DS Charger Question

[hrk]

Yes I've Searched and Yes Downloaded the Manual

My DS was showing a constant yellow light, no power, barely moves
when hooking up charger as normal, it won't kick on.

So I did the over ride on the breaker with the charge per the Manual 3-13 section and then connected to the cart, the charge popped up an on showing
about 18 amps approx and I ran it for a couple of hours. The yellow light went out which I guess means it has power stored.

Dekka Batteries about 3 years old, plenty of water, wires are good, no bad fuses.

Anyway, returned the charger to normal by moving the wires back to original
position and plugged into cart and it never kicked on.

So what could the issue be the yellow light is out

1) Fully Charged in two hours?
2) Bad Relay in Charger?

Can the relay be replaced/serviced in the charger?

[Tbinkley3]

The relay can be replaced. Have you checked each battery for voltage and with a Hydrometer?

[gaminde]

well you did not say what year but this should work for most!!

backside of charge receptacle center wire GREY follow it up to the OBC is there a rubber boot if so pull it back the wire should unplug there ground that wire to the neg 48 volts at ( I think) # 6 battery with the charger plugged in (both 120 and to cart) Does Charger come on??

if there is no boot at OBC and wire does not disconnect there then get a fuse housing from auto parts store and a 1/2 amp fuse and ground the GREY wire at the Receptacle Does Charger com on??

[gaminde]

If it does come on (next step)

If you had to do step 2 above then check the fuse or continuity of GREY wire from OBC to Receptacle.

Check red wire going to OBC for +48 vdc
Check smallest black wire (there are three) going to OBC for - 48 vdc

Do A OBC Reset

[hrk]

What I did was bypass the relay moving the tan wire to the main breaker
and the charger kicked on, that means the charger works, but it points at
the Relay.

Easy test would be to pop it on another cart, so stopped by the Cart Shop at
lunch they test for no fee, and the charger would not come on with another cart.

Replaced relay (which the by-pass indicated might be the problem) and the charger
works. $27 for a relay and I thought HD screwed people LOL

There are Kits on Ebay for $30 to $40 for all the parts, next time
I'll just order a complete kit with breaker, heat sink and relay....

But had to get the cart charged up the kids are in town...

[Tbinkley3]

and away they go

[gaminde]

I understand what you did!! you should have run the GREY wire test first, this would isolate key areas for you. a relay is less than $4.00, so you can check it first or start replacing parts up to you next time.

[hrk]

Have to thank the postings of others I read through
and then the posting of the charger manual, after going
through that and assessing the problems it was
pointing at the charger as the culprit...

Glad it was, because it was a ton cheaper than new batteries...

[gaminde]

Tbinkley3 how do you make the little animations

[Tbinkley3]

Hey gaminde
when you click on the "Post Reply" button the window for your response pops up and on the right you should see the "Smiles" and under the 15 or so that are there is a (more) link to some of the coolest ones