Ford TSB TSB 05-4-12 Diagnostic Manual

DIAGNOSTIC PROCEDURE FOR TH!NK NEIGHBOR
ON-BOARD BATTERY CHARGER
THINK:
2002 Th!nk Neighbor
ISSUE
Some TH!NK Neighbor electric vehicles may display
a low range, no start or a no charging condition.
This may be due to the on-board battery charger
either overcharging, undercharging or not charging
at all. These conditions may cause associated
damage to the battery pack, resulting in battery
pack replacement.
ACTION
The following is an optional service procedure to
supplement the Workshop Manual procedure to
properly diagnose the function of the on-board
battery charger.
SERVICE PROCEDURE
WARNING
THIS VEHICLE CONTAINS HIGH-VOLTAGE
COMPONENTS AND WIRING. THE BATTERY
PACK ASSEMBLY CAN DELIVER IN EXCESS OF
72 VOLTS OF DC POWER. HIGH-VOLTAGE
INSULATED SAFETY GLOVES AND FACE
SHIELD MUST BE WORN WHEN PERFORMING
THIS TSB. FAILURE TO FOLLOW THIS
WARNING, OR IMPROPER HANDLING OF THE
BATTERY PACK MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH. ONLY
AUTHORIZED PERSONNEL TRAINED TO WORK
WITH HIGH-VOLTAGE AND BATTERY PACK
COMPONENTS ARE PERMITTED TO HANDLE
THE BATTERIES.
CAUTION
BEFORE WORKING ON THE BATTERY PACK,
THE SERVICE DISCONNECT SWITCH (SDS)
MUST BE TURNED OFF. THE SDS SHOULD
REMAIN OFF FOR THE DURATION OF THIS
PROCEDURE.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company's on-line technical resources.
Copyright 2005 Ford Motor Company
NOTE
FORD MOTOR COMPANY MAY REQUEST THE
RETURN OF THE CAUSAL COMPONENT(S)
LEADING TO BATTERY PACK REPLACEMENT.
WHEN BATTERIES ARE REPLACED UNDER
WARRANTY, ALL RELATED CAUSAL
COMPONENTS MUST BE HELD FOR 30 DAYS
FROM THE CLAIM SUBMISSION DATE. BE SURE
TO INCLUDE BATTERY PACK AND INDIVIDUAL
BATTERY VOLTAGES, ALONG WITH BATTERY
CHARGER OUTPUT VOLTAGE, IN COMMENTS
AREA OF THE REPAIR ORDER.
1. Remove the front seat stanchion and check
battery pack voltage by placing a DVOM
positive (+) probe onto the positive terminal of
battery #6, and the DVOM negative (-) probe
onto the negative terminal of battery #1 (Figure
1).
a. If the voltage reading is above 20V, proceed
to Step 7.
b. If voltage is below 20V, proceed to Step 2.
Figure 1 - Article 05-4-12
TSB 05-4-12
PAGE 1