obc bypass

augustus54

2000 club car series is not taking a charge. Cart tech at CC authorized dealership told me bypassing the obc will not always allow batteries to charge as per the case with mine. Would like for y'all to verify his statement if you agree please. I didn't read anywhere in the troubleshooting sticky that said bypassing did not always work. Charger tested good and the AC circuit is good.
Appreciate the help.
kraus

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

sidewalkman

You've undoubtedly checked both fuses right?
What's the symptoms? Does the charger click and then not move the needle? Having just gone through this.
Check the main fuse on the charging receptacle. Then verify the charger is clicking on when you plug it in, takes a couple of secs. Then check the fuse in the grey wire.

joesam

Fuse / breaker or bad connection somewhere on your cart seems most likely. Normally I would say look at the relay too - but you said the charger was checked with another cart - right? The grey wire (sense wire) at the back of the socket is notorious for corroding slowly to the point where a soft wiggle/pull will pull it off. Worth checking that too.

NoleFan4Ever

Bypassing will ALWAYS work "if" the OBC has failed....We completely remove them from carts with smart chargers or lithium packs as they are no longer needed. Bypassing the OBC is only a temporary measure to get you charged/charging while you replace the OBC or you purchase a smart charger and then permanently bypass the OBC. An OBC is utilized for several things in your Series cart, but its main purpose it to cut on and regulate the charging algorithm wile locking the cart out while being plugged in. If you bypass it and run it like that, you are only surface charging the batteries and they will not have a long life that way AND you have to monitor the charge so you can cut it off once it reaches ~60-~62vdc.

augustus54

Appreciate the responses.
When the tech told me it didn't always work I wondered how that could be unless something else was bad. Now for locating the something else.

NoleFan4Ever

How did you bypass it? What steps did you take??

augustus54

The tech did the bypass. Dealership stated insurance reasons for not allowing me to watch. I did see where he had spliced the sensing wire and assume he jumpered the right black. Also noticed a black sticky substance coming from the receptacle where the sensing wire exits. Quite a bit in fact. Have also noticed warmth, but not hot, to the touch, at the 3 prong plug while charging. Of course this is before it quit charging altogether. Individual lowest battery voltage was 8.3 with 8.4 and 8.5 on the rest.

NoleFan4Ever

If he jumpered both the black 10g wire AND the grey sense wire that comes out the back of your receptacle, over to the Main Pack Negative post, then that is correct and the charger should cut on unless the grey wire pulled out the receptacle (internally) and it is not sensing it. You can verify he hooked them up correctly and then if it is still not cutting the charger on, you can take a volt meter and set it to "Continuity" setting and probe the receptacle pins for both the end of the grey wire and the black wire at the post to insure they are not broken internally. Check the red one too while you are there. (It runs to the main pack Positive post.) If this will be a permanent bypass, you also need to run a jumper wire from the B- at the controller over to where the yellow wire is landed on the solenoid small post. After that, you can remove the OBC if you like.

Note- There is a large bubble covered fuse on the charging receptacle on your cart. You need to probe it with your continuity meter and insure it is not blown or you cart will not charge. It is #6 in the attached pic.

After all these checks, if it does not work, let us know and we will help you troubleshoot the charger....

Attached Images

DS_Charger_Receptacle.jpg (236.5 KB, 0 views)

augustus54

Pretty sure this has all been covered but will double check.
Just did the obc bypass to see if it would charge thus indicating a bad obc. Did not want to replace obc and still have a no charge situation.
Thanks for all the suggestions.

NoleFan4Ever

Just remember the sense wire has to be in tact to trigger the charger to come on.

If after these continuity checks it still will not charge, it is time to go inside the charger and find the issue. First will be to jumper around the relay.

See here http://www.buggiesgonewild.com/elect...ml#post1525413