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Unread 10-31-2011, 08:13 PM   #1
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Default 2002 DS Charger blowing breaker

We are a high school football team and have a golf cart our trainer uses. My knowledge is minimal but our budget is even worse!! When we plug in the charger, it blows the 15 amp breaker. I have read in post that the breaker may be weak so I replaced with identical size fuse. I plugged it in and it ran for 2 seconds and blew the fuse. I therefore think my breaker is working correctly. Every battery has between 7.89 and 8.25 volts. ( I did charge them individually so they all had 8 plus for a few days) That did not solve the problem. All wiring looks good. All terminals taken off and wire brushed both wires and terminals. All fuses (the one in the glass and the one in the fuse holder) are good. Some post said that this may happen if your batteries have too few amps. How do I test this and what should it read. Batteries are January 2010 new. Do you think it is the charger, batteries, or what. Always worked fine until the other day. I am all ears!!!
Thanks
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Unread 10-31-2011, 08:28 PM   #2
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Default Re: 2002 DS Charger blowing breaker

Quote:
Originally Posted by BVDBASS View Post
We are a high school football team and have a golf cart our trainer uses. My knowledge is minimal but our budget is even worse!! When we plug in the charger, it blows the 15 amp breaker. I have read in post that the breaker may be weak so I replaced with identical size fuse. I plugged it in and it ran for 2 seconds and blew the fuse. I therefore think my breaker is working correctly. Every battery has between 7.89 and 8.25 volts. ( I did charge them individually so they all had 8 plus for a few days) That did not solve the problem. All wiring looks good. All terminals taken off and wire brushed both wires and terminals. All fuses (the one in the glass and the one in the fuse holder) are good. Some post said that this may happen if your batteries have too few amps. How do I test this and what should it read. Batteries are January 2010 new. Do you think it is the charger, batteries, or what. Always worked fine until the other day. I am all ears!!!
Thanks

Post what charger you have. Are you blowing the service breaker of the charger breaker?
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Unread 10-31-2011, 08:45 PM   #3
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Default Re: 2002 DS Charger blowing breaker

I will get that info for you tomorrow. It is the 15 amp black breaker that pops as soon as charger kicks in. I have just read the manual posted by someone and that will help trouble shoot it. Check back on Tuesday. Thanks for the help!!
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Unread 10-31-2011, 08:55 PM   #4
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Default Re: 2002 DS Charger blowing breaker

Quote:
Originally Posted by BVDBASS View Post
It is the 15 amp black breaker that pops as soon as charger kicks in. {\
Not to be redundant, but are you talking about the black breaker that is part of the charger or the black breaker that is in the main service panel/disconnect in the building?
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Unread 10-31-2011, 08:59 PM   #5
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Default Re: 2002 DS Charger blowing breaker

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Originally Posted by Stevegrmich View Post
Not to be redundant, but are you talking about the black breaker that is part of the charger or the black breaker that is in the main service panel/disconnect in the building?

Steve that is why asked that too. I think he means the one on the charger as he states it pops out but I agree clarification is in order.
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Unread 11-01-2011, 08:24 AM   #6
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Default Re: 2002 DS Charger blowing breaker

It sounds like your rectifier(aka, diod tree) has failed in the charger. It is a $15-$20 fix. Very east to replace, just get the 4 wires back on the correct plug!
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Unread 11-01-2011, 11:48 AM   #7
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Default Re: 2002 DS Charger blowing breaker

the diode/heatsink being bad will cause the breaker to trip....you may want to address that and as mentioned its a pretty cheap fix..........................
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Unread 11-10-2011, 07:02 PM   #8
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Default Re: 2002 DS Charger blowing breaker

You might want to identify if your charger has 2-diodes or

A diode bridge which is a black 1" square with four terminals sticking out .

Here is some information collected from this site that might be helpful


THe one below is with 2-diodes

........
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This one is with a diode bridge. To test for a suspected diode bridge short blowing the circuit breaker.
Remove terminals 1 & 5 on the BRIDGE and power up to see if your circuit breaker blows note charger must be activated by plugging also into golf cart
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Unread 04-25-2016, 06:14 PM   #9
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Default Re: 2002 DS Charger blowing breaker

I think it's safe to hijack this thread after 5 years. My 2006 is doing the same thing, 48v Power Drive CC charger. Does anyone know which diagram would apply?
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Unread 04-26-2016, 07:50 PM   #10
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Default Re: 2002 DS Charger blowing breaker

Ok so I have the one with the bridge. I disconnected #1 and #5. The circuit breaker doesn't trip. Does that mean the bridge is bad?
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