ELECTRICAL—TH!NK VEHICLES—BATTERY
Article No.
RECOVERY/BALANCING AND BATTERY RANGE TIPS
03-8-6
THINK:
2002 TH!NK NEIGHBOR
If the battery pack voltage is from 68.3V to 80V, the
ISSUE
vehicle should enable. If it does not enable, follow
Some 2002 Th!nk Neighbor vehicles may exhibit a
the TH!NK Neighbor no enable troubleshooting flow
no start condition, inability to charge, or reduced
chart found in TSB 02-25-9. If the battery pack is
mileage range. This may be due to a deeply
greater than 20Vdc and less than 68.3Vdc, the
discharged battery pack, failed battery modules, or
charger should charge the batteries. Refer to the
an unbalanced battery pack.
charging section of this TSB for direction. If the
pack is under 20V, the on-board charger will not
ACTION
charge the pack and the battery modules must be
Diagnose the health of battery pack and individual
individually charged. Refer to the battery pack
battery modules to determine repair action. Follow
balancing & recovery section.
Flow Chart 1 (Figure 6) for direction. This TSB
outlines procedures for evaluating battery health,
If the vehicle mileage range is drastically reduced
replacing individual battery modules, battery
from the normal range experienced by the
recovery, and balancing battery modules to
customer, the pack must be checked referencing
maximize pack performance.
the vehicle range concern section. It is possible the
batteries have been discharged to a very low level
SERVICE INFORMATION
and have become unbalanced, if so, refer to the
Battery recovery and “top of charge” (TOC) battery
battery pack balancing section.
pack balancing is the main subject matter of this
DIAGNOSTICS
article. It must be noted that the DPI smart chargers
used for recovery and battery pack balancing will
Follow Flow Chart 1 (Figure 6) to determine proper
not initiate charge unless the battery is above 3Vdc.
repair procedures.
NOTE
Use Figure 1 to assess the state of charge of the
THE NEW VEHICLE LIMITED WARRANTY DOES
battery pack. Verify that the charger and charging
NOT COVER DAMAGE CAUSED BY FAILURE TO
receptacle are functioning properly, by measuring
MAINTAIN THE VEHICLE OR IMPROPERLY
pack voltage as shown in Figure 2 while the vehicle
MAINTAINING THE VEHICLE. IF THE BATTERIES
is on charge. With the vehicle on charge, pack
ARE REPLACED UNDER WARRANTY, ALL
voltage should rise above the static pack voltage. If
CAUSAL PARTS OF THE ASSOCIATED DAMAGE
there is no rise in pack voltage after 15 minutes of
TO THE BATTERIES MUST BE RETURNED PER
charging, the charger, charging circuit, charger cord,
WARRANTY RETURN TAG INSTRUCTIONS AND
or charging inlet receptacle is malfunctioning. If
MAY BE ANALYZED FOR FAILURE. IN THE
pack voltage is less than 20 volts the batteries must
ABSENCE OF A CASUAL PART, WHICH HAS
be individually charged with DPI chargers specified
CAUSED THE BATTERIES TO DISCHARGE
within this TSB. DPI smart chargers will not activate
BELOW MINIMUM VOLTAGE, IT IS PRESUMED
if the battery is below 3Vdc.
THAT THE BATTERIES WERE NOT MAINTAINED
CORRECTLY AND ALLOWED TO DISCHARGE.
BATTERY RECOVERY IS AT THE CUSTOMERS
DISCRETION AND IS NOT COVERED UNDER
WARRANTY.
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.
Copyright
2003 Ford Motor Company
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