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Unread 04-22-2011, 09:03 AM   #1
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Default 03 DS won't charge

Here at work we have a 03 ds that will not charge, put some distilled water in it and checked all the cables, all good, the batteries got ran down super low, their a 42.9-43.0 volts. any infowould be appreciated.
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Unread 04-22-2011, 11:30 AM   #2
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Default Re: 03 DS won't charge

The charger won't charge them if they're too low. You need a 12v charger and do two batteries at a time. Link them positive to negitive and then jump across the two with the charging leads. I had the exact same problem. Once they get enough juice the carts charger will be able to take over.

A charger at 10 amps is preferable.
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Unread 04-22-2011, 11:32 AM   #3
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Default Re: 03 DS won't charge

Normally if you have less than 35-38 volts the charger wont turn on, so if pack is at posted amount thats not your problem? I would test the inline 3/8 fuse located behind the charger receptical, normally in a yellow inline holder. If fuse is good then do following to test OBC ( On Board Computer ) which controls charger functions. Install a bypass wire from receptical fuse holder to pack ground. If charger turns on this is your problem, and if not go to the STICKIES under "Complete Manual For Power Drive Charger" to diagnose charger problems.
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Unread 04-22-2011, 01:43 PM   #4
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Default Re: 03 DS won't charge

did all of that, put the primary coil black wire on the circuit breaker it charges, tested the relay shows good?
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Unread 04-22-2011, 03:06 PM   #5
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Default Re: 03 DS won't charge

Sorry? Are you saying that when you remove the "output wire" on AC circuit breaker ( meaning that the breaker is working on front of charger ) directly to the input wire on transformer input coil it charges? By doing this you have eliminated the relay and control wiring to relay, is this correct?
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Unread 04-22-2011, 03:35 PM   #6
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Default Re: 03 DS won't charge

yes sir
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Unread 04-22-2011, 04:00 PM   #7
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Default Re: 03 DS won't charge

If you have done the OBC bypass test and relay inside charger DOES NOT CLOSE, AND as you say relay tested good it must be in wiring? I would do charger "DC cable" tests as shown in manual to confrim connections from OBC through charger receptical on cart to charger blue lead to relay control circuit. Then confirm connection of "RED" leads from relay to heat sink and back to relay. My own charger had several badly corroded contacts that kept giving me problems until I removed and cleaned all connections.
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Unread 04-22-2011, 04:10 PM   #8
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Default Re: 03 DS won't charge

ok its like it has a low battery but has 51 volts, battery light keeps coming on, going off, etc... the cart runs for a bit and then it will just creep, but still has good volatge. what tell if the battery is low, the obc?
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Unread 04-22-2011, 04:45 PM   #9
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Default Re: 03 DS won't charge

At 51 volts your pack should be fully charged ( 50.96 ) so there must be a bad cell or cells some where in pack. Have you tested each battery voltage as each should be 8.49 volts fully charged, then if all shows fully charged do hydrometer test on each cell for low reading ( full charged 1.277 ), then if all else fails do load test on battery pack. Sounds like you only have surface charge? By the way how much distilled water did you add? as cells may be toasted by being dry?
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Unread 04-23-2011, 10:21 AM   #10
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Default Re: 03 DS won't charge

Bump
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