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Unread 07-11-2015, 09:35 PM   #1
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Default 01 Club Cart OBC getting hot, Cart won't move.

First I want say this is an excellent forum. Also, my first time posting.
The problem I am having is my cart just stopped in travel. It seems as if it lost power to everything or something that's controls the braking on the motor because it will now free roll with it in the run mode. The OBC will get very warm when I switch to run mode and it has what looks to be a burnt spot on the plastic cover of the OBC. I have seen some post about by-passing the OBC is this possible?

By the way my cart is an 01 regen 2 I believe.

Thanks in advance for any help you may be able to give me.
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Unread 07-11-2015, 11:39 PM   #2
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

Can anyone tell me how to by-pass the OBC?
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Unread 07-12-2015, 09:21 AM   #3
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

If you bypass the OBC the charger will not kick off. Your best bet is to buy a charger that has its own logic onboard (doesn't need an OBC) and remove the factory OBC - OR - you can also simply put on a new OBC, if going this route I recommend using Revolution Golf Cars, TahoeDawgZ71 here on the forum. Just installed one for a fellow yesterday that I got from Tahoe.
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Unread 07-12-2015, 09:44 AM   #4
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

http://www.lesterelectrical.com/search/pdf/39443_A1.pdf

Bypassing the OBC is so you can use a different charger, I do think the OBC gives an "OK" input to the controller so the charger interlock will work,


Electric Club Car wiring diagrams

I see three items in that circuit, Fuse, Switch and the diode, might be a problem and should be ruled out before another OBC is installed,


Common failure mode for diodes is fail shorted-could be letting current to the OBC when the switch is in Run,

Just Guessing though,
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Unread 07-12-2015, 10:28 AM   #5
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

The by-pass procedure for the Regen2 is a little different since the OBC actually provides power to part of the system in that design.

You need to disconnect the 6-pin OBC connector and jump the Red/White with the Blue wire on the harness side.

The brown spot is most likely the result of the SCR inside the OBC overheating.

If the cart runs, You have the option of replacing the OBC or get a different charger that does not use the OBC and completely by-pass the OBC off the system.
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Unread 07-12-2015, 10:35 AM   #6
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

I have no movement in either direction. No reverse buzzer. It will charge up and cut off. Maybe my problem is not the OBC. I am not sure.
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Unread 07-12-2015, 10:42 AM   #7
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

That is because the reverse buzzer as well as the FNR is powered by the OBC.

You need to bypass the OBC power interlock function with the jumper I mentioned.
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Unread 07-12-2015, 10:47 AM   #8
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

Ok I will go try try that now. Thanks
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Unread 07-12-2015, 10:54 AM   #9
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

I just jumped those and did not get any results.
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Unread 07-12-2015, 11:32 AM   #10
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Default Re: 01 Club Cart OBC getting hot, Cart won't move.

Correction: I now get the reverse buzzer for about 1 second and nothing else.
my serial number is ac0104-984601 I hope I told you the correct type of cart.
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