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Old 06-11-2016, 06:36 PM   #1
Beckster
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Default 1994 EZGO Medalist 36V battery charger

So...after dumping 1200 into all new wiring, controller, f/r switch, and motor I think my battery charger just took a ****. Is there a way to fix the charger? I looked up the same model charger and they want 1200 bucks for it. Any recommendation on a cheaper alternative? Thanks in advance!
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Old 06-11-2016, 07:01 PM   #2
JohnnieB
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Default Re: 1994 EZGO Medalist 36V battery charger

http://www.cartsunlimited.net/battery-chargers.html

Just curious, but what is the make/model of the $1,200.00 charger?
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Old 06-11-2016, 07:43 PM   #3
Beckster
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Default Re: 1994 EZGO Medalist 36V battery charger

Attachment is the charger I current have.
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Old 06-11-2016, 08:10 PM   #4
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Default Re: 1994 EZGO Medalist 36V battery charger

That is absolutely, positively, completely and without a doubt a total ripoff.

You can buy a TC-III piece by piece for half that and used ones are sold for about $100.

Unless the transformer is bad, it can be repaired for under $150 at most, probably less.

Here is the Service & Parts manual for it.
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File Type: pdf Total Charge III Parts and service-1.pdf (3.28 MB, 0 views)
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Old 06-11-2016, 10:03 PM   #5
Beckster
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Default Re: 1994 EZGO Medalist 36V battery charger

Is there a way to tell what has gone bad in the charger? What is the common weak link? I wanted to wait to buy a new 48v charger when I need to buy new batteries. Any help is appreciated!
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Old 06-12-2016, 09:04 AM   #6
JohnnieB
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Default Re: 1994 EZGO Medalist 36V battery charger

A TC-III is fairly easy to troubleshoot. The charger portion of it consists of just a transformer, a capacitor and two diodes.

There is also a PCB called the control board, but all it controls is turning the charger on and off. Basically, a semi-smart power switch.

Plus an ammeter, an AC input fuse and a DC output circuit breaker.

-----------
With the TC-III connected to AC power, does it hum when it is plugged into the cart's charge receptacle?

If not check the battery pack's voltage. It has to be at least 30V or so before the control board will turn on the TC-III.

If the pack voltage is above about 30V, bypass the relay on the control board and the TC-III will power up whenever it is plugged into AC power.

With the relay bypassed, you can use it as a completely manual charger.
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Old 06-12-2016, 05:45 PM   #7
Beckster
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Default Re: 1994 EZGO Medalist 36V battery charger

Thanks JohnnieB. The charger does not hum when it's plugged into the receptacle. The pack voltage is at 37.4. For what it's worth, the last time I plugged it in I noticed there was no hum, so I gave it a good shake and it turned on for about 10 min. I noticed a chlorine/clean water smell coming from the charger and then it shut off. Now it doesn't do anything when it's plugged in. So, im not sure how to bypass the relay. Can you break it down for me. Thanks again.
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Old 06-12-2016, 05:52 PM   #8
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Default Re: 1994 EZGO Medalist 36V battery charger

So I opened the charger up and this is what I found on the control board. looks like a new control board should get me up and running. What are your thoughts?
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Old 06-12-2016, 05:58 PM   #9
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Default Re: 1994 EZGO Medalist 36V battery charger

Looks like you might just have to replace the relay on that board. By the way somebody was going to rip you off big time if they want that much for a charger. I don't think you can find a charger that is that expensive!
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Old 06-12-2016, 05:59 PM   #10
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Default Re: 1994 EZGO Medalist 36V battery charger

If you get the part number for that relay you can probably find it at an electronics house like DigiKey, Newark, Mouser, etc.
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