FLEET 2023 Ford E-Transit All-Electric Van Owner’s Manual
- June 9, 2024
- FLEET
Table of Contents
2023 Ford E-Transit All-Electric Van
Owner’s Manual
Battery Removal Guide
**High Voltage Battery Depowering
**
WARNING:
THE HIGH-VOLTAGE SYSTEM MAY RETAIN A DANGEROUS LEVEL OF VOLTAGE FOR A SHORT
TIME AFTER THE SERVICE DISCONNECT HAS BEEN OPENED. WAIT 5 MINUTES FOR THE
VOLTAGE TO DISSIPATE BEFORE BEGINNING SERVICE. FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
REMOVING THE BATTERY HIGH VOLTAGE SERVICE DISCONNECT DOES NOT DISSIPATE
VOLTAGE INSIDE THE BATTERY PACK. THE BATTERY PACK REMAINS LIVE AND DANGEROUS.
CONTACT WITH THE HIGH VOLTAGE BATTERY PACK INTERNALS MAY RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.
WARNING:
ELECTRIC VEHICLES DAMAGED BY A CRASH MAY HAVE COMPROMISED HIGH VOLTAGE
SAFETY SYSTEMS AND PRESENT A POTENTIAL HIGH VOLTAGE ELECTRICAL SHOCK HAZARD.
EXERCISE CAUTION AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE)
INCLUDING HIGH VOLTAGE SAFETY GLOVES AND BOOTS. REMOVE ALL METALLIC JEWELRY,
INCLUDING WATCHES AND RINGS. ISOLATE THE HIGH VOLTAGE SYSTEM AS DIRECTED BY
THE FORD EMERGENCY RESPONSE GUIDE FOR THE VEHICLE. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
TO PREVENT THE RISK OF HIGH-VOLTAGE SHOCK, ALWAYS FOLLOW PRECISELY ALL
WARNINGS AND SERVICE INSTRUCTIONS INCLUDING INSTRUCTIONS TO DEPOWER THE
SYSTEM. THE TOTAL VOLTAGE OF THE VEHICLE HV BATTERY PACK MAY BE UP TO
APPROXIMATELY 450 VOLTS DC. THIS VOLTAGE IS PROVIDED THROUGH HIGH-VOLTAGE
CABLES TO ITS COMPONENTS AND MODULES. THE HIGH-VOLTAGE CABLES AND WIRING ARE
IDENTIFIED BY ORANGE HARNESS TAPE OR ORANGE WIRE COVERING. ALL HIGH-VOLTAGE
COMPONENTS ARE MARKED WITH HIGH-VOLTAGE WARNING LABELS WITH A HIGH-VOLTAGE
SYMBOL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.
WARNING:
SERVICE OF THE HIGH VOLTAGE SYSTEM ON THIS VEHICLE IS RESTRICTED TO
QUALIFIED PERSONNEL. THE REQUIRED QUALIFICATIONS VARY BY REGION. ALWAYS
OBSERVE LOCAL LAWS AND LEGISLATIVE DIRECTIVES REGARDING ELECTRIC VEHICLE
SERVICE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.
WARNING:
NEVER CONNECT THE SERVICE DISCONNECT WHEN A HIGH-VOLTAGE COVER IS REMOVED.
ALWAYS INSTALL THE COVER PRIOR TO CONNECTING THE SERVICE DISCONNECT. THE COVER
PREVENTS INADVERTENT CONTACT WITH THE HIGH VOLTAGE WHICH IS PRESENT AT SEVERAL
POINTS UNDER THE COVER. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
WARNING:
DISCONNECT THE 12V BATTERY BEFORE SERVICING THE DIRECT CURRENT TO
ALTERNATING CURRENT (DC-AC) INVERTER OR ALTERNATING CURRENT (AC) POWERPOINT TO
PREVENT THE RISK OF HIGH VOLTAGE SHOCK. FAILURE TO FOLLOW THIS INSTRUCTION MAY
RESULT IN SERIOUS PERSONAL INJURY.
NOTICE:
Do not backprobe, splice or repair the high voltage (orange) wiring.
Voltage in the system is approximately 450 volts DC. Damage may occur to
equipment added to the system.
NOTICE:
None of the High Voltage Traction Battery (HVTB) wiring should be tapped or
spliced to check for battery voltage (power), ground or signals.
NOTICE:
Modification of Low-Voltage (LV) power & control wires connecting to the
High-Voltage (HV) battery system can damage or disable the HV Battery system.
Do not open or modify High Voltage battery pack High Voltage Battery
Depowering using FDRS WARNING:
Before beginning any service procedure in this manual, refer to health and
safety warnings. Failure to follow this instruction may result in serious
personal injury.
WARNING:
To prevent the risk of high-voltage shock, always follow precisely all
warnings and service instructions, including instructions to depower the
system. The high-voltage system utilizes approximately 450 volts DC, provided
through high-voltage cables to its components and modules. The high-voltage
cables and wiring are identified by orange harness tape or orange wire
covering. All high-voltage components are marked with high-voltage warning
labels with a high-voltage symbol. Failure to follow these instructions may
result in serious personal injury or death.
-
Using the FDRS CARRY OUT the BECM — High Voltage System De-energizing and follow the on-screen instructions.
-
Release the Connector Position Assurance (CPA)
-
NOTE: The tab must be depressed prior to pushing the connector back in or damage to the connector may result.
Depress the tab while pulling the connector until the hole is completely visible on the top of the connector. -
Insert a suitable tool inside the connector hole to prevent the connector from closing.
-
Using the FDRS COMPLETE the BECM-High Voltage System De-energizing and verify the High Voltage System has been de-energized.
Manual De-Energizing WARNING:
To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 450 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death
WARNING:
Before beginning any service procedure in this manual, refer to health and
safety warnings in WSM Section 100-00 General Information. Failure to follow
this instruction may result in serious personal injury.
NOTICE
Manual De-energization should only be performed when a Ford-specific
diagnostic tool is not available.
NOTICE:
Excessive use of this method may cause damage to electrical connectors.
NOTICE:
To prevent the risk of high voltage shock, the high voltage battery cover
must not be removed if any of the following condition exist:
- BECM DTC POAA6:00 that has been diagnosed to be an internal fault with the high voltage Battery.
- BECM Diagnostic Trouble Codes (DTCs) POAA1:00 AND POAA4:00 are present.
- BECM Diagnostic Trouble Codes (DTCs) PODOF:00 AND POAA4:00 are present.
-
Disconnect the Electric Vehicle Supply Equipment (EVSE) from the vehicle charge port and BEV.
-
Turn the ignition ON without depressing the brake pedal (Accessory mode).
NOTE:
A scan tool that is capable of performing a self-test on the BECM is required.
Using a scan tool perform BECM self test and record the Diagnostic Trouble Codes (DTCs).
If BECM Diagnostic Trouble Codes (DTCs) POAA1:00 AND POAA4:00 are present. Refer to WSM procedures in section 414-03B High Voltage Battery, Mounting and Cables, Diagnosis and Testing.
Turn the ignition OFF. -
Release the Connector Position Assurance (CPA) clip.
-
NOTE: The tab must be depressed prior to pushing the connector back in or damage to the connector may result.
Depress the tab while pulling the connector until the hole is completely visible on the top of the connector. -
Insert a suitable tool inside the connector hole to prevent the connector from closing.
-
Disconnect the low voltage electrical connector at the High Voltage Battery.
-
Disconnect the high voltage electrical connector at the High Voltage Battery.
-
Wait a minimum of 5 minutes.
Battery Removal
NOTE: Before proceeding ensure the high voltage service disconnect
procedure has been preformed.
NOTICE: Enable the “Emergency Tow” feature to allow the vehicle to remain
in neutral while depowered.
NOTE: Vehicles equipped with manual seats do not have a vertical seat
adjustment.
-
Raise and position the left hand front seat forward.
-
Release the retainers and remove the left hand front seat rear trim panel.
-
Position the LH front seat backrest cover to release a retainer.
NOTE: Seat not shown for clarity. -
Remove the battery disconnect access cover.
a. If equipped, position the battery cover insulator. -
Remove the nut and position the battery cable.
-
Disconnect the coolant hoses. Use the General Equipment: Locking Pliers
a. Clamp the coolant hoses.
b. Disconnect the coolant hoses.
-
Disconnect the high voltage battery electrical connector.
a. Remove the nuts.
b. Release the lock lever and disconnect the high voltage battery electrical connector.
NOTE:
To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.
-
Disconnect the high voltage battery electrical connectors.
a. Release the lock lever and disconnect the high voltage battery electrical connector.
b. If equipped, fully loosen the boly and disconnect the high voltage battery electrical connector.
c. Disconnect the retainers. Release the locking tab and disconnect the high voltage battery electrical connector.
NOTE: To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.
-
Release the lock lever and disconnect the high voltage battery electrical connector.
NOTE:
To aid in disconnecting the high voltage battery electrical connector, gently pull the base of the connector while releasing the lock lever.
-
Install a drain tube to one port of the high voltage battery coolant tube assembly. Using compressed air, remove the coolant from inside of the high voltage battery. NOTE:
Be prepared to collect escaping fluids.
-
Remove mounting bolt(s).
-
Remove nuts and bolts.
NOTICE:
Only apply enough pressure from the powertrain lift table to contact and support the high voltage battery during the removal.
Excessive pressure placed under the high voltage battery may cause damage to the high voltage battery. -
Position a suitable powertrain lift table under the high voltage battery.
Special Service Tool: 014-3KLIFTTABLE
-
Remove the bolts from the high voltage battery.
NOTICE:
Be careful not to damage the electrical connectors when lowering the battery. -
With the aid of an assistant, remove the high voltage battery.
SPECIAL NOTE TO DISMANTLERS AND SALVAGE YARDS
If a vehicle with a high voltage battery is to be scrapped, the high voltage
battery must be disposed of following all local, state/provincial and federal
guidelines.
The vehicle’s Lithium-Ion High Voltage Battery pack (Li-Ion HVB) is fully
recyclable and should be shipped to a permitted recycling facility. The
guidelines below are for Li-Ion HVBs which have been removed from the vehicle
and discharged.
General Packaging, Transport, and Recycling Guidelines
Once the battery has been removed from the vehicle and discharged:
- Store the battery components in a building or under shelter so that batteries are kept dry and not exposed to high temperatures.
- Protect battery components from damage (e.g. crushed or punctured).
- It is recommended to ask about the specific packaging requirements for battery shipments to the recycler who will be receiving the battery components in order to avoid inappropriate repacking/stacking of the batteries.
- Batteries should be sorted by type. Keep lead acid batteries, NiMH batteries, and Li-Ion batteries separated from each other (e.g. separate pallets or storage locations).
- Make sure the battery recycler is aware of the battery type. Li-ion batteries cannot be recycled in the same manner as lead acid or NiMH
Though Ford Motor Company makes no representations or endorsements, there are companies that have the capability to accept, consolidate and recycle undamaged Li-Ion HVBs, and a few are listed below. Contact the appropriate battery manufacturer for additional information.
North America Battery Recyclers
Once the battery has been removed from the vehicle and discharged:
Kinsbursky Brothers, Inc. 1125 Beacon Street Brea, CA 92801: Phone:
800-502-9258 Retriev Technologies, Inc.
265 Quarry Rd SE Lancaster, OH 43130: Phone:
740-653-6290 Applicable
Laws/Regulations
The following is a general explanation of certain applicable laws; however,
these laws change from time to time, additional regulations are under
development and Ford Motor Company makes no representation that this is a
complete summary.
Packaging and Transport
Packaging and Transport The U.S. Department of Transportation (DOT) outlines packaging and shipping requirements for Li-Ion batteries. Certain exceptions on packaging and transportation regulations for large format Li-Ion batteries may be found in 49CFR 173.185 (d) and (f). Make sure that the shipping paperwork is filled out correctly and that the shipment is properly labeled per federal, state, and local laws and regulations. Ensure that you are complying with any record keeping requirements. Generally, under U.S. DOT regulations, Li-Ion batteries are considered a dangerous good and regulated as hazardous materials when transported. Li-Ion batteries are classified as Class 9 hazardous material. Only certified hazardous material shippers should offer transport of a hazardous material. Batteries for recycling should be shipped by ground or vessel only. Do not ship batteries for recycling by air.
NOTE:
A damaged battery (one that is leaking electrolyte from the battery pack) might need to be shipped as a hazardous waste. If you are transporting a damaged battery, utilize a company that specializes in hazardous waste transport and management. Ensure that you comply with all applicable hazardous waste management laws and regulations.
Recycling
40 CFR 261 states that manufactured articles that yield extracts which
exceed one or more of the concentration limits of regulated listed
constituents, or meets the definition of ignitability, corrosivity or
reactivity are defined as hazardous wastes and must be disposed of in
accordance with federal and state regulations. Since there are many variations
in the specific chemistry of Li-Ion batteries, additional classifications may
be necessary to determine if the battery is a hazardous waste. It is the
responsibility of the generator to make this determination. Generally, under
federal and state law, sealed, Li-Ion batteries may be considered dry cell
batteries and therefore may be managed as a universal waste; damaged or
leaking Li-Ion batteries may be regulated as hazardous waste under federal and
state regulations.
© Copyright Ford 2023 FoMoCo
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