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Unread 03-08-2014, 09:10 AM   #41
South LA Coonass
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Default Re: Drained Batteries

All batteries have been charged with the 12v charger and now read 6.6v each. Total voltage is 39.6v.
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Unread 03-08-2014, 08:48 PM   #42
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Default Re: Drained Batteries

I'll have to find a multimeter to test the diodes. Plugged the 36v charger in with 37.1v on the newly installed volt meter on the cart and voltmeter climbed to 40.1v, but charger was at 18A and then shutoff with no gradual taper down to 0.
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Unread 03-10-2014, 12:32 PM   #43
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Default Re: Drained Batteries

Got a multimeter with diode test. Below are test results.

Top stud - red lead on bolt and black lead on copper plate gives a reading of 460. Swap lead and no reading.

Bottom stud - red lead on bolt and black lead on copper plate gives a reading of 596. Swap leads and no reading.

Last edited by MudHog; 03-10-2014 at 01:38 PM.. Reason: Got new meter
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Unread 03-10-2014, 09:27 PM   #44
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Default Re: Drained Batteries

Seems like I'm posting to my own thread. Guess it gets really bad when I start answering myself.


Update as of this evening: I called Lester and George had me bypass the relay. Pulled the two black wire off the relay and used a piece of wire to jump them. Plugged the DC plug in first (as advised), heard a click from the relay (as advised), and then plugged in the AC plug. Charger turned on and ammeter was at 18A. Bank voltage was at 37.2 and started climbing. Charger stayed on and voltage got to 40.1 when I heard a loud click. No change and charger stayed on. Ammeter stayed at 18A after roughly 10 minutes of staying on and I unplugged the charger at 40.2 volts to be safe. Will call George back tomorrow to give him the results of the bypass test and go from there.
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Unread 03-11-2014, 07:57 AM   #45
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Default Re: Drained Batteries

Since from a previous post you said the FNR switch was in neutral, which removes any possibility of having the coils in parallel with the batteries, they will most likely tell you to replace the timer circuit in the charger.
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Unread 03-11-2014, 01:17 PM   #46
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Default Re: Drained Batteries

Quote:
Originally Posted by MudHog View Post
Seems like I'm posting to my own thread. Guess it gets really bad when I start answering myself.


Update as of this evening: I called Lester and George had me bypass the relay. Pulled the two black wire off the relay and used a piece of wire to jump them. Plugged the DC plug in first (as advised), heard a click from the relay (as advised), and then plugged in the AC plug. Charger turned on and ammeter was at 18A. Bank voltage was at 37.2 and started climbing. Charger stayed on and voltage got to 40.1 when I heard a loud click. No change and charger stayed on. Ammeter stayed at 18A after roughly 10 minutes of staying on and I unplugged the charger at 40.2 volts to be safe. Will call George back tomorrow to give him the results of the bypass test and go from there.
Sorry I didn't get back to you sooner! What "Sergio" said is a good possibility. I would try reconnecting the charger (with the relay jumped) and let it charge. Leave it on even when you hear the relay click and see if the charge rate (amps) falls off after an hour or so. Monitor the battery pack voltage while you are doing this and it should rise to 43 - 45V in a few hours. If this occurs, then I would say your charger is fine and Sergio's suggestion is what is wrong. You'd better be sitting down when you see what the board costs!
http://www.golfcartking.com/Club-Car...-p/cgr-011.htm
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Unread 03-11-2014, 01:33 PM   #47
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Default Re: Drained Batteries

simple man, no worries. I just got off the phone with George and seen your reply.

Latest from George in troubleshooting is to pull the wires off the relay and check the operation of the relay. Put battery voltage to the relay and check continuity across black terminals to verify relay operation. To check the control board, he wants me to remote the Orange and Brown wires from the relay and plug the charger into DC and AC. Check voltage on Orange and Brown wires and I should have battery voltage. If not, then bad control board.


He did quote me $216 + shipping for a brand new 36v charger.


George called me back and I was able to ask him some more quick questions. I asked if I could leave the charger on charge while in bypass mode. He said the way the automatic charger works is that it checks voltage live while on charge and their threshold is 2.5-2.6 volts for a fully charged flooded cell battery. Optimum charged 36v condition is 45-46 volts. This would explain why I've always noticed my cart to be somewhat slow. At first it will seem spunky, but then die off. That's because my voltage has never been near 45-46, much less over 40. George also said that voltage to start charging is 70% of the voltage to close the relay. Which in the case of a 36v system, that is roughly 25 volts needed to close the relay to start charging.


Now a question I have concerning the "fully charged" voltage chart. Is that chart batteries sitting idle? I ask because if I have 38V on the batteries idle and I go forward, the voltage will drop quikly to 34V. So one would use the chart as truely a idle voltage level and not an in use voltage level?
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Unread 03-11-2014, 09:05 PM   #48
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Default Re: Drained Batteries

Yes, that is idle voltage after the charging process has ceased for several hours. You may have a battery problem also. Your voltage shouldn't drop that far under load unless you're in soft dirt or going uphill. I would do a driving load test on each battery individually. Just connect your meter to one battery and drive the cart. Go to the next battery, and do this for all of them. You may find one that is quite lower in voltage than the others. All it takes is one battery to bring the cart to a stop!
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Unread 03-12-2014, 10:23 AM   #49
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Default Re: Drained Batteries

Results last tonight lean toward faulty relay. With charger plugged in, I was able to read battery voltage on the Orange and Brown wires. Per Lester, a faulty timer would show zero voltage on these wires.

I ran the charger for 5 hours last night with the relay bypassed and charged up to 45.2V (LOCV). Measured battery voltage at the O&B wires with my Fluke and matched battery voltage with my voltmeter on cart. Ammeter on charger started at 18A and over the course of 5 hours was down to 6A when I unplugged the charger. Batteries sat overnight and when I walked up to the cart this morning, the voltmeter was 39.2V.
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Unread 03-12-2014, 12:48 PM   #50
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Default Re: Drained Batteries

That is good news! At least you know the basic charger is good! The relay is fairly cheap. That would be a good place to start.
http://www.golfcartking.com/ProductD...FcyhOgodCXIANw
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