Ford Battery Charger TSB 05 4 12 User Manual

DIAGNOSTIC PROCEDURE FOR TH!NK NEIGHBOR  
ON-BOARD BATTERY CHARGER  
TSB 05-4-12  
THINK:  
2002 Th!nk Neighbor  
NOTE  
ISSUE  
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.  
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.  
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).  
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.  
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.  
Figure 1 - Article 05-4-12  
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 ªdo-it-yourselfersº. 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  
PAGE 1  
 

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