Ford TSB 05-4-12 User Manual

DIAGNOSTIC PROCEDURE FOR TH!NK NEIGHBOR TSB 05-4-12
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.

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.

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.

Figure 1 - Article 05-4-12

Copyright  2005 Ford Motor Company PAGE 1

TSB 05-4-12 (Continued)

2. Obtain two (2) known good batteries (Part # d. Turn-on power to the charger by pressing

10655). Check the batteries to be sure they the (RESET) button on the GFCI cord
produce at least 11V each or 22V combined. breaker.
These batteries will be referred to as batteries
A and B for the remainder of this TSB.

3. CRITICAL, USING HIGH VOLTAGE GLOVES, rise.
disconnect the following battery cables: battery
#3 (+), and battery #4 (-).

4. Connect the (+) terminal of battery A to the (-) monitor the DVOM until the voltage hits its
terminal of battery B, (an extra TH!NK Neighbor highest point (peaks).
battery cable or a jumper cable may be used to
make the connection).

5. Connect the (+) terminal of battery B to the (-) replaced.
terminal of the battery pack #4 battery (Figure

2). Connect the (-) terminal of battery A to the
(+) terminal of the battery pack #3 battery.

8. Within 3 minutes of plugging the charger in, the
voltage reading on the DVOM should start to

a. If the voltage rises, this means that the

charger is working. However, continue to

(1) If the voltage rises above 90V, the

charger is overcharging and should be

(2) If the voltage rises but never reaches

75V or above, the charger is under
charging and should be replaced.

b. If the voltage does not rise after 5 minutes,

the charging system is not charging.

Figure 2 - Article 05-4-12

6. Place the DVOM (+) probe onto the (+) terminal
of battery #6 and the (-) probe onto the (-)
terminal of battery #1.

7. Using the customer’s GFCI cord:
a. Plug the cord into the 110V wall outlet.
b. Turn-off the GFCI cord breaker by pressing

the (TEST) button on the GFCI block.

c. Plug in the GFCI receptacle end into the

vehicle charge inlet.

(1) Check the function of charging system

components such as the GFCI cord,
the charger, 30-amp fuse and the
charge circuit. Make repairs as
necessary and retest. If no faults are
found with the system components,
replace the charger.

9. After completing the charger diagnostics,
shut-off the power through the GFCI charge
cord by pressing the (TEST) button on the
GFCI breaker on the GFCI cord, and remove
the cord from the vehicle plug inlet.

10. CRITICAL, USING HIGH VOLTAGE GLOVES,
disconnect battery cables from the A and B
jumper batteries to the vehicle batteries at
battery #3 (+), and battery #4 (-). Reconnect
the vehicle pack battery cables.

WARRANTY STATUS: Information Only

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