battery FORD C MAX ENERGI 2016 Service Manual

Note:The service disconnect has an outerlever to aid in the proper seating of theservice disconnect lever. Remove this todisconnect the high-voltage servicedisconnect.
The high-voltage service disconnect islocated behind the rear fold down seats.
Service disconnect location for non-Energivehicles.
Service disconnect location for Energivehicles.
Disabling the High-Voltage Battery
1. Fold down the rear seats and removethe cover panel.
2. Locate the access door and removethe plastic cover.
3. Pull the outer cover off to expose theservice disconnect lever.
4. Slide the handle on the servicedisconnect outboard to the right. ForEnergi vehicles, slide the handleoutboard and to the left.
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5.Pull the handle toward you and removethe service disconnect from the vehicleto disable the high-voltage battery.
Reactivating the High-Voltage Battery
Note:If you have manually disconnectedyour high-voltage shut off circuit, you willneed to reconnect the circuit before you canreactivate it. The system will detect if theelectrical system is safe and turn onautomatically.
CHARGING THE HIGH
VOLTAGE BATTERY
WARNINGS
Do not use the 120 volt conveniencecord with an extension cord,two-prong adapter, surge protector,timer or other adapter.
In Canada, do not use the 120 voltconvenience cord in commercialgarages.
This equipment has arcing orsparking parts, do not expose toflammable vapors. Position thisequipment at least 18 in (45 cm) abovethe floor.
The AC wall plug must fit firmly intothe AC outlet. If the connection feelsloose, worn or the AC outlet isdamaged, please have a qualifiedelectrician replace the AC outlet. Using aconvenience cord with a worn outlet maycause burns, property damage andincrease the risk of electric shock.
Charging Equipment
Your vehicle is equipped with a standard120 volt convenience cord located in thefloor compartment behind the driver seat.
Note:The 120 volt convenience cord allowsyou to charge the high voltage battery usinga standard 120 volt household outlet. Ittakes approximately seven hours tocompletely charge an empty battery usingthe standard 120 volt convenience cord.
We recommend upgrading to the optional240 volt charging station for faster moreefficient charging. It takes approximately2.5 hours to completely charge an emptybattery using a 240 volt charging station.
Your electrical source must meet certainrequirements for the high voltage batteriesto charge:
•The AC outlet must be a three-prong110-120 volt AC outlet that is properlygrounded, 15–20 amps (or greater),and in good condition.
•You must use a dedicated line, whichmeans you cannot have otherappliances connected to the samecircuit.
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Note:If you do not have a dedicated circuit,contact a licensed professional electricianfor proper installation.
Make sure that the 120 volt conveniencecord is completely unwound beforecharging. Always plug the cord into the ACoutlet before connecting the chargingcoupler into the charge port on yourvehicle.
120 Volt Convenience Cord
Power.A.
Check outlet.B.
Fault.C.
Vehicle.D.
Note:When the convenience cord is plugged into an outlet, use the following table todetermine your vehicle charge status. If the POWER indicator light is off after plugging inthe convenience cord, use a different outlet.
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A
B
C
D

StatusConvenience Cord LED Indicators
VehicleFaultCheckOutlet
The convenience cord is not connected to yourvehicle.OffOffOff
The convenience cord is connected, but yourvehicle is not charging.OnOffOff
Your vehicle is charging.BlinkOffOff
Ground Fault Circuit Interrupter (GFCI) FaultDetected.OffBlinkOff
The convenience cord is retrying to charge.
Ground Fault Circuit Interrupter (GFCI) FaultDetected.OffOnOff
The convenience cord has exhausted its retryattempts. Your vehicle is not charging, or there isan internal fault in the charging equipment.
The convenience cord detected a high temper-ature at the AC plug and is waiting for the AC plugto return to a normal operating temperature.*
OffOffBlink
The convenience cord detected a high temper-ature at the AC plug. The AC plug has returned toa normal operating temperature. Your vehicle isready to charge at a reduced current.*
OnOffBlink
The convenience cord detected a high temper-ature at the AC plug. The AC plug has returned toa normal operating temperature. Your vehicle ischarging at a reduced current.*
BlinkOffBlink
The convenience cord detected a high temper-ature at the AC plug. Your vehicle is not charging.The convenience cord has exhausted its retryattempts.*
OffOnBlink
*Have the outlet checked by a qualified electrician and make sure the AC plug fits firmlyinto the outlet. Contact an authorized EV certified dealer if problem persists.
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High Voltage Battery

Charge Port
The charge port is located between thefront left-hand side door and the frontleft-hand side wheel well. Press theindentation on the charge port door toopen and close it.
Note:Do not force the charge port dooropen or closed. Forcing the door open orclosed damages the charge port.
You can modify the light ring illuminationsettings. The light ring located around thecharge port indicates the charge status ofthe high voltage battery in your vehicle.Divided into four quadrants, the chargeport light ring displays the state of chargein 25 percent increments.
You can press the unlock button on yourkey fob to view the charge status of yourvehicle. Based on which quadrants light,you can determine the current state ofcharge. If the charge is below 25 percent,the light ring does not light. Do not forgetto press the lock button on your key fob tore-lock your vehicle.
The light ring also displays the currentstate of charge when opening the doors.
The cord acknowledgment featureactivates when you initiate a charge cycle.The four light quadrants each individuallyflash in a clockwise motion, starting withthe top right-hand side light and endingwith the top left-hand side, two timesconfirming that the system detects thecharging coupler.
Charging
Note:Your vehicle must be in park (P) tocharge.
To charge your high voltage battery:
1.Put your vehicle in park (P) and switchoff your vehicle.
2. Press the indentation on the chargeport door to open it.
3. Plug the charging coupler into thecharge port on your vehicle. Make surethe button clicks confirming you havecompletely engaged the coupler.
4. Verify that the cord acknowledgmentfeature activates. The cordacknowledgment feature activateswhen you initiate a charge cycle.
5. If using a 240 volt charging station,follow the instructions on the chargestation to begin the charging process.
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The light ring located around the chargeport indicates the charge status of the highvoltage battery in your vehicle:
•When the top right-hand side quadrantis pulsing, the charge is between 0-25percent.
•When the top right-hand side quadrantis on and the bottom right-handquadrant is pulsing, the charge isbetween 25-50 percent.
•When both right-hand side quadrantsare on and the bottom left-hand sidequadrant is pulsing, the charge isbetween 50-75 percent.
•When three quadrants are on and thetop left-hand side quadrant is pulsing,the charge is between 75-100 percent.
•When all the lights on the light ring areon, the charge is complete.
Note:The light ring will turn off one minuteafter reaching a full charge.
Locking the Charging Coupler
Note:To lock the charging coupler, youneed a padlock or a combination lock witha shackle diameter of 0.2 in (5 mm) or less.Also, the straight portion of the shacklemust be 1.0 in (25.4 mm) or longer.
1. Insert the lock through the hole in thecharging coupler button.
2. Lock the padlock or combination lock.
Waiting to Charge
When you select Value Charge, chargingmay not begin upon plugging in. Thevehicle may delay charging to takeadvantage of off-peak electricity rates. Thevehicle will optimize the charge scheduleto be complete by the next GO Time.
When waiting to charge (not activelycharging), the light ring will indicate thepresent state of charge of the high voltagebattery as follows:
•When the top right quadrant light is off,the charge is between 0–25 percent.
•When the top right quadrant light is onand the bottom right quadrant is off,the charge is between 25–50 percent.
•When both right side quadrant lightsare on and the bottom left quadrant isoff, the charge is between 50–75percent.
•When three quadrant lights are on andthe top left quadrant is off, the chargeis between 75–100 percent.
•When all lights on the entire ring areon, the charge is 100 percent.
Note:When the vehicle is waiting to charge,the light ring will turn off one minute afterdisplaying the present state of charge. Whenthe vehicle automatically begins charging,the light ring will turn on and display howfar along the charge is per the section above.
Note:If the system detects a vehiclecharging system fault at any point in acharge cycle, the entire light ring will flashcontinuously for one minute and then turnoff. If this happens, unplug the chargingcoupler and then plug it back into the chargeport receptacle. If the problem persists,contact an authorized dealer.
You can modify the light ring lightingconditions by using the touchscreensystem.
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Disconnecting the ChargingCoupler
Note:Do not pull the wall plug from thewall while the vehicle is charging. Doing somay damage the outlet and the cord.
1. Remove the lock from the chargingcoupler button.
2. Press the button on the chargingcoupler.
3. While holding the button, remove thecharging coupler from the charge portreceptacle on your vehicle.
4.Close the charge port door by pressingthe indentation on the charge portdoor. Continue pressing the indentationwhile the door rotatescounterclockwise and closes.
HIGH VOLTAGE BATTERY CUT-
OFF SWITCH
The high-voltage shut off operation shutsoff power from the high-voltage batteryafter a collision, or if your vehicle receivesa substantial physical jolt.
To reactivate your vehicle after eitherevent, perform the following steps:
1. Turn the ignition off.
2. Turn the ignition on.
3.If your vehicle is not powered after thissequence, repeat steps 1 and 2 up totwo more times.
For vehicles equipped with a push buttonstart system:
1. Press the START/STOP button toturn ignition off.
2. Press the brake pedal and press theSTART/STOP button.
3.If your vehicle is not powered after thissequence, repeat steps 1 and 2 up totwo more times.
Note:During this process, your vehicle willdetect if the electrical system is safe andreactivate. Once your vehicle determinesthe electrical system safe, you can start yourvehicle as you would normally by eitherturning the ignition key or by pressing thebrake in combination with theSTART/STOP button.
Note:In the event your vehicle does notreactivate after the third key cycle, contactan authorized dealer.
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AUTOMATIC TRANSMISSION
WARNINGS
Always set the parking brake fullyand make sure the gearshift islatched in park (P). Turn the ignitionto the off position and remove the keywhenever you leave your vehicle.
Do not apply the brake pedal andaccelerator pedal simultaneously.Applying both pedals simultaneouslyfor more than three seconds will limitengine rpm, which may result in difficultymaintaining speed in traffic and could leadto serious injury.
Note:Do not leave your vehicle with thetransmission in neutral (N). Leaving yourvehicle with the transmission in neutral (N)will drain the battery and you may not beable to start your vehicle.
Automatic Transmission
Putting your vehicle in gear:
1. Fully press down the brake pedal.
2.Move the gearshift lever to the desiredgear.
3. Come to a complete stop.
4. Move the gearshift lever and securelylatch it in park (P).
Park (P)
This position locks the transmission andprevents the front wheels from turning.Come to a complete stop before puttingyour vehicle into and out of park (P).
Reverse (R)
With the gearshift lever in reverse (R), yourvehicle will move backward. Always cometo a complete stop before shifting into andout of reverse (R).
Neutral (N)
With the gearshift lever in neutral (N), yourvehicle can be started and is free to roll.Hold the brake pedal down while in thisposition.
Drive (D)
Drive (D) is the normal driving position forthe best fuel economy.
Low (L)
•Provides maximum engine braking.
•The transmission may be shifted intolow (L) at any vehicle speed.
•Is not intended for use under extendedor normal driving conditions and resultsin lower fuel economy.
Grade assist:
Press the transmission control switch onthe side of the gearshift lever to activategrade assist.
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•Provides additional grade braking witha combination of engine motoring andhigh-voltage battery charging to helpmaintain vehicle speed whendescending a grade.
•As your vehicle determines the amountof engine motoring and high-voltagebattery charging, you may notice theengine speed increasing anddecreasing to help maintain yourvehicle speed when descending agrade.
•The grade assist lamp in the instrumentcluster is illuminated.
The grade assist lamp willappear in the instrument clusterwhen grade assist is turned on.
Press the transmission control switchagain to return to normal drive (D).
Brake-Shift Interlock
WARNINGS
Do not drive your vehicle until youverify that the brake lamps areworking.
WARNINGS
When doing this procedure, you willbe taking your vehicle out of parkwhich means your vehicle can rollfreely. To avoid unwanted vehiclemovement, always fully set the parkingbrake prior to doing this procedure. Usewheel chocks if appropriate.
If the parking brake is fully released,but the brake warning lamp remainsilluminated, the brakes may not beworking properly. See your authorizeddealer.
Note:See your authorized dealer as soonas possible if this procedure is used.
Note:For some markets this feature will bedisabled.
Use the brake shift interlock lever to movethe gearshift lever from the park positionin the event of an electrical malfunction orif your vehicle has a dead battery.
Apply the parking brake and turn theignition off before performing thisprocedure.
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GENERAL INFORMATION
Note:Occasional brake noise is normal. Ifa metal-to-metal, continuous grinding orcontinuous squeal sound is present, thebrake linings may be worn-out. Have thesystem checked by an authorized dealer. Ifthe vehicle has continuous vibration orshudder in the steering wheel while braking,have it checked by an authorized dealer.
Note:Brake dust may accumulate on thewheels, even under normal drivingconditions. Some dust is inevitable as thebrakes wear and does not contribute tobrake noise. See Cleaning the AlloyWheels (page 245).
See Warning Lamps andIndicators (page 89).
Wet brakes result in reduced brakingefficiency. Gently press the brake pedal afew times when driving from a car wash orstanding water to dry the brakes.
Brake Over Accelerator
In the event the accelerator pedalbecomes stuck or entrapped, apply steadyand firm pressure to the brake pedal toslow the vehicle and reduce engine power.If you experience this condition, apply thebrakes and bring your vehicle to a safestop. Move the transmission to park (P),switch the engine off and apply the parkingbrake. Inspect the accelerator pedal forany interference. If none are found and thecondition persists, have your vehicle towedto the nearest authorized dealer.
Brake Assist
Brake assist detects when you brakeheavily by measuring the rate at which youpress the brake pedal. It providesmaximum braking efficiency as long as youpress the pedal. Brake assist can reducestopping distances in critical situations.
Anti-lock Brake System
This system helps you maintain steeringcontrol during emergency stops by keepingthe brakes from locking.
This lamp momentarilyilluminates when you turn theignition on. If the light does notilluminate during start up, remains on orflashes, the system may be disabled. Havethe system checked by an authorizeddealer. If the anti-lock brake system isdisabled, normal braking is still effective.
If the brake warning lampilluminates when you release theparking brake, have the systemchecked by an authorized dealer.
Regenerative Braking System
This feature is used to simulate the enginebraking of an internal combustion engineand assist the standard brake system whilerecovering some of the energy of motionand storing it in the battery to improve therange of your vehicle. The standard brakesystem is designed to fully stop the car ifregenerative braking is not available.During regenerative braking, the motor isspun as a generator to create electricalcurrent. This recharges the battery andslows the vehicle. In effect, once theaccelerator pedal is released, the motorchanges from an energy user to an energyproducer.
When the accelerator pedal is released orthe brake pedal is applied, the brakecontroller automatically detects theamount of deceleration requested andoptimizes how much of the decelerationwill be produced by regenerative braking.The remaining portion is generated by
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