacturers installation communication equipment in Ford vehicles. Additional sources of information are included in this resource. Special design considerations are incorporated into all Ford vehicle electronic systems to provide immunity to radio frequency signals. To maintain compatibility with vehicle electronic systems, mobile radio and telephone equipment must be properly installed, by trained personnel with experience in this area. The following guidelines should be observed: The antenna cable should be a fully shielded coaxial cable, and kept as short as practical. Avoid routing the antenna cable in parallel with vehicle wiring over long distances. Carefully match the antenna and cable to the radio to achieve a low Standing Wave Ratio (SWR) and to avoid RF currents on the antenna cable shield. The procedure to accomplish this is described in the section Antenna Tuning below. Radio transmitters are regulated by the Federal Communications Commission (FCC) in the United States. Compliance with FCC regulations is the responsibility of the manufacturer and/or user of the transmitter equipment and not Ford Motor Company.

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. Pass the wire from the engine to passengers compartment through a hole in the accelerators cable hole plug. Use care when routing this wire to avoid chafing or pinching. Seal the hole to prevent moisture intrusion into the passenger compartment.
Connect to the auxiliary battery ground connection using a ring terminal at the ground M6 weldnut behind the LH (drivers) side kick panel. Maintain as great a distance as possible between mobile radio power leads and the vehicles wiring. Avoid running power leads in parallel with vehicle wiring over long distances.
Transceiver location A transceiver location should be selected that provides a solid mounting point which does not interfere with the vehicle operator controls and provides adequate ventilation. Do not mount any transceiver, microphones, speakers, or any other item in the deployment path of the airbag system. Before using screws to mount the transceiver equipment, be sure to check for vehicle wiring under the carpet or behind the instrument panel which could be pinched, cut or otherwise damaged. Antenna location and installation Permanently installed sheet metal mount antennas are preferable over magnetic, glass, or body lip mounts for anything other than low power or temporary installations. Most of these alternate antennas can reflect significant power back at the feed point. This reflected power could then radiate from the feed line inside the passenger compartment and be picked up by the vehicle wiring.
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. Antenna Cable Routing Always use a high quality one piece coaxial cable (at least 95% shield coverage). Connector quality and termination techniques are just as important. The ARRL handbook provides excellent guidelines for terminating coaxial cables. The antenna cable should be treated in the same way as the control and power cables. Avoid sharp edges and pinches and keep the cable as short as possible. Also, avoid routing the antenna cable in parallel with vehicle wiring over long distances. If it is necessary to cross over wiring, cross at right angles.

Troubleshooting Most interaction problems can be eliminated by following these installation guidelines. If vehicle/radio interaction develops following installation, the source of the problem should be identified prior to further operation of the vehicle. Possible causes of vehicle/radio interaction include: Antenna location (move antenna to a position on the vehicle roof) Antenna feed line routing (locate as far as possible from vehicle electronics and wiring) Inadequate shielding or loose/corroded connectors associated with the antenna feed line Mismatched antenna or high SWR Power feeds not connected directly to the vehicle battery Power feed routing (locate as far as possible away from vehicle electronics and wiring) If any vehicle/radio interaction problems exist after following these guidelines, contact your radio equipment manufacturer for additional assistance. Additional sources of information The American Radio Relay League, Inc. Technical Information Service 225 Main St, Newington, CT 06111 Phone: (860)5940200/Fax: (860)5940259 email: http://www.arrl.org/tis Radio Frequency Interference: How to Find It and Fix It ISBN: 0872593754 Giving Two-Way Radio Its Voice (booklet) Champion Spark Plug Company Automotive Technical Services Dept. P.O. Box 910, Toledo, OH 43661
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..25 fluid, checking and adding.50 fluid, refill capacities.55 fluid, specifications.56 Capacities for refilling fluids.55 Charging..13 lead-acid traction battery.15 nickel metal hydride traction battery..16 to connect the PCS.13 to disconnect the PCS.17 Coolant..48 checking and adding.49 recovery reservoir..48 refill capacities.49,55 specifications..56 Driving under special conditions snow and ice..29 Engine coolant..48 Fuel fuel pump shut-off switch.31 Fuses..32 Gauges..6 battery state of charge gauge.7 distance to empty gauge.7 economy gauge..7 motor enabled gauge.8 Hood..Jump-starting your vehicle.41 Lights, warning and indicator.3 anti-lock brakes (ABS).5 auxiliary battery..4 brake..3 charging system.3 econ mode..5 electrical hazard warning.4 low fuel..4 oil pressure..3 power limit..4 power reset..5 service indicator..3 Motorcraft parts.55 Parts (see Motorcraft parts).55 Power distribution box (see Fuses)..34 Power steering..26 fluid, checking and adding.50 fluid, refill capacity.55 fluid, specifications.56 Refill capacities for fluids..55 Starting your vehicle.22 Tires..52 changing.37 checking the pressure.52 replacing.53 rotating..52 snow tires and chains.54 spare tire..37 Towing trailer towing..29 Transaxle automatic operation..26 lubricant specifications.56 Warning lights (see Lights).3 Washer fluid reservoir.48 Windshield washer fluid and wipers reservoir.48 Wrecker towing..44

EVAMERICA

PERFORMANCE STATISTICS
At 100% SOC: 11.6 sec At 50% SOC: 12.3 sec Max. Power: 87.4 kW Performance Goal: 13.5 sec at 50% SOC At 1/4 Mile: 61.6 mph At 1 Mile: 74.5 mph Performance Goal: 70 mph in one mile

ACCELERATION 0-50 mph

MAXIMUM SPEED @ 50% SOC
CONSTANT SPEED RANGE @ 45 mph3
Range: 86.9 miles Energy Used: 20.63 kWh Average Power: 10.71 kW Efficiency: 237 Wh/mile Specific Energy: 23.7 Wh/kg
CONSTANT SPEED RANGE @ 60 mph3

1998 Ford Ranger EV

VEHICLE SPECIFICATIONS

PURPOSE-BUILT VEHICLE

Base Vehicle: 1998 Ford Ranger VIN: 1FTCR100XWSA00951 Seatbelt Positions: Three Standard Features: AM/FM Stereo Radio Tilt Steering Wheel Cabin Heat Dual Air Bags Power Steering (Electro-Hydraulic) Power Brakes Four Wheel Disc Brakes Four Wheel Anti-Lock Brakes Regenerative Braking Full-Bed Tonneau Cover Aluminum Wheels Low Rolling Resistance Tires Options As Tested Air Conditioning Battery Heater
Range: 57.9 miles Energy Used: 20.60 kWh Average Power: 21.41 kW Efficiency: 356 Wh/mile Specific Energy: 23.7 Wh/kg

DRIVING CYCLE RANGE3

Range per SAE J1634: 65.1 miles Energy Used: 21.96 kWh Average Power: 9.54 kW Efficiency: 337 Wh/mile Specific Energy: 25.2 Wh/kg Performance Goal: 60 miles

WEIGHTS

Design Curb Weight: 4700 lbs Delivered Curb Weight: 4731 lbs Distribution F/R: 51/49% GVWR: 5400 lbs GAWR F/R: 2659/2808 lbs Payload: 700 lbs1 Performance Goal: 600 lbs

BRAKING FROM 60 mph

Controlled Dry: 162.8 feet Controlled Wet: 202.1 feet Panic Wet: 201.1 feet Course Deviation: 0.0 feet

DIMENSIONS

Wheelbase: 111.6 inches Track F/R: 58.6/57.3 inches Length: 187.5 inches Width: 69.4 inches Height: 66.0 inches Ground Clearance: 5.2 inches at GVWR Performance Goal: 5.0 inches at GVWR

HANDLING

Avg Time @ 90% SOC: 56.9 sec Avg Time @ 50% SOC: 56.8 sec Avg Time @ 20% SOC: 56.8 sec Avg S-10 ICE Time: 58.3 sec4 Maximum Speed @ 3%: 68.3 mph Maximum Speed @ 6%: 58.1 mph Maximum Grade: 34.4% Time on 3% Grade: 10 min 48 sec3,5 Performance Goal: 15 Min from 50% SOC
GRADEABILITY (Calculated)

CHARGER

Location: On-board w/Off-Board PCS2 Type: Conductive Input Voltages: 187 to 264 VAC

CHARGING EFFICIENCY

Efficiency: 484 Wh-AC/mile Energy Cost @ 10 /kWh: 4.84 /mile Max Charger Ground Current: <0.01 mA Max Battery Leakage Current: 0.02 MIU Max DC Charge Current: 13.69 Amps Max AC Charge Current: 20.92 Amps Pwr Factor @ Max Current: 0.989 THD(I) @ Max Current: 3.30% Peak Demand: 4.16 kW-AC Time to Recharge: 8 Hrs 51 min6 Performance Goal: 8 hours
Tire Mfg: Uniroyal Tire Model: Tigerpaw AWP Radial Tire Size: P255/70R15 Tire Pressure F/R: 50/50 psi Spare Installed: No

BATTERY

Manufacturer: Delphi Type: VRLA Number of Modules: 39 Weight of Module: 19.3 kg Weight of Pack(s): 870.1 kg Pack Locations: Underbody Nominal Module Voltage: 8 V Nominal System Voltage: 312 V Nominal Capacity (C/2): 60 Ah

TEST NOTES:

Design payload value; value as tested was 669 lbs. Required Power Control Station (PCS) is purchased separately and cannot be used with a GFCI protected circuit. 3. Testing was terminated upon illumination of the Power Limit telltale. 4. ICE Vehicle tested was a 1992 rear wheel drive with a 4.3 liter V-6 engine. 5. Vehicle completed 21 minutes 54 seconds from 100% SOC. 6. Charging time was extended due to high temperature conditions. 7. The vehicle's Battery Control Module failed during the Test Program and was replaced 8. One battery module failed during the Test Program and was replaced. 9. Vehicle was removed from the Test Program for three 24-hour repair periods. This Vehicle meets all EV America Minimum Requirements listed on back. Values in red indicate the Performance Goal was not met. All Power and Energy values are DC unless otherwise specified. 1. 2.
Electric Transportation Applications All Rights Reserved
This vehicle meets the following EV America Minimum Requirements: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Vehicle has a payload of at least 400 pounds. The OEM GVWR has not been increased. The OEM GAWRs have not been increased. Seating capacity is a least two (2) occupants. A battery recycling plan has been submitted. The OEM passenger space has not been intruded upon by the electrical conversion materials. The vehicle has a parking mechanism or parking brake as required by 49 CFR 571.105. The vehicle has a minimum range between charges of at least 50 miles when loaded with two 166pound occupants and operated at a constant 45 mph. The vehicle manufacturer has certified that this vehicle complies with the Federal Motor Vehicle Safety Standards (FMVSS) applicable on the date of manufacture. The vehicle manufacturer has certified the batteries and battery enclosures comply with SAE J1766 and 49 CFR 571.301. Batteries comply with the requirements of SAE J1718 and NEC 625 for charging in enclosed spaces without vent fans. The vehicle manufacturer has certified that concentrations of explosive gases in the battery box do not exceed 25% of the Lower Explosive Limit (LEL) during and following normal or abnormal charging and operation of the vehicle. The battery charger is capable of recharging the main propulsion batteries to a state of full charge from any state of discharge in less than 12 hours. The vehicle manufacturer has certified the charger is capable of accepting input voltages of 208V and 240V single phase 60 Hertz alternating current service, with a tolerance of 10% of rated voltage. Charger input current is compatible with the requirements for Level II chargers and complies with the requirements of SAE J1772. Personnel protection systems are in accordance with UL Proposed Standards 2231-1 and 2231-2. The charger has a true power factor of.95 or greater and a harmonic distortion rated at < 20% (current at rated load). The charger is fully automatic, determining when "end of charge" conditions are met and transitioning into a mode that maintains the main propulsion battery at a full state of charge while not overcharging it, if continuously left on charge. The vehicle does not contain exposed conductors, terminals, contact blocks or devices of any type that create the potential for personnel to be exposed to 50 volts or greater. The vehicle will be accompanied by non-proprietary manuals for parts, service, operation, maintenance, interconnection wiring diagrams and schematics. The vehicle has a state of charge indicator for the main propulsion batteries. Propulsion power is isolated from the vehicle chassis and battery leakage is less than 0.5 MIU under static conditions. Charging circuits are isolated from the vehicle chassis such that ground current from the grounded chassis any time the vehicle is connected to a charger does not exceed 5 mA in accordance with UL Proposed Standards 2231-1 and 2231-2. Replacement tires are commercially available to the end user. The vehicle is interlocked such that: o The controller does not energize to move the vehicle with the gear selector in any position other than "Park" or "Neutral" o The start key is removable only when the "ignition key" is in the "Off" position, with the drive selector in "Park" o The controller does not initially energize or excite with a pre-existing accelerator input, such that the vehicle can be moved under its own power from this condition The vehicle manufacturer has certified that the vehicle complies with the FCC requirements for unintentional emitted electromagnetic radiation, as identified in 47 CFR 15, Subpart B, "Unintentional Radiators." The vehicle manufacturer has certified failure of a battery or battery pack has deemed to have occurred if the actual battery capacity is not at least 80% of the nominal ampere hour capacity. This vehicle is equipped with an automatic disconnect and a manual service disconnect. The charging system is compatible with the Personnel Protection requirements of SAE J1772. Material Safety Data Sheets (MSDS) have been supplied for all on-board batteries. The level of charge below which the batteries should not be discharged and how the controller automatically limits battery discharge below this level have been identified by the manufacturer. The vehicle manufacturer has verified that the method(s) of charging the propulsion batteries and the charging algorithm have been reviewed and approved by the battery manufacturer. The charger is capable of meeting the requirements of Section 625 of the National Electric Code (NEC). The vehicle complies with the requirements of 49 CFR 571.301 for fuel fired heaters. The vehicle has an on-board Battery Energy Management System (BMS).

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This information was prepared with the support of the U. S. Department of Energy (DOE) Award No. DE-FC07-96ID 13475. However, any opinions, findings, conclusions or recommendations expressed herein are those of the author(s) and do not necessarily reflect the views of DOE.