battery FORD C MAX HYBRID 2016 2.G Service Manual

Note:
The service disconnect has an outer
lever to aid in the proper seating of the
service disconnect lever. Remove this to
disconnect the high-voltage service
disconnect.
The high-voltage service disconnect is
located behind the rear fold down seats.
Service disconnect location for non-Energi
vehicles. Service disconnect location for Energi
vehicles.
Disabling the High-Voltage Battery
1. Fold down the rear seats and remove
the cover panel.
2. Locate the access door and remove the plastic cover. 3. Pull the outer cover off to expose the
service disconnect lever. 4. Slide the handle on the service
disconnect outboard to the right. For
Energi vehicles, slide the handle
outboard and to the left. 154
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5.
Pull the handle toward you and remove
the service disconnect from the vehicle
to disable the high-voltage battery.
Reactivating the High-Voltage Battery
Note: If you have manually disconnected
your high-voltage shut off circuit, you will
need to reconnect the circuit before you can
reactivate it. The system will detect if the
electrical system is safe and turn on
automatically.
CHARGING THE HIGH
VOLTAGE BATTERY WARNINGS
Do not use the 120 volt convenience
cord with an extension cord,
two-prong adapter, surge protector,
timer or other adapter. In Canada, do not use the 120 volt
convenience cord in commercial
garages.
This equipment has arcing or
sparking parts, do not expose to
flammable vapors. Position this
equipment at least 18 in (45 cm) above
the floor. The AC wall plug must fit firmly into
the AC outlet. If the connection feels
loose, worn or the AC outlet is
damaged, please have a qualified
electrician replace the AC outlet. Using a
convenience cord with a worn outlet may
cause burns, property damage and
increase the risk of electric shock. Charging Equipment
Your vehicle is equipped with a standard
120 volt convenience cord located in the
floor compartment behind the driver seat.
Note:
The 120 volt convenience cord allows
you to charge the high voltage battery using
a standard 120 volt household outlet. It
takes approximately seven hours to
completely charge an empty battery using
the standard 120 volt convenience cord.
We recommend upgrading to the optional
240 volt charging station for faster more
efficient charging. It takes approximately
2.5 hours to completely charge an empty
battery using a 240 volt charging station.
Your electrical source must meet certain
requirements for the high voltage batteries
to charge:
• The AC outlet must be a three-prong
110-120 volt AC outlet that is properly
grounded, 15– 20 amps (or greater),
and in good condition.
• You must use a dedicated line, which
means you cannot have other
appliances connected to the same
circuit.
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Note:
If you do not have a dedicated circuit,
contact a licensed professional electrician
for proper installation.
Make sure that the 120 volt convenience
cord is completely unwound before
charging. Always plug the cord into the AC
outlet before connecting the charging
coupler into the charge port on your
vehicle. 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 to
determine your vehicle charge status. If the POWER indicator light is off after plugging in
the convenience cord, use a different outlet.
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A
B
C
D

Status
Convenience Cord LED Indicators
Vehicle
Fault
Check
Outlet
The convenience cord is not connected to yourvehicle.
Off
Off
Off
The convenience cord is connected, but yourvehicle is not charging.
On
Off
Off
Your vehicle is charging.
Blink
Off
Off
Ground Fault Circuit Interrupter (GFCI) FaultDetected.
Off
Blink
Off
The convenience cord is retrying to charge.
Ground Fault Circuit Interrupter (GFCI) Fault Detected.
Off
On
Off
The convenience cord has exhausted its retry
attempts. Your vehicle is not charging, or there is an internal fault in the charging equipment.
The convenience cord detected a high temper-
ature at the AC plug and is waiting for the AC plug to return to a normal operating temperature.*
Off
Off
Blink
The convenience cord detected a high temper-
ature at the AC plug. The AC plug has returned to a normal operating temperature. Your vehicle is ready to charge at a reduced current.*
On
Off
Blink
The convenience cord detected a high temper-
ature at the AC plug. The AC plug has returned to a normal operating temperature. Your vehicle is charging at a reduced current.*
Blink
Off
Blink
The convenience cord detected a high temper-
ature at the AC plug. Your vehicle is not charging. The convenience cord has exhausted its retry attempts.*
Off
On
Blink
*Have the outlet checked by a qualified electrician and make sure the AC plug fits firmly
into the outlet. Contact an authorized EV certified dealer if problem persists.
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Charge Port
The charge port is located between the
front left-hand side door and the front
left-hand side wheel well. Press the
indentation on the charge port door to
open and close it.
Note:
Do not force the charge port door
open or closed. Forcing the door open or
closed damages the charge port.
You can modify the light ring illumination
settings. The light ring located around the
charge port indicates the charge status of
the high voltage battery in your vehicle.
Divided into four quadrants, the charge
port light ring displays the state of charge
in 25 percent increments.
You can press the unlock button on your
key fob to view the charge status of your
vehicle. Based on which quadrants light,
you can determine the current state of
charge. If the charge is below 25 percent,
the light ring does not light. Do not forget
to press the lock button on your key fob to
re-lock your vehicle.
The light ring also displays the current
state of charge when opening the doors. The cord acknowledgment feature
activates when you initiate a charge cycle.
The four light quadrants each individually
flash in a clockwise motion, starting with
the top right-hand side light and ending
with the top left-hand side, two times
confirming that the system detects the
charging coupler.
Charging
Note:
Your vehicle must be in park (P) to
charge.
To charge your high voltage battery:
1. Put your vehicle in park (P) and switch
off your vehicle.
2. Press the indentation on the charge port door to open it.
3. Plug the charging coupler into the charge port on your vehicle. Make sure
the button clicks confirming you have
completely engaged the coupler. 4. Verify that the cord acknowledgment
feature activates. The cord
acknowledgment feature activates
when you initiate a charge cycle.
5. If using a 240 volt charging station, follow the instructions on the charge
station to begin the charging process.
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The light ring located around the charge
port indicates the charge status of the high
voltage battery in your vehicle:
•
When the top right-hand side quadrant
is pulsing, the charge is between 0-25
percent.
• When the top right-hand side quadrant
is on and the bottom right-hand
quadrant is pulsing, the charge is
between 25-50 percent.
• When both right-hand side quadrants
are on and the bottom left-hand side
quadrant is pulsing, the charge is
between 50-75 percent.
• When three quadrants are on and the
top left-hand side quadrant is pulsing,
the charge is between 75-100 percent.
• When all the lights on the light ring are
on, the charge is complete.
Note: The light ring will turn off one minute
after reaching a full charge.
Locking the Charging Coupler
Note: To lock the charging coupler, you
need a padlock or a combination lock with
a shackle diameter of 0.2 in (5 mm) or less.
Also, the straight portion of the shackle
must be 1.0 in (25.4 mm) or longer. 1. Insert the lock through the hole in the
charging coupler button.
2. Lock the padlock or combination lock. Waiting to Charge
When you select Value Charge, charging
may not begin upon plugging in. The
vehicle may delay charging to take
advantage of off-peak electricity rates. The
vehicle will optimize the charge schedule
to be complete by the next GO Time.
When waiting to charge (not actively
charging), the light ring will indicate the
present state of charge of the high voltage
battery as follows:
•
When the top right quadrant light is off,
the charge is between 0– 25 percent.
• When the top right quadrant light is on
and the bottom right quadrant is off,
the charge is between 25–50 percent.
• When both right side quadrant lights
are on and the bottom left quadrant is
off, the charge is between 50– 75
percent.
• When three quadrant lights are on and
the top left quadrant is off, the charge
is between 75– 100 percent.
• When all lights on the entire ring are
on, the charge is 100 percent.
Note: When the vehicle is waiting to charge,
the light ring will turn off one minute after
displaying the present state of charge. When
the vehicle automatically begins charging,
the light ring will turn on and display how
far along the charge is per the section above.
Note: If the system detects a vehicle
charging system fault at any point in a
charge cycle, the entire light ring will flash
continuously for one minute and then turn
off. If this happens, unplug the charging
coupler and then plug it back into the charge
port receptacle. If the problem persists,
contact an authorized dealer.
You can modify the light ring lighting
conditions by using the touchscreen
system.
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Disconnecting the Charging
Coupler
Note:
Do not pull the wall plug from the
wall while the vehicle is charging. Doing so
may damage the outlet and the cord.
1. Remove the lock from the charging coupler button.
2. Press the button on the charging coupler.
3. While holding the button, remove the charging coupler from the charge port
receptacle on your vehicle. 4.
Close the charge port door by pressing
the indentation on the charge port
door. Continue pressing the indentation
while the door rotates
counterclockwise and closes.
HIGH VOLTAGE BATTERY CUT-
OFF SWITCH
The high-voltage shut off operation shuts
off power from the high-voltage battery
after a collision, or if your vehicle receives
a substantial physical jolt.
To reactivate your vehicle after either
event, perform the following steps:
1. Turn the ignition off.
2. Turn the ignition on. 3.
If your vehicle is not powered after this
sequence, repeat steps 1 and 2 up to
two more times.
For vehicles equipped with a push button
start system:
1. Press the START/STOP button to
turn ignition off.
2. Press the brake pedal and press the START/STOP
button.
3. If your vehicle is not powered after this
sequence, repeat steps 1 and 2 up to
two more times.
Note: During this process, your vehicle will
detect if the electrical system is safe and
reactivate. Once your vehicle determines
the electrical system safe, you can start your
vehicle as you would normally by either
turning the ignition key or by pressing the
brake in combination with the
START/STOP
button.
Note: In the event your vehicle does not
reactivate after the third key cycle, contact
an authorized dealer.
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AUTOMATIC TRANSMISSION
WARNINGS
Always set the parking brake fully
and make sure the gearshift is
latched in park (P). Turn the ignition
to the off position and remove the key
whenever you leave your vehicle. Do not apply the brake pedal and
accelerator pedal simultaneously.
Applying both pedals simultaneously
for more than three seconds will limit
engine rpm, which may result in difficulty
maintaining speed in traffic and could lead
to serious injury. Note:
Do not leave your vehicle with the
transmission in neutral (N). Leaving your
vehicle with the transmission in neutral (N)
will drain the battery and you may not be
able 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 desired
gear.
3. Come to a complete stop.
4. Move the gearshift lever and securely latch it in park (P). Park (P)
This position locks the transmission and
prevents the front wheels from turning.
Come to a complete stop before putting
your vehicle into and out of park (P).
Reverse (R)
With the gearshift lever in reverse (R), your
vehicle will move backward. Always come
to a complete stop before shifting into and
out of reverse (R).
Neutral (N)
With the gearshift lever in neutral (N), your
vehicle can be started and is free to roll.
Hold the brake pedal down while in this
position.
Drive (D)
Drive (D) is the normal driving position for
the best fuel economy.
Low (L)
•
Provides maximum engine braking.
• The transmission may be shifted into
low (L) at any vehicle speed.
• Is not intended for use under extended
or normal driving conditions and results
in lower fuel economy.
Grade assist:
Press the transmission control switch on
the side of the gearshift lever to activate
grade assist.
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•
Provides additional grade braking with
a combination of engine motoring and
high-voltage battery charging to help
maintain vehicle speed when
descending a grade.
• As your vehicle determines the amount
of engine motoring and high-voltage
battery charging, you may notice the
engine speed increasing and
decreasing to help maintain your
vehicle speed when descending a
grade.
• The grade assist lamp in the instrument
cluster is illuminated. The grade assist lamp will
appear in the instrument cluster
when grade assist is turned on.
Press the transmission control switch
again to return to normal drive (D).
Brake-Shift Interlock WARNINGS
Do not drive your vehicle until you
verify that the brake lamps are
working. WARNINGS
When doing this procedure, you will
be taking your vehicle out of park
which means your vehicle can roll
freely. To avoid unwanted vehicle
movement, always fully set the parking
brake prior to doing this procedure. Use
wheel chocks if appropriate. If the parking brake is fully released,
but the brake warning lamp remains
illuminated, the brakes may not be
working properly. See your authorized
dealer. Note:
See your authorized dealer as soon
as possible if this procedure is used.
Note: For some markets this feature will be
disabled.
Use the brake shift interlock lever to move
the gearshift lever from the park position
in the event of an electrical malfunction or
if your vehicle has a dead battery.
Apply the parking brake and turn the
ignition off before performing this
procedure.
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GENERAL INFORMATION
Note:
Occasional brake noise is normal. If
a metal-to-metal, continuous grinding or
continuous squeal sound is present, the
brake linings may be worn-out. Have the
system checked by an authorized dealer. If
the vehicle has continuous vibration or
shudder in the steering wheel while braking,
have it checked by an authorized dealer.
Note: Brake dust may accumulate on the
wheels, even under normal driving
conditions. Some dust is inevitable as the
brakes wear and does not contribute to
brake noise. See Cleaning the Alloy
Wheels (page 245). See
Warning Lamps and
Indicators (page 89).
Wet brakes result in reduced braking
efficiency. Gently press the brake pedal a
few times when driving from a car wash or
standing water to dry the brakes.
Brake Over Accelerator
In the event the accelerator pedal
becomes stuck or entrapped, apply steady
and firm pressure to the brake pedal to
slow the vehicle and reduce engine power.
If you experience this condition, apply the
brakes and bring your vehicle to a safe
stop. Move the transmission to park (P),
switch the engine off and apply the parking
brake. Inspect the accelerator pedal for
any interference. If none are found and the
condition persists, have your vehicle towed
to the nearest authorized dealer.
Brake Assist
Brake assist detects when you brake
heavily by measuring the rate at which you
press the brake pedal. It provides
maximum braking efficiency as long as you
press the pedal. Brake assist can reduce
stopping distances in critical situations. Anti-lock Brake System
This system helps you maintain steering
control during emergency stops by keeping
the brakes from locking. This lamp momentarily
illuminates when you turn the
ignition on. If the light does not
illuminate during start up, remains on or
flashes, the system may be disabled. Have
the system checked by an authorized
dealer. If the anti-lock brake system is
disabled, normal braking is still effective. If the brake warning lamp
illuminates when you release the
parking brake, have the system
checked by an authorized dealer.
Regenerative Braking System
This feature 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
and storing it in the battery to improve the
range of your vehicle. The standard brake
system is designed to fully stop the car if
regenerative braking is not available.
During regenerative braking, the motor is
spun as a generator to create electrical
current. This recharges the battery and
slows the vehicle. In effect, once the
accelerator pedal is released, the motor
changes from an energy user to an energy
producer.
When the accelerator pedal is released or
the brake pedal is applied, the brake
controller automatically detects the
amount of deceleration requested and
optimizes how much of the deceleration
will be produced by regenerative braking.
The remaining portion is generated by
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