Azure Dynamics Transit Connect Electric User manual

Service Assistance And Supplemental Information
For Vehicle Owners And Operators
Azure Dynamics vehicles are sold and serviced through a network of authorized dealers who will
assist you with any periodic maintenance or service required for your vehicle.
The information contained in this publication
was current at time of publication,.
To ensure that you have the most up-to-date
reference on operation of your vehicle and its
systems, Azure Dynamics provides updated
and supplemental information on its Product Support website: AZDtec.com.
The information below contains both normal URL links and special electronic ―QR‖ links that may
be accessed through an appropriate reader on your web-enabled ―Smartphone‖.
Supplemental Update Information
http://azdtec.com/azdvehicles/ogs_updates/tce/
Or scan QR Bar Code at left.
Authorized Azure Dynamics Dealer Locations
http://azdtec.com/dealer/index.php
Or scan QR Bar Code at left.
Driver Orientation Video
http://www.youtube.com/watch?v=yjw8EVehflU
Or scan QR Bar Code at left.
P/N 107384-A, 9/8/2011

Introduction
3
INTRODUCTION 2
INSTRUMENT CLUSTER 6
CLIMATE CONTROLS 13
TIRES, WHEELS & LOADING 14
DRIVING 15
ROADSIDE EMERGENCIES 21
CLEANING 24
MAINTENANCE & SPECIFICATIONS 25
SCHEDULED MAINTENANCE 32
HIGH VOLTAGE BATTERY CHARGING 35

Introduction
4
OVERVIEW
The Transit Connect Electric is an electric vehicle produced by Azure Dynamics
Corporation and Ford Motor Company.
The vehicle is powered by a high voltage traction motor—mounted under the hood—
which drives the front wheels through a transmission. Power for the motor is supplied by
a high voltage battery pack which is mounted under the cargo area forward of the rear
wheels.
A junction box—mounted underneath the floor between the front seats—provides a
connection point between the high voltage battery and other system components. High
Voltage wiring is identified with distinctive orange cabling.
DRIVER CONTROLS
All Driver controls are used as they would be on a standard Transit Connect. This
includes power steering, power brakes, gear selection, and climate controls.
ELECTRICAL OPERATION
The Transit Connect Electric uses both High Voltage and Low Voltage systems. A
conventional 12 V battery maintains normal vehicle systems, however it is maintained by
the High Voltage Battery. All electrical power used comes from this High Voltage
Battery, which is maintained by recharging the vehicle from an external source.
See the High Voltage Battery Charging chapter at the back of this Supplement for
details.

Introduction
5
VEHICLE HIGH VOLTAGE BATTERY CHARGING
A charge port for external AC power is provided on the right side of the vehicle behind
the filler door.
An on-board charger is located under the hood and is electrically
connected to the charge port and the High Voltage Battery.
NOTE: Electric Vehicle Supply Equipment (EVSE) must be
properly and safely connected to the electrical grid to ensure
proper vehicle charging. Always have a certified Electrician install any EVSE or outlets
to support an EVSE.
See the High Voltage Battery Charging chapter at the back of this Supplement for
details.

Instrument Cluster
6
WARNING LIGHTS AND CHIMES
Power Limit: This lamp will illuminate (solid) to indicate that the estimated
range is less than 0.5 kilometers (0.3miles), or that the vehicle power output is
being limited. The vehicle can continue to be driven with a solid Power Limit
lamp.
This lamp will flash to indicate a condition where the vehicle power output is being
significantly limited. If the Power Limit lamp is flashing, safely manoeuvre the vehicle
to the side of the road and have the vehicle towed to an authorized AZD repair
facility.
Anti-lock brake system: If the ABS light stays illuminated or continues to
flash, a malfunction has been detected, have the system serviced by your
authorized dealer. Normal braking is still functional unless the brake warning light also is
illuminated.
.
Warning lights and gauges can alert you to a
vehicle condition that may become serious
enough to cause expensive repairs.
A warning light may illuminate when a
problem exists with one of your vehicle’s
functions. Many lights will illuminate—as a
check—when you start your vehicle. If any
light remains on after starting the vehicle,
refer to the respective system warning light
for additional information.
The following warning lights are located on the left side of the instrument cluster on the
Range Indicator face.

Instrument Cluster
Powertrain Service: This lamp will illuminate (solid) to indicate that the
vehicle has logged a fault requiring service. The vehicle can continue to be
driven; the Powertrain Service condition will be re-evaluated at the next key-
cycle. Contact your authorized dealer as soon as possible.
Charging Indicator: This lamp will illuminate while the High Voltage
Battery is being charged if the key is in the II position (on). The vehicle can
not be started while being charged.
Airbag readiness: If this light fails to illuminate when the ignition is turned to
on, continues to flash or remains on, have the system serviced immediately by
your authorized dealer. A Chime will sound when there is a malfunction in the
indicator light.
Speed Control: Refer to the Driver Controls chapter of the Ford Transit
Connect Owner’s Guide for more information.
Stop Safely Hazard Warning: This lamp will illuminate to indicate an high
voltage component fault/failure that will cause the vehicle to shutdown, fail
to start, or enter a limited operating mode.
Note: If the vehicle is still on, the vehicle may soon shutdown without
further warning and should be stopped safely. Safely maneuver the vehicle to the
side of the road and have the vehicle towed to an authorized AZD repair facility.
Low tire pressure warning: Illuminates when your tire pressure is low. If the light
remains on at start up or while driving, the tire pressure should be checked.
Refer to Inflating your tires in the Tires, Wheels and Loading chapter of this
Supplement.
When the ignition is first turned to on, the light will illuminate for three
seconds to ensure the bulb is working. If the light does not turn on or begins
to flash, have the system inspected by your authorized dealer.
For more information on this system, refer to Tire pressure monitoring
system (TPMS) in the Tires, Wheels and Loading chapter of the Ford Transit Connect
Owner’s Guide.
7

Instrument Cluster
8
WARNING LIGHTS AND CHIMES
AdvanceTrac®This lamp illuminates when the AdvanceTrac®is active. If
the light remains on, contact your authorized dealer as soon as possible.
Refer to the Driving chapter of the Ford Transit Connect Owner’s Guide for
more information.
Anti-theft system: Flashes when the SecuriLock®Passive Anti-theft
system has been activated.
High Voltage Battery (Layered Battery): This lamp illuminates (solid)
to indicate approximately 5 miles (8 km) of range. This lamp flashes to
indicate approximately 0 mile (0 km) of range.
Brake system warning light: To confirm the brake system warning light
is functional, it will momentarily illuminate when the ignition switch is
turned to the on position , or in a position between on and start, or by
applying the parking brake when the ignition is turned to the on position.
If the brake system warning light does not illuminate at this time, seek service
immediately from your authorized dealer. Illumination after releasing the parking brake
indicates low brake fluid level and the brake system should be inspected immediately by
your authorized dealer.
A chime will sound when there is a malfunction in the indicator light.
The following warning lights are located
on the right side of the instrument cluster
on the Speedometer face.

Instrument Cluster
9
DC/DC Charging system: Illuminates when the 12V battery has low volt-
age.
Headlamps: Illuminates when the low–beam headlamps are turned on.
High beams: Illuminates when the high-beam headlamps are turned on.
Door ajar: Illuminates when the ignition is in the on position and any door
is open.
Safety belt: Reminds you to fasten your front driver and passenger safety belt.
A Belt-Minder®chime will also sound to remind you to fasten your safety belt.
Refer to the Seating and Safety Restraints chapter of the Ford Transit Connect
Owner’s Guide to activate/deactivate the Belt-Minder® chime feature.
Turn signal: Illuminates when the left or right turn signal or the hazard
lights are turned on. If the indicators stay on or flash faster, check for a
burned out bulb.
Rear fog lamps: Illuminates when the rear fog lamps are turned on (if
equipped).
WARNING: Driving a vehicle with the brake system warning
light on is dangerous. A significant decrease in braking performance may
occur. It will take you longer to stop the vehicle. Have the vehicle checked by
your authorized dealer. Driving extended distances with the parking brake engaged can
cause brake failure and the risk of personal injury.

Instrument Cluster
10
Key-in-ignition warning chime: Sounds when the key is left in the ignition in
the off or accessory position and the driver’s door is opened.
Park warning chime: Sounds when the transmission is not in Park, the driver’s door is
opened and the ignition is off or in accessory position.
Headlamps on warning chime: Sounds when the headlamps or parking lamps are on
and the driver’s door is opened.
Seatbelt warning chime: The seatbelt chime sounds when the driver’s seatbelt is not
fastened. When the ignition is in run and the seatbelt is not fastened, the chime will
chime for 6 seconds. The chime will turn off if the driver’s seatbelt is fastened or if the
ignition returns to off or accessory position.
Belt minder warning chime: This chime periodically sounds to remind the driver and/
or passenger that their seatbelt is unbuckled. The seatbelt warning lamp in the cluster
will also illuminate once vehicle speed has exceeded 6 mph (10 km/h).
Airbag secondary warning chime: This chime sounds to indicate a fault with the sup-
plemental restraint system in the event that the airbag readiness warning light is not oper-
ating.
Door ajar warning chime: The door ajar reminder chime informs the driver that one or
more doors are open while the ignition is in the run position.
Power Limit chime: A chime will sound to indicate the Power Limit lamp has been
turned on or off.
High Voltage Battery (Layered Battery): A chime will sound to indicate the High
Voltage Battery lamp has been turned on or off.

Instrument Cluster
11
GAUGES
Range Gauge: Marked in increments showing
approximate range remaining in miles or kilome-
ters based on stored vehicle usage history.
The range gauge is active after the vehicle has
been started.
Speedometer: Indicates the current vehicle
speed.
NOTE:
The Range Gauge operates based on 400 miles of stored vehicle usage history. The
Gauge may not be at the maximum after charging if the vehicle 400 mile average is
lower. Your actual range may differ.
Vehicle range is affected by operating conditions.
For maximum range, avoid heavy acceleration and excessive vehicle speeds.
The use of any vehicle electrical equipment will affect range as well.
To maximize range, minimize use of heater and air conditioner whenever possible. See
State of Charge Gauge.

Instrument Cluster
12
Temperature Gauge: High Voltage electrical
components including the traction motor and High
Voltage Battery are liquid cooled. The coolant
temperature is maintained by the vehicle radiator
and electric fans.
At normal operating temperature, the needle will be
in the normal range, below the red line and the H
indicator.
If the Temperature Gauge indicates an over-temperature condition, the Power Limit lamp
will illuminate, and the vehicle will go into the Power Limit Mode to attempt to lower
the temperature.
The vehicle can still be driven in Power Limit Mode.
State of Charge Gauge: This shows the charge
level of the High Voltage Battery.
This gauge is used in conjunction with the Range
Gauge and High Voltage Battery Warning lamp to
inform the driver of the High Voltage Battery
charge level and of the estimated range before
charging is required.
After fully charging the HV Battery, this gauge will
read full.
With a full SOC reading, the vehicle can achieve the maximum range given the driving
style and electrical accessory loading (heater and air conditioning).
See Range Gauge.
WARNING: Never remove the coolant reservoir cap while the
Vehicle is started or hot.

Climate Controls
13
CLIMATE CONTROLS
Any operation of the heater or air conditioning systems during vehicle operation will
have an adverse effect on vehicle range. See Range Gauge and State of Charge Gauge.
If use is needed during normal vehicle operation, use the minimum amount of heating
and cooling consistent with occupant comfort.
See the Climate Controls chapter of the Ford Transit Connect Owner’s Guide for details
on heating and air conditioning controls and other general information.

Tires, Wheels & Loading
14
TIRE PRESSURES
Refer to the Tire and Loading Information sticker on the Driver’s door-jam for tire infla-
tion information.
See the Tires, Wheels & Loading chapter in the Ford Transit Connect Owner’s Guide for
details and other general information.

Driving
15
STARTING PREPARATIONS
Positions of the ignition
0(Off) —Locks the steering wheel and gearshift lever
and allows key removal.
This position also shuts off all the electrical accessories
and disconnects all high voltage components from the
high voltage battery pack.
I (Accessory) —Allows the electrical accessories
such as the radio to operate while the vehicle is not
started.
II (On) —Driving Mode: All vehicle control circuits are operational. Warning lights
illuminated. Key position when driving —after vehicle is started.
II (On) —Charging Mode: Used during vehicle charging to allow cabin pre-
conditioning (if equipped).
III (Start) —Connects the high voltage system and readies the vehicle for operation.
Turn the key and release to start the vehicle.
Preparing to start your vehicle
This is an electric vehicle but is powered-up in the same way as a conventional vehicle is
started.
Since there are no typical engine sounds, your indications that the high voltage system is
ready for driving are the instrument cluster readings for the Range Indicator and State of
Charge Indicator (See Instrument Cluster Section).
 Key to ON position—Range indicator moves up to OFF position from maximum
downscale; State of Charge Indicator moves to bottom indication.
 Key to START position—Range indicator moves from off position up to indicate
available range. State of Charge Indicator moves up from bottom indication to show
current state of charge.

Driving
16
With key in II (on) position, Range
Indicator and State of Charge Indi-
cators move to bottom of range
only.
VEHICLE IS NOT READY FOR
DRIVING
With the key in the III (start) posi-
tion and released, both Range Indi-
cator and State of Charge Indicator
move.
VEHICLE IS READY FOR
DRIVING
Before starting the vehicle:
1. Make sure all occupants buckle their safety belts. For
more information on safety belts and their proper usage,
refer to the Seating and Safety Restraints chapter in the
Transit Connect Owner’s Guide.
2. Make sure the headlamps and electrical accessories are
off.
 Make sure the parking brake is set.
 Make sure the gearshift is in P (Park).

Driving
17
1. Turn the key to II (On) without turning the key to III
(Start).
Some warning lights will briefly illuminate. See
Warning Lights and Chimes in the Instrument Cluster
chapter of this Supplement for more information
regarding the warning lights.
2. Turn the key to III (Start), then release the key when the Range Indicator and State of
Charge Indicator move up scale. This indicates that the vehicle has been started and is
ready to drive.
The vehicle is shut off by moving key switch to 0 (Off) position after bringing it to a
complete stop and shifting into Park.
3. After verifying normal instrument indications, use this procedure:
 Depress brake pedal.
 Shift out of park into Drive or Reverse.
 Release parking brake and drive.
STARTING UP—INITIALIZATION
NOTE:
Maximum vehicle speed is limited to 75 mph (120 km/hr). This top-speed is maintained
by the vehicle software and indicates normal operation.

Driving
18
NOTE:
Vehicle range is affected by operating conditions. For maximum range, avoid heavy
acceleration and excessive vehicle speeds.
The use of any vehicle electrical equipment will affect range as well. To maximize
range, minimize use of heater and air conditioner whenever possible. See Range Gauge
and State of Charge Gauge.
To set the parking brake (1), pull the
parking brake handle up as far as possible.
The BRAKE warning lamp will illuminate
and will remain illuminated until the
parking brake is released.
To release, press and hold the button (2),
pull the handle up slightly,
then push the handle down.
WARNING: Always set the parking brake fully before putting the gearshift
into P (Park).
WARNING: 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 as soon as possible

Driving
19
SHIFTER OPERATION
This vehicle does not have a conventional multi-speed transmission, instead it uses a
single-speed transmission to provide gear reduction and provide differential action for
the front wheels.
Driving the vehicle is the same as driving with an automatic transmission since the
electric traction motor provides sufficient speed range without the need for gear changes.
The shifter functions normally in the Park, Reverse, Neutral and Drive positions. The
2nd and 1st gear positions have the same function as Drive, but with progressively
higher levels of regenerative braking.
P (Park)
This position locks the transmission and prevents the front wheels
from turning.
To put your vehicle in gear:
• Start the vehicle.
• Press the brake pedal
• Press the shifter button and move the gearshift lever into the
desired position.
To put your vehicle in P (Park):
• Come to a complete stop With the brake pedal depressed, engage
the parking brake.
• Move the gearshift lever and securely latch it in P (Park)
WARNING: Always set the parking brake fully before putting the gearshift
into P (Park). Turn the ignition to the off position and remove the key
whenever you leave your vehicle.

Driving
20
R (Reverse)
With the gearshift lever in R (Reverse), the vehicle will move backward.
Always come to a complete stop before shifting into and out of R (Reverse).
N (Neutral)
With the gearshift lever in N (Neutral), the vehicle can be powered-up and is
free to roll. Apply the brakes when powering-up the vehicle in Neutral.
D (Drive)
The driving position for forward movement.
2, 1 (Drive)
These driving positions provide higher regenerative braking levels. This simulates the
engine-braking effect in a conventional vehicle when coasting in the 2 or 1 gear posi-
tions. The 2 position provides more regenerative braking than D (Drive), and 1 provides
more regenerative braking than 2.
DRIVING THROUGH WATER
If driving through deep or standing water is unavoidable, proceed very slowly until the
depth is known. Never drive through water that is higher than the bottom of the
wheel rims. Water can damage electrical components and mechanical systems by enter-
ing vents.
When driving through water, traction or brake capability may be limited.
Once through the water, always dry the brakes by moving your vehicle slowly while
applying light pressure on the brake pedal. Wet brakes do not stop the vehicle as
quickly as dry brakes.