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Unread 12-07-2012, 01:09 PM   #1
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Default Cleaning up an electrical mess

I started on a customers cart this morning that is turning out to be a real mess. It is an electric Club Car, and when it came in, the customer said it just wouldn't run or charge any more. I started to load test the batteries, which is where the confusion started. 4 were NAPA 8V, 1 was a Rural King 8V with a different amp rating than the NAPA batteries, and the last one was a Duralast 6V. I asked the customer why there was a 6V battery in the middle of a pack of 8V batteries, and he said he had replaced it about a year ago, and thought they were all 6V batteries. I looked at the charger, which is a Power Drive model 17930, and states it is 48V. I checked the carts #, which is A0029-907958, and compared it to the sticky, to see if it would tell me whether the cart should be 36V or 48V, and that was no help either. I went ahead and replaced all the batteries with new 8V's, and made new 4 ga. cables, hooking them all up to the system. When we check the pack with a multimeter, we get a little over 49V for the whole pack, but when I attach the charger, I get nothin. I put a jumper in the charger wires that lets me bypass the OBC in the cart, still nothin. I check the breaker in the charger and it tested good. I know I probably have more than one problem here, but I am the newbie in this biz and am not sure which to try and tackle first. I might have a bad charger, a bad OBC, and/or other problems I haven't even considered yet.

Please tell me where I should start first.

Thanks guys

Robin
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Unread 12-08-2012, 10:13 AM   #2
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Default Re: Cleaning up an electrical mess

Decided to do a little further testing, and found that we get a 49V reading when touching the multimeter contacts to each end of the pack, but when we test the positive and negative posts at the female charging recepticle, we get a reading of 36V. I don't understand how that can be, can someone please enlighten me. I am going to the sticky's to see if I can find something there that might lead me in the right direction.

Robin

Also, I should state for the record, based on my research of the sticky's that this is a series cart, not a regen.
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Unread 12-08-2012, 10:29 AM   #3
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Default Re: Cleaning up an electrical mess

Sounds like a wire is hooked up wrong somewhere but not sure how you got 36.. If they are 8 volts that math doesn't work..
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Unread 12-08-2012, 10:44 AM   #4
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Default Re: Cleaning up an electrical mess

Not that familiar with CC, but trace your charge receptacle wires to where they connect on the batteries. One ( or both ) may just be on the wrong battery! You must have the full pack voltage at the charging port, and in the correct polarity!
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Unread 12-08-2012, 10:53 AM   #5
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Default Re: Cleaning up an electrical mess

The other thing is that the main negative bat cable that goes to b- on the controller must pass through the hole in the obc or it will not charge.
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Unread 12-08-2012, 11:11 AM   #6
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Default Re: Cleaning up an electrical mess

Okay, after checking a manual for the charger (in sticky's), I re-examined the back of the carts charging recepticle. It has a red (+) and black (-) lead coming from it. The red one goes over to the first positive terminal in the pack. The black one goes into a small device on the back of the receptical that looks like a leveling bubble, then into the harness that goes to the back of the cart, and to the OBC, controller, etc. The 3rd terminal on the charging plug is supposed to connect to a sensor in the OBC that shuts off the motor if a charger is connected, so no one can drive the cart away if the charger is connected. As I understand it, this sensor also shuts the charger off when the pack is fully charged, and turns it back on when a charge is needed, for long term, off season charging and battery conditioning, etc. Should there be a wire coming out the back of the recepticle where this sensor terminal plugs in, because there is not one there. I am not sure if there is a connection inside the recepticle, and the diagrams I have looked at are not clear as to the charging connection to the pack.

I hope I am making sense to you guy's because the more research I do, the more confused I am making myself.

Also, my mechanic and I checked the cables for correct hookup (polarity) twice before I ever thought about posting, but thanks for keeping me honest.

Robin
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Unread 12-09-2012, 12:30 PM   #7
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Default Re: Cleaning up an electrical mess

I believe that you have a Club Car DS built in 2000, week 29. The Power Drive 17930 is a proper charger for the cart. It is a 48V system.

I have attached a drawing from the IPL for a 2001-2002 DS as well as a test procedure for a 2009 Precedent.

It seems to me that most Club Car's have basically the same type of power receptacle. The wires coming out of the back of the receptacle are typically a red ( goes directly to the + terminal of the battery pack ), a black wire, and a gray one that goes to the OBC. I believe that the black and gray are directly connected, but that may or may not be the case in your cart.

Assuming all of this is true I believe that you could run the attached test procedure to help sort out the problem. I don't see how you could damage anything, but.........no guarantee here.
Attached Images
File Type: jpg OBC test 1.jpg (105.3 KB, 0 views)
Attached Files
File Type: pdf PowerDrive w-Potentiometer.pdf (466.4 KB, 0 views)
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Unread 12-10-2012, 09:32 AM   #8
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Default Re: Cleaning up an electrical mess

Okay LJ, thanks for the help, now I think we are getting somewhere. We ran all these tests, and will keep them in the archives for future use. They all showed that the OBC is probably good, so it must be a charger issue. We tested the 15 amp breaker, and it tested okay. We can see the fuse in the visible window on the front of the charger is not burned out. They had the gray wire with the inline yellow fuse housing spliced into a seperate black wire that hooked into the pack somewhere. I am not sure where it was hooked into the old pack, since we took it apart, and was a mess to begin with. But now we will hook it back into the back of the charger recepticle. I will check the sticky's again to see what other diagnostic help I can find to see what is wrong with the charger, but if any of you experienced guys can already see what the most likely culprit is, don't hesitate to post a reply, especially if it will save us some time. After all, time is money, and thanks for the help again.

Robin
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Unread 12-10-2012, 02:32 PM   #9
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Default Re: Cleaning up an electrical mess

Well, it looks like we found the problem, and the charger is now working as it should. Apparently when I disconnected the wire leads in the charger out from where they belong in order to bypass them and see if the OBC was the problem, I put them back in backwards. We switched them back where they belong, reattached the grey wire that was supposed to be the 3rd wire on the back of the charging recepticle, and viola, the charger now works as it should.

Thanks for all the great help guys, I appreciate it.

Robin
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