I purchased a Ford Think that had been epically neglected. It came with a new (refurbished) cluster and dead batteries, so I couldn’t test anything out. I installed the cluster and installed new batteries. They were fully charged. I turned it on and the cluster came on and really nothing else seems to work. I think the contactor is trashed as I get a good continuity test, but there is no voltage reading on the output side of the contactor. It makes no sense to me. Another thing I am seeing is when I connect the multimeter to pin 1 and 14 on the cluster I only get 37.2v. When I connect to the first 2 pins of the DC to DC converter, it also only gives me 37.2 volts. I also get the same connecting pin 1 and any other pin on the DC to DC converter plug. I expected that even though the power contactor is not allowing voltage through, I would’ve thought the power on the cluster pin1 to pin 14 would be 72v. Am I doing something wrong?
You should inspect the voltage at the batteries, the 400A megafuse, and the service toggle. Sounds like you’re only getting half the batteries connected. Also worth checking to make sure you’re connecting the batteries like the attached photo. 72V to the IC and DC converter come directly from the batteries after the service toggle switch. I have my motor controller removed and I still get 72V to the IC and DC converter. I tested my contactor with a power supply and it turned on at 61V.
I get 72v when testing from battery 1 neg to battery 6 positive. So I think the 400A fuse is good. The batteries are connected according to the service manual. The previous owner used 10A automotive fuses in place of the tube style fuses for a couple of the fuses because the tube style connectors were broken. I ordered some replacements for the fuse holders and will remedy that once they arrive. I will check the service switch next. Thank you for the help. I hope it’s the switch.
I have owned my Think since it was new in 2002. I have had to replace the service switch twice. Check the voltage through it is one of the first things I do when nothing works. Replaced it and issues were resolved.
I was down to trying to replace the service switch as it seems to be the only thing preventing the contractor from closing. I appreciate all the information from everyone. I will update when I have a minute to get it changed out.
Can you jump the switch to see if it does anything different?
The thought hadn’t crossed my mind. Might try that tomorrow.