Quote:
Originally Posted by 93yellowclubcar
After I looked at the diagram I realized Harley REALLY overcomplicated the design of the resistor components! 
Almost like the parent company was trying to build a nuclear reactor in there. Oh, wait.....  |
Boy did they ever!
I have determined that there was excessive resistance in the 36v half of the circuit. At the charge point, I was only getting 0.9v, where it should read 36v.
That explains why the charger wasn't charging.
Right now I have all the wiring taken out of the cart and am cleaning each and every connection and wire terminal. I am really hoping she runs right after all this.
While I have all the wiring out, I figured I'd replace the battery trays (they needed it, the PO had put license plates under the batteries!).
I replaced the trays with aluminum angle. Will I have an issue since the frame is steel? I didn't think of this till after the install.
I charged each of the batteries individually. All but one charged up, and the sick one is only putting out 4v. I may try to find a used one in similar condition to the rest to replace it with.
That's it for now, next up is putting all the wiring back together and crossing my fingers...