03 Club Car - OBC, Charger or other?

dogleg69

2003 Club Car DS that will not charge. I've read hundreds of posts and tried the OBC reset to no avail. The charger will not come on. It is plugged in and the outlet does have power. Was working yesterday. Son and wife used cart and ran it down, but still able to drive it.

Reset OBC using the steps provided on this site (which means taking off the #6 NEG). Battery pack #1 POS to #6 NEG is 46.8 volts. Voltage at the receptacle is 46.5 volts. Plug in the charger (Power Drive 2), it does not come on. Unplug charger from receptacle and test voltage again. Battery pack #1 POS to #6 NEG is 46.8 volts. However, the voltage at the receptacle has now dropped 34.6 volts. (tried with cheap voltmeter and expensive)

Take the negative off #6. Put back on. Pack at 46.8v, receptacle back to 46.5v. Plug it in to charger, nothing. Test receptacle, down to 34.6v.

The cart will run, but is very sluggish. I do not have another cart or charger available to test with. I do have a 12v car battery charger and a booster pack to jump a car.

Has anyone seen where the drop in voltage after plugging in a charger that will not come on? Any help would be appreciated before I load this up. Live on a farm and now that it is down, we see how much we rely on it to get around and haul feed/trash/limbs/etc...

thanks.

BGW

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dogleg69

BTW - I did meter out each battery. Each one was 7.8 volts.

If I have the voltmeter in the receptacle and it is reading 46.5v and then I open the yellow fuse holder, the voltage goes down to the 34.6v. I put the fuse back together and it stays at 34.6v. I have to take off the negative to get the receptacle to read 46.5v again.

dogleg69

I assume given that opening the yellow fuse holder and then closing it causes the voltage to drop (with the charger out of the loop) eliminates the charger and points to the OBC?

I opened the yellow fuse, ran a #10 wire from cart side to #6 battery NEG (left on the negative that goes through the OBC) and plugged in the charger. It did not come on.

Do you leave the #6 NEG that goes to the OBC connected when trying to bypass the OBC?

Sergio

The correct procedure to by-pass the OBC charging activation circuit is to run the receptacle side of the fuse holder to pack negative.

If that causes the charger to start, then the OBC is BAD.

The reason the voltage You get on the charger receptacle changes is because the negative wire goes through an SCR inside the OBC, which is used to regulate the charging current.

Remember that with the OBC by-passed (Fuse holder directly to pack negative), the charger will not shut off on its own.

Keep taking voltage readings until the pack reaches 60v, then disconnect the AC plug from the wall followed by the DC plug.

Go ahead and charge your batteries right away as the low voltage state you current have is very detrimental to the health of the batteries.

TahoeDawgZ71

We have a full troubleshooting guide on our website for these charging systems. Here's a link.

http://www.revolutiongolfcars.com/#!...eshooting/cvwm

dogleg69

Thank you very much Sergio and TahoeDawg.

@serigo - I ran the #10 wire from the receptacle side of the fuse to the #6 NEG battery. Plugged in the charger and nothing happened.

@TahoeDawg - I followed the four steps on your website. Steps 1,2,3 passed. Fuses passed continuity test. I pulled the cover off the charger and attempted step #4. When I plugged in the charger to the cart and had the leads on those wires, it read 5v. Unplugged the charger from cart and it went to zero volts after a number of seconds (maybe drain?).

Maybe both charger and OBC are bad? When going from the receptacle fuse to #6 NEG, does the negative cable that goes into the OBC need to be removed from the batter?

TahoeDawgZ71

No. It needs to stay connected.

If it failed the test with the battery connected, I'd put a relay in the charger and an OBC on the cart.

What's your vehicle serial number? I'll point you in the direction of the correct OBC.

dogleg69

Thank you. AQ0314-269035

TahoeDawgZ71

Relay Part Number 103414901
OBC Part Number 103359401

dogleg69

Thank you very much. Would you recommend relay and OBC or a new DPI charger that I have read so much about?