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Unread 04-17-2015, 05:16 PM   #41
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Default Re: Charger wont charge.

Quote:
Originally Posted by mShall View Post
So...after all this it seems that its the OBC. My attempts at bypassing the OBC with a wire from the golfcart receptacle to the last neg battery terminal was fruitless as was my attempt at resetting the OBC. But that seems to be the problem.

It's only mystifying to think the man at the shop said he charged my cart with my charger all night. My cart was dead as a doornail when I dropped it off, and completely charged when I picked it up, so he definitely charged it somehow. intriguing.
You do have some contradicting data on the tests and symptoms.

First, just to be clear the wire that was discussed to by-pass the OBC in your case was the Negative wire from the charger receptacle.

If you have any trust on the place You took the cart, please verify how they charged the cart. You may be dealing with a bad connection or wiring if they indeed used your charger.

Even if they used another charger, but plugged it to your cart receptacle, that would mean your OBC is working and Your charger is bad.
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Unread 04-17-2015, 06:21 PM   #42
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Default Re: Charger wont charge.

While the charger was plugged into the wall outlet and the cart (and it was totally dead, doing nothing) I wired a piece of #6 copper wire from the fused side on the back of the receptacle in the cart, to the last NEG battery terminal. Nothing happened. Maybe I was doing it wrong. Maybe its not the OBC.

My buddy is bringing over his voltmeter after work. We are going to try to get the pack voltage from the wires in the charger relay with his meter.
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Unread 04-19-2015, 02:51 PM   #43
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Default Re: Charger wont charge.

Well, I tried my buddies voltmeter, it was just a craftsman ordinary meter. I set it on DC and 200. When I touched the wires in the charger relay, it just showed 0.00. I'm going to buy a new OBC and go from there, because frankly, I have no idea. I'm off next weekend so that's going to be a good time to get it done. I'll let you know what the outcome is.
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Unread 04-19-2015, 04:44 PM   #44
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Default Re: Charger wont charge.

Why not just take the cart and charger to the shop you had it to before and ask them to show you how they hooked it to your cart and charged it. They may have used a jumper or something. Heck maybe you have to use you left hand to plug it up. at any rate you will likely save a lot of money.
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Unread 04-20-2015, 06:01 PM   #45
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Default Re: Charger wont charge.

'Use your left hand to plug it in'....now that's funny. I needed a good laugh after all this.
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Unread 04-30-2015, 01:39 PM   #46
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Default Re: Charger wont charge.

I have totally enjoyed this thread. My sister and a friend of mine both have Club Car carts that are having issues with the charging system. New batteries & cables in the friends cart and he said that when he plugged his charger in, nothing happened. We are installing new batteries and cables into my Sisters cart this weekend. They have been having issues with they're charger also. So now I can trouble shoot both of these and find out what the problems are.

Thank you from a Yamaha guy
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Unread 05-04-2015, 09:27 AM   #47
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Default Re: Charger wont charge.

Well my sister's cart is all fixed and charging great. My Brother in law forgot to connect the red wire to the battery pack. New batteries and all connected correctly. All is well.

Now for my friend's cart. His charger does nothing when plugged in. We tried another charger and it worked fine. Yesterday we opened up the charger and unplugged the top two wires on the relay. Then we plugged the charger into the cart, but NOT into the wall outlet. I put my meter on the two spade terminals on the Relay, and nothing. So I assume the relay is bad. Is that correct?
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Unread 05-04-2015, 09:44 AM   #48
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Default Re: Charger wont charge.

If another charger worked on the cart, and the charger relay in the original charger does not click when you plug it in, the relay is bad.

The relay has 2 small spade connectors (.187") for the coil and 2 larger ones (.250") for the Normally open contacts.

With the DC cord unplug from the cart and the 2 small terminals unplugged from the relay, test the 2 spaded connectors for the diode that is in between both of them.

You need to put a new diode in if the existing one is bad or the OBC will eventually get damaged.

This only applies if your charger has a stand alone relay, If you have a powerdrive 3, the suppression is already built in the small relay board you will replace.
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Unread 05-04-2015, 10:43 AM   #49
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Default Re: Charger wont charge.

I am not sure which charger model it is. The label is mostly gone. I am not sure where the diode is located. The relay part number is T9AP1D52-48-01. Can you tell if it is internal?
Thanks
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Unread 05-04-2015, 10:52 AM   #50
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Default Re: Charger wont charge.

That is a regular relay.

The diode is in the wires that go from the 2 small terminals in the relay.

If Your meter does not have a diode check, or you are not sure how to test it, just buy a new "Voltage suppressor" from the same place You order the relay.
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