Yamaha 48 Volt Golf Cart Charger Troubleshooting? | Guide

Do you own a 48-volt Yamaha golf cart? Isn’t the golf cart charging? Is the problem with the charger or the battery?

When charging a golf cart, it’s usually the battery that gets in the way. However, sometimes the problem is with the charger. This could be because you’re using the wrong charger. Perhaps there is an issue with the wiring inside the charger. Perhaps you connected the battery to the charger using the incorrect terminals.

To understand why your charger isn’t working properly, you must first understand the various charger issues and their underlying causes. We will review some of these issues, their causes, and the appropriate solutions.

yamaha 48 volt charger troubleshooting

What Are The Symptoms Of Yamaha 48 Volt Charger Problems?

If you’re having trouble charging your golf cart, the problem is most likely with the battery.

However, in some cases, the issue is with the charger. The following are some key indicators that the charger is at fault.

1. Incorrect Timing Of The Duration Of Charging

One of the most obvious signs of a bad or faulty charger is that it does not charge the battery accurately.

It either exceeds or falls short of the required time limit. Either issue indicates a problem with the device’s internal computer.

2. Clicking Sounds

When you plug in the charger, you may notice that it makes a loud clicking sound, indicating that it is charging.

However, despite the sound, you discover that the battery is not charging, indicating a fault within the battery.

3. Golf Cart Issues

In some cases, the problem is with the golf cart rather than with the battery or charger.  The internal computer of the golf cart is the only component capable of detecting the charge stored in the battery.

As a result, you may notice that the charge remaining in the battery is greater than the bare minimum, but the cart’s computer fails to detect it. That is a strong indication that the cart’s computer is to blame.

4. Battery Decoloration

Examine the batteries to see if they are discoloured. Battery discolouration indicates that the batteries have been damaged.

The damage is the result of using the incorrect charger instead of the vehicle’s original 48-volt charger.

5. Error Lights

The second and third lights on the cart are known as error lights, and they indicate charging problems.

Yamaha 48 Volt Charger Troubleshooting Guide

Before we can fix the charger, we must first understand what is causing the charging problems.

1. Low Charge On The Batteries

For the golf cart to begin charging, the charger must be turned on. However, if the battery voltage is less than 25-30 volts, the charger will not be able to detect it.

This occurs when you leave the golf cart uncharged for an extended period of time, causing the battery to discharge.

A fault in the charger’s internals may also prevent the charger from fully charging the battery.

2. Loose Connections

If the golf cart battery is not properly connected, electricity cannot flow through it.

There is a significant power loss if the battery terminals are weak or worn out, and the charger will not function properly.

As a result, ensure that the battery is properly connected and that the terminals are not corroded.

3. Corrosion Of The Battery Terminals

Battery corrosion is caused by sulfuric gases emitted by batteries as they lose charge.

Corrosion builds up on the battery terminals over time, causing the battery to fail. Remove the corrosion, and the batteries will begin charging again. 

4. Fault With The Receptacle

Faults within the receptacle, such as dirt or looseness, can cause problems with all types of batteries, new or old.

To deal with this, it is best to leave it to the dealer, who will clean it and tighten it up.

The plastic wrapping on the prongs is another issue with the receptacle. If the plastic covering breaks, the battery cannot connect to the charger.

5. Pack Voltage 

Another factor that can cause charging problems is low voltage. The charging cycle is halted due to low pack voltage.

This causes the battery charge to drain and deplete faster, preventing the batteries from charging to their full capacity.

How To Fix Yamaha 48 Volt Charger Problems? 

So far, we’ve discussed some of the most common charger-related issues. When these issues arise, they can be extremely inconvenient.

The good news is that you can easily solve them by following a simple procedure. Let’s take a closer look at some of those corrective measures-

1. Check The Battery For Damage      

First, make sure the batteries are not damaged. If they are, check if the charger is labelled 48 volts.

Batteries are frequently damaged as a result of using the incorrect charger. As a result, ensure that the charger used is the original 48-volt charger that came with the golf cart.

2. Make Sure The Charger Is Plugged In Correctly

The charger includes a DC output lead as well as an AC plug. Ensure the DC component is plugged into the golf cart receptacle and the AC component is connected to the power source.

The pins are designed to fit into the correct ports, so don’t try to force them in if you have trouble plugging them in.

3. Keep The Main Switch Off

The main switch key must always be turned off before plugging in the charger; otherwise, the battery will not charge. So keep it turned off and the charger plugged in.

4. Switch To The “Tow” Position

If you still have charging problems after that, look for the “Tow” switch under the golf cart. Then, flip the switch to the “Tow” position.

5. Check The Indicator Lights

Examine the lights on the charger next. The first light is the power light, and the remaining two are error lights. If the last two lights are red, the battery is not charged.

Reconnect the battery to the charger and attempt charging once more. When the charger is properly plugged into an AC power source, the power light illuminates.

How Serious Is The Yamaha 48 Volt Charger?

Most golf cart safety issues stem from the batteries, not the chargers.

The lead acid batteries that power these golf carts emit hydrogen. This is a major fire hazard, especially if the golf cart is charging inside an enclosed space like a garage.

Another issue with golf cart batteries is thermal runaway. When the battery is charged more than necessary, it overheats and begins a chemical reaction inside the cell.

Golf cart chargers are typically safer to use than batteries. Safety hazards are typically associated with older models introduced before 2015 and have since become obsolete.

How Much Does It Cost To Fix Yamaha 48 Volt Charger Problem?

If the charger is faulty, replacing the parts is usually sufficient. However, in some cases, the entire charger must be replaced. As a result, a new charger will be required, which will cost between $170 and $220.

1. The Cost Of Replacing Parts 

When it comes to replacing the parts, the costs can vary because each individual part has its own price.

A new charging board, for example, can cost between $150 and $200. It will cost between $100 and $150 to replace the DC plug and cord.

Smaller parts will be much less expensive. A receptacle, for example, will cost between $30 and $50 USD. Plug handles and fuse holders will be roughly the same, if not less expensive. 

2. Cost Of Mechanic/Repair Service

Parts replacement incurs fees paid to the mechanic. The cost of the repair service can range between $170 and $240. 

Conclusion 

One thing to remember is that the problem is usually with the battery rather than the charger. Always have the battery checked before diagnosing the charger.

If the battery is corroded, check to see if that is true. Sometimes, the problem is with the golf cart’s computer. Before considering fixes, ensure you use the correctly labelled charger and that the terminals are properly plugged in.