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either overcharging, undercharging or not charging WHEN BATTERIES ARE REPLACED UNDER at all. These conditions may cause associated WARRANTY, ALL RELATED CAUSAL damage to the battery pack, resulting in battery COMPONENTS MUST BE HELD FOR 30 DAYS pack replacement. FROM THE CLAIM SUBMISSION DATE. BE SURE TO INCLUDE BATTERY PACK AND INDIVIDUAL ACTION BATTERY VOLTAGES, ALONG WITH BATTERY The following is an optional service procedure to CHARGER OUTPUT VOLTAGE, IN COMMENTS supplement the Workshop Manual procedure to AREA OF THE REPAIR ORDER. 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 SERVICE PROCEDURE positive (+) probe onto the positive terminal of battery #6, and the DVOM negative (-) probe WARNING onto the negative terminal of battery #1 (Figure THIS VEHICLE CONTAINS HIGH-VOLTAGE 1). COMPONENTS AND WIRING. THE BATTERY PACK ASSEMBLY CAN DELIVER IN EXCESS OF a. If the voltage reading is above 20V, proceed 72 VOLTS OF DC POWER. HIGH-VOLTAGE to Step 7. INSULATED SAFETY GLOVES AND FACE b. If voltage is below 20V, proceed to Step 2. 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. 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 “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 a 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. 8. Within 3 minutes of plugging the charger in, the voltage reading on the DVOM should start to 3. CRITICAL, USING HIGH VOLTAGE GLOVES, rise. disconnect the following battery cables: battery #3 (+), and battery #4 (-). a. If the voltage rises, this means that the charger is working. However, continue to 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). (1) If the voltage rises above 90V, the charger is overcharging and should be 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 (2) If the voltage rises but never reaches (+) terminal of the battery pack #3 battery. 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. (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 Figure 2 - Article 05-4-12 GFCI breaker on the GFCI cord, and remove the cord from the vehicle plug inlet. 6. Place the DVOM (+) probe onto the (+) terminal of battery #6 and the (-) probe onto the (-) 10. CRITICAL, USING HIGH VOLTAGE GLOVES, terminal of battery #1. disconnect battery cables from the A and B jumper batteries to the vehicle batteries at 7. Using the customer’s GFCI cord: battery #3 (+), and battery #4 (-). Reconnect a. Plug the cord into the 110V wall outlet. the vehicle pack battery cables. b. Turn-off the GFCI cord breaker by pressing WARRANTY STATUS: Information Only the (TEST) button o...