Ford Explorer: High Voltage Battery, Mounting and Cables / Description and Operation - High Voltage Battery, Mounting and Cables - Overview

OVERVIEW

  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 300 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.

NOTICE: The high voltage battery in a Hybrid Electric Vehicle (HEV) can be affected and damaged by excessively high temperatures. The temperature in some body shop paint booths can exceed 60°C (140°F). Therefore, during refinishing operations, the paint booth temperature must be set at or below 60°C (140°F) with a bake time of 45 minutes or less. Temperatures exceeding 60°C (140°F) or bake durations longer than 45 minutes require the high voltage battery be removed from the vehicle prior to placing in the paint booth.

The vehicle is powered primarily by an internal combustion engine, much like any ordinary vehicle. However, it also transforms the energy that is normally wasted during stop and go operation (when coasting and braking) into electricity. The generated electricity is stored in the high voltage battery until it is needed by the electric motor or the 12-volt system. The electric motor supports the engine during acceleration and uphill driving.

In low-speed driving situations the vehicle may move under only battery power and without the internal combustion engine running. The internal combustion engine may automatically shut off when the vehicle is stopped/idling or when coasting under 100 km/h (62 mph). The engine may restart when the accelerator is pressed, when the electric motor needs assistance, or if the high voltage battery state of charge is low. This avoids using excess fuel when the vehicle is not in motion.

The energy provided by the engine and the regenerative braking, via the electric motor (used as a generator) charges the high voltage battery.

The high voltage battery pack consists of the following servicable components:

• BECM
• High voltage battery mounting brackets
• High voltage battery upper cover seal
• High voltage battery lower seal
• Coolant port assembly
• Vent patch
• High voltage battery electronics wiring harness (includes the high voltage cell array negative cable)
• High voltage battery junction box
• High voltage high current fuse (mounted in the high voltage battery junction box)
• High voltage low current fuse (mounted in the high voltage battery junction box)

All of the high voltage battery components listed above can be serviced separately. All other components are serviced as part of the high voltage battery pack and should not be removed. If the high voltage battery pack is replaced it includes all of the components in the list.

The high-voltage system consists of the following components:

• High-voltage battery cable
• Electric motor 3 phase AC cable
• Inverter System Controller (ISC) also known as the SOBDMC
• Electric motor assembly (mounted to the front of the transmission)
• Direct Current/Direct Current (DC/DC) converter control module
• ACCM and A/C compressor assembly located on the lower LH side of the engine block
• High voltage battery pack