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Unread 08-02-2015, 01:48 PM   #1
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Default 2004 Club Car won't charge so testing things

I have a 2004 Club Car DS IQ cart 48v. Charger will not come on...relay does not click and amp meter does not move. 50.3 pack voltage. Cart runs normal. Reverse buzzer sounds and will buzz when you push the cart. First thing I did was an OBC reset. No change. I tried jumping the grey wire on charge connector to battery ground. No change. I also checked the fuse and resistance was less the 2. I removed the charger cover. I installed a 15 amp fuse to eliminate breaker. I also removed the 2 black wires from the relay and jumped them. No change. I also jumped the gray wire on the charge receptacle to battery ground after I jumped than 2 black wires on the relay. No change. I will say this. Before I jumped the 2 black wires on the relay I could not feel any vibration in the charger as if current was passing through it. After I removed the 2 black wires from the relay and jumped them I could feel a very slight vibration from the charger which seems to indicate the charger was energized. Now to be clear there is no hum from the charger doing this just the slightest of vibration almost not detectable. I do not have another charger to try or another cart to try my charger on. Any thoughts or what to try next.
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Unread 08-02-2015, 09:43 PM   #2
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Default Re: 2004 Club Car won't charge so testing things

Unless You had multiple failures, the only thing that can cause both of those symptoms is the connection from charger receptacle to pack positive.

Measure the voltage from pack negative to the positive wire on the charger receptacle.
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Unread 08-02-2015, 11:55 PM   #3
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Default Re: 2004 Club Car won't charge so testing things

Hey thanks for the reply Sergio. I'll check that voltage out and report back. I just checked the rectifier and measurements seem pretty close to the manual. Here is a dumb question. I was looking at the round charge plug that plugs into the carts charge receptacle. The positive and negative lead stick out further than the 3rd lead which I guess is neutral. That makes me wonder if that lead is making contact when it's plugged in. Is it suppose to be like that? I gave the lead a slight tug with a pair of pliers to see if it would pull out a little but did not want to break anything and it did not move.
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Unread 08-03-2015, 07:01 AM   #4
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Default Re: 2004 Club Car won't charge so testing things

The center pin is shorter by design.

That is the "sense" wire pin and it is connected to one side of the relay coil inside the charger.

The idea is that the positive and negative pins are making good connection when the "sense/relay" pin makes contact and 15+amps flows through the cable.
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Unread 08-08-2015, 12:57 PM   #5
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Default Re: 2004 Club Car won't charge so testing things

Quote:
Originally Posted by Sergio View Post
Unless You had multiple failures, the only thing that can cause both of those symptoms is the connection from charger receptacle to pack positive.

Measure the voltage from pack negative to the positive wire on the charger receptacle.
I checked this and it was the same as the pack voltage. I also finished testing the battery charger following all of the test procedures outlined in the Power Drive 2 manual. Everything check out per the manual except the rectifier. The manual states that with your tester in the diode mode place the black tester lead on the positive and test the different positions with the positive lead. The value you should get when your red lead is on the negative of the rectifier is 878 mV. On mine it was 1056 mV. I called and talked to Club car technical support. He said with a value that high it could cause it to not charge. I ordered the kit off of ebay for the relay, rectifier and ac breaker. Any opinions on this? The jury is out until Wednesday when the parts arrive.
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Unread 08-08-2015, 03:50 PM   #6
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Default Re: 2004 Club Car won't charge so testing things

i have uploaded my copy of the 2005 Domestic Battery Charger Maintenance and Service Manual
section 5 is for the PowerDrive 2
as for rectifier here is what manual says
Quote:
4. Using a multimeter set to the diode test function (), place the black (–) probe of the multimeter on the
positive (+) terminal of the rectifier. Move the positive (+) probe to each of the remaining three rectifier
terminals and note the readings
(Figure 5-12, Page 5-16)
.
4.1. The multimeter should indicate approximately 878 mV with the positive (+) probe on the negative
(–) rectifier terminal.
4.2. The multimeter should indicate approximately 483 mV with the positive (+) probe on one of the AC
rectifier terminals.
4.3. The multimeter should indicate approximately 483 mV with the positive (+) probe on the other AC
rectifier terminal.
4.4. If any other reading is obtained, the rectifier has failed and must be replaced
your 1056 mV would intricate it is bad
Attached Files
File Type: pdf Club_Car_Chargers(1).pdf (5.86 MB, 0 views)

Last edited by crash test dummy; 08-08-2015 at 03:52 PM.. Reason: i wish i could spell
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Unread 08-08-2015, 04:43 PM   #7
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Default Re: 2004 Club Car won't charge so testing things

Quote:
Originally Posted by crash test dummy View Post
i have uploaded my copy of the 2005 Domestic Battery Charger Maintenance and Service Manual
section 5 is for the PowerDrive 2
as for rectifier here is what manual says


your 1056 mV would intricate it is bad
Your manual agrees with mine. I just wanted a second opinion if the 1056 reading being high would cause the charger to not come on. The other 2 readings I got on the AC terminals of the rectifier were correct. Not knowing the theory behind the numbers I was not sure of the consequences of an elevated reading. Thanks
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Unread 08-08-2015, 04:52 PM   #8
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Default Re: 2004 Club Car won't charge so testing things

A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. The process is known as rectification.
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Unread 08-08-2015, 05:13 PM   #9
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Default Re: 2004 Club Car won't charge so testing things

Quote:
Originally Posted by crash test dummy View Post
A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. The process is known as rectification.
Crash

Thanks for that explanation. Any theory on what happens with a rectifier that has an elevated number on one post as mine does?
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Unread 08-08-2015, 05:25 PM   #10
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Default Re: 2004 Club Car won't charge so testing things

wild guess .... it is making to much dc power
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