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Unread 12-26-2013, 07:22 PM   #61
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Default Re: charger is draining batteries

My meter is a Fluke 337.
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Unread 12-26-2013, 07:49 PM   #62
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Default Re: charger is draining batteries

Sergio,

Based on all the info you have provided, and comparing that to the wiring diagrams in the service manual, leads me to believe my entire problem is the key switch?

Do you agree? Since we have determined the reducer is energized by the key switch, and the reducer is the what is powered from the #12 blue wire that is plugged into the #10 blue wire stub on the pack + battery.

And if you see i posted that i was getting continuity thru the key switch, sporadicly while the key switch was off. This makes me believe that is why the batteries are draining even though i am not using the cart..

Let me know your thoughts. Man i appreciate so much the time you have spent with me over this. thanks.
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Unread 12-26-2013, 08:03 PM   #63
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Default Re: charger is draining batteries

Hold on , this is what i just did :

I hooked the blue wire back to the pack + ( it has been off for 3 days, with no draining of the batteries).

After hooking blue wire up, i put amprobe on blue wire, got ZERO. This is with key switch on or off, with lite switch off. Once lite switch is turned on, i get reading of 2 amps on amprobe.

So i tried continuity across switch, and get continuity. HOWEVER, if i remove the green and blue wire from the switch, i then get NO CONTINUITY when switch is off. So this tells me my switch is good, i am getting the continuity reading only when wires are attached to switch.

Now i am confused. I think now key switch is good, but am back to the drain issue.

I am going to leave blue wire hooked up, key switch off for a couple days and see what i get.
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Unread 12-26-2013, 09:56 PM   #64
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Default Re: charger is draining batteries

I think that one of the wires either green or blue belong on the other side of the switch. It should have the supply wire on one side (48V) and on the other side of the switch should be two wires one to power the cart and one to power the lights.(converter) If the lights come on w/o the key sw on this has to be the case. If that's not clear let me know and I'll try to scan a picture for you.
This would make your case that it was bad from day one. The dealer wired it wrong.
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Unread 12-26-2013, 10:08 PM   #65
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Default Re: charger is draining batteries

No, the lites DO NOT come on, UNLESS the key switch is on.

There are only 2 wires going to the key switch, so it wouldn't matter which side the wires are on.
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Unread 12-26-2013, 10:48 PM   #66
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Default Re: charger is draining batteries

OK SOMETHING NEW ---

I see the fat red and black wires that are coming from the converter are the 12 volt load wires.

I just unplugged the nylon 12 wire connector, and put tester on the black and red wires that are coming from the converter. The key switch is off, and i get zero volts when measuring between these 2 wires. Then when the key switch is on, i read 12-13 volts between these same 2 fat wires.

NOW, still with the key switch off, and the nylon connector unplugged, i then put my negative probe on pack-, and my red probe on each of the 2 fat wires. I get 50.6 ( pack voltage ) on the red wire, and i get 49.8 on the black wire. AGAIN, these two wires are disconnected from the connector. Should there be any voltage on either wire?

Is something bleeding thru?
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Unread 12-27-2013, 10:05 AM   #67
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Default Re: charger is draining batteries

If I am reading the 12 volts on the fat red wire that is coming from the converter ( reading is taken from wire to pack - ), while the key is off, doesn't that mean the converter is using power? That's not right is it?
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Unread 12-27-2013, 10:12 AM   #68
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Default Re: charger is draining batteries

Quote:
Originally Posted by smokey tennis shoe View Post
If I am reading the 12 volts on the fat red wire that is coming from the converter ( reading is taken from wire to pack - ), while the key is off, doesn't that mean the converter is using power? That's not right is it?
If the fat red wire is the OUTPUT side of the converter it should only have voltage when the converter is running.
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Unread 12-27-2013, 10:33 AM   #69
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Default Re: charger is draining batteries

That is a nice meter.
A few things, You cannot check resistance or continuity on an energized circuit, meaning all wires must be disconnected from the device you are checking.
Also, when troubleshooting electrical circuits is always better to only do one thing at the time so you don't end up going in loops.
Your original post said there was a current drain, you then removed the blue wire and the batteries held charge, but then you tested the blue wire and there was no current drain...
Maybe there was a problem with the wires behind the dash that got resolved when you took it apart.
The reason I am saying this is one of your readings (-12v) to pack negative with the keyswitch off (trigger wire to converter off) showed a reading. This tells me that you have an "isolated" type converter where the 48v and 12v do not share the same negative. Those are nice but you need to make sure at no point in you accessory connections the -12v connects to any other negative in the harness.
Try this:
Setup: Key switch off, Tow-Run switch set to Run, lights off.

Put meter probe on pack negative.

If current drawn is shown:
Put meter probe on blue wire on pack
IF current draw is shown on blue wire
Troubleshoot converter and accessory connections
IF no current on blue wire
Turn Tow-Run switch to TOW
Put meter probe back on pack negative
IF current draw is shown
Troubleshoot controller side of circuit
IF no current
Troubleshoot Tow-Run fed circuits & devices
This will help isolate where the current drain is coming from.
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Unread 12-27-2013, 11:05 AM   #70
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Default Re: charger is draining batteries

Sergio, IN THE last thread you were telling me to put my probe ( black I guess?) on the pack-. Where am I putting the red probe?

Also let me add this : I just plugged my charger in, and during the charging ( it only took about 45 minutes) I kept reading the voltage. The highest the volts ever got during this 45 minute charge was 56.3 volts. IS IT possible the batteries are not getting fully charged?

I ask this, because I thought I read the charger should be putting out over 60 volts?
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