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Old 08-30-2019, 04:42 PM   #1
buckeyejudge
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Default 2003 club car DS issues.

So, a friend of a friend brought me a cart that sat for a couple years. It had an issue, new batteries didnt solve it, and so it sat for a couple years until the new batteries went bad too.
So, I put new batteries in it, then fixed the inline fuse holder on the back of the charge port and lo and behold it ran. It ran about 7 mph, but it ran. This tells me the speed sensor is bad. So that's on order.
Anyway, I plugged in the charger to confirm it works and that the new batteries had a full charge. At first, after plugging it into the cart and the wall, nothing happened. So I unplugged it from the cart, and plugged it back in. Then I heard a sizzle, smelled something burnt. Not sure if it's the charger or the cart, but after unplugging everything, the cart no longer runs, and the battery light on the dash comes on.
What have I done? What can I test? What needs replaced? How do I test the charger before plugging it back in and frying something I've replaced?

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Old 08-30-2019, 08:52 PM   #2
NoleFan4Ever
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Default Re: 2003 club car DS issues.

Series or Sepex cart?
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Old 08-31-2019, 05:05 AM   #3
buckeyejudge
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Default Re: 2003 club car DS issues.

Quote:
Originally Posted by NoleFan4Ever View Post
Series or Sepex cart?
I guess I dont know that, I'm not too familiar with CC, how do I tell the difference?

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Old 09-02-2019, 06:23 AM   #4
NoleFan4Ever
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Default Re: 2003 club car DS issues.

A Fwd/Rev Rocker switch or an FNR lever.....?
Run/Tow switch under the seat....
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Old 09-10-2019, 08:53 PM   #5
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Default Re: 2003 club car DS issues.

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A Fwd/Rev Rocker switch or an FNR lever.....?
Run/Tow switch under the seat....
Wow, not sure how I missed your response, but I do have F/R rocker switch and therefore a Sepex cart.
I ran a wire from the negative on the charge port to the last negative, thinking that's bypassing the OBC, but nothing changed. I also jumped the grey wire to the negative and didnt hear anything.
So, at this point, when I hit gas, I get no solenoid click, no noise except the micro switches, and the battery light flicks on and goes right off.
What can I check next?

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Old 09-10-2019, 09:46 PM   #6
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Default Re: 2003 club car DS issues.

I'm sure there are other issues, but what is the voltage of the battery pack?
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Old 09-10-2019, 09:48 PM   #7
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Default Re: 2003 club car DS issues.

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I'm sure there are other issues, but what is the voltage of the battery pack?
Its at 49.7, and they still havent gotten charged since I bought them.

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Old 09-10-2019, 11:46 PM   #8
NoleFan4Ever
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Default Re: 2003 club car DS issues.

If you ran the the black from the charge receptacle to the main pack negative, and the grey sense wire, then your charger should be cutting on. You need to open up the charger and see if there is an visual issues. Then check the fuse and breaker and see where you are losing the power.

As MC said, the voltage should be checked. Then you need to check the solenoid and see if it is clicking and closing. If not, we need to trouble shoot that.
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Old 09-11-2019, 07:19 AM   #9
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Default Re: 2003 club car DS issues.

Quote:
Originally Posted by NoleFan4Ever View Post
If you ran the the black from the charge receptacle to the main pack negative, and the grey sense wire, then your charger should be cutting on. You need to open up the charger and see if there is an visual issues. Then check the fuse and breaker and see where you are losing the power.

As MC said, the voltage should be checked. Then you need to check the solenoid and see if it is clicking and closing. If not, we need to trouble shoot that.
So, I wasnt trying to get the cart to charge earlier, I was trying to make it run.
So, I went back to the garage, rehooked the grey & black to the main negative. Then, when I plugged in the charger, it smoked the black wire and melted it right in two.
So, on the bright side, the charger seems to have power, but it doesn't seem to be going where it should be going. Thoughts?

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Old 09-11-2019, 07:27 AM   #10
BBBHC
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Default Re: 2003 club car DS issues.

buckeyejudge, I sent you a PM
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