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Unread 07-17-2013, 05:30 PM   #1
Not Yet Wild
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Arrow Help me diagnose my OBC

2000 48 V CC DS Series cart, not regen.

Heres what I have done so far:
1) Bypassed the little yellow wire from the solenoid to the neg connector on the controller. This got my cart running
2) Checked the fuse on the grey wire coming out of the charging receptical and its good.

When I plug the charger in, the charger makes a small click, the needle jumps, then goes to 0. After 3 seconds, it clicks off. Then nothing else happens. It does not charge.

Current voltage across the pack is 45v

Is my OBC bad? Is there any other diagnostic I can do before I spend the money?

Thanks all
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Unread 07-17-2013, 06:05 PM   #2
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Default Re: Help me diagnose my OBC

first see if charger is good by using it on another cart
if it works then bypass the OBC charge batteries 45v is way low
charge to 50v

to by pass OCB
DO AT YOUR OWN RISK.…do not attempt unless you are familiar with electricity and electronics!
There are two ways to force the charger to turn on regardless of the OBC.

The first method is to disconnect the cart’s gray wire at the fuse near the charger receptacle. Then using a jumper wire, connect the receptacle side of the fused connector to the cart’s negative battery terminal. This will energize the charger’s 48V relay. If the charger doesn’t come on, it could be bad connections, wiring or charger relay.

The second method is to open the charger and remove the 120V wires from the relay and jump these together. This totally bypasses the relay and the OBC wire.


(If charger comes on but the charger ammeter shows 0 amps, check the fuse at the charging receptacle under the clear plastic cover.)

Both of these methods should both be temporary measures for troubleshooting, or as an emergency method of charging the batteries when they have been discharged so far that the OBC will not charge them.

The OBC provides the optimum method of charging the cart’s batteries. If the OBC is bad, it should be replaced
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Unread 07-17-2013, 06:11 PM   #3
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Default Re: Help me diagnose my OBC

you might want to reset the OBC also


To reset the OBC the following must be done in this order:

If no Tow/Run Switch then skip that step

• Key Switch to Off
• Forward/Reverse to Neutral
• Tow/Run Switch to Tow
• Disconnect the Battery NEGATIVE (–) wire from the Battery Minus terminal on the battery pack.
• Put the Tow/Run to Run
• Forward/Reverse Switch to Reverse
• Key Switch to On
• Lock the throttle pedal down

The reverse buzzer will sound and go off in about 30 seconds.
Leave the cart like that for 5 min to cause the OBC to reset.

To reconnect the OBC back into the system:
• Key Switch to Off
• Forward/Reverse Switch to Neutral
• Tow/Run switch to Tow
• Reconnect the Batt – wire to the battery minus
terminal on the battery pack.
• Tow/Run switch to Run
• Key Switch to ON
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Unread 07-17-2013, 06:19 PM   #4
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Default Re: Help me diagnose my OBC

Awesome thanks. I did reset the obc per instructions. Nothing happened. The reverse horn didnt buzz either.
also I noticed 2 black wires to the neg side of the pack. 1 goes through the obc, 1 does not. Both go to the same terminal on the controller.

As far as the voltage, the batteries are brand new. Ran cart about 15 minutes. My meter is no that great and I have to put on 150v scale
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Unread 07-17-2013, 06:41 PM   #5
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Default Re: Help me diagnose my OBC

Quote:
Originally Posted by wayneh View Post
also I noticed 2 black wires to the neg side of the pack. 1 goes through the obc, 1 does not. Both go to the same terminal on the controller.
sounds like someone by passed OBC
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Unread 07-17-2013, 10:10 PM   #6
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Default Re: Help me diagnose my OBC

OK Test result: I did procedure in first pic, jumped the gray wire to the neg terminal of the pack. Plugged in charger. It clicked on and stayed on. However, the meter did not go up hardly at all. I only left it hooked up this way for a couple of minutes because the wire I used to jump was pretty small.

Is this pretty sure OBC failure?

thanks all
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Unread 07-17-2013, 10:14 PM   #7
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Default Re: Help me diagnose my OBC

BY THE WAY, I checked the fuse on the charger receptical last night. I took the glass off and inspected It looks more like a fuseable link than a fuse, it is a pretty thick piece of metal. It appears in tact,
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Unread 07-18-2013, 04:09 AM   #8
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Default Re: Help me diagnose my OBC

Quote:
Originally Posted by wayneh View Post
OK Test result: I did procedure in first pic, jumped the gray wire to the neg terminal of the pack. Plugged in charger. It clicked on and stayed on. However, the meter did not go up hardly at all. I only left it hooked up this way for a couple of minutes because the wire I used to jump was pretty small.

Is this pretty sure OBC failure?

thanks all
yep that sounds like a bad OBC

you have a couple choices
1) replace the OBC

2) buy a DPI charger, it eliminates the OBC
ScottyB sells a great dpi charger at a good price
http://www.cartsunlimited.net/48v_Battery_Charger.html

3) buy an O.B.C. replacement timer, it mounts to charger by passing the OBC
http://www.golfcartking.com/Club-Car...er-p/30931.htm
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