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Unread 08-08-2015, 08:39 PM   #1
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Default Charger plug on 2000 DS cart

Some of you may remember I had charger problems a month ago AnD ended up getting a new to me PD3 up and running after my PD2 died. All has been fine until yesterday. I plug it onto the cart and get nothing, wiggle the cord or remove and plug in ever so easily and it may come on. The charger end looks new and its a tight fit .

are the female cart charger ends known to wear out ?
Or should I be looking at the charger itself.

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Unread 08-08-2015, 08:57 PM   #2
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Default

OK i got it working but I checked it after my post and its off again . I know the cart was pretty dead and 20 mins is not going to give it a full charge. I don't know where to look . i can plug it in and of will come on and go right off. Could it be a OBC issue ?

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Unread 08-08-2015, 09:07 PM   #3
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Default Re: Charger plug on 2000 DS cart

Spray the charge port with WD 40. Tat should help.
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Unread 08-09-2015, 08:33 AM   #4
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What's that going to do?

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Unread 08-09-2015, 08:47 AM   #5
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Default Re: Charger plug on 2000 DS cart

Be sure of connections and wires that have corroded , insulation is fine but the wire inside has strands broken,

(wiggle the cord or remove and plug in ever so easily and it may come on).


this is from the 1998/1999 PowerDrive Plus Maintenance and Service Supplement

Test Procedure 11 - Onboard Computer Silicon Controlled Rectifier (SCR) Circuit
1. A silicon controlled rectifier (SCR) acts as a switch between the two black wires in the OBC to complete the negative side of the circuit to allow the charger to charge the batteries. See WARNING on page 11-11.
2. A black 10 gauge wire is connected to the battery negative (B-) terminal on the controller and goes to the
onboard computer. Another black 10 gauge wire is attached to the onboard computer and goes to the
charger receptacle.
3. Use the following procedure to test the SCR:
3.1. Using a multimeter set to 200 volts DC, place the red lead on the positive post of battery No. 1 and place
the black lead on the receptacle fuse terminal that has the black 10 gauge OBC wire attached to it. The
reading should be approximately 36-42 volts.
3.2. If the reading is zero volts, check the black 10 gauge wire connections at the controller and receptacle.
Check the continuity of the black 10 gauge wires. If the wires and connections are okay, the SCR has
failed. Replace the OBC. If the reading is correct, proceed to step 4.
4. Plug in AC and DC cords. When charger relay clicks ON, reading should be approximately 48 volts (full battery voltage).
If the reading does not rise from approximately 40 volts to full battery voltage when the DC cord is plugged in and the
relay clicks ON, check the receptacle fuse and black wire terminal socket in the receptacle.
Test Procedure 12 - OBC Gray Wire and Fuse
1. Using a multimeter set to 200 volts DC, connect red lead to positive post of battery No. 1 and black lead (with
insulation probe) to gray 16 gauge wire at a point between fuse and receptacle. Reading should be approximately
48 volts. If reading is zero volts, check gray wire fuse and fuse holder. See WARNING on page 11-11.
2. If the reading in step 1 is 48 volts, plug the DC cord into the vehicle’s charger receptacle. The voltage reading
should drop to approximately 4.0 volts before the charger relay clicks on.
3. When the charger relay is activated, the reading should rise to approximately 48 volts.
4. If voltage does not drop to approximately 4.0 volts when the DC cord is plugged in and then rise to approximately 48
volts when the charger relay clicks ON, the gray wire circuit in the OBC has failed. Replace the OBC.
Test Procedure 13 - Voltage At Charger Receptacle Red Wire Socket
1. Using a multimeter set to 200 volts DC, place the black lead on the negative post of battery No. 6 and place the red
lead on the charger receptacle socket connected to the red 10 gauge wire. The reading should be 48-50 volts (full battery
voltage). See WARNING on page 11-11.
2. If the reading is zero volts, check the continuity of the 10 gauge red wire from the positive post of battery No. 1 to the
receptacle socket.
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Unread 08-15-2015, 09:32 AM   #6
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Default Re: Charger plug on 2000 DS cart

i found the gray wire on the back of the cart plug to be corroded and basically fell out of the boot . replaced with a new one and charger kicked right on.
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Unread 08-15-2015, 10:06 AM   #7
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Default Re: Charger plug on 2000 DS cart

Quote:
Originally Posted by glassk View Post
Be sure of connections and wires that have corroded , insulation is fine but the wire inside has strands broken,

(wiggle the cord or remove and plug in ever so easily and it may come on).


this is from the 1998/1999 PowerDrive Plus Maintenance and Service Supplement

Test Procedure 11 - Onboard Computer Silicon Controlled Rectifier (SCR) Circuit
1. A silicon controlled rectifier (SCR) acts as a switch between the two black wires in the OBC to complete the negative side of the circuit to allow the charger to charge the batteries. See WARNING on page 11-11.
2. A black 10 gauge wire is connected to the battery negative (B-) terminal on the controller and goes to the
onboard computer. Another black 10 gauge wire is attached to the onboard computer and goes to the
charger receptacle.
3. Use the following procedure to test the SCR:
3.1. Using a multimeter set to 200 volts DC, place the red lead on the positive post of battery No. 1 and place
the black lead on the receptacle fuse terminal that has the black 10 gauge OBC wire attached to it. The
reading should be approximately 36-42 volts.
3.2. If the reading is zero volts, check the black 10 gauge wire connections at the controller and receptacle.
Check the continuity of the black 10 gauge wires. If the wires and connections are okay, the SCR has
failed. Replace the OBC. If the reading is correct, proceed to step 4.
4. Plug in AC and DC cords. When charger relay clicks ON, reading should be approximately 48 volts (full battery voltage).
If the reading does not rise from approximately 40 volts to full battery voltage when the DC cord is plugged in and the
relay clicks ON, check the receptacle fuse and black wire terminal socket in the receptacle.
Test Procedure 12 - OBC Gray Wire and Fuse
1. Using a multimeter set to 200 volts DC, connect red lead to positive post of battery No. 1 and black lead (with
insulation probe) to gray 16 gauge wire at a point between fuse and receptacle. Reading should be approximately
48 volts. If reading is zero volts, check gray wire fuse and fuse holder
. See WARNING on page 11-11.
2. If the reading in step 1 is 48 volts, plug the DC cord into the vehicle’s charger receptacle. The voltage reading
should drop to approximately 4.0 volts before the charger relay clicks on.
3. When the charger relay is activated, the reading should rise to approximately 48 volts.
4. If voltage does not drop to approximately 4.0 volts when the DC cord is plugged in and then rise to approximately 48
volts when the charger relay clicks ON, the gray wire circuit in the OBC has failed. Replace the OBC.
Test Procedure 13 - Voltage At Charger Receptacle Red Wire Socket
1. Using a multimeter set to 200 volts DC, place the black lead on the negative post of battery No. 6 and place the red
lead on the charger receptacle socket connected to the red 10 gauge wire. The reading should be 48-50 volts (full battery
voltage). See WARNING on page 11-11.
2. If the reading is zero volts, check the continuity of the 10 gauge red wire from the positive post of battery No. 1 to the
receptacle socket.
Did you find the 1/2 inch plates you wanted,??
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Unread 08-15-2015, 11:47 AM   #8
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Default Re: Charger plug on 2000 DS cart

Quote:
Originally Posted by glassk View Post
Did you find the 1/2 inch plates you wanted,??
yes and the best price around i found on ebay
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