textron charger putting out low amps

[plantguy90]

I was told my a local guy that the charger is only putting out about 5 amps and is killing my batteries.

How do I troubleshoot this?

Can I just connect my ampmeter to the output and get a reading?

[JohnnieB]

In an earlier post, you identified your charger as a Textron #26984, so it is a Total Charge III, which is a ferroresonant transformer type charge with automatic cutoff.

Here is the Owner/service/parts manual for it.

Only putting out 5A can mean:
1. The battery pack is fully charged, or close to it.
2. One of Diodes is blown
3. Capacitor is bad.
4. Transformer is bad.
5. High resistance in charging loop.

1. When charger first turns on, even with fully charged battery, the ammeter will jump to about 20A momenterally. If it doesn't, something is wrong.

2. Check the two diodes. If one is bad, replace both. 1N1184 or 1N1188 are typically used for replacements, but just about any power rectifier over 30A and 100V will work.

3 & 4 The same test checks both Capacitor and Transformer.
Attached is how to test them. The Lester design was used in Total Charge and Powerwise units, so the voltages given are correct for your charger.
Warning - The capacitor will bite you even when charger is unplugged!!!!!

If transformer is bad, replace your charger. Replacement transforms are available, but the cost more than new chargers, like the 36V DPI that I use.

5. If the above all check out, Ohm out the wires, cables and connections in the charging loop, both inside the charger and inside the cart.

Hope this helps.

Added: As for connecting your ammeter to output. The ammeter on charger is most likely pretty close. Connecting a voltmeter (DVM) to battery pack while on-charge would be more telling.
It should start at whatever the pack voltage was discharged down to and climb up to about about 42.5 while about 20A are showing on charger's ammeter, then taper off to about 5-8A or so as voltage continues to climb (more slowly now) and the charger should automatically cut-off when the pack voltage gets into the 44 to 46 volt range.

[graysonk95]

My neighbor's TXT charger had the same issue. The charger would only go up to 5 no matter how dead the cart was.
He took it to the nearby cart shop and they diagnosed it as a bad capacitor.
They replaced it and now it charges fine.

If it is the capacitor be very careful replacing it as stated below.

[plantguy90]

Alright, the info helps a lot. How do you test the diodes?

[JohnnieB]

Originally Posted by plantguy90

How do you test the diodes?

Disconnect the wire from the transformer from the diode.
Connect Red ohmmeter test lead to terminal wire was removed from and Black lead to heatsink. Note Ohm reading.
Reverse test leads and read Ohms again.
Should be high Ohms on one direction and low Ohms in other.

Some DMMs don't put out enough voltage in Ohmmeter mode to turn on diode, but they will have a continuity function. Usually had a diode symbol in that selector switch position.
Do same with test leads.
Continuity in one direction no continuity in other.

OR, you could test them like I used to test vacuum tubes.
Drop on hard surface from waist height.
If it bounces, it's bad
If it breaks, it was good.

[plantguy90]

I just went ahead and got 2 new diodes and replaced them. In a few hours when the cart comes back we'll find out if that was the ticket. Did notice that the capacitor did not bite, not sure if that tells anything, the charger was unplugged and don't know how many days its been since its last use.

[plantguy90]

About that capacitor, do I have to get that #17077-g1, or is it possible to get one locally from an electronic store? What kind of store, like radio shack?

[JohnnieB]

Same caps are used as motor start capacitors, try you local electrical supply.

Be sure to get same MFD, I believe it is 20.0MFD.

[plantguy90]

Well, after the diode replacement the ampmeter is currently reading about 18, so problem solved, right? Is is possible this charger is also not putting out enough volts?

[yurtle]

Originally Posted by JohnnieB

Same caps are used as motor start capacitors, try you local electrical supply.

Be sure to get same MFD, I believe it is 20.0MFD.

Should that be motor "run"? Start cap are only in the circuit for a short time, but run caps are always energized. I'm far from an expert, but I've always tried to use run caps whenever in doubt.