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Unread 06-27-2011, 02:09 PM   #11
Gone Wild
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Default Re: 99 Club Car Not Charging

Ok pick up a fuse housing with some 1/2 amp fuses that fit the housing
with the charger plugged in, both 120 and to cart find the grey wire that comes from the OBC and goes to the charge receptacle and connect it through the fuse to the black wire on the charge receptacle. It may be easier to pull the receptacle for the test. charger should kick on and start charging.

Better yet if your OBC has the grey wire going to it with a boot at the OBC and if you pull the boot back there is a connection there that would be a better place to jump to the -48 volt battery ( battery with a small black and large black wires together on the neg termainal, doing this will test the grey wire also as some have fuses in them and some do not !! if this does not work then do the one above at the Receptacle.
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Unread 06-27-2011, 03:12 PM   #12
The Last Moja Morani
 
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Default Re: 99 Club Car Not Charging

why not just open the charger and swap 2 wires? simple and you,ll know 100%.................................
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Unread 06-27-2011, 03:37 PM   #13
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Default Re: 99 Club Car Not Charging

Tom !! actually my way is 100% the other way is not if you would like I can explain it !!!
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Unread 06-27-2011, 03:47 PM   #14
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Default Re: 99 Club Car Not Charging

please do........and i wasn,t implying that ( your ) way was any less effective but theres no danger of someone screwing something else up if they bypass the low voltage sensor in charger instead of playing around in cart but yes explaine..............................
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Unread 06-27-2011, 03:49 PM   #15
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Default Re: 99 Club Car Not Charging

first of all where is this low voltage sensor you keep talking about in the charger
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Unread 06-27-2011, 03:57 PM   #16
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Default Re: 99 Club Car Not Charging

ok you got me its more of a relay.....the little black box with the 2 wires plugged in...one little 2 inch wire and the long one anyways by swapping the wires charger will turn on and run it just won,t shut off....thats what you do when the battery pack is to low for charger to kick on but also when cart has a bad OBC you can swap them and charger will work.......................
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Unread 06-27-2011, 04:12 PM   #17
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Default Re: 99 Club Car Not Charging

Ok my lift kit does not come for a few days I have time to explain.

The OBC controls all the charging functions the charger does not have any sensors in it (other than ammeter ).
If you jump the charger per the manual you are jumping the 120 volt circuit straight to the transformer. this tests most of the charger. It does not test the relay or circuitry associated with it.

Now if you jump the grey wire @ the OBC to ground you test the grey wire, grey wire fuse, the grey wire through the receptacle, and through the plug, to the relay and you energize the relay, thus checking the contacts and coil portion of the relay. This also checks the red wire from the cart through the same receptacle and plug, wires ect to the other side of the relay coil in the charger. The only other thing that is out of the circuit is the OBC, now the OBC will not turn the charger on if the battery voltage is too low this is either an ADC, or Comparator chip built into the OBC circuit, and not a low voltage sensor. At this point if all comes on then the OBC is either bad or there is a low battery condition no loose wires bad connections checks everything to the OBC.
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Unread 06-27-2011, 04:24 PM   #18
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Default Re: 99 Club Car Not Charging

correction for above

The black wire does not get tested !!
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Unread 06-27-2011, 04:45 PM   #19
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Default Re: 99 Club Car Not Charging

i,m not gonna tell you don,t beleive everything you read and i,m not gonna argue this at all ...........i will say this i have checked i can,t tell you how many 48 volt C.C,s for non charging non running issue .....charger wouldn,t turn on cart wouldn,t run so i open charger and swap 2 wires( i call it bypassing low voltage sensor along with hundreds of others ) plug charger in and guess what charger starts running................so i than replace OBC and put charger wires back where they should be and guess what.....cart runs, charger works and shuts off as it should and away goes a happy camper customer...................so your not gonna tell me one has nothing to do with the other.....don,t waste your fingers typing it........i have did this same thing to well over 100 carts in the past 9 years with 100% success rate.......thats speaks for itself..... you want to do yourself a favor start by not posting everything you read in a service manual or you google i don, buy it, do i beleive it service manuals yes i do i think anyone who works on their own cart thats the 1st thing they should buy....................but just like theres a time to put down the meter and go with your gut.......same goes for the manual.......anyways thanks for explaining it...by the book..................
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Unread 06-28-2011, 07:12 AM   #20
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Default Re: 99 Club Car Not Charging

Quote:
Originally Posted by shadowman View Post
i,m not gonna tell you don,t beleive everything you read and i,m not gonna argue this at all ...........i will say this i have checked i can,t tell you how many 48 volt C.C,s for non charging non running issue .....charger wouldn,t turn on cart wouldn,t run so i open charger and swap 2 wires( i call it bypassing low voltage sensor along with hundreds of others ) plug charger in and guess what charger starts running................so i than replace OBC and put charger wires back where they should be and guess what.....cart runs, charger works and shuts off as it should and away goes a happy camper customer...................so your not gonna tell me one has nothing to do with the other.....don,t waste your fingers typing it........i have did this same thing to well over 100 carts in the past 9 years with 100% success rate.......thats speaks for itself..... you want to do yourself a favor start by not posting everything you read in a service manual or you google i don, buy it, do i beleive it service manuals yes i do i think anyone who works on their own cart thats the 1st thing they should buy....................but just like theres a time to put down the meter and go with your gut.......same goes for the manual.......anyways thanks for explaining it...by the book..................
Touche' . . .
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