Indemnification

I would prefer to repair all the Thinks in the world with my own labor at a reasonable price. But I’m afraid traveling to the locations of all Thinks that are in need of repair would not be feasible unless the price was wildly unreasonable.

So I will provide the best advice that I can to anyone that chooses to take up the challenge of Think repair. By accessing the advice on this website you agree to not hold me liable for any damage or injury that may result from attempted repairs or maintenance. Continue reading Indemnification

Water infiltration in the low voltage traction battery wire harness

The circular plastic connector that plugs into the traction battery is fitted with heat-shrinkable tubing lined with adhesive which makes a pretty good water-tight seal between the connector body and the plastic loom that protects the wire harness. Unfortunately, the upstream end on the wire harness often leaks, and the seal only serves to hold the water in. The connector includes a rubber weather-pack around every single wire, but because the harness slopes up, the water in the loom is pressurized by gravity and eventually works past the seal and causes galvanic corrosion. I have seen a few cases in which pins actually broke off inside of sockets and could only be removed using a specialized tool: a paperclip.

I don’t think that the water that gets into the connector goes on to enter the battery– I don’t think any pressure would build up on the weather-pack on the bulkhead-mounted socket, the battery-side of the connector. But water definitely finds a way in through other flaws in the battery case seal.

IMG_20160607_125311

IMG_20160607_125433

Every Think that I have ever done any battery work on has that heat-shrink broken loose from the connector to allow water to drain.

Think Service Centers

Here’s a list of Think service providers that I’ve taken and modified from Jim McL’s blog:

http://minie458.blogspot.com/2012/04/service-center-summary-for-think-evs.html

I’ve made a few updates, but maintaining and revising this list will be an ongoing process. Please let me know your experiences with your local shops so that other Think owners in your area can benefit from your wisdom. Continue reading Think Service Centers

Zebra -> Enerdel retrofit photos

You can see there is just a large hole cut in the web of the frame where the traction battery cables go through. Below is the bracket/box/cover that protects that hole from from weather, but does not seal it out completely; it mounts on 4 studs on the frame. Good luck, Nikolay!

ThinkWithTractionBatteryRemoved

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Trying to get in touch with Enerdel; UPDATE: Disappointing Success

Here is the response from Enerdel:

From: Battery Support <support@enerdel.com>
Date: Fri, Jun 17, 2016 at 7:22 AM
Subject: Inquiring on Think City Car
To: “john.mayer@greendropgarage.com” <john.mayer@greendropgarage.com>

Thank you for Inquiry.

We are sorry for your inconvenience, however, we no longer provide
replacement parts for the Think City Car.

Continue reading Trying to get in touch with Enerdel; UPDATE: Disappointing Success

Programming RLEC ID’s

I have Enerdel’s ProgTool (specifically Programming Tool V4.16), which when configured properly I simply need to transmit a single message to the RLEC to set a new slave index/ID:

(For a description of the hardware required to connect to the RLEC, go to this post. You’ll need the PCAN adapter and the modified 4-wire RLEC wire harness.)

Enter message:
7E0 04 15 0X 00 00 00 00 00
Where X is the RLEC location ID ( 0-15 )
represented in hex ( 0-F )

But the ProgTool actually sends and receives a few messages (some kind of unlock procedure) before transmitting that message. Here’s a screen shot:
IMG_20160511_095050

In the first sentence I glossed over the details of configuring the settings. Here’s what you need to do before you type in the transmission message:

  • Check the box for “Use CAN.”
  • In the Transmission section, select the radio button for “Manual mode.”
  • Check the box for “SEC 13.” (This option will only show up in the Transmission section after you have selected “Manual mode.”)

Now replace the text in the “Enter message: ” text box with the message described above and click “Send.”

Now, when you install it into the pack make sure you put it in the correct position. Even Enerdel’s CommTool has inconsistent ways of referring to RLECs. Is the data that you’re looking at referring to the RLECs position in that pack by natural numbering (e.g. the first RLEC is number 1), or is it referring to the RLEC by its ID which is numbered in the way that is more conventional to computer programming (e.g. the first number is zero (aka 0, aka 0x0). It’s almost like they’re trying to trick you, so stay on your toes. Also it helps to know how they’re laid out in the pack.

Good luck!